Refer to “throttle body removal and installation” .
Disassembly
Caution identify the position of each removed part. Organize the parts in their respective groups so that they can be reinstalled in their original positions. |
Caution be careful not to twist the fuel delivery pipes and t-joint (6) when removing them, or joint part “a” of the fuel delivery pipe get damage. |
Special tool
: 09930–11950 (torx wrench (5 mm))
Note prior to disassembly, mark each sensor’s original position with a paint or scribe for accurate reinstallation. |
Caution never remove the stva (14) from the throttle body. |
Caution never remove the throttle valves (15) and secondary throttle valves (16). |
Caution
|
Assembly
Reassemble the throttle body in the reverse order of disassembly. Pay attention to the following points:
Note
|
: Grease 99000–25010 (suzuki
super
grease “a” or equivalent)
Special tool
: 09930–11950 (torx wrench (5 mm))
Tightening torque stp sensor mounting screw: 3.5 N·m (0.35 Kgfm, 2.5 Lbf-ft)
Note
|
Caution
|
: Grease 99000–25010 (suzuki
super
grease “a” or equivalent)
Special tool
: 09930–11950 (torx wrench (5 mm))
Tightening torque tp sensor mounting screw: 3.5 N·m (0.35 Kgf-m, 2.5 Lbf-ft)
Note
|
Special tool
: 09930–11960 (torx wrench (4 mm))
Tightening torque isc valve mounting screw (a): 2 n·m (0.2 Kgf-m, 1.5 Lbf-ft)
Caution replace the o-rings and cushion seals with new ones. |
Caution be careful not to twist the fuel delivery pipes and t-joint when installing them, or joint part “e” of the fuel delivery pipe may get damage. |
Caution never turn the injector while pushing it. |
Note align the coupler “f” of injector with boss “g” of the delivery pipe. |
Tightening torque fuel delivery pipe mounting screw (b): 3.5 N·m ( 0.35 Kgf-m, 2.5 Lbf-ft)
Connect the hoses properly. Refer to “throttle body construction” .
Light bulb replacement
The wattage rating of each bulb is
shown in the following chart.
When replacing a burned-out
bulb, always use the same wattage
rating according to the following
chart.
Caution
Using a light bulb with the
wrong wattage rating can
cause electrical system damage
or shorte ...
Crankshaft journal bearing inspection and
selection
Refer to “engine bottom side disassembly” (page 1d-
49).
Refer to “engine bottom side assembly” .
Inspection
Inspect each upper and lower crankcase bearing for
any damage.
Set the crankshaft onto the upper crank case.
Install the plastigauge onto each crankshaft jour ...
Starter relay inspection
Inspect the starter relay in the following procedures:
remove the starter relay. Refer to “starter relay removal and
installation” .
Apply 12 v to “a” and “b” terminals and check for
continuity between the positive and negative
terminals using the multi-circuit tester. If th ...