Suzuki GSX-R1100, GSX-R1300 Repair Service Manuals

Complete service repair manual with Electrical Wiring Diagrams for Suzuki GSX-R1100, GSX-R1300, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.

Suzuki GSX-R1100, GSX-R1300 Motorcycles workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

Suzuki GSX-R1000 (K9) Service Manual 2009 (EN).pdf
Suzuki GSX-R1000 (K1-K2) Service Manual 2001-2002 (EN).pdf
Suzuki GSX-R1000 (K1) Service Manual 2001 (EN).pdf
Suzuki GSX-R1000 (K3) Service Manual 2003 (EN).pdf.pdf
Suzuki GSX-R1000 (K5) Service Manual 2005 (EN).pdf
Suzuki GSX-R1000 (K7) Service Manual 2007 (EN).pdf
Suzuki GSX-R1000(K3) Manuale Di Servizio 2003 (IT).pdf
Suzuki GSX-R1000 Service Manual 2003 (EN).pdf
Suzuki GSX-R1000 Wartungsanleitung 2001 (DE).pdf
Suzuki GSX-R1100 Parts Catalog.pdf
Suzuki GSX-R1100 Service Manual '89-'92.pdf
Suzuki GSX-R1100W Service Manual '93-'96.pdf
Suzuki GSX-R1300 (GSX-R1300K8, GSX-R1300K9) Hayabusa 2008-2009 Service Manual.pdf
Suzuki GSX-R1300 Hayabusa  (GSX-R1300RX, GSX-R1300RY, GSX-R1300RK1, GSX-R1300RK2) Service Manual  1999-2002.pdf

PRODUCT DETAILS:
Total Pages: 6,195 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English

TABLE OF CONTENTS
Suzuki GSX-R1000  (K9) Service Manual 2009 (EN)...2
  99500-39380-01E GSX-R1000 SERVICE MANUAL...2
    FOREWORD...3
    TABLE OF CONTENTS...4
    Precautions...6
      Precautions...7
        Precautions...7
          Warning / Caution / Note...7
          General Precautions...7
          Precautions for Electrical Circuit Service...8
    General Information...14
      General Information...15
        General Description...15
          Symbols...15
          Abbreviations...15
          Vehicle Side View...16
          Vehicle Identification Number...17
          Fuel and Oil Recommendation...17
          Engine Coolant Recommendation...18
          BREAK-IN Procedures...18
          Cylinder Identification...18
          Country and Area Codes...19
          Wire Color Symbols...19
          Warning, Caution and Information Labels Location...20
        Component Location...21
          Electrical Components Location...21
        Specifications...23
          Specifications...23
        Special Tools and Equipment...25
          Special Tool...25
      Maintenance and Lubrication...29
        Precautions...29
          Precautions for Maintenance...29
        General Description...29
          Recommended Fluids and Lubricants...29
        Scheduled Maintenance...30
          Periodic Maintenance Schedule Chart...30
          Lubrication Points...31
        Repair Instructions...31
          Air Cleaner Element Replacement...31
          Air Cleaner Element Inspection...31
          Exhaust Pipe Bolt and Muffler Bolt Inspection...32
          Exhaust Control Valve Inspection...32
          Valve Clearance Inspection and Adjustment...33
          Spark Plug Replacement...37
          Spark Plug Inspection and Cleaning...37
          Fuel Line Inspection...38
          Evaporative Emission Control System Inspection (E-33 only)...38
          Engine Oil and Filter Replacement...38
          Throttle Cable Play Inspection and Adjustment...40
          PAIR System Inspection...40
          Throttle Valve Synchronization...40
          Cooling System Inspection...40
          Clutch Cable Play Inspection and Adjustment...42
          Drive Chain Inspection and Adjustment...42
          Drive Chain Cleaning and Lubricating...44
          Brake System Inspection...44
          Tire Inspection...46
          Steering System Inspection...46
          Front Fork Inspection...47
          Rear Suspension Inspection...47
          Chassis Bolt and Nut Inspection...47
          Compression Pressure Check...49
          Oil Pressure Check...49
          SDS Check...49
        Specifications...49
          Tightening Torque Specifications...49
        Special Tools and Equipment...50
          Recommended Service Material...50
          Special Tool...50
      Service Data...51
        Specifications...51
          Service Data...51
          Tightening Torque List...59
    Engine...64
      Precautions...69
        Precautions...69
          Precautions for Engine...69
      Engine General Information and Diagnosis...70
        General Description...70
          Injection Timing Description...70
          Self-Diagnosis Function...72
        Schematic and Routing Diagram...73
          FI System Wiring Diagram...73
          Terminal Alignment of ECM Coupler...75
        Component Location...76
          FI System Parts Location...76
        Diagnostic Information and Procedures...77
          Engine Symptom Diagnosis...77
          Self-Diagnostic Procedures...81
          Use of SDS Diagnosis Reset Procedures...83
          Show Data When Trouble (Displaying Data at the Time of DTC)...84
          SDS Check...85
          DTC Table...89
          Fail-Safe Function Table...91
          FI System Troubleshooting...92
          Malfunction Code and Defective Condition Table...94
          DTC “C11” (P0340): CMP Sensor Circuit Malfunction...98
          DTC “C12” (P0335): CKP Sensor Circuit Malfunction...101
          DTC “C13” (P0105-H/L): IAP Sensor Circuit Malfunction...104
          DTC “C14” (P0120-H/L): TP Sensor Circuit Malfunction...112
          DTC “C15” (P0115-H/L): ECT Sensor Circuit Malfunction...119
          DTC “C21” (P0110-H/L): IAT Sensor Circuit Malfunction...124
          DTC “C22” (P1450-H/L): AP Sensor Circuit Malfunction...129
          DTC “C23” (P1651-H/L): TO Sensor Circuit Malfunction...137
          DTC “C24” (P0351), “C25” (P0352), “C26” (P0353) or “C27” (P0354): Ignition System Malfunction...144
          DTC “C28” (P1655): Secondary Throttle Valve Actuator (STVA) Malfunction...144
          DTC “C29” (P1654-H/L): Secondary Throttle Position Sensor (STPS) Circuit Malfunction...148
          DTC “C31” (P0705): GP Switch Circuit Malfunction...155
          DTC “C32” (P0201), “C33” (P0202), “C34” (P0203) or “C35” (P0204): Primary Fuel Injector Circuit Malfunction...157
          DTC “C36” (P1764), “C37” (P1765), “C38” (P1766) or “C39” (P1767): Secondary Fuel Injector Circuit Malfunction...160
          DTC “C40” (P0505 / P0506 / P0507): ISC Valve Circuit Malfunction...163
          DTC “C41” (P0230-H/L): FP Relay Circuit Malfunction...167
          DTC “C41” (P2505): ECM Power Input Signal Malfunction...170
          DTC “C42” (P1650): IG Switch Circuit Malfunction...172
          DTC “C44” (P0130/P0135): HO2 Sensor (HO2S) Circuit Malfunction...172
          DTC “C46” (P1657-H/L or P1658): EXCV Actuator Circuit Malfunction...178
          DTC “C49” (P1656): PAIR Control Solenoid Valve Circuit Malfunction...190
          DTC “C60” (P0480): Cooling Fan Relay Circuit Malfunction...193
          DTC “C62” (P0443): EVAP System Purge Control Solenoid Valve Circuit Malfunction (E-33 only)...196
          DTC “C91” (P0500): Vehicle Speed Sensor Circuit Malfunction...200
          DTC “C93” (P1769): Steering Damper Solenoid Valve Circuit Malfunction...203
        Specifications...207
          Service Data...207
        Special Tools and Equipment...208
          Special Tool...208
      Emission Control Devices...210
        Precautions...210
          Precautions for Emission Control Devices...210
        General Description...210
          Fuel Injection System Description...210
          Crankcase Emission Control System Description...211
          Exhaust Emission Control System Description...212
          PAIR System Diagram...213
          Noise Emission Control System Description...213
          Evaporative Emission Control System Diagram (Only for E-33)...214
        Schematic and Routing Diagram...215
          PAIR System Hose Routing Diagram...215
          EVAP Canister Hose Routing Diagram (Only for E-33)...216
        Repair Instructions...217
          Heated Oxygen Sensor (HO2S) Removal and Installation...217
          Heated Oxygen Sensor (HO2S) Inspection...217
          PAIR Reed Valve Removal and Installation...217
          PAIR Control Solenoid Valve Removal and Installation...218
          PAIR System Inspection...218
          Crankcase Breather (PCV) Hose Inspection...220
          Crankcase Breather (PCV) Hose / Reed Valve / Cover Removal and Installation...220
          Crankcase Breather (PCV) Cover Inspection...221
          Evaporative Emission Control System Removal and Installation (Only for E-33)...221
          Evaporative Emission Control System Inspection (Only for E-33)...223
        Specifications...225
          Service Data...225
          Tightening Torque Specifications...225
        Special Tools and Equipment...225
          Recommended Service Material...225
          Special Tool...225
      Engine Electrical Devices...226
        Precautions...226
          Precautions for Engine Electrical Device...226
        Component Location...226
          Engine Electrical Components Location...226
        Diagnostic Information and Procedures...226
          Engine Symptom Diagnosis...226
        Repair Instructions...226
          ECM Removal and Installation...226
          CMP Sensor Inspection...227
          CMP Sensor Removal and Installation...227
          CKP Sensor Inspection...227
          CKP Sensor Removal and Installation...227
          IAP Sensor Inspection...227
          IAP Sensor Removal and Installation...227
          TP Sensor Inspection...227
          TP Sensor Removal and Installation...228
          TP Sensor Adjustment...228
          ECT Sensor Removal and Installation...229
          ECT Sensor Inspection...229
          IAT Sensor Removal and Installation...230
          IAT Sensor Inspection...230
          AP Sensor Inspection...230
          AP Sensor Removal and Installation...230
          TO Sensor Inspection...230
          TO Sensor Removal and Installation...231
          STP Sensor Inspection...231
          STP Sensor Adjustment...231
          STP Sensor Removal and Installation...232
          STV Actuator Inspection...232
          STV Actuator Removal and Installation...232
          ISC Valve Inspection...232
          ISC Valve Removal and Installation...232
          ISC Valve Preset and Opening Initialization...233
          HO2 Sensor Inspection...233
          HO2 Sensor Removal and Installation...233
          GP Switch Inspection...233
          GP Switch Removal and Installation...233
        Specifications...234
          Service Data...234
          Tightening Torque Specifications...234
        Special Tools and Equipment...235
          Special Tool...235
      Engine Mechanical...236
        Schematic and Routing Diagram...236
          Camshaft and Sprocket Assembly Diagram...236
          Throttle Cable Routing Diagram...237
        Diagnostic Information and Procedures...238
          Engine Mechanical Symptom Diagnosis...238
          Compression Pressure Check...238
        Repair Instructions...239
          Engine Components Removable with the Engine in Place...239
          Air Cleaner Element Removal and Installation...241
          Air Cleaner Box Removal and Installation...242
          Air Cleaner Element Inspection and Cleaning...242
          Throttle Cable Removal and Installation...242
          Throttle Cable Inspection...242
          Throttle Cable Play Inspection and Adjustment...242
          Throttle Body Components...243
          Throttle Body Construction...244
          Throttle Body Removal and Installation...245
          Throttle Body Disassembly and Assembly...246
          Throttle Body Inspection and Cleaning...251
          ISC Valve Visual Inspection...251
          Throttle Valve Synchronization...251
          ISC Valve Reset...253
          TP Reset...254
          Engine Assembly Removal...255
          Engine Assembly Installation...259
          Engine Top Side Disassembly...261
          Engine Top Side Assembly...263
          Cylinder Head Cover Disassembly and Assembly...270
          Cylinder Head Cover Related Parts Inspection...271
          Camshaft Inspection...271
          Camshaft Sprocket...273
          Cam Chain Tension Adjuster Inspection...273
          Cam Chain Guide / Cam Chain Tensioner Removal and Installation...274
          Cam Chain Guide Inspection...275
          Cam Chain Tensioner Inspection...275
          Cylinder Head Disassembly and Assembly...275
          Cylinder Head Related Parts Inspection...279
          Valve Guide Replacement...282
          Valve Seat Repair...284
          Engine Bottom Side Disassembly...284
          Engine Bottom Side Assembly...291
          Cylinder Inspection...304
          Piston Ring Removal and Installation...304
          Piston and Piston Ring Inspection...306
          Balancer Shaft Disassembly and Assembly...308
          Balancer Shaft Inspection...308
          Balancer Shaft Journal Bearing Removal and Installation...309
          Balancer Shaft Journal Bearing Inspection and Selection...310
          Conrod Crank Pin Bearing Removal and Installation...311
          Conrod and Crankshaft Inspection...312
          Conrod Crank Pin Bearing Inspection and Selection...313
          Crankshaft Journal Bearing Inspection and Selection...314
          Crankshaft Thrust Clearance Inspection and Selection...317
        Specifications...319
          Service Data...319
          Tightening Torque Specifications...321
        Special Tools and Equipment...322
          Recommended Service Material...322
          Special Tool...323
      Engine Lubrication System...326
        Precautions...326
          Precautions for Engine Oil...326
        Schematic and Routing Diagram...327
          Engine Lubrication System Chart Diagram...327
          Engine Lubrication Circuit Diagram...328
        Diagnostic Information and Procedures...330
          Engine Lubrication Symptom Diagnosis...330
          Oil Pressure Check...330
        Repair Instructions...331
          Engine Oil and Filter Replacement...331
          Engine Oil Level Inspection...331
          Oil Pan / Oil Pressure Regulator / Oil Strainer Removal and Installation...331
          Oil Pressure Regulator / Oil Strainer Inspection...332
          Oil Cooler / Oil Cooler Hose Inspection and Cleaning...332
          Oil Cooler / Oil Cooler Hose Removal and Installation...333
          Oil Pressure Switch Removal and Installation...334
          Oil Pressure Switch Inspection...335
          Oil Jet Removal and Installation...335
          Oil Jet Inspection...337
          Oil Pump Removal and Installation...337
          Oil Pump Inspection...339
          Oil Pump Drive Sprocket Removal and Installation...339
        Specifications...339
          Service Data...339
          Tightening Torque Specifications...339
        Special Tools and Equipment...340
          Recommended Service Material...340
          Special Tool...340
      Engine Cooling System...341
        Precautions...341
          Precautions for Engine Cooling System...341
          Precautions for Engine Coolant...341
        General Description...341
          Engine Coolant Description...341
        Schematic and Routing Diagram...342
          Cooling Circuit Diagram...342
          Water Hose Routing Diagram...343
        Diagnostic Information and Procedures...344
          Engine Cooling Symptom Diagnosis...344
        Repair Instructions...344
          Cooling Circuit Inspection...344
          Radiator Cap Inspection...345
          Radiator Inspection and Cleaning...345
          Radiator / Cooling Fan Motor Removal and Installation...346
          Water Hose Inspection...347
          Water Hose Removal and Installation...348
          Radiator Reservoir Tank Inspection...348
          Radiator Reservoir Tank Removal and Installation...348
          Cooling Fan Inspection...349
          Cooling Fan Relay Inspection...349
          ECT Sensor Removal and Installation...350
          ECT Sensor Inspection...350
          Thermostat Removal and Installation...350
          Thermostat Inspection...351
          Water Pump Components...352
          Water Pump Construction...353
          Water Pump Removal and Installation...353
          Water Pump Disassembly and Assembly...354
          Water Pump Related Parts Inspection...357
        Specifications...358
          Service Data...358
          Tightening Torque Specifications...359
        Special Tools and Equipment...359
          Recommended Service Material...359
          Special Tool...359
      Fuel System...360
        Precautions...360
          Precautions for Fuel System...360
        General Description...361
          Fuel Injection System Description...361
        Schematic and Routing Diagram...362
          Fuel Tank Drain Hose and Breather Hose Routing Diagram...362
        Diagnostic Information and Procedures...363
          Fuel System Diagnosis...363
        Repair Instructions...364
          Fuel Pressure Inspection...364
          Fuel Pump Inspection...365
          Fuel Discharge Amount Inspection...365
          Fuel Pump Relay Inspection...366
          Fuel Hose Inspection...366
          Fuel Level Gauge Inspection...366
          Fuel Tank Construction...367
          Fuel Tank Removal and Installation...368
          Fuel Pump Components...369
          Fuel Pump Disassembly and Assembly...370
          Fuel Mesh Filter Inspection and Cleaning...372
          Fuel Injector / Fuel Delivery Pipe / T-joint Removal and Installation...372
          Fuel Injector Inspection and Cleaning...372
        Specifications...373
          Service Data...373
          Tightening Torque Specifications...373
        Special Tools and Equipment...374
          Recommended Service Material...374
          Special Tool...374
      Ignition System...375
        General Description...375
          Immobilizer Description (For E-02, 19, 24, 51)...375
          Drive Mode Selector Description...376
        Schematic and Routing Diagram...377
          Ignition System Diagram...377
          Ignition System Components Location...377
        Diagnostic Information and Procedures...378
          Ignition System Symptom Diagnosis...378
          No Spark or Poor Spark...379
        Repair Instructions...380
          Ignition Coil and Spark Plug Removal and Installation...380
          Spark Plug Inspection and Cleaning...381
          Ignition Coil Inspection...381
          CKP Sensor Inspection...383
          CKP Sensor Removal and Installation...384
          Engine Stop Switch Inspection...384
          Ignition Switch Inspection...384
          Ignition Switch Removal and Installation...385
          Drive Mode Selector Inspection...386
        Specifications...387
          Service Data...387
          Tightening Torque Specifications...387
        Special Tools and Equipment...388
          Recommended Service Material...388
          Special Tool...388
      Starting System...389
        Schematic and Routing Diagram...389
          Starting System Diagram...389
        Component Location...389
          Starting System Components Location...389
        Diagnostic Information and Procedures...389
          Starting System Symptom Diagnosis...389
          Starter Motor Will Not Run...390
          Starter Motor Runs But Does Not Crank The Engine...390
        Repair Instructions...391
          Starter Motor Components...391
          Starter Motor Removal and Installation...392
          Starter Motor Disassembly and Assembly...392
          Starter Motor Inspection...393
          Starter Relay Removal and Installation...394
          Starter Relay Inspection...394
          Turn Signal / Side-stand Relay Removal and Installation...395
          Side-stand / Ignition Interlock System Parts Inspection...395
          Starter Torque Limiter Removal and Installation...397
          Starter Torque Limiter Inspection...398
          Starter Clutch Removal and Installation...398
          Starter Clutch Inspection...399
          Starter Button Inspection...400
        Specifications...400
          Service Data...400
          Tightening Torque Specifications...400
        Special Tools and Equipment...401
          Recommended Service Material...401
          Special Tool...401
      Charging System...402
        Schematic and Routing Diagram...402
          Charging System Diagram...402
        Component Location...402
          Charging System Components Location...402
        Diagnostic Information and Procedures...402
          Charging System Symptom Diagnosis...402
          Battery Runs Down Quickly...403
        Repair Instructions...404
          Battery Current Leakage Inspection...404
          Regulated Voltage Inspection...404
          Generator Inspection...404
          Generator Removal and Installation...405
          Regulator / Rectifier Construction...408
          Regulator / Rectifier Removal and Installation...408
          Regulator / Rectifier Inspection...409
          Battery Components...410
          Battery Charging...410
          Battery Removal and Installation...412
          Battery Visual Inspection...413
        Specifications...413
          Service Data...413
          Tightening Torque Specifications...413
        Special Tools and Equipment...414
          Recommended Service Material...414
          Special Tool...414
      Exhaust System...415
        Precautions...415
          Precautions for Exhaust System...415
        General Description...415
          Exhaust Control System Description...415
          Exhaust Control System Operation...416
        Repair Instructions...418
          Exhaust Control System Construction...418
          Exhaust System Components...419
          EXCV Cable Removal and Installation...420
          EXCVA Removal and Installation...421
          EXCVA Inspection...423
          EXCVA Pulley Inspection...423
          EXCVA Adjustment...423
          Muffler / Muffler Chamber / Exhaust Pipe Removal and Installation...425
          Exhaust System Inspection...427
        Specifications...428
          Service Data...428
          Tightening Torque Specifications...428
        Special Tools and Equipment...429
          Recommended Service Material...429
          Special Tool...429
    Suspension...430
      Precautions...431
        Precautions...431
          Precautions for Suspension...431
      Suspension General Diagnosis...432
        Diagnostic Information and Procedures...432
          Suspension and Wheel Symptom Diagnosis...432
      Front Suspension...433
        Repair Instructions...433
          Front Fork Components...433
          Front Fork Removal and Installation...434
          Front Suspension Adjustment...436
          Front Fork Disassembly and Assembly...436
          Front Fork Parts Inspection...442
          Rod Guide Case Tightening Torque...442
        Specifications...443
          Service Data...443
          Tightening Torque Specifications...443
        Special Tools and Equipment...444
          Recommended Service Material...444
          Special Tool...444
      Rear Suspension...445
        Repair Instructions...445
          Rear Suspension Components...445
          Rear Suspension Assembly Construction...446
          Rear Shock Absorber Removal and Installation...447
          Rear Suspension Inspection...447
          Rear Shock Absorber Inspection...448
          Rear Shock Absorber Bearing Removal and Installation...448
          Rear Shock Absorber Adjustment...449
          Rear Shock Absorber Disposal...450
          Cushion Lever Removal and Installation...451
          Cushion Lever Inspection...451
          Cushion Rod Removal and Installation...451
          Cushion Rod Inspection...452
          Cushion Rod Bearing Removal and Installation...453
          Swingarm Removal and Installation...453
          Swingarm Pivot Boss Removal and Installation...456
          Swingarm Related Parts Inspection...456
          Swingarm Bearing Removal and Installation...457
        Specifications...459
          Service Data...459
          Tightening Torque Specifications...459
        Special Tools and Equipment...460
          Recommended Service Material...460
          Special Tool...460
      Wheels and Tires...461
        Precautions...461
          Precautions for Wheel and Tire...461
        Repair Instructions...462
          Front Wheel Components...462
          Front Wheel Assembly Construction...463
          Front Wheel Assembly Removal and Installation...464
          Front Wheel Related Parts Inspection...466
          Front Wheel Dust Seal / Bearing Removal and Installation...467
          Rear Wheel Components...469
          Rear Wheel Assembly Construction...470
          Rear Wheel Assembly Removal and Installation...471
          Rear Wheel Related Parts Inspection...472
          Rear Wheel Dust Seal / Bearing Removal and Installation...473
          Tire Removal and Installation...474
          Wheel / Tire / Air Valve Inspection and Cleaning...476
          Air Valve Removal and Installation...476
          Wheel Balance Check and Adjustment...477
        Specifications...478
          Service Data...478
          Tightening Torque Specifications...478
        Special Tools and Equipment...479
          Recommended Service Material...479
          Special Tool...479
    Driveline / Axle...480
      Precautions...481
        Precautions...481
          Precautions for Driveline / Axle...481
      Drive Chain / Drive Train / Drive Shaft...482
        Diagnostic Information and Procedures...482
          Drive Chain and Sprocket Symptom Diagnosis...482
        Repair Instructions...482
          Drive Chain Related Components...482
          Engine Sprocket Removal and Installation...483
          Rear Sprocket / Rear Sprocket Mounting Drum Removal and Installation...484
          Drive Chain Related Parts Inspection...486
          Sprocket Mounting Drum Dust Seal / Bearing Removal and Installation...486
          Drive Chain Replacement...488
        Specifications...491
          Service Data...491
          Tightening Torque Specifications...491
        Special Tools and Equipment...492
          Recommended Service Material...492
          Special Tool...492
    Brake...494
      Precautions...495
        Precautions...495
          Precautions for Brake System...495
          Brake Fluid Information...495
      Brake Control System and Diagnosis...496
        Schematic and Routing Diagram...496
          Front Brake Hose Routing Diagram...496
          Rear Brake Hose Routing Diagram...497
        Diagnostic Information and Procedures...498
          Brake Symptom Diagnosis...498
        Repair Instructions...498
          Brake Pedal Height Inspection and Adjustment...498
          Front Brake Light Switch Inspection...498
          Rear Brake Light Switch Inspection...499
          Rear Brake Light Switch Inspection and Adjustment...499
          Brake Fluid Level Check...499
          Brake Hose Inspection...499
          Air Bleeding from Brake Fluid Circuit...499
          Brake Fluid Replacement...501
          Front Brake Hose Removal and Installation...503
          Rear Brake Hose Removal and Installation...503
          Front Brake Master Cylinder Components...504
          Front Brake Master Cylinder Assembly Removal and Installation...505
          Front Brake Master Cylinder / Brake Lever Disassembly and Assembly...506
          Front Brake Master Cylinder Parts Inspection...508
          Rear Brake Master Cylinder Components...509
          Rear Brake Master Cylinder Assembly Removal and Installation...510
          Rear Brake Master Cylinder Disassembly and Assembly...511
          Rear Brake Master Cylinder Parts Inspection...512
          Rear Brake Pedal Construction...513
          Rear Brake Pedal Removal and Installation...513
        Specifications...514
          Service Data...514
          Tightening Torque Specifications...514
        Special Tools and Equipment...515
          Recommended Service Material...515
          Special Tool...515
      Front Brakes...516
        Repair Instructions...516
          Front Brake Components...516
          Front Brake Pad Inspection...517
          Front Brake Pad Replacement...517
          Front Brake Caliper Removal and Installation...518
          Front Brake Caliper Disassembly and Assembly...518
          Front Brake Caliper Parts Inspection...520
          Front Brake Disc Removal and Installation...521
          Front Brake Disc Inspection...521
        Specifications...522
          Service Data...522
          Tightening Torque Specifications...522
        Special Tools and Equipment...523
          Recommended Service Material...523
          Special Tool...523
      Rear Brakes...524
        Repair Instructions...524
          Rear Brake Components...524
          Rear Brake Pad Inspection...525
          Rear Brake Pad Replacement...525
          Rear Brake Caliper Removal and Installation...526
          Rear Brake Caliper Disassembly and Assembly...527
          Rear Brake Caliper Parts Inspection...529
          Rear Brake Disc Removal and Installation...529
          Rear Brake Disc Inspection...530
        Specifications...530
          Service Data...530
          Tightening Torque Specifications...531
        Special Tools and Equipment...531
          Recommended Service Material...531
          Special Tool...531
    Transmission / Transaxle...532
      Precautions...533
        Precautions...533
          Precautions for Transmission / Transaxle...533
      Manual Transmission...534
        Diagnostic Information and Procedures...534
          Manual Transmission Symptom Diagnosis...534
        Repair Instructions...535
          Transmission Components...535
          Transmission Removal...536
          Transmission Installation...538
          Transmission Construction...542
          Countershaft Gear / Driveshaft Gear Disassembly and Assembly...543
          Transmission Related Parts Inspection...545
          Gear Position (GP) Switch Inspection...546
          Gear Position (GP) Switch Removal and Installation...547
          Gearshift Lever Construction...548
          Gearshift Lever Removal and Installation...548
          Gearshift Lever Height Inspection and Adjustment...549
          Gearshift Shaft / Gearshift Cam Plate Components...549
          Gearshift Shaft Construction...550
          Gearshift Shaft / Gearshift Cam Plate Removal and Installation...550
          Gearshift Linkage Inspection...553
          Gearshift Shaft Oil Seal / Bearing Removal and Installation...553
        Specifications...554
          Service Data...554
          Tightening Torque Specifications...555
        Special Tools and Equipment...555
          Recommended Service Material...555
          Special Tool...556
      Clutch...557
        Precautions...557
          Precautions for Clutch System...557
        Schematic and Routing Diagram...557
          Clutch Cable Routing Diagram...557
        Diagnostic Information and Procedures...557
          Clutch System Symptom Diagnosis...557
        Repair Instructions...558
          Clutch Lever Position Switch Inspection...558
          Clutch Cable Inspection...558
          Clutch Cable Removal and Installation...558
          Clutch Control System Components...559
          Clutch Components...560
          Clutch Removal...561
          Clutch Installation...563
          Clutch Parts Inspection...567
          Clutch Lifter Pin Inspection and Adjustment...569
        Specifications...570
          Service Data...570
          Tightening Torque Specifications...570
        Special Tools and Equipment...571
          Recommended Service Material...571
          Special Tool...571
    Steering...572
      Precautions...573
        Precautions...573
          Precautions for Steering...573
      Steering General Diagnosis...574
        Diagnostic Information and Procedures...574
          Steering Symptom Diagnosis...574
      Steering / Handlebar...575
        Repair Instructions...575
          Handlebar Components...575
          Handlebar Removal and Installation...576
          Handlebars Inspection...578
          Steering Components...579
          Steering Damper Construction...580
          Steering / Steering Damper Removal and Installation...580
          Steering / Steering Damper Related Parts Inspection...583
          Steering System Inspection...584
          Steering Stem Bearing Removal and Installation...584
          Steering Tension Adjustment...585
        Specifications...586
          Tightening Torque Specifications...586
        Special Tools and Equipment...587
          Recommended Service Material...587
          Special Tool...587
    Body and Accessories...588
      Precautions...590
        Precautions...590
          Precautions for Electrical System...590
        Component Location...590
          Electrical Components Location...590
      Wiring Systems...591
        Schematic and Routing Diagram...591
          Wiring Diagram...591
          Wiring Harness Routing Diagram...597
        Specifications...601
          Service Data...601
          Tightening Torque Specifications...601
        Special Tools and Equipment...601
          Recommended Service Material...601
      Lighting Systems...602
        Repair Instructions...602
          Headlight Components...602
          Headlight Removal and Installation...602
          Headlight Bulb and Position Light Bulb Replacement...603
          Headlight Beam Adjustment...604
          Front Turn Signal Light Components...604
          Front Turn Signal Light Removal and Installation...605
          Front Turn Signal Light Bulb Replacement...605
          Rear Lighting System Construction...606
          Rear Combination Light Removal and Installation...607
          Rear Combination Light Replacement...607
          License Plate Light Components...608
          License Plate Light Removal and Installation...608
          License Plate Light Bulb Replacement...609
          Rear Turn Signal Light Components...610
          Rear Turn Signal Light Removal and Installation...610
          Rear Turn Signal Light Bulb Replacement...611
          Reflex Reflector Construction...611
          Turn Signal / Side-Stand Relay Inspection...612
          Turn Signal / Side-Stand Relay Removal and Installation...612
          Hazard Switch Inspection...612
          Turn Signal Switch Inspection...613
          Dimmer / Passing Light Switch Inspection...613
        Specifications...614
          Service Data...614
          Tightening Torque Specifications...614
        Special Tools and Equipment...614
          Recommended Service Material...614
          Special Tool...614
      Combination Meter / Fuel Meter / Horn...615
        General Description...615
          Combination Meter System Description...615
        Repair Instructions...616
          Combination Meter Components...616
          Combination Meter Removal and Installation...616
          Combination Meter Disassembly and Assembly...617
          Combination Meter Inspection...617
          Engine Coolant Temperature Indicator Light Inspection...618
          ECT Sensor Removal and Installation...618
          Fuel Level Indicator Inspection...619
          Fuel Level Gauge Inspection...619
          Speedometer Inspection...619
          Speed Sensor Removal and Installation...619
          Speed Sensor Inspection...620
          Oil Pressure Indicator Inspection...620
          Oil Pressure Switch Removal and Installation...621
          Oil Pressure Switch Inspection...621
          Ignition Switch Inspection...621
          Ignition Switch Removal and Installation...621
          Horn Inspection...622
          Horn Removal and Installation...622
        Specifications...623
          Service Data...623
          Tightening Torque Specifications...623
        Special Tools and Equipment...623
          Special Tool...623
      Exterior Parts...624
        Repair Instructions...624
          Exterior Parts Construction...624
          Rear Fender Construction...625
          Frame Cover Construction...626
          Rear View Mirror Construction...627
          Fastener Removal and Installation...628
          Exterior Parts Removal and Installation...629
        Specifications...635
          Tightening Torque Specifications...635
      Body Structure...636
        Repair Instructions...636
          Body Frame Construction...636
          Front Footrest Bracket Construction...637
          Side-stand Construction...638
          Pillion Footrest Construction...639
          Side-stand Removal and Installation...639
        Specifications...640
          Tightening Torque Specifications...640
        Special Tools and Equipment...640
          Recommended Service Material...640
Suzuki GSX-R1000 (K1) Service Manual 2001 (EN)...643
  1 General Info...652
  2 Periodic Maintenance...662
  3 Engine...692
    Balancer Bearings...751
    Rod Bearings...754
    Main Bearings...756
    Case Assembly...763
    Head Install...783
  4 FI/PAIR/Exh Systems...792
    Engine Codes...826
  5 Cooling & Lube Sys...883
  6 Chassis...905
    Forks...918
    Triples...929
    Rear Wheel...937
    Shock...945
    Rear Suspension...949
    Front Brake...958
    Rear Brake...966
  7 Electrical...979
  8 Servicing Info...1013
    Tools...1040
    Specifications...1047
  9 Emissions...1056
  Wiring Diagrams...1063
Suzuki GSX-R1000 (K1-K2) Service Manual 2001-2002 (EN)...1067
  Cover...1067
  Index...1068
  1. General Info...1076
  2. Periodic Maintenance...1086
  3. Engine...1116
  4. Fuel Injection System...1216
  5. Cooling & Lube System...1306
  6. Chassis...1329
  7. Electrical System...1404
  8. Service Information...1438
  9. Emission Control Information...1482
  2002 Model Updates...1489
    Specifications...1490
    Clutch...1500
    Fuel Pump & Level Switch...1501
    Fast Idle...1502
  Wiring Diagrams...1503
Suzuki GSX-R1000 (K3) Service Manual 2003 (EN).pdf...1511
Suzuki GSX-R1000 (K5) Service Manual 2005 (EN)...1804
  GSX-R1000_SM_2005.pdf...0
    GSX-R1000_SM_2005.pdf...0
      99500-39270-01E GSX-R1000 SERVICE MANUAL...1804
        FOREWORD_GROUP INDEX...1805
          HOW TO USE THIS MANUAL...1806
            TO LOCATE WHAT YOU ARE LOOKING FOR:...1806
            COMPONENT PARTS AND WORK TO BE DONE...1806
            SYMBOL...1807
          ABBREVIATIONS USED IN THIS MANUAL...1808
            WIRE COLOR...1810
        01 GENERAL INFORMATION...1811
          WARNING/CAUTION/NOTE...1812
          GENERAL PRECAUTIONS...1812
          SUZUKI GSX-R1000K5 (’05-MODEL)...1814
          SERIAL NUMBER LOCATION...1814
          FUEL, OIL AND ENGINE COOLANT RECOMMENDATION...1815
          BREAK-IN PROCEDURES...1817
          CYLINDER IDENTIFICATION...1817
          INFORMATION LABELS...1818
          SPECIFICATIONS...1819
        02 PERIODIC MAINTENANCE...1821
          PERIODIC MAINTENANCE SCHEDULE...1822
          MAINTENANCE AND TUNE-UP PROCEDURES...1824
          COMPRESSION PRESSURE CHECK...1852
          OIL PRESSURE CHECK...1853
          SDS CHECK...1854
        03 ENGINE...1857
          ENGINE COMPONENTS REMOVABLE WITH ENGINE IN PLACE...1858
          ENGINE REMOVAL AND INSTALLATION...1859
          ENGINE DISASSEMBLY...1871
          ENGINE COMPONENTS INSPECTION AND SERVICE...1883
          ENGINE REASSEMBLY...1930
        04 FI SYSTEM DIAGNOSIS...1963
          PRECAUTIONS IN SERVICING...1965
          FI SYSTEM TECHNICAL FEATURES...1972
          ECM TERMINAL...1977
          SELF-DIAGNOSIS FUNCTION...1979
          FAIL-SAFE FUNCTION...1983
          FI SYSTEM TROUBLESHOOTING...1985
          SENSORS...2057
        05 FUEL SYSTEM AND THROTTLE BODY...2060
          FUEL DELIVERY SYSTEM...2061
          FUEL SYSTEM...2062
          THROTTLE BODY...2071
        06 EXHAUST SYSTEM...2089
          EXHAUST SYSTEM...2090
          EXCVA (EXHAUST CONTROL VALVE ACTUATOR) AND EXCV (EXHAUST CONTROL VALVE)...2092
        07 COOLING AND LUBRICATION SYSTEM...2105
          ENGINE COOLANT...2106
          COOLING CIRCUIT...2107
          RADIATOR AND WATER HOSES...2108
          COOLING FAN...2110
          ECT SENSOR...2111
          THERMOSTAT...2113
          WATER PUMP...2115
          LUBRICATION SYSTEM...2121
        08 CHASSIS...2126
          EXTERIOR PARTS...2128
          FRONT WHEEL...2134
          FRONT FORK...2142
          STEERING DAMPER...2153
          STEERING...2155
          HANDLEBARS...2161
          REAR WHEEL...2165
          REAR SHOCK ABSORBER...2173
          REAR SUSPENSION...2177
          FRONT BRAKE...2187
          REAR BRAKE...2198
          TIRE AND WHEEL...2207
          DRIVE CHAIN...2211
        09 ELECTRICAL SYSTEM...2215
          CAUTIONS IN SERVICING...2217
          LOCATION OF ELECTRICAL COMPONENTS...2220
          CHARGING SYSTEM...2222
          STARTER SYSTEM AND SIDE-STAND/IGNITION INTERLOCK SYSTEM...2226
          IGNITION SYSTEM...2234
          COMBINATION METER...2243
          LAMPS...2249
          RELAYS...2251
          BATTERY...2254
        10 SERVICING INFORMATION...2257
          TROUBLESHOOTING...2259
          WIRING HARNESS, CABLE AND HOSE ROUTING...2274
          TIGHTENING TORQUE...2301
          SERVICE DATA...2305
        11 EMISSION CONTROL INFORMATION...2315
          EMISSION CONTROL SYSTEMS...2316
          PAIR (AIR SUPPLY) SYSTEM AND EMISSION CONTROL SYSTEM INSPECTION...2320
          PAIR (AIR SUPPLY) SYSTEM DIAGRAM...2322
          PAIR (AIR SUPPLY) SYSTEM HOSE ROUTING...2323
        12 WIRING DIAGRAM...2324
Suzuki GSX-R1000 (K7) Service Manual 2007 (EN)...2328
  GSX-R1000_(K7)_SM_2007.pdf...0
    GSX-R1000_(K7)_SM_2007.pdf...0
      GSXR1000K7 S-M...2328
      00 Group Index...2329
      01 General information...2330
      02 Periodid Maintenance...2340
      03 Engine...2377
      04 FI System Diagnosis...2483
      05 Fuel System & Throttle Body...2596
      06 Exhaust System...2625
      07 Cooling & Lubrication System...2641
      08 Chassis...2662
      09 Electrical System...2762
      10 Servicing Information...2806
      11 Emission Control Information...2865
      12 Wiring Diagrams...2873
Suzuki GSX-R1000 Service Manual 2003 (EN)...2877
Suzuki GSX-R1000 Wartungsanleitung 2001 (DE)...3337
Suzuki GSX-R1000(K3) Manuale Di Servizio 2003 (IT)...3731
  Indice generale...3731
  1 Informazioni generali...3738
  2 Manutenzione peridica...3750
  3 Motore...3782
  4 Diagnosi sistema F.i...3886
  5 Sistema alimentazione...3949
  6 Sistema di scarico...3978
  7 Raffreddamento e lubrificazione...3992
  8 Telaio...4014
  9 Impianto elettrico...4097
  10 Info manutenzione...4133
  11 Info controllo emissioni...4179
  12 Schema elettrico...4187
Suzuki GSX-R1100 Parts Catalog...4191
Suzuki GSX-R1100 Service Manual '89-'92...4243
Suzuki GSX-R1100W Service Manual '93-'96...4601
Suzuki GSX-R1300 (GSX-R1300K8, GSX-R1300K9) Hayabusa 2008-2009 Service Manual...4981
  FOREWORD...4981
  TABLE OF CONTENTS ...4983
  00. PRECAUTIONS...4987
    PRECAUTIONS...4988
      PRECAUTIONS...4988
        WARNING / CAUTION / NOTE...4988
        GENERAL PRECAUTIONS...4988
        PRECAUTIONS FOR ELECTRICAL CIRCUIT SERVICE...4989
  0. GENERAL INFORMATION...4995
    GENERAL INFORMATION...4996
      GENERAL DESCRIPTION...4996
        SYMBOLS...4996
        ABBREVIATIONS...4996
        SAE-TO-FORMER SUZUKI TERM...4997
        VEHICLE SIDE VIEW...4998
        VEHICLE IDENTIFICATION NUMBER...4999
        FUEL AND OIL RECOMMENDATION...4999
        ENGINE COOLANT RECOMMENDATION...5000
        BREAK-IN PROCEDURES...5000
        CYLINDER IDENTIFICATION...5000
        COUNTRY AND AREA CODES...5001
        WIRE COLOR SYMBOLS...5001
        WARNING, CAUTION AND INFORMATION LABELS LOCATION...5002
      COMPONENT LOCATION...5003
        ELECTRICAL COMPONENTS LOCATION...5003
      SPECIFICATIONS...5005
        SPECIFICATIONS...5005
      SPECIAL TOOLS AND EQUIPMENT...5007
        SPECIAL TOOL...5007
    MAINTENANCE AND LUBRICATION...5011
      PRECAUTIONS...5011
        PRECAUTIONS FOR MAINTENANCE...5011
      GENERAL DESCRIPTION...5011
        RECOMMENDED FLUIDS AND LUBRICANTS...5011
      SCHEDULED MAINTENANCE...5011
        PERIODIC MAINTENANCE SCHEDULE CHART...5011
        LUBRICATION POINTS...5012
      REPAIR INSTRUCTIONS...5013
        AIR CLEANER ELEMENT REPLACEMENT...5013
        AIR CLEANER ELEMENT INSPECTION...5013
        EXHAUST PIPE BOLT AND MUFFLER BOLT INSPECTION...5013
        VALVE CLEARANCE INSPECTION AND ADJUSTMENT...5014
        SPARK PLUG REPLACEMENT...5019
        SPARK PLUG INSPECTION AND CLEANING...5019
        FUEL LINE INSPECTION...5020
        ENGINE OIL AND FILTER REPLACEMENT...5020
        THROTTLE CABLE PLAY INSPECTION AND ADJUSTMENT...5022
        THROTTLE VALVE SYNCHRONIZATION...5022
        EVAPORATIVE EMISSION CONTROL SYSTEM INSPECTION (E-33 ONLY)...5023
        PAIR SYSTEM INSPECTION...5023
        COOLING SYSTEM INSPECTION...5023
        CLUTCH SYSTEM INSPECTION...5024
        CLUTCH HOSE REPLACEMENT...5025
        CLUTCH FLUID REPLACEMENT...5025
        DRIVE CHAIN INSPECTION AND ADJUSTMENT...5025
        DRIVE CHAIN CLEANING AND LUBRICATING...5027
        BRAKE SYSTEM INSPECTION...5027
        TIRE INSPECTION...5029
        STEERING SYSTEM INSPECTION...5030
        FRONT FORK INSPECTION...5030
        REAR SUSPENSION INSPECTION...5030
        CHASSIS BOLT AND NUT INSPECTION...5031
        COMPRESSION PRESSURE CHECK...5033
        OIL PRESSURE CHECK...5033
        SDS CHECK...5033
      SPECIFICATIONS...5033
        TIGHTENING TORQUE SPECIFICATIONS...5033
      SPECIAL TOOLS AND EQUIPMENT...5034
        RECOMMENDED SERVICE MATERIAL...5034
        SPECIAL TOOL...5034
    SERVICE DATA...5035
      SPECIFICATIONS...5035
        SERVICE DATA...5035
        TIGHTENING TORQUE LIST...5043
  01. ENGINE...5047
    PRECAUTIONS...5051
      PRECAUTIONS...5051
        PRECAUTIONS FOR ENGINE...5051
    ENGINE GENERAL INFORMATION AND DIAGNOSIS...5052
      GENERAL DESCRIPTION...5052
        INJECTION TIMING DESCRIPTION...5052
        SELF-DIAGNOSIS FUNCTION...5053
      SCHEMATIC AND ROUTING DIAGRAM...5054
        FI SYSTEM WIRING DIAGRAM...5054
        TERMINAL ALIGNMENT OF ECM COUPLER...5056
      COMPONENT LOCATION...5057
        FI SYSTEM PARTS LOCATION...5057
      DIAGNOSTIC INFORMATION AND PROCEDURES...5059
        ENGINE SYMPTOM DIAGNOSIS...5059
        SELF-DIAGNOSTIC PROCEDURES...5063
        USE OF SDS DIAGNOSIS RESET PROCEDURES...5065
        SHOW DATA WHEN TROUBLE (DISPLAYING DATA AT THE TIME OF DTC)...5066
        SDS CHECK...5068
        DTC TABLE...5071
        FAIL-SAFE FUNCTION TABLE...5073
        FI SYSTEM TROUBLESHOOTING...5075
        MALFUNCTION CODE AND DEFECTIVE CONDITION TABLE...5076
        DTC “C11” (P0340) CMP SENSOR CIRCUIT MALFUNCTION...5079
        DTC “C12” (P0335): CKP SENSOR CIRCUIT MALFUNCTION...5081
        DTC “C13” (P0105-H/L): IAP SENSOR CIRCUIT MALFUNCTION...5084
        DTC “C14” (P0120-H/L): TP SENSOR CIRCUIT MALFUNCTION...5091
        DTC “C15” (P0115-H/L): ECT SENSOR CIRCUIT MALFUNCTION...5098
        DTC “C21” (P0110-H/L): IAT SENSOR CIRCUIT MALFUNCTION...5103
        DTC “C22” (P01450-H/L): AP SENSOR CIRCUIT MALFUNCTION...5108
        DTC “C23” (P1651-H/L): TO SENSOR CIRCUIT MALFUNCTION...5115
        DTC “C24” (P0351), “C25” (P0352), “C26” (P0353) OR “C27” (P0354): IGNITION SYSTEM MALFUNCTION...5122
        DTC “C28” (P1655): SECONDARY THROTTLE VALVE ACTUATOR (STVA) MALFUNCTION...5122
        DTC “C29” (P1654-H/L): SECONDARY THROTTLE POSITION SENSOR (STPS) CIRCUIT MALFUNCTION...5126
        DTC “C31” (P0705): GP SWITCH CIRCUIT MALFUNCTION...5133
        DTC “C32” (P0201), “C33” (P0202), “C34” (P0203) OR “C35” (P0204): PRIMARY FUEL INJECTOR CIRCUIT MALFUNCTION...5135
        DTC “C36” (P1764), “C37” (P1765), “C38” (P1766) OR “C39” (P1767): SECONDARY FUEL INJECTOR CIRCUIT MALFUNCTION...5139
        DTC “C40” (P0505 / P0506 / P0507): ISC VALVE CIRCUIT MALFUNCTION...5143
        DTC “C41” (P0230-H/L): FP RELAY CIRCUIT MALFUNCTION...5148
        DTC “C41” (P2505): ECM POWER INPUT SIGNAL MALFUNCTION...5151
        DTC “C42” (P1650): IG SWITCH CIRCUIT MALFUNCTION...5153
        DTC “C44” (P0130/P0135): HO2 SENSOR (HO2S) CIRCUIT MALFUNCTION...5153
        DTC “C49” (P1656): PAIR CONTROL SOLENOID VALVE CIRCUIT MALFUNCTION...5159
        DTC “C60” (P0480): COOLING FAN RELAY CIRCUIT MALFUNCTION...5163
        DTC “C62” (P0443): EVAP SYSTEM PURGE CONTROL SOLENOID VALVE CIRCUIT MALFUNCTION (E-33 ONLY)...5166
      SPECIFICATIONS...5169
        SERVICE DATA...5169
      SPECIAL TOOLS AND EQUIPMENT...5170
        SPECIAL TOOL...5170
    EMISSION CONTROL DEVICES...5172
      PRECAUTIONS...5172
        PRECAUTIONS FOR EMISSION CONTROL DEVICES...5172
      GENERAL DESCRIPTION...5172
        FUEL INJECTION SYSTEM DESCRIPTION...5172
        CRANKCASE EMISSION CONTROL SYSTEM DESCRIPTION...5173
        EXHAUST EMISSION CONTROL SYSTEM DESCRIPTION...5174
        NOISE EMISSION CONTROL SYSTEM DESCRIPTION...5177
        EVAPORATIVE EMISSION CONTROL SYSTEM DIAGRAM (ONLY FOR E-33)...5178
      SCHEMATIC AND ROUTING DIAGRAM...5179
        EVAP CANISTER HOSE ROUTING DIAGRAM (ONLY FOR E-33)...5179
      REPAIR INSTRUCTIONS...5180
        HEATED OXYGEN SENSOR (HO2S) REMOVAL AND INSTALLATION...5180
        HEATED OXYGEN SENSOR (HO2S) INSPECTION...5180
        PAIR REED VALVE REMOVAL AND INSTALLATION...5180
        PAIR CONTROL SOLENOID VALVE REMOVAL AND INSTALLATION...5181
        PAIR SYSTEM INSPECTION...5182
        CRANKCASE BREATHER (PCV) HOSE INSPECTION...5183
        CRANKCASE BREATHER (PCV) HOSE / REED VALVE / COVER REMOVAL AND INSTALLATION...5183
        CRANKCASE BREATHER (PCV) COVER INSPECTION...5184
        EVAPORATIVE EMISSION CONTROL SYSTEM REMOVAL AND INSTALLATION (ONLY FOR E-33)...5185
        EVAPORATIVE EMISSION CONTROL SYSTEM INSPECTION (FOR E-33 ONLY)...5186
      SPECIFICATIONS...5188
        SERVICE DATA...5188
        TIGHTENING TORQUE SPECIFICATIONS...5188
      SPECIAL TOOLS AND EQUIPMENT...5189
        RECOMMENDED SERVICE MATERIAL...5189
        SPECIAL TOOL...5189
    ENGINE ELECTRICAL DEVICES...5190
      PRECAUTIONS...5190
        PRECAUTIONS FOR ENGINE ELECTRICAL DEVICE...5190
      COMPONENT LOCATION...5190
        ENGINE ELECTRICAL COMPONENTS LOCATION...5190
      DIAGNOSTIC INFORMATION AND PROCEDURES...5190
        ENGINE SYMPTOM DIAGNOSIS...5190
      REPAIR INSTRUCTIONS...5191
        ECM REMOVAL AND INSTALLATION...5191
        CMP SENSOR INSPECTION...5191
        CMP SENSOR REMOVAL AND INSTALLATION...5191
        CKP SENSOR INSPECTION...5191
        CKP SENSOR REMOVAL AND INSTALLATION...5191
        IAP SENSOR INSPECTION...5192
        IAP SENSOR REMOVAL AND INSTALLATION...5192
        TP SENSOR INSPECTION...5192
        TP SENSOR REMOVAL AND INSTALLATION...5192
        TP SENSOR ADJUSTMENT...5193
        ECT SENSOR REMOVAL AND INSTALLATION...5194
        ECT SENSOR INSPECTION...5194
        IAT SENSOR REMOVAL AND INSTALLATION...5195
        IAT SENSOR INSPECTION...5195
        AP SENSOR INSPECTION...5195
        AP SENSOR REMOVAL AND INSTALLATION...5195
        TO SENSOR INSPECTION...5195
        TO SENSOR REMOVAL AND INSTALLATION...5196
        STP SENSOR INSPECTION...5196
        STP SENSOR ADJUSTMENT...5196
        STP SENSOR REMOVAL AND INSTALLATION...5197
        STV ACTUATOR INSPECTION...5198
        STV ACTUATOR REMOVAL AND INSTALLATION...5198
        ISC VALVE INSPECTION...5198
        ISC VALVE REMOVAL AND INSTALLATION...5198
        ISC VALVE PRESET AND OPENING INITIALIZATION...5198
        HO2 SENSOR INSPECTION...5199
        HO2 SENSOR REMOVAL AND INSTALLATION...5199
        GP SWITCH INSPECTION...5199
        GP SWITCH REMOVAL AND INSTALLATION...5199
      SPECIFICATIONS...5200
        SERVICE DATA...5200
        TIGHTENING TORQUE SPECIFICATIONS...5201
      SPECIAL TOOLS AND EQUIPMENT...5201
        RECOMMENDED SERVICE MATERIAL...5201
        SPECIAL TOOL...5201
    ENGINE MECHANICAL...5202
      SCHEMATIC AND ROUTING DIAGRAM...5202
        CAMSHAFT AND SPROCKET ASSEMBLY DIAGRAM...5202
        THROTTLE CABLE ROUTING DIAGRAM...5203
      DIAGNOSTIC INFORMATION AND PROCEDURES...5204
        ENGINE MECHANICAL SYMPTOM DIAGNOSIS...5204
        COMPRESSION PRESSURE CHECK...5204
      REPAIR INSTRUCTIONS...5205
        ENGINE COMPONENTS REMOVABLE WITH THE ENGINE IN PLACE...5205
        AIR CLEANER ELEMENT REMOVAL AND INSTALLATION...5207
        AIR CLEANER BOX REMOVAL AND INSTALLATION...5207
        AIR CLEANER ELEMENT INSPECTION AND CLEANING...5208
        THROTTLE CABLE REMOVAL AND INSTALLATION...5208
        THROTTLE CABLE INSPECTION...5208
        THROTTLE CABLE PLAY INSPECTION AND ADJUSTMENT...5208
        THROTTLE BODY COMPONENTS...5209
        THROTTLE BODY CONSTRUCTION...5210
        THROTTLE BODY REMOVAL AND INSTALLATION...5211
        THROTTLE BODY DISASSEMBLY AND ASSEMBLY...5213
        THROTTLE BODY INSPECTION AND CLEANING...5217
        ISC VALVE VISUAL INSPECTION...5217
        THROTTLE VALVE SYNCHRONIZATION...5217
        ISC VALVE RESET...5219
        TP RESET...5220
        ENGINE ASSEMBLY REMOVAL...5220
        ENGINE ASSEMBLY INSTALLATION...5225
        ENGINE TOP SIDE DISASSEMBLY...5228
        ENGINE TOP SIDE ASSEMBLY...5232
        CAMSHAFT INSPECTION...5243
        CAMSHAFT SPROCKET / BEARING INSPECTION...5245
        CAM CHAIN TENSION ADJUSTER INSPECTION...5246
        CAM CHAIN GUIDE REMOVAL AND INSTALLATION...5247
        CAM CHAIN GUIDE INSPECTION...5247
        CAM CHAIN TENSIONER INSPECTION...5247
        CYLINDER HEAD DISASSEMBLY AND ASSEMBLY...5248
        CYLINDER HEAD RELATED PARTS INSPECTION...5253
        VALVE GUIDE REPLACEMENT...5257
        VALVE SEAT REPAIR...5258
        CYLINDER DISASSEMBLY AND ASSEMBLY...5259
        CYLINDER INSPECTION...5260
        PISTON RING REMOVAL AND INSTALLATION...5261
        PISTON AND PISTON RING INSPECTION...5262
        ENGINE BOTTOM SIDE DISASSEMBLY...5264
        ENGINE BOTTOM SIDE ASSEMBLY...5272
        CRANK BALANCER DISASSEMBLY AND ASSEMBLY...5289
        CRANK BALANCER INSPECTION...5290
        CONROD REMOVAL AND INSTALLATION...5290
        CONROD AND CRANKSHAFT INSPECTION...5292
        CONROD CRANK PIN BEARING INSPECTION AND SELECTION...5293
        CRANKSHAFT JOURNAL BEARING INSPECTION AND SELECTION...5295
        CRANKSHAFT THRUST CLEARANCE INSPECTION AND SELECTION...5297
      SPECIFICATIONS...5299
        SERVICE DATA...5299
        TIGHTENING TORQUE SPECIFICATIONS...5301
      SPECIAL TOOLS AND EQUIPMENT...5302
        RECOMMENDED SERVICE MATERIAL...5302
        SPECIAL TOOL...5303
    ENGINE LUBRICATION SYSTEM...5306
      PRECAUTIONS...5306
        PRECAUTIONS FOR ENGINE OIL...5306
      SCHEMATIC AND ROUTING DIAGRAM...5306
        ENGINE LUBRICATION SYSTEM CHART DIAGRAM...5306
        ENGINE LUBRICATION CIRCUIT DIAGRAM...5308
      DIAGNOSTIC INFORMATION AND PROCEDURES...5310
        ENGINE LUBRICATION SYMPTOM DIAGNOSIS...5310
        OIL PRESSURE CHECK...5310
      REPAIR INSTRUCTIONS...5311
        ENGINE OIL AND FILTER REPLACEMENT...5311
        ENGINE OIL LEVEL INSPECTION...5311
        OIL PAN / OIL STRAINER / OIL PRESSURE REGULATOR REMOVAL AND INSTALLATION...5311
        OIL PRESSURE REGULATOR / OIL STRAINER INSPECTION...5312
        OIL COOLER / OIL COOLER HOSE INSPECTION AND CLEANING...5313
        OIL COOLER / OIL COOLER HOSE REMOVAL AND INSTALLATION...5313
        OIL PRESSURE SWITCH REMOVAL AND INSTALLATION...5314
        OIL PRESSURE SWITCH INSPECTION...5315
        OIL JET / OIL GALLERY JET REMOVAL AND INSTALLATION...5315
        OIL JET / OIL GALLERY JET INSPECTION...5317
        OIL PUMP REMOVAL AND INSTALLATION...5317
        OIL PUMP INSPECTION...5318
      SPECIFICATIONS...5319
        SERVICE DATA...5319
        TIGHTENING TORQUE SPECIFICATIONS...5319
      SPECIAL TOOLS AND EQUIPMENT...5320
        RECOMMENDED SERVICE MATERIAL...5320
        SPECIAL TOOL...5320
    ENGINE COOLING SYSTEM...5321
      PRECAUTIONS...5321
        PRECAUTIONS FOR ENGINE COOLING SYSTEM...5321
        PRECAUTIONS FOR ENGINE COOLANT...5321
      GENERAL DESCRIPTION...5321
        ENGINE COOLANT DESCRIPTION...5321
      SCHEMATIC AND ROUTING DIAGRAM...5322
        COOLING CIRCUIT DIAGRAM...5322
        WATER HOSE ROUTING DIAGRAM...5323
      DIAGNOSTIC INFORMATION AND PROCEDURES...5324
        ENGINE COOLING SYMPTOM DIAGNOSIS...5324
      REPAIR INSTRUCTIONS...5324
        COOLING CIRCUIT INSPECTION...5324
        RADIATOR CAP INSPECTION...5325
        RADIATOR INSPECTION AND CLEANING...5325
        RADIATOR / COOLING FAN MOTOR REMOVAL AND INSTALLATION...5326
        WATER HOSE INSPECTION...5327
        WATER HOSE REMOVAL AND INSTALLATION...5328
        RADIATOR RESERVOIR TANK REMOVAL AND INSTALLATION...5328
        RADIATOR RESERVOIR TANK INSPECTION...5328
        COOLING FAN INSPECTION...5328
        COOLING FAN RELAY INSPECTION...5329
        ECT SENSOR REMOVAL AND INSTALLATION...5329
        ECT SENSOR INSPECTION...5329
        THERMOSTAT COVER / THERMOSTAT REMOVAL AND INSTALLATION...5329
        THERMOSTAT INSPECTION...5330
        WATER PUMP COMPONENTS...5331
        WATER PUMP CONSTRUCTION...5332
        WATER PUMP REMOVAL AND INSTALLATION...5332
        WATER PUMP DISASSEMBLY AND ASSEMBLY...5333
        WATER PUMP RELATED PARTS INSPECTION...5336
      SPECIFICATIONS...5337
        SERVICE DATA...5337
        TIGHTENING TORQUE SPECIFICATIONS...5338
      SPECIAL TOOLS AND EQUIPMENT...5338
        RECOMMENDED SERVICE MATERIAL...5338
        SPECIAL TOOL...5338
    FUEL SYSTEM...5339
      PRECAUTIONS...5339
        PRECAUTIONS FOR FUEL SYSTEM...5339
      GENERAL DESCRIPTION...5340
        FUEL INJECTION SYSTEM DESCRIPTION...5340
      SCHEMATIC AND ROUTING DIAGRAM...5341
        FUEL TANK DRAIN HOSE AND BREATHER HOSE ROUTING DIAGRAM...5341
      DIAGNOSTIC INFORMATION AND PROCEDURES...5342
        FUEL SYSTEM DIAGNOSIS...5342
      REPAIR INSTRUCTIONS...5343
        FUEL PRESSURE INSPECTION...5343
        FUEL PUMP INSPECTION...5344
        FUEL DISCHARGE AMOUNT INSPECTION...5344
        FUEL PUMP RELAY INSPECTION...5345
        FUEL HOSE INSPECTION...5345
        FUEL LEVEL GAUGE INSPECTION...5345
        FUEL TANK CONSTRUCTION...5346
        FUEL TANK HEAT SHIELD CONSTRUCTION...5347
        FUEL TANK REMOVAL AND INSTALLATION...5347
        FUEL PUMP COMPONENTS...5349
        FUEL PUMP DISASSEMBLY AND ASSEMBLY...5350
        FUEL MESH FILTER INSPECTION AND CLEANING...5352
        FUEL INJECTOR / FUEL DELIVERY PIPE / T-JOINT REMOVAL AND INSTALLATION...5352
        FUEL INJECTOR INSPECTION AND CLEANING...5352
      SPECIFICATIONS...5353
        SERVICE DATA...5353
        TIGHTENING TORQUE SPECIFICATIONS...5353
      SPECIAL TOOLS AND EQUIPMENT...5354
        RECOMMENDED SERVICE MATERIAL...5354
        SPECIAL TOOL...5354
    IGNITION SYSTEM...5355
      GENERAL DESCRIPTION...5355
        IMMOBILIZER DESCRIPTION (FOR E-02, 19, 24)...5355
        DRIVE MODE SELECTOR DESCRIPTION...5356
      SCHEMATIC AND ROUTING DIAGRAM...5357
        IGNITION SYSTEM DIAGRAM...5357
        IGNITION SYSTEM COMPONENTS LOCATION...5357
      DIAGNOSTIC INFORMATION AND PROCEDURES...5358
        IGNITION SYSTEM SYMPTOM DIAGNOSIS...5358
        NO SPARK OR POOR SPARK...5359
      REPAIR INSTRUCTIONS...5360
        IGNITION COIL / PLUG CAP AND SPARK PLUG REMOVAL AND INSTALLATION...5360
        SPARK PLUG INSPECTION AND CLEANING...5361
        IGNITION COIL / PLUG CAP INSPECTION...5361
        CKP SENSOR INSPECTION...5364
        CKP SENSOR REMOVAL AND INSTALLATION...5365
        ENGINE STOP SWITCH INSPECTION...5365
        IGNITION SWITCH INSPECTION...5366
        IGNITION SWITCH REMOVAL AND INSTALLATION...5366
        DRIVE MODE SELECTOR INSPECTION...5367
        IMMOBILIZER ANTENNA REMOVAL AND INSTALLATION (FOR E-02, 19, 24)...5368
      SPECIFICATIONS...5368
        SERVICE DATA...5368
        TIGHTENING TORQUE SPECIFICATIONS...5368
      SPECIAL TOOLS AND EQUIPMENT...5369
        RECOMMENDED SERVICE MATERIAL...5369
        SPECIAL TOOL...5369
    STARTING SYSTEM...5370
      SCHEMATIC AND ROUTING DIAGRAM...5370
        STARTING SYSTEM DIAGRAM...5370
      COMPONENT LOCATION...5370
        STARTING SYSTEM COMPONENTS LOCATION...5370
      DIAGNOSTIC INFORMATION AND PROCEDURES...5370
        STARTING SYSTEM SYMPTOM DIAGNOSIS...5370
        STARTER MOTOR WILL NOT RUN...5371
        STARTER MOTOR RUNS BUT DOES NOT CRANK THE ENGINE...5371
      REPAIR INSTRUCTIONS...5372
        STARTER MOTOR COMPONENTS...5372
        STARTER MOTOR REMOVAL AND INSTALLATION...5373
        STARTER MOTOR DISASSEMBLY AND ASSEMBLY...5373
        STARTER MOTOR INSPECTION...5374
        STARTER RELAY REMOVAL AND INSTALLATION...5375
        STARTER RELAY INSPECTION...5376
        TURN SIGNAL / SIDE-STAND RELAY REMOVAL AND INSTALLATION...5376
        SIDE-STAND / IGNITION INTERLOCK SYSTEM PARTS INSPECTION...5377
        STARTER TORQUE LIMITER / STARTER CLUTCH REMOVAL AND INSTALLATION...5379
        STARTER TORQUE LIMITER INSPECTION...5381
        STARTER CLUTCH INSPECTION...5381
        STARTER BUTTON INSPECTION...5382
      SPECIFICATIONS...5382
        SERVICE DATA...5382
        TIGHTENING TORQUE SPECIFICATIONS...5382
      SPECIAL TOOLS AND EQUIPMENT...5383
        RECOMMENDED SERVICE MATERIAL...5383
        SPECIAL TOOL...5383
    CHARGING SYSTEM...5384
      SCHEMATIC AND ROUTING DIAGRAM...5384
        CHARGING SYSTEM DIAGRAM...5384
      COMPONENT LOCATION...5384
        CHARGING SYSTEM COMPONENTS LOCATION...5384
      DIAGNOSTIC INFORMATION AND PROCEDURES...5384
        CHARGING SYSTEM SYMPTOM DIAGNOSIS...5384
        BATTERY RUNS DOWN QUICKLY...5385
      REPAIR INSTRUCTIONS...5386
        BATTERY CUSHION RUBBER ATTACHMENT CONSTRUCTION...5386
        BATTERY CURRENT LEAKAGE INSPECTION...5387
        REGULATED VOLTAGE INSPECTION...5387
        GENERATOR INSPECTION...5388
        GENERATOR REMOVAL AND INSTALLATION...5389
        REGULATOR / RECTIFIER CONSTRUCTION...5392
        REGULATOR / RECTIFIER REMOVAL AND INSTALLATION...5393
        REGULATOR / RECTIFIER INSPECTION...5393
        BATTERY COMPONENTS...5394
        BATTERY CHARGING...5394
        BATTERY REMOVAL AND INSTALLATION...5397
        BATTERY VISUAL INSPECTION...5397
      SPECIFICATIONS...5398
        SERVICE DATA...5398
        TIGHTENING TORQUE SPECIFICATIONS...5398
      SPECIAL TOOLS AND EQUIPMENT...5399
        RECOMMENDED SERVICE MATERIAL...5399
        SPECIAL TOOL...5399
    EXHAUST SYSTEM...5400
      PRECAUTIONS...5400
        PRECAUTIONS FOR EXHAUST SYSTEM...5400
      REPAIR INSTRUCTIONS...5401
        EXHAUST SYSTEM CONSTRUCTION...5401
        EXHAUST PIPE / MUFFLER REMOVAL AND INSTALLATION...5402
        EXHAUST SYSTEM INSPECTION...5406
      SPECIFICATIONS...5407
        TIGHTENING TORQUE SPECIFICATIONS...5407
      SPECIAL TOOLS AND EQUIPMENT...5407
        RECOMMENDED SERVICE MATERIAL...5407
  02. SUSPENSION...5409
    PRECAUTIONS...5410
      PRECAUTIONS...5410
        PRECAUTIONS FOR SUSPENSION...5410
    SUSPENSION GENERAL DIAGNOSIS...5411
      DIAGNOSTIC INFORMATION AND PROCEDURES...5411
        SUSPENSION AND WHEEL SYMPTOM DIAGNOSIS...5411
    FRONT SUSPENSION...5412
      REPAIR INSTRUCTIONS...5412
        FRONT FORK COMPONENTS...5412
        FRONT FORK REMOVAL AND INSTALLATION...5413
        FRONT SUSPENSION ADJUSTMENT...5416
        FRONT FORK DISASSEMBLY AND ASSEMBLY...5417
        FRONT FORK PARTS INSPECTION...5423
      SPECIFICATIONS...5424
        SERVICE DATA...5424
        TIGHTENING TORQUE SPECIFICATIONS...5424
      SPECIAL TOOLS AND EQUIPMENT...5425
        RECOMMENDED SERVICE MATERIAL...5425
        SPECIAL TOOL...5425
    REAR SUSPENSION...5426
      REPAIR INSTRUCTIONS...5426
        REAR SUSPENSION COMPONENTS...5426
        REAR SUSPENSION ASSEMBLY CONSTRUCTION...5427
        REAR SHOCK ABSORBER / CUSION LEVER REMOVAL AND INSTALLATION...5428
        REAR SUSPENSION INSPECTION...5429
        REAR SHOCK ABSORBER INSPECTION...5429
        REAR SUSPENSION ADJUSTMENT...5429
        REAR SHOCK ABSORBER DISPOSAL...5430
        CUSHION LEVER REMOVAL AND INSTALLATION...5431
        CUSHION LEVER INSPECTION...5431
        CUSHION LEVER BEARING REMOVAL AND INSTALLATION...5432
        SWINGARM / CUSHION ROD REMOVAL AND INSTALLATION...5433
        SWINGARM RELATED PARTS INSPECTION...5436
        SWINGARM BEARING REMOVAL AND INSTALLATION...5437
      SPECIFICATIONS...5438
        SERVICE DATA...5438
        TIGHTENING TORQUE SPECIFICATIONS...5438
      SPECIAL TOOLS AND EQUIPMENT...5439
        RECOMMENDED SERVICE MATERIAL...5439
        SPECIAL TOOL...5439
    WHEELS AND TIRES...5440
      PRECAUTIONS...5440
        PRECAUTIONS FOR WHEEL AND TIRE...5440
      REPAIR INSTRUCTIONS...5441
        FRONT WHEEL COMPONENTS...5441
        FRONT WHEEL ASSEMBLY CONSTRUCTION...5442
        FRONT WHEEL ASSEMBLY REMOVAL AND INSTALLATION...5443
        FRONT WHEEL RELATED PARTS INSPECTION...5445
        FRONT WHEEL DUST SEAL / BEARING REMOVAL AND INSTALLATION...5446
        REAR WHEEL COMPONENTS...5448
        REAR WHEEL ASSEMBLY CONSTRUCTION...5449
        REAR WHEEL ASSEMBLY REMOVAL AND INSTALLATION...5450
        REAR WHEEL RELATED PARTS INSPECTION...5451
        REAR WHEEL DUST SEAL / BEARING REMOVAL AND INSTALLATION...5452
        TIRE REMOVAL AND INSTALLATION...5454
        WHEEL / TIRE / AIR VALVE INSPECTION AND CLEANING...5455
        AIR VALVE REMOVAL AND INSTALLATION...5456
        WHEEL BALANCE CHECK AND ADJUSTMENT...5457
      SPECIFICATIONS...5457
        SERVICE DATA...5457
        TIGHTENING TORQUE SPECIFICATIONS...5458
      SPECIAL TOOLS AND EQUIPMENT...5458
        RECOMMENDED SERVICE MATERIAL...5458
        SPECIAL TOOL...5458
  03. DRIVELINE / AXLE...5461
    PRECAUTIONS...5462
      PRECAUTIONS...5462
        PRECAUTIONS FOR DRIVELINE / AXLE...5462
    DRIVE CHAIN / DRIVE TRAIN / DRIVE SHAFT...5463
      DIAGNOSTIC INFORMATION AND PROCEDURES...5463
        DRIVE CHAIN AND SPROCKET SYMPTOM DIAGNOSIS...5463
      REPAIR INSTRUCTIONS...5463
        DRIVE CHAIN RELATED COMPONENTS...5463
        ENGINE SPROCKET REMOVAL AND INSTALLATION...5464
        REAR SPROCKET / REAR SPROCKET MOUNTING DRUM REMOVAL AND INSTALLATION...5466
        DRIVE CHAIN RELATED PARTS INSPECTION...5467
        SPROCKET MOUNTING DRUM DUST SEAL / BEARING REMOVAL AND INSTALLATION...5467
        DRIVE CHAIN REPLACEMENT...5469
      SPECIFICATIONS...5473
        SERVICE DATA...5473
        TIGHTENING TORQUE SPECIFICATIONS...5473
      SPECIAL TOOLS AND EQUIPMENT...5473
        RECOMMENDED SERVICE MATERIAL...5473
        SPECIAL TOOL...5474
  04. BRAKE...5475
    PRECAUTIONS...5476
      PRECAUTIONS...5476
        PRECAUTIONS FOR BRAKE SYSTEM...5476
        BRAKE FLUID INFORMATION...5476
    BRAKE CONTROL SYSTEM AND DIAGNOSIS...5477
      SCHEMATIC AND ROUTING DIAGRAM...5477
        FRONT BRAKE HOSE ROUTING DIAGRAM...5477
        REAR BRAKE HOSE ROUTING DIAGRAM...5478
      DIAGNOSTIC INFORMATION AND PROCEDURES...5479
        BRAKE SYMPTOM DIAGNOSIS...5479
      REPAIR INSTRUCTIONS...5479
        BRAKE PEDAL HEIGHT INSPECTION AND ADJUSTMENT...5479
        FRONT BRAKE LIGHT SWITCH INSPECTION...5479
        REAR BRAKE LIGHT SWITCH INSPECTION...5480
        REAR BRAKE LIGHT SWITCH INSPECTION AND ADJUSTMENT...5480
        BRAKE FLUID LEVEL CHECK...5480
        BRAKE HOSE INSPECTION...5480
        AIR BLEEDING FROM BRAKE FLUID CIRCUIT...5480
        BRAKE FLUID REPLACEMENT...5482
        FRONT BRAKE HOSE REMOVAL AND INSTALLATION...5484
        REAR BRAKE HOSE REMOVAL AND INSTALLATION...5484
        FRONT BRAKE MASTER CYLINDER COMPONENTS...5485
        FRONT BRAKE MASTER CYLINDER ASSEMBLY REMOVAL AND INSTALLATION...5486
        FRONT BRAKE MASTER CYLINDER / BRAKE LEVER DISASSEMBLY AND ASSEMBLY...5487
        FRONT BRAKE MASTER CYLINDER PARTS INSPECTION...5488
        REAR BRAKE MASTER CYLINDER COMPONENTS...5489
        REAR BRAKE MASTER CYLINDER ASSEMBLY REMOVAL AND INSTALLATION...5490
        REAR BRAKE MASTER CYLINDER DISASSEMBLY AND ASSEMBLY...5491
        REAR BRAKE MASTER CYLINDER PARTS INSPECTION...5492
        REAR BRAKE PEDAL CONSTRUCTION...5493
        REAR BRAKE PEDAL REMOVAL AND INSTALLATION...5493
      SPECIFICATIONS...5494
        SERVICE DATA...5494
        TIGHTENING TORQUE SPECIFICATIONS...5494
      SPECIAL TOOLS AND EQUIPMENT...5495
        RECOMMENDED SERVICE MATERIAL...5495
        SPECIAL TOOL...5495
    FRONT BRAKES...5496
      REPAIR INSTRUCTIONS...5496
        FRONT BRAKE COMPONENTS...5496
        FRONT BRAKE PAD INSPECTION...5497
        FRONT BRAKE PAD REPLACEMENT...5497
        FRONT BRAKE CALIPER REMOVAL AND INSTALLATION...5498
        FRONT BRAKE CALIPER DISASSEMBLY AND ASSEMBLY...5499
        FRONT BRAKE CALIPER PARTS INSPECTION...5501
        FRONT BRAKE DISC REMOVAL AND INSTALLATION...5502
        FRONT BRAKE DISC INSPECTION...5502
      SPECIFICATIONS...5503
        SERVICE DATA...5503
        TIGHTENING TORQUE SPECIFICATIONS...5503
      SPECIAL TOOLS AND EQUIPMENT...5504
        RECOMMENDED SERVICE MATERIAL...5504
        SPECIAL TOOL...5504
    REAR BRAKES...5505
      REPAIR INSTRUCTIONS...5505
        REAR BRAKE COMPONENTS...5505
        REAR BRAKE PAD INSPECTION...5506
        REAR BRAKE PAD REPLACEMENT...5506
        REAR BRAKE CALIPER REMOVAL AND INSTALLATION...5507
        REAR BRAKE CALIPER DISASSEMBLY AND ASSEMBLY...5508
        REAR BRAKE CALIPER PARTS INSPECTION...5510
        REAR BRAKE DISC REMOVAL AND INSTALLATION...5510
        REAR BRAKE DISC INSPECTION...5511
      SPECIFICATIONS...5512
        SERVICE DATA...5512
        TIGHTENING TORQUE SPECIFICATIONS...5512
      SPECIAL TOOLS AND EQUIPMENT...5513
        RECOMMENDED SERVICE MATERIAL...5513
        SPECIAL TOOL...5513
  05. TRANSMISSION / TRANSAXLE...5515
    PRECAUTIONS...5516
      PRECAUTIONS...5516
        PRECAUTIONS FOR TRANSMISSION / TRANSAXLE...5516
    MANUAL TRANSMISSION...5517
      DIAGNOSTIC INFORMATION AND PROCEDURES...5517
        MANUAL TRANSMISSION SYMPTOM DIAGNOSIS...5517
      REPAIR INSTRUCTIONS...5518
        TRANSMISSION COMPONENTS...5518
        TRANSMISSION REMOVAL...5519
        TRANSMISSION INSTALLATION...5520
        TRANSMISSION CONSTRUCTION...5523
        COUNTERSHAFT GEAR / DRIVESHAFT GEAR DISASSEMBLY AND ASSEMBLY...5523
        TRANSMISSION RELATED PARTS INSPECTION...5526
        GEAR POSITION (GP) SWITCH INSPECTION...5527
        GEAR POSITION (GP) SWITCH REMOVAL AND INSTALLATION...5527
        GEARSHIFT LEVER CONSTRUCTION...5529
        GEARSHIFT LEVER REMOVAL AND INSTALLATION...5530
        GEARSHIFT LEVER HEIGHT INSPECTION AND ADJUSTMENT...5530
        GEARSHIFT SHAFT / GEARSHIFT CAM PLATE COMPONENTS...5530
        GEARSHIFT SHAFT CONSTRUCTION...5531
        GEARSHIFT SHAFT / GEARSHIFT CAM PLATE REMOVAL AND INSTALLATION...5532
        GEARSHIFT LINKAGE INSPECTION...5533
        GEARSHIFT SHAFT OIL SEAL / BEARING REMOVAL AND INSTALLATION...5533
      SPECIFICATIONS...5535
        SERVICE DATA...5535
        TIGHTENING TORQUE SPECIFICATIONS...5535
      SPECIAL TOOLS AND EQUIPMENT...5536
        RECOMMENDED SERVICE MATERIAL...5536
        SPECIAL TOOL...5536
    CLUTCH...5537
      PRECAUTIONS...5537
        PRECAUTIONS FOR CLUTCH SYSTEM...5537
        CLUTCH FLUID (BRAKE FLUID) INFORMATION...5537
      SCHEMATIC AND ROUTING DIAGRAM...5538
        CLUTCH HOSE ROUTING DIAGRAM...5538
      DIAGNOSTIC INFORMATION AND PROCEDURES...5539
        CLUTCH SYSTEM SYMPTOM DIAGNOSIS...5539
      REPAIR INSTRUCTIONS...5539
        CLUTCH LEVER POSITION SWITCH INSPECTION...5539
        CLUTCH FLUID LEVEL CHECK...5539
        CLUTCH HOSE INSPECTION...5539
        AIR BLEEDING FROM CLUTCH FLUID CIRCUIT...5540
        CLUTCH FLUID REPLACEMENT...5540
        CLUTCH HOSE REMOVAL AND INSTALLATION...5541
        CLUTCH CONTROL SYSTEM COMPONENTS...5542
        CLUTCH MASTER CYLINDER ASSEMBLY REMOVAL AND INSTALLATION...5543
        CLUTCH MASTER CYLINDER / CLUTCH LEVER DISASSEMBLY AND ASSEMBLY...5544
        CLUTCH MASTER CYLINDER COMPONENTS INSPECTION...5546
        CLUTCH RELEASE CYLINDER / PUSH ROD REMOVAL AND INSTALLATION...5546
        CLUTCH PUSH ROD INSPECTION...5548
        CLUTCH RELEASE CYLINDER DISASSEMBLY AND ASSEMBLY...5548
        CLUTCH RELEASE CYLINDER INSPECTION...5548
        CLUTCH COMPONENTS...5549
        CLUTCH REMOVAL...5550
        CLUTCH INSTALLATION...5553
        CLUTCH PARTS INSPECTION...5557
      SPECIFICATIONS...5559
        SERVICE DATA...5559
        TIGHTENING TORQUE SPECIFICATIONS...5559
      SPECIAL TOOLS AND EQUIPMENT...5560
        RECOMMENDED SERVICE MATERIAL...5560
        SPECIAL TOOL...5560
  06. STEERING ...5561
    PRECAUTIONS...5562
      PRECAUTIONS...5562
        PRECAUTIONS FOR STEERING...5562
    STEERING GENERAL DIAGNOSIS...5563
      DIAGNOSTIC INFORMATION AND PROCEDURES...5563
        STEERING SYMPTOM DIAGNOSIS...5563
    STEERING / HANDLEBAR...5564
      REPAIR INSTRUCTIONS...5564
        HANDLEBAR COMPONENTS...5564
        HANDLEBAR CONSTRUCTION...5565
        HANDLEBAR REMOVAL AND INSTALLATION...5566
        HANDLEBARS INSPECTION...5567
        STEERING COMPONENTS...5568
        STEERING DAMPER CONSTRUCTION...5569
        STEERING REMOVAL AND INSTALLATION...5569
        STEERING RELATED PARTS INSPECTION...5573
        STEERING SYSTEM INSPECTION...5573
        STEERING STEM BEARING REMOVAL AND INSTALLATION...5574
        STEERING TENSION ADJUSTMENT...5575
      SPECIFICATIONS...5576
        TIGHTENING TORQUE SPECIFICATIONS...5576
      SPECIAL TOOLS AND EQUIPMENT...5576
        RECOMMENDED SERVICE MATERIAL...5576
        SPECIAL TOOL...5577
  09. BODY AND ACCESSORIES...5579
    PRECAUTIONS...5581
      PRECAUTIONS...5581
        PRECAUTIONS FOR ELECTRICAL SYSTEM...5581
      COMPONENT LOCATION...5581
        ELECTRICAL COMPONENTS LOCATION...5581
    WIRING SYSTEMS...5582
      SCHEMATIC AND ROUTING DIAGRAM...5582
        WIRING DIAGRAM...5582
        WIRING HARNESS ROUTING DIAGRAM...5586
      SPECIFICATIONS...5590
        SERVICE DATA...5590
        TIGHTENING TORQUE SPECIFICATIONS...5590
      SPECIAL TOOLS AND EQUIPMENT...5590
        RECOMMENDED SERVICE MATERIAL...5590
    LIGHTING SYSTEMS...5591
      REPAIR INSTRUCTIONS...5591
        HEADLIGHT COMPONENTS...5591
        HEADLIGHT REMOVAL AND INSTALLATION...5592
        HEADLIGHT BULB AND POSITION LIGHT BULB REPLACEMENT...5592
        HEADLIGHT BEAM ADJUSTMENT...5593
        FRONT TURN SIGNAL LIGHT COMPONENTS...5593
        FRONT TURN SIGNAL LIGHT REMOVAL AND INSTALLATION...5594
        FRONT TURN SIGNAL LIGHT BULB REPLACEMENT...5594
        REAR LIGHTING SYSTEM CONSTRUCTION...5595
        REAR COMBINATION LIGHT REMOVAL AND INSTALLATION...5595
        REAR COMBINATION LIGHT REPLACEMENT...5596
        LICENSE PLATE LIGHT COMPONENTS...5596
        LICENSE PLATE LIGHT REMOVAL AND INSTALLATION...5597
        LICENSE PLATE LIGHT BULB REPLACEMENT...5597
        REAR TURN SIGNAL LIGHT COMPONENTS...5598
        REAR TURN SIGNAL LIGHT REMOVAL AND INSTALLATION...5598
        REAR TURN SIGNAL LIGHT BULB REPLACEMENT...5598
        REFLEX REFLECTOR CONSTRUCTION...5599
        TURN SIGNAL / SIDE-STAND RELAY INSPECTION...5599
        TURN SIGNAL / SIDE-STAND RELAY REMOVAL AND INSTALLATION...5599
        HAZARD SWITCH INSPECTION...5600
        TURN SIGNAL SWITCH INSPECTION...5600
        PASSING LIGHT SWITCH INSPECTION...5601
        DIMMER SWITCH INSPECTION...5601
      SPECIFICATIONS...5602
        SERVICE DATA...5602
        TIGHTENING TORQUE SPECIFICATIONS...5602
      SPECIAL TOOLS AND EQUIPMENT...5602
        RECOMMENDED SERVICE MATERIAL...5602
        SPECIAL TOOL...5602
    COMBINATION METER / FUEL METER / HORN...5603
      GENERAL DESCRIPTION...5603
        COMBINATION METER SYSTEM DESCRIPTION...5603
      REPAIR INSTRUCTIONS...5604
        COMBINATION METER COMPONENTS...5604
        COMBINATION METER REMOVAL AND INSTALLATION...5604
        COMBINATION METER DISASSEMBLY AND ASSEMBLY...5605
        COMBINATION METER INSPECTION...5605
        ENGINE COOLANT TEMPERATURE METER AND INDICATOR LIGHT INSPECTION...5606
        ECT SENSOR REMOVAL AND INSTALLATION...5607
        FUEL METER INSPECTION...5607
        FUEL LEVEL GAUGE INSPECTION...5608
        SPEEDOMETER INSPECTION...5608
        SPEED SENSOR REMOVAL AND INSTALLATION...5608
        SPEED SENSOR INSPECTION...5609
        OIL PRESSURE INDICATOR INSPECTION...5609
        OIL PRESSURE SWITCH REMOVAL AND INSTALLATION...5609
        OIL PRESSURE SWITCH INSPECTION...5610
        IGNITION SWITCH INSPECTION...5610
        IGNITION SWITCH REMOVAL AND INSTALLATION...5610
        HORN INSPECTION...5611
        HORN REMOVAL AND INSTALLATION...5611
      SPECIFICATIONS...5612
        SERVICE DATA...5612
        TIGHTENING TORQUE SPECIFICATIONS...5612
      SPECIAL TOOLS AND EQUIPMENT...5612
        SPECIAL TOOL...5612
    EXTERIOR PARTS...5613
      SCHEMATIC AND ROUTING DIAGRAM...5613
        SEAT LOCK CABLE ROUTING DIAGRAM...5613
      REPAIR INSTRUCTIONS...5614
        EXTERIOR PARTS CONSTRUCTION...5614
        REAR UNDER COWLING HEAD SHIELD ATTACHMENT...5615
        INTAKE COVER PROTECTION TAPE ATTACHMENT...5615
        INNER UNDER COWLING CUSHION ATTACHMENT...5616
        UNDER COWLING HEAT SHIELD ATTACHMENT...5616
        PILLION RIDER HANDLEBAR CONSTRUCTION...5617
        PANEL CUSHION ATTACHMENT...5618
        REAR FENDER CONSTRUCTION...5619
        FRAME COVER CONSTRUCTION...5620
        COWLING CUSHION ATTACHMENT...5621
        FLAME COVER CUSHION ATTACHMENT...5622
        MUDGUARD CONSTRUCTION...5623
        REAR FENDER CUSHION ATTACHMENT...5624
        BODY COWLING COVER CUSHION ATTACHMENT...5624
        FASTENER REMOVAL AND INSTALLATION...5625
        EXTERIOR PARTS REMOVAL AND INSTALLATION...5626
      SPECIFICATIONS...5634
        TIGHTENING TORQUE SPECIFICATIONS...5634
      SPECIAL TOOLS AND EQUIPMENT...5634
        RECOMMENDED SERVICE MATERIAL...5634
        SPECIAL TOOL...5634
    BODY STRUCTURE...5635
      REPAIR INSTRUCTIONS...5635
        BODY FRAME CONSTRUCTION...5635
        FRONT FOOTREST BRACKET CONSTRUCTION...5636
        SIDE-STAND CONSTRUCTION...5637
        PILLION FOOTREST BRACKET CONSTRUCTION...5637
        FOOTREST CONSTRUCTION...5638
        SIDE-STAND REMOVAL AND INSTALLATION...5639
      SPECIFICATIONS...5639
        TIGHTENING TORQUE SPECIFICATIONS...5639
      SPECIAL TOOLS AND EQUIPMENT...5639
        RECOMMENDED SERVICE MATERIAL...5639
  10. GSX1300RK9 (2009 MODEL)...5641
    SPECIFICATIONS...5642
    WIRING HARNESS ROUTING DIAGRAM...5643
Suzuki GSX-R1300 Hayabusa  (GSX-R1300RX, GSX-R1300RY, GSX-R1300RK1, GSX-R1300RK2) Service Manual  1999-2002...5644
  1999-2000 Suzuki GSX-R1300 Hayabusa (GSX-R1300R-X_Y)...5644
    COVER...5644
    Foreword...5645
    How to use this manual...5646
    1 - GENERAL INFORMATION...5651
    2 - PERIODIC MAINTENANCE...5661
    3 - ENGINE...5693
    4 - FI SYSTEM and INTAKE 1...5824
    4 - FI SYSTEM and INTAKE 2...5825
    5 - COOLING AND LUBRICATION...5899
    6 - CHASSIS 1...5921
    6 - CHASSIS 2...5922
    7 - ELECTRICAL SYSTEM...6009
    8 - SERVICING INFORMATION...6051
    9 - EMISSION CONTROL...6106
    10 - 2000 GSX1300RY SUPPLEMENT...6113
  2001 Suzuki GSX-R1300 Hayabusa (GSX-R1300R-K1)...6147
  2002 Suzuki GSX-R1300 Hayabusa (GSX-R1300R-K2)...6178
 
Suzuki GSX-R1100, GSX-R1300 Repair Service Manuals