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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): 09930–82720 (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
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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 ...

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