Suzuki GSX-R 1000 Service Manual: Excva removal and installation

Removal

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

Special tool (a): 09930–82720 (mode selection
switch)

5. Check that the cable slots of the excva pulley comes to the middle (adjustment position) “a”.
6.  Turn the ignition switch off.

7. Disconnect the excva coupler (1).

8. Remove the excv cables (2). Refer to “excv cable removal and installation” .
9. Remove the excva (3) with the bracket.

10. Remove the bracket from the excva

11. Hold the pulley with an adjustable wrench, and loosen the pulley mounting bolt (4).

12. Remove the pulley from the excva body.

Installation

Install the excva in the reverse order of removal. Pay attention to the following points:

•  install the excva pulley to the shaft.

• Hold the pulley with an adjustable wrench, and then tighten the pulley mounting bolt (1) to the specified torque.

Tightening torque excva pulley mounting bolt (a): 5 n·m (0.5 Kgfm, 3.5 Lbf-ft)

• Install the excv cables. Refer to “excv cable removal and installation” .
• Adjust the excva. Refer to “excva adjustment” .

Excva inspection

Refer to “dtc “c46” (p1657-h/l or p1658): excv actuator circuit malfunction” in section 1a (page 1a- 109).