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:
Schematic and routing diagram
Fuel tank drain hose and breather hose routing diagram
Fuel tank water drain hose
Fuel tank breather hose no. 1
Fuel tank breather hose no. 2
Fuel tank breather hose no. 3
3-Way joint
Frame
White marking
Set the
hose end to the root of tank nippl ...
Break-in procedures
During manufacture only the best possible materials are
used and all machined parts are finished to a very high
standard but it is still necessary to allow the moving parts
to “break-in” before subjecting the engine to maximum
stresses. The future performance and reliability of the
engine depen ...
Break-in
The first 800 km (500 miles) is the
most important in the life of your
motorcycle. Proper operation during
this break-in period will help
assure maximum life and performance
from your new motorcycle.
The following guidelines explain
proper break-in procedures.
Maximum engine speed recommen ...