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Suzuki 2005 DL650K5, Service Manual

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ENGINE     3-71

• Install the snap ring 

 

2

.

GEARSHIFT SHAFT/GEARSHIFT ARM

DISASSEMBLY

• Remove the following parts from the gearshift shaft/gearshift

arm.

 

1

 Washer

 

5

 Washer

 

2

 Snap ring

 

6

 Plate return spring

 

3

 Gearshift shaft return spring

 

7

 Gearshift cam drive plate

 

4

 Snap ring

INSPECTION

Check the gearshift shaft/gearshift arm for wear or bend.
Check the return springs for damage or fatigue.

REASSEMBLY

• Install the following parts to the gearshift shaft/gearshift arm

as shown in the right illustration.

 

1

 Washer

 

5

 Washer

 

2

 Snap ring

 

6

 Plate return spring

 

3

 Gearshift shaft return spring

 

7

 Gearshift cam drive plate

 

4

 Snap ring

NOTE:
When installing the gearshift shaft return spring 

 

3

, position the

stopper 

 

B

 of the gearshift arm between the shaft return spring

ends 

 

A

.

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Summary of Contents for 2005 DL650K5

Page 1: ...This manual has been prepared on the basis of the latest specifications at the time of publi cation If modifications have been made since then differences may exist between the con tent of this manual...

Page 2: ...03 ENGINE book Page 105 Tuesday February 28 2006 3 03 PM P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6...

Page 3: ...11 12 13 SUPPLEMENTS DL650K5 05 MODEL DL650K6 06 MODEL DL650 AK7 07 MODEL 14 15 DL650 AK9 09 MODEL DL650 AK8 08 MODEL 16 WIRING DIAGRAM P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6...

Page 4: ...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 exploded view Work instructions and other service information...

Page 5: ...a ratio of 1 1 Use fork oil 99000 99001 SS8 Apply SUZUKI SUPER GREASE A 99000 25030 USA 99000 25010 Others Apply or use brake fluid Apply SUZUKI MOLY PASTE 99000 25140 Measure in voltage range Apply S...

Page 6: ...ing Unit D DC Direct Current DMC Dealer Mode Coupler DOHC Double Over Head Camshaft DRL Daytime Running Light E ECM Engine Control Module Engine Control Unit ECU FI Control Unit ECT Sensor Engine Cool...

Page 7: ...kcase Breather R RH Right Hand ROM Read Only Memory S SAE Society of Automotive Engineers STC System Secondary Throttle Control System STCS STP Sensor Secondary Throttle Position Sensor STPS ST Valve...

Page 8: ...peed Evaporative Emission Evaporative Emission Canister F Fan Control Fuel Level Sensor Fuel Pump G Generator Ground ACL BARO B CMP Sensor CKP Sensor DLC DTM DTC EI ECM ECL ECT RPM EVAP EVAP Canister...

Page 9: ...le Valve Actuator T Throttle Body Throttle Body Fuel Injection Throttle Position Sensor V Voltage Regulator Volume Air Flow ISC IC ICM IAT MIL MAP MAF OBD OL PROM PAIR Purge Valve RAM ROM AIR STCS STV...

Page 10: ...wn with White tracer G B Green with Black tracer G Y Green with Yellow tracer Gr B Gray with Black tracer Gr R Gray with Red tracer Gr W Gray with White tracer O B Orange with Black tracer O Bl Orange...

Page 11: ...NE 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 WATER FOR MIXING 1 5 ANTI FREEZE ENGINE COOLANT 1 6 LIQUID AMOUNT OF WATER ENGINE COOLANT 1...

Page 12: ...nd 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 pro...

Page 13: ...r 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...

Page 14: ...istering the 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 t...

Page 15: ...rding to the right chart BRAKE FLUID Specification and classification DOT 4 FRONT FORK OIL Use fork oil SS8 or an equivalent fork oil ENGINE COOLANT Use an anti freeze engine coolant compatible with a...

Page 16: ...still necessary to allow the moving parts to BREAK IN before subjecting the engine to maximum stresses The future performance and reliability of the engine depends on the care and restraint exercised...

Page 17: ...RAL INFORMATION 1 7 CYLINDER IDENTIFICATION The two cylinders of this engine are identified as NO 1 and NO 2 cylinder as viewed from front to rear 5 4 NO 2 NO 1 P a r t S h a r k c o m 8 7 7 9 9 9 5 6...

Page 18: ...l A For E 03 28 33 3 Vacuum hose routing label A For E 33 4 Fuel caution label A For E 02 24 5 Manual notice label A For E 03 33 6 Frame caution plate A A 7 Screen warning label A A 8 Steering warning...

Page 19: ...twin Number of cylinders 2 Bore 81 0 mm 3 189 in Stroke 62 6 mm 2 465 in Displacement 645 cm 39 4 cu in Compression ratio 11 5 1 Carburetion Fuel injection Air cleaner Non woven fabric element Starter...

Page 20: ...6 0 kC 10 Ah 10 HR Generator Three phase A C generator Main fuse 30 A Fuse 15 15 10 10 15 15 A Headlight 12 V 60 55 W 2 H4 Position Parking light 12 V 5 W 2 Except E 03 24 33 Brake light Taillight 12...

Page 21: ...llowing codes stand for the applicable country ies and area s MODEL CODE COUNTRY or AREA DL650 E 02 E 03 E 19 E 24 E 28 E 33 U K U S A Except for california EU Australia Canada California U S A DL650...

Page 22: ...P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6...

Page 23: ...TER 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 COOLING SYSTEM 2...

Page 24: ...torcycles that are used under severe conditions PERIODIC MAINTENANCE CHART Interval Item km 1 000 6 000 12 000 18 000 24 000 miles 600 4 000 7 500 11 000 14 500 months 2 12 24 36 48 Air cleaner elemen...

Page 25: ...T Tighten Interval Item km 1 000 6 000 12 000 18 000 24 000 miles 600 4 000 7 500 11 000 14 500 months 2 12 24 36 48 Brake fluid I I I I Replace every 2 years Tires I I I I Steering I I I Front forks...

Page 26: ...ean 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 o...

Page 27: ...ry 6 000 km 4 000 miles 12 months and replace every 18 000 km 11 000 miles 36 months Always use air pressure on the throttle body side of the air cleaner element If air pressure is used on the other s...

Page 28: ...iator lower side to forward Remove the spark plug cap 2 NOTE Be careful not to damage the radiator fins Remove the spark plug with the special tool 09930 10121 Spark plug socket wrench set Inspect eve...

Page 29: ...e the plug gap with a thickness gauge If out of specifi cation adjust it to the following gap Spark plug gap A Standard 0 7 0 8 mm 0 028 0 031 in 09900 20803 Thickness gauge ELECTRODES CONDITION Check...

Page 30: ...fts 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 taken when each cylinder is...

Page 31: ...between the 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 3 4 turns to set the No 2 Rear...

Page 32: ...to 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 surfac...

Page 33: ...41 0 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 2 10 2 15 2 20 0 46 0 50 1 55 1 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 51 0 55 1 60 1 65 1 70 1 75 1 80 1...

Page 34: ...20 0 46 0 50 1 55 1 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 51 0 55 1 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 56 0 60 1 65 1 70 1 75 1 80 1 85 1 90 1...

Page 35: ...in oil by removing the drain plug 1 and filler cap 2 Tighten the drain plug 3 to the specified torque and pour fresh oil through the oil filler The engine will hold about 2 7 L 2 9 2 4 US Imp qt of oi...

Page 36: ...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 h...

Page 37: ...4 0 mm 0 08 0 16 in at the throttle grip Tighten the lock nut 5 while holding the adjuster 7 Third step While holding the throttle grip at the fully closed position slowly turn out the adjuster 4 of t...

Page 38: ...cable adjuster 2 to obtain a slack of 1 0 mm 0 04 in Tighten the lock nut 1 securely THROTTLE VALVE SYNCHRONIZATION Inspect the throttle valve synchronization periodically 5 32 EVAPORATIVE EMISSION CO...

Page 39: ...hat position slowly turn the adjuster screw 3 in until it stops Turn the adjuster screw 3 out 1 4 rotation and tighten the lock nut 4 Loosen the lock nuts 5 turn the cable adjuster 6 to obtain 10 15 m...

Page 40: ...the water drain bolt A to the specified torque Water drain bolt 13 N m 1 3 kgf m 9 5 lb ft Pour the specified engine coolant up to the radiator inlet Bleed the air from the engine coolant circuit as...

Page 41: ...the air trapped in the thermostat case 1 Add engine coolant up to the radiator inlet Repeat the above procedure until bleed no air from the radia tor inlet Close the radiator cap 2 securely After war...

Page 42: ...l Loose pins Excessive wear Damaged rollers Improper chain adjustment Dry or rusted links Missing O ring seals Kinked or binding links 1 O ring 2 Grease If any defects are found the drive chain must b...

Page 43: ...m 0 8 1 2 in of slack A in the middle between engine and rear sprockets The ends of left and right spacers must be at the same position on the scales B to ensure that the front and rear wheels are cor...

Page 44: ...lene gasoline or any similar fluids These fluids have too great a dissolving power for this chain and what is more important they can damage the O rings or seals confining the grease in the bush to pi...

Page 45: ...erent types of fluid such as silicone based or petro leum based Do not use any brake fluid taken from old used or unsealed containers Never re use brake fluid left over from the last servicing or stor...

Page 46: ...etighten the lock nut 1 to secure the push rod 2 in the proper position Brake pedal height A 20 30 mm 0 79 1 18 in Rear brake master cylinder rod lock nut 1 17 N m 1 7 kgf m 12 5 lb ft REAR BRAKE SWIT...

Page 47: ...ar 6 N m 0 6 kgf m 4 3 lb ft Front brake Bleed the 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...

Page 48: ...ars and safe running Overtight steering prevents smooth turning of the handlebars and too loose steering will cause poor stability Check that there is no play in the steering stem while grasping the l...

Page 49: ...ssary 7 45 EXHAUST PIPE BOLT Tighten the exhaust pipe bolts and muffler mounting bolts to the specified torque Muffler mounting bolt nut A 23 N m 2 3 kgf m 16 5 lb ft Exhaust pipe bolt BCD 23 N m 2 3...

Page 50: ...23 2 3 16 5 8 Front brake master cylinder mounting bolt 10 1 0 7 0 9 Front brake caliper mounting bolt 39 3 9 28 0 0 Brake hose union bolt 23 2 3 16 5 A Air bleeder valve Front 7 5 0 75 5 5 B Air blee...

Page 51: ...PERIODIC MAINTENANCE 2 29 P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6...

Page 52: ...kPa 13 kgf cm 185 psi even when they measure 1 100 kPa 11 kgf cm 156 psi and more COMPRESSION TEST PROCEDURE NOTE Before testing the engine for compression pressure make sure that the cylinder head bo...

Page 53: ...r 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 in the following manner Remove the main oil gallery plug 1...

Page 54: ...P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6...

Page 55: ...36 CAMSHAFT CAMSHAFT JOURNAL 3 37 CYLINDER HEAD 3 40 CYLINDER 3 50 PISTON AND PISTON RING 3 51 CONROD AND CRANKSHAFT 3 53 CRANKCASE 3 57 CRANKSHAFT JOURNAL BEARING 3 61 CRANKCASE BEARING AND OIL SEAL...

Page 56: ...3 33 3 85 Clutch release 3 5 3 17 Starter idle gear 3 26 3 93 PARTS REMOVAL INSTALLATION Clutch 3 27 3 90 Primary driven gear 3 29 3 70 3 70 3 90 Primary drive gear 3 31 3 87 Oil pump 3 29 3 89 Gearsh...

Page 57: ...ng steps Reinstall the engine by reversing the removal procedure Drain the engine oil 2 13 Drain the engine coolant 2 18 Remove the seat 7 4 Disconnect the battery lead wire 1 Remove the fuel tank 2 5...

Page 58: ...caps Remove the left side frame cover 7 5 Disconnect the gear position switch lead wire coupler 1 Disconnect the generator lead wire coupler 2 and CKP sen sor lead wire coupler 3 Remove the ECT senso...

Page 59: ...clutch push rod 6 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 A of the clutch release...

Page 60: ...oosen the chain adjusters 2 Remove the engine sprocket 3 Disconnect the engine ground lead wire 4 Disconnect the HO2 sensor lead wire coupler 5 and release the HO2 sensor lead wire from the clamp 6 Re...

Page 61: ...the front exhaust pipe mounting bolts 2 Remove the front exhaust pipe 3 Loosen the rear exhaust pipe mounting bolts Remove the muffler Remove the right footrest bracket mounting bolts Remove the oil...

Page 62: ...the engine with an engine jack Remove the engine mounting nut 3 and bolt 4 Loosen the engine mounting thrust adjuster lock nut with the special tool 09940 14990 Engine mounting thrust adjuster socket...

Page 63: ...oil lead wires 2 Disconnect the water hose clamp 3 Remove the engine mounting nut Loosen the engine mounting thrust adjuster lock nut 09940 14990 Engine mounting thrust adjuster socket wrench Loosen t...

Page 64: ...oosen the pinch bolt 1 Gradually lower the engine assembly by removing the bolt 2 3 Be careful not to damage the frame and engine when removing the engine from the frame P a r t S h a r k c o m 8 7 7...

Page 65: ...he 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 FWD RH LH RH LH ITEM N m kgf m l...

Page 66: ...to the crankcase properly as shown Install the left engine mounting bracket 2 Apply THREAD LOCK to the engine mounting bracket bolts Tighten the engine mounting bracket bolts to the specified torque E...

Page 67: ...ck nuts to the specified torque with the special tool 09940 14990 Engine mounting thrust adjuster socket wrench Engine mounting thrust adjuster lock nut 45 N m 4 5 kgf m 32 5 lb ft After tightening th...

Page 68: ...ghten the union bolt to the specified torque Oil cooler union bolt 23 N m 2 3 kgf m 16 5 lb ft Install the new gaskets Apply THREAD LOCK to the muffler mounting bolt 99000 32050 THREAD LOCK 1342 P a r...

Page 69: ...ke pedal height A Standard 20 30 mm 0 79 1 18 in Install the gearshift arm as shown Gearshift arm angle A Approx 63 6 Apply PARMATEX 1372 Apply PARMATEX 1372 ITEM N m kgf m lb ft ABCD 23 2 3 16 5 63 6...

Page 70: ...hten the engine sprocket nut 1 to the specified torque Engine sprocket nut 145 N m 14 5 kgf m 105 lb ft Bend the lock washer Adjust the drive chain slack 2 21 Tighten the rear axle nut 2 to the specif...

Page 71: ...0 25140 SUZUKI MOLY PASTE Assemble the clutch release so that the lever arm A will be angle of 80 degree with axle B Adjust the clutch cable play 2 17 NOTE After installing the clutch release make sur...

Page 72: ...e harness cables and hoses properly 9 16 Adjust the following items Engine oil 2 14 Engine coolant 2 19 Engine idle speed 2 15 Throttle cable play 2 15 Clutch cable play 2 17 Throttle body synchroniza...

Page 73: ...the thermostat case 3 along with the hoses 4 NOTE Refer to the section 6 for their servicing Remove the water unions 5 and intake pipes 6 Identify the position of each removed part Organize the parts...

Page 74: ...ove the rear exhaust pipe 8 and gasket Remove the valve timing inspection plug 9 and generator cover plug 0 CYLINDER HEAD COVER Remove the front cylinder head cover 1 Remove the dowel pin 2 and O ring...

Page 75: ...generator rotor to the index mark B 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 pre...

Page 76: ...ournal holders Remove the dowel pins 6 Remove the intake camshaft 7 Remove the exhaust camshaft 8 NOTE Do not drop the dowel pins into the crankcase FRONT CYLINDER HEAD Remove the cylinder head bolt M...

Page 77: ...STON 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 1 Remove the piston 2 by driving out the piston pin NOTE Scribe...

Page 78: ...ve the cam chain tension adjuster cap bolt 2 spring and gasket Remove the cam chain tension adjuster 3 Remove the intake camshaft journal holder 4 Remove the exhaust camshaft journal holder 5 NOTE Mar...

Page 79: ...bolts loosen each bolt little by little diagonally Remove the cylinder head 4 Remove the cylinder head gasket 5 dowel pins 6 and cam chain guide 7 REAR CYLINDER Remove the cylinder nuts 1 and clamp R...

Page 80: ...he cylinder number on the head of the piston STARTER MOTOR Remove the starter motor mounting bolts and the clamp 1 Remove the starter motor 2 ENGINE BOTTOM SIDE OIL FILTER Remove the oil filter 1 with...

Page 81: ...e generator rotor 1 with the special tool 09930 44530 Rotor holder Remove the clutch springs NOTE Loosen the clutch spring set bolts little by little and diagonally Remove the pressure plate 2 Remove...

Page 82: ...wire Remove the clutch drive plates and driven plates Remove the spring washer 7 and spring washer seat 8 Flatten the clutch sleeve hub nut lock washer Hold the clutch sleeve hub with the special too...

Page 83: ...primary driven gear assembly B Remove the spacer C OIL PUMP Remove the snap ring 1 Remove the oil pump driven gear 2 NOTE Do not drop the snap ring 1 into the crankcase Remove the pin 3 and the washer...

Page 84: ...SYSTEM Remove the snap ring 1 and washer 2 Remove the gearshift shaft assembly 3 and washer 4 Remove the gearshift cam plate bolt 5 Remove the gearshift cam plate 6 Remove the gearshift cam stopper 7...

Page 85: ...OIL PIPE Remove the oil pipe stopper 1 Remove the oil pipe 2 PRIMARY DRIVE GEAR Hold the generator rotor with the special tool 09930 44530 Rotor holder Remove the primary drive gear bolt This bolt has...

Page 86: ...2 into the crankcase Remove the rear cam chain 3 and cam chain drive sprocket 4 GENERATOR ROTOR Hold the generator rotor with the special tool 09930 44530 Rotor holder Remove the generator rotor bolt...

Page 87: ...NT CAM CHAIN Remove the cam chain tensioner 1 NOTE Do not drop the washer 2 into the crankcase Remove the front cam chain 3 GEAR POSITION SWITCH Remove the driveshaft oil seal retainer 1 Remove the ge...

Page 88: ...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 to...

Page 89: ...crankshaft 1 TRANSMISSION Remove the gearshift fork shafts 1 Remove the gearshift cam 2 Remove the gear shift forks 3 Remove the driveshaft assembly 4 and countershaft assem bly 5 Remove the engine sp...

Page 90: ...eposit If any damage or the carbon deposit is found in the reed valve replace it with a new one REASSEMBLY Install the PAIR reed valve as shown Be sure to identify each removed part as to its loca tio...

Page 91: ...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 1 and cords 2 stamped on the camshaft end...

Page 92: ...rance with the camshaft installed in place Use the plastigauge to read the clearance at the widest por tion which is specified as follows Camshaft journal oil clearance Service Limit IN EX 0 150 mm 0...

Page 93: ...05 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 09900 20607 Dial...

Page 94: ...ngers or magnetic hand Using special tools compress the valve springs and remove the two cotter halves 3 from valve stem 09916 14510 Valve lifter 09916 14521 Valve lifter attachment 09916 84511 Tweeze...

Page 95: ...t any position of the straightedge exceeds the limit replace the cylinder head Cylinder head distortion Standard 0 05 mm 0 002 in 09900 20803 Thickness gauge VALVE STEM RUNOUT Support the valve using...

Page 96: ...the 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...

Page 97: ...into the hole with the special tools 09916 43210 Valve guide installer remover 09916 53330 Attachment NOTE Install the valve guide until the attachment 1 contacts with the cylinder head 2 After instal...

Page 98: ...35 0 043 in VALVE SEAT SERVICING The valve seats 1 for both the intake valve 2 and exhaust valve 3 are machined to four different angles The seat contact surface is cut at 45 09916 21111 Valve seat cu...

Page 99: ...valve seat is pitted or burned use the 45 cutter to con dition the seat some more TOP NARROWING CUT If the contact area W is too high on the valve or if it is too wide use the 15 for the exhaust side...

Page 100: ...components Fill the intake and exhaust ports with gasoline to check for leaks If any leaks occur inspect the valve seat and face for burrs or other things that could prevent the valve from sealing NO...

Page 101: ...r free length and also by the force required to compress them If the spring length is less than the service limit or if the force required to compress the spring does not fall within the range specifi...

Page 102: ...aint Put on the valve spring retainer 1 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 2 to wedge in between retaine...

Page 103: ...IL JET REMOVAL Remove the oil jets 1 OIL JET INSPECTION AND CLEANING Check the oil jets for clogging If they are clogged clean their oil passage with a proper wire and compressed air 1 Oil jet 8 For c...

Page 104: ...g at any position of the straightedge exceeds the limit replace the cylinder Cylinder distortion Service Limit 0 05 mm 0 002 in 09900 20803 Thickness gauge CYLINDER BORE Inspect the cylinder wall for...

Page 105: ...previous measurement 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 Piston to cylinder clearance...

Page 106: ...e 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 Piston...

Page 107: ...ore gauge 18 35 mm Measure the piston pin outside diameter at three positions using the micrometer If any of the measurements are out of specification replace the piston pin Piston pin O D Service Lim...

Page 108: ...21 00 mm 0 825 0 827 in 09900 20205 Micrometer 0 25 mm CRANK PIN WIDTH Check the crank pin width A Crank pin width Standard 42 17 42 22 mm 1 660 1 662 in CONROD REMOVAL AND BEARING INSPECTION Loosen t...

Page 109: ...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 sele...

Page 110: ...n 1 41 000 41 008 mm 1 6142 1 6145 in 2 41 008 41 016 mm 1 6145 1 6148 in Code O D specification 1 37 992 38 000 mm 1 4957 1 4961 in 2 37 984 37 992 mm 1 4954 1 4957 in 3 37 976 37 984 mm 1 4951 1 495...

Page 111: ...the above torque tighten them 1 4 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 pressu...

Page 112: ...n it to the specified torque 99104 31140 SUZUKI BOND 1207B USA 99000 31140 SUZUKI BOND 1207B Others Oil pressure switch 13 N m 1 3 kgf m 9 5 lb ft NOTE Be careful not to apply SUZUKI BOND to the hole...

Page 113: ...oil starainer plate screw to the specified torque Oil strainer plate screw 10 N m 1 0 kgf m 7 0 lb ft OIL JET Removal Remove the oil jets 1 2 from the left and right crankcase halves Remove the oil se...

Page 114: ...lves Apply a small quantity of THREAD LOCK to the bolts and tighten them to the specified torque 99000 32050 THREAD LOCK 1342 Piston cooling oil jet bolt 10 N m 1 0 kgf m 7 0 lb ft Push the oil jet in...

Page 115: ...d 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 1 A B or C is stamped on the inside of ea...

Page 116: ...he special tool 09913 60221 Journal bearing remover installer NOTE Remove the crankshaft journal bearings in only one direction from inside to outside of each crankcase half Color Part No Thickness Gr...

Page 117: ...ing installer set 09910 20116 Conrod holder 09913 60221 Journal bearing remover installer Set the specified crankshaft journal bearings to the special tool NOTE The upper and lower bearings are same T...

Page 118: ...bearing from inside to outside of each crankcase halves Before installing the bearings lightly shave off the sharp edge part A of the crankcase chamfer by using an oilstone and wash the crankcase bore...

Page 119: ...s the special tool 4 NOTE Using the hand press is recommended to install the crankshaft journal bearings However the crankshaft journal bearings can be installed by using the following special tools 0...

Page 120: ...nd smooth rotation while the bearings are in the crankcase Replace the bearing with new ones if there is anything unusual Inspect the oil seals for any damage REMOVAL Remove the oil seals with the spe...

Page 121: ...h the special tool 09921 20240 Bearing remover set NOTE Select the suitable size attachment as following illustration Bearing remover attachment 1 25 mm 2 17 mm 3 20 mm A Left crankcase B Right crankc...

Page 122: ...attachment as following illustration Bearing installer attachment Apply SUZUKI SUPER GREASE to the oil seal lip 99000 25030 SUZUKI SUPER GREASE A USA 99000 25010 SUZUKI SUPER GREASE A Others Bearing...

Page 123: ...Service Limit 11 5 mm 0 453 in 09900 20102 Vernier calipers CLUTCH DRIVEN PLATES NOTE Wipe off engine oil from the clutch driven plates with a clean rag Measure each driven plate for distortion with...

Page 124: ...e 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...

Page 125: ...aft gearshift arm for wear or bend Check the return springs for damage or fatigue REASSEMBLY Install the following parts to the gearshift shaft gearshift arm as shown in the right illustration 1 Washe...

Page 126: ...ve gears 7 then remove the 2nd drive gear circlip 8 Remove the 2nd drive gear 6 6th drive gear 5 bushing and washer Remove the snap ring 9 and 3rd 4th drive gears 0 Remove the snap ring A washer B and...

Page 127: ...e the washer 1 and 1st driven gear 2 Remove the 1st driven gear bushing 3 washer 4 and 5th driven gear 5 Remove the snap ring 6 washer 7 and 4th driven gear 8 Remove the 4th driven gear bushing 9 lock...

Page 128: ...ring D and 6th driven gear E Remove the snap ring F and 2nd driven gear bushing G Remove the 2nd driven gear H INSPECTION Inspect the each gear and bushing for wear and damage If they are found to be...

Page 129: ...ission attention must be given to the locations and positions of washers and snap rings The cross sectional view shows the correct position of the gears bushings washers and snap rings 3 77 When insta...

Page 130: ...shaft install lock washer No 2 5 onto the driveshaft and position it so it fits into the groove Then fit lock washer No 1 6 into lock washer No 2 5 When installing the 6th drive gear 3rd driven gear a...

Page 131: ...en gear 2 5th drive gear 8 4th driven gear 3 3rd 4th drive gear 9 3rd driven gear 4 6th Top drive gear 0 6th Top driven gear 5 2nd drive gear A 2nd driven gear 6 1st Low driven gear A 145 N m 14 5 kgf...

Page 132: ...auge 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 Measure the gearshift fork groove wid...

Page 133: ...er clutch contacting surface on the starter driven gear for wear and damage If they are found to be damaged replace them with new ones Inspect the starter driven gear bearing for any damage DISASSEMBL...

Page 134: ...5 kgf m 18 0 lb 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 gener...

Page 135: ...hly If it does not move smoothly replace the oil pump assembly CLUTCH RELEASE INSPECTION Check the teeth of clutch release for any damage and wear Do not attempt to disassemble the oil pump assem bly...

Page 136: ...ON Install the countershaft assembly 1 and the driveshaft assembly 2 to the left crankcase half Install the washer 3 onto the driveshaft assembly 2 GEARSHIFT Install the gearshift forks 1 2 3 gearshif...

Page 137: ...rface of the left crank case 99104 31140 SUZUKI BOND 1207B USA 99000 31110 SUZUKI BOND 1215 Others NOTE Use of SUZUKI BOND is as follows Make surfaces free from moisture oil dust and other foreign mat...

Page 138: ...nstall the oil plate 1 and the oil plate bolts tighten to the specified torque Oil plate bolt 10 N m 1 0 kgf m 7 0 lb ft ENGINE SPROCKET SPACER Install the new O ring 1 into the engine sprocket spacer...

Page 139: ...e specified torque Gear position switch bolt 6 5 N m 0 65 kgf m 4 7 lb ft Install the drive shaft oil seal retainer 4 NOTE Pass through the gear position switch lead wire under the drive shaft oil sea...

Page 140: ...t completely Install the generator rotor assembly onto the crankshaft While holding the generator rotor with the special tool tighten its bolt to the specified torque 09930 44530 Rotor holder Generato...

Page 141: ...kgf m 7 0 lb ft NOTE The front and rear cam chain tensioners are the same PRIMARY DRIVE GEAR Install the primary drive gear 1 and water pump drive gear 2 Hold the generator rotor crankshaft with the s...

Page 142: ...ARSHIFT SYSTEM Install the gearshift cam stopper 1 its bolt 2 washer 3 and return spring 4 Gearshift cam stopper bolt 10 N m 1 0 kgf m 7 0 lb ft Confirm the gearshift cam stopper movement Check the ne...

Page 143: ...READ LOCK 1342 Gearshift cam stopper plate bolt 13 N m 1 3 kgf m 9 5 lb ft Install the gearshift shaft gearshift arm 7 with the washer 8 as shown Locate the gearshift arm stopper 9 between return spri...

Page 144: ...assembly 2 onto the counter shaft NOTE Be sure to engage the oil pump drive and driven gears primary drive and driven gears Install the thrust washer 3 Install the clutch sleeve hub 4 and lock washer...

Page 145: ...the spring washer seat 7 and spring washer 8 onto the clutch sleeve hub correctly Insert the clutch drive plates 9 0 and driven plates A one by one into the clutch sleeve hub in the prescribed order N...

Page 146: ...g D Hold the generator rotor crankshaft with the special tool 09930 44530 Rotor holder Install the clutch pressure plate Tighten the clutch spring set bolts to the specified torque Clutch spring set b...

Page 147: ...ns 3 and gasket 4 Install the generator cover Generator cover bolt 10 N m 1 0 kgf m 7 0 lb ft NOTE Fit the gasket washers to the generator cover bolts A correctly as shown OIL FILTER Install the oil f...

Page 148: ...he 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 1 After placing the spacer fit the two side rails 2 NOTE Side designations to...

Page 149: ...nstalling the pistons front and rear the indents D 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...

Page 150: ...hown in the illustration CYLINDER Coat SUZUKI BOND lightly to the mating surfaces at the part ing line between the right and left crankcases as shown 99104 31140 SUZUKI BOND 1207B USA 99000 31110 SUZU...

Page 151: ...t 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...

Page 152: ...hen 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 I...

Page 153: ...tor rotor with the index mark B of the valve timing inspection hole while keeping the cam chains pulled upward Pull the cam chain lightly The No 1 exhaust camshaft sprocket has an arrow mark 1F C Inst...

Page 154: ...ion adjuster is secured No 1 FRONT CYLINDER HEAD Install the dowel pins 1 Apply engine oil to the camshaft journal holders Install the camshaft journal holders intake and exhaust Fasten the camshaft j...

Page 155: ...ion adjuster mounting bolt 10 N m 1 0 kgf m 7 0 lb ft Install the spring 4 gasket 5 and spring holder bolt 6 Tighten the cam chain tension adjuster cap bolt to the speci fied torque Cam chain tension...

Page 156: ...et has an arrow mark 1R C Install the intake camshaft so that the arrow C is aligned with the mating surface of the cylinder head 3 103 Engage the cam chain with the intake camshaft sprocket NOTE Befo...

Page 157: ...the 16th roller pin D on the cam chain with the arrow mark 3 on the exhaust sprocket 3 103 NOTE The cam chain should now be on all three sprockets Be careful not to move the crankshaft until the cams...

Page 158: ...ten the camshaft journal holder bolts to the specified torque Camshaft journal holder bolt 10 N m 1 0 kgf m 7 0 lb ft Recheck the rear camshaft positions intake and exhaust Cam chain tension adjuster...

Page 159: ...ENGINE 3 105 No 1 Front cylinde TDC of compression stroke 1 Cam chain guide 2 Cam chain guide A Forward 2 1 R 3 1 F 2 1 R 3 1F 2 1 R 3 1F 2 1 R 3 1 F P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6...

Page 160: ...rs The cylinder head covers can be distinguished by the embossed letters A F Front cylinder head cover R Rear cylinder head cover Install the cylinder head covers on each cylinder head Fit the gaskets...

Page 161: ...SUPER GREASE to the O ring 99000 25030 SUZUKI SUPER GREASE A USA 99000 25010 SUZUKI SUPER GREASE A Others Make sure that the UP mark A faces upward Install the intake pipes NOTE The intake pipe can be...

Page 162: ...lug 23 N m 2 3 kgf m 16 3 lb ft Generator cover plug 11 N m 1 1 kgf m 8 0 lb ft THERMOSTAT CASE AND WATER HOSE Install the thermostat case 1 along with the water hoses 2 and tighten the clamp screws s...

Page 163: ...03 ENGINE book Page 105 Tuesday February 28 2006 3 03 PM P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6...

Page 164: ...LF DIAGNOSIS RESET 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 C...

Page 165: ...9 TPS ADJUSTMENT 4 49 ECT SENSOR INSPECTION 4 49 ECT SENSOR REMOVAL AND INSTALLATION 4 49 IAT SENSOR INSPECTION 4 50 IAT SENSOR REMOVAL AND INSTALLATION 4 50 TO SENSOR INSPECTION 4 50 TO SENSOR REMOVA...

Page 166: ...d the coupler body and do not pull the lead wires Inspect each terminal on the connector coupler for looseness or bending Inspect each terminal for corrosion and contamination The terminals must be cl...

Page 167: ...pening Also check the coupler for locking loose ness corrosion dust etc 1 Coupler 2 Probe 3 Where male terminal fits FUSE When a fuse blows always investigate the cause correct it and then replace the...

Page 168: ...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...

Page 169: ...ion of the coupler lock if equipped 1 Sensor 2 ECM A Check for loose connection Using a test male terminal check the female terminals of the circuit being checked for contact tension Check each termin...

Page 170: ...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...

Page 171: ...iagnosis will be misled Measure resistance between terminal at one end of circuit A terminal in figure and body ground If continuity is indicated there is a short circuit to ground between terminals A...

Page 172: ...th the multi circuit tester 1 will be shown as 10 00 M 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 Afte...

Page 173: ...ns These compensations are determined according to the signals from various sensors that detect the engine and driving conditions Intake Air Pressure Sensor IAP Sensor Intake air pressure signal Engin...

Page 174: ...he fuel injection time volume A longer injection time is needed to adjust injection volume in the case of low voltage ENGINE RPM SIGNAL At high speed the injection time volume is increased ACCELERATIO...

Page 175: ...RTS LOCATION A Speedometer F Fuel injector No 1 B CKP sensor G Fuel injector No 2 C TP sensor H Ignition coil No 1 D Gear position sensor I STVA E STP sensor J TO sensor ECM A I F G C E J H B D P a r...

Page 176: ...4 12 FI SYSTEM DIAGNOSIS K IAP sensor N Fuel pump relay L IAT sensor O Ignition coil No 2 M ECT sensor P PAIR control valve K L M N O P ECM P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6...

Page 177: ...CONTROL VALVE SIDE STAND SWITCH GEAR POSITION SWITCH CLUTCH SWITCH FP DON AT B CLT IG 1 THW THA VCC TPS E2 STPS HO2 OXH HO2 OX GP N E1 TS PM TACO E01 E02 TECH SOL Fl 1 Fl 2 MO MO IG 2 IGNITION COIL 3...

Page 178: ...e does not run CHEC The LCD panel indicates CHEC when no communication signal from the ECM is received for 3 seconds For Example The ignition switch is turned ON and the engine stop switch is turned O...

Page 179: ...ed in the code form 09930 82720 Mode select switch Do not disconnect the ECM lead wire couplers before checking the malfunction code or the malfunction code memory is erased and the malfunction code c...

Page 180: ...MALFUNCTION PART REMARKS C00 C12 C13 C14 C15 C21 C23 C24 C25 C28 C29 C31 C32 C33 C41 C42 C44 C49 None Crankshaft position sensor CKPS Intake air pressure sensor IAPS Throttle position sensor TPS Engin...

Page 181: ...to full open position and STV is fixed at 1 2 open position Ignition timing is also fixed NO YES Engine coolant temperature sensor Engine coolant temperature value is fixed to 80 C 176 F YES YES Inta...

Page 182: ...N Sometimes ON Always OFF Good condition Malfunction display code LCD User mode No display Malfunction display Dealer mode No code Malfunction code PROBLEM SYMPTOMS Difficult Starting Poor Driveabilit...

Page 183: ...ays Sometimes times day month Only once Under certain condition Road Urban Suburb Highway Mountainous Uphill Downhill Tarmacadam Gravel Other Motorcycle condition Engine condition Cold Warming up phas...

Page 184: ...how to use it Be sure to read PRECAUTIONS for Electrical Circuit Service 4 2 before inspection and observe what is written there Remove the seat 7 4 Connect the special tool to the dealer mode coupler...

Page 185: ...ne coolant tem perature sensor The sensor voltage should be the following 0 1 V sensor voltage 4 6 V Without the above range for 4 sec and more C15 is indicated Engine coolant temperature sensor lead...

Page 186: ...e gets 1 3 V and less C32 or C33 is indicated Injector wiring coupler connection power supply to the injector C41 Fuel pump relay No voltage is applied to the both injectors 1 2 for 3 sec after the co...

Page 187: ...h terminal and ground CKP sensor continuity Infinity White Ground Green Ground 09900 25008 Multi circuit tester set Tester knob indication Resistance Are the resistance and continuity OK DETECTED COND...

Page 188: ...n measure the CKP sensor peak voltage at the ECM terminals P T 09900 25008 Multi circuit tester set Tester knob indication voltage Is the voltage OK 2 2 V YES B W or White wire open or shorted to grou...

Page 189: ...circuit tester set Tester knob indication Voltage Is the voltage OK DETECTED CONDITION POSSIBLE CAUSE IAP sensor voltage is out of the specified range 0 1 V Sensor voltage 4 8 V NOTE Note that atmosph...

Page 190: ...round terminal and terminal to the Vcc 2 terminal Check the voltage between Vout 3 and ground Also check if voltage reduces when vacuum is applied up to 400 mmHg by using vacuum pump gauge 4 27 09917...

Page 191: ...ATMOSPHERIC PRESSURE OUTPUT VOLTAGE ft m mmHg kPa V 0 2 000 0 610 760 707 100 94 Approx 3 3 3 6 2 001 5 000 611 1 524 707 634 94 85 Approx 3 0 3 3 5 001 8 000 1 525 2 438 634 567 85 76 Approx 2 7 3 0...

Page 192: ...then measure the voltage at the Red wire and B Br wire TP sensor input voltage 4 5 5 5 V Red Ground Red B Br 09900 25008 Multi circuit tester set Tester knob indication Voltage Is the voltage OK DETE...

Page 193: ...TP sensor resistance between A and B 6 Turn the throttle grip and measure the resistance TP sensor resistance Throttle valve is closed Approx 1 12 k Throttle valve is opened Approx 4 26 k 09900 25008...

Page 194: ...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 3 V YES Red P W or B Br wire open or...

Page 195: ...OK then measure the voltage between B BI wire terminal 1 and B Br wire terminal 2 ETC sensor voltage 4 5 5 5 V B BI Ground B BI B Br 09900 25008 Multi circuit tester set Tester knob indication Voltage...

Page 196: ...Is the resistance OK 2 YES B Br or B Bl wire open or shorted to ground or poor X or Z connection If wire and connection are OK intermittent trou ble or faulty ECM Recheck each terminal and wire harnes...

Page 197: ...l 1 and ground 6 If OK then measure the voltage between Dg wire terminal 1 and B Br wire terminal 2 IAT sensor voltage 4 5 5 5 V Dg Ground Dg B Br 09900 25008 Multi circuit tester set Tester knob indi...

Page 198: ...is the same way as that of the ECT sensor Refer to page 6 10 for details 2 YES Dg or B Br wire open or shorted to ground or poor D or X connection If wire and connection are OK intermittent trou ble...

Page 199: ...A and B terminals TO sensor resistance 19 1 19 7 k A B terminals 09900 25008 Multi circuit tester set Tester knob indication Resistance Is the resistance OK DETECTED CONDITION POSSIBLE CAUSE The sens...

Page 200: ...nsor voltage 3 7 4 4 V Br W B Br 09900 25008 Multi circuit tester set 09900 25009 Needle pointed probe set Tester knob indication Voltage Is the voltage OK C24 or C25 IGNITION SYSTEM MALFUNCTION Refer...

Page 201: ...measure the STVA resistance STVA resistance Approx 7 14 09900 25008 Multi circuit tester set Tester knob indication Resistance Is the resistance OK DETECTED CONDITION POSSIBLE CAUSE The operation volt...

Page 202: ...r wire STP sensor input voltage 4 5 5 5 V Red Ground Red B Br 09900 25008 Multi circuit tester set Tester knob indication Voltage Is the voltage OK DETECTED CONDITION POSSIBLE CAUSE Signal voltage is...

Page 203: ...ully by turning the actuator shaft end 1 and measure the STP sensor resis tance with both STV positions STP sensor resistance Secondary throttle valve is closed Approx 0 58 k Secondary throttle valve...

Page 204: ...sor output voltage Secondary throttle valve is closed Approx 0 58 V Secondary throttle valve is opened Approx 4 40 V 09900 25008 Multi circuit tester set 09900 25009 Needle pointed probe set Tester kn...

Page 205: ...ifting 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 pointed probe set Tester knob indication Voltage Is the...

Page 206: ...Injector resistance 11 13 at 20 C 68 F No 1 1 2 No 2 3 4 5 If OK then check the continuity between injector terminals and ground Injector continuity Infinity No 1 1 Ground No 2 3 Ground 09900 25008 M...

Page 207: ...voltage can be detected only 2 seconds after ignition switch is turned ON 09900 25008 Multi circuit tester set Tester knob indication Voltage Is the voltage OK V V 2 YES Gr W or Gr B wire open or shor...

Page 208: ...injectors for 3 sec after the contact of fuel pump relay is turned ON Or voltage is applied to the both injectors when the contact of fuel pump is OFF Fuel pump relay circuit open or short Fuel pump r...

Page 209: ...ve coupler and mea sure the resistance between terminals PAIR control solenoid valve resistance 20 24 at 20 C 68 F 09900 25008 Multi circuit tester set Tester knob indication Resistance Is the resista...

Page 210: ...control solenoid valve voltage Battery voltage Brown Ground 09900 25008 Multi circuit tester set 09900 25009 Needle pointed probe set Tester knob indication Voltage Is the voltage OK 2 V YES Brown wir...

Page 211: ...tage for few sec onds it is good condition Heater voltage Battery voltage O W Ground NOTE Battery voltage can be detected only during few seconds after ignition switch is turned ON 09900 25008 Multi c...

Page 212: ...n the ignition switch OFF 2 Disconnect the HO2 sensor coupler 3 Check the resistance between the terminals White White of the HO2 sensor HO2 heater resistance 4 5 at 23 C 73 4 F White White NOTE Tempe...

Page 213: ...nstall 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...

Page 214: ...l NOTE When installing the TO sensor the UP mark A must be pointed upward STP SENSOR INSPECTION STP SENSOR REMOVAL AND INSTALLA TION The secondary throttle position sensor is installed at the left sid...

Page 215: ...R REMOVAL 5 10 FUEL MESH FILTER INSPECTION AND CLEANING 5 12 FUEL PUMP AND FUEL MESH FILTER INSTALLATION 5 12 THROTTLE BODY AND STV ACTUATOR 5 14 CONSTRUCTION 5 14 AIR CLEANER AND THROTTLE BODY REMOVA...

Page 216: ...ssure regulator As the fuel pressure applied to the fuel injector the fuel pressure in the fuel delivery pipe is always kept at absolute fuel pressure of 300 kPa 3 0 kgf cm2 43 psi the fuel is injecte...

Page 217: ...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...

Page 218: ...lar direction due to fluid friction This process continuously takes place causing fuel pressure to be built up The pressurized fuel is then let out from the pump chamber and discharged through the mot...

Page 219: ...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...

Page 220: ...the side stand relay and the fuel pump relay so that the pump continues to function A tip over sensor is provided in the fuel pump control circuit By this provision anytime the motorcycle tips over th...

Page 221: ...fuel pump lead wire coupler 1 Place a rag under the fuel feed hose and disconnect the fuel feed hose 2 from the fuel tank Disconnect the fuel tank drain hose 3 Remove the fuel tank mounting bolt and...

Page 222: ...pressure Fuel pressure Approx 300 kPa 3 0 kgf cm 43 psi If the fuel pressure is lower than the specification inspect the following items Fuel hose leakage Clogged fuel filter Pressure regulator Fuel p...

Page 223: ...uring cylinder Disconnect the ECM lead wire coupler from the ECM Push the lock A to pull out the power source lead wire Yel low with black tracer V Connect the ECM to the ECM lead wire coupler Apply 1...

Page 224: ...nals to 3 and to 4 and check the continuity between 1 and 2 If there is no continuity replace it with a new one FUEL PUMP AND FUEL FILTER REMOVAL Remove the fuel tank 5 7 Remove the fuel pump assembly...

Page 225: ...screws Remove the fuel pump assy 4 from the fuel pump plate 5 Remove the fuel pump holder 6 Remove the fuel mesh filter 7 Remove the fuel pressure regulator holder 8 and the fuel pressure regulator 9...

Page 226: ...LTER INSTALLATION Install the fuel pump and fuel mesh filter in the reverse order of removal Pay attention to the following points Install the new O rings to the fuel pressure regulator and fuel pipe...

Page 227: ...orque in the above tightening order Fuel pump mounting bolt 10 N m 1 0 kgf m 7 3 lb ft NOTE Apply a small quantity of the THREAD LOCK to the thread por tion of the fuel pump mounting bolt 99000 32050...

Page 228: ...P sensor A STP sensor mounting screw 2 STP sensor B TP sensor mounting screw 3 STVA C Fuel delivery pipe mounting screw ITEM N m kgf m lb ft A 2 0 0 2 1 5 4 Fuel delivery pipe 1 Do not turn the screw...

Page 229: ...onnect the IAT sensor coupler 1 Remove the IAP sensor vacuum hose 2 Disconnect the IAP sensor coupler 3 Loosen the throttle body clamp screws Disconnect the PAIR hose Disconnect the PAIR lead wire cou...

Page 230: ...k 5 7 Remove the air cleaner box 5 15 Disconnect the various lead wire couplers 1 TP sensor 2 STP sensor 3 STVA motor Remove the injector lead wire coupler Disconnect the idle stop screw Loosen the th...

Page 231: ...ul 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 fu...

Page 232: ...hrottle link rod 3 NOTE The throttle link rod 2 is longer than the secondary throttle link rod 3 Remove the fuel delivery pipe 4 Remove the fuel injectors Be careful not to damage the throttle lever w...

Page 233: ...9930 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 7 Do n...

Page 234: ...throttle stop screw 9 NOTE Measure the length A for accurate reinstallation Never loosen the throttle stop screw B on the No 2 throt tle body Never remove the throttle valve and secondary throttle val...

Page 235: ...ND THROTTLE BODY 5 21 Remove the fast idle link lever 0 Remove the spring A Remove the spring B bushing C and plastic washer D Never remove the throttle body link plates P a r t S h a r k c o m 8 7 7...

Page 236: ...nes and fuel tank Some carburetor cleaning chemicals especially dip type soaking solutions are very corrosive and must be handled carefully Always follow the chemical man ufacturer s instructions on p...

Page 237: ...the throttle stop screw tip and the both ends of a spring 99000 25030 SUZUKI SUPER GREASE A USA 99000 25010 SUZUKI SUPER GREASE A Others Install the plastic washer 1 and bushing 2 NOTE The concave of...

Page 238: ...s 99000 25030 SUZUKI SUPER GREASE A USA 99000 25010 SUZUKI SUPER GREASE A Others Install the seal 9 Apply a small quantity of SUZUKI SUPER GREASE to the shaft ends and seal lips 99000 25030 SUZUKI SUP...

Page 239: ...9930 11960 Torx wrench STP sensor mounting screw 2 0 N m 0 2 kgf m 1 5 lb 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...

Page 240: ...ounting screw 5 0 N m 0 5 kgf m 3 7 lb ft Install the throttle link rod B and secondary throttle link rod C NOTE The throttle link rod B is longer than the secondary throttle link rod C Install the IA...

Page 241: ...A B from top of the throttle body 1 to the throttle valve 2 While holding above No 1 STV position turn the adjust screw 3 so that the throttle valve height C will be same as D THROTTLE BODY INSTALLAT...

Page 242: ...o set the ST valve to fully open position Measure the STP sensor voltage at fully open position STP sensor voltage ST valve is fully opened Approx 4 38 V and more Yellow Black 09900 25008 Multi circui...

Page 243: ...he warmed up engine and connect the special tool to the dealer mode coupler 5 20 09930 82720 Mode select switch If the TP sensor adjustment is necessary loosen the TP sen sor mounting screws Turn the...

Page 244: ...nd ambient temperature as shown in the following table the fast idle is cancelled allowing the engine to resume idle speed 1 Fast idle link lever 2 Fast idle cam 3 STVA NOTE The fast idle link lever o...

Page 245: ...voltage is out of specification turn the fast idle adjusting screw 1 and adjust the output voltage to specification TP sensor output voltage 1 21 V Red B Br 09900 25008 Multi circuit tester set 09900...

Page 246: ...AIR control valve sensor couplers Connect the IAP sensor coupler and vacuum hose Connect the PAIR hose Remove the rubber cap 1 from the No 1 throttle body Connect one of the four rubber hoses of the v...

Page 247: ...he 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 7 to the center line The balancer gauge is now ready for u...

Page 248: ...s 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 NOTE Make sure that the throttle lever should have a gap A between the t...

Page 249: ...P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6...

Page 250: ...8 REMOVAL 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 R...

Page 251: ...6 1 6 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 P a r t S h...

Page 252: ...50 and less Refer to below figure Do not use a radiator anti leak additive Anti freeze 950 ml 2 01 1 67 US lmp pt Water 950 ml 2 01 1 67 US lmp pt 20 40 60 80 100 Density 0 10 20 30 40 50 60 70 32 14...

Page 253: ...filler Give a pressure of about 120 kPa 1 2 kgf cm 17 0 psi and see if the system holds this pressure for 10 seconds If the pressure should fall during this 10 second interval it means that there is a...

Page 254: ...AL Remove the cowling 7 5 Drain the engine coolant 2 18 Disconnect the right and left radiator hoses from the radiator Disconnect the siphon hose 1 from the radiator Disconnect the horn lead wire coup...

Page 255: ...p 4 With the hooks A unlocked remove the radiator from the radiator shroud 5 Remove the cooling fan and thermo switch lead wire coupler 6 from the radiator shroud Remove the cooling fan 7 Disconnect t...

Page 256: ...er INSTALLATION Install the radiator in the reverse order of removal Pay attention to the following points Install the cooling fan and horn 1 Cooling fan horn mounting bolt 8 N m 0 8 kgf m 6 0 lb ft I...

Page 257: ...d 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...

Page 258: ...e fan motor does not turn replace the fan motor assembly with a new one NOTE When making above test it is not necessary to remove the cool ing fan REMOVAL Remove the cowling 7 5 Drain the engine coola...

Page 259: ...meter 2 when the switch closes or opens 09900 25008 Multi circuit tester set Tester knob indication Continuity test Cooling fan thermo switch operating temperature Standard OFF ON Approx 98 C 208 F ON...

Page 260: ...read the column thermometer 2 and 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 If the resistance n...

Page 261: ...ten the ECT sensor to the specified torque ECT sensor 19 N m 1 9 kgf m 13 5 lb ft Pour engine coolant 2 18 Bleed air from the cooling circuit 2 19 Take special care when handling the ECT sensor It may...

Page 262: ...e as shown in the photograph Immerse the 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 be...

Page 263: ...requirements start to open temperature and valve lift must be replaced INSTALLATION Apply engine coolant to the rubber seal on the thermostat Install the thermostat NOTE The jiggle valve A of the ther...

Page 264: ...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...

Page 265: ...tch cover Remove the screws and separate the water pump Remove the O rings 7 Remove the E ring from the impeller shaft Remove the impeller from the other side Remove the mechanical seal ring 5 and rub...

Page 266: ...EARING Inspect the play of the bearing by hand while it is in the water pump case Rotate the inner race by hand to inspect for abnormal noise and smooth rotation Replace the bearing if there is anythi...

Page 267: ...aring case for damage Replace the water pump body if necessary REASSEMBLY AND INSTALLATION Install the oil seal with the special tool 09913 70210 Bearing installer set 22 mm NOTE The stamped mark on t...

Page 268: ...tall it into the impeller NOTE The paint marked side A of the mechanical seal ring faces to the impeller Apply SUZUKI SUPER GREASE to the impeller shaft 99000 25030 SUZUKI SUPER GREASE A USA 99000 250...

Page 269: ...gine coolant to the O ring 4 Install a new O ring Connect the water hoses Pour engine coolant 2 18 Pour engine oil 2 14 Use a new O ring to prevent engine coolant leakage 4 5 N m 0 45 kgf m 3 3 lb ft...

Page 270: ...YSTEM LUBRICATION SYSTEM OIL PRESSURE 2 31 OIL FILTER 2 14 OIL PRESSURE REGULATOR 3 57 OIL STRAINER 3 58 OIL JET 3 49 59 60 and 96 OIL PUMP 3 81 and 89 OIL PRESSURE SWITCH 3 58 and 8 34 P a r t S h a...

Page 271: ...ler fin guard net 1 Remove the oil hoses 2 INSPECTION AND 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...

Page 272: ...1 Connect the oil hoses Install the oil cooler Oil cooler mounting bolt 10 N m 1 0 kgf m 7 0 lb ft Tighten the oil cooler hose union bolts to the specified torque Oil cooler hose union bolt 23 N m 2...

Page 273: ...HEAD INTAKE CAMSHAFT CAM FACES CRANK PIN FRONT AND REAR CONROD BIG END BEARINGS STARTER CLUTCH CAM FACES CAM CHAIN EXHAUST CAMSHAFT FRONT PISTON AND CYLINDER WALL REAR PISTON AND CYLINDER WALL PISTON...

Page 274: ...6 24 COOLING AND LUBRICATION SYSTEM ENGINE LUBRICATION CIRCUIT FRONT CYLINDER P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6...

Page 275: ...COOLING AND LUBRICATION SYSTEM 6 25 REAR CYLINDER P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6...

Page 276: ...ANDLEBAR 7 26 CONSTRUCTION 7 26 REMOVAL 7 27 INSPECTION AND DISASSEMBLY 7 30 REASSEMBLY AND REMOUNTING 7 31 STEERING TENSION ADJUSTMENT 7 34 REAR WHEEL 7 35 CONSTRUCTION 7 35 REMOVAL 7 36 INSPECTION A...

Page 277: ...SEMBLY 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...

Page 278: ...ver 6 Cowling body 2 Wind screen 7 Combination meter panel 3 Wind screen brace 8 Cowling inner cover 4 Cowling brace 9 Left cowling ITEM N m kgf m lb ft 5 Right cowling A Cowling brace mounting bolt A...

Page 279: ...CHASSIS 7 3 1 Seat rail 4 Mud guard 2 Rear fender No 1 5 Frame cover ITEM N m kgf m lb ft 3 Rear fender No 2 A Seat rail mounting bolt A 50 5 0 36 0 P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6...

Page 280: ...the seat with the ignition key 1 FUEL TANK SIDE COVER Remove the seat 7 4 Remove the fuel tank side covers 1 NOTE indicates hook location CARRIER Remove the seat 7 4 Remove the carrier 1 P a r t S h...

Page 281: ...hook location REAR FENDER Remove the seat 7 4 Remove the carrier 7 4 Remove the bolts 1 Disconnect the brake light taillight lead wire coupler 2 and seat lock cable 3 Remove the rear fender COWLING AN...

Page 282: ...he combination meter panel mounting screws 4 Remove the combination meter panel 5 NOTE indicates hook location Disconnect the speedometer lead wire coupler 6 Remove the cowling inner cover 7 by removi...

Page 283: ...g 8 Remove the right cowling 9 Remove the wind screen brace 0 Disconnect the turn signal light lead wire couplers A Remove the screws B Remove the cowling body C NOTE indicates hook location P a r t S...

Page 284: ...everse order of removal Pay attention to the following points Install the wind screen brace 1 as shown in the photograph NOTE Install the larger diameter bolts on the wind screen brace attach ing sect...

Page 285: ...HEEL CONSTRUCTION 1 Brake disc 5 Front wheel 2 Dust seal 6 Tire valve ITEM N m kgf m lb ft 3 Bearing A Front axle A 65 6 5 47 0 4 Center spacer B Brake disc bolt B 23 2 3 16 5 P a r t S h a r k c o m...

Page 286: ...cle with a jack or a wooden block Remove the front axle 2 and the front wheel NOTE After removing the front wheel fit the calipers temporarily to the original positions INSPECTION AND DISASSEMBLY TIR...

Page 287: ...oosened wheel bearings and can be reduced by replac ing the bearings If bearing replacement fails to reduce the runout replace the wheel Wheel inspection 7 79 Wheel runout Service Limit Axial and Radi...

Page 288: ...der of removal and disassembly Pay attention to the following points A Left B Right 39 N m 3 9 kgf m 28 0 lb ft 23 N m 2 3 kgf m 16 5 lb ft 39 N m 3 9 kgf m 28 0 lb ft 23 N m 2 3 kgf m 16 5 lb ft 65 N...

Page 289: ...tall the right wheel bearing and spacer with the special tools and used bearing 09941 34513 Bearing Steering race installer set 09913 70210 Bearing installer set 40 1 Spacer 2 Old bearing A Left B Rig...

Page 290: ...the front axle and tighten the front axle temporarily 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 lb ft NOTE...

Page 291: ...t front fork leg move the front fork up and down 4 or 5 times without applying front brake Tighten the axle pinch bolt 1 on the right front fork leg to the specified torque Front axle pinch bolt 23 N...

Page 292: ...acer E Oil lock piece 5 Spring F Outer tube 6 Rebound spring G Cylinder 7 Inner tube H Washer 8 Slide metal A Front fork cap bolt ITEM N m kgf m lb ft 9 Gasket B Front axle pinch bolt A 23 2 3 16 5 0...

Page 293: ...fork upper clamp bolts 3 NOTE Slightly loosen the front fork cap bolts 4 before loosening the lower clamp bolts to facilitate later disassembly Loosen the front fork lower clamp bolts NOTE Hold the f...

Page 294: ...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 i...

Page 295: ...the following parts A Oil seal B Oil seal retainer C Guide metal D Slide metal E Oil lock piece Remove the pin F Remove the washer G Remove the spring adjuster H from front fork cap bolt The slide me...

Page 296: ...place 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 Front fork spring free length Service limit 435 mm 17 1...

Page 297: ...with care not to drop the oil lock piece out NOTE After installing the inner tube into the outer tube keep the oil lock piece into the inner tube by compressing the front fork fully Insert the inner t...

Page 298: ...t 99000 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 Cylinder bolt 20 N m 2 0 kgf m 14 5 lb ft NOTE If...

Page 299: ...kes 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...

Page 300: ...htly to the O ring Install the spring adjuster to the front fork cap bolt Apply fork oil lightly to the O ring Tighten the front fork cap bolt temporarily Set the front fork to the front fork lower br...

Page 301: ...5 lb ft Install the front wheel 7 10 Install the front brake calipers 7 59 NOTE After install the brake calipers front brake should be efficient by pumping the front brake lever SUSPENSION SETTING Aft...

Page 302: ...bar clamp bolt ITEM N m kgf m lb ft 5 Bearing lower B Steering stem head nut A 23 2 3 16 5 6 Steering stem lower bracket C Front fork upper clamp bolt B 90 9 0 65 0 7 Steering stem nut D Steering stem...

Page 303: ...nting screw and then pull the balancer assembly out of handlebars Remove the front brake master cylinder 3 Remove the right handlebar switch box 4 and throttle case 5 Disconnect the clutch switch lead...

Page 304: ...lutch lever holder B STEERING STEM Remove the front forks 7 17 Remove the handlebars 7 27 Remove the guides 1 Remove the brake hose guide 2 Remove the ignition switch 3 with the special tools 09930 11...

Page 305: ...stem nut wrench socket Remove the washer 4 Remove the steering stem nut with the special tools 09940 14911 Steering stem nut wrench 09940 14960 Steering stem nut wrench NOTE When loosing the steering...

Page 306: ...bars 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 Drive out the stee...

Page 307: ...the lower bearing to the steering stem lower bracket Install the upper bearing bearing inner race dust seal onto the frame 99000 25030 SUZUKI SUPER GREASE A USA 99000 25010 SUZUKI SUPER GREASE A Other...

Page 308: ...t Install the steering stem upper bracket and tighten the steer ing stem nut lightly Install the ignition switch 1 and harness guide 2 8 38 Install the front fork to the steering stem and tighten the...

Page 309: ...SUZUKI SUPER GREASE to the throttle cables and their holes 99000 25030 SUZUKI SUPER GREASE A USA 99000 25010 SUZUKI SUPER GREASE A Others Align the mating surface B of the throttle case with the punch...

Page 310: ...igure and read the graduation when the handle bar starts moving Do the same on the other grip end Initial force 200 500 grams 09940 92720 Spring scale If the initial force read on the scale when the h...

Page 311: ...3 Brake disc C Rear sprocket 4 Collar D Bearing 5 Bearing E Dust seal 6 Rear wheel F Collar 7 Tire valve A Brake disc bolt ITEM N m kgf m lb ft 8 Damper B Rear sprocket nut A 23 2 3 16 5 9 Spacer C R...

Page 312: ...d draw out the rear axle Remove the collars 1 2 Remove the rear sprocket mounting drum assembly 3 from the wheel hub NOTE Before removing the rear sprocket mounting drum slightly loosen the rear sproc...

Page 313: ...al gauge check the rear axle for runout If the runout exceeds the limit replace the rear axle Axle shaft runout Service Limit 0 25 mm 0 010 in 09900 20607 Dial gauge 1 100 mm 09900 20701 Magnetic stan...

Page 314: ...set A Normal wear B Excessive wear DUST SEAL Inspect 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...

Page 315: ...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 too...

Page 316: ...nt the rear wheel in the reverse order of removal and disassembly Pay attention to the following points A Left B Right 60 N m 6 0 kgf m 43 5 lb ft 23 N m 2 3 kgf m 16 5 lb ft 100 N m 10 0 kgf m 72 5 l...

Page 317: ...70210 Bearing installer set 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 spa...

Page 318: ...he brake disc should face to the out side Apply THREAD LOCK to the disc bolts and tighten them to the specified torque 99000 32130 THREAD LOCK SUPER 1360 Brake disc bolt 23 N m 2 3 kgf m 16 5 lb ft RE...

Page 319: ...m 6 0 kgf m 43 5 lb ft Install the collar REAR AXLE Remount the rear wheel and rear axle install the washer and rear axle nut Adjust the chain slack after rear wheel installation 2 21 Tighten the rea...

Page 320: ...K ABSORBER CONSTRUCTION 1 Rear shock absorber B Rear shock absorber lower mounting nut ITEM N m kgf m lb ft A Rear shock absorber upper mount ing nut A 50 5 0 36 0 B 50 5 0 36 0 P a r t S h a r k c o...

Page 321: ...e pre load adjuster 1 Remove the cushion lever rod bolts nuts and the cushion rods 2 Disconnect the pre load adjuster hose from the clamp 3 Remove the rear shock absorber upper mounting bolt 4 Remove...

Page 322: ...h a 3 mm drill Do not attempt to disassemble the rear shock absorber unit It is unserviceable The rear shock unit contains high pressure nitrogen gas Mishandling can cause explosion Keep away from fir...

Page 323: ...ck absorber lower mounting nut 50 N m 5 0 kgf m 36 0 lb ft Rear shock absorber upper mounting nut 50 N m 5 0 kgf m 36 0 lb ft NOTE When installing the rear shock absorber the outlet hose of the prel l...

Page 324: ...position 2 A STD position B Stiffest position C Softest position DAMPING FORCE ADJUSTMENT The rebound damping force is adjusted by turning the adjuster Fully turn the damping adjuster 1 clockwise It...

Page 325: ...kgf m lb ft 4 Spacer B Cushion lever nut A 50 5 0 36 0 5 Bearing C Cushion rod nut B 78 7 8 56 5 6 Washer D Swingarm pivot shaft C 78 7 8 56 5 7 Pivot spacer E Swingarm pivot lock nut D 15 1 5 11 0 8...

Page 326: ...e cushion rods 2 Remove the shock absorber lower mounting bolt 3 Remove the cushion lever 4 Remove the swingarm pivot shaft lock nut with the special tool 09940 14940 Swingarm pivot thrust adjuster so...

Page 327: ...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 Inspect the chain buffer for damage and exce...

Page 328: ...over set 17 mm 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 1 100 mm 10 mm 09900 20701 Magnetic stand 0990...

Page 329: ...arings with the special tool 09921 20240 Bearing remover set 20 mm and 17 mm CUSHION ROD Inspect the cushion rods for damage and distortion The removed bearings must be replaced with the new ones P a...

Page 330: ...Frame 2 Rear shock absorber 3 Washer 4 Cushion lever 5 Cushion rod 6 Swingarm A Left B Right 50 N m 5 0 kgf m 36 0 lb ft 50 N m 5 0 kgf m 36 0 lb ft 90 N m 9 0 kgf m 65 0 lb ft 78 N m 7 8 kgf m 56 5...

Page 331: ...tool 09941 34513 Steering race installer NOTE When installing the bearing the dust seal that is embedded in the bearing must face outside CUSHION LEVER BEARING Press the bearings into the cushion lev...

Page 332: ...11 0 lb ft 09944 28320 Hexagon bit 19 mm Hold the swingarm pivot shaft 1 with the special tool and tighten the swingarm pivot nut 2 to the specified torque 09944 28320 Hexagon bit 19 mm Swingarm pivo...

Page 333: ...rod nut 4 and rear shock absorber lower mounting nut 5 to the specified torque Cushion lever nut 78 N m 7 8 kgf m 56 5 lb ft Cushion rod nut 78 N m 7 8 kgf m 56 5 lb ft Rear shock absorber lower mount...

Page 334: ...hose C Caliper 5 Pin A Front brake master cylinder mounting bolt ITEM N m kgf m lb ft 6 Pad mounting pin B Brake hose union bolt A 10 1 0 7 0 7 Brake pad spring C Air bleeder valve B 23 2 3 16 5 8 Br...

Page 335: ...servicing or stored for long periods When storing the brake fluid seal the container completely and keep away from children When replenishing brake fluid take care not to get dust into fluid When was...

Page 336: ...on a level surface and keep the handle bars straight Remove the brake fluid reservoir cap and diaphragm Suck up the old brake fluid as much as possible Fill the reservoir with the new brake fluid Spec...

Page 337: ...unting bolts Remove the caliper holder 1 Remove the pad spring 2 Never reuse the brake fluid left over from previous servicing and which has been stored for long peri ods of time Bleed air from the br...

Page 338: ...e 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...

Page 339: ...L Install the piston seals as shown in the illustration Install the piston to the caliper 1 Dust seal 2 Piston seal 3 Caliper Wash the caliper components with fresh brake fluid before reassembly Never...

Page 340: ...the brake pads 7 59 NOTE Before remounting the caliper push the piston all the way into the caliper Install the brake caliper to the front fork Tighten each bolt to the specified torque Front brake c...

Page 341: ...mm 09900 20701 Magnetic stand Brake disc removal 7 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...

Page 342: ...rn spring 7 Piston 8 Secondary cup 9 Primary cup 0 Return spring MASTER CYLINDER INSPECTION Inspect the master cylinder bore for any scratches or other dam age Inspect the piston surface for any scrat...

Page 343: ...brake master cylinder mounting bolt to the specified torque and first tighten the upper mounting bolt Front brake master cylinder mounting bolt 10 N m 1 0 kgf m 7 0 lb ft 9 Master cylinder holder C UP...

Page 344: ...ting bolt ITEM N m kgf m lb ft 6 Dust boot C Rear brake master cylinder rod lock nut A 23 2 3 16 5 B 10 1 0 7 0 7 Piston seal D Air bleeder valve C 18 1 8 13 0 8 Dust seal E Brake caliper mounting bol...

Page 345: ...r stored for long periods When storing the brake fluid seal the container completely and keep away from children When replenishing brake fluid take care not to get dust into fluid When washing brake c...

Page 346: ...brake caliper mounting bolt 22 N m 2 2 kgf m 16 0 lb ft Rear brake pad mounting pin 17 N m 1 7 kgf m 12 5 lb ft Install the plug 9 to the specified torque Pad pin plug 2 5 N m 0 25 kgf m 1 8 lb ft NO...

Page 347: ...the brake pads 7 69 Place a rag underneath the union bolt to catch any spilt brake fluid Disconnect the brake hose by removing the brake hose union bolt 1 Bleed air from the brake system 2 25 Do not r...

Page 348: ...ing 3 Remove the spacer 4 and boot 5 from the caliper Remove the brake caliper sliding pin 6 Place a rag over the piston to prevent it from popping out and then force out the piston using compressed a...

Page 349: ...any scratches and other damage If any damage is found replace the caliper piston with a new one BRAKE CALIPER SLIDING PIN Inspect the brake caliper sliding pin for wear and other damage If any damage...

Page 350: ...owing points Specification and Classification DOT 4 PISTON SEAL Install the piston seals as shown in the illustration Install the piston to the caliper 1 Dust seal 2 Piston seal 3 Caliper BRAKE CALIPE...

Page 351: ...ecurely Install the brake pad 7 69 Tighten the brake hose union bolt 6 with the brake hose union pipe seated in the cutout on the caliper Rear brake hose routing 9 27 Brake hose union bolt 23 N m 2 3...

Page 352: ...er rod 5 Disconnect the reservoir hose 6 Remove the connector 7 by removing the snap ring 8 Remove the O ring 9 Pull out the dust boot 0 then remove the snap ring A Remove the push rod piston primary...

Page 353: ...luid to the piston cup set Install the following parts 1 Spring 2 Piston primary cup 3 Push rod 4 Snap ring 5 Dust boot Apply the SUZUKI MOLY PASTE to the push rod 99000 25140 SUZUKI MOLY PASTE Instal...

Page 354: ...ting 9 27 Tighten the brake hose union bolt 0 to the specified torque Brake hose union bolt 23 N m 2 3 kgf m 16 5 lb ft Adjust the brake pedal height 2 24 Install the master cylinder Tighten the maste...

Page 355: ...to indicate the tire position relative to the valve position Even though the tire is refitted to the original position after repairing puncture the tire may have to be balanced again since such a repa...

Page 356: ...al deforma tion replace the valve with a new one VALVE INSTALLATION Any dust or rust around the valve hole 1 must be cleaned off Then install the valve in the rim NOTE To properly install the valve in...

Page 357: ...r 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 reuse the valve whi...

Page 358: ...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 adju...

Page 359: ...special tool DRIVE CHAIN CUTTING Set up the special tool as shown in the illustration 1 Tool body 2 Grip handle 3 Pressure bolt A 4 Pressure bolt B 5 Bar 6 Adjuster bolt with through hole 7 Pin remove...

Page 360: ...handle without hole 3 Joint plate holder 6 Pressure bolt A engraved mark F520 7 Bar 4 Wedge holder wedge pin Connect both ends of the drive chain with the joint pin 8 inserted from the wheel side A as...

Page 361: ...press the joint plate over the joint pins Continue pressing the joint plate until the distance between the two joint plates come to the specification Joint plate distance specification W JOINT PIN STA...

Page 362: ...nd diameter specification D Adjust the drive chain after connecting it 2 21 DID 5 5 5 8 mm 0 217 0 228 in After joining of the chain has been completed check to make sure that the link is smooth and n...

Page 363: ...MOVAL AND DISASSEMBLY 8 14 STARTER MOTOR INSPECTION 8 15 STARTER MOTOR REASSEMBLY 8 16 STARTER RELAY INSPECTION 8 19 SIDE STAND IGNITION INTERLOCK SYSTEM PARTS INSPECTION 8 20 IGNITION SYSTEM 8 23 TRO...

Page 364: ...es Inspect each terminal on the coupler for being loose or bent Inspect each terminal for corrosion and contamination CLAMP Clamp the wire harness at such positions as indicated in WIRE HARNESS ROUTIN...

Page 365: ...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 conven...

Page 366: ...tage 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 us...

Page 367: ...Fuel injector 4 42 3 STP sensor 4 38 4 TP sensor 4 28 5 STV actuator 4 37 6 Fuel pump 5 9 7 Speed sensor 8 35 8 Ignition coil No 1 9 CKP sensor 4 23 0 Generator 8 10 A Gear position switch 8 20 B Sid...

Page 368: ...side stand relay 8 37 6 Starter relay 8 19 7 Battery 8 IAP sensor 4 25 9 IAT sensor 4 33 0 PAIR control valve 10 7 A Regulator rectifier 8 11 B Cooling fan thermo switch 6 9 C HO2 sensor 4 47 D ECT s...

Page 369: ...essories being installed Step2 1 Check the battery for current leaks 8 9 Is the battery for current leaks OK Step3 1 Measure the charging voltage between the battery terminals 8 9 Is the battery charg...

Page 370: ...he regulator rectifier OK Step7 1 Inspect the wire harness Is the wire harness OK Battery overcharges Faulty regulator rectifier Faulty battery Poor contact of generator lead wire coupler YES Go to St...

Page 371: ...ED VOLTAGE Remove the seat 7 4 Start the engine and keep it running at 5 000 r min with the dimmer switch turned HI position Measure the DC voltage between the and battery termi nals using the multi c...

Page 372: ...7 Black Black Black Ground NOTE When making above test it is not necessary to remove the gen erator GENERATOR NO LOAD PERFORMANCE Remove the right cowling 7 5 Disconnect the generator coupler Start th...

Page 373: ...within the specified value replace the regulator rectifier with a new one 09900 25008 Multi circuit tester set Tester knob indication Diode test Unit V 1 4 V and more tester s battery voltage NOTE If...

Page 374: ...the ignition switch with the engine stop switch in the RUN position and side stand switch in the ON position 2 Listen for a click from the starter relay when the starter button is pushed Is a click so...

Page 375: ...he side stand down 1 Inspect the side stand switch 8 20 Is the side stand switch OK Engine does not turn though the starter motor runs Faulty starter clutch 3 79 YES Go to Step4 NO Faulty gear positio...

Page 376: ...tor as shown in the illustration 1 Housing end rear bracket 6 Armature A Thrust stopper 2 Brush spring 2 pcs 7 Starter motor case B O ring 2 pcs 3 Brush holder 8 Seal ring 2 pcs C O ring 4 Terminal 9...

Page 377: ...using a clean dry cloth If there is no undercut scrape out the insulator with a saw blade 1 Insulator 2 Segment ARMATURE COIL INSPECTION Check for continuity between each segment and between each seg...

Page 378: ...E A USA 99000 25010 SUZUKI SUPER GREASE A Others Apply a small quantity of SUZUKI MOLY PASTE to the arma ture shaft 99000 25140 SUZUKI MOLY PASTE Install the spacer 1 to brush terminal When installing...

Page 379: ...marks A on the rear bracket with cut point B at the starter motor case Install the washers 9 slip washer 0 and thrust stopper A NOTE The number of washer 9 varies according to individual Install the...

Page 380: ...specified torque Starter motor housing bolt 3 5 N m 0 4 kgf m 2 45 lb ft Install the starter motor Install the clamp B as shown First tighten the starter motor lower mounting bolt C then tighten the s...

Page 381: ...t tester If the starter relay clicks and continuity is found the relay is ok 09900 25008 Multi circuit tester set Tester knob indication Continuity test Measure the relay coil resistance between the t...

Page 382: ...test NOTE If the tester reads under 1 4 V when the tester probes are not connected replace its battery GEAR POSITION SWITCH Remove the left frame cover 7 5 Disconnect the gear position switch coupler...

Page 383: ...the multi circuit tester use the needle pointed probe to the back side of the lead wire coupler and connect the probes of tester to them Use a needle pointed probe outer diameter being below 0 5 mm to...

Page 384: ...er set Tester knob indication Continuity test 1 Diode 2 Side stand relay 3 Turn signal relay DIODE INSPECTION Measure the voltage between the terminals using the multi cir cuit tester Refer to the fol...

Page 385: ...ure the fuse is not blown and the battery is fully charged before diagnosing Step1 1 Check the ignition system couplers for poor connections Is there connection in the ignition switch couplers Step 2...

Page 386: ...8 26 Is the ignition coil OK Step6 1 Measure the CKP sensor peak voltage and its resistance NOTE The CKP sensor peak voltage inspection is applicable only with the multi circuit tester and peak volt a...

Page 387: ...ith peak voltage adaptor as follows No 1 ignition coil Probe White Blue terminal Probe Ground No 2 ignition coil Probe Black terminal Probe Ground 1 Peak volt adaptor 2 Ignition coil No 1 or No 2 3 Ne...

Page 388: ...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 rep...

Page 389: ...epeat the above procedure a few times and measure the highest peak voltage 1 CKP sensor 2 CKP sensor coupler 3 ECM coupler 4 Peak volt adaptor Tester knob indication Voltage CKP sensor peak voltage 3...

Page 390: ...ced and re checked 5 CKP sensor 6 CKP sensor coupler 7 Peak volt adaptor CKP SENSOR RESISTANCE Measure the resistance between the lead wires and ground If the resistance is not specified value the CKP...

Page 391: ...nation meter 1 Disassemble the combination meter as follows When disconnecting and connecting the combination meter coupler make sure to turn OFF the ignition switch or electronic parts may get damage...

Page 392: ...n 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 A pressed t...

Page 393: ...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...

Page 394: ...e A Variable resister B ECT sensor When connecting and disconnecting the ECT sensor lead wire coupler make sure to turn OFF the ignition switch or electronic parts may get damaged Resistance 1 148 k a...

Page 395: ...e at each fuel level gauge float position If the resistance is incorrect replace the fuel level gauge with a new one 09900 25008 Multi circuit tester set Tester knob indication Resistance Install the...

Page 396: ...elow If any abnor mality is found replace the combination meter with a new one OIL PRESSURE INDICATOR INSPECTION NOTE Before inspecting the oil pressure switch check the engine oil level 2 13 Disconne...

Page 397: ...7 10 Disconnect the speed sensor coupler 8 35 Remove the speed sensor Install the speed sensor in the reverse order of removal SPEED SENSOR INSPECTION Connect the four 1 5 V dry cells 10 k resistance...

Page 398: ...02 19 BRAKE LIGHT TAIL LIGHT 12 V 21 5 W TURN SIGNAL LIGHT 12 V 21 W HEADLIGHT BEAM ADJUSTMENT Adjust the headlight beam both vertical and horizontal A Vertical adjuster B Horizontal adjuster NOTE To...

Page 399: ...es 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...

Page 400: ...r 1 Remove the ignition switch mounting bolts with the special tools 09930 11920 Torx bit JT40H 09930 11940 Bit holder 1 99000 32050 THREAD LOCK 1342 USA 2 99000 32110 THREAD LOCK SUPER 1322 Others Wh...

Page 401: ...Position IGNITION SWITCH HAZARD OIL PRESSURE SWITCH PASSING LIGHT SWITCH DIMMER SWITCH HORN BUTTON FRONT BRAKE SWITCH REAR BRAKE SWITCH CLUTCH SWITCH ENGINE STOP SWITCH STARTER BUTTON TURN SIGNAL LIGH...

Page 402: ...NOTE After filling the electrolyte completely use the removed cap 2 as the sealed caps of battery filler holes Do not remove or pierce the sealed areas 3 of the electrolyte container Insert the nozzle...

Page 403: ...above the upper surface of the battery s top cover For initial charging use the charger specially designed for MF battery Never use anything except the specified battery Once the caps have been instal...

Page 404: ...echarging time 1 4 A for 5 to 10 hours or 6 A for one hour After recharging wait for more than 30 minutes and check the battery voltage with a multi circuit tester If the battery voltage is less than...

Page 405: ...OTTLE BODY INSTALLATION HOSE ROUTING 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...

Page 406: ...C15 Engine coolant tem perature sensor The sensor voltage should be the following 0 1 V sensor voltage 4 6 V Without the above range for 4 sec and more C15 is indicated Engine coolant temperature sens...

Page 407: ...e gets 1 3 V and less C32 or C33 is indicated Injector wiring coupler connection power supply to the injector C41 Fuel pump relay No voltage is applied to the both injectors 1 2 for 3 sec after the co...

Page 408: ...Clogged fuel filter or fuel hose Defective fuel pump Defective fuel pressure regulator Defective fuel injector Defective fuel pump relay Defective ECM Open circuited wiring connections 4 Incorrect fue...

Page 409: ...ECT sensor Defective thermostat Defective IAT sensor Damaged or cracked vacuum hose 2 Fuel injector improperly operating Defective fuel injectors No injection signal from ECM Open or short circuited...

Page 410: ...utch 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 jour...

Page 411: ...flow system Clogged air cleaner element Defective throttle valve Defective secondary throttle valve Sucking air from throttle body joint Defective ECM Imbalanced throttle valve synchronization 3 Defec...

Page 412: ...ective fuel pump or ECM Defective CKP sensor and ignition coils Symptom possible causes and remedy 2 Defective control circuit or sensor Low fuel pressure Defective TP sensor Defective IAT sensor Defe...

Page 413: ...ive chain is too tight Clean Add oil Replace or clean Retighten or replace Change See radiator section Repair or replace Repair or replace Repair or replace Replace Replace Replace Adjust Symptom poss...

Page 414: ...er spring on gearshift stopper Replace Replace Replace Symptom possible causes and remedy Not enough engine coolant Radiator core and oil cooler core clogged with dirt or scale Faulty cooling fan Defe...

Page 415: ...Worn front wheel bearings Defective or incorrect tire Loose axle or axle pinch bolt Incorrect front fork oil level Incorrect front wheel weight balance Replace Replace Replace Retighten Adjust Adjust...

Page 416: ...sion on friction surface of pads Worn disc Air in hydraulic system Not enough brake fluid in the reservoir Repair or replace Replace Clean disc and pads Replace Bleed air Replenish Symptom possible ca...

Page 417: ...rich Idling speed set too high Incorrect gasoline Dirty air cleaner element Too cold spark plugs Inspect FI system Adjust fast idle or throttle stop screw Change Clean or replace Replace with hot type...

Page 418: ...the battery Damaged or defective resistor element in the regulator rectifier Poorly grounded regulator rectifier Replace the battery Replace Clean and tighten ground connection Symptom possible causes...

Page 419: ...ir active material as a result of overcharging Internal short circuit in the battery Too low battery voltage Too old battery Check the generator regulator rectifier and circuit connections and make ne...

Page 420: ...rotruded section 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 provided on the frame 2 HO2 sensor...

Page 421: ...2 Magneto lead wire 4 Cut the clamp end 3 Ignition coil No 2 5 Do not slack the lead wire 1 Clamp the turn signal light read wire 6 Pass through the PAIR reed valve lead wire between the frame and PAI...

Page 422: ...ROUTING FOR E 02 19 1 2 1 HO2 sensor For E 02 19 1 Route the HO2 sensor lead wire along the fuel tank drain hose 2 HO2 sensor lead wire 2 Pass through the HO2 sensor lead wire forward the swingarm 3 W...

Page 423: ...tor lead wire Clamp Starter motor lead wire 1 Battery ground lead wire Generator cover A Starter motor lead wire mounting nut 1 45 and less ITEM N m kgf m lb ft B CKP sensor set bolt 2 First tighten t...

Page 424: ...20 mm 0 79 in 1 Speed sensor lead wire 1 Cut the clamp end 2 Clamp 2 Route speed sensor lead wire to come outside the brake hose guide 3 Brake hose 3 Route speed sensor lead wire on inside of front fo...

Page 425: ...ORMATION 9 21 THROTTLE CABLE ROUTING 1 Throttle cable No 1 4 Wiring harness 2 Throttle cable No 2 1 Fit the cable boots securely 3 Front brake hose 0 mm 0 in 0 mm 0 in 1 P a r t S h a r k c o m 8 7 7...

Page 426: ...te left handle switch wiring harness in the groove of radiator shroud 3 Handle switch wiring harness 2 Route left handle switch wiring harness to come outside throttle and clutch cables 4 Clutch cable...

Page 427: ...take pipe clamp 2 Vacuum damper 1 To canister For E 33 3 Throttle body assembly 2 Pass through the vacuum hose inside the PAIR hose 4 Air cleaner box 3 E 33 Only 5 Fuel pump assembly 4 HO2 sensor clam...

Page 428: ...hose and oil pressure switch lead wire 3 Oil pressure switch 5 Fill the bearing with engine oil until engine oil comes out from the hole of the be bearing hous ing 4 Oil filter 6 Clamp bolt head must...

Page 429: ...n point 90 90 1 Clamp 2 Matching mark White 2 Jiggle valve 3 Marking Yellow 3 Union 4 Clamp bolt head must face downward 4 Radiator hose 5 Clamp bolt head must face left side 1 Marking 6 Leave clearan...

Page 430: ...topper 21 Brake hose 42 1 After the brake hose union has contacted the stopper tighten the union bolt 4 Assemble the brake hose firmly 2 After positioning the brake hose junction with the stopper tigh...

Page 431: ...A A 1 Frame 1 Clamp ends should face forward 2 Stopper 2 White paint faces outside 3 Brake hose 3 After the brake hose union has contacted the stopper tighten the union bolt 4 Brake hose guide 4 Pass...

Page 432: ...2 1 Route fuel tank drain hose so that its curve faces forward 3 Make sure to position the clamp in the specified direction 2 Route fuel tank drain hose to come inside left side gear position sensor...

Page 433: ...29 FUEL TANK INSTALLATION 1 2 mm 0 04 0 08 in 27 mm 1 06 in 1 1 Fuel tank center shield 1 Align the front end of fuel tank center shield with this position 2 Fuel tank side cushion P a r t S h a r k c...

Page 434: ...ING INFORMATION PAIR AIR SUPPLY SYSTEM HOSE ROUTING 1 1 Matching mark White 1 Pass the PAIR hose between the cylinder head cover and intake pipe 2 Matching mark Yellow P a r t S h a r k c o m 8 7 7 9...

Page 435: ...MP SET UP 1 Seat lock cable VIEW OF LEFT VIEW OF TOP 1 2 3 1 Adhere cushion along the ridge line of lens 3 Right and left cushions shall be attached sym metrically 2 Start to adhere cushion from the c...

Page 436: ...ABSORBER HOSE ROUTING BATTERY CUSHION INSTALLATION 1 Absorber hose 3 Rear fender Front 2 Clamp 1 1 FRONT VIEW OF LEFT 12 Battery protector 1 Adhere battery protector at the upper end P a r t S h a r k...

Page 437: ...ION 9 33 SIDE STAND SET UP BRAKE PEDAL FOOTREST SET UP ITEM N m kgf m lb ft A 40 4 0 29 0 B 50 5 0 36 0 C 100 10 0 72 5 1 Pin 3 Footrest 2 E ring 4 Brake light switch A A A A P a r t S h a r k c o m 8...

Page 438: ...9 34 SERVICING INFORMATION ENGINE CAP INSTALLATION 1 VIEW OF RIGHT VIEW OF LEFT 1 Engine cap 1 Push the center of cap so as to thoroughly remove looseness P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6...

Page 439: ...FOOTREST SET UP HANDLEBAR BALANCER INSTALLATION NOTE After installing the RH balancer weight check that throttle grip rotate smoothly by turning it ITEM N m kgf m lb ft A 5 5 0 55 4 P a r t S h a r k...

Page 440: ...1 mm 09900 20607 Dial gauge 1 100 mm 10 mm 09900 20701 Magnetic stand 09900 20803 09900 20806 Thickness gauge 09900 20805 Tire depth gauge 09900 21304 V block set 100 mm 09900 22301 09900 22302 Plast...

Page 441: ...hment 09915 77331 Meter for high pressure 09916 10911 Valve lapper set 09916 14510 Valve lifter 09916 14521 Valve lifter attachment 09916 21111 Valve seat cutter set 09916 20640 Solid pilot N 100 4 5...

Page 442: ...h set 09930 11920 Torx bit JT40H 09930 11940 Bit holder 09930 11950 Torx wrench 09930 11960 Torx wrench 09930 30450 Rotor remover 09930 44530 Rotor holder 09930 82720 Mode select switch 09940 14911 St...

Page 443: ...e gauge adaptor 09940 40220 Fuel pressure gauge hose attachment 09940 52861 Front fork oil seal installer 09940 92720 Spring scale 09941 34513 Bearing steering race installer set 09941 54911 Bearing o...

Page 444: ...ve gear bolt 70 7 0 50 5 Generator cover plug 10 1 0 7 0 Valve timing inspection plug 23 2 3 16 3 Generator rotor bolt 120 12 0 87 Starter clutch bolt 25 2 5 18 0 Generator stator set bolt 11 1 1 8 0...

Page 445: ...4 5 32 5 Engine mounting bracket bolt 35 3 5 25 5 Engine mounting pinch bolt 25 2 5 18 0 Cooling fan thermo switch 17 1 7 12 5 ECT sensor 19 1 9 13 5 Fuel pump mounting bolt 10 1 0 7 0 Fuel delivery p...

Page 446: ...and Rear 23 2 3 16 5 Rear brake caliper mounting bolt 22 2 2 16 0 Rear brake caliper sliding pin 27 2 7 19 5 Rear brake pad mounting pin 17 1 7 12 5 Rear brake pad mounting pin plug 2 5 0 25 1 8 Rear...

Page 447: ...ked bolt N m kgf m lb ft N m kgf m lb ft 4 1 5 0 15 1 0 2 3 0 23 1 5 5 3 0 3 2 0 4 5 0 45 3 0 6 5 5 0 55 4 0 10 1 0 7 0 8 13 1 3 9 5 23 2 3 16 5 10 29 2 9 21 0 50 5 0 36 0 12 45 4 5 32 5 85 8 5 61 5 1...

Page 448: ...1776 Valve stem O D IN 4 465 4 480 0 1758 0 1764 EX 4 455 4 470 0 1754 0 1760 Valve stem deflection IN EX 0 35 0 014 Valve stem runout IN EX 0 05 0 002 Valve head thickness IN EX 0 5 0 02 Valve seat...

Page 449: ...3201 33 18 1 3063 Camshaft journal oil clearance IN EX 0 032 0 066 0 0013 0 0026 0 150 0 0059 Camshaft journal holder I D IN EX 22 012 22 025 0 8666 0 8671 Camshaft journal O D IN EX 21 959 21 980 0 8...

Page 450: ...7 7 6 0 30 2nd Approx 11 0 43 8 8 0 35 Piston ring end gap 1st 0 20 0 35 0 008 0 014 0 70 0 028 2nd 0 20 0 35 0 008 0 0014 0 70 0 028 Piston ring to groove clearance 1st 0 180 0 0071 2nd 0 150 0 0059...

Page 451: ...0 Crankshaft journal oil clearance 0 002 0 029 0 0001 0 0011 0 080 0 0031 Crankshaft journal O D 41 985 42 000 1 6529 1 6535 Crankshaft runout 0 05 0 002 ITEM STANDARD LIMIT Oil pressure at 60 C 140 F...

Page 452: ...18 3rd 1 380 29 21 4th 1 125 27 24 5th 0 961 25 26 Top 0 851 23 27 Shift fork to groove clearance 0 1 0 3 0 004 0 012 0 50 0 020 Shift fork groove width 5 5 5 6 0 217 0 220 Shift fork thickness 5 3 5...

Page 453: ...g fan thermo switch operating temperature OFF ON Approx 98 C 208 F ON OFF Approx 92 C 198 F Engine coolant type Use an antifreeze coolant compatible with aluminum radiator mixed with distilled water o...

Page 454: ...r input voltage 4 5 5 5 V IAT sensor resistance Approx 2 45 k at 20 C 68 F TO sensor resistance 19 1 19 7 k TO sensor voltage Normal 0 4 1 4 V Br W B Br Leaning 65 3 7 4 4 V GP switch voltage 1 0 V an...

Page 455: ...peak voltage 3 7 V and more When cranking Ignition coil primary peak voltage 150 V and more Generator coil resistance 0 2 0 7 Generator Max output Approx 375 W at 5 000 r min Generator no load voltage...

Page 456: ...arking light 12 V 5 W 2 Brake light Taillight 12 V 21 5 W 2 Turn signal light 12 V 21 W License light 12 V 5 W Speedometer light LED Turn signal indicator light LED High beam indicator light LED Neutr...

Page 457: ...cylinder piston diam Front 15 827 15 854 0 6231 0 6242 Rear 13 957 13 984 0 5495 0 5506 Brake caliper cylinder bore Front 30 230 30 306 1 1902 1 1931 Rear 38 180 38 256 1 5031 1 5061 Brake caliper pi...

Page 458: ...Front fork stroke 150 5 9 Front fork spring free length 444 1 17 5 435 17 1 Front fork oil level without spring outer tube fully compressed 143 5 63 Front fork spring adjuster 3 groove from Top Sprin...

Page 459: ...than 5 methanol with appropriate cosolvents and corrosion inhibitor is permissible E 03 28 33 Gasoline used should be graded 91 octane or higher An unleaded gasoline is recommended Others Fuel tank ca...

Page 460: ...P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6...

Page 461: ...ATIVE EMISSION CONTROL SYSTEM Only for E 33 10 5 PAIR AIR SUPPLY SYSTEM INSPECTION 10 6 HOSES 10 6 PAIR REED VALVE 10 6 PAIR CONTROL SOLENOID VALVE 10 7 PAIR AIR SUPPLY SYSTEM HOSE ROUTING 10 8 HEATED...

Page 462: ...l This fuel injection system is precision designed manufactured and adjusted to comply with the applicable emission limits 1 Fuel filter For high pressure A BEFORE PRESSURIZED FUEL 2 Fuel pressure reg...

Page 463: ...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 1 PAIR reed valve A FRESH AIR 2 Breather hose B...

Page 464: ...and 28 The fresh air is drawn into the exhaust port with the PAIR solenoid valve and PAIR reed valve The PAIR solenoid valve is operated by the ECM and the fresh air flow is controlled according to th...

Page 465: ...E ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW Removing or puncturing the muffler baffles header pipes screen type spark arrester if equipped or any other component which conducts e...

Page 466: ...ve cover 3 36 Inspect the reed valve for the carbon deposit If the carbon deposit is found in the reed valve replace the PAIR reed valve with a new one Installation is in the reverse order of removal...

Page 467: ...rminals 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 PAIR con trol solenoid valve Resistance 20 24 at 20...

Page 468: ...10 8 EMISSION CONTROL INFORMATION PAIR AIR SUPPLY SYSTEM HOSE ROUTING 9 30 HEATED OXYGEN SENSOR HO2S WIRE ROUTING E 02 19 9 18 P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6...

Page 469: ...sensor with a new one NOTE Temperature of the sensor affects resistance value largely Make sure that the sensor heater is at correct temperature Connect the HO2 sensor coupler securely Installation is...

Page 470: ...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 A positioned upward the air can pass through to the canister si...

Page 471: ...mp ends should face outside 2 Wiring harness 3 White paint mark should face top side 3 EVAP canister 4 Pass through the purge hose between the frame and wiring harness 4 Frame 5 To throttle body 1 Cla...

Page 472: ...P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6...

Page 473: ...are the same as K4 MODEL CONTENTS DL650K5 05 MODEL DL650K5 05 MODEL 11 11 1 SERVICE DATA 11 3 SPECIFICATIONS 11 2 EXHAUST PIPE MUFFLER INSTALLATON 11 15 STARTER BUTTON INSPECTION INFORMATION 11 15 P a...

Page 474: ...k type coil spring oil damped Front fork stroke 150 mm 5 9 in Rear wheel travel 150 mm 5 9 in Caster 26 Trail 110 mm 4 33 in Steering angle 40 right left Turning radius 2 6 m 8 5 ft Front brake Disc b...

Page 475: ...55 4 470 0 1754 0 1760 Valve stem deflection IN EX 0 35 0 014 Valve stem runout IN EX 0 05 0 002 Valve head thickness IN EX 0 5 0 02 Valve seat width IN EX 0 9 1 1 0 035 0 043 Valve head radial runout...

Page 476: ...EX 0 032 0 066 0 0013 0 0026 0 150 0 0059 Camshaft journal holder I D IN EX 22 012 22 025 0 8666 0 8671 Camshaft journal O D IN EX 21 959 21 980 0 8645 0 8654 Camshaft runout IN EX 0 10 0 004 Cam cha...

Page 477: ...iston ring free end gap 1st Approx 9 5 0 37 7 6 0 30 2nd Approx 11 0 43 8 8 0 35 Piston ring end gap 1st 0 20 0 35 0 008 0 014 0 70 0 028 2nd 0 20 0 35 0 008 0 0014 0 70 0 028 Piston ring to groove cl...

Page 478: ...01 0 0011 0 080 0 0031 Crankshaft journal O D 41 985 42 000 1 6529 1 6535 Crankshaft runout 0 05 0 002 ITEM STANDARD LIMIT Oil pressure at 60 C 140 F Above 100 kPa 1 0 kgf cm 14 psi Below 400 kPa 4 0...

Page 479: ...Top 0 851 23 27 Shift fork to groove clearance 0 1 0 3 0 004 0 012 0 50 0 020 Shift fork groove width 5 5 5 6 0 217 0 220 Shift fork thickness 5 3 5 4 0 209 0 213 Drive chain Type DID525V8 Links 116 l...

Page 480: ...prox 98 C 208 F ON OFF Approx 92 C 198 F Engine coolant type Use an antifreeze coolant compatible with aluminum radiator mixed with distilled water only at the ratio of 50 50 Engine coolant including...

Page 481: ...rox 2 45 k at 20 C 68 F TO sensor resistance 19 1 19 7 k TO sensor voltage Normal 0 4 1 4 V Br W B Br Leaning 65 3 7 4 4 V GP switch voltage 1 0 V and more From 1st to Top Injector voltage Battery vol...

Page 482: ...oil primary peak voltage 150 V and more Generator coil resistance 0 2 0 7 Generator Max output Approx 375 W at 5 000 r min Generator no load voltage When cold 60 V AC and more at 5 000 r min Regulated...

Page 483: ...21 5 W 2 Turn signal light 12 V 21 W License light 12 V 5 W Speedometer light LED Turn signal indicator light LED High beam indicator light LED Neutral indicator light LED Oil pressure Coolant temp Fu...

Page 484: ...242 Rear 13 957 13 984 0 5495 0 5506 Brake caliper cylinder bore Front 30 230 30 306 1 1902 1 1931 Rear 38 180 38 256 1 5031 1 5061 Brake caliper piston diam Front 30 150 30 200 1 1870 1 1890 Rear 38...

Page 485: ...ngth 444 1 17 5 435 17 1 Front fork oil level without spring outer tube fully compressed 143 5 63 Front fork spring adjuster 3 groove from Top Spring adjuster height 9 mm 0 35 in Front fork oil type S...

Page 486: ...and corrosion inhibitor is permissible E 03 28 33 Gasoline used should be graded 91 octane or higher An unleaded gasoline is recommended Others Fuel tank capacity 22 L 5 8 4 8 US lmp gal Engine oil ty...

Page 487: ...es with new ones WIRE COLOR O R Orange with Red tracer O W Orange with White tracer Y G Yellow with Black tracer Y W Yellow with White tracer Apply PARMATEX 1372 Apply PARMATEX 1372 ITEM N m kgf m lb...

Page 488: ...03 ENGINE book Page 105 Tuesday February 28 2006 3 03 PM P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6...

Page 489: ...arly indicated with the asterisk marks CONTENTS DL650K6 06 MODEL DL650K6 06 MODEL 12 12 1 EMISSION CONTROL SYSTEM 12 15 SPECIFICATIONS 12 2 SERVICE DATA 12 3 This chapter describes service data servic...

Page 490: ...ear suspension Link type coil spring oil damped Front fork stroke 150 mm 5 9 in Rear wheel travel 150 mm 5 9 in Caster 26 Trail 110 mm 4 33 in Steering angle 40 right left Turning radius 2 6 m 8 5 ft...

Page 491: ...5 4 480 0 1758 0 1764 EX 4 455 4 470 0 1754 0 1760 Valve stem deflection IN EX 0 35 0 014 Valve stem runout IN EX 0 05 0 002 Valve head thickness IN EX 0 5 0 02 Valve seat width IN EX 0 9 1 1 0 035 0...

Page 492: ...aft journal oil clearance IN EX 0 032 0 066 0 0013 0 0026 0 150 0 0059 Camshaft journal holder I D IN EX 22 012 22 025 0 8666 0 8671 Camshaft journal O D IN EX 21 959 21 980 0 8645 0 8654 Camshaft run...

Page 493: ...nder distortion 0 05 0 002 Piston ring free end gap 1st Approx 9 5 0 37 7 6 0 30 2nd Approx 11 0 43 8 8 0 35 Piston ring end gap 1st 0 20 0 35 0 008 0 014 0 70 0 028 2nd 0 20 0 35 0 008 0 0014 0 70 0...

Page 494: ...l clearance 0 002 0 029 0 0001 0 0011 0 080 0 0031 Crankshaft journal O D 41 985 42 000 1 6529 1 6535 Crankshaft runout 0 05 0 002 ITEM STANDARD LIMIT Oil pressure at 60 C 140 F Above 100 kPa 1 0 kgf...

Page 495: ...1 125 27 24 5th 0 961 25 26 Top 0 851 23 27 Shift fork to groove clearance 0 1 0 3 0 004 0 012 0 50 0 020 Shift fork groove width 5 5 5 6 0 217 0 220 Shift fork thickness 5 3 5 4 0 209 0 213 Drive cha...

Page 496: ...rating temperature OFF ON Approx 98 C 208 F ON OFF Approx 92 C 198 F Engine coolant type Use an antifreeze coolant compatible with aluminum radiator mixed with distilled water only at the ratio of 50...

Page 497: ...V IAT sensor resistance Approx 2 45 k at 20 C 68 F TO sensor resistance 19 1 19 7 k TO sensor voltage Normal 0 4 1 4 V Br W B Br Leaning 65 3 7 4 4 V GP switch voltage 1 0 V and more From 1st to Top...

Page 498: ...more When cranking Ignition coil primary peak voltage 150 V and more Generator coil resistance 0 2 0 7 Generator Max output Approx 375 W at 5 000 r min Generator no load voltage When cold 60 V AC and...

Page 499: ...Brake light Taillight 12 V 21 5 W 2 Turn signal light 12 V 21 W License light 12 V 5 W Speedometer light LED Turn signal indicator light LED High beam indicator light LED Neutral indicator light LED...

Page 500: ...ront 15 827 15 854 0 6231 0 6242 Rear 13 957 13 984 0 5495 0 5506 Brake caliper cylinder bore Front 30 230 30 306 1 1902 1 1931 Rear 38 180 38 256 1 5031 1 5061 Brake caliper piston diam Front 30 150...

Page 501: ...5 9 Front fork spring free length 444 1 17 5 435 17 1 Front fork oil level without spring outer tube fully compressed 143 5 63 Front fork spring adjuster 3 groove from Top Spring adjuster height 9 mm...

Page 502: ...opriate cosolvents and corrosion inhibitor is permissible E 03 28 33 Gasoline used should be graded 91 octane or higher An unleaded gasoline is recommended Others Fuel tank capacity 22 L 5 8 4 8 US lm...

Page 503: ...he PAIR solenoid valve and PAIR reed valve The PAIR solenoid valve is operated by the ECM and the fresh air flow is controlled according to the TPS ECTS IATS and IAPS 1 ECM 6 HO2 sensor E 02 19 2 Air...

Page 504: ...P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6...

Page 505: ...ULE 13 11 PERIODIC MAINTENANCE CHART 13 11 MAINTENANCE AND TUNE UP PROCEDURES 13 12 SPARK PLUG 13 12 THROTTLE CABLE PLAY 13 14 THROTTLE VALVE SYNCHRONIZATION 13 14 FI SYSTEM DIAGNOSIS 13 15 ECM TERMIN...

Page 506: ...JS1VP54B 72100001 DL650P E 41 Greece JS1B1111100100001 DL650AP E 41 Greece JS1B1112100100001 DL650UE E 19 E U JS1B1211100100001 DL650AUE E 19 E U JS1B1212100100001 13 2 DL650K7 AK7 07 MODEL ABS UNIT S...

Page 507: ...l 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 Canister Canister...

Page 508: ...S SAE Society of Automotive Engineers SDS Suzuki Diagnosis System STC System Secondary Throttle Control System STCS STP Sensor Secondary Throttle Position Sensor STPS ST Valve Secondary Throttle Valv...

Page 509: ...Connector DLC Dealer Mode Coupler Diagnostic Test Mode DTM Diagnostic Trouble Code DTC Diagnostic Code Malfunction Code E Electronic Ignition El Engine Control Module ECM Engine Control Module ECM Fl...

Page 510: ...c Open Loop OL P Programmable Read Only Memory PROM Pulsed Secondary Air lnjection PAIR Pulse Air Control PAIR Purge Valve Purge Valve Purge Valve SP Valve R Random Access Memory RAM Read Only Memory...

Page 511: ...ers 2 Bore 81 0 mm 3 189 in Stroke 62 6 mm 2 465 in Displacement 645 cm3 39 4 cu in Compression ratio 11 5 1 Fuel system Fuel injection Air cleaner Non woven fabric element Starter system Electric Lub...

Page 512: ...generator Main fuse 30 A Fuse 15 15 10 10 15 15 A Headlight 12 V 60 55 W 2 H4 Position Parking light 12 V 5 W 2 Except for E 03 24 28 33 Brake light Taillight 12 V 21 5 W 2 Licence plate light 12 V 5...

Page 513: ...ers 2 Bore 81 0 mm 3 189 in Stroke 62 6 mm 2 465 in Displacement 645 cm3 39 4 cu in Compression ratio 11 5 1 Fuel system Fuel injection Air cleaner Non woven fabric element Starter system Electric Lub...

Page 514: ...30 A Fuse 15 15 10 10 15 15 A ABS fuse 40 25 A Headlight 12 V 60 55 W 2 H4 Position Parking light 12 V 5 W 2 Except for E 03 24 28 33 Brake light Taillight 12 V 21 5 W 2 Licence plate light 12 V 5 W T...

Page 515: ...as necessary R Replace T Tighten Interval Item km 1 000 6 000 12 000 18 000 24 000 miles 600 4 000 7 500 11 000 14 500 months 2 12 24 36 48 Air cleaner element I I R I Exhaust pipe bolts and muffler b...

Page 516: ...emove the radiator mounting bolt Move the radiator lower side to forward Remove the spark plug caps 1 2 NOTE Be careful not to damage the radiator fins Remove the spark plugs with the special tool 099...

Page 517: ...gauge If out of specifi cation adjust it to the following gap Spark plug gap A Standard 0 7 0 8 mm 0 028 0 031 in 09900 20803 Thickness gauge ELECTRODES CONDITION Check to see the worn or burnt condi...

Page 518: ...adjuster 6 Third step While holding the throttle grip at the fully closed position slowly turn out the adjuster 3 of the throttle returning cable 1 to feel resistance Tighten the lock nut 2 while hol...

Page 519: ...0 Power source for back up Q CKP sensor signal CKP A Power source R B Sensor ground E2 S Blank C ECM ground E1 T Blank D U Serial data for speedometer TECH E V Serial data for self diagnosis F W G HO2...

Page 520: ...or Engine coolant temperature value is fixed to 80 C YES YES Intake air temperature sensor Intake air temperature value is fixed to 40 C YES YES Ignition signal 1 IG coil 1 1 Ignition off and 1 Fuel c...

Page 521: ...ted to VCC or ground circuit open L Sensor voltage is lower than specified value TP sensor circuit open or shorted to ground or VCC circuit open C15 P0115 ECT sensor The sensor voltage should be the f...

Page 522: ...no actuator control signal is supplied from the ECM communica tion signal does not reach ECM or operation voltage does not reach STVA motor C28 P1655 is indicated STVA can not operate STVA motor STVA...

Page 523: ...sition is incorrect C41 P0230 Fuel pump relay No voltage is applied to the fuel pump although fuel pump relay is turned ON or voltage is applied to fuel pump although fuel pump relay is turned OFF Fue...

Page 524: ...AP sensor 1 Turn the ignition switch OFF 2 Lift and support the fuel tank DL650K4 5 7 ECM coupler Harness side DETECTED CONDITION POSSIBLE CAUSE IAP sensor voltage low or high 0 1 V Sensor voltage 4 8...

Page 525: ...ensor output voltage at the wire side coupler Front cylinder side between G B and B Br wires Rear cylinder side between G Y and B Br wires IAP sensor output voltage Approx 1 6 V at idle speed Front cy...

Page 526: ...86 F YES G B R or B Br wire open or shorted to ground or poor 3 5 or B connection Front cylinder side R B Br or G Y wire open or shorted to ground or poor 5 B or L connection Rear cylinder side If wi...

Page 527: ...P0120 Output voltage is not within the following range Difference between actual throttle open ing and opening calculated by ECM is larger than specified value 0 1 V Sensor voltage 4 8 V TP sensor mal...

Page 528: ...Approx 4 3 V 09900 25008 Multi circuit tester set 09900 28630 TPS test wire harness Tester knob indication Voltage Is the voltage OK YES Go to Step 2 NO Loose or poor contacts on the ECM coupler termi...

Page 529: ...sensor coupler for loose or poor contacts If OK then measure the IAT sensor voltage at the wire side coupler 4 Disconnect the IAT sensor coupler and turn the ignition switch ON ECM coupler Harness sid...

Page 530: ...TE IAT sensor resistance measurement method is the same way as that of the EOT sensor Refer to DL650 service manual 6 10 for details YES Go to Step 2 NO Loose or poor contacts on the ECM coupler Termi...

Page 531: ...are located as shown in the illustration Refer to the DL650 service manual 4 35 for details C24 P0351 or C25 P0352 IGNITION SYSTEM MALFUNCTION When indicating C24 P0351 for IG coil 1 When indicating...

Page 532: ...ull open 10 open Is the operating OK DETECTED CONDITION POSSIBLE CAUSE The operation voltage does not reach the STVA ECM does not receive communication signal from the STVA STVA malfunction STVA circu...

Page 533: ...C Terminal D 09900 25008 Multi circuit tester set Tester knob indication Resistance Is the resistance OK 2 2 YES B Lg P W G and W B wire open or shorted to ground or poor Y d and f connection If wire...

Page 534: ...anual for further details 2 Turn the ignition switch ON 3 Click Secondary throttle operating control 1 4 Click each button 2 At this time if an operation sound is heard from the STVA the function is n...

Page 535: ...age Is the voltage OK DETECTED CONDITION POSSIBLE CAUSE C29 P1654 Signal voltage is not within the following range Difference between actual throttle open ing and opening calculated by ECM is larger t...

Page 536: ...t Tester knob indication Voltage Is the voltage OK C31 P0705 GP SWITCH CIRCUIT MALFUNCTION On model K7 the connector terminals to be used for checking sensors for voltage resistance or continuity at t...

Page 537: ...ontacts If OK then measure the injector resistance 4 Disconnect the injector coupler and measure the resistance between terminals Injector resistance 11 13 at 20 C 68 F Terminal Terminal DETECTED COND...

Page 538: ...25008 Multi circuit tester set Tester knob indication Voltage Is the voltage OK YES Go to Step 2 NO Replace the injector with a new one Page 54 YES Gr B wire open or shorted to ground or poor k conne...

Page 539: ...SC valve hose C40 P0506 Idle speed is lower than the desired idle speed Air passage clogged ISC valve is fixed ISC valve PRE SET position is incorrect C40 P0507 Idle speed is higher than the desired i...

Page 540: ...d 4 ISC valve continuity Approx Infinity Terminal 1 Terminal 3 Terminal 2 Terminal 4 4 If OK then measure the resistance between terminals 1 and 2 terminals 3 and 4 ISC valve resistance Approx 30 1 2...

Page 541: ...in the specified idle rpm Check 2 1 Click the button 1 and decrease the Spec 2 to 1 200 rpm slowly 2 Check that the Desired idle speed 3 is nearly equal to the Spec 2 At the same time check that the n...

Page 542: ...Increase the Spec 1 to 1 800 rpm 2 Check that the Desired idle speed 2 is approx 1 800 rpm 3 Check that the Engine speed 3 is close to 1 800 rpm NOTE Be careful not to increase the Spec to more than 1...

Page 543: ...sistance or continuity at the ECM terminal are located as shown in the illustration Refer to the DL650 service manual 4 44 for details C42 P01650 IG SWITCH CIRCUIT MALFUNCTION Refer to the DL650 servi...

Page 544: ...rd from the tester the circuit condi tion is OK 09900 25008 Multi circuit tester set Tester knob indication Continuity test DETECTED CONDITION POSSIBLE CAUSE C44 P0130 HO2 sensor output voltage is not...

Page 545: ...tput voltage at idle speed 0 4 V and less W G B Br 4 If OK then pinch the PAIR hose 1 with a proper hose clamp 5 Measure the HO2 sensor output voltage while holding the engine speed at 5 000 r min HO2...

Page 546: ...ater resistance 11 15 at 23 C 73 4 F White White 09900 25008 Multi circuit tester set Tester knob indication Resistance Is the voltage OK YES W G wire or B Br wire open or shorted to ground or poor 6...

Page 547: ...E CIRCUIT MALFUNCTION On model K7 the connector terminals to be used for checking sensors for voltage resistance or continuity at the ECM terminal are located as shown in the illustration Refer to the...

Page 548: ...and apply 12 volts to the fuel pump between Y R wire and B W wire for 6 seconds and measure the amount of fuel discharged Battery terminal Yellow with red tracer Battery terminal Black with white trac...

Page 549: ...l level gauge 5 Fuel pump 2 O ring 6 Fuel mesh filter 3 Fuel pressure regulator 7 O ring ITEM N m kgf m lb ft 4 O ring A Fuel pump mounting bolt A 10 1 0 7 0 DL650K7 AK7 07 MODEL 13 45 P a r t S h a r...

Page 550: ...ving its mounting bolts diagonally DISASSEMBLY Remove the screws Disconnect the terminals and Remove the fuel level gauge 1 Remove the fuel pressure regulator holder 2 Gasoline is highly flammable and...

Page 551: ...pressure regulator 3 Remove the O ring 4 and fuel pump holder 5 Remove the fuel mesh filter 6 Remove the fuel pump 7 Remove the fuel joint pipe 8 DL650K7 AK7 07 MODEL 13 47 P a r t S h a r k c o m 8 7...

Page 552: ...fuel filter cartridge with a new one FUEL PUMP REASSEMBLY AND INSTALLATION Reassemble and Install the fuel pump in the reverse order of removal Pay attention to the following points Install the new O...

Page 553: ...ding 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 0 lb ft NOTE Apply a small quantity of the THREAD LOCK to t...

Page 554: ...rod 3 O ring 0 STVA 4 Fuel delivery pipe hose A STP sensor mounting screw ITEM N m kgf m lb ft 5 Fuel injector B TP sensor mounting screw A 3 5 0 35 2 5 6 O ring C Fuel delivery pipe mounting screw B...

Page 555: ...er 3 Remove the clamp and disconnect the IAP sensor F coupler 4 Loosen the throttle body clamp screws Disconnect the PAIR hose and ISC valve hose Disconnect the PAIR lead wire coupler 5 Disconnect the...

Page 556: ...ous lead wire couplers 1 TP sensor 2 STP sensor 3 STVA Remove the injector lead wire couplers Disconnect the ISC valve hoses Loosen the throttle body clamp screws 13 52 DL650K7 AK7 07 MODEL P a r t S...

Page 557: ...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...

Page 558: ...ensor s original position with a paint or scribe for accurate reinstallation Never remove the STVA 9 and throttle body link plates 0 These adjusting screws A B C are factory adjusted at the time of de...

Page 559: ...ns are very corrosive and must be handled carefully Always follow the chemical man ufacturer s instructions for proper use handling and storage Do not use wire to clean passageways Wire can dam age pa...

Page 560: ...kgf m 2 5 lb ft NOTE Make sure the STP valve open or close smoothly If the STP sensor adjustment is necessary refer to page 59 for STP sensor setting procedure With the throttle valve fully closed in...

Page 561: ...ghten the fuel delivery pipe mounting screws to the speci fied torque Fuel delivery pipe mounting screw 5 N m 0 5 kgf m 3 5 lb ft Install the throttle link rod 8 and secondary throttle link rod 9 NOTE...

Page 562: ...at each coupler is installed in the correct position The color on each lead wire coupler refers to the appropriate fuel injector Front injector lead wire coupler 3 Brown Rear injector lead wire couple...

Page 563: ...er and measure the STP sensor out put voltage STP sensor output voltage ST valve is full closed Approx 0 6 V Yellow B Br 09900 25008 Multi circuit tester set 09900 25009 Needle pointed probe set Teste...

Page 564: ...0K4 5 7 5 If the throttle position sensor adjustment is necessary loosen the screw and turn the throttle position sensor and bring the line to the middle 6 Then tighten the screw to fix the throttle p...

Page 565: ...t the fuel tank DL650K4 5 7 Remove the rubber caps 1 from each vacuum nipple on the throttle body Connect the vacuum tester hoses 2 to each vacuum nipple Step 2 Connect a tachometer Set up the SDS too...

Page 566: ...nd keep it running at idling speed NOTE Always set the engine rpm at idle rpm 09913 10130 Carburetor adjuster driver If the adjustment is not yet correct remove each air screw and clean them with a sp...

Page 567: ...new one Visual inspection Remove the screws Check the ISC valve for wear damage or carbon deposited replace it with a new one Be careful not to disconnect the ISC valve coupler at least 5 seconds afte...

Page 568: ...l tool to the dealer mode coupler and turn its switch to ON position 09930 82720 Mode select switch 4 Turn the ignition switch to the ON position 5 Turn the ignition switch to the OFF position 6 Then...

Page 569: ...lead wire coupler for B W wire 09900 25009 Needle pointed probe set Connect the multi circuit tester with the peak voltage adaptor as follows Ignition coil for 1cylinder B W wire Probe Ground Probe NO...

Page 570: ...inted probe Ignition coil primary peak voltage 150 V and more Tester knob indication Voltage If the voltages are lower than the standard values inspect the ignition coil below IGNITION COIL RESISTANCE...

Page 571: ...Yellow Black and Black White lead wires at the wire harness Turn the ignition switch ON position and wait for approx 40 seconds Check the display of fuel meter as shown below If any abnor mality is fo...

Page 572: ...UNIT ABS control unit calculates signals input from each one of front and rear wheel speed sensors monitors the slipping conditions of the wheels and at the same time sends control signal to Hydraulic...

Page 573: ...alculating process Calculating process when a malfunction occurs Ignition switch turned to ON ABS control unit Initialization Self diagnosis during start up Self diagnosis while riding Wheel speed sen...

Page 574: ...the rear except for the pump drive motor which is shared by both systems Rear brake switch Rear wheel speed sensor Front wheel speed sensor Rear system Front system ABS indicator light Front brake swi...

Page 575: ...function The special tool when connected to the mode select coupler enables the ABS indicator light to display the diagnostic trouble codes ABS INDICATOR LIGHT The ABS indicator light informs the ride...

Page 576: ...hen connecting meter probe from the terminal side of the coupler where connection from harness side not being possi ble use extra care not to force and cause the male terminal to bend or the female te...

Page 577: ...E For battery and battery connection precautions DL650K4 4 4 and 8 3 ABS CONTROL UNIT HU Never allow dust or water to contact the ABS control unit HU Never subject the ABS control unit HU to strong im...

Page 578: ...ion USING THE TESTER Incorrectly connecting the and probes may cause the inside of the tester to burnout If the voltage and current are not known make measure ments using the highest range When measur...

Page 579: ...ON 1 ABS indicator light 4 ABS control unit HU 2 Front wheel speed sensor rotor 5 Rear wheel speed sensor rotor 3 Front wheel speed sensor 6 Rear wheel speed sensor DL650K7 AK7 07 MODEL 13 75 P a r t...

Page 580: ...25A B O R R B B W B R W Y Gr R Bl W R O Y B Y HEAD HI IGNITION SIGNAL HEAD LO FUEL FAN SPARE SPARE WIRE COLORS B Bl Br O G O R O Y P W R B R W W R W Y Y B Black Blue Brown Orange with Green tracer Or...

Page 581: ...OCK P IGNITION SWITCH BATTERY 1 MAIN 30 A STARTER RELAY 1 FUSE BOX 1 HEAD HI 2 HEAD LO 3 FUEL 4 IGNITION 5 SIGNAL 6 FAN 15 A 15 A 10 A 10 A 15 A 15 A 1 2 3 4 5 6 ABS FWS RWS ABS VALVE FUSE 25 A ABS MO...

Page 582: ...ght 25 11 16 5 7 19 4 1 3 2 12 18 4 3 2 1 15 14 13 12 11 10 9 8 7 6 5 26 25 24 23 22 21 20 19 18 17 16 1 Front inlet valve 2 Front outlet valve 3 Rear inlet valve 4 Rear outlet valve Fuse 40 A Fuse 25...

Page 583: ...PERATION AND ABS INDICATOR LIGHT The ABS indicator light shows the ABS operating condition Dur ing normal operation the ABS indicator light lights up when the ignition switch is turned to ON and goes...

Page 584: ...g to the DTCs output Page 90 If troubleshooting procedures cannot be performed try to determine the cause of the malfunction according to the information gathered in 1 through 4 and inspect the wiring...

Page 585: ...the ABS control unit Page 89 7 Delete the DTCs and check the brake operation Page 91 5 Perform appropriate troubleshooting procedures according to the DTCs output Page 90 If troubleshooting procedure...

Page 586: ...erefore a questionnaire has been created to improve the information gathering proce dure Questionnaire Example NOTE The above form is a standard sample It should be modified according to characteristi...

Page 587: ...tion switch to OFF Remove the seat DL650K4 7 4 Measure the voltage between the and battery terminals using the multi circuit tester Battery voltage 12 0 V and more 09900 25008 Multi circuit tester set...

Page 588: ...sor rotor clearance 0 3 1 5 mm 0 012 0 059 in 09900 20803 Thickness gauge 09900 20806 Thickness gauge ABS control unit HU ground wire inspection Turn the ignition switch to OFF Remove the seat DL650K4...

Page 589: ...of coupler and battery ter minal 09900 25008 Multi circuit tester set Tester knob indication Continuity If there are no continuity repair the coupler or wire harness ABS control unit coupler Harness e...

Page 590: ...the ABS indicator light go off The ABS indicator light does not light up Step 3 1 Remove the seat DL650K4 7 4 2 Open the fuse box and inspect the signal fuse 1 Signal fuse 15 A Is the signal fuse OK...

Page 591: ...ion Continuity Are there continuity between 4 and body ground Step 6 The ABS indicator light does not go off 1 Turn the ignition switch to OFF 2 Remove the seat DL650K 7 4 3 Open the fuse box and insp...

Page 592: ...tween H and 4 normal Step 8 1 Turn the ignition switch to ON with the ABS control unit cou pler disconnected measure the voltage between B terminal and 4 terminal at the coupler Normal value 7 5 9 5 V...

Page 593: ...switch to ON The ABS indicator light starts flashing to indicate the DTC NOTE If there is a DTC recorded the ABS indicator light repeatedly flashes in a cyclic manner However when five minutes have el...

Page 594: ...the start code is displayed DTCs appear from the smallest number code If no DTC is recorded the light repeats flashing for 3 6 seconds in a cyclic manner 1 About 2 seconds Initial minimum light ON ti...

Page 595: ...utput set the special tool to OFF In the DTC deletion mode switch the ABS test switch from OFF to ON 3 times each time leaving it at ON for more than 1 second NOTE After deleting DTC with the mode sel...

Page 596: ...left stored con fusion may occur and unnecessary repairs may be made Afterwards ride the motorcycle at more than 30 km h 18 6 mile h and quickly apply the brakes to check that the ABS activates corre...

Page 597: ...lt comparison with the normal data that have been saved or filed can allow the specific ABS failure to be determined Remove the seat DL650K4 7 4 Set up the SDS tool Page 94 09904 41010 SDS set tool 99...

Page 598: ...bserve what is written there Remove the seat DL650K4 7 4 Set up the SDS tool Refer to the SDS operation manual for further details Read the DTC Diagnostic Trouble Code and show data when trouble displ...

Page 599: ...ns stored in the ABS HU Therefore erase the history code memorized in the ABS HU using SDS tool NOTE The DTC is memorized in the ABS HU also when the wire cou pler of any sensor is disconnected Theref...

Page 600: ...Follow the displayed instructions Check that both Current DTC 4 and Past DTC 5 are deleted NIL 13 96 DL650K7 AK7 07 MODEL P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6...

Page 601: ...the SDS tool Refer to the SDS operation manual for further details 2 Turn the ignition switch ON 3 Click ABS 1 4 Click Active control 2 5 Click ABS HU operating 3 DL650K7 AK7 07 MODEL 13 97 P a r t S...

Page 602: ...6 It progresses to the next according to the following indication of screens Return Next Cancel Help Return Next Cancel Help 13 98 DL650K7 AK7 07 MODEL P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6...

Page 603: ...nt wheel off the ground using a jack Two operators are needed in this work One should apply a rotational force to the front wheel Return Next Cancel Help Return Next Cancel Help DL650K7 AK7 07 MODEL 1...

Page 604: ...sound will be heard The ABS HU motor operates for 6 seconds and then stops automatically NOTE Inspect the rear brake as the same manner of front brake If the ABS does not function the cause may lie in...

Page 605: ...el speed sensor connector wheel speed sen sor not securely fastened input amplifier in ABS control unit failure etc 42 C1642 Wheel speed sensor circuit open F 2 ON Page 106 Wheel speed sensor circuit...

Page 606: ...and check that no foreign objects are caught in the rotor open ings Are the rotors OK POSSIBLE CAUSE Incorrect tire size poor tire pressure deformed wheel wheel spinning incorrect tooth count interfe...

Page 607: ...e thickness gauge Wheel speed sensor sensor rotor clearance 0 3 1 5 mm 0 012 0 059 in 09900 20803 Thickness gauge 09900 20806 Thickness gauge Are the clearances OK YES Replace the ABS control unit HU...

Page 608: ...1 terminal at the coupler Normal value Battery voltage 12 0 V and more 09900 25008 Multi circuit tester set Tester knob indication Voltage Is the voltage between 2 and 1 normal POSSIBLE CAUSE Motor re...

Page 609: ...tor open ings Is the sensor rotor OK Step 3 1 Check that the front wheel speed sensor is mounted steadily Is the sensor mounted steadily POSSIBLE CAUSE Too great air gap worn or missing teeth noise in...

Page 610: ...mal value Infinity Tester knob indication Resistance Is the resistance between F and ground OK Step 3 1 Disconnect the front wheel speed sensor coupler 2 Measure the resistance between 2 terminal and...

Page 611: ...knob indication Continuity test Is there continuity between F and 2 Step 7 1 Check for continuity between 5 terminal on the ABS control unit coupler and 1 terminal on the front wheel speed sensor coup...

Page 612: ...V Measure the current between dry cell terminal and F ter minal on the ABS control unit coupler Normal value 5 9 16 8 mA Tester knob indication Current 20 mA Is the current OK YES Replace the ABS con...

Page 613: ...tor open ings Is the sensor rotor OK Step 3 1 Check that the rear wheel speed sensor is mounted steadily Is the sensor mounted steadily POSSIBLE CAUSE Too great air gap worn or missing teeth noise int...

Page 614: ...e Infinity Tester knob indication Resistance Is the resistance between 7 and ground OK Step 3 1 Disconnect the rear wheel speed sensor coupler 2 Measure the resistance between 2 terminal and ground at...

Page 615: ...tinuity test Is there continuity between 7 and 2 Step 7 1 Check the continuity between I terminal on the ABS control unit coupler and 1 terminal on the rear wheel speed sensor coupler Normal value Con...

Page 616: ...terminal and 7 ter minal on the ABS control unit coupler Normal value 5 9 16 8 mA 09900 25008 Multi circuit tester set 09900 25009 Needle pointed probe set Tester knob indication Current 20 mA Is the...

Page 617: ...Voltage Is the voltage over 12 V Step 2 1 Run the engine at 5 000 r min with the dimmer switch set to HI 2 Measure the voltage between the and battery termi nals Regulated voltage 14 0 15 5 V at 5 00...

Page 618: ...5 000 r min with the dimmer switch set to HI 5 Measure the voltage between H terminal and 4 terminal at the coupler 09900 25009 Needle pointed probe set Tester knob indication Voltage Is the voltage s...

Page 619: ...ion Voltage Is the voltage over 12 V Step 2 1 Run the engine at 5 000 r min with the dimmer switch set to HI 2 Measure the voltage between the and battery termi nals Regulated voltage 14 0 15 5 V at 5...

Page 620: ...5 000 r min with the dimmer switch set to HI 5 Measure the voltage between H terminal and 4 terminal at the coupler 09900 25009 Needle pointed probe set Tester knob indication Voltage Is the voltage s...

Page 621: ...ects are caught in the rotor openings Are the rotors OK Step 3 1 Check that the front and rear wheel speed sensors are mounted steadily Are the sensors mounted steadily Step 4 1 Delete DTCs Page 91 an...

Page 622: ...gh the ABS is operating correctly a DTC is memo rized in any of the following conditions After carrying out DTC deleting and ABS operation check Page 91 explain to the customer that the ABS is oper at...

Page 623: ...10 Remove the front wheel speed sensor bracket 1 Remove the front wheel speed sensor rotor 2 The ABS is made up of many precision parts never subject it to strong impacts or allow it to become dirty o...

Page 624: ...ensor if any metal particle or foreign material stuck on it Check that no wheel speed sensor rotor teeth are broken and that no foreign objects are caught in the wheel speed sensor INSTALLATION Instal...

Page 625: ...eck the clearance between the front wheel speed sensor and sensor rotor using the thickness gauge Wheel speed sensor sensor rotor clearance 0 3 1 5 mm 0 012 0 059 in 09900 20803 Thickness gauge 09900...

Page 626: ...FRONT WHEEL SPEED SENSOR INSTALLATION Front wheel speed sensor Right Left 0 3 1 5 mm 0 012 0 059 in 13 122 DL650K7 AK7 07 MODEL P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6...

Page 627: ...seat DL650K4 7 4 Disconnect the sensor coupler and remove the rear wheel speed sensor Page 134 The ABS is made up of many precision parts never subject it to strong impacts or allow it to become dirt...

Page 628: ...ION Installation is in the reverse order of removal Pay attention to the following points Install the wheel speed sensor rotor as the letters 50T face outside Check the clearance between the rear whee...

Page 629: ...REAR WHEEL SPEED SENSOR INSTALLATION For E 03 28 33 Right Left 0 3 1 5 mm 0 012 0 059 in Rear wheel speed sensor DL650K7 AK7 07 MODEL 13 125 P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6...

Page 630: ...e system is filled with an ethylene glycol based DOT 4 brake fluid Do not mix differ ent types of fluid such as silicone based or petroleum based Do not use any brake fluid taken from old used or unse...

Page 631: ...ollowing points Tighten the brake pipe flare nuts to the specified torque Brake pipe flare nut 16 N m 1 6 kgf m 11 5 lb ft Bleed air from the brake fluid circuit DL650K4 2 25 Route the brake hoses and...

Page 632: ...harness Stop lamp switch ABS sensor DL650A Fuel pump coupler Taping clamp Clamp Rectifier Breather hose IAP sensor 1 Solenoid Clamp ISC valve coupler Speed sensor 2 Wire harness Handle switch L R 3 C...

Page 633: ...ame and PAIR control solenoid valve 3 Clamp the high tension cord 6 Pass through the licence lamp wire in front of the seat lock cable Clamp 1 Clamp 2 1 Ignition coil ABS brake hose DL650A only Reserv...

Page 634: ...e stopper tighten the clamp bolt 3 Brake hose clamp 4 Assemble the brake hose firmly 4 Throttle cables 5 Clamp the brake hose firmly 1 After the brake hose union has contacted the stopper tighten the...

Page 635: ...n the union bolt 3 Throttle cable Pull 2 Clamp the brake hose firmly 4 Clutch cable 3 Set the white painted marking side of the hose to the joint 5 Harness 4 Clamp pipes on line painted 6 Front brake...

Page 636: ...Pass through the reservoir hose outside of the seat rail 4 Brake hose 6 Clamp ends should face forward 1 After the brake hose union has contacted the stopper tighten the union bolt 7 Clamp ends shoul...

Page 637: ...r lead wire forward of the brake hose 4 Set the wheel speed sensor lead wire to the part of the brake hose union with a clamp 11 Clamp the wheel speed sensor lead wire for ward of the brake hose 5 Hol...

Page 638: ...sor lead wire to the brake hose at white painted marking 2 Wheel speed sensor lead wire 2 Pass through the sensor lead wire inside of brake hose guide 3 Brake hose 3 Letters should face outside 3 2 1...

Page 639: ...the brake pipe For ABS model 3 Reservoir tank inlet hose 2 Pass through the hoses outside of brake pipe and reservoir tank hose 4 HO2 sensor For E 02 19 24 41 3 Make sure to position the clamp in the...

Page 640: ...6 Align the marking with the rib of pipe 3 Clamp ends should face left side 10 N m 1 0 kgf m 7 0 lb ft 5 6 1 1 5 To canister Purge hose E 33 only 25 FR RH LH RH LH Air cleaner side Engine side FR RR R...

Page 641: ...switch 6 Clamp bolt head upward 4 Oil filter 7 Clamp bolt head downward 1 Clamp end downward 8 Pass through the reservoir overflow hose between the brake pipe and reservoir inlet hose 2 Matching mark...

Page 642: ...bolt head left side 4 Radiator hose 6 Make clearance between bulge of union and clamp 1 Marking 7 Clamp face left side 2 Matching mark White 0 90 90 90 90 1 2 5 7 4 5 3 Marking position 6 1 1 Installa...

Page 643: ...prox 20 1 Matching mark White 4 PAIR control solenoid valve 2 Matching mark Yellow 1 Pass through the PAIR hose between the cylin der head cover and intake pipe 3 Hose DL650K7 AK7 07 MODEL 13 139 P a...

Page 644: ...ALLATION 1 Align the top of protector with the upper surface of the battery holder FWD 45 mm 1 77 in 3 12 mm 0 12 in 6 2 mm 0 24 in 20 mm 0 79 in 1 1 13 140 DL650K7 AK7 07 MODEL P a r t S h a r k c o...

Page 645: ...river 09917 47011 Vacuum pump gauge 09930 10121 Spark plug socket wrench set 09930 11950 Torx wrench 09930 82710 Mode select switch 09930 82720 Mode select switch 99565 01010 008 CD ROM Ver 8 ITEM N m...

Page 646: ...80 0 1758 0 1764 EX 4 455 4 470 0 1754 0 1760 Valve stem deflection IN EX 0 35 0 014 Valve stem runout IN EX 0 05 0 002 Valve head thickness IN EX 0 5 0 02 Valve seat width IN EX 0 9 1 1 0 035 0 043 V...

Page 647: ...journal oil clearance IN EX 0 032 0 066 0 0013 0 0026 0 150 0 0059 Camshaft journal holder I D IN EX 22 012 22 025 0 8666 0 8671 Camshaft journal O D IN EX 21 959 21 980 0 8645 0 8654 Camshaft runout...

Page 648: ...er distortion 0 05 0 002 Piston ring free end gap 1st Approx 7 0 28 5 6 0 22 2nd Approx 11 0 43 8 8 0 35 Piston ring end gap 1st 0 20 0 35 0 008 0 014 0 70 0 028 2nd 0 20 0 35 0 008 0 0014 0 70 0 028...

Page 649: ...earance 0 002 0 029 0 0001 0 0011 0 080 0 0031 Crankshaft journal O D 41 985 42 000 1 6529 1 6535 Crankshaft runout 0 05 0 002 ITEM STANDARD LIMIT Oil pressure at 60 C 140 F Above 100 kPa 1 0 kgf cm 1...

Page 650: ...5 27 24 5th 0 961 25 26 Top 0 851 23 27 Shift fork to groove clearance 0 1 0 3 0 004 0 012 0 50 0 020 Shift fork groove width 5 5 5 6 0 217 0 220 Shift fork thickness 5 3 5 4 0 209 0 213 Drive chain T...

Page 651: ...temperature OFF ON Approx 98 C 208 F ON OFF Approx 92 C 198 F Engine coolant type Use an antifreeze coolant compatible with alumi num radiator mixed with distilled water only at the ratio of 50 50 Eng...

Page 652: ...Br Leaning 65 3 7 4 4 V GP switch voltage 1 0 V and more From 1st to Top Injector voltage Battery voltage STP sensor input voltage 4 5 5 5 V STP sensor output voltage Closed Approx 0 6 V Y B Br Opened...

Page 653: ...d more When cranking Ignition coil primary peak voltage 150 V and more Generator coil resistance 0 2 0 7 Generator Max output Approx 375 W at 5 000 r min Generator no load voltage When cold 60 V AC an...

Page 654: ...rake light Taillight 12 V 21 5 W 2 Turn signal light 12 V 21 W License light 12 V 5 W Speedometer light LED Turn signal indicator light LED High beam indicator light LED Neutral indicator light LED Oi...

Page 655: ...13 957 13 984 0 5495 0 5506 Rear 13 957 13 984 0 5495 0 5506 Brake caliper cylinder bore Front 27 000 27 076 1 0630 1 0660 Rear 38 180 38 230 1 5031 1 5051 Brake caliper piston diam Front 26 920 26 97...

Page 656: ...T Front fork stroke 150 5 9 Front fork spring free length 444 1 17 5 435 17 1 Front fork oil level without spring outer tube fully compressed 139 5 47 Front fork spring adjuster 3 grooves from Top Spr...

Page 657: ...te cosolvents and corro sion inhibitor is permissible E 03 28 33 Gasoline used should be graded 91 octane or higher An unleaded gasoline is recommended Others Fuel tank capacity 22 L 5 8 4 8 US lmp ga...

Page 658: ...480 0 1758 0 1764 EX 4 455 4 470 0 1754 0 1760 Valve stem deflection IN EX 0 35 0 014 Valve stem runout IN EX 0 05 0 002 Valve head thickness IN EX 0 5 0 02 Valve seat width IN EX 0 9 1 1 0 035 0 043...

Page 659: ...journal oil clearance IN EX 0 032 0 066 0 0013 0 0026 0 150 0 0059 Camshaft journal holder I D IN EX 22 012 22 025 0 8666 0 8671 Camshaft journal O D IN EX 21 959 21 980 0 8645 0 8654 Camshaft runout...

Page 660: ...er distortion 0 05 0 002 Piston ring free end gap 1st Approx 7 0 28 5 6 0 22 2nd Approx 11 0 43 8 8 0 35 Piston ring end gap 1st 0 20 0 35 0 008 0 014 0 70 0 028 2nd 0 20 0 35 0 008 0 0014 0 70 0 028...

Page 661: ...earance 0 002 0 029 0 0001 0 0011 0 080 0 0031 Crankshaft journal O D 41 985 42 000 1 6529 1 6535 Crankshaft runout 0 05 0 002 ITEM STANDARD LIMIT Oil pressure at 60 C 140 F Above 100 kPa 1 0 kgf cm 1...

Page 662: ...5 27 24 5th 0 961 25 26 Top 0 851 23 27 Shift fork to groove clearance 0 1 0 3 0 004 0 012 0 50 0 020 Shift fork groove width 5 5 5 6 0 217 0 220 Shift fork thickness 5 3 5 4 0 209 0 213 Drive chain T...

Page 663: ...temperature OFF ON Approx 98 C 208 F ON OFF Approx 92 C 198 F Engine coolant type Use an antifreeze coolant compatible with alumi num radiator mixed with distilled water only at the ratio of 50 50 Eng...

Page 664: ...Br Leaning 65 3 7 4 4 V GP switch voltage 1 0 V and more From 1st to Top Injector voltage Battery voltage STP sensor input voltage 4 5 5 5 V STP sensor output voltage Closed Approx 0 6 V Y B Br Opened...

Page 665: ...nking Ignition coil primary peak voltage 150 V and more Generator coil resistance 0 2 0 7 Generator Max output Approx 375 W at 5 000 r min Generator no load voltage When cold 60 V AC and more at 5 000...

Page 666: ...aillight 12 V 21 5 W 2 Turn signal light 12 V 21 W License light 12 V 5 W Speedometer light LED Turn signal indicator light LED High beam indicator light LED Neutral indicator light LED Oil pressure C...

Page 667: ...7 13 984 0 5495 0 5506 Brake caliper cylinder bore Front 27 000 27 076 1 0630 1 0660 Rear 38 180 38 230 1 5031 1 5051 Brake caliper piston diam Front 26 920 26 970 1 0598 1 0618 Rear 38 080 38 130 1 4...

Page 668: ...T Front fork stroke 150 5 9 Front fork spring free length 444 1 17 5 435 17 1 Front fork oil level without spring outer tube fully compressed 139 5 47 Front fork spring adjuster 3 grooves from Top Spr...

Page 669: ...te cosolvents and corro sion inhibitor is permissible E 03 28 33 Gasoline used should be graded 91 octane or higher An unleaded gasoline is recommended Others Fuel tank capacity 22 L 5 8 4 8 US lmp ga...

Page 670: ...03 ENGINE book Page 105 Tuesday February 28 2006 3 03 PM P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6...

Page 671: ...TS PAGE SERVICE DATA DL650K8 14 2 SERVICEDATA DL650A AUEK8 14 14 NOTE Specifications are the same as the K7 MODEL DL650 AK 0 MODEL DL650 AK8 08 MODEL 14 1 8 8 14 P a r t S h a r k c o m 8 7 7 9 9 9 5...

Page 672: ...4 480 0 1758 0 1764 EX 4 455 4 470 0 1754 0 1760 Valve stem deflection IN EX 0 35 0 014 Valve stem runout IN EX 0 05 0 002 Valve head thickness IN EX 0 5 0 02 Valve seat width IN EX 0 9 1 1 0 035 0 0...

Page 673: ...ft journal oil clearance IN EX 0 032 0 066 0 0013 0 0026 0 150 0 0059 Camshaft journal holder I D IN EX 22 012 22 025 0 8666 0 8671 Camshaft journal O D IN EX 21 959 21 980 0 8645 0 8654 Camshaft runo...

Page 674: ...ylinder distortion 0 05 0 002 Piston ring free end gap 1st Approx 7 0 28 5 6 0 22 2nd Approx 11 5 0 45 8 8 0 35 Piston ring end gap 1st 0 20 0 30 0 08 0 12 0 70 0 028 2nd 0 30 0 45 0 12 0 018 0 70 0 0...

Page 675: ...l clearance 0 002 0 029 0 0001 0 0011 0 080 0 0031 Crankshaft journal O D 41 985 42 000 1 6529 1 6535 Crankshaft runout 0 05 0 002 ITEM STANDARD LIMIT Oil pressure at 60 C 140 F Above 100 kPa 1 0 kgf...

Page 676: ...125 27 24 5th 0 961 25 26 Top 0 851 23 27 Shift fork to groove clearance 0 1 0 3 0 004 0 012 0 50 0 020 Shift fork groove width 5 5 5 6 0 217 0 220 Shift fork thickness 5 3 5 4 0 209 0 213 Drive chai...

Page 677: ...ng temperature OFF ON Approx 98 C 208 F ON OFF Approx 92 C 198 F Engine coolant type Use an antifreeze coolant compatible with alumi num radiator mixed with distilled water only at the ratio of 50 50...

Page 678: ...W B Br Leaning 65 3 7 4 4 V GP switch voltage 1 0 V and more From 1st to Top Injector voltage Battery voltage STP sensor input voltage 4 5 5 5 V STP sensor output voltage Closed Approx 0 6 V Y B Br Op...

Page 679: ...more When cranking Ignition coil primary peak voltage 150 V and more Generator coil resistance 0 2 0 8 Generator Max output Approx 400 W at 5 000 r min Generator no load voltage When cold 65 V AC and...

Page 680: ...2 Brake light Taillight 12 V 21 5 W 2 Turn signal light 12 V 21 W License light 12 V 5 W Speedometer light LED Turn signal indicator light LED High beam indicator light LED Neutral indicator light LED...

Page 681: ...ont 13 957 13 984 0 5495 0 5506 Rear 13 957 13 984 0 5495 0 5506 Brake caliper cylinder bore Front 27 000 27 076 1 0630 1 0660 Rear 38 180 38 230 1 5031 1 5051 Brake caliper piston diam Front 26 920 2...

Page 682: ...SPEC LIMIT Front fork stroke 150 5 9 Front fork spring free length 444 1 17 5 435 17 1 Front fork oil level without spring outer tube fully compressed 139 5 47 Front fork spring adjuster 3 grooves fro...

Page 683: ...priate cosolvents and corro sion inhibitor is permissible E 03 28 33 Gasoline used should be graded 91 octane or higher An unleaded gasoline is recommended Others Fuel tank capacity 22 L 5 8 4 8 US lm...

Page 684: ...65 4 480 0 1758 0 1764 EX 4 455 4 470 0 1754 0 1760 Valve stem deflection IN EX 0 35 0 014 Valve stem runout IN EX 0 05 0 002 Valve head thickness IN EX 0 5 0 02 Valve seat width IN EX 0 9 1 1 0 035 0...

Page 685: ...ft journal oil clearance IN EX 0 032 0 066 0 0013 0 0026 0 150 0 0059 Camshaft journal holder I D IN EX 22 012 22 025 0 8666 0 8671 Camshaft journal O D IN EX 21 959 21 980 0 8645 0 8654 Camshaft runo...

Page 686: ...linder distortion 0 05 0 002 Piston ring free end gap 1st Approx 7 0 28 5 6 0 22 2nd Approx 11 5 0 45 8 8 0 35 Piston ring end gap 1st 0 20 0 30 0 08 0 12 0 70 0 028 2nd 0 30 0 45 0 12 0 018 0 70 0 02...

Page 687: ...l clearance 0 002 0 029 0 0001 0 0011 0 080 0 0031 Crankshaft journal O D 41 985 42 000 1 6529 1 6535 Crankshaft runout 0 05 0 002 ITEM STANDARD LIMIT Oil pressure at 60 C 140 F Above 100 kPa 1 0 kgf...

Page 688: ...125 27 24 5th 0 961 25 26 Top 0 851 23 27 Shift fork to groove clearance 0 1 0 3 0 004 0 012 0 50 0 020 Shift fork groove width 5 5 5 6 0 217 0 220 Shift fork thickness 5 3 5 4 0 209 0 213 Drive chai...

Page 689: ...ing temperature OFF ON Approx 98 C 208 F ON OFF Approx 92 C 198 F Engine coolant type Use an antifreeze coolant compatible with alumi num radiator mixed with distilled water only at the ratio of 50 50...

Page 690: ...W B Br Leaning 65 3 7 4 4 V GP switch voltage 1 0 V and more From 1st to Top Injector voltage Battery voltage STP sensor input voltage 4 5 5 5 V STP sensor output voltage Closed Approx 0 6 V Y B Br Op...

Page 691: ...ing Ignition coil primary peak voltage 150 V and more Generator coil resistance 0 2 0 8 Generator Max output Approx 400 W at 5 000 r min Generator no load voltage When cold 65 V AC and more at 5 000 r...

Page 692: ...t Taillight 12 V 21 5 W 2 Turn signal light 12 V 21 W License light 12 V 5 W Speedometer light LED Turn signal indicator light LED High beam indicator light LED Neutral indicator light LED Oil pressur...

Page 693: ...3 957 13 984 0 5495 0 5506 Brake caliper cylinder bore Front 27 000 27 076 1 0630 1 0660 Rear 38 180 38 230 1 5031 1 5051 Brake caliper piston diam Front 26 920 26 970 1 0598 1 0618 Rear 38 080 38 130...

Page 694: ...SPEC LIMIT Front fork stroke 150 5 9 Front fork spring free length 444 1 17 5 435 17 1 Front fork oil level without spring outer tube fully compressed 139 5 47 Front fork spring adjuster 3 grooves fr...

Page 695: ...priate cosolvents and corro sion inhibitor is permissible E 03 28 33 Gasoline used should be graded 91 octane or higher An unleaded gasoline is recommended Others Fuel tank capacity 22 L 5 8 4 8 US lm...

Page 696: ...03 ENGINE book Page 105 Tuesday February 28 2006 3 03 PM P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6...

Page 697: ...KHHGT HTQO VJQUG QH VJG 1 CPF 1 016 P FKHHGTGPEGU DGVYGGP VJG 1 QT 1 CPF 1 CPF 1 KP URGEKHKECVKQPU CTG ENGCT KPFKECVGF YKVJ CP CUVGTKUM OCTM 2NGCUG TGHGT VQ VJG ECRVGTU VJTQWIJ HQT FGVCKNU YJKEJ CTG P...

Page 698: ...il spring oil damped Rear suspension Link type coil spring oil damped Front fork stroke 150 mm 5 9 in Rear wheel travel 150 mm 5 9 in Caster 26 Trail 110 mm 4 33 in Steering angle 40 right left Turnin...

Page 699: ...A E R R T H G I L L A N G I S N R U T R A E R L T H G I L L A N G I S E S N E C I L T H G I L Y R E T T A B A 0 3 N I A M 1 R E T R A T S R O T O M R E T R A T S Y A L E R 1 X O B E S U F I H D A E H...

Page 700: ...B W Y B W Gr W Y R Gr B Y R B Br G Y R ON OFF LOCK P OFF RUN PUSH OFF ON ON OFF M FREE PUSH ON OFF FREE PUSH PUSH L PUSH R HI LO ON OFF HANDLEBAR SWITCH R REAR BRAKE SWITCH IGNITION COIL 1 IGNITION C...

Page 701: ...r B Y R O Bl B W B Lg P W G W B R Y B Br ON OFF LOCK P OFF RUN PUSH OFF ON ON OFF M FREE PUSH ON OFF FREE PUSH PUSH L PUSH R HI LO ON OFF HANDLEBAR SWITCH R REAR BRAKE SWITCH IGNITION COIL 1 IGNITION...

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