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3-85)ENGINE 245 [ET Thrust bearing selection table Clearance betore inserting left-side Ester Tinea beri Thrust clearance thrust bearing (arta) | thiclenost 2.560 — 2.585 mm ‘white 2.475 - 2500 mm 0.060 - 0.110 mm (2.1008 -0.1018 in)_| _(72228-17E00-0FO) | (0.0974-0.0984 in) | (0.0024 - 0.0043 in "2.535 — 2.560 mm Yellow 2450-2475 mm G0s0-O110mm — | (0.0998 - 0.1008 in) | (12228-17E00-0E0) | (0.0985- 0.0974 in) | (0.0024 - 0.0043 in) 2510 — 2.595 mm Green ‘2.425 — 2.450 mm 0.060 - 0.110 mm (0.0968 ~ 0.0998 in)_|_(12228-17E00-0D0) | (0.0955-0.0085 in) | (0.0024 - 0.0043 in) 2495 —2.510 mm Blue 2400 - 2.425 mm 0.060 — 0.110 mm (9.0978 ~ 0.0988 in) | (12228-17E00-0C0) | (0.0945- 0.0955 in)_| (0.0024 ~ 0.0049 in) 2.460 ~2.485 mm Black 2375 —2.400 mm 0.060 - 0.110 mm (0.0869 ~ 0.0978 in) | (12228-17EO.080) | (0.0935 0.0045 in)_| (0.0024 - 0.0049 in) 2.490 — 2.460 mm Red 7350-2375 mm 0.088 ~ 0.110 mm (0.0857 ~ 0.0868 in) | _(12228-17ED0.0A0) | (0.0925~0.0835 in) | (0.0022 - 0.0043 in) + After selecting a left-side thrust beating, insert it and again perform the thrust clearance measurement fo make sure it falls within the standard range. NOTE: Right-side thrust bearing has the same specitication as the GREEN (12228-17E00-G00) of ett-side thrust bearing. ClareE66 _ ENGINE: ENGINE REASSEMBLY + Reessemble the engine in the reverse order of disassenibiy, + The following stens require special attention or precauslonary measures should be taken NOTE: Apply engine oil to each running and sliding part before reas- -sembling. *+ Be sure to install the following llams to the crankcase. * Crankshatt journal bearing (7 3-62) * Gearshitt fork (7" 3-56) * Gearshift fork shaft (7° 3-56) * Gearshitt shaft bearing (7" 3-55) * Gearshitt cam bearing (I 8-55) * Gearshift fork bearing (9° 3-55) * Gearshitt cam (7 3-55) * Bearing retainer (7 3-56) * Olljets (CF 3-58) PISTON AND GONROD * Position the gaps of the three rings as shown. Before inserting each piston into the cylinder, check that tha gaps ate 50 lo- cated ‘+ lub a small quantity of molybdenum ail solution onto each pis- ton pin. “Py movrevenum on © Assemiis the piston and canrod. NOTE: * When instaling the pistons, the indent (A) on the piston head must be laced to another side of ID cada 'B on conrod tace, * install the: pistons. NOTE: Be sure to instal! the pistons in the oylindars from which they weve removed in disassembiy: refer to the ylinder numbers, “7” through 4", scribed an the piston. ‘= Install the piston pin circtips A CAUTION, End gap of the circlip shauid not be aligned with the cutaway in the piston pin bore.* Apply engine oll to the sliding surface of the pistons and cyline der walls. ‘+ Install the pistons and conrods into the cylinders from upside, NOTE: When installing the pistons, the indent &) of the piston head must be faced fo each extaust side, ‘A CAUTION |_Becarefull not to damage the cylinder wall by the conrod, ‘= Check that iD code @ on the each conrods taces toward intake side, (& CAUTION Be sure to clean the conrod big end. * Apply molybdenum oll solution to the crank pin bearings sur- face. “Pi movvevenum om soLution‘348 ENGINE CRANKSHAFT + Position the Na.2 and No.3 cenrod big ends teward same side land the No.t and No.4 conred big ends toward opposite side ot Noz and Nos. ‘+ Sot the crankshatt fo the conrods and unper crankcase © Apply molybdenum oii solution to the crank pin and bearing surface. “Fi movyscenum ol SOLUTION & CAUTION) Be sure to clean the canrod big end. * When fiting the conrod cap, make sure that 1.0. code ‘Bon each conrod taces toward intake valve side. * Appiy-angine oil to ne beanng cap baits. * Tighten the bearing cap bolt by using a 10 mm, 12 point socket wrench as following two steps CE) Conrod beating eap bolt: Initial: 15 Nm (1.5 kat-m, 17.0 tb-tt) Final: 80° (74 turn) + Apply engine oil to the conrod big end side surfaces, + Check the conrod movement for smooth turning‘CRANKSHAFT * Apply molybdenum cil solution to each crankshaft journal bear- ing lightly “Ty movvepenum olL SOLUTION ‘+ Insert the right and let-thrust bearings with oll groove ‘facing the erank web, NOTE; ight-theust bearing has green painting, CRANKCASE + Clean the mating surfaces of the crenkcases. * Install the dowel pins“) and O-ring @ to the upper crankcase.370_ ENGINE * Apply SUZUKI BOND to the mating surtace of tha middle crank- case, Gg 99109-31140: SUZUKI BOND “12078” (For USA) GET] 99000-31110; SUZUKI BOND “1215" (For the athers) NOTE: Use of SUZUKI BOND is as follows: * Make surtaces tree from moisture, oll, dust and other foreign materials, * Spread on surtaces thinly fo form an even layer, and assemble the crankeases within few minutes, * Take extreme care not to apply any BOND to the oi hote, oll groove and bearing. * Apply to distorted surfaces as It forms a comparatively: thick ‘firm mae Align the gearshift forks with the each gear, * Tighten the crankcase bolt (8 mm) in ascending order of num- bers assigned to these bolts. Tighten each bolt a little at a time to equalize the pressure. (7) Crankcase bolt: (M3) initial: 18 Nom (1.8 kgfm, 13.0 b-ft) Final; 32 Nom (3.2 kgfm, 23.0 Ib-ft)* Tighten the other crankcase bolts a littia at a time to equalize the pressure. @) crankcase bolt: (16) initial: 6 Nom (0.8 kgm, 4.5 It) Final: 11 Nem (1.1 kgfm, 8.0 lb-ft) NOTE: Fit the clamp to the crankcase bot‘. ‘NOTE: Fil the gasket la the crankcase bott NOTE: ‘After the crankcase bolts have been tightened, check i the erank- shatt rotates smoothly372 _ ENGINE ‘TRANSMISSION : © Install the bearing pins (7) and the C-ring @ on the upper crank- case. * Install the countershaft assembly on the upper crankcase. NOTE: Align the C-ring with the groove on the bearing and the: bearing pin with the indent on the bearing. + Install the driveshafi assembly on the upper crankcase, NOTE. Align the beanng ring with the groove an the crankcase ant the bearing pin with the indent on the bearing. + Install the olf seal ‘= Turn the bearings to install the bearing dowel pins @ in the respective positions. * Install the O-rings. > Install the dowel pins {®ENGINE 3-73 * Apply SUZUKI BOND to the mating surface of the lower crank- case GH] 99104-31140: SUZUKI BOND "12078" (For USA) sq] 99000-31110; SUZUKI BOND “1215” (For the others) NOTE: Use of SUZLIKI BOND is as follows: * Make surtaces free from moisture, oil, dust and other foreign materials. * Spread on surfaces thinly to form an even ayer, and assemble the crankcases within few minutes. * Take extreme care not to apply any BOND to the oi! hole, oi groove and bearing. * Apply to distorted surfaces as it forms a comparatively thick thir, ‘+ Match the middle and lower crankcases, NOTE. Align the gearshift forks with their grooves,4 7_ ENGINE * Tighten the crankcase bolts a little at a lime to equaliz pressure, {© Crankcase bolt:(Mé) initial: 6 Nom (0.6 kgtm, 4.5 ib-ft) Final :11 Nem (1.1 kgf-m, 8.0 Ib-ft) (MB) initial: 15 Nem (1.5 kgf, 10.8 Ib-ft) Final : 26 Nem (2,6 kgf, 19.0 tb-tt} NOTE: * Fit the copper waisher to tha crankcase bolts ®). * Fit the gasket washer fo the crankcase bolts i. * Check the driveshait and countershatt to rotate smoothlyOIL STRAINER + instal the O-ring. NOTE: Apply grease to the O-ring. Af 99000-25010; SUZUKI SUPER GREASE “A” CAUTION |_ Use the new O-ring to prevent oll leakag ‘Install the oll strainar as shown. [7] ol strainer bott: 10 Nem (1.0 kgt-m, 7.0 Ibeft) OIL PRESSURE REGULATOR ‘= Apply grease to the O-ring and press in the oil prassure taguta- tor to the crankcase, fax 99000-25010: SUZUKI SUPER GREASE “A” CAUTION Use the new O-ring to prevent oil leakage. OIL PAN © Install the gasket 4 CAUTION. Use the new gaskel to prevent oll leakage. * Install the off pan, NOTE Fit the gasket washer to the oll pan bott B + Tighten the oil pan bolts diagonally to the specified torque. (7) Ol! pan bolt: 10 N-m (1.0 kgt-m, 7.0 lb-ft) * Install the cowling brackets and 23.76_ENGINE Ol. PRESSURE SWITCH Apply SUZUKI BOND "12076" to the thread part of the oil pres- sure switch (D) and tighten ito the specified torque, Gj 99000-31140; SUZUKI BOND "12078" (7) Oil pressure switch: 14.N-m (1.4 kgf-m, 10.0 Ib-tt) NOTE: Be careful nat to apply SUZUKI BOND "12078" to the hate of the thread end, OlL COOLER * Apply the grease to the O-ring Sf 99000-25010: SUZUKI SUPER GREASE “A” ‘@ CAUTION | Use the new O-ring to prevent oll leakage. ++ Install the oll cooler as shown. 1) Ol cooler bolt: 19 Nem (1.0 kgt-m, 7.0 Ib-ft) OW FILTER * Install the oil titer using the special toot, (C7 2-14) (09915-40610: OFF filter wrenchENGINE 377 * Install the gasket. «Install the breather eover. () Breather cover bolt: 10 N-m (1.0 kgf-m, 7.0 tb-tt) GEAR POSITION SWITCH ‘Install the gear position switch contacts () and the springs (2, * Apply the grease to the O-ring 93 99000-25010: SUZUKI SUPER GREASE “A” + Install the gear position switch as shown.‘78 ENGINE WATER PUMP + Apply grease to the O-ring A CAUTION Use the new O-ring to prevent oll leakage. Jak 99000-25010; SUZUKI SUPER GREASE “A” © Tighten the water pump mounting bolts to the specified torque, (©) water pump mounting bolt: 10 N-m (1.0 kgf-m, 7.0 lb-ft) NOTE: Pass through the gear position swlich lead wire under the warter pump it. * Apply the engina coolant to the O-ring + Install the water inlet cover, [E) Water inlet cover bolt: 10 Nem (1.0 kgt-m, 7.0 Ib-tt) ‘+ Install the radiator hoses. (-7"8-24)ENGINE 379 GENERATOR ROTOR, = Degraase the tapered portion af the generator rotor and also the crankshaft. Use nanfiammable cleaning solvent ta wipe off oily or greasy matter and make these surfaces completely cry, * Install the generator rotor onto the crankshaft * Install the rotor bolt with the washer + Holding the generator rotor with the special too! and tighten its bolt to the specified torque, (09930-44520: Rotor halder [F] Generator rotor bolt: 120 Nem (12.0 kgtm, GENERATOR COVER * Apply SUZUKI BOND “12078" lightly fo the mating surfaces at the parting line between the upper and lower crankeases as shown, "€22] 99000-31140: SUZUKI BOND “12078" * Install the dowel pins and new gasket ([ 4 CAUTION | Use the new gaskets to prevent oil leakage. * Install the generator cover and tighten the generator cover botts to the specified torque. (© Generator cover bolt: 10 Nm (1.0 kaf-m, 7.0 Ib-ft) Be careful not topinch the tinger between the generator cover and the crankcase, NOTE: Fit the gasket washer to the bois ®0 ENGINE = Install the CKP sensor, * Apply SUZUKI BOND "12078" light to the groove of the signal generator lead wire gromet 7] 99000-21140: SUZUKI BOND "12078" CAM CHAIN DRIVE SPROCKET * Install the cam chain drive sprocket onto the crankshaft NOTE: Align the punched! mark (K) on the cam chain drive sprocket with the punched mark f on the crankshan CAM CHAIN TENSIONER AND CAM CHAIN GUIDE * Install the cam chain, © Apply a small quantity of THREAD LOCK ~1342" to ie cam chain tensioner bolt and cam chain guide bol. * Install the cam chain tensioner <), washer @ and cam chain gui Zl 99000-32050; THREAD Lock "1342" {Ei cam chain tensioner bolt: 10 N-m (1.0 kgf-m, 7.0 lb-ft) (Cam chain guide bolt: 10 N-m (1.0 kgfm, 7.0 lb-ft)ENGINE 3.81 STARTER CLUTCH * Install the washer 7 * Install the starter clutch assembly onto the crankshatt NOTE: Align ttre engraved line ®) on the starter clitch with the punched markiB on the crankshaft * Install the starter clutch bolt with the washer. + Hold the starter clutch with special tool and tighten its ott to the specified torque. (09920-34820: Starter clutch (F Starter clutch bolt: 55 Nem (5.5 kgt-m, 40.0 tb-ft) ‘STARTER IDLE GEAR * Install the starter idle gear No.2) its shatt ‘2 and the wave washer + Apply SUZUK! BOND 12078" lightly 1a the mating surtaces ® ‘at the parting line between the upper and lower crankcases ‘and surlace (B: as shown. 29 99000-31140: SUZUKI BOND "12078"$42_ ENGINE * Install the new gasket (D) and the dowel pins. A CAUTION | |_ Use a new gasket to prevent oil leakage. “Install the starter clutch cover and tighten its batt as shown. NOTE: * Fit the wive clamp to the starter clulch cover bolt ®) as shown, * Fit the new gasket washer to the starter ciutch cover bolt 8) as shown. @ CAUTION Use the new gasket washer to prevent oil leakage. [P) starter idle gear cover: 10 Nem (1.0 kkgttm, 7.0 Ibeft) + Install the starter idle gear'Ne.t shaft (D and the tirust washer 2 the bearing (3) and the starteridle gear No.1) the washor and the wave washer ‘5 * Install the dowel pins and the new gasket 7: _& CAUTION "Use a new gasket to prevent ail leakage. install the starter idle gear cover and tighten its bolts to the Specie’ toraue (© Starter idie gear cover: 10 Nem (1.0 kaf-m, 7.0 Ib-ft) NOTE: Fit the gasket washer to the baitGEARSHIFT SYSTEM * Install the gearshitt cam stopper ‘f), its bolt 2, the washer 2 and the return spring @). NOTE: Apply 4 small quantity of THREAD LOCK “1342"fo the gearshift cam stopper bolt) and tighten it fo the specified torque, Gq 99000-32050: THREAD LOCK "1342" (8) Gearshift cam stopper bolt: 10 Nem (1,0 kgf-m, 7.0 It-ft) NOTE. ‘Hook the return spring end to the stopper ‘t + Confirm the gearshift cam stopper movement + Check the neutral position, * Install the gearshift cam stopper plate after aligning the gear- shift cam pin ) with the gearshift cam stopper plate hole + Apply small quantity of THREAD LOCK "1342" to the gaar- shift cam stopper plate bolt and tighten itto the spocified torque. Zl 29000-32050: THREAD LOCK “1342” (F) Gearshift cam stopper plate bolt: 10 Nom (1.0 kgtm, 7.0 lb-ft)S44 ENGINE + Install the gearshift shattigearshitt arm ) with the washers as shown. NOTE: Pinch the gearshift arm stopper (2 with return spring ends () + Install the washer) and circlip @). Ol PUMP * Install the O-ring to the ail pump and apply grease to i. “da CAUTION __Use the new O-ring to prevent oil leakage. Sfx 99000-25010: SUZUKI SUPER GREASE “A” NOTE: ‘Set the oll pump shaft end to the water pump stat. + Install the oll pump with the three bolts and then tighten them 10 the specitied torque, (aii pump mounting bolts: 10 Nem (1.0 kgf-m, 7.0 Ib-tt) © Install the washer @ and the pin (2. NOTE: Be careful not to crap the washer }) and the pin into the cramke case, ‘© Install the oll pump driven gear * Install the circtip @ (© 09000-26107: snap ring pliersCLUTCH * Install the thrust washer onto the countershatt | NOTE: ‘The chamier sido & ofthe thrust washer faces crankcase sige. | + Install the oll pump drive gear () to the primary driven gear assembly. NOTE: Be careful not to contact the primary driven gear with the crankwab when installing the clutch housing + Install the bearing @ and spacer 2 and apply engine ail to them, + Install the primary driven gear assembly.386 ENGINE * Install the thrust washer install the clutch sleeve hub (2: orto the countershatt, * Install the washer 'Si.and spring washer NOTE: The convex side of the washer @ faces eutsiae, * Install the clutch sieeve hub nut * Hold the clutch sleeve hub using the special tool (& 09020-53740: Clutch sleeve nub holder * Tighten the clutch sleeve nub nut to the specitied torque () clutch sieeve hub aut: 180 N-m (15.0 kafm, 108 Ib-ft) *# Lock the clutch sleeve hub nut with a eenter punch,CLUTCH « Insert the washer (f) and spring washer 2: = + Insert the clutch detve plates and driven pistes one by one into the clutch sleeve hub in the prescribed ordes NOTE: Insert the outermost drive plate claws ® to the other sits ®) of clutch housing as shown, WORIVE PLATE Ne. 1 (40 itn pes) :7 pes bb DRIVE PLATE No 2 (48 frictan es) 1 pe © DRIVE PLATE No.3 (With damoer) <1 pe @POAVEN PLATE No Theses: 26mm). 6-6 pes DRIVEN PLATE No.2 Total pos {Thickrass: 23:mm): 0-2 poe Freon pec + Install the clutch push tad () into the countershalt * Install the clutch push piece 2, the bearing “and the thrust ‘washer @) to the countershatt NOTE: Thrust washer @ is located between the pressure plate and the bearing @38 ENGINE * Install the clutch pressure plate. * Install the clutch springs * Hold the clutch housing using the special toot. “& CAUTION “Be careful not to damage the clutch housing or clutch | plates, (3 09920-53740: Clutch sleeve hub holder ‘+ Tighten the clutch spring set bolts to the specitied torque. {8 Clutch spring set bolt: 10 Nem (1.0 kgf-m, 7.0 tb-ft) Non Tighten the clutch spring set bolts eagonaily CLUTCH COVER + Apply SUZUK! BOND "1/2078" lightly to the mating surtaces at the parting line between the upper, middle and lower crank- cases as shown, GE] 99000-31140: SUZUKI BOND “12075” * Install the gasket Gand the dowel pins, ‘A CAUTION Use the new gasket to prevent oll leakage, + Install the clutch cover and tighten its bolis to the specified torque. clutch cover bolt: 10 N-m (1.0 kgfm, 7.0 Ibeft) NOTE: * Fit the clamp to the boit ®) as shown. * Fit the gaskets to the bolts as shown,ENGINE 3489 CYLINDER HEAD * Fit the dowel pins and the new cylinder head gasket ({) to the cylinder. 4 CAUTION | Use the new gasket to prevent gas leakage. + Place the cylinder head on the cylinder. + Install the cylinder head side bol and gasket 3) and tighten It to the specified torque. [F) cytinder head side bolt: 14 N-m (1.4 kat-m, 10.0 Ib-tt) NOTE: * The metal side of the gasket ® faces out. * Install the cylinder head side bolt between the cam chain. NOTE: When installing the cyfinder head, keep the cam chain taut. * Tighten the cylinder head bolts (M10) to the specified two-step torque with a torque wrench sequentially and diagonally, [) cylinder head bolt (M10): Initial: 25 Nem (2.5 kgfom, 18.0 Ib-ft) Final: 46 Nem (4.6 kgf, 33.3 thet) NOTE: * Install the washers fo the cylinder head botts (M10) as shown, * Apply engine ofl to the washers and thread partion of the bolts before installing the cylinder head bolts. + Tighten the cylinder head bolts to the specified torque. (7) cylinder head ott (Nae); 10 Nm (1.0 kam, 7.0 tb-Fi)* Fit the gasket 7) and tighten the water temp. gauge. (7) Water temp. gauge: 18 N-m (1.8 kgt-m, 13.0 Ib-tt) + Install the thermostat. (75-10) * Install the thermostat cover, (Thermostat cover bolt: 10 N-m (1.0 kgfm, 7.0 lb-ft) NOTE: Fit the clamp to she bolt ®. + Install the water hose. ([—7'B-24)CAMSHAFT + Tum the crankshaft counterclockwise with the box wrench and align the line & on the starter olutch with the index mark '® of the valve timing inspection hole while keeping the cam chain pulled upward Pull the cam chain upward, or the chain will be caught between crankcase and cam drive sprocket. & CAUTION To adjust the camshaft timing correctly, be sure to align the line & with the index mark & and hold this position | when installing the camshaits, | * The cam shafts are identified by the embossed letters * Before placing the camshaits on cylinder head, apply molyb- denum ail solution to their journals and cam faces. + Apply engine oll fo the camshaft journal holders Ti mouvapenum on so.ution NOTE: Before installing the camshatt, check that the tappets are inétallod correctly, * Pull the cam chain tightly * The exhaust camshatt sprocket has an arrow marked “1" Turn the exhaust camshalt so that the arrow is aligned with the gasket surtace of tne cylinder head + Engage the carn chain with the exhaust camshalt sprocket * Bind the cam chain and the sprocket with a proper wire clamp 4) to prevent the cam chain disengagement while installing the camshaft journal halders + The other arrow marked “2" (Bi should naw be pointing straight up. Starting from the roller pin that Is directly above the arrow marked "2", count out 14 roller pins (Irom the exhaust cam shalt side going towards the intake camshaft side). * Engage the 14 rollar pin ‘C) on the cam chain with the asrow marked “3" on the intake sprackat + Bind the cam chain and the sprocket with 4 proper wire clamp 1 to prevent the cam chain disengagement while installing the camshaft journal holders.382 ENGINE NOTE! The cam chain should now be on ail three Sprockets. Ba careful ‘Rot to move the crankshaft until the camshatt journal halders and cam chain tension adjuster are secured.+ Install the dowel pins. © Install the camshatt journal holders, intake and exhaust and cam chain guide. ‘+ Fasten the camshaft journal nokders evenly by tightening the camshatt journal holder bolts sequentially and diagonally. NOTE: * Damage to head or camsnalt journal holder thrust surfaces may resuttfthe camishat journal hakders are nat drawn down evenly. * Each camshaft journal holder is kientified with a cast-an tetters a © Tighten the camshatt jaurnal holder bolts in ascending order of numbers (see below) to the specified torque. (©) camshaft journal holder bolt: 10 Nem (1.0 kgf, 7,0 Ib-ft) & CAUTION ‘The camshaft journal holder bolts are made of a special material and much superior in strength, compared with other types of high strength bolts. ‘Take special care not to use other types of bolts.4 ENGINE ‘Cam chain tension adjuster ‘+ Retract the push rod by pushing the rach * |nstall the bail @) to the cam chain tension adjuster, Sy * Install the new gasket 2). (A CAUTION | Use the new gasket to prevent oil leakage. | * Install the cam chain tension adjuster and tighten the mounting bolts. {F) cam chain tension adjuster mounting bolt: 10 Nm (1.0 kgfom, 7.0 theft) * Install the spring D. © Install the oll hase as shown in illustratioit. (CoFNext page) ‘Install the gaskets and tighten the union bolt {8 Oi hose union bolt: 12 Nem (1.2 kgm, 8.7 Ib-tt) ‘+ Install the gaskets and the cam chain tension adjuster cap bolt, NOTE: Glick sound is heard when the cam chain tension adjuster cap bolt fs installed. * Tighten the cam chain tension adjuster cap bolt to the speci- fied torque. [F) cam chain tension adjuster cap bolt: 23 Nem (2.3 kat-m, 16.5 Ib-ft) CAUTION After installing the cam chain tension adjuster, check to be sure thot the adjuster work properly by checking the slack of cam chain, * Cut the wire clamps. * After installing the cam chain tension adjuster, rotate the eranik- shaft (some tums), and recheck the pasitions of the camshats. (3-98)35 6a. Hi a (wa eeu 21) & es fa) /. uo un odo ‘hur Eo: Sa in Wa oe wba) ‘No! “wo a 990 29) eu on i pe Botinas S ‘uo/SUR HEE UNE yo sana we UBhY48 ENGINE * Tighten the valve timing Inspection plug @ to the specified torque. {© Valve timing inspection plug: 11 N-m (1.1 kgm, 8.0 lb-ft) CYLINDER HEAD COVER * Pour engine oil in each oll pocket in the cylinder head. NOTE, Be sure to check the vaive clearance. (J 2-8) © Install the dowel pins * Install the O-rings. * Install the new gaskets to the cylinder head cover, + Apply SUZUKI BOND ~1207B"to the cam end caps of the oas- kats as shown, eq] 99000-31140: SUZUKI BOND “12078” ‘4 CAUTION Use the new gaskets to prevent oil leakage. + Plaoe the cylinder head cover on the cylinder head, Fit the new gaskets to-sach hasd cover bolt. ‘a CAUTION © Tighten the head cover bolts to the specified torque. [Head cover bolt: 14 Nim (1.4 kgm, 10.0 [bfENGINE 347 PAIR VALVE * Install the PAIR reed valve T), (Co> 8-22) * Apply THREAD LOGK ta the bolts, instal the PAIR valve ane! hose. (78-22) ‘f@2} 99000-32050; THREAD LOCK "1342" [F)PAIR reed valve cover bolt: 10 Nem (1.0 kgt+m, 7.0 tht) STARTER MOTOR «Apply the groase to the O-ring, SG 99000-25010: SUZUKI SUPER GREASE "A" * Install te starter motor (© Starter motor mounting bolt: 10 Nem (1.0 kgt+m, 7 tb-ft) * Install the spark plugs. (2FI SYSTEM AND INTAKE AIR SYSTEM CONTENTS PRECAUTIONS IN SEAVICING ... FI SYSTEM TECHNICAL FEATURE: INJECTION TIME .. COMPENSATION OF INJECTION TINE... INJECTION STOP CONTROL .. FUEL DELIVERY SYSTEM. FUEL PUMP ... FUEL PRESSURE REGULATOR FUEL INJECTOR... FUEL PUMP CONTROL SYSTEM ECM (Fl CONTROL UNIT)... INJECTION TIMING .. SENSORS. INTAKE AIR SYSTEM SECONDARY THROTTLE CONTROL SYSTEM OPERATION ... 4-21 FI SYSTEM PARTS LOCATION 4-22 FI SYSTEM DIAGRAM. 4-24 FI SYSTEM WIRING DIAGRAM. SELF-DIAGNOSIS FUNCTION USER MODE .. DEALER MODE FAIL-SAFE FUNCTION FI SYSTEM TROUBLE CUSTOMER COMPLAINT ANALYSIS. SELF-DIAGNOSTIC PROCEDURES SELF-DIAGNOSIS RESET PROCEDURE... MALFUNCTION CODE AND DEFECTIVE CONDITION. "C11" CMP SENSOR CIRCUIT MALFUNCTION. "C12" CKP SENSOR CIRCUIT MALFUNCTION. JAP SENSOR CIRCUIT MALFUNCTION... “TP SENSOR CIRCUIT MALFUNCTION ECT SENSOR CIRCUIT MALFUNCTION. "IAT SENSOR CIRCUIT MALFUNCTION .. "AP SENSOR GIRGUIT MALFUNCTION TO SENSOR CIRCUIT MALFUNCTION “C24”, "C25", C26" or “C27” IGNITION SYSTEM MALFUNCTION....... - C28” STV ACTUATOR CIRCUIT MALFUNCTION “C29” STP SENSOR CIRCUIT MALFUNCTION “C30” STC UNIT CIRCUIN MALFUNCTION ... est GEAR POSITION SWITCH CIRCUIT MALFUNCTION "633", “C34” or “C35” FUEL INJECTION MALFUNCTION. “C41” FP RELAY CIRCUIT MALFUNCTION. “€42" IG SWITCH CIRCUIT MALFUNCTION.FISYSTEMANDINTAKE AIRSYSTEM 4-1 FUEL SYSTEM... FUEL TANK LIFT-UP FUEL TANK REMOVAL .. 4-52 FUEL TANK INSTALLATION. 4-52 FUEL PRESSURE INSPECTION. 4-53 FUEL PUMP INSPECTION... 4-54 FUEL PUMP RELAY INSPECTIOI 4-56 FUEL PUMP AND FUEL FILTER REMOVAL 4-56 FUEL MESH FILTER INSPECTION AND CLEANING 4-58 FUEL PUMP AND FUEL MESH FILTER INSTALLATION. 4-58 THROTTLE BODY AND STV ACTUATOR 2 461 CONSTRUCTION... 4-61 AIR CLEANER 8OX ANO THROTTLE BODY REMOVAL . 4-62 THROTTLE BODY DISASSEMBLY .. THROTTLE BODY CLEANING INSPECTION... THROTTLE BODY REASSEMBLY THROTTLE BODY INSTALLATION STP SENSOR ADJUSTMENT.. FUEL INJECTOR INSPECTION FUEL INJECTOR REMOVAL.. FUEL INJECTOR INSTALLATION ... FAST IDLE ADJUSTMENT... THROTTLE VALVE SYNCHRONIZATION | THROTTLE POSITION SENSOR (TPS) SE THROTTLE CABLE ADJUSTMENT. SENSORS.......... IAP SENSOR INSPECTION. JAP SENSOR REMOVAL/INSTALLATION. TP SENSOR INSPECTION..... TP SENSOR REMOVAL/INSTALLATION KP SENSOR INSPECTION........... CKP SENSOR REMOVAL/INSTALLATION CMP SENSOR INSPECTION... CMP SENSOR REMOVAL/INSTALLATION IAT SENSOR INSPECTION IAT SENSOR REMOVAL/INSTALLATION .. ECT SENSOR INSPECTION .. ECT SENSOR REMOVAL/INSTALLATION AP SENSOR INSPECTION... AP SENSOR REMOVAL/INSTALLATIO! TO SENSOR INSPECTION... TO SENSOR REMOVALIINSTALLATION STP SENSOR INSPECTION . z STP SENSOA REMOVALIINSTALLATION(£2 FISYSTEMANDINTAKE AIRSYSTEM PRECAUTIONS IN SERVICING When handling the Fl component parts or servicing the Fl sys- ‘tam, obsarve the following points for the salety of the system, CONNECTOR/COUPLER + When connecting & connector, be sure to push it m until a click is fet. * With a lock type coupler, be sure to release the lock when dis- ‘connecting, and push ft in fully til the lock works when cone necting it. ‘= When disconnecting the coupler, be sure to hold the coupler tbody and da not pull the lead wires. ‘= Inspect each terminal on the connectoricoupler tor looseness ‘or bending ‘+ Inspect each terminal for corrosion and contamination. The terminals must be clean and free of any foreign material ‘which could impede proper terminat contact. Inspect each lead wire circuit for poor connection by shaking it by hand lightly. If any abnormal condition is found, repair or replace, + When taking measurements at electrical connectors using a tester probs, he sure to insert the probe from the wire hamess side (backside) of the connactoricoupler. * When conhecting meter probe from the terminal side of the ‘coupler (connection trom harass side not being passible), use extra: care not to force and cause the male terminal to bend or the temale terminal 1o open, Connect the prabe as shown to avaid opening of female termi- pal. Never push in the probe whore male terminal is supposed fa fn. + Check the male connector for bend and female connector for excessive opening, Also check the coupler for lacking (leose- ness), corrasion, dust. etc: otek @ x ae D coupier (@D Probe. D yrmeremaie: | Mein isFUSE + When a fuse blows, always investigate the cause, correct it and then replace ths fuse, + Do not use a fuse of a cifterent capacity + Do not use wire or any other substitute for the fuse. ECM/VARIOUS SENSORS + Since each component is a high-precision part, great care should be taken not to apply any sharp impacts during removal and instalation, + Be carstul not to touch the electrioal terminals of the EGM. ‘The static electricity from your body may damage this part. * When disconnecting and connecting the ECM couplers, make sure fa turn OFF the ignition switch, or electronic parts may get damaged. + Batiery connection in reverse polarity is strictly prohibited. Such wrong connecticn wil damage the compenents of the Fl ays- tem instantly when reverse pawer is applied. FISYSTEMANO INTAKEAIR SYSTEM £34 FISYSTEMANDINTAKE AIRSYSTEM. + Removing any battery terminal of a running engine is strietty prohipites, ‘The moment such removal is made, damaging counter electro- ‘motive force will be applied to the ECM which may result in Serious damage. * Before measuring voltage at eacn terminal, check to make sure that battery voltage is 11V or higher. Terminal woHlage ‘check at low battery voltage will lead to erroneous diagnasis. + Newer connect any tester (voltmeter, ohmmeter, ar whatever) to the ECM when its coupler is disconnected, Otherwise, dam- age to ECM may result, » Never connect an chmmator to the ECM with its coupler con nected, If attempted, damage ta ECM or sensors may result. * Be sure fo use a specified voltmetariohmmeter Otherwise, ac- curate measurements may not be obtained and personal injury may resutt ELECTRICAL CIRCUIT INSPECTION PROCEDURE While there: are various. methods for electrical circult inspection, described here is 2 general method to check for open and short ‘cireult using an chmmeter and a voltmeter. OPEN CIRCUIT CHECK Possible causes for the open circuit are as follows. As the cause can exist In the connectoricoupler or terminal, thay need to be chistked carelully, * Loose connection af connesteticcupler * Poor contact af terminal (due 16 dirt, corrosion oF rust. paor contact tension, entry of foreign object etc:) * Wire hamess being open + Poor tarminahto-wire connectionFISYSTEMAND INTAKE AFISYSTEM 45 + Discannect the negative cable trom the battery. + Chack each connectar/coupler at both ends of the circuit being checked for loose connection. Also check for condition of the coupler tock tt equipped. * Using a test male terminal, check the female terminals of the circuit being checked for contact tension (Check each terminal visually for poor contact (possibly caused by dirt, corrosion, rust, entry of foreign object, etc.).Atthe same time, check to make sure that each terminal is fully inserted in the coupler and locked Ireontact tension is not enough. reetity the contact to increase tension or replece. ‘The terminals must be clean and tree of any foreign material which could impede proper terminal contact. + Using continuity inspect or voltage check procedure as de- ‘scribed below, inspect the vrire hamess terminals for open cir- ‘cuit and poor connection, Locate abnormality, if any. ‘Continuity check + Measure resisiance across coupler ‘8 (between ‘A’ and © in ‘the figure}, If no continuity is indicated {infinity or over limit}, the circuit is open between terminals (and, * Disconnect the coupler and measure resistance between couplers @ and Be If no continuity is indicated, the circuit is open between cous plers A and (If continuity Is indicated, there is an open cir- cuit between couplers 1 and © or an abnormality in coupler @ of coupler hack cra enaion by inserting Z rier A, crack each erat or bene are proper alignment Dic Doven SD Tie i few tract et444 FISYSTEM AND INTAKE ARSYSTEM VOLTAGE CHECK I voltage is supolied to tho circuit being checked, voltage check can be used as ciroult check. * With all connectorsicouplars cannected and voltage applied to the circuit being checked, measure vollage between each ter- minal and body ground, Imeasurements were taken as shown in the figure at the right ‘and results are as listed below, it means that the circuit is pen between terminals 4 and 6. Voltage Between: and body ground: Approx. SV © and body ground: Approx. 5V ® and bady ground: ov Also, if measured values are as listed below, a resistance {ab- narmaiity) exists which causes the voltage drop in the circuit between terminals ® and ‘i and body ground: Approx, SV ‘and body ground: Approx. SV—— PV voltage drop A and body ground: Approx. aV— ey SHORT CIRCUIT CHECK (WIRE HARNESS TO GROUND) * Disconnect the negative cable {ram the battory * Disconnect the connectors/counlers at bath ends of the circuit to be checked. Nore: I the circuit ta be checked branches 1o other parts as shown, disconnect all connectors‘couplers of these parts. Otherwise, di- agnosis will be misled, + Moasure resistance between terminal at one end of circurt (1) terminal in figure) andl body ground. I continuity is indicated, there is a short clroutt to ground between terminals A and °CFISYSTEMANO INTAKE AIRSYSTEM 47 * Disconnect the connectoricoupler included in circuit (coupler 4) and measure resistance between terminal ® and body oraun, If continuity is indicated, the circuit is. shorted to the ground between terminals) and Eb USING TESTERS * Use the Suzuki multi-circuit tester (09900-25008). * Use well-charged batteries in the tastar, + Be sure fo set the tester to the carrect testing range. Using the tester * Incorrectly connecting the @ and © probes may cause ine inside of the tester to burnout * it he voltage and current are nat known, make measurements using the highest range. * Reset the pocket tester 1a 02 belore measuring each resis: tance or after changing the resistance range. * When measuring the resistance with the mult-circuit tester, also ‘measure the resistance with no-load. Sub-tract that resistance from the resistance measured undar lad in order to get the true resistance, (Measured _ (No-load fesistance) resistance) = When measuring the resistance with the muti-circuit tester, « will ba Shawn 88 10,00MQ and “1” flashes in the display. ‘+ Check that no voltage is agpliad before making the measure- ment. It voltage IS applied, the testar may be damaged. * After using the tester, tum the power off (1 09900-25008: Multi-circuit tester NOTE: * When connecting the mult ercuit tester, install fixe copper wires (C20 is bolow 0.5 mm) to the back side of the laad wire coupier and connect the probes of tester to therm. * Use a fine copper wire, the outer diameter being below 0.5 ‘mm. to prevent the rubber of ihe water proof coupler feom damn age. = (True resistance) [ Maer-cincur TESTER48 FISYSTEMANDINTAKE AIR SYSTEM. Fl SYSTEM TECHNICAL FEATURES INJECTION TIME (INJECTION VOLUME) ‘The factors to determine the injection time include the basic fuel injection time which is basis of the intake air pressure, engi ulated on the speed and throtle opening angle, and various compensations which ‘are datermined according ta the signals fram varlous Sensors that detect the engine and driving conditions SSeS ECM ————— ————— | Intake Air Pressure intake air pressure | | Sensor {IAP Sensor) signal "| | Basic GCrankshatt Position Engine speed | tut ‘Sensor (CKP Sensor) signal | * injectian | time Throtie Position Sensor (TP Sensor) |_Throtie opening | signal Various Various signals Sener = >) Compensation Utinate ————— te le! Injection signal Injectors - Injection timeFISYSTEMANO INTAKE AIRSYSTEM 48 COMPENSATION OF INJECTION TIME (VOLUME) The following ditferent signals are output fram the respective sensors for compensation of the tuel injection time (volume). DESCRIPTION NAL ATMOSPHERIC PRESSURE SENSOR SIG. | When atmospheric pressure |s low, the sensor sends the signal to the ECM and reduce the injaction time (voluma). ENGINE COOLANT TEMPERATURE SEN- SOR SIGNAL When engine coolant temperature is low, injection time (vol ume) Is increased INTAKE AIR TEMPERATURE SENSOR SIG- NAL When intake air temperature Is tow, Injection time (volume) ‘s increased. BATTERY VOLTAGE SIGNAL ECM operates on the battery voltage and at the same time, it monitors the votage signal for compensation of the fuel injection time (volume). A longer injection time is needed to adjust injection volume in the case of low wattage, ENGINE RPM SIGNAL STARTING SIGNAL | ACCELERATION SIGNAL’ DECELERATION SIGNAL At high speed, the injection time (volume) is increased, This is the compensation of the SAAD. When starting engine, additional [uel is injected during crank: ing engine. During acceleration, the fuel injection time (volume) is ine creased, in accordance wrth the throttle opening speed and | engine rpm. During deceleration, the fuel injection time (wae uma) is decreased INJECTION STOP CONTROL SIGNAL DESCRIPTION TIP OVER SENSOR SIGNAL ‘When the motorcycle tips over, the tip over sensor sends a (FUEL SHUT-OFF) ‘signal to the ECM. Then, this sighal cuts OFF current sup- plied to the tual pump, tue! injectors and ignition coils. OVER-AEV, LIMITER SIGNAL ‘The fuel injectors stop operation when engine rpm reaches te. limit rpm410_FISYSTEM AND INTAKE AIRSYSTEM FUEL DELIVERY SYSTEM The fual delivery system consists of the fuel tank, fuel pump, fuel fiers, Tuel feed hose, {ust delivery pipe {including fuel injectors) and fuel pressure regulstor. There is no fue! return hose. The fuel in the fuel tank is Pumped up by the fuel pump and pressurized fuel to flow into the injector Installed in the tuel delivery pipe. Fuel pressure is regulated by the tuel pressure regulator As the fuel pressure: applied to the fuel injector (the fuel pressure in the fuel delivery pipe) is always kept absolute Tuel pressure of 3.0 kgtiom* (300 KPa, 43 psi), the fuel Is injected into the throttle body in conic dispersion when the injector opens according to the Injection signal from tha ECM, The tuo! relieved by the fuel pressure regulator flaws Out to the tue! tank, Ful td basa > el mest titer (Fer low pressure) File purrs si ee He ccurses fio! Fllieved tuo < Behre pressurized hie!FISYSTEM ANDINTAKE AIRSYSTEM 41 FUEL PUMP The electric fuel pup is mounted at the bottom cf the fuel tank. which consists of the armature, magnet, impeller, brush, check valve and relief waive. The ECM controls its ON/OFF operation a5 controlled under the FUEL PUMP CONTROL SYSTEM. ‘When elecirical energy is supplied to the fuel pump, the motor in the pump runs and sa.does the impeller. This ‘CaUSES a pressure difference fo occur betwean both sides of the impeller as there are many grooves around ft. Then the fuel is drawn through the inlet port, and with its pressure increased, it ia discharged through the: ‘outlet port. The fuel pump has-a check valve to Keep some pressure in the tuel feed hose even when the fuel pump is stepped, Also, the reliel valve 's equipped in the fuel pump, which releases pressurized tuel to the fue! tank when the outlet of the tue! pressure Nas increased up to 4.5.~ 6.0 kat/om* (450 ~ 800 kPa, 64-85 psi) Rate cane Magret poser When the impeller is driven by the motor, pressure differential occurs between the front part and the rear part of the bide groove as viewed in angular direction due to fluid friction. This process continuously takes place causing fuel pressure to be built up. The pressurized fuel is then let out from the pump chamber and iischarped through the motor section and the chack valve. Blade cxner in pate4-32. FISYSTEMAND PVTAKE AIRSYSTEM. FUEL PRESSURE REGULATOR ‘The fuel pressure reguiator consists of the spring and vaive. It keaps absolute fuel pressure of 3.0 kgticm® (900 kPa, 43 psi) applied to the injector at all times, When the jus! pressure rises more than 3.0 kgt/cm* (400 KPa, 43 psi), tha fuel pushes the valve in the Fequlator open and exc695 fue! returns to the fuel tank. at at | coo | FUEL INJECTOR ‘The tue! injector consists of the solenoid coll, plunger, needle valve and filer Iris an electromagnetic type injection nozzle which injects fuel in the throttle body according to the signal from the ECM, When! the-solencid coll of the injector is energized by the ECM, it becomes.an electromagnet and attracts the plunger. At the same lime, the needle valve incorporated with the plunger opens and the injectar which is unger the fuel pressure injects fuel in conic dispersion. AS the lift stroke of the needle valve of the injector is set Constant, the volume of the fue! injected at one time is determined by the length of time during which the solenoid coll is energized (injection time),FISYSTEM ANDINTAKE AR SYSTEM. 419, FUEL PUMP CONTROL SYSTEM When the ignition switch is tured an, current from the battery flows to the fuel pump motor through the side-stand relay and the fue! pump relay causing tha motor to tum. Since the ECM has a timer function, the fuel pump motor stops turing in three seconds after the switch has been tuned on, ‘Thoteatter, when the crankshatt is turned by the starter motor ar the engine has been started, the engine revolving signal is input to the ECM. Than, current flows to the fuel purtp motot from the battery through the side-stand relay and the fal pump relay sa that the pump continues to funetion. A tip over Sensor is provided in the fuel pump sentiol circuit. By this provision, anytime the motorcycle tips ‘over, the tip over sensor sends a signal to the ECM to turn off power to the fue! pump retay, causing the fuel pump motor to stop. At the same time, current to the tuel injectors as well as the ignition coil is interrupted, which then stops the angina. \a.swrex ae cia on l ioe ewes eRe tester nae seems Sweat(414 FISYSTEMAND INTAKE AIRSYSTEM ECM (FI CONTROL UNIT) The ECM is located under the seat. The ECM consists of CPU (Gentral Processing Unit), mamory (HOM) and VO (InpuvOutput} sections. The signal from each sensor is sent to the input section and then sent to CPU, Qn the basis of signal information received, (CPU calculates the volume of fuel necessary for injection using maps programmed for varying engine conditions, ‘Then, the operation signal of the fuet injection is sent from the output section to the fue! injector, The eight kinds of independent program maps are programmed in the ROM. ‘These eight kinds of maps are designed to compensate for differences ot the intaka/exhaust systems and voting performance. LIGHT LOAD: When the engine is running in @ light load, the fue! injected volume (time) is determined the ‘basis of the intake air pressure and engine speod. HEAVY LOAD: When the engine is running ih a heavy load, the fuel injected volume: (time) is determined the basis of the thratbe valve opening and engine speed,FISYSTEMANDINTAKE AIRSYSTEM 4-15, INJECTION TIMING ‘The system employs 4 sequential, four-cylinder independent injection type, using the: crankshalt position sensor (signal generator) to determine the piston position (injection timing and ignition timing) and the ‘camshait position sensor to identity the cylinder during operation, and these information are sent to the ECM. This makes it possible to inject the optimum volume of tuel in the best timing for the engine operating sonditions. When the crankshaft begins to turn at the time of starting, the ECM sends the signals-to the four injectors, 1M, #2, #3 and #4 to have them inject fuel simultaneously, From the second turn onward, the sequential four-cylinder independent injection occurs as exptained above. cKP signal ley. 20. e230 whey Ignition ‘irwing Cermak angie we Os igor 720° Tuening 2 3 4 5 TUANS Toc. lea‘416 SYSTEM AND INTAKE AIR SYSTEM SENSORS: INTAKE AIR PRESSURE SENSOR (IAP SENSOR) ‘The intake air pressure sensor is incated at the rear side ot the air cleaner box and its vacuum hose is cannected to the thrattie body. The sensor detects the intake: alr pressure, which is then con verted into: voltage signal and sant to the ECM, The basic fuel injection time (volume) is determined according to the voltage signal (output voage) ‘The voltage signal increases when the intake air pressure is high. Intake a prassutetrenet) i-— ha Low High an wezaur Thaw vacuum) THROTTLE POSITION SENSOR (TP SENSOR) ‘The throttle position sensor is installed on the No.4 throttle body. ‘The throttle postion sensor is a kine of variable resistor which dotects the throttis opening angie. The battery voltage in the sensor is changed to the throttle posi- tion voltage which is then sent fo the ECM. ‘The basic fuel injection time (volume) is determined according to the voltage signal (output voltage) ‘The voltage signal increases as the throttle is opened wider. Cua Throte rahe Lopeninpibegr2a) veFISYSTEMANO INTAKE AIR SYSTEM £17 CRANKSHAFT POSITION SENSOR (CKP SENSOR) The signal rotor is mounted on the right end of the erankshatt and the crankshaft position sensor (Pick-up call) is installed on the right side of the middie crankcase. The sensor generates the pick-up signal 10 be supy ECM. The ECM calculates and decides bath the fuel injection timing ‘and ignition timing. ‘The injection volume incteases when the engine rpm is high to the CAMSHAFT POSITION SENSOR (CMP SENSOR} ‘The signal rotor is Matalled on the intake camshaft. and the cam- shaft position sensor (Pick-up coil} is installed on the cylinder head cover. The sensor generates the pick-up signal to be supplied to the ECM, The ECM calculates and decides the cylinder Identity and se- ‘auential injection timing INTAKE AIR TEMPERATURE SENSOR (IAT SENSOR) The intake alr tomperature sensor is installed at the right side of the air cleaner box The sensor detects the intake alt temperature in thermistor resis- lance valve. With this resistance value converted to voltage sig- Pal, the signal is sent to the ECM. The injection volume increases as intake air temperature decreases The thermistor resistance value increases when the intake alr temperature is low, and decreases when the intake air tempera ture is high Thormstor Lim 2—e High Se4.18 FISYSTEM AND INTAKE AIRSYSTEM ENGINE COOLANT TEMPERATURE SENSOR (ECT SENSOR) ‘The engine coolant temperature sensor is installed at the rear ide of the cylinder head ‘The sensor detects the engine coolant temperature in thermistor resistance value, which is then converted to voliage signal and sent to the ECM, Ths injection volume increases as coolant tem- perature decreases. ‘The thermistor resistance value increases when the engine cool lant temperature is low, and decreases when the engine cootant temperature is high asinine vaca — ne 3 f \ : Thecmisioe 5 cr Core engh Terese ATMOSPHERIC PRESSURE SENSOR (AP SENSOR) ‘The atmospheric pressure sensor is located over the EGM. ‘The sensor detects the atmospheric pressure, The detected pres: ure is converted into voltage signal and sent to the ECM. The injection time (volume) is controlled according to ms voltage signal (output voltage}, ‘The voliage signal increases as the atmospheric pressure rises. Mrssmnete fae rami)FISYSTEMAND NTAKE ARRSYSTEM 419 TIP OVER SENSOR (TO SENSOR) The tip aver serisor is located in ahead of the battery holder The sensor detects the leaning of the motoroyele, When it leans more than 43°, the mechanical switch tums ON and a signal is sent to the ECM. At the same time, this signal cuts OFF current supply to the fue! pump, fue! injectors and ignition calls. SECONDARY THROTTLE POSITION SENSOR (STP SENSOR) The secondary throttie position sensor is installed an the No.4 throttle body. The secondary throttle position sensor is a kind of variable re. sistor which detects the secondary throttle opening angie. ‘The STP sensor detects the STV actuator movement by the vol ‘age signal which is then sent to the ECM. The ECM determines the ST valve angle based on the opera- tion map. ‘The voltage signa! increases 5 the secondary throtile is opaned wider. Canaan = ™ f | : 1 5 Toto valve 5 opening Deqse6) ral ——= Lange£20_FISYSTEMANDINTAKE AR.SYSTEM INTAKE AIR SYSTEM SECONDARY THROTTLE CONTROL SYSTEM ‘The secondary throttle contro! system (STC system) consists of tha secondary throttle valve (ST valve), secondary throttie valve actuator (STV actuator) and secondary throttie position sensar (STP sensor) ST vahe is installed in each thratie body. STV actuator and STP sensor are installed! an the right side of the throttle body assembly. The ST valve is turned by the STV actuator, This system is designed ta control the volume and the velocity of intake ait s as to improve angina output power. The system produces more seamless and linear throttle respanse. This is performed by opening or closing the throttle botly intake port according 10 the gear positions and engine rpm. When the engine is: running in a low speed range, the intake part is almost closed for controlled intake air volume, This improves the effect to intake alr Now pu'sation so that the engine can output higher power in this speed range. As the engine spoed grows faster, the intake port are gradually pen for guiding the proper volume sf ait into the thrattle bodies so that the engine can produce the maximum power in each speed range. ~ ™ Secondary thotle position sensar (STPS) ‘Secondary thraste valve ‘sry Seconaery throttle vate actuator TVA}FISYSTEM ANDINTAKE AIRSYSTEM 421 OPERATION Tha secondary throttle control system (STC system) operates on the signal supplied from the ECM. The ‘apen’close operation of tha sacondary throttle valve (ST valve) is performed by the secondary throttle valve actuatar (STV actuator) which is controlled by the STC: unit to change the eurrent direction into the matar of the STV actuator. ‘The STP sensor detects the STV actuator movement by measuring vallage and the ECM determines the ST valve angle based on the operation map. ‘When turning the ignition switch ON, every time the STV actuator automatically drives the ST valve and ‘checks tully close and open position voltage and rétum to original position to confirm each ST vaive position voltage Secondary throne vaten (STV) Secondary thats poster serany (STS) ‘Secondary throtle valve ‘euator (STV)FISYSTEM AND INTAKE AIR SYSTEM £23,4:28 SYSTEM AND IVTAKE AIRSYSTEM Fl SYSTEM DIAGRAMFISYSTEMANDINTAKE AIRSYSTEM 425 FISYSTEM WIRING DIAGRAM4:25 SYSTEM AND IVTAKE AIRSYSTEM SELF-DIAGNOSIS FUNCTION ‘The self-diagnosis function is incorporatad in the ECM. The function has two modes, “User moda’ and “Depler mode”, The user can only be notified by the LCD (DISPLAY) panel and LED (Fi light). To chack the function of the individual Fi system devices, the dealer mode is prepared, In this check, the special tool is necessary to read the code of the malfunction items, USER MODE LCD (DISPLAY) FLUIGHT MALFUNCTION INGICRION NoierGON INDICATION MODE “NO” Coolant Temp. — = ee Coolant Tamp. and Filight tums ON. | Each 2 sec. Temp. “FI letters, or FF is indicated. a Engine can start Engine can not start | “FT letter Fi light turns ON “FT is indicated 2 and blinks. continupaisy. 4 When one of the signals is not recelved by ECM, the fail-safe circuit works and injection is not stopped. in this case, “FI' and coolant temp. are indicated in the LCD panel and motorcycle can run. Et ‘The injection signal is stopped, when the camshatt position sensor signal, crankshatt position sensor signal, tip aver sansor signal , #1/#2, #3 and #4 ignition signals. #1, #2, #3 and #4 injector signals, fuel pump retay signal ar ignition switch signal is not sent to ECM. In this case, “Fl” is indicated in the LCD panel. Motorcycle dees not run, “CHEC*: Tha LCD panel indicates “CHEC™ when no communication signal from the ECM is received for 5 seconds. For Example: ‘The ignition siteh is turned ON, and the engine stop switch is tured OFF: in this case, he speed- ‘ameter does not receive any signal from the ECM, and the panel indicates “CHEC". It CHEC is indicated, the LCD does not indicate the trouble coda. It is neoassary to check the wiring hares between ECM and speadometer couplers. ‘The possible cause of this indloation is as follows: Engine stop switch is in OFF pasition, Side-stand/ignition inter-lock system és not working: Ignition fuse is burnt, NOTE: Uniti starting the engina, the Flight turns ON. The FI light fs also turned GN when engine femperature is high, or olf pressure i low:FISYSTEMAND INTAKE AI SYSTEM $27 DEALER MODE ‘The detective function is memorized in the computer. Use the special teof's coupler to connect to the dealer mode coupler. The mamorized maifunchon code i$ displayed on LOD (DISPLAY) panel, Mattunction means that the ECM does not receive signal from the devices. These alfected devices are indicated in the code form, (09990-82710: Mode select switch ‘CAUTION Before checking the malfunction code, do not disconnect the ECM lead wire couplers. If the couplers trom the ECM are disconnected, the malfunction code memory is erased and the |_maifunetion eode ean not checked. | LED (DISPLAY) MALEUNCTION UOMICN FILIGHT INDICATION | INDICATION MODE “NGF 00 = 7 code is indicated — Fon crval nomarito. | Fight tums OFF: For sich 2 eee, cae moon indicated.4:28_FISYSTEM AND INTAKE AIRSYSTEM CODE MALFUNCTION FART REMARKS: 200 | None No detective part C11 | Camshatt position sensor (CMP sensor) 12 | Crankshatt position sensor (CKP sensor) Pick-up oil signal, signal generator 13 | Intake sir pressure sensor (IAP sensor) 14 | Throttle positian sensor (TP sensor) 3 £15. | Engine coalant temp, sensor (ECT sensor) cat Intake air temp. sensor (IAT sensor) 22 | Atmospheric pressure sansor (AP Sansor} €23 | Tip over sensor (TO sensor) 24 | ignition signal #1 (1G coll #1) For #1 cylinder 25 | Ignition signal #2 {IG coll #2) | For #2 cylinder €26 | Ignition signal #3 (1G coll #3) For #3 cylinder 27 | Ignition signal #4 (1G coil) For #4 cylinder 28 | Secondary throttle valve actuator (STW actuator) 229. | Secondary throttie pusition sensor (STP sensor) ¢30 | Secondary throttie contro! unit (STC unit} 231 | Gear position signal (GP switch) 682 | Injector signal #1 (FI #1) For #1 cylinder 633 | Injector signal #2 (Fi #2) For #2 eylinder 654 | Injector signal #3 (Fl #3) For #3 cylinder 1635. | Injector signal ed (Fi #4) For #4 cylinder Fug! pump control system (FP contro| system) Fus! pump, Fue! pump relay | Ignition switch signal (IG switch signal) Antisthett In the LOD (DISPLAY) panel, the malfunction code is indicated from small code to large code. 3 To get the proper signal trom the throttle position sensor, the sensor basic position is indicated in the LCD (DISPLAY) panel. The maltunction code is indicated in three digits. in front of the three digits, a line appears in any of the position, upper, migdte or lower fing. the indication is upper o lower line when engine rpm is 1.300 ram, sightly tum the throttle position sensor and bring the line to middle. In the normal condition, the throttle valve stop screw pushes throttle valves sfightly, and indication point is middle line Setting procedure: 1.Adjust the engine rpm to 1 300 rpm. (= 2-15) 2.Slop the engine and connect the special lool (Mode ‘select switch) to the dealer mods coupler at the wiring hamess. 4.1 the throttle position sensor adjustment is necessary, joosen the screws and tun the thrattle position sensor and bring the tine 10 middle 4. Then, tighten the screws to fix the throttle pasition sensor, (09930-11960: Torx wrench SCO | = ieoreet - COG | — Correct position zc00 | The LOD indicates 0.4 sec.jime, and two times show the cor rect position, where itis fixed. InearrectFISYSTEMANDINTAKE AIRSYSTEM 429 FAIL-SAFE FUNCTION Fi system is provided with fail-safe function to allow the engine to start and the motorcycle to run in a minimum performance necessary even under malunction condition. [Tem FAICSAFE MODE | STARTING ABILITY | AUNNING ABILITY, Camshatt position | When camshait position ees sensor signathas faled during running, NO" “ves” | he ECM determines cyinder | Motoreyeie an run, but ohe engine stops, engine as # belors occurrence of | can not start. such a failure Grankshalt positon | The motorcycle stops, . cone sensor NOE __ Intake air pressure | inlake Sir pressure i ined z ae sensor 19 760 mmbg. WES abe Thratile postion |The throttle opening Is sensor fixed to full open position. "ES" "YES" dh ing is also fixed. Engine coolant | Engine coolant temperature a temperature sensor| value is fixed to 60°C. ae es intake alr intake air temperature - : temperature sensor| value is fixed to 40°C, “yES" “vES' ‘imaspheric ‘Almospheric pressure iS 7 pressure sensor _|{ixed to 760 mmHg. ES XE Ignition wi lepnensn ES" YES* = signal eres [92.93 #4 cylinders can run. YES" es" #2 | [Fenian #1, #98 Ma oylindere can run 3 | #3 tgnition-off Le tem n Geers 1, #2 & WS cylinders can Tun “YES "YES" 4 | Fei iprttoneatt Wi, #2 8 85 cylinders can run. Teen “YES ES || St heeces 32, #3 B #4 cylinders can run, leek "VES" ES a2 [Pe Roane 1, #3. #4 cylinders can ran "YES" ES #3. | #3 Fusteut #1, #2 & #4 cylinders can nun. "YES" ES [eee ecco Hy, #2 & W3 cyinders can fun, Secondary voile | Secondary twrotta vale e wes “yes” valve actuator _| fixed to half open position. ‘Secondary throtte | Secondary throta valve le oe position sensor _| fixed to full open position. es: ne ‘Secondary thratie | Secondary thratie valve i a control unit fixed to full open position. Bid NEE ‘Gear position signal) Gear position signal is fixed ] a to 6th gear. = tes "Yes" means that the engine can start and can run evan If the above signal is not received from each sensar. But, the engine sunning condition is not complete, providing onty emergency help (by fail-safe ciccuit} In this caso, it ls necessary to bring the matorcycle to the workshop lor complete repair When two ignition signals or two injector signals are not received by ECM, the tall-sale circuit ean not work and ignition oF injection is stopped42-90. FISYSTEM AND INTAKE AIRSYSTEAE Fl SYSTEM TROUBLE SHOOTING CUSTOMER COMPLAINT ANALYSIS Record details of the problem (failure, complaint) and how it occurred as: described by the customer. Far {his purpose, use of such an inspection form will facilitate collacting information to the point required tor proper analysis and diagnosis EXAMPLE: CUSTOMER PROBLEM INSPECTION FORM User name: Woda Ne Date of eve: ato Flea, [Date of problem Mileage: Waltunelion indicator lamp candition (LED) Waltunetion User mode] No display 1 Malfunction dlepiay ( 7 displaylcode (LCD) Dealer maveTi No code 1 Malfunction code. } PROBLEM SYMPTOMS DiPoor Driveability Hesitation on acceleratiin CBack frei After fre CLack of pawer Always ON [) Sometimes QN [J AWways OFF Cl Good condition Osurging Abnormal knocking DOther DEngine Stall when Poor fast Idle Dimmediately after start ‘Abnormal idling speed Thraitle valve is opened (CHigh Clow) { — ofmin) OThrotle valve is closed (Unstable Load is applied Hunting timin. 12min) Botner Dorner, TGTHERS: MOTORCYCLE/ENVIRONMENTAL CONDITION WHEN PROBLEM OCCURS Environmental condition ‘Weather Fair O Cloudy Cl Rain 6 Snow Always © Other ‘Temperature Hot C1 Warm (Cool ©) Cold ( “Fi °C) DAlways Frequency | ClAlWays Sometimes times’ day, manth) C1 Only once Under certain condition Road Urban C1 Suburb O Highway C! Mountainous (CI Uphill CI Downhill) OTarmacadam [Gravel 0 Other Motoreycie condition Engine DCold Warming up phase ClWarmed up [Aways [J Other at starting candition Climmediately ater start C1 Racing without load Cl Engine speed ( simi) | Motorcycle During driving: (J Constant speed (] Accelerating () Decelerating condition CO Right hand corner © Lefthand corner 1 When shifing (Gear position ) CIAtstop Cl Motoreycle speed when problem occurs { kmh, Mish) 1 Other, NOTE: Tha above form 8 a standard sample it should be modified according to conditions characteristic of each market.SELF-DIAGNOSTIC PROCEDURES + Don't disconnect couplers trom ECM, battery cable rom bat- tery, ECM ground wire hamess trom engine oF main fuse be- fore confirming malfunction coca (sel-dkagnostic trauble code} stored in memory. Such disconnection will erase memorized information in ECM memory. + Maltunction code stored in ECM memory can be checked by the special tao}, * Before checking maifunction code. read SELF-DIAGNOSIS FUNCTION “USER MODE and DEALER MODE (>> 4-26 and -27) carefully to have good understanding as to what func+ tions are available and how t0.use it, * Be sure to read ‘PRECAUTIONS for Electrical Circuit Service” (C7 4-4) betore inspection and otserve what Is written there. Remove the rear set Connect the special tool to the dealer mods coupler 4) st the witing harness, and start the engine or crank the engine for mora than 4 seconds. * Tum the special too!'s switch ON and check the malfunction ode fo determine the malfunction part, (09930-82710: Mode select switch ‘SELF-DIAGNOSIS RESET PROCEDURE * Aftor repairing the trouble, turn OFF tho ignition switch and tum ON again. I the maitunction code indicates (c00), the malfunction is cleared + Disconnect the special tool from the dealer mode coupler. FISYSTEMANDINTAKEAR SYSTEM $31 (99090-50710 Made seaet swt442_AISYSTEM AND INTAME-AIR SYSTEM MALFUNCTION CODE AND DEFECTIVE CONDITION MALFUNCTION | DeteeTeD ITEM DETECTED FAILURE CONDITION CODE CHECK FOR a0 NO FAULT Camshalt position ‘The signal does not reach ECM tor more than 4 see. after re- sensor the starier signal en ‘The camshatt position sensor wiring and mechanical parts. (Camshaft positon sensor, intake cam pin, wiring/coupler con nection) Crankshaft position | The signal does not reach ECM for more than 4 sec. after re- sensor | ceiving the starler signal te ‘The crankshaft position sensor wiring and mechanical parts, (Crankshalt position sensor, wiring/coupler connection) Intake ait pressure | The sensar should produce following voltage. e138 sensor (0.5 V = sensor voltage < 4.85 V) the above range, c1S is indicated =| intake air pressure sensor, wiring'coupler connection. ‘Thrattle position ‘The sensor should produce tollowing voltage. old sensor (0.2 V & sensor vollage < 4.8 V) | With above range, ct. ed _ - ‘Throttle position sensor, wiring/coupler connection. Engine coolant —_| The sensor voltage shuld te the following, ae temperature sensor | (0.15 < sensar voltage < 4.85 V) [Witnaut the above range. c1S is indicated, [ Engine coolant temperature: sensor, wiring/coupler connection intake air ‘The sensor voltage should be the following. at temperature sensar | (0.15 V S sensor voltage < 4.65 V) Without the above range, c21 is indicated. Intake air temperature sensor, wiring’coupler connection. | Atmospheric ‘The sensor voltage should be the following. 22 pressure sensor | (0.5'V sensor voltage < 4.85 V) Without the above range, c22 is indicated. Atm. pressure sensor, wiring/coupler connection, Tip over sensor ‘The sensor voltage should be less than the following for mare: than 2 sec, after ignition switch turns ON. c23 (0.25 = sensor voltage < 4.85 V) | Without the abave value, ¢23 is indicated. 7 ‘Tip over sensi, wiringicoupler connection | Ignition signal Crankshaft position sensar (pick-up coll) signal is produced but eee | signal from ignition coil is interrupted continuous by two times or 26 oF cot | ror. mis cae th ode 2, Soe erika. Ignition coil, wiring/coupler connection, power supply trom the battery.FISYSTEMANDINTAKE ARISYSTEM 4:33 c28 | Secondary throttle valve actuator When no actuator contro! signal ts supplied from the ECM or ‘communication signal does nat reach EGM or operation vol -age does not reach STV actuator, 28 is indicated, STV actua- STV actuator lead wireicoupler. 029 | Secondary throttle | position sensor [Secondary throttle pasion eansor, wiring/Gcupier connection. The sensor shauld produce following voltage. (0.2 V = sensor vohage < 4.8 V) [Without the above range, 229 is indicated. 30 | Secondary throttle control unit ‘When no communication signal is supplied from the ECM or [STC unit, witing’coupler connection, power supply to STC uni cat Gear position signal ‘Gear position signal voltage should be higher than the fallow- ing for more than 3 seconds. (Gear position sensor voltage > 0.60 ¥) Without the above value, ¢31 i indicated. ‘Gear position sensor, witing/coupler conection, Gearshifi cam etc 632, 089, cot or ea Fue! injector signal When fuel injection signal stops, the ¢32, ¢33, ¢34 ar 035 is indicated Injector, wiring/coupier connection, power supply 19 the in-| Jsstor. Fuel pump relay signal | When no signal is supilled from fuel pump relay. C41 is indicated | Fue! pump relay, connacting lead, power soures to fuel pump relay. | Ignition switch signal [Honition switch signal is not input in the ECM.494_FISYSTEM AND INTAKE AIR SYSTEM “C11" CMP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION IBLE CAUSE No CMP sensor signal for @ seconds at engine | = Metal particles or foreign material being cranking attached on the CMP sensor and rotor tip = CMP sensor circuit open or short «CMP sensor matfunction. + ECM malfunction, INSPECTION * Lift and support the tual tank with its prop stay. (4-52) + Remove the air cleanor bax, ({"F"462) T] Turn the ignition switch OFF. ‘Check the CMP sensor coupler for loose or poor contacts WOK, then measure the CMP sensor resistance. Disconnect the CMP sensor coupler and measure the re-| sistance. | EM. cmp sensor resistance: 0.9 - 1.7 kQ j (Terminal ~ Terminal) IF OK, then check the continuity between each terminal and ground, [EEA cup sensor continuity: =f (Infinity) | (Terminal - Ground) GB 09900-25008: Multi circuit tester GE! Tester knob indication: Resistance (£2) No_, Replace the GMP sensor with a-new one. + Yes Disconnact the CMP sensor coupler, (Crank the engine 2 lew seconds with the starter motor. and. ‘measure the CMP sensor peak vollage at the sensor. CMP sensor peak voltage: More than 0.7 V (BI - Br} Repeat the above test procedure a few times and mea- Suré the highest peak voltage. ILOK, then measure the CMP sensor peak voltage at the| ECM terminals, (GwG- or 28) | |G 09900-25008: Mult! circuit tester \ fp! Tester knob indication: Voltage (= _No_, Loose or poor contacts on the CMP sensor coupler or ECM coupler, | Replace the CMP sanzor with a yes new ane. B/¥ or Br wire open or sharted to ground, or poor & ar @ oe connection. (<3 4-25} If wire and connection are OX, intormittent trouble or faulty ECM Recheck each terminal and wire hamess for open circuit and commis And) aM Soles Replace the ECM with a naw one, and inspect it again, —FISYSTEMANDINTAKE AIRSYSTEM 4435 “C12" CKP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE No CKP sensor signal for 4 seconds at engine | » Meial particles or foreign material being cranking, attached on the CKP sensor and rotor tps. * CKP sensor circult open or short * GKP sensor mattunction + ECM malfunction INSPECTION «Litt and support the fuel tank with its prop stay. (C* 4-62) “Tum the ignition switch OFF Check the CKP sensor coupler for loase or poor contacts. OK, thon measure the CKP sensor resistance. Disconnect the CKP sensor coupler and measure the 16: | sistance. (EM ck sensor resistance: 70 - 220 0 (Black — Green) Hf OK, then check the continuity between each terminal and ground. (BA ckP sensor continuity: £2 (Infinity) Black — Ground \Green - Ground & 09900-25008: Multi circuit tester fe) Tester knob Indication: Resistance (Q) No, Replace the CKP sensor | with a new tes ih anew ane, [2! Disconnect the CKP sensor coupler. Crank the engine & few seconds with the starter motor, and measure the GKP sensor peak voltage at the coupler | BRE CKP sensor peak voltage: More than 0.5 V (Black ~ Green) Ropeat the above test procedure a few times and mea sure the highest peak voltage Hf OK, then measure the CKP sensor peak voltage at the | ECM terminals. (NN or Gv) | 09200-25008: Multi circuit tester ‘Ge! Tester knob indication: Voltage (=) [No Loose or poor contacts on the CKP sensor coupler or ECM coupler. = Replace the CKP sensor with ves Tewone. Black or Green wire open or shorted to ground, or poor @ or connection. (7 4-25) | twire and connactian are OX, intermittent trouble ar faulty ECM, Racheck each terminal and wire harness for open circuit and | poor connection. (°F" 44) Replace the ECM with a new ono, ‘and inspect It again. ECMocugtors4.35 FISYSTEMAND INTAKE ARSYSTEM “C13” IAP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE. Low pressure and low voltage. © Clogged vacuum passage between throttle High pressure and high voltage, body and IAP sensor, (O89 = Senco votage < 485 Al being drawn trom vacuum passage without the above range, between throttis body and IAP sensor, NOTE: + Red wire circuit open or shorted to ground. Note hat atmospheric pressure vanes depending | » B/Br or G’B wire circut shortest ta ground, (on weather conditions as well as afktuce, AP sensor mattunction, Jake that into consideration when vowage.| + ECM malfunction. INSPECTION + -Liff and support the fuel tank with its prop stay. (—7" 4-52) [1] Turn the ignition switch OFF ] Check the IAP sensor coupler far loose or poor contacts. If OK, then measure the IAP sensor input voltage. Disconnect the IAP sensor coupler, Turn the ignition switch ON, Measure the voltage at the Fed wire and ground. IfOK, then measure the voltage at the Fled wire ard BB wire (EXD Ap sensor input voltage: 4.5 ~5.5V - ( Red — =Ground ) 1 @Red - BiB | v (@& 09900-25008: multi circuit tester iy fe) Tester knob indication: Voltage 2» Loose or peor contacts on the ECM coupler. Open or short circuit in 1 the Red wire or B/Br wire = ie [2] Connect the IAP sensor coupler. Insert the copper wires to the lead wire coupler Start the engine at idling speed. Measure the IAP sensor autput voltage at the wire side ‘coupler (between G/B and B/Br wires) [XUIIAP sensor output voltage: Approx. 1.32 V at idle speed (G/B — = B/Br) (& 09900-25008: Mult circuit tester | fe) Tester knob indication: Voltage (=) | Ni j-—*" > Gheck the vacuum hase for crack or damage, Open or short circuit in the G/B wira Rioplace the IAP sensor with & new ane,FISYSTEM ANDINTAKE AR'SYSTEM 437 [3] Remove tne tAP sensor. Connect the vacuum pump gauge to the vacuum port at the IAP sensor Arrange 3 new 1.5 V batteries in series (check that total valiage is 4.5 — 5.0 V) and connect =) terminal to the) graund terminal and & terminal to the Woo terminal, ‘Chack the voltage between Vout and ground. Also, check! if voltage reduces when vacuum is applied up to 40 cmHg| ‘by using vacuum pump gauge. (See table below.) (GB 09917-47010: vacuum pump gauge (09900-25008: Multi circuit tester (BD Tester knob indication: Voltage (=) No Hf check result is not satistactory [replace IAP sensor with a new ¥ Yes One | Red, GIB or BVBr wire open or shorted to ground. or poor #8. & of @ connection. (IF 4-25) wire and connection are OK, intermittent trouble or faulty ECM Recheck each terminal and wire harness for open circuit and poor connection, (<7 4-4), = Replace the ECM with a new one, and inspect it-agai Output voltage (Vee voltage 4.5 - 5.0'V, ambient temp. 20 - 30°C, 68 - 86°F) ALTITUDE, ATMOSPHERIC | OUTPUT (Relerence) PRESSURE _| VOLTAGE tm) tmmig) [a | a a 760 100 | | | 31-36 2000 610 707 aa 2001 en 707 aa | | | | 28-34 soo | 1524 aaa a5 3001 1525 4 55 | | | | 26-31 goo | 2438 567 76 8001 2499 367 76 t | I | 24-29 10000 } 3048 526 704-98 FISYSTEMAND INTAKE AIRSYSTEM “C14” TP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE Signal vottage low or high ° TP sensor maladjusted. Difference between actual throttle opening and | * TP sensor circuit open ar short opening calculated by ECM in larger than spacified| « TP sensor mattunction. valug. + ECM malfunction. ((SeY ss Sermonthtaye <8 ¥ without the abave range. INSPECTION ‘Litt and support the fusl tank with its prop stay, (7° 4-82) Turn the ignition switch OFF Chack the TP sensor coupler for joose or poor contacts. WOK, then measure the TP sensor input voltage. Disconnect the TP sensor coupier ‘urn the ignition switch ON. Measure the voltage at the Red wire and ground | 1OK, then measure the votage af the Fled wire and B/Br wiv | BRE) TPS sonsor input voltage: 4.5 - 5.5V (a8: Ground) | Rod ~ =8/6r | 09900-25008: Multi circuit tester fe! Tester knob indication: Voltage No, Loose-orpoorcantactsan the ECM coupier. Open at short circuit inthe Ried wire or BVBr wire: Yes 42! Tum the ignition switch OF Disconnect the TP sensor coupler Check the continuity between Yellow wire and ground FEN TP sensor continuity: =f (Infinity) | (Yellow wire ~ Ground) i¥.OK, then measure the TP sensor resistance at the cou | let between Yellow and Black wires) ‘Turn the throttle grip and measure the resistance. |GBEVTF censor resistance | Throttle valve is closed: Approx. 1.1 kQ Throttle valve is opened: Approx. 4.3 | ©} 09900-25008; Multi circuit tester bx! Tester knob indication: Resistance (Q) —— NO» Reset the TP sensor position correctly. Replace the TP sensor y Yes with @ naw one:FISYSTEMANO INTAKE ARSYSTEM 429 [8] connect tne TP sensor coupler. Insert the copper wires to the lead wire coupler Tuff the ignition switch ON. Measure the TP sensor cutput voltage at the couplr (be- ween Yellow and Black wires) by turning the thrattle grip. EXES TP sensor output voltage Throttle valve is closed: Approx. 1.1 V Throttle valve is opened: Approx. 4.3 V (Cy 09900-25008: Multi circuit tester ‘fe! te knob ication: Voltage (=} NO. it-check result is not satistactory, replace TP sensor with a new one. Yes | ed, PIG or BYBr wire apen or shorted to ground, er poor, | | or S connection. ((—* 4-25) [Hite and connection are OX, inleritient rouble or tauty ECM Recheck aach terminal and wire hamess for opon clreuit and poor connection. (C7 4-4) = Heplace the ECM with a new one, and pect it again,42:40, FISYSTEM ANDINTAKE AIRSYSTEM “C15” ECT SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE High engine coolant temp. (Low voltage—Low | » BB circuit shorted to ground. resistance) * BIBr circuit open. Low engine coolant temp. (High voltage—High | + ECT sensor matftunction. resistance) + ECM malfunction INSPECTION + Lift and support the fuel tank with its prop stay, (C= 4-52) +L tum the jonition switch OFF | Check the ECT sensor coupler tor loose or poor contacts. IFOK, then measure the EGT sensor voltage at the ware side coupler. Disconnect the coupler and turn the ignition switch ON. Measure the voltage between B/B! wire terminal and ground. ITOK, than measure the voltage between G/B! wire term- ral and B/Br wire terminal, [BREVECT sensor voltage: 4.5-55V_ (= 8/8 - = BiB (® 09900-25008: Multi circuit tester fg! Tester knob indication: Voltage No, Loose or poor contacts on the ECM coupler. ‘Open or short circuit in the ‘es BIBI wire: or BAB wire. the ignition switch OFF 2) tun Measure the ECT sensor resistance. TAQVECT sensor resistance: 2.3 - 2.6 kQ at 20°C (68°F) (Terminal - Terminal) (09900-25008; muti circuit tester Ga! Tester knob indication: Resistance (@) Reler to page 56 for details, | No, Replace the EGT sensor fies Withha naw one. BIBI oF B/BF wire Open oF shafted to ground, of poor or] eanhection. (7 4-25) HF wire and cannection are OK, intermittent trouble or faulty ECM.| [Engine Coolant Alecheck each terminal and wire hamess for open circuit and Temp. Resistance peer ce meee, (=F 44) 20°C ( 68°F) | Approx 2.45 kdl LS Replace the ECM with a new one BOG (12°F) | Approx O81 kal and Inspect it again BOC (176°F) | Approx 0.318 kA Ee ce? CORSTIT) | [fiero ea0°Fy [Approx 0.742 ka [oo a ECM couplersFISYSTEMANDINTAKEARRSYSTEN 441 “C21” IAT SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION | POSSIBLE CAUSE High intake air temp. (Low vatage — Low * Dg circuit shorted to ground! resistance) + BIBr circuit opan Low intake alr temp. (High vohage — High + IAT sensor mattunction. resistance) + ECM matfunction INSPECTION + Litt and support the fuel tank wi [1] Turn the ignition switch OFF Check the IAT sensor coupler far loose or poor contacts WOK. then measure the IAT sensor voltage at the wire side coupler. Disconnect the coupler and tum the ignition switch ON. Measure the voltage between Dg wire terminal and ground HVOK, then measure the voltage between Dg wire termi- nal and B/Br wire terminal, FEB) at sensor voltage: 4.5-5.5V @0g- = Dg - = B/Br ( oa900-25008: multi circuit tester ‘Gg! Tester knob indication: Voltage ( No, Loose of poor eontacts on the ECM coupler. ‘Open of short circuitin the Dg wire or EVBr wire. Yes Turn the ignition switch OFF ] Measure the IAT sensor resistance. BREN iAT sensor resistance: 2.2 - 2.7 k(t at 20°C (68°F) (Terminal — Terminal) (> 09900-25008: Multi circuit tester |) Tester knob indication: Resistance (0) | Replace the IAT sensor we. with a new one, |Dg or BYBr wire open or shorted ta ground. oF poor Sor & connection. (e=7" 4-25) |Ifwire and connection are GK, intermittent trouble or faulty ECM. | Recheck each terminal and wire hamess for open circuit and) [Intake Aw Temp. | Alesisiance [poor connection. (7" 4-8) | [TR CTSe°F) Approx, 245 ko L___ Replace the ECM with a new one, 50°C (122°) | Approx. 0.808 Ki? and inspect it again, [eo°C (76 "F) | Approx. 0.322 ko 110°C (290°F) | Approx: 0.148 hit NOTE: JAT sensor resistance measurement mathod is the same way as that of the EGT sensor Refer lo page 5-8 for detais4:42 FISYSTEM AND INTAKE AIRS STEM “C22” AP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION fr POSSIBLE CAUSE Low pressure and iow voltage, + Clogged alr passage with dust High pressure and high voltage. + Fed wire circuit open oF shorted to ground, (05 Sonsor Votage < 4.5V + BIBr oF GY wire circu shorted to ground. without the above range © AP sensor malfunction: NOTE: + ECM malfunction. Note that atmospheric pressure varies depending on weather conditions as well as altitude. Take that into consideration when inspecting voltage. INSPECTION + Remove the front seat, (776-8) [1] sum the ignition switch OFF Check the AP sensor coupler for loose or poor contacts. | OK, then measure the AP sensor input voltage. Turn the ignition switch ON Disconnect the AP sensor coupler. Measure the voltage between Fled wire and ground. MOK, then measure the voltage between Red wire and B/Br wire AP sensor Input voltage: 4.5 ~ 5.5 V_ (2aes- Red — | 09000-25008: mult! circuit tester G2 Tester knob indicatian: Voltage (= Ground Br | No, Loose ar poor cantacis an the ECM coupier: Open orshort circuitin the Raed wate or B/Br wre, oes 2 Connect the AP sensor coupler, Ineert the cooper wes tothe lead wire coupe | Tum the ignition switch ON Measure the AP sensor autput voltage at the wire sida coupler between GY and B/Br wires [XIN AP sensor output voltage: Approx. 3.6 V at 760 mmHg (100 kPa) | (2GN¥ - = 8/6) (> 09900-25008: Multi circuit tester | [BI Tester knob indication: Voltage (=) Roa | Nos: nec sha passage for clagaing, ‘Open or short circuit inthe GY wire Replace the AP sensor ‘with a new ono, ¥ YosFISYSTEM ANDINTAKE ARRSYSTEM 443 [3] Remove the AP sensor. ] ‘Connect the vacuum pump gauge to the air passage port ol the AP sensor Arrange 3 new 1.6 V batteries in series (check tnat total voltage Is 4.5 — 5,0 ¥) and connect © terminal to the| ground terminal and ® terminal to the Voc terminal. ‘Check the voltage between Vout and ground. Also, check) it voltage reduces when vacuum iS applied up to 40 cmHg| | __ by using vacuurn pump gauge. (See table below} (& 09917-47010: vacuum pump gauge (09900-25008: Multi circuit tester {{@) Tester knob Indication: Voltage {- H check result Is not satistactory. replace AP sensor with a new one. Red, G/Y or B/Br wire open or shorted to ground, or poor 8, & of @ connection, (C7 4-25) It wire and connection ate OK, intermittent trouble ar faulty ECM. Flecheck sach terminal and wire harness for open circult and) poor connection. (=7" 4-4) > Replace the ECM with a new one, and inspect tt again, Qutput voltage (Vee voltage 4.5 — 5.0 V, ambient temp. 20 - 30°C, 68 ~ 86°F} ALTITUDE: ATMOSPHERIC | OUTPUT (Reterence} PRESSURE VOLTAGE i) (mb (mmHg) kPa (vy) a o 760 100 | | | 1-36 2.000 610 707 94 2001 eit | 707 3a | t | 28-34 sooo | 1524 aaa 85 3 001 ass 4 85 | | | l 28-31 sooo | 2438 567 76 eon | 24a9 567 76 | | | | 24-29 30000 | 3048 526 mw a] Graind EC couplers4444_ FISYSTEM AND INTAKE AIR SYSTEM “C23"TO SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE No TO sensor signal for mare than 2 seconds. | + TO sensor circuit open or short. alter ignition switch tums ON. | + 70 sensor mattunetion. Sansoe voltage high, + ECM maitunction. ( 0.25 V = Sensor Voltage < 4.85 Y without the abave range. INSPECTION + Lift and support the fuel tank with its prop stay LU Turn the ignition switch OFF ‘Check the TO sensor coupler tor loase or poor contacts. 1 OK, then measure tne TO sensor resistance Disconnect tne TO sensor coupler. Measure the resistance between Black and BW wie ter- minais. TO sensor resistance: 60-64 kQ (Black — B/W) (> 09000-25008: Multi circuit tester GB) Tester knob indication: Resistance (2) F 4-52) No, Replace the TO sensor ‘rath & new one. = }2) Connect the TO sensor coupler. Insart the copper wires to the wire lead coupler ‘Turn the ignition switch ON. Measure the voltage at the wire side coupler betwoan Bisck and B/Br wires. | BENTO sensor voltage: Approx. 2.5 (Black ~ B/Br) ‘Aisa, measure the voltage when leaning of the motorcycle. Dismount the TO sensor ftom its bracket and measure the voltage when it is leaned more than 43°, lett an right, from the horizontal level | EEXTO sensor voltage: 0'V (Black ~ B/Br) (08900-25008: Multi circuit tester fe) Tester knob indication: Voltage No_, Loose or poor contacts on the ECM coupler, ‘Open or short circuit inthe Black wire or BBr wire Replage the TO sensor ‘with & new one, __¥ Yes [Black or BBr wire open oF shorted to ground, or poor G or & ‘cannection, (7 4-25) tvaire and connection are OK, intermittent trouble or fauty ECM. | Recheck each terminal and wire hamess for open circuit and] +4) » — Replace the ECM with a new one, and inspect it again,|FLSYSTEM AND INTAKE AIR SYSTEM 4.45 “C24”, "C25", “C26” or "C27" IGNITION SYSTEM MALFUNCTION “Reter to the IGNITION SYSTEM for details. (77-17) “C28” STV ACTUATOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE ‘The operation voltage does not reach the STV | STV actuator maltunction actuator. + STV actuator circuit open or short ECM does not receive communication signal from | + STVA motor maltunction. the STC unit INSPECTION © Lit and support the fuel tank with its prop stay, ([7" 4-52} + Remove the air cleaner element. [LT urn the ignition switch OFF Gheck the STV actuator lead wire coupler for loose or poar| contacts, Tur the ignition switch ON. Check the operation of the STV actuator by the STV move. ment, {Operating order: Half open —+ Full close — Full apen | Half open) | ——** + Locee or poor contacts on Yes the STC unit coupler Open or short crcuitin the Rod or Black wee — —___¥_ Turn the ignition switch OFF Disconnect the STV actuator lead wire coupler. ‘Check the continuity between Red wire and ground FEY TY actuator continuity: =£2 (Infinity) WOK, then measure the STV actuator resistance, (between Red and Black wives) EM STV actuator resistance: Approx. 5.6 0 (= Red - > Black) (© 09900-25008: Multi circuit tester (fe)! Tester knob indication: Resistance (Q) |_No_. pepiace the STV actuator with anew one. yes, Loose of poor contacts an the STV actuator coupler or STC unit coupler. it wire and connection are OK, intermittent trouble or taulty STG unit. Recheck each terminal and wire harness for open clreut and poor connection. (7-4-4) |___s Replace the ST unit with few one, and inspect it again¢H45_FISYSTEMANDINTAKE AIRSYSTEM “C29" STP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE _ Signal voltage law or high + STP sensor maladjusted. Ditferencs between actual throtwe opening and | * STP: sensor circuit open or short. ‘opening calculated by ECM in larger than specified| + STP sensor malfunction. value * STC unit maitunction {ina Ree son ce) + ECM malfunction without the above range. INSPECTION + Lift and support the fuel tank with its prop stay (=F 4-62) [2] turn the ignition switch OFF Check the STP sensor coupler for laose or poor contacts, WOK, then measure the STP sensor input voltage. Disconnect the STP sensor coupler Turn the Ignition switch ON. Measure the voltage at the BIUe wire and ground WOK, then measure the voltage at the Blus wire and Black! wre, (RAY sTP sensor input voltage: 4.5 ~5.5V | ( Blue — Ground Blue - GB 09900-25008: Multi circuit tester ‘Ga! Tester knob indication: Voltage | ___NO. Loase-or poor contacts. on i the ECM coupler, Y Open or short circuitin the: | ‘te: Blue wire or Black wire. Turn the ignition switch OFF Flemove the sir cleaner element Disconnect the STP sensor coupler. Check the continuity between ‘allow wire and ground ‘[EXSSTP sensor continuity:e£ (Infinity) (Yellow wire ~ Ground) HOK, then measure the STP sensor resistanos al the coupler (between Yellow and Black wires) Close the secondary throttle vaive by finger and measure the valve closing resistance. Turn the ignition switch ON and measure the Valve opening resistance. ‘EGQQ)sTP sensor resistance Secondary thrattie valve is closed: Approx. 0.8 ka Secondary thrattle valve is opened: Approx. 3.9 ki } 0e900-25008; Multi circuit tester )) Testor knob Indication: Resistance (9) = Reset the STP sensor position correctly rer) Roplace the STP sensor with a new one. ]FISYSTEMANDINTAKE AIRSYSTEM 2.47, 13! Turn the ignision switen OFF: Connect the STP sensor coupler Insert the copper wires to the: lead wire coupler Turn the ignition switch ON, Measure the STP sensor output voltage at the coupler (between Yallow and Black wires) by turning the second: ary throttle vaive (close and open) with a finger EMI STP sensor output voltage Throttle valve is closed: Approx. 0.8 ¥ Throttle valve is opened: Approx. 4.0 08900-25008: Multi circuit tester Gi) Tester knob indication: Voltage ( [No it chack result is not satistactory, replace STP sensor with.a new one. Yos ‘Blue, Yellow or Black wire pen or shorted to ground, or poor] i connection. (C=7" 4-25) | I wire and connection are OK, intermittent trouble or STC unit! faulty or faulty ECM Rlocheck each terminal and wire hamess for open circuit ang} poor cannection, (F 4-4) Replace the STC unit or ECM with a ew one, and inspect it again. ECM coupiors448 SYSTEM AND INTAKE AR SYSTEM “C30” STC UNIT CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE | The power source does not reach the STC unit TC unit malfunction. ECM does not recive communication signal trom | « STG unit cireuit open or short. the STC unit. INSPECTION + Remove the frame cover. (7 [1] Turn the ignitan switch OFF Cheek the STC. unt lead wire coupler tor loose or poor contacts. if OK, then measure the STC unit input voltage incon the copper wires to the lead wico coupler Tum the ignition switch ON, and measure the voltage be- tween the O/W wire and ground. OK, then measure the voltage between the OW wire] and BW wire. | RQQsTc unit input vottage: Battery voltage (5 09900-25008; multi circuit tester (ai! Tester knob indication: Voltage (=) No. Open or short circuit in the OW wire or BAY wire, ves [OW BAW oF Dor wie open or shoried to ground, or poor i] Joonnection, (7 4-25) Measure the STC unit voltage with the mult citoult fester. (I°7- 22) [twit and connection are OK, intermittent trouble or STC unit ity or faulty ECM, locheck each terminal and wire hamess for open circuit and! poor connection. 44) + Replace the STC unit with a new one, and inspect it again. EctAcoumiersFISYSTEMAND INTAKE AIR SYSTEM 49 $A __ FSSA INTAKE AIR SYSTEM 49 “C31” GEAR POSITION (GP) SWITCH CIRCUIT MALFUNCTION DETECTED CONDITION | POSSIBLE CAUSE No Gear Position switeh voltage * Gear Position switch circuit open or short. Switch voltage low. * Gear Position switch malfunction (Senege os + ECM malfunction without the above range. INSPECTION + Litt and support the fuel tank with is prop stay: (4-52) Turn the ignitian switch OFF: ‘Check the GP switch coupler tor loose or poor contacts. OK, then measure the GP switch voltage. ‘Support the motorcycle with a jack. Turn the side-stand to up-right position: Turn the enaine stop switch ON Insert the copper wire to the lead wire coupler Tur the ignition switch ON. Measure the voltage at the wire side coupler between| Pink wire and ground, when shitting the gearshift lever from 1st to Top, GP switch voltage: More than 0.6 V (Pink ~ Groung) (09900-25008: Mult! circuit tester ‘fe! Tester knob indication: Voltage (=) | No | pen or short circuit in the Pink wire Replace the GP switch with a new one, Pink wire open or shorted to ground, or poor ‘=: connection |r 4-25) wire and connection are OK, intermittent trauble-or faulty ECM. Recheck each terminal and wire harness for open circuit and [poor connection, (I 4-4) Replace the EOM with a new one, | sand inspect it again ECM coupler:-$50_FISYSTEM ANDIVTAKE AR SYSTEN “C32", “C33”, “C34” or "C35" FUEL INJECTION MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE No injector current. * injector circuit open or short. + Injector maltunetion * ECM malfunction, INSPECTION [Lit and support the fuel tank with its prop stay. (7 4-82) [1] Turn the ignition switch OFF: (Check the injector caupler for loose or paor contacts. WOK, then measure the injector resistance Disconnect the coupler and measure the resistance be- tween teeminals Injector resistance: 1 = 16 0. at 20°C (68°F) (Terminal ~ Terminal) IPOK, then check the continuity between each terminl |__ and ground. Injector continuity: =f (Infinity) | (Terminal = Ground) GB 09900-25008; Muti circult tester BD) Tester knob indication; Resistance (2) ee ee eee eres | N Cm Replace the injector with anew one. (7° 4-64) be +2] Turn the igaition witch ON Measure the injector vollage between WR wire and] | ground. (YR = Ground) NOTE: Injector voltage can be detected only 3 seconds after ig- nition switch 1s tured ON. (09900-25008: Multi circuit tester | {@)! Tester knob indication: Voltage P Injector voltage: Battery voltage -_N2__» open circuit in the Yellow! Fed wire | vos + , GriB, Griy, Gr or ¥/R wire open or shorted to ground, oF poor 4), i, 6) (7) oF # connection. (7° 4-25) Ihwire and connection are OK, intermittent trouble or faulty ECM, Recheck each terminal and wire harness for apen circuit and poor connection. ("7 4-4) |g Replace the ECM with a naw one. and inspect it againFISYSTENLAND INTAKEAIR SYSTEM 4-51 “C41" FP RELAY CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE No signal from fue! pump relay. © Fuel pump relay circuit open ar short. * Fuel pump relay malfunction, = &CM maifunction. INSPECTION ‘* Fomave the front seat + Lift and support the fuel tank with its prop stay (C- Tuen the ignition switch OFF ‘Check the FP relay coupler for loose oF paor contacts. OK, then check the insulation and continuity, Refer to page 4-55 tor details, 4-52) No f —S Replace the FP relay with a pew one 1 Yes {YIB or OM wire open or shorted to ground, oF pact ® or ® connection. ((F* 4-25) wire and connection are-Ok, intermittent trouble oF faulty ECM. Recheck each terminal and wire harass for open circuit |___ and poor connection. (7" 4-4) compos ooo Tit Tort \——+ Replace the ECM with a new one, ot do and inspect it again. : ECM covples “C42” IG SWITCH CIRCUIT MALFUNCTION * Refer to the IGNITION SWITCH INSPECTION for dotalls. © Remove the right under cowling. (7 6-3) * Inspect the ignition switch. (3° 7-31)£52. SYSTEM ANDIOTIAKE AR SYSTEM. FUEL SYSTEM FUEL TANK LIFT-UP = Flemove the front seat. * Flemove the fuel tank mounting bolts. * Lift and support the fuel tank wrth the fuel tank prop stay FUEL TANK REMOVAL + Liftand support the fuel tank with the fuel tank prop stay (See above) + Disconnect the tusl pump lead wire coupler (f + Place a rag under the fue! feed hose and remave the fuel feed hose @ @& CAUTION | When removing the fuel tank, do not remain the fuel feed hose ‘2 at the fuel tank side. [Gasoline is highly flammable and explosive. | Keep heat, spark and flame away. = Remove the fuel tank bracket mounting bolts, * Remove the fuel tank FUEL TANK INSTALLATION * Installation i in the reverse order ot removalFISYSTEM ANDIVTAKE ARSYSTEM 4-53 FUEL PRESSURE INSPECTION * Lift and support the fuel tank with its prop stay. (4-52) * Place a rag under the fuel feed hose. (7-462) * Remove the tus! feed hose and install the special tools be- tween the fuel tank and fuel delivery pipe 19940-40211: Fuel pressure gauge adaptor 09940-40220: Fuel pressure gauge hose attachment 09915-77390: Oil pressure gauge 0995-74520; Oi pressure gauge hose Turn the ignition switch ON and check the tue! pressure. Fuel pressure: Approx. 300 kPa (3.0 kgticm?, 43 psi) {the fue! pressure is lower than the specified, inspect the fol- owing ems: * Fuel hose leakage * Clogged fuel titer * Pressure regulator > Fuel pump Whe fuel pressure is higher than the specified, inspect the fol. lowing items: * Fuel pump check valve * Pressure regulator POI * Before removing the special tools, turn the ignition | Mand release the fuel pressure * Gasoline is highly flammable and explosive. Keep heat, sparks and flame away: To huel diivery sine a{{54_FISYSTEM AND INTANE AIR SYSTEM FUEL PUMP INSPECTION Tum the igrition switch ON and sheck that the fuel pump oper: ates for few seconds. Hf the fuel pump motor does nat make operating sound, replace 5 the fual pump assembly or inspect the fuel pump relay and tip over sensor FUEL DISCHARGE AMOUNT INSPECTION Gasoline is highly flammable and explosive. | Keep heat, spark and flame away, ++ Lift and support the tuel tank with its prop stay: ((7"4-82) ** Disconnect the fuel feed hase (7) fram the fuel pump, * Connect a proper fuel nose 2 to the fuel pump. * Disconnect the ECM lead wire coupler * Push the ook (A) 10 pull ou! the power source lead wire (Yellow ‘with red tracer 2), ECM couple |FISYSTEM ANDINTAKE AIR SYSTEM 4-55, * Place the measuring cylinder and inseit the: hiel hase end into tha measuring oyinder. * Apply 12 volts 1o the fuel pump for 20 seconds and measure the amount af fuel discharged Battery © terminal — Power source lead wire (Veliow with red tracer) Ifthe discharge amount is not specified i means that the fue! pump is defective or thal the fuel fter s clogged. (EM) Fuel discharge amount: Approx. 1200 mi/30 sec. (1.3/1.1 USAmp 0230 sec. NOTE: The battery must be in fully charged condition.(£55_FISYSTEM ANDINTAKEARR SYSTEM FUEL PUMP RELAY INSPECTION Fuel pump relay is located in ahead of the battery. « Remove the front an rear seats: * Lift and support the fuel tank with its prop stay. ((7"4-52) + Remove the fue! pump relay, First, check the insulation between () and 2 terminals with pocket taster. Then apply 12 volts to Zi and @ terminals, # to 3 and © to @, and check the continuity between) and 2 there Is no continuity, replace it with @ naw one, FUEL PUMP AND FUEL FILTER REMOVAL CONSTRUCTION a {) Fuel pessire regulator 2 Fos! pure case Fue! tar [EN [etm | et cantioge i 16] 70 (Forregh pressure) SBntoure 4) Fuel mesh tar (Foriow pressure) Thermistar F O-mgFISYSTEMANDIVTAKE AIRSYSTEM 4-57 REMOVAL * Flemove the fuel tank, (7°4-52) + Remove the fuel pump assembly by removing its: mounting otis diagonally. | Gasoline is highly flammable and explosive. Keep heat, spark and flame away. * Remove the nuts. + Remove the screws, * Blemove the fuel pump assy from the fuel pump plate + Remove the tuel pump holder(£58 FISYSTEM AND INTAKE AIRSYSTEM. * Remove the fuel mesh filter * Remove the fuel pressure regulator holder 7) and the fue! pressure regulator FUEL MESH FILTER INSPECTION AND CLEANING ff the fuel mesh filter is clogged with sediment or nist, fuel will ‘not flow smoothly and Joss in engine power may result Blow the fuel mesh fiter with compressed air, NOTE: If the fuel mesh fiter is clogoed with many seaiment or rust, replace the el titer cartridge with a new one. FUEL PUMP AND FUEL MESH FILTER INSTALLATION Install the fuel pump and fuel mesh fiter in the reverse order of removal, and pay attention to the following points: ‘Install the new O-rings to the fuel pressure regulator and fuel pipe * Apply thin coat of the engine oil to the O-rings: a CAUTIONFISYSTEMAND INTAKE ARSYSTEN 4.59 ‘+ Pass thraugh the wires behind the thermistors. | thecretar for hightever | Thirst toe tow fava - So. *+ Be sure to connect the wires fo the proper terminals, A @ terminal for fuel pump ~ Therristor for lov level _ Therrtistor for high level pee Pass mrough tne wires baled Be thermistor(460_FISYSTENAND INTAKE AIRSYSTEM * Install the O-ring and apply grease to it gow 99000-25010: SUZUKI SUPER GREASE "A" ‘The O-ring must be replaced with a new one to prevent | fuel leakage. + When installing the fuel pum: assembly. lightly tighten ail the fuel pump assembly mounting bolts in the ascending order of humbers, and then tighten them to the specified torque in the above manner. [¥] Fuct pump mounting bolt: 10 Nem (1.0 kgf-m, 7.0 Ib-tt) NOTE: Apply a small quantity of the THREAD LOCK "1342"to the thread portion of the fuel pump mounting voit. AGS) 99000-32050: THREAD LOCK “1342”FISYSTEM ANDINTAKE AIR SYSTEM £41 THROTTLE BODY AND STV ACTUATOR CONSTRUCTION | TP sensor | SSTP sensor 7STVadhustngectew Look rut {) STV balance adusting screw 3 Throtie etop sora { Fastice-cam #2 Fast ize adjusting screw Thro cable drum a Dane Mann eee (Oe hates 20 oS o ss ‘wisn {Os tgm 97m) Manm [ties Soin Meum f Cee ioe Mf mm (O3Skohm 25teH) | lazkghm 1.5 th 2a (02 bgt 1.5 A)|U62_FISYSTEM ANDINTAKE AIR SYSTEM AIR CLEANER BOX AND THROTTLE BODY REMOVAL AIR CLEANER BOX © Lift and support the tus! tank with its prop stay. ([—F-4-82) + Disconnect the IAT sensor coupler (f) and PAIR hose: (2 * Rleméve the IAP sensor @) along with the vacuum hose * Disconnect the crankcase breather hose * Loosen the throttia body clamp screws, © Remove the air cleaner box mounting bolt * Remove the air cleaner boxFISYSTEM AND INTAKE AIRSYSTEM 4-63 THROTTLE BODY * Disconnect tha thrattle cables trom their drum, * Disconnect the fast idle cable trom its cam. ‘After disconnecting the throttle cables, do not snap the | throttle valve from full open to full close. It may cause | damage to the throttie valve and throttle bod + Place a rag under the fuel feed hose and disconnect the fuel feed hose from the fuel tank. + Disconnect the vacuum hase 7) from the PAIR valve. + Discorinect the fuel injector lead wire coupler @ * Loosen the throttle body clamp screws at the intake pipe side. * Remove the throttle body assembly{L54_FISYSTEM AND INTAKE AIR SYSTEM “ THROTTLE BODY DISASSEMBLY * Disconnect the respective vaccum hoses trom each throttle body. + Remove the lead wire clamps. * Disconnect the TP sensor lead wire coupler (f), STP sensor lead wire coupler 2, STVA motor lead wire coupler @) and fuel injoctor lead wire couplers 2) * Remove the fuel delivery pipe assembly (6) by removing its ‘mounting screws. + Remove the fuel injectors + Separate the four throtte bodies respectively by removing thelr connecting bolts. * Remove the TP sensor (i! with the special tool (00990-11960: Torx wrenchFAISYSTEMAND INTAKE AIRSYSTEM 445, + Remove the STVA motor cover 4) along with the STP sensor 2 NOTE: Prior to disassembly, mark the STP sensor's original position with a paint or scribe for accurate seinstallation. + Remave the STVA motor lead wh the screw, connector by removing ‘+ Remove the STVA motor yoke ® along with STVA motor 5), ‘Never remove the STVA motor frame 5 Avold removing the STV adjuster 4 unless absolutely necessary. a CAUTION | | Never remove the secondary throttle vaive and throttle: _ valve.465. FISYSTEMANO INTAKE AIRSYSTEM THROTTLE BODY CLEANING ‘Some carburetor cleaning chemicals, especially dip-type soaking solutions, are very corrosive and must be handled caretully. Always follow the chemical | manufacturer's instructions on proper use, handling and storage. * Clean all passageways with a spray-type carburetor cleaner and blow dry with compressed air cA Do not use wire to clean passageways. Wire ean dam- age passageways. Ifthe components cannot be cleaned with a spray cleaner it may be necessary to use 5 dip- type cleaning solution and allow them to soak. Always follow the chemical manutacturer's instructions for | proper use and cleaning of the throttle body compo- nents. De not apply carburetor cleaning chemicals to the rubber and plastic materials. INSPECTION Check following items (or any damage or clogging. * O-ring * Fuel injector titer * Throttle shaft bushing and seal * Injector cushion seal * Throtite valve * Injector dust seal * Secondary throtile valve * Vacuum hoseTHROTTLE BODY REASSEMBLY Reassemble the throttle body in the reverse order of disassem- by Pay attension to the following points: * Install the STVA motor yoke 7) along with the STVA motor 2 (©) STVA motor yoke mounting bolt:3.5 Nm (0.35 kat-m, 2.5 Ib-tt) + Align the groove ® on the:secondary throtile shat end with tha lip of the STP sensor. NOTE: Apply grease “A” to the groove ®) if necessary. (E)STVA motor cover nut: 2.0 Nem (0.2 kgf-m, 1.5 lb-ft) NOTE: It the STP sensor adjustment is necessary refer to page 4-71 for STP sensor setting procedure * Align the groove (© on the throws shat end with the: ti the TP sensor (09930-11960: Torx wrench NOTE: Apply grease “A’ to the groove ©) W necessary. TP sensor setting procedure (“74.28 * Pasition the TV contral lever @) between the TV synchronizing serew Zand spring as shown, Set each'TV to the same opening by turning the balance screws 2 * Position the STV control lever @) between the STV synchra- nizing screw @ and spring () as shown, Place the throttie body assemiily on the surlace plate and tighten the connecting boits. (7) Throttle body connecting bolt:5 Nm (0.5 kgtm, 3.7 Ib FISYSTEM ANDINTARE AIR SYSTEM £67(V6 FISYSTEM ANDINTAKEAIR SYSTEM + Apply thin coat of the engine oil ta the new fuel injector cust Jon seals @), and install them to each fual injector, (A CAUTION Replace the cushion seal with a new one. * Install the seats (2) and O-rings ‘3 to each fuel injector. * Apply thin coat of the engine oil fa the new O-rings (5 * Install the fusl injectors by pushing them straight 1a each throttle body, ‘A CAUTION Replace the dust seal and O-ring with the new ones. Never turn the injector while pushing It. | * Install the fuel delivery pipe assembly to the thratile body as- sembly. A CAUTION Never turn the fuel injectors while installing them. + Tighten the fuel delivery pipe mounting screws () Fue! delivery pipe mounting screw: 5 Nm (0.5 kgfim, 3.7 Ibeft) + Connect the fuel injector couplers to each {uel injects WIRE COLOR No.1 coupler: Gray, WIE No.2 coupler: Gray, Black Nod coupler: Gray, Yellow Not coupler: Gray, Green+ With the STV fully opened and using a proper scale, set the No 4 and No. 3 ST walves to the same opening by turning the balance screw (7) Jj)4-70_FIS¥STEM AND INTAKE AFRSYSTEM STPS couptar (ATS coupler THROTTLE BODY INSTALLATION Installation is in the reverse order of removal. Pay al the following points: + Connectthe thrattle pulling cable (P)and throttle returning cable 2'to the throttle cable drum. * Adjust the throttle cable play with the cable adjusters (J) and Rieter to page 4-76 for details © Connect the fast idie cable 5! and agjust the fast idle cable play with the cable adjuster tion toFISYSTEMANDITAKE ARSYSTEM 471 STP SENSOR ADJUSTMENT it the STP sensor adjustment is necessary, measure’ the sensor resistance and adjust the STP sensor positioning as follows: * Disconnect thie STP sensor coupler. ‘+ Sat the ST valve to fully close position by finger and measure the resistance between yellow and black wires. [BES STP sensor setting resistance ST valve is fully closed: Approx. 0.8 ka (® Yellow ~ = Black) 09900-25008: Multi circuit tester fi! Tester knob indication: Resistance (a) ‘© Loosen the STP sensor mounting screws. + Adjust the STP sensor until resistance is. within specification and tighten the STP sensor mounting screws. (09930-11960: Torx wrench (STP sensor mounting screw:2.0 Nm (0.2 kgt-m, 1.5 tb-tt) I the measured resistance is not within specification, adjust the: STV adjuster 7) as follows: + Under above candition, loosen the lock 2 and tum in or out the STV adjuster until the resistance becomes specified value. it the measured resistance is not obtain, replace the STF sen- or with a new one, and adjust the STP sensor posit again (STV adjuster lock nut: 1.0 Nem (0.1 kgfm, 0.73 Ib-ft) NOTE: Aiter adjusting the STV adjuster, apply THREAD LOCK "1342" to the fock mit THROTTLE BODY CLAMP POSITION ead ] MIEW OF TOP To IAP sonar272 _F1SYSTEM AND INTAKE AIR SYSTEW FUEL INJECTOR INSPECTION ‘The fuet injector ean be checked without removing it trom the throttle body, Reler to page 4-50 tor details FUEL INJECTOR REMOVAL + Litt and support the fuel tank with its prop stay. ((2 * Remove the air clesnet box. (C7 4-62) * With battery negative cable disconnected, disconnect tha ins Jector couplers. + Remove the fuel delivery pipe assembly. (> 4-64) + Remove the fuel injectors No.1, No.2, No.3 and Na. (or 464) INSPECTION Check tuel injector fiter for evidence of dirt and contamination, It present, clean and check for presence of cit in the fuel tines anct fuel tank. 483) FUEL INJECTOR INSTALLATION * Apply thin coat of the engine oil to new injector cushion seals and O-rings. * Install the injector by pushing it straight to the throttle ody, Never turn the injector while pushing it. ((=7" 4-68} FAST IDLE ADJUSTMENT Tha fast idle system is a kind of starter system, which opens ‘rata valve by the fast idle cam mechanically, The tast idle cam is turned by the tast idle cable and the cam pushes throttie valve shalt bracket. The bracket then opens trwattle valve a litle 19 in- ‘erease the engine speed, and al the fully:pulled condition the engine speed rises to 3 900 rpm when warmed up. + Connect a tachameter * Start Up the engine and run it in idle condition for warming up. + Sat tha idle spsed to 1 200 rpm. * Tum the last idie lever (choke lever) (fully and check the fast ide setting rpm. the engine speed is notin the specified range adjust itto 3 000 rpm as explained in the fasowing procedures: 4)Li. and support the fuel tank with its prop stay ([=7-4-52) 2)Start up ine engine and keep tne fast idle lever in fully-pulled ‘cpndition, 3)Adjust the fast lala engine speed to 3 000 mpm by turing the Yast idle adjusting screw (2. (Fast idle adjusting screw :2) is focated behing the throttle cable drum.) ‘After adjusting the fast idle speed, set the idle speed to 1 300 rpm (EMD) Fast idle setting rpm ; 3.000 rpm (When the engine is warmed.) Engine idle rpm: 1300 rpm (When the engine warmed.)Fl SYSTEM AND INTAKE AIR SYSTEM 4-73 THROTTLE VALVE SYNCHRONIZATION Check and adjust the throttle valve synchronization among four cylinders. CALIBRATING EACH GAUGE * Lift and support the fuel tank. (9° 4-52) * Start up the engine and run it in idling condition for warming up. * Stop the warmed-up engine. * Disconnect the IAT sensor coupler T) and remave the |AT sen sor from the air cleaner Dex. * Connact the removed IAT sensor to its coupler and place it on the frame. * Remove the IAP sensor mounting screw 2 + Remove the air cleanor Dox. (7 4-62) + Disconnect tha vacuum hose 3) fram the No throttle body, © Connect proper rubber cap “4 to the nipple on the No.3 throttle body.4:74 _F1SYSTEM AND INTAKE AIR SYSTEM + Connect ane of the four nubber hoses af the vacuum balancer gauge to the nipple (7) on the No.{ throttle body (09819-13121; Vacuum balancer gauge * Connect a tachomater, * Start up the engine and keep it running at 1 300 rpm by turning ‘tyottie stop screw 2 UTION | Avoid drawing dirt into the throttle body while running * Turn the air sorew (3) of the gauge so that the wacuum aeting on {he tube of tat nose will bring the stee! ball in the tube to the center iine NOTE: The racuurn gauge 8 positioned approx. 30° front the horizontal love. * Alter making sure that the steel ball stays steady at the center line, disconnect the hose from the No.1 throttle body nipple and connect the next hose to this nipple. * Turn air screw to bring the other stee| ball) to the center ling, * Repeat the above process an tha third and fourth hoses. The balancer gauge is now ready for use in balancing the throttle valves.Fl SYSTEM AND INTAKE AIA SYSTEM 4-75, ‘THROTTLE VALVE SYNCHRONIZATION * Tosynchroniza thwoitie valves, remove the rubber caps ‘fy and vacuum hase @ trom each vacuum nipple and connect the vacuum balanear gauge hoses to the vacuum nipples respec- tively 09913-13121: Vacuum balancer gauge * Connect tachometer and start up the engine, * Bring the engine rpm to 1 300 rpm by the throttle sto screw. * Check tha vacuum of the four cylinders and balance the four throttle valves The vacuum gauge is positioned approx. 30° from the horizontal level, and in this position the four balls should be within one ball dia. 11 the diifarence is larger than one ball, turn the balance ad- justing screw on the throttle body and bring the ball to the same level: A correctly adjusted throttle valve synchronization has the tals Inthe No, 1 through 4 at the same level 4 CAUTION | Avoid drawing dirt inte the throttle body while running the engine without alr cleaner box. Dirt drawn into the engine will the internal engine parts, NOTE: * During balancing the throttle valves. always Sef the engine ypm at 1 300 rpm, using throttle stop screw: * Alter balancing the-four valves, set the idle rpm to 1 300 rpm by the throttle stop screw after instafing the air cleaner box.4£-76_FLSYSTEM ANO INTAKE AiR SYSTEM THROTTLE POSITION SENSOR (TPS) SETTING Aftar all adjustments are completed, check or adjust the TPS set- ting concfition (Reter to page 28 tor TPS setting procedure) THROTTLE CABLE ADJUSTMENT NOTE: ‘Minor adjustment can be made by the throtife gp side adjuster. (> 216) MAJOR ADJUSTMENT + Loosen the lock nuts ©) of the thrattie retuming eable (2 + Turnthe returning cable adjuster () to obtain proper cable play. * Loosen the lock nuts @ of the thrattie pulling cable + Tum the pulling cable adjustar in or out until the throttle cable Play ® should be 2.0 - 4:0 mm (0.08 ~ 0.16 in} at the throttla a. ‘+ Tighten the lock nuts @ securely while holding the adjuster ‘While holding the throttle grip a! the fuly closed position, slowly turn the returning cable adjuster @) ta abtain a cable siack Bi of 41.0 mm (0.04 in) Tighten the look nuts
4~tt)
IAT SENSOR REMOVAL/INSTALLATION
* Litt and support the fuel tank, (2 4-52)
* Disconnect the IAT sensor coupler (7) and remove the IAT sen-
sor from the air cleaner bor.
‘+ [Installation is in the reverse order af removal
(EIAT sensor: 18 N-m (1.8 kam, 13.0 Ib-ft)4-78_F1SYSTEM AND INTAKE AIR SYSTEM
ECT SENSOR INSPECTION
Ths engine coolant temperature: sensor is installed al the rear
side af the cylinder head. (I 4-40 and 5-8)
ECT SENSOR REMOVAL/INSTALLATION
(7 5-8 ang -9)
AP SENSOR INSPECTION
‘The atmospheric pressure sensor is locatect aver the: ECM. (I~
442)
AP SENSOR REMOVAL/INSTALLATION
+ Remove the front seat: (=7"6-6)
© Disconnect the coupler ‘
+ Rlemove the AP sensor
+ Installation is in the reverse order of removal
TO SENSOR INSPECTION
The tip over sensor is located in ahead of the battery holder,
TO SENSOR REMOVAL/INSTALLATION
* Remove the front seat, ((7"6-6)
* Lift and support the fuel tank. (¢7"4-52)
* Disconnect the coupler (j) and remove the TO sensor from the
fuel tank bracket,
‘ Insiallation (s in tha reverse order of removal
NOTE:
Whee installing the TO sensor, bring the "UPPER" Jaiter on it to
the top.
‘STP SENSOR INSPECTION
The secondary throttle position sensor is installed on the STV
actuator, (74-46)
STP SENSOR REMOVAL/INSTALLATION
* Lift and support the fuel tank. (4-52)
* Flemove the STP sensor setting screws ‘P and disconnect tha
coupler 2
+ Install the STF sensorto the STV actuator, Refer to page 4-71
for STP sensor setting procedure.COOLING AND LUBRICATION SYSTEM 51
COOLING AND LUBRICATION SYSTEM
al CONTENTS —
ENGINE COOLANT...
COOLING CIRCUIT ..
COOLING CIRCUIT INSPECTION.
RADIATOR AND WATER HOSES...
RADIATOR REMOVAL .....
RADIATOR CAP INSPECTION ........0
RADIATOR INSPECTION AND CLEANING
RADIATOR REMOUNTING
WATER HOSE INSPECTION ....
COOLING FAN
REMOVAL
INSPECTION ..
INSTALLATION je. .cerse
COOLING FAN THERMO-SWITCH ......
REMOVAL
INSPECTION ..
INSTALLATION és
COOLING FAN CONTROL RELAY
INSPECTION ... on
ENGINE COOLANT TEMPERATURE SENSOR.
REMOVAL
INSPECTION ...
INSTALLATION.
THERMOSTAT.
REMOVAL
INSPECTION
INSTALLATION.
WATER PUMP
WO SSHSEVIYNNRODABVGHNHARAR GON
REMOVAL AND DISASSEMBL 5-11
INSPECTION ..... 514
REASSEMBLY AND INSTALLATION 515
LUBRICATION SYSTEM. 5-18
OIL PRESSURE... 518
OIL FILTER ... 518
OIL PRESSURE REGULATOR . 518
OlL STRAINER
Ol JET.
OlL PUMP ..
OlL PRESSURE SWITCH .... 5-18
ENGINE LUBRICATION SYSTEM CHART. #19
ENGINE LUBRICATION SYSTEM... 5-20$2 COOLING AND LUBRICATION SYSTEM
ENGINE COOLANT
At the time of manulacture, the cooling system is filed with a
50:50 mixture of distilied water and ethylene glycol anti-freeze.
This: 0:50 mixture will provide the optimum corrosion protection
and excellent heat protection, and will proteet the cooling system
fram freezing at temperatures abova ~34°C (-24°F)
It the motorcycle is to ne exposed to temparatures below ~21°C
(-24°F), this mixing ratio shauld be increased up 10.55% or 60%
according to the figure.
4 CAUTION
"Use a high quality ethylene glycol base anti-freeze,
mixed with distilled water. Do not mix sn alcohol base
antifreeze and different brands of anti-freeze.
* Do not put in more than 60% anti-freeze or less than
50%. (Refer to Right figure.)
* Do not use a radiator antiteak addi
50% Engine coolant including reserve tank capacity
Aniitigeze | Freezing point
50% =30°C 24°F)
55% 406 FF
Be 55°C 67
Antitreeze [1200 mi (3.1726 USimp. pt)
Water [4200 mi (9.172.6 USAmp. pl}
0 40 a 80 100
Denaiy (5)
Fig Engine coca conatyrazing
rr ey Get")
aco 180)
2ee 49] 18
ee 130) 7 os
os
‘Gauge proseine
lie poi
g
8
0 0m wm 4 8 oO
Deity (5)
Fig2 Engine coolant density:boiing
point curve.
* You can be injured by scalding fluid or steam if you open the radiator cap when the engine is
hot. After the engine cools, wrap a thick cloth around cap and carefully remove the cap by
turning it a quarter turn to allow pressure to escape and then turn the cap all the way otf.
* The engine must be cool betore servicing the cooling system.
* Coolant is harmful:
+ Iitcomes in contact with skin or eyes, flush with water.
+ I swallawed accidentally, induce vomiting and call physician immediately.
+ Keop it away from children,COOLING AND LUBRICATION SYSTEM _ 5.3
COOLING CIRCUIT
[RESERVE OSTAT| ENGINE COOLANT]
a THERMOSTAT | CYLINDER HEAD f= TEMPERATURE
SENSOR
COOLING
FAN THERMO =o aoiator|
| evumoen
|_“'swirey
WATER
| —— =
COOLING CIRCUIT INSPECTION
Before removing the radiator and draining the engine coolant.
inspect tne egoling circuit for tightness.
+ Hemove the under cowling. (6-3)
* Hemove the radiator cap ?) and connect the tester 2) to the
filler.
Do not remove the radiator cap when the engine is hot. |
Give a pressure of about 120 kPa (1.2 kgtiem’, 17 psi) and see
if the system holds this pressure for 10 seconds.
pressure should tall during this 10-second interval, it
means that thers is a leaking point in the sysiem. in such a
case, inspect the entire system and replace the leaking com-
panent or part
POO
When removing the radiat
cap tester, put arag on the |
| Do not allow the pressure to exceed the radiator cap re-
jease pressure, or the radiator can be damaged.54 COOLING AND LUBRICATION SYSTEM
RADIATOR AND WATER HOSES:
RADIATOR REMOVAL
* Remove the under cowling. (