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SUZUKI GSX-R1000 SERVICE MANUAL

Table of Contents
Group index
Supplements
Component parts and work to be done
Symbol
Abbreviations used in this manual
SAE-to-former SUZUKI term
Wire color
General information
Warning/Caution/Note
General precautions
SUZUKI GSX-R1000K5 ('05-Model)
Serial number location
Fuel, oil and engine coolant recommendation fuel (For USA and
Canada)
Fuel (For other countries)
Engine oil (For USA)
Front fork oil
Engine coolant
Water for mixing
Anti-freeze/Engine coolant
Braek-in Procedures
Cylinder Identification
Information labels
Specifications
Periodic maintenance
Periodic maintenance schedule
Periodic maintenance chart
Lubrication points
Maintenance and tune-up procedures
Air cleaner
Spark plug
Valve clearance
Intake side
Exhaust side
Engine oil and oil filter
Exhaust control valve
Oil filter replacement
Fuel line
Engine idle speed
Throttle valve synchronization
Evaporative emission control system (E-33 only)
Pair (air supply) system
Throttle cable play
Clutch
Cooling system
Engine coolant level check
Engine coolant change
Air bleeding the cooling circuit
Radiator hoses
Drive chain
Cleaning and lubricating
Brake
Brake fluid level check
Brake pads
Brake pedal height
Brake light switch
Air bleeding from brake fluid circuit
Front brake (Caliper side)
Front brake (Master cylinder side)
Rear brake
Tires
Steering
Tire tread condition
Tire pressure
Front fork
Rear suspension
Exhaust pipe bolt and nut
Chassis bolts and nuts
Compression pressure check
Compression test procedure
Oil pressure check
SDS check
Data sampled from cold starting through warm-up
Data at 3000 r/min under no load
Data at the time of racing
Data of intake negative pressure during idling (100 °C)
Data of secondary throttle valve operation at the time of starting
Engine
Engine components removable with engine in place
Engine removal and installation
Engine mounting
Engine installation
Engine disassembly
Engine components inspection and service
Cylinder head cover
CMP sensor
Pair reed valve
Camshaft
Cam chain tension adjuster
Cam chain tensioner
Cam chain guide
Cylinder head and valve
Clutch
Clutch drive plate inspection
Clutch driven plate inspection
Clutch spring inspection
Clutch bearing inspection
Clutch lifter
Clutch lifter pin adjustment
Oil pump
Wave spring washer inspection
Starter clutch
Generator
Gearshift system
Gearshift shaft/Gearshift arm disassembly
Gearshift shaft/Gearshift arm inspection
Gearshift shaft/Gearshift arm resassembly
Oil pressure regulator
Oil strainer
Transmission
Transmission parts location
Cylinder
Cylinder distortion
Cylinder bore
Piston and piston ring
Piston diameter
Piston-to-cylinder clearance
Piston pin and pin bore
Piston ring-to-groove clearance
Piston ring free end gap and piston ring end gap
Crankcase
Gearshift fork and gearshift cam
Gearshift fork-to-groove clearance
Gearshift for groove width
Gearshift fork thickness
Gearshift cam bearing and gearshift shaft bearing
Oil jet
Plug
Balancer shaft
Balancer shaft journal bearing
Crankshaft and conrod
Crankshaft runout
Conrod big end side clearance
Conrod-big end bearing inspection
Conrod-big end bearing selection
Crank pin O.D.
Bearing thickness
Crankshaft journal bearing
Bearing selection table
Crankcase I.D. specification
Crankshaft journal O.D. specification
Bearing thickness specification
Crankshaft thrust bearing
Crankshaft thrust clearance adjustment
Thrust bearing selection table
Engine reassembly
Piston and conrod
FI system diagnosis
Precautions in servicing
Electrical parts
Connector/Coupler
Fuse
ECM/Various sensors
Electrical circuit inspection procedure
Open circuit check
Continuity check
Short circuit check (wire harness to ground)
Using the multi-circuit tester
FI system technical features
Injection time (injection volume)
Compensation of injection time (volume)
Injection stop control
FI system parts location
FI system wiring diagram
ECM terminal
Self-diagnosis function
User mode
Dealer mode
TPS adjustment
Fail-safe function
FI system troubleshooting
Customer complain analysis
Visual inspection
Self-diagnosis procedures
Self-diagnosis reset procedure
Use of SDS diagnostic procedures
Use of SDS diagnosis reset procedure
Show data when trouble (Displaing data at the time of DTC)
Malfunction code and defective condition
"C11" (P0340) CMP sensor circuit malfunction
"C12" (P0335) CKP sensor circuit malfunction
"C13" (P0105-H/L) IAP sensor circuit malfunction
"C14" (P0120-H/L) TP sensor circuit malfunction
"C15" (P0115-H/L) ECT sensor circuit malfunction
"C21" (P0110-H/L) IAT sensor circuit malfunction
"C22" (P1450-H/L) AP sensor circuit malfunction
"C23" (P1651-H/L) TO sensor circuit malfunction
"C28" (P1655) STV actuator circuit malfunction
Active control inspection
"C29" (P1654-H/L) STP sensor circuit malfunction
"C31" (P0705) GP switch circuit malfunction
"C32" (P0201), "C33" (P0202), "C34" (P0203) or "C35" (P0204)
Primary fuel injector circuit malfunction
"C36" (P1764), "C37" (P1765), "C38" (P1766) or "C39" (P1767)
secondary fuel injector circuit malfunction
"C41" (P0230-H/L) FP relay circuit malfunction
"C42" (P01650) IG switch circuit malfunction
"C46" (P1657-H/L or P1658) EXCV actuator circuit malfunction
"C49" (P1656) pair control solenoid valve circuit malfunction
"C60" (P0480) cooling fan relay circuit malfunction
Sensors
Fuel system and throttle body
Fuel delivery system
Fuel system
Fuel tank lift-up
Fuel tank removal
Fuel tank installation
Fuel pressure inspection
Fuel pump inspection
Fuel discharge amount inspection
Fuel pump relay inspection
Fuel pump and fuel filter removal
Construction
Fuel mesh filter inspection and cleaning
Fuel pump and fuel mesh filter installation
Throttle body (Construction)
Air cleaner box removal
Throttle body removal
Throttle body disassembly
Throttle body cleaning
Throttle body reassembly
Throttle body installation
Air cleaner box installation
Fuel injector removal
Fuel injector inspection
Fuel injector installation
Fast idle
Fast idle adjustment
Throttle valve synchronization
Use of digital vacuum tester
Use of vacuum balancer gauge
Throttle position sensor (TPS) setting
Exhaust system
Exhaust control system
Operation
EXCVA (Exhaust control valve actuator) and EXCV (Exhaust control
valve)
EXCVA removal
EXCVA installation
EXCV cable replacement
EXCVA adjustment
EXCV/Muffler removal
EXCV Inspection
EXCV/Muffler installation
Cooling and lubrication system
Engine coolant
Cooling circuit
Cooling circuit inspection
Radiator and water hoses
Radiator removal
Radiator cap inspection
Radiator inspection and cleaning
Radiator installation
Water hose inspection
Cooling fan
Cooling fan relay inpection
ECT sensor
Thermostat
Water pump
Mechanical seal
Oil seal
Impeller shaft journal
Seal washer
Engine lubrication system chart
Engine lubrication system
Chassis
Exterior parts
Fastener removal and installation
Screen
Body cowling cover and lower bracket cover
Under cowling
Body cowling
Ait intake pipe
Cowling brace
Front seat
Rear seat and seat tail cover
Frame cover
Front Wheel (Construction)
Axle shaft
Wheel
Wheel bearings
Reassembly and installation
Front fork (Construction)
Inner and outer tubes
Damper rod
Oil seal and dust seal
Damper rod bolt
Fork oil
Front fork inner rod lock nut
Fork spring
Front fork cap bolt
Suspension setting
Steering damper (Construction)
Steering (Construction)
Front fork and steering stem upper bracket
Steering tension adjustment
Handlebars (Construction)
Rear wheel (Construction)
Reassembly and installation
Wheel damper
Dust seals
Brake disc
Rear axle
Rear shock absorber (Construction)
Rear shock absorber disposal
Gas pressure release
Suspension setting
Damping force adjustment
Rear suspension (Construction)
Swingarm pivot boss removal and installation
Cushion lever bearing
Cushion lever and cushion lever rods
Swingarm pivot shaft
Chain buffer
Reassembly
Swingarm pivot thrust clearance adjustment
Final inspection and adjustment
Shock absorber and cushion lever mounting nut
Front brake (Construction)
Brake pad replacement
Brake fluid replacement
Caliper removal
Caliper disassembly
Caliper inspection
Caliper reassembly
Brake disc inspection
Master cylinder removal and disassembly
Master cylinder inspection
Master cylinder reassembly
Master cylinder installation
Rear brake (Construction)
Master cylinder removal
Tire and wheel
Tire removal
Valve inspection
Tire installation
Balancer weight installation
Drive chain
Drive chain cutting
Drive chain connecting
Joint plate installation
Joint pin staking
Electrical system
Cautions in servicing
Location of electrical components
Charging system
Troubleshooting
Battery runs down quickly
Battery overcharges
Battery current leakage
Starter system and side-stand/Ignition interlock system
Starter motor will not run
Starter motor removal
Starter motor runs but does not crank the engine
Starter motor disassembly
Starter motor inspection
Starter relay inspection
Side stand/Ignition interlock system parts inspection
Turn signal/Side-stand relay
Side-stand relay inspection
Diode inspection
Ignition system
Immobilizer (Except for E-03, 28, 33)
No spark or poor spark
Ignition coil primary peak voltage
Combination meter
Fuel level indicator light inspection
Lamps
Headlight, brake light/Taillight, license plate light and turn signal light
Relays
Ignition switch removal
Ignition switch installation
Switches inspection
Battery specifications
Initial charging
Servicing
Recharging operation
Servicing information
FI system malfunction code and defective condition
Engine
Radiator (Cooling system)
Chassis
Brakes
Electrical
Battery
Wiring harness, cable and hose routing
Wiring harness routing
Cable routing
Throttle body hose routing
Fuel tank drain hose routing
Cooling system hose routing
Front brake hose routing
Rear brake hose routing
Pair (air supply) system hose routing
Fuel tank installation
Fuel tank lower side cover cushion rubber/Fastener installation
Cowling installation
Frame cover installation
Seat lock cable routing
Rear fender installation
Under cowling heat shield installation
Body cowling cover cushion installation
Windscreen tape cushion installation
Headlight tape cushion installation
Air intake cover tape cushion installation
Side-stand installation
Gearshift pedal installation
Handlebar balancer
Front footrest installation
Rear view mirror installation
Rear combinator light installation
Regulator/Rectifier installation
Special tools
Tightening torque
Tightening torque chart
Service data
Valve + Valve guide
Camshaft + Cylinder head
Cylinder + Piston + Piston ring
Conrod + Crankshaft
Balancer
Oil pump
Clutch
Transmission + Drive chain
Thermostat + Radiator + Fan + Coolant
Injector + Fuel pump + Fuel pressure regulator
FI sensors
Throttle body
Electrical
Wattage
Brake + Wheel
Tire
Suspension
Fuel + Oil
Emission control information
Emission control systems
Fuel injection system
Crankcase emission control system
Exhaust emission control system (Pair system)
Noise emission control system
Evaporative emission control system (Only for E-33)
Pair (Air supply) system and emission control system inspection
Pair (Air supply) system diagram
Pair (Air supply) system hose routing
Fuel-shut off valve
Evap canister hose routing (Only for E-33)
GSX-R1000K6
Specifications
service data
oil pump
throttle body
Battery holder cushion rubber installation
Wiring diagram E-02, 19, 24
E-03, 28, 33
 GSX-R1000

Service
Manual

*99500-39271-03E*
* 9 9 5 0 0 - 3 9 2 7 1 - 0 3 E *
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 IMPORTANT
All street-legal Suzuki motorcycles with engine
displacement of 50 cc or greater are subject to
Environmental Protection agency emission
regulations. These regulations set specific standards
for exhaust emission output levels as well as particular
servicing requirements. This manual includes specific
information required to properly inspect and service
this street-legal motorcycle in accordance with all EPA
regulations. It is strongly recommended that the
chapter on Emission Control, Periodic Servicing and FI
System and Fuel System be thoroughly reviewed
before any type of service work is performed. Further
information concerning the EPA emission regulations
and U.S. Suzuki’s emission control program can be
found in the U.S. SUZUKI EMISSION CONTROL
PROGRAM MANUAL/SERVICE BULLETIN.

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 SUPPLEMENTS

GSX-R1000K6 12

WIRING DIAGRAM 13

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 2-30 PERIODIC MAINTENANCE

CHASSIS BOLTS AND NUTS

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

Check that all chassis bolts and nuts are tightened to their specified torque. (Refer to page 2-31 for the loca-
tions of the following nuts and bolts on the motorcycle.)

Item N•m kgf-m Ib-ft

1 Steering stem head nut 90 9.0 6.5
2 Steering stem lock-nut 90 9.0 65.0
3 Front fork upper clamp bolt 23 2.3 16.5
4 Front fork lower clamp bolt 23 2.3 16.5
5 Front fork cap bolt 23 2.3 16.5
6 Front axle bolt 100 10.0 72.5
7 Front axle pinch bolt 23 2.3 16.5
8 Handlebar clamp bolt 23 2.3 16.5
9 Front brake master cylinder mounting bolt 10 1.0 7.0
0 Front brake caliper mounting bolt 39 3.9 28.0
A Front brake caliper housing bolt 22 2.2 16.0
B Brake hose union bolt (Front & Rear) 23 2.3 16.5
C Air bleeder valve (Front brake caliper) 7.5 0.75 5.5
D Air bleeder valve (Master cylinder & Rear brake caliper) 6.0 0.6 4.5
E Brake disc bolt (Front) 23 2.3 16.5
F Brake disc bolt (Rear) 35 3.5 25.5
G Rear brake caliper mounting bolt 25 2.5 18.1
H Rear brake caliper housing bolt 37 3.7 27.0
I Rear brake master cylinder mounting bolt 10 1.0 7.0
J Rear brake master cylinder rod lock-nut 18 1.8 13.0
K Front footrest bracket mounting bolt 23 2.3 16.5
L Swingarm pivot nut 100 10.0 72.5
M Swingarm pivot lock-nut 90 9.0 65.0
N Rear suspension bracket nut 115 11.5 83.0
O Rear shock absorber mounting bolt/nut (Upper & Lower) 50 5.0 36.0
P Cushion rod nut 78 7.8 56.5
Q Cushion lever mounting nut 78 7.8 56.5
R Rear axle nut 100 10.0 72.5
S Rear sprocket nut 60 6.0 43.5
T Steering damper bolt/nut 23 2.3 16.5

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 8-44 CHASSIS

REASSEMBLY AND INSTALLATION

Reassemble and install the rear wheel in the reverse order of
removal and disassembly. Pay attention to the following points:

Left Right

100 N·m
(10.0 kgf-m, 72.5 lb-ft)

60 N·m 35 N·m
(6.0 kgf-m, 43.5 lb-ft) (3.5 kgf-m, 25.5 lb-ft)

E-02, 19, 24 25 N·m

(2.5 kgf-m, 18.0 lb-ft)

E-03, 28, 33

100 N·m
(10.0 kgf-m, 72.5 lb-ft)

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 CHASSIS 8-47

• Tighten the sprocket mounting nuts to the specified torque.

 Rear sprocket nut: 60 N·m (6.0 kgf-m, 43.5 lb-ft)
NOTE:
Stamped mark A on the sprocket should face outside.
• Install the collar 2.

BRAKE DISC
• Apply THREAD LOCK to the disc bolts and tighten them to
the specified torque.
NOTE:
Make sure that the brake disc is clean and free of any greasy
matter.
 99000-32130: THREAD LOCK SUPER “1360”
 Brake disc bolt: 35 N·m (3.5 kgf-m, 25.5 lb-ft)
• Install the collar 1.

REAR AXLE
• Remount the rear wheel and rear axle shaft, and install the
washer 1 (Except for E-03, 28, 33) and rear axle nut 2.
• Adjust the chain slack after rear wheel installation. (2-21)

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 9-36 ELECTRICAL SYSTEM

HEADLIGHT BEAM ADJUSTMENT

• Adjust the headlight beam.
NOTE:
* Use a screw driver + for adjuster A, B and C.
* To adjust the headlight beam, adjust the beam horizontally
first, then adjust vertically.

A: Horizontal adjuster (Low beam)

B: Vertical adjuster (Low beam)
C: Horizontal adjuster (High beam)
D: Vertical adjuster (High beam)

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 SERVICING INFORMATION 10-47

CHASSIS
ITEM N·m kgf-m lb-ft
Steering stem head nut 90 9.0 65.0
Steering stem lock-nut 90 9.0 65.0
Steering damper bolt and nut 23 2.3 16.5
Front fork upper clamp bolt 23 2.3 16.5
Front fork lower clamp bolt 23 2.3 16.5
Front fork cap bolt 23 2.3 16.5
Front fork inner rod lock-nut 29 2.9 21.0
Front fork damper rod bolt 23 2.3 16.5
Front axle bolt 100 10.0 72.5
Front axle pinch bolt 23 2.3 16.5
Handlebar clamp bolt 23 2.3 16.5
Front brake master cylinder mounting bolt 10 1.0 7.0
Front brake caliper mounting bolt 39 3.9 28.0
Front brake caliper housing bolt 22 2.2 16.0
Front brake pad mounting pin 15 1.5 11.0
Brake hose union bolt 23 2.3 16.5
Clutch lever holder mounting bolt 10 1.0 7.0
Air bleeder valve (Front brake caliper) 7.5 0.75 5.5
Air breeder valve (Master cylinder and Rear brake caliper) 6.0 0.6 4.3
Brake disc bolt (Front) 23 2.3 16.5
Brake disc bolt (Rear) 35 3.5 25.5
Rear brake caliper mounting bolt 25 2.5 18.0
Rear brake caliper housing bolt 37 3.7 27.0
Rear brake pad mounting pin 17 1.7 12.5
Rear brake master cylinder mounting bolt 10 1.0 7.0
Rear brake master cylinder rod lock-nut 18 1.8 13.0
Front footrest bracket mounting bolt 23 2.3 16.5
Swingarm pivot shaft 15 1.5 11.0
Swingarm pivot nut 100 10.0 72.5
Swingarm pivot lock-nut 90 9.0 65.0
Swingarm pivot boss nut 65 6.5 47.0
Cushion lever mounting nut 78 7.8 56.5
Cushion rod mounting nut 78 7.8 56.5
Rear shock absorber mounting bolt and nut
50 5.0 36.0
(Upper and Lower)
Rear axle nut 100 10.0 72.5
Rear sprocket nut 60 6.0 43.5
Side-stand mounting bracket bolt 50 5.0 36.0
Cowling brace bolt and nut 23 2.3 16.5
Rear shock absorber bracket nut 115 11.5 83.0
Seat rail bolt 50 5.0 36.0
Rear view mirror nut 10 1.0 7.0

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 GSX-R1000K6
12

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 SPECIFICATIONS
DIMENSIONS AND DRY MASS
Overall length ...................................................................................... 2 030 mm (79.9 in)
Overall width........................................................................................ 710 mm (28.0 in)
Overall height ...................................................................................... 1 130 mm (44.5 in)
Wheelbase .......................................................................................... 1 405 mm (55.3 in)
Ground clearance................................................................................ 130 mm (5.1 in)
Seat height .......................................................................................... 810 mm (31.9 in)
Dry mass ............................................................................................. 167 kg (368 lbs) ....... E-33
166 kg (365 lbs) ....... Others

ENGINE
Type..................................................................................................... Four stroke, liquid-cooled, DOHC
Number of cylinders ............................................................................ 4
Bore..................................................................................................... 73.4 mm (2.900 in)
Stroke .................................................................................................. 59.0 mm (2.323 in)
Displacement ...................................................................................... 999 cm3 (61.0 cu. in)
Compression ratio ............................................................................... 12.5 : 1
Fuel system ......................................................................................... Fuel injection
Air cleaner ........................................................................................... Paper element
Starter system ..................................................................................... Electric
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............................................................................. 2.470 (42/17)
Drive chain .......................................................................................... DID530, 110 links

CHASSIS
Front suspension................................................................................. Inverted telescopic, coil spring, oil damped
Rear suspension ................................................................................. Link type, coil spring, oil damped
Front fork stroke .................................................................................. 120 mm (4.7 in)
Rear wheel travel ................................................................................ 130 mm (5.1 in)
Steering angle ..................................................................................... 27°
Caster.................................................................................................. 23° 45’
Trail...................................................................................................... 96 mm (3.78 in)
Turning radius...................................................................................... 3.4 m (11.2 ft)
Front brake .......................................................................................... Disc brake, twin
Rear brake........................................................................................... Disc brake
Front tire size....................................................................................... 120/70ZR17M/C (58 W), tubeless
Rear tire size ....................................................................................... 190/50ZR17M/C (73 W), tubeless

ELECTRICAL
Ignition type......................................................................................... Electronic ignition (Transistorized)
Ignition timing ...................................................................................... 10° B.T.D.C. at 1 150 r/min
Spark plug ........................................................................................... NGK CR9E or DENSO U27ESR-N
Battery................................................................................................. 12 V 36.0 kC (10 Ah)/10 HR
Generator ............................................................................................ Three phase A.C. generator
Main fuse............................................................................................. 30 A
Fuse .................................................................................................... 15/10/10/10/10/10 A
Headlight ............................................................................................. 12 V 55 W (H7) + 12 V 60 W (HB3)
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 × 2
Oil pressure/Coolant temperature/Fuel injection warning light............ LED
Fuel level indicator light....................................................................... LED
Engine RPM indicator light .................................................................. LED
Imobirizer indicator light ...................................................................... LED ................ E-02,19, 24

CAPACITIES
Fuel tank, including reserve ............................................................... 17.5 L (4.6/3.8 US/Imp gal)....... E-33
18.0 L (4.8/4.0 US/Imp 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/Imp qt)
overhaul............................................................................ 3 600 ml (3.8/3.2 US/Imp qt)
Coolant................................................................................................ 2.4 L (2.5/2.1 US/Imp qt)

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 SERVICE DATA
VALVE + VALVE GUIDE Unit: mm (in)
ITEM STANDARD LIMIT
Valve diam. IN. 30 —
(1.18)
EX. 24 —
(0.94)
Valve clearance (when cold) IN. 0.10 – 0.20 —
(0.004 – 0.008)
EX. 0.20 – 0.30 —
(0.008 – 0.012)
Valve guide to valve stem IN. 0.010 – 0.037 —
clearance (0.0004 – 0.0015)
EX. 0.030 – 0.057 —
(0.0012 – 0.0022)
Valve guide I.D. IN. & EX. 4.500 – 4.512 —
(0.1772 – 0.1776)
Valve stem O.D. IN. 4.475 – 4.490 —
(0.1762 – 0.1768)
EX. 4.455 – 4.470 —
(0.1754 – 0.1760)
Valve stem deflection IN. & EX. — 0.25
(0.010)
Valve stem runout IN. & EX. — 0.05
(0.002)
Valve seat width IN. & EX. 0.9 – 1.1 —
(0.035 – 0.043)
Valve head radial runout IN. & EX. — 0.03
(0.001)
Valve spring free length IN. & EX. — 37.5
(1.48)
Valve spring tension IN. & EX. Approx. 147 N (15.0 kgf, 33.1 lbs) —
at length 33.55 mm (1.32 in)

CAMSHAFT + CYLINDER HEAD Unit: mm (in)

ITEM STANDARD LIMIT
Cam height IN. 37.58 – 37.63 37.28
(1.480 – 1.481) (1.468)
EX. 36.28 – 36.33 35.98
(1.428 – 1.430) (1.417)
Camshaft journal oil clearance IN. & EX. 0.032 – 0.066 0.150
(0.0013 – 0.0026) (0.0059)
Camshaft journal holder I.D. IN. & EX. 24.012 – 24.025 —
(0.9454 – 0.9459)
Camshaft journal O.D. IN. & EX. 23.959 – 23.980 —
(0.9433 – 0.9441)

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 ITEM STANDARD LIMIT
Camshaft runout — 0.10
(0.004)
Cam chain pin (at arrow “3”) 14th pin —
Cylinder head distortion — 0.20
(0.008)

CYLINDER + PISTON + PISTON RING Unit: mm (in)

ITEM STANDARD LIMIT
Compression pressure 1 300 – 1 700 kPa 1 000 kPa
(13 – 17 kgf/cm², 185 – 242 psi) (10 kgf/cm2, 142 psi)
Compression pressure difference — 200 kPa
(2 kgf/cm2, 28 psi)
Piston to cylinder clearance 0.035 – 0.045 0.120
(0.0014 – 0.0018) (0.0047)
Cylinder bore 73.400 – 73.415 Nicks or
(2.8900 – 2.8903) Scratches
Piston diam. 73.360 – 73.375 73.280
(2.8882 – 2.8888) (2.8850)
Measure at 15 mm (0.6 in) from the skirt end.
Cylinder distortion — 0.02
(0.008)
Piston ring free end gap 1st Approx. 6.5 (0.26) 5.2
(0.20)
2nd T Approx. 8.0 (0.31) 6.4
(0.25)
Piston ring end gap 1st 0.06 – 0.18 0.50
(0.002 – 0.007) (0.020)
2nd T 0.06 – 0.18 0.50
(0.002 – 0.007) (0.020)
Piston ring to groove clearance 1st — 0.180
(0.0071)
2nd — 0.150
(0.0059)
Piston ring groove width 1st 1.30 – 1.32 —
(0.0512 – 0.0520)
2nd 0.81 – 0.83 —
(0.0319 – 0.0327)
Oil 1.51 – 1.53 —
(0.0594 – 0.0602)
Piston ring thickness 1st 1.08 – 1.10 —
(0.0425 – 0.0433)
2nd 0.77 – 0.79 —
(0.0303 – 0.0311)
Piston pin bore I.D. 15.002 – 15.008 15.030
(0.5906 – 0.5909) (0.5917)
Piston pin O.D. 14.995 – 15.000 14.980
(0.5903 – 0.5906) (0.5898)

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 CONROD + CRANKSHAFT Unit: mm (in)
ITEM STANDARD LIMIT
Conrod small end I.D. 15.010 – 15.018 15.040
(0.5909 – 0.5913) (0.5921)
Conrod big end side clearance 0.10 – 0.20 0.30
(0.004 – 0.008) (0.012)
Conrod big end width 19.95 – 20.00 —
(0.7854 – 0.7874)
Crank pin width 20.10 – 20.15 —
(0.7913 – 0.7933)
Conrod big end oil clearance 0.032 – 0.056 0.080
(0.0013 – 0.0022) (0.0031)
Crank pin O.D. 34.976 – 35.000 —
(1.3770 – 1.3780)
Crankshaft journal oil clearance 0.010 – 0.028 0.080
(0.0004 – 0.0011) (0.0031)
Crankshaft journal O.D. 34.982 – 35.000 —
(1.3772 – 1.3780)
Crankshaft thrust bearing thickness Right side 2.420 – 2.440 —
(0.0953 – 0.0961)
Left side 2.360 – 2.500 —
(0.0929 – 0.0984)
Crankshaft thrust clearance 0.060 – 0.110 —
(0.0024 – 0.0043)
Crankshaft runout — 0.05
(0.002)

BALANCER Unit: mm (in)

ITEM STANDARD LIMIT
Balancer shaft journal oil clearance 0.028 – 0.052 0.080
(0.0011 – 0.0020) (0.0031)
Balancer shaft journal O.D. 22.976 – 22.992 —
(0.9046 – 0.9052)

OIL PUMP
ITEM STANDARD LIMIT
Oil pressure (at 60 °C, 140 °F) 100 – 400 kPa
(1.0 – 4.0 kgf/cm², 14 – 57 psi) —
at 3 000 r/min

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 CLUTCH Unit: mm (in)
ITEM STANDARD LIMIT
Clutch lever play 10 – 15 —
(0.4 – 0.6)
Clutch release screw 1/2 turn back —
Drive plate thickness No. 1, 2 and 3 2.72 – 2.88 2.42
(0.107 – 0.113) (0.095)
Drive plate claw width No. 1, 2 and 3 13.85 – 13.96 13.05
(0.5453 – 0.5496) (0.5138)
Driven plate distortion — 0.10
(0.004)
Clutch spring free height 57.01 54.2
(2.244) (2.134)
Clutch lifter adjusting pin screw 0.2 – 0.4 —
height (0.008 – 0.016)
Wave spring washer height — 4.30
(0.169)

TRANSMISSION + DRIVE CHAIN Unit: mm (in) Except ratio

ITEM STANDARD LIMIT
Primary reduction ratio 1.553 (73/47) —
Final reduction ratio 2.470 (42/17) —
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) —
Shift fork to groove clearance 0.10 – 0.30 0.50
(0.004 – 0.012) (0.020)
Shift fork groove width 5.0 – 5.1 —
(0.197 – 0.201)
Shift fork thickness 4.8 – 4.9 —
(0.189 – 0.193)
Drive chain Type DID530 V9 —
Links 110 links —
20-pitch length — 319.4
(12.57)
Drive chain slack (on side-stand) 20 – 30 —
(0.79 – 1.18)
Gearshift lever height 50 – 60 —
(1.97 – 2.36)

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 THERMOSTAT + RADIATOR + FAN + COOLANT
ITEM STANDARD/SPECIFICATION NOTE
Thermostat valve opening temper- Approx. 82 °C (180 °F) —
ature
Thermostat valve lift 8 mm (0.31 in) and over at 95 °C (203 °F) —
ECT sensor resistance 20 °C Approx. 2.45 kΩ —
(68 °F)
50 °C Approx. 0.811 kΩ —
(122 °F)
80 °C Approx. 0.318 kΩ —
(176 °F)
110 °C Approx. 0.142 kΩ —
(230 °F)
Radiator cap valve opening pres- 93 – 123 kPa —
sure (0.93 – 1.23 kgf/cm², 13.2 – 17.5 psi)
Cooling fan operating temperature OFF→ON Approx. 105 °C (221 °F) —
ON→OFF Approx. 100 °C (212 °F) —
Engine coolant type Use an antifreeze/coolant compatible with alumi-
num radiator, mixed with distilled water only, at the —
ratio of 50:50.
Engine coolant Reserve Approx. 250 ml —
tank side (0.3/0.2 US/lmp qt)
Engine Approx. 2 150 ml —
side (2.3 – 1.9 US/lmp qt)

INJECTOR + FUEL PUMP + FUEL PRESSURE REGULATOR

ITEM SPECIFICATION NOTE
Injector resistance 11 – 13 Ω at 20 °C (68 °F)
(primary and secondary)
Fuel pump discharge amount 168 ml (5.7/5.9 US/lmp oz) and more/10 sec.
Fuel pressure regulator operating Approx. 300 kPa (3.0 kgf/cm², 43 psi)
set pressure

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 FI SENSORS
ITEM SPECIFICATION NOTE
CMP sensor resistance 0.9 – 1.7 kΩ
CMP sensor peak voltage 0.5 V and more When cranking
CKP sensor resistance 142 – 194 Ω
CKP sensor peak voltage 0.5 V and more When cranking
IAP sensor input voltage 4.5 – 5.5 V
IAP sensor output voltage Approx. 2.6 V at idle speed
TP sensor input voltage 4.5 – 5.5 V
TP sensor resistance Approx. 4.68 kΩ
Closed Approx. 1.1 kΩ
Opened Approx. 4.3 kΩ
TP sensor output voltage Closed Approx. 1.1 V
Opened Approx. 4.3 V
ECT sensor input voltage 4.5 – 5.5 V
ECT sensor output voltage 0.15 – 4.85 V
ECT sensor resistance Approx. 2.45 kΩ at 20 °C (68 °F)
IAT sensor input voltage 4.5 – 5.5 V
IAT sensor output voltage 0.15 – 4.85 V
IAT sensor resistance Approx. 2.45 kΩ at 20 °C (68 °F)
AP sensor input voltage 4.5 – 5.5 V
AP sensor output voltage Approx. 2.6 V at 760 mmHg (100 kPa)
TO sensor resistance 16.5 – 22.3 kΩ
TO sensor voltage Normal 0.4 – 1.4 V
Leaning 3.7 – 4.4 V When
leaning 65°
GP switch voltage 0.6 V and more From 1st to Top
Injector voltage Battery voltage
Ignition coil primary peak voltage 80 V and more When cranking
STP sensor input voltage 4.5 – 5.5 V
STP sensor resistance Approx. 4.69 kΩ
Closed Approx. 0.5 kΩ
Opened Approx. 3.9 kΩ
STP sensor output voltage Closed Approx. 0.5 V
Opened Approx. 3.9 V
STV actuator resistance Approx. 6.5 Ω
EXCVA position sensor input volt- 4.5 – 5.5 V
age
EXCVA position sensor resistance Approx. 3.1 kΩ At adjustment
position
EXCVA position sensor output volt- Closed 0.5 – 1.3 V
age Opened 3.7 – 4.5 V
PAIR control solenoid valve resis- 18 – 22 Ω at 20 – 30 °C (68 – 86 °F)
tance

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 THROTTLE BODY
ITEM SPECIFICATION
Bore size 44 mm
I.D. No. 41G1 (For E-33), 41G0 (For the others)
Idle r/min 1 150 ± 100 r/min
Fast idle r/min 1 400 – 2 000 r/min (When cold engine)
Throttle cable play 2.0 – 4.0 mm
(0.08 – 0.16 in)

ELECTRICAL Unit: mm (in)

ITEM SPECIFICATION NOTE
Firing order 1.2.4.3
Spark plug Type NGK: CR9E
DENSO: U27ESR-N
Gap 0.7 – 0.8
(0.028 – 0.031)
Spark performance Over 8 (0.3) at 1 atm.
CKP sensor resistance 142 – 194 Ω
CKP sensor peak voltage 0.5 V and more When cranking
Ignition coil resistance Primary 1.1 – 1.9 Ω Terminal –
Terminal
Secondary 10.8 – 16.2 kΩ Plug cap –
Terminal
Ignition coil primary peak voltage 80 V and more When cranking
Generator coil resistance 0.2 – 0.9 Ω
Generator no-load voltage 65 V (AC) and more at 5 000 r/min
(When engine is cold)
Regulated voltage 14.0 – 15.5 V at 5 000 r/min
Starter relay resistance 3–6Ω
GP switch voltage 0.6 V and more (From 1st to Top)
Battery Type FT12A-BS
designation
Capacity 12 V 36 kC (10 Ah)/10 HR
Fuse size HI 10 A
Headlight
LO 10 A
Signal 10 A
Ignition 10 A
Fuel 10 A
Fan 15 A
Main 30 A

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 WATTAGE Unit: W
STANDARD/SPECIFICATION
ITEM
E-03, 28, 33 Others
Headlight HI 60 ←
LO 55 ←
Position/Parking light 5×2 ←
Brake light/Taillight LED ←
Turn signal light 21 × 4 ←
License plate light 5 ←
Combination meter light LED ←
Turn signal indicator light LED ←
High beam indicator light LED ←
Neutral indicator light LED ←
FI indicator light/Oil pressure indi-
cator light/Engine coolant temp. LED ←
indicator light
Fuel level indicator light LED ←
Engine RPM indicator light LED ←
Immobilizer indicator light LED

BRAKE + WHEEL Unit: mm (in)

ITEM STANDARD LIMIT
Rear brake pedal height 55 – 65 —
(2.2 – 2.6)
Brake disc thickness Front 5.3 – 5.7 5.0
(0.209 – 0.224) (0.20)
Rear 4.8 – 5.2 4.5
(0.189 – 0.205) (0.18)
Brake disc runout — 0.30
(0.012)
Master cylinder bore Front 19.050 – 19.093 —
(0.7500 – 0.7517)
Rear 14.000 – 14.043 —
(0.5512 – 0.5529)
Master cylinder piston diam Front 19.018 – 19.034 —
(0.7487 – 0.7494)
Rear 13.957 – 13.984 —
(0.5495 – 0.5506)
Brake caliper cylinder bore Leading 30.280 – 30.356 —
(1.1921 – 1.1951)
Front
Trailing 34.010 – 34.086 —
(1.3390 – 1.3420)
Rear 38.180 – 38.230 —
(1.5031 – 1.5051)
Brake caliper piston diam Leading 30.150 – 30.200 —
(1.1870 – 1.1890)
Front
Trailing 33.884 – 33.934 —
(1.3340 – 1.3360)
Rear 38.080 – 38.130 —
(1.4992 – 1.5012)
Brake fluid type DOT 4 —

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 ITEM STANDARD LIMIT
Wheel rim runout Axial — 2.0
(0.08)
Radial — 2.0
(0.08)
Wheel rim size Front 17 M/C × MT 3.50 —
Rear 17 M/C × MT 6.00 —
Wheel axle runout Front — 0.25
(0.010)
Rear — 0.25
(0.010)

TIRE
ITEM STANDARD LIMIT
Cold inflation tire pressure Front 250 kPa —
(Solo riding) (2.50 kgf/cm², 36 psi)
Rear 290 kPa —
(2.90 kgf/cm², 42 psi)
Cold inflation tire pressure Front 250 kPa —
(Dual riding) (2.50 kgf/cm², 36 psi)
Rear 290 kPa —
(2.90 kgf/cm², 42 psi)
Tire size Front 120/70 ZR17 M/C (58 W) —
Rear 190/50 ZR17 M/C (73 W) —
Tire type E-02, 19 BRIDGESTONE: —
BT014F SJ
Front
Others BRIDGESTONE: —
BT014F J
E-02, 19 BRIDGESTONE: —
BT014R J
Rear
Others BRIDGESTONE: —
BT014R E
Tire tread depth Front — 1.6
(Recommended depth) (0.06)
Rear — 2.0
(0.08)

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 SUSPENSION Unit: mm (in)
ITEM STANDARD LIMIT
Front fork stroke 120 —
(4.92)
Front fork spring free length 230.0 225
(9.06) (8.86)
Front fork oil level (without spring, 101 —
outer tube fully compressed) (3.98)
Front fork oil type SUZUKI FORK OIL L01 or an equivalent fork oil —
Front fork oil capacity (each leg) 510 ml —
(17.2/17.9 US/Imp oz)
Front fork spring adjuster 4 th groove from top —
Front fork damping force adjuster Rebound 11 clicks out from stiffest position —
(For E-02, 19) Compression 16 clicks out from stiffest position —
Front fork damping force adjuster Rebound 9 clicks out from stiffest position —
(For E-03, 24, 28, 33) Compression 14 clicks out from stiffest position —
Rear shock absorber spring pre-set 177.6 —
length (6.99)
Rear shock absorber damping Rebound 12 clicks out from stiffest position —
force adjuster Compression 14 clicks out from stiffest position —
Rear wheel travel 130 —
(5.1)
Swingarm pivot shaft runout — 0.3
(0.01)

FUEL + OIL
ITEM SPECIFICATION NOTE
Fuel type Use only unleaded gasoline of at least 90 pump
octane (R/2 + M/2).
Gasoline containing MTBE (Methyl Tertiary Butyl
E-03, 28, 33
Ether), less than 10% ethanol, or less than 5%
methanol with appropriate cosolvents and corro-
sion inhibitor is permissible.
Gasoline used should be graded 95 octane or
Others
higher. An unleaded gasoline is recommended.
Fuel tank capacity 17.5 L E-33
Including (4.6/3.8 US/lmp gal)
reserve 18 L
(4.8/4.0 US/lmp gal) Others
Fuel level Approx. 4.5 L
indicator light (1.2/1.0 US/lmp gal)
lighting
Engine oil type SAE 10 W-40, API SF/SG or SH/SJ with JASO MA
Engine oil capacity Change 3.0 L
(3.2/2.6 US/lmp qt)
Filter change 3.3 L
(3.5/2.9 US/lmp qt)
Overhaul 3.6 L
(3.8/3.2 US/lmp qt)

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 BATTERY HOLDER CUSHION RUBBER INSTALLATION

Forward

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 13

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Downloaded from www.Manualslib.com manuals search engine
 Prepared by

2005
Part No. 99500-39271-03E
Printed in U.S.A.

543

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 Printed in USA
K5 K6

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