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Suzuki GSX-R 1000 Service Manual: Throttle body disassembly and assembly

Suzuki GSX-R 1000 Service Manual / Engine / Engine mechanical / Repair instructions / Throttle body disassembly and assembly

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.

  1. Disconnect the fuel feed hose (1), isc valve hose (2) and vacuum hoses (3).
  2. Disconnect the purge hose (4). (E-33 only)

Suzuki GSX-R. Disassembly


  1. Remove the fuel delivery pipe assembly (5).
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.

Suzuki GSX-R. Disassembly


  1. Remove the primary fuel injectors (7) and secondary fuel injectors (8) from the fuel delivery pipes.

Suzuki GSX-R. Disassembly


  1. Remove the fuel pipe (9) from the primary fuel injectors (7).

Suzuki GSX-R. Disassembly


  1. Remove the t-joint (6) from the fuel delivery pipes.

Suzuki GSX-R. Disassembly


  1. Remove the isc valve hoses (10) and isc valve (11).

Suzuki GSX-R. Disassembly


  1. Remove the tp sensor (12) and stp sensor (13) with the special tool.

Special tool : 0993011950 (torx wrench (5 mm))


Note

prior to disassembly, mark each sensors original position with a paint or scribe for accurate reinstallation.

Suzuki GSX-R. Disassembly


Caution

never remove the stva (14) from the throttle body.

Suzuki GSX-R. Disassembly


Caution

never remove the throttle valves (15) and secondary throttle valves (16).

Suzuki GSX-R. Disassembly


Caution

  •  these adjusting screws (17), (18) and (19) are factory-adjusted at the time of delivery and do not turn or remove them.
  •  Do not separate the throttle body.

Suzuki GSX-R. Disassembly


Assembly

Reassemble the throttle body in the reverse order of disassembly. Pay attention to the following points:

Note

  •  apply thin coat of engine oil to the o-ring.
  •  Align the secondary throttle valve shaft end a with the groove b of the stp sensor.
  •  Apply grease to the secondary throttle valve shaft end a if necessary.

: Grease 9900025010 (suzuki
super grease a or equivalent)

Special tool : 0993011950 (torx wrench (5 mm))


Tightening torque stp sensor mounting screw: 3.5 Nm (0.35 Kgfm, 2.5 Lbf-ft)

Suzuki GSX-R. Assembly


Note

  •  make sure the secondary throttle valves smoothly open and close.
  •  If necessary, adjust the stp sensor. Refer to stp sensor adjustment in section 1c .

Suzuki GSX-R. Assembly


Caution

  •  apply thin coat of engine oil to the o-ring.
  •  Align the throttle valve shaft end c with the groove d of the tp sensor.
  •  Apply grease to the throttle valve shaft end c if necessary.

: Grease 9900025010 (suzuki
super grease a or equivalent)

Special tool : 0993011950 (torx wrench (5 mm))


Tightening torque tp sensor mounting screw: 3.5 Nm (0.35 Kgf-m, 2.5 Lbf-ft)

Suzuki GSX-R. Assembly


Note

  •  make sure the throttle valves smoothly open and close.
  •  If necessary, adjust the tp sensor. Refer to tp sensor adjustment in section 1c .

Suzuki GSX-R. Assembly


Special tool : 0993011960 (torx wrench (4 mm))


Tightening torque isc valve mounting screw (a): 2 nm (0.2 Kgf-m, 1.5 Lbf-ft)

Suzuki GSX-R. Assembly


Caution

replace the o-rings and cushion seals with new ones.

Suzuki GSX-R. Assembly


Suzuki GSX-R. Assembly


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.

Suzuki GSX-R. Assembly


Caution

never turn the injector while pushing it.

 

Note

align the coupler f of injector with boss g of the delivery pipe.

Suzuki GSX-R. Assembly


Tightening torque fuel delivery pipe mounting screw (b): 3.5 Nm ( 0.35 Kgf-m, 2.5 Lbf-ft)

Suzuki GSX-R. Assembly


Connect the hoses properly. Refer to throttle body construction .

Throttle body removal and installation
Removal Remove the side cowlings. Refer to exterior parts removal and installation in section 9d (page 9d- 6).  Remove the air cleaner box. Refer to air cleaner box removal and in ...

Throttle body inspection and cleaning
Refer to throttle body disassembly and assembly . Cleaning Some carburetor cleaning chemicals, especially dip-type soaking solutions, are very corrosive and must be handled carefu ...

Other materials:

Cylinder inspection
Refer to engine top side disassembly . Refer to engine top side assembly . Cylinder distortion Check the gasket surface of the cylinder for distortion. Use a straightedge and thickness gauge. Take clearance readings at several places. If any reading exceeds the service limit, replace t ...

Piston ring removal and installation
Removal Remove the piston. Refer to engine bottom side disassembly .  Carefully spread the ring opening with your thumbs and then push up the opposite side of the 1st ring to remove it. Note do not expand the piston ring excessively since it is apt to be broken down. ...

Malfunction code and defective condition table
* : Immobilizer system equipped model only. ...

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