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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): 0993082720 (mode selection
switch)

Suzuki GSX-R. Excva 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 excva, be sure to set the excva pulley to the adjustment position.

Suzuki GSX-R. Excva removal and installation


  1. Disconnect the excva coupler (1).

Suzuki GSX-R. Excva removal and installation


  1. Remove the excv cables (2). Refer to excv cable removal and installation .
  2. Remove the excva (3) with the bracket.

Suzuki GSX-R. Excva removal and installation


  1. Remove the bracket from the excva

Suzuki GSX-R. Excva removal and installation


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

  •  when loosening or tightening the pulley bolt, be sure to fix the pulley with an adjustable wrench, or excva may get damaged.
  •  Do not use the adjustable wrench to turn excva pulley so as not to cause damage to the internal gear of excva.
  1. Remove the pulley from the excva body.

Suzuki GSX-R. Excva removal and installation


Installation

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

Note

align the shafts line a and cable slots b.

Suzuki GSX-R. Excva removal and installation


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

Caution

when loosening or tightening the pulley bolt, be sure to fix the pulley with an adjustable wrench, or excva may get damaged.

Suzuki GSX-R. Excva removal and installation


Excva inspection

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

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 ...

Excva pulley inspection
Inspect the excva pulley in the following procedures:  remove the excva pulley. Refer to excv cable removal and installation .  Visually inspect the excva pulley for wear and da ...

Other materials:

Inspecting the drive chain
When inspecting the chain, look for the following:  loose pins  damaged rollers dry or rusted links  kinked or binding links  excessive wear  improper chain adjustment If you find anything wrong with the drive chain condition or adjustment, correct the pr ...

Gearshift lever construction
Gearshift lever bracket Gearshift lever shaft Washer Snap ring Gearshift lever Footrest top surface 65 75 Mm (2.6 3.0 In) 28 Nm (2.8 Kgf-m, 20.0 Lbf-ft) 40 Nm (4.0 Kgf-m, 29.0 Lbf-ft) Apply grease. Grease. ...

Drive chain replacement
Use the special tool in the following procedures, to cut and rejoin the drive chain. Note when using the special tool, apply a small quantity of grease to the threaded parts of the special tool. Special tool : 0992222711 (drive chain cutting and joint tool set) Driv ...

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