Suzuki GSXR1000 2K7 Service Manual

GSX-R1000

9 9 5 0 0 - 3 9 3 1 0 - 0 1 E

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FOREWORD

This manual contains an introductory description on the SUZUKI GSX-R1000 and procedures for its inspection/service and overhaul of its main components.

Other information considered as generally known is not included.

Read the GENERAL INFORMATION section to familiarize yourself with the motorcycle and its maintenance. Use this section as well as other sections to use as a guide for proper inspection and service. This manual will help you know the motorcycle better so that you can assure your customers of fast and reliable service.

*This manual has been prepared on the basis of the latest specifications at the time of publication. If modifications have been made since then, differences may exist between the content of this manual and the actual motorcycle.

*Illustrations in this manual are used to show the basic principles of operation and work procedures. They may not represent the actual motorcycle exactly in detail.

*This manual is written for persons who have enough knowledge, skills and tools, including special tools, for servicing SUZUKI motorcycles. If you do not have the proper knowledge and tools, ask your authorized SUZUKI motorcycle dealer to help you.

Inexperienced mechanics or mechanics without the proper tools and equipment may not be able to properly perform the services described in this manual.

Improper repair may result in injury to the mechanic and may render the motorcycle unsafe for the rider and passenger.

GROUP INDEX

	GENERAL INFORMATION	1
	PERIODIC MAINTENANCE	2
	ENGINE	3
	FI SYSTEM DIAGNOSIS	4
	FUEL SYSTEM AND THROTTLE	5
	BODY
	EXHAUST SYSTEM	6
	COOLING AND LUBRICATION	7
	SYSTEM
	CHASSIS	8
	ELECTRICAL SYSTEM	9
	SERVICING INFORMATION	10
	EMISSION CONTROL	11
	INFORMATION
	WIRING DIAGRAM	12

© COPYRIGHT SUZUKI MOTOR CORPORATION 2007

GENERAL INFORMATION 1-1

GENERAL INFORMATION

1

CONTENTS

WARNING/CAUTION/NOTE........................................................................	1- 2
GENERAL PRECAUTIONS .........................................................................	1- 2
SUZUKI GSX-R1000K7 (’07-MODEL).........................................................	1- 4
SERIAL NUMBER LOCATION ....................................................................	1- 4
FUEL, OIL AND ENGINE COOLANT RECOMMENDATION......................	1- 5
FUEL (FOR USA AND CANADA) .........................................................	1- 5
FUEL (FOR OTHER COUNTRIES) .......................................................	1- 5
ENGINE OIL (FOR USA).......................................................................	1- 5
ENGINE OIL (FOR OTHER COUNTRIES)............................................	1- 5
BRAKE FLUID.......................................................................................	1- 5
FRONT FORK OIL.................................................................................	1- 6
ENGINE COOLANT...............................................................................	1- 6
WATER FOR MIXING............................................................................	1- 6
ANTI-FREEZE/ENGINE COOLANT ......................................................	1- 6
LIQUID AMOUNT OF WATER/ENGINE COOLANT ............................	1- 6
BREAK-IN PROCEDURES..........................................................................	1- 7
CYLINDER IDENTIFICATION......................................................................	1- 7
INFORMATION LABELS .............................................................................	1- 8
SPECIFICATIONS........................................................................................	1- 9
DIMENSIONS AND DRY MASS............................................................	1- 9
ENGINE .................................................................................................	1- 9
DRIVE TRAIN ........................................................................................	1- 9
CHASSIS ...............................................................................................	1-10
ELECTRICAL ........................................................................................	1-10
CAPACITIES .........................................................................................	1-10

COUNTRY AND AREA CODES

The following codes stand for the applicable country(-ies) and area(-s).

CODE	COUNTRY or AREA	EFFECTIVE FRAME NO.
E-02	U.K.	JS1CL111100100001 –
E-03	U.S.A. (Except for California)	JS1GT77A 72100001 –
E-19 (GSX-R1000)	E.U.	JS1CL111100100001 –
E-19 (GSX-R1000UF)	E.U.	JS1CL211100100001 –
E-24	Australia	JS1CL111200100001 –
E-28	Canada	JS1GT77A 72100001 –
E-33	California (U.S.A.)	JS1GT77A 72100001 –

1-2 GENERAL INFORMATION

WARNING/CAUTION/NOTE

Please read this manual and follow its instructions carefully. To emphasize special information, the symbol and the words WARNING, CAUTION and NOTE have special meanings. Pay special attention to the messages highlighted by these signal words.

Indicates a potential hazard that could result in death or injury.

Indicates a potential hazard that could result in motorcycle damage.

NOTE:

Indicates special information to make maintenance easier or instructions clearer.

Please note, however, that the warnings and cautions contained in this manual cannot possibly cover all potential hazards relating to the servicing, or lack of servicing, of the motorcycle. In addition to the WARNINGS and CAUTIONS stated, you must use good judgement and basic mechanical safety principles. If you are unsure about how to perform a particular service operation, ask a more experienced mechanic for advice.

GENERAL PRECAUTIONS

*Proper service and repair procedures are important for the safety of the service mechanic and the safety and reliability of the motorcycle.

*When 2 or more persons work together, pay attention to the safety of each other.

*When it is necessary to run the engine indoors, make sure that exhaust gas is forced outdoors.

*When working with toxic or flammable materials, make sure that the area you work in is wellventilated and that you follow all of the material manufacturer’s instructions.

*Never use gasoline as a cleaning solvent.

*To avoid getting burned, do not touch the engine, engine oil, radiator and exhaust system until they have cooled.

*After servicing the fuel, oil, water, exhaust or brake systems, check all lines and fittings related to the system for leaks.

GENERAL INFORMATION 1-3

*If parts replacement is necessary, replace the parts with Suzuki Genuine Parts or their equivalent.

*When removing parts that are to be reused, keep them arranged in an orderly manner so that they may be reinstalled in the proper order and orientation.

*Be sure to use special tools when instructed.

*Make sure that all parts used in reassembly are clean. Lubricate them when specified.

*Use the specified lubricant, bond, or sealant.

*When removing the battery, disconnect the negative cable first and then the positive cable.

*When reconnecting the battery, connect the positive cable first and then the negative cable, and replace the terminal cover on the positive terminal.

*When performing service to electrical parts, if the service procedures do not require use of battery power, disconnect the negative cable from the battery.

*When tightening the cylinder head or case bolts and nuts, tighten the larger sizes first. Always tighten the bolts and nuts diagonally from the inside toward outside and to the specified tightening torque.

*Whenever you remove oil seals, gaskets, packing, O-rings, locking washers, self-locking nuts, cotter pins, circlips and certain other parts as specified, be sure to replace them with new ones. Also, before installing these new parts, be sure to remove any left over material from the mating surfaces.

*Never reuse a circlip. When installing a new circlip, take care not to expand the end gap larger than required to slip the circlip over the shaft. After installing a circlip, always ensure that it is completely seated in its groove and securely fitted.

*Use a torque wrench to tighten fasteners to the specified torque. Wipe off grease and oil if a thread is smeared with them.

*After reassembling, check parts for tightness and proper operation.

*To protect the environment, do not unlawfully dispose of used motor oil, engine coolant and other fluids: batteries and tires.

*To protect Earth’s natural resources, properly dispose of used motorcycle and parts.

1-4 GENERAL INFORMATION

SUZUKI GSX-R1000K7 (’07-MODEL)

RIGHT SIDE

LEFT SIDE

• Difference between illustration and actual motorcycle may exist depending on the markets.

SERIAL NUMBER LOCATION

The frame serial number or V.I.N. (Vehicle Identification Number) is stamped on the right side of the steering head pipe. The engine serial number is located on the rear side of the crankcase. These numbers are required especially for registering the machine and ordering spare parts.

GENERAL INFORMATION 1-5

FUEL, OIL AND ENGINE COOLANT RECOMMENDATION

FUEL (FOR USA AND CANADA)

Use only unleaded gasoline of at least 90 pump octane (R/2 + M/2).

Gasoline containing MTBE (Methyl Tertiary Butyl Ether), less than 10% ethanol, or less than 5% methanol with appropriate cosolvents and corrosion inhibitor is permissible.

FUEL (FOR OTHER COUNTRIES)

Gasoline used should be graded 95 octane (Research Method) or higher. Unleaded gasoline is recommended.

ENGINE OIL (FOR USA)

Oil quality is a major contributor to your engine’s performance and life. Always select good quality engine oil. Suzuki recommends the use of SUZUKI PERFORMANCE 4 MOTOR OIL or equivalent engine oil. Use of SF/SG or SH/SJ in API with MA in JASO.

Suzuki recommends the use of SAE 10W-40 engine oil. If SAE 10W-40 engine oil is not available, select an alternative according to the following chart.

ENGINE OIL (FOR OTHER COUNTRIES)

Oil quality is a major contributor to your engine’s performance and life. Always select good quality engine oil. Use of SF/SG or SH/SJ in API with MA in JASO.

Suzuki recommends the use of SAE 10W-40 engine oil. If SAE 10W-40 engine oil is not available, select an alternative according to the right chart.

BRAKE FLUID

Specification and classification: DOT 4

Since the brake system of this motorcycle is filled with a glycol-based brake fluid by the manufacturer, do not use or mix different types of fluid such as silicone-based and petroleum-based fluid for refilling the system, otherwise serious damage will result.

Do not use any brake fluid taken from old or used or unsealed containers.

Never re-use brake fluid left over from a previous servicing, which has been stored for a long period.

1-6 GENERAL INFORMATION

FRONT FORK OIL

Use fork oil L01 or an equivalent fork oil.

ENGINE COOLANT

Use an anti-freeze/engine coolant compatible with an aluminum radiator, mixed with distilled water only.

WATER FOR MIXING

Use distilled water only. Water other than distilled water can corrode and clog the aluminum radiator.

ANTI-FREEZE/ENGINE COOLANT

The engine coolant performs as a corrosion and rust inhibitor as well as anti-freeze. Therefore, the engine coolant should be used at all times even though the atmospheric temperature in your area does not go down to freezing point.

Suzuki recommends the use of SUZUKI COOLANT anti-freeze/engine coolant. If this is not available, use an equivalent which is compatible with an aluminum radiator.

LIQUID AMOUNT OF WATER/ENGINE COOLANT

Solution capacity (total): Approx. 2 500 ml (2.6/2.2 US/Imp qt)

For engine coolant mixture information, refer to cooling system section in page 7-2.

Mixing of anti-freeze/engine coolant should be limited to 60%. Mixing beyond it would reduce its efficiency. If the anti-freeze/engine coolant mixing ratio is below 50%, rust inhabiting performance is greatly reduced. Be sure to mix it above 50% even though the atmospheric temperature does not go down to the freezing point.

GENERAL INFORMATION 1-7

BREAK-IN PROCEDURES

During manufacture only the best possible materials are used and all machined parts are finished to a very high standard but it is still necessary to allow the moving parts to “BREAK-IN” before subjecting the engine to maximum stresses. The future performance and reliability of the engine depends on the care and restraint exercised during its early life. The general rules are as follows.

• Keep to these break-in engine speed limits:

Initial	800 km (	500 miles): Below 6 500 r/min
Up to	1 600 km (1	000 miles): Below 10 000 r/min
Over to 1 600 km (1		000 miles): Below 13 750 r/min

•Upon reaching an odometer reading of 1 600 km (1 000 miles) you can subject the motorcycle to full throttle operation.

However, do not exceed 13 750 r/min at any time.

CYLINDER IDENTIFICATION

The four cylinders of this engine are identified as No. 1, No. 2, No. 3 and No. 4 cylinder, as counted from left to right (as viewed by the rider on the seat).

#1

#2

#3

#4

1-8 GENERAL INFORMATION

INFORMATION LABELS

	GSX-R1000	GSX-R1000UF
Noise label	A (For E-03, 24, 33)
Information label	A (For E-03, 28, 33)
Vacuum hose routing label	A (For E-33)
Fuel caution label	A (For E-02, 24)
Fuel information label	A	A
Manual notice label	A (For E-03, 33)
Screen label	A	A
Warning steering label	A	A
Tire information label	A	A
General warning label	A	A
ICES Canada label	A (For E-28)
I.D. plate	A (For E-02, 19, 24)	A
E-19 I.D. label		A
Safety plate	A (For E-03, 28, 33)
A: Attached

*1: This label is attached on the left side of rear fender. *2: This label is attached on the upper side of rear fender.

	*1
Others	*1
	E-28 (English)
	Side cowling

Frame (Right side)

Frame (Left side)

*2

Chain case

Rear fender

		GENERAL INFORMATION 1-9
SPECIFICATIONS
DIMENSIONS AND DRY MASS
Overall length ..........................................................................	2 045 mm (80.5 in)
Overall width ...........................................................................	720 mm (28.3 in)
Overall height ..........................................................................	1 130 mm (44.5 in)
Wheelbase ..............................................................................	1 415 mm (55.7 in)
Ground clearance....................................................................	130 mm (5.1 in)
Seat height ..............................................................................	810 mm (31.9 in)
Dry mass .................................................................................	173 kg (381 lbs) ...........		E-33
	172 kg (379 lbs) ...........		Others
ENGINE
Type ........................................................................................	Four stroke, liquid-cooled, DOHC
Number of cylinders ................................................................	4
Bore.........................................................................................	73.4 mm (2.900 in)
Stroke ......................................................................................	59.0 mm (2.323 in)
Displacement ..........................................................................	999 cm³ (61.0 cu. in)
Compression ratio ...................................................................	12.5 : 1
Fuel system .............................................................................	Fuel injection
Air cleaner ...............................................................................	Paper element
Starter system .........................................................................	Electric
Lubrication system ..................................................................	Wet sump
Idle speed................................................................................	1 150	± 100 r/min
DRIVE TRAIN
Clutch ......................................................................................	Wet multi-plate type
Transmission ...........................................................................	6-speed constant mesh
Gearshift pattern .....................................................................	1-down, 5-up
Primary reduction ratio ............................................................	1.553	(73/47)
Gear ratios, Low ....................................................................	2.562	(41/16)
2nd .....................................................................	2.052	(39/19)
3rd......................................................................	1.714	(36/21)
4th ......................................................................	1.500	(36/24)
5th ......................................................................	1.360	(34/25)
Top.....................................................................	1.269	(33/26)
Final reduction ratio.................................................................	2.529	(43/17)
Drive chain ..............................................................................	DID530 VA9, 112 links

1-10 GENERAL INFORMATION

CHASSIS

Front suspension ....................................................................	Inverted telescopic, coil spring, oil damped
Rear suspension .....................................................................	Link type, coil spring, oil damped
Front fork stroke......................................................................	125 mm (4.9 in)
Rear wheel travel ....................................................................	135 mm (5.3 in)
Steering angle.........................................................................	27°
Caster .....................................................................................	23° 45’
Trail .........................................................................................	98.4 mm (3.87 in)
Turning radius .........................................................................	3.4 m (11.2 ft)
Front brake..............................................................................	Disc brake, twin
Rear brake ..............................................................................	Disc brake
Front tire size ..........................................................................	120/70 ZR 17 M/C (58 W), tubeless
Rear tire size...........................................................................	190/50 ZR 17 M/C (73 W), tubeless

ELECTRICAL

Ignition type.............................................................................	Electronic ignition (Transistorized)
Ignition timing..........................................................................	4° B.T.D.C.at 1 150 r/min
Spark plug...............................................................................	NGK CR9EIA-9 or DENSO IU27D
Battery.....................................................................................	12	V 36.0 kC (10 Ah)/10 HR
Generator................................................................................	Three-phase A.C. generator
Main fuse ................................................................................	30	A
Fuse ........................................................................................	15/15/10/10/10/10 A
Headlight.................................................................................	12	V 55 W (H7) + 12 V 65 W (H9)
Turn signal light.......................................................................	12	V 21 W
License plate light ...................................................................	12	V 5 W
Brake light/Taillight..................................................................	LED
Speedometer light...................................................................	LED
Tachometer light .....................................................................	LED
Neutral indicator light ..............................................................	LED
High beam indicator light ........................................................	LED
Turn signal indicator light ........................................................	LED
Position/Parking light ..............................................................	12	V 5 W × 1
Oil pressure/Coolant temperature/Fuel injection warning light ....	LED
Fuel level indicator light ..........................................................	LED
Engine RPM indicator light......................................................	LED
Immobilizer indicator light .......................................................	LED .........		E-02, 19, 24

CAPACITIES

Fuel tank, including reserve ....................................................	16.5	L (4.4/3.6 US/lmp gal) ......	E-33
	17.5	L (4.6/3.8 US/lmp gal) ......	Others
Engine oil, oil change .............................................................	3 000 ml (3.2/2.6 US/Imp qt)
with filter change ..................................................	3 300 ml (3.5/2.9 US/lmp qt)
overhaul................................................................	3 600 ml (3.8/3.2 US/lmp qt)
Coolant....................................................................................	2.5	L (2.6/2.2 US/lmp qt)

These specifications are subject to change without notice.

PERIODIC MAINTENANCE 2-1

PERIODIC MAINTENANCE

	CONTENTS
PERIODIC MAINTENANCE			2- 2
	SCHEDULE ....................................................				2
PERIODIC MAINTENANCE CHART.....................................................			2- 2
LUBRICATION POINTS ........................................................................			2- 3
MAINTENANCE AND TUNE-UP
PROCEDURES ............................................................................................			2- 4
AIR CLEANER.......................................................................................			2- 4
SPARK PLUG........................................................................................			2- 5
VALVE CLEARANCE............................................................................			2- 7
ENGINE OIL AND OIL FILTER .............................................................			2-12
EXHAUST CONTROL VALVE ..............................................................			2-13
FUEL LINE.............................................................................................			2-14
THROTTLE VALVE SYNCHRONIZATION ...........................................			2-14
EVAPORATIVE EMISSION CONTROL SYSTEM (E-33 ONLY) ..........			2-14
PAIR (AIR SUPPLY) SYSTEM..............................................................			2-14
THROTTLE CABLE PLAY ....................................................................			2-15
CLUTCH ................................................................................................			2-16
COOLING SYSTEM...............................................................................			2-18
DRIVE CHAIN........................................................................................			2-21
BRAKE ..................................................................................................			2-23
TIRES.....................................................................................................			2-27
STEERING.............................................................................................			2-28
FRONT FORK........................................................................................			2-28
REAR SUSPENSION ............................................................................			2-28
EXHAUST PIPE BOLT AND MUFFLER BOLT ....................................			2-29
CHASSIS BOLTS AND NUTS ..............................................................			2-30
COMPRESSION PRESSURE CHECK ........................................................			2-32
COMPRESSION TEST PROCEDURE ..................................................			2-32
OIL PRESSURE CHECK .............................................................................			2-33
SDS CHECK.................................................................................................			2-34

2-2 PERIODIC MAINTENANCE

PERIODIC MAINTENANCE SCHEDULE

The chart below lists the recommended intervals for all the required periodic service work necessary to keep the motorcycle operating at peak performance and economy. Mileages are expressed in terms of kilometers, miles and time for your convenience.

NOTE:

More frequent servicing may be required on motorcycles that are used under severe conditions.

PERIODIC MAINTENANCE CHART

km	1 000	6 000	12 000	18 000	24 000
miles	600	4 000	7 500	11 000	14 500
months	2	12	24	36	48

	Air cleaner element	----	I	I	R	I
	Exhaust pipe bolts and muffler bolts	T	----	T	----	T
	Exhaust control valve	I	----	I	----	I
	Valve clearance	----	----	----	----	I
	Spark plugs	----	I	R	I	R
	Fuel line	----	I	I	I	I
	Evaporative emission control system	----	----	I	----	I
	(E-33 only)
	Engine oil	R	R	R	R	R
	Engine oil filter	R	----	----	R	----
	Throttle cable play	I	I	I	I	I
	Throttle valve synchronization	I	----	I	----	I
		(E-33 only)
	PAIR (air supply) system	----	----	I	----	I
	Engine coolant		Replace every 2 years.
	Radiator hose	----	I	I	I	I
	Clutch fluid	----	I	I	I	I
			Replace every 2 years.
	Clutch hose	----	I	I	I	I
			Replace every 4 years.
	Drive chain	I	I	I	I	I
		Clean and lubricate every 1 000 km (600 miles).
	Brakes	I	I	I	I	I
	Brake fluid	----	I	I	I	I
			Replace every 2 years.
	Brake hoses	----	I	I	I	I
			Replace every 4 years.
	Tires	----	I	I	I	I
	Steering	I	----	I	----	I
	Front forks	----	----	I	----	I
	Rear suspension	----	----	I	----	I
	Chassis bolts and nuts	T	T	T	T	T

NOTE:

I = Inspect and clean, adjust, replace or lubricate as necessary, R = Replace, T = Tighten

PERIODIC MAINTENANCE 2-3

LUBRICATION POINTS

Proper lubrication is important for smooth operation and long life of each working part of the motorcycle. Major lubrication points are indicated below.

Brake lever holder

Brake pedal pivot and footrest pivot

Clutch lever holder

Side-stand pivot	Footrest pivot and
and spring hook		Drive chain
	gearshift lever pivot

NOTE:

*Before lubricating each part, clean off any rusty spots and wipe off any grease, oil, dirt or grime.

*Lubricate exposed parts which are subject to rust, with a rust preventative spray whenever the motorcycle has been operated under wet or rainy conditions.

2-4 PERIODIC MAINTENANCE

MAINTENANCE AND TUNE-UP PROCEDURES

This section describes the servicing procedures for each item of the Periodic Maintenance requirements.

AIR CLEANER

Inspect every 6 000 km (4 000 miles, 12 months). Replace every 18 000 km (11 000 miles, 36 months).

•Lift and support the fuel tank. ( 5-3)

•Remove the air cleaner box cover .

•Remove the air cleaner element.

•Inspect the air cleaner element for clogging.

If the air cleaner element is clogged with dust, replace the air cleaner element with a new one.

Do not blow the air cleaner element with compressed air.

NOTE:

If driving under dusty conditions, replace the air cleaner element more frequently. Make sure that the air cleaner is in good condition at all times. The life of the engine depends largely on this component.

•Install the air cleaner element in the reverse order of removal.

•Remove the drain plug from the air cleaner box to allow any water to drain out.

PERIODIC MAINTENANCE 2-5

SPARK PLUG

Inspect every 6 000 km (4 000 miles, 12 months).

Replace every 12 000 km (7 500 miles, 24 months).

SPARK PLUG AND IGNITION COIL/PLUG CAP REMOVAL

•Lift and support the fuel tank. ( 5-3)

•Remove the air cleaner box. ( 5-14)

• Disconnect all lead wire couplers from the ignition coil/plug caps.

Disconnect the lead wire coupler before removing the ignition coil/plug cap to avoid lead wire coupler damage.

• Remove the ignition coils/plug caps.

*Do not pry up the ignition coil/plug cap with a screw driver or a bar to avoid its damage.

*Be careful not to drop the ignition coil/plug cap to prevent short/open circuit.

•Remove the spark plugs.

09930-10121: Spark plug wrench set

HEAT RANGE

•Check spark plug heat range by observing electrode color. If the electrode of the spark plug is wet appearing or dark color, replace the spark plug with hotter type one. If it is white or glazed appearing, replace the spark plug with colder type one.

	Hot type	Standard	Cold type
NGK	CR8EIA-9	CR9EIA-9	CR10EIA-9
ND	IU24D	IU27D	IU31D

2-6 PERIODIC MAINTENANCE

SPARK PLUG GAP

•Measure the spark plug gap with a wire gauge.

•If it is not within the specification, replace the spark plug.

*To prevent the damage of iridium center electrode, use a wire gauge to check the gap.

* Never adjust the spark plug gap.

Spark plug gap:

Standard: 0.8 – 0.9 mm (0.031 – 0.035 in)

ELECTRODE’S CONDITION

•Check the condition of the electrode.

•If it is extremely worn or burnt, replace the spark plug. Replace the spark plug if it has a broken insulator, damaged thread, etc.

Confirm the thread size and reach when replacing the plug. If the reach is too short, carbon will be deposited on the screw portion of the plug hole and engine damage may result.

SPARK PLUG AND IGNITION COIL/PLUG CAP

INSTALLATION

•Screw the spark plugs into the cylinder head with fingers, and then tighten them to the specified torque.

Spark plug: 11 N·m (1.1 kgf-m, 8.0 Ib-ft)

Do not cross thread or over tighten the spark plug, or such an operation will damage the aluminum threads of the cylinder head.

• Install the ignition coils/plug caps and connect their lead wire couplers.

* Do not hit the ignition coil/plug cap with a plastic hammer when installing it.

*Place the ignition coil/spark plug cap so that the coupler does not touch the cylinder head cover.

CONTACT

INCORRECT INCORRECT

PERIODIC MAINTENANCE 2-7

VALVE CLEARANCE

Inspect every 24 000 km (14 500 miles, 48 months).

• Remove the right under cowling. ( 8-5)

• Lift and support the fuel tank. ( 5-3)

• Remove the air cleaner box. ( 5-14)

•Disconnect the CMP sensor coupler .

•Remove the PAIR control solenoid valve .

•Remove the spark plugs. ( 2-5)

•Loosen the throttle body clamp screws at the intake pipe side. ( 5-16)

•Move the throttle body assembly.

• Remove the cylinder head cover. ( 3-15)

The valve clearance specification is different for intake and exhaust valves. Valve clearance must be checked and adjusted, 1) at the time of periodic inspection, 2) when the valve mechanism is serviced, and 3) when the camshafts are removed for servicing.

Valve clearance (when cold):

Standard: IN. : 0.08 – 0.18 mm (0.003 – 0.007 in) EX.: 0.18 – 0.28 mm (0.007 – 0.011 in)

NOTE:
* The cam must be at positions, or , when checking or
adjusting the valve clearance. Clearance readings should not	EX. IN.
be taken with the cam in any other position than these two
positions.

*The clearance specification is for COLD state.

*To turn the crankshaft for clearance checking, be sure to use a wrench, and rotate in the normal running direction. All spark plugs should be removed.

•Remove the valve timing inspection cap .

2-8 PERIODIC MAINTENANCE

•Turn the crankshaft to bring the “Top” line on the starter clutch to the index mark and also to bring the notches on the left ends of both camshafts (Ex. and In.) to the positions as shown.

•In this condition, read the valve clearance at the valves (In. and Ex. of No.4 cylinder, Ex. of No.3 and In. of No.2).

•If the clearance is out of specification, adjust the clearance. ( 2-9)

09900-20803: Thickness gauge

•Turn the crankshaft 360° (one rotation) to bring the “TOP” line on the starter clutch to the index mark of valve timing inspection hole and also to bring the notches to the position as shown.

•Read the clearance at the rest of the valves and adjust the clearance if necessary. ( 2-9)

	Cam position	Notch position
		Exhaust Camshaft	Intake Camshaft
		← Front	← Front
		← Front	← Front

Front

Front

PERIODIC MAINTENANCE 2-9

VALVE CLEARANCE ADJUSTMENT

The clearance is adjusted by replacing the existing tappet shim by a thicker or thinner shim.

•Remove the intake or exhaust camshafts. ( 3-16)

•Remove the tappet and shim by fingers or magnetic hand.

•Check the figures printed on the shim. These figures indicate the thickness of the shim, as illustrated.

•Select a replacement shim that will provide a clearance within the specified range. For the purpose of this adjustment, a total of 21 sizes of tappet shim are available ranging from 1.20 to 2.20 mm in steps of 0.05 mm. Fit the selected shim to the valve stem end, with numbers toward tappet. Be sure to

check shim size with micrometer to ensure its size. Refer to the tappet shim selection table ( 2-10 and -11) for details.

170	1.70 mm

NOTE:

*Be sure to apply engine oil to tappet shim top and bottom faces.

*When seating the tappet shim, be sure the figure printed surface faces the tappet.

NOTE:

Reinstall the camshafts in the specified manner. ( 3-99)

•After replacing the tappet shim and installing the camshafts, rotate the engine so that the tappet is depressed fully. This will squeeze out oil trapped between the shim and the tappet that could cause an incorrect measurement. Then check the clearance again to confirm that it is within the specified range.

•After finishing the valve clearance adjustment, reinstall the following items.

*Cylinder head cover ( 3-104)

*Spark plug and plug cap ( 2-6)

*Throttle body assembly ( 5-22)

*Valve timing inspection plug ( 3-104)

*PAIR control solenoid valve ( 11-7)

TAPPET SHIM SELECTION TABLE [INTAKE]

TAPPET SHIM NO. (12892-05C00-XXX)

TAPPET SHIM SET (12800-05830)

	SUFFIX		120	125	130	135	140	145	150	155	160	165	170	175	180	185	190	195	200	205		210	215	220
		NO.
MEASURED
	PRESENT
VALVE
	SHIM SIZE
CLEARANCE
		(mm)	1.20	1.25	1.30	1.35	1.40	1.45	1.50	1.55	1.60	1.65	1.70	1.75	1.80	1.85	1.90	1.95	2.00	2.05		2.10	2.15	2.20
(mm)
0.00 – 0.02					1.20	1.25	1.30	1.35	1.40	1.45	1.50	1.55	1.60	1.65	1.70	1.75	1.80	1.85	1.90	1.95		2.00	2.05	2.10
0.03 – 0.07				1.20	1.25	1.30	1.35	1.40	1.45	1.50	1.55	1.60	1.65	1.70	1.75	1.80	1.85	1.90	1.95	2.00		2.05	2.10	2.15
0.08 – 0.18									SPECIFIED CLEARANCE/NO					ADJUSTMENT REQUIRED
0.19 – 0.28			1.30	1.35	1.40	1.45	1.50	1.55	1.60	1.65	1.70	1.75	1.80	1.85	1.90	1.95	2.00	2.05	2.10	2.15		2.20	2.20
0.29 – 0.33			1.35	1.40	1.45	1.50	1.55	1.60	1.65	1.70	1.75	1.80	1.85	1.90	1.95	2.00	2.05	2.10	2.15	2.20
0.34 – 0.38			1.40	1.45	1.50	1.55	1.60	1.65	1.70	1.75	1.80	1.85	1.90	1.95	2.00	2.05	2.10	2.15	2.20
0.39 – 0.43			1.45	1.50	1.55	1.60	1.65	1.70	1.75	1.80	1.85	1.90	1.95	2.00	2.05	2.10	2.15	2.20
0.44 – 0.48			1.50	1.55	1.60	1.65	1.70	1.75	1.80	1.85	1.90	1.95	2.00	2.05	2.10	2.15	2.20
0.49 – 0.53			1.55	1.60	1.65	1.70	1.75	1.80	1.85	1.90	1.95	2.00	2.05	2.10	2.15	2.20
0.54 – 0.58			1.60	1.65	1.70	1.75	1.80	1.85	1.90	1.95	2.00	2.05	2.10	2.15	2.20
0.59 – 0.63			1.65	1.70	1.75	1.80	1.85	1.90	1.95	2.00	2.05	2.10	2.15	2.20
0.64 – 0.68			1.70	1.75	1.80	1.85	1.90	1.95	2.00	2.05	2.10	2.15	2.20
0.69 – 0.73			1.75	1.80	1.85	1.90	1.95	2.00	2.05	2.10	2.15	2.20
0.74 – 0.78			1.80	1.85	1.90	1.95	2.00	2.05	2.10	2.15	2.20
0.79 – 0.83			1.85	1.90	1.95	2.00	2.05	2.10	2.15	2.20
0.84 – 0.88			1.90	1.95	2.00	2.05	2.10	2.15	2.20
0.89 – 0.93			1.95	2.00	2.05	2.10	2.15	2.20
0.94 – 0.98			2.00	2.05	2.10	2.15	2.20					HOW TO USE THIS CHART:
0.99 – 1.03			2.05	2.10	2.15	2.20
												I.	Measure valve clearance. “ENGINE IS COLD”
1.04 – 1.08			2.10	2.15	2.20
												II.	Measure present shim size.
1.09 – 1.13			2.15	2.20
												III. Match clearance in vertical column with present shim size in horizontal
1.14 – 1.18			2.20
													column.
														EXAMPLE
													Valve clearance is					0.23 mm
													Present shim size					1.70 mm
													Shim size to be used					1.80 mm

SIDE)(INTAKE	MAINTENANCE PERIODIC 10-2

TAPPET SHIM SELECTION TABLE [EXHAUST]

TAPPET SHIM NO. (12892-05C00-XXX)

TAPPET SHIM SET (12800-05830)

		SUFFIX	120	125	130	135	140	145	150	155	160	165	170	175	180	185	190	195	200	205	210	215	220
		NO.
	MEASURED	PRESENT
	VALVE
		SHIM SIZE
	CLEARANCE
		(mm)	1.20	1.25	1.30	1.35	1.40	1.45	1.50	1.55	1.60	1.65	1.70	1.75	1.80	1.85	1.90	1.95	2.00	2.05	2.10	2.15	2.20
	(mm)
	0.03 – 0.07					1.20	1.25	1.30	1.35	1.40	1.45	1.50	1.55	1.60	1.65	1.70	1.75	1.80	1.85	1.90	1.95	2.00	2.05
	0.08 – 0.12				1.20	1.25	1.30	1.35	1.40	1.45	1.50	1.55	1.60	1.65	1.70	1.75	1.80	1.85	1.90	1.95	2.00	2.05	2.10
	0.13 – 0.17			1.20	1.25	1.30	1.35	1.40	1.45	1.50	1.55	1.60	1.65	1.70	1.75	1.80	1.85	1.90	1.95	2.00	2.05	2.10	2.15
	0.18 – 0.28								SPECIFIED CLEARANCE/NO ADJUSTMENT REQUIRED
	0.29 – 0.38		1.30	1.35	1.40	1.45	1.50	1.55	1.60	1.65	1.70	1.75	1.80	1.85	1.90	1.95	2.00	2.05	2.10	2.15	2.20	2.20
	0.39 – 0.43		1.35	1.40	1.45	1.50	1.55	1.60	1.65	1.70	1.75	1.80	1.85	1.90	1.95	2.00	2.05	2.10	2.15	2.20
	0.44 – 0.48		1.40	1.45	1.50	1.55	1.60	1.65	1.70	1.75	1.80	1.85	1.90	1.95	2.00	2.05	2.10	2.15	2.20
	0.49 – 0.53		1.45	1.50	1.55	1.60	1.65	1.70	1.75	1.80	1.85	1.90	1.95	2.00	2.05	2.10	2.15	2.20
	0.54 – 0.58		1.50	1.55	1.60	1.65	1.70	1.75	1.80	1.85	1.90	1.95	2.00	2.05	2.10	2.15	2.20
	0.59 – 0.63		1.55	1.60	1.65	1.70	1.75	1.80	1.85	1.90	1.95	2.00	2.05	2.10	2.15	2.20
	0.64 – 0.68		1.60	1.65	1.70	1.75	1.80	1.85	1.90	1.95	2.00	2.05	2.10	2.15	2.20
	0.69 – 0.73		1.65	1.70	1.75	1.80	1.85	1.90	1.95	2.00	2.05	2.10	2.15	2.20
	0.74 – 0.78		1.70	1.75	1.80	1.85	1.90	1.95	2.00	2.05	2.10	2.15	2.20
	0.79 – 0.83		1.75	1.80	1.85	1.90	1.95	2.00	2.05	2.10	2.15	2.20
	0.84 – 0.88		1.80	1.85	1.90	1.95	2.00	2.05	2.10	2.15	2.20
	0.89 – 0.93		1.85	1.90	1.95	2.00	2.05	2.10	2.15	2.20
	0.94 – 0.98		1.90	1.95	2.00	2.05	2.10	2.15	2.20
	0.99 – 1.03		1.95	2.00	2.05	2.10	2.15	2.20

1.04 – 1.08	2.00	2.05	2.10	2.15 2.20			HOW TO USE THIS CHART:
							I.	Measure valve clearance. “ENGINE IS COLD”
1.09 – 1.13	2.05	2.10	2.15	2.20
							II.	Measure present shim size.
1.14 – 1.18	2.10	2.15	2.20
							III.	Match clearance in vertical column with present shim size in horizontal
1.19 – 1.23	2.15	2.20
								column.
1.24 – 1.28	2.20
								EXAMPLE
								Valve clearance is	0.33 mm
								Present shim size	1.70 mm
								Shim size to be used	1.80 mm

SIDE) (EXHAUST

11-2 MAINTENANCE PERIODIC

2-12 PERIODIC MAINTENANCE

ENGINE OIL AND OIL FILTER

(ENGINE OIL)

Replace initially at 1 000 km (600 miles, 2 months) and every 6 000 km (4 000 miles, 12 months) thereafter.

(OIL FILTER)

Replace initially at 1 000 km (600 miles, 2 months) and every 18 000 km (11 000 miles, 36 months) thereafter.

ENGINE OIL REPLACEMENT

•Place an oil pan below the engine, and drain oil by removing the oil drain plug and filler cap .

•Tighten the drain plug to the specified torque, and pour fresh oil through the oil filler. The engine will hold about 3.0 L (3.2/2.6 US/Imp qt) of oil. Use of SF/SG or SH/SJ in API with MA in JASO.

Oil drain plug: 23 N·m (2.3 kgf-m, 16.5 lb-ft)

•Start up the engine and allow it to run for several minutes at idling speed.

•Turn off the engine and wait about three minutes.

• Hold the motor cycle vertically and check the oil level through	F
the inspection window. If the level is below mark “L”, add oil to
“F” level. If the level is above mark “F”, drain oil to “F” level.	L

PERIODIC MAINTENANCE 2-13

OIL FILTER REPLACEMENT

•Drain the engine oil as described in the engine oil replacement procedure.

•Remove the right under cowling. ( 8-5)

•Remove the oil filter with the special tool.

09915-40610: Oil filter wrench

•Apply engine oil lightly to the gasket of the new oil filter before installation.

•Install the new oil filter. Turn it by hand until you feel that the oil filter gasket contacts the oil filter mounting surface. Then, tighten the oil filter two full turns (or to specified torque) with the special tool.

NOTE:

To properly tighten the oil filter, use the special tool. Never tighten the oil filter by hand.

Oil filter: 20 N·m (2.0 kgf-m, 14.5 lb-ft)

•Add new engine oil and check the oil level is as described in the engine oil replacement procedure.

NECESSARY AMOUNT OF ENGINE OIL:

Oil change	: 3.0	L (3.2/2.6 US/Imp qt)
Oil and filter change : 3.3		L (3.5/2.9 US/Imp qt)
Engine overhaul	: 3.6	L (3.8/3.2 US/Imp qt)

ONLY USE A GENUINE SUZUKI MOTORCYCLE OIL FILTER. Other manufacturer’s oil filters may differ in thread specifications (thread diameter and pitch), filtering performance and durability which may lead to engine damage or oil leaks. Also, do not use a genuine Suzuki automobile oil filter on this motorcycle.

EXHAUST CONTROL VALVE

Inspect initially at 1 000 km (600 miles, 2 months) and every 12 000 km (7 500 miles, 24 months) thereafter.

•Check the exhaust control valve actuator for its movement when the ignition switch is turned on.

•If the exhaust valve actuator does not move, check exhaust valve actuator electrical circuit and exhaust valve carbon sticking.

•Check the exhaust control valve cable play. ( 6-9)

After contacting the gasket, tighten 2 turns.

(20 N·m, 2.0 kgf-m, 14.5 lb-ft)

2-14 PERIODIC MAINTENANCE

•Remove the right under cowling. ( 8-5)

•Check the lock-nuts tightness. If the lock-nuts are loose, adjust the cable play ( 6-9) and tighten them.

FUEL LINE

Inspect every 6 000 km (4 000 miles, 12 months).

•Inspect the fuel feed hose for damage and fuel leakage. If any defects are found, the fuel feed hose must be replaced.

THROTTLE VALVE SYNCHRONIZATION

Inspect initially at 1 000 km (600 miles, 2 months) (E-33 only) and every 12 000 km (7 500 miles, 24 moths).

•Inspect the throttle valve synchronization periodically. ( 5-27)

EVAPORATIVE EMISSION CONTROL SYSTEM (E-33 ONLY)

Inspect every 12 000 km (7 500 miles, 24 months). Replace vapor hose every 4 years.

• Inspect the evaporative emission control system periodically.

PAIR (AIR SUPPLY) SYSTEM

Inspect every 12 000 km (7 500 miles, 24 months).

• Inspect the PAIR (air supply) system periodically. ( 11-6)

PERIODIC MAINTENANCE 2-15

THROTTLE CABLE PLAY

Inspect initially at 1 000 km (600 miles, 2 months) and every 6 000 km (4 000 miles, 12 months) thereafter.

• Adjust the throttle cable play as follows.

•Loosen the lock-nut of the throttle pulling cable .

•Turn the adjuster in or out until the throttle cable play (at the throttle grip) is between 2.0 – 4.0 mm (0.08 – 0.16 in).

•Tighten the lock-nut while holding the adjuster .

Throttle cable play : 2.0 – 4.0 mm (0.08 – 0.16 in)

After the adjustment is completed, check that handlebar movement does not raise the engine idle speed and that the throttle grip returns smoothly and automatically.

2-16 PERIODIC MAINTENANCE

CLUTCH

(CLUTCH HOSE AND CLUTCH FLUID)

Inspect every 6 000 km (4 000 miles, 6 months). Replace hose every 4 years.

Replace fluid every 2 years.

CLUTCH FLUID LEVEL

•Keep the motorcycle upright and place the handlebars straight.

•Check the clutch fluid level by observing the lower line on the clutch fluid reservoir.

•If the level is found to be lower than the lower line, replenish with BRAKE FLUID that meets the following specification.

Specification and classification: DOT 4

*The clutch system of this motorcycle is filled with a glycol-based brake fluid. Do not use or mix different types of fluid such as silicone-based or petroleum based. Do not use any brake fluid taken from old, used or unsealed containers. Never re-use brake fluid left over from the last servicing or stored for a long periods.

*Brake fluid, if it leaks, will interfere with safe running and immediately discolor painted surfaces. Check the clutch hose and hose joints for cracks and fluid leakage before riding.

PERIODIC MAINTENANCE 2-17

BLEEDING AIR FROM THE CLUTCH FLUID CIRCUIT

The clutch fluid circuit may be purged of air in the following manner.

•Keep the motorcycle upright and place the handlebars straight.

•Fill up the clutch master cylinder reservoir to the upper line. Place the reservoir cap to prevent entry of dirt.

•Attach a hose to the bleeder valve and insert the free end of the hose into a receptacle.

•Squeeze and release the clutch lever several times in rapid succession, and squeeze the lever fully without releasing it. Loosen the bleeder valve by turning it a quarter of a turn so that the fluid runs into the receptacle; this will remove the tension of the clutch lever causing it to touch the handlebar grip. Then, close the valve, pump and squeeze the lever, and open the valve. Repeat this process until the fluid flowing into the receptacle contains no air bubbles.

•Close the bleeder valve, and disconnect the pipe. Fill the reservoir with brake fluid to the upper line.

Air bleeder valve: 6.0 N·m (0.6 kgf-m, 4.5 lb-ft)

2-18 PERIODIC MAINTENANCE

COOLING SYSTEM

Inspect every 6 000 km (4 000 miles, 12 months). Replace engine coolant every 2 years.

ENGINE COOLANT LEVEL CHECK

•Keep the motorcycle upright.

•Check the engine coolant level by observing the upper and lower lines on the engine coolant reservoir.

Upper line

Lower line

•If the level is below the lower line, lift and support the fuel tank ( 5-3), and add engine coolant to the full line from the

engine coolant reservoir filler.

ENGINE COOLANT CHANGE

•Remove the under cowlings. ( 8-5)

•Remove the radiator cap .

•Drain engine coolant by disconnecting the radiator hose from the water pump.

*Do not open the radiator cap when the engine is hot, as you may be injured by escaping hot liquid or vapor.

*Engine coolant may be harmful if swallowed or if it comes in contact with skin or eyes. If engine coolant gets into the eyes or in contact with the skin, flush thoroughly with plenty of water. If swallowed, induce vomiting and call physician immediately!

•Flush the radiator with fresh water if necessary.

•Connect the radiator hose securely.

•Pour the specified engine coolant up to the radiator inlet.

Engine coolant capacity (excluding reservoir):

2 250 ml (2.4/2.0 US/lmp qt)

•Bleed the air from the engine coolant circuit in the following procedure. ( 2-19)

ENGINE COOLANT INFORMATION ( 7-2)