Suzuki GSX-R 1000 Service Manual: Excv cable removal and installation
Removal
- Turn the ignition switch off.
- Remove the front seat. Refer to “exterior parts
removal and installation” in section 9d (page 9d-
6).
- Remove the left side cowling. Refer to “exterior parts removal and
installation” in section 9d .
- Connect the special tool (mode select switch) to the dealer mode
coupler. Refer to “self-diagnostic procedures” in section 1a .
- After turning the mode select switch on, turn the
ignition switch on.
Special tool
(a): 09930–82720 (mode selection
switch)

- Check that the cable slots of the excva pulley
comes to the middle (adjustment position) “a”.
- Turn the ignition switch off.
Caution
before removing the excv cables, be sure to
set the excva pulley to the adjustment
position. |

- Loosen the lock-nut (1) on the no. 2 Cable (2) and
turn in the cable adjuster (3) fully.
- Loosen the lock-nut (4) on the no. 1 Cable (5) and
turn in the cable adjuster (6) fully.

- Disconnect the no. 2 Cable (2) and no. 1 Cable (5)
from the excva pulley (7).

- Loosen the lock-nuts.
- Disconnect the no. 2 Cable (2) and no. 1 Cable (5)
from the excv pulley (8).

Installation
Caution
the cable slots of excva pulley must be
located adjustment position. |
- Temporarily connect the excv cable no. 1
(47H0cl) (1) and no. 2 (47H0op) (2) to the exhaust
pipe and excv pulley.
Note
the excv cables are identified by the letters.
No. 1 Cable (1): 47h0cl
no. 2 Cable (2): 47h0op |
- Tighten the lock-nuts (3) on the no. 1 Cable.
- Adjust the inner cable length “a” of no. 1 Cable in 42
– 43 mm (1.65 – 1.69 In) by turning the adjuster (4),
then tighten the lock-nuts (5).
- Turn in the adjuster (6) on the no. 2 Cable fully.
- Turn the no. 2 Cable adjuster (7) in or out until the
inner cable length “b” becomes 60 – 61 mm (2.36 –
2.40 In).
After adjusting the inner cable length “b”, tighten the
lock-nuts (8).

- Connect the other end of excv cable no. 1 (1) And
no. 2 (2) To the excva pulley (9).

- After connecting the no. 2 Cable (2), loosen the locknut
(10) and turn the adjuster (6) in or out until 11 –
12 mm (0.43 – 0.47 In) of the thread length “c” on the
cable adjuster can be provided and tighten the locknut
(10).

- Inspect the excva position sensor output voltage.
Refer to “excva adjustment” .
Exhaust pipe gasket
Exhaust pipe assembly
Ho2 sensor
Connector
: install the connector so that the
chamfer side faces backward.
Muffler chamber
Muffler ...
Removal
Turn the ignition switch off.
Remove the left side cowling. Refer to “exterior parts removal and
installation” in section 9d .
Connect the special tool (mode select swit ...
Other materials:
Specifications
Service data
Injector + fuel pump + fuel pressure regulator
Fuel
Tightening torque specifications
Note
the specified tightening torque is described in the following.
“Fuel pump components”
Reference: for the tightening torque of fastener not specified in this
se ...
Cushion lever removal and installation
Removal
Remove the right side cowling and side frame covers. Refer to “exterior
parts removal and installation” in section 9d .
Support the motorcycle with a jack to relieve load on
the cushion levers.
Remove the left muffler and muffler chamber heat guard no. 2. Refer to
...
Front suspension adjustment
After installing the front fork, adjust the spring pre-load
and two kinds of damping force as follows:
Adjust the
left and right front forks to the
same setting.
Spring pre-load adjustment
Turn the spring pre-load adjuster (1) counterclockwise
fully. From that position (softe ...