Suzuki GSX-R 1000 Service Manual: Excv cable removal and installation
Removal
- Turn the ignition switch off.
- Remove the front seat. Refer to “exterior parts removal and installation” in section 9d (page 9d- 6).
- Remove the left side cowling. Refer to “exterior parts removal and installation” in section 9d .
- Connect the special tool (mode select switch) to the dealer mode coupler. Refer to “self-diagnostic procedures” in section 1a .
- After turning the mode select switch on, turn the ignition switch on.
Special tool
(a): 09930–82720 (mode selection
switch)
- Check that the cable slots of the excva pulley comes to the middle (adjustment position) “a”.
- Turn the ignition switch off.
| Caution before removing the excv cables, be sure to set the excva pulley to the adjustment position. |
- Loosen the lock-nut (1) on the no. 2 Cable (2) and turn in the cable adjuster (3) fully.
- Loosen the lock-nut (4) on the no. 1 Cable (5) and turn in the cable adjuster (6) fully.
- Disconnect the no. 2 Cable (2) and no. 1 Cable (5) from the excva pulley (7).
- Loosen the lock-nuts.
- Disconnect the no. 2 Cable (2) and no. 1 Cable (5) from the excv pulley (8).
Installation
| Caution the cable slots of excva pulley must be located adjustment position. |
- 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 |
- Tighten the lock-nuts (3) on the no. 1 Cable.
- 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).
- Turn in the adjuster (6) on the no. 2 Cable fully.
- 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).
- Connect the other end of excv cable no. 1 (1) And no. 2 (2) To the excva pulley (9).
- 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).
- 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:
Swingarm related parts inspection
Refer to “swingarm removal and installation” (page 2c-
9).
Spacers
Remove the collar and spacer from the swingarm.
Inspect the collars and spacer for wear and damage.
If any defects are found, replace them with new
ones.
Chain buffer
Inspect the chain buffer for wear and ...
Corrosion prevention
It is important to take good care of
your motorcycle to protect it from
corrosion and keep it looking new
for years to come.
Important information about
corrosion
Common causes of corrosion
Accumulation of road salt, dirt,
moisture, or chemicals in hardto-
reach areas.
Chipping ...
Transmission installation
Install the transmission in the reverse order of removal.
Pay attention to the following points:
Bearing and oil seal
Caution
replace the removed bearings and oil seals
with new ones.
Install the driveshaft left bearing oil seal into the
retainer using the special tool.
...