Suzuki GSX-R 1000 Service Manual: 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 installation” .
- Remove the clamps (1).
- Disconnect the iap sensor (2) from the vacuum hose.
- Disconnect the stva lead wire coupler (3).
- Disconnect secondary fuel injector couplers (4) and primary fuel injector couplers (5).
- Disconnect the purge hose (6) from the evap system purge control solenoid valve. (E-33 only)
- Remove the clamp (7).
- Disconnect the isc valve coupler (8).
- Place a rag under the fuel feed hose (9) and disconnect the fuel feed hose from the fuel pump.
 For e-33
models, drain fuel from the fuel tank before disconnecting the fuel feed hose to prevent fuel leakage. |
- Loosen the throttle body clamp screws, left and right.
- Lift up the throttle body from the intake pipes.
- Disconnect the stp sensor coupler (10) and tp sensor coupler (11).
- Disconnect the throttle cables.
| Caution after disconnecting the throttle cables, do not snap the throttle valve from full open to full close. It may cause damage to the throttle valve and throttle body. |
- Remove the throttle body.
Installation
Installation is in the reverse order of removal. Pay attention to the following points:
- connect the primary injector couplers (1) and secondary injector couplers (2) to the respective fuel injectors. Make sure that each coupler is installed in the correct position. The color on each lead wire refers to the appropriate fuel injector.
- Connect the throttle cable no. 1 (3) And throttle cable no. 2 (4) To the throttle cable drum.
|
- Loosen each throttle cable lock-nut.
- Turn in each throttle cable adjuster fully and locate each outer cable so that the clearance “a” is 0 – 1 mm (0 – 0.04 In).
- Tighten each lock-nut.
Tightening torque throttle cable lock-nut: 4.5 N·m (0.45 Kgf-m, 3.0 Lbf-ft)
- Adjust the throttle cable play. Refer to “throttle cable play inspection and adjustment” in section 0b .
- Reset the isc valve and tp sensor learned values.
Refer to “isc valve reset” and “tp reset” .
Throttle body construction
Intake pipe
Evap system purge control solenoid valve
(e-33 only)
Evap canister (e-33 only)
Iat sensor
Isc valve hose
Ho2 sensor
Face
the clamp end ...
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 ...
Other materials:
Radiator inspection and cleaning
Radiator hose inspection
Refer to “cooling system inspection” in section 0b .
Radiator inspection
Inspect the radiator for water leaks. If any defects are
found, replace the radiator with a new one.
If the fins are bent or dented, repair them by carefully
straightening them with the blade of ...
Starter relay 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).
Disconnect the battery (–) lead wire (1) from the
battery.
Remove the starter relay cover (2) and disconnect
the starter rel ...
Show data when trouble (displaying data at
the time of DTC)
Use of sds
Ecm stores the engine and driving conditions (in the form of data as shown in
the figure) at the moment of the
detection of a malfunction in its memory. This data is called “show data when
trouble”.
Therefore, it is possible to know engine and driving conditions (e.G., Whether
...