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Suzuki GSX-R 1000 Service Manual: Evaporative emission control system removal and installation (only for e-33)

Suzuki GSX-R 1000 Service Manual / Engine / Emission control devices / Repair instructions / Evaporative emission control system removal and installation (only for e-33)

Hose removal

  1. Lift and support the fuel tank. Refer to “fuel tank removal and installation” in section 1g (page 1g- 9).
  2.  Remove the frame cover assembly. Refer to “exterior parts removal and installation” in section 9d .
  3.  Remove the evap hoses as shown in the evap canister hose routing diagram. Refer to “pair system hose routing diagram” .

Installation

  1. Install the evap hoses as shown in the evap canister hose routing diagram. Refer to “evap canister hose routing diagram (only for e-33)” .
  2.  Reinstall the removed parts.

Evap canister removal

  1. Remove the frame cover assembly. Refer to “exterior parts removal and installation” in section 9d .
  2.  Disconnect the surge hose (1) and purge hose (2).
  3. Remove the evap canister (3) from the bracket.

Suzuki GSX-R. Evap canister removal


Installation

  1. Install the evap canister as shown in the evap canister hose routing diagram. Refer to “evap canister hose routing diagram (only for e-33)” .
  2.  Reinstall the removed parts.

Evap system purge control solenoid valve removal

  1. Lift and support the fuel tank with the prop stay.

    Refer to “fuel tank removal and installation” in section 1g .

  2. Disconnect the coupler (1) and purge hoses (2).
  3.  Remove the evap system purge control solenoid valve (3) with the bracket.

Suzuki GSX-R. Evap system purge control solenoid valve removal


  1. Remove the evap system purge control solenoid valve from the bracket.

Suzuki GSX-R. Evap system purge control solenoid valve removal


Installation

Install the evap system purge control solenoid valve in the reverse order of removal. Pay attention to the following point:

Tightening torque evap system purge control solenoid valve mounting nut (a): 6.5 N·m (0.65 Kgf-m, 4.5 Lbf-ft)

Suzuki GSX-R. Evap system purge control solenoid valve


Tightening torque evap system purge control solenoid valve bracket bolt (b): 10 n·m (1.0 Kgf-m, 7.0 Lbf-ft)

Suzuki GSX-R. Evap system purge control solenoid valve


Fuel shut-off valve removal

  1. Remove the front seat. Refer to “exterior parts removal and installation” in section 9d (page 9d- 6).
  2.  Remove the battery. Refer to “battery removal and installation” in section 1j .
  3.  Remove the ecm. Refer to “ecm removal and installation” in section 1c .
  4.  Remove the frame cover assembly. Refer to “exterior parts removal and installation” in section 9d .
  5.  Disconnect the cooling fan relay (1) from the rear fender (front).
  6. Disconnect the license plate light coupler (2).

Suzuki GSX-R. Fuel shut-off valve


  1. Remove the rear fender (rear) (3).

Suzuki GSX-R. Fuel shut-off valve


  1. Remove the battery mat (4).

Suzuki GSX-R. Fuel shut-off valve


  1. Disconnect the fuse box (5), ap sensor (6) and to sensor (7) from the rear fender (front).
  2.  Remove the rear fender (front) mounting bolt (8).

Suzuki GSX-R. Fuel shut-off valve


  1. Disconnect the surge hose (9).

Suzuki GSX-R. Fuel shut-off valve


  1. Move the rear fender (front) backward.
  2.  Disconnect the surge hose (10).
  3.  Remove the bracket (11) and fuel shaft-off valve (12).

Suzuki GSX-R. Fuel shut-off valve


Installation

Install the fuel shut-off valve in the reverse order of removal. Pay attention to the following point:

Crankcase breather (pcv) cover inspection
Inspect the crankcase breather (pcv) cover in the following procedures:  remove the crankcase breather (pcv) cover. Refer to “crankcase breather (pcv) hose / reed valve / cover removal an ...

Evaporative emission control system inspection (only for e-33)
Refer to “evaporative emission control system removal and installation (only for e-33)” . Hose Inspect the hoses for wear or damage. If it is worn or damage, replace the hose with a new one. ...

Other materials:

Fuel tank removal and installation
Removal Keep away from fire or spark.  Spilled gasoline should be wiped off immediately.  Work in a well-ventilated area. Remove the front seat. Refer to “exterior parts removal and installation” in section 9d (page 9d- 6).  Take ...

Use of sds diagnosis reset procedures
Note the malfunction code is memorized in the ecm also when the lead wire coupler of any sensor is disconnected. Therefore, when a lead wire coupler has been disconnected at the time of diagnosis, erase the stored malfunction history code using sds. After repairing ...

Precautions
Precautions for engine cooling system You can be injured by boiling fluid or steam if you open the radiator cap when the engine is hot. After the engine cools, wrap a thick cloth around cap and carefully remove the cap by turning it a quarter turn to allow pr ...

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