Benutzeranleitung / Produktwartung GSX-R600 des Produzenten Suzuki
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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.
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.
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.
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 fte.
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 P.
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 : .
GENE RAL IN FO RMATIO N 1 -1 1 GENERAL INFORMA TION CONTENT S WARNING/CAUTION/NOTE .... ........ ....... ....... ........ ....... ....... ........ ....... ....... ... 1 - 2 GENERAL PRECAUTIONS ..... ........ ....... ....... ........ ....... ....... ..
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 .
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.
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.
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 .
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.
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.
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 .
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 ......... ...... ............. ...... .
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 ....... ............ ...... ............. ...... .
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.
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.
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.
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.
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.
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 .
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.
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 .
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.
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.
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 .
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.
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 .
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 .
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 .
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.
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.
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.
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 .
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.
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.
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.
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 .
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.
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.
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 .
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 .
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.
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.
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 .
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.
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.
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 ....... ....... ....... ........ ....... .
3-2 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.
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.
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 .
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.
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.
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 .
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 .
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 .
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 .
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 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 .
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 .
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.
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 .
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 .
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 .
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 .
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.
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.
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 .
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 .
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 .
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 .
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.
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 .
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.
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.
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.
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.
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.
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.
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 .
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.
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.
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.
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.
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.
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.
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 .
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.
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.
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 re.
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 .
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.
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 .
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 .
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 .
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 .
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.
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.
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.
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.
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 .
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.
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 .
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 .
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.
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.
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.
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 .
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.
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.
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.
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 .
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.
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.
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.
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.
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.
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.
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 .
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.
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.
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.
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 .
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.
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.
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.
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 .
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.
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 .
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.
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 .
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 ... ....
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.
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.
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.
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.
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.
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 .
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 .
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.
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 .
FI SYSTEM DIAGN OSIS 4-1 4 CONTENT S FI SYSTEM DIAGNOSIS PRECAUTIONS IN SERVICI NG ...... ....... ....... ........ ....... ....... ........ ....... ....... ... 4- 3 ELEC TRI CAL P ARTS .... ....... ....... ........ ....... ....... .... ....... .......
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 .
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.
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.
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 .
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.
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 .
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 .
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.
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.
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) .
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 .
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 (.
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.
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.
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.
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) .
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 .
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.
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.
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 .
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) .
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 .
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 .
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.
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 .
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 .
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 .
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.
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.
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 .
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.
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.
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.
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 .
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- 25.
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 ).
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.
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 .
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 .
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 .
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 .
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.
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 .
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.
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 .
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.
4-4 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.
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.
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 .
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 .
4-5 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.
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.
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.
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 .
4-5 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 .
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 .
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.
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 .
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 .
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 .
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 .
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.
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.
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.
4-6 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.
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.
4-6 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 .
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 .
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 .
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.
4-7 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.
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.
4-7 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.
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 .
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.
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.
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 e.
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 co.
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 .
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 se.
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 nec.
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.
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.
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 .
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.
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.
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 .
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.
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 .
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.
4-9 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.
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.
4-9 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.
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.
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.
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 .
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.
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 .
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.
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) .
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.
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 .
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 .
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.
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.
FUEL SYSTEM AND THROTTLE BODY 5 - 1 5 FUEL SYSTEM AND THROTTLE BODY CONTENT S FUEL DELIVERY SYSTEM... ....... ....... ........ ....... ....... ........ ....... ....... ........... .. 5- 2 FUEL SYSTEM....... ....... ........ ....... ....... ........ ..
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.
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 .
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 .
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.
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 .
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 .
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 .
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.
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.
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 .
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.
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 .
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.
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 .
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.
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 .
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.
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.
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.
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 .
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 .
5-24 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 .
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.
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 .
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.
EXHAUST SYS TEM 6 - 1 4 6 EXHAUST SYSTEM CONTENT S EXHAUST SYSTEM ... ....... ....... ........ ....... ....... ........ ....... ....... ........... ........ ..... 6- 2 EXHAUST CONTROL SYSTEM ...... ....... ........ ....... ....... ........ ....... ...
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 ).
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.
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.
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.
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.
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 .
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).
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.
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.
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 .
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.
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.
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.
CO OLING AND LU BRICA TION SYS TEM 7- 1 7 COOLING AND LU BRICATION SYSTEM CONTENT S ENGINE COOLANT ...... ........ ....... .... ....... ....... ........ ... ........ ....... ....... ........... .. 7- 2 COOLING CIRCUIT ...... ........ ... ........ ....
7-2 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 .
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.
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.
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.
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 .
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.
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 .
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 .
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.
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.
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 .
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.
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.
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 .
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.
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.
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 PRESSUR.
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 P.
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 .
CHASSIS CONTENTS 8-2 CHA SSIS R EMOVAL ....... ........... ....... ........ ....... ....... ........ ....... ........... ....... ........ ..... 8-49 INSPECTION ....... ....... ....... ........ ....... .... ....... ....... ........ ........... ....... .
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.
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.
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.
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 .
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.
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.
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.
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 .
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.
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.
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 .
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.
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.
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.
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.
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 .
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 .
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.
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 .
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.
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.
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.
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.
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.
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 .
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.
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.
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.
8-32 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.
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.
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.
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) .
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 .
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 .
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 .
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.
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.
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.
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 .
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.
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.
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.
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.
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.
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.
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.
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 .
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 .
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 .
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.
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 .
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.
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.
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.
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.
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.
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.
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.
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.
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 .
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.
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.
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.
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.
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.
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 .
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 .
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.
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.
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.
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 .
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.
8-78 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.
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.
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.
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.
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 .
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.
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.
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.
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.
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.
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.
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 .
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 .
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.
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.
ELEC TRICAL SYS TEM 9-1 9 ELECTRICAL SYSTEM CONTENT S CAUTIONS IN SERV ICING ..... ........ ....... ....... ........ ... ........ ....... ....... ........ ..... 9- 3 CONNECTOR ......... ........ ....... ........... ....... ........ ....... ....... ...
ELECTRICAL SYSTEM CONTENT S 9-2 ELEC TRICAL SYSTEM RELAYS .. ....... .... ....... ....... ....... .... ....... ........ ....... .... ....... ....... ........ ... ........ ..... 9 -37 TURN S IGNAL/SIDE-ST A ND 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 .
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.
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.
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.
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 P.
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.
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 .
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.
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.
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 .
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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 .
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.
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”.
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 .
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 .
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 .
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.
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.
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 .
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.
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 .
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 L.
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.
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.
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 .
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.
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 .
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 .
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.
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.
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 .
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 .
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.
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.
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.
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.
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.
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.
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.
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.
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 .
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.
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.
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.
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 mo.
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 Iginiti.
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.
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.
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.
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.
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.
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.
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.
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.
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 Und.
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.
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.
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 c.
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 09.
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.
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 .
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.
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 .
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.
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.
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 .
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 .
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.
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.
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.
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.
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.
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 .
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.
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.
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 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.
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.
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.
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.
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.
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 .
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 .
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).
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.
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.
Prepared by December, 2005 Part No. 99500-35100-01E Printed in Japan 518.
Printed in Japan K6.
Ein wichtiger Punkt beim Kauf des Geräts Suzuki GSX-R600 (oder sogar vor seinem Kauf) ist das durchlesen seiner Bedienungsanleitung. Dies sollten wir wegen ein paar einfacher Gründe machen:
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Wenn Sie aber schon Suzuki GSX-R600 besitzen, und noch keine Gelegenheit dazu hatten, die Bedienungsanleitung zu lesen, sollten Sie es aufgrund der oben beschriebenen Gründe machen. Sie erfahren dann, ob Sie die zugänglichen Funktionen richtig genutzt haben, aber auch, ob Sie keine Fehler begangen haben, die den Nutzungszeitraum von Suzuki GSX-R600 verkürzen könnten.
Jedoch ist die eine der wichtigsten Rollen, die eine Bedienungsanleitung für den Nutzer spielt, die Hilfe bei der Lösung von Problemen mit Suzuki GSX-R600. Sie finden dort fast immer Troubleshooting, also die am häufigsten auftauchenden Störungen und Mängel bei Suzuki GSX-R600 gemeinsam mit Hinweisen bezüglich der Arten ihrer Lösung. Sogar wenn es Ihnen nicht gelingen sollte das Problem alleine zu bewältigen, die Anleitung zeigt Ihnen die weitere Vorgehensweise – den Kontakt zur Kundenberatung oder dem naheliegenden Service.
