Suzuki Electronic Jet Kit Installation Instructions

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Filed Under (Suzuki) by admin on 12-02-2012

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at anytime during install or tuning please callus for any and all help, we can’thelpifyoudon’tcall ) 1. Before installing the TFI you must first disconnect the negative lead from the battery. 2. Determinea location for the TFI unit. Suggested locations areas follows: Under the seat, behinda side cover or tail section. 3. The TFIcomeswitha harness with injector connectors that match the factory injector connectors. 4. Locate the factory fuel injectors (see owners manual if you are not sure).** **: Some models are equipped with two sets of injectors (primary and secondary); the unit is designed to interface with the primary injectors. If the TFI harness does not match your injectors do not proceed and call tech support at 877-764-3337. 5. Disconnect the factory injector connectors from the fuel injectors and replace with the TFI injector connectors from the TFI unit, basically unhook the factory injector connector and plug the matching TFI connector (female) to the injector and then connect the factory injector connector to the TFI connector that simulates the injector (male). There is no order to hookup the TFI harness to the factory harness just make sure the original factory connector goes toits’original cylinder. It isa good idea to make sure there is a little slack in the harness to prevent engine vibration from damaging/breakingawireon the connectors. 6. Be sure to check the wires are not indirect contact with any sharp edges, exhaust and/or other objects, which could result in long term wear and/or damage. 7. Connect the TFI ground lead to the negative terminal of the battery along with the factory ground lead. 8. With the rubber plug removed from the TFI, turn the motorcycle key switch to the “ON”position. As the bikes electrical system goes through initial startup mode you may see LED’sflashingonthe TFI.

Suzuki 240 Hayabusa Swingarm Installation Instructions

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Filed Under (Suzuki) by admin on 12-02-2012

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installation Instructions 1.) Stock Component Removal To begin installing this kit it is necessary to raise the rear end of the bike using a suitable hoist. Be sure to keep the bike centered on the front wheel to keep the bike from tipping over. Once you have the bike lifted and properly secured, begin with the removal of the following stock components ( For detailed information on the removal of these parts, please consult your factory manual) : 1.) Muffler or mufflers 2.) Left side and lower body panels 3.) Voltage regulator (08 model only) 4.) Front sprocket cover 5.) Front sprocket 6.) Chain 7.) Rear Axel, wheel and brake assembly 8.) Pivot tube and swingarm
2.) New Swingarm Installation A. Most of the pieces needed are installed on the swing-arm. You’ll need to install the shock mount block with the 4 supplied flat head 5/16″bolts, use red loctite and torque to 25 ft lbs. B. Insert the 2 supplied pivot bushings in the pivot tube. Move your new swingarm into position. Once you have the swingarm in position reinsert the pivot tube to hold it in place. C. On some bikes (07′ and earlier Busa’s) it is necessary to grind approximately 1/8″ off the frame for chain clearance. Not all bikes will require this, but it is best to mock up and test fit before final assembly.

SUZUKI GSR 600 Accessories

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Filed Under (Suzuki) by admin on 12-02-2012

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YBA – Pearl suzuki deep blue no.2 P/N 99000-99074-69N YD8 – Metallic sonic silver P/N 99000-99074-70N YHL – Candy sonoma red P/N 99000-99074-71N YKV – Metallic matt black no.2 P/N 99000-99074-72N YAY – Pearl nebular black P/N 000-99074-73N YMD – Metallic mistic silver P/N 99000-99074-74N YME – Candy max orange P/N 99000-99074-75N YLF – Metallic thunder gray P/N 99000-99074-76N 1 Not in combination with crash pad set (pos. 110) From exhaust to cockpit: the GSR600 is all dressed up 3 102 103 104 106 107 105 102 GSR600 exhaust system by Yoshimura 1 GSR600, model year 2006-2009 P/N 99000-79N12-023 103 Chain guard GSR600, model year 2006-2009 Polished aluminium P/N 990D0-44G10-000 104 Frame covers set GSR600, model year 2006-2009 Carbon look P/N 990D0-44GFC-CRB 105 Tankpad P/N 990D0-44G00-PAD 106 Rear lamp cover GSR600, model year 2006-2009 For original equiped exhaust system P/N 990D0-44G25-PAD For Yoshimura exhaust system P/N 990D0-44G30-PAD 107 Ignition lock cover GSR600, model year 2006-2009 P/N 990D0-44G15-PAD 108 Speedometer cover GSR600, model year 200

Suzuki DRZ 400K Dual Sport Kit Installation Manual

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Filed Under (Suzuki) by admin on 11-02-2012

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DRZ 400 (Kick Start) Dual Sport Kit Installation Manual 1. Get a degree in Mechanical and Electrical Engineering. (Just kidding!) 2. Remove the side panels, seat, and gas tank. 3. Unplug the headlight from the stock wiring and remove. 4. Unplug the kill button from the stock wiring and remove (Photo 2). The connector is a gray two-conductor connector located under the fuel tank. Release detent on connector to separate. Kill switch connector Photo 2 5. Unplug the stock taillight and remove. Using a utility knife, trim the taillight mounting tabs flush with the underside of the fender. ¼” Photo 3 Countersunk screw and bezel, 4 Places 6. Taillight Installation Position the taillight assembly so that the edge of the red taillight extends past the edge of the fender about 1/4″ as shown in Photo 3. With the taillight positioned as shown Photos 3 & 4 , transfer the four mounting hole locations into the bottom of the fender. Drill the mounting holes at 1/4″ diameter. Use the 6 x 16 mm counter-sunk fasteners and bezels for mounting the taillight

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SUZUKI GSX-R600 X-TRE Power Box Installation and Operation Manual

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Filed Under (Suzuki) by admin on 10-02-2012

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Installation Disclaimer: Do not attempt to install the product if you don’t have basic mechanical skills. HealTech Electronics Ltd. and its distributors shall not be liable for any loss or damage caused by improper installation. 1. Check the supplied parts: – X-TRE Power Box – Wiring harness – Yellow butt connectors, gel-filled (2 pcs) – Red tap connector, gel-filled – 4p jumper-plug – Cable ties (2+1 pcs) – Velcro strips – HealTech stickers (2+2 pcs) – Manual 2. Make sure the ignition key is in OFF position. Remove the seat. 3. Locate the ECM (Engine Control Module) under the seat. 4. Release the fuse box and relay switch to clean the area around the ECM connectors. 5. Locate the Black wire with thin dark Green stripe (B/G) , in the ECM connector. The wire position for different models is as follows: GSX-R600 K8-K9 GSX-R750 K8-K9 GSX-R1000 K7-K9 Black connector, pin no. 23 Middle row, 2nd wire from left to right at the back (wire) side of the connector ALL other years and models Black connector, pin no. 6 Top row, 6th wire from right to left at the back (wire) side of the connector

SUZUKI INTRUDER 1500 LC BOTH WHEELS REMOVAL AND INSTALLATION MANUAL

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Filed Under (Suzuki) by admin on 27-02-2011

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In order to keep the proper balance on the bike lift, I would suggest that the front wheel be removed first, this is comparatively easier than the rear wheel which will be explained later. Front wheel removal : Remove the end caps, remove the front axle “Pinch Bolt” front left fork ( item (2) in manual ) remove caliper bolts both (2) both sides (2003 model year) secure calipers, secure wheel from dropping while removing axle from left side. Remove front axle, caution : there are (2) spacers on this axle, left & right, make sure you mark them, as they are both different in shape & in length, & must be re-assembled in same order to provide proper cetrallity of the front wheel with the forks & the brake calipers.both spacers have large flanges which go towards the bearing, the right spacer has (2) flanges, the largest dia. goes towards the bearing. ( very important) Now comes the tough part, I had the original stock pipes, so if you have different pipes, or your bike is a different year, (2003) your choices may be different from mine. Remove OEM right side saddlebag, slack off muffler coupling brackets # 8 & # 8a which connect muffler crossover tank to top muffler, this is where the power of the allen socket wrench set will come in handy, they’re pretty tight with the heat,remove top exhaust pipe bracket bolt (item 19 in manual) the top exhaust pipe should now swing down clear of the rear axle. You may be forced to provide more room for the exit and/or re-installation of the rear wheel by removing the bolt which secures the underside mufflet tank on the lower left side of the frame, (item # 13 in manual) then the (2) bolts, ( items # 14 in manual) which will allow the rear muffler body ( lower exhaust pipe ) to be pulled over to the right to provide access for easier rear wheel entry or removal

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2005 SUZUKI SV1000 SPECIFICATIONS AND SERVICE MANUAL

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Filed Under (Suzuki) by admin on 26-02-2011

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TIRE PRESSURE FUEL + OIL COLD INFLATION TIRE PRESSURE FRONT REAR SOLO RIDING ITEM Fuel type kPa 250 250 DUAL RIDING kPa 250 290 NOTE E-03, 28, 33 The others E-33 The others Fuel tank Engine oil type Engine oil capacity SPECIFICATfON Use only unleaded gasoline of at least 87 pump octane (R12 + M12) or 91 octane or higher rated by the research method. Gasoline containing MTBE (Methyl Tertiary Butyl Ether), less than 10% etha- nol, or less than 5% methanol with appropriate cosolvents and corrosion inhibitor is permissible. Gasoline used should be graded 91 octane or higher. An unleaded gasoline is recommended. 16 L (4.2/3.5 USnrnp gal) 17 L (4.513.7 USIlmp gal) * SAE 10W-40, API SFlSG or SHISJ with JASO MA kgf/cm2 2.50 2.50 Change Filter change Overhaul psi 36 36 kgflcrn2 2.50 2.90 2 700 rnl (2.912.4 USllmp qi) 2 900 ml (3.112-6 US/lmp qt) 3 300 ml (3.U2.9 USllrnp qt) psi 36 42 CRANKCASE-CRANKSHAFT BEARING SELECTION Select the specrffed bearings from the crankcase bore I. D. code. The crankcase bore I.D. code (A) “A, “6″ or “C”, is stamped on the inside of each crankcase half. Bearing selection table Bearing thickness I.D. code @9 A B C Bearing must be replaced as a set. I.P. specification 52.000 – 52.006 mrn (2.0472 – 2.0475 in) 52.006 – 52.01 2 mm (2.0475 – 2.0477 in) 52.01 2 – 52,018 mm (2.0477 – 2.0479 in) Color (Part No.) Green (1 2229-1 6GOO-OAO) Black (1 2229- tGG00-OBO) Brown (I 2229- 16GOO-OCO) Color code 9 Bearing Green Black Brown Thickness 1.999 – 2.002 mrn (0.0787 – 0.0788 in) 2.002 – 2.005 mm (0.6788 – 0.0789 in) 2.005 – 2.008 rnm (0.0789 – 0.0791 in) FI SYSTEM WIRING DIAGRAM I ECM TERMINAL (For KCModel) ‘& ECM TERMINAL (For K5-Model) FAIL-SAFE FUNCTION & FI system is provided with fail-safe function ta allow the engine to start and the motorcycle to run in a mini- mum performance necessary even under malfunction condition

SUZUKI SV650 Fl SYSTEM DIAGNOSIS SERVICE MANUAL

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Filed Under (Suzuki) by admin on 26-02-2011

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PRECAUTIONS IN SERVICING When handling the component parts or servicing the FI system, observe the following points for the safety of the system . ELECTRICAL PARTS CONNECTOR/COUPLER • * When connecting a connector, be sure to push it in until a click is felt. •With a lock type coupler, be sure to release the lock when isconnecting, and push it in fully till the works when connecting it. • * When disconnecting the coupler, be sure to hold the coupler body and do not pull the lead wires . • * Inspect each terminal on the connector/coupler for looseness or bending. • * Inspect each terminal for corrosion and contamination. The terminals must be clean and free of any foreign material which could impede proper terminal contact . •Inspect each lead wire circuit for poor connection by shaking it by hand lightly. If any abnormal condition is found, repair or replace. •When taking measurements at electrical connectors using a tester probe, be sure to insert the probe from the wire harness side (backside) of the connector/coupler . 0 4 40 O/ 40 16~ Id •When connecting meter probe from the terminal side of the coupler (connection from harness side not being possible), use extra care not to force and cause the male terminal to bend or the female terminal to open . Connect the probe as shown to avoid opening of female ter- minal. Never push in the probe where male terminal is supposed to fit. •Check the male connector for bend and female connector for excessive opening. Also check the coupler for locking (looseness), corrosion, dust, etc . FUSE • * When a fuse blows, always investigate the cause correct it and then replace the fuse . • * Do not use a fuse of a different capacity . • * Do not use wire or any other substitute for the fuse . ECMNARIOUS SENSORS •Since each component is a high-precision part, great care should be taken not to apply any sharp impacts during removal and installation. • * Be careful not to touch the electrical terminals of the ECM . The static electricity from your body may damage this part . FI SYSTEM DIAGNOSIS 4-3
4-4 FI SYSTEM DIAGNOSIS • When disconnecting and connecting the ECM, make sure to turn OFF the ignition switch, or electronic parts may get dam- aged. • * Battery connection in reverse polarity is strictly prohibited . Such a wrong connection will damage the components of the FI system instantly when reverse power is applied . • * Removing any battery terminal of a running engine is strictly prohibited. The moment such removal is made, damaging counter electromotive force will be applied to the ECM which may result in serious damage.

SUZUKI SV1000S EMISSION CONTROL INFORMATION/ SERVICE MANUAL

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Filed Under (Suzuki) by admin on 26-02-2011

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EMISSION CONTROL SYSTEMS FUEL INJECTION SYSTEM SV1000S motorcycles are equipped with a fuel injection system for emission level control. This fuel injection system is precision designed, manufactured and adjusted to comply with the applicable emission limits. BEFORE-PRESSURIZED FUEL PRESSURIZED FUEL * I’ RELIEVED FUEL ~%~~~ Ift 0 0 9 0 0 0 EMISSION CONTROL INFORMATION 9-3 CRANKCASE EMISSION CONTROL SYSTEM The engine is equipped with a PCV system . Blow-by gas in the engine is constantly drawn into the crankcase, which is returned to the combustion chamber through the breather hose, air cleaner and throttle body . C * FRESH AIR FUEL/AIR MIXTURE 411111110 BLOW-BY GAS 9-4 EMISSION CONTROL INFORMATION EXHAUST EMISSION CONTROL SYSTEM (PAIR SYSTEM) The exhaust emission control system is composed of the PAIR system and THREE-WAY CATALYST system. The fresh air is drawn into the exhaust port with the PAIR solenoid valve and PAIR reed valve . The PAIR solenoid valve is operated by the ECM, and the fresh air flow is controlled according to the TPS, ECTS, IATS, ZAPS and CKPS. H02 sensor (Except for USA) I 0 0 0 0 0 NOISE EMISSION CONTROL SYSTEM TAMPERING WITH THE NOISE CONTROL SYSTEM PROHIBITED : Federal law prohibits the following acts or the causing thereof: 1. The removal or rendering inoperative by any person, other than for purposes of maintenance, repair or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use, or 2. The use of the vehicle after such device or element of design has been removed or rendered inoperative by any person. AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW : • * Removing or puncturing the muffler, baffles, header pipes, screen type spark arrester (if equipped) or any other component which conducts exhaust gases . • * Removing or puncturing the air cleaner case, air cleaner cover, baffles or any other component which conducts intake air . • * Replacing the exhaust system or muffler with a system or muffler not marked with the same model specific code as the code listed on the Motorcycle Noise Emission Control Information label . EVAPORATIVE EMISSION CONTROL SYSTEM (FOR E-33)

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SUZUKI SV1000 ELECTRICAL SYSTEM SERVICE MANUAL

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Filed Under (Suzuki) by admin on 26-02-2011

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COUPLER •With a lock type coupler, be sure to release the lock before disconnecting it and push it in fully till the lock works when connecting it . • * When disconnecting the coupler, be sure to hold the coupler itself and do not pull the lead wires . • * Inspect each terminal on the coupler for being loose or bent . • * Inspect each terminal for corrosion and contamination. CLAMP • * Clamp the wire harness at such positions as indicated in “WIRE HARNESS ROUTING”. (C” -78-14) • * Bend the clamp properly so that the wire harness is clamped securely . • * In clamping the wire harness, use care not to allow it to hang down. • * Do not use wire or any other substitute for the band type clamp. FUSE • * When a fuse blows, always investigate the cause, correct it and then replace the fuse . • * Do not use a fuse of a different capacity . • * Do not use wire or any other substitute for the fuse . SEMI-CONDUCTOR EQUIPPED PART • * Be careful not to drop the part with a semi-conductor built in such as a ECM. • * When inspecting this part, follow inspection instruction strictly . Neglecting proper procedure may cause damage to this part . ELECTRICAL SYSTEM 7- 3 7-4 ELECTRICAL SYSTEM BATTERY •The MF battery used in this motorcycle does not require maintenance (e.g., electrolyte level inspection, distilled water replenishment) . • * During normal charging, no hydrogen gas is produced. However, if the battery is overcharged, hydrogen gas may be produced. Therefore, be sure there are no fire or spark sources (e.g., short circuit) nearby when charging the battery . • * Be sure to recharge the battery in a well-ventilated and open area. • Note that the charging system for the MF battery is different from that of a conventional battery. Do not replace the MF battery with a conventional battery . CONNECTING THE BATTERY •When disconnecting terminals from the battery for disassembly or servicing, be sure to disconnect the O battery lead wire, first. • * When connecting the battery lead wires, be sure to connect the OO battery lead wire first . • * If the terminal is corroded, remove the battery, pour warm water over it and clean it with a wire brush . • * After connecting the battery, apply a light coat of grease to the battery terminals. • * Install the cover over the O battery terminal. WIRING PROCEDURE • * Properly route the wire harness according to the “WIRE HARNESS ROUTING” section. (CJ8-14)

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