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GSX1400 Service manual, Parts Book & Set up Manuals PDF GSX1400 Service Manuals
GSX1400 Set up Manual
GSX1400 Owners Handbooks
GSX1400 Parts Manual To save right click on links and click "save target as" ---------------------------------------------------------------------------------
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Individual Sections of the Service manual - K2 to K5
(PDF)
SERIAL NUMBER LOCATION
......................................................... 1- 4 FUEL AND OIL RECOMMENDATION
.............................................. 1- 5 FUEL
..............................................................................................
1- 5 ENGINE
OIL...................................................................................
1- 5 BRAKE FLUID
...............................................................................
1- 5 FRONT FORK OIL
......................................................................... 1- 5 BREAK-IN
PROCEDURES............................................................... 1- 6 CYLINDER IDENTIFICATION
........................................................... 1- 6 INFORMATION LABELS
.................................................................. 1- 7 SPECIFICATIONS
............................................................................. 1-
8 COUNTRY AND AREA CODES
....................................................... 1-10
Section 2 -
Periodic Maintenance <<click to download
(2.1mb) PERIODIC MAINTENANCE
SCHEDULE......................................... 2- 2 PERIODIC MAINTENANCE
CHART............................................. 2- 2 LUBRICATION
POINTS................................................................. 2- 3 MAINTENANCE AND TUNE-UP PROCEDURES
............................ 2- 4 AIR CLEANER
...............................................................................
2- 4 SPARK PLUG
................................................................................
2- 5 VALVE
CLEARANCE.....................................................................
2- 6 ENGINE OIL AND OIL FILTER
..................................................... 2-13 FUEL HOSE
...................................................................................
2-14 ENGINE IDLE SPEED
................................................................... 2-14 THROTTLE VALVE SYNCHRONIZATION
..................................... 2-15 THROTTLE CABLE PLAY
............................................................. 2-15 CLUTCH
.........................................................................................
2-16 DRIVE CHAIN
................................................................................
2-17
BRAKE...........................................................................................
2-19 TIRE
...............................................................................................
2-22 STEERING
.....................................................................................
2-23 FRONT FORK
................................................................................
2-24 REAR
SUSPENSION.....................................................................
2-24 EXHAUST PIPE BOLT AND NUT
................................................. 2-24 CHASSIS BOLT AND
NUT............................................................ 2-25 COMPRESSION PRESSURE CHECK
............................................. 2-27 OIL PRESSURE CHECK
.................................................................. 2-28
Section 3 -
Engine <<click to download (9.0mb) ENGINE COMPONENTS REMOVABLE WITH THE ENGINE IN PLACE
................................................................... 3- 2 ENGINE REMOVAL AND INSTALLATION
....................................... 3- 3 ENGINE REMOVAL
....................................................................... 3- 3 ENGINE INSTALLATION
............................................................... 3- 8 ENGINE DISASSEMBLY
.................................................................. 3-11 ENGINE COMPONENTS INSPECTION AND SERVICE .................
3-22 PAIR VALVE
...................................................................................
3-22 CYLINDER HEAD COVER
............................................................ 3-23 CAMSHAFT
...................................................................................
3-23 CAM CHAIN TENSION
ADJUSTER.............................................. 3-25 CAM CHAIN TENSIONER/CAM CHAIN GUIDE
........................... 3-25 CYLINDER HEAD AND VALVE
..................................................... 3-26 CYLINDER
.....................................................................................
3-34 PISTON AND PISTON RING
......................................................... 3-35 CLUTCH
.........................................................................................
3-37 GEARSHIFT
SYSTEM................................................................... 3-39 GENERATOR
.................................................................................
3-40 OIL PUMP
......................................................................................
3-40 OIL PRESSURE REGULATOR/OIL STRAINER ..........................
3-41 CRANK BALANCER
..................................................................... 3-41 TRANSMISSION
............................................................................
3-42 CRANKSHAFT AND CONROD.....................................................
3-45 CRANKCASE/OIL PAN
................................................................. 3-53 ENGINE REASSEMBLY
................................................................... 3-56
Section 4 -
F.I. System (Fuel Injection) <<click to download
(4.0mb)
PRECAUTIONS IN SERVICING .......................................................
4- 2 FI SYSTEM TECHNICAL FEATURES
.............................................. 4- 8 INJECTION TIME
........................................................................... 4- 8 COMPENSATION OF INJECTION
TIME....................................... 4- 9 INJECTION STOP
CONTROL....................................................... 4- 9 FUEL DELIVERY SYSTEM
........................................................... 4-10 FUEL
PUMP...................................................................................
4-11 FUEL PRESSURE
REGULATOR.................................................. 4-12 FUEL INJECTOR
........................................................................... 4-12 FUEL PUMP CONTROL SYSTEM
................................................ 4-13 ECM (FI CONTROL
UNIT)............................................................. 4-14 INJECTION TIMING
....................................................................... 4-14 SENSORS
......................................................................................
4-15 FI SYSTEM PARTS LOCATION
....................................................... 4-19 FI SYSTEM
DIAGRAM......................................................................
4-21 FI SYSTEM WIRING
DIAGRAM........................................................ 4-22 SELF-DIAGNOSIS
FUNCTION......................................................... 4-23 USER
MODE..................................................................................
4-23 DEALER MODE
.............................................................................
4-24 FAIL-SAFE
FUNCTION.....................................................................
4-26 FI SYSTEM
TROUBLESHOOTING................................................... 4-27 CUSTOMER COMPLAINT ANALYSIS
......................................... 4-27 SELF-DIAGNOSTIC PROCEDURES
............................................ 4-28 SELF-DIAGNOSIS RESET
PROCEDURE.................................... 4-28 MALFUNCTION CODE AND DEFECTIVE CONDITION .............. 4-29 “C11” CMP SENSOR CIRCUIT MALFUNCTION .........................
4-31 “C12” CKP SENSOR CIRCUIT MALFUNCTION .........................
4-32 “C13” IAP SENSOR CIRCUIT MALFUNCTION
........................... 4-33 “C14” TP SENSOR CIRCUIT
MALFUNCTION............................. 4-35 “C15” EOT SENSOR CIRCUIT MALFUNCTION..........................
4-37 “C21” IAT SENSOR CIRCUIT MALFUNCTION
........................... 4-38 “C22” AP SENSOR CIRCUIT MALFUNCTION
............................ 4-39 “C23” TO SENSOR CIRCUIT MALFUNCTION
............................ 4-41 “C24” or “C25” IGNITION SYSTEM MALFUNCTION .................
4-42 “C28” STV ACTUATOR CIRCUIT MALFUNCTION......................
4-42 “C29” STP SENSOR CIRCUIT MALFUNCTION
.......................... 4-43 “C31” GEAR POSITION SWITCH CIRCUIT MALFUNCTION ..... 4-45 “C32”, “C33”, “C34” or “C35” FUEL INJECTION MALFUNCTION
.............................................................................
4-46 “C41” FP RELAY CIRCUIT
MALFUNCTION................................ 4-47 “C42” IG SWITCH CIRCUIT MALFUNCTION
.............................. 4-47 FUEL
SYSTEM..................................................................................
4-48 FUEL TANK REMOVAL
................................................................. 4-48 FUEL TANK INSTALLATION
......................................................... 4-48 FUEL PRESSURE INSPECTION
.................................................. 4-49 FUEL PUMP INSPECTION
........................................................... 4-50 FUEL PUMP RELAY INSPECTION
.............................................. 4-51 FUEL PUMP AND FUEL FILTER REMOVAL
............................... 4-51 FUEL MESH FILTER INSPECTION AND CLEANING .................
4-52 FUEL PUMP AND FUEL MESH FILTER INSTALLATION ........... 4-53 THROTTLE BODY AND STV ACTUATOR
....................................... 4-54
CONSTRUCTION...........................................................................
4-54 THROTTLE BODY
REMOVAL....................................................... 4-55 THROTTLE BODY DISASSEMBLY
.............................................. 4-56 THROTTLE BODY CLEANING
..................................................... 4-59 INSPECTION
.................................................................................
4-59 THROTTLE BODY REASSEMBLY
............................................... 4-59 STP SENSOR ADJUSTMENT
...................................................... 4-62 TP SENSOR ADJUSTMENT
......................................................... 4-64 THROTTLE BODY INSTALLATION
.............................................. 4-64 FUEL INJECTOR
INSPECTION.................................................... 4-64 FUEL INJECTOR REMOVAL
........................................................ 4-64 FUEL INJECTOR INSTALLATION
................................................ 4-64 FAST IDLE INSPECTION
.............................................................. 4-65 FAST IDLE ADJUSTMENT
........................................................... 4-65 THROTTLE VALVE SYNCHRONIZATION
.................................... 4-66 THROTTLE CABLE ADJUSTMENT
............................................. 4-66 SENSORS
....................................................................................
4-67 IAP SENSOR INSPECTION
.......................................................... 4-67 IAP SENSOR
REMOVAL/INSTALLATION.................................... 4-67 TP SENSOR INSPECTION
........................................................... 4-67 TP SENSOR REMOVAL/INSTALLATION
..................................... 4-67 STP SENSOR INSPECTION
......................................................... 4-67 STP SENSOR
REMOVAL/INSTALLATION................................... 4-67 CKP SENSOR INSPECTION
........................................................ 4-67 CKP SENSOR REMOVAL/INSTALLATION
.................................. 4-67 CMP SENSOR INSPECTION
........................................................ 4-68 CMP SENSOR
REMOVAL/INSTALLATION.................................. 4-68 IAT SENSOR
INSPECTION........................................................... 4-68 IAT SENSOR REMOVAL/INSTALLATION
.................................... 4-68 EOT SENSOR
INSPECTION......................................................... 4-68 EOT SENSOR REMOVAL/INSTALLATION
.................................. 4-68 AP SENSOR INSPECTION
........................................................... 4-68 AP SENSOR
REMOVAL/INSTALLATION..................................... 4-68 TO SENSOR INSPECTION
........................................................... 4-68 TO SENSOR
REMOVAL/INSTALLATION..................................... 4-68
Section 5 -
Oil Cooling & Lubrication System <<click to
download (1.6mb)
OIL COOLING SYSTEM/LUBRICATION SYSTEM ......................... 5- 2 CYLINDER HEAD OIL COOLING CIRCUIT
................................. 5- 2 CYLINDER HEAD COOLING SYSTEM CHART ..........................
5- 3 ENGINE LUBRICATION CIRCUIT
................................................ 5- 4 ENGINE LUBRICATION SYSTEM CHART
.................................. 5- 6 OIL COOLER AND OIL HOSE
......................................................... 5- 7 OIL COOLER REMOVAL
.............................................................. 5- 7 OIL COOLER INSPECTION AND CLEANING
............................. 5- 7 OIL HOSE/OIL PIPE
INSPECTION............................................... 5- 8 OIL COOLER INSTALLATION
...................................................... 5- 8 COOLING FAN
..................................................................................
5- 8 REMOVAL
......................................................................................
5- 8 INSPECTION
.................................................................................
5- 9 INSTALLATION
..............................................................................
5- 9 COOLING FAN THERMO-SWITCH
.................................................. 5- 9 REMOVAL
......................................................................................
5- 9 INSPECTION
.................................................................................
5-10 INSTALLATION
..............................................................................
5-10 OIL TEMPERATURE
SENSOR......................................................... 5-11 REMOVAL
......................................................................................
5-11 INSPECTION
.................................................................................
5-11 INSTALLATION
..............................................................................
5-11 OIL PRESSURE
................................................................................
5-12 OIL
FILTER........................................................................................
5-12 OIL
STRAINER..................................................................................
5-12 OIL JET
.............................................................................................
5-12 OIL
PUMP..........................................................................................
5-12 OIL PRESSURE
SWITCH................................................................. 5-12
Section 6 -
Chassis<<click to download (4.8mb)
EXTERIOR
PARTS............................................................................
6- 2
CONSTRUCTION...........................................................................
6- 2 REMOVAL
......................................................................................
6- 3 REMOUNTING
...............................................................................
6- 4 FASTENER REMOVAL AND REINSTALLATION .........................
6- 5 FRONT WHEEL
.................................................................................
6- 6
CONSTRUCTION...........................................................................
6- 6 REMOVAL
......................................................................................
6- 7 INSPECTION AND
DISASSEMBLY.............................................. 6- 7 REASSEMBLY AND REMOUNTING
............................................ 6- 9 FRONT FORK
...................................................................................
6-12
CONSTRUCTION...........................................................................
6-12 REMOVAL AND DISASSEMBLY
.................................................. 6-13 INSPECTION
.................................................................................
6-16 REASSEMBLY AND REMOUNTING
............................................ 6-17 SUSPENSION SETTING
............................................................... 6-22 STEERING AND HANDLEBARS
..................................................... 6-23
CONSTRUCTION...........................................................................
6-23 REMOVAL AND DISASSEMBLY
.................................................. 6-24 INSPECTION AND
DISASSEMBLY.............................................. 6-27 REASSEMBLY AND REMOUNTING
............................................ 6-28 STEERING TENSION ADJUSTMENT
.......................................... 6-31 REAR WHEEL
...................................................................................
6-32
CONSTRUCTION...........................................................................
6-32 REMOVAL
......................................................................................
6-33 INSPECTION AND
DISASSEMBLY.............................................. 6-34 REASSEMBLY AND REMOUNTING
............................................ 6-36 REAR SHOCK ABSORBER
............................................................. 6-40
CONSTRUCTION...........................................................................
6-40 REMOVAL
......................................................................................
6-41 INSPECTION
.................................................................................
6-42 REAR SHOCK ABSORBER SCRAPPING PROCEDURE........... 6-42 REMOUNTING
...............................................................................
6-42 SUSPENSION SETTING
............................................................... 6-43 REAR SWINGARM
........................................................................... 6-44
CONSTRUCTION...........................................................................
6-44 REMOVAL
......................................................................................
6-45 INSPECTION AND
DISASSEMBLY.............................................. 6-46 REASSEMBLY
...............................................................................
6-47 REMOUNTING
...............................................................................
6-48 FINAL INSPECTION AND ADJUSTMENT
................................... 6-48 FRONT BRAKE
.................................................................................
6-49
CONSTRUCTION...........................................................................
6-49 BRAKE PAD REPLACEMENT
...................................................... 6-50 BRAKE FLUID
REPLACEMENT................................................... 6-50 CALIPER REMOVAL AND DISASSEMBLY
................................. 6-51 CALIPER INSPECTION
................................................................ 6-52 CALIPER REASSEMBLY AND REMOUNTING ...........................
6-52 BRAKE DISC INSPECTION
.......................................................... 6-53 MASTER CYLINDER REMOVAL AND DISASSEMBLY .............. 6-54 MASTER CYLINDER
INSPECTION.............................................. 6-55 MASTER CYLINDER REASSEMBLY AND REMOUNTING ........ 6-55 REAR BRAKE
...................................................................................
6-57
CONSTRUCTION...........................................................................
6-57 BRAKE PAD REPLACEMENT
...................................................... 6-58 BRAKE FLUID
REPLACEMENT................................................... 6-58 CALIPER REMOVAL AND DISASSEMBLY
................................. 6-59 CALIPER INSPECTION
................................................................ 6-60 CALIPER REASSEMBLY AND REMOUNTING ...........................
6-60 MASTER CYLINDER REMOVAL AND DISASSEMBLY .............. 6-61 MASTER CYLINDER
INSPECTION.............................................. 6-62 MASTER CYLINDER REASSEMBLY AND REMOUNTING ........ 6-62 CLUTCH RELEASE CYLINDER AND MASTER CYLINDER.......... 6-64
CONSTRUCTION...........................................................................
6-64 CLUTCH FLUID
REPLACEMENT................................................. 6-65 CLUTCH RELEASE CYLINDER REMOVAL AND DISASSEMBLY.. 6-65 CLUTCH RELEASE CYLINDER INSPECTION............................
6-66 CLUTCH RELEASE CYLINDER REASSEMBLY AND REMOUNTING
...............................................................................
6-66 CLUTCH MASTER CYLINDER REMOVAL AND DISASSEMBLY ... 6-67 CLUTCH MASTER CYLINDER
INSPECTION.............................. 6-68 CLUTCH MASTER CYLINDER REASSEMBLY AND REMOUNTING
...............................................................................
6-69 TIRE AND WHEEL
............................................................................
6-70 TIRE
REMOVAL.............................................................................
6-70 INSPECTION
.................................................................................
6-70 VALVE INSTALLATION
................................................................. 6-71 TIRE INSTALLATION
.................................................................... 6-71
Section 7 -
Electrical <<click to download (2.1mb)
CAUTIONS IN SERVICING
............................................................... 7- 2 LOCATION OF ELECTRICAL COMPONENTS
............................... 7- 4 CHARGING SYSTEM
....................................................................... 7- 6 TROUBLESHOOTING
................................................................... 7- 6 INSPECTION
.................................................................................
7- 7 STARTER SYSTEM AND SIDE-STAND/IGNITION INTERLOCK SYSTEM
...................................................................... 7-11 TROUBLESHOOTING
................................................................... 7-11 STARTER MOTOR REMOVAL AND DISASSEMBLY .................. 7-12 STARTER MOTOR INSPECTION
................................................. 7-13 STARTER MOTOR REASSEMBLY
............................................... 7-13 STARTER RELAY INSPECTION
................................................... 7-14 SIDE-STAND/IGNITION INTERLOCK SYSTEM PARTS INSPECTION
.................................................................................
7-15 IGNITION SYSTEM
........................................................................... 7-18 TROUBLESHOOTING
................................................................... 7-18 INSPECTION
.................................................................................
7-20 COMBINATION
METER.................................................................... 7-23 REMOVAL AND DISASSEMBLY
.................................................. 7-23 INSPECTION
.................................................................................
7-24 LAMPS
..............................................................................................
7-28
RELAYS.............................................................................................
7-29 SWITCHES
........................................................................................
7-29
BATTERY...........................................................................................
7-31
SPECIFICATIONS..........................................................................
7-31 INITIAL CHARGING
...................................................................... 7-31 SERVICING
....................................................................................
7-32 RECHARGING
OPERATION......................................................... 7-33
Section 8 -
Servicing Information <<click to download
(1.8mb)
TROUBLESHOOTING
...................................................................... 8- 2 FI SYSTEM MALFUNCTION CODE AND DEFECTIVE CONDITION
.............................................................. 8- 2
ENGINE..........................................................................................
8- 4 COOLING
SYSTEM....................................................................... 8-
9
CHASSIS........................................................................................
8-10 BRAKES
........................................................................................
8-11
ELECTRICAL.................................................................................
8-12 BATTERY
.......................................................................................
8-13 WIRING DIAGRAM
........................................................................... 8-14 FI SYSTEM WIRING
DIAGRAM........................................................ 8-15 WIRE HARNESS, CABLE AND HOSE
ROUTING........................... 8-16 WIRE HARNESS
ROUTING.......................................................... 8-16 HIGH-TENSION CORD ROUTING
................................................ 8-17 ENGINE ELECTRICAL PARTS SET-UP
....................................... 8-18 CLUTCH HOSE
ROUTING............................................................ 8-19 THROTTLE CABLE ROUTING
..................................................... 8-20 FUEL PUMP/FUEL LEVEL GAUGE SET-UP
............................... 8-21 FRONT BRAKE HOSE ROUTING
................................................ 8-22 REAR BRAKE HOSE ROUTING
.................................................. 8-23 SIDE-STAND SET-UP
.................................................................... 8-24 CENTER STAND
SET-UP.............................................................. 8-24 SEAT LOCK CABLE ROUTING AND LUGGAGE HOOK
SET-UP............................................................ 8-25 BRAKE PEDAL
SET-UP................................................................ 8-25 FUEL HOSE ROUTING
................................................................. 8-26 FUEL TANK SET-UP
...................................................................... 8-27 THROTTLE BODY SET-UP
........................................................... 8-28 PAIR (AIR SUPPLY) SYSTEM HOSE
ROUTING.......................... 8-29 SPECIAL TOOLS
..............................................................................
8-30 TIGHTENING
TORQUE..................................................................... 8-33 SERVICE DATA
.................................................................................
8-37
SPECIFICATIONS................................................................................
9- 2 ENGINE
................................................................................................
9- 3 GEARSHIFT
CAM........................................................................ 9- 3
CHASSIS..............................................................................................
9- 3 STEERING
...................................................................................
9- 3 WIRING DIAGRAM
..............................................................................
9- 4 WIRE HARNESS ROUTING
................................................................ 9- 5 SERVICE DATA
...................................................................................
9- 6
SPECIFICATIONS
.............................................................................
10- 2 SERVICE DATA
................................................................................
10- 3 PERIODIC MAINTENANCE CHART
................................................ 10-12 WIRING DIAGRAM
...........................................................................
10-13
SPECIFICATIONS
.............................................................................
11- 2 SERVICE DATA
................................................................................
11- 3 IMMOBILIZER
...................................................................................
11-12 EXHAUST PIPE/MUFFLER INSTALLATION
................................... 11-14 CENTRE STAND INSTALLATION
................................................... 11-15 WIRE HARNESS ROUTING
............................................................. 11-16 WIRING DIAGRAM
...........................................................................
11-17
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