Suzuki GSX-R 1000 Service Manual: Throttle body removal and installation
Removal
- Remove the side cowlings. Refer to “exterior parts
removal and installation” in section 9d (page 9d-
6).
- Remove the air cleaner box. Refer to “air cleaner box removal and
installation” .
- Remove the clamps (1).
- Disconnect the iap sensor (2) from the vacuum
hose.
- Disconnect the stva lead wire coupler (3).
- Disconnect secondary fuel injector couplers (4) and
primary fuel injector couplers (5).
- Disconnect the purge hose (6) from the evap
system purge control solenoid valve. (E-33 only)
- Remove the clamp (7).
- Disconnect the isc valve coupler (8).
- Place a rag under the fuel feed hose (9) and
disconnect the fuel feed hose from the fuel pump.
For e-33
models, drain fuel from the fuel tank
before disconnecting the fuel feed hose to
prevent fuel leakage. |
- Loosen the throttle body clamp screws, left and right.
- Lift up the throttle body from the intake pipes.
- Disconnect the stp sensor coupler (10) and tp
sensor coupler (11).
- Disconnect the throttle cables.
Caution
after disconnecting the throttle cables, do
not snap the throttle valve from full open to
full close. It may cause damage to the throttle
valve and throttle body. |
- Remove the throttle body.
Installation
Installation is in the reverse order of removal. Pay
attention to the following points:
- connect the primary injector couplers (1) and
secondary injector couplers (2) to the respective fuel
injectors. Make sure that each coupler is installed in
the correct position. The color on each lead wire
refers to the appropriate fuel injector.
- Connect the throttle cable no. 1 (3) And throttle cable
no. 2 (4) To the throttle cable drum.
- Loosen each throttle cable lock-nut.
- Turn in each throttle cable adjuster fully and locate
each outer cable so that the clearance “a” is 0 – 1 mm
(0 – 0.04 In).
- Tighten each lock-nut.
Tightening torque
throttle cable lock-nut: 4.5 N·m (0.45 Kgf-m, 3.0
Lbf-ft)
Intake pipe
Evap system purge control solenoid valve
(e-33 only)
Evap canister (e-33 only)
Iat sensor
Isc valve hose
Ho2 sensor
Face
the clamp end ...
Refer to “throttle body removal and installation” .
Disassembly
Caution
identify the position of each removed part.
Organize the parts in their respective groups
so that they can be ...
Other materials:
Modification
Modification of the motorcycle, or
removal of original equipment
may render the vehicle unsafe or
illegal. Obey all applicable equipment
regulations in your area.
The frame of this motorcycle is
made of an aluminum alloy.
Therefore, never make any modifications
such as drilling or weldin ...
Symbols
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.
Abbreviations
A:
abdc: after bottom dead center
ac: alternating current
acl: air cleaner, air cleaner box
api: ame ...
DTC “c62” (p0443): evap system purge
control solenoid valve circuit malfunction
(e-33 only)
Detected condition and possible cause
Detected condition
Possible cause
Evap system purge control valve voltage is not input to
ecm.
Evap system purge control valve circuit open or short.
Evap system purge control valve malfunction.
Ecm malfunction. ...