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Suzuki GSX-R 1000 Service Manual: Excv cable removal and installation

Suzuki GSX-R 1000 Service Manual / Engine / Exhaust system / Repair instructions / Excv cable removal and installation

Removal

  1. Turn the ignition switch off.
  2.  Remove the front seat. Refer to exterior parts removal and installation in section 9d (page 9d- 6).
  3.  Remove the left side cowling. Refer to exterior parts removal and installation in section 9d .
  4.  Connect the special tool (mode select switch) to the dealer mode coupler. Refer to self-diagnostic procedures in section 1a .
  5.  After turning the mode select switch on, turn the ignition switch on.

Special tool (a): 0993082720 (mode selection
switch)

Suzuki GSX-R. Excv cable removal and installation


  1. Check that the cable slots of the excva pulley comes to the middle (adjustment position) a.
  2.  Turn the ignition switch off.
Caution

before removing the excv cables, be sure to set the excva pulley to the adjustment position.

Suzuki GSX-R. Excv cable removal and installation


  1. Loosen the lock-nut (1) on the no. 2 Cable (2) and turn in the cable adjuster (3) fully.
  2.  Loosen the lock-nut (4) on the no. 1 Cable (5) and turn in the cable adjuster (6) fully.

Suzuki GSX-R. Excv cable removal and installation


  1. Disconnect the no. 2 Cable (2) and no. 1 Cable (5) from the excva pulley (7).

Suzuki GSX-R. Excv cable removal and installation


  1. Loosen the lock-nuts.
  2.  Disconnect the no. 2 Cable (2) and no. 1 Cable (5) from the excv pulley (8).

Suzuki GSX-R. Excv cable removal and installation


Installation

Caution

the cable slots of excva pulley must be located adjustment position.

  1. Temporarily connect the excv cable no. 1 (47H0cl) (1) and no. 2 (47H0op) (2) to the exhaust pipe and excv pulley.
Note

the excv cables are identified by the letters.

No. 1 Cable (1): 47h0cl no. 2 Cable (2): 47h0op

  1. Tighten the lock-nuts (3) on the no. 1 Cable.
  2.  Adjust the inner cable length a of no. 1 Cable in 42 43 mm (1.65 1.69 In) by turning the adjuster (4), then tighten the lock-nuts (5).
  3.  Turn in the adjuster (6) on the no. 2 Cable fully.
  4.  Turn the no. 2 Cable adjuster (7) in or out until the inner cable length b becomes 60 61 mm (2.36 2.40 In).

    After adjusting the inner cable length b, tighten the lock-nuts (8).

Suzuki GSX-R. Excv cable removal and installation


  1. Connect the other end of excv cable no. 1 (1) And no. 2 (2) To the excva pulley (9).

Suzuki GSX-R. Excv cable removal and installation


  1. After connecting the no. 2 Cable (2), loosen the locknut (10) and turn the adjuster (6) in or out until 11 12 mm (0.43 0.47 In) of the thread length c on the cable adjuster can be provided and tighten the locknut (10).

Suzuki GSX-R. Excv cable removal and installation


  1. Inspect the excva position sensor output voltage.

    Refer to excva adjustment .

Exhaust system components
Exhaust pipe gasket Exhaust pipe assembly Ho2 sensor Connector : install the connector so that the chamfer side faces backward. Muffler chamber Muffler ...

Excva removal and installation
Removal Turn the ignition switch off.  Remove the left side cowling. Refer to exterior parts removal and installation in section 9d .  Connect the special tool (mode select swit ...

Other materials:

Excva adjustment
Inspect the excva operation and adjust it if necessary in the following steps: Step 1 Set the excva to the adjustment position. Refer to excv cable removal and installation (page 1k- 6). Step 2 Turn the ignition switch off.  Turn the mode select switch off.  Turn the ...

Rear brake hose routing diagram
Hose clamp : face the clamp end backward. Stopper : after the brake hose union has contacted to the stopper, tighten the union bolt. Brake pad pin Plug Caliper sliding pin b Caliper sliding pin a White marking Yellow marking Pass the ...

Swingarm bearing removal and installation
Removal Remove the swingarm. Refer to swingarm removal and installation .  Remove the swingarm pivot bearings (1) using the special tool. Special tool (a): 0992120240 (bearing remover set) Remove the center spacer (2). Remove the cushion lever bearing (3) usin ...

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