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.

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

Suzuki GSX-R. Disassembly

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

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

Suzuki GSX-R. Disassembly

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

Suzuki GSX-R. Disassembly

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

Suzuki GSX-R. Disassembly

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

Suzuki GSX-R. Disassembly

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

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.

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:

with the secondary throttle valves fully opened, install the stp sensor (black) and tighten the stp sensor mounting screw to the specified torque.

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 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)

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

With the throttle valves fully closed, install the tp sensor (gray) and tighten the tp sensor mounting screw to the specified torque.

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 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)

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

Apply a thin coat of engine oil to the o-ring, install the isc valve to the throttle body and tighten the isc valve mounting screw to the specified torque.

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)

Suzuki GSX-R. Assembly

Apply thin coat of engine oil to the new o-rings (1) and cushion seals (2).

Caution

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

Suzuki GSX-R. Assembly

Assemble the fuel delivery pipes so the t-joint is set in proper angle as shown in the figure.

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

Install each fuel injector by pushing it straight to the delivery pipe.

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

Install the fuel delivery pipe assembly to the throttle body.
Tighten the fuel delivery pipe mounting screws to the specified torque.

Tightening torque fuel delivery pipe mounting screw (b): 3.5 N·m ( 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:

Throttle cable play inspection and adjustment
Inspect throttle cable play initially at 1 000 km (600 miles, 2 months) and every 6 000 km (4 000 miles, 12 months) thereafter Inspect and adjust the throttle cable play “a” as follows: Throttle cable play “a” 2.0 – 4.0 Mm (0.08 – 0.16 In) Remove the boot (1). Loosen the lock-nu ...

Rear brake master cylinder parts inspection
Refer to “rear brake master cylinder disassembly and assembly” . Master cylinder Inspect the master cylinder bore for any scratches or other damage. Piston / rubber parts Inspect the piston surface for any scratches or other damage. Inspect the primary cup, secondary cup and dust boot ...

Oil cooler / oil cooler hose inspection and cleaning
Refer to “exterior parts removal and installation” in section 9d . Oil cooler hose inspection Inspect the oil cooler hoses for any damage and oil leakage. If any defects are found, replace the oil cooler hose with a new one. Oil cooler inspection Remove the oil cooler guard (1). ...