Suzuki GSX-R1000. Service Manual - part 4

 

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Suzuki GSX-R1000. Service Manual - part 4

 

 

0C-5 Service Data: 

FI Sensors

Item

Standard/Specification

Note

CKP sensor resistance

142 – 194 

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. 2.7 V at idle speed

TP sensor input voltage

4.5 – 5.5 V

TP sensor output voltage

Closed

Approx. 1.1 V

Opened

Approx. 4.4 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 k

 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. 2.58 k

 at 20 

°

C (68 

°

F)

AP sensor input voltage

4.5 – 5.5 V

AP sensor output voltage

Approx. 3.6 V at 100 kPa (760 mmHg)

TO sensor resistance

16.5 – 22.3 k

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

HO2 sensor output voltage

0.3 V and less at idle speed

0.6 V and more at 5 000 r/min

HO2 sensor heater resistance

6.7 – 9.5 

 at 23 

°

C (73 

°

F)

PAIR control solenoid valve 
resistance

20 – 24 

 at 20 – 30 

°

C (68 – 86 

°

F)

STP sensor input voltage

4.5 – 5.5 V

STP sensor output voltage

Closed

Approx. 0.7 V

Opened

Approx. 4.1 V

STVA resistance

Approx. 6.5 

EXCVA position sensor input 
voltage

4.5 – 5.5 V

EXCVA position sensor output 
voltage

Closed

0.45 – 1.4 V

Opened

3.6 – 4.55 V

EXCVA position sensor resistance

Approx. 3.1 k

At adjustment 

position

EVAP system purge control 
solenoid valve resistance

Approx. 32 

 at 20 

°

C (68 

°

F)

E-33 only

ISC valve resistance

Approx. 80 

 at 20 

°

C (68 

°

F)

Steering damper solenoid valve 
resistance

Approx. 12.5 

 at 20 

°

C (68 

°

F)

Steering damper solenoid valve 
voltage

Approx. 10 V

When battery fully 

charged

-------------------------------------------------------------------------------------------------------------------------------------------------------------

Service Data:  0C-6

Throttle Body

Electrical

Unit: mm

Item

Specification

Bore size

44 mm (1.73 in)

I.D. No.

47H1 (For E-33), 47H0 (For others)

Idle r/min

1 150 

±

 100 r/min

Throttle cable play

2.0 – 4.0 mm (0.08 – 0.16 in)

Item

Specification

Note

Firing order

 2 

 4 

 3

Spark plug

Type

NGK: CR9EIA-9

DENSO: IU27D

Gap

0.8 – 0.9 (0.031 – 0.035)

Spark performance

Over 8 (0.3) at 1 atm.

CKP sensor resistance

142 – 194 

CKP sensor peak voltage

0.5 V and more

When cranking

Ignition coil resistance

Primary

1.1 – 1.9 

Terminal – 

Terminal

Secondary

6.4 – 9.6 k

Plug cap – 

Terminal

Ignition coil primary peak voltage

80 V and more

When cranking

Generator coil resistance

0.12 – 0.6 

Generator maximum output

Approx. 375 W at 5 000 r/min

Generator no-load voltage (When 
engine is cold)

85 V (AC) and more at 5 000 r/min

Regulated voltage

14.0 – 15.5 V at 5 000 r/min

Starter motor brush length

Standard

7.0 (0.28)

Limit

3.5 (0.14)

Starter relay resistance

3 – 6 

Battery

Type designation

FT12A-BS

Capacity

12 V 36.0 kC (10 Ah)/10 HR

Fuse size

Headlight

HI

10 A

LO

10 A

Ignition

15 A

Signal

10 A

Fuel

10 A

Fan

15 A

Main

30 A

-------------------------------------------------------------------------------------------------------------------------------------------------------------

0C-7 Service Data: 

Wattage

Unit: W

Brake + Wheel

Unit: mm (in)

Tire

Item

Specification

E-02, 19, 24, 51

E-03, 14, 28, 33

Headlight

HI

65

LO

55

Position light

5 x 2

Brake light/Taillight

LED

Turn signal light

21 x 4

License plate light

5

Combination meter light

LED

Turn signal indicator light

LED

High beam indicator light

LED

Neutral position indicator light

LED

Oil pressure/Engine coolant temp. 
indicator light

LED

FI/Steering damper indicator light

LED

Fuel level indicator light

LED

Engine RPM indicator light

LED

Immobilizer indicator light

LED

Item

Standard

Limit

Rear brake pedal height

65 – 75 (2.6 – 3.0)

Brake disc thickness

Front

5.3 – 5.7 (0.21 – 0.22)

 5.0 (0.20)

Rear

4.8 – 5.2 (0.19 – 0.20)

 4.5 (0.18)

Brake disc runout

 0.30 (0.012)

Master cylinder bore

Front

17.460 – 17.503 (0.6874 – 0.6891)

Rear

14.000 – 14.043 (0.5512 – 0.5529)

Master cylinder piston diam.

Front

17.417 – 17.444 (0.6857 – 0.6868)

Rear

13.957 – 13.984 (0.5495 – 0.5506)

Brake caliper cylinder bore

Front

Leading 30.280 – 30.330 (1.1921 – 1.1941)

Trailing 32.080 – 32.130 (1.2630 – 1.2650)

Rear

30.230 – 30.280 (1.1902 – 1.1921)

Brake caliper piston diam.

Front

Leading 30.167 – 30.200 (1.1877 – 1.1890)

Trailing 31.967 – 32.000 (1.2585 – 1.2588)

Rear

30.148 – 3.0198 (1.1869 – 1.1889)

Brake fluid type

DOT 4

Wheel rim runout

Axial

2.0 (0.08)

Radial

Wheel rim size

Front

17 M/C x MT 3.50

Rear

17 M/C x MT 6.00

Wheel axle runout

Front

 0.25 (0.010)

Rear

Item

Standard

Limit

Cold inflation tire pressure
(Solo riding)

Front

250 kPa (2.50 kgf/cm

2

, 36 psi)

Rear

290 kPa (2.90 kgf/cm

2

, 42 psi)

Cold inflation tire pressure
(Dual riding)

Front

250 kPa (2.50 kgf/cm

2

, 36 psi)

Rear

290 kPa (2.90 kgf/cm

2

, 42 psi)

Tire size

Front

120/70 ZR17M/C (58 W)

Rear

190/50 ZR17M/C (73 W)

Tire type

Front

BRIDGESTONE BT016F N

Rear

BRIDGESTONE BT016R N

Tire tread depth 
(Recommended depth)

Front

1.6 mm (0.06 in)

Rear

2.0 mm (0.08 in)

-------------------------------------------------------------------------------------------------------------------------------------------------------------

Service Data:  0C-8

Suspension

Unit: mm (in)

Fuel + Oil

Item

Standard

Limit

Front fork stroke

125 (4.9)

Front fork spring free length

241 (9.49)

236 (9.29)

Front fork oil level (Without spring, 
outer tube fully compressed)

75 (2.95)

70 (2.76) 10 min. after adjustment

Front fork oil type

SUZUKI FORK OIL SS-05 or an equivalent fork oil

Front fork oil capacity (Each leg)

476 ml (16.1/16.8 US/lmp oz)

Front fork inner tube O.D.

43 (1.7)

Front fork spring adjuster

4 turns in from softest position

Front fork damping force adjuster

Rebound

4 turns out from stiffest position

Compression

5 turns from stiffest position

Rear shock absorber spring pre-set 
length

184.3 (7.26)

Rear shock absorber damping force 
adjuster

Rebound

2-3/4 turns from stiffed position

Compression

Lo: 2-1/4 turns from stiffest position

Hi: 3 turns from stiffest position

Rear wheel travel

130 (5.12)

Swingarm pivot shaft runout

0.3 (0.01)

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 Ether), less 
than 10% ethanol, or less than 5% methanol with 
appropriate cosolvents and corrosion inhibitor is permissible.

E-03, 14, 28, 33

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

E-02, 19, 24, 51

Fuel tank capacity

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

Fuel level 

indicator light 

lighting

Approx. 3.5 L (0.9/0.8 US/lmp gal)

Engine oil type

SAE 10W-40, API SF/SG or SH/SJ with JASO MA

Engine oil capacity

Change

2 800 ml (3.0/2.5 US/lmp qt)

Filter change

3 300 ml (3.5/2.9 US/lmp qt)

Overhaul

3 600 ml (3.8/3.2 US/lmp qt)

-------------------------------------------------------------------------------------------------------------------------------------------------------------

0C-9 Service Data: 

Tightening Torque List

B947H10307002

Engine

Item

N

m

kgf-m

lbf-ft

Exhaust pipe bolt

23

2.3

16.5

Muffler chamber connecting bolt

30

3.0

21.5

Muffler chamber bracket bolt

25

2.5

18.0

Muffler chamber mounting bolt

23

2.3

16.5

Muffler connecting bolt

23

2.3

16.5

Muffler mounting bolt

25

2.5

18.0

Speed sensor rotor bolt

28

2.8

20.0

Speed sensor mounting bolt

6.5

0.65

4.5

Engine sprocket nut

145

14.5

105.0

Engine mounting bolt (Cylinder)

55

5.5

39.8

Engine mounting nut (Crankcase)

75

7.5

54.0

Engine mounting thrust adjuster

23

2.3

16.5

Engine mounting thrust adjuster lock-nut

45

4.5

32.5

Engine mounting pinch bolt

23

2.3

16.5

Cylinder head cover bolt

Initial

10

1.0

7.0

Final

14

1.4

10.0

PAIR reed valve cover bolt

10

1.0

7.0

Spark plug

11

1.1

8.0

Cam chain guide No. 2 bolt

10

1.0

7.0

Cam chain guide No. 1 bolt

23

2.3

16.5

Camshaft journal holder bolt

10

1.0

7.0

Cam chain tension adjuster service cap

23

2.3

16.5

Cam chain tension adjuster mounting bolt

10

1.0

7.0

Cam chain tensioner bolt

23

2.3

16.5

Cylinder head bolt

[M10]

31 N

m (3.1 kgf-m, 22.5 lbf-ft) then turn in 1/6 

(60

°

) turn

[M6]

10

1.0

7.0

Water jacket plug

9.5

0.95

6.9

Clutch cover bolt

10

1.0

7.0

Clutch sleeve hub nut

95

9.5

68.5

Clutch spring set bolt

10

1.0

7.0

Clutch release adjuster cap

11

1.1

8.0

Clutch release adjusting screw lock-nut

6

0.6

4.5

Clutch lifter pin lock-nut

23

2.3

16.5

Valve timing inspection cap

11

1.1

8.0

Starter clutch bolt

54

5.4

39.0

Generator cover bolt

10

1.0

7.0

Generator rotor bolt

145

14.5

105.0

Generator stator set bolt

11

1.1

8.0

Generator lead wire set bolt

5.5

0.55

4.0

Oil pressure switch

14

1.4

10.0

Oil pressure switch lead wire screw

1.5

0.15

1.0

Oil filter

20

2.0

14.5

Crankshaft journal bolt

[M9]

18 N

m (1.8 kgf-m, 13.0 lbf-ft) then turn in 50

°

Crankcase bolt

[M6]

12

1.2

8.5

[M8]

Initial

15

1.5

11.0

Final

26

2.6

19.0

Oil gallery plug

Cylinder head

10

1.0

7.0

[M6]

10

1.0

7.0

[M10]

18

1.8

13.0

[M12]

15

1.5

11.0

[M26]

11

1.1

8.0

Oil drain plug

23

2.3

16.5

Piston cooling oil jet bolt

10

1.0

7.0

Oil pump mounting bolt

10

1.0

7.0

Oil pump driven sprocket bolt

10

1.0

7.0

-------------------------------------------------------------------------------------------------------------------------------------------------------------

Service Data:  0C-10

FI System + Intake Air System

Cooling System

Conrod cap bolt

37 N

m (3.7 kgf-m, 26.5 lbf-ft) then turn in 1/6 

(60

°

) turn

Breather cover bolt

10

1.0

7.0

Oil pan bolt

10

1.0

7.0

Oil cooler mounting bolt

10

1.0

7.0

Driveshaft bearing case bolt (LH and RH)

12

1.2 

8.7

Driveshaft oil seal retainer screw

12

1.2 

8.7

Gearshift arm stopper

19

1.9

13.5

Gearshift cam stopper bolt

10

1.0

7.0

Gearshift cam plate bolt

13

1.3 

9.5

Gearshift cam bearing retainer screw

10

1.0 

7.0

Gearshift shaft end screw

8.5

0.85 

6.0

GP switch mounting bolt

6.5

0.65 

4.5

Starter motor mounting bolt

10

1.0 

7.0

Starter motor lead wire mounting bolt

3

0.3

2.0

Starter motor housing bolt

5

0.5

3.5

Regulator/rectifier mounting bolt

10

1.0 

7.0

Intake pipe bolt

8.5

0.85

6.5

Bypass hose union

12

1.2 

8.5

Item

N

m

kgf-m

lbf-ft

CMP sensor bolt

10

1.0 

7.0

TP sensor mounting screw

3.5

0.35 

2.5

STP sensor mounting screw

3.5

0.35

2.5

ISC valve mounting screw

2

0.2 

1.5

CKP sensor mounting bolt

6.5

0.65

4.5

HO2 sensor

25

2.5 

18.0

Fuel delivery pipe mounting screw

3.5

0.35

2.5

Fuel pump mounting bolt

10

1.0 

7.0

EXCVA pulley mounting bolt

5

0.5 

3.5

IAT sensor mounting screw

1.3

0.13 

1.0

EVAP system purge control solenoid valve mounting nut (E-33 only)

6.5

0.65

4.5

EVAP system purge control solenoid valve bracket bolt (E-33 only)

10

1.0 

7.0

Item

N

m

kgf-m

lbf-ft

Impeller securing bolt

8

0.8

6.0

Water pump case screw

6

0.6

4.5

Water pump mounting bolt

10

1.0

7.0

ECT sensor

18

1.8 

13.0

Thermostat cover bolt

10

1.0

7.0

Water inlet connector bolt

10

1.0

7.0

Water pump air bleeder bolt

13

1.3

9.5

Item

N

m

kgf-m

lbf-ft

-------------------------------------------------------------------------------------------------------------------------------------------------------------

0C-11 Service Data: 

Chassis

Item

N

m

kgf-m

lbf-ft

Steering stem head nut

90

9.0

65.0

Steering stem lock-nut

80

8.0

58.0

Steering damper bolt

23

2.3

16.5

Steering damper nut

23

2.3

16.5

Front fork clamp bolt (Upper and Lower)

23

2.3

16.5

Front fork cap

35

3.5

25.5

Front fork piston rod nut

28

2.8

20.0

Rod guide case

90

9.0

65.0

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 holder bolt (Upper and Lower)

10

1.0

7.0

Front brake caliper mounting bolt

39

3.9

28.0

Front brake pad mounting pin

15

1.5

11.0

Brake hose union bolt

23

2.3

16.5

Air bleeder valve (Front caliper)

7.5

0.75

5.5

Air bleeder valve (Rear caliper)

6

0.6

4.5

Air bleeder valve (Front master cylinder)

6

0.6

4.5

Brake disc bolt (Front)

18

1.8

13.0

Brake disc bolt (Rear)

35

3.5

25.5

Rear brake pad mounting pin

17

1.7

12.5

Rear brake pad mounting pin plug

2.5

0.25

2.0

Rear brake master cylinder mounting bolt

10

1.0

7.0

Rear brake master cylinder rod lock-nut

17

1.7

12.5

Rear brake caliper sliding pin A

27

2.7

19.5

Rear brake caliper sliding pin B

12

1.2

8.5

Brake lever pivot bolt

1

0.1

0.7

Brake lever pivot bolt lock-nut

6

0.6

4.5

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

98

9.8

71.0

Cushion rod mounting nut (Front and Rear)

98

9.8

71.0

Rear shock absorber bracket nut

115

11.5

83.0

Rear shock absorber mounting nut (Upper and Lower)

50

5.0

36.0

Rear axle nut

100

10.0

72.5

Rear sprocket nut

60

6.0

43.0

Rear combination light mounting bolt

2.8

0.28

2.0

License plate light mounting nut

5

0.5

3.5

Side-stand nut

40

4.0

29.0

Side-stand bolt

50

5.0

36.0

Side-stand bracket mounting bolt

50

5.0

36.0

Bank sensor bolt

18

1.8

13.0

Footrest bracket bolt

23

2.3

16.5

Footrest guard screw

4.5

0.45

3.0

Footrest holder bolt

35

3.5

25.5

Seat rail mounting bolt

50

5.0

36.0

Cowling brace mounting bolt

23

2.3

16.5

Rear view mirror mounting nut

10

1.0

7.0

-------------------------------------------------------------------------------------------------------------------------------------------------------------

Service Data:  0C-12

Tightening Torque Chart

For other bolts and nuts not listed in the preceding page, refer to this chart:

Bolt Diameter 

“a” (mm)

Conventional or “4” marked bolt

“7” marked bolt

N

m

kgf-m

lbf-ft

N

m

kgf-m

lbf-ft

4

1.5

0.15

1.0

2.3

0.23

1.5

5

3

0.3

2.0

4.5

0.45

3.0

6

5.5

0.55

4.0

10

1.0

7.0

8

13

1.3

9.5

23

2.3

16.5

10

29

2.9

21.0

50

5.0

36.0

12

45

4.5

32.5

85

8.5

61.5

14

65

6.5

47.0

135

13.5

97.5

16

105

10.5

76.0

210

21.0

152.0

18

160

16.0

115.5

240

24.0

173.5

3

2

1

“ a ”

“ a ”

“ a ”

I649G1030001-04

1. Conventional bolt

2. “4” marked bolt

3. “7” marked bolt

-------------------------------------------------------------------------------------------------------------------------------------------------------------

0C-13 Service Data: 

-------------------------------------------------------------------------------------------------------------------------------------------------------------

Table of Contents 1- i

1

Section 1

CONTENTS

Engine

Precautions .................................................1-1

Precautions............................................................. 1-1

Precautions for Engine.......................................... 1-1

Engine General Information and 
Diagnosis ................................................. 1A-1

General Description .............................................1A-1

Injection Timing Description ................................ 1A-1
Self-Diagnosis Function ...................................... 1A-3

Schematic and Routing Diagram........................1A-4

FI System Wiring Diagram .................................. 1A-4
Terminal Alignment of ECM Coupler................... 1A-6

Component Location ...........................................1A-7

FI System Parts Location .................................... 1A-7

Diagnostic Information and Procedures............1A-8

Engine Symptom Diagnosis ................................ 1A-8
Self-Diagnostic Procedures .............................. 1A-12
Use of SDS Diagnosis Reset Procedures......... 1A-14
Show Data When Trouble (Displaying Data at 

the Time of DTC) ............................................ 1A-15

SDS Check ....................................................... 1A-16
DTC Table......................................................... 1A-20
Fail-Safe Function Table ................................... 1A-22
FI System Troubleshooting ............................... 1A-23
Malfunction Code and Defective Condition 

Table ............................................................... 1A-25

DTC “C11” (P0340): CMP Sensor Circuit 

Malfunction...................................................... 1A-29

DTC “C12” (P0335): CKP Sensor Circuit 

Malfunction...................................................... 1A-32

DTC “C13” (P0105-H/L): IAP Sensor Circuit 

Malfunction...................................................... 1A-35

DTC “C14” (P0120-H/L): TP Sensor Circuit 

Malfunction...................................................... 1A-43

DTC “C15” (P0115-H/L): ECT Sensor Circuit 

Malfunction...................................................... 1A-50

DTC “C21” (P0110-H/L): IAT Sensor Circuit 

Malfunction...................................................... 1A-55

DTC “C22” (P1450-H/L): AP Sensor Circuit 

Malfunction...................................................... 1A-60

DTC “C23” (P1651-H/L): TO Sensor Circuit 

Malfunction...................................................... 1A-68

DTC “C24” (P0351), “C25” (P0352), “C26” 

(P0353) or “C27” (P0354): Ignition System 
Malfunction......................................................1A-75

DTC “C28” (P1655): Secondary Throttle 

Valve Actuator (STVA) Malfunction.................1A-75

DTC “C29” (P1654-H/L): Secondary Throttle 

Position Sensor (STPS) Circuit Malfunction....1A-79

DTC “C31” (P0705): GP Switch Circuit 

Malfunction......................................................1A-86

DTC “C32” (P0201), “C33” (P0202), “C34” 

(P0203) or “C35” (P0204): Primary Fuel 
Injector Circuit Malfunction..............................1A-88

DTC “C36” (P1764), “C37” (P1765), “C38” 

(P1766) or “C39” (P1767): Secondary Fuel 
Injector Circuit Malfunction..............................1A-91

DTC “C40” (P0505 / P0506 / P0507): ISC 

Valve Circuit Malfunction.................................1A-94

DTC “C41” (P0230-H/L): FP Relay Circuit 

Malfunction......................................................1A-98

DTC “C41” (P2505): ECM Power Input Signal 

Malfunction....................................................1A-101

DTC “C42” (P1650): IG Switch Circuit 

Malfunction....................................................1A-103

DTC “C44” (P0130/P0135): HO2 Sensor 

(HO2S) Circuit Malfunction ...........................1A-103

DTC “C46” (P1657-H/L or P1658): EXCV 

Actuator Circuit Malfunction ..........................1A-109

DTC “C49” (P1656): PAIR Control Solenoid 

Valve Circuit Malfunction...............................1A-121

DTC “C60” (P0480): Cooling Fan Relay 

Circuit Malfunction.........................................1A-124

DTC “C62” (P0443): EVAP System Purge 

Control Solenoid Valve Circuit Malfunction 
(E-33 only).....................................................1A-127

DTC “C91” (P0500): Vehicle Speed Sensor 

Circuit Malfunction.........................................1A-131

DTC “C93” (P1769): Steering Damper 

Solenoid Valve Circuit Malfunction................1A-134

Specifications ...................................................1A-138

Service Data....................................................1A-138

Special Tools and Equipment .........................1A-139

Special Tool ....................................................1A-139

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1-ii Table of Contents

Emission Control Devices ...................... 1B-1

Precautions...........................................................1B-1

Precautions for Emission Control Devices .......... 1B-1

General Description .............................................1B-1

Fuel Injection System Description....................... 1B-1
Crankcase Emission Control System 

Description ........................................................ 1B-2

Exhaust Emission Control System 

Description ........................................................ 1B-3

PAIR System Diagram ........................................ 1B-4
Noise Emission Control System Description....... 1B-4
Evaporative Emission Control System 

Diagram (Only for E-33) .................................... 1B-5

Schematic and Routing Diagram ........................1B-6

PAIR System Hose Routing Diagram ................. 1B-6
EVAP Canister Hose Routing Diagram (Only 

for E-33) ............................................................ 1B-7

Repair Instructions ..............................................1B-8

Heated Oxygen Sensor (HO2S) Removal and 

Installation ......................................................... 1B-8

Heated Oxygen Sensor (HO2S) Inspection ........ 1B-8
PAIR Reed Valve Removal and Installation........ 1B-8
PAIR Control Solenoid Valve Removal and 

Installation ......................................................... 1B-9

PAIR System Inspection ..................................... 1B-9
Crankcase Breather (PCV) Hose Inspection..... 1B-11
Crankcase Breather (PCV) Hose / Reed 

Valve / Cover Removal and Installation .......... 1B-11

Crankcase Breather (PCV) Cover Inspection ... 1B-12
Evaporative Emission Control System 

Removal and Installation (Only for E-33) ........ 1B-12

Evaporative Emission Control System 

Inspection (Only for E-33) ............................... 1B-14

Specifications.....................................................1B-16

Service Data...................................................... 1B-16
Tightening Torque Specifications...................... 1B-16

Special Tools and Equipment ...........................1B-16

Recommended Service Material ....................... 1B-16
Special Tool ...................................................... 1B-16

Engine Electrical Devices ....................... 1C-1

Precautions...........................................................1C-1

Precautions for Engine Electrical Device ............1C-1

Component Location ...........................................1C-1

Engine Electrical Components Location .............1C-1

Diagnostic Information and Procedures ............1C-1

Engine Symptom Diagnosis ................................1C-1

Repair Instructions ..............................................1C-1

ECM Removal and Installation............................1C-1
CMP Sensor Inspection ......................................1C-2
CMP Sensor Removal and Installation ...............1C-2
CKP Sensor Inspection .......................................1C-2
CKP Sensor Removal and Installation ................1C-2
IAP Sensor Inspection.........................................1C-2
IAP Sensor Removal and Installation..................1C-2
TP Sensor Inspection..........................................1C-2
TP Sensor Removal and Installation...................1C-3
TP Sensor Adjustment ........................................1C-3
ECT Sensor Removal and Installation ................1C-4

ECT Sensor Inspection .......................................1C-4
IAT Sensor Removal and Installation ..................1C-5
IAT Sensor Inspection .........................................1C-5
AP Sensor Inspection..........................................1C-5
AP Sensor Removal and Installation...................1C-5
TO Sensor Inspection .........................................1C-5
TO Sensor Removal and Installation ..................1C-6
STP Sensor Inspection .......................................1C-6
STP Sensor Adjustment ......................................1C-6
STP Sensor Removal and Installation ................1C-7
STV Actuator Inspection .....................................1C-7
STV Actuator Removal and Installation ..............1C-7
ISC Valve Inspection ...........................................1C-7
ISC Valve Removal and Installation ....................1C-7
ISC Valve Preset and Opening Initialization .......1C-8
HO2 Sensor Inspection .......................................1C-8
HO2 Sensor Removal and Installation ................1C-8
GP Switch Inspection ..........................................1C-8
GP Switch Removal and Installation ...................1C-8

Specifications .......................................................1C-9

Service Data........................................................1C-9
Tightening Torque Specifications ........................1C-9

Special Tools and Equipment ...........................1C-10

Special Tool ......................................................1C-10

Engine Mechanical .................................. 1D-1

Schematic and Routing Diagram ........................1D-1

Camshaft and Sprocket Assembly Diagram .......1D-1
Throttle Cable Routing Diagram..........................1D-2

Diagnostic Information and Procedures ............1D-3

Engine Mechanical Symptom Diagnosis .............1D-3
Compression Pressure Check ............................1D-3

Repair Instructions ..............................................1D-4

Engine Components Removable with the 

Engine in Place .................................................1D-4

Air Cleaner Element Removal and Installation ....1D-6
Air Cleaner Box Removal and Installation...........1D-7
Air Cleaner Element Inspection and Cleaning ....1D-7
Throttle Cable Removal and Installation .............1D-7
Throttle Cable Inspection ....................................1D-7
Throttle Cable Play Inspection and 

Adjustment ........................................................1D-7

Throttle Body Components .................................1D-8
Throttle Body Construction..................................1D-9
Throttle Body Removal and Installation ............1D-10
Throttle Body Disassembly and Assembly ........1D-11
Throttle Body Inspection and Cleaning .............1D-16
ISC Valve Visual Inspection ..............................1D-16
Throttle Valve Synchronization .........................1D-16
ISC Valve Reset ................................................1D-18
TP Reset ...........................................................1D-19
Engine Assembly Removal ...............................1D-20
Engine Assembly Installation ............................1D-24
Engine Top Side Disassembly ..........................1D-26
Engine Top Side Assembly ...............................1D-28
Cylinder Head Cover Disassembly and 

Assembly.........................................................1D-35

Cylinder Head Cover Related Parts 

Inspection........................................................1D-36

-------------------------------------------------------------------------------------------------------------------------------------------------------------

Table of Contents 1-iii

Camshaft Inspection .........................................1D-36
Camshaft Sprocket ...........................................1D-38
Cam Chain Tension Adjuster Inspection...........1D-38
Cam Chain Guide / Cam Chain Tensioner 

Removal and Installation.................................1D-39

Cam Chain Guide Inspection ............................1D-40
Cam Chain Tensioner Inspection......................1D-40
Cylinder Head Disassembly and Assembly ......1D-40
Cylinder Head Related Parts Inspection ...........1D-44
Valve Guide Replacement ................................1D-47
Valve Seat Repair .............................................1D-49
Engine Bottom Side Disassembly .....................1D-49
Engine Bottom Side Assembly..........................1D-56
Cylinder Inspection ...........................................1D-69
Piston Ring Removal and Installation ...............1D-69
Piston and Piston Ring Inspection ....................1D-71
Balancer Shaft Disassembly and Assembly......1D-73
Balancer Shaft Inspection .................................1D-73
Balancer Shaft Journal Bearing Removal and 

Installation .......................................................1D-74

Balancer Shaft Journal Bearing Inspection 

and Selection ..................................................1D-75

Conrod Crank Pin Bearing Removal and 

Installation .......................................................1D-76

Conrod and Crankshaft Inspection ...................1D-77
Conrod Crank Pin Bearing Inspection and 

Selection .........................................................1D-78

Crankshaft Journal Bearing Inspection and 

Selection .........................................................1D-79

Crankshaft Thrust Clearance Inspection and 

Selection .........................................................1D-82

Specifications.....................................................1D-84

Service Data .....................................................1D-84
Tightening Torque Specifications......................1D-86

Special Tools and Equipment ...........................1D-87

Recommended Service Material .......................1D-87
Special Tool ......................................................1D-88

Engine Lubrication System .................... 1E-1

Precautions........................................................... 1E-1

Precautions for Engine Oil .................................. 1E-1

Schematic and Routing Diagram........................ 1E-2

Engine Lubrication System Chart Diagram ......... 1E-2
Engine Lubrication Circuit Diagram..................... 1E-3

Diagnostic Information and Procedures............ 1E-5

Engine Lubrication Symptom Diagnosis ............. 1E-5
Oil Pressure Check ............................................. 1E-5

Repair Instructions .............................................. 1E-6

Engine Oil and Filter Replacement ..................... 1E-6
Engine Oil Level Inspection ................................ 1E-6
Oil Pan / Oil Pressure Regulator / Oil Strainer 

Removal and Installation................................... 1E-6

Oil Pressure Regulator / Oil Strainer 

Inspection.......................................................... 1E-7

Oil Cooler / Oil Cooler Hose Inspection and 

Cleaning ............................................................ 1E-7

Oil Cooler / Oil Cooler Hose Removal and 

Installation ......................................................... 1E-8

Oil Pressure Switch Removal and Installation .... 1E-9

Oil Pressure Switch Inspection .........................1E-10
Oil Jet Removal and Installation........................1E-10
Oil Jet Inspection...............................................1E-12
Oil Pump Removal and Installation ...................1E-12
Oil Pump Inspection ..........................................1E-14
Oil Pump Drive Sprocket Removal and 

Installation .......................................................1E-14

Specifications .....................................................1E-14

Service Data......................................................1E-14
Tightening Torque Specifications......................1E-14

Special Tools and Equipment ...........................1E-15

Recommended Service Material .......................1E-15
Special Tool ......................................................1E-15

Engine Cooling System ...........................1F-1

Precautions........................................................... 1F-1

Precautions for Engine Cooling System.............. 1F-1
Precautions for Engine Coolant .......................... 1F-1

General Description ............................................. 1F-1

Engine Coolant Description................................. 1F-1

Schematic and Routing Diagram ........................ 1F-2

Cooling Circuit Diagram ...................................... 1F-2
Water Hose Routing Diagram ............................. 1F-3

Diagnostic Information and Procedures ............ 1F-4

Engine Cooling Symptom Diagnosis................... 1F-4

Repair Instructions .............................................. 1F-4

Cooling Circuit Inspection ................................... 1F-4
Radiator Cap Inspection...................................... 1F-5
Radiator Inspection and Cleaning ....................... 1F-5
Radiator / Cooling Fan Motor Removal and 

Installation ......................................................... 1F-6

Water Hose Inspection........................................ 1F-7
Water Hose Removal and Installation................. 1F-8
Radiator Reservoir Tank Inspection.................... 1F-8
Radiator Reservoir Tank Removal and 

Installation ......................................................... 1F-8

Cooling Fan Inspection ....................................... 1F-9
Cooling Fan Relay Inspection ............................. 1F-9
ECT Sensor Removal and Installation .............. 1F-10
ECT Sensor Inspection ..................................... 1F-10
Thermostat Removal and Installation................ 1F-10
Thermostat Inspection....................................... 1F-11
Water Pump Components................................. 1F-12
Water Pump Construction ................................. 1F-13
Water Pump Removal and Installation.............. 1F-13
Water Pump Disassembly and Assembly ......... 1F-14
Water Pump Related Parts Inspection .............. 1F-17

Specifications ..................................................... 1F-18

Service Data...................................................... 1F-18
Tightening Torque Specifications...................... 1F-19

Special Tools and Equipment ........................... 1F-19

Recommended Service Material ....................... 1F-19
Special Tool ...................................................... 1F-19

Fuel System ............................................. 1G-1

Precautions.......................................................... 1G-1

Precautions for Fuel System .............................. 1G-1

General Description ............................................ 1G-2

Fuel Injection System Description...................... 1G-2

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1-iv Table of Contents

Schematic and Routing Diagram ....................... 1G-3

Fuel Tank Drain Hose and Breather Hose 

Routing Diagram .............................................. 1G-3

Diagnostic Information and Procedures ........... 1G-4

Fuel System Diagnosis ...................................... 1G-4

Repair Instructions ............................................. 1G-5

Fuel Pressure Inspection ................................... 1G-5
Fuel Pump Inspection ........................................ 1G-6
Fuel Discharge Amount Inspection .................... 1G-6
Fuel Pump Relay Inspection .............................. 1G-7
Fuel Hose Inspection ......................................... 1G-7
Fuel Level Gauge Inspection ............................. 1G-7
Fuel Tank Construction ...................................... 1G-8
Fuel Tank Removal and Installation................... 1G-9
Fuel Pump Components .................................. 1G-10
Fuel Pump Disassembly and Assembly........... 1G-11
Fuel Mesh Filter Inspection and Cleaning........ 1G-13
Fuel Injector / Fuel Delivery Pipe / T-joint 

Removal and Installation................................ 1G-13

Fuel Injector Inspection and Cleaning.............. 1G-13

Specifications.................................................... 1G-14

Service Data..................................................... 1G-14
Tightening Torque Specifications..................... 1G-14

Special Tools and Equipment .......................... 1G-15

Recommended Service Material ...................... 1G-15
Special Tool ..................................................... 1G-15

Ignition System........................................ 1H-1

General Description .............................................1H-1

Immobilizer Description (For E-02, 19, 24, 51) ....1H-1
Drive Mode Selector Description.........................1H-2

Schematic and Routing Diagram ........................1H-3

Ignition System Diagram .....................................1H-3
Ignition System Components Location................1H-3

Diagnostic Information and Procedures ............1H-4

Ignition System Symptom Diagnosis...................1H-4
No Spark or Poor Spark ......................................1H-5

Repair Instructions ..............................................1H-6

Ignition Coil and Spark Plug Removal and 

Installation .........................................................1H-6

Spark Plug Inspection and Cleaning ...................1H-7
Ignition Coil Inspection ........................................1H-7
CKP Sensor Inspection .......................................1H-9
CKP Sensor Removal and Installation ..............1H-10
Engine Stop Switch Inspection..........................1H-10
Ignition Switch Inspection..................................1H-10
Ignition Switch Removal and Installation...........1H-11
Drive Mode Selector Inspection ........................1H-12

Specifications.....................................................1H-13

Service Data......................................................1H-13
Tightening Torque Specifications......................1H-13

Special Tools and Equipment ...........................1H-14

Recommended Service Material .......................1H-14
Special Tool ......................................................1H-14

Starting System ......................................... 1I-1

Schematic and Routing Diagram ......................... 1I-1

Starting System Diagram ..................................... 1I-1

Component Location ............................................ 1I-1

Starting System Components Location ................ 1I-1

Diagnostic Information and Procedures ............. 1I-1

Starting System Symptom Diagnosis ................... 1I-1
Starter Motor Will Not Run ................................... 1I-2
Starter Motor Runs But Does Not Crank The 

Engine ................................................................ 1I-2

Repair Instructions ............................................... 1I-3

Starter Motor Components ................................... 1I-3
Starter Motor Removal and Installation ................ 1I-4
Starter Motor Disassembly and Assembly ........... 1I-4
Starter Motor Inspection ....................................... 1I-5
Starter Relay Removal and Installation ................ 1I-6
Starter Relay Inspection ....................................... 1I-6
Turn Signal / Side-stand Relay Removal and 

Installation .......................................................... 1I-7

Side-stand / Ignition Interlock System Parts 

Inspection........................................................... 1I-7

Starter Torque Limiter Removal and 

Installation .......................................................... 1I-9

Starter Torque Limiter Inspection ....................... 1I-10
Starter Clutch Removal and Installation ............. 1I-10
Starter Clutch Inspection .................................... 1I-11
Starter Button Inspection.................................... 1I-12

Specifications ...................................................... 1I-12

Service Data....................................................... 1I-12
Tightening Torque Specifications ....................... 1I-12

Special Tools and Equipment ............................ 1I-13

Recommended Service Material ........................ 1I-13
Special Tool ....................................................... 1I-13

Charging System ...................................... 1J-1

Schematic and Routing Diagram ........................ 1J-1

Charging System Diagram .................................. 1J-1

Component Location ........................................... 1J-1

Charging System Components Location............. 1J-1

Diagnostic Information and Procedures ............ 1J-1

Charging System Symptom Diagnosis................ 1J-1
Battery Runs Down Quickly ................................ 1J-2

Repair Instructions .............................................. 1J-3

Battery Current Leakage Inspection.................... 1J-3
Regulated Voltage Inspection ............................. 1J-3
Generator Inspection........................................... 1J-3
Generator Removal and Installation.................... 1J-4
Regulator / Rectifier Construction ....................... 1J-7
Regulator / Rectifier Removal and Installation .... 1J-7
Regulator / Rectifier Inspection ........................... 1J-8
Battery Components ........................................... 1J-9
Battery Charging ................................................. 1J-9
Battery Removal and Installation ...................... 1J-11
Battery Visual Inspection................................... 1J-12

Specifications ..................................................... 1J-12

Service Data...................................................... 1J-12
Tightening Torque Specifications ...................... 1J-12

Special Tools and Equipment ........................... 1J-13

Recommended Service Material ....................... 1J-13
Special Tool ...................................................... 1J-13

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Table of Contents 1-v

Exhaust System....................................... 1K-1

Precautions...........................................................1K-1

Precautions for Exhaust System ......................... 1K-1

General Description .............................................1K-1

Exhaust Control System Description................... 1K-1
Exhaust Control System Operation..................... 1K-2

Repair Instructions ..............................................1K-4

Exhaust Control System Construction ................ 1K-4
Exhaust System Components............................. 1K-5
EXCV Cable Removal and Installation................ 1K-6
EXCVA Removal and Installation ....................... 1K-7
EXCVA Inspection .............................................. 1K-9

EXCVA Pulley Inspection....................................1K-9
EXCVA Adjustment .............................................1K-9
Muffler / Muffler Chamber / Exhaust Pipe 

Removal and Installation.................................1K-11

Exhaust System Inspection...............................1K-13

Specifications .....................................................1K-14

Service Data......................................................1K-14
Tightening Torque Specifications......................1K-14

Special Tools and Equipment ...........................1K-15

Recommended Service Material .......................1K-15
Special Tool ......................................................1K-15

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1-1 Precautions: 

Engine

Precautions

Precautions

Precautions for Engine

B947H11000001

Refer to “General Precautions” in Section 00 (Page 00-1) and “Precautions for Electrical Circuit Service” in Section 00 
(Page 00-2)
.

-------------------------------------------------------------------------------------------------------------------------------------------------------------

Engine General Information and Diagnosis:  1A-1

Engine

Engine General Information and Diagnosis

General Description

Injection Timing Description

B947H11101001

Injection Time (Injection Volume)

The factors to determine the injection time include the basic fuel injection time, which is calculated on the basis of the 
intake air pressure, engine speed and throttle opening angle, and various compensations. These compensations are 
determined according to the signals from various sensors that detect the engine and driving conditions.

I947H1110126-02

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