Suzuki GSX-R600 manual

GSX-R600 99500-35100-01E[...]

GR OUP INDEX GENERAL INFORM A TION 1 PERIODIC MAIN TENANCE 2 ENGINE 3 FI SYSTEM DIA GNOSIS 4 FUEL SYST EM AND THRO T TLE BOD Y 5 EXHA UST SYSTEM 6 COOLING AND LUBRIC A TION S YSTEM 7 CHASSIS 8 ELECTRI CAL SYSTEM 9 SER V ICING INFO RMA TIO N 10 EMISSION CONT R OL INFORMA T ION 11 WIRING DIA GRAM 12 FOREWORD This manual con tains an intro ducto ry de[...]

HOW TO U SE THIS M ANUAL TO LOCAT E WHAT YOU ARE LOOKING F OR: 1. The text o f th is manu al is divid ed into s ection s. 2. Th e sec tion ti tles ar e listed in the GRO UP I ND EX. 3. Hol ding th e manua l as sho wn a t the r ight will allow you to find the fi rst pag e o f the s ection easi ly. 4. The conte nts a re lis ted on the first p age of [...]

SYMBOL Liste d in th e t able b elow ar e th e sym bols i ndicating ins tructi ons a nd othe r in formatio n ne cess ary for serv ic- ing . The m ean ing o f each symbo l is a lso in cluded in the table . SYMB OL D EFINIT ION S YM BOL DE FIN ITION T orqu e con trol re quired. Data beside it indi cates specif ied torque. A pply T HREAD LOC K SU PER [...]

ABBREVIATIONS USED I N THIS MANUAL A A BDC : A fter Bot tom Dead C en ter A C : A lternati ng Cu rrent AC L : Ai r Cl ea ner , Ai r Cl ea ner Bo x A PI : A merica n Pe troleum Insti tute A TDC : A fter T op Dea d Cent er ATM Pre ssure : A tmosp heric P ressu re : A tmosp heric Pressu re sens or (APS, AP Sensor) A/ F : Ai r Fu el Mix tur e B B BDC :[...]

M MAL -Code : Malfunct ion C ode ( D ia gn o st ic C od e ) Max : Max imum MIL : M alfunct ion In dicator Lamp (LED) Mi n : Mi nimu m N NOX : Nit rogen Oxid es O OHC : Over Head Ca msha ft OPS : Oil Pressure Switc h P PCV : Posi tive Cran kcase V entilation (Cr ankca se Breath er) R RH : Right H an d ROM : Read Onl y Memo ry S SAE : So ciety of Aut[...]

WIRE COLOR B : Black G : G reen P :Pink B l : Bl ue Gr : Gr ay R : Red B r : Brow n Lbl : Li ght bl ue W : Whi te Dg : Dark gre en Lg : Lig ht gree n Y : Y ellow Dgr : D ar k gr ay O : Ora nge B/Bl : Bl ack with Bl u e tracer B/Br : Bl ack with Brown tr a cer B /G : Blac k with Green trace r B/Lg : Bla ck with Light gr een tracer B /R : Black with [...]

GENE RAL IN FO RMATIO N 1 -1 1 GENERAL INFORMA TION CONTENT S WARNING/CAUTION/NOTE .... ........ ....... ....... ........ ....... ....... ........ ....... ....... ... 1 - 2 GENERAL PRECAUTIONS ..... ........ ....... ....... ........ ....... ....... ........... ........ ...... 1- 2 SUZUKI GSX-R600K6 ( ’ 06-MODEL) ...... ....... ........ ....... ..[...]

1- 2 GE NERAL INF ORMAT IO N WARNING/CAUTION/ NOTE Plea se rea d this ma nual an d follow its instr uctions c arefu lly. To em pha size spe cial info rmati on, the s ymb ol and the wor ds WAR NING , CA UTION and N OTE h ave speci al mea nings. Pay sp ecial at tention to the mes - sag es high ligh ted by thes e signa l words .  Indi cates a poten[...]

GENE RAL IN FO RMATIO N 1 -3  * If parts repla cemen t is nece ssary, r eplace the part s wi th Suzu ki Genuine Parts or their eq uiva - lent. * When remo ving parts that are to be reused , keep them a rrang ed in an orderl y man ner so that t hey may be re ins tal led in t he prope r order and or ie ntat ion. * Be s ure to u se sp eci al t ool [...]

1- 4 GE NERAL INF ORMAT IO N SU ZUKI GSX-R 600K6 (’06-M ODEL) • Difference betw een illustrat ion s and actual mot orcycle may exi st depending on the markets. SERIAL NUMBER LO CA TION The fr ame se rial num ber or V .I.N . (Veh icle Identi fication Num ber) 1 is stam ped on t he r ight side of the stee ring head pipe. T he engi ne s erial numb[...]

GENE RAL IN FO RMATIO N 1 -5 FUEL, OIL AND ENGINE COO LANT RECOMMENDATION FUEL (FOR USA AND CANADA) Us e only u nlead ed ga soline of at leas t 87 pu mp octan e (R/2 + M/2) or 91 oc tane o r hig her rated by the resear ch method . Ga soline cont aining MTBE ( Me thyl T ertiary Bu tyl Ether) , less th an 1 0% et han ol, or les s th an 5% me thanol w[...]

1- 6 GE NERAL INF ORMAT IO N FRO NT FOR K OIL Use fork oi l SS- 05 or an equ ivalen t fo rk oil. ENGINE COO LANT Use an ant i-freez e/eng ine c oola nt com patib le w ith an aluminu m rad iator , mixed with disti lled wa ter on ly. WATER F OR MIXING Use distilled w ater on ly. W ater o ther th an di stilled water can co rrode and clog t he a luminu[...]

GENE RAL IN FO RMATIO N 1 -7 BREAK-IN P ROCEDURES Dur ing m anufac ture only th e be st po ssible materia ls a re used and all ma chined pa rts are finished to a ver y high standard but it is still necessary to allo w the moving parts to “BREAK-IN” before subject ing the e ng ine to ma xim um st resse s. The fu ture p erfor man ce an d reliabi [...]

1- 8 GE NERAL INF ORMAT IO N INFORMATION L AB ELS A: Atta ch ed *1: Re ar fender (front) *2: Ch ain c ase GSX -R 600 GS X-R 600UE G SX-R6 00U F 1 Noi se lab el A (Fo r E-03 , 24 , 33) 2 Infor ma tion lab el A (Fo r E-03 , 28 , 33) 3 V acuum ho se r outing labe l A (Fo r E-33 ) 4 Fue l cauti on l abel A (F or E- 02, 24) 5 M anual noti ce la bel A (F[...]

GENE RAL IN FO RMATIO N 1 -9 S PEC IFIC A TIO NS DIMENSION S AND DRY M ASS Over all l ength .. ............ ...... ............. ...... ............ ....... ...... .......... 2 040 m m ( 80 .3 in) Over all wi dth ......... ...... ............. ...... ............ ...... ............. ...... .... 7 15 m m (28 .1 in) Over all hei ght .. ............ [...]

1-10 G ENERA L INF ORMA TION CHASSIS Fro nt susp ensi on ...... ............ ...... ............. ...... ............ ....... ...... Inverted telesc opic, coil sp ring , oil dam pe d Rear suspe ns ion ....... ............ ...... ............. ...... ............ ....... ...... Link type , coi l spr ing, o il damp ed Fro nt fork s trok e . ....... .[...]

PERIO DIC M AINTE NANC E 2 -1 2 PERIODIC MAINTEN ANCE CONTENT S PERIODIC MAINTENANCE S CHEDULE ... ... ........ ....... ....... ........ ....... ....... .. 2- 2 PERIODIC M AINTENANCE CHAR T....... ........ ....... ....... ........ ... ........ ..... 2 - 2 LUBRICATION PO INTS .... ........ ....... ....... ........ ....... ....... .... ....... ......[...]

2- 2 PER IODIC M AIN T E NANCE PERIODIC MAINTE NANC E S CHEDULE The char t bel ow lists the reco mmend ed interv als for all th e req uire d period ic service work nec essar y to keep the mo tor cycle op erating a t pea k perfor manc e and ec onomy . Mile ages a re expre ssed i n terms o f kilom e- ters , miles a nd time f or yo ur conv enienc e. I[...]

PERIO DIC M AINTE NANC E 2 -3 LUBRICAT ION POIN TS Proper l ubricati o n is imp ortant f or smooth operat ion and l ong life of each working p art of the motor cycle. M ajor lubr icatio n poi nts are i ndica ted bel ow. NOT E : * Before lubricat ing ea ch pa rt, c lean off any rusty spot s and wipe off any gre ase, o il, di rt or g rime. * Lubr ica[...]

2- 4 PER IODIC M AIN T E NANCE MAINTENANCE AND TUNE-UP PROCEDURE S This secti on d esc ribes the servi cing procedu re s fo r each item o f the P eriodi c M aintenanc e re quir ements. AIR CLEANER • R em ove th e fron t seat . (  8-7) • L ift and supp ort the fue l tank. (  5-3) • R em ove th e air cl eaner eleme nt by removi ng the scr[...]

PERIO DIC M AINTE NANC E 2 -5 SPARK PLUG SPA RK PLUG AND I GNIT IO N CO IL/ PLUG CAP REMOVA L • R em ove t he fron t sea t. (  8-7) • L ift an d sup port th e fu el tan k. (  5-3) • R em ove the a ir cl eaner box. (  5-14) • D isco nnec t all lead wir e cou plers f rom i gnition coil/ plug ca ps.  • R em ove the i gnit ion coi[...]

2- 6 PER IODIC M AIN T E NANCE SP ARK PLUG GAP • M easu re the spark plug gap with a thick ness gau ge. • Ad jus t the s park pl ug ga p if ne cess ary.  Spa rk plu g gap: Stan dard: 0 .7 – 0.8 mm (0.028 – 0 .031 in )  09900- 208 03: Thi ckness g aug e ELEC TRODE’S CO NDITION • C he ck the co nditi on of th e e lectrod e. • If i[...]

PERIO DIC M AINTE NANC E 2 -7 VALVE CLEARANCE • R em ove t he right und er cowli ng. (  8- 5) • L ift an d sup port th e fu el tan k. (  5-3) • R em ove the a ir cl eaner box. (  5-14) • D isco nnec t the CM P s ens or coup ler 1 . • R em ove t he PA IR c ontrol so lenoi d valv e 2 . • R em ove the s park p lugs . (  2-5) ?[...]

2- 8 PER IODIC M AIN T E NANCE • T urn t he crank sha ft to br ing th e line A on the CKP sens or roto r to the r ib B b ehind the cl utch co ver and a lso to bring th e not ch es A on the l eft en ds o f bo th ca mshafts (Ex . and In. ) to the posi tions as shown. • In this c onditio n, read t he val ve clea ran ce at the v alves B (In . and E[...]

PERIO DIC M AINTE NANC E 2 -9 VALV E CLEA RANCE A DJUS TME NT The clearance is adjus ted by replac ing the exi sting tapp et shim by a thick er or th inner shim. • R em ove t he intak e or e xhaust cams hafts . (  3-14 ) • R em ove the t app et an d shim by fing ers or mag netic h and . • C he ck the figur es pri nted on the shim . Thes e [...]

2-10 PE RIODIC MA INTE NANCE MEASURED V AL VE CLEARANCE (mm) SUFFIX NO . 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 PRESENT SHIM SIZE (mm) 1.20 1.25 1.30 1.35 1.40 1.45 1.50 1.55 1.60 1.65 1.70 1.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20 0.00 – 0.04 1.20 1.25 1.30 1.35 1.40 1.45 1.50 1.55 1.60 1.65 1[...]

PERI ODIC M AINTEN ANCE 2-1 1 HO W T O USE THIS CHART : I. Measure v alve clearance. “ENGINE IS COLD” II. Measure present shim size . III. Match clearance in v er tical column with present shim siz e in horizontal column. EXAMPLE V alv e clearance is 0.33 mm Present shim size 1.70 mm Shim size to be used 1.80 mm T APPET SHIM SELECTION T ABLE [E[...]

2-12 PE RIODIC MA INTE NANCE ENGINE OIL AND OIL FILTER ENGIN E OIL REPL ACEME NT • R em ove th e unde r cow lings. (  8- 5) • Keep the motorcycle upright. • Pl ace an oi l pan below th e engi ne, a nd drain o il by remo ving the o il drai n pl ug 1 and f iller c ap 2 . • Tight en the drai n plug 1 to the spe cified to rque, an d p our fr[...]

PERI ODIC M AINTEN ANCE 2-1 3 OIL FI LTER R EPLAC EMENT • D rai n the engi ne oil as des crib ed in the e ngine oil repl ace- m ent pr oced ure. • R em ove the o il filter 1 with the s pecial tool .  09915- 406 10: Oil filter wrench • A pply engin e oil lightly to the gas ket o f the new oil filter be fore instal lation. • I nstall the n[...]

2-14 PE RIODIC MA INTE NANCE • R em ove th e unde r cow lings. (  8- 5) • Chec k t h e l ock -n ut s t igh tne ss. If th e l oc k- nut s ar e lo ose, adj ust the cabl e p la y and ti ght en t he l ock- nut s. FUEL LINE • In spect th e fue l feed hose 1 for da mag e an d fuel lea kage . If any defec ts are foun d, th e fuel fee d h ose m us[...]

PERI ODIC M AINTEN ANCE 2-1 5 THROTT LE VALVE SYNCHRONIZATION • I nspect th e thr ottle va lve sync hro nization pe riod ically . (  5- 26) EVAPORATIVE EMISSI ON CONTROL SYSTEM (E -33 ONLY) • Inspect t he evap orati ve emissio n contro l syst em perio dically . PAIR ( AIR SUPP LY) S YSTEM • Inspect the PAIR (air supply) system pe rio d ica[...]

2-16 PE RIODIC MA INTE NANCE CLUTCH • L ift and supp ort the fue l tank w ith its prop stay. (  5-3) • T urn in the adjus ter 1 al l the way into the clut ch leve r assem - bl y. • L oosen the lock-nu t 2 an d turn the clut ch cabl e adj uste r 3 to ob tain p rop er cabl e play . • R em ove th e clutch rele ase a djuster cap . • L oose[...]

PERI ODIC M AINTEN ANCE 2-1 7 COOLING SYSTEM ENG INE COOL ANT LEVEL C HECK • Keep the motorcycle upright. • C he ck the engine c oolan t leve l by obser ving the full and lo wer lines on th e e ngine coolan t res ervoir. A Full li ne B Lower line • If the lev el is bel ow th e low er line , remo ve th e right u nder co wling (  8 -5), an d[...]

2-18 PE RIODIC MA INTE NANCE AIR BL EED ING THE C OO LING CIR C UIT • Ad d e ngine coolan t up to the r adia tor inl et. • Support t he m otorcycle uprig ht. • Slowly swing the mot o rcycle , ri g ht a nd l e ft, to blee d the air trap ped in the cooling circ uit. • Ad d e ngine coolan t up to the r adia tor inl et. • St art up the engin [...]

PERI ODIC M AINTEN ANCE 2-1 9 RADI ATO R HOSE S • R em ove t he unde r co wlings. (  8- 5) • L ift an d sup port th e fu el tan k. (  5-3) • C heck th e radia tor hoses for crack , damag e or en gine coo lant lea kage . • I f an y defe ct is foun d, r eplac e the r adiato r hos e with n ew one.[...]

2-20 PE RIODIC MA INTE NANCE DRIVE CHAIN Visual ly c heck th e drive chain f or the p oss ible def ects l isted belo w. (Sup port th e mo torc ycle by a jack a nd a woo den block, turn the rear whe el slow ly by hand wi th the transm ission shifte d to Neutr al.) * Loos e pins * Exce ssive we ar * Dam age d rolle rs * Improp er chai n adj ustm ent [...]

PERI ODIC M AINTEN ANCE 2-2 1 • C ount out 21 pins (20 pitc hes) on the chai n and meas ure th e dista nce b etw een the tw o po ints. If the distanc e ex ceed s the se rvice l imit, th e cha in mu st be replac ed.  Driv e ch ain 20- pit ch len gth: Ser vic e limi t: 319 .4 mm ( 12 .57 in) AD JUS TING • L oose n or tighte n both c hain adjus[...]

2-22 PE RIODIC MA INTE NANCE CLE AN ING AN D LUBR IC ATIN G • C lean the dr ive c hain w ith ke rosine . If the drive chai n tends to rust quick ly, the inter va ls must be shortene d.  • Af ter was hin g and dryi ng the c hain, oi l it with a hea vy weight mo tor oi l.  Do n ot use trich loroe thylen e, gaso line or an y s im ilar solv e[...]

PERI ODIC M AINTEN ANCE 2-2 3 BRAKE BRAK E FLUI D LEVE L CHECK • K eep th e motor cycle up right and pl ace th e handl ebars straig h t. • C heck the brake f luid level r elativ e to th e low er l imit li nes o n the f ron t and r ear brak e fl uid res ervoi rs. • When the level is bel o w the lower limit line, replenish with br ake f lui d t[...]

2-24 PE RIODIC MA INTE NANCE BRAK E PADS Fron t brake The e xtent o f brak e pad wea r can be c hecke d by obs ervi ng the groo ved limit lin e A on the pad. W hen the wea r exceed s the groo ved li mit li ne, rep lace th e pa ds w ith th e new o nes. (  8-65 )  Rear b ra ke The e xtent o f brak e pad wea r can be c hecke d by obs ervi ng the[...]

PERI ODIC M AINTEN ANCE 2-2 5 BRAK E LIGH T SWITC H • Adju st t he re ar br ak e li ght s wit ch s o th at t he b ra ke li ght wil l co me on just befo re press ure is felt wh en the brake pe dal is depr essed . AIR B LEE DING FR OM BRAK E FLU ID CIRC UIT Air trapp ed in the br ake fluid c ircuit acts l ike a cus hion to a bsor b a la rge p ropor[...]

2-26 PE RIODIC MA INTE NANCE FRONT B RAKE (Mas ter cyli nder sid e) • Blee d air fr om the ma ster cylind er in th e sam e m anner as fron t brak e (cal iper si de).  Air ble eder valve : 6.0 N ·m ( 0.6 kg f-m, 4. 3 Ib- ft) NOT E : If air i s trapp ed in t he m aster cylin der, blee d air from t he m aster cylin der fi rst. REA R BRAK E • B[...]

PERI ODIC M AINTEN ANCE 2-2 7 TIR ES TI RE TR EAD C ONDI T ION Operatin g th e moto rcycle w ith excessi ve l y worn tire s will decrease ridin g stab ility and conseq uently invit e a dangerous situa tion. It is h ighl y rec ommend ed to re place a tir e whe n th e rema ining d epth of tire tre ad rea ches th e fo llowing s pec ificatio n.  099[...]

2-28 PE RIODIC MA INTE NANCE FRO NT FOR K • Insp ec t th e fr ont for ks f or oi l l eak ag e, s cor in g or sc rat che s on the out er sur face o f the inne r tubes . Repl ace any de fectiv e parts, if n e cess ary. (  8-18) REAR SUSPENSION • In spec t the rea r shock ab sorb ers for oil lea kage an d check that th ere is no play in the sw [...]

PERI ODIC M AINTEN ANCE 2-2 9 EXHAUST PIPE BOLT AND NUT • T ight en the e xhaust pipe b olts , muffl er mou nting bolt and n ut to th e spe cified torque .  Tig hten ini tially at 1 000 km (600 m iles , 2 m ont hs) and every 12 0 00 km (7 50 0 m iles, 2 4 mo nths) there after . 1 Gasket 2 Exhaus t pipe conn ecter  ITEM N ·m kgf-m lb-ft AB [...]

2-30 PE RIODIC MA INTE NANCE CHASSIS BOLTS AND NUTS Chec k that all ch assis bo lts and nuts are tighten ed to th eir specifi ed torqu e. (Refe r to page 2- 31 for the loc a- tion s of th e follow ing nuts a nd bol ts on the mo torcyc le.) Tig hten initia lly at 1 000 km (600 mi les, 2 mont hs) an d every 6 00 0 km ( 4 000 miles , 12 mont hs) th er[...]

PERI ODIC M AINTEN ANCE 2-3 1[...]

2-32 PE RIODIC MA INTE NANCE COMPRESSION P RESSURE CHECK The comp ression pr essure r ead ing of a c ylin der is a good indic ator of its inter nal co nditi on. The decis ion to ov erhau l the cylind er is often b ased on th e resul ts of a com pre ssion te st. P eriod ic main te- nanc e recor ds ke pt a t your de aler ship s hould i nclude comp re[...]

PERI ODIC M AINTEN ANCE 2-3 3 OIL P RE SSURE CHE CK Chec k t he engi ne oi l press ure p erio dically. T his w ill g ive a g ood i ndicati on of the condition of the mov ing part s. OIL PR ESSURE SPECIFICATION If the oil pressu re is lowe r or h igher tha n th e spe cificat ion, th e follow ing causes may be c onside red . LOW OI L PRESSUR E * Cl o[...]

2-34 PE RIODIC MA INTE NANCE SDS CHECK Using SDS, take th e sample of data from the new motor cycle and at the time o f periodic m aintenance a t you r dealer ship. Sa ve the d ata in th e comp uter or by printi ng and fi ling the hard c opies. T he sa ved or fi l e d data ar e usef ul for troub leshoo ting as they can b e comp ared p eriodi cally [...]

PERI ODIC M AINTEN ANCE 2-3 5 Da ta at 3 0 00 r/ min un der no l oad Da ta at th e tim e of racin g 3 000 r/min Check the manif old absolute pressure. XXX mmHg Throttle: Quick wide open Throttle: Slowly open Secondar y throttle v alve opens closes in according with the engine r/min.[...]

2-36 PE RIODIC MA INTE NANCE Da ta of in ta ke ne ga tiv e pr ess ure du rin g i dli ng (1 00 °C) Da ta of seco nd ary th rott le valve opera tio n at the tim e of star tin g Check the manif old absolute pressure. Appro x. XXX mmHg Closes fully in appro x. XX sec.[...]

ENGIN E 3 -1 ENGINE CONTENT S 3 ENGINE COMPONENTS REMOVABLE WITH ENGINE IN P LACE ..... ..... 3- 2 ENGINE REMOVAL AND INSTALLATION ....... ....... ........ ... ........ ....... ....... .. 3- 3 ENGINE REMOVA L ....... ....... ....... ........ ....... ....... ........ ....... ....... ........... .. 3- 3 ENGINE INSTALLATION ...... ....... ........ ...[...]

3-2 EN GINE ENGINE COMP ONENTS REMOVABLE WI T H E NGINE IN PLACE The p arts lis ted bel ow can be remo ved an d rein stalled wi thout r em oving the engin e from the fra me. Refe r to page l isted in ea ch sec tion for remo val and re instal lation ins tructio ns. EN GIN E CE NTE R ENGINE R IGHT SIDE ENGINE LE FT SID E ITEM REMOVA L INSPEC TI ON IN[...]

ENGIN E 3 -3 ENGINE REMOVAL AND I NS T ALLATION ENGINE REMO VAL Be fore taking the engi ne out of the f rame, wa sh t he eng ine using a steam clea ner. Engin e rem oval is seq uen tially expl aine d in the fol low ing ste ps. R einsta ll the eng ine b y rev ersin g the remo val pr oced ure. • Rem ove t he u nder co wli ngs. (  8- 5) • Lif t[...]

3-4 EN GINE RADI ATO R • D isco nnect the by -pass hos e 1 and r adiat or inlet ho se 2 . • D isco nnect the oi l cooler outle t hos e 3 . • D isco nnect the c ooling fan co upler 4 . • R em ove th e radia tor mou nting bolts. • R em ove th e radia tor 5 .  Be care ful not t o bent t he radi ato r f ins .[...]

ENGIN E 3 -5 EXHA UST PIPE A ND MUFF LER • Rem ove t he E XCV cabl es a long wi th the b ra cket 1 . • Loos en th e mu ffler connec ting bolt. • Rem ove t he H O2 se nsor 2 (For E -02 , 19). (  6- 10) • Rem ove t he e xhau st pipe bolts. • Rem ove t he e xhau st pipe. • Rem ove t he e xhau st pipe gaskets . • Rem ove t he rad iator[...]

3-6 EN GINE • Disconnect the fo llowing couple rs. 3 GP switch lead wir e 4 CK P se nsor l ead wi re 5 Gr ound lead w ire 6 S tarter mo tor lead wire 7 S peed s enso r lead w ire 8 ECT se nsor l ead wir e • D isco nnect the ig nition coil/p lug cap lead wire coup lers.  • D isco nnect the CM P s enso r lead w ire co upler 9 and re gula- to[...]

ENGIN E 3 -7 ENGIN E SPROC KET AND GEA RSHIFT L EVER • Di seng age the gearshi ft lever 1 . • Rem ove t he e ngine sproc ket co ver 2 . • Rem ove t he cl utch push rod 3 . • Rem ove t he sp eed sensor roto r 4 . • Rem ove t he e ngine sproc ket n ut 5 and the w ashe r 6 . • Rem ove t he co tter pi n. (F or E- 03, 28, 33) • Loos en th [...]

3-8 EN GINE • R em ove th e engine spr ocket 0 . ENG INE MOUNT ING • Su ppo rt the engine using an engine jack. • R em ove th e engine mo unting bolt A . • L oosen the engine m oun ting p inch bo lt 1 . • R em ove th e engine mo unting bolt B .[...]

ENGIN E 3 -9 • Rem ove t he e ngine mounti ng nu t 2 . • Rem ove the engine moun ting thrus t adju ster lock -nut 3 wi th the s pec ial tool. • Loos en th e en gine m ou nting thrust ad juster 4 fully.  09940- 149 80: En gin e mo untin g thrust adju ster socket wren ch • Rem ove t he e ngine mounti ng nu t 5 . • Loos en the eng ine m o[...]

3-10 EN GINE ENGI NE INST ALLATION Inst all the e ngine in th e rev erse or der o f engi ne rem oval. Pa y atte ntion to the fo llowi ng poi nts: NOT E : Be car eful no t to damag e the fram e and e ngine whe n ins tallin g the en gine. • Be fore i nstalli ng the eng ine, i nsta ll the eng ine mo unting thrust adjusters 1 and 2 . • G rad ually [...]

ENG INE 3- 11 a Left b Ri ght  LENGTH IT EM N· m kgf-m lb-ft ITEM mm in AB 55 5.5 4 0.0 Bolt A 45 1. 77 1 23 2.3 1 6.5 B 55 2. 17 34 23 2.3 1 6.5 C 215 8 .46 56 45 4.5 3 2.5 D 205 8 .07 78 75 7.5 5 4.0 Sp acer 2 30 .5 1 .20 Adjuster 34 40 1. 57[...]

3-12 EN GINE • In stall the eng ine s prock et and the wa sher. • Ap ply a sma ll q uantit y of THR EAD LOC K to the d rives haft thre ad p ortion.  99000 -3 2050: THR EAD LOCK “13 42” • T ight en the e ngine spr ocket n ut to the s pecified torque .  Eng ine sp roc ket nut: 11 5 N ·m (11.5 kg f-m, 83 .0 lb- ft) • Inst al l t he [...]

ENG INE 3- 13 • Tight en the m uffle r mounting bolts, ex haus t pipe bo lts and m uffle r connec ting bolt to th e spe cifie d torqu e.  Muff ler mounti ng bolt: 23 N·m ( 2.3 kg f-m, 16.5 lb-f t) Muf fler co nne cting b olt: 2 3 N·m (2.3 kgf- m, 16 .5 lb- ft) Ex haus t pipe b olt : 23 N ·m ( 2.3 kg f-m, 16 .5 lb -ft) • Inst al l th e HO [...]

3-14 EN GINE ENGINE DISASSEMBLY  • R em ove th e spa rk plu gs. (  2-5 ) STAR TER M OTOR • R em ove th e sta rter moto r 1 . CY LIND ER HE AD CO V ER • R em ove th e cylin der he ad co ver 1 and i t s gaskets. • R em ove th e PA IR ree d valv es 2 with th eir g askets . CAMS HAFT • R em ove th e valve timi ng insp ection c ap 1 . Id[...]

ENG INE 3- 15 • Tur n the cra nkshaf t to bring the line A on th e CK P s ensor roto r to the rib B be hind the clutc h co ver an d also to bring th e ca ms to the pos ition as show n. • Rem ove t he cam cha in tens ion adj ust er cap bo lt 2 an d spring. • Rem ove t he ca m cha in ten sion ad jus ter 3 . • Rem ove t he ca m cha in gu ide N[...]

3-16 EN GINE CY LIND ER HE AD • R em ove th e ther mosta t cover 1 . • R em ove th e ther mosta t 2 and th ermos tat c onec tor 3 . THE RMOST A T INSPEC TION (  7-9) • R em ove th e ECT senso r 4 . ECT SENSOR INSPECTION (  7- 7) • R em ove th e cylin der he ad bol ts (M6) 5 . • R em ove th e O-ring s 6 . • R em ove th e cylin der [...]

ENG INE 3- 17 • Hol d the c lutch hous ing w ith th e spe cial tool .   09920- 537 40: C lutch sle eve hu b hold er • Rem ove t he cl utch sprin gs. NOT E : Lo osen the c lutch spr ing se t bo lts little b y l ittle and diag ona lly. • Rem ove t he p ressu re plate 3 . • Rem ove t he cl utch drive plates 4 and dr iven plates 5 . • R[...]

3-18 EN GINE • H old t he clutc h s leeve h ub wi th the s pec ial tool.  09920- 537 40: C lutch sle eve hu b hold er • R em ove th e clutch sle eve h ub nut. • Rem ove th e wa shers C , D a nd E from the clutc h slee ve hub. • R em ove the wave s pring washe rs F and c lutch lifter driven cam G . • R em ove th e clutch lifte r drive c[...]

ENG INE 3- 19 OIL PU MP DRIVE SPRO CKET • Rem ove t he sp acer 1 . • Rem ove t he o il pump drive sproc ket 2 and cha in 3 . • Rem ove t he t hrust w asher 4 . GE ARSH IFT S YST E M • W ith the sna p ring 1 and was her remo ved, r emove the ge ar- shift sha ft assembly 2 . • Rem ove the gears hift cam plate bolt 3 and ge ars hift ca m pl [...]

3-20 EN GINE • R em ove th e sha ft 4 , bear ing 5 and t hrus t was her 6 . • R em ove th e gene rator cover . • R em ove th e dowe l pi ns an d gas ket. • R em ove th e sta rter idle gea r No. 2 7 and s haft 8 . CAM C HAIN /CAM CH AIN TE NSI ONE R/CA M CHAI N GU IDE • W hile holding the gener ator roto r wi th the s pecial tool, r emo ve[...]

ENG INE 3- 21 GE NERA TOR RO TOR A ND STA RTER DRI VEN G EAR • Hol d the g ene rator rotor w ith the speci al to ol.  09930- 445 20: Rot or hol der • Rem ove t he g enera tor ro tor bo lt. • Install a bolt A of suitable s ize t o the left e nd of c ranks haft. SU IT AB LE B OL T A [ M12, le ngt h: 2 8 – 38 m m ( 1.1 – 1 .5 in )] • Re[...]

3-22 EN GINE GEAR POSITION SWITCH • R em ove th e gear position swi tch 1 . CRANK CASE BR EATHER (PCV) COVER • R em ove th e crank case breath er c over 1 . • R em ove th e gas ket 2 . OIL PRESSU RE SWI TCH • R em ove th e oil pres sure s wi tch 1 . OIL FI LTER • R em ove th e oil fil ter w ith the special tool .  09915- 406 10: Oil fi[...]

ENG INE 3- 23 OIL COOLER • Rem ove t he o il coo ler 1 . OIL PAN • Rem ove t he p late 1 a nd oil p an. • Rem ove t he g asket. OIL PRESS URE R EGULATOR • Rem ove t he o il press ure regulato r 1 . OIL STR AINER • Rem ove t he o il straine r 2 . OIL PUM P • Rem ove t he o il pump 1 . • Rem ove t he d owel pins a nd O- ring 2 . LOW ER [...]

3-24 EN GINE • R em ove th e uppe r crank case bolts. • R em ove th e lower cra nkcase b olts (M8). • R em ove th e crank sha ft journa l bolts (M9 ). • R em ove the l ower crank case a ssemb ly. • R em ove th e dowe l pi ns, O- ring 2 and cap 3 . COU NTERS HAFT • R em ove th e dowe l pi n. • R em ove the r eta iner 1 , bu shing 2 , g[...]

ENG INE 3- 25 CRAN KSHA FT • Loos en the c onrod b earing cap bo lts by us ing a 10 mm , 12 -point sock et wr en ch, a nd tap the bear ing ca p b olts l ightly wi th a pl astic ha mme r to r emove th e be aring c ap. • Rem ove t he cr anksh aft a nd thr ust be arings 1 . PI S T ON AND CON ROD • P ush the con rod to cyli nder he ad side and re[...]

3-26 EN GINE EN GIN E C OMP ON ENT S I NSP ECT ION AND SERVICE  CYLINDER HEAD COVER • C lean a nd check the gask et grooves A and P AIR re ed valv e ga sket m ating sur faces B of cylind er hea d cov er. • If it is damage d, repl ace the c ylinder hea d cove r with a new one. CMP SENSOR REM OVAL • R em ove th e CMP sens or 1 from the cylin[...]

ENG INE 3- 27 INSPECT ION • Ins pect the reed valv e for the carbon dep osit. • If the car bon depos it is fo und in th e reed valv e, rep lace th e P AIR reed va lve with a new one. CRANKCASE BREAT HER REED VALVE REM OVAL • Rem ove the c rankc ase breath er reed v alve 1 from the cran k- ca se breat her cover . INSPECT ION • Ins pect the r[...]

3-28 EN GINE CAMSHAFT CAMSH AFT I DENTI FICATION The exha ust cam s haft can be disti nguishe d from th at of th e inta ke by the embo ss ed letters “EX ” (for exhau st) as aga inst let- te rs “IN” ( for i ntake ). CAM W EAR • C heck t he ca msha ft for w ear or dama ge. • M easu re the cam height H with a microme ter.  Cam he ight H[...]

ENG INE 3- 29 NOT E : Do n ot r otate th e cam shaft with the plasti gauge in pl ace. • Rem ove the cams haft hol ders, an d read the width of the com- pre ssed pl ast igaug e with en vel ope s cale. • This m easurem ent shou ld be taken at the w idest p art. • If the cam shaft jour nal o il clea rance m eas ured excee ds th e limi t, meas ur[...]

3-30 EN GINE CAM CHAI N TENSION ADJUSTER INSPECT ION • R em ove th e cam cha in ten sion ad juster cap b olt an d spri ng. • C he ck that the pus h ro d slid es smo oth ly whe n rel easing stop- per 1 . • If it does n ot sl ide sm oothly, r epla ce the cam ch ain ten sion adj uster w ith a n ew one. CAM CHAI N TENSIONER INSPECT ION • C he c[...]

ENG INE 3- 31 • Ins tall th e spe cia l tool 3 bet ween the v alve spri ng and cylin- der hea d. • Using the special tool s, c ompress the valve spri ng and rem ove t he t wo cotter ha lves fro m t he va l ve stem.  09916- 145 10: V alv e lif ter 09916- 145 30: V alv e lifte r atta chme nt 09916- 845 11: T we eze rs 09919- 286 10: Sle eve pr[...]

3-32 EN GINE VAL VE STEM RU NOUT • Su pport the valve u sing V- bl ocks and check its runout u sing the d ial g auge a s sh own. • If the runou t excee ds the ser vice limit, re place th e valv e.  V alv e stem run out: Ser vice L imit : 0.05 mm  09900- 206 07: D ial gaug e (1/10 0 mm ) 09900- 207 01: Magn etic s tand 09900- 213 04: V -bl[...]

ENG INE 3- 33 VAL VE STEM DE FLECTION • Lif t the v alve ab out 10 mm from th e val ve se at. • M easu re th e va lve s tem d eflec tion i n tw o d irection s, p erpen- dicu lar t o eac h other , by p ositio ning the dial gauge as s hown. • If th e d eflecti on m easur ed excee ds t he lim it, the n determ ine whe ther the v alve or th e guid[...]

3-34 EN GINE • C oo l down the n ew valve guide s in a fre ezer for about on e hour and he at the cylin der head to 100 °C – 150 ° C (212 °F – 302 ° F) w ith a hot pl ate.  • Ap ply engi ne oil to the v alve gu ide h ole. • D rive t he va lve guide into t he h ole usi ng the valv e guid e instal ler 1 and at tachm ent 2 .  09916[...]

ENG INE 3- 35 • If the s eat wid th W m eas ured exce eds the standa rd value or se at wid th is no t un iform, r eface the se at using the seat cutter.  V alv e se at wid th W : Stan dard: 0 .9 – 1.1 mm (0.035 – 0 .043 in ) I f th e v alv e se at i s out of s pec ifi cat io n, r e-c ut t he se at. VAL VE SEAT SER VICING • The valv e s e[...]

3-36 EN GINE VAL VE SPRING The forc e of the coi l spr ing kee ps th e valv e se at tig ht. W eak- ened s pring r esult in reduced engine pow er outpu t, and ofte n accou nt for t he c hatterin g n oise comi ng fr om th e va lve mec ha- nism. • C heck the v alve spring for proper stre ngth by mea suring its free lengt h and a lso by the force r e[...]

ENG INE 3- 37 • P ut on th e va lve sprin g reta iner 2 , an d u sing th e spe cia l tool 3 , pres s do wn the s pring, fi t the co tter halv es 4 to th e st em end, an d releas e the lifter to al low the c otter hal ves to wedg e in betw een retain er and stem.  09916- 145 10: V alv e lif ter 09916- 145 30: V alv e lifte r atta chme nt 09916-[...]

3-38 EN GINE • Ap ply SUZUKI SUPE R GREASE “A” to the O-rings.  99000 -2 5010: SUZU KI SUP ER G REA SE “A ” (o r equivalen t grea se) • In stall the in take pipes. • Ap ply THR EAD LOC K to the bolts .  99000 -3 2050: THR EAD LOCK “13 42” CLUTCH CLUT CH DRIVE PL ATE INSPE CTION NOT E : * W ipe o ff en gine o il from the c lu[...]

ENG INE 3- 39 CLUT CH SPRING INSPECT ION • Mea sur e th e fr ee l eng th of each coi l sp rin g wit h a v er n ie r ca li - pe rs, and com pare th e len gth with t he sp ecified l imit. • Rep lac e all the spr ings i f any sprin g is not within the limit.  Clu tch sprin g fr ee len gth: Ser vic e Limit : 53.2 mm (2.094 in)  09900- 201 02:[...]

3-40 EN GINE CL UTC H LIFT ER PIN ADJU S T M ENT NOT E : Wh en adjusti ng the clutch lifte r, it i s not nece ssary to instal l the clutc h onto the coun tersh aft. • As se mble the follow ing par ts into the prim ary drive n g ear as semb ly. (  3- 85 t o -88 ) * Cl utch sl eev e hub * Sp ring wa sher sea t, Sp ring wash er * Cl utch d rive p[...]

ENG INE 3- 41 WAVE SPRING W ASHER IN SPECTION • M easu re th e free hei ght H of e ach wa ve spr ing was her w ith a vernier ca lipers. • If eac h wa ve sprin g washer he ight H is not withi n the s pec i- fie d limi t, replac e it with a new one .  09900- 201 02: V ern ier ca lipers  W a ve sp rin g wa sher hei ght H Ser vice L imit : 4.[...]

3-42 EN GINE DISASSEM BLY • W ith hol ding th e rotor with the s pecial tool remo ve the star ter clutc h bol ts.  09930- 445 20: R otor hold er • R em ove th e one w ay cl utch 1 and guide 2 from t he rot or. REA S SE MBLY • W hen fitting th e o ne wa y cl utch 1 to th e g uide 2 , po si ti on flan ge side A of one wa y clu tch to the ro [...]

ENG INE 3- 43 GENERATOR INSPECT ION (  9-10) REA S SE MBLY • W hen insta lling the g enerat or stator set bol ts, tight en the m to the s pec ified to rque.  Ge ne ra to r s tat o r se t b o lt: 1 1 N ·m (1 .1 k gf - m, 8.0 lb -f t) NOT E : Be sure to ins tall the gromm et 1 to the ge nerato r cove r. WATER PUMP  7-11 GEARSHIF T SYSTEM [...]

3-44 EN GINE • In stall th e follow ing parts to the gea rshift s haft/ge ar shift ar m as shown in the illust ration. 1 Washer 5 Plat e ret urn sp ring 2 Sn ap ri ng 6 Washer 3 Gea rshift sh aft return spr ing 7 Screw 4 Ge ars hi ft c am dr iv e pl at e OI L PR ES SU RE REG U LA TO R • In spect th e ope ratio n of the oi l pressu re reg ulator[...]

ENG INE 3- 45 TRANSMISSION DRIV ESHAFT RE MOVA L (  3-51) DISASSEM BLY Disa sse mble the c ounte rsha ft an d drive shaft. Pay atte ntion to the fo llow ing p oints: • Rem ove th e 6th drive g ear snap ring 1 f ro m i ts gr oove and sli de it tow ards the 3r d/4t h drive ge ar s 2 . • S lide t he 6t h 3 a nd 2nd 4 drive ge ars to ward th e 3[...]

3-46 EN GINE REA S SE MBLY Ass embl e the coun tershaft and drivesh aft in the reve rse or der of disas sem bly. Pay atten tion t o th e follow ing p oints: NOT E : * Rot ate the bear ings by ha nd to inspect for smooth ro tation . Rep lac e the be arin gs if the re i s anyth ing un usua l. * B efore ins talling th e ge ars, ap ply engi ne oil t o [...]

ENG INE 3- 47 TR ANSM ISSI ON PA RTS LO CAT IO N 1 Coun tersha ft 2 D riveshaft[...]

3-48 EN GINE CYLINDER CRANK CASE SERVICING (  3- 51) CY LIND ER DI STOR TIO N • C he ck the gask eted su rface of the c ylinder for distor tion wit h a s traighted ge and thi cknes s ga uge, taki ng a c learan ce re ad- ing at se veral places as in dicated . • If the large st rea ding a t any p ositio n of the str aigh tedge ex ceed s th e l[...]

ENG INE 3- 49 PISTON AND PISTON RING PISTON D IAMETER • Us ing a microm eter , meas ure th e pisto n outs ide d iamet er at 1 5 mm ( 0.6 in) A from the pi ston skirt e nd. • If the me asur ement is less than t he lim it, rep lace the pis ton.  Pi ston diam e ter: Ser vice Lim it: 66 .88 mm (2. 6331 in) at 15 mm (0.6 in ) from t he s kir t en[...]

3-50 EN GINE PISTON RIN G-TO-GROOVE CLE ARANCE • M easu re th e si de c learan ces o f t he 1s t and 2 nd pi ston rings us ing t he t hic knes s ga uge . • If an y of th e cl eara nces e xc eeds the l imit, repla ce both th e pi ston and pis ton ri ngs .  09900- 208 03: Thi ckness g aug e 09900- 202 05: Mi cr om eter ( 0 – 25 m m)  Pis [...]

ENG INE 3- 51 CRANKCASE DRIV E SHAF T AN D GEAR SH IFT CA M Remo v a l • Rem ove t he sc rew s. • Rem ove the gea rshift for k shaft 1 , ge arshi ft cam 2 and gear shift fo rks 3 . • Rem ove t he sp acer 4 . • Rem ove t he d rivesha ft left bea ring dus t se al 5 . • Rem ove t he d rivesha ft left bea ring c ase b olts. • By us in g sui[...]

3-52 EN GINE • R em ove th e driv eshaft as sem bly 8 . GEARSHI FT FORK- TO-GROOVE CLEARANC E • U sing a thic kness ga uge , check the g ears hift fo rk clear ance in the g roo ve of its gea r. • T he clea ranc e for ea ch gea rshift fork plays a n impo rtant r ole in t he sm oothne ss a nd pos itivenes s o f the s hifting action.  Sh if t[...]

ENG INE 3- 53 BEA RING AN D DUST SEA L Insp ectio n • Ins pect the ge ar shift cam b earing 1 for abno rmal noise an d sm ooth r otat ion. • Rep lac e the be arin gs if the re is anyth ing un usua l. • Ins pect the ge arsh ift cam b earing 2 , ge arshift sha ft bear ings 3 (LH) an d 4 (RH) fo r abno rmal no ise and s m ooth r otatio n whi le [...]

3-54 EN GINE • In spect the dri veshaf t left bearin g d ust se al fo r we ar an d d am- age. • R ep lace the dust seal i f there is anyth ing u nusua l. Rem oval • R em ove th e gear shift ca m be arin g with the spec ial to ols .  09923- 745 11: B earing rem over 09930- 301 04: Sli ding sh aft  • R em ove th e oil sea l. (L H o nly)[...]

ENG INE 3- 55 • Rem ove the drives haft l eft bear ing dust s eal from th e retai ner us ing th e spe cial tool .  09913- 501 21: Oil sea l remover Inst allati on • Ins tall the bea rings with the sp ecial too l.  09913- 702 10: B earing in stall er set ( 1  32) ( 2 , 3  20) NOT E : The stam ped mark s ide of the gea rshift shaft be[...]

3-56 EN GINE • Ins tall th e d rivesha ft left bea ring du st se al w ith t he spec ial tool .  09913- 702 10: B earing in stalle r se t (  62) • Pu t th e driv eshaf t assem bly 1 into t he lower cr ankcase. • In stall the dr ivesh aft right bea ring as sem bly 2 . • A ppl y THR EAD L OCK to th e b olts a nd tighte n t hem to th e s [...]

ENG INE 3- 57 • A pply T HREA D LOC K to the b olts and tighte n them to th e sp ecifie d torq ue.  9900 0-3 2050: THR EAD L OC K “13 42”   Dr ivesha ft left bearing ca se bolt : 12 N·m (1.2 kgf-m , 8.7 lb -ft) • Apply SUZ UKI SUPER G REASE “A” to the dust seal lip and O-ri ng. • A pply T HREA D LOC K to the b olts and tight[...]

3-58 EN GINE • R em ove the oil jet 2 (for tr ansm ission) from th e lo wer cr ank- case. • R em ove th e oil jet 3 ( for cam chai n tens ion a djuster) from th e cyl inder he ad. Ins pection a nd cleani ng • C he ck the o il jets for c logging . • If they are clogg ed, cle an their oi l passage wi th a prope r wire and compre ssed air . 1 [...]

ENG INE 3- 59 • Ins tall the oil je t (for tr ansmis sion) . • A pply en gine o il to the O- ring. • Ins tall the oil je t (for c am ch ain te nsion adjuste r). PLU G Rem oval • Remo ve th e oi l ga ll er y pl ugs 1 and 2 . • Remo ve th e oi l ga ll er y pl ugs 3 and 4 . • Rem ove t he w ater ja cke t plug s 5 and 6 .[...]

3-60 EN GINE Inst allati on • Ap ply THR EAD LOCK to the oil gallery plug 2 .  99000 -3 2050: THR EAD LOCK “13 42” NOT E : * I t is not r equi red to apply T HRE AD LO CK w hen instal ling th e othe r remov ed oil gallery plugs. * A fter tight ening the p lug 2 , mak e sure tha t the plug e nd is flu sh w ith the cover mati ng su rface. ?[...]

ENG INE 3- 61 CRANKSHAFT AND CONRO D CRAN KSHA FT RU NOUT • S upport the cranksha ft with V -bloc ks as show n, with the tw o end journals r e sti n g on the blo cks. • S et up th e dial gaug e, as s how n. • Rota te t he crank sh aft slow ly to r ead the ru nout. • Rep lac e the c ranks haft i f the ru nout i s great er than the limit . ?[...]

3-62 EN GINE CO NRO D-B IG EN D B EA RING INS PE CTION • Ins pect the bea ring surfac es f or any sign of fusi on, pi tting , bur n, or fl aws . If any , r epl ace t hem wi th a sp e ci fi ed se t of bear ings. CON ROD-BI G END BEARIN G SEL E C TION • Pl ace the pla stigaug e axial ly along th e cra nk pin, a voi ding th e oi l hol e, as s how [...]

ENG INE 3- 63 • Che ck the co rrespo nding conrod I.D . cod e numb er (“ 1” or “ 2”) A . • Che ck th e corre spond ing cra nk pin O .D. code num ber (“1” , “2” o r “3”) B .  Bear ing s ele ction t able  Conr od I. D. Cr ank pin O.D . B Co de 123 Conr od I.D A 1 Gr een Bl ack Br own 2B l a c k B r o w n Y e l l o w Cod [...]

3-64 EN GINE  Cr ank pin O . D.  09900- 202 02: Mi cr om eter ( 25 – 50 mm )  Beari ng t hickness  Co de O.D. speci ficati on 1 30.992 – 31 .000 mm (1.220 2 – 1.2205 in ) 2 30.984 – 30 .992 mm (1.219 8 – 1.2202 in ) 3 30.976 – 30 .984 mm (1.219 5 – 1.2198 in ) Colo r C (P art No.) Th ick ness Yellow (12 164 -29G00- 0D0) 1.[...]

ENG INE 3- 65 CRANKSHAFT J OURNAL BEARING INSPECT ION • Ins pect ea ch bea ring of uppe r an d lower cra nkcas es for any dama ge. SELEC TION • P lace th e p lastigaug e a xially al ong t he cranksh aft journal , av oiding t he o il hole, a s s hown.  09900- 223 01: Pla stig auge  • Mat e t he l ow er crank cas e wi th t he u ppe r cr a[...]

3-66 EN GINE • C heck the corr espondi ng crank case j ournal I.D . code num ber A , “A”, “B ” or “C” whi ch is stam ped on the rea r of upper crankca se. • C heck th e cor respon ding c ranks haft j ourna l O.D. c ode n um- ber B , “A” , “B” or “C ” wh ich is sta mp ed o n the c ranks haft.  Beari ng se lec tion tabl[...]

ENG INE 3- 67  Cr anks haft jo urna l O .D. sp ec ificatio n  09900- 202 02: M icrometer ( 25 – 50 m m)  Bear ing t hickne ss s pecifica tion NOT E : Uppe r a nd lower cr anksha ft jou rnal bearings are the s ame. INSTA LLATION • W hen fi tting the c ranks haft j ourna l bea rings to the up per an d m iddle crankca ses , be s ure to fi[...]

3-68 EN GINE CRANKSH AFT THRUST BEARING • W ith the cran kshaft, righ t-side t hrust be aring and left-sid e thru st be arin g inse rted in the uppe r crank case, mea sure th e thru st clea rance on th e left sid e by us ing the th icknes s gauge . L : Left- side th rust bea ring R : Rig ht-sid e thru st bea ring NOT E : Pu ll the crank sha ft to[...]

ENG INE 3- 69  Thru s t beari ng selec tion table • A fter sel ecting a lef t-side thrust b eari ng, in sert i t and ag ain per form the thr ust cleara nce mea sureme nt to make s ure it fal ls withi n the s tanda rd ra nge. A Co lor co de NOT E : Rig ht-sid e thru st bea ring has th e sam e spe cificat ion as th e GR EEN (1222 8-17E0 0- 0D0) [...]

3-70 EN GINE ENGINE RE ASSEMBLY • R easse mble the e ngine in th e rever se orde r o f disass embl y. • T he fol lowing steps r equire s pec ial atten tion or precau tiona ry m easu res sh ould be ta ken. NOT E : Ap ply eng ine oil to eac h run ning a nd sliding part be fore r eas- sembli ng. • Be sur e to install the fol lowin g item s to t [...]

ENG INE 3- 71 •1 s t r i n g 4 and 2nd ring 3 hav e let ters “ IT” a nd “T” marke d o n one si de. Be su re to brin g the mark ed si de up ward when fit - tin g them t o th e piston . • P osition th e ga ps of the thr ee ring as s hown. Befo re in serting eac h piston in to the cylind er, check that the gaps are so loca ted. C 2nd ring [...]

3-72 EN GINE • In stall the pi stons a nd conrods into the c ylinder s fro m ups ide. NOT E : Wh en instal ling the pist ons, the inden t C of e ach pist on hea d mus t be br oug ht to the exha ust s ide.  • C he ck that I.D. c ode D on e ach c onr od fa ces inta ke s ide.  • A pply a M OLYB DENU M OIL SO LUT ION to e ach c ran k pin be[...]

ENG INE 3- 73 • S et the c ranks haft to the conrods and upp er cran kcas e. • A pply en gine o il to the cra nk pin and bearing sur face.  • W hen fit ting th e conrod cap, m ake s ure th at I.D. c ode A on each conrod f aces intake si de. • A pply en gine o il to the be aring c ap bol ts. • Tight en th e conrod b ear ing cap b olt by[...]

3-74 EN GINE • In ser t the righ t an d left thrust b eari ngs w ith oil g roov e B fac- in g th e cran k w eb. NOT E : Rig ht thru st be aring has green painting . COU NTERS HAFT • In stall the C -ring 1 and be ar i n g pin 2 to the u pper cr ank- case. • In stall the c ounter shaft assemb ly t o the up per c rankc ase. NOT E : Align the C- [...]

ENG INE 3- 75 CRAN KCAS E • Cl ean the ma ting sur face s of th e crank case s. • Ins tall the dow el pin s. • Ins tall the dow el pin s, O-ri ng 1 and c ap 2 .  • A pply SUZ UKI B OND t o the ma ting sur face of th e lower crankcas e .  9900 0-3 1110: SU ZUKI BON D “121 5” (or e quiv alent bond ) NOT E : Use of SUZU KI BOND is as[...]

3-76 EN GINE • T ight en the cran ksh aft journa l bolts (M9 ) in asc endin g order of num ber s assig ned to the se bol ts. Ti ghten ea ch bol t a little at a t ime to equ alize the pr essur e in t he fo llowing two step s.  Cr anksh aft journ al bolt: (M9 ) Initia l : 1 8 N·m (1.8 k gf-m , 13. 0 lb-ft ) Fin al : 5 0 °  • T ight en the[...]

ENG INE 3- 77 • Ins tall the clu tch pus h rod oil se al retai ner 1 . • A pply T HREA D LOC K to the bolts.  9900 0-3 2110: THR EAD L OC K SU PER “13 22” (or e quivalent t hread lo ck) OIL PUM P • Ins tall the O-ri ng. • Apply SUZUKI SUPER GR EASE “A” to the O -ring.  99000-2501 0: SUZUKI SU PER GREASE “A” (o r equivalen [...]

3-78 EN GINE OIL PAN • In stall new ga ske t. • Inst al l t he p lat e 1 and oil pan . NOT E : * F it the c lam p to the bolt A . * F it n ew gas ket wash er to t he b olt B .  • T ight en the o il pan b olts diag onally to the speci fied torq ue.  Oil p an b olt: 1 0 N·m (1.0 k gf- m, 7.0 lb-f t) OIL PRESSU RE SWI TCH • Ap ply S UZU[...]

ENG INE 3- 79 OIL FI LTER • Ins tall the oil fi lter wi th the s pec ial tool. (  2-13)  09915- 406 10: Oil filter wrench  Oil filter: 20 N· m (2 .0 k gf-m, 14.5 lb -ft) CRANK CASE BR EATHER COVER • Ins tall a n ew gasket 1 . • Insta ll the crankca se breath er cover 2 .  Crankca se breather cov e r bolt: 10 N·m (1.0 kgf-m, 7.0 [...]

3-80 EN GINE WATER PUMP • Ap ply SUZUKI SUPE R GREASE “A” to the O-ring.   99000 -2 5010: SUZU KI SUP ER G REA SE “A ” (o r equivalen t grea se) • In stall the wa ter pump. NOT E : Se t the wa ter pump shaft end A to th e o il pump shaft B as shown. • T ight en the wat er pum p mou nting bolts to th e sp ecifie d torq ue.  W [...]

ENG INE 3- 81 GE NERA TOR RO TOR A ND STA RTER DRI VEN G EAR • Deg reas e the taper ed porti on A o f g enerat or ro tor a nd al so the c ranks haft B . Use no nflam mab le clea ning solv ent to wip e off oi ly or greas y matter and make thes e surfac es com pletely dr y. • Ins tall the gen erator r oto r onto the cran ksh aft. • Ins tall the[...]

3-82 EN GINE • W hile h olding th e gener ator ro tor with the spec ial tool, ti ghten the C KP s ens or ro tor/cam chain d rive s prock et bol t.  09930- 445 20: R otor hold er  CKP se nsor r otor/ cam cha in driv e spr oc ket bol t: 54 N· m (5.4 kg f-m, 39.0 lb-ft) STAR TER I DLE GEA R • In stall the s tarter idle ge ar No . 2 1 and s [...]

ENG INE 3- 83 • Ins tall the start er idle gear N o. 1 s haft 5 , thru st washer 6 , bear ing 7 , star ter idle ge ar No. 1 8 , washer 9 , a nd sprin g was her 0 . • Apply SUZUKI SUPER GR EASE “A” to the O -ring.  9900 0- 2501 0: SUZUKI SU PER GREA SE “A” (o r equivalen t gre ase) • Ins tall th e sta rter idle g ear c ov er an d ti[...]

3-84 EN GINE • In stall the gea rshift cam sto ppe r plate 5 . NOT E : Align the gea rsh ift cam pi n B wi th the ge arsh ift cam stop per plat e hole C . • Ap ply a sma ll quanti ty of THRE AD L OCK t o the gearshi ft ca m sto pper p late b olt an d tigh ten it to the s pec ified to rque.  99000 -3 2050: THR EAD LOCK “13 42”  Gea rsh[...]

ENG INE 3- 85 • Ins tall the oil pum p d rive spr ocket 1 to th e cou ntersha ft. NOT E : Teeth A on the spro cket must f a ce the clu tch sid e. • P ass the c hain bet we en th e oil pum p drive and driv en s prock- et s. CL UTC H • Ins tall the prim ary dr iven ge ar as sem bly 1 . NOT E : * Befo re as semb ling the clutc h, adj ust t he cl[...]

3-86 EN GINE • In stall the c lutch s leeve hub as sem bly onto the coun tershaft . • In stal l the wash er 9 and spri n g wash er 0 . NOT E : * Befor e ins tallin g the w ash er 9 , visually ins pect the was her su rfac e for wea r and dam ag e. If nece ssary, r eplace it with a new on e. * The conical cu rve side of spring was her 0 faces o u[...]

ENG INE 3- 87 • Inst al l th e cl utch pus h r od C into th e cou nters haft. • Ins tall th e clutc h pu sh p iece D , b earing E and th rus t was her F to the coun ter shaft . NOT E : Thru st w a s h er F is l oca ted be twe en the pr essur e pl ate an d bear ing E . • Ins ert th e clutc h dr ive pl ates and dr iven plates one by o ne in to [...]

3-88 EN GINE *1: Di recti on of ou tsid e *2: Pa int DRIVE PLA TE: a No. 2 Dr ive plate ... .... 1 pc. [ Black paint /I.D. 11 1 m m (4.4 in)] b No. 1 Dr ive plate ... .... 6 pcs. [ Pur ple pa int/I.D. 1 11 m m (4. 4 in) ] c No. 3 Dr ive plate ... .... 1 pc. [ NIL/I.D . 11 8 mm (4.6 in)] NOT E : No.3 dr ive plate can b e d isting uished by th e insi[...]

ENG INE 3- 89 CL UTC H COV ER • A pply SU ZUKI BON D lightly to the ma ting surfac es a t the par ting lin e betwe en th e upper and l ower crank cases as shown.  9910 4-3 1140: SU ZUKI BON D “ 1207B” (U SA) 9900 0-3 1140: SU ZUKI BON D “ 1207B” (Ot hers) • Ins tall new g asket 1 and d owe l pin.  • A pply SU ZUK I BO ND l ightl[...]

3-90 EN GINE • Place the cyl ind er h ead on the cyl inder. NOT E : Wh en inst alling the c ylind er hea d, kee p the c am chain taut . • T ight en the c ylinder head bolts (M1 0) in the foll owin g four -ste p. St ep 1: • T ight en the c ylinder h ead b olts to the s pecified to rqu e with a torq ue wr ench seque ntiall y and diag onally. St[...]

ENG INE 3- 91 • A pply en gine co olant to th e O-ring . • Ins tall the the rmostat conec tor 3 .   Th ermo stat co ne ct or bol t: 10 N·m (1. 0 kg f-m , 7. 0 lb- ft ) • Ins tall the the rmostat 4 . NOT E : T he ji gg le va lv e A of thermost at face s upside. • Ins tall the the rmostat cov er 5 .  Th ermo stat co ve r bo lt : 10 [...]

3-92 EN GINE The cams hafts ar e ide ntified by th e em bossed lette rs. • Be fore r ep lacing th e cam shaf ts on cylind er head, a pply M OLYBD EN UM O IL SOL UTIO N to th eir jou rnal s and ca m faces. • App ly a M OLYB DENU M OIL SOLU TI ON t o t he ca msha ft jo ur - nal holde rs.  MOL YBDENUM OIL S OLUTI ON NOT E : Be fore ins talling [...]

ENG INE 3- 93 • Ins tall the dow el pin s. • Ins tall O -rings 3 to the cam shaft journal hold ers.  • Inst al l th e cam sha ft jo ur nal h ol der s. NOT E : * Each cams haft j ourn al ho lder i s ident ified w ith a n e mbos sed letter . “A”: N o.1 and No .2 cy linde rs “B”: N o.3 and No .4 cy linde rs * Che ck that emb ossed let[...]

3-94 EN GINE • T ight en the c amsh aft jou rnal holde r b olts in the asc endin g or der of num ber s to the spec i fie d to rque .  Ca m sh af t jo ur na l h ol de r bo lt : 10 N ·m (1. 0 kg f- m, 7. 0 lb -f t)  CAM C HAIN TENSI ON ADJU STER • R etrac t the p ush r od by pushi ng the s toppe r 1 . • F it a new ga sket 2 .  • In [...]

ENG INE 3- 95 • Ins tall th e gasket 5 and cam ch ain tension adj uster c ap bolt 6 . NOT E : Clic k sou nd is h eard w hen the c am chain tension adjus ter cap bol t is in stalled. • Tight en the cam chai n tension adjuster cap bolt to the spec i- fi ed t or que .  Cam chain ten sion adjuste r ca p bolt : 23 N·m (2.3 k gf-m, 16.5 lb-ft) ?[...]

3-96 EN GINE 10 N·m (1.0 kgf-m, 7.0 lb-ft) 23 N·m (2.3 kgf-m, 16.5 lb-ft)[...]

ENG INE 3- 97 • Tight en the valv e timing inspec tion cap 7 to th e sp ecified torq ue.  V alve timi ng insp e ction ca p: 1 1 N·m (1.1 k gf- m, 8.0 lb-f t) CY LIND ER HE AD C OV ER • P our en gine o il in eac h oi l pocket i n the cylinde r h ead. NOT E : Be sure to check t h e valve clearance. (  2- 7) • Ins tall the PAIR reed valv [...]

3-98 EN GINE • T ight en the h ead cover bolts t o th e spe cified tor que.  Head cover bol t: 14 N·m (1.4 kg f-m, 1 0.0 lb-ft) STAR TER M OTOR • Ap ply SUZUKI SUPE R GREASE “A” to the O-ring.  99000 -2 5010: SUZU KI SUP ER G REA SE “A ” (o r equivalen t grea se) • In stall the s tarter mo tor 1 .  Sta rter mot or mounti ng [...]

FI SYSTEM DIAGN OSIS 4-1 4 CONTENT S FI SYSTEM DIAGNOSIS PRECAUTIONS IN SERVICI NG ...... ....... ....... ........ ....... ....... ........ ....... ....... ... 4- 3 ELEC TRI CAL P ARTS .... ....... ....... ........ ....... ....... .... ....... ........ ....... .... ...... 4 - 3 FU SE.. ....... ....... ....... ........ ....... ....... ........ .....[...]

4-2 FI SYST EM DIAG NOSIS CONTENT S FI SYSTEM DIAGNOSIS “C31” (P0705) G P SWITCH CIRCUIT MALFUNCTION ... ....... ........ ...... 4-75 “C32 ” ( P020 1), “ C33” (P 0202 ), “ C34” (P 0203 ) or “ C35” (P0 204) PRIMARY FUEL INJECTOR CIRCUI T MALFUNCTION .. ....... ........ ... ... 4-77 “C36 ” ( P176 4), “ C37” (P 1765 ), “ [...]

FI SYSTEM DIAGN OSIS 4-3 PRECAUTIONS I N SERVICING When ha ndling th e componen t parts or servicing the F I system , obs erve the fol lowin g poi nts fo r the saf ety of the syste m. ELECTRICAL P A RTS CON NECTO R/COU PLE R • W hen c onnec ting a con necto r, be sure to push it i n unti l a click i s felt. • W ith a lock type cou pler, be sur [...]

4-4 FI SYST EM DIAG NOSIS • W hen conne cting me ter pro be from the te rminal side of th e cou pler (w here co nnecti on fro m ha rness side not b eing p ossi- ble ), use extra ca re not to force and caus e the mal e t erminal to be nd o r the f ema le termi nal to open. Con nect the probe as sh ow n to av oid openi ng of fem ale te r- mi nal . [...]

FI SYSTEM DIAGN OSIS 4-5 • W hen di sconne cting and conne cti ng the ECM , ma ke sure to turn OF F th e ig nition switc h 1 , or electr onic p arts m ay g et dama ged . • B attery c onnec tion in rev erse po larity is str ictly pr ohib ited. S uch a wr ong c onnec tion will d am age th e co mpo nents of th e FI system inst a ntly w h en re ve [...]

4-6 FI SYST EM DIAG NOSIS ELECTRICAL CIRCUIT INSPECTION PROCEDURE Wh ile ther e are var ious me thod s for ele ctrical c ircuit ins pection , des cribed here is a gen eral method to ch eck for op en and shor t circui t usin g an oh mme ter an d a voltmet er. OP EN CI RCUIT CHE CK Po ssible causes for the op en ci rcuit s are a s foll ows. As th e c[...]

FI SYSTEM DIAGN OSIS 4-7 Con tinui ty check • M easure res istance a cross couple r B (betw ee n A and C in t he f ig ure ). If no c onti nuity is indic ated (infini ty or ov er li mit), the c ircu it is open bet we en term inals A and C . 1 ECM • Di sconne ct the coup ler B and m easure r esistanc e bet wee n co uplers A and B . If no conti nu[...]

4-8 FI SYST EM DIAG NOSIS SHORT C IRCUIT CH ECK (WI RE HARNESS T O GRO UND) • D isco nnect the neg ativ e cabl e from the battery. • D isco nnect the con necto rs/co uplers at both en ds of th e circ uit to be chec ked . NOT E : If the ci rcuit to b e ch eck ed br anch es t o o ther parts as s hown , disc onnec t all con necto rs/c oupler s of [...]

FI SYSTEM DIAGN OSIS 4-9 USING T HE MULTI-CIRCUIT TESTER • Us e the S uz uki multi -circ uit test er set ( 099 00-250 08). • Us e wel l-cha rged b atteries in the tes ter. • B e sure to set t he t ester to the correc t testi ng ran ge. USING THE TES TER • Inc orre ctly con nectin g the + and - pr obe s may ca use th e insi de of t he t este[...]

4-1 0 FI SYSTEM DIAGN OSIS FI S Y STEM TECHNICAL F EATURES INJECTI ON TIME (INJECTION VO LUME) The factor s to deter mine the in jection ti me i nclude the bas ic fuel i njection time, wh ich i s calcu lated on the bas is of i ntake air pre ssure , engi ne sp eed and throt tle op ening ang le, an d vari ous com pe nsation s. Thes e com pens ations [...]

FI SYSTEM D IAG N OSIS 4-11 COMP ENSA TION OF INJECT ION T IME ( VOLUME ) The follow ing d iffer ent s ignals a re ou tput from the respec tive sensor s fo r comp ensat ion o f th e fuel injecti on t im e (vol um e) . INJECTI ON STOP CONTR OL SIGNAL D ESCRIPTION A TMOSPH ERIC PRESS URE SE NSOR SIGNAL When atmos pher ic pr essur e is l o w , the s e[...]

4-1 2 FI SYSTEM DIAGN OSIS FI SYST EM PARTS LOCATION A Thr ottle position s ens or (TPS ) B Seco nda ry thro ttle po sitio n sen sor (ST PS) C Se conda ry thro ttle val ve a ctuat or (STVA ) D Intake ai r pressure sensor (IAPS) E Exha ust c ontr ol valve actu ator ( EXC VA) F HO2 sen sor (For E -02, 19) G Cra nkshaft posi tion se nsor ( CKP S) H F [...]

FI SYSTEM D IAG N OSIS 4-13 J Cooling fan rela y K Cool ing fan L Intak e ai r tempe ratur e sen sor (IA TS) M PAI R contro l solen oid valve N Cam shaft posi tion se nsor (C MP S) O Ig nitio n coil ( IG C OIL) P Se cond ary fuel injecto r Q P ri m ar y fue l in je c to r R En gine coolant tem peratu re sens or ( ECTS) S Sp eed sensor T Atmospheric[...]

4-1 4 FI SYSTEM DIAGN OSIS FI SYSTEM WIRING DIAGRAM 10 A 10 A 30 A 15 A Speedometer Camshaft position sensor (CMPS) Crankshaft position sensor (CKPS) Throttle position sensor (TPS) Intake air pressure sensor (IAPS) Atmospheric pressure sensor (APS) Engine coolant temperature sensor (ECTS) Intake air temper ature sensor (IA TS) Tip-ov er sensor (T O[...]

FI SYSTEM D IAG N OSIS 4-15 ECM TERM INAL TER M INA L NO. C IRCUI T TERMINA L NO. CIR CUIT 1 STV A sig nal ( STV A. 2A) H STV A s igna l (STV A. 2B ) 2 STV A sig nal ( STV A. 1A) I STV A s igna l (STV A. 1B ) 3 EXC V A power (MO –) J STP s ens or sig nal (S TP) 4 EXCVA po wer (MO+) K Igni tion switch signal [For E- 03, 28, 3 3] 5 EXC V A positi o[...]

4-1 6 FI SYSTEM DIAGN OSIS TERMIN AL NO. C IRCUI T TERMINA L NO. CIR CUIT Y — l — Z — m — [ — n — T ac home ter o — ] Fuel pump r elay (FP Relay) p — ^ Immobili zer co mmunicat ion [F or E-02 , 19 , 24 ] q Im mobilizer c omm unication [For E-0 2, 19, 2 4] a HO2 sensor he ater (O XH ) [F or E-02 , 19 ] r Mode s e lect switch b Star[...]

FI SYSTEM D IAG N OSIS 4-17 SELF-DI AGNOSIS FUNCTION The self-d iagno sis f unction is in corpor ated i n the EC M. The fu nction has t wo mo des, “ Use r mod e” and “De aler mo de” . Th e us er can on ly be no tified b y th e L CD (DI SPLA Y) panel and LED (F I light) . To che ck the func tion of the i ndividu al FI syst em dev ices, th e [...]

4-1 8 FI SYSTEM DIAGN OSIS DEALER MODE The defe ctive fun ctio n is m emo rized in the com pute r. Use the special tool ’s co upler to conn ect to the deal er mode c ouple r. The memor ized mal func tion code is di splay ed on LCD (DI SPLAY ) panel . M alfunctio n mean s that th e EC M d oes n ot recei ve signa l fro m th e devices . Th ese af fe[...]

FI SYSTEM D IAG N OSIS 4-19 In the LC D (D ISPLA Y) p anel, the ma lfuncti on co de is ind ica ted fro m sm all co de to l arge co de. *1 To g et th e prop er sig nal from the throttl e pos ition sen sor , the s ensor ba sic p osi tion is i ndicate d in th e L CD (DIS PLAY) pan el. The mal func tion code is indicate d in thre e digits . In front of[...]

4-2 0 FI SYSTEM DIAGN OSIS TPS ADJUSTMENT 1. Ad just the en gine rpm to 1 30 0 r/min. (  2-14) 2. C onnec t the sp ecial tool (Mo de sel ect switc h) to the d ealer m ode c oupler a t th e wiring h arnes s. 3. If the t hrottl e pos ition sens or ad justme nt is necessa ry, r emov e the a ircle aner b ox an d lift up the thrott le bod y. (  5-[...]

FI SYSTEM D IAG N OSIS 4-21 FAIL- S AFE F UN CT ION FI system is provi ded with fail- safe funct ion to allow the engine to sta rt and the motorcycl e to run in a mini- m um per forma nce n ecess ary ev en und er mal functi on co ndition . ITEM FAI L-SAFE MO DE ST ARTING A BILITY RUNN ING A BILITY CM P senso r Wh en ca msha ft pos ition si gnal h a[...]

4-2 2 FI SYSTEM DIAGN OSIS The eng ine can star t and ca n r un ev en if the abo ve si gnal is n ot r eceived fr om each sens or. Bu t, th e engi ne runn ing conditi on i s not c ompl ete, p ro viding o nly emer ge ncy h elp (by fail-s afe c ircuit) . In this ca se, it is n ec- essar y to bring th e mo torcy cle to th e w orksh op for comp lete rep[...]

FI SYSTEM D IAG N OSIS 4-23 FI SY STEM TRO UBL ESH OO TING CUSTOMER COM PLAINT ANALYSIS Rec ord de tai ls of the prob lem ( f ail ur e, c omp la int ) and how i t oc cur re d as desc r ibed by th e cu st omer . For t hi s purp ose, use of su ch a n insp ecti on for m su ch a s below wi ll fac ilitate c ollecti ng i nform ation requir ed for prop er[...]

4-2 4 FI SYSTEM DIAGN OSIS NOT E : The ab ove for m is a stan dard sam ple. Th e form s hould b e mod ified ac cordi ng to cond itions and c haract eris- tics of e ach marke t. VISUAL IN SPECTION • Pr ior to di agnos is using th e mode s elect swi tch or SD S, per form th e following visua l inspe ctions . The rea- son for visual inspec tion is t[...]

FI SYSTEM D IAG N OSIS 4-25 SELF-DIAGNO STIC PROCEDURES NOT E : * Do not disc onnec t c oupl ers from the EC M, the batte ry cable from th e b attery, E CM ground w ire har ness fr om the eng ine or main f use b efore con firm ing th e malf unction code (self- diag- nostic trou ble code ) stor ed i n m emory. Su ch d iscon nection w ill erase th e [...]

4-2 6 FI SYSTEM DIAGN OSIS USE OF SDS DI AGNOSTIC PROCEDURES * D on’t disconne ct co uplers from EC M, the b atte ry cable from the bat ter y, ECM groun d wire ha rness from the engine or mai n fus e b efore confi rming the malfuncti on code (self-di agnos tic tro uble co de) stored in me mory . Suc h disc onnec tion will era se the m em orized i[...]

FI SYSTEM D IAG N OSIS 4-27 USE OF SDS DIAGNOSIS RESET PROCE- DURE • A fter repa iring the troub le, tu rn O FF the ign ition sw itch an d turn ON aga in. • Cl ick th e DT C insp ecti on butto n 1 . • Che ck the DTC. • The p revious malf unction histor y cod e (Past D TC) still rem ains stored in the ECM . There fore, er ase th e history co[...]

4-2 8 FI SYSTEM DIAGN OSIS SHOW DATA WHEN TROUBLE (DISPLAIN G DATA AT THE T IME OF DTC) EC M stor es th e e ngine a nd driving cond itions (in th e form o f d ata as show n in the figu re) at t he moment of the de tecti on of a ma lfuncti on in its mem ory . This data i s calle d “Sho w d ata wh en t rouble” . Ther efore , it is pos sible t o k[...]

FI SYSTEM D IAG N OSIS 4-29 MALFUNCT ION CODE A ND DEFECTIVE CONDIT ION DT C No. DETE CTED ITEM D ET EC TED F AIL UR E CO NDIT ION C HE CK FOR C00 NO F A U L T ––––––––––– ––––––––––– C11 CMP sen sor T he signal do es no t r each ECM for 3 sec. or more , afte r receivin g the star ter signa l. CM P sen so[...]

4-3 0 FI SYSTEM DIAGN OSIS DT C No. DET ECTED ITEM D ET EC TED F AIL URE CO NDIT ION C HE CK FO R C21 IA T s ensor T he sens or voltag e sho uld be the fol- lowing. 0.15 V senso r v o ltage < 4.85 V In oth er than the above range, C 21 (P011 0) i s indi cated. IA T s ensor , lead wire/c oupl er conn ection P0110 H Se nsor voltage is highe r than[...]

FI SYSTEM D IAG N OSIS 4-31 * : Imm obilizer system is equipped model o nly. DT C No. DETE CTED ITEM D ET EC TED F AIL UR E CO NDIT ION C HE CK FOR C29 STP sen sor The sensor sho uld pr oduc e f o llowing vol ta g e. 0.15 V sens or v o ltage < 4 .85 V In oth er than the ab o ve rang e , C29 (P16 54) i s indi cated . STP sen sor , le ad wi re/cou[...]

4-3 2 FI SYSTEM DIAGN OSIS DT C No. DET ECTED ITEM D ET EC TED F AIL URE CO NDIT ION C HE CK FO R C44 HO2 sensor (For E-02, 19) HO 2 sen sor out put v o ltage is not input to E CM du ri ng engi ne op eratio n and ru nning cond ition. (Sens or volta ge < 0. 55 V ) In oth er than the above value, C44 (P013 0) i s indi cated. HO2 senso r circu it o[...]

FI SYSTEM D IAG N OSIS 4-33 “C11” (P0340) CMP SENSOR CI RCUIT MALFUNCT ION INSPECT ION 1) T urn t he ign ition switch OF F. 2) L ift and supp ort the fue l tank. (  5-3) 3) R em ove th e a ir clean er box. (  5-14 ) 4) C he ck the C MP sensor cou pler for loose or poo r co ntacts. If O K, th en mea sure the CM P s ens or pea k vol tage. 5[...]

4-3 4 FI SYSTEM DIAGN OSIS 6) Unde r this co ndition , if a suitable sc rewd river touc hing th e pick -up sur face o f the CMP s ens or is move d, the tester re ad- ing voltage chan ges ( 0.8 V and les s ↔ 4.3 V an d mor e). . Is t he vo ltage OK?  7) Af ter repairi ng the trou ble, clea r the DTC us ing SD S tool. (  4- 27) YES • B/Y , [...]

FI SYSTEM D IAG N OSIS 4-35 “C12” (P0335) CKP SENSOR CIRCUI T MALFUNCTION INSPECT ION Step 1 1) T urn t he ign ition switch OF F. 2) L ift and supp ort the fue l tank. (  5-3) 3) C he ck the C KP se nsor coup ler for loose o r p oor con tacts . I f OK , t hen me asur e t he C KP se ns or re sist anc e. 4) Disco nne ct th e CK P s ens or cou [...]

4-3 6 FI SYSTEM DIAGN OSIS 5) If OK , the n check the conti nuit y betw een eac h ter minal an d grou nd.  CKP sen sor cont inuity: ∞ Ω (In finity) (B – Gr ound) (G – Gr ound)  09900- 250 08: Mult i-circuit t ester s et  T ester k nob in dicat ion : Res istance ( Ω ) Are th e res istanc e and cont inuity OK? 6) After repair ing t[...]

FI SYSTEM D IAG N OSIS 4-37 . Is the volt age OK?  3) A fter repa iring the tr ou ble, c lear th e D TC using SD S t ool. (  4- 27) YES • G/W or O/BI wire open o r sh or te d to gro und. • Loose o r poor conta cts on th e CK P sens or cou- pler o r EC M coupl er ( ter minal D or U ). • If wire and co nnec tion ar e OK, inter m itten t t[...]

4-3 8 FI SYSTEM DIAGN OSIS “C13” (P 0105-H/L) IAP SENSOR CI RCUIT MA LFUNCTION INSPECT ION Ste p 1 (Whe n indicat ing C13: ) 1) Tur n the i gnitio n switc h O FF. 2) Lift and s uppor t the fuel tank . (  5-3 ) 3) Chec k th e IAP senso r co upler for loo se or po or c ontac ts. If O K, th en mea sure the IAP se nsor inpu t voltag e. DE TECTE [...]

FI SYSTEM D IAG N OSIS 4-39 4) D isco nne ct the IAP se nsor couple r. 5) T urn t he ign ition switch ON. 6) M easu re the vo ltage at t he R wire a nd ground . 7) If OK , then mea sure the vol tage at the R wi re A and B/Br wir e B .  IAP sen sor in put voltag e: 4 .5 – 5.5 V ( + R – - Groun d) ( + R – - B/B r)  09900- 250 08: M ulti-c[...]

4-4 0 FI SYSTEM DIAGN OSIS 6) Disc onne ct the ECM cou pler. 7) Chec k th e con tinuity b etw een G /B w ire C and ter minal 9 . 8) If OK, then chec k the c onti nuity bet wee n B/Br wi re B and te r- mi nal S .  IAP S lead wire con tinuity: Cont inuit y (  )  09900- 250 08: Mult i-circuit t ester s et 09900- 250 09: N eedle point ed probe[...]

FI SYSTEM D IAG N OSIS 4-41 7) D isco nnec t the E CM cou pler . 8) C he ck the c onti nuity b etw een R wire A and termi nal A . 9) Al so, check the conti nui ty betw een G /B wi re C and termi nal 9 .  IAPS lead wire c o nt inuit y: Conti nuity (  )  09900- 250 08: M ulti-circui t tes ter set 09900- 250 09: N eedle point ed p ro b e set [...]

4-4 2 FI SYSTEM DIAGN OSIS Step 3 1) Tur n the i gnitio n switc h O FF. 2) Rem ove th e IA P sens or. 3) Conn ect the v acuu m pum p g aug e to t he vacuum p ort o f the IA P senso r. Arr ange 3 n ew 1.5 V batter ies in series 1 (chec k th at total volta ge is 4 .5 – 5.0 V) and co nnect - termina l to the gr ound term inal 2 and + ter mina l to t[...]

FI SYSTEM D IAG N OSIS 4-43 Ou tput voltag e (VCC volt age 4.5 – 5.0 V, ambien t t emp . 20 – 30 °C , 6 8 – 86 ° F) ALTITUDE (R eferen ce) ATMOSP HERIC PRESSU RE OUTPUT VOL TA GE (f t) (m ) (m m Hg ) k Pa (V ) 0 2 000 0 610 760 707 100 94 3.1 – 3.6 2 001 5 000 611 1 524 707 634 94 85 2.8 – 3.4 5 001 8 000 1 525 2 438 634 567 85 76 2.6 ?[...]

4-4 4 FI SYSTEM DIAGN OSIS “C14” (P 0120-H/L) TP SENSOR CIRCUIT MALFUNCTIO N INSPECT ION Ste p 1 (Whe n indicat ing C14: ) 1) Tur n the i gnitio n switc h to O FF . 2) Lift and s uppor t the fuel tank . (  5-3 ) 3) Chec k th e TP s ens or coup ler f or loos e or p oor con tacts . If O K, th en mea sure the TP sens or inp ut vo ltage. 4) Disc[...]

FI SYSTEM D IAG N OSIS 4-45  TP s en sor in put voltag e: 4.5 – 5 .5 V ( + R – - Gr ound) ( + R – - B/B r)  09900- 250 08: M ulti-circui t tes ter set  T ester k nob in dica tion : V oltag e (  ) Is t he vo ltage OK? Step 1 (Wh e n indica ting P 0120 -H:) 1) T urn t he ign ition switch OF F. 2) L ift and supp ort the fue l tank. ([...]

4-4 6 FI SYSTEM DIAGN OSIS Is t he co ntinuity OK? 9) Af ter repairi ng the trou ble, clea r the DTC us ing SD S tool. (  4- 27) Step 1 (Wh en in dica ting P 0120- L:) 1) Tur n the i gnitio n switc h O FF. 2) Lift and s uppor t the fuel tank . (  5-3 ) 3) Chec k th e TP s ens or coup ler f or loos e or p oor con tacts . If O K, th en ch eck t[...]

FI SYSTEM D IAG N OSIS 4-47 Step 2 1) T urn t he ign ition switch OF F. 2) D isco nne ct the TP sens or cou pler . 3) In stal l the test h arness to the TP senso r. 4) C he ck the c onti nuity b etween ter mina l A and ground .  TP sens or cont inu i t y : ∞ Ω ( Infinit y) (Term in al A – Grou nd) 5) If OK , th en meas ure t he TP sen sor [...]

4-4 8 FI SYSTEM DIAGN OSIS Step 3 1) Conn ect th e TP sen sor c ouple r 1 to the tes t har ness. 2) Tur n the i gnitio n switc h O N. 3) M easure t he TP s ens or outp ut voltag e at the co upler (bet wee n + P/B and - B/B r) by turning the thrott le gr ip.  TP sens or ou tput v olt age Throttle v a lve is clo sed: Approx. 1.1 V Thr ott le v alv[...]

FI SYSTEM D IAG N OSIS 4-49 “C15” (P0115-H/L) ECT SENSOR CIRCUI T MALFUN CTION INSPECT ION Step 1 (Wh e n indica ting C 15:) 1) T urn t he ign ition switch OF F. 2) L ift and supp ort the fue l tank. (  5-3) 3) C he ck the E CT sen sor co upler fo r loo se or po or c ontac ts. If O K, the n meas ure the E CT sens or vol tage at th e wir e si[...]

4-5 0 FI SYSTEM DIAGN OSIS Step 1 (Wh en in dica ting P 0115- H:) 1) Tur n the i gnitio n switc h O FF. 2) Lift and s uppor t the fuel tank . (  5-3 ) 3) Chec k th e ECT senso r co upler for loo se or poor conta cts. If O K, th en ch eck the EC T se nsor lead wir e con tinuity . 4) Disco nne ct the ECT s ens or coup ler a nd ECM coup ler. 5) Che[...]

FI SYSTEM D IAG N OSIS 4-51 Step 1 (Wh e n indica ting P 0115 -L:) 1) T urn t he ign ition switch OF F. 2) L ift and supp ort the fue l tank. (  5-3) 3) C he ck the E CT sen sor co upler fo r loo se or po or c ontac ts. If O K, th en mea sure the ou tput voltage . 4) D isco nne ct the ECT se nsor coup ler. 5) C he ck the c onti nuity b etween B/[...]

4-5 2 FI SYSTEM DIAGN OSIS Step 2 1) Tur n the i gnitio n switc h O FF. 2) Disc onne ct the ECT s ens or coup ler. 3) M easure the E CT sen sor resistan ce.  ECT senso r resis tance : Appr o x. 2. 45 k Ω at 20 °C (6 8 °F) (T erm inal – T erm inal)  09900- 250 08: Mult i-circuit t ester s et  T ester k nob in dicat ion : Res istance ([...]

FI SYSTEM D IAG N OSIS 4-53 “C21” (P0110 -H/L) IAT SE N SOR CIRCUIT M A LFUNCT ION INSPECT ION Step 1 (Wh e n indica ting C 21:) 1) T urn t he ign ition switch OF F. 2) L ift and supp ort the fue l tank. (  5-3) 3) C he ck the I AT sensor cou pler for loose or poo r co ntacts. If OK, then me asure the IAT senso r voltag e at the w ire side c[...]

4-5 4 FI SYSTEM DIAGN OSIS Step 1 (Wh en in dica ting P 0110- H:) 1) Tur n the i gnitio n switc h O FF. 2) Lift and s uppor t the fuel tank . (  5-3 ) 3) Chec k th e IAT sens or coup ler for loos e or poor con tacts . If O K, th en ch eck the IAT sen sor le ad wire continu ity. 4) Disco nne ct the IAT s enso r coupl er an d ECM c oupl er. 5) Che[...]

FI SYSTEM D IAG N OSIS 4-55 Step 1 (Wh e n indica ting P 0110 -L:) 1) T urn t he ign ition switch OF F. 2) L ift and supp ort the fue l tank. (  5-3) 3) C he ck the I AT sensor cou pler for loose or poo r co ntacts. If O K, th en ch eck th e IAT sen sor le ad wire cont inuity . 4) D isco nne ct the IAT sen sor co upler . 5) Chec k th e cont inu [...]

4-5 6 FI SYSTEM DIAGN OSIS Step 2 1) Tur n the i gnitio n switc h O FF. 2) M easure the I AT sens or r esistanc e.  IA T sensor resist ance: Appr o x . 2.45 k Ω at 20 °C ( 68 °F) (T erminal – T erminal)  09900- 250 08: Mult i-circuit t ester s et  T ester k nob in dicat ion : Res istance ( Ω ) Is th e res istance OK ?   I A T[...]

FI SYSTEM D IAG N OSIS 4-57 “C22” (P1450-H/L) AP SENSOR CIR CUIT MALFUNCT ION INSPECT ION Step 1 (Wh e n indica ting C 22:) 1) T urn t he ign ition switch OF F. 2) R em ove th e fron t seat . (  8-7) 3) C he ck the A P s enso r coupl er for l oose or po or conta cts . If O K, th en mea sure the A P se nsor i nput v oltag e. DET ECTED C ONDIT[...]

4-5 8 FI SYSTEM DIAGN OSIS 4) Disco nne ct the AP sen sor coupler . 5) Tur n the i gnitio n switc h O N. 6) M easure the vo ltage at the R w ire and g round . 7) If O K, th en mea sure the v oltag e at the R w ire A and B/Br wi re B .  AP sens or in put voltage : 4.5 – 5. 5 V ( + R – - Ground ) ( + R – - B/Br)  09900- 250 08: Mult i-cir[...]

FI SYSTEM D IAG N OSIS 4-59 6) D isco nnec t the E CM cou pler . 7) C he ck the c onti nuity b etween G/Y wire C and termina l P . 8) If OK, then c he ck the conti nuity be twe en B/Br wi re B and ter- mi nal S .  APS lea d wire conti nuity: Co ntinuit y (  )  09900- 250 08: M ulti-circui t tes ter set 09900- 250 09: N eedle point ed p ro [...]

4-6 0 FI SYSTEM DIAGN OSIS 7) Disc onne ct the ECM cou pler. 8) Chec k th e con tinuity betw een R wire A and termina l A . 9) If OK, the n chec k the contin uity betwe en G/Y wir e C and ter- mi nal P .  APS lea d wire conti nuity: Conti nuity (  )  09900- 250 08: Mult i-circuit t ester s et 09900- 250 09: N eedle point ed probe set  T[...]

FI SYSTEM D IAG N OSIS 4-61 Step 3 1) R em ove th e AP senso r. 2) Con nect the vac uum pum p gaug e to the vacuu m por t of the AP senso r. Arr ange 3 new 1.5 V batte ries in s eries 1 (chec k th at total vo ltage is 4 .5 – 5.0 V) and co nnec t - termina l to the gr oun d term inal 2 and + termina l to th e VC C ter mina l 3 . 3) C he ck the vol[...]

4-6 2 FI SYSTEM DIAGN OSIS Ou tput volt age (VC C voltag e 4.5 – 5.0 V, am bient te mp. 20 – 30 °C , 6 8 – 86 ° F) AL TITUD E (Re ference ) ATMOSPH ERIC PRESSU RE OUTPUT VOLT AGE (ft) (m ) (mm Hg ) kPa (V) 0 2 000 0 610 760 707 100 94 3. 1 – 3 .6 2 001 5 000 611 1 524 707 634 94 85 2. 8 – 3 .4 5 001 8 000 1 524 2 438 634 567 85 76 2. 6 [...]

FI SYSTEM D IAG N OSIS 4-63 “C23” (P1651-H/L) TO SENSOR CIR CUIT MALF UNCTION INSPECT ION Step 1 (Wh e n indica ting C 23:) 1) T urn t he ign ition switch OF F. 2) R em ove th e fram e cov er. (  8-8 ) 3) C he ck the T O se nsor coup ler for loose o r poor con tacts. If O K, th en mea sure the T O sens or r esistanc e. 4) D isco nne ct the T[...]

4-6 4 FI SYSTEM DIAGN OSIS Step 1 (Wh en in dica ting P 1651- H:) 1) Tur n the i gnitio n switc h O FF. 2) Rem ove th e fr ame c ove r. (  8- 8) 3) Chec k th e TO s ens or coupl er fo r loos e or p oor c ontacts . If O K, th en ch eck the TO senso r lea d wire c onti nuity. 4) D isco nne ct the TO s ensor c oupl er. 5) Che ck the c onti nuity b [...]

FI SYSTEM D IAG N OSIS 4-65 Step 1 (Wh e n indica ting P 1651 -L:) 1) T urn t he ign ition switch OF F. 2) R em ove th e fram e cov er. (  8-8 ) 3) C he ck the T O se nsor coup ler for loose o r poor con tacts. If O K, th en ch eck th e TO senso r lea d wire conti nuity. 4) D isco nne ct the TO s ensor c oupl er. 5) C he ck the c onti nuity betw[...]

4-6 6 FI SYSTEM DIAGN OSIS Step 2 1) Conn ect th e TO sen sor co upler an d EC M c ouple r. 2) Ins ert the nee dle poi nted pr obe s to the l ead w ire coupler . 3) Tur n the i gnitio n switc h O N. 4) M easure the vo ltage betwee n B and B/Br wi res.  T O s ensor v oltage (No rm al): 0 .4 – 1.4 V ( + B – - B/B r) Also, measure th e voltage [...]

FI SYSTEM D IAG N OSIS 4-67 “C28” (P1655) STV ACTUATO R CIRCUIT MALFUNCTION INSPECT ION Step 1 1) L ift and supp ort the fue l tank. (  5-3) 2) R em ove th e a ir clean er box. (  5-14 ) 3) C heck the S TVA lead wi re cou pler for l oose or poo r contac ts. 4) T urn t he ign ition s witch ON to che ck the STV ope ration. (ST V op erating [...]

4-6 8 FI SYSTEM DIAGN OSIS Step 2 1) Tur n the i gnitio n switc h O FF. 2) Disc onne ct the STV A lead wire c oupl er. 3) Chec k th e con tinuity b etw een eac h ter mina l and ground .  STV A con tin uity: ∞ Ω (Infin ity) (T ermina l – Gr ound) 4) If O K, then m easu re the STV A re sista nce (be twe en term inal A and ter mina l B ) and [...]

FI SYSTEM D IAG N OSIS 4-69 ACTIVE CONTROL INSPECT ION 1) S et u p the SDS to ol. (Re fer to the SDS o per ation manu al for furt her de tails. ) 2) Tur n t he ign ition sw itch ON. 3) C lick “S eco ndary th rottl e oper ating control ” 1 . 4) Cli ck each button 2 . At this tim e, if an operati on soun d i s heard fro m the ST VA, the fu ncti o[...]

4-7 0 FI SYSTEM DIAGN OSIS “C29” (P 1654-H/L) STP SENSOR C IRCUIT MALFUNCT ION INSPECT ION Ste p 1 (Whe n indicat ing C29: ) 1) Tur n the i gnitio n switc h O FF. 2) Lift and s uppor t the fuel tank . (  5-3 ) 3) Chec k th e STP sens or coup ler for loos e or poor c ontacts . If O K, th en mea sure the STP s enso r input v olt age. 4) Disc o[...]

FI SYSTEM D IAG N OSIS 4-71 Step 1 (Wh e n indica ting P 1654 -H:) 1) T urn t he ign ition switch OF F. 2) L ift and supp ort the fue l tank. (  5-3) 3) C he ck the S TP sensor cou pler for loose or poo r co ntacts. If O K, th en ch eck th e ST P sen sor le ad wi re cont inui ty. 4) D isco nne ct the STP s enso r coupl er. 5) C he ck the c onti [...]

4-7 2 FI SYSTEM DIAGN OSIS Step 1 (Wh en in dica ting P 1654- L:) 1) Tur n the i gnitio n switc h O FF. 2) Lift and s uppor t the fuel tank . (  5-3 ) 3) Chec k th e STP sens or coup ler for loos e or poor con tacts . If O K, th en ch eck the ST P sen sor le ad wi re conti nuit y. 4) Disc onne ct the STP senso r co upler. 5) Chec k th e con tinu[...]

FI SYSTEM D IAG N OSIS 4-73 Step 2 1) T urn t he ign ition switch OF F. 2) L ift and supp ort the fue l tank. (  5-3) 3) D isco nne ct the STP s enso r coupl er. 4) C he ck the c onti nuity b etween each term ina l and gr oun d.  STP sen sor conti nuity: ∞ Ω ( Infinit y) (T ermina l – Gr ound) 5) If OK , t hen meas ure the S TP sen sor [...]

4-7 4 FI SYSTEM DIAGN OSIS Step 3 1) Turn t he ign ition s witch OF F. 2) C on nect t he STP sens or cou pler. 3) In ser t the needle p ointed pr obes to the S TP sensor cou pler. 4) D isco nne ct the STVA lead wire co upler . 5) Turn t he ign ition s witch ON. 6) M eas ure the STP sens or ou tput v oltag e at the coupler (bet we en + Y w ire an d [...]

FI SYSTEM D IAG N OSIS 4-75 “C31” (P0705) G P SWITCH CIRCUI T MALFUNCTIO N INSPECT ION Step 1 1) T urn t he ign ition switch OF F. 2) L ift and supp ort the fue l tank. (  5-3) 3) C he ck the G P switch c oupl er fo r loose or po or conta cts . If O K, th en mea sure the G P sw itch v oltag e. 4) Support th e motor cycle with a jack. 5) F ol[...]

4-7 6 FI SYSTEM DIAGN OSIS Is th e volta ge OK ?  10)Af ter r epa iring the tr ouble , clear the DTC using SD S to ol. (  4- 27) YES • P w ire ope n or s hor te d to ground • If wi re and conn ection are O K, int er mitten t trou- ble or faulty EC M. • Rec heck eac h ter mi nal a nd wire har ne ss f o r open c ircu it and poor conne cti[...]

FI SYSTEM D IAG N OSIS 4-77 “C3 2” (P 0201 ), “ C33” (P0 202), “C34 ” (P0 20 3) or “C3 5” (P 0204 ) PRIMARY FUEL INJECTOR CIRCUIT MALFUNCTIO N INSPECT ION Step 1 1) T urn t he ign ition switch OF F. 2) L ift and supp ort the fue l tank (  5-3) 3) C he ck the i njecto r co upler fo r loo se or po or c ontac ts. If O K, th en mea s[...]

4-7 8 FI SYSTEM DIAGN OSIS 5) If OK , the n check the conti nuit y betw een eac h ter minal an d grou nd.  Inje ctor c ont inuity: ∞ Ω (In finit y)  09900- 250 08: Mult i-circuit t ester s et  T ester k nob in dicat ion : Res istance ( Ω ) Are th e res istanc e and cont inuity OK? 6) Af ter repairi ng the trou ble, clea r the DTC us [...]

FI SYSTEM D IAG N OSIS 4-79 Is t he vo ltage OK?  3) A fter repa iring the tr ou ble, c lear th e D TC using SD S t ool. (  4- 27) YES • Gr /W wire o pen o r shor te d to groun d, or poor h con nection (#1 c ylin der side) • Gr /B wi re ope n or sho r ted to grou nd, o r poor g con nection (#2 c ylin der side) • Gr /Y wi re ope n or sho[...]

4-8 0 FI SYSTEM DIAGN OSIS “C3 6” (P 1764) , “C 37” (P 1765 ), “C38 ” (P1 766) or “C3 9” (P17 67) SECONDA RY FUEL INJECT OR CIRCUIT MALFUNCTION INSPECT ION Step 1 1) Tur n the i gnitio n switc h O FF. 2) Lift and s uppor t the fuel tank . (  5-3 ) 3) Chec k th e injecto r co upler for loo se or poor conta cts. If O K, th en mea s[...]

FI SYSTEM D IAG N OSIS 4-81 5) If OK , then c heck th e cont inuity betwee n each termi nal an d gro und.  Inje ctor c ont inuity: ∞ Ω (In finit y)  09900- 250 08: M ulti-circui t tes ter set  T ester k nob in dica tion : Res istance ( Ω ) Are t he res istan ce an d con tinuity OK? 6) A fter repa iring the tr ou ble, c lear th e D TC[...]

4-8 2 FI SYSTEM DIAGN OSIS Is th e volta ge OK ?  3) Af ter repairi ng the trou ble, clea r the DTC us ing SD S tool. (  4- 27) YES • Lg wire op en or shor t ed t o groun d, or p oor x con nection (#1 c ylin der side) • Lg /W wire op en o r shor ted to gr ound, or poor w con nection (#2 c ylin der side) • Lg /G wire o pen or shor ted to[...]

FI SYSTEM D IAG N OSIS 4-83 “C41” (P0230 -H/L) FP REL AY CIRCUIT MALF UNCTION INSPECT ION Step 1 (Wh e n indica ting C 41:) 1) T urn t he ign ition switch OF F. 2) L ift and supp ort the fue l tank. (  5-3) 3) C he ck the F P rel ay co upler for loo se or poor conta cts. If O K, th en ch eck th e FP relay . (  5-7) DE TECTE D C OND IT IO [...]

4-8 4 FI SYSTEM DIAGN OSIS Is t he FP relay O K ?  4) Af ter repairi ng the trou ble, clea r the DTC us ing SD S tool. (  4- 27) Step 1 (Wh en in dica ting P 0230- H:) 1) Tur n the i gnitio n switc h O FF. 2) Lift and s uppor t the fuel tank . (  5-3 ) 3) Chec k th e FP r elay c oupler for l oose or po or conta cts. If O K, th en ch eck th[...]

FI SYSTEM D IAG N OSIS 4-85 Step 1 (Wh e n indica ting P 0230 -L:) 1) T urn t he ign ition switch OF F. 2) L ift and supp ort the fue l tank. (  5-3) 3) C he ck the F P rel ay co upler for loo se or poor conta cts. If O K, th en ch eck th e FP relay . (  5-7) Is th e F P r el ay OK? 4) A fter repa iring the tr ou ble, c lear th e D TC using S[...]

4-8 6 FI SYSTEM DIAGN OSIS “C42” ( P01650) IG SWIT CH CIRCUIT MALFUNCTION INSPECT ION * R efer to t he IG NIT ION SWIT CH IN SPE CT ION f o r det ail s. (  9-3 9) DE TECTED COND ITI ON POSS IBL E C AUSE Ignition s witch signa l is not input to th e ECM. • Ig nition system circuit open or sho r t • EC M ma lfunction Wh en th e ID agr eem [...]

FI SYSTEM D IAG N OSIS 4-87 “C44” (P0130/P0135) HO2 SENSOR (HO2 S) CIRCUIT MA LFUNCTION (F or E- 02, 19) INSPECT ION Step 1 (Wh e n indica ting C 44/ P0130: ) 1) T urn t he ign ition switch OF F. 2) L ift and supp ort the fue l tank. (  5-3) 3) C he ck the H O2 se nsor for l oose or po or conta cts. If O K, th en ch eck th e H O2 sen sor lea[...]

4-8 8 FI SYSTEM DIAGN OSIS 7) D isco nne ct the E CM cou pler . 8) Che ck the co ntinui ty b etween W/G wire A and termina l B . 9) Al so, chec k th e conti nuit y be tween B/ Br wir e B and ter m ina l S .  HO2S lead wire cont inuity: Cont inuit y (  )  09900- 250 08: Mult i-circuit t ester s et 09900- 250 09: N eedle point ed probe set ?[...]

FI SYSTEM D IAG N OSIS 4-89 Is t he vo ltage OK?  6) A fter r epairi ng the t roubl e, clea r the D TC usin g SDS t ool. (  4- 27) Step 1 (Wh e n indica ting C 44/ P0135: ) 1) T urn t he ign ition switch OF F. 2) L ift and supp ort the fue l tank. (  5-3) 3) C he ck the H O2 se nsor for l oose or po or conta cts. I f OK , t hen me asur e t[...]

4-9 0 FI SYSTEM DIAGN OSIS Step 2 (Wh en in dica ting C 44/P 013 5:) 1) C on nect t he HO 2 se nsor c ouple r. 2) Inser t the nee dle p ointed probe to the HO2 sensor cou pler. 3) T urn t he ignition s wi tch ON and m easur e the hea ter v oltag e betw een W (O /W) w ire a nd gro und . 4) If th e tes ter vo ltage indic ates the b atte ry voltage , [...]

FI SYSTEM D IAG N OSIS 4-91 “C46” (P1657-H/L o r P1658) EXCV ACTUATO R CIRCUIT MALFUNCTION INSPECT ION Step 1 (Wh e n indica ting C 46:) 1) T urn t he ign ition switch OF F. 2) R em ove th e fram e cov er. (  5-8 ) 3) Che ck the E XCVA lead wire c ouple rs for loos e or poo r con- tacts. 4) T urn t he ign ition switch ON. 5) Chec k th e oper[...]

4-9 2 FI SYSTEM DIAGN OSIS Step 1 (Wh en in dica ting P 1657- H:) 1) Tur n the i gnitio n switc h O FF. 2) Rem ove th e fr ame c ove r. (  5- 8) 3) Chec k th e EX CVA position sens or coup ler for loos e or p oor con tacts. If OK, th en chec k the EXC VA posi tion sen sor lead wi re conti- nui ty. 4) Disc onne ct the EXC VA po sitio n sen sor co[...]

FI SYSTEM D IAG N OSIS 4-93 Step 1 (Wh e n indica ting P 1657 -L:) 1) T urn t he ign ition switch OF F. 2) R em ove th e fram e cov er. (  5-8 ) 3) Che ck the E XCV A pos ition sensor cou pler for loos e or poor co ntacts. If O K, then chec k the EX CVA po sition sen sor l ead w ire con ti- nui ty. 4) D isco nne ct the EXCV A pos ition s ens or [...]

4-9 4 FI SYSTEM DIAGN OSIS Step 1 (Wh en in dica ting P 1658: ) 1) Tur n the i gnitio n switc h O FF. 2) Rem ove th e fr ame c ove r. (  5- 8) 3) Chec k th e EX CVA motor coup ler for loose o r p oor cont acts . Is t he co ntacting OK? 4) Af ter repairi ng the trou ble, clea r the DTC us ing SD S tool. (  4- 27) Step 2 1) Tur n the i gnitio n[...]

FI SYSTEM D IAG N OSIS 4-95 Step 3 1) T urn t he ign ition switch OF F. 2) C he ck the c onti nuity b etween Y w ire and gr ound.  P osit i o n sensor cont inuit y: ∞ Ω (In finity) 3) If OK , then mea sure the po sition senso r resi stance . 4) C on nect t he pos ition s ens or coup ler. 5) S et th e EXC VA to a djustme nt p osition. (  6[...]

4-9 6 FI SYSTEM DIAGN OSIS Step 4 1) Tur n the i gnitio n switc h O FF. 2) Conn ect th e p ositio n sens or coupl er. 3) M easure t he po sition s enso r outpu t voltage at fu lly close po si- tion and ful ly op en p osition. 4) Ins ert the nee dle poi nted pr obe s to the back side o f th e pos i- tion senso r lea d wire c oupl er. ( + Y – - B/B[...]

FI SYSTEM D IAG N OSIS 4-97 Step 5 1) If the positi on se nsor ou tput voltage is 0.5 V and less at fully clos e pos ition, a djust th e ou tput v oltage to spe cified by turn- ing out the No . 1 ca ble ad juster 1 . 2) R ep eat the a bove pro cedure (Step 4) un til the o ut put v oltag e bec om es speci fied value . (If C46/ P165 7 code is indic a[...]

4-9 8 FI SYSTEM DIAGN OSIS Step 6 1) Tur n the i gnitio n switc h O FF. 2) Disc onne ct the moto r lead w ire c ouple r of th e EXC VA. 3) Ap ply 12 V to the te rminal and ch eck the o perati on of EXCVA. 4) Then , sw ap t he wir es su ppli ed 1 2 V and ch ec k th e op era tion of EXC VA. (C heck th e op erat io n of E XCVA bot h way. ) Is t he ope[...]

FI SYSTEM D IAG N OSIS 4-99 ACTIVE CONTROL INSPECT ION 1) S et up th e SD S too l. (Refer to the SDS oper atio n manual for furt her de tails.) 2) T urn t he ign ition switch ON. 3) C lick “E xha ust valv e oper ating cont rol” 1 . 4) Cli ck each button 2 . At this tim e, if an ope ration sou nd is heard from the EXCV A, the fu ncti on is n orm[...]

4-1 00 FI SYSTEM DIA GNOSIS “C49” (P 1656) PAIR CONTROL SOL ENOID VALVE CI RCUIT MA LFUNCTION INSPECT ION Step 1 1) Turn t he ign ition s witch OF F. 2) R em ove th e a ir clean er box. (  5- 14) 3) C he ck the P AIR c ontro l solenoi d valv e cou pler for loose or poor cont acts. If O K, the n meas ure th e PAIR control s olen oid valv e re[...]

FI SYSTEM D IAG N OSI S 4-10 1 Step 2 1) Tur n t he ign ition sw itch ON. 2) M easu re the voltage be tween O /W wire a nd ground .  P AIR valve voltag e: Ba ttery voltage ( + O/W – - Gr ound)  09900- 250 08: M ulti-circui t tes ter set  T ester k nob in dica tion : V oltag e (  ) Is t he vo ltage OK?  3) A fter r epairi ng the t r[...]

4-1 02 FI SYSTEM DIA GNOSIS 4) Cli ck eac h but to n 2 . At this ti me, if an opera tion soun d is he ard from the P AIR con trol so lenoid valve , the fu ncti on is no rmal .[...]

FI SYSTEM D IAG N OSI S 4-10 3 “C60” (P0480 ) CO OLING FAN RELAY CI RCUIT MALFUNCTION INSPECT ION Step 1 1) T urn t he ign ition switch OF F. 2) L ift and supp ort the fue l tank. (  5-3) 3) Che ck the cool ing fa n relay cou pler for loo se or po or c ontac ts. If O K, t hen in spection the cooli ng fan r elay. (  7-7) Is t he co oling f[...]

4-1 04 FI SYSTEM DIA GNOSIS ACTIVE CONT ROL I NSPEC TION 1) Se t up th e SD S tool. (Re fer to the SDS operati on man ual for furth er det ails.) 2) St art the engin e and r un it idling c ondi tion. 3) Click “Cooli ng fan relay co ntrol ” 1 . 4) C lick th e op erate butt on 2 . At this ti me, if an ope ra tion soun d is hear d from th e cooli [...]

FI SYSTEM D IAG N OSI S 4-10 5 SEN SORS CMP SENSOR INSPECTION Th e cam shaf t po sit ion sens or i s i ns tall ed on t he c yl in der h ead cover. (  4- 33) CMP SE NSO R REMO VAL AND IN STALLA TIO N • Rem ove t he C MP sensor . (  3- 26) • Ins tall the CM P sen sor in the reverse order of removal .  CMP sen sor: 10 N·m (1.0 kgf- m, 7.[...]

4-1 06 FI SYSTEM DIA GNOSIS ECT SENSOR INS PECTION The en gine coo lant tem pe rature sensor is installed at the cy lin- der h ead . (  4-49 ) ECT SE NSOR REMOV AL A ND INSTALLATION • R em ove th e ECT senso r. (  7-7 ) • In stall the E CT se nsor in the re ver se order of re mova l.  EC T senso r: 18 N·m ( 1.8 kgf-m , 13.0 lb-f t) IA[...]

FI SYSTEM D IAG N OSI S 4-10 7 STP SENSOR ADJUSTMENT • A djust th e ST P se nsor. (  5- 22) HO2 SENSOR INSPECTION (For E- 02, 1 9) The he ated o xyg en s ensor is in stalled t o th e ex haus t pip e. (  4-87 ) HO2 SENSOR REMOVAL AND INSTAL LATION • Rem ove t he ri ght und er cowling. (  8-5) • Lif t and s uppor t th e fuel tank. ( ?[...]

FUEL SYSTEM AND THROTTLE BODY 5 - 1 5 FUEL SYSTEM AND THROTTLE BODY CONTENT S FUEL DELIVERY SYSTEM... ....... ....... ........ ....... ....... ........ ....... ....... ........... .. 5- 2 FUEL SYSTEM....... ....... ........ ....... ....... ........ ....... ....... ........ ........... ....... ....... .. 5- 3 FUEL TANK LIFT-UP ..... ....... ....... [...]

5-2 FU EL SYSTEM AND THROTTLE BODY FUE L DELI VERY SYST EM The fue l delivery syste m cons ists of the fue l tank, fuel pump, fuel f ilters, fuel feed hos e, fuel deliv ery pipe (inc luding f uel inj ecto rs) and fue l pres sure r egula tor. Th ere is no fu el r eturn hose. The fu el in th e f uel ta nk is pumpe d up by th e fue l pump an d pres su[...]

FUEL SYSTEM AND THROTTLE BODY 5 - 3 FU EL SY STEM FU EL TA NK LIFT -UP • Rem ove t he se ats. (  8 -7 and -8) • Tak e out the fuel tank prop stay 1 . • Rem ove t he f uel ta nk bo lt. • Lif t and s uppor t th e fuel tank with the f uel ta nk pr op s tay.[...]

5-4 FU EL SYSTEM AND THROTTLE BODY FUEL TANK REMOVAL • L ift and supp ort the fue l tank. (  above ) • D isco nnect the fue l pum p l ead wi re cou pler 1 . • D isco nnect the fue l tank b reathe r hose 2 and fu el t ank drain hos e 3 . • Pl ace a rag und er the fue l feed h ose 4 and d iscon nect th e fuel feed h ose .   • R em [...]

FUEL SYSTEM AND THROTTLE BODY 5 - 5 • Ins tall th e sp ecia l tools bet ween the fuel tank and f uel d elive ry pi pe.  09940- 402 11: Fu el pres su re gaug e ad apto r 09940- 402 20: Fu el pres su re gaug e ho se at tachmen t 09915- 773 31: Oil pressu re gaug e 09915- 745 21: Oil pressu re gaug e hos e Tur n the i gnition switc h O N and chec[...]

5-6 FU EL SYSTEM AND THROTTLE BODY FUEL D ISCHARGE AMOUNT IN SPECTION  • L ift and supp ort the fue l tank. (  5-3) • T urn t he ign ition sw itch OFF. • D isco nnect the bat tery - lead wire. • Pl ace a ra g unde r the fue l feed ho se and dis conn ect th e fuel feed hos e 1 fro m th e fuel pump. • C onnec t a pr ope r fuel ho se 2[...]

FUEL SYSTEM AND THROTTLE BODY 5 - 7 • Con nect a pro per lead wire to the fue l pum p lead wire coupler (fue l pump side ) a nd app ly 12 V to the fuel pum p (betwee n Y /R wire and B/W wire) for 10 second s and me asur e the am ount o f fu el disc harged . B attery + term inal (Y/R te rm inal) B attery - term inal (B/W ter mina l) If the p ump d[...]

5-8 FU EL SYSTEM AND THROTTLE BODY FUEL PUMP AND FUEL FILTER REMOVAL CO NST RUC T ION 1 Fu el l e v el ga uge 5 Ho lder  2 Fu el pu mp ca se /F uel f il ter cartri dge 6 Fuel m esh fil ter ITE M N·m kgf-m lb-ft 3 Fue l pump 7 O- r i n g A 10 1.0 7 .0 4 Rubbe r cu shion A Fuel pu mp mou nting bol t[...]

FUEL SYSTEM AND THROTTLE BODY 5 - 9 REM OVAL • Rem ove t he f uel ta nk. (  5-4) • Rem ove t he f uel p ump as sem bly 1 by r emo ving its moun ting bol ts diag ona lly.  • Rem ove t he n uts. • Rem ove t he lea d w ire 1 , scr ews an d fue l lev el gau ge 2 . • Rem ove t he sc rew . • Rem ove t he f uel pu mp 3 fro m th e fuel pu[...]

5-10 FUEL SYSTEM AND THROTTLE BODY • R em ove th e fuel me sh fi lter 7 . • R em ove the fuel pump 8 fr om th e fuel pump case /fuel filter cart ri dge 9 . FUEL MESH FILTER INSPECTION AND CLEANING If the fu el m esh filter is c logg ed wi th s edim ent or rus t, fu el w ill not fl ow s moothl y an d loss i n engi ne pow er m ay re sult. Blow th[...]

FUEL SYSTEM AND TH RO TTLE B OD Y 5-11 • B e sure to conn ect th e w ires t o the pr oper termi nals. A (Bl ) . ...... . + t erminal for f uel pu mp B (R) .. ...... . + term inal fo r fuel l evel ga uge • Ins tall a new O-ring an d apply SUZ UKI SUP ER GRE ASE “A” to i t.  99000-2501 0: SUZUKI SU PER GREASE “A” (or e quivalent g reas[...]

5-12 FUEL SYSTEM AND THROTTLE BODY • W hen instal ling the fue l pum p asse mbly, fi rst ti ghten a ll the fuel pump mou nting bolts l ightly a nd t hen to t he sp ecifie d torq ue, in the ascend ing o rder of numb ers.  Fuel pump mounti ng bolt: 10 N ·m (1 .0 kgf -m , 7. 0 lb-ft ) NOT E : Ap ply a s mall qu antity o f the THR EAD LOCK to th [...]

FUEL SYSTEM AND TH RO TTLE B OD Y 5-13 THROTTLE BODY CONSTRUC TI ON Only f or E-33 1 TP sensor 8 F a st id le ad ju st in g s cre w 2 STP sensor 9 Thro ttle stop screw 3 STV A 0 V acuum hose  4 Fuel del iver y pipe A Fuel del iver y pipe mou nting screw ITEM N ·m kgf-m lb-ft 5 O-rin g B S TP s ensor m oun ting scr ew A 5.0 0.5 3.7 6 Fuel in jec[...]

5-14 FUEL SYSTEM AND THROTTLE BODY AIR CLEANER BOX REMOVAL AND I NSTAL- LAT I ON REM OVAL • L ift and supp ort the fue l tank. (  5-3) • D isco nnect the fu el pu mp relay 1 , cool ing fan re lay 2 and IA T sens or lead wir e cou pler 3 . • D isco nnect the PC V ho se 4 . • R em ove th e air cl eaner mou nting bol t 5 . • D isco nnect [...]

FUEL SYSTEM AND TH RO TTLE B OD Y 5-15 THROTT LE BODY REMOVAL • Rem ove t he a ir clean er box . (  5-14) • Di sconne ct the thrott le c ables f rom the ir d rum.  • P lace a rag u nde r the fuel feed ho se a nd remove the fu el feed hos e. • Di sconne ct th e S TVA l ead w ire coup ler 1 , STP sens or lea d w ire c ou pl er 2 TP se n[...]

5-16 FUEL SYSTEM AND THROTTLE BODY • R em ove th e thro ttle bo dy asse mbly . THROTT LE BODY DISASSEMBLY  • Disconnect the respectiv e vacuum hoses 1 from each thrott le body. • R em ove th e IAP senso r 2 • R em ove th e fuel de liver y pipe assemb ly 3 . • R em ove th e cush ion sea l 4 f rom th e th rottle body . • R em ove th e [...]

FUEL SYSTEM AND TH RO TTLE B OD Y 5-17 • Rem ove t he T P se nsor an d ST P sen sor with the sp ecial too l.  09930- 119 50: T o rx w rench NOT E : Pr io r t o di sas s emb ly , m ark th e eac h se ns or ’s o ri gi nal pos it ion wit h a paint or scribe for acc urate reinst alla tion.    Neve r remo ve the STVA 7 fro m the thr ott l[...]

5-18 FUEL SYSTEM AND THROTTLE BODY THROTTLE BODY CL E A NING  • C lean all pas sage way s with a spr ay-typ e carbur et or clea ner and blow dr y with compre ssed air .  INSPECTI ON Chec k fo llowing i tems for a ny da mage o r clog ging. *O - r i n g * Thr ottle valve * Se cond ary throttle va lve * Va cuum hose Som e c arbure tor clean in[...]

FUEL SYSTEM AND TH RO TTLE B OD Y 5-19 THROTTL E BODY REASSEMBLY Reas sem ble t he thr ottle b ody in the re verse order of di sassem- bly. P ay att ention to the fol lowing point s: • W ith th e STV fu lly o pen , install the S TP sen sor 1 and tighten the S TP sensor mo unting s crew t o th e spe cified tor qu e. NOT E : * Apply thin coat of th[...]

5-20 FUEL SYSTEM AND THROTTLE BODY • Install the fuel inje ct or 5 by push ing it straight to the delive ry pi pe 6 . NOT E : Align th e bo ss E of the i njecto r with the gr oove F of the d elive ry pipe .  • In stall the fu el d elivery pipe a ssemb ly 7 to the throttl e body as semb ly.  Tigh ten th e fu el deliv ery pi pe mou nting s [...]

FUEL SYSTEM AND TH RO TTLE B OD Y 5-21 THROTT LE BODY INSTALLAT ION Ins tallati on is in t he rev erse o rd er of rem ov al. Pa y atte ntion to the fo llow ing p oints: • Con nect the fuel in jector co uplers t o the fuel injec tors. M ake su re that each coupl er is inst alled in the c orrect po sitio n. The co lor on eac h lead wire r efers to [...]

5-22 FUEL SYSTEM AND THROTTLE BODY STP SE N SOR ADJ USTMENT If the S TP sensor ad justme nt is nec es sary, m easu re the sensor output vol tage an d ad just the ST P sen sor pos ition as foll ows : • R em ove th e air cl eaner box . (  5-14) • L oosen the throt tle body c lamp scr ews at the in take p ipe side . • L ift up the thr ottle b[...]

FUEL SYSTEM AND TH RO TTLE B OD Y 5-23 FUE L INJECTOR REMOVAL • Rem ove t he a ir clean er box . (  5-14) • W ith batt ery negat ive ca ble dis conne cted, disc onnec t the injec tor coupler s. • Rem ove t he f uel de livery pi pe as sem blies . (  5-16) • Rem ove th e pr imary and sec ondar y fuel i njector s #1, #2, # 3 and #4. ( ?[...]

5-24 FUEL SYSTEM AND THROTTLE BODY FAST IDLE The fast id le system is auto matic type . Wh en the fas t idle cam is turned by the se conda ry th rottle v alve actu ator, th e cam p ushes th e lev er on the throttl e valve s haft cau sing the thr ottle valv e to open an d raise the eng ine speed . Wh en the eng ine has warm ed up, dep end ing on th [...]

FUEL SYSTEM AND TH RO TTLE B OD Y 5-25 • C alc ulate the v oltage di ffere nce b etween T P sen sor outp ut vo ltage a t idle a nd TP sen sor outp ut volta ge w ith th e STV fu ll open ed. Ex amp le: T P sens or ou tput v ol tage with t he ST V ful l y open Minus TP se nsor out put voltage at id le is 0. 025 V STV fully op en 1. 150 V Idle - 1. 1[...]

5-26 FUEL SYSTEM AND THROTTLE BODY THROTTLE VAL VE SYNCHRONIZATION Chec k a nd ad just the th rottl e va lve sy nchron izat ion a mong four cylinde rs. Step 1 • L ift and supp ort the fue l tank. (  5-3) • Start up th e engine and r un it in idli ng condition for warming up . • St op t he war med- up engi ne. • D isco nnect the IAP se ns[...]

FUEL SYSTEM AND TH RO TTLE B OD Y 5-27 Step 3 • Tur n in all the idle ai r screw s to t he co mplet e clos e pos ition. • Che ck for differ ence of va cuum be tween # 1 a nd #2. • E qualize the se two by grad ually tu rning bac k the a ir screw on the higher va cuum side until t he vacu um comes down to the low er. Simi larly per form the sa [...]

EXHAUST SYS TEM 6 - 1 4 6 EXHAUST SYSTEM CONTENT S EXHAUST SYSTEM ... ....... ....... ........ ....... ....... ........ ....... ....... ........... ........ ..... 6- 2 EXHAUST CONTROL SYSTEM ...... ....... ........ ....... ....... ........ ....... ....... .. 6- 2 OPERATION . .......... ........ ....... ....... ........ ....... ....... ........... .[...]

6-2 EXH AUST SYSTE M EXHAUST SYSTEM EXHAUST CONTROL SYSTEM The exha ust con tro l syst em (EXC S) con sists o f the e xhaus t c ontrol va lve (EXCV ), e xhau st cont rol va lve actu ator ( EXC VA) and exha ust c ontr ol valv e cab les (EX CV ca bles ). EX CV i s in sta lle d t he exh aus t pi pes . EX CVA is m oun ted on th e ri ght si de o f t h e[...]

EXHAUST SYS TEM 6 - 3 OPERATIO N The EXC S is opera ted by the s ignal sup pli ed from the E CM. The open /clos e oper ation o f the EX CV is perform ed b y the EX CVA whic h is cont rolled b y the E CM by cha nging the c urr ent dire ction of t he ac tuator m otor. Th e p ositio n sens or ( incorp orated in the EX CVA ) detec ts the E XCVA mo veme[...]

6-4 EXH AUST SYSTE M EXCVA (E XHAUST CONTROL VALVE ACTUATOR) AND E XCV (EXHAUST CONTROL V AL VE) EXCVA REMOVAL • T urn t he ign ition sw itch OFF. • R em ove th e fram e cove r. (  8-8) • C on nect the sp ecial to ol (Mode s elect swi tch) to the dealer m ode c oupler. (  4-18) • Af ter tu rning th e sp ecial too l’s s witc h ON , t[...]

EXHAUST SYS TEM 6 - 5 • Hol d the EXC VA p ulle y with an ad jus table wrench , an d loo sen t he pul ley mo unting bolt.  • Rem ove t he E XCVA pull ey from the EXC VA b ody. EXCVA PULLEY INSPE CTION • Ins pect the E XCV A pulley g ro ove fo r wea r and dam age. • If a ny de fec ts ar e fo und , r epl ace t he E XCVA pull ey w it h a n [...]

6-6 EXH AUST SYSTE M • T ight en the EX CVA mo unting bolts t o the speci fied torque .  EXC V A mou nting bolt : 6.0 N·m ( 0.6 kg f-m, 4 .5 lb -ft) • T urn in the two c able a djuste rs fu lly. • C on nect th e No.1 c able 1 (01H 0CL) and No. 2 cable 2 (01H 0OP ) to the EXC VA p ulle y. No. 1 c able : 01H0CL No.2 ca ble: 01H 0OP • Af t[...]

EXHAUST SYS TEM 6 - 7 EXCV CABLE REPLACEMENT • Lif t and s uppor t th e fuel tank. (  5-3) • Che ck the E XCV A to adj ustm ent pos ition. (  6-4)  • Disc onn ect t he E XCV c abl es f r om th e EX C VA p ull e y. (  6-4) • M easu re the thread lengt h A be for e discon necti ng the No .1 ca ble. • Disc onn ect t he E XCV c ab[...]

6-8 EXH AUST SYSTE M • C onnec t the N o. 1 cab le 1 an d No .2 c abl e 2 to the EXCVA pul ley . • L oosen the lock-nu t 9 an d turn th e N o.2 ca ble adju ster 0 in or out until the thre ad leng th D bec omes 11. 0 – 12.0 m m (0.4 3 – 0.47 i n). • tigh ten the lock-nu t 9 . EXCVA ADJUSTMENT 1st st ep: • Se t th e EXC VA to adj ustme nt[...]

EXHAUST SYS TEM 6 - 9 • To set the EXC V to fu lly close pos ition, a pply 1 2 V to A an d B term inal s. Ba ttery + te rm in al–– A (Pink le ad wire) t erm inal Ba ttery - te rm in al–– B ( Gra y le ad wi re ) te rm in al  • Tur n the i gni tion sw itch O N. • M easu re the posi tion sen sor output volta ge at fully clos e pos i- [...]

6-1 0 EXHAUST SYSTEM Meas ure the position sen sor output vol tage a t fu lly open po si- tion .  P osit i o n sensor outp ut v olt age EXC V is fully op en: 3.7 ou tpu t vol tag e 4. 5 (V) ( + Y e llow – - B/Br ) If the m easu red voltag e is mor e than s pec ificati on, adj ust th e No.2 cabl e adj uster as follo ws: • Se t th e EXC VA to [...]

EX H AUST S YSTEM 6-1 1 • Loos en th e exh aust p ipe c onnec tor b olt 5 . • Rem ove t he m uffler moun ting b olts 6 . • Loos en th e exh aust p ipe b olts 7 . • Rem ove t he m uffler b ody A . • Rem ove t he e xhau st pipe bolts 7 . • Rem ove t he e xhau st pipe B . NOT E : Wh en an ex haus t pipe sep arates , no t to thro w or drop,[...]

6-1 2 EXHAUST SYSTEM EXCV INSPECTIO N • T urn t he E XCV by ha nd and chec k tha t it m oves s mooth ly. • If it d oes not mo ve smo othly, re place the EXC V toget her with the e xhaus t pi pe. • D ecarbo nize the E XCV if nec essar y.  EXCV/EXHAUST PIPE, MUFFL ER INSTAL LATION Inst all the exhau st pipe and muffl er in th e rev erse or d[...]

EX H AUST S YSTEM 6-1 3 • Tight en t he rad iator mounting bo lts to th e spe cified torqu e.  Radi ato r mount ing bo l t : 10 N· m (1 . 0 k gf-m, 7. 0 lb -ft) • Inst al l t he E XCV cabl es . (  6-7)[...]

6-1 4 EXHAUST SYSTEM 10 N·m (1.0 kgf-m, 7.0 lb-ft) ! * When adjusting the No. 1 and No. 2 cables, the cable slots of EXCV A pulley m ust be located to adjustment position. * Do not use the adjustable wrench to turn EXCV A pul- ley so as not to cause dama ge to the internal gear of EXCV A. 23 N·m (2.3 kgf-m, 16.5 lb-ft) 23 N·m (2.3 kgf-m, 16.5 lb[...]

CO OLING AND LU BRICA TION SYS TEM 7- 1 7 COOLING AND LU BRICATION SYSTEM CONTENT S ENGINE COOLANT ...... ........ ....... .... ....... ....... ........ ... ........ ....... ....... ........... .. 7- 2 COOLING CIRCUIT ...... ........ ... ........ ....... ....... ........... ........ ....... ....... ........ ..... 7- 3 COOLING CIRCUIT INSPE C T ION [...]

7-2 COOLING A ND L UBRICATI ON SYSTEM ENGINE COOLANT At the time of ma nufac ture, the cooli ng syste m is fi lled with a 50:50 mix ture of distille d water an d e thylene glyc ol an ti-freeze . This 50:50 m ixt ure w ill provi de the o ptimu m cor rosi on pro tection and ex cell ent heat pro- tect ion, a nd wi ll protec t the c ooling syst em fro [...]

CO OLING AND LU BRICA TION SYS TEM 7- 3 COOLING CI RC UIT COOLING C IRCUIT INSPECTIO N Be fore rem ov ing the ra diato r and draini ng the en gine coolan t, inspe ct the cool ing circuit for tigh tness. • Rem ove t he ri ght und er cowling. (  8-5) • Rem ove the ra diator cap 1 an d con nect the tes ter 2 to the filler.  • Giv e a p res[...]

7-4 COOLING A ND L UBRICATI ON SYSTEM RADIATOR AND W ATER HOSES RADIATOR REMO VAL • R em ove th e unde r cow lings. (  8- 5) • D rain the en gine co olant. (  2- 17) • R em ove th e radia tor as sem bly. (  3-4) • R em ove the r eser voir tan k 1 , cooling fan 2 from the radia- to r. RADIATO R CAP INSPECTION • F it th e cap 1 to [...]

CO OLING AND LU BRICA TION SYS TEM 7- 5 Fins bent do wn or den ted ca n be repaire d by str aigh tening them wit h the bl ade o f a sm all scr ewdr iver. RADIATO R INSTALLATION • Ins tall the cooli ng fan.  Cool ing fan mo unting bol t: 8 N· m (0. 8 kgf- m , 6. 0 lb-ft ) • Ins tall the radi ator. • Rou te th e radiat or hoses proper ly. ([...]

7-6 COOLING A ND L UBRICATI ON SYSTEM COOLIN G FA N REMOVAL (  7-4) INSPECTI ON • R em ove th e right unde r cowl ing. (  8- 5) • D isco nnect the c ooling fan co upler 1 . • T est the c ool ing f an mo tor fo r l oad c urre nt with an a mmeter connected as sho wn in the illust ration . • T he vo ltmete r is for mak ing sur e that the[...]

CO OLING AND LU BRICA TION SYS TEM 7- 7 COOL ING FAN R ELAY IN SPECTIO N Cool ing fan r elay i s lo cated on th e a ir clea ner b ox ( left side o ne). • Lif t and s uppor t th e fuel tank. (  8- 3) • Rem ove t he co olin g fan r elay 1 . First ch eck the insu la ti o n be tween A an d B te rm inals with tes ter. T hen a pply 12 V to C an d [...]

7-8 COOLING A ND L UBRICATI ON SYSTEM • If the E CT sens or oh mic v alue does not c hange i n the pr opor- tion indic ated, r epla ce it w ith a n ew one .  T emp eratu re senso r s pe cificatio n  Cool i n g fan op e ra ting te mperatur e: Sta ndar d (OFF → ON): Ap pro x . 10 5 °C (221 ° F) (ON → OFF): A ppr ox. 100 °C (2 1 2 °F )[...]

CO OLING AND LU BRICA TION SYS TEM 7- 9 THER MO STA T REMOVAL • Dr ain en gine coolant . (  2-17) • Lif t and s uppor t th e fuel tank. (  5- 3) • P lace a r ag und er the the rmos tat co ver. • Rem ove t he t hermo stat cov er 1 . • Rem ove t he t hermo stat 2 . INSPECTI ON Ins pect t he ther mosta t pelle t for s igns o f cra ckin[...]

7- 10 COOLI NG AND LU BRICA TI ON SY STEM • Ke ep on heat ing th e w ater to raise its tem peratu re. • J ust wh en t he wat er temper ature reac hes sp ecifie d value , th e ther mosta t valv e sh ould h ave lifted by a t leas t 8 mm (0.31 in).  T her m os ta t valv e lift A Standard: 8.0 m m an d over a t 95 ° C (0. 31 in a nd over at 20 [...]

CO OLING AND L UBRIC ATION SY STEM 7-1 1 WATE R PUMP REMOVAL AND DI SASS EMBLY NOT E : Be fore drai ning engin e oil and eng ine coo lant, ins pec t engi ne oil and co olant leakag e betw een the wate r pum p and crank case. If engi ne oil is leak ing , vis ually in spect the oil seal and O-r ing. If engi ne coola nt is leaki ng, visu ally inspec t[...]

7- 12 COOLI NG AND LU BRICA TI ON SY STEM • R em ove the me chani cal seal ring 4 and r ubber seal 5 from the impell er. • R em ove th e imp eller shaft 6 and wash er 7 . • R em ove th e mec hani cal seal with the s pecial to ol.  09921- 20240: Beari ng re mover se t (12 m m) NOT E : If the re is n o abnorm al co nditi on, th e mech anical[...]

CO OLING AND L UBRIC ATION SY STEM 7-1 3 INSPECTI ON M ECHA NIC AL S EAL • V isually i nspe ct the m echan ical se al for d am age, with p articu- lar at tent ion giv en to t he se aling fa ce. • Rep lac e the mec hanica l seal th at show s indic ations of leak- age. Al so repl ace the s eal ring i f nec essary. OIL SEAL • Vis uall y in sp ec[...]

7- 14 COOLI NG AND LU BRICA TI ON SY STEM REASSEMBLY AND INSTALLATION • In stall the oi l seal w ith the spec ial to ol.  09913- 70 210: B earing in stall er set (  22) NOT E : The stamp ed mar k on the oil seal face s mechani cal seal side. • Ap ply a small quantity of the SUZUKI SU PER GR EASE “ A ” to the oil seal l ip.  9900 0-[...]

CO OLING AND L UBRIC ATION SY STEM 7-1 5 • Ins tall the rubbe r se al 1 into th e imp ell er. • A fter wiping of f the oil y or greasy matter fr om the me chani cal seal ring, in stall it into the i mpeller. NOT E : The paint mark ed sid e B of mec hani cal s eal ring faces the r ub- ber seal . • Ins tall th e w ash er 2 and seal w ashe r 3 o[...]

7- 16 COOLI NG AND LU BRICA TI ON SY STEM • In stall the wa ter pump. NOT E : Se t the wa ter pump shaft end F to th e o il pump shaft G as shown. • T ight en the wat er pum p mou nting bolts to th e sp ecifie d torq ue.  W a ter pump mo untin g bolt : 10 N ·m ( 1.0 kgf-m , 7.0 lb -ft) • C on nect the w ate r hos es. (  1 0-24) • Po [...]

CO OLING AND L UBRIC ATION SY STEM 7-1 7 LUBRICATION S YSTEM OIL COOL ER INSPECT ION Ins pect th e oil c oole r and oil co oler wa ter hos es for eng ine o il lea kage and eng ine coola nt l eak age. Repl ace any d efect ive par ts if ne cess ary. REM OVAL • Rem ove t he u nder co wli ngs. (  8- 5) • Dr ain engine oi l. (  2-12) • Dr ai[...]

7- 18 COOLI NG AND LU BRICA TI ON SY STEM OIL PRESSURE  2- 33 OIL FILTER  2- 13 OI L PR ES SU RE REG U LA TO R  3- 44 OIL STRAINER  3- 44 OIL J ET  3- 58 OIL P UMP  3- 41 OIL PRESSURE SWITCH  9- 34[...]

CO OLING AND L UBRIC ATION SY STEM 7-1 9 ENGINE LUBRICATION SYSTEM CHART INT AKE CAMSHAFT CAM DRIVE CHAIN CAM CHAIN TENSION ADJUSTER #1 PIST ON COOLING OIL JET #1 PIST ON AND CYLINDER W ALL #1 CRANK PIN BEARING #1 CRANKSHAFT JOURNAL BEARING ORIFICE GENERA TOR GENERA TOR & ST ARTER CLUTCH #2 CRANKSHAFT JOURNAL BEARING #3 CRANKSHAFT JOURNAL BEARI[...]

7- 20 COOLI NG AND LU BRICA TI ON SY STEM ENGINE LU BRICATION S YSTEM[...]

CO OLING AND L UBRIC ATION SY STEM 7-2 1[...]

CHASSIS 8- 1 8 CHASSIS CONTENTS EXTERIOR PARTS ....... ........ ....... ....... ........ ........... ....... ....... ........ ....... ....... .. 8- 3 FASTEN ER RE M OVAL AND INSTALLATI ON ...... ....... ........ ....... ....... .. 8- 3 BODY COWLING COVER AND LOWER BRACKET COVER ........ ..... 8- 5 INNER UNDER COWLING ........... ........ ....... ..[...]

CHASSIS CONTENTS 8-2 CHA SSIS R EMOVAL ....... ........... ....... ........ ....... ....... ........ ....... ........... ....... ........ ..... 8-49 INSPECTION ....... ....... ....... ........ ....... .... ....... ....... ........ ........... ....... ....... .. 8 -51 REAR SHOCK ABSORBER SCRAPPING PROCEDURE ... ....... .... ..... 8-51 INSTALLATION .[...]

CHASSIS 8- 3 EXTERIOR PARTS FAS TEN ER REM OV AL AND IN STAL LA TION FA ST EN ER (T yp e A) Remo v a l • Dep re ss the h ead of f asten er c enter p iece 1 . • P ull out t he fas tener a . Inst allati on • Le t th e ce nte r pi ece s tic k ou t to wa rd the h ead so th at t he pawl s 2 c lose. • Ins ert the faste ner i nto the instal lation[...]

8-4 CHA SSIS Inst allati on • In ser t the fas tener into the in stallati on hol e. NOT E : To pr even t t he pa w l 2 from da mag e, insert th e fasten er all the way into the ins tallation hol e. • Pu sh i n the h ead of ce nter piec e.[...]

CHASSIS 8- 5 BODY COWL ING COVER AN D LOWER BRACKET COVER REM OVAL • Remove the body cowling c ov e r 1 by r emoving the screws and faste ners. • Rem ove t he low er br acket cov er 2 by remo ving th e bo lts. INSTA LLATION • Ins tall the lo wer brac ket cov er and bo dy cowl ing cov er in the reverse o r der of re m ova l. INNER UNDER COWLIN[...]

8-6 CHA SSIS SCREEN REM OVAL • R em ove th e scr een 1 b y re moving the screws . INSTA LLATION • In stall two nu ts (m iddle o nes) as sho wn . • Inst al l t he w indo w sc reen . BOD Y COWLING REM OVAL • R em ove th e left and rig ht un der cow lings . (  8-5 ) • R em ove th e scr een. (  Above) • R em ove th e com bina tion m e[...]

CHASSIS 8- 7 AIR INT AKE PIPE REM OVAL • Rem ove t he b ody co wli ng. (  8- 6 ) • Rem ove t he f asten ers. • Rem ove t he a ir inta ke pipe s 1 . ( LH/ RH) INSTA LLATION • Ins tall the air intake p ipes i n the r ever se o rder of r em oval. COWLIN G BRACE REM OVAL • Rem ove t he b ody co wli ng. (  8- 6 ) • Rem ove t he co wli [...]

8-8 CHA SSIS REAR SEAT/SEAT T AIL COVER REM OVAL • R em ove th e rear s eat ( seat t ail co ver) u sing the igni tion ke y. INSTA LLATION • Ins ert th e sea t hook to th e g uide and pus h down th e sea t (seat tail cov er) firmly unti l the seat (se at tail c ove r) snaps i nto the locked po sition. FRAME COVER REM OVAL • R em ove th e fron [...]

CHASSIS 8- 9 FRONT WHEEL CONSTRUC TI ON 1 B rak e disc 6 F r ont ax le  2 Collar 7 F r ont wh eel ITEM N·m kg f-m lb -ft 3 Dus t s eal A F ront axle bo lt A 1 00 10.0 72.5 4 B earing B B rake disc bolt B 23 2.3 16. 5 5 S pacer[...]

8-10 CH ASSIS REMOVAL AND DI S A S SEMBLY • R em ove th e brake calip ers.  • L oosen two ax le pinch b olts 1 on the r ight front f ork le g. • R em ove th e fron t axle b olt 2 . • R em ove th e unde r cow ling. (  8-5) • R aise th e fron t w heel o ff the g rou nd and supp ort the mo torcy- cle w ith a jack or a w ooden bloc k. ?[...]

CH A S SI S 8 - 11 • Remove the brak e discs, lef t and righ t. • Rem ove t he d ust sea ls o n both side s with the specia l tool .  09913- 501 21: Oil sea l remover  • Rem ove t he w heel bearing s wi th the spec ial too l.  09921- 20240: Beari ng re mover se t  • Rem ove t he sp acer 5 . Th e removed dus t seals mu st be rep [...]

8-12 CH ASSIS INSPECTI ON TIRE IN SPECTION (  8-85 ) BRAK E DI SC IN SPEC TION (  8-70) AXLE SHAFT • U sing a dial ga uge , ch eck th e axle sh aft for r unout an d repla ce i t if the runou t excee ds th e li mit.  09900- 206 07: D ial gaug e (1/10 0) 09900- 207 01: Magn etic s tand 09900- 213 04: V -block set (100 m m)  Axle s haft [...]

CH A S SI S 8 - 13 REASSEMBLY AND INSTALLATI ON Reas sem ble an d install the fro nt wheel in th e reverse order of remo val an d dis assem bly . Pay a ttenti on to th e fo llowing p oints : WHE EL BE ARING • Apply SUZUKI SUPER GR EASE “A” to the w heel bearings.  9900 0- 2501 0: SUZUKI SU PER GREA SE “A” (o r equivalen t gre ase) 23 N[...]

8-14 CH ASSIS • In stall the wh eel be ar ings w ith the speci al tool s as fo llows .  09924- 845 10: B earing in stalle r se t  • In stall the dus t se al with the speci al to ol.  09913- 702 10: B earing in stalle r se t • Apply SU ZUKI SUPER GR EASE “A” to the dust seal li p .  99000 -2 5010: SUZU KI SUP ER G REA SE “A ?[...]

CH A S SI S 8 - 15 • Install t he coll a r 1 in the right side. WHEEL • Ins tall the front w he el with the front a xle and ha nd-ti ghten th e front axle bolt temporarily .  BRAK E CALI PER • Tight en the brake cali per mounti ng bo lts to th e sp eci fied torq ue.  Fr ont bra ke cal ipe r mou nting bol t: 39 N·m (3.9 k gf-m, 28.0 lb-[...]

8-16 CH ASSIS • T ight en two a xle pi nch b olts on t he left front fo rk leg to th e s pe c if ie d t o rq u e.  Front ax le pin ch bo lt: 23 N ·m ( 2.3 kgf-m , 16.5 l b-ft)[...]

CH A S SI S 8 - 17 FRONT FORK CONSTRUC TI ON 1 Ad ju st er rod 9 Oil seal stop per ri ng 2 S pring re tainer 0 Dust seal 3 S pacer A In ner tub e  4 Sp ri ng A F r ont f ork c ap bol t ITE M N·m k gf- m lb- f t 5 Inne r rod/ Da mper r od (car tri dge) B Lo ck-nut A 35 3. 5 25.5 6 Ou ter tub e C F ro nt ax le pinch b olt B 20 2. 0 14 .5 7 Oil se[...]

8-18 CH ASSIS REMOVAL AND DI S A S SEMBLY • R em ove the und er c owling cove r and the low er brac ket cover . (  8- 5) • R em ove th e fron t whee l. (  8-10) • D isco nnect the br ake h ose from the brak e hose g uides at th e fron t fen der. • R em ove th e fron t fender . • L oosen the front fork upp er c lamp bolts 1 , l eft a[...]

CH A S SI S 8 - 19 • Rem ove the front fork cap bolt f rom th e inn er rod b y l oosen ing the l ock n ut. • Com pr ess the fork spr ing with the s pecial tool and remo ve the sp ecial tool. • Rem ove the fron t for k cap b olt 5 , adj us te r ro d 6 , s pring ret ainer 7 , space r 8 a nd sp ring 9 .  • Inv ert the front fo rk a nd strok[...]

8-20 CH ASSIS • R em ove th e damp er ro d bol t with the s pecial to ol an d a hexa- gon w renc h.  09940- 302 21: Front fo rk assem blin g tool • R em ove th e inner rod/da mpe r rod (cartri dge) B .  • Sl ide the oute r tube to r emov e it f rom th e inne r tube . NOT E : Be careful not to dam age the “A NTI- FRIC TIO N” me tals.[...]

CH A S SI S 8 - 21 • Rem ove t he o il sea l E with the s pec ial tool.  09913- 501 21: Oil sea l remover  • Rem ove t he o il sea l retainer F . INSPECTI ON INNE R A N D OU TER TU BE S • Ins pect the i nner tube o uter surfa ce an d o uter tube i nner sur- face for scratch es. • Ins pect the “AN TI-FR ICTIO N” met al surfaces for[...]

8-22 CH ASSIS DAM PER ROD • M ove t he inn er ro d by h and to exam ine i t for sm ooth ness. • If any d efects a re foun d, r epla ce inner r od/d amper rod ( car- tridge ) wi th a new o ne. REASSEMBLY Reas sem ble the front for k in the r evers e order of di sassem bly . Pa y atte ntion to the fo llowi ng poi nts: OIL SEAL AND DU ST SEAL • [...]

CH A S SI S 8 - 23 DAMP ER RO D BOLT • Ins ert the inne r rod /damper rod (cartr idge) i nto the inner tube. • A pply TH REA D LOCK to the d amp er rod bolt an d tighten i t to the s pec ified to rque w ith th e spe cial tool.  9900 0-3 2110: THR EAD L OC K SU PER “13 22” (or e quivalent t hread lo ck)   09940- 302 21: Front fo rk [...]

8-24 CH ASSIS • M ove the inner rod s lowly wi th the sp ecial to ol ten times an d m ore un til no m ore bu bbles co me out from the oil .  0994 0- 52841: Inner rod holder NOT E : Refi ll front fork o il up to the top of the oute r tube so that bub bles are vi sibl e while blee ding a ir. • R efil l specified front for k oil up to th e top [...]

CH A S SI S 8 - 25 • Ins ert the ad juster rod to the fro nt fork c ap bo lt. • A pply for k oil to the O-ring .  • B e sure to c heck or adj ust the heigh t D of th e rebou nd damp- ing force a djus ter as f ollo ws. H : 1.5 mm (0.05 in) • S lowly tur n the ca p bolt com plete ly by ha nd un til the end of the c ap bo lt s eats on the i[...]

8-26 CH ASSIS INSTAL LATION Inst all the front fork in t he re verse order of r emov al. P ay at ten- tion to the fo llo wing poi nts: • Se t th e upper sur face of the oute r tube heig ht A a t 5. 0 mm (0.1 96 in) from the upp er surface of the steer ing stem upper brac ket an d tigh ten the front fork l ower clamp bolts 1 to t h e s pe c if ie [...]

CH A S SI S 8 - 27 SUSPENSION SETTI NG Aft er insta lling the fro nt fork, adj ust the spr ing pre- load an d damp ing fo rce a s foll ows. SPRIN G PRE-LOA D ADJU STMENT Tur n the da mp ing forc e adj uster 1 coun ter clockw ise full y. It is at s oftes t positi on and turn i t out t o stan dard s etti ng pos ition.  ST D po sit ion: 7 tur ns i [...]

8-28 CH ASSIS STEERING DAMPER CON S TRUCT ION 1 S teer ing da mper 4 Conve x cu r v e side of the w a sher faces down side.  2 Dus t s eal ITEM N ·m kgf-m lb-f t 3 S teer ing stem he ad nut A Dam per rod b olt AB 23 2 .3 1 6.5 B Dam per rod nut 3 90 9 .0 65.0[...]

CH A S SI S 8 - 29 REMOVAL • Rem ove t he low er br acket cov er. (  8-5) • Rem ove t he n ut 1 by holding the nut 2 . • Rem ove t he b olt 3 and remo ve th e stee ring dampe r. INSPECTI ON • Ins pect the ste ering dam per b ody, be arin g and oil sea l for dama ge and oil leaki ng. • M ove the steeri ng damper rod by hand to inspec t [...]

8-30 CH ASSIS STEERING CON S TRUCT ION 1 S teer ing stem up per bracket 8 S teer ing s tem l o wer brack e t  2 Han dleba rs A S teer ing stem he ad nut IT EM N·m kgf -m lb-ft 3 Han dleba r bal ance r B S teer ing stem lock-nu t A 9 0 9.0 65.0 4 S teer ing stem nut C F ront f o rk up per clamp bolt B 80 8.0 58.0 5 Dust s e al cov e r D H andl e[...]

CH A S SI S 8 - 31 REMOVAL • Rem ove t he u nder co wli ng. (  8-5) • S upport the mot orcyc le wi th a ja ck or a wood en block.  • Rem ove t he f ront w heel. (  8- 10) • Rem ove t he f ront fo rks. (  8- 18) • Rem ove t he ste erin g damp er. (  8-29) • Rem ove t he ste erin g stem head nut 1 a nd was her 2 . • Rem o[...]

8-32 CH ASSIS • R em ove the dust seal cover 1 , dust seal 2 , st eer ing s tem uppe r b earing inn er race 3 an d be aring 4 . INSPECTION AND DISASSEMBLY Insp ect th e rem oved parts for th e follow ing a bno rmalit ies. * Han dleba rs dis tortion * Rac e wear and br inelling * Be aring w ear or dama ge * Ab norma l noise o f be aring If any ab [...]

CH A S SI S 8 - 33 REASSEMBLY Reas sem ble th e steeri ng stem in the rever se or der of dis assem- bly. P ay att ention to the fol lowing point s: OUT E R RACE • P ress in the u ppe r and low er be aring o ute r ra ces w ith th e sp ecial tools.  09941- 345 13: Stee ring o ute r race in stalle r se t 09913- 702 10: B earing in stall er set ( [...]

8-34 CH ASSIS • T urn th e stee ring st em lower brac ket a bout fi ve or six ti mes t o the l eft and righ t so th at the a ngu lar b all bea rings w ill be sea ted pr ope rly. • L oosen the stem nut by 1/4 – 1/2 turn. NOT E : This ad justment will va ry from motorcycl e to mo torcycle. NOT E : Wh en in stalling the was her, a lign the stop [...]

CH A S SI S 8 - 35 STEERING TE NSION ADJUSTM ENT Chec k th e ste ering mo veme nt in the fol lowing proced ure. • By suppo rting the motorcycl e with a ja c k, li f t the front w h eel unti l it i s off the fl oor by 20 – 30 mm ( 0.8 – 1. 2 in) . • Rem ove t he ste erin g damp er. (  8-29) • Che ck t o mak e sure th at th e cab les and[...]

8-36 CH ASSIS HANDLEBARS CON S TRUCT ION REMOVAL • R em ove the b rake ma ster cyli nder 1 . • R em ove th e right hand le switc h 2 . • R em ove th e hand le balan cer 3 . • R em ove th e right hand le throt tle gr ip 4 . FW D FWD 1 Left hand le grip 5 H andl ebar ( RH) 2 Ri ght han dle th rottl e grip 6 Hand leb ar ( LH)  3 Ri ght han [...]

CH A S SI S 8 - 37 • Rem ove the le ft h andle switc h 5 an d d iscon nect the c lutch lever switch lead wire . • Rem ove t he h andle bala ncer 6 . • Rem ove t he lef t ha ndle g rip 7 . • Disconn ect the cl utch cable 8 . • Rem ove t he cl utch lever holder 9 . • Loos en the han dleba r clamp bo lts an d f ro nt fork upper clam p bol [...]

8-38 CH ASSIS • Inse rt t he prot rus ion A of the han dlebars i nto the ho le B of the s teerin g stem up per br acket. • T ight en the front fork up per clam p b olts 1 and h and lebar clam p bo lts 2 to th e spe cified tor qu e.  Fr ont f ork upp er cla mp bolt: 2 3 N·m (2 .3 kgf- m, 16. 5 lb- ft) Han dleba r clam p bolt : 23 N ·m ( 2.3[...]

CH A S SI S 8 - 39 • A pply th e SUZU KI S UPE R G REA SE “A” to th e t hrottle cabl es and ca ble drum.  9900 0- 2501 0: SUZUKI SU PER GREA SE “A” (o r equivalen t gre ase) • W hen rem ount ing the right and l eft handl e switche s, engag e the s toppe r wi th the h and lebar ho le. Aft er ins talling the stee ring, the fol lowing a[...]

8-40 CH ASSIS REAR WHE EL CON S TRUCT ION 1* 1 Rear ax le 0 Sprocket mounting dr um 2 Brake d isc A Sp r ocket 3 Collar B Bear ing 4 Dust seal C Dust seal 5 Rear whe el D C ollar  6 Sp acer A Brake disc bolt IT E M N·m k gf -m lb-f t 7 Bearing B Re a r sp ro cke t n ut A 35 3.53 25 .5 8 Cus hio n C R ear axl e nu t B 93 9.3 67.5 9 Sp acer *1 Ex[...]

CH A S SI S 8 - 41 REMOVAL • Rem ove t he co tter pi n. (F or E- 03, 28, 33) • Loos en the axl e nut 1 . • Rem ove t he u nder co wli ng. (  8-5) • Rai se t he rea r whe el off the gro und and supp ort the mo torc y- cle w ith a jac k or wo ode n blo ck. • Rem ove t he a xle nut and draw out the rear axle. • Rem ove t he rea r whe el[...]

8-42 CH ASSIS • R em ove th e dus t sea l with t he sp ecial tool .  09913- 501 21: Oil sea l remove r  • R em ove th e dus t sea l with t he sp ecial tool .  09913- 501 21: Oil sea l remove r  INSPECTION AND DISASSEMBLY TIRE IN SPECTION (  2 -x an d 8- 85) WHEEL IN SPECTION (  8-85) REA R AXLE • U sing a dial gauge , chec k[...]

CH A S SI S 8 - 43 SPROC KET • Ins pect the sp rocke t teeth f or wear. • If they are w orn as s hown , re place th e two s prock ets an d driv e ch ain as a set. A Nor mal we ar B Excessive wear BEA RINGS • Ins pect th e play of the whee l bear ing an d sproc ket m oun ti n g dru m bea ring by hand whil e they are i nstalled i n place. R ota[...]

8-44 CH ASSIS REASSEMBLY AND INSTALLATION Reas sem ble an d install the rear w hee l in the re verse ord er of remo val and dis assem bly . Pay a ttenti on to the foll owing p oints : Left Right 100 N·m (10.0 kgf-m, 72.5 lb-ft) E-02, 19, 24 E-03, 28, 33 93 N·m (9.3 kgf-m, 67.5 lb-ft) 35 N·m (3.5 kgf-m, 25.5 lb-ft) 100 N·m (10.0 kgf-m, 72.5 lb-f[...]

CH A S SI S 8 - 45 BEA RINGS • Apply SUZUKI SUP ER GREASE “A” to t he bearings before instal ling.  9900 0- 2501 0: SUZUKI SU PER GREA SE “A” (o r equivalen t gre ase) • Ins tall the n ew bearing t o the sproc ket mo untin g drum with th e sp ecial tool.  09913- 702 10: B earing in stall er set • Fi rst install the right wh eel [...]

8-46 CH ASSIS WHEEL D AMPER • T o in stall the w he el dam pers, a pply a sp ecial ti re lubr icant or neu tr al soap y li qui d t o t he d amp er s ur fac e.  DUST SE ALS • In stall the new du st seal with th e spe cia l tool.  09913- 702 10: B earing in stalle r se t • Apply SU ZUKI SUPER GR EASE “A” to the du s t seal lip befor e[...]

CH A S SI S 8 - 47 BRAK E DISC • A pply TH REA D LO CK to the di sc bol ts and tig hten them to the s pec ified to rque. NOT E : M ake sur e that the brak e disc is clean and fre e of an y greas y m atter.  9900 0-3 2130: THR EAD L OC K SU PER “13 60”  Br ake di sc bo lt: 35 N ·m ( 3.5 k gf-m , 25.5 lb -ft) • Install t he coll a r 1 [...]

8-48 CH ASSIS REAR S HOCK ABSORBE R CON S TRUCT ION 1 Rea r sh ock abso rber A Rear sh ock abs orbe r mo unt - in g bol t/n ut  ITEM N ·m kgf- m lb -ft 2 Rea r sh ock abso rber bracket B R ea r shock absorbe r bracket nut A 50 5.0 36.0 B 115 1 1.5 83.0[...]

CH A S SI S 8 - 49 REMOVAL • Rem ove t he f ront sea t. (  8-5) • Rem ove t he f uel ta nk. (  5-4) • Di sconne ct the HO 2 s enso r lead w ire co upler . (  10- 40) • Rem ove t he u nder co wli ng. (  8-5) • Rem ove t he e xhau st muf fler. (  6-10) • Loos en the axl e nut. • Support th e m otorcycle with a ja ck re li[...]

8-50 CH ASSIS • R em ove th e brake fluid r eser voir m ounti ng bol t. • L oosen the rear s hock a bsor ber br acket. • R em ove the r ea r shock ab sorber uppe r and lowe r mount ing bol ts and nuts . • R em ove th e rear s hoc k absor ber.[...]

CH A S SI S 8 - 51 INSPECTI ON Ins pect the s hock a bsor ber b ody a nd bus hin g for dam age an d oil l eaka ge. If any defec ts are fou nd, re place th e sho ck absorbe r wi th a new one.  REAR SH OCK ABSORBER SCRAPPING PROC E D URE  REA R SHOCK ABSORBE R GAS R E L EASE • Rem ove t he va lve cap 1 . Do not a ttempt to disa ssemble the re[...]

8-52 CH ASSIS • Pr ess the valve with a sc rewd river to bl eed out th e nitr ogen gas .  INSTAL LATION Remo unt the r ear shock abs orber in th e r everse or der o f remo val. P ay a ttention t o th e follow ing p oints: • In stall th e rear sho ck abso rber and ti ghten the rear shoc k abs orber upper /low er mou nting bolts a nd n uts. ?[...]

CH A S SI S 8 - 53 SUSPENSION SETTI NG Aft er installin g the rear suspe nsi on, adjust the spring pre-loa d and d amp ing fo rce as follow s. SPRIN G PRE-LOA D ADJU STMENT The set leng th 1 76.4 mm (6 .94 in) pr ovide s the m axi mum s pring pre- load . The set len gth 18 6.4 mm (7.34 in) provid es th e min imum sprin g pre- load .  STD leng th[...]

8-54 CH ASSIS REAR S USPENSI ON CON S TRUCT ION 1 Rear sh ock abs orbe r 0 Plate 2 Rear cushi o n rod A Rear shock a bsorber moun ting bolt/ n ut  3 Rear cushion le ve r ITEM N· m kgf-m lb- ft 4 Sp acer B Re ar cus hion le ve r bolt/nut A 50 5.0 36.0 5 Bearing C Re ar cu shion rod bo lt/nut B 98 9.8 71.0 6 Chai n co v er D Sw ingar m piv o t s [...]

CH A S SI S 8 - 55 REMOVAL • Cut the driv e chain. (  8-89 an d -90) NOT E : It is not nece ssary to cut the drive chain, unle ss replac ing d rive ch ain o r sw in gar m. • Rem ove t he rea r sh ock abs orbe r. (  8-49 and - 50) • Rem ove t he cu shio n leve r moun ting b olt/nu t 1 . • Rem ove t he cu shio n leve r 2 . • Rem ove t[...]

8-56 CH ASSIS • R em ove th e plate 0 . INSPECTI ON SW INGARM PIV OT SHAFT • U sing a di al gau ge, che ck the piv ot shaf t run out a nd replac e it if th e runo ut e xceeds the li mit.  Swin garm pi vot s haft r unout: Ser vic e limit: 0.3 mm (0. 01 i n)  09900- 206 07: D ial gaug e (1/10 0 mm , 10 m m) 09900- 207 01: Magn etic s tand 0[...]

CH A S SI S 8 - 57 SWI NG ARM • Ins pect the s wingar m for damage . If any dama ges are f oun d, re plac e t he s w in garm with a ne w o ne. CUS HION ROD • Ins pect the cu shion r od for damag e a nd disto rtio n. • If any defects ar e found, rep lace the c ushion rod with a new one. CUSHION LEVER • Ins pect the cus hion lever for dam age[...]

8-58 CH ASSIS SW INGA RM BE ARIN G • In ser t the s pac er into bea ring an d ch eck the p lay wh en mo v- ing the s pacer u p an d do wn. • If exces siv e pla y is note d, repla ce th e bear ing with a new one . CUS HION R O D BEAR ING • In ser t the s pac er into bea ring an d ch eck the p lay wh en mo v- ing the s pacer u p an d do wn. •[...]

CH A S SI S 8 - 59 DISASSEMBLY SWI NG ARM BE ARING • Dr aw out the swinga rm pivot b eari ngs wi th the s pec ial tool.  09921- 20240: Beari ng re mover se t ( 1 28 mm)  • Rem ove t he ce nter s pace r. CUS HION ROD BEAR ING • Dr aw out the cus hion rod bea rings with the s pecial too l.  09921- 20240: Beari ng re mover se t  CUSH[...]

8-60 CH ASSIS REASSEMBLY AND INSTALLATION Reas sem ble a nd insta ll the sw ingar m in the re verse order of dis assemb ly and remov al. Pa y atte ntion to the fo llowi ng poi nts: Left Right 115 N·m (11.5 kgf-m, 83.0 lb-ft) 50 N·m (5.0 kgf-m, 36.0 lb-ft) 50 N·m (5.0 kgf-m, 36.0 lb-ft) 78 N·m (7.8 kgf-m, 56.5 lb-ft) 78 N·m (7.8 kgf-m, 56.5 lb-[...]

CH A S SI S 8 - 61 SWI NG ARM BE ARING • Ins tall the cente r sp acer. • P ress the bea rings into the s win garm piv ot with the s pecial tool .  09941- 345 13: Stee ring ra ce i nstaller NOT E : Wh en i nstallin g the bea ring, s tamped m ark on the be aring m ust fa ce ou tside. CUS HION ROD BEAR ING • P ress t he bear ings i nto the cu[...]

8-62 CH ASSIS • R em ount the plate 1 . • R em ount the chai n cases 2 ch ai n bu ff er 3 an d rear fen der (low e r ) 4 . SW INGARM PIV OT THRUST CLEAR ANCE ADJU STMENT Adjust swingarm p i vot thr ust clearance in th e fol lowi ng procedure. • In ser t the s wing arm p ivot s haft an d tigh ten to the s pec ified torq ue.  09944- 283 20: [...]

CH A S SI S 8 - 63 SHOCK ABSO RBER, CUS HION LEVER A ND C USHION RO D MOUNT ING BOLT /NUT • Install t he cush ion lever . • Tight en the cush ion le ver mounti ng nut 1 to th e sp ecified torq ue.  Cush i o n le ver mo untin g nut: 98 N·m (9.8 k gf-m, 71.0 lb-ft) • Install t he cush ion rod. • Tight en t he cush ion r od moun ting n ut [...]

8-64 CH ASSIS FRONT BRAKE CON S TRUCT ION 1 B rak e le ver A Maste r cylinde r m ounti ng bolt  2 Dus t boot B Brake hose union bolt ITE M N·m kgf- m lb- ft 3 Piston set C Caliper m oun ting b olt A 10 1.0 7.0 4 Piston seal D Cal ipe r air bleeder valve B 23 2.3 16 .5 5 Dus t s eal E Calipe r housing bolt C 35 3.5 25.5 6 B rak e calipe r piston[...]

CH A S SI S 8 - 65   BRAKE PAD REPL A CEMENT • Loos en th e pa d m ountin g pin s 1 . • Rem ove th e bra ke calip er by rem oving the calipe r moun ting bol ts 2 . • Rem ove t he p ad mou nting pins 1 , brak e pads and sprin g.  NOT E : * Whe n the brak e caliper is rem oved , care mus t b e used so as not to ca use str ess to the br[...]

8-66 CH ASSIS • In stall th e spring to the c aliper , b ring its wide r side of paw l A fac ing to p. • In stall the new brak e pad s. • In stall the br ake cal iper. • T ight en eac h bol t to the speci fied t orque.  P ad mounti ng pin 1 : 15 N·m (1.5 kgf- m, 11 .0 lb- ft) Fr ont bra ke ca l ipe r mounti ng bol t 2 : 39 N· m (3.9 kg[...]

CH A S SI S 8 - 67 CALIPER REMOVAL • Rem ove t he b rake ho se fr om the c aliper by rem ovin g the uni on bolt 1 an d c at ch th e br ak e fl ui d i n a su itab le r ecep ta - cle. NOT E : Place a ra g under neath t he u nion b olt on t he bra ke cal iper to cat ch an y split b rak e fluid. • Rem ove t he b rake pa ds an d spr ing. (  8-65 [...]

8-68 CH ASSIS • R em ove th e dus t sea ls 4 and pis ton se als 5 .  CALIPER INSPECTI ON BRAK E CALI PER • In spect t he b rake c aliper cyl inder w all for nicks, scratch es or other dama ge. BRAKE CALIPER PISTON • In spect th e br ake ca liper p iston s urface f or any scra tches or other dama ge. CALIPER REASSEMBLY Reas sem ble th e cal[...]

CH A S SI S 8 - 69 PISTON SE AL • Ins tall the piston seal s as s hown in th e illustr atio n. O-RI NG • Ins tall the new O-ring 1 and reas sem ble cal iper ha lves .  • Tem po rarily t ighten the air bleed er v alve 2 . • Tight en e ach b olt to the s pecifi ed tor que.  Fr ont bra ke cal ipe r hou s ing bolt 3 : 22 N·m (2.2 k gf-m,[...]

8-70 CH ASSIS BRAKE DISC INSPECTION • Visually ch e ck the brake disc for damage or cra cks. • M easu re the thic kness w ith a m icrom ete r. • Replace the disc if t he th ickness is less t h an the ser vice limit or if d ama ge is fo und .  Front d isc th ickness : Serv ice Limit: 5.0 m m (0 .20 in )  09900- 202 05: Mi cr om eter ( 0 [...]

CH A S SI S 8 - 71 MASTER CYLINDER REMO VAL AND DISASSEMBLY • Dr ain th e brake fluid . (  8-66 ) • Di sconne ct the front brak e light switc h lea d wires 1 . • P lace a rag u nderne ath the un ion bo lt 2 on the master cyl in- der to catch an y sp lit brake fluid . Remov e the un ion bol t and disc onnec t the brake hos e.  • Rem ov[...]

8-72 CH ASSIS • R em ove th e dus t boot 9 pus h ro d 0 and snap ring A . • R em ove th e follow ing parts. B Se cond ary cu p C Piston D Primary cup E Retu rn sprin g F Retu rn sprin g guid e G Air blee der val ve • R em ove th e dus t rubb er H and s nap ring I . • R em ove th e con necto r J a nd O -ring K . MASTER CYLINDER INSPECT ION ?[...]

CH A S SI S 8 - 73 • Ins pect the pi ston su rfac e for a ny scra tches o r o ther da mage. • Ins pect the pr ima ry cu p, se cond ary c up and d ust se al for wear or damag e. MASTER CYLI NDER REASSEMBLY Reas sem ble t he mas ter cy linder in the r ever se ord er of d isa s- sem bly. P ay attenti on to th e fo llowing p oints :   Spec if[...]

8-74 CH ASSIS • Apply S UZUKI SILICONE GR EASE t o the brake lever pivot bol t.  99000 -2 5100: SUZU KI SILICO NE G RE ASE  Br ake lever p iv ot bolt: 1 N·m (0.1 k gf- m, 0.7 lb-ft) Br ake lever lo ck-nut: 6 N·m (0.6 kgf-m , 4.5 lb -ft) • Al ign the co nvex par t A of brake light switc h with the ho le B of ma ster cylind er wh en ins t[...]

CH A S SI S 8 - 75 REAR B RAKE CONSTRUC TI ON 1 Brake pedal A Calipe r air bleede r valve  2 Pist o n/Cup se t B Brake hos e uni on bo lt ITEM N·m k gf-m lb -ft 3 Re ser v o i r hose C Brake calip er mo unting bolt A 7.5 0.7 5 5 .5 4 Brake hose D Brake mast er cylinder mou nting bolt B 23 2.3 16.5 5 Brake pad E Brake master cylinde r rod lock-n[...]

8-76 CH ASSIS   BRAKE PAD REPL ACEM ENT • R em ove th e pad m oun ting p in 1 . • R em ove th e calipe r m ounting b olt 2 . • R em ove th e brake pad s with the rear c aliper pivoted up. • C lean up the c alipe r es peciall y aroun d the caliper piston .  • In stall the new brak e pad s.  Pad mo untin g pin : 15 N·m ( 1.5 kg[...]

CH A S SI S 8 - 77 BRAKE FLUID REPLACEMENT • Rem ove t he b rake fl uid res ervoi r mou nting bolt 1 . • P lace a r ag und ernea th th e brake flui d reser voir to catch any sp lit bra ke flui d. Rem ove t he b rake fl uid reser voir cap 2 . • Rep lac e the br ake flui d in the same mann er as the fro nt br ake. (  8-66)  Spec ific atio[...]

8-78 CH ASSIS • R em ove th e brake pad sprin g. • R em ove th e calipe r air bl eeder valv e 4 . • R em ove th e spa cer 5 and rubbe r boot 6 from th e cal iper. • Pl ace a r ag ov er the pi ston to p reve nt i t from p oppin g out an d then for ce ou t the pis tons using c ompr essed air.  • R em ove th e dus t sea l 7 and pist on se[...]

CH A S SI S 8 - 79 CALIPER INS PECTION BRAKE CALIPER AND BRA KE CALI PER PISTON • Inspe ct the bra ke caliper cyli nder wall for ni cks, s cratches a nd othe r d amage. If a ny d amage is foun d, rep lac e the c aliper wi th a new o ne. • Ins pect the br ake cal iper p iston s urface for any scratch es an d othe r d amage. If a ny d amage is fo[...]

8-80 CH ASSIS CALIPER REASSEMBLY Reas sem ble th e caliper in the r eve rse orde r of dis assem bly. P ay attenti on to the followi ng poin ts: • C lean the calip er bor es and p istons wi th spe cified bra ke fluid , esp ecial ly the d ust sea l gr ooves a nd piston se al gr oove s.  Speci ficat ion a nd clas sificatio n: D O T 4  PISTON S[...]

CH A S SI S 8 - 81 CALIPER IN STALLATION Ins tall the cal iper in th e rev erse order of r em oval. P ay a tten tion to the foll owin g poin ts: • Tight en e ach b olt to the s pecifi ed tor que.  Brak e h ose un ion bol t 1 : 23 N·m (2.3 k gf-m, 16.5 lb-ft) Br ake cal iper moun ting b olt 2 : 17 N·m (1.7 k gf-m, 12.5 lb-ft) Br ake cal iper [...]

8-82 CH ASSIS • R em ove th e reser voir ca p 7 , insu lator 8 , d iaphrag m 9 an d reser voir tank 0 . • R em ove th e sna p ring A wi th the s pec ial tool .  09900- 061 08: Snap ring pliers • R em ove th e con necto r B . • R em ove th e O-ring C .  • Pul l out the dust boo t D , t hen remove the snap ring E .  09900- 061 08: [...]

CH A S SI S 8 - 83 MASTER CYLI ND ER IN SPECTION CYLI NDE R, P ISTO N AND CU P SET • Ins pect t he cylin der bor e wall for a ny sc ratches or oth er dam- age. • Ins pect the cu p set and ea ch ru bber p art for dama ge. MASTER CYLI NDER REASSEMBLY Reas sem ble t he mas ter cy linder in the r ever se ord er of d isa s- sem bly. P ay attenti on [...]

8-84 CH ASSIS MASTER CYLINDER INST ALLATION Inst all the mas ter cylind er in th e reverse or der of remo val . Pay attenti on to the followi ng poin ts: • Ap ply THR EAD LOCK to the mast er cyli nder m ou nting b olts.  99000 -3 2110: THR EAD LOCK SU PER “13 22” (or e quivalent th read lock) • T ight en eac h bol t to the speci fied t o[...]

CH A S SI S 8 - 85 TI RE AND W HEE L TIRE REMOVAL The most cr itica l factor of tubel ess tir e is the seal betwe en th e whee l rim an d the t ire bead. F o r this r eason , it is reco mme nded to us e a ti re chan ger tha t can sati sfy this seali ng re quireme nt and c an ma ke th e op erati on effic ient a s we ll as functio nal. For operat ing[...]

8-86 CH ASSIS VALVE I NSPECTION • In spect t he va lve after t he tire i s remo ved f rom the r i m . • R ep lace the val ve with a ne w one if the seal A rubber is peel- ing or has dam age . NOT E : If the ex terna l appea ranc e of the v alve show s no abn or mal con- dition , r e moving of the v a lve i s not necessar y. If the s ea l ha s a[...]

CH A S SI S 8 - 87 TIRE INSTALLATIO N • A pply tire lubr icant t o the tire be ad. • W hen in stallin g the ti re ont o the wheel , obs erve the follow ing poi nt s.  • W hen in stallin g the ti re, the arrow A on the side wall s houl d poi nt to th e dir ection o f w heel rotation. • A lign the cha lk ma rk put on th e tire a t the time[...]

8-88 CH ASSIS • In this c ondit ion, che ck the “ rim line” B cast on the tir e side wal ls. The line m ust be eq uidi stant from the wh eel rim all arou nd. If the d istanc e betw ee n the r im li ne and wh eel ri m vari es, this indic ates that the be ad is not proper ly seat ed. If this i s the case, de flate t he tir e com pletely an d un[...]

CH A S SI S 8 - 89 DRIVE CH AI N Us e the s pecia l tool i n the fo llo wing pr ocedu res, to cu t and r ejoin the dr ive c hain .  09922- 227 11: D rive cha in cu tting and joini ng tool s et NOT E : Wh en using the spec ial tool, app ly a smal l quan tity of grea se to th e threa ded pa rts o f the s pecial tool . DRIVE CHAIN CUTTING • S et [...]

8-90 CH ASSIS • Pl ace the driv e chain li nk being disjoint ed on the h older part 8 of the too l. • T urn in bo th the adjuste r bolt 6 and pr essur e bolt “A” 3 so that e ach of t heir end h ole fits ov er the chain j oint pi n prope rly. • T ight en the p ressu re bol t “A” 3 with the bar . • T urn in th e pre ssure bolt “B”[...]

CH A S SI S 8 - 91 • A pply g reas e on t he reces sed p ortion of t he join t pla te hol der 3 and s et the joi nt pla te 0 . NOT E : Wh en po sit ioning the joint pla te 0 on the to ol, its stam p ma rk m ust fa ce the joint p late h older 3 side. • S et the drive cha in on th e tool as illustrate d and tur n in th e adj uster bo lt 5 to se c[...]

8-92 CH ASSIS • St ake the joint pin b y tur ning (app roxim ately 7 /8 turn) th e p res su re b o lt “A ” 3 wi th the b ar un til the p in e nd di ameter bec omes the s pecified dimen sio n.  Pi n en d di amet er s pec ifi cati on D  • Ad jus t the dr ive c hain, after co nne cting it. (  2- 20 ) RK 5.45 – 5.85 mm (0.21 5 – 0.[...]

ELEC TRICAL SYS TEM 9-1 9 ELECTRICAL SYSTEM CONTENT S CAUTIONS IN SERV ICING ..... ........ ....... ....... ........ ... ........ ....... ....... ........ ..... 9- 3 CONNECTOR ......... ........ ....... ........... ....... ........ ....... ....... ........ ....... ....... .. 9- 3 COUPLER ..... ....... ....... .... ....... ....... ........ ....... .[...]

ELECTRICAL SYSTEM CONTENT S 9-2 ELEC TRICAL SYSTEM RELAYS .. ....... .... ....... ....... ....... .... ....... ........ ....... .... ....... ....... ........ ... ........ ..... 9 -37 TURN S IGNAL/SIDE-ST A ND RELAY .... ........ ........... ....... ....... ........ ..... 9-37 STARTER RELAY ...... ....... ........ ....... ....... ........ ....... ..[...]

ELEC TRICAL SYS TEM 9-3 CAUTIONS I N SERVICING CONNECTOR • W hen c onnec ting a con necto r, be sur e to pu sh i t in u ntil a click i s felt. • Ins pect the co nnec tor for c orro sion, con tam ination and break- a ge in its co v er . COUPLER • W ith a lock type cou pler, be sur e to relea se th e lock wh en dis- co nnect ing, an d push in f[...]

9-4 ELEC TRICAL SYSTEM SEMI-CONDUCTOR EQUI PPED PART • Be car eful n ot to dr op the par t with a semi -condu ctor built in such as a ECM. • W hen inspec ting this par t, fol low insp ecti on instr uction strictl y. Neg lect ing prop er pr ocedu re ma y caus e dam age to this part. BATTERY • The MF battery u sed in this motor cycle do es not [...]

ELEC TRICAL SYS TEM 9-5 USING T HE MULTI-CIRCUIT TESTER • Pro perl y u se t he mul ti -c ir cui t t es ter + a nd - p robes . Improper use ca n cause d amage to t he mot orcycl e a n d tes te r. • If the vol tage and cur rent val ues are not know n, begi n mea- su ring in the hi ghes t rang e. • W hen meas uring the re sistanc e, m ake sur e [...]

9-6 ELEC TRICAL SYSTEM LOCATION O F ELECTRICAL COMPONENTS 1 Fuel p ump relay (  5- 7) 2 IAT s ens or (  4-53) 3 Cool ing fan relay (  7- 7) 4 PAI R co ntrol soleno id v alve (  11-7 ) 5 CMP se nsor (  4-33) 6 Igni tion coi l (No. 1, 2 , 3, 4) 7 Hor n 8 Fuel l eve l gaug e 9 Fue l pum p (  5- 8) 0 Regulator/Rect ifier A Oil pressu [...]

ELEC TRICAL SYS TEM 9-7 1 Battery 2 AP se nsor (  4- 57) 3 Mode sele ction sw itch c oupl er (  4-18) 4 Fuse B ox 5 EC M (Eng ine C ontrol M odu le) 6 Seco nda ry fuel injec tor (  4- 80) 7 Prim ary fue l injec tor (  4- 7 7) 8 EC T sens or (  4- 49 ) 9 STV a c tuator (  4-67 ) 0 STP se nsor (  4-70) A TP s ens or (  4-44) B[...]

9-8 ELEC TRICAL SYSTEM CHARGING SYSTEM TROUBLESHOO TING Batt ery runs do wn quick ly Step 1 1) Chec k a ccesso ries w hich u se exc essi ve a mounts of el ectricity . Are ac cessories being instal led? Step 2 1) Chec k th e batte ry fo r cu rrent le aks. (  9-9) Is t he batte ry fo r cu rrent le aks O K? Step 3 1) M easure the reg ulate d vol ta[...]

ELEC TRICAL SYS TEM 9-9 Step 5 1) M easu re the gen erator no-loa d pe rform ance . (  9-11) Is the gene ra tor no-l oad pe rform ance OK? Step 6 1) In spec t the r eg ulato r/rectifier . (  9-11) Is the regulat or/rect ifier OK? Step 7 1) In spec t wi rings . Is the wi rings OK? Bat ter y o ve rch arge s • Fau lty re gulato r/recti fier ?[...]

9-1 0 ELECTRICAL SYSTEM R EG ULA TE D V OLT A GE • R em ove th e fron t seat . (  8-7) • St art the en gine a nd kee p it run ning a t 5 000 r/m in with th e dim me r swit ch turne d H I pos ition. • M easu re the D C v oltage b etw een the + a nd - batter y te rmi- nal s usi ng the mu lti-circui t tes ter. If the v oltag e is no t wit hin[...]

ELE C TRICA L SYST EM 9-11 GE NERA TOR NO -LOA D PERFO RMANCE • Lif t and s uppor t th e fuel tank. (  5- 3) • Di sconne ct the ge nerato r coupl er. • S tart the engi ne and keep it run ning at 5 000 r/mi n. • U si ng the multi -circ uit teste r, meas ure th e voltag e bet ween thr ee l ead wi re s. If th e te ster r ead s un der th e s[...]

9-1 2 ELECTRICAL SYSTEM STAR TER S YSTEM AN D S IDE-S TAND/I GNITI ON IN TERLO CK S YSTEM TROUBLESHOO TING Mak e sure t hat the fu ses a re not blown an d the ba ttery is full y-cha rged b efore d iagno sing. Starter m otor will n ot run Step 1 1) Sh ift the transm ission t o ne utral . 2) Pu ll the cl utch lever , turn on the igni tion s witch w i[...]

ELE C TRICA L SYST EM 9-13 Step 3 1) M easu re t he sta rter relay voltag e at the s tarte r relay conn ectors (b etw een Y/G + and B/Y - ) w he n th e sta rter b utton i s pu shed. Is a voltag e OK? Step 4 1) Check the star ter rela y. (  9-16) Is the st a rt er rel a y O K? Start er motor ru ns b ut does not cra nk the en gine Step 1 1) T he s[...]

9-1 4 ELECTRICAL SYSTEM STARTER M OTOR DISASSEMBLY • D isas semb le the starter motor as sho wn i n the i llustratio n. STARTER M OTOR INSPECT I ON CARB ON BR USH Inspect the brush es for abnormal wear, cr acks, or smoothne ss in th e brush holde r. If any dam ages are foun d, replac e the br ush a ssembly with a new o ne. Mak e sure that the len[...]

ELE C TRICA L SYST EM 9-15 ARM AT URE COIL INS PE CTIO N Chec k for c ontinu ity betw een eac h segm ent and be tw een eac h seg men t and th e arma ture s haft u sin g the mu lti-c ircuit te ster. If the re is no co ntinu ity betwee n th e seg ments or th ere i s con ti- nui ty be tween the seg ments and s haft, re place the ar ma ture wit h a new[...]

9-1 6 ELECTRICAL SYSTEM • T ight en the sta rte r moto r lead w ire mounti ng bo lt to th e spe ci- fied torqu e.  Lea d wir e mount i n g bolt : 6 N·m (0 .6 kgf- m, 4.5 lb -ft) STARTER REL AY INSPECTI ON • R em ove th e fron t seat . (  8-7) • D isco nnect the bat tery - le ad wi re from t he b atte ry. • R em ove th e fram e cove r[...]

ELE C TRICA L SYST EM 9-17 SIDE STAND/IG NITION INTERLOCK SYSTEM PARTS INSPECTI ON Check th e interl o c k system for p roper ope ration. I f th e interlock system does not operate pr o perly, check each com ponen t for dama ge o r abnor malities . If any abno rmal ity is fou nd, re place the c om ponent with a ne w one. SI DE-ST AND SWI TCH The si[...]

9-1 8 ELECTRICAL SYSTEM GEAR POSITION SWITCH • R em ove th e fron t seat . • D isco nnect the bat tery - le ad wi re from t he b atte ry. • L ift and supp ort the fue l tank. (  5-3) • Dis connect the gear posi tion switch co upler and check the con tinuity betwe en Blue and Bl ack/W hite wi th the tr ansm is- sion in “NEUT RAL”. [...]

ELE C TRICA L SYST EM 9-19 TURN SIGNAL/SIDE-ST AND RELA Y The turn s igna l/side-sta nd rel ay is com posed of the tu rn s ignal relay , side- stan d relay and d iode. • Rem ove t he f ront sea t.(  8-7) • Di sconne ct the ba ttery - lead wire fr om the b atte ry. • Rem ove t he f rame co ver. (  8- 8) • Rem ove t he t urn sig nal/si [...]

9-2 0 ELECTRICAL SYSTEM IGN ITION SYST EM NOT E : The fu el cut -off c irc uit is inc orporated in th is E CM in o rder to p reve nt over-run ning of engi ne. W hen e ngine spe ed reac hes 1 5 500 r/min , this circu it cuts off fuel at the fue l injec tor. But unde r no load, the clutch lever is pulled or the ge ar pos ition is neutr al, th is cir [...]

ELE C TRICA L SYST EM 9-21 IMMO BI LIZ ER (E x cept for E-03 , 2 8, 3 3) DESC RIPTION The immobil izer, an anti -theft syste m, is insta lled as a st andard equi p ment. The immobi lizer verifi es tha t th e key ID a grees with ECM ID by means of rad io commu nic ation throu gh the immobiliz e r antenn a. When the ID agreement is ve rified, the sys[...]

9-2 2 ELECTRICAL SYSTEM Op eration Wh en the ign ition swi tch is turne d ON with the eng ine stop s witch in ON, the im mobi -anten na and E CM are po wered ON . The ECM tran smits a s ignal to th e tran spond er throu gh the im mobi -anten na in orde r to m ake c ompa rison betwe en the key ID and ECM ID. With the signal r eceiv ed, the t rans po[...]

ELE C TRICA L SYST EM 9-23 TROUBLESHOO TING No spa rk or poor spar k NOT E : Chec k th at the t ran smiss ion is in ne utral and the engi ne sto p sw itch is in the “RU N” po sition . Gras p the clutc h le ver. Ch eck that the fuse is n ot blo wn an d the ba ttery i s fully-c harge d be fore d iagno sing. Step 1 1) C heck the ign iti on system [...]

9-2 4 ELECTRICAL SYSTEM Step 5 1) Ins pect t he ign ition coi l/plug caps. (  9- 26) Is t he ign ition co il/plug cap O K? Step 6 1) M easure the CK P se nsor pe ak v oltag e and i ts res istance . (  9- 27 to -28) NOT E : The C KP sensor pe ak voltag e ins pect ion is app licab le only with the mul ti circui t tes ter an d peak volt ad apt o[...]

ELE C TRICA L SYST EM 9-25 INSPECTI ON IGN ITIO N CO IL P RIM AR Y PE AK VOL TAGE • Rem ove t he a ir clean er box . (  5-14) • Di sconne ct a ll the ign ition c oil/p lug ca p lead wire coup lers befo re remov ing the igniti on co il/plug caps. • Rem ove a ll o f the i gnition coil/p lug cap s.  • Con nect t he new four spark plugs t[...]

9-2 6 ELECTRICAL SYSTEM NOT E : Use the sp ecial t ool, to pre vent th e rubbe r of the w ater p roof co uple r fr om dam age . • Sh ift the trans miss ion into neutr al an d tu rn igniti on sw itch “ON”. • C rank the engi ne a few s econ ds with th e start er motor by depr essi ng starter button an d chec k the ign ition coi l prima ry pea[...]

ELE C TRICA L SYST EM 9-27 CKP SENSO R PEA K VOLTAG E • Rem ove t he f ront sea t. (  8-7) NOT E : Be su re that al l coupler s are co nnec ted prop erly an d the batte ry use d is i n fully-ch ar ged c ondition . • Di sconne ct the bo th cou plers 1 . • Con nect th e multi -circu it tester with peak volt adap tor as fo l- lows. • M easu[...]

9-2 8 ELECTRICAL SYSTEM If the p eak v olt age is low er than th e sta nda rd range, chec k th e peak voltag e a t the CK P s enso r lead w ire coupler . • R em ove th e fron t seat . (  8-7) • L ift and supp ort the fue l tank. (  5-3) • D isco nnect the CK P s ensor l ead wi re cou pler and conn ect th e m ulti-circu it tes ter w ith [...]

ELE C TRICA L SYST EM 9-29 COMBINATION METE R DESCRIPTIO N This comb ination me ter mainl y con sists of the steppin g motor , LCD (Liqu id Cry stal D isplay) an d LE D (Li ght Em itting D iode ). This c om binatio n meter is ligh t, th in an d of hi gh respo nse c ompa red to those cur rently in use beca use o f this c ompos ition . The rpm po int[...]

9-3 0 ELECTRICAL SYSTEM REMOVAL AND DI S A S SEMBLY • R em ove th e scr ew 1 . • W ith the hoo ked pa rts 2 of the c ombi nation me ter pulled f rom the hea dlig ht hous ing, disco nnec t the co mbin ation me ter lead wi re coupler. • R em ove th e com bina tion m eter.  • Disassemble th e combi nation meter a s follo ws.  When di sco[...]

ELE C TRICA L SYST EM 9-31 INSPECTI ON LED ( LIG HT EMIT TING DIO DE) Chec k tha t the LE D lights [F I light, F uel lev el indic ator lig ht, En gine RP M ind icator light and imm obil izer indi- cat or light (For E -02, 19 , 24)] imm edia tely after tur ning the ign ition swi tch o n. Also, o the r LED l ights ( Neutr al ind icator light, H igh-b[...]

9-3 2 ELECTRICAL SYSTEM ENG INE COOL ANT TEMP ERA TURE METE R AND INDI CA TOR EC T senso r insp ecti on (  7-7 ) • R em ove th e fron t seat .(  8-7) • L ift and supp ort the fue l tank. (  5-3) • D isco nnect the EC T se nsor c ouple r 1 .  • C onnec t the v ariabl e re sistor A betwe en the termi nals. • D isco nnect the o i[...]

ELE C TRICA L SYST EM 9-33 FUE L LEVEL GAU GE INSPE CTION • Rem ove t he f uel pu mp as sembly. (  5-9) • M easu re the resi stance at each fuel l evel ga uge floa t pos ition. If the re sistanc e is i ncorre ct, repl ace the fue l leve l gaug e wi th a ne w o ne.  09900- 250 08: M ulti-circui t tes ter set  T ester k nob in dica tion [...]

9-3 4 ELECTRICAL SYSTEM SPEEDOM ETER If the s peed ome ter, od ome ter or tr ip me ter doe s not funct ion prop erly, ins pec t the s peedom ete r sens or and conn ection o f cou plers. If t he spe ed sen sor a nd con nection are func tion ing prop erly, r epla ce the meter with a new one . SPEED S ENSOR • R em ove th e fron t seat .(  8-7) ?[...]

ELE C TRICA L SYST EM 9-35 LAMPS HEADL IGHT, B RAKE LI GHT/TAI LLIGH T, LIC ENSE PLAT E LIGH T AND TU RN SIGN AL LIGH T HEA DLIGHT 12 V 55 W H7 1 12 V 65 W H9 2 POSIT ION LIGHT 3 12 V 5 W × 2 BRAKE LIGH T/TAIL LIGHT: LED LICENC E PLATE L IGHT 4 12 V 5 W TURN SIGNA L LIGHT 5 12 V 21 W × 4  If y ou ha v e t ouched a nd the bu lb with y o ur ba r[...]

9-3 6 ELECTRICAL SYSTEM HEA DLIGH T BEAM ADJU STME N T • Ad jus t the he adlight bea m. NOT E : * Use a scr ew dr ive r + for ad juster A and B . * To adjus t the he adli ght beam , ad just the b eam hori zonta lly firs t, then adjus t ve rticall y. A : Hori zon tal ad juster B : Verti cal adju ster To a djust the beam ho rizont ally : • T urn [...]

ELE C TRICA L SYST EM 9-37 RELAYS TURN SIG NAL/SIDE-STAND RELAY The turn s igna l/side-sta nd rel ay is com posed of the tu rn s ignal relay , side- stan d relay and d iode. INSPECT ION Be fore rem ov ing the t urn signa l/side -stand relay, check the oper ation of th e turn signal light. If the tur n signal light doe s not illum ina te, insp ect t[...]

9-3 8 ELECTRICAL SYSTEM IGNIT ION SWITCH REMOVAL • R em ove th e air cl eaner box. (  5- 14) • D isco nnect the ig nition switc h lea d wire co upler (G reen) 1 . • D isco nnect the im mobi lizer lead wir e cou pler (Black) 2 . (Fo r E- 02, 19, 24) • R em ove th e cable guid e 3 . • Rem ove th e ign ition switch m ou nting bolts w ith [...]

ELE C TRICA L SYST EM 9-39 SWITCHES INSPECTI ON Color P osition IGNITION SWITCH (For E-02, 19, 24) HAZARD SWITCH Inspect each s witch for continuity with a tester . If any abnor mality is f ound, replace the respective s witch assemblies with ne w ones. NO TE: Bef ore inspecting the oil pressure switch, chec k if the engine oil le vel is correct. ([...]

9-4 0 ELECTRICAL SYSTEM BATTERY SPECIFICATIO NS 1 Upp er c over br eat her 5 Te rm in al 2 Catho de plates 6 Safe ty val ve 3 Sto pper 7 Anode p lates 4 Fi lter 8 S epa rat or (F iber gl ass pl a te ) INITIAL CH ARGING Fillin g el ectrol yte • R em ove the a luminum t ape 1 sealing the batte ry electr olyte filler holes A . NOT E : Wh en fi lling[...]

ELE C TRICA L SYST EM 9-41 NOT E : If no a ir bubb les are com in g up from a filler por t, tap the botto m of the elec troly te con taine r two or three t imes . Nev er r emov e the c ontainer from the battery. • A fter confi rming th at th e electr olyte ha s ente red the b atte ry co mplet ely, rem ove th e electr olyte con tainer s from the b[...]

9-4 2 ELECTRICAL SYSTEM SERVICING Visual ly insp ect the surf ace of the battery c ontai ner. If any s igns of crac king or e lectro lyte leak age from the sides of the batte ry hav e o ccurred , repl ace the b atte ry with a new one. If the b atte ry term inal s are fou nd to be co ated wi th rus t or a n acidi c wh ite powd ery subs tance, c lean[...]

SER VIC ING IN FORMA TIO N 10 -1 10 SERVICING INFORMATION CONTENT S TROUBLESHOOTING .. ........ ....... ....... .... ....... ........ ....... .... ....... ....... ........ ... 10 -2 FI SYSTEM MALFUNCTION CODE AND DEFECTIV E CONDITION 10 -2 ENGINE ........ ....... ....... ....... ........ ....... ....... ........... ........ ....... ....... ........[...]

10-2 SE RVICIN G IN FORMA TIO N TROUBLESHOOTING FI SYSTEM MALFUNCTION CODE AN D DEFECTIVE CONDITION DT C No. DET ECTED ITEM D ET EC TED F AIL URE CO NDIT ION C HE CK FO R C00 NO F A U L T ––––––––––– ––––––––––– C11 CMP sen sor The signal does not r each ECM f or 3 sec. o r more, af ter rece iving t he st[...]

SER VIC ING IN FORMA TIO N 10 -3 DT C No. DETE CTED ITEM D ET EC TED F AIL UR E CO NDIT ION C HE CK FOR C21 IA T s ensor The sens or voltag e sho uld b e the fol- lowing. 0.15 V s ens or voltage < 4 .85 V In oth er than the ab o ve rang e , C21 (P01 10) i s indi cated . IA T s enso r , lea d wire/c oupl er conn ection P0110 H Se nsor voltage is [...]

10-4 SE RVICIN G IN FORMA TIO N * : Immobili ze r syst em is equippe d mo de l only. DT C No. DET ECTED ITEM D ET EC TED F AIL URE CO NDIT ION C HE CK FO R C29 STP senso r T he sensor sho uld prod uce following vol ta g e. 0.15 V s enso r voltage < 4 .85 V In oth er than the above range, C 29 (P165 4) i s indi cated. STP senso r , lea d wire/ co[...]

SER VIC ING IN FORMA TIO N 10 -5 DT C No. DETE CTED ITEM D ET EC TED F AIL UR E CO NDIT ION C HE CK FOR C44 H O2 s en sor (For E-02, 19) HO 2 se nsor ou tput v o ltage is not input to E CM du ri ng eng ine op eration an d ru nning cond ition. (Sen sor vo ltage < 0.55 V) In oth er than the ab ov e va lue, C4 4 (P01 30) i s indi cated . HO2 senso [...]

10-6 SE RVICIN G IN FORMA TIO N ENGINE Com plain t Sym ptom and possib le cause s R emed y Engin e w ill no t sta rt or is h ard to star t. Compr essi on too lo w 1. V alve clea rance out of a djus tment 2. Wor n v a lve guides or poor seating of valves 3. Mistim ing va lv e s 4. Excessiv ely worn piston rings 5. Wor n-down cy linder bor es 6. T oo[...]

SER VIC ING IN FORMA TIO N 10 -7 Com plain t Sympt om a nd po ssible caus es R eme dy Eng ine i dle s p oorl y . 1. V a lv e clea rance ou t of adjustm ent 2. P oo r seati ng of valves 3. D ef ective valve guides 4. Wor n down c amsha fts 5. T oo wi de sp ark p lug ga ps 6. D efective ignitio n coil/pl ug ca ps 7. D ef ective C KP se nsor 8. D ef e[...]

10-8 SE RVICIN G IN FORMA TIO N Com plain t Sym ptom and possib le cause s R emed y Noisy eng ine E xce ssiv e valve cha tter 1. T oo lar ge tap pet clearan ce 2. Weakene d or br oken valve spr ings 3. Wor n tapp et o r ca m surface 4. Wor n and burnt camshaft jou rn al No ise seem s to c ome from pis ton 1. Wor n down pistons o r cylinder s 2. C a[...]

SER VIC ING IN FORMA TIO N 10 -9 Com plain t Sympt om a nd po ssible caus es R eme dy Eng ine ru ns p oorl y in h igh speed r ange. Def ective engi ne in terna l/elect rica l par ts 1. Weakene d valve sprin gs 2. Wor n camsha fts 3. V a lv e timi ng out o f ad justmen t 4. T oo n arrow s park p lug g aps 5. Ig nition n ot a dvanced s uffici ently d[...]

10-1 0 SE RVIC ING IN FORMA TIO N Com plain t Sym ptom and possib le cause s R emed y Engin e lacks p ower . D efective en gine in terna l/elect rical pa r ts 1. Lo ss of ta ppe t cleara nce 2. Weakene d valve sprin gs 3. V al v e ti mi ng ou t of adj us tm ent 4. Wor n piston r ings or cy linder s 5. P oo r seati ng of valves 6. Fouled spar k plug[...]

SER VICIN G IN FORMA TIO N 10- 11 Com plain t Sympt om a nd po ssible caus es R eme dy Engine overhea ts Def ective engi ne inte rnal p art s 1. H eavy ca rbon d eposit on p iston cr owns 2. N ot enou gh o il in the eng ine 3. D ef ective o il pump or clo gged oi l circui t 4. Su cking air from i ntake pip es 5. U se inc orrec t engi ne oil 6. Def [...]

10-1 2 SE RVIC ING IN FORMA TIO N RADIATOR (COOL ING SYSTEM) Com plain t Sym ptom and possib le cause s R emed y En gine o verhe ats 1. Not e nough e ngine coolan t 2. R adiato r core clogge d w ith dir t or s cale 3. Faulty coo ling fan 4. D efective cooling f an rela y , or op en- or sho r t- circu ited 5. D ef ective EC M 6. D ef ective EC T sen[...]

SER VICIN G IN FORMA TIO N 10- 13 CHASSIS Com plain t Sympt om a nd po ssible caus es R eme dy Heav y stee ring 1. O ver tighte ned steer ing s tem nut 2. Br oken be aring in s teer ing ste m 3. D istor te d stee ri ng st em 4. N ot e nough p res sure i n tires Adjust . R epl ace . R epl ace . Adjust . W obbl y ha ndle bar s 1. Lo ss of b alanc e b[...]

10-1 4 SE RVIC ING IN FORMA TIO N BRAKES Com plain t Sym ptom and possib le cause s R emed y In s u ffic ient bra ke powe r 1. Leakage of br ake fluid from hydr a uli c system 2. Wor n pads 3. O il adh esion o f en gagin g surface of pa ds/s hoe 4. Wor n disc 5. Air i n hyd rauli c system 6. N ot enou gh b rake fluid i n the r eser voir Repa ir or [...]

SER VICIN G IN FORMA TIO N 10- 15 ELECTRICAL Com plain t Sympt om a nd po ssible caus es R eme dy No s parki ng or p oor sparki ng 1. Def ective ign i tion coils 2. D ef ective spa rk plug s 3. D ef ective C MP se nsor 4. D ef ective C KP se nsor 5. D ef ective EC M 6. D efective T O se nsor 7. O pen- circuited wir ing conn ections R epl ace . R ep[...]

10-1 6 SE RVIC ING IN FORMA TIO N BATTERY Com plain t Sym ptom and possib le cause s R emed y “ Sulfa tion” , acid ic whi te po wdery su b- st an ce or sp ots o n surfac e of cel l p lat es 1. C rack ed ba tter y cas e 2. Ba tter y ha s bee n left in a r un- down condit ion for a long time. Rep lac e the ba tter y . Rep lac e the ba tter y . Ba[...]

SER VICIN G IN FORMA TIO N 10- 17 WIRING HARNESS, CABLE AND HOSE ROUTING WIRING HA RNESS ROUTING *5 *3 *4 *2 Clamp Wiring har ness Brak e light switch HO2 sensor (E-02, 19) Wiring har ness Star ter motor lead wire Clamp *2 *1 1 Integrated clam p 8 Pro t e ct or 2 C ool in g f an rel a y *1 T o EC T se ns or 3 Fuel pum p r elay * 2 Cut the ti p afte[...]

10-1 8 SE RVIC ING IN FORMA TIO N *2 Clamp P osition light (LH) Wiring har ness T ur n signal light (RH) *3 6 N·m (0.6 kgf-m, 4.5 lb-ft) Wiring har ness Batter y - lead wire *4 *1 Clamp Guide Iginition s witch Handlebar s witch (RH) 1 Rea r co mbina tion light 8 B rak e light s w itch 2 EXC V A 9 Horn 3 A P senso r 0 Regulator/re ctifie r 4 S tar [...]

SER VICIN G IN FORMA TIO N 10- 19 *1 10 N·m (1.0 kgf-m, 7.0 lb-ft) 6 N·m (0.6 kgf-m, 4.5 lb-ft) 5 N·m (0.5 kgf-m, 3.5 lb-ft) 11 N·m (1.1 kgf-m, 8.0 lb-ft) 7 N·m (0.7 kgf-m, 5.0 lb-ft) 14 N·m (1.4 kgf-m, 10 lb-ft) 1 B atter y - lea d w ire *1 F ix the c lam p in p arallel w ith the cover surface. 2 W hite t ape[...]

10-2 0 SE RVIC ING IN FORMA TIO N HO2 SENSOR HARNESS ROUTING (For E-02, 19) *1 *2 *3 48 N·m (4.8 kgf-m, 34.5 lb-ft) *4 1 HO 2 sensor *2 Cl amp the HO2 sens or lead wire so as not to ov er- la p the oi l inspec tion win dow . 2 Clu tch cab le 3 Oil pan *3 Pass th e H O2 sen sor lead w ire thr ough b etwe en the f rame an d en gine. 4 Unde r co wli [...]

SER VICIN G IN FORMA TIO N 10- 21 CABLE RO UTING *1 *2 0 mm *3 0 mm 0 mm 1 Clutch cable *1 Cl utch cable mus t be cla mpe d on the gromm et. 2 Throt tle cable No.1 *2 Pass th e th rottle c ables above the c lutch cable. 3 Throt tle cable No .2 * 3 P ass th e th rottle cable No.2 oute r from N o .1.[...]

10-2 2 SE RVIC ING IN FORMA TIO N FUEL TANK HOSE ROUTIN G *2 *1 *3 1 Fue l tank wa ter drain ho se *1 Pass th e fu el tank drain hose and br eather hose thro ugh behind t he P CV h ose. 2 Fue l tank breath er hose *2 S et th e fuel tank drain hos e and breath er hose with le ngt hwis e bac kw ar d. 3 P CV (br eather ) hose *3 W hite m ark ing[...]

SER VICIN G IN FORMA TIO N 10- 23 COOLING SYSTEM HOSE ROUTING 1 R es er v oi r tan k o v er flo w ho se *1 Cl amp sh oul d f ac e do w nw ar d. 2 Rese r v o ir ta nk inl et hos e *2 Clamp s houl d f ace right side. 3 Oil coo ler o utlet hos e *3 Y ellow mar king 4 Clearanc e *4 White mar king 5 Radia tor inl et hos e *5 Cl amp s houl d f ac e backw[...]

10-2 4 SE RVIC ING IN FORMA TIO N FRONT BRAKE HOSE ROU TING *1 *2 *5 1 – 2 mm (0.04 – 0.08 in) 42˚ *3 *4 *3 *6 *7 *3 42˚ 14˚ *4 1 B rak e hose guide *4 Cl amp the brake hose firm ly . *1 Clamp shou ld face d o w nwa rd. *5 Afte r posi tioning the clamp w ith sto ppe r , tig hten the c lamp bolt. *2 Clamp shou ld face backwar d. *6 Inse r t t[...]

SER VICIN G IN FORMA TIO N 10- 25 REAR BRAKE HOSE R OUTING *1 *2 28˚ 28˚ *4 28˚ 23 N . m 2.3 kgf-m 16.5 lb-ft *6 *5 23 N . m 2.3 kgf-m 16.5 lb-ft *3 *3 1 Rear b rake hose *2 Pass th e reser voir hose above the brake h ose. 2 Brake fluid r eser voir hose *3 Positio n the bra ke union w ith th e sto pper b efore tighteni ng. 3 Stop per *4 F ac e t[...]

10-2 6 SE RVIC ING IN FORMA TIO N FUEL TANK INSTALLATION *1 *1 *1 1 Ve l c r o f a s t e n i n g 4 Fuel t ank side cushi o n 2 F rame cov er cushio n *1 App ly adhe sive agen t. (equivalent to A R ON ALP HA 2 01) 3 Fue l tank f ron t cov e r[...]

SER VICIN G IN FORMA TIO N 10- 27 COW LING INST ALLATIO N Intake co ver (RH) Air intake pipe (RH) Side cowling (LH) T o head light Under cowling cov er (RH) Side cowling (RH) T o frame T o oil pan Under cowling (RH) Heat shield Heat shield Body cowling Under cowling (LH) Under cowling cov er (LH) Wind screen Cowling brace Air intakepipe (LH) Intake[...]

10-2 8 SE RVIC ING IN FORMA TIO N FRAME CO VER I NSTALLA TION SEAT LOCK CABLE RO UTING[...]

SER VICIN G IN FORMA TIO N 10- 29 REAR FENDER I NSTALLATION 1 Seat rail 4 Rear fender (rea r) 2 Rear fende r (fr ont) 5 Rear fender (lower ) 3 Rea r fe nd e r co ver (fr on t) 6 Sw ingar m[...]

10-3 0 SE RVIC ING IN FORMA TIO N SIDE-STAND INSTALLATION UNDER COWLING CUSHION RUBBER/HE AT SHIELD INSTAL LATION 40 N·m (4.0 kgf-m, 29.0 lb-ft) 50 N·m (5.0 kgf-m, 36.0 lb-ft) 50 N·m (5.0 kgf-m, 36.0 lb-ft) 1 Sid e-sta nd spri ng No.1 2 Side- stand spri ng No.2 Max. 3 mm (0.12 in) 2 mm (0.08 in) 1 Unde r co wli ng (L H) 3 Under c owling ( RH) 2 [...]

SER VICIN G IN FORMA TIO N 10- 31 FRON T FOOTREST I NSTAL LATIO N 18 N . m (1.8 kgf-m, 13.0 lb-ft) *1 10 N . m (1.0 kgf-m, 7.0 lb-ft) 46 N . m (4.6 kgf-m, 33.5 lb-ft) 18 N . m (1.8 kgf-m, 13.0 lb-ft) 23 N·m (2.3 kgf-m, 16.5 lb-ft) *2 23 N·m (2.3 kgf-m, 16.5 lb-ft) *2 1 Fo o t r e s t 7 F r ont footrest N o. 2 brack et (R H) 2 Bank s ensor 8 F r o[...]

10-3 2 SE RVIC ING IN FORMA TIO N REAR VIEW MIRROR IN S TAL LATION *1 1 B ody cowl ing 5 T ur n s igna l lead w ire c ouple r 2 Cowl ing b race 6 M ir ro r cover 3 Cus h i on 7 M i rror b ody 4 T ur n s ign al lead wire *1 L ocate the tur n sign al le ad wi re coup ler 5 betw e en the mi rror co ve r 6 an d mir ror body 7 .[...]

SER VICIN G IN FORMA TIO N 10- 33 SPECIAL TO OLS 0990 0- 06107 S nap rin g p liers 09900 -0 6108 Sna p ring pl ier s 09900- 187 40 H ex ago n soc k et ( 24 mm) 0990 0-2 0101 0990 0-2 0102 V e rnie r calip ers 09900- 20 202 Mi cr omet er (25 – 50 mm ) 0990 0- 20203 M icrometer (5 0 – 75 mm) 09900 -2 0205 M icr om eter (0 – 25 mm ) 09900- 205 0[...]

10-3 4 SE RVIC ING IN FORMA TIO N 0991 0- 20115 C onr od s to p pe r 09913 -10 750 Ad ap ter 09913- 501 21 Oil se al rem o ver 09913 -7 0210 Bearing i nstaller set 09915- 40 610 Oil f ilter wr ench 0991 5- 64512 Compression gauge set 09915 -74 521 Oil pressu re gauge hose 09915- 745 40 Oil p ressu re ga ug e attachm ent 09915 -7 7331 Me t er (for h[...]

SER VICIN G IN FORMA TIO N 10- 35 0991 7- 47011 V acu um pump gauge 09919 -2 8610 Sl ee ve pr ot ecto r 09920- 348 30 S ta r te r cl u t ch hol de r 0992 0-5 3740 Clu tch sl eeve hub holde r 09921- 20 210 Bearin g rem over 0992 1- 20240 Bearing remo ver set 09922 -2 2711 Drive c hain cutting and joining tool 09923- 745 11 Bearing remo v er 0992 4-8[...]

10-3 6 SE RVIC ING IN FORMA TIO N NOT E : Wh en ord er the spec ial too l, pleas e c onfirm w hether it is availab le or not. 09940- 149 40 Sw in ga rm pi vot thrust adju ster so ck et wr enc h 09940 -1 4990 Engi ne mou nting thrust adjust er socket wren ch 09940- 302 21 Fr on t f ork asse m- bl ing t ool 09940 -4 0211 Fuel pressure gauge ada ptor [...]

SER VICIN G IN FORMA TIO N 10- 37 TIGHTE N ING T ORQUE ENGINE ITEM N·m k gf-m lb -ft Exhau st pipe bolt 23 2.3 16.5 Muffle r conne ctin g bolt 2 3 2 .3 16.5 Muffle r moun ting b olt 23 2.3 16.5 Spee d sen sor rot or bolt 25 2.5 18.0 Spee d sen sor bol t 4.5 0.45 3.0 Engine spr ock e t nut 115 1 1.5 83.0 Engine mo unting bo lt (C ylinder ) 5 5 5 .5[...]

10-3 8 SE RVIC ING IN FORMA TIO N FI SYSTEM AND INTAKE AIR SYSTEM COOLING SYSTEM ITEM N·m k gf-m lb -ft Crankcase bolt (M: 6) (Ini tial) 6 0.6 4.5 (Final) 1 1 1 .1 8.0 (M: 8) (Ini tial) 15 1 .5 1 1.0 (Final ) 26 2 .6 1 9.0 Cran kcas e bol t (Inne r hex a gon) (M: 8) ( Initial) 15 1 .5 1 1.0 (Final ) 22 2 .2 1 6.0 Cran kshaft jour nal bol t ( M: 9 [...]

SER VICIN G IN FORMA TIO N 10- 39 CHASSIS ITEM N · m kgf -m lb -ft Stee ring s tem h ead nut 9 0 9 .0 65.0 St eeri ng st em lo ck -nu t 80 8.0 58 .0 Stee ring d amp er bolt a nd n u t 2 3 2.3 16.5 F ron t fork u pper cl amp bo lt 2 3 2 .3 16.5 F ron t fork lower clamp bolt 23 2.3 16.5 F ron t fork cap bo lt 35 3.5 25.5 F ront f ork inne r r od l o[...]

10-4 0 SE RVIC ING IN FORMA TIO N TIGHTE NING TORQUE C HART For other nuts and bol ts no t listed i n the pre ceding page, r efe r to th is ch art: ITEM N · m kgf -m lb -f t S eat rail bolt 50 5.0 3 6.0 Rea r view m irro r nut 10 1 .0 7.0 Bolt Di ameter A (mm) Convent i onal o r “4” marked bolt “7” ma rked bolt N· m kgf -m lb-ft N ·m kgf[...]

SER VICIN G IN FORMA TIO N 10- 41 SERVICE DATA VALVE + VALVE GUID E Unit : mm (in ) CAMSHAFT + CYLINDER HEAD Unit : mm (in) IT EM STAN DARD LI MIT V alve diam. IN. 27. 2 (1.07) — EX. 22. 0 (0.87) — V alve clearanc e (w hen c old) IN . 0 .08 – 0 .18 (0.0 031 – 0.007 1) — EX. 0.18 – 0 .28 (0.0 071 – 0.011 0) — V alve guide to valv e s[...]

10-4 2 SE RVIC ING IN FORMA TIO N CYLINDER + PISTON + PISTON RI NG Un it: mm (in) IT EM STA NDARD L IMIT Com press ion pre ssu re 1 200 – 1 600 k Pa (12 – 16 kgf/cm² , 171 – 22 8 psi) 900 kPa (9 kg f/cm 2 , 12 8 ps i) Com press ion p ressu re difference — 200 kPa (2 kg f/cm 2 , 28 psi) Pi st on t o cyl in der cl ear a nce 0 . 030 – 0 .04[...]

SER VICIN G IN FORMA TIO N 10- 43 CONROD + CRANKSHAFT Unit : mm (in) OIL P U M P IT EM STAN DARD LI MIT Conro d sm all e nd I.D . 14.010 – 14 .01 8 (0.55 16 – 0.551 9) 14.040 (0.5 528 ) Conro d b ig end side cl earance 0.10 – 0. 20 (0.0 04 – 0.008 ) 0. 30 (0.012 ) Conro d b ig end wid th 19.95 – 20 .00 (0.78 54 – 0.787 4) — Crank pi n[...]

10-4 4 SE RVIC ING IN FORMA TIO N CLUTCH Un it: m m (in) TRANSMISSION + DRIVE CHAIN Unit: mm (in) Ex cep t ratio IT EM STA NDARD L IMIT Clutch le ver p la y 10 – 15 (0.4 – 0.6) — Clutch re lease sc rew 1/2 tu rn back — Drive p late th ickness No. 1, 2 and 3 2.72 – 2. 88 (0.107 – 0. 113) 2. 42 (0. 095 ) D riv e pl ate cla w widt h No. 1,[...]

SER VICIN G IN FORMA TIO N 10- 45 THERMOSTAT + R ADIATOR + FAN + COO LANT INJECTOR + FUEL PUMP + FUEL PRESSURE REG U LATOR ITEM STAND ARD/SPECIF ICATION NOTE Ther mos tat valve openi ng tem pe r- ature Ap prox . 82 °C (180 °F) — Ther mos tat valve lift 8 m m (0. 31 in) an d over a t 95 °C (203 °F) — ECT sensor res istance 20 °C (68 ° F) A[...]

10-4 6 SE RVIC ING IN FORMA TIO N FI SENSORS ITEM SPECIFICATION N OTE CKP sensor res istance 14 2 – 194 Ω CKP sensor peak voltage 0.2 8 V and mor e Wh en cr anking IAP sen sor input v o ltage 4.5 – 5 .5 V IA P se nso r out put vol t age Appr ox. 2. 7 V at idl e sp eed TP se nsor i nput voltag e 4.5 – 5 .5 V TP se nsor r esist ance App rox. [...]

SER VICIN G IN FORMA TIO N 10- 47 THROTT LE BODY ELECTRICAL Unit : mm (in ) ITEM SPE CIFICATION Bore s ize 40 m m (1. 575 in ) I.D . No. 01H1 ( For E-33) , 01H0 (For the ot her s) Idle r/mi n 1 300 ± 1 00 r/min F ast idle r /min 1 500 – 2 0 00 r/m in (W hen cold e ngine ) Thro ttle cable pl a y 2.0 – 4.0 mm (0.08 – 0 .16 in) ITEM SPEC IFICAT[...]

10-4 8 SE RVIC ING IN FORMA TIO N WATTAGE Unit: W BRAKE + WHEEL Un it: mm (in) ITEM ST ANDAR D/SPECIFICAT ION E- 03, 28, 33 Oth e rs Hea dlight HI 6 5 ← LO 55 ← P osit ion/Parking l igh t 5 × 2 ← Brake l i ght/T aillight LED ← T ur n sign al ligh t 21 × 4 ← Licens e pla te ligh t 5 ← Com bina tion m eter li ght L ED ← T ur n sign al[...]

SER VICIN G IN FORMA TIO N 10- 49 TIR E IT EM STAN DARD LI MIT Whe el rim r unout Axial — 2.0 (0.08) Radi al — 2. 0 (0.08) Wh eel r im siz e Fr ont 17 M /C × MT 3.5 0 — R ear 17 M /C × MT 5.5 0 — Whe el axl e ru nout Fr o nt — 0. 25 (0.010 ) Rea r — 0.2 5 (0.010 ) IT EM STAN DARD LI MIT Cold i n flati on tire press ure ( Sol o rid in [...]

10-5 0 SE RVIC ING IN FORMA TIO N SUSPENSION Unit: mm (in) FUE L + OIL IT EM STA NDARD L IMIT F r ont f ork st rok e 1 20 (4.92) — F ron t fork spr in g free lengt h 268 (10 .55) 241.2 (9.50) F ront f ork o i l lev el (without spring, outer t ube fully co mpress ed) 107 (4.21) — F ron t fork o il type SUZU KI FOR K O IL SS -05 o r equiv alen t [...]

EMISS IO N CON TRO L INFOR MAT ION 11 - 1 11 EMISSION CONTROL INFORMATION CONTENT S EMISSION CONTROL SYSTEMS ....... ....... ........ ....... ....... ........ ....... ....... .....11- 2 FUEL INJECTI O N SYSTEM...... ........ ....... ....... ........ ....... ....... ........ ... .....11- 2 CRANKCASE EMISSION CONTRO L SYSTEM ..... ....... ....... ...[...]

11-2 EMI SSIO N CO NTRO L INF ORMAT ION EMIS SION CO NTRO L SYST EMS FUEL INJ ECTION SY STEM GSX-R600 moto cycles a re equipped w ith a fu el i n jectio n sy stem fo r emissi o n level contr ol. This fuel in jec- tion syst em is p rec ision des ign ed, man ufa ctured a nd adjuste d to com ply wi th the app licable emiss ion limits. With a vie w to [...]

EMISS IO N CON TRO L INFOR MAT ION 11 - 3 CRANKCASE EMISSIO N CONTROL SYSTEM The engine is equipped with a PCV system to p r event discharg ing crankcase emissions into the atomo- sph ere. Bl ow-b y gas in t he en gine is co nstan tly draw n into t he cra nkcas e, whi ch is retu rned to the com bus- tion cham ber th rough the PCV (breathe r) ho se,[...]

11-4 EMI SSIO N CO NTRO L INF ORMAT ION EXHAUST EMISSION CONTROL SYSTEM (PAIR SYSTEM) The exhaust emissi on control syste m is composed of the PAIR system, exhaust contr ol system and three -way catalys t syste m. The fre sh air is draw n into the exh aust po rt throu gh the PAI R control soleno id valv e and P AIR r eed v alve. T he PA IR co ntrol[...]

EMISS IO N CON TRO L INFOR MAT ION 11 - 5 NOISE EMISSI ON CO NTROL SYSTEM TAMP ERING WITH THE NOISE CONTRO L SYSTEM PROHIBITED: Local law or fed eral law prohibits the follow ing a cts or the causing the reof: 1. The rem oval or rende ring ino perative by any per son, ot her than fo r purpo ses of m ainte nance , rep air or rep laceme nt, of a ny d[...]

11-6 EMI SSIO N CO NTRO L INF ORMAT ION PAI R (AI R SUP PLY) SY STEM A ND EMI SSION CON TROL SYST EM IN SPECT ION PAIR HOSES • In spect t he P AIR hose s for we ar or dam age. • In spect t he P AIR hose s is se cure ly connec ted. PAIR REE D VAL VE • R em ove th e cylin der he ad co ver. (  3-14) • R em ove th e PA IR ree d valv e 1 w it[...]

EMISS IO N CON TRO L INFOR MAT ION 11 - 7 PAIR CONT ROL SOLE NOID VALVE • Rem ove t he a ir clean er box . (  5-14) • Di sconne ct the PA IR c ontrol s oleno id valve lea d wir e coupler 1 and P A IR hose s. • Rem ove t he P AIR contr ol solen oid v alve 2 . • Che ck t hat air fl ows thr oug h the ai r inle t port to the air ou tlet por [...]

11-8 EMI SSIO N CO NTRO L INF ORMAT ION PA IR (AI R S UPP LY) SYS TE M H OSE R OUT ING Appro x. 0˚ Appro x. 0˚ Appro x. 0˚ *2 *1 *1 1 PAIR control sole n oid valve *1 Wh i te marking 2 P AIR re ed va lve *2 Y ellow marki ng (Op posi te side )[...]

EMISS IO N CON TRO L INFOR MAT ION 11 - 9 HO2 SENSO R INSPE CTION ( For E-02, 19) Th e HO2 s e ns or c oup le r 1 is loca ted und er the fuel ta nk. • Ins pect th e HO2 sensor and its c ircuit re ferring to f low tabl e of the m alfun ctio n cod e C44 (P0130 /P01 35). • Che ck the res istan ce betw een the ter mina ls of the HO2 s en- sor.  [...]

12 WIRING DIAGRAM E-02 , 19, 24 Wiring diag ram s wir e colo r, refe r t o secti on “W IRE COL OR” . O/B O/W O/G W/B Y/G O W/Y O/B O/W B/R B/Bl Y/G O/R Y/W G B/W O W/B O/G W/B O/W W/Bl O/W B O/W Y O/W G O/W W/G G B/W B/W B/W Lg Lg/W Lg/G Lg/Bl B/Y Bl B/Br O/Bl Bl/W Bl/B Bl/G W/Bl B Y Gr/W Gr/B Gr/Y Gr/R W/G O/R Y/G W/B R/Y Y/B Y/Bl Bl/Y B/W Y/R[...]

E-03 , 28, 33 O/B O/W O/G W/B Y/G O W/Y O/B O/W B/R B/Bl Y/G O/R Y/W G B/W O W/B O/G W/B O/W W/Bl O/W B O/W Y O/W G O/W W/G G B/W B/W B/W Lg Lg/W Lg/G Lg/Bl B/Y Bl B/Br Bl/W Bl/B Bl/G W/Bl B Y Gr/W Gr/B Gr/Y Gr/R W/G O/R Y/G Y/B Y/Bl Bl/Y B/W Y/R Gr O/Bl B/Br B/Br Dg G/Y Dgr P B O/Y Y/W B/Lg G O/W R/Bl Bl/R G/W B/Y R B/Bl G/B P/B W B/G Y B/R R/B P/[...]

Prepared by December, 2005 Part No. 99500-35100-01E Printed in Japan 518[...]

Printed in Japan K6[...]