User manual SUZUKI GSX-R600 - SERVICE MANUAL

GSX-R600 99500-35100-01E FOREWORD This manual contains an introductory description on the SUZUKI GSX-R600 and procedures for its inspection/service and overhaul of its main components. Other information considered as generally known is not included. Read the GENERAL INFORMATION section to familiarize yourself with the motorcycle and its maintenance. Use this section as well as other sections to use as a guide for proper inspection and service. This manual will help you know the motorcycle better so that you can assure your customers of fast and reliable service. * This manual has been prepared on the basis of the latest specifications at the time of publication. If modifications have been made since then, differences may exist between the content of this manual and the actual motorcycle. * Illustrations in this manual are used to show the basic principles of operation and work procedures. They may not represent the actual motorcycle exactly in detail. * This manual is written for persons who have enough knowledge, skills and tools, including special tools, for servicing SUZUKI motorcycles. If you do not have the proper knowledge and tools, ask your authorized SUZUKI motorcycle dealer to help you. GROUP INDEX GENERAL INFORMATION PERIODIC MAINTENANCE ENGINE FI SYSTEM DIAGNOSIS FUEL SYSTEM AND THROTTLE BODY EXHAUST SYSTEM COOLING AND LUBRICATION SYSTEM CHASSIS ELECTRICAL SYSTEM SERVICING INFORMATION EMISSION CONTROL INFORMATION WIRING DIAGRAM 1 2 3 4 5 6 7 8 9 10 11 12 A S P M E L Inexperienced mechanics or mechanics without the proper tools and equipment may not be able to properly perform the services described in this manual. Improper repair may result in injury to the mechanic and may render the motorcycle unsafe for the rider and passenger. © COPYRIGHT SUZUKI MOTOR CORPORATION 2006 HOW TO USE THIS MANUAL TO LOCATE WHAT YOU ARE LOOKING FOR: 1. The text of this manual is divided into sections. 2. The section titles are listed in the GROUP INDEX. 3. Holding the manual as shown at the right will allow you to find the first page of the section easily. 4. The contents are listed on the first page of each section to help you find the item and page you need. COMPONENT PARTS AND WORK TO BE DONE Under the name of each system or unit, is its exploded view. Work instructions and other service information such as the tightening torque, lubricating points and locking agent points, are provided. Example: Front wheel 1 2 3 4 5 6 7 A B Brake disc Collar Dust seal Bearing Spacer Front axle Front wheel Front axle bolt Brake disc bolt ITEM A B N·m 100 23 kgf-m 10.0 2.3 lb-ft 72.5 16.5 A S E L P M SYMBOL Listed in the table below are the symbols indicating instructions and other information necessary for servicing. The meaning of each symbol is also included in the table. SYMBOL DEFINITION Torque control required. Data beside it indicates specified torque. Apply oil. Use engine oil unless otherwise specified. Apply molybdenum oil solution. (Mixture of engine oil and SUZUKI MOLY PASTE in a ratio of 1:1) Apply SUZUKI SUPER GREASE "A" or equivalent grease. 99000-25010 Apply SUZUKI MOLY PASTE. 99000-25140 Apply SUZUKI BOND "1215" or equivalent bond. 99000-31110 SYMBOL DEFINITION Apply THREAD LOCK SUPER "1360". 99000-32130 Use engine coolant. 99000-99032-11X (Except USA) Use fork oil. 99000-99001-SS5 Apply SUZUKI BOND "1207B". 99104-31140 (USA) A S E L P M Apply or use brake fluid. Measure in voltage range. Measure in current range. Measure in resistance range. Apply SUZUKI BOND "1207B". 99000-31140 (Except USA) Measure in diode test range. Apply THREAD LOCK SUPER "1303". 99000-32030 Apply THREAD LOCK SUPER "1322" or equivalent thread lock. 99000-32110 Apply THREAD LOCK "1342". 99000-32050 Measure in continuity test range. Use special tool. Indication of service data. ABBREVIATIONS USED IN THIS MANUAL A ABDC AC ACL API ATDC ATM Pressure : After Bottom Dead Center : Alternating Current : Air Cleaner, Air Cleaner Box : American Petroleum Institute : After Top Dead Center : Atmospheric Pressure : Atmospheric Pressure sensor (APS, AP Sensor) : Air Fuel Mixture E : Engine Control Module Engine Control Unit (ECU) (FI Control Unit) ECT Sensor : Engine Coolant Temperature Sensor (ECTS), Water Temp. Sensor (WTS) EVAP : Evaporative Emission EVAP Canister : Evaporative Emission Canister (Canister) EXC System : Exhaust Control System (EXCS) EXC Valve : Exhaust Control Valve (EXCV) EXCV Actuator : Exhaust Control Valve Actuator (EXCVA) ECM A/F B BBDC BTDC B+ : Before Bottom Dead Center : Before Top Dead Center : Battery Positive Voltage F C CKP Sensor : Crankshaft Position Sensor (CKPS) CKT : Circuit CLP Switch : Clutch Lever Position Switch (Clutch Switch) CMP Sensor : Camshaft Position Sensor (CMPS) CO : Carbon Monoxide CPU : Central Processing Unit A S P M G GEN GND GP Switch FI FP FPR FP Relay E L : Fuel Injection, Fuel Injector : Fuel Pump : Fuel Pressure Regulator : Fuel Pump Relay : Generator : Ground : Gear Position Switch H HC : Hydrocarbons D DC DMC DOHC DRL DTC : Direct Current : Dealer Mode Coupler : Double Over Head Camshaft : Daytime Running Light : Diagnostic Trouble Code I IAP Sensor IAT Sensor IG : Intake Air Pressure Sensor (IAPS) (MAP Sensor) : Intake Air Temperature Sensor (IATS) : Ignition L LCD LED LH : Liquid Crystal Display : Light Emitting Diode (Malfunction Indicator Lamp) : Left Hand M MAL-Code Max MIL Min : Malfunction Code (Diagnostic Code) : Maximum : Malfunction Indicator Lamp (LED) : Minimum N NOX : Nitrogen Oxides O OHC OPS : Over Head Camshaft : Oil Pressure Switch P PCV : Positive Crankcase Ventilation (Crankcase Breather) R RH ROM : Right Hand : Read Only Memory S SAE SDS STC System : Society of Automotive Engineers : Suzuki Diagnosis System : Secondary Throttle Control System (STCS) STP Sensor : Secondary Throttle Position Sensor (STPS) ST Valve : Secondary Throttle Valve (STV) STV Actuator : Secondary Throttle Valve Actuator (STVA) A S E L P M T TO Sensor TP Sensor : Tip-Over Sensor (TOS) : Throttle Position Sensor (TPS) WIRE COLOR B Bl Br Dg Dgr B/Bl B/G B/R B/Y Bl/G Bl/W Br/Y G/Bl G/W Gr/B Gr/W Lg/BI Lg/W O/BI O/R O/Y P/W R/Bl R/W W/Bl W/R Y/B Y/G Y/W : Black : Blue : Brown : Dark green : Dark gray : : : : : : : : : : : : : : : : : : : : : : : : G Gr Lbl Lg O : Green : Gray : Light blue : Light green : Orange B/Br B/Lg B/W Bl/B Bl/R Bl/Y G/B G/R G/Y Gr/R Gr/Y Lg/G O/B O/G O/W P/B R/B R/Y W/B W/G W/Y Y/Bl Y/R P R W Y :Pink : Red : White : Yellow Black with Blue tracer Black with Green tracer Black with Red tracer Black with Yellow tracer Blue with Green tracer Blue with White tracer Brown with Yellow tracer Green with Blue tracer Green with White tracer Gray with Black tracer Gray with White tracer Light green with Blue tracer Light green with White tracer Orange with Blue tracer Orange with Red tracer Orange with Yellow tracer Pink with White tracer Red with Blue tracer Red with White tracer White with Blue tracer White with Red tracer Yellow with Black tracer Yellow with Green tracer Yellow with White tracer A S P M : Black with Brown tracer : Black with Light green tracer : Black with White tracer : Blue with Black tracer : Blue with Red tracer : Blue with Yellow tracer : Green with Black tracer : Green with Red tracer : Green with Yellow tracer : Gray with Red tracer : Gray with Yellow tracer : Light green with Green tracer : Orange with Black tracer : Orange with Green tracer : Orange with White tracer : Pink with Black tracer : Red with Black tracer : Red with Yellow tracer : White with Black tracer : White with Green tracer : White with Yellow tracer : Yellow with Blue tracer : Yellow with Red tracer E L GENERAL INFORMATION 1-1 GENERAL INFORMATION 1 CONTENTS WARNING/CAUTION/NOTE......................................................................... 1- 2 GENERAL PRECAUTIONS .......................................................................... 1- 2 SUZUKI GSX-R600K6 ('06-MODEL)............................................................ 1- 4 SERIAL NUMBER LOCATION ..................................................................... 1- 4 FUEL, OIL AND ENGINE COOLANT RECOMMENDATION....................... 1- 5 FUEL (FOR USA AND CANADA).......................................................... 1- 5 FUEL (FOR OTHER COUNTRIES) ........................................................ 1- 5 ENGINE OIL (FOR USA)........................................................................ 1- 5 ENGINE OIL (FOR OTHER COUNTRIES)............................................. 1- 5 BRAKE FLUID........................................................................................ 1- 5 FRONT FORK OIL.................................................................................. 1- 6 ENGINE COOLANT................................................................................ 1- 6 WATER FOR MIXING............................................................................. 1- 6 ANTI-FREEZE/ENGINE COOLANT....................................................... 1- 6 LIQUID AMOUNT OF WATER/ENGINE COOLANT ............................. 1- 6 BREAK-IN PROCEDURES........................................................................... 1- 7 CYLINDER IDENTIFICATION....................................................................... 1- 7 INFORMATION LABELS .............................................................................. 1- 8 SPECIFICATIONS......................................................................................... 1- 9 DIMENSIONS AND DRY MASS............................................................. 1- 9 ENGINE .................................................................................................. 1- 9 DRIVE TRAIN ......................................................................................... 1- 9 CHASSIS ................................................................................................ 1-10 ELECTRICAL ......................................................................................... 1-10 CAPACITIES .......................................................................................... 1-10 A S P M E L COUNTRY AND AREA CODES The following codes stand for the applicable country(-ies) and area(-s). CODE E-02 E-19 (GSX-R600) E-19 (GSX-R600U2) E-19 (GSX-R600U3) E-24 E-03 E-28 E-33 COUNTRY or AREA U.K. E.U. E.U. E.U. Australia U.S.A. (Except for California) Canada California (U.S.A.) EFFECTIVE FRAME NO. JS1CE111100100001 ­ JS1CE111100100001 ­ JS1CE211100100001 ­ JS1CE311100100001 ­ JS1CE121300100001 ­ JS1GN7DA 62100001 ­ JS1GN7DA 62100001 ­ JS1GN7DA 62100001 ­ 1-2 GENERAL INFORMATION WARNING/CAUTION/NOTE Please read this manual and follow its instructions carefully. To emphasize special information, the symbol and the words WARNING, CAUTION and NOTE have special meanings. Pay special attention to the messages highlighted by these signal words. Indicates a potential hazard that could result in death or injury. Indicates a potential hazard that could result in motorcycle damage. NOTE: Indicates special information to make maintenance easier or instructions clearer. Please note, however, that the warnings and cautions contained in this manual cannot possibly cover all potential hazards relating to the servicing, or lack of servicing, of the motorcycle. In addition to the WARNINGS and CAUTIONS stated, you must use good judgement and basic mechanical safety principles. If you are unsure about how to perform a particular service operation, ask a more experienced mechanic for advice. GENERAL PRECAUTIONS * Proper service and repair procedures are important for the safety of the service mechanic and the safety and reliability of the motorcycle. * When 2 or more persons work together, pay attention to the safety of each other. * When it is necessary to run the engine indoors, make sure that exhaust gas is forced outdoors. * When working with toxic or flammable materials, make sure that the area you work in is wellventilated and that you follow all of the material manufacturer's instructions. * Never use gasoline as a cleaning solvent. * To avoid getting burned, do not touch the engine, engine oil, radiator and exhaust system until they have cooled. After servicing the fuel, oil, water, exhaust or brake systems, check all lines and fittings related to the system for leaks. A S P M E L GENERAL INFORMATION 1-3 * If parts replacement is necessary, replace the parts with Suzuki Genuine Parts or their equivalent. * When removing parts that are to be reused, keep them arranged in an orderly manner so that they may be reinstalled in the proper order and orientation. * Be sure to use special tools when instructed. * Make sure that all parts used in reassembly are clean. Lubricate them when specified. * Use the specified lubricant, bond, or sealant. * When removing the battery, disconnect the negative cable first and then the positive cable. * When reconnecting the battery, connect the positive cable first and then the negative cable, and replace the terminal cover on the positive terminal. * When performing service to electrical parts, if the service procedures do not require use of battery power, disconnect the negative cable from the battery. * When tightening the cylinder head or case bolts and nuts, tighten the larger sizes first. Always tighten the bolts and nuts diagonally from the inside toward outside and to the specified tightening torque. * Whenever you remove oil seals, gaskets, packing, O-rings, locking washers, self-locking nuts, cotter pins, circlips and certain other parts as specified, be sure to replace them with new ones. Also, before installing these new parts, be sure to remove any left over material from the mating surfaces. * Never reuse a circlip. When installing a new circlip, take care not to expand the end gap larger than required to slip the circlip over the shaft. After installing a circlip, always ensure that it is completely seated in its groove and securely fitted. * Use a torque wrench to tighten fasteners to the specified torque. Wipe off grease and oil if a thread is smeared with them. * After reassembling, check parts for tightness and proper operation. * To protect the environment, do not unlawfully dispose of used motor oil, engine coolant and other fluids: batteries and tires. * To protect Earth's natural resources, properly dispose of used motorcycle and parts. A S P M E L 1-4 GENERAL INFORMATION SUZUKI GSX-R600K6 ('06-MODEL) RIGHT SIDE · Difference between illustrations and actual motorcycle may exist depending on the markets. A S P M E L LEFT SIDE SERIAL NUMBER LOCATION The frame serial number or V.I.N. (Vehicle Identification Number) 1 is stamped on the right side of the steering head pipe. The engine serial number 2 is located on the right side of the crankcase. These numbers are required especially for registering the machine and ordering spare parts. GENERAL INFORMATION 1-5 FUEL, OIL AND ENGINE COOLANT RECOMMENDATION FUEL (FOR USA AND CANADA) Use only unleaded gasoline of at least 87 pump octane (R/2 + M/2) or 91 octane or higher rated by the research method. Gasoline containing MTBE (Methyl Tertiary Butyl Ether), less than 10% ethanol, or less than 5% methanol with appropriate cosolvents and corrosion inhibitor is permissible. FUEL (FOR OTHER COUNTRIES) Gasoline used should be graded 91 octane (Research Method) or higher. Unleaded gasoline is recommended. ENGINE OIL (FOR USA) Oil quality is a major contributor to your engine's performance and life. Always select good quality engine oil. Suzuki recommends the use of SUZUKI PERFORMANCE 4 MOTOR OIL or equivalent engine oil. Use of SF/SG or SH/SJ in API with MA in JASO. Suzuki recommends the use of SAE 10W-40 engine oil. If SAE 10W-40 engine oil is not available, select an alternative according to the following chart. ENGINE OIL (FOR OTHER COUNTRIES) Oil quality is a major contributor to your engine's performance and life. Always select good quality engine oil. Use of SF/SG or SH/SJ in API with MA in JASO. Suzuki recommends the use of SAE 10W-40 engine oil. If SAE 10W-40 engine oil is not available, select an alternative according to the right chart. BRAKE FLUID Specification and classification: DOT 4 A S P M E L Since the brake system of this motorcycle is filled with a glycol-based brake fluid by the manufacturer, do not use or mix different types of fluid such as silicone-based and petroleum-based fluid for refilling the system, otherwise serious damage will result. Do not use any brake fluid taken from old or used or unsealed containers. Never re-use brake fluid left over from a previous servicing, which has been stored for a long period. 1-6 GENERAL INFORMATION FRONT FORK OIL Use fork oil SS-05 or an equivalent fork oil. ENGINE COOLANT Use an anti-freeze/engine coolant compatible with an aluminum radiator, mixed with distilled water only. WATER FOR MIXING Use distilled water only. Water other than distilled water can corrode and clog the aluminum radiator. ANTI-FREEZE/ENGINE COOLANT The engine coolant performs as a corrosion and rust inhibitor as well as anti-freeze. Therefore, the engine coolant should be used at all times even though the atmospheric temperature in your area does not go down to freezing point. Suzuki recommends the use of SUZUKI COOLANT anti-freeze/engine coolant. If this is not available, use an equivalent which is compatible with an aluminum radiator. LIQUID AMOUNT OF WATER/ENGINE COOLANT Solution capacity (total): Approx. 2 700 ml (2.9/2.4 US/Imp qt) For engine coolant mixture information, refer to cooling system section in page 7-2. Mixing of anti-freeze/engine coolant should be limited to 60%. Mixing beyond it would reduce its efficiency. If the anti-freeze/engine coolant mixing ratio is below 50%, rust inhabiting performance is greatly reduced. Be sure to mix it above 50% even though the atmospheric temperature does not go down to the freezing point. A S P M E L GENERAL INFORMATION 1-7 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 depends on the care and restraint exercised during its early life. The general rules are as follows. · Keep to these break-in engine speed limits: Initial 800 km ( 500 miles): Below 8 000 r/min Up to 1 600 km (1 000 miles): Below 12 000 r/min Over to 1 600 km (1 000 miles): Below 16 000 r/min · Upon reaching an odometer reading of 1 600 km (1 000 miles) you can subject the motorcycle to full throttle operation. However, do not exceed 16 000 r/min at any time. CYLINDER IDENTIFICATION The four cylinders of this engine are identified as No. 1, No. 2, No. 3 and No. 4 cylinder, as counted from left to right (as viewed by the rider on the seat.) #1 A S P M #2 #3 E L #4 1-8 GENERAL INFORMATION INFORMATION LABELS 1 Noise label 2 Information label 3 Vacuum hose routing label 4 Fuel caution label 5 Manual notice label 6 Screen label 7 Screen label 8 Screen label 9 Warning steering label 0 Warning steering label A Tire information label B Tire information label C General warning label D General warning label E General warning label F General warning label G ICES Canada label H I.D. plate I E-19 I.D. label J Safety plate A: Attached *1: Rear fender (front) *2: Chain case GSX-R600 A (For E-03, 24, 33) A (For E-03, 28, 33) A (For E-33) A (For E-02, 24) A (For E-03, 33) A (Except E-19 ) A (For E-28) A (For E-19) A (For E-03, 33) A (Except E-03, 33) A (For E-03, 33) A (Except E-03, 33) A (Except E-19, 28) A (For E-28) A (For E-19) A (For E-28) A (For E-02, 19, 24) GSX-R600UE GSX-R600UF A A A A A A A A (For E-03, 28, 33) A S P M E L A A A A *2 *1 GENERAL INFORMATION 1-9 SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length .......................................................................... 2 040 mm (80.3 in) Overall width ........................................................................... 715 mm (28.1 in) Overall height .......................................................................... 1 125 mm (44.3 in) Wheelbase .............................................................................. 1 400 mm (55.1 in) Ground clearance.................................................................... 130 mm (5.1 in) Seat height .............................................................................. 810 mm (31.9 in) Dry mass ................................................................................. 162 kg (357 lbs) ...........E-33 161 kg (354 lbs) ...........Others ENGINE Type ........................................................................................ Number of cylinders ................................................................ Bore......................................................................................... Stroke ...................................................................................... Displacement .......................................................................... Compression ratio ................................................................... Fuel system ............................................................................. Air cleaner ............................................................................... Starter system ......................................................................... Lubrication system .................................................................. Idle speed................................................................................ Four stroke, liquid-cooled, DOHC 4 67.0 mm (2.638 in) 42.5 mm (1.673 in) 599 cm³ (36.5 cu. in) 12.5 : 1 Fuel injection Paper element Electric Wet sump 1 300 ± 100 r/min DRIVE TRAIN Clutch ...................................................................................... Transmission........................................................................... Gearshift pattern ..................................................................... Primary reduction ratio ............................................................ Gear ratios, Low ...................................................................... 2nd....................................................................... 3rd........................................................................ 4th........................................................................ 5th........................................................................ Top....................................................................... Final reduction ratio................................................................. Drive chain .............................................................................. A S P M E L Wet multi-plate type 6-speed constant mesh 1-down, 5-up 1.974 (77/39) 2.785 (39/14) 2.052 (39/19) 1.714 (36/21) 1.500 (36/24) 1.347 (31/23) 1.208 (29/24) 2.687 (43/16) RK525SMOZ7Y, 114 links 1-10 GENERAL INFORMATION CHASSIS Front suspension .................................................................... Rear suspension ..................................................................... Front fork stroke...................................................................... Rear wheel travel .................................................................... Steering angle......................................................................... Caster ..................................................................................... Trail ......................................................................................... Turning radius ......................................................................... Front brake.............................................................................. Rear brake .............................................................................. Front tire size .......................................................................... Rear tire size........................................................................... Inverted telescopic, coil spring, oil damped Link type, coil spring, oil damped 120 mm (4.7 in) 130 mm (5.1 in) 27° 23° 45' 97 mm (3.8 in) 3.4 m (11.2 ft) Disc brake, twin Disc brake 120/70 ZR 17 M/C (58 W), tubeless 180/55 ZR 17 M/C (73 W), tubeless ELECTRICAL Ignition type............................................................................. Ignition timing.......................................................................... Spark plug............................................................................... Battery..................................................................................... Generator................................................................................ Main fuse ................................................................................ Fuse ........................................................................................ Headlight................................................................................. Turn signal light....................................................................... License plate light ................................................................... Brake light/Taillight.................................................................. Position light............................................................................ Speedometer light................................................................... Tachometer light ..................................................................... Neutral indicator light .............................................................. High beam indicator light ........................................................ Turn signal indicator light ........................................................ Fuel level indicator light .......................................................... Oil pressure/Coolant temperature/FI warning light ..................... Engine RPM indicator light...................................................... Immobilizer indicator light ....................................................... A S E L P M Electronic ignition (Transistorized) 6° B.T.D.C.at 1 300 r/min NGK CR9E or DENSO U27ESR-N 12 V 28.8 kC (8 Ah)/10 HR Three-phase A.C. generator 30 A 10/10/15/15/10/10 A 12 V 55 W (H7) + 12 V 65 W (H9) 12 V 21 W 12 V 5 W LED 12 V 5 W × 2 LED LED LED LED LED LED LED LED LED .........E-02, 19, 24 CAPACITIES Fuel tank, including reserve .................................................... Engine oil, oil change ............................................................. with filter change .................................................. overhaul................................................................ Coolant.................................................................................... These specifications are subject to change without notice. 15.5 L (4.1/3.4 US/lmp gal) ......E-33 16.5 L (4.4/3.6 US/lmp gal) ......Others 2 200 ml (2.3/1.9 US/Imp qt) 2 500 ml (2.6/2.2 US/lmp qt) 2 900 ml (3.1/2.6 US/lmp qt) 2.7 L (2.9/2.4 US/lmp qt) PERIODIC MAINTENANCE 2-1 PERIODIC MAINTENANCE CONTENTS PERIODIC MAINTENANCE SCHEDULE .................................................... PERIODIC MAINTENANCE CHART..................................................... LUBRICATION POINTS ........................................................................ MAINTENANCE AND TUNE-UP PROCEDURES ....................................... AIR CLEANER....................................................................................... SPARK PLUG........................................................................................ VALVE CLEARANCE............................................................................ ENGINE OIL AND OIL FILTER ............................................................. EXHAUST CONTROL VALVE .............................................................. FUEL LINE............................................................................................. ENGINE IDLE SPEED ........................................................................... THROTTLE VALVE SYNCHRONIZATION ........................................... EVAPORATIVE EMISSION CONTROL SYSTEM (E-33 ONLY) .......... PAIR (AIR SUPPLY) SYSTEM .............................................................. THROTTLE CABLE PLAY .................................................................... CLUTCH ................................................................................................ COOLING SYSTEM............................................................................... DRIVE CHAIN........................................................................................ BRAKE .................................................................................................. TIRES..................................................................................................... STEERING............................................................................................. FRONT FORK........................................................................................ REAR SUSPENSION ............................................................................ EXHAUST PIPE BOLT AND NUT......................................................... CHASSIS BOLTS AND NUTS .............................................................. COMPRESSION PRESSURE CHECK ........................................................ COMPRESSION TEST PROCEDURE .................................................. OIL PRESSURE CHECK ............................................................................. SDS CHECK................................................................................................. 2- 2 2- 2 2- 3 2- 4 2- 4 2- 5 2- 7 2-12 2-13 2-14 2-14 2-15 2-15 2-15 2-15 2-16 2-17 2-20 2-23 2-27 2-27 2-28 2-28 2-29 2-30 2-32 2-32 2-33 2-34 2 A S P M E L 2-2 PERIODIC MAINTENANCE PERIODIC MAINTENANCE SCHEDULE The chart below lists the recommended intervals for all the required periodic service work necessary to keep the motorcycle operating at peak performance and economy. Mileages are expressed in terms of kilometers, miles and time for your convenience. IMPORTANT (For E-28): The periodic maintenance intervals and service requirements have been established in accordance with EPA regulations. Following these instructions will ensure that the motorcycle will not exceed emission standards and it will also ensure the reliability and performance of the motorcycle. NOTE: More frequent servicing may be required on motorcycles that are used under severe conditions. PERIODIC MAINTENANCE CHART Interval miles km months 600 1 000 2 ---------I R R ---I I (E-33 only) ---4 000 6 000 12 I I ------R ---I I ---7 500 12 000 24 I R ---I R ---I I I I 11 000 18 000 36 R I ------R R I I ------14 500 24 000 48 I R I I R ---I I I I Item Air cleaner element Spark plugs Valve clearance Exhaust control valve Engine oil Engine oil filter Fuel line Idle speed Throttle valve synchronization Evaporative emission control system (E-33 only) PAIR (air supply) system Throttle cable play Clutch cable play Radiator hoses Engine coolant Drive chain Brakes Brake hoses Brake fluid A S P M ---I ------- E L ---- Tires Steering Front forks Rear suspension Exhaust pipe bolts and muffler bolt and nut Chassis bolts and nuts ---I ---I I I I I I I I I I I I I Replace every 2 years. I I I I I Clean and lubricate every 1 000 km (600 miles). I I I I I ---I I I I Replace every 4 years. ---I I I I Replace every 2 years. ---I I I I I ---I ---I ------I ---I ------I ---I T ---T ---T T T T T T NOTE: I = Inspect and clean, adjust, replace or lubricate as necessary; R = Replace; T = Tighten PERIODIC MAINTENANCE 2-3 LUBRICATION POINTS Proper lubrication is important for smooth operation and long life of each working part of the motorcycle. Major lubrication points are indicated below. Brake lever holder A S Clutch lever holder P M Brake pedal pivot and footrest pivot E L Footrest pivot and gearshift lever pivot Side-stand pivot and spring hook Drive chain NOTE: * Before lubricating each part, clean off any rusty spots and wipe off any grease, oil, dirt or grime. * Lubricate exposed parts which are subject to rust, with a rust preventative spray whenever the motorcycle has been operated under wet or rainy conditions. 2-4 PERIODIC MAINTENANCE MAINTENANCE AND TUNE-UP PROCEDURES This section describes the servicing procedures for each item of the Periodic Maintenance requirements. AIR CLEANER Inspect every 6 000 km (4 000 miles, 12 months). Replace every 18 000 km (11 000 miles, 36 months). · Remove the front seat. (8-7) · Lift and support the fuel tank. (5-3) · Remove the air cleaner element by removing the screws. · Remove the air cleaner element. · Inspect the air cleaner element for clogging. If the air cleaner element is clogged with dust, replace the air cleaner element with a new one. Do not blow the air cleaner element with compressed air. NOTE: If driving under dusty conditions, replace the air cleaner element more frequently. Make sure that the air cleaner is in good condition at all times. The life of the engine depends largely on this component. · Install a new air cleaner element in the reverse order of removal. · Remove the drain plug from the air cleaner box to allow any water to drain out. A S P M E L PERIODIC MAINTENANCE 2-5 SPARK PLUG Inspect every 6 000 km (4 000 miles, 12 months). Replace every 12 000 km (7 500 miles, 24 months). SPARK PLUG AND IGNITION COIL/PLUG CAP REMOVAL · Remove the front seat. (8-7) · Lift and support the fuel tank. (5-3) · Remove the air cleaner box. (5-14) · Disconnect all lead wire couplers from ignition coil/plug caps. Disconnect the lead wire coupler before removing the ignition coil/plug cap to avoid lead wire coupler damage. · Remove the ignition coils/plug caps. * Do not pry up the ignition coil/plug cap with a screw driver or a bar to avoid its damage. * Be careful not to drop the ignition coil/plug cap to prevent short/open circuit. · Remove the spark plugs with a spark plug wrench. HEAT RANGE · Check spark plug heat range by observing electrode color. If the electrode of the spark plug is wet appearing or dark color, replace the spark plug with hotter type one. If it is white or glazed appearing, replace the spark plug with colder type one. Hot type CR8E U24ESR-N Standard CR9E U27ESR-N Cold type CR10E U31ESR-N A S P M E L NGK ND NOTE: "R" type spark plug has a resistor built into at the center electrode to prevent radio noise. CARBON DEPOSITS · Check carbon deposits on the spark plug. · If carbon is deposited, remove it using a spark plug cleaner machine or carefully use a tool with a pointed end. 2-6 PERIODIC MAINTENANCE SPARK PLUG GAP · Measure the spark plug gap with a thickness gauge. · Adjust the spark plug gap if necessary. Spark plug gap: Standard: 0.7 ­ 0.8 mm (0.028 ­ 0.031 in) 09900-20803: Thickness gauge ELECTRODE'S CONDITION · Check the condition of the electrode. · If it is extremely worn or burnt, replace the spark plug. Replace the spark plug if it has a broken insulator, damaged thread, etc. Confirm the thread size and reach when replacing the plug. If the reach is too short, carbon will be deposited on the screw portion of the plug hole and engine damage may result. SPARK PLUG AND IGNITION COIL/PLUG CAP INSTALLATION · Screw the spark plugs into the cylinder head with fingers, and then tighten them to the specified torque. Spark plug: 11 N·m (1.1 kgf-m, 8.0 Ib-ft) Do not cross thread or over tighten the spark plug, or such an operation will damage the aluminum threads of the cylinder head. · Install the ignition coils/plug caps and connect their lead wire couplers. * Do not hit the ignition coil/plug cap with a plastic hammer when installing it. * Place the ignition coil/spark plug cap so that the coupler does not touch the cylinder head cover. A S P M E L CONTACT INCORRECT INCORRECT PERIODIC MAINTENANCE 2-7 VALVE CLEARANCE Inspect every 24 000 km (14 500 miles, 48 months). · · · · · · · · · · · Remove the right under cowling. (8-5) Lift and support the fuel tank. (5-3) Remove the air cleaner box. (5-14) Disconnect the CMP sensor coupler 1. Remove the PAIR control solenoid valve 2. Remove the spark plugs. (2-5) Loosen the throttle body clamp screws at the intake pipe side. Move the throttle body assembly. Move the radiator forward. (6-10) Remove the regulator/rectifier and horn. (3-6) Remove the cylinder head cover. (3-14) The valve clearance specification is different for intake and exhaust valves. Valve clearance must be checked and adjusted, 1) at the time of periodic inspection, 2) when the valve mechanism is serviced, and 3) when the camshafts are removed for servicing. Valve clearance (when cold): Standard: IN. : 0.08 ­ 0.18 mm (0.003 ­ 0.007 in) EX. : 0.18 ­ 0.28 mm (0.007 ­ 0.011 in) NOTE: * The cam must be at positions, A or B, when checking or adjusting the valve clearance. Clearance readings should not be taken with the cam in any other position than these two positions. * The clearance specification is for COLD state. * To turn the crankshaft for clearance checking, be sure to use a wrench, and rotate in the normal running direction. All spark plugs should be removed. · Remove the valve timing inspection cap 1. A S P M E L EX. IN. 2-8 PERIODIC MAINTENANCE · Turn the crankshaft to bring the line A on the CKP sensor rotor to the rib B behind the clutch cover and also to bring the notches A on the left ends of both camshafts (Ex. and In.) to the positions as shown. · In this condition, read the valve clearance at the valves B (In. and Ex. of No. 4 cylinder, Ex. of No. 3 and In. of No. 2). · If the clearance is out of specification, adjust the clearance. (2-9) 09900-20803: Thickness gauge · Turn the crankshaft 360 degrees (one rotation) to bring the line on the CKP sensor rotor to the index mark of valve timing inspection hole and also to bring the notches A to the position as shown. · Read the clearance at the rest of the valves C and adjust the clearance if necessary. (2-9) Cam position B C Notch A position Exhaust Camshaft Intake Camshaft Front Front Front Front Front A S P M E L Front PERIODIC MAINTENANCE 2-9 VALVE CLEARANCE ADJUSTMENT The clearance is adjusted by replacing the existing tappet shim by a thicker or thinner shim. · Remove the intake or exhaust camshafts. (3-14) · Remove the tappet and shim by fingers or magnetic hand. · Check the figures printed on the shim. These figures indicate the thickness of the shim, as illustrated. · Select a replacement shim that will provide a clearance within the specified range. For the purpose of this adjustment, a total of 21 sizes of tappet shim are available ranging from 1.20 to 2.20 mm in steps of 0.05 mm. Fit the selected shim to the valve stem end, with numbers toward tappet. Be sure to check shim size with micrometer to ensure its size. Refer to the tappet shim selection table (2-10 and -11) for details. 170 1.70 mm NOTE: * Be sure to apply engine oil to tappet shim top and bottom faces. * When seating the tappet shim, be sure the figure printed surface faces the tappet. NOTE: Reinstall the camshafts in the specified manner. (3-92) · After replacing the tappet shim and camshafts, rotate the engine so that the tappet is depressed fully. This will squeeze out oil trapped between the shim and the tappet that could cause an incorrect measurement. Then check the clearance again to confirm that it is within the specified range. · After finishing the valve clearance adjustment, reinstall the following items. * * * * * Cylinder head cover (3-97) Spark plug and plug cap (2-6) Throttle body assembly (5-21) Valve timing inspection plug (3-97) PAIR control solenoid valve (11-7) A S P M E L 2-10 (INTAKE SIDE) TAPPET SHIM SELECTION TABLE [INTAKE] TAPPET SHIM NO. (12892-05C00-XXX) TAPPET SHIM SET (12800-05830) PERIODIC MAINTENANCE SUFFIX NO. 120 140 145 150 155 160 165 170 175 180 185 190 195 200 205 125 130 135 210 215 220 MEASURED VALVE CLEARANCE (mm) PRESENT SHIM SIZE (mm) 1.20 1.25 1.30 1.35 1.40 1.45 1.50 1.55 1.60 1.65 1.70 1.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20 0.00 ­ 0.04 1.20 SPECIFIED CLEARANCE/NO ADJUSTMENT REQUIRED 1.70 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20 2.10 2.15 2.20 2.05 2.00 2.05 2.10 2.15 2.20 1.95 2.00 1.90 1.95 2.00 2.05 2.10 2.15 2.20 1.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20 2.05 2.10 2.15 2.20 1.25 1.30 1.35 1.40 1.45 1.50 1.55 1.60 1.65 1.70 1.75 1.80 1.85 1.90 1.20 1.25 1.30 1.35 1.40 1.45 1.50 1.55 1.60 1.65 1.70 1.75 1.80 1.85 1.90 1.95 1.95 2.00 2.00 2.05 2.05 2.10 2.10 2.15 0.05 ­ 0.09 A S 1.50 1.75 1.80 1.55 1.60 1.65 2.10 2.15 2.20 1.55 1.60 1.65 1.70 1.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20 2.20 2.15 2.20 2.10 2.15 2.20 2.05 2.10 2.15 2.20 2.00 2.05 2.10 2.15 2.20 1.95 2.00 2.05 2.10 2.15 1.90 1.95 2.00 2.05 2.10 1.85 1.90 1.95 2.00 2.05 1.80 1.85 1.90 1.95 2.00 1.75 1.80 1.85 1.90 1.95 1.70 1.75 1.80 1.85 1.90 1.65 1.70 1.75 1.80 1.85 1.60 1.65 1.70 0.10 ­ 0.20 1.30 1.35 1.40 1.45 1.50 1.55 1.60 1.65 1.70 1.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20 2.20 2.15 2.20 2.10 2.15 2.20 2.05 2.10 2.15 2.00 2.05 2.10 1.95 2.00 2.05 1.90 1.95 2.00 1.85 1.90 1.95 1.80 1.85 1.90 1.75 1.80 1.85 1.70 1.75 1.80 1.65 1.70 1.75 1.60 1.65 1.70 1.55 1.60 1.65 1.50 1.55 1.60 1.45 1.50 1.55 1.40 1.45 1.50 1.35 1.40 1.45 0.21 ­ 0.25 2.15 2.20 2.20 2.20 0.26 ­ 0.30 0.31 ­ 0.35 0.36 ­ 0.40 0.41 ­ 0.45 0.46 ­ 0.50 0.51 ­ 0.55 P M E L 0.56 ­ 0.60 0.61 ­ 0.65 0.66 ­ 0.70 0.71 ­ 0.75 0.76 ­ 0.80 0.81 ­ 0.85 0.86 ­ 0.90 0.91 ­ 0.95 0.96 ­ 1.00 1.01 ­ 1.05 1.06 ­ 1.10 1.11 ­ 1.15 HOW TO USE THIS CHART: I. Measure valve clearance. "ENGINE IS COLD" II. Measure present shim size. III. Match clearance in vertical column with present shim size in horizontal column. EXAMPLE Valve clearance is 0.23 mm Present shim size 1.70 mm Shim size to be used 1.80 mm TAPPET SHIM SELECTION TABLE [EXHAUST] TAPPET SHIM NO. (12892-05C00-XXX) TAPPET SHIM SET (12800-05830) (EXHAUST SIDE) SUFFIX NO. 120 140 145 150 155 160 165 170 175 180 185 190 195 200 205 125 130 135 210 215 220 MEASURED VALVE CLEARANCE (mm) PRESENT SHIM SIZE (mm) 1.20 1.25 1.30 1.35 1.40 1.45 1.50 1.55 1.60 1.65 1.70 1.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20 0.05 ­ 0.09 1.20 1.20 SPECIFIED CLEARANCE/NO ADJUSTMENT REQUIRED 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.05 2.10 2.15 2.20 2.20 2.00 1.95 2.00 2.05 2.10 2.15 2.20 1.90 1.95 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20 2.00 2.05 2.10 2.15 2.20 2.05 2.10 2.15 2.20 1.30 1.35 1.40 1.45 1.50 1.55 1.60 1.65 1.70 1.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20 2.20 2.15 2.20 2.10 2.15 2.20 2.05 2.10 2.15 2.20 2.00 2.05 2.10 2.15 2.20 1.95 2.00 2.05 2.10 2.15 2.20 1.90 1.95 2.00 2.05 2.10 2.15 2.20 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15 1.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15 1.70 1.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10 1.65 1.70 1.75 1.80 1.85 1.90 1.95 2.00 2.05 1.60 1.65 1.70 1.75 1.80 1.85 1.90 1.95 2.00 1.55 1.60 1.65 1.70 1.75 1.80 1.85 1.90 1.95 1.50 1.55 1.60 1.65 1.70 1.75 1.80 1.85 1.90 1.45 1.50 1.55 1.60 1.65 1.70 1.75 1.80 1.85 1.40 1.45 1.50 1.55 1.60 1.65 1.70 1.75 1.80 1.35 1.40 1.45 1.50 1.55 1.60 1.65 1.70 1.75 1.25 1.30 1.35 1.40 1.45 1.50 1.55 1.60 1.65 1.70 1.75 1.80 1.85 1.25 1.30 1.35 1.40 1.45 1.50 1.55 1.60 1.65 1.70 1.75 1.80 1.85 1.90 1.20 1.25 1.30 1.35 1.40 1.45 1.50