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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:

Wheel / tire / air valve inspection and cleaning
Refer to “tire removal and installation” . Wheel Wipe the wheel clean and check for the following points:  distortion and crack  any flaws and scratches at the bead seating area.  Wheel rim runout. Refer to “front wheel related parts inspection”  and “rear wheel rela ...

DTC “c41” (p2505): ecm power input signal malfunction
Detected condition and possible cause Detected condition Possible cause C41/P2505 No voltage is applied to the ecm. Lead wire/coupler connection of ecm terminal to fuel fuse. Fuel fuse. Wiring diagram Troubleshooting C ...

DTC “c28” (p1655): secondary throttle valve actuator (stva) malfunction
Detected condition and possible cause Detected condition Possible cause The operation voltage does not reach the stva. Ecm does not receive communication signal from the stva. Stva can not operate properly or its motor locked Stva malfunction.   ...

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