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Suzuki 2004 DL650K4, Service Manual

The Suzuki 2004 DL650K4 Service Manual is an essential resource for DL650K4 motorcycle owners. This comprehensive manual provides detailed instructions and diagrams for maintaining and repairing your bike. Download it for free from manualshive.com to access the valuable information you need to keep your Suzuki in top shape.

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Summary of Contents for 2004 DL650K4

Page 1: ...I SERVICE MANUAL I ...

Page 2: ...le illustrations in this manual are used to show the basic principles of operation and work procedures They may not represent the actual motorcycle exactly in detail This manual is written for persons who have enough knowledge skills and tools including special tools for servicing SUZUKI motorcy cles If you do not have the proper knowledge and tools ask your authorized SUZUKI motorcycle dealer to ...

Page 3: ...y 4 The contents are listed on the first page of each section to help you find the item and page you need COMPONENT PARTS AND WORK TO BE DONE Under the name of each system or unit is its explodedview Work instructions and other service information such as the tightening torque lubricatingpoints and locking agent points are provided Example Front wheel 1Brakedisc OI u s t seal I IBearing I Center s...

Page 4: ... USA 99000 25010 Others Apply SUZUKl MOLY PASTE 99000 25140 Apply SUZUKl SILICONE GREASE 99000 25100 Apply SUZUKl BOND 1215 99000 31110 Except USA Apply SUZUKl BOND 12078 99104 31140 USA 99000 31140 Others Apply THREAD LOCK SUPER 1303 99000 32030 Apply THREAD LOCK SUPER 1322 99000 32110 Except USA Apply THREAD LOCK 1342 99000 32050 SYMBOL DEFINITION Apply THREAD LOCK SUPER 1360 99000 32130 Use eng...

Page 5: ...ide CPU Central ProcessingUnit D DC DMC DOHC DRL Direct Current Dealer Mode Coupler Double Over Head Camshaft Daytime Running Light E ECM Engine Control Module Engine Control Unit ECU FI Control Unit ECT Sensor Engine Coolant Temperature Sensor ECTS Water Temp Sensor WTS EVAP Evaporative Emission EVAP Canister Evaporative Emission F FI FP FPR FP Relay G GEN GND GP Switch H HC I IAP Sens IAT Sensor...

Page 6: ...Camshaft Oil PressureSwitch Positive Crankcase Ventilation Crankcase Breather Right Hand Read Only Memory Society of Automotive Engineers Secondary Throttle Control System STCS Secondary Throttle Position Sensor STPS Secondary Throttle Valve STV STV Actuator Secondary Throttle Valve Actuator STVA T TO Sensor Tip Over Sensor TOS TP Sensor Throttle Position Sensor TPS v VD Vacuum Damper ...

Page 7: ...rative Emission Evaporative Emission Canister F Fan Control Fuel Level Sensor Fuel Pump G Generator Ground ABBREVIATION ACL BAR0 B CMP Sensor CKP Sensor DLC DTM DTC El ECM ECL ECT RPM EVAP EVAP Canister FC FP GEN GND FORMER SUZUKl TERM Air Cleaner Air Cleaner Box Barometric Pressure Atmospheric Pressure APS AP Sensor Battery Voltage B Camshaft PositionSensor CMPS Crankshaft Position Sensor CKPS Cr...

Page 8: ...tuator T Throttle Body Throttle Body Fuel lnjection Throttle Position Sensor v Voltage Regulator Volume Air Flow ABBREVIATION ISC IC ICM IAT MIL MAP MAF OBD OL PROM PA1R Purge Valve RAM ROM AIR STCS STV STVA TB TBI TP Sensor VR VAF FORMER SUZUKl TERM Electronic Spark Advance ESA lntake Air Temperature IAT Air Temperature LED Lamp Malfunction Indicator Lamp MIL lntake Air Pressure IAP lntake Vacuum...

Page 9: ...ite with Black tracer White with Green tracer Yellow with Black tracer Yellow with Green tracer Yellow with White tracer B Br B O BNV BI B BI R BIN BrNV G N Gr R O B O G ONV PNV RNV W BI W R Y BI Y R R Red W White Y Yellow Black with Brown tracer Black with Orange tracer Black with White tracer Blue with Black tracer Blue with Red tracer Blue with Yellow tracer Brown with White tracer Green with Y...

Page 10: ...NTRIES 1 4 ENGINE OIL FOR USA 1 5 ENGINE OIL FOR OTHER COUNTRIES 1 5 BRAKE FLUID 1 5 FRONT FORK OIL 1 5 ENGINE COOLANT 1 5 WATERFOR MIXING 1 5 ANTI FREEZWENGINE COOLANT 1 6 LIQUIDAMOUNT OF WATEWENGINE COOLANT 1 6 BREAK IN PROCEDURES 1 6 CYLINDER IDENTIFICATION 1 7 INFORMATION LABELS 1 8 SPECIFICATIONS 1 9 DIMENSIONSAND DRY MASS 1 9 ENGINE 1 9 DRIVE TRAIN 1 9 CHASSIS 1 10 ELECTRICAL 1 10 CAPACITIES...

Page 11: ...t use good judgement and basic mechanical safety principles If you are unsure about how to perform a particular service operation ask a more experienced mechanic for advice GENERAL PRECAUTIONS Proper service and repair procedures are important for the safety of the service mechanic and the safety and reliability of the motorcycle When 2 or more persons work together pay attention to the safety of ...

Page 12: ...d nuts tighten the larger sizes first Always tighten the bolts and nuts diagonally from the inside toward outside and to the speci fied tightening torque Whenever you remove oil seals gaskets packing O rings locking washers self locking nuts cotter pins circlips and certain other parts as specified be sure to replace them with new ones Also before installing these new parts be sure to remove any l...

Page 13: ...s are required especially for registeringthe machine and ordering spare parts FUEL OIL AND ENGINE COOLANT RECOMMENDATION FUEL FOR USA AND CANADA Use only unleaded gasoline of at least 87 pump octane or 91 octane or higher rated by the research method 2 Gasoline containing MTBE Methyl Tertiary Butyl Ether less than 10 ethanol or less than 5 methanol with appropriate cosolventsand corrosion inhibito...

Page 14: ...elect an alternative according to the right chart BRAKE FLUID Specificationand classification DOT 4 Since the brakesystem of this motorcycle is filled with a glycol based brakefluid by the manu facturer do not use or mix different types of fluid such as silicone basedand petroleum based fluid for refilling the system otherwise serious damage will result Do not use any brakefluid taken from old or ...

Page 15: ...ngine coolant mixing ratio is below 50 rust inhabiting perfor mance is greatly reduced Be sure to mix it above 50 even though the atmospheric tempera ture does not go down to the freezing point BREAK IN PROCEDURES During manufacture only the best possible materials are used and all machined parts are finished to a very high standard but it is still necessary to allow the moving parts to BREAK IN b...

Page 16: ...GENERAL INFORMATION 1 7 CYLINDER IDENTIFICATION The two cylinders of this engine are identified as NO l and N0 2 cylinder as viewed from front to rear ...

Page 17: ...creen warning label 0Steerina warnina label DL650UE Tire information label I Warning safetv label A For E 03 33 A A A ICES Canada label Rear carrier warnina label I A I A For Enalish I A A A For E 28 ID plate Safetv plate A Attached 1 For E 28 French 2 Exceptfor E 28 3 For E 28 4 These labels are attached on the right frame 5 This label is attached on the up side of chain cover A A A I 4 A A A Exc...

Page 18: ...s Low 2nd 3rd 4th 5th Top Drive chain 2 290 mm 90 2 in 840 mm 33 1 in 1 390 mm 54 7 in Lowwindshield position STD 1420 mm 55 9 in Middle windshield position 1450 mm 57 1 in High windshield position 1 540 mm 60 6 in 165 mm 6 5 in 820 mm 32 3 in 190 kg 418 Ibs 4 stroke liquid cooled DOHC 90 degree V twin 2 81 0 mm 3 189 in 62 6 mm 2 465 in 645 cm3 39 4 cu in 11 5 1 Fuel injection Non wovenfabric ele...

Page 19: ... spring oil damped Linktype coil spring oil damped 150 mm 5 9 in 150 mm 5 9 in 26 110 mm 4 33 in 40 right left 2 6 m 8 5 ft Disc brake twin Disc brake 110180 R19 MIC 59H tubeless 150170 R17 MIC 69H tubeless Electronic ignition Transistorized 4 B T D C at 1 300 rlmin NGK CR8E or DENS0 U24ESR N 12V36 0 k c 10 Ah l 0 HR Three phase A C generator 30 A 15115110110115115A 12V 60155 W x 2 H4 12 V 5 W x 2...

Page 20: ... AND AREA CODES The following codes stand for the applicable country ies and area s COUNTRY or AREA U K U S A Except for california EU Australia Canada California U S A EU MODEL DL650 DL650 UE CODE E 02 E 03 E 19 E 24 E 28 E 33 E 19 ...

Page 21: ...L FILTER 2 13 ENGINE IDLE SPEED 2 15 THROTTLE CABLE PLAY 2 15 THROTTLE VALVE SYNCHRONIZATION 2 16 EVAPORATIVE EMISSION CONTROL SYSTEM E 33 ONLY 2 16 PAIR AIR SUPPLY SYSTEM 2 16 CLUTCH 2 17 COOLINGSYSTEM 2 18 DRlVE CHAIN 2 20 BRAKE 2 22 TIRE 2 26 STEERING 2 26 FRONT FORK 2 27 REAR SUSPENSION 2 27 EXHAUST PIPE BOLT 2 27 CHASSIS BOLT AND NUT 2 28 COMPRESSION PRESSURE CHECK 2 30 COMPRESSION TESTPROCED...

Page 22: ...may be performed on motorcycles that are used under severe conditions PERIODIC MAINTENANCE CHART I Air cleaner element I I I I I I R 1 1 1 Interval km miles months 1 000 600 2 Exhaust pipe bolts and muffler bolts Valve clearance Spark plugs Fuel line Engineoil Enaine oil filter 6000 4 000 12 T Idle speed Throttle cable play Throttle valve synchronization I I Clutch I I I I 1 R R Evaporative emissi...

Page 23: ... I T I T I T I T P I 1 000 600 2 Tires Steering Front forks Rear sus ension NOTE Inspect and clean adjust replace or lubricate as necessary R Replace T Tighten Replace every 2 years I 6 000 4 000 12 I I 12000 7 500 24 I I 18000 11000 36 I I I I 1 24000 14500 48 I I I I I ...

Page 24: ...dicated below Clutch lever holder ISide stand pivot I 1and spring hook I IFootrestpivot 1 Brake pedal pivot and footrest pivot NOTE Before lubricating each part clean off any rusty spots and wipe off any grease oil dirt or grime Lubricate exposed parts which are subject to rust with a rust preventative spray whenever the motorcycle has been operated under wet or rainy conditions ...

Page 25: ... air pressure on the throttle body side of the air cleaner element If air pressure is used on the other side dirt will be forced into the pores of the air cleaner element thus restricting air flow through the air cleaner element Install the O ring properly Reinstall the cleaned or new air cleaner element in the reverse order of removal CAUTION I If driving under dusty condition clean the air clean...

Page 26: ...km 7 500 miles 24 months NO l FRONT SPARK PLUG REMOVAL Remove the cowling 7 5 Removethe radiator mounting bolt a Move the radiator lower side to forward Remove the spark plug cap Q NOTE Be careful not to damage the radiator fins The hot radiator and the hot engine can burn you Wait until the radiator and the engine are cool enough to touch Removethe spark plug with the special tool m09930 10121 Sp...

Page 27: ...is deposited remove it with a spark plug cleaner machine or carefully using a tool with a pointedend SPARK PLUG GAP Measurethe plug gap with a thickness gauge If out of specifi cation adjust it to the following gap Spark plug gap Standard 0 7 0 8 mm 0 028 0 031 in a09900 20803 Thickness gauge ELECTRODES CONDITION Check to see the worn or burnt condition of the electrodes If it is extremely worn or...

Page 28: ... covers The valve clearance specification is exhaust valves different for intake and Valve clearance must be checked and adjusted 1 at the time of periodic inspection 2 when the valve mechanism is serviced and 3 when the camshafts are disturbed by removing them for servicing Valve clearance when cold IN 0 10 0 20 mm 0 004 0 008 in EX 0 20 0 30 mm 0 008 0 012 in NOTE The valve clearance should be t...

Page 29: ...ce use a thickness gauge betweenthe tappet and the cam If the clear ance is out of specification adjust it into the specified range 09900 20803 Thickness gauge Turn the crankshaft 270 degrees 314 turns to set the No 2 Rear cylinder at TDC of compression stroke Align the R I T line on the generator rotor to the index mark of valve timing inspection hole and also bring the camshafts to the position ...

Page 30: ...to ensure its size Referto the tappet shim selection table Pages 2 11 and 12 for details NOTE Be sure to apply engine oil to tappet shim top and bottom faces When seating the tappet shim be sure to face figure printed surface to the tappet piiimiq Reinstallthe camshafts as the specified manner W3 99 After replacing the tappet shim and camshafts rotate the engine so that the tappet is depressed ful...

Page 31: ...ET 12800 05830 I HOWTO USETHIS CHART I Measure tappet clearance ENGINE IS COLD It Measure present shim size Ill Match clearance in vertical column with present shim size in horizontal column EXAMPLE Tappet clearance is 0 23 mm Present shim size 1 65 mm Shim size to be used 1 75 mm ...

Page 32: ... 60 1 65 1 70 1 75 1 80 1 85 1 90 1 95 2 00 2 05 2 10 2 15 2 20 0 05 0 09 1 20 1 25 1 30 1 35 1 40 1 45 1 50 1 55 1 60 1 65 1 70 1 75 1 80 1 85 1 90 1 95 2 00 2 05 HOWTO USETHIS CHART I Measure tappet clearance ENGINE IS COLD II Measure present shim size Ill Matchclearance in vertical column with present shim size in horizontal column EXAMPLE Tappet clearance is 0 33 mm Presentshim size 1 65 mm Sh...

Page 33: ...t 1 000 km 600 miles 2 month and every 18 000 km 11 000 miles 36 months thereafter Oil should be changed while the engine is warm Oil filter replacement at the above intervals should be done together with the engine oil change ENGINE OIL REPLACEMENT Keep the motorcycle upright Place an oil pan below the engine and drain oil by removing the drain plug and filler cap 0 Tighten the drain plug to the ...

Page 34: ...el that the fil ter gasket contacts the mounting surface Then tighten it 2 turns with the special tool 09915 40610 Oil filter wrench NOTE To properly tighten the filter use the special tool Never tighten the filter by hand Afler contcting the gasket tighten 2 turns Pour fresh engine oil and check the oil level in the same man ner of engine oil replacement procedure Engine oil capacity Oil change 2...

Page 35: ... the lock nut of the throttle returning cable and turn inthe adjuster fully into the threads Secondstep Loosen the lock nut of the throttle pullingcable Turn the adjuster in or out until the throttle cable play should be 2 0 4 0 mm 0 08 0 16 in at the throttle grip Tighten the lock nut while holding the adjuster O Third step While holding the throttle grip at the fully closed position slowly turn ...

Page 36: ...y turn the returning cable adjuster to obtain a slack of 1 0 mm 0 04 in Tighten the lock nut securely After the adjustment is completed check that handle bar movement does not raise the engine idle speed and that the throttle grip returns smoothly and auto matically THROTTLE VALVE SYNCHRONIZATION lnspect initially at 1 000 km 600 miles 2 months E 33 only and every 12 000 km 7 500 miles 24 months l...

Page 37: ...ut and turn out the adjusting screw T a r two or three rotations From that position slowly turn the adjuster screw in until it stops Turn the adjuster screw out 114 rotation and tighten the lock nut C I Loosen the lock nuts 0 turn the cable adjuster 10 15 mm 0 4 0 6 in of free play at the end Tighten the lock nuts 0 Clutch cable play 10 15 mm 0 4 0 6 Clutch releasescrew 114 turns back to obtain cl...

Page 38: ...g 7 5 Remove the radiator cap 0 Drain the engine coolant by removing the drain bolt Do not open the radiator cap when the engine is hot as you may be injured by escaping hot liquid or vapor Engine coolant may be harmful if swallowed or if it comes in contact with skin or eyes If engine coolant gets into the eyes or in contact with the skin flush thoroughly with plenty of water If swallowed induce ...

Page 39: ...t and left to bleed the air trapped in the thermostat case O P Add engine coolant up to the radiator inlet Repeat the above procedure until bleed no air from the radia tor inlet l Close the radiator cap securely After warming up and cooling down the engine several times add the engine coolant up to the full level of the reserve tank Installthe cowling W 7 8 I Repeat the above procedure several tim...

Page 40: ...ain for the possible defects listed below Support the motorcycle by a jack and a wooden block turn the rear wheel slowly by hand with the transmission shifted to Neutral Loose pins Excessive wear Damaged rollers Improper chain adjustment Dry or rusted links Missing O ring seals Kinked or binding links O O ring O Grease If any defects are found the drive chain must be replaced NOTE When replacing t...

Page 41: ...ers until the chain has 20 30 mm 0 8 1 2 in of slack in the middle between engine and rear sprockets The ends of left and right spacers must be at the same position on the scales g to ensure that the front and rear wheels are correctly aligned Place the motorcycle on its side stand for accurate adjust ment After adjusting the drive chain tighten the axle nut to the specified torque Recheck the dri...

Page 42: ...drive chain oil Such oil can damage the On rings or seals The standard drive chain is DID525V8 SUZUKl rec ommends that this standard drive chain should be used for the replacement BRAKE BRAKE lnspect initially at 1 000 km 600 miles 2 month and every 6 000 km 4 000 miles 12 months thereafter BRAKE HOSE AND BRAKE FLUID Inspect every 6 000 km 4 000 miles 12 months Replace hoses every 4 years Replace ...

Page 43: ...ing or stored for a long period Brake fluid if it leaks will interfere with safe running and immediately discolor painted surfaces Check the brake hoses and hosejoints for cracks and oil leakage before riding BRAKE PADS Removethe brake caliper Front The extent of brake pad wear can be checked by observing the grooved limit on the pad When the wear exceeds the grooved limit replace the pads with th...

Page 44: ...the footrest Retighten the lock nut to secure the push rod a in the proper position Brake pedal height 20 30 mm 0 79 1 I8 in Rear brake master cylinder rod lock nut 0 17 N rn 1 7 kgf m 12 5 Ib ft REAR BRAKE SWITCH Adjust the rear brake switch so that the brake light will come on just before pressure is felt when the brake pedal is depressed e E xitan tan ...

Page 45: ...ft Air bleeder valve Rear 6 N m 0 6 kgf m 4 3 Ib ft Front brake Bleedthe air from the air bleeder valve Squeeze and release the brake lever several times in rapid succession and squeeze the lever fully without releasing it Loosen the bleeder valve by turning it a quarter of a turn so that the brake fluid runs into the receptacle this will remove the tension of the brake lever causing it to touch t...

Page 46: ...2 25 1 33 1 TlRE PRESSURE I L I I REAR 1250 1 2 50 1 36 1 280 1 2 80 1 4 1 The standard tire fitted on this motorcycle is 110180 R19MlC 59H for front and 150170 R17MlC 69H for I kPa I kgf cmzI psi I kPa Ikgf cm2I psi rear The use of tires other than those specified may cause instability It is highly recommended to use a SUZUKl Genuine Tire TlRE TYPE BRIDGESTONE Front TW101F Rear TW152F STEERING ln...

Page 47: ...for oil leakage and the spring unit for dam age Check that there is no play in the swingarm assembly Replace any defective parts if necessary W 7 4 5 EXHAUST PIPE BOLT Tighten initially at 1 000 km 600 miles 2 month and every 6 000 km 4 000 miles 12 months thereafter Tighten the exhaust pipe bolts and muffler mounting bolts to the specified torque Muffler mounting bolt h u t 23 N m 2 3 kgf m 16 5 ...

Page 48: ... I 0 6 1 4 3 I Handlebarclamp bolt Front brake master cylinder mounting bolt Front brake caliper mounting bolt 0Brake hose union bolt Air bleeder valve Front 8 0 2 3 2 3 1 0Front footrest bracket mountinq bolt I 25 1 2 5 I 18 0 I 58 0 16 5 16 5 23 10 39 23 7 5 Brake disc bolt Front Rear Rear brake caliper mounting bolt Rear brake master cylinder mounting bolt Rear brake master cvlinder rod lock nu...

Page 49: ...PERIODIC MAINTENANCE 2 29 ...

Page 50: ...s is 200 kPa 2 kgf cm2 28 psi and more All compression pressure are below 1 300 kPa 13 kgf cm2 185 psi even when they measure 1 100 kPa 11 kgfIcm2 156 psi and more COMPRESSIONTEST PROCEDURE NOTE Before testing the engine for compression pressure make sure that the cylinder head bolts are tightened to the specified torque values and valves are properly adjusted Have the engine warmed up by idling b...

Page 51: ...passage way Combination of the above items OIL PRESSURETEST PROCEDURE Start the engine and check if the oil pressure indicator light is turned on If it keeps on lighting check the oil pressure indicator light circuit If it is in good condition check the oil pressure inthe following manner Removethe main oil gallery plug Install the oil pressure gauge with attachment in the position shown in the fi...

Page 52: ...NDERHEAD COVER 3 36 CAMSHAFTKAMSHAFT JOURNAL 3 37 CYLINDER HEAD 3 40 CYLINDER 3 50 PISTON AND PISTON RING 3 51 CONRODAND CRANKSHAFT 3 53 CRANKCASE 3 57 CRANKSHAFT JOURNAL BEARING 3 61 CRANKCASE BEARING AND OIL SEAL 3 66 CLUTCH 3 69 PRIMARY DRIVEN GEAR ASSEMBLY 3 70 GEARSHIFT SHAFTIGEARSHIFT ARM 3 71 TRANSMISSION 3 72 STARTER CLUTCH 3 79 GENERATORAND SIGNAL GENERATOR 3 80 OIL PUMP 3 81 CLUTCHRELEAS...

Page 53: ... 26 3 32 3 33 3 1 6 3 86 3 93 3 85 ENGINE RIGHT SIDE I Primary drive gear I 3 31 I 3 87 I 1Priman driven gear 1 I INSTALLATION 3 90 PARTS Clutch 3 29 3 70 ENGINE CENTER 1 PARTS REMOVAL INSTALLATION I REMOVAL 3 27 3 70 3 90 Oil pump Gearshift shaft Water pump 3 29 3 30 6 1 4 IThrottle body 5 15 5 23 I 3 22 3 25 I 3 97 I 1Cylinder heads 3 89 3 89 6 1 7 Cylinder head covers Camshafts 1Cylinders I 3 2...

Page 54: ...xplained in the following steps Reinstall the engine by reversing the removal procedure Drain the engine oil W2 13 Drainthe engine coolant 2 18 Removethe seat 7 4 Disconnect the battery leadwire a Removethe fuel tank 0 5 7 Disconnect the cooling fan motor and thermo switch leadwire coupler W 6 5 Removethe radiator and water hoses W 6 5 Removethe air cleaner box 0 5 1 5 ...

Page 55: ... d Disconnect the spark plug caps Remove the left side frame cover 7 5 Disconnect the gear position switch lead wire coupler a Disconnect the generator lead wire coupler and CKP sen sor lead wire coupler Remove the ECT sensor lead wire coupler ...

Page 56: ...and spring Removethe clutch push rod Remove the clutch cable from the generator cover NOTE If it is necessary to replace the clutch cable or clutch release lever pry up and bend down the stopper of the clutch release lever Flattenthe lock washer Remove the engine sprocket depressing the brake pedal nut I and lock washer while ...

Page 57: ...3 Loosen the rear axle nut 0 Loosenthe chain adjusters Remove the engine sprocket Disconnectthe engine ground leadwire Disconnect the H02 sensor lead wire coupler and release the H02 sensor leadwire from the clamp Remove the muffler mounting bolts ...

Page 58: ...ffler mounting bolt Loosenthe front exhaust pipe mounting bolts Q Removethe front exhaust pipe Loosenthe rear exhaust pipe mounting bolts Remove the muffler Removethe right footrest bracket mounting bolts Remove the oil cooler ...

Page 59: ...witch lead wire Support the engine with an engine jack Remove the engine mounting nut and bolt 0 Loosen the engine mounting thrust adjuster lock nut with the special tool 09940 14990 Engine mounting thrust adjuster socket wrench Loosen the engine mountingthrust adjuster ...

Page 60: ...Disconnectthe ignition coil lead wires a Disconnectthe water hose clamp Remove the engine mounting nut Loosen the engine mountingthrust adjuster lock nut 09940 14990 Engine mounting thrust adjuster socket wrench Loosenthe engine mountingthrust adjuster ...

Page 61: ...3 10 ENGINE Loosen the pinch bolt Gradually lower the engine assembly by removingthe bolt 0 ICAUTION Be careful not to damage the frame and engine when removing the engine from the frame ...

Page 62: ...e in the reverse order of engine removal Pay attentionto the following points NOTE The engine mounting nuts are self locking Once the nut has been removed it is no longer of any use Be sure to use new nuts and then tighten them to the specified torque ...

Page 63: ...er 0 Installthe collar onto the crankcase properly as shown Installthe left engine mounting bracket Apply THREAD LOCK to the engine mounting bracket bolts Tighten the engine mounting bracket bolts to the specified torque Engine mounting bracket bolt 35 N m 3 5 kgf m 25 5 Ib ft a99000 32050 THREAD LOCK 1342 ...

Page 64: ...unting thrust adjuster lock nuts to the specifiedtorque with the special tool 09940 14990 Engine mounting thrust adjuster socket wrench rnEngine mounting thrust adjuster lock nut 45 N m 4 5 kgf m 32 5 Ib ft After tightening the bolt rnEngine mounting Engine mounting engine mounting bolt tighten the pinch bolt 55 N m 5 5 kgf m 40 0 Ib ft pinch bolt 25 N m 2 5 kgf m 18 0 lb ft Tighten the engine mou...

Page 65: ...l the washers and tighten the union bolt to the specified torque Oil cooler union bolt 23 N m 2 3 kgf m 16 5 Ib ft w4 Cr Installthe new gaskets Apply THREAD LOCK to the muffler mounting bolt a99000 32050 THREAD LOCK 1342 ...

Page 66: ...INE 3 15 Adjust the brake pedal height C1 rnBrake pedal height Standard 20 30 mm 0 79 1 18 in ITEM 8 0 3 0 0 Install the gearshift arm as shown rnGearshift arm angle Approx 63 6 N m 23 kgf m 2 3 Ib ft 16 5 ...

Page 67: ... THREAD LOCK 1342 Tighten the engine sprocket nut to the specifiedtorque rnEngine sprocket nut 145 N m 14 5 kgf m 105 Ib ft Bendthe lock washer Adjust the drive chain slack W 2 2 1 Tighten the rear axle nut to the specified torque rnRear axle nut 100 N m 10 0 kgf m 72 5 Ib ft Install the cotter pin For E 03 28 33 Apply SUZUKl SUPER GREASE to the clutch push rod and install it 99000 25030 SUZUKl SU...

Page 68: ...Y PASTEto the clutch release 99000 25140 SUZUKl MOLY PASTE Assemble the clutch release so that the lever arm will be angle of 80 degree with axle Adjust the clutch cable play W2 17 NOTE After installing the clutch release make sure that there is clear ance between the clutch cable end and the driveshaft end ...

Page 69: ...engine route the wire harness cables and hoses properly 9 1 6 Adjust the following items Engine oil 2 1 4 Engine coolant 2 1 9 Engine idle speed 2 1 5 Throttle cable play 2 1 5 Clutch cable play 2 17 Throttle body synchronization 5 32 ...

Page 70: ...tive groups e g intake exhaust so that they can be reinstalled in their origi nal positions Removethe spark plugs W 2 6 Disconnect the crankcase breather hoses I Disconnect the PAIR hoses Removethe thermostat case along with the hoses I NOTE Refer to the section 6 for their servicing Removethe water unions and intake pipes 0 ...

Page 71: ...he oil cooler bracket a Remove the rear exhaust pipe and gasket Remove the valve timing inspection plug cover plug OD CYLINDER HEAD COVER Removethe front cylinder head cover a and generator Removethe dowel pin and O ring ...

Page 72: ... bringthe 1 F line on generator rotor to the index mark of the valve inspection hole and also to bring the cams to the position as shown in illustration NOTE At the above condition the front cylinder is at TDC of com pression stroke Before removing the camshafts inspect the valve clearance W2 8 Removethe cam chain guide ...

Page 73: ...on as F to the camshaftjournal holders Removethe dowel pins 0 Remove the intake camshaft O Remove the exhaust camshaft NOTE Do not drop the dowel pins into the crankcase FRONT CYLINDER HEAD Removethe cylinder head bolt M6 0 Removethe cylinder head bolts M6 Removethe cylinder head bolts and washers NOTE When loosening the cylinder head bolts loosen each bolt little by little diagonally Removethe cy...

Page 74: ...e crankcase FRONT PISTON Place a clean rag over the cylinder base so as not to drop the piston pin circlip into the crankcase Remove the piston pin circlip O Remove the piston by driving out the piston pin NOTE Scribe the cylinder number on the head of the piston REAR CAMSHAFTS Rotate the generator 360 degrees 1 turn counterclockwise and align the IF line on the generator rotor with the index mark...

Page 75: ...ove the cam chain guide a Remove the cam chain tension adjuster cap bolt spring and gasket Remove the cam chain tension adjuster Remove the intake camshaftjournal holder Remove the exhaust camshaft journal holder NOTE Mark the cylinder location as I to the camshaftjournal holders Remove the dowel pins Remove the intake camshaft a Remove the exhaust camshaft ...

Page 76: ...n loosening the cylinder head bolts loosen each bolt little by little diagonally Removethe cylinder head I Remove the cylinder head gasket dowel pins and cam chain guide a REAR CYLINDER Remove the cylinder nuts and clamp Removethe cylinder Removethe cylinder base gasket and dowel pins C NOTE Make sure that the oiljet is inserted in the crankcase ...

Page 77: ...he piston pin NOTE Scribe the cylinder number on the head of the piston STARTER MOTOR Wv Remove the starter motor mounting bolts and the clamp 0 Remove the starter motor 3 ENGINE BOTTOM SIDE OIL FILTER Remove the oil filter with the special tool 09915 40610 Oil filter wrench GENERATOR COVER Removethe generator cover Remove the gasket and dowel pins Remove the starter idle gear and its shaft 6 ...

Page 78: ... and gasket I CLUTCH Holdthe generator rotor with the special tool a09930 44530 Rotor holder Removethe clutch springs NOTE Loosen the clutch spring set bolts little by little and diagonally Removethe pressure plate Remove the clutch push piece 0 the bearing and thrust washer ...

Page 79: ...use a magnetic hand or a wire Remove the clutch drive plates and driven plates Remove the spring washer and spring washer seat Flatten the clutch sleeve hub nut lock washer Hold the clutch sleeve hub with the special tool 09920 53740 Clutch sleeve hub holder Remove the clutch sleeve hub nut ...

Page 80: ...primary driven gear assembly Removethe spacer Q OIL PUMP Removethe snap ring a Remove the oil pump driven gear a NOTE Do not drop the snap ring into the crankcase Removethe pin and the washer I I NOTE Do not drop the pin and washer into the crankcase ...

Page 81: ...Removethe oil pump GEARSHIFT SYSTEM Remove the snap ring I and washer I Remove the gearshift shaft assembly and washer Remove the gearshift cam plate bolt Remove the gearshift cam plate Remove the gearshift cam stopper a ...

Page 82: ...topper spring J Washer OIL PIPE Removethe oil pipe stopper 6 Removethe oil pipe PRIMARY DRIVE GEAR Hold the generator rotor with the special tool 09930 44530 Rotor holder Removethe primary drive gear bolt This bolt has left hand thread Turning it counter clockwise may cause damage ...

Page 83: ...E Do not drop the washer into the crankcase i r 7 m a Remove the rear cam chain and cam chain drive sprocket 8 a GENERATOR ROTOR Holdthe generator rotor with the special tool m09930 44530 Rotor holder Removethe generator rotor bolt Remove the generator rotor with the special tools 09930 30450 Rotor remover 09930 44530 Rotor holder ...

Page 84: ...e the starter driven gear FRONT CAM CHAIN Removethe cam chain tensioner NOTE Do not drop the washer into the crankcase Remove the front cam chain GEAR POSITION SWITCH Remove the driveshaft oil seal retainer Removethe gear positionswitch ...

Page 85: ... the crankcase bolts diagonally and smaller sizes first Separate the crankcase into 2 parts right and left with the special tool 09920 13120 Crankcase separating tool NOTE Fit the crankcase separating tool so that the tool arms are in parallel with the side of crankcase The crankshaft and transmission components should remain in the left crankcase half ...

Page 86: ...el pins CRANKSHAFT Removethe crankshaft a Remove the driveshaft assembly and countershaft assem bly TRANSMISSION Remove the gearshift fork shafts Remove the gearshift cam 0 Removethe gear shift forks Removethe engine sprocket spacer and O ring a ...

Page 87: ...out in groups designated as NO No 2 Exhaust Intake so that each will be restored to the original location during assembly Remove the PAIR reed valve cover a INSPECTION Inspect the PAIR reed valve for damage and the carbon deposit If any damage or the carbon deposit is found in the reed valve replace it with a new one REASSEMBLY Installthe PAIR reed valve as shown ...

Page 88: ...ocationduring assembly CAMSHAFT All camshafts should be checked for runout and also for wear of cams and journals if the engine has been noted as giving abnormal noise vibration or lack power output Any of these conditions may be caused by camshafts worn down or dis torted to the service limit The camshafts can be identified by the embossed letters and cords astamped on the camshaft ends 1 I Lette...

Page 89: ... measuring the oil clearance with the camshaft installed in place Use the plastigauge to read the clearance at the widest por tion which is specified as follows rnCamshaft journal oil clearance Service Limit IN EX 0 150 mm 0 0059 in a09900 22301 Plastigauge 09900 22302 Plastigauge NOTE Install camshaftjournal holder to their original positions W3 99 3 102 Do not rotate the camshaft with the plasti...

Page 90: ...m 0 8645 0 8654 in a09900 20205 Micrometer 0 25 mm CAMSHAFT RUNOUT Measure the runout using the dial gauge Replace the camshaft if the runout exceeds the limit Camshaft runout Service Limit IN EX 0 1 mm 0 004 in a09900 20607 Dial gauge 1M00 mm 09900 20701 Magnetic stand 09900 21304 V block set 100 mm CAM CHAIN TENSION ADJUSTER Checkthat the push rod can slide smoothlywith the lock of the ratchet m...

Page 91: ... tappets and shims by fingers or magnetic hand 1 Identifythe position of each removed part 3 f a a Using special tools compress the valve springs and remove the two cotter halves from valve stem 0991 6 14510 Valve lifter 09916 14521 Valve lifter attachment 09916 84511 Tweezers Removethe valve spring retainer and valve springs piimiq Be careful not to damage the tappet sliding surface with the spec...

Page 92: ... reading at several places indicated If the largest readingat any position of the straightedgeexceeds the limit replacethe cylinder head Cylinder head distortion Standard 0 05 mm 0 002 in 09900 20803 Thickness gauge VALVE STEM RUNOUT Support the valve using V blocks and check its runout using the dial gauge as shown If the runout exceeds the service limit replace the valve Valve stem runout Servic...

Page 93: ...e valve seat Measurethe valve stem deflection in two directions X and Y perpendicular to each other by positioning the dial gauge as shown If the deflection measured exceeds the limit then determine whether the valve or the guide should be replaced with a new one rnValve stem deflection IN EX Service Limit 0 35 mm 0 014 in 09900 20607 Dial gauge 11100 mm 09900 20701 Magnetic stand VALVE STEM WEAR ...

Page 94: ...lve guide hole always turn it clockwise Apply engine oil to the valve guide hole and valve guide Drivethe valve guide into the hole with the special tools rn09916 43210 Valve guide installer remover 09916 53330 Attachment NOTE Install the valve guide until the attachment contacts with the cylinder head CAUTION I Failure to oil the valve guide hole before driving the new guide into place may result...

Page 95: ...singthe seat cutter Valve seat width Standard 0 9 1 1 mm 0 035 0 043 in VALVE SEAT SERVICING The valve seats for both the intake valve and exhaust valve are machined to four different angles The seat contact surface is cut at 45 EXHAUST N 121 09916 21111 Valve seat cutter set 09916 22430 Valve seat cutter N 128 09916 20640 Solid pilot N 100 4 5 NOTE The valve seat cutters N 121 N 122 and N 111 are...

Page 96: ... close to the camshaft If the valve seat is pitted or burned use the 45 cutter to con dition the seat some more TOP NARROWING CUT If the contact area is too high on the valve or if it is too wide use the 15 for the exhaust side 0 and the 30 for the intake side to lower and narrow the contact area NOTE Contactarea too hight and too wide on face of valve BOlTOM NARROWING CUT If the contact area I is...

Page 97: ...e lapping compound after the final cut is made The finished valve seat should have a velvety smooth finish but not a highly polished or shiny finish This will provide a soft surface for the final seating of the I valve which will occur during the first few seconds of I engine operation Clean and assemble the head and valve components Fill the intake and exhaust ports with gasoline to check for lea...

Page 98: ...ngth by measuring their free length and also by the force required to compress them If the spring length is lessthan the service limit or if the force required to compress the spring does not fall within the range specified replace both the inner and outer springs as a set Valve spring free length IN EX Service limit INNER 36 8 rnrn 1 45 in OUTER 39 8 rnrn 1 57 in Valve spring tension Standard IN ...

Page 99: ...eal 3MOLYBDENUM OIL SOLUTION Install the valve springs with the small pitch portion facing cylinder head Large pitch portion 0UPWARD 0Paint Put on the valve spring retainer 0 and using the valve lifter press down the springs fit the cotter halves to the stem end and release the lifter to allow the cotter to wedge in between retainer and stem Be sure that the rounded lip of the cotter fits snugly i...

Page 100: ...ace faces the tappet OIL JET REMOVAL Remove the oil jets a OIL JET INSPECTIONAND CLEANING Check the oil jets for clogging If they are clogged clean their oil passage with a proper wire and compressed air O Oil jet 8 For cam chain tension adjuster OIL JET INSTALLATION Fit the new O ringsto each oil jets pimiq Usethe new O rings to prevent oil leakage NOTE Apply grease to the O rings when installing...

Page 101: ...L Y 9 4 If the largest reading at any position of the straightedge exceeds 1 the limit replace the cylinder C rnCylinder distortion Service Limit 0 05 mrn 0 002 in rn09900 20803 Thickness gauge CYLINDER BORE Inspect the cylinder wall for any scratches nicks or other dam age Measure the cylinder bore diameter at six places rnCylinder bore Standard 81 000 81 015 rnm 3 1890 3 1896 in 09900 20508 Cyli...

Page 102: ...NCE As a result of the previousmeasurement if the piston to cylinder clearance exceeds the service limit rebore the cylinder and use an oversize piston or replace both the cylinder and piston rnPiston to cylinder clearance Standard 0 055 0 065 mm 0 0022 0 0026 in PISTON RING TO GROOVECLEARANCE Measure the side clearances of the 1st and 2nd piston rings using the thickness gauge If any of the clear...

Page 103: ...using vernier calipers Next fit the piston ring squarely into the cylinder and measure the piston ring end gap using the thickness gauge If any of the measurements exceed the service limit replace the piston ring with a new one rnPiston ring free end gap Service Limit 1st 7 6 mm 0 30 in 2nd 8 8 mm 0 35 in 09900 20102 Vernier calipers rnPiston ring end gap Service Limit 1st 0 70 mm 0 028 in 2nd 0 7...

Page 104: ...2 Dial gauge 111000 mm 09900 22403 Small bore gauge 18 35 mm COLOR Measurethe piston pin outside diameter at three positions using the micrometer If any of the measurementsare out of specification replace the piston pin Piston pin O D Service Limit 19 98 mm 0 7866 in 09900 20205 Micrometer 0 25 mm SIDE RAIL NIL BLUE CONROD AND CRANKSHAFT CONROD SMALL END I D Using a small bore gauge measure the in...

Page 105: ...nd width Standard 20 95 21 OO mm 0 825 0 827 in a09900 20205 Micrometer 0 25 mm CRANK PIN WIDTH Check the crank pin width Crank pin width Standard 42 17 42 22 mm 1 660 1 662 in CONROD REMOVAL AND BEARING INSPECTION Loosen the bearing cap bolts and tap the bearing cap bolt lightly with plastic hammer to remove the bearing cap Remove the conrods and mark them to identify the cylinder position Inspec...

Page 106: ... the width of the com pressed plastigauge using the envelope scale This measure ment should be taken at the widest part of the compressed plastigauge Conrod big end oil clearance Standard 0 032 0 056 mm 0 0013 0 0022 in Service Limit 0 080 mm 0 0031 in If the oil clearance exceeds the service limit select the speci fied bearings from the bearing selectiontable Check the corresponding conrod I D co...

Page 107: ...1 OAO Black 12164 46E01 OBO Brown 12164 46E01 OCO ICAUTION I The bearings must be replaced as a set Thickness 1 480 1 484 mm 0 0583 0 0584 in 1 484 1 488 mm 0 0584 0 0586 in 1 488 1 492 mm 0 0586 0 0587 in Yellow 12164 46E01 ODO Color code CONROD AND BEARING REASSEMBLY When fitting the bearings to the bearing cap and conrod be sure to fix the stopper part first and press in the other end 1 492 1 4...

Page 108: ...ter tightening the bolts to the above torque tighten them 114 of a turn 90 Apply engine oil to the conrod big end side surfaces Check the conrod movement for smooth turning CRANKCASE OIL PRESSURE REGULATOR Remove the oil pressure regulator Check the operation of the oil pressure regulator by pushing on the piston with a proper bar If the pistondoes not operate replace the oil pressure regulatorwit...

Page 109: ... pressure switch and tighten it to the specifiedtorque a99104 31140 SUZUKl BOND 12078 USA 99000 31140 SUZUKl BOND 12078 Others Oil pressure switch 13 N m 1 3 kgf rn 9 5 Ib ft NOTE Be careful not to apply SUZUKI BOND to the hole of the thread end OIL STRAINER Removethe oil strainer plate a Removethe oil strainer a Clean the oil strainer with a compressedair ...

Page 110: ...tion Install the oil strainer plate and tighten the oil starainer plate screw to the specified torque m 7 OIL JET Removal Remove the oil jets a from the left and right crankcase halves Removethe oil seal and oil gallery plug Remove the oil jet from left crankcase half NOTE If it is difficult to remove the oiljet use a sting ...

Page 111: ...the piston cooling oil jets to the left and right crank case halves Apply a small quantity of THREAD LOCK to the bolts and tighten them to the specified torque a99000 32050 THREAD LOCK 1342 ZJPiston cooling oil jet bolt 10 N m 1 0 kgf m 7 0 Ib ft Push the oil jet into the left crankcase half until it stops Tighten the oil gallery plug to the specifiedtorque 2 Oil gallery plug M8 18 N m 1 8 kgf m 1...

Page 112: ...ecial tool Crankshaftjournal O D Standard 41 985 42 000 mm 1 6529 1 6535 in 09900 20202 Micrometer 25 50 mm Select the specified bearings from the crankcase bore I D code The crankcase bore I D code A B or C is stamped on the inside of each crankcase half Bearing selection table Crankcase I D Bearingcolor 1 Green I Black I Brown I Crank shaft journal I D I D code I D s ecification 1 r R 1 8110 1 8...

Page 113: ...88 in 2 002 2 005 mm 12229 27G00 OCO REPLACEMENT Use the special tool to replace the crankshaft journal bearings The replacement procedure is as follows Set the special tool as shown to remove the crankshaft journal bearingswith the special tool 0 0788 0 0789 in m09913 60221 Journal bearing remover installer NOTE Remove the crankshaft journal bearings in only one direction from inside to outside o...

Page 114: ...s can be removed by using with the following special tools a09924 84510 Bearing installer set 09910 20116 Conrod holder 09913 60221 Journal bearing remover installer Set the specified crankshaft journal bearings to the special tool Before setting the bearing apply enough engine oil to the special tool and bearings When setting the bearing align the bearing side with the engraved line and also the ...

Page 115: ...ghtly shave off the sharp edge part of the crankcase chamfer by using an oilstone and wash the crankcase bore with enough engine oil Set the bearings installed in the special tool to the crankcase half as shown pmi6q crankcase bore Align the bearinglspecial tool mating surface with NOTE Install the bearing from inside to outside of each crankcase halves ...

Page 116: ...e special tool contacts the special tool NOTE Using the hand press is recommended to install the crankshaft journal bearings However the crankshaftjournal bearings can be installed by using the following special tools 09924 84510 Bearing installer set 09910 20116 Conrod holder 09913 60221 Journal bearing remover installer After installingthe bearings check the bearing surface for any scratch or da...

Page 117: ...or abnormal play noise and smooth rotation while the bearings are in the crankcase Replacethe bearing with new ones if there is anything unusual Inspect the oil seals for any damage REMOVAL Remove the oil seals with the special tool or a suitable bar O9913 SOl21 Oil seal remover Removethe bearing retainers ...

Page 118: ...kcase bearings by with the special tool 09921 20240 Bearing remover set p r n NOTE r e 1 Select the suitable size attachment as following illustration 4 Bearing removerattachment Q25mm 617 mm 20 mm Left crankcase Right crankcase ...

Page 119: ...10 Bearing installer set 7 NOTE Select the suitable size attachment as following illustration Bearing installer attachment I Bearing I Oil seal I Left crankcase 0Right crankcase Apply SUZUKl SUPER GREASE to the oil seal lip 99000 25030 SUZUKl SUPER GREASE A USA 99000 25010 SUZUKl SUPER GREASE A Others B L A p ...

Page 120: ...nDrive plate claw width Service Limit 11 5 mm 0 453 in rn09900 20102 Vernier calipers CLUTCH DRIVEN PLATES NOTE Wipe off engine oil from the clutch drivenplates with a clean rag Measure each driven plate for distortion with a thickness gauge and surface plate Replacedriven plates which exceed the limit rnDriven plate distortion Service Limit 0 10 mm 0 004 in rn09900 20803 Thickness gauge CLUTCH SP...

Page 121: ...M BLY lnspect the slot of the clutch sleeve hub and primary driven gear assembly for damage or wear caused by the clutch plates If necessary replace it with a new one PRIMARY DRIVEN GEAR ASSEMBLY DISASSEMBLY Remove the snap ring Removethe oil pump drive gear and pin INSPECTION lnspect the primary driven gear bushingfor any damage lnspect the spring of primary driven gear for any damages If necessa...

Page 122: ...ION Check the gearshift shawgearshiftarm for wear or bend Check the return springs for damage or fatigue REASSEMBLY Install the following parts to the gearshift shawgearshift arm as shown in the right illustration I Washer Washer Snap ring Plate return spring Gearshift shaft return spring aGearshift cam drive plate Snap ring NOTE When installing the gearshift shaft return spring position the stopp...

Page 123: ...locationduring assembly Remove the 6th drive gear snap ring from its groove and slide it towards the 3rdl4th drive gears I Remove the concaved washer and O ring Slide the 6th and 2nd drive gears toward the 3rdl4th drive gears a then remove the 2nd drive gear circlip Removethe 2nd drive gear 6th drive gear bushing and washer Removethe snap ring and 3rdI4th drive gears Removethe snap ring a washer I...

Page 124: ...ENGINE 3 73 Removethe 5th drive gear bushing DRIVESHAFT DISASSEMBLY Removethe washer and 1st driven gear Remove the 1st driven gear bushing driven gear washer and 5th ...

Page 125: ... and washer 0 Remove the snap ring and 6th driven gear Remove the snap ring and 2nd driven gear bushing Remove the 2nd driven gear INSPECTION Inspect the each gear and bushingfor wear and damage If they are found to be damaged replace them with new ones ...

Page 126: ...e a snap ring After a snap ring has been removed from a shaft it should be discarded and a new snap ring must be installed When installing a new snap ring do not expand the end gap larger than required to slip the snap ring over the shaft After installing a snap ring make sure that it is com pletely seated in its groove and securely fitted NOTE When reassembling the transmission attention must be ...

Page 127: ... the shaft oil hole with the bushing oil hole I 6th drive gear bushing 3rd driven gear bushing 4th driven gear bushing After installing the 3rd driven gear onto the driveshaft install lock washer No 2 onto the driveshaft and position it so it fits into the groove Then fit lock washer No 1 0into lock washer No 2 0 ...

Page 128: ...e gear 1 13rd driven gear I 1st Low drive gearlcountershaft 5th drive aear 8 6th Top drive gear 2nd drive gear 1st Low driven gear 5th driven gear 4th driven aear 6th Top driven gear 2nd driven gear 145 N m 14 5 kgf m 105 Ib ft ...

Page 129: ...900 20803 Thickness gauge 09900 20102 Vernier calipers If the clearance checked is noted to exceed the limit specified replace the fork or its gear or both GEARSHIFT FORK GROOVE WIDTH Measurethe gearshift fork groove width using the vernier cali pers rnShift fork groove width Standard 5 5 5 6 mm 0 217 0 220 in rn09900 20102 Vernier calipers GEARSHIFT FORK THICKNESS Measure the gearshift fork thick...

Page 130: ... starter clutch or the starter clutch contacting surface on the starter driven gear for wear and damage If they are found to be damaged replace them with new ones Inspectthe starter driven gear bearing for any damage DISASSEMBLY Hold the generator rotor with the special tool and remove the starter clutch bolts 09930 44530 Rotor holder Remove the one way clutch from the guide REASSEMBLY When insert...

Page 131: ...clutch bolt 25 N m 2 5 kgf m 18 0 Ib ft Apply engine oil to the one way clutch GENERATOR AND SIGNAL GENERATOR INSPECTION Refer to pages 8 10 27 for generator and CKP sensor inspec tion REASSEMBLY When installing the generator starter set bolts and the CKP sensor set bolts tighten them to the specified torque Generator stator set bolt 11 N m 1 1 kgf m 8 0 Ib ft CKP sensor set bolt 6 5 N m 0 65 kgf ...

Page 132: ...eck that it moves smoothly If it does not move smoothly replace the oil pumpassembly 1 Do not bly The oil attempt to disassemble the oil pump assem pump is available only as an assembly CLUTCH RELEASE INSPECTION Checkthe teeth of clutch releasefor any damage and wear ...

Page 133: ...ore reas sembling ENGINE BOTTOM SIDE TRANSMISSION Install the countershaft assembly and the driveshaft assembly 0to the left crankcase half Installthe washer onto the driveshaft assembly a GEARSHIFT Installthe gearshift forks I gearshift cam I and gear shift fork shafts NOTE Identify the gearshift forks as follows For 5th driven gear For 6th driven gear For 3rdl4th drive gear For 5th driven gear F...

Page 134: ...dowel pins Apply SUZUKl SUPER GREASE to the O ringsa 0 99000 25030 SUZUKI SUPER GREASE A USA 99000 25010 SUZUKI SUPER GREASE A Others Apply SUZUKl BOND to the mating surface of the left crank case a99104 31140 SUZUKI BOND 12O7B USA a99000 31110 SUZUKI BOND 1215 Others NOTE Use of SUZUKI BONDis as follows Make surfaces free from moisture oil dust and other foreign materials Spread on surfaces thinl...

Page 135: ...heck if the crankshaft the driveshaft and the countershaft rotate smoothly Fit the clamp to the bolt 0as shown OIL PLATE Install the oil plate I and the oil plate bolts tighten to the specified torque rnOil plate bolt 10 N rn 1 0 kgf rn 7 0 Ib ft ENGINE SPROCKET SPACER lnstall the new O ring into the engine sprocket spacer p i i I Use the new O ring to prevent oil leakage 1 Installthe engine sproc...

Page 136: ...sitionswitch bolt to the specifiedtorque rnGear positionswitch bolt 6 5 N m 0 65 kgf m 4 7 Ib ft lnstall the drive shaft oil seal retainer NOTE Pass through the gear position switch lead wire under the drive shaft oil seal retainer FRONT CAM CHAIN lnstallthe front cam chain 6 lnstall the cam chain tensioner a washer and cam chain tensioner bolt Tighten the cam chain tensioner bolt I to the specifi...

Page 137: ... slot on the crankshaft completely Installthe generator rotor assembly onto the crankshaft I a While holding the generator rotor with the special tool tighten its bolt to the specified torque a09930 44530 Rotor holder Generator rotor bolt 120 N m 12 0 kgf m 87 Ib ft CAM CHAIN DRIVE SPROCKET Installthe cam chain drive sprocket 0onto the crankshaft NOTE Align the punched mark on the cam chain drive ...

Page 138: ...sioner bolt 10 N m 1 0 kgf m 7 0 Ib ft NOTE Thefront and rear cam chain tensionersare the same PRIMARY DRIVE GEAR Install the primary drive gear and water pump drive gear 0 Holdthe generator rotor crankshaft with the special tool 09930 44530 Rotor holder Tighten the primarydrive gear bolt to the specified torque Primary drive gear bolt 70 N m 7 0 kgf m 50 5 Ib ft NOTE Thisbolt has left hand thread...

Page 139: ...the groove of its stopper GEARSHIFT SYSTEM Installthe gearshift cam stopper 0 its bolt washer and return spring 1 1Gearshift cam stopper bolt 10 N m 1 0 kgf m 7 0 Ib ft Confirmthe gearshift cam stopper movement Check the neutral position NOTE Hook the return spring end to the stopper Install the gearshift cam stopper plate with the gearshift cam pins inserted into the gearshift cam stopper plate h...

Page 140: ...cifiedtorque a99000 32050 THREAD LOCK 1342 Gearshift cam stopper plate bolt 13 N m 1 3 kgf m 9 5 Ib ft Install the gearshift shawgearshift arm with the washer as shown Locate the gearshift arm stopper between return spring ends 0 Installthe washer I and snap ring I OIL PUMP Installthe oil pump with the three screws ...

Page 141: ...ll the primary driven gear assembly onto the counter shaft NOTE Be sure to engage the oil pump drive and driven gears primaly drive and driven gears lnstall the thrust washer lnstall the clutch sleeve hub and lock washer Replace the lock washer with a new one lnstall the clutch sleeve hub nut NOTE The chamfer side of the clutch sleeve hub nut faces outward ...

Page 142: ...the lock washer to lock the nut securely Install the spring washer seat and spring washer onto the clutch sleeve hub correctly Insert the clutch drive plates and driven plates one by one intothe clutchsleeve hub in the prescribedorder No 2 drive plate being insertedfirst NOTE Apply the ENGINE OIL to the clutch driven and drive plates before installing them No 2 Drive plate I No 1 Drive plate Direc...

Page 143: ...e plate and bearing Hold the generator rotor crankshaft with the special tool a09930 44530 Rotor holder Installthe clutch pressure plate Tighten the clutch spring set bolts to the specified torque Clutch spring set bolt 10 N m 1 0 kgf rn 7 0 Ib ft NOTE Tighten the clutch spring set bolts diagonally CLUTCH COVER Installthe gasket and dowel pins a I Use the new gasket to prevent oil leakage I ...

Page 144: ...tall the dowel pins and gasket 1 Use the new gasket to preventoil leakage lnstall the generator cover Generator cover bolt 10 Nem 1 0 kgf m 7 0 Ib ft NOTE Fit the gasket washers to the generator cover bolts correctly as shown ICAUTION I I Use the new gasket washers to prevent oil leakage I OIL FILTER lnstallthe oil filter with the special tool 2 1 3 09915 40610 Oil filter wrench ...

Page 145: ...the starter motor mounting bolt ENGINE TOP SIDE PISTON Install the piston rings in the order of oil ring 2nd ring and 1st ring The first member to go into the oil ring groove is a spacer a After placing the spacer fit the two side rails a NOTE Side designations top and bottom are not applied to the spacer and side rails you can position each either way CAUTION I When installingthe spacer be carefu...

Page 146: ...IL SOLUTION NOTE When installing the pistons front and rear the indents 0 on the piston heads must be located to each exhaust side Place a clean rag over the cylinder base so as not to drop the piston pin circlips into the crankcase Installthe pistons a front and rear Installthe piston pin circlips pmzq Use new piston pin circlips to prevent circlip failure which will occur with a bend one NOTE En...

Page 147: ...ht crankcase as shown in the illustration CAUTlONI Use the new O rings to prevent oil leakage CYLINDER Coat SUZUKl BOND lightly to the mating surfaces at the part ing line between the right and left crankcases as shown a99104 31140 SUZUKI BOND 1207B USA a99000 31110 SUZUKI BOND 1215 Others Apply engine oil to the sliding surface of the pistons Fit the dowel pins and new gaskets to the crank case p...

Page 148: ...ns taut The cam chain must not be caught between cam drive sprocket and crankcase when turning the crankshaft Tighten the cylinder nuts M6 temporarily CYLINDER HEAD The cylinder heads can be distinguished by the embossed let ters F Front cylinder head R Rear cylinder head Pull the cam chain out of the cylinder and install the cam chain guide I There is the guide holder for the bottom end of the ca...

Page 149: ...cylinder head bolts Place the rear cylinder head on the cylinder NOTE When installing the cylinder head keep the cam chain taut Tighten the cylinder head bolts M10 to the specified two step torque with a torque wrench sequentially and diago nally Cylinder head bolt M10 Initial 25 N m 2 5 kgf m 18 0 Ib ft Final 42 N m 4 2 kgf m 30 5 Ib ft After firmly tightening the cylinder head bolts MlO install ...

Page 150: ...ne on the generator rotor with the index mark I of the valve timing inspection hole while keeping the cam chains pulled upward ICAUTIONI Pull the cam chains upward or the chain will be caught between crankcase and cam drive sprocket To adjust the camshaft timing correctly be sure to align IF line I with the index mark and hold this position when installingthe camshafts Pullthe cam chain lightly Th...

Page 151: ... not to move the crankshaft until the camshaft journal holders and cam chain tension adjuster is secured No 1 FRONT CYLINDER HEAD Apply engine oil to the camshaft journal holders Installthe camshaft journal holders intake and exhaust Fasten the camshaft journal holders evenly by tightening the crankshaft journal holder bolts sequentially and diagonally NOTE Align the flange of the camshafts with t...

Page 152: ...nsion adjuster release locking of the ratchet mecha nism I and push the push rod all the way in Installthe gasket and oil jet Installthe cam chain tension adjuster I with UP mark faced to the top of cylinder head Tighten the cam chain tension adjuster mounting bolts to the specified torque p i E q I Usethe new gasket to prevent oil leakage I Cam chaintension adjuster mountingbolt 10 N m 1 0 kgf m7...

Page 153: ...chain will be caught between crankcase and cam drive sprocket To adjust the camshaft timing correctly be sure to align IF line with the index mark and hold this position when installing the camshafts Pull the cam chain lightly The No 2 intake camshaft sprocket has an arrow mark 1R 0 Install the intake camshaft so that the arrow 0is aligned with the mating surface of the cylinder head W3 103 Engage...

Page 154: ...ller pins from the intakecamshaft side going towardsthe exhaust camshaft side Engage the 16th roller pin 0on the cam chain with the arrow mark 3 on the exhaust sprocket W3 103 NOTE The cam chain should now be on all three sprockets Be careful not to move the crankshaft until the camshaft journal holders and cam chain tension adjuster is secured No 2 REAR CYLINDER HEAD Installthe dowel pins I ...

Page 155: ...h a cast on letter 0 Tighten the camshaft journal holder bolts to the specified torque Camshaft journal holder bolt 10 N m 1 O kgf m 7 0 Ib ft The camshaft journal holder bolts are made of a spe cial material and much superior in strength compared with other types of high strength bolts Take special care not to use other types of bolts instead of these special bolts To identify these bolts each of...

Page 156: ...ENGINE 3 105 No 1 Front cylinde TDC of compression stroke Cam chain guide Cam chain guide Forward ...

Page 157: ...SUZUKI BOND 1215 Others pmim Use the new gaskets to prevent oil leakage The cylinder head covers can be distinguished by the embossed letters F Front cylinder head cover R Rear cylinder head cover Installthe cylinder head covers on each cylinder head Fit the gaskets to each head cover bolt piEim Use the new gaskets to prevent oil leakage I NOTE Themetal side of the gasket must face to the bolt fla...

Page 158: ... I When installing the water union apply engine coolant to the O ring ENGINE COOLANT INTAKE PlPE Apply SUZUKl SUPER GREASE to the O ring 99000 25030 SUZUKl SUPER GREASE A USA 99000 25010 SUZUKI SUPER GREASE A Others pE6i 1 Use the new O ring to prevent air from sucking through the joint Make sure that the UP mark faces upward Installthe intake pipes NOTE The intake pipe can be identified by the ma...

Page 159: ... Valve timing inspection plug 23 N m 2 3 kgf my16 3 Ib ft Generator cover plug 11 N m 1 1 kgf my8 0 Ib ft 1 Use the new O ring to prevent oil leakage I THERMOSTAT CASE AND WATER HOSE Install the thermostat case along with the water hoses and tighten the clamp screws securely 9 24 SPARK PLUG AND HOSES Connect the PAIR hoses Connect the crankcase breather hoses Installthe spark plugs 2 8 ...

Page 160: ...ES 4 20 SELF DIAGNOSISRESET PROCEDURE 4 20 MALFUNCTION CODE AND DEFECTIVE CONDITION 4 21 C12 CKP SENSOR CIRCUIT MALFUNCTION 4 23 C13 IAP SENSOR CIRCUIT MALFUNCTION 4 25 C14 TP SENSOR CIRCUIT MALFUNCTION 4 28 C15 ECT SENSOR CIRCUIT MALFUNCTION 4 31 C21 IAT SENSOR CIRCUIT MALFUNCTION 4 33 C23 TO SENSOR CIRCUIT MALFUNCTION 4 35 C24 or C25 IGNITION SYSTEM MALFUNCTION 4 36 C28 STV ACTUATOR CIRCUIT MALF...

Page 161: ...AL AND INSTALLATION 4 49 TPS ADJUSTMENT 4 49 ECT SENSOR INSPECTION 4 49 ECT SENSOR REMOVAL AND INSTALLATION 4 49 AT SENSOR INSPECTION 4 50 IAT SENSOR REMOVAL AND INSTALLATION 4 50 TO SENSOR INSPECTION 4 50 TOSENSOR REMOVAL AND INSTALLATION 4 50 STP SENSOR INSPECTION 4 50 STP SENSOR REMOVAL AND INSTALLATION 4 50 STP SENSOR ADJUSTMENT 4 50 H02 SENSOR INSPECTION E 02 19 4 50 H02 SENSOR REMOVAL AND IN...

Page 162: ...ing the coupler be sure to hold the coupler body and do not pull the lead wires lnspect each terminal on the connector coupler for looseness or bending lnspect each terminal for corrosion and contamination The terminals must be clean and free of any foreign material which could impede proper terminal contact lnspect each lead wire circuit for poor connection by shaking it by hand lightly If any ab...

Page 163: ...male connector for excessive opening Also check the coupler for locking loose ness corrosion dust etc O Coupler Probe 3 Where male terminal fits 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 ...

Page 164: ...tromotive force will be applied to the ECM which may result in serious damage Before measuring voltage at each terminal check to make sure that battery voltage is 11 V or higher Terminal voltage check at low battery voltage will lead to erroneous diagnosis Never connect any tester voltmeter ohmmeter or whatever to the ECM when its coupler is disconnected Otherwise damage to ECM may result Never co...

Page 165: ...nnection Also check for condition of the coupler lock if equipped Sensor ECM Check for loose connection Using a test male terminal check the female terminals of the circuit being checked for contact tension Check each terminal visually for poor contact possibly caused by dirt corrosion rust entry of foreign object etc At the same time check to make sure that each terminal is fully insertedin the c...

Page 166: ... the circuit being checked voltage check can be used as circuit check With all connectors couplers connected and voltage applied to the circuit being checked measure voltage between each terminal and body ground If measurements were taken as shown in the figure at the right and results are as listed below it means that the circuit is open between terminals and 0 Voltage Between 0and body ground Ap...

Page 167: ...ouplers of those parts Otherwise diagnosis will be misled Measure resistance between terminal at one end of circuit terminal in figure and body ground If continuity is indicated there is a short circuit to ground between terminals and 0 To other parts Other parts Disconnect the connector coupler included in circuit coupler and measure resistance between terminal and body ground If continuity is in...

Page 168: ...ring the resistancewith the multi circuittester I will be shown as 10 00 Mi2 and 1 flashes in the display Check that no voltage is applied before making the measure ment If voltage is applied the tester may be damaged After using the tester turn the power off 09900 25008 Multi circuittester set NOTE When connecting the multi circuit tester use the needle pointed probe to the back side of the lead ...

Page 169: ... and various compensations These compensationsare determined according to the signals from various sensors that detect the engine and driving conditions I IntakeAir Pressure Intake air pressure Sensor IAP Sensor signal I Basic Crankshaft Position Enginespeed Sensor CKP Sensor signal injection time Throttle Position Throttle opening Sensor TP Sensor signal Various Sensors Various signals II ICompen...

Page 170: ... time it monitors the voltage signal for compensation of the fuel injection time volume A longer injection time is needed to adjust injection volume in the case of low voltage At high speed the injection time volume is increased During acceleration the fuel injection time volume is increased in accordancewith the throttle openingspeed and engine rpm During deceleration the fuel injectiontime vol u...

Page 171: ...FlSYSTEM DIAGNOSIS 4 11 FI SYSTEM PARTS LOCATION Speedometer I CKP sensor 0TP sensor 0Gear positionsensor O STP sensor Fuel injector No 1 Fuel injector No 2 Ignition coil No 1 STVA TO sensor ...

Page 172: ...4 12 FI SYSTEM DIAGNOSIS IAP sensor Q IAT sensor G ECT sensor 0 Fuel pump relay 0 Ignition coil No 2 PAIR control valve ...

Page 173: ...ECM FP DON 0 A T Q B CLT O IGi IG2 THW D SOL cD FI R 1 6 FI1 1 2 MO QD MO THA am vcc 0 TPS QD 2 STPS 0 H02 OXH 24 H02 OX I TACO EJTECH B M I I WR U MODESELECTIONSWITCH G B I ILI ...

Page 174: ...nel and motorcycle can run 2 The injection signal is stopped when the crankshaft position sensor signal tip over sensor signal 1 2 ignitionsignals 1 2 injector signals fuel pump relay signal or ignition switch signal is not sent to ECM In this case FI is indicated in the LCD panel Motorcycle does not run CHEC The LCD panel indicates CHEC when no communicationsignal from the ECM is receivedfor 3 se...

Page 175: ...evices are indicated in the code form 09930 82720 Mode select switch EGiEq Do not disconnect the ECM lead wire couplers before checking the malfunction code or the malfunction code memory is erased and the malfunction code can not be checked Confirm the malfunction code after ignition ON or cranking the engine for few seconds I YES INDICATION I INDICATION I INUILH LCD DISPLAY TlON MODE FI LIGHT I ...

Page 176: ...sor H02S PAIR control solenoid valve REMARKS No defective part Pick up coil signal signal generator For I cylinder For 2 cylinder For I cylinder For 2 cylinder Fuel pump Fuel pump relay Anti theft For E 02 19 In the LCD DISPLAY panel the malfunctioncode is indicated from small code to large code TPS ADJUSTMENT 1 Warm up the engine and adjust the engine idle speed to 1 300 f100 rpm 2 1 5 2 Stop the...

Page 177: ...ke air temperature value is fixed to 40 C 104 OF 1 Fuel cut 2 Fuel cut YES YES YES YES YES 2 YES 1 YES I YES YES YES YES 2cvlinder can run ISecondary throttle valve actuator 2 cylinder can run YES 2 Fuel cut ECM stops controlling STV I YES I YES I I cylinder can run ISecondary throttle position sensor YES ECM stops controlling STV The engine can start and can run even if the above signal is not re...

Page 178: ...lways ON El Sometimes ON Always OFF Good condition I PROBLEM SYMPTOMS Malfunctiondisplaytcode LCD Difficult Starting Poor Driveability 1 User mode No display Malfunction display 1 Dealer mode No code El Malfunction code 0No cranking No initial combustion Hesitationon acceleration 0 Back fire10 After fire 0No combustion 0 Lack of power 0 Poor starting at 0 Surging 0 cold warm 0always 0Abnormal knoc...

Page 179: ...ain condition Urban Suburb 0Highway 0Mountainous UUphill Downhill 0Tarmacadam 0Gravel Other Motorcycle condition Cold Warming up phase 0Warmed up Always Other at starting Immediately after start Racingwithout load Enginespeed rimin During driving q Constant speed Accelerating q Decelerating 0Right hand corner Left hand corner 0At stop Motorcyclespeed when problem occurs km h Milelh I 0Other The ab...

Page 180: ...tions are available and how to use it Be sure to read PRECAUTIONS for Electrical Circuit Service W 4 2 before inspection and observe what is written there Removethe seat 7 4 Connect the special tool to the dealer modecoupler at the wir ing harness and start the engine or crank the engine for 4 seconds and more Turn the special tool s switch ON and check the malfunction code to determine the malfun...

Page 181: ...tion sensor lead wire coupler connection The sensor voltage should be the following perature sensor sensor 10 1 V S sensor voltage 4 6 V 0 1 V sensor voltage 4 6 V Without the above ranae for 4 sec and more C15 is indicated lntake air temperature IWithout the above ranae for 4 sec and more C21 is indicated Engine coolant temperature sensor lead wire coupler connec tion The sensor voltage should be...

Page 182: ... voltage is 0 2 V and less Gear position sensor wiring coupler connection Gearshiftcam etc When fuel injector voltage gets 1 3 V and less C32 or C33 is indicated Injector wiringlcouplerconnection power supply to the injector No voltage is applied to the both injectors 1 2for 3 sec after the contact of fuel pump relay is turned ON Or voltage is applied to the both injectors 11 2 when the contact of...

Page 183: ...ignitionswitch OFF 2 Check the CKP sensor coupler for loose or poor contacts If OK then measure the CKP sensor resistance 3 Disconnect the CKP sensor coupler and measure the resis tance CKP sensor resistance 130 240 R White Green 4 If OK then check the continuity between each terminal and ground CKP sensor continuity R Infinity White Ground Green Ground 09900 25008 Multi circuit tester set i Teste...

Page 184: ...est peak voltage If OK then measure the CKP sensor peak voltage at the ECM terminals 09900 25008 Multi circuit tester set g Tester knob indication voltage Is the voltage OK YES NO BIW or White wire open or shortedto ground or poor I or O Dconnection If wire and connection are OK intermittent trou ble or faulty ECM Recheck each terminal and wire harness for open circuit and poor connection Loose or...

Page 185: ... consideration when inspecting volt aae 4 Disconnect the IAP sensor coupler 5 Turn the ignitionswitch ON 6 Measure the voltage at the Red wire I and ground If OK then measure the voltage at the Red wire and BIBr wire 0 IAP sensor input voltage 4 5 5 5 V Red Ground Red B Br 09900 25008 Multi circuit tester set 9 Tester knob indication Voltage I Is the voltage OK Cloggedvacuum passage betweenthrottl...

Page 186: ...tep 3 1 Removethe IAP sensor 4 49 2 Connect the vacuum pump gauge to the vacuum port of the IAP sensor Arrange 3 new 1 5 V batteries in series check that total voltage is 4 5 5 0 V and connect terminal to the ground terminal and terminal to the Vcc terminal Check the voltage between Vout and ground Also check if voltage reduces when vacuum is applied up to 400 mmHg by using vacuum pump gauge 4 27 ...

Page 187: ...ALTITUDE ATMOSPHERIC I Reference I PRESSURE I z E I 0 I 2 000 2 001 I 5 000 0 I 610 5 001 I 8 000 611 I 1 524 8 001 1 10 000 760 I 707 1 525 I 2 438 707 I 634 2 439 I 3 048 loo I 94 634 1 567 Approx 3 3 3 6 94 I 85 567 I 526 Approx 3 0 3 3 85 1 76 Approx 2 7 3 0 76 I 70 Approx 2 5 2 7 ...

Page 188: ...pecified range 0 1 V 5 Sensor voltage c 4 8 V Turn the ignition switch ON Measurethe voltage at the Red wire and ground If OK then measure the voltage at the Red wire and B Br wire POSSIBLE CAUSE TP sensor maladjusted TP sensor circuit open or short TP sensor malfunction ECM malfunction TP sensor input voltage 4 5 5 5 V Red Ground Red BIBr 09900 25008 Multi circuit tester set i Tester knob indicat...

Page 189: ...ound 5 If OK then measure the TP sensor resistance between and 6 Turn the throttle grip and measure the resistance TP sensor resistance Throttlevalve is closed Approx 1 12 k S Z Throttlevalve is opened Approx 4 26 k S Z 09900 25008 Multi circuit tester set k BTester knob indication Resistance SZ Are the resistanceand continuity OK NO Reset the TP sensor position correctly Replace the TP sensor wit...

Page 190: ...lve is closed Approx 1 12 V Throttle valve is opened Approx 4 26 V 09900 25008 Multi circuit tester set 09900 25009 Needle pointed probe set Tester knob indication Voltage Is the voltage OK YES a ECM coupler Red PNV or B Br wire open or shorted to ground or poor or I connection If wire and connection are OK intermittenttrou ble or faulty ECM Recheck each terminal and wire harness for open circuit ...

Page 191: ...re side coupler 3 Disconnectthe coupler and turn the ignition switch ON 0 1 V S Sensor voltage c 4 6 V 4 Measure the voltage between BIB1 wire terminal and ground 5 If OK then measure the voltage between BIB1 wire terminal and B Br wire terminal a ETC sensor voltage 4 5 5 5 V BIB1 Ground BIB1 BIBr 09900 25008 Multi circuit tester set m Tester knob indication Voltage ECT sensor malfunction ECM malf...

Page 192: ...er knob indication Resistance 8 NO IReplace the ECT sensor with a new one Is the resistance OK I Engine Coolant Temp 1 Resistance I YES I 20 C 68 OF I Approx 2 45 k B I BIBr or BIB1wire open or shorted to ground or poor or connection If wire and connection are OK intermittent trou ble or faulty ECM Recheck each terminal and wire harness for open circuit and poor connection ECM coupler 60 O C 140 O...

Page 193: ...sensor coupler for loose or poor contacts If OK then measure the IAT sensor voltage at the wire side coupler 4 Disconnect the coupler and turn the ignition switch ON 5 Measure the voltage between Dg wire terminal and ground 6 If OK then measure the voltage between Dg wire terminal and B Br wire terminal IAT sensor voltage 4 5 5 5 V Dg Ground Dg WBr a09900 25008 Multi circuit tester set Tester knob...

Page 194: ...orted to ground or poor or connection If wire and connection are OK intermittent trou YES I ble or faulty ECM Intake Air Temp Resistance I NO Recheck each terminal and wire harness for open circuit and poor connection Replace the IAT sensor with a new one 20 C 68 O F Approx 2 45 W2 I NOTE 40 C 104 O F AT sensor resistance measurement method is the same way as Approx 1 148 W2 60 C 140 O F 80 C 176 ...

Page 195: ...sure the resistance between and terminals DETECTED CONDITION The sensor voltage shouldbethe following for 2sec and more after ignition switch turns ON 0 2V 5 Sensor voltage 5 4 6V TO sensor resistance 19 1 19 7 kQ terminals POSSIBLE CAUSE TO sensor circuit open or short TO sensor malfunction ECM malfunction 09900 25008 Multi circuit tester set fimTester knob indication Resistance Q Is the resistan...

Page 196: ...om the horizontal level TO sensor voltage 3 7 4 4 V BrMI BIBr a09900 25008 Multi circuit tester set 09900 25009 Needle pointed probe set i Tester knob indication Voltage Is the voltage OK YES Red BrNV or BIBr wire open or shorted to ground or poor I or a connection If wire and connectionare OK intermittenttrou ble or faulty ECM Recheck each terminal and wire harnessfor open circuit and poor connec...

Page 197: ...ort STVA motor malfunction I No I Looseor poor contacts on the STVA coupler Open or short circuit in the B R and RIB wires Step 2 1 Turn the ignitionswitch OFF 2 Check the STVA coupler for loose or poor contacts 3 Disconnectthe STVA coupler 4 Check the continuity between terminal and ground STVA continuity R Infinity I NO IReplacethe STVA with a new one I 5 If OK then measurethe STVA resistance ST...

Page 198: ...sor circuit open or short STP sensor malfunction ECM malfunction 3 Check the STP sensor coupler for loose or poor contacts If OK then measure the STP sensor input voltage 4 Disconnect the STP sensor coupler 5 Turn the ignition switch ON 6 Measurethe voltage at the Red wire and ground 7 If OK then measure the voltage at the Red wire and BIBr wire STP sensor input voltage 4 5 5 5 V Red Ground Red BI...

Page 199: ...econdary throttle valve fully by turning the actuator shaft end 0 and measurethe STP sensor resis tance with both STV positions STP sensor resistance Secondary throttle valve is closed Approx 0 58 kQ Secondary throttle valve is opened Approx 4 38 kQ m09900 25008 Multi circuit tester set i mTester knob indication Resistance Q pimq Do not use the tool for turning the STVA shaft to pre vent breakdown...

Page 200: ...ctu ator shaft end 0 STP sensor output voltage Secondary throttle valve is closed Approx 0 58 V Secondary throttle valve is opened Approx 4 40 V e09900 25008 Multi circuit tester set 09900 25009 Needle pointed probe set i mTester knob indication Voltage Do not use the tool for turning the STVA shaft to pre vent breakdown Is the voltage OK YES Red Yellow or BIBr wire open or shorted to ground or po...

Page 201: ... to up right position 6 Make sure the engine stop switch is in the RUN position 7 Insertthe needle pointed probes to the GP switch coupler 8 Turn the ignition switch ON 9 Measure the voltage at the wire side coupler between Pink wire and ground when shifting the gearshift lever from 1st to Top GP switch voltage 1 0 V and more Pink Ground 09900 25008 Multi circuit tester set 09900 25009 Needle poin...

Page 202: ...ts If OK then measurethe injector resistance 4 Disconnectthe injector couplers and measure the resistance between terminals lnjector resistance 11 13 Q at 20 C 68 O F No 1 O 0 N0 2 I 5 If OK then check the continuity between injector terminals and ground lnjector continuity 00 Q Infinity No 1 Ground No 2 I Ground 09900 25008 Multi circuit tester set i m e s t e r knob indication Resistance Q POSSI...

Page 203: ...ge NOTE lnjector voltage can YIR detected Ground only 2 seconds after ignition switch is turned ON a09900 25008 Multi circuit tester set i mTester knob indication Voltage Is the voltage OK YES NO GrNV or Gr B wire open or shortedto ground or poor or connection If wire and connection are OK intermittent trou ble or faulty ECM Recheck each terminal and wire harness for open circuit and poor connecti...

Page 204: ... check the insulation and continuity Refer to page 5 10 for details Is the FP relay OK NO IReplace the FP relay with a new one YES NOTE When the both fuel injectors break down at a time C41 is indi Y Bor O G OIW For E 03 24 28 and 33 wire open or shortedto ground or poor or con nection If wire and connection are OK intermittenttrou ble or faulty ECM Recheck each terminal and wire harnessfor open c...

Page 205: ...is not input in ECM 4 Removethe air cleaner box 5 1 5 5 Disconnect the PAIR control solenoid valve coupler and mea sure the resistance between terminals PAlR control solenoid valve resistance 20 24 Q at 20 OCI68 O F 09900 25008 Multi circuit tester set Tester knob indication Resistance Q Is the resistance OK POSSIBLE CAUSE PAlR control solenoid valve circuit open or short PAIR control solenoidvalv...

Page 206: ...rown wire and ground 11 PAlR control solenoid valve voltage Battery voltage Brown Ground 09900 25008 Multi circuit tester set 09900 25009 Needle pointed probe set u Tester knob indication Voltage Isthe voltage OK 0 Brown wire open or shortedto ground or connection If wire and connection are OK intermittent trou ble or faulty ECM Recheck each terminal and wire harnessfor open circuit and poor conne...

Page 207: ... the ignition switch ON and measure the heater voltage betweenONV wire ECM side and ground 6 If the tester voltage indicatesthe battery voltage for few sec onds it is good condition POSSIBLE CAUSE H02 sensor or its circuit open or short Fuelsystem malfunction ECM malfunction Heater voltage Battery voltage O M Ground NOTE Battery voltage can be detected only during few seconds after ignition switch...

Page 208: ...e voltage OK 1 YES GO to Step 3 I NO IReplacethe H02 sensor with a new one I Step 3 1 Turn the ignition switch OFF 2 Disconnectthe H02 sensor coupler 3 Check the resistance between the terminals White White of the H02 sensor rnH02 heater resistance 4 5 52 at 23 CR3 4 O F White White NOTE Temperatureof the sensor affects resistance value largely Make sure that the sensor heater is at correct temper...

Page 209: ...he air cleaner box Install the IAP sensor in the reverse order of removal TP SENSOR INSPECTION The throttle position sensor is installed at the left side of the No 2 throttle body 4 28 TP SENSOR REMOVAL AND INSTALLATION Removethe air cleaner box 5 1 5 Removethe TP sensor 5 1 9 Installthe TP sensor in the reverse order of removal rnTP sensor mounting screw 3 5 N m 0 35 kgf m 2 5 Ib ft TPS ADJUSTMEN...

Page 210: ...verse order of removal NOTE When installing the TO sensor the U P mark must be pointed upward STP SENSOR INSPECTION STP SENSOR REMOVAL AND INSTALLA TION The secondary throttle position sensor is installedat the left side of the No 2 throttle body Removethe air cleaner box 5 1 5 Removethe STP sensor 5 1 9 Installthe STP sensor in the reverse order of removal rnSTP sensor mounting screw 2 0 N m 0 2 ...

Page 211: ......

Page 212: ...ulatedby the fuel pressure regulator As the fuel pressureapplied to the fuel injector the fuel pressure in the fuel delivery pipe is always kept at absolute fuel pressure of 300 kPa 3 0 kgflcm2 43 psi the fuel is injected into the throttle body in conic dispersion when the injector opens accordingto the injectionsignal from the ECM The fuel relieved by the fuel pressure regulator flows back to the...

Page 213: ...ressure difference to occur on both sides of the impeller as there are many grooves around it Then the fuel is drawn through the inlet port and with its pressure increased it is discharged through the outlet port The fuel pump has a check valve to keep some pressure in the fuel feed hose even when the fuel pump is stopped Also the relief valve is equipped in the fuel pump which releases pressur iz...

Page 214: ...oove as viewed in angular direction due to fluid friction This process continuously takes place causing fuel pressure to be built up The pressurizedfuel is then let out from the pump chamber and discharged through the motor section and the check valve 1 IFlow clearance I ITurning direction I 3 3 Outlet Blade groove Inlet 7 Impeller Motor shaft Vortex flow ...

Page 215: ... 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 energized by the ECM it becomes an electromagnet and attracts the plunger At the same time the needle valve incorporatedwith the plunger opens and the injector which is under the fuel pre...

Page 216: ...e fuel pump motor from the battery through the side stand relay and the fuel pump relay so that the pump continuesto function A tip over sensor is provided in the fuel pump control circuit By this provision anytime the motorcycle tips over the tip over sensor sends a signal to the ECMto turn off power to the fuel pump relay causingthe fuel pump motor to stop At the same time current to the fuel in...

Page 217: ...ank 5 7 Disconnect the fuel pump lead wire coupler I Gasoline is highly flammable and explosive I Place a rag under the fuel feed hose and disconnect the fuel feed hose from the fuel tank Disconnect the fuel tank drain hose pEiGq I r Keep heat spark and flame away When removing the fuel tank do not leave the fuel feed hose on the fuel tank side a Removethe fuel tank mounting bolt and nut 1 Removet...

Page 218: ...h ON and check the fuel pressure Fuel pressure Approx 300 kPa 3 0 kgf cm2 43 psi If the fuel pressure is lower than the specification inspect the following items Fuel hose leakage Clogged fuel filter Pressure regulator Fuel pump If the fuel pressure is higher than the specification inspect the following items Fuel pump check valve Pressure regulator Before removing the special tools turn the ignit...

Page 219: ...oper fuel hose to the fuel pump Placethe measuring cylinder and insert the fuel hose end into the measuring cylinder Disconnect the ECM lead wire coupler from the ECM Push the lock Jto pull out the power source lead wire Yel low with black tracer Connect the ECM to the ECM lead wire coupler Apply 12 volts to the fuel pump for 10 seconds and measure the amount of fuel discharged Battery terminal Po...

Page 220: ...pply 12 volts to and terminals to and to and check the continuity between and If there is no continuity replace it with a new one FUEL PUMP AND FUEL FILTER REMOVAL Removethe fuel tank 5 7 Remove the fuel pump assembly by removing its mounting bolts diagonally Gasoline is highly flammable and explosive Keep heat spark and flame away Remove the screws Remove the nuts and screw a Disconnect the clamp...

Page 221: ...THROTTLE BODY 5 11 Removethe screws Removethe fuel pump assy from the fuel pump plate a Remove the fuel pump holder Removethe fuel mesh filter a Remove the fuel pressure regulator holder and the fuel pressure regulator ...

Page 222: ...P AND FUEL MESH FILTER INSTALLATION Install the fuel pump and fuel mesh filter in the reverse order of f removal Pay attentionto the following points d a Install the new O rings to the fuel pressure regulator and fuel pipe Apply thin coat of the engine oil to the O rings I Use the new O rings to prevent fuel leakage I Tighten the screw together with the lead wire terminal Tighten the nuts together...

Page 223: ...the fuel pump assembly mounting bolts lightly in the ascending order of numbers and then tighten them to the specified torque in the above tightening order Fuel pump mounting bolt 10 N m 1 0 kgf m 7 3 Ib ft NOTE Apply a small quantity of the THREAD LOCK to the thread por tion of the fuel pump mounting bolt a99000 32050 THREAD LOCK 1342 0 Fuel pressure regulator Fuelpumpcaselfuel filter cartridge F...

Page 224: ...Y AND STV ACTUATOR CONSTRUCTION I ITP sensor 1 ISTP sensor mounting screw I I IFuel delivery pipe I I Do not turn the screw 9 I IInjector I STP sensor PI ITEM 8 TP sensor mounting screw Fuel delivery pipe mounting screw N m 2 0 kgf m 0 2 Ib ft 1 5 ...

Page 225: ...ove the fuel tank 5 7 Disconnect the IAT sensor coupler a Remove the IAP sensor vacuum hose Disconnect the IAP sensor coupler Loosen the throttle body clamp screws Disconnect the PAIR hose Disconnect the PAIR lead wire coupler Disconnect the crankcase breather hoses Remove the air cleaner box ...

Page 226: ...LE BODY Removethe fuel tank 5 7 Removethe air cleaner box D 5 1 5 Disconnectthe various lead wire couplers TP sensor STP sensor STVA motor Removethe injector lead wire coupler Disconnect the idle stop screw Loosenthe throttle body clamp screws ...

Page 227: ... body assembly Be careful not to damage the throttle cable bracket and fast idle lever when dismounting or remounting the throttle body assembly 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 ...

Page 228: ...dy is assembled precisely in factory Do not disassemble it other than shown in this man ual Remove the IAP sensor vacuum damper and its hose Disconnect the fuel feed hose a Remove the throttle link rod and secondary throttle link rod 0 NOTE The throttle link rod is longer than the secondary throttle link rod 0 Remove the fuel delivery pipe Remove the fuel injectors ...

Page 229: ...he special tool 09930 11950 Torx wrench TH 25 09930 11960 Torx wrench TH 20 NOTE Prior to disassembly mark each sensor s original position with a paint or scribe for accurate reinstallation Remove the oil seals a I Do not turn the screws 0 I I Never removethe STVA I ...

Page 230: ...LE BODY Remove the throttle stop screw NOTE Measure the length I for accurate reinstallation CAUTION1 Never loosen the throttle stop screw I on the No 2 throt tle body Never remove the throttle valve and secondary throttle valve ...

Page 231: ...FUELSYSTEM AND THROTTLE BODY 5 21 I Never remove the throttle body link plates I Remove the fast idle link lever 0 Remove the spring Remove the spring bushing and plastic washer ...

Page 232: ...nents cannot be cleaned with a spray cleaner it may be necessary to use a dip type cleaning solution and allow them to soak Always follow the chemical manufacturer s instructions for proper use and cleaning of the throttle body components Do not apply carburetor cleaning chemicals to the rubber and plastic materials THROTTLE BODY INSPECTION Check following itemsfor any damage or clogging O ring Se...

Page 233: ...y SUZUKl SUPER GREASE to the throttle stop screw tip and the both ends of a spring 99000 25030 SUZUKl SUPER GREASE A USA 99000 25010 SUZUKl SUPER GREASE A Others Installthe plastic washer and bushing 0 NOTE The concave of a bushing is faced outside Installthe spring Apply SUZUKl MOLY PASTE to the fast idle link lever 99000 25140 SUZUKl MOLY PASTE Installthe spring ...

Page 234: ...Eto the seal lips 99000 25030 SUZUKI SUPER GREASE A USA 99000 25010 SUZUKI SUPER GREASE A Others Installthe seal Apply a small quantity of SUZUKI SUPER GREASE to the shaft ends and seal lips 99000 25030 SUZUKl SUPER GREASE A USA 99000 25010 SUZUKI SUPER GREASE A Others a Turn the TP sensor counterclockwiseand installthe mounting screws Tighten the TP sensor mounting screws 09930 11950 Torx wrench ...

Page 235: ...r mountingscrews a09930 11960 Torx wrench STP sensor mounting screw 2 0 N m 0 2 kgf m 1 5 Ib ft NOTE Make sure the ST valve open or close smoothly Apply thin coat of the engine oil to the new fuel injector cush ion seal and install it to the fuel injector I Replacethe cushion seal and O ring with a new one 1 Installthe O ring 0 3to the fuel injector Apply thin coat of the engine oil to the new O r...

Page 236: ...er turn the fuel injectors while installingthem Tighten the fuel delivery pipe mountingscrews Fuel delivery pipe mounting screw 5 0 N m 0 5 kgf m 3 7 Ib ft Install the throttle link rod and secondary throttle link rod 8 NOTE The throttle link rod is longer than the secondary throttle link rod 0 lnstallthe IAP sensor vacuum damper and hose ICAUTIONI I The stamp 0of the IAP sensor vacuum damper face...

Page 237: ...the tool for turning the STVA shaft to pre vent breakdown NOTE Measure the throttle valve height I from top of the throttle body to the throttle valve While holding above No 1 STV position turn the adjust screw so that the throttle valve height 0 will be same as 0 THROTTLE BODY INSTALLATION Installation is in the reverse order of removal Pay attention to the following points Connect the throttle p...

Page 238: ... valve to fully open position Measurethe STP sensor voltage at fully open position STP sensor voltage ST valve is fully opened Approx 4 38 V and more Yellow Black rn09900 25008 Multi circuit tester set 09900 25009 Needle pointed probe set 3 Tester knob indication Voltage Do not use the tool for turning the STVA shaft to pre vent breakdown Loosen the STP sensor mounting screws Adjust the STP sensor...

Page 239: ...peedto 1300 rpm Stop the warmed up engine and connect the special tool to the dealer mode coupler W5 20 09930 82720 Mode select switch If the TP sensor adjustment is necessary loosenthe TP sen sor mountingscrews Turn the TP sensor and bring the line to middle Tighten the TP sensor mounting screws 09930 11950 Torx wrench TP sensor mounting screw 3 5 N m 0 35 kgf m 2 5 Ib ft Incorrect Correct positi...

Page 240: ...he water tem perature and ambient temperature as shown in the following table the fast idle is cancelled allowing the engine to resume idle speed Fast idle link lever Fast idle cam STVA NOTE The fast idle link lever opens throttle valve a little to increase the engine speed Fast idle cancelling Water Fast idle rpm ITemp If under the above conditions the fast idle cannot be cancelled the cause may ...

Page 241: ... sensor pimq Do not use the tool for turning the STVA shaft to pre vent breakdown If the TP sensor output voltage is out of specification turn the fast idle adjusting screw and adjust the output voltage to specification TP sensor output voltage 1 21 V Red BIBr 09900 25008 Multi circuit tester set 09900 25009 Needle pointed probe set Tester knob indication Voltage After adjusting the fast idle spee...

Page 242: ...Connect the IAT and PAIR control valve sensor couplers Connect the IAP sensor coupler and vacuum hose Connect the PAIR hose Remove the rubber cap I from the No 1 throttle body Connect one of the four rubber hoses of the vacuum balancer gauge to the nipple on the No 1 throttle body 09913 13121 Vacuum balancer gauge Start up the engine and keep it running at 1 300 rpm by turn ing throttle stop screw...

Page 243: ...enter line disconnect the hose from the No 1 throttle body nipple and connect the next hose of the gauge to this nipple Turn air screw to bring the other steel ball 3 to the center line The balancer gauge is now ready for use in balancing the throt tle valves THROTTLE VALVE SYNCHRONIZATION To synchronize throttle valves remove the rubber caps from each vacuum nipples on No 1 and No 2 throttle body...

Page 244: ... the throttle valves always set the engine rpm at 1 300 rpm using throttle stop screw After balancing the two valves set the idle rpm to 1 300 rpm ICAUTION I Avoid drawing dirt intothe throttle body while running the engine without the air cleaner box Dirt drawn into the engine will damagethe internal engine parts NOTE Make sure that the throttle lever should have a gap between the throttle lever ...

Page 245: ...AL 6 8 INSTALLATION 6 8 COOLING FAN THERMO SWITCH 6 9 REMOVAL 6 9 INSPECTION 6 9 INSTALLATION 6 9 ECT SENSOR 6 10 REMOVAL 6 10 INSPECTION 6 10 INSTALLATION 6 11 THERMOSTAT CASE ASSEMBLY 6 12 REMOVAL 6 12 INSPECTION 6 12 INSTALLATION 6 13 WATERPUMP 6 14 REMOVAL AND DISASSEMBLY 6 14 INSPECTION 6 16 REASSEMBLY AND INSTALLATION 6 17 LUBRICATION SYSTEM 6 20 OIL PRESSURE 6 20 OIL FILTER 6 20 OIL PRESSUR...

Page 246: ...GAND LUBRICATIONSYSTEM 6 1 OIL PUMP 6 20 OIL PRESSURE SWITCH 6 20 OIL COOLER 6 21 REMOVAL 6 21 INSPECTION AND CLEANING 6 21 INSTALLATION 6 22 ENGINE LUBRICATION FLOW CHART 6 23 ENGINE LUBRICATION CIRCUIT 6 24 ...

Page 247: ...brands of anti freeze Do not rut in 60 and more anti freeze or 50 and less Refer to below figure Do not use a radiator anti leak additive 50 10Engine coolant including reserve tank capacity I Water 1 950 ml 2 0111 67 US1lmp pt I 20 40 60 80 100 0 10 20 30 40 50 60 Density Density Fig 1 Engine coolant density freezing Fig 2 Engine coolant density boiling point curve point curve You can be injured b...

Page 248: ...ster to the filler Do not remove the radiator cap when the engine is hot Give a pressure of about 120 kPa 1 2 kgflcm2 17 0 psi and see if the system holds this pressurefor 10 seconds If the pressure should fall during this 10 second interval it means that there is a leaking point in the system In such a case inspect the entire system and replace the leaking com ponent or part When removing the rad...

Page 249: ...TION SYSTEM RADIATOR REMOVAL Remove the cowling 7 5 Drain the engine coolant 2 1 8 Disconnectthe right and left radiator hoses from the radiator Disconnectthe siphon hose from the radiator Disconnectthe horn lead wire coupler ...

Page 250: ...ead wire from the clamp With the hooks unlocked remove the radiator from the radiatorshroud Remove the cooling fan and from the radiator shroud thermo switch lead wire coupler Removethe coolingfan 0 Disconnect the cooling fan thermo switch lead wire coupler and removethe cooling fan thermo switch Removethe horn ICAUTION I When removing the horn hold the nut by spanner to prevent the horn bracket d...

Page 251: ...radiator in the reverse order of removal Pay attention to the following points Installthe cooling fan and horn 0 Cooling fanthorn mounting bolt 8 N m 0 8 kgf m 6 0 Ib ft lnstallthe coolingfan thermo switch 6 8 Routethe radiator hoses properly 9 24 Install the drain plug with a new sealing washer and pour engine coolant W2 18 Bleed air from the cooling circuit 2 1 9 Installthe cowling W 7 8 ...

Page 252: ...hat with the tester held stand still the cap is capable of holding that pressure for at least 10 seconds Replace the cap if it is found not to satisfy above require ments Radiator cap valve opening pressure Standard 95 125 kPa 0 95 1 25 kgf cm2 13 5 17 8 psi WATER HOSE INSPECTION Removethe cowling 7 5 Any water hose found in a cracked condition or flattened or water leaked must be replaced Any lea...

Page 253: ...amperes and more If the fan motor does not turn replace the fan motor assembly with a new one NOTE Whenmaking above test it is not necessary to remove the cool ing fan REMOVAL Remove the cowling W 7 5 Drain the engine coolant 2 1 8 Removethe radiator W 6 4 Disconnect the cooling fan thermo switch coupler a Remove the cooling fan INSTALLATION Installthe cooling fan to the radiator Cooling fan motor...

Page 254: ... col umn thermometer when the switch closes or opens 09900 25008 Multi circuit tester set Tester knob indication Continuity test 4 Cooling fan thermo switch operating temperature Standard OFF ON Approx 98 O C 208 O F ON OFF Approx 92 O C 198 O F p 5 m m l Take special care when handling the thermo switch It may cause damage if it gets a sharp impact Do not contact the cooling fan thermo switch and...

Page 255: ...owly and read the column thermometer aand the ohmmeter If the ECT sensor ohmic valve does not change in the propor tion indicated replace it with a new one Temperature sensor specification Temperature Standard resistance I I If the resistance noted to show infinity or too much different 20 C 68 O F 40 C 104 O F 60 C 140 O F 80 C 176 O F resistancevalue replace the ECT sensor with a new one Approx ...

Page 256: ...ing washer a Tighten the ECT sensor to the specifiedtorque ECT sensor 19 N m 1 9 kgf m 13 5 Ib ft piimiq Take special care when handling the ECT sensor It may cause damage if it gets a sharp impact Pour engine coolant W 2 1 8 Bleed air from the cooling circuit 2 19 ...

Page 257: ... a string between flange as shown in the photograph Immersethe thermostat in the WATER contained in a beaker as shown in the illustration Note that the immersed thermo stat is in suspension Heat the water by placing the beaker on a stove I and observe the rising temperature on a thermom eter a Readthe thermometer just when opening the thermostat This reading which is the temperature level at which...

Page 258: ...g to satisfy either of the two requirements start to opentemperature and valve lift must be replaced INSTALLATION Apply engine coolant to the rubber seal on the thermostat Installthe thermostat NOTE Thejiggle valve of the thermostatfaces upside Installthe thermostat case cap 0 NOTE The rib of the thermostat case cap should be faced upward Tighten the thermostat case bolts to the specified torque T...

Page 259: ...and clutch cover 3 2 7 NOTE Before draining engine oil and engine coolant inspect engine oil and coolant leakage between the water pump and clutch cover If engine oil is leaking visually inspect the oil seal and O ring If engine coolant is leaking visually inspect the mechanical seal and seal ring 1 1 7 6 16 Remove the snap ring and water pump driven gear Remove the pin I and washer ...

Page 260: ... water pump from the clutch cover Remove the screws and separate the water pump Remove the O rings D Remove the E ring from the impeller shaft Remove the impeller from the other side Remove the mechanical seal ring and rubber seal from the impeller ...

Page 261: ...ondition the mechanicalseal and the oil seal removal is not necessary The removed mechanical seal and oil seal must be replaced with a new one INSPECTION BEARING Inspect the play of the bearing by hand while it is in the water pump case Rotatethe inner race by hand to inspect for abnormal noise and smooth rotation Replace the bearing if there is anything unusual MECHANICAL SEAL Visually inspect th...

Page 262: ...ally inspect the bearing case for damage Replace the water pump body if necessary REASSEMBLY AND INSTALLATION m Installthe oil seal with the special tool a09913 70210 Bearing installer set 022 mm w NOTE The stamped mark on the oil seal faces impeller side m Apply a small quantityof the SUZUKl SUPER GREASE to the oil seal lip 99000 25030 SUZUKl SUPER GREASE A USA 99000 25010 SUZUKl SUPER GREASE A O...

Page 263: ... mechanical seal ring install it into the impeller NOTE The paint marked side of the mechanical seal ring faces to the impeller Apply SUZUKl SUPER GREASE to the impeller shaft 99000 25030 SUZUKI SUPER GREASE A USA 99000 25010 SUZUKl SUPER GREASE A Others lnstall the impeller to the water pump body Fix the impeller shaft with the E ringa Apply SUZUKI SUPER GREASE to the O rings 99000 25030 SUZUKI S...

Page 264: ...RICATIONSYSTEM 6 19 Apply engine coolant to the O ring Installa new O ring pmq Use a new O ring to preventengine coolant leakage Connect the water hoses Pour engine coolant 2 1 8 Pour engine oil 2 1 4 0 45 kgf m 3 3 Ib ft ...

Page 265: ...ND LUBRICATIONSYSTEM LUBRICATIONSYSTEM OIL PRESSURE W 2 3 1 OIL FILTER W 2 1 4 OIL PRESSURE REGULATOR 3 57 OIL STRAINER W 3 5 8 OIL JET W 3 4 9 59 60 and 96 OIL PUMP W 3 8 1and 89 OIL PRESSURE SWITCH W 3 5 8and 8 34 ...

Page 266: ... cooler Removethe oil cooler fin guard net 0 Remove the oil hoses a INSPECTIONAND CLEANING Inspect the oil cooler and hose joints for oil leakage If any defect are found replace the oil cooler and oil hoses with the new ones Roaddirt or trash stuck to the fins must be removed Use of compressed air is recommendedfor this cleaning ...

Page 267: ...ew gasket washers Use the new gasket washers to prevent engine oil leakage Connect the oil hoses Install the oil cooler rnOil cooler mounting bolt 10 N m 1 0 kgf m 7 0 Ib ft Tighten the oil cooler hose union bolts to the specifiedtorque rnOil cooler hose union bolt 23 N m 2 3 kgf m 16 5 Ib ft p i i E q The oil cooler hoses should be contacted with the stoppers ...

Page 268: ...ENSION t t t CRANK PIN 9 INTAKE 1CAMSHAFT I FRONT AND REAR CONROD BIG END BEARINGS 1 1 1 b b b I 1 0 I b b b IFRONT PISTONAND I I REAR PISTONAND 1 CYLINDER WALL I I CYLINDERWALL I t t O 1 REAR CYLINDER I I OIL JET l4 I OIL JET 14 OIL GALLERY I 4 OIL JET 14 DRIVEN GEAR AND BUSHING t DRIVE SHAFT 1 4 4 CLUTCH PUSH PEACE A 1 1i r i 4 1 0 I 4 bb I CLUTCH PLATES I OIL PRESSURE I 1 bb t OfL PAN ...

Page 269: ...6 24 COOLING AND LUBRICATION SYSTEM ENGINE LUBRICATION CIRCUIT FRONT CYLINDER ...

Page 270: ...COOLINGAND LUBRICATIONSYSTEM 6 25 REAR CYLINDER ...

Page 271: ...7 25 STEERINGAND HANDLEBAR 7 26 CONSTRUCTION 7 26 REMOVAL 7 27 INSPECTIONAND DISASSEMBLY 7 30 REASSEMBLY AND REMOUNTING 7 31 STEERING TENSIONADJUSTMENT 7 34 REAR WHEEL 7 35 CONSTRUCTION 7 35 REMOVAL 7 36 INSPECTIONAND DISASSEMBLY 7 37 REASSEMBLY AND REMOUNTING 7 40 REAR SHOCK ABSORBER 7 44 CONSTRUCTION 7 44 REMOVAL 7 45 INSPECTION 7 46 REAR SHOCK ABSORBER DISPOSAL 7 46 REMOUNTING 7 47 SUSPENSION S...

Page 272: ... 66 MASTER CYLINDERREASSEMBLY AND REMOUNTING 7 67 REAR BRAKE 7 68 CONSTRUCTION 7 68 BRAKE PAD REPLACEMENT 7 69 BRAKE FLUID REPLACEMENT 7 71 CALIPER REMOVAL AND DISASSEMBLY 7 71 CALIPER INSPECTION 7 73 BRAKE DISC INSPECTION 7 74 CALIPER REASSEMBLY AND REMOUNTING 7 74 MASTER CYLINDERREMOVAL AND DISASSEMBLY 7 75 MASTER CYLINDERINSPECTION 7 77 MASTER CYLINDERREASSEMBLY AND REMOUNTING 7 77 TIREAND WHEE...

Page 273: ...ERIOR PARTS CONSTRUCTION I I I Wind screen brace I 1 Cowling inner cover I m I Cowling brace Left cowling Right cowling Cowling brace mounting bolt Wind screen cover Wind screen 3 Cowling body Combination meter wanel ...

Page 274: ...CHASSIS 7 3 Seat rail Rear fender No 1 Rear fender No 2 Mud guard Frame cover Seat rail mountina bolt PI ITEM N m 50 kgf m 5 0 Ib ft 36 0 ...

Page 275: ...IS REMOVAL SEAT Remove the seat with the ignition key 0 CARRIER Remove the seat 7 4 Remove the carrier a FUEL TANK SIDE COVER Remove the seat 7 4 Removethe fuel tank side covers a NOTE b indicates hook location ...

Page 276: ... NOTE I 11 ts indicates hook location REAR FENDER T Removethe seat 7 4 Remove the carrier U 7 4 Removethe bolts a Disconnect the brake light taillight lead wire coupler and seat lock cable I Remove the rear fender COWLING AND COWLING BRACE Remove the seat 7 4 Disconnect the battery lead wire Remove the wind screen covers 0 ...

Page 277: ...k top cover Remove the combination meter panel mountingscrews Remove the combination meter panel 0 NOTE I h 19 b indicates hook location Disconnectthe speedometer leadwire coupler 0 Remove the cowling inner cover aby removing two screws and seven fasteners ...

Page 278: ... 7 7 Remove the left cowling Remove the right cowling w Removethe wind screen brace Disconnect the turn signal light lead wire couplers Remove the screws Remove the cowling body NOTE 2 indicates hook location ...

Page 279: ...exterior parts in the reverse order of removal Pay attention to the following points Install the wind screen brace as shown in the photograph NOTE lnstall the larger diameter bolts on the wind screen brace attach ing section NOTE The wind screen height can be adjusted by changing the wind screen brace installed position ...

Page 280: ...CHASSIS 7 9 FRONT WHEEL CONSTRUCTION IoIBrake disc I 1 Front wheel I m 1 1 I ITire valve Y 1 ITEM I N m Iksf m1 Ib ft I Bearing I IFront axle I I ICenter spacer I IBrake disc bolt ...

Page 281: ...9900 18710 Hexagon bit 12 mm Raisethe front wheel off the ground and support the motorcy cle with a jack or a wooden block Remove the front axle and the front wheel NOTE After removing the front wheel fit the calipers temporarily to the original positions INSPECTIONAND DISASSEMBLY TIRE 7 79 BRAKE DISC W7 65 Removethe brake discs DUST SEAL Inspect the dust seal lip for wear or damage If any damages...

Page 282: ...rvice limit An excessive runout is usually due to worn or loosenedwheel bearingsand can be reducedby replac ing the bearings If bearing replacement fails to reduce the runout replacethe wheel Wheel inspection 7 79 rnWheel runout Service Limit Axial and Radial 2 0 mm 0 08 in WHEEL BEARING Inspect the play of the wheel bearings by finger while they are in the wheel Rotate the inner race by finger to...

Page 283: ...7 12 CHASSIS REASSEMBLY AND REMOUNTING Reassemble and remount the front wheel in the reverse order of removal and disassembly Pay attention to the following points Left Right ...

Page 284: ...left wheel bearing then install the right wheel bearing and spacer with the special tools and used bearing 09941 34513 BearingJSteeringrace installer set 09913 70210 Bearing installerset i40 I The sealed cover of the bearing must face outside Spacer Old bearing Left Right 0Clearance DUST SEAL Installthe dust seal with the special tool 09913 70210 Bearing installerset Q 40 ...

Page 285: ...ll the front wheel with the front axle and tighten the front axle temporarily The directional arrow on the wheel must point to the wheel rotation when remounting the wheel BRAKE CALIPER Tighten the brake caliper mounting bolts to the specified torque Front brake caliper mounting bolt 39 N m 3 9 kgf m 28 0 Ib ft NOTE Push thepistons all the way into the caliper and remount the cal ipers FRONT AXLE ...

Page 286: ...e pinch bolt on the right front fork leg move the front fork up and down 4 or 5 times without applying front brake Tighten the axle pinch bolt on the right front fork leg to the specified torque Front axle pinch bolt 23 N m 2 3 kgf m 16 5 Ib ft ...

Page 287: ... ISpacer 1 4 3IOil lock piece I ISpring I Outertube I Spring adjuster 0 rina 0IOil seal 1Oil seal retainer Slide metal Front fork cap bolt Gasket Front axle pinch bolt Dust seal 3 2 Cylinder bolt Oil seal stopper ring 73 Rebound spring Inner tube 6 3 Cylinder Washer m ...

Page 288: ... front fender Loosen the front fork upper clamp bolts NOTE slightly loosen the front fork cap bolts before loosening the lower clamp bolts to facilitate later disassembly Loosen the front fork lower clamp bolts NOTE Hold the front fork by the hand to prevent sliding out of the steer ing stem Removethe front fork Removethe front fork cap bolt Removethe spacer washer aand spring ...

Page 289: ...bolt For right front fork reg Remove the damper rod bolt with the special tools Remove the damper rod 09940 34520 T Handle 09940 34531 Attachment A NOTE If the damper rod turns together with the damper rod bolt tem porarily install the fork spring spacer washer and cap bolt to prevent the damper rod from turning Remove the dust seal Removethe rebound spring and cylinder ...

Page 290: ...ge the inner tube ICAUTION The slide metals oil seal and dust seal must be replaced with the new ones when reassembling the front fork Remove the following parts 0Oil seal Oil seal retainer Q Guide metal Slide metal O Oil lock piece Remove the pin Remove the washer Remove the spring adjuster from front fork cap bolt ...

Page 291: ...any defects are found replace them with the new ones FORK SPRING Measure the fork spring free length If it is shorter than the ser vice limit replace it with a new one Frontfork spring free length Service limit 435 mm 17 1 in CYLINDER lnspect the cylinder and cylinder ring for damage If any defect is found replace them with a new one ...

Page 292: ...d seals with new ones Apply fork oil to the Anti friction metals and lip of the oil seal Assemble the following parts as shown 0Oil seal 0 Oil seal retainer Guide metal Slide metal NOTE Stamped mark on the oil seal must face upward Installthe oil lock piece into the inner tube Install the inner tube into the outer tube with care not to drop the oil lock piece out NOTE After installing the inner tu...

Page 293: ...ylinder bolt jCAUTlON Use a new gasket to prevent oil leakage a99000 32050 THREAD LOCK 1342 Tighten the cylinder bolt to the specified torque with the spe cial tools 09940 34520 T Handle 09940 34531 Attachment A I ICylinder bolt 20 N m 2 0 kgf m 14 5 Ib ft NOTE If the cylinder turns together with the cylinder bolt temporarily install the fork spring spacer washer and cap bolt to prevent the cylind...

Page 294: ...and down several strokes until no more bubbles come out from the oil Keep the front fork vertically and leave it during 5 6 minutes NOTE Take extreme attention to pump out air completely Hold the front fork vertically and adjust the fork oil level with the special tool NOTE When adjusting the fork oil level remove the fork spring and compress the inner tube fully 09943 74111 Front fork oil level g...

Page 295: ...ork oil lightly to the O ring p m 5 K I Use a new O ring to prevent oil leakage I Install the spring adjuster to the front fork cap bolt Apply fork oil lightly to the O ring 1 Use a new O ring to prevent oil leakage I Tighten the front fork cap bolt temporarily Set the front fork to the front fork lower bracket temporarily by tightening the lower clamp bolts ...

Page 296: ...amp bolt 23 N m 2 3 kgf m 16 5 Ib ft Installthe front wheel 7 1 0 Installthe front brake calipers W7 59 NOTE After install the brake calipers front brake should be efficient by pumping the front brake lever SUSPENSION SETTING After installing the front fork adjust the spring per load as fol lows SPRING PRE LOAD ADJUSTMENT There are four grooved lines on the side of the spring adjuster Position0 pr...

Page 297: ...clamp bolt I Bearing lower I 1Steeringstem head nut I Handlebars Steerina stem uooer bracket IHandlebar balancer 03 IFront fork lower clamp bolt I O O i Expander Spacer Washer U ITEM I N m I kgf m1 Ib ft I Steering stem lower bracket Steerina stem nut 0 0 Front fork upper clamp bolt Steerina stem lock nut ...

Page 298: ...moving the handlebar balancer Slightly loosen the mounting screw and then pull the balancer assembly out of handlebars Removethe front brake master cylinder I Remove the right handlebar switch box and throttle case Remove the left handlebarswitch box 0 Removethe grip rubber Loosen the clutch lever holder bolt Disconnect the clamps Removethe clamp bolt caps ...

Page 299: ...bolts m Removethe clutch lever holder 3 STEERING STEM Remove the front forks 7 17 Remove the handlebars 7 27 Removethe guides I Remove the brake hose guide 1 3 Remove the ignitionswitch 1 3 with the special tools O 9 9 3 O i i 9 2 O Tom bit JT40H 09930 11940 Bit holder ...

Page 300: ...940 14960 Steering stem nut wrench socket Remove the washer I Remove the steeringstem nut with the special tools a09940 14911 Steering stem nut wrench 09940 14960 Steering stem nut wrench NOTE When loosing the steering stem nut hold the steering stem lower bracket to prevent it from falling Remove the steering stem lower bracket Remove the dust seal Q and bearing inner race ...

Page 301: ...earing noise Handlebars distriction Race wear and brinelling If any abnormal points are found replace defective parts with the new ones Remove the steering stem lower bearing inner race using a chisel I The removed bearing inner race and dust seal must be I replacedwith the new ones I Drive out the steering stem upper and lower bearing races with the special tools 09941 54911 Bearingouter race rem...

Page 302: ...ngs and dust seal Installthe lower bearing to the steering stem lower bracket lnstall the upper bearing bearing inner race dust seal onto the frame 99000 25030 SUZUKl SUPER GREASE A USA 99000 25010 SUZUKl SUPER GREASE A Others STEERING STEM Tighten the steering stem nut to the specified torque with the special tools 09940 14911 Steering stem nut wrench 09940 14960 Steering stem nut wrench socket S...

Page 303: ...0 N m 8 0 kgf m 58 0 Ib ft Installthe steering stem upper bracket and tighten the steer ing stem nut lightly Installthe ignition switch and harness guide a 8 38 Installthe front fork to the steering stem and tighten the lower 7 k h clamp bolts temporarily Tighten the steering stem head nut to the specified torque rnSteering stem head nut 90 N m 9 0 kgf m 65 0 Ib ft Remount the front forks and the ...

Page 304: ...e cable case Apply SUZUKI SUPER GREASE to the throttle cables and their holes 99000 25030 SUZUKl SUPER GREASE A USA 99000 25010 SUZUKl SUPER GREASE A Others Align the matingsurface I of the throttle case with the punch mark on the handlebars a Install the right handlebar switch box to the handlebars by engaging the stopper with the handlebar s hole a Installthe front brake master cylinder W 7 6 7 ...

Page 305: ...s shown in the figure and read the graduationwhen the handle bar starts moving Do the same on the other grip end Initialforce 200 500 grams 09940 92720 Spring scale If the initial force read on the scale when the handlebar starts turning is either too heavy or too light adjust it till it satisfies the specification 1 First loosen the front fork upper clamp bolts steering stem head nut and steering...

Page 306: ... I Retainer 1 1 I u s t seal I I ISprocket mounting drum 1 I 1Bearing 1 1 u s t seal I 0 IRear wheel I Icollar 1 PI O Tire valve Brake disc bolt Damper I Rear sprocket nut Spacer 0 Rear axle nut 43 5 Brake disc Collar I IBearing I Rear sprocket Bearina ...

Page 307: ...ck Remove the axle nut and draw out the rear axle I Do not operate the brake pedal while removing the I rear wheel Remove the collars a Remove the rear sprocket mounting drum assembly from the wheel hub NOTE Before removing the rear sprocket mounting drum slightly loosen the rear sprocket nuts to facilitate later disassembly Remove the rear sprocket mounting drum retainer ...

Page 308: ...79 REAR AXLE Using a dial gauge check the rear axle for runout If the runout exceeds the limit replacethe rear axle Axle shaft runout Service Limit 0 25 mm 0 010 in a09900 20607 Dial gauge 11100 mm 09900 20701 Magneticstand 09900 21304 V block set 100 mm WHEEL DAMPER Inspectthe dampers for wear and damage Replace the damper if there is anything unusual ...

Page 309: ...t and drive chain as a set Normalwear Excessivewear DUST SEAL lnspect the wheel dust seal lip and sprocket mounting drum dust seal lips for wear or damage If any damages are found replace the dust seal with a new one Remove the dust seal with the special tool 09913 50121 Oil seal remover ICAUTION I I DOnot reuse the removed dust seal I ...

Page 310: ... and drum Rotate the inner race by hand to inspect for abnormal noise and smooth rotation Replace the bearing if there is anything unusual Remove the sprocket mounting drum bearing and wheel bear ings with the special tool 09921 20240 Bearing remover set a 030 8020 1 The removed bearings must be replaced with the new ones 4 ...

Page 311: ...7 40 C H A S S I S REASSEMBLY AND REMOUNTING Reassemble and remount the rear wheel in the reverse order of removal and disassembly Pay attention to the following points Left Right ...

Page 312: ...ingdrum with the special tool 09913 70210 Bearing installerset Q 62 NOTE When installing the bearing non sealed side of bearing must face the special tool First install the right wheel bearing then install the left wheel bearing and spacer with the special tools 09941 34513 BearingISteeringrace installer set 09913 70210 Bearing installer set 47 p G i q The sealed cover of the bearing must face out...

Page 313: ...OTE The stamped mark on the brake disc should face to the out side Apply THREAD LOCK to the disc bolts and tighten them to the specified torque a99000 32130 THREAD LOCK SUPER 1360 P Brake disc bolt 23 Nmm 2 3 kgf m 16 5 Ib ft REAR SPROCKET Installthe rear sprocket to the rear sprocket mountingdrum NOTE Stamped mark on the sprocket must face outside Apply SUZUKl SUPER GREASE to the rear sprocket mo...

Page 314: ... Rear sprocket nut 60 N m 6 0 kgf m 43 5 Ib ft lnstall the collar REAR AXLE Remount the rear wheel and rear axle installthe washer and rear axle nut Adjust the chain slack after rear wheel installation 2 21 Tighten the rear axle nut to the specified torque tT Rear axle nut 100 N m 10 0 kgf m 72 5 Ib ft lnstall the new cotter pin For E 03 28 33 ...

Page 315: ...7 44 CHASSIS REAR SHOCK ABSORBER CONSTRUCTION Rear shock absorber lower mounting nut U ITEM 1 N m I kaf m 1 Ib ft I Rear shock absorber upper mount ing nut ...

Page 316: ... jack or wooden block Remove the pre loadadjuster Removethe cushion lever rod boltslnutsand the cushion rods 0 Disconnectthe pre loadadjuster hose from the clamp Remove the rear shock absorber upper mountingbolt Removethe rear shock absorber lower mounting bolt Removethe rear shock absorber ...

Page 317: ...rom fire and heat High gas pressure caused by heat can cause an explosion Release gas pressure before disposing GAS PRESSURE RELEASE Mark the drill hole at shown in the illustration with a center punch Cover the rear shock absorber with a transparent vinyl bag Holdthe rear shock absorber Q with a vice Make a hole with a 3 mm drill Be sure to wear protective glasses since drilling chips and oil may...

Page 318: ...mountingnuts rnRear shock absorber lower mounting nut 50 N m 5 0 kgf m 36 0 Ib ft Rear shock absorber upper mounting nut 50 N rn 5 0 kgf rn 36 0 Ib ft NOTE When installing the rear shock absorber the outlet hose of the prel load adjuster faces backward Clamp the pre loadadjuster hose a Installthe cushion rod 0 Tighten the cushion rod nuts to the specifiedtorque rnCushion rod nut 78 N m 7 8 kgf m 5...

Page 319: ...he stiffest spring pre load STD position 2 STD position I Stiffest position O Softest position DAMPING FORCE ADJUSTMENT The rebound damping force is adjusted by turning the adjuster Fully turn the damping adjuster I clockwise It is at stiffest posi tion and turn it out to standard setting position STD position 1 turn back from stiffest position E 02 19 24 1 112 turns back from stiffest position E ...

Page 320: ...f m 1 Ib ft I Rear cushion rod Rear cushion lever 1 0IPivot spacer I ISwingarm pivot lock nut I 3 I I IChain cover I O 1Swingarrn pivot nut I I 1Chain buffer Spacer Bearing Washer Rear shock absorber lower mounting nut I Center spacer Rear shock absorber umer m 0 0 Cushion lever nut Cushion rod nut Swinaarm pivot shaft ...

Page 321: ...r brake hose guides Remove the cushion rods a Remove the shock absorber lower mounting bolt Removethe cushion lever Remove the swingarm pivot shaft lock nut with the special tool a09940 14940 Swingarm pivot thrust adjuster socket wrench Hold the swingarm pivot shaft and remove the swingarm pivot nut Remove the swingarm pivot shaft with the special tool a09944 28320 Hexagon bit 19 mm Removethe chai...

Page 322: ... Removethe spacers from swingarm and cushion lever Inspect the spacers for any flaws or other damage If any defect is found replace the spacers with the new ones CHAIN BUFFER lnspect the chain buffer for damage and excessive wear If any defect is found replacethe chain buffer with a new one ...

Page 323: ...rings with the special tool rn09921 20240 Bearing remover set 17 mm ICAUTION I DOnot reuse the removed bearings I SWINGARM PIVOT SHAFT Using a dial gauge check the pivot shaft runout and replace it if the runout exceeds the limit 09900 20607 Dial gauge 11100 mm 10 mm 09900 20701 Magnetic stand 09900 21304 V block 100 mm Swingarm pivot shaft runout Service limit 0 3 mm 0 01 in CUSHION LEVER BEARING...

Page 324: ...e cushion lever bearings with the special tool a09921 20240 Bearing remover set 20 mm and 17 mm pmKq 1 The removed bearings must be replaced with the new I ones CUSHION ROD Inspect the cushion rods for damage and distortion ...

Page 325: ...HASSIS REASSEMBLY Reassemble the swingarm in the reverse order of disassembly and removal Pay attention to the following points Frame Rear shock absorber Swingarm Left 0Right Washer Cushion lever Cushion rod ...

Page 326: ...earingswith the special tool a09941 34513 Steering race installer NOTE When installing the bearing the dust seal that is embedded in the bearing must face outside CUSHION LEVER BEARING Pressthe bearings into the cushion lever with the special tool 09941 34513 Steering race installer NOTE When installing the bearing the dust seal that is embedded in the bearing must face outside Apply SUZUKl SUPER ...

Page 327: ...shaft 15 N m 1 5 kgf m 11 O Ib ft a09944 28320 Hexagon bit 19 mm Hold the swingarm pivot shaft I with the special tool and tighten the swingarm pivot nut ato the specified torque 09944 28320 Hexagon bit 19 mm rnSwingarm pivot nut 100 N m 10 0 kgf m 72 5 Ib ft Tighten the swingarm pivot lock nut to the specified torque with the special tool 09940 14940 Swingarm pivot thrust adjuster socket wrench r...

Page 328: ...on lever nut cushion rod nut and rear shock absorber lower mounting nut to the specified torque Cushion lever nut 78 N m 7 8 kgf m 56 5 Ib ft Cushion rod nut 78 N m 7 8 kgf m 56 5 Ib ft Rear shock absorber lower mounting nut 50 N m 5 0 kgf m 36 0 Ib ft Installthe rear wheel W 7 4 0 Installthe exhaust pipe and muffler W3 14 FINAL INSPECTION AND ADJUSTMENT After installing the rear suspension and wh...

Page 329: ... mIFront brake master cylinder I I Pistonlcup set Brake hose a I 03 Pad mounting pin Brake pad spring Brake pad Piston seal Caliper holder Caber e 0 0 mounting bolt Brake hose union bolt Air bleeder valve Brake caliper mountingbolt 39 ITEM 0 3 9 N m 10 23 7 5 28 0 kgf m 1 0 2 3 0 75 Ib fl 7 0 16 5 5 5 ...

Page 330: ...se cleaning solvent A contaminated brake disc or brake pad reduces braking performance Discard contaminated pads and clean the disc with high quality brakecleaner or neutral detergent Handle brake fluid with care the fluid reacts chemically with paint plastics rubber materials etc and will damage then severly 1 BRAKE PAD REPLACEMENT Remove the caliper piiEm 1 Do not operate the brake lever while r...

Page 331: ...ce the motorcycle on a level surface and keep the handle bars straight Removethe brake fluid reservoir cap and diaphragm Suck up the old brake fluid as much as possible Fill the reservoir with the new brake fluid fiSpecification and Classification DOT 4 Connect a clear hose to the caliper air bleeder valve and insert the other end of hose into a receptacle Loosen the air bleeder valve and pump the...

Page 332: ... NOTE Place a rag underneath the union bolt on the brake caliper to catch any spilt brake fluid Remove the brake calipers by removing the caliper mounting bolts 1CAUTION Do not reuse the brake fluid left over from previous servicing and stored for long periods of time I Brake fluid if it leaks will interfere with safe running I and discolor painted surfaces Check the brake hose and hosejoints for ...

Page 333: ...on seals to prevent fluid leakage CALIPER INSPECTION BRAKE CALIPER lnspect the brake caliper cylinder wall for nicks scratches and other damage If any damage is found replace the caliper with a new one BRAKE CALIPER PISTON Inspect the brake caliper piston surface for any scratches and other damage If any damage is found replace the caliper pis tons with the new ones CALIPER HOLDER lnspect the cali...

Page 334: ...ation DOT 4 pimq Wash the caliper components with fresh brake fluid before reassembly Never use cleaning solvent or gasoline to wash them Do not wipe the brake fluid off after washing the components with a rag When washing the components use the specified brake fluid Never use different types of fluid or cleaning solvent such as gasoline kerosine or the others Replace the piston seals and dust sea...

Page 335: ... caliper R 7 a Install the brake pads 7 59 NOTE Before remounting the caliper push the piston all the way into the caliper lnstallthe brake caliper to the front fork Tighten each bolt to the specifiedtorque Front brake caliper mounting bolt a 39 N m 3 9 kgf m 28 0 Ib ft Front brake hose union bolt I 23 N m 2 3 kgf m 16 5 Ib ft pi Kq 1 The seal washers should be replaced with the new 1 ones to prev...

Page 336: ...607 Dial gauge 11100 mm 09900 20701 Magnetic stand Brake disc removal W7 10 Brake disc installation 7 14 MASTER CYLINDER REMOVAL AND DISAS SEMBLY Remove the rear view mirror and brake lever cover Drain the brake fluid 7 60 Disconnectthe front brake switch coupler I chemically with paint plastics and rubber materials Place a rag underneath the union bolt on the master cylinder to catch any spilt br...

Page 337: ...move the piston and return spring Piston Secondary cup Primary cup Return spring MASTER CYLINDER INSPECTION lnspect the master cylinder bore for any scratches or other dam age lnspect the piston surface for any scratches or other damage lnspect the primary cup secondary cup and dust seal for wear or damage ...

Page 338: ...ton and cups Installthe following parts to the master cylinder Dust boot Snap ring O Secondarycup Piston Primary cup Returnspring When remounting the brake master cylinder O onto the han dlebars align the master cylinder holder s mating surface with punch mark on the handlebars as shown Tighten the front brake master cylinder mounting bolt to the specifiedtorque and first tighten the upper mountin...

Page 339: ...eeder valve Diaphragm Reservoirtank hose 8 6 3 IPad shim 1 IBrake caliper sliding pin Push rod Dust boot Caliper bracket Caliper C1 1 ITEM 1 N m Ikaf m1 Ib ft 1 Dust seal Piston I Rear brake master cylinder mountingbolt Rear brake master cylinder rod lock nut 0 Pad insulator Brake pad Brake caliper mounting bolt Pad mountina pin Q3 IPlug ...

Page 340: ...brake components use fresh brake fluid Never use cleaning solvent A contaminated brake disc or brake pad reduces braking performance Discard contaminated pads and clean the disc with high quality brake cleaner or neutral detergent ICAUTION1 a n d l e brake fluid with care the fluid reacts chemically with paint plastics rubber materials etc and will damagethem severly BRAKE PAD REPLACEMENT Removeth...

Page 341: ...er on the caliper bracket Tighten the caliper mounting bolt aand pad mounting pin to the specified torque Rear brake caliper mounting bolt 22 N m 2 2 kgf m 16 0 Ib ft Rear brake pad mounting pin 17 N m 1 7 kgf m 12 5 Ib ft Install the plug to the specified torque Pad pin plug 2 5 N m 0 25 kgf m 1 8 Ib ft NOTE After replacing the brake pads pump the brake pedal several times in order to operate the...

Page 342: ...REMOVAL AND DISASSEMBLY Drain the brake fluid 7 71 Removethe brake pads 7 69 Place a rag underneath the union bolt to catch any spilt brake fluid Disconnect the brake hose by removingthe brake hose union bolt ICAUTIONI Do not reuse the brake fluid left over from previous servicing and stored for long periods Brake fluid if it leaks will interfere with safe running and discolor painted surfaces Che...

Page 343: ...et 4 r d C Remove the pad spring Removethe spacer and boot from the caliper Remove the brake caliper sliding pin Place a rag over the pistonto prevent it from poppingout and then force out the piston using compressed air 1 I DO not use high pressure air to prevent piston dam I age ...

Page 344: ... caliperwith a new one BRAKE CALIPER PISTON lnspect the brake caliper piston surface for any scratches and other damage If any damage is found replacethe caliper piston with a new one BRAKE CALIPER SLIDING PIN lnspectthe brake caliper sliding pin for wear and other damage If any damage is found replacethe brake caliper sliding pin with a new one lnspect the boot and spacer for damage and wear If a...

Page 345: ... Pay attention to the following points mm5i j Wash the caliper components with fresh brake fluid before reassembly Never use cleaning solvent or gasoline to wash them Apply brake fluid to the caliper bore and piston to be inserted into the bore fi Specification and Classification DOT 4 PISTON SEAL Installthe piston seals as shown in the illustration Installthe piston to the caliper Dust seal Pisto...

Page 346: ...aliper sliding pin securely Installthe brake pad 7 69 Tighten the brake hose union bolt 6 with the brake hose union pipeseated in the cutout on the caliper Rear brake hose routing 9 27 Brake hose union bolt 23 N m 2 3 kgf m 16 5 Ib ft p m m q The seal washers should be replaced with the new ones to preventfluid leakage Bleed air from the system after reassemblingthe cal iper W2 25 MASTER CYLINDER ...

Page 347: ...y wipe off any brake fluid contacting any parts of the motorcycle The fluid reacts chemically with paint plastic and rubber mate rials etc and will damage them severely Remove rod 0 the master cylinder by turning the master cylinder Disconnectthe reservoir hose Removethe connector by removing the snap ring Remove the O ring Replace the O ring with a new one I Pull out the dust boot then remove the...

Page 348: ... components with fresh brake fluid before reassembly Never use cleaning solvent or gasoline to wash them Do not wipe the components with a rag Apply brake fluid to the cylinder bore and all the component to be inserted into the bore aSpecification and Classification DOT 4 Apply brake fluid to the pistonlcup set Installthe following parts Spring Pistonlprimaty cup Push rod Snap ring Dust boot Apply...

Page 349: ...ar brake hose routing W 9 2 7 Tighten the brake hose union bolt D to the specified torque I Brake hose union bolt 23 N m 2 3 kgf m 16 5 Ib ft pmiq The seal washers should be replaced with the new ones to prevent fluid leakage Bleed air from the system after reassembling the master cylinder W 2 2 5 Adjust the brake pedal height W 2 2 4 lnstall the master cylinder Tighten the master cylinder mountin...

Page 350: ...rk the tire with a chalk to indicate the tire position relative to the valveposition Even though the tire is refitted to the original position after repairing puncture the tire may have to be balancedagainsince such a repair can cause imbalance INSPECTION WHEEL Wipe the wheel clean and check for the following Distortionand crack Any flaws and scratches at the bead seating area Wheel rim runout 7 1...

Page 351: ...ore If the seal has abnormal deforma tion replace the valve with a new one VALVE INSTALLATION Any dust or rust around the valve hole must be cleaned off Then install the valve in the rim NOTE Toproperly install the valve into the valve hole apply a special tire lubricant or neutral soapy liquid to the valve Be careful not to damage the lip of valve Wheel Valve lip 3Valve ...

Page 352: ...e tire at the time of removalwith the valve position For installation procedure of tire onto the wheel follow the instructions given by the tire changer manufacturer Bounce the tire several times while rotating This makes the tire bead expand outward to contact the wheel thereby facili tating air inflation Inflate the tire Do not inflate the tire to more than 400 kPa 4 0kgfl cm2 If inflated beyond...

Page 353: ...the case deflate the tire completely and unseat the bead for both sides Coat the bead with lubricant and fit the tire again When the bead has been fitted properly adjust the pressure to specification As necessary adjust the tire balance 1 DOnot run with a repaired tire at a high speed I Tire pressure Solo riding Front 225 kPa 2 25 kgf cm2 33 psi Rear 250 kPa 2 50 kgf cm2 36 psi Dual riding Front 2...

Page 354: ...e to the threaded parts of the special tool DRIVE CHAIN CUTTING Set up the special tool as shown in the illustration Tool body Grip handle Pressure bolt A Pressure bolt B Bar Adjuster bolt with through hole Pin remover Chain holder engraved mark 500 with reamer bolt M5 x 10 NOTE The tip of pin remover should be positioned inside approx imately 5 mm 0 2 in from the end face of pressure bolt A I as ...

Page 355: ...r reuse joint pins O rings and plates After joint pins O rings and plates have been removed from the drive chain the removed joint pins O rings and plates should be discarded and new joint plate O rings and plate must be installed DRIVE CHAIN CONNECTING JOINT PLATE INSTALLATION Set up the special tool as shown in the illustration Tool body Adjuster bolt 3 Grip handle without hole 3Joint plate hold...

Page 356: ...g the bar O to pressthe joint plate over the joint pins Continue pressing the joint plate until the distance between the two joint platescome to the specification Joint plate distance specification DID 18 70 18 90mrn 0 736 0 744 in Should pressingof the joint platebe made excessively beyond the specified dimension the work should be redone using the new joint parts JOINT PIN STAKING Set up the spe...

Page 357: ...d any abnormal condition be found reassem ble the chain link using the new joint parts Stake the joint pin by turning approximately 718 turn the pressure bolt A with the bar until the pin end diameter becomes the specified dimension Pin end diameter specification 0 Adjust the drive chain after connecting it 2 21 DID 5 5 5 8 mm 0 217 0 228 in ...

Page 358: ...RTERMOTOR REMOVAL AND DISASSEMBLY 8 14 STARTERMOTOR INSPECTION 8 15 STARTER MOTOR REASSEMBLY 8 16 STARTER RELAYINSPECTION 8 19 SIDE STAND IGNITIONINTERLOCK SYSTEM PARTS INSPECTION 8 20 IGNITION SYSTEM 8 23 TROUBLESHOOTING 8 23 INSPECTION 8 25 COMBINATION METER 8 29 REMOVAL AND DISASSEMBLY 8 29 INSPECTION 8 30 INDICATORS 8 32 LAMPS 8 36 HEADLIGHT BRAKE LlGHTflAlLLlGHT AND TURN SIGNAL LIGHT 8 36 REL...

Page 359: ... the lead wires lnspect each terminal on the coupler for being loose or bent lnspect each terminal for corrosionand contamination CLAMP Clamp the wire harness at such positions as indicated in WIRE HARNESS ROUTING W 9 1 6to 9 18 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 substi...

Page 360: ... 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 conventionalbattery CONNECTING THE BATTERY When disconnectingterminals from the battery for disassem bly or servicing be sure to disconnect the battery lead wire first When connecting the b...

Page 361: ...tester If the voltage and current values are not known begin mea suring in the highest range When measuring the resistance make sure that no voltage is applied If voltage is applied the tester will be damaged After using the tester be sure to turn the switch to the OFF position ICAUTIONI Before using the multi circuit tester read its instruction manual ...

Page 362: ...OF ELECTRICAL COMPONENTS Horn Fuel injector W4 42 STP sensor W4 38 TP sensor 4 28 STV actuator 4 37 Fuel pump 5 9 Speed sensor W8 35 Ignitioncoil No 1 CKP sensor 4 23 Generator 8 1 0 Gear positionswitch W8 20 Side standswitch W8 20 ...

Page 363: ...Fuse box Turn signallside stand relay W 8 3 7 Starter relay W 8 1 9 O Battery IAP sensor W 4 2 5 IAT sensor W 4 3 3 PAIR control valve 10 7 Regulatorlrectifier 8 1 1 Cooling fan thermo switch W 6 9 Q H02 sensor W 4 4 7 ECT sensor W 4 3 1 Ignition coil No 2 Oil pressure switch 0Starter motor ...

Page 364: ...lectricity Are accessories being installed YES NO Remove accessories Go to Step2 Step2 1 Check the battery for current leaks 8 9 Isthe battery for current leaks OK YES NO Go to Step3 Short circuit of wire harness Faulty electrical equipment Step3 1 Measurethe charging voltage betweenthe battery terminals 8 9 Is the battery charging of voltage OK YES NO Faulty battery Abnormal driving condition Go ...

Page 365: ...tor no loadperformanceOK Step6 1 Inspect the regulatorJrectifier 8 1 1 Is the regulatorlrectifier OK YES NO Go to Step6 Faultv aenerator Step7 1 Inspect the wire harness Is the wire harness OK YES NO YES IFaultv batterv I Go to Step7 Faultv reaulatorlrectifier Battery overcharges Faulty regulatorlrectifier Faulty battery Poor contact of generator lead wire coupler NO Short circuit of wire harness ...

Page 366: ...Do not turn the ignition switch to the ON position when measuringcurrent When checking to find the excessive current leakage remove the couplers and connectors one by one checking each part REGULATEDVOLTAGE Removethe seat 7 4 Start the engine and keep it running at 5 000 rlmin with the dimmer switch turned HI position Measure the DC voltage between the and battery termi nals using the multi circui...

Page 367: ...rator coil resistance 0 2 0 7 Q Black Black Q Black Ground NOTE Whenmaking above test it is not necessary to remove the gen erator GENERATOR NO LOAD PERFORMANCE Removethe right cowling 7 5 Disconnect the generator coupler Start the engine and keep it running at 5 000 rlrnin Usingthe rnulti circuit tester measure the voltage betweenthree lead wires If the tester reads under the specifiedvalue repla...

Page 368: ...s using the multi cir cuit tester as indicated in the table below If the voltage is not within the specified value replace the regulatorlrectifier with a new one 09900 25008 Multi circuit tester set f i j Tester knob indication Diode test fe Unit V 1 4 V and more tester s battery voltage NOTE If the tester reads 1 4 V and below when the tester probes are not connected replace its battery ...

Page 369: ...sp the clutch lever turn on the ignition switch with the engine stop switch in the RUN position and side stand switch in the ON position 2 Listenfor a click from the starter relay when the starter button is pushed Is a click sound heard lYES IGOto t e 2 I INO IGo to Step3 Step2 1 Check if the starter motor runswhen its terminal is connectedto the batteryterminal Do not use a thin wire because a la...

Page 370: ... I Open circuit in wire harness Step4 1 Inspectthe starter relay W8 19 Is the starter relay OK 1YES IPoor starter relav connection INO Faulty starter relay I The starter motor runs when the transmission is neutral with the side stand up or down but does not run when the transmission is in any position other than neutral with the side standdown I Inspectthe side standswitch 8 2 0 Is the side stands...

Page 371: ...ect the starter motor lead wire a Disassemblethe starter motor as shown in the illustration Housing end rear bracket Armature I Thrust stopper Brush spring 2 pcs aStarter motor case O ring 2 pcs O Brush holder Seal ring 2 pcs 0O ring Terminal 3 Washer Washer J Slip washer Housing end front bracket ...

Page 372: ...nd paper and wipe it using a clean dry cloth If there is no undercut scrape out the insulator with a saw blade Insulator Q Segment ARMATURE COIL INSPECTION Check for continuity between each segment and between each segment and the armature shaft using the multi circuit tester If there is no continuity between the segments or there is conti nuity between the segments and shaft replace the armature ...

Page 373: ...e and moisture a Apply SUZUKl SUPER GREASE to the lip of the oil seal 99000 25030 SUZUKI SUPER GREASE A USA 99000 25010 SUZUKI SUPER GREASE A Others Apply a small quantity of SUZUKl MOLY PASTE to the arma ture shaft 99000 25140 SUZUKl MOLY PASTE Install the spacer to brush terminal When installing the brush holder on the rear bracket set the projection of the brush holder into the groove 8of the r...

Page 374: ...e seal rings to starter motor case a When install the rear bracket to starter motor case align the marks on the rear bracket with cut point at the starter motor case Replace the seal rings with the new ones to prevent oil leakage and moisture Installthe washers slip washer and thrust stopper NOTE I The number of washer varies according to individual A 1 181 Installthe front bracket b Align the mar...

Page 375: ... prevent oil leakage 1 Tighten the starter motor housing bolts to the specified torque Starter motor housing bolt 3 5 N m 0 4 kgf m 2 45 lb ft Install the starter motor Installthe clamp as shown First tighten the starter motor lower mounting bolt then tighten the starter motor upper mounting bolt I Connect the starter motor read wire as shown Tighten the nut and fit the cap ...

Page 376: ... multi cir cuit tester If the starter relay clicks and continuity is found the relay is ok rn09900 25008 Multi circuit tester set Tester knob indication Continuity test 4 mmGq Do not apply a battery voltage to the starter relay for five seconds and more since the relay coil may over heat and get damaged Measure the relay coil resistance between the terminals using the multi circuit tester If the r...

Page 377: ... indication Diodetest fe Side stand up NOTE If the tester reads under 1 4 V when the tester probes are not connected replace its battery Side stand down I GEAR POSITION SWITCH Remove the left frame cover 7 5 Disconnect the gear position switch coupler and check the continuity between Blue and BlacWhite with the transmis sion in NEUTRAL rn09900 25008 Multi circuit tester set r mTester knob indicati...

Page 378: ...age Gear position NOTE When connecting the multi circuit tester use the needle pointed probe to the back side of the lead wire coupler and connect theprobes of tester to them Use a needle pointed probe outer diameter being below 0 5 mm toprevent the rubber of the waterproof coupler from dam age Voltage TURN SIGNAUSIDE STAND RELAY REMOVAL AND INSTALLATION The turn signallside stand relay is compose...

Page 379: ... one a09900 25008 Multi circuit tester set i m Tester knob indication Continuitytest 4 Diode Side stand relay Turn signal relay DIODE INSPECTION Measure the voltage between the terminals using the multi cir cuit tester Refer to the following table Unit V Probe of tester to 1 4 V and more 0 4 0 6 a09900 25008 Multi circuit tester set L mTester knob indication Diodetest U NOTE If the multi circuit t...

Page 380: ...n up right position Make sure the fuse is not blown and the battery is fully charged before diagnosing Step1 1 Check the ignition system couplersfor poor connections Is there connection in the ignition switch couplers Step 2 1 Measure the battery voltage between input lead wire OIG and BIW at the ECM with the ignition switch in the ON position Is the voltage OK YES NO lYES IGO to t e 3 I Go to Ste...

Page 381: ... OK Step5 1 lnspect the ignitioncoil 8 26 Is the ignitioncoil OK YES NO 1YES IGo to Step6 1 lmproper spark plug connection Go to Step5 Faulty spark plug INO IFaulty ignitioncoil I Step6 1 Measure the CKP sensor peak voltage and its resistance NOTE The CKPsensor peak voltage inspection is applicable only with the multi circuit tester and peak volt adaptor Is the peak voltage and resistance OK Fault...

Page 382: ...nect the multi circuit tester with peak voltage adaptor as follows No 1 ignitioncoil Probe WhiteIBlueterminal Probe Ground No 2 ignitioncoil Probe Black terminal Probe Ground Peak volt adaptor Q Ignitioncoil No 1 or No 2 New spark plug ECM Battery NOTE Do not disconnect the ignition coil primary wire coupler 09900 25008 Multi circuit tester set Before using the multi circuit tester and peak volt a...

Page 383: ... is lower than the specified values inspect the ignition coil 8 26 IGNITIONCOIL RESISTANCE Lift and support the fuel tank 5 7 Disconnect the spark plug caps and ignition coil lead wires Measure the ignition coil resistance in both the primary and sec ondary windings If the resistance is not within the standard range replace the ignition coil with a new one 09900 25008 Multi circuit tester set u Te...

Page 384: ...sition Pull the clutch lever Pushthe starter buttonand allow the engine to crank for a few seconds and then measure the CKP sensor peak voltage Repeat the above procedure a few times and measure the highest peak voltage I CKP sensor O CKP sensor coupler O ECM coupler Peak volt adaptor 4 Tester knob indication Voltage rnCKP sensor peak voltage 3 7 V and more If the peak voltage is less than the spe...

Page 385: ...the CKP sensor must be replaced and re checked CKP sensor CKP sensor coupler aPeak volt adaptor CKP SENSOR RESISTANCE Measure the resistance between the lead wires and ground If the resistance is not specified value the CKP sensor must be replaced CKP sensor CKP sensor coupler 09900 25008 Multi circuit tester set Tester knob indication Resistance R CKP sensor resistance 130 240 SZ White Green 00 S...

Page 386: ...l W 7 6 Remove the combination meter When disconnecting and connecting the combination meter coupler make sure to turn OFF the ignition switch or electronic parts may get damaged Disassemblethe combinationmeter as follows Do not attempt to disassemble the combination meter unit I Combination meter cover I ICombination meter unit I ...

Page 387: ...r NOTE The pointer may not return to the proper position even turning the ignition switch on under low temperature condition In that case you can reset the pointer to the proper position by following the instruction below 1 With the ADJ switch pressed turn the ignition switch on 2 Keep pushing the ADJ switch for 3 to 5 seconds 3 Push the ADJ switch twice within 1second Reset Complete the operation...

Page 388: ...rip meter indicates when the trip meter is faulty In case the odometer works normaly perform the trip meter reset If the trip meter isn t restored after above reset replace the combination meter unit with a new one TRIP METER RESET PROCEDURE 1 Turn the ignition ON 2 Selectthe trip meter by pushingthe SEL switch 3 Push the ADJ switch for 2 seconds ...

Page 389: ...witch ON Check the display of engine coolant temperature meter as shown below If any abnormality is found replace the combi nation meter with a new one Variable resister I ECT sensor Water tem erateurel39 Cand below I 40 59 C 60 79 C 80 111 C Resistance and more IWater temperateurel 112 119 C 1 120 C and over 1 122 C and over I Engine coolant temperature meter G 0 I 3 n n IResistance 1 0 140 0 116...

Page 390: ...urethe resistance at each fuel level gauge float position If the resistance is incorrect replace the fuel level gauge with a k new one I Float position Resistance I 09900 25008 Multi circuit tester set um ester knob indication Resistance GI 8 F Full E Empty Installthe fuel pump 5 12 Approx 4 R Approx 182R ...

Page 391: ...onds Check the display of fuel meter as shown below If any abnor mality is found replace the combination meter with a new one Resistance 67 0 I More than Fuel level meter OIL PRESSURE INDICATOR INSPECTION NOTE Before inspecting the oil pressure switch check the engine oil level 0 2 13 Disconnect the oil pressure switch lead wire from the oil pres sure switch Turn the ignition switch ON position Ch...

Page 392: ...TION Remove the front wheel 7 1 0 Disconnect the speed sensor coupler W8 35 Remove the speed sensor Installthe speed sensor in the reverse order of removal SPEED SENSOR INSPECTION Connect the four 1 5V dry cells 10 kQ resistance and the tester to the speed sensor lead wire coupler as shown 09900 25008 Multi circuit tester set Q Tester knob indication Voltage Lift and turn the front wheel and check...

Page 393: ...6 0 5 5 W 5 W ONLY E 02 19 BRAKE LlGHTrrAlL LIGHT 12 V 2115 W TURN SIGNAL LIGHT 1 2 v 2 1 W HEADLIGHT BEAM ADJUSTMENT Adjust the headlight beam both vc 0 Vertical adjuster 0 Horizontaladjuster NOTE To adjust the headlight beam adjust then adjust the vertically rtical and horizontal the beam horizontally first ...

Page 394: ...he turn signal light does not illuminate inspect the bulb turn signal switch and circuit connection If the bulb turn signal switch and circuit connection are OK the turn signal relay may be faulty therefore replace the turn signal1 side stand relay with a new one NOTE Make sure that the battery is fully charged Refer to the page 8 22 for the side stand relay and diode inspection Diode Side stand r...

Page 395: ...he ignition switch coupler a Remove the ignition switch mounting bolts with the special tools 09930 11920 Torx bit JT40H 09930 11940 Bit holder When reusing the ignition switch bolt clean thread and apply the THREAD LOCK SUPER 1322 or THREAD LOCK 1342 a99000 32050 THREAD LOCK 1342 USA a99000 32110 THREAD LOCK SUPER 1322 Others ...

Page 396: ...ecting the oilpressure switch check the engine oil level p 2 13 PUSH I 0 I I PUSH I 0 I 0 0 WIRE COLOR BIB1 Blackwith Bluetracer ENGINE STOP SWITCH B Black BMI Blackwith White tracer Br Brown B N Blackwith Yellow tracer Lbl Light blue BIR Blackwith Redtracer Lg Light green GN Green with Yellow tracer 0 Orange OIB Orange with Blacktracer R Red OIR Orange with Redtracer Y Yellow OMI Orange with Whit...

Page 397: ...moved from the vehicleand must be put on the level ground Remove the caps NOTE After filling the electrolyte completely use the removed cap as the sealed caps of battery filler holes Do not remove or pierce the sealed areas of the electrolyte container Insert the nozzles of the electrolyte container into the bat tery s electrolyte filler holes holding the container firmly so that it does not fall ...

Page 398: ... caps do not protrudeabove the upper surfaceof the battery s top cover 1CAUTION1 Never use anything except the specified battery Once the caps have been installed to the battery do not removethe caps Do not tap the caps with a tool such as hammer when installingthem For initial charging use the charger specially designed for MF battery pEEi6iq For charging the battery make sure to use the charger ...

Page 399: ...p charging CAUTlONI When recharging the battery remove the battery from the motorcycle Do not remove the caps on the battery top while recharging Recharging time 1 4 A for 5 to 10 hours or 6 A for one hour Be careful not to permit the charging current to exceed 6 A at any time After recharging wait for more than 30 minutesand check the battery voltage with a multi circuit tester If the battery vol...

Page 400: ...9 22 THROTTLE BODY INSTALLATIONIHOSEROUTING 9 23 COOLING SYSTEM HOSE ROUTING 9 24 FRONT BRAKE HOSE ROUTING 9 26 REAR BRAKE HOSE ROUTING 9 27 FUEL TANK DRAIN HOSE ROUTING 9 28 FUEL TANK INSTALLATION 9 29 PAIR AIR SUPPLY SYSTEM HOSE ROUTING 9 30 SEAT LOCK CABLE ROUTING 9 31 HEAD LAMP SET UP 9 31 ABSORBER HOSE ROUTING 9 32 BATTERY CUSHION INSTALLATION 9 32 SIDE STAND SET UP 9 33 BRAKE PEDAUFOOTREST S...

Page 401: ...coolant tem perature sensor lntake air temperature sensor Ignitionsignal 1 2 Throttle position sensor lead wirelcoupler connection The sensor voltage should be the following 0 1 V S sensor voltage 4 6 V Without the above rangefor 4 sec and more C15 is indicated Engine coolant temperature sensor lead wirelcoupler connec tion The sensor voltage should be the following 0 1 V 5 sensor voltage 4 6 V Wi...

Page 402: ...ltage is 0 2 V and less Gear position sensor wiringlcoupler connection Gearshift cam etc When fuel injector voltage gets 1 3 V and less C32 or C33 is indicated Injector wiing coupler connection power supply to the injector No voltage is applied to the both injectors 11 2for 3 sec after the contact of fuel pump relay is turned ON Or voltage is applied to the both injectors 11 2 when the contact of ...

Page 403: ...ngthe intake manifold Clogged fuel filter or fuel hose Defective fuel pump Defectivefuel pressure regulator Defectivefuel injector Defectivefuel pump relay Defective ECM Open circuitedwiring connections 4 Incorrectfuellair mixture TP sensor out of adjustment Defectivefuel pump Defective fuel pressure regulator Defective TP sensor Defective CKP sensor DefectiveIAP sensor Defective ECM Defective ECT...

Page 404: ... injector improperlyoperating Defective fuel injectors No injection signal from ECM Open or short circuited wiring connection Defective battery or low battery voltage 3 Control circuit or sensor improperly operating Defective ECM Defectivefuel pressure regulator DefectiveTP sensor Defective IAT sensor Defective CKP sensor Defective ECT sensor Defectivefuel pump relay 4 Engine internal parts improp...

Page 405: ...tch plates Distorted clutch plates driven and drive Worn clutch release bearing Weakened clutch dampers 5 Noise seems to come from crankshaft Rattling bearings due to wear Worn and burnt big end bearings Worn and burnt journal bearings 6 Noise seems to come from transmission Worn or rubbing gears Worn splines Worn or rubbing primary gears Worn bearings 7 Noise seems to come from water pump Too muc...

Page 406: ...ement 2 Defectiveair flow system Clogged air cleaner element Defectivethrottle valve Defective secondary throttle valve Sucking air from throttle body joint Defective ECM Imbalancedthrottle valve synchronization 3 Defective control circuit or sensor Low fuel pressure DefectiveTP sensor Defective IAT sensor DefectiveCKP sensor DefectiveGP switch Defective IAP sensor Defective ECM TP sensor out of a...

Page 407: ...se Too much engine oil Defectivefuel pump or ECM Defective CKP sensor and ignition coils Symptom possible causes and remedy 2 Defectivecontrol circuit or sensor Low fuel pressure Defective TP sensor Defective IAT sensor Defective CKP sensor Defective GP switch Defective IAP sensor Defective ECM lmbalanced throttle valve synchronization TP sensor out of adjustment Defective STP sensor and or STVA A...

Page 408: ...iblecauses and remedy Too much engine oil in the engine Worn piston rings or cylinders Worn valve guides Scored or scuffed cylinder walls Worn valves stems Defectivestem seal Worn oil ring side rails SLIPPING CLUTCH Symptom possiblecauses and remedy Weakened clutch springs Worn or distorted pressure plates Distortedclutch plates or pressure plates DRAGGING CLUTCH Symptom possiblecauses and remedy ...

Page 409: ...ATS Symptom possible causes and remedy Not enough engine coolant Radiator core and oil cooler core clogged with dirt or scale Faulty cooling fan Defective cooling fan thermo switch Clogged water passage Air trapped inthe cooling circuit Defectivewater pump Use of incorrect engine coolant Defectivethermostat ENGINE OVERCOOLS Symptom possible causes and remedy Defectivecooling fan thermo switch Extr...

Page 410: ...N TOO SOFT Symptom possible causes and remedy Weakened springs Not enough fork oil Wrong viscous fork oil Improperly set front fork spring adjuster FRONT SUSPENSIONTOO STIFF Symptom possiblecauses and remedy Too viscous fork oil Too muchfork oil Improperly set front fork spring adjuster Bent front axle NOISY FRONT SUSPENSION Symptom possible causes and remedy Not enough fork oil Loose bolts on sus...

Page 411: ...AKING Symptom possible causes and remedy Carbon adhesion on pad surface Tilted pad Damagedwheel bearing Loose front wheel axle or rear wheel axle Worn pads or disc Foreign material in brake fluid Clogged return port of master cylinder EXCESSIVE BRAKE LEVER STROKE Symptom possiblecauses and remedy Air in hydraulic system Insufficient brake fluid Improperquality of brake fluid LEAKAGE OF BRAKE FLUID...

Page 412: ...e stop screw Incorrect gasoline Change Dirty air cleaner element Clean or replace Too cold spark plugs Replacewith hot type plugs SPARK PLUG BECOME FOULEDTOO SOON Symptom possible causes and remedy Worn piston rings Replace Worn piston or cylinders Replace Excessive clearance of valve stems in valve Replace guides Worn stem oil seal Replace SPARK PLUG ELECTRODES OVERHEAT OR BURN Symptom possible c...

Page 413: ...ery Damaged or defective resistor element in the Replace regulatorlrectifier Poorly grounded regulatorlrectifier Clean and tighten ground connection UNSTABLE CHARGING Symptom possible causes and remedy Lead wire insulation frayed due to vibration Repair or replace resulting in intermittent short circuiting Internally short circuited generator Replace Defective regulatorlrectifier Replace STARTER B...

Page 414: ...rectifier and circuit connections and make necessary adjustments to obtain specified charging operation Cell plates have lost much of their active material Replace and correct the charging system as a result of overcharging Internal short circuit in the battery Replace Too low battery voltage Rechargefully Too old battery Replace BATTERY SULFATION Symptom possible causes and remedy Incorrect charg...

Page 415: ...cable Clutch cable Handlebar switch left Water hose High tensioncord Side standswitch j 2 Insert the protrudedsection each on the handle bar switch lead wire coupler ignition switch lead wire coupler and cooling fan motor lead wire cou pler into the respective holes providedon the frame Route the wiring harness under the cowlingfas tener fitted section ...

Page 416: ...to the exhaust side I 1 3 Magneto leadwire Ignitioncoil No 2 t z Iseat lock cable Clamp the turn signal light read wire Passthrough the license light read wire over the Ivalve 4 5 I Cut the clamp end Do not slack the leadwire 6 Pass through the PAIR reedvalve lead wire between the frame and PAIR controlsolenoid ...

Page 417: ...XYGEN SENSOR H02S WIRE ROUTING FOR E 02 19 mIH02 sensor For E 02 19 I Route the H02 sensor lead wire along the fuel J w H02 sensor lead wire Wiring harness I L 1the swingarm tank drain hose Pass through the H02 sensor lead wire forward ...

Page 418: ...9 19 ENGINE ELECTRICAL PARTS SET UP n Generator lead wirevl cover Starter motor lead wire mounting 1 45 and less nut I ICKP sensor set bolt First tighten the starter motor lower mount in bolt U 1 ITEM 1 N m I knf m 1 Ib ft I ...

Page 419: ...LEAD WIRE ROUTING 1 0ISpeed sensor lead wire I 1 ICut the clamp end 1 Route speed sensor lead wire to come outside the brake hose guide I IBrake hose Route speed sensor lead wire on inside of front fork outer tube boss I I m IS e e d sensor I ...

Page 420: ...SERVICING INFORMATION 9 21 THROTTLE CABLE ROUTING I IThrottle cable No 1 I 1Wiring harness Throttle cable No 2 Front brake hose 1 IFit the cable boots securely ...

Page 421: ...h wiring harness Reserve tank bracket Route left handle switch wiring harness in the I 2 Clutch cable Throttle cable auide groove of radiator shroud Route left handle switch wiring harnessto come 3 4 outside throttle and clutch cables Route clutch cable insidethe guide Route clutch cable insidethe auide IRadiator shroud I ...

Page 422: ... Pass through the vacuum hose inside the PAIR 1 2 1hose I IAir cleaner box 1 3 1 E 33 Only IAT sensor Vacuum damper I IOutlet tube clamp I 1 Intake pipe clamp To canister For E 33 Fuel pump assembly ECT sensor TP sensor 4 5 6 H02 sensor clamp For E 02 19 Matchingmark Yellow Matchingmark White ...

Page 423: ...hing mark White I Matchingmark Yellow Clamp the water drain hose and oil pressure switch lead wire Fill the bearing with engine oil until engine oil comes out from the hole of the be bearing hous ing I Oil filter Clamp end must face downward 6 7 Clamp bolt head must face upward Clamp bolt head must face downward ...

Page 424: ...ion point I IUnion 1 4 1Clamp bolt head must face downward I I I V Iclamp 2 3 Clamp Jiaale valve I Matchingmark White Marking Yellow Radiator hose Marking 5 c Clamp bolt head must face left side Leave clearance between bulge of union and ...

Page 425: ...fter the brake hose union has contactedthe stopper tighten the union bolt After positioningthe brake hose junction with the stopper tighten the bolt After positioningthe clamp with the stopper tighten the damp bolt 4 5 Assemble the brake hose firmly Clamp the brake hose firmly ...

Page 426: ...OUTING A A IFrame Istopper 1 2 Clamp ends should face forward White paint faces outside Brakehose Brake hose guide 3 4 After the brake hose union has contacted the stopper tighten the union bolt Pass through the brake hose outside the seat rail ...

Page 427: ...9 28 SERVICING INFORMATION FUEL TANK DRAIN HOSE ROUTING ...

Page 428: ...SERVICINGINFORMATION 9 29 FUEL TANK INSTALLATION I IFuel tank side cushion I IAlign the front end of fuel tank center shield with I 1this position 0 Fuel tank center shield ...

Page 429: ...9 30 SERVICING INFORMATION PAIR AIR SUPPLY SYSTEM HOSE ROUTING 1 Matching mark White I 1Pass the PAIR hose between the cylinder head I 1 1 I I 1cover and intake i e I I I I IaIMatchina mark Yellow I ...

Page 430: ...BLE ROUTING VlEW OF TOP VlEW OF LEFT I 1Seat lock cable I HEAD LAMP SET UP I IAdhere cushion along the ridge line of lens I IRight and left cushions shall be attached sym I I 2 Start to adhere cushion from the corner of lens J Imetrically I ...

Page 431: ... 32 SERVICING INFORMATION ABSORBER HOSE ROUTING BATTERY CUSHION INSTALLATION I I VIEW OF LEFT 1 0 81Battery protector I 1 Adherebattery protector at the upper end 1 Absorber hose Clamp Rear fender Front ...

Page 432: ...SERVICING INFORMATION 9 33 SIDE STAND SET UP U ITEM I N m Ikgf m I Ib ft 1 0 1 100 I 10 0 1 72 5 1 BRAKE PEDAUFOOTREST SET UP Footrest Brake light switch Pin E rina ...

Page 433: ...9 34 SERVICINGINFORMATION ENGINE CAP INSTALLATION VlEW OF LEFT u VlEW OF RIGHT 1remove looseness I 0 1 Engine cap Push the center of cap so as to thoroughly ...

Page 434: ...SERVICING INFORMATION 9 35 FOOTREST SET UP HANDLEBAR BALANCER INSTALLATION NOTE After installing the RH balancer weight check that throttle grip rotate smoothly by turning it ...

Page 435: ...000mm 1 mm 19900 21304 rl blockset 100 rnm 19910 20116 Zonrod holder 19900 20202 Micrometer 25 50 mm 19900 20607 Dial gauge 1 l00 mm 10 mm Plastigauge 19900 20204 Micrometer 1 7 5 100 mm 19900 20701 Magnetic stand 19900 22403 Small bore gauge 1 18 35 mm 19913 13121 Vacuum balancer 3auge 19900 20205 Ulicrometer 0 25 mm 19900 20803 19900 20806 rhickness gauge 19900 25008 blulticircuit tester se 1991...

Page 436: ... 39916 21111 rlalve seat cutter set 39916 34580 Valve guide reamer 10 8 mm 19915 40610 3il filter wrench 19915 77331 Meter for high pressure 19916 20640 Solid pilot N 100 4 5 19916 43210 rlalve guide nstallerlremover 09915 64512 Compression gauge 09916 10911 Valve lapper set 09916 22430 Valve seat cutter heac N 128 09916 53330 Attachment 09915 74511 Oil pressure gauge set 09916 14510 Valve lifter ...

Page 437: ...t wrench set 09930 30450 Rotor remover 09940 14960 Steering stem nut wrench socket 09920 53740 Clutch sleeve hub holder 09930 11920 Torx bit JT40H 09930 44530 Rotor holder 09940 14990 Enginemountingthrust adjuster socket wrench 3earing removerset 19930 11940 3it holder 19930 82720 Mode select switch 19940 34520 T Handle 09924 84510 Bearing installer set 09930 11950 Torx wrench 09940 14911 Steering...

Page 438: ... emover D9940 40220 Fuelpressuregauge hose attachment D9943 74111 Front fork oil level gauge 19940 52861 ront fork oil seal nstaller 19944 28320 iexagon bit 19 mm Spring scale 19941 34513 3earinglsteering ace installer set When order the special tool please confirm whether it is available or not ...

Page 439: ...ver plug Valve timing ins ection l u q 9 5 36 0 1 O 1 O 10 70 Generator rotor bolt I Starter clutch bolt I ear shift cam stopper bolt I 10 1 1 0 1 7 0 7 0 7 0 10 23 Generator stator set bolt CKP sensor set bolt 1 O 7 0 120 25 7 0 50 5 1 O 2 3 11 6 5 Gearshift cam stopper plate bolt Gearshift arm stopper bolt 1 Generator cover bolt M 61 1 10 1 1 0 1 7 0 7 0 16 3 12 0 1 Oil gallery plug M 81 1 18 1 ...

Page 440: ...ne mountinathrust adiuster Cooling fan thermo switch ECT sensor 93 35 25 Fuel pump mounting bolt Fuel delivery pipe mountingscrew 17 19 Coolingfanlhorn mountingbolt Thermostat case bolt IOil cooler hose union bolt 23 2 3 16 5 8 5 9 3 12 3 5 2 5 10 5 0 Ioilcooler mounting bolt 1 I I FI SYSTEM PARTS 67 5 1 2 25 5 18 0 1 7 1 9 8 10 ITEM Nmm kgf m Ib ft I 12 5 13 5 1 O 0 5 7 0 10 7 0 3 7 0 8 1 0 1 O 6...

Page 441: ...6 5 16 5 Rear caliper air bleeder valve Brake disc bolt Front and Rear Rear brake caliper mountina bolt IRear brake master cvlinder rod lock nut 1 18 I 1 8 1 13 0 1 6 23 22 Rear brake pad mounting pin Rear brake pad mounting pin plug Rear brake master cvlinder mountina bolt 1Front footrest bracket mounting bolt 1 25 1 2 5 1 18 0 1 ISwingarm pivot shaft I 15 1 1 5 1 11 0 I 0 6 2 3 2 2 17 2 5 10 4 3...

Page 442: ...t BoltDiameter mm 4 5 6 8 10 12 14 16 18 7 marked bolt Conventional or 4 marked bolt 7 marked bolt Ib ft 1 O 2 0 4 0 9 5 21 O 32 5 47 0 76 0 115 5 N m 1 5 3 5 5 13 29 45 65 105 160 kgf m 0 15 0 3 0 55 1 3 2 9 4 5 6 5 10 5 16 0 Ib ft 1 5 3 0 7 0 16 5 36 0 61 5 97 5 152 0 173 5 N m 2 3 4 5 10 23 50 85 135 210 240 kgf m 0 23 0 45 1 O 2 3 5 0 8 5 13 5 21 O 24 0 ...

Page 443: ...out IValve head thickness Valve seat width IValve head radial runout Valve spring free length IN EX Valve spring tension IN EX EX I Unit mm ir STANDARD IN I LIMIT IN EX EX I IN EX I 0 10 0 20 0 004 0 008 0 20 0 30 0 008 0 012 IN I EX I IN EX I IN EX IN EX I IN EX IN EX 1 0 35 0 014 INNER I OUTER I 0 5 0 02 INNER OUTER at length 29 9 mm 1 I8 in 17 0 19 6 kgf 37 48 43 21 Ibs at length 33 4 mm 1 31in...

Page 444: ...Camshaft journal holder I D Camshaft journal O D Camshaft runout LIMIT 35 18 1 3850 STANDARD IN EX IN EX I I 1 IN IN EX IN EX Cam chain in at arrow 3 I I 35 48 35 53 1 3968 1 3988 0 032 0 066 0 0013 0 0026 22 012 22 025 0 8666 0 8671 16th in 1 Cylinder head distortion 0 150 0 0059 21 959 21 980 0 8645 0 8654 1 0 05 0 10 0 004 ...

Page 445: ...diam 13 17kgflcmz 185 242 psi Cvlinder distortion Measure at 20 mm 0 79 in from the skirt end Piston ring free end gap Piston ring end gap 2nd Piston ring to groove clearance I lStI Ist Approx 1 1 0 43 Piston ring groove width Approx 9 5 0 37 Oil 2 01 2 03 0 0791 0 0799 Piston ring thickness Piston pin bore Piston pin O D 1s t 2nd 1 17 1 19 0 0461 0 0469 0 97 0 99 0 0382 0 0390 20 002 20 008 0 787...

Page 446: ...0 827 42 17 42 22 1 660 1 662 0 032 0 056 Crankshaft runout 0 7890 0 5 0 02 0 080 0 0013 0 0022 37 976 38 000 0 0031 I I Below 400 kPa 4 0 kgf cm2 57 psi 1 1 ITEM Oil pressure at 60 C 140 OF CLUTCH Unit mm in STANDARD Above 100 kPa 1 0 kgf cm2 14 psi I ITEM 1 STANDARD LIMIT 1 LIMIT Clutch cable play Clutch release screw Drive plate thickness Drive plate claw width IClutch spring free length 10 15 ...

Page 447: ...3 47115 1 ITEM Gear ratios STANDARD LIMIT Low Shift fork groove width 5th TOP Shift fork to groove clearance Shift fork thickness 2 461 32113 Drive chain 0 961 25126 0 851 23127 0 1 0 3 0 004 0 012 0 50 0 020 Type Links Drive chain slack on side stand DlD525V8 116 links Gearshift lever height 20 pitch length 25 0 98 319 4 12 57 20 30 0 79 1 18 ...

Page 448: ... Approx 0 322 kR I 95 125 kPa 0 95 1 25 kgf cm2 13 5 17 8 psi OFF ON Approx 98 C 208 O F ON OFF Approx 92 O C 198 O F Jse an antifreeze coolantcompatiblewith aluminum adiator mixed with distilled water only at the ratio f 50 50 Reserve Approx 250 ml tank side 0 5310 44 US lmp qt Engine Approx 1650 ml side 3 4912 90 US lmp qt for 10 sec at 300 kPa 3 0 kgf cm2 43 psi INJECTOR FUEL PUMP FUEL PRESSURE...

Page 449: ...or resistance ITO sensor resistance I 19 1 19 7kR I I P W 0 BIBr Approx 2 45kR at 20 C 68O F ISTP sensor input voltage I 4 5 5 5V 1 I IAT sensor input voltaae TO sensor voltage GP switch voltage lniector voltaae 4 5 5 5V I STV actuator resistance I 7 14R 1 I Normal Leaning 65 STP sensor resistance STP sensor output voltage IPAIR solenoid valve resistance I 20 24 kQ at 20 C 68O F I I THROTTLE BODY ...

Page 450: ... I crankina W G O tap Otap 130 240 R 24 37 kR IIgnition coil primary peak voltage I 150 V and more I Primary O tap Plug cap IGenerator coil resistance 0 2 0 7 R 2 5 R IGenerator Max output Approx 375 W at 5 000 rtrnin IGenerator no loadvoltage When cold 60 V AC and more at 5 000 rtmin Fuse size Headlight 14 0 15 5 V at 5 000 rtmin 3 6 R YTX12 BS Regulatedvoltage Starter relay resistance Battery Ty...

Page 451: ...CATION l u r n signal indicator light LED t I E 03 24 28 33 1 2 V 5 W x 2 t t t PositionJParkinglight I High beam indicator light I LED I t I Others Brake lightrraillight Turn signal light License liaht 12 V 2115 W x 2 12V21 W 1 2 V 5 W Neutral indicator light Oil pressure1Coolanttemp Fuel injection warning LED LED t t ...

Page 452: ...m Brakecaliper cylinder bore 5 0 20 5 0 20 Front Rear I Front I 4 5 0 18 4 5 0 18 15 870 15 913 0 6248 0 6265 Front 1 Rear I 0 3 0 012 13 957 13 984 0 5495 0 5506 Brake caliper piston diam 15 827 15 854 0 6231 0 6242 1 Front I Brake fluid type I DOT 4 I Rear Wheel rim runout I Axial I 38 098 38 148 1 4999 1 5019 Wheel rim size Wheel axle runout Rear I Front 1 Radial Front 17 M C x MT4 00 19 M C x ...

Page 453: ...Front fork stroke Front fork spring free length Front fork spring adjuster 1 3 groove from TopISpring adjuster height 9 mm I 2 0 0 08 Front fork oil level without spring outer tube fully compressed 0 35 in STDISPEC 150 5 9 444 1 17 5 Front fork oil type LIMIT 435 17 1 143 5 63 SUZUKI FORK OIL SS 08 or eauivalent fork oil Front fork oil capacity each leg 524 ml 17 7118 5 US lmp oz Rear shock absorb...

Page 454: ...containing MTBE Methyl Tertiary Butyl Ether less than 10 ethanol 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 22 L 5 814 8 USIlrnp gal SAE 10 W 40 API SF or SG Change I 2 300 ml 2 412 0 U S A D at Filter change I 2 700 ml 2 912 4 USllmr at NOTE Overhaul Others 3 100m...

Page 455: ...EVAPORATIVE EMISSION CONTROL SYSTEM Only for E 33 10 5 PAIR AIR SUPPLY SYSTEM INSPECTION 1 0 6 HOSES 1 6 PAIR REED VALVE 10 6 PAIR CONTROL SOLENOID VALVE 1 7 PAIR AIR SUPPLY SYSTEM HOSE ROUTING 10 8 HEATED OXYGEN SENSOR H02S WIRE ROUTING E 02 19 10 8 EVAPORATIVE EMlSSlON CONTROL SYSTEM INSPECTION Only for E 33 1 0 10 HOSES 10 10 EVAP CANISTER 10 10 FUEL SHUT OFF VALVE 10 10 EVAP CANISTER HOSE ROUT...

Page 456: ...ped 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 I IFuel injector 1 0I RELIEVED FUEL I 2 Fuel filter For high pressure Fuel pressure reaulator BEFORE PRESSURIZEDFUEL PRESSURIZEDFUEL ...

Page 457: ...tem Blow by gas in the engine is constantly drawn into the crank case which is returned to the combustion chamber through the breather hose air cleaner and throttle body I 1Air cleaner box 1 1 I 0IBLOW BY GAS 1 PAIR reed valve 1Breather hose I IPAIR control solenoid valve I 8 I FRESH AIR FUEUAIR MIXTURE ...

Page 458: ...ALYST sys tem Except for E 03 24 and 28 The fresh air is drawn into the exhaust port with the PAlR solenoid valve and PAlR reed valve The PAlR solenoid valve is operated by the ECM and the fresh air flow is controlled according to the TPS ECTS IATS and IAPS ECM Air cleaner box Injector PAIR reedvalve PAIR control solenoid valve PAIR reed valve 8 FRESH AIR EXHAUST GAS ...

Page 459: ...y person AMONG THOSE ACTS PRESUMEDTO CONSTITUTETAMPERING ARE THE ACTS LISTED BELOW Removing or puncturingthe 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 syste...

Page 460: ...ar or damage lnspect that the hoses are securely connected PAlR REED VALVE Remove the PAlR reed valve cover 3 36 lnspect the reed valve for the carbon deposit If the carbon deposit is found in the reed valve replace the PAlR reed valve with a new one Installation is in the reverse order of removal ...

Page 461: ...ntrol solenoid valve terminals and check the air flow If air does not flow out the solenoid valve is in normal condi tion Check the resistance between the terminals of the PAlR con trol solenoid valve Resistance 20 24 at 20 OW68 O F a09900 25008 Multi circuit tester set m Tester knob indication Resistance a If the resistance is not within the standard range replace the PAlR control solenoid valve ...

Page 462: ...10 8 EMISSIONCONTROL INFORMATION PAIR AIR SUPPLY SYSTEM HOSE ROUTING 9 30 HEATED OXYGEN SENSOR H02S WIRE ROUTING E 02 19 9 18 ...

Page 463: ...the terminals white white of the H02 sensor Resistance 4 5 R at 23 Cn3 4 O F 09900 25008 Multi circuit tester set L g Tester knob indication Resistance R If the resistance is not within the standard range replace the H02 sensor with a new one NOTE Temperatureof the sensor affects resistance value largely Make sure that the sensor heater is at correct temperature Connect the H02 sensor coupler secu...

Page 464: ...nspect the fuel shut off valve operation in the following proce dure Remove the fuel shut off valve When air is blown into the fuel shut off valve with its side positioned upward the air can pass through to the canister side When air is blown into the fuel shut off valve with its side positionedsideways the air cannot pass through to the canis ter side If the fuel shut off valve operates otherwise...

Page 465: ... clamp ends should face inside 1 61Clamp ends should face down side I 0 I Purge hose Wiring harness EVAP canister Frame 2 3 4 5 Clamp ends should face outside White paint mark should face top side Passthrough the purge hose betweenthe frame and wiring harness To throttle bodv ...

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