FOREWORDThis manual contains an introductory description on the SUZUKI GSX1300R and procedures for its inspection/service ...
00                                                            TABLE OF CONTENTS                                           ...
SUPPLEMENTSGSX1300RK9                    10
Table of Contents 00- i                                                                  Section 00                       ...
00-1 Precautions:PrecautionsPrecautions                                                          PrecautionsWarning / Caut...
Precautions:         00-2   • Never reuse a circlip. When installing a                   • Before refitting the sealed cou...
00-3 Precautions:• Check the male connector for bend and female                          Switch  connector for excessive o...
Precautions:        00-4Battery                                                        • Never connect any tester (voltmet...
00-5 Precautions: 3) Using a test male terminal, check the female                             Continuity check    terminal...
Precautions:       00-63) Also, if measured values are as listed following, a              Short circuit check (Wire harne...
00-7 Precautions: 4) Disconnect the connector/coupler included in circuit              Using the testers    (coupler “B”) ...
Table of Contents 0- i                                                                    Section 0                       ...
0A-1 General Information:General InformationGeneral Information                                                  General D...
General Information:     0A-2F:                                                       SAE-to-Former SUZUKI TermFI: Fuel In...
0A-3 General Information:M:                                                       Vehicle Side ViewMalfunction Indicator L...
General Information:    0A-4Vehicle Identification Number                                   Engine Oil (For Other Countrie...
0A-5 General Information:Engine Coolant Recommendation                                 BREAK-IN Procedures                ...
General Information:     0A-6Country and Area Codes                                                                       ...
0A-7 General Information:Warning, Caution and Information Labels Location                                                 ...
General Information:          0A-8                                          Component LocationElectrical Components Locati...
0A-9 General Information:                          17                                           22                        ...
General Information:   0A-10                                           SpecificationsSpecifications                       ...
0A-11 General Information:Chassis                Item                                   Specification                  Rem...
General Information:       0A-12                                    Special Tools and EquipmentSpecial Tool               ...
0A-13 General Information:09913–70210             09915–40610            09915–63311             09915–64512           099...
General Information:       0A-1409924–84510             09924–84521              09925–18011              09930–10121     ...
0A-15 General Information:09940–94930         09941–34513             09941–54911          09941–74911        09943–74111F...
Maintenance and Lubrication:       0B-1Maintenance and LubricationGeneral Information                                     ...
0B-2 Maintenance and Lubrication:                                                                                         ...
Maintenance and Lubrication:         0B-3                                             Repair InstructionsAir Cleaner Eleme...
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Service manual Suzuki GSXR-1300 Hayabusa k8
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Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
Service manual Suzuki GSXR-1300 Hayabusa k8
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Service manual Suzuki GSXR-1300 Hayabusa k8

  1. 1. FOREWORDThis manual contains an introductory description on the SUZUKI GSX1300R and procedures for its inspection/service and overhaul of its main components.Other information considered as generally known is not included.Read the GENERAL INFORMATION section to familiarize yourself with the motorcycle and its maintenance. Usethis section as well as other sections to use as a guide for proper inspection and service.This manual will help you know the motorcycle better so that you can assure your customers of fast and reliableservice. * This manual has been prepared on the basis of the latest specifications at the time of publication. If modifi- cations have been made since then, differences may exist between the content of this manual and the actual motorcycle. * Illustrations in this manual are used to show the basic principles of operation and work procedures. They may not represent the actual motorcycle exactly in detail. * This manual is written for persons who have enough knowledge, skills and tools, including special tools, for servicing SUZUKI motorcycles. If you do not have the proper knowledge and tools, ask your authorized SUZUKI motorcycle dealer to help you. ! WARNING Inexperienced mechanics or mechanics without the proper tools and equipment may not be able to properly perform the services described in this manual. Improper repair may result in injury to the mechanic and may render the motorcycle unsafe for the rider and passenger. © COPYRIGHT SUZUKI MOTOR CORPORATION 2007
  2. 2. 00 TABLE OF CONTENTS 0Precautions............................................................... 00-i Precautions ............................................................ 00-1 1General Information ................................................... 0-i General Information ............................................... 0A-1 Maintenance and Lubrication ................................. 0B-1 Service Data...........................................................0C-1 2Engine ......................................................................... 1-i Precautions .............................................................. 1-1 Engine General Information and Diagnosis ........... 1A-1 Emission Control Devices ...................................... 1B-1 3 Engine Electrical Devices.......................................1C-1 Engine Mechanical.................................................1D-1 Engine Lubrication System .................................... 1E-1 Engine Cooling System.......................................... 1F-1 Fuel System ...........................................................1G-1 4 Ignition System.......................................................1H-1 Starting System....................................................... 1I-1 Charging System.....................................................1J-1 Exhaust System ..................................................... 1K-1 5Suspension................................................................. 2-i Precautions .............................................................. 2-1 Suspension General Diagnosis.............................. 2A-1 Front Suspension ................................................... 2B-1 Rear Suspension....................................................2C-1 6 Wheels and Tires ...................................................2D-1Driveline / Axle ........................................................... 3-i Precautions .............................................................. 3-1 Drive Chain / Drive Train / Drive Shaft ................... 3A-1Brake ........................................................................... 4-i Precautions .............................................................. 4-1 Brake Control System and Diagnosis .................... 4A-1 Front Brakes........................................................... 4B-1 Rear Brakes ...........................................................4C-1Transmission / Transaxle .......................................... 5-i Precautions .............................................................. 5-1 Manual Transmission ............................................. 5B-1 9 Clutch .....................................................................5C-1Steering....................................................................... 6-i Precautions .............................................................. 6-1 Steering General Diagnosis ................................... 6A-1 Steering / Handlebar .............................................. 6B-1Body and Accessories............................................... 9-i Precautions .............................................................. 9-1 Wiring Systems ...................................................... 9A-1 Lighting Systems.................................................... 9B-1 Combination Meter / Fuel Meter / Horn..................9C-1 Exterior Parts .........................................................9D-1 Body Structure ....................................................... 9E-1
  3. 3. SUPPLEMENTSGSX1300RK9 10
  4. 4. Table of Contents 00- i Section 00 00 Precautions CONTENTSPrecautions ...............................................00-1 General Precautions ........................................... 00-1 Precautions........................................................... 00-1 Precautions for Electrical Circuit Service ............ 00-2 Warning / Caution / Note..................................... 00-1
  5. 5. 00-1 Precautions:PrecautionsPrecautions PrecautionsWarning / Caution / Note • To avoid getting burned, do not touch the B815H20000001 engine, engine oil, radiator and exhaustPlease read this manual and follow its instructions system until they have cooled.carefully. To emphasize special information, the symboland the words WARNING, CAUTION and NOTE have • After servicing the fuel, oil, water, exhaustspecial meanings. Pay special attention to the messages or brake systems, check all lines andhighlighted by these signal words. fittings related to the system for leaks. ! WARNING ! CAUTION Indicates a potential hazard that could result • If parts replacement is necessary, replace in death or injury. the parts with Suzuki Genuine Parts or their equivalent. ! CAUTION • When removing parts that are to be reused, Indicates a potential hazard that could result keep them arranged in an orderly manner in motorcycle damage. so that they may be reinstalled in the proper order and orientation. NOTE • Be sure to use special tools when instructed. Indicates special information to make maintenance easier or instructions clearer. • Make sure that all parts used in reassembly are clean. Lubricate themPlease note, however, that the warnings and cautions when specified.contained in this manual cannot possibly cover all • Use the specified lubricant, bond orpotential hazards relating to the servicing, or lack of sealant.servicing, of the motorcycle. In addition to the • When removing the battery, disconnect theWARNINGS and CAUTIONS stated, you must use good negative (–) cable first and then thejudgement and basic mechanical safety principles. If you positive (+) cable.are unsure about how to perform a particular service • When reconnecting the battery, connectoperation, ask a more experienced mechanic for advice. the positive (+) cable first and then the negative (–) cable, and replace the terminalGeneral Precautions cover on the positive (+) terminal. B815H20000002 ! WARNING • When performing service to electrical parts, if the service procedures do not • Proper service and repair procedures are require use of battery power, disconnect important for the safety of the service the negative (–) cable the battery. mechanic and the safety and reliability of • When tightening the cylinder head or case the motorcycle. bolts and nuts, tighten the larger sizes • When 2 or more persons work together, first. Always tighten the bolts and nuts pay attention to the safety of each other. diagonally from the inside toward outside • When it is necessary to run the engine and to the specified tightening torque. indoors, make sure that exhaust gas is • Whenever you remove oil seals, gaskets, forced outdoors. packing, O-rings, locking washers, self- • When working with toxic or flammable locking nuts, cotter pins, circlips and materials, make sure that the area you certain other parts as specified, be sure to work in is well ventilated and that you replace them with new ones. Also, before follow all of the material manufacturer’s installing these new parts, be sure to instructions. remove any left over material from the mating surfaces. • Never use gasoline as a cleaning solvent.
  6. 6. Precautions: 00-2 • Never reuse a circlip. When installing a • Before refitting the sealed coupler, make sure its seal new circlip, take care not to expand the rubber is positioned properly. The seal rubber may end gap larger than required to slip the possibly come off the position during disconnecting circlip over the shaft. After installing a work and if the coupler is refitted with the seal rubber circlip, always ensure that it is completely improperly positioned, it may result in poor water seated in its groove and securely fitted. sealing. • Use a torque wrench to tighten fasteners to the specified torque. Wipe off grease and oil if a thread is smeared with them. • After reassembling, check parts for tightness and proper operation. • To protect the environment, do not unlawfully dispose of used motor oil, engine coolant and other fluids: batteries, and tires. • To protect Earth’s natural resources, properly dispose of used motorcycle and I310G1000002-01 parts. • Inspect each lead wire circuit for poor connection by shaking it by hand lightly. If any abnormal condition is found, repair or replace.Precautions for Electrical Circuit Service B815H20000003When handling the electrical parts or servicing the FI andABS systems, observe the following points for the safetyof the systems.Electrical PartsConnector / Coupler• When connecting a connector, be sure to push it in until a click is felt. I310G1000003-02 • When taking measurements at electrical connectors using a tester probe, be sure to insert the probe from the wire harness side (rear) of the connector/coupler. 2 I823H1000002-01• With a lock type coupler, be sure to release the lock when disconnecting, and push it in fully to engage the lock when connecting.• When disconnecting the coupler, be sure to hold the 1 coupler body and do not pull the lead wires.• Inspect each terminal on the connector/coupler for I649G1000013-02 looseness or bending. 1. Coupler 2. Probe• Push in the coupler straightly. An angled or skewed insertion may cause the terminal to be deformed, • When connecting meter probe from the terminal side possibly resulting in poor electrical contact. of the coupler (where connection from harness side• Inspect each terminal for corrosion and not being possible), use extra care not to force and contamination. The terminals must be clean and free cause the male terminal to bend or the female of any foreign material which could impede proper terminal to open. Connect the probe as shown to terminal contact. avoid opening of female terminal. Never push in the probe where male terminal is supposed to fit.
  7. 7. 00-3 Precautions:• Check the male connector for bend and female Switch connector for excessive opening. Also check the Never apply grease material to switch contact points to coupler for locking (looseness), corrosion, dust, etc. prevent damage. ECM / Various sensors • Since each component is a high-precision part, great 4 care should be taken not to apply any severe impacts during removal and installation. “A” 3 4 I649G1000030-02 3. Coupler 4. Probe “A”: Where male terminal fitsClamp• Clamp the wire harness at such positions as indicated I310G1000007-01 in “Wiring Harness Routing Diagram in Section 9A • Be careful not to touch the electrical terminals of the (Page 9A-5)”. electronic parts (ECM, etc.). The static electricity from• Bend the clamp properly so that the wire harness is your body may damage them. clamped securely.• In clamping the wire harness, use care not to allow it to hang down.• Do not use wire or any other substitute for the band type clamp. CORRECT INCORRECT I310G1000008-01 • When disconnecting and connecting the coupler, make sure to turn OFF the ignition switch, or I718H1000001-02 electronic parts may get damaged.Fuse 1• When a fuse is blown, always investigate the cause to OFF ON PUSH correct it and then replace the fuse. LOC K• Do not use a fuse of different capacity. P IGNITION• Do not use wire or any other substitute for the fuse. I815H1000001-01 1. Ignition switch I649G1000001-02
  8. 8. Precautions: 00-4Battery • Never connect any tester (voltmeter, ohmmeter, or• Battery connection in reverse polarity is strictly whatever) to the electronic unit when its coupler is prohibited. Such a wrong connection will damage the disconnected. Otherwise, damage to electronic unit components of the FI and ABS systems instantly may result. when reverse power is applied. • Never connect an ohmmeter to the electronic unit with its coupler connected. If attempted, damage to ECM or sensors may result. • Be sure to use a specified voltmeter/ohmmeter. Otherwise, accurate measurements may not be obtained and personal injury may result. Electrical Circuit Inspection Procedure While there are various methods for electrical circuit inspection, described here is a general method to check for open and short circuit using an ohmmeter and a voltmeter. I718H1000004-01 Open circuit check• Removing any battery terminal of a running engine is Possible causes for the open circuit are as follows. As strictly prohibited. The moment such removal is made, the cause can exist in the connector/coupler or terminal, damaging counter electromotive force will be applied they need to be checked carefully. to the electronic unit which may result in serious • Loose connection of connector/coupler damage. • Poor contact of terminal (due to dirt, corrosion or rust, poor contact tension, entry of foreign object etc.) • Wire harness being open. • Poor terminal-to-wire connection. When checking system circuits including an electronic control unit such as ECM, ABS control unit/HU, etc., it is important to perform careful check, starting with items which are easier to check. 1) Disconnect the negative (–) cable from the battery. 2) Check each connector/coupler at both ends of the circuit being checked for loose connection. Also I310G1000011-01 check for condition of the coupler lock if equipped.• Before measuring voltage at each terminal, check to make sure that battery voltage is 11 V or higher. Terminal voltage check with a low battery voltage will “A” lead to erroneous diagnosis. “A” 1 ECM I718H1000005-02 1. Sensor “A”: Check for loose connection I310G1000012-02
  9. 9. 00-5 Precautions: 3) Using a test male terminal, check the female Continuity check terminals of the circuit being checked for contact 1) Measure resistance across coupler “B” (between “A” tension. and “C” in figure). Check each terminal visually for poor contact If no continuity is indicated (infinity or over limit), the (possibly caused by dirt, corrosion, rust, entry of circuit is open between terminals “A” and “C”. foreign object, etc.). At the same time, check to make sure that each terminal is fully inserted in the “A” coupler and locked. If contact tension is not enough, rectify the contact to increase tension or replace. The terminals must be “B” ECM clean and free of any foreign material which could impede proper terminal contact. “C” “B” I705H1000006-02 2) Disconnect the coupler “B” and measure resistance between couplers “A” and “B-1”. “C” If no continuity is indicated, the circuit is open between couplers “A” and “B-1”. If continuity is I649G1000027-02 indicated, there is an open circuit between couplers “B”: Check contact tension by inserting and removing. “B-2” and “C” or an abnormality in coupler “B-2” or “C”: Check each terminal for bend and proper alignment. coupler “C”. 4) Using continuity inspect or voltage check procedure “A” as described below, inspect the wire harness terminals for open circuit and poor connection. “B-2” Locate abnormality, if any. ECM “B” “C” “B-1” “D” “F” “E” I705H1000010-02 I649G1000028-02 Voltage check ”D”: Looseness of crimping If voltage is supplied to the circuit being checked, voltage “E”: Open “F”: Thin wire (A few strands left) check can be used as circuit check. 1) With all connectors/couplers connected and voltage applied to the circuit being checked, measure voltage between each terminal and body ground. 2) If measurements were taken as shown in the figure and results were listed in the following, it means that the circuit is open between terminals “A” and “B”. Voltage between “A” and body ground: Approx. 5 V “B” and body ground: Approx. 5 V “C” and body ground: 0 V
  10. 10. Precautions: 00-63) Also, if measured values are as listed following, a Short circuit check (Wire harness to ground) resistance (abnormality) exists which causes the 1) Disconnect the negative (–) cable from the battery. voltage drop in the circuit between terminals “A” and 2) Disconnect the connectors/couplers at both ends of “B”. the circuit to be checked. Voltage between “A” and body ground: Approx. 5 V NOTE “B” and body ground: Approx. 5 V – 2 V voltage If the circuit to be checked branches to other drop parts as shown, disconnect all connectors/ “C” and body ground: 3 V – 2 V voltage drop couplers of those parts. Otherwise, diagnosis will be wrong. “A” 3) Measure resistance between terminal at one end of circuit (“A” terminal in figure) and body ground. If continuity is indicated, there is a short circuit to ground between terminals “A” and “C”. ECM “A” “B” “C” “D” “B” ECM “C” “E” 5V 5V 5V 0V 5V “A” “B” “C” “A” “C” I705H1000007-01 I705H1000008-01 “D”: To other parts “E”: Other parts
  11. 11. 00-7 Precautions: 4) Disconnect the connector/coupler included in circuit Using the testers (coupler “B”) and measure resistance between • Incorrectly connecting the (+) and (–) probes may terminal “A” and body ground. If continuity is cause the inside of the tester to be burned. indicated, the circuit is shorted to the ground • If the voltage and current are not known, make between terminals “A” and “B”. measurements using the highest range. • When measuring the resistance with the multi-circuit “A” tester (1), ∞ will be shown as 10.00 MΩ and “1” “D” flashes in the display. • Check that no voltage is applied before making the ECM measurement. If voltage is applied the tester may be damaged. “B” • After using the tester, turn the power off. “C” Special tool : 09900–25008 (Multi-circuit tester set) I705H1000009-02 “D”: To other partsUsing The Multi-Circuit Testers• Use the Suzuki multi-circuit tester set.• Use well-charged batteries in the tester.• Be sure to set the tester to the correct testing range. Special tool (A): 09900–25008 (Multi-circuit tester set) I649G1000002-02 (A) NOTE • When connecting the multi-circuit tester, use the needle pointed probe to the back side of the lead wire coupler and connect the probes of tester to them. • Use the needle pointed probe to prevent I649G1000024-03 the rubber of the water proof coupler from damage. • When using the multi-circuit tester, do not strongly touch the terminal of the ECM coupler with a needle pointed tester probe to prevent the terminal damage or terminal bend. Special tool (A): 09900–25009 (Needle pointed probe set) (A) I649G1000025-03
  12. 12. Table of Contents 0- i Section 0 General Information 0 CONTENTSGeneral Information ................................ 0A-1 Spark Plug Replacement ....................................0B-9 General Description .............................................0A-1 Spark Plug Inspection and Cleaning ...................0B-9 Symbols .............................................................. 0A-1 Fuel Line Inspection ..........................................0B-10 Abbreviations ...................................................... 0A-1 Engine Oil and Filter Replacement ...................0B-10 SAE-to-Former SUZUKI Term ............................ 0A-2 Throttle Cable Play Inspection and Vehicle Side View ............................................... 0A-3 Adjustment ......................................................0B-12 Vehicle Identification Number ............................. 0A-4 Throttle Valve Synchronization .........................0B-12 Fuel and Oil Recommendation ........................... 0A-4 Evaporative Emission Control System Engine Coolant Recommendation ...................... 0A-5 Inspection (E-33 only) .....................................0B-13 BREAK-IN Procedures........................................ 0A-5 PAIR System Inspection ...................................0B-13 Cylinder Identification.......................................... 0A-5 Cooling System Inspection................................0B-13 Country and Area Codes .................................... 0A-6 Clutch System Inspection..................................0B-14 Wire Color Symbols ............................................ 0A-6 Clutch Hose Replacement ................................0B-15 Warning, Caution and Information Labels Clutch Fluid Replacement .................................0B-15 Location ............................................................ 0A-7 Drive Chain Inspection and Adjustment ............0B-15 Component Location ...........................................0A-8 Drive Chain Cleaning and Lubricating...............0B-17 Electrical Components Location ......................... 0A-8 Brake System Inspection ..................................0B-17 Tire Inspection...................................................0B-19 Specifications.....................................................0A-10 Steering System Inspection ..............................0B-20 Specifications .................................................... 0A-10 Front Fork Inspection ........................................0B-20 Special Tools and Equipment ...........................0A-12 Rear Suspension Inspection .............................0B-20 Special Tool ...................................................... 0A-12 Chassis Bolt and Nut Inspection .......................0B-21 Compression Pressure Check ..........................0B-23Maintenance and Lubrication................. 0B-1 Oil Pressure Check ...........................................0B-23 Precautions...........................................................0B-1 SDS Check........................................................0B-23 Precautions for Maintenance .............................. 0B-1 Specifications .....................................................0B-23 General Description .............................................0B-1 Tightening Torque Specifications......................0B-23 Recommended Fluids and Lubricants................. 0B-1 Special Tools and Equipment ...........................0B-24 Scheduled Maintenance ......................................0B-1 Recommended Service Material .......................0B-24 Periodic Maintenance Schedule Chart................ 0B-1 Special Tool ......................................................0B-24 Lubrication Points ............................................... 0B-2 Repair Instructions ..............................................0B-3 Service Data ............................................. 0C-1 Air Cleaner Element Replacement...................... 0B-3 Specifications .......................................................0C-1 Air Cleaner Element Inspection .......................... 0B-3 Service Data........................................................0C-1 Exhaust Pipe Bolt and Muffler Bolt Inspection .... 0B-3 Tightening Torque List ........................................0C-9 Valve Clearance Inspection and Adjustment ...... 0B-4
  13. 13. 0A-1 General Information:General InformationGeneral Information General DescriptionSymbols B815H20101001Listed in the table below are the symbols indicating instructions and other information necessary for servicing.The meaning of each symbol is also included in the table. Symbol Definition Torque control required. Data beside it indicate specified torque. Apply oil. Use engine oil unless otherwise specified. Apply molybdenum oil solution. (Mixture of engine oil and SUZUKl MOLY PASTE in a ratio of 1:1). Apply SUZUKI SUPER GREASE “A” or equivalent. 99000-25010 Apply SUZUKI MOLY PASTE or equivalent. 99000-25140 Apply SUZUKI SILICONE GREASE or equivalent. 99000-25100 Apply SUZUKI BOND “1207B” or equivalent. 99000-31140 Apply THREAD LOCK SUPER “1303” or equivalent. 99000-32030 Apply THREAD LOCK SUPER “1322” or equivalent. 99000-32110 Apply THREAD LOCK SUPER “1360” or equivalent. 99000-32130 Use engine coolant or equivalent. 99000-99032-11X Use fork oil or equivalent. 99000-99044-L01 Apply MUFFLER SEAL LOCTITE “5920” (commercially available) or equivalent. Apply or use brake fluid. Use special tool. Do not reuse. Note on reassembly.Abbreviations CLP Switch: Clutch Lever Position Switch (Clutch B815H20101002 Switch)A: CMP Sensor: Camshaft Position Sensor (CMPS)ABDC: After Bottom Dead Center CO: Carbon MonoxideAC: Alternating Current CPU: Central Processing UnitACL: Air Cleaner, Air Cleaner Box D:API: American Petroleum Institute DC: Direct CurrentATDC: After Top Dead Center DMC: Dealer Mode CouplerATM Pressure: Atmospheric Pressure, Atmospheric DOHC: Double Over Head Camshaft Pressure Sensor (APS, AP Sensor) DRL: Daytime Running LightA/F: Air Fuel Mixture DTC: Diagnostic Trouble codeB: E:BBDC: Before Bottom Dead Center ECM: Engine Control Module Engine Control UnitBTDC: Before Top Dead Center (ECU) (FI Control Unit)B+: Battery Positive Voltage ECT Sensor: Engine Coolant Temperature SensorBARO: Barometric pressure (Atmospheric pressure) (ECTS)C: Water Temp. Sensor (WTS)CKP Sensor: Crankshaft Position Sensor (CKPS) EVAP: Evaporative EmissionCKT: Circuit
  14. 14. General Information: 0A-2F: SAE-to-Former SUZUKI TermFI: Fuel Injection, Fuel Injector B815H20101012FP: Fuel pump This list shows SAE (Society of Automotive Engineers)FPR: Fuel Pressure Regulator J1930 terms and abbreviations which may be used inFP Relay: Fuel Pump Relay this manual in compliance with SAE recommendations,G: as well as their former SUZUKI names.GEN: Generator Ex. SAE term (Abbreviation): Former SUZUKI termGND: Ground A:GP Switch: Gear Position Switch Air Cleaner (ACL): Air Cleaner, Air Cleaner BoxH: B:HC: Hydrocarbons Barometric Pressure (BARO): Barometric Pressure,HO2 sensor: Heated Oxygen Sensor (HO2S) Atmospheric Pressure (APS, AP Sensor)I: Battery Positive Voltage (B+): Battery Voltage, +BIAP Sensor: Intake Air Pressure Sensor (IAPS) C:IAT Sensor: Intake Air Temperature Sensor (IATS) Camshaft Position Sensor (CMP Sensor): CamshaftIG: Ignition Position Sensor (CMPS)ISC Valve: Idle Speed Control Valve (ISCV) Crankshaft Position Sensor (CKP Sensor):J: Crankshaft Position Sensor (CKPS), Crank AngleJASO: Japanese Automobile Standards Organization D:L: Data Link Connector (DLC): Dealer Mode CouplerLCD: Liquid Crystal Display Diagnostic Test Mode (DTM): —LED: Light Emitting Diode (Malfunction Indicator Lamp) Diagnostic Trouble Code (DTC): Diagnostic Code,LH: Left Hand Malfunction CodeM: E:MAL-CODE: Malfunction Code (Diagnostic Code) Electronic Ignition (EI): —Max: Maximum Engine Control Module (ECM): Engine ControlMIL: Malfunction Indicator Lamp (LED) Module (ECM), Fl Control Unit, Engine Control UnitMin: Minimum (ECU)N: Engine Coolant Level (ECL): Coolant LevelNOx: Nitrogen Oxides Engine Coolant Temperature (ECT): CoolantO: Temperature, Engine Coolant Temperature, WaterOHC: Over Head Camshaft TemperatureOPS: Oil Pressure Switch Engine Speed (RPM): Engine Speed (RPM)P: Evaporative Emission (EVAP): Evaporative EmissionPAIR: Pulsed Secondary Air Injection Evaporative Emission Canister (EVAP Canister): —PCM: Power Control Module (Canister)PCV: Positive Crankcase Ventilation (Crankcase F: Breather) Fan Control (FC): —R: Fuel Level Sensor: Fuel Level Sensor, Fuel LevelRH: Right Hand GaugeROM: Read Only Memory Fuel Pump (FP): Fuel Pump (FP)S: G:SAE: Society of Automotive Engineers Generator (GEN): GeneratorSDS: Suzuki Diagnosis System Ground (GND): Ground (GND, GRD)STC System: Secondary Throttle Control System H: (STCS) Hydrocarbons (HC): HydrocarbonsSTP Sensor: Secondary Throttle Position Sensor Heated Oxygen Sensor (HO2S): Heated Oxygen (STPS) Sensor (HO2S), O2 sensorST Valve: Secondary Throttle Valve (STV) I:STV Actuator: Secondary Throttle Valve Actuator Ignition Control Module (ICM): — (STVA) Intake Air Temperature (IAT): Intake Air TemperatureT: (IAT), Air TemperatureTO Sensor: Tip-over Sensor (TOS) Idle Speed Control (ISC): —TP Sensor: Throttle Position Sensor (TPS) Ignition Control (IC): Electronic Spark Advance (ESA)TPC Valve: Tank Pressure Control Valve (TPCV) Ignition Control Module (ICM): — Intake Air Temperature (IAT): Intake Air Temperature (IAT), Air Temperature
  15. 15. 0A-3 General Information:M: Vehicle Side ViewMalfunction Indicator Lamp (MIL): LED Lamp, B815H20101003 NOTE Malfunction Indicator Lamp (MIL)Manifold Absolute Pressure (MAP): Intake Air Difference between illustrations and actual Pressure (IAP), Intake Vacuum motorcycles may exist depending on theMass Air Flow (MAF): Air Flow markets.O:On-Board Diagnostic (OBD): Self-Diagnosis Function, SUZUKI GSX1300R (2008-model) DiagnosticOpen Loop (OL): — Right SideP:Power Control Module (PCM): —Programmable Read Only Memory (PROM): —Pulsed Secondary Air Injection (PAIR): Pulse Air Control (PAIR)Purge Valve (Purge Valve): Purge Valve (SP Valve)R:Random Access Memory (RAM): —Read Only Memory (ROM): ROMS:Secondary Air Injection (AIR): —Secondary Throttle Control System (STCS): STC I815H1010001-02 System (STCS)Secondary Throttle Valve (STV): ST Valve (STV)Secondary Throttle Valve Actuator (STVA): STV Left Side Actuator (STVA)T:Throttle Body (TB): Throttle Body (TB)Throttle Body Fuel Injection (TBI): Throttle Body Fuel Injection (TBI)Throttle Position Sensor (TP Sensor): TP Sensor (TPS)Tank Pressure Control Valve: TPC Valve (TPCV)V:Voltage Regulator (VR): Voltage RegulatorVolume Air Flow (VAF): Air Flow I815H1010002-02
  16. 16. General Information: 0A-4Vehicle Identification Number Engine Oil (For Other Countries) B815H20101004 Oil quality is a major contributor to your engine’sThe frame serial number or V.I.N. (Vehicle Identification performance and life. Always select good quality engineNumber) “A” is stamped on the right side of the steering oil. Use of SF/SG or SH/SJ in API with MA in JASO.head pipe. The engine serial number “B” is located on Suzuki recommends the use of SAE 10W-40 engine oil.the upper crankcase. These numbers are required If SAE 10W-40 engine oil is not available, select anespecially for registering the machine and ordering alternative according to the chart.spare parts. “A” I310G1010005-01 Brake Fluid I815H1010003-01 Specification and classification: DOT 4 ! WARNING Since the brake system of this motorcycle is filled with a glycol-based brake fluid by the manufacturer, do not use or mix different types of fluid such as silicone-based and petroleum-based fluid for refilling the system, otherwise serious damage will result. “B” Do not use any brake fluid taken from old or used or unsealed containers. I815H1010004-01 Never reuse brake fluid left over from a previous servicing, which has been storedFuel and Oil Recommendation for a long period. B815H20101005Fuel (For USA and Canada)Use only unleaded gasoline of at least 90 pump octane Front Fork Oil(R/2 + M/2). Use fork oil L01 or equivalent fork oil.Gasoline containing MTBE (Meltyl Tertiary Butyl Ether),less than 10% ethanol, or less than 5% methanol withappropriate cosolvents and corrosion inhibitor ispermissible.Fuel (For Other Countries)Gasoline used should be graded 95 octane (ResearchMethod) or higher. Unleaded gasoline is recommended.Engine Oil (For USA)Oil quality is a major contributor to your engine’sperformance and life. Always select good quality engineoil.Suzuki recommends the use of SUZUKIPERFORMANCE 4 MOTOR OIL or equivalent engineoil. Use of SF/SG or SH/SJ in API with MA in JASO.Suzuki recommends the use of SAE 10W-40 engine oil.If SAE 10W-40 engine oil is not available, select andalternative according to the chart.
  17. 17. 0A-5 General Information:Engine Coolant Recommendation BREAK-IN Procedures B815H20101006 B815H20101007Engine Coolant During manufacture only the best possible materials areUse an anti-freeze/engine coolant compatible with an used and all machined parts are finished to a very highaluminum radiator, mixed with distilled water only. standard but it is still necessary to allow the moving parts to “BREAK-IN” before subjecting the engine to maximumWater for mixing stresses. The future performance and reliability of theUse distilled water only. Water other than distilled water engine depends on the care and restraint exercisedcan corrode and clog the aluminum radiator. during its early life. The general rules are as follows. 1) Keep to these break-in engine speed limits:Anti-freeze / Engine coolantThe engine coolant perform as a corrosion and rust Speed limitsinhibitor as well as anti-freeze. Therefore, the engine Initial 800 km (500 miles): Below 5 500 r/mincoolant should be used at all times even though the Up to 1 600 km (1 000 miles): Below 8 000 r/minatmospheric temperature in your area does not go down Over 1 600 km (1 000 miles): Below 11 000 r/minto freezing point. 2) Upon reaching an odometer reading of 1 600 km (1Suzuki recommends the use of SUZUKI COOLANT anti- 000 miles) you can subject the motorcycle to fullfreeze/engine coolant. If this is not available, use an throttle operation. However, do not exceed 11 000 r/equivalent which is compatible with an aluminum min at any time.radiator. Cylinder IdentificationLiquid amount of water / Engine coolant B815H20101008 The four cylinders of this engine are identified as #1, 2, 3Solution capacity (total) and #4 cylinder, as counted from left to right (as viewed2 950 ml (3.1/2.6 US/Imp qt) by the rider on the seat).For engine coolant mixture information, refer to “EngineCoolant Description in Section 1F (Page 1F-1)”. #1 ! CAUTION #2 #3 Mixing of anti-freeze/engine coolant should #4 be limited to 60%. Mixing beyond it would reduce its efficiency. If the anti-freeze/engine coolant mixing ratio is below 50%, rust inhabiting performance is greatly reduced. Be sure to mix it above 50% even though the atmospheric temperature does not go down to the freezing point. I815H1010005-02
  18. 18. General Information: 0A-6Country and Area Codes B815H20101009The following codes stand for the applicable country(-ies) and area(-s). Code Country or Area Effective Frame No.GSX1300R K8 (E-02) U.K. JS1CK111200100001 –GSX1300R K8 (E-19) E.U. JS1CK111100100001 –GSX1300RUF K8 (E-19) E.U. JS1CK211100100001 –GSX1300R K8 (E-03) U.S.A (Except for California) JS1GX72A 82100001 –GSX1300R K8 (E-24) Australia JS1CK111300100001 –GSX1300R K8 (E-28) Canada JS1GX72A 82100001 –GSX1300R K8 (E-33) California (U.S.A) JS1GX72A 82100001 –Wire Color Symbols B815H20101010 Symbol Wire Color Symbol Wire Color B Black Bl/Y Blue with Yellow tracer Bl Blue Br/B Brown with Black tracer Br Brown G/B Green with Black tracer Dbr Dark brown G/Y Green with Yellow tracer Dg Dark green Gr/B Gray with Black tracer G Green Gr/R Gray with Red tracer Gr Gray Gr/W Gray with White tracer Lbl Light blue Gr/Y Gray with Yellow tracer Lg Light green O/G Orange with Green tracer O Orange O/R Orange with Red tracer P Pink O/W Orange with White tracer R Red O/Y Orange with Yellow tracer W White P/B Pink with Black tracer Y Yellow P/W Pink with White tracer B/Bl Black with Blue tracer R/B Red with Black tracer B/Br Black with Brown tracer R/Bl Red with Blue tracer B/G Black with Green tracer W/B White with Black tracer B/Lg Black with Light green tracer W/Bl White with Blue tracer B/O Black with Orange tracer W/G White with Green tracer B/R Black with Red tracer W/R White with Red tracer B/W Black with White tracer W/Y White with Yellow tracer B/Y Black with Yellow tracer Y/B Yellow with Black tracer Bl/B Blue with Black tracer Y/Bl Yellow with Blue tracer Bl/G Blue with Green tracer Y/R Yellow with Red tracer Bl/W Blue with White tracer Y/W Yellow with White tracer
  19. 19. 0A-7 General Information:Warning, Caution and Information Labels Location B815H20101011 [A] [B] [C] 3 1, 2 7, 8, 9 10, 11 19 8 6 1, 2, 20 14, 15, 16, 17 4 [D] [E] 18 19, 21 12, 13 5 I815H1010008-01 1. Noise label (For E-03, 24, 33) 15. General warning label (French) (For GSX1300RUF E-19) 2. Information label (For E-03, 28, 33) 16. General warning label (English/French) (For E-28) 3. Vacuum hose routing label (For E-33) 17. General warning label (French/German/Italian/Swedish) (For E-19) 4. Fuel caution label (For E-02, 24) 18. ICES Canada label (For E-28) 5. Fuel information label 19. I.D. plate (For E-02, 19, 24) 6. Manual notice label (For E-03, 33) 20. I.D. label (For GSX1300RUF E-19) 7. Screen label (English) (For E-02, 03, 24, 28, 33) 21. Safety plate (For E-03, 28, 33) 8. Screen label (French) (For E-28, GSX1300RUF E-19) [A]: Frame (RH) 9. Screen label (French/German/Italian/Swedish) (For E-19) [B]: Rear fender, front 10. Steering warning label (English) (For E-03, 33) [C]: Upper panel 11. Steering warning label (French/German/English) (For E-02, 19, 24, 28) [D]: Swingarm 12. Tire information label (English) (For E-03, 33) [E]: Frame (LH) 13. Tire information label (French/German/English) (For E-02, 19, 24, 28) 14. General warning label (English) (For E-02, 03, 24, 33)
  20. 20. General Information: 0A-8 Component LocationElectrical Components Location B815H20103001 2 7 6 4 8 3 1 5 10 9 11 13 15 14 16 12 I815H1010007-02 1. STV actuator 7. PAIR control solenoid valve 13. Starter motor 2. STP sensor 8. Cooling fan (RH) 14. GP switch 3. TP sensor 9. IAP sensor 15. HO2 sensor 4. CMP sensor 10. Drive mode selector 16. Oil pressure switch 5. ISC valve 11. TO sensor 6. Ignition coil 12. Regulator/Rectifier
  21. 21. 0A-9 General Information: 17 22 18 20 23 21 25 19 24 27 29 30 28 26 32 31 36 37 35 34 33 38 39 I815H1010006-03 17. Turn signal/Side-stand relay 25. ECT sensor 33. Horn 18. Fuse box 26. Ignition switch 34. Cooling fan (LH) 19. Cooling fan relay 27. AP sensor 35. IAT sensor 20. Secondary fuel injector 28. Battery 36. CKP sensor 21. Primary fuel injector 29. Mode select switch coupler 37. Speed sensor 22. Fuel level gauge 30. ECM 38. Side-stand switch 23. Fuel pump 31. Fuel pump relay 39. Generator 24. EVAP system purge control solenoid valve (E-33 only) 32. Starter relay/Main fuse
  22. 22. General Information: 0A-10 SpecificationsSpecifications B815H20107001 NOTE These specifications are subject to change without notice.Dimensions and dry mass Item Specification RemarkOverall length 2 190 mm (86.2 in)Overall width 735 mm (28.9 in)Overall height 1 165 mm (48.9 in)Wheelbase 1 480 mm (52.3 in)Ground clearance 120 mm (4.7 in)Seat height 805 mm (31.7 in) 221 kg (487 lbs) E-33Dry mass 220 kg (485 lbs) OthersEngine Item Specification RemarkType 4-stroke, Liquid-cooled, DOHCNumber of cylinders 4Bore 81.0 mm (3.189 in)Stroke 65.0 mm (2.559 in)Displacement 1 340 cm3 (81.8 cu. in)Compression ratio 12.5 : 1Fuel system Fuel injection systemAir cleaner Paper elementStarter system ElectricLubrication system Wet sumpIdle speed 1 150 ± 100 r/minDrive train Item Specification RemarkClutch Wet multi-plate typeTransmission 6-speed constant meshGearshift pattern 1-down, 5-upPrimary reduction ratio 1.596 (83/52) Low 2.615 (34/13) 2nd 1.937 (31/16) 3rd 1.526 (29/19)Gear ratios 4th 1.285 (27/21) 5th 1.136 (25/22) Top 1.043 (24/23)Final reduction ratio 2.388 (43/18)Drive chain RK GB50GSV Z4, 114 links
  23. 23. 0A-11 General Information:Chassis Item Specification RemarkFront suspension Inverted telescopic, coil spring, oil dampedRear suspension Link type, coil spring, oil dampedFront suspension stroke 120 mm (4.7 in)Rear wheel travel 140 mm (5.5 in)Caster 23° 25’Tail 93 mm (3.7 in)Steering angle 30° (right & left)Turning radius 3.3 m (10.8 ft)Front brake Disc brake, twinRear brake Disc brakeFront tire size 120/70ZR17M/C (58W), tubelessRear tire size 190/50ZR17M/C (73W), tubelessElectrical Item Specification RemarkIgnition type Electronic ignition (Transistorized)Ignition timing 5° B.T.D.C. at 1 150 r/minSpark plug NGK CR9EIA-9 or DENSO IU27DBattery 12 V 36 kC (10 Ah)/10 HRGenerator Three-phase A.C. generatorMain fuse 30 AFuse 15/15/15/10/10/10/10 A High 12 V 65 W (H9)Headlight Low 12 V 55 W (H7)Position/Parking light 12 V 5 W x 2Brake light/Taillight LEDLicense plate light 12 V 5 WTurn signal light 12 V 21 WSpeedometer light LEDTachometer light LEDFuel level indicator light LEDTurn signal indicator light LEDNeutral indicator light LEDHigh beam indicator light LEDEngine coolant temperature LEDindicator lightOil pressure indicator light LEDFI indicator light LEDEngine R.P.M. indicator light LEDCapacities Item Specification Remark 20 L (5.3/4.4 US/lmp gal) E-33Fuel tank 21 L (5.5/4.6 US/lmp gal) Others Oil change 3 100 ml (3.3/2.7 US/lmp qt)Engine oil With filter change 3 300 ml (3.5/2.9 US/lmp qt) Overhaul 4 000 ml (4.2/3.5 US/lmp qt)Engine coolant 2.95 L (3.1/2.6 US/lmp qt)
  24. 24. General Information: 0A-12 Special Tools and EquipmentSpecial Tool B815H2010800109900–06104 09900–06107 09900–06108 09900–18740 09900–20102Snap ring pliers Snap ring pliers Snap ring pliers Hexagon socket (24 Vernier calipers (1/20 mm) mm, 200 mm)09900–20202 09900–20204 09900–20205 09900–20530 09900–20602Micrometer (1/100 Micrometer (75 – 100 Micrometer (0 – 25 Cylinder gauge set Dial gauge (1/1000mm, 25 – 50 mm) mm) mm) mm, 1 mm)09900–20605 09900–20607 09900–20701 09900–20803 09900–20805Dial calipers (1/100 Dial gauge (1/100 mm, Magnetic stand Thickness gauge Tire depth gaugemm, 10 – 34 mm) 10 mm)09900–21304 09900–22301 09900–22302 09900–22403 09900–25008V-block (100 mm) Plastigauge (0.025 – Plastigauge (0.051 – Small bore gauge (18 Multi-circuit tester set 0.076 mm) 0.152 mm) – 35 mm)09900–25009 09900–28630 09904–41010 09910–60611 09913–50121Needle pointed probe TPS test wire harness SDS set Universal clamp Oil seal removerset wrench
  25. 25. 0A-13 General Information:09913–70210 09915–40610 09915–63311 09915–64512 09915–74521Bearing installer set Oil filter wrench Compression gauge Compression gauge Oil pressure gauge attachment hose09915–74540 09915–77331 09916–10911 09916–14510 09916–14522Oil pressure gauge Meter (for high Valve lapper set Valve spring Valve springattachment pressure) compressor compressor attachment09916–34542 09916–34570 09916–34580 09916–44310 09916–53350Reamer handle Valve guide reamer Valve guide reamer Valve guide remover/ Attachment (5.0 mm) (10.8 mm) installer09916–74521 09916–74550 09916–84511 09917–47011 09919–28620Holder body Band (Piston diam.: 73 Valve adjuster driver Vacuum pump gauge Sleeve protector – 85 mm)09920–34830 09920–53740 09921–20240 09922–22711 09923–74511Starter clutch holder Clutch sleeve hub Bearing remover set Drive chain cutting Bearing remover holder and joining tool
  26. 26. General Information: 0A-1409924–84510 09924–84521 09925–18011 09930–10121 09930–11920Bearing installer set Bearing installer set Steering bearing Spark plug wrench set Torx bit (JT40H) installer09930–11930 09930–11940 09930–11950 09930–30104 09930–30450Torx bit (JT30H) Bit holder Torx wrench Rotor remover slide Rotor remover bolt shaft09930–44530 09930–73140 09930–73170 09930–82720 09940–14911Rotor holder Starter torque limiter Starter torque limiter Mode select switch Steering stem nut socket holder wrench09940–14960 09940–14970 09940–14990 09940–30221 09940–40211Steering nut wrench Swingarm pivot thrust Engine mounting Front fork assembling Fuel pressure gaugesocket adjuster socket thrust adjuster socket tool adapter wrench wrench09940–40220 09940–52841 09940–52861 09940–92720 09940–94922Fuel pressure gauge Inner rod holder Front fork oil seal Spring scale Front fork springhose attachment installer stopper plate
  27. 27. 0A-15 General Information:09940–94930 09941–34513 09941–54911 09941–74911 09943–74111Front fork spacer Steering race installer Bearing outer race Steering bearing Fork oil level gaugeholder remover installer99565–01010–012CD-ROM Ver.12
  28. 28. Maintenance and Lubrication: 0B-1Maintenance and LubricationGeneral Information PrecautionsPrecautions for Maintenance B815H20200001The “Periodic Maintenance Schedule Chart” lists the recommended intervals for all the required periodic service worknecessary to keep the motorcycle operating at peak performance and economy. Maintenance intervals are expressedin terms of kilometers, miles and months for your convenience.IMPORTANT: The periodic maintenance intervals and service requirements have been established inaccordance with EPA regulations. Following these instructions will ensure that the motorcycle will not exceedemission standards and it will also ensure the reliability and perfomance of the motorcycle. NOTE More frequent servicing may be required on motorcycles that are used under severe conditions. General DescriptionRecommended Fluids and Lubricants B815H20201001Refer to “Fuel and Oil Recommendation in Section 0A (Page 0A-4)” and “Engine Coolant Recommendation in Section0A (Page 0A-5)”. Scheduled MaintenancePeriodic Maintenance Schedule Chart B815H20205001 NOTE I = Inspect and clean, adjust, replace or lubricate as necessary. R = Replace. T = Tighten. Interval km 1 000 6 000 12 000 18 000 24 000 Item miles 600 4 000 7 500 11 000 14 500 months 2 12 24 36 48 Air cleaner element — I I R I Exhaust pipe bolts and muffler bolts T — T — T Valve clearance — — — — I Spark plugs — I R I R Fuel line — I I I I Engine oil R R R R R Engine oil filter R — — R — Throttle cable play I I I I I I Throttle valve synchronization — I — I (E-33 only) Evaporative emission control system — — I — I (E-33 only) PAIR (air supply) system — — I — I Engine coolant Replace every 2 years. Radiator hoses — I I I I — I I I I Clutch fluid Replace every 2 years. — I I I I Clutch hose Replace every 4 years. I I I I I Drive chain Clean and lubricate every 1 000 km (600 miles).
  29. 29. 0B-2 Maintenance and Lubrication: Interval km 1 000 6 000 12 000 18 000 24 000 Item miles 600 4 000 7 500 11 000 14 500 months 2 12 24 36 48Brakes I I I I I — I I I IBrake fluid Replace every 2 years. — I I I IBrake hoses Replace every 4 years.Tires — I I I ISteering I — I — IFront forks — — I — IRear suspension — — I — IChassis bolts and nuts T T T T TLubrication Points B815H20205002Proper lubrication is important for smooth operation and long life of each working part of the motorcycle.Major lubrication points are indicated as follows. NOTE • Before lubricating each part, clean off any rusty spots and wipe off any grease, oil, dirt or grime. • Lubricate exposed parts which are subject to rust, with a rust preventative spray whenever the motorcycle has been operated under wet or rainy conditions. 5 1 4 6 7 3 2 I815H1020050-01 1. Clutch lever holder 6. Brake lever holder 2. Gearshift lever pivot 7. Brake pedal pivot and footrest pivot 3. Side-stand pivot and spring hook : Apply oil. 4. Footrest pivot : Apply grease. 5. Drive chain
  30. 30. Maintenance and Lubrication: 0B-3 Repair InstructionsAir Cleaner Element Replacement B815H20206001Replace air cleaner elementEvery 18 000 km (11 000 miles, 36 months)Refer to “Air Cleaner Element Removal and Installationin Section 1D (Page 1D-6)”.Air Cleaner Element Inspection B815H20206002 1Inspect air cleaner elementEvery 6 000 km (4 000 miles, 12 months) I815H1020002-01Inspection 5) Reinstall the drain plug. 1) Remove the air cleaner element. Refer to “Air Cleaner Element Removal and Installation in Section Exhaust Pipe Bolt and Muffler Bolt Inspection 1D (Page 1D-6)”. B815H20206003 2) Inspect the air cleaner element for clogging. If it is Tighten exhaust pipe bolts and muffler bolts clogged with dirt, replace it with a new one. Initially at 1 000 km (600 miles, 2 months) and every 12 000 km (7 500 miles, 24 months) thereafter ! CAUTION Check the exhaust pipe bolts and muffler bolts to the Do not blow the air cleaner element with specified torque. compressed air. Tightening torque NOTE Exhaust pipe bolt (a): 23 N·m (2.3 kgf-m, 16.5 lb-ft) Exhaust pipe mounting bolt (b): 23 N·m (2.3 kgf-m, If driving under dusty conditions, replace the 16.5 lb-ft) air cleaner element more frequently. Make Muffler connecting bolt (c): 23 N·m (2.3 kgf-m, 16.5 sure that the air cleaner is in good condition lb-ft) at all times. The life of the engine depends Muffler mounting bolt (d): 25 N·m (2.5 kgf-m, 18.0 largely on this component. lb-ft) (d) (d) I815H1020001-01 3) After finishing the air cleaner element inspection, reinstall the removed parts. 4) Drain water from the air cleaner box by removing the drain plug (1). (c) (c) (b) (a) I815H1020003-04

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