Suzuki GSX-R1000. Service Manual

1K-9 Exhaust System:

Installation

Install the EXCVA in the reverse order of removal. Pay
attention to the following points:

• Install the EXCVA pulley to the shaft.

NOTE

Align the shaft’s line “A” and cable slots “B”.

• Hold the pulley with an adjustable wrench, and then

tighten the pulley mounting bolt (1) to the specified
torque.

Tightening torque
EXCVA pulley mounting bolt (a): 5 N·m (0.5 kgf-
m, 3.5 lbf-ft)

CAUTION

When loosening or tightening the pulley bolt,
be sure to fix the pulley with an adjustable
wrench, or EXCVA may get damaged.

• Install the EXCV cables. Refer to “EXCV Cable

Removal and Installation” (Page 1K-6).

• Adjust the EXCVA. Refer to “EXCVA Adjustment”

(Page 1K-9).

EXCVA Inspection

B947H11B06005

Refer to “DTC “C46” (P1657-H/L or P1658): EXCV
Actuator Circuit Malfunction” in Section 1A (Page 1A-
109).

EXCVA Pulley Inspection

B947H11B06006

Inspect the EXCVA pulley in the following procedures:

1) Remove the EXCVA pulley. Refer to “EXCV Cable

Removal and Installation” (Page 1K-6).

2) Visually inspect the EXCVA pulley for wear and

damage. If there is anything unusual, replace the
pulley with a new one.

3) Install the pulley and EXCVA. Refer to “EXCVA

Removal and Installation” (Page 1K-7).

EXCVA Adjustment

B947H11B06007

Inspect the EXCVA operation and adjust it if necessary
in the following steps:

Step 1

1) Set the EXCVA to the adjustment position. Refer to

“EXCV Cable Removal and Installation” (Page 1K-
6).

Step 2

1) Turn the ignition switch OFF.

2) Turn the mode select switch OFF.

3) Turn the ignition switch ON and check the operation

of EXCVA.
(EXCVA operation order: Full close

→

Full open

→

Approx. 60% open)

“A”

“B”

I823H11B0017-02

(a)

I947H11B0039-01

I823H11B0021-01

I947H11B0018-01

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Exhaust System: 1K-10

4) Turn the mode select switch ON. If DTC “C46” is not

indicated on the LCD display, the adjustment is
correctly completed. If “C46” is indicated, repeat the
procedures from Step 3 to Step 4.

Step 3

1) Turn the ignition switch OFF.

2) Set up the SDS tools. Refer to “Self-Diagnostic

Procedures” in Section 1A (Page 1A-12).

3) Turn the ignition switch ON.

4) Click “Exhaust valve operating control” (1).

5) Click “Full closed” (2).

6) Insert the needle pointed probes into the back side

of the EXCVA coupler (3). ((+) Y – (–) W)

7) Measure the EXCVA position sensor output voltage

at EXCV fully closed position.

Special tool

(A): 09900–25008 (Multi circuit tester set)
(B): 09900–25009 (Needle-point probe set)

Tester knob indication
Voltage (

)

EXCVA position sensor output voltage
EXCV is fully closed: 0.45

≤

Output voltage

≤

1.4

V ((+) Y – (–) W)

8) If the measured voltage is less than specification,

adjust the No. 1 cable adjuster (4) as follows:

a) Set the EXCVA to the adjustment position. Refer

to “EXCV Cable Removal and Installation”
(Page 1K-6).

CAUTION

Adjusting the No. 1 cable with the EXCV fully
closed can damage the EXCVA. Be sure to
adjust the No. 1 cable with the EXCV set in
the adjustment position.

b) Turn the No. 1 cable adjuster (4) in or out to set

the output voltage within the specified value.

NOTE

If C46 code is indicated after adjusting the
voltage, increase the voltage to 0.9 V.

I947H11B0019-01

I947H11B0040-01

I947H11B0020-02

(A)

(B)

I947H11B0021-02

I947H11B0022-01

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1K-11 Exhaust System:

Step 4

1) Click “Full opened” (1).

2) Measure the EXCVA position sensor output voltage

at EXCV fully opened position.

Special tool

(A): 09900–25008 (Multi circuit tester set)
(B): 09900–25009 (Needle-point probe set)

EXCVA position sensor out put voltage
EXCV is fully opened: 3.6

≤

Output voltage

≤

4.55

V ((+) Y – (–) W)

3) If the measured voltage is more than specification,

adjust the No. 2 cable adjuster (2) as follows:

a) Set the EXCVA to the adjustment position. Refer

to “EXCV Cable Removal and Installation”
(Page 1K-6).

CAUTION

Adjusting the No. 2 cable with the EXCV fully
opened can damage the EXCVA. Be sure to
adjust the No. 2 cable with the EXCV set in
adjustment position.

b) Turn out the No. 2 cable adjuster (2) in or out to

set the output voltage within the specified value.

4) After adjusting the EXCV cables, perform Step 2 to

confirm DTC “46” is not indicated.

Muffler / Muffler Chamber / Exhaust Pipe
Removal and Installation

B947H11B06008

Removal

1) Loosen the muffler connecting bolts (1).

2) Remove the mufflers (2) by removing the mounting

bolt and nut (3).

NOTE

Support the muffler to prevent it from falling.

I947H11B0023-02

(A)

(B)

I947H11B0024-02

I947H11B0025-02

I947H11B0027-01

I947H11B0026-01

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Exhaust System: 1K-12

3) Remove the side cowlings. Refer to “Exterior Parts

Removal and Installation” in Section 9D (Page 9D-
6).

4) Lift and support the fuel tank with the prop stay.

Refer to “Fuel Tank Removal and Installation” in
Section 1G (Page 1G-9).

5) Disconnect the HO2 sensor coupler (4).

6) Remove the muffler chamber heat guard No. 2 (5).

(RH only)

7) Loosen the muffler chamber connecting bolt (6).

8) Remove the muffler chamber (7).

9) Remove the muffler chamber heat guard No. 1 (8)

and HO2 sensor (9) from the muffler chamber.

CAUTION

• Be careful not to expose the HO2 sensor to

an excessive shock.

• Be careful not to twist or damage the HO2

sensor lead wires.

10) Remove the EXCV cables (10). Refer to “EXCV

Cable Removal and Installation” (Page 1K-6).

11) Move the radiator and oil cooler forward. Refer to

“Radiator Inspection and Cleaning” in Section 1F
(Page 1F-5).

I947H11B0028-01

I947H11B0029-01

I947H11B0030-03

I947H11B0031-01

I947H11B0032-01

I947H11B0033-01

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1K-13 Exhaust System:

12) Remove the exhaust pipe assembly by removing the

exhaust pipe bolts.

CAUTION

Take care not to bend the radiator/oil cooler
fins.

NOTE

Support the exhaust pipe assembly to
prevent it from falling.

13) Remove the exhaust pipe gaskets (11).

Installation

Installation is in the reverse order of removal. Pay
attention to the following points:

• Tighten the HO2 sensor to the specified torque.

Tightening torque
HO2 sensor (a): 25 N·m (2.5 kgf-m, 18.0 lbf-ft)

CAUTION

• Be careful not to expose the HO2 sensor to

an excessive shock.

• Do not use an impact wrench when

installing the HO2 sensor.

• Be careful not to twist or damage the HO2

sensor lead wires.

• Do not apply oil or other materials to the

sensor air holes.

• Install new gaskets and connectors and tighten each

bolt to the specified torque. Refer to “Exhaust System
Components” (Page 1K-5).

CAUTION

Replace the gaskets and connectors with
new ones.

NOTE

When installing a new connector, remove all
of the old sealer. Apply the exhaust gas
sealer to both the inside and outside of the
new connector.

: Muffler seal (MUFFLER SEAL LOCTITE

5920 (commercially available) or equivalent)

• Install the EXCVA cables. Refer to “EXCV Cable

Removal and Installation” (Page 1K-6).

Exhaust System Inspection

B947H11B06009

Inspect the exhaust pipe, muffler chamber and muffler
connection for exhaust gas leakage and mounting
condition. If any defect is found, replace the exhaust
pipe, muffler chamber or muffler with a new one.
Check the exhaust pipe bolts, muffler connecting bolts
and muffler mounting bolts are tightened to their
specified torque. Refer to “Exhaust System
Components” (Page 1K-5).

I947H11B0034-01

I947H11B0035-01

(a)

I947H11B0036-01

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Exhaust System: 1K-14

Specifications

Service Data

B947H11B07001

FI Sensors

Tightening Torque Specifications

B947H11B07002

NOTE

The specified tightening torque is described in the following.
“Exhaust Control System Construction” (Page 1K-4)
“Exhaust System Components” (Page 1K-5)

Reference:

For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List” in Section 0C
(Page 0C-9).

Item

Standard/Specification

Note

HO2 sensor output voltage

0.3 V and less at idle speed

0.6 V and more at 5 000 r/min

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

Ω

At adjustment

position

Fastening part

Tightening torque

Note

⋅

kgf-m

lbf-ft

EXCVA pulley mounting bolt

0.5

3.5

)

(Page 1K-9)

HO2 sensor

2.5

18.0

)

(Page 1K-13)

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1K-15 Exhaust System:

Special Tools and Equipment

Recommended Service Material

B947H11B08001

NOTE

Required service material is also described in the following.
“Exhaust System Components” (Page 1K-5)

Special Tool

B947H11B08002

Material

SUZUKI recommended product or Specification

Note

Muffler seal

MUFFLER SEAL LOCTITE 5920
(commercially available) or
equivalent

—

)

(Page 1K-13)

09900–25008

09900–25009

Multi circuit tester set

Needle-point probe set

09930–82720
Mode selection switch

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2-1 Precautions:

Suspension

Precautions

Precautions for Suspension

B947H12000001

Refer to “General Precautions” in Section 00 (Page 00-1).

WARNING

All suspensions, bolts and nuts are an important part in that it could affect the performance of vital
parts. They must be tightened to the specified torque periodically and if the suspension effect is lost,
replace it with a new one.

CAUTION

Never attempt to heat, quench or straighten any suspension part. Replace it with a new one, or
damage to the part may result.

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Suspension General Diagnosis: 2A-1

Suspension

Suspension General Diagnosis

Diagnostic Information and Procedures

Suspension and Wheel Symptom Diagnosis

B947H12104001

Condition

Possible cause

Correction / Reference Item

Wobbly front wheel

Distorted wheel rim.

Replace.

Worn front wheel bearings.

Replace.

Defective or incorrect tire.

Replace.

Loose front axle nut.

Tighten.

Loose front axle pinch bolts.

Tighten.

Incorrect fork oil level.

Adjust.

Incorrect front wheel weight balance.

Adjust.

Front suspension too soft

Weak spring.

Replace.

Insufficient fork oil.

Check level and add.

Wrong weight fork oil.

Replace.

Improperly set front fork spring adjuster.

Adjust.

Improperly set front fork damping force
adjuster.

Adjust.

Front suspension too stiff

Excessively viscous fork oil.

Replace.

Excessive fork oil.

Check level and drain.

Bent front axle.

Replace.

Front suspension too
noisy

Insufficient fork oil.

Check level and add.

Loose front suspension bolt/nut.

Tighten.

Wobbly rear wheel

Distorted wheel rim.

Replace.

Worn rear wheel bearings.

Replace.

Defective or incorrect tire.

Replace.

Worn swingarm bearings.

Replace.

Worn rear suspension bearings.

Replace.

Loose rear suspension bolt/nut.

Tighten.

Incorrect rear wheel weight balance.

Adjust.

Rear suspension too soft

Weak rear shock absorber spring.

Replace.

Rear shock absorber leaks oil.

Replace.

Improperly set rear spring pre-load
adjuster.

Adjust.

Improperly set damping force adjuster.

Adjust.

Rear suspension too stiff

Bent rear shock absorber shaft.

Replace.

Bent swingarm pivot shaft.

Replace.

Worn swingarm bearings.

Replace.

Worn rear suspension bearings.

Replace.

Improperly set rear spring pre-load
adjuster.

Adjust.

Improperly set damping force adjuster.

Adjust.

Rear suspension too
noisy

Loose rear suspension bolt/nut.

Tighten.

Worn rear suspension bearings.

Replace.

Worn swingarm bearings.

Replace.

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2B-1 Front Suspension:

Suspension

Front Suspension

Repair Instructions

Front Fork Components

B947H12206001

FWD

(d)

(a)

(c)

(b)

I947H1220001-03

1. Front fork cap

8. Rod guide case

15. Outer tube

22. Front axle pinch bolt

2. O-ring

9. Spring

16. Guide bushing

: 35 N

⋅

m (3.5 kgf-m, 25.5 lbf-ft)

3. Rebound damping force adjuster rod

10. Piston rod

17. Oil seal spacer

: 28 N

⋅

m (2.8 kgf-m, 20.0 lbf-ft)

4. Compression damping force adjuster rod

11. Spring collar B

18. Oil seal

: 90 N

⋅

m (9.0 kgf-m, 65.0 lbf-ft)

5. Piston rod nut

12. Spring

19. Stopper ring

: 23 N

⋅

m (2.3 kgf-m, 16.5 lbf-ft)

6. O-ring

13. Spring collar A

20. Dust seal

: Apply fork oil.

7. Piston ring

14. Slide bushing

21. Inner tube

: Do not reuse.

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Front Suspension: 2B-2

Front Fork Removal and Installation

B947H12206002

NOTE

The right and left front forks are installed
symmetrically and therefore the removal
procedure for one side is the same as that for
the other side.

Removal

1) Remove the front wheel. Refer to “Front Wheel

Assembly Removal and Installation” in Section 2D
(Page 2D-4).

CAUTION

• Make sure that the motorcycle is

supported securely.

• Do not operate the front brake lever with

the front wheel removed.

2) Disconnect the brake hoses from the clamps on the

front fender.

3) Remove the reflex reflectors (1). (Except for E-02,

19, 51)

4) Remove the front fender (2) by removing the bolts.

5) Loosen the front fork upper clamp bolt (3).

6) Loosen the handlebar clamp bolt (4).

NOTE

Slightly loosen the front fork cap (5) to
facilitate later disassembly.

Special tool

: 09941–53670 (Front fork cap socket

wrench (45 mm))

7) Loosen the front fork lower clamp bolts (6) and

remove the front fork.

NOTE

Hold the front fork by hand to prevent it
sliding out of the steering stem.

Installation

1) Set the front fork to the steering stem lower bracket

temporarily by tightening the lower clamp bolts (1).

I947H1220002-01

I947H1220003-01

I947H1220004-01

I947H1220005-01

I947H1220006-01

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2B-3 Front Suspension:

2) Tighten the front fork cap (2) to the specified torque.

Tightening torque
Front fork cap (a): 35 N·m (3.5 kgf-m, 25.5 lbf-ft)

3) Loosen the lower clamp bolts.

4) Set the front fork with the edge of the outer tube

positioned 7.0 mm (0.28 in) “a” from the upper
surface of the upper bracket.

5) Tighten the front fork lower clamp bolts (1).

Tightening torque
Front fork lower clamp bolt (b): 23 N·m (2.3 kgf-
m, 16.5 lbf-ft)

6) Tighten the front fork upper clamp bolt (3).

Tightening torque
Front fork upper clamp bolt (c): 23 N·m (2.3 kgf-
m, 16.5 lbf-ft)

7) Tighten the handlebar clamp bolt (4).

Tightening torque
Handlebar clamp bolt (d): 23 N·m (2.3 kgf-m,
16.5 lbf-ft)

8) Install the front wheel. Refer to “Front Wheel

Assembly Removal and Installation” in Section 2D
(Page 2D-4).

WARNING

After remounting the brake calipers, pump
the brake lever until the pistons push the
pads correctly.

NOTE

Before tightening the front axle bolt and front
axle pinch bolts, move the front fork up and
down four or five times.

“a”: 7.0 mm (0.28 in)

“ a ”

(a)

I947H1220007-02

(b)

I947H1220045-01

(d)

(c)

I947H1220008-01

I947H1220009-01

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Front Suspension: 2B-4

Front Suspension Adjustment

B947H12206003

After installing the front fork, adjust the spring pre-load
and two kinds of damping force as follows:

WARNING

Adjust the left and right front forks to the
same setting.

Spring Pre-load Adjustment

Turn the spring pre-load adjuster (1) counterclockwise
fully. From that position (softest), turn it clockwise to the
specified position.

STD position
4 turns in from softest position

Damping Force Adjustment
Rebound damping force

Fully turn the rebound damping force adjuster (1)
clockwise. From that position (stiffest), turn it out to
standard setting position.

STD position
4 turns out from stiffest position

Compression damping force

Fully turn the compression damping force adjuster (1)
clockwise. From that position (stiffest), turn it out to
standard setting position.

STD position
5 turns from stiffest position

Front Fork Disassembly and Assembly

B947H12206004

Refer to “Front Fork Removal and Installation” (Page 2B-
2).

NOTE

The right and left front forks are installed
symmetrically and therefore the disassembly
procedure for one side is the same as that for
the other side.

Disassembly

1) Turn the spring pre-load adjuster (1) to the softest

position.

I947H1220010-01

I947H1220011-01

I947H1220012-01

I947H1220013-01

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2B-5 Front Suspension:

2) Loosen the front fork cap using the special tool and

vise.

CAUTION

Do not clamp the outer tube too tight.

Special tool

(A): 09941–53670 (Front fork cap socket

wrench (45 mm))

3) Loosen the rod guide case installed in the inner tube

using the special tool.

Special tool

(B): 09940–84710 (Rod guide case wrench)

WARNING

Hold the front fork cap when removing the
rod guide case, or it will jump out due to the
spring pressure.

4) Remove the piston rod assembly (2).

5) Remove the spring collar B (3) and spring (4).

6) Drain fork oil and remove the spring collar A (5).

7) Remove the dust seal (6).

8) Remove the oil seal stopper ring (7).

CAUTION

• Scratches on the inner tube could cause

oil leaks.

• Avoid scratching when removing.

(A)

I947H1220014-01

(B)

I947H1220015-01

I947H1220016-01

I947H1220017-01

I947H1220018-01

I947H1220019-01

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Front Suspension: 2B-6

9) Pull out the inner tube from the outer tube.

10) Remove the slide bushing (8) from the inner tube.

11) Remove the following parts from the inner tube.

a) Guide bushing (9)

b) Oil seal spacer (10)

c) Oil seal (11)

d) Oil seal stopper ring (7)

e) Dust seal (6)

12) Hold the piston rod assembly with the special tool

and vise.

Special tool

(A): 09941–53670 (Front fork cap socket

wrench (45 mm))

13) Loosen the piston rod nut (12) and disassemble the

piston rod as shown.

Assembly

CAUTION

• Clean all fork parts before reassembling.

• Replace the O-rings, seals and bushings

with new ones.

• Apply specified front fork oil when

installing the O-rings, slide bushing and
guide bushing.

1) Cover the inner tube with a plastic film.

2) Install the following parts to the inner tube.

a) New dust seal (1)

b) Stopper ring (2)

c) New oil seal (3)

CAUTION

• Scratches on the oil seal lip may cause oil

leakage. When installing the seals, place a
plastic film over the slide bushing groove
and edges of the inner tube to avoid
damaging the seals’ lip.

• Misdirecting of the parts may cause

inferior operation and oil leakage.

• Face the stamp mark side “A” of the oil

seal to the dust seal side.

I947H1220020-01

I947H1220021-01

(A)

I947H1220022-01

“A”: Stamp mark

I947H1220023-01

“A”

I947H1220024-01

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Suzuki GSX-R1000. Service Manual - part 27