Fuel delivery system — construction The fuel delivery system consists of the fuel tank, fuel pump, fuel filters, fuel feed hose, fuel delivery pipe (including fuel injectors) and fuel pressure regulator. There is no fuel return hose. The fuel in the fuel tank is pumped up by the fuel...
Fuel pump — construction The electric fuel pump is mounted at the bottom of the fuel tank, which consists of the armature, magnet, impeller, brush, check valve and relief valve. The ECM controls its ON/OFF operation as controlled under the FUEL PUMP CONTROL SYSTEM. When...
Fuel pressure regulator — construction The fuel pressure regulator consists of the spring and valve. It keeps absolute fuel pressure of 300 kPa (3.0 kgf/cm², 43 psi) to be applied to the injector at all times. When the fuel pressure rises more than 300 kPa (3.0 kgf/cm², 43 psi), the fuel...
Fuel injector — construction The fuel injector consists of the solenoid coil, plunger, needle valve and filter. It is an electromagnetic type injection nozzle which injects fuel in the throttle body according to the signal from the ECM. When the solenoid coil of the injector is...
Fuel pump control system — construction When the ignition switch is turned on, current from the battery flows to the fuel pump motor through the sidestand relay and the fuel pump relay causing the motor to turn. Since the ECM has a timer function, the fuel pump motor stops turning in...
Fuel tank lift-up Remove the seat. ( 7-4 ) Remove the cowring. ( 7-5 ) Remove the fuel tank mounting bolt and fuel tank mount stay (1). Lift and support the fuel tank with the fuel tank mount stay.
Fuel tank — removal and installation Fuel tank removal Lift and support the fuel tank. ( 5-7 ) Disconnect the fuel pump lead wire coupler (1). Place a rag under the fuel feed hose and disconnect the fuel feed hose (2) from the fuel tank. Disconnect the fuel tank drain hose (3)....
Fuel pressure inspection Lift and support the fuel tank. ( 5-7 ) Place a rag under the fuel feed hose. Remove the fuel feed hose and install the special tools between the fuel tank and fuel delivery pipe. 09940-40211: Fuel pressure gauge adaptor 09940-40220: Fuel pressure...
Fuel pump inspection Turn the ignition switch ON and check that the fuel pump operates for few seconds. If the fuel pump motor does not make operating sound, replace the fuel pump assembly or inspect the fuel pump relay and tip over sensor. Fuel discharge amount...
Fuel pump relay inspection Fuel pump relay is located behind the ECM. Remove the seat. ( 7-4 ) Remove the fuel pump relay. First, check the insulation between (1) and (2) terminals with pocket tester. Then apply 12 volts to (3) and (4) terminals, (+) to (3) and (-) to (4),...
Fuel pump and fuel filter removal Remove the fuel tank. ( 5-7 ) Remove the fuel pump assembly by removing its mounting bolts diagonally. Warning! Gasoline is highly flammable and explosive. Keep heat, spark and flame away. Remove the screws. Remove the nuts (1) and screw (2)....
Fuel mesh filter inspection and cleaning If the fuel mesh filter is clogged with sediment or rust, fuel will not flow smoothly and loss in engine power may result. Blow the fuel mesh filter with compressed air. Note: If the fuel mesh filter is clogged with many sediment or rust, replace...
Fuel pump and fuel mesh filter installation Install the fuel pump and fuel mesh filter in the reverse order of removal. Pay attention to the following points: Install the new O-rings to the fuel pressure regulator and fuel Pipe. Apply thin coat of the engine oil to the O-rings. Caution! Use...
Throttle body and STV actuator construction 1. TP sensor; 2. STP sensor; 3. STVA; 4. Fuel delivery pipe; 5. Injector; A. STP sensor mounting screw; B. TP sensor mounting screw; C. Fuel delivery pipe mounting screw; *1 Do not turn the screw. ITEM N·m kgf·m lb·ft (A) 2.0 0.2 1.5 (B) 3.5 0.35...
Air cleaner and throttle body removal Air cleaner box Remove the fuel tank. ( 5-7 ) Disconnect the IAT sensor coupler (1). Remove the IAP sensor vacuum hose (2). Disconnect the IAP sensor coupler (3). Loosen the throttle body clamp screws. Disconnect the PAIR hose. Disconnect the PAIR...
Throttle body disassembly Caution! Be careful not to damage the throttle lever when disassembling the throttle body. The throttle body is assembled precisely in factory. Do not disassemble it other than shown in this manual. Remove the IAP sensor vacuum damper and its hose....
Throttle body cleaning Warning! Some carburetor cleaning chemicals, especially diptype soaking solutions, are very corrosive and must be handled carefully. Always follow the chemical manufacturer's instructions on proper use, handling and storage. Clean all passageways...
Throttle body inspection Check following items for any damage or clogging. O-ring Throttle shaft bushing and seal Throttle valve Secondary throttle valve Injector cushion seal Vacuum hose Check the fuel injector filter for evidence of dirt and contamination. If present,...
Throttle body reassembly Reassemble the throttle body in the reverse order of disassembly. Pay attention to the following points: Apply SUZUKI SUPER GREASE to the throttle stop screw tip and the both ends of a spring. 99000-25030: SUZUKI SUPER GREASE "A" (USA) 99000-25010:...
STV synchronization Install the throttle body. ( 5-27 ) Turn the ignition switch OFF, if STV synchronization is performed on the vehicle. Turn the STVA shaft with a finger so that the throttle valve height (A) will be same as (B). Caution! Do not use the tool for...
Throttle body installation Installation is in the reverse order of removal. Pay attention to the following points: Connect the throttle pulling cable and throttle returning cable to the throttle cable drum. Connect the fuel injector couplers to the fuel injectors. Notes: The...
STP sensor adjustment If the STP sensor adjustment is necessary, measure the sensor resistance and adjust the STP sensor positioning as follows: Disconnect the STVA coupler (1) and turn the ignition switch ON. To set the ST valve to fully open position. Measure the STP...
TP sensor adjustment After checking or adjusting the throttle valve synchronization, adjust the TP sensor positioning as follows: After warming up engine, adjust the idling speed to 1300 rpm. Stop the warmed-up engine and connect the special tool to the dealer mode...
Fast idle inspection The fast idle system is automatic type. When the fast idle cam is turned by the secondary throttle valve actuator, the cam pushes the lever on the throttle valve shaft causing the throttle valve to open and raise the engine speed. When the engine...
Fast idle adjustment Remove the fuel tank. ( 5-7 ) Remove the air cleaner box. ( 5-15 ) Disconnect the STVA lead wire coupler and turn the ignition switch ON. Open the STV fully with a finger. Measure the output voltage of the TP sensor. Caution! Do not use the tool for...
Throttle valve synchronization Check and adjust the throttle valve synchronization between two cylinders. Calibrating each gauge (For vacuum balancer gauge) Start up the engine and run it in idling condition for warming up. Stop the warmed-up engine. Remove the fuel tank. ( 5-7 )...