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)
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 ...
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:
Body frame construction
Frame
Seat rail
Seat rail bolt
Collar
Engine mounting thrust adjuster
Engine mounting thrust adjuster lock-nut
Engine mounting pinch bolt
50 N·m (5.0 Kgf-m,
36.0 Lbf-ft)
23 N·m
(2.3 Kgf-m, 16.5 Lbf-ft)
45 N·m
(4.5 Kgf-m, 32. ...
Damping force adjustment
The rebound and compression
damping force can be individually
adjusted by turning the respective
adjusters. The rebound damping
force adjuster 1 is located at the
bottom of the rear suspension.
The compression damping force
adjuster 2 is located at the left
side of the motorcycle.
To ad ...
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 ...