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Suzuki 2009 AN400, Supplementary Service Manual

The Suzuki 2009 AN400 Supplementary Service Manual is a comprehensive resource for enthusiasts of this model. Packed with useful insights and detailed instructions, this manual is a must-have for any AN400 owner. Download this invaluable resource for free from manualshive.com and unlock the full potential of your Suzuki AN400.

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Summary of Contents for 2009 AN400

Page 1: ...AN400 A ZA 9 9 5 0 1 3 4 1 7 0 0 1 E SUPPLEMENTARY SERVICE MANUAL USE THIS MANUAL WITH AN400 SERVICE MANUAL 99500 34101 01E ...

Page 2: ...ustomers of fast and reliable service COPYRIGHT SUZUKI MOTOR CORPORATION 2009 Manual Name Manual No AN400 SERVICE MANUAL 99500 34101 01E This manual has been prepared on the basis of the latest specifications at the time of publication If modifi cations have been made since then differences may exist between the content of this manual and the actual motorcycle Illustrations in this manual are used...

Page 3: ...Rear Suspension 2C 1 Wheels and Tires 2D 1 Driveline Axle 3 Precautions 3 Drive Chain Drive Train Drive Shaft 3A Brake 4 i Precautions 4 Brake Control System and Diagnosis 4A 1 Front Brakes 4B Rear Brakes 4C Parking Brake 4D ABS 4E 1 Transmission Transaxle 5 i Precautions 5 Automatic Transmission 5A 1 Steering 6 i Precautions 6 Steering General Diagnosis 6A Steering Handlebar 6B 1 Body and Accesso...

Page 4: ......

Page 5: ...ions 00 1 Warning Caution Note 00 General Precautions 00 Precautions for Electrical Circuit Service 00 Precautions for ABS AN400A ZAK9 00 1 NOTE For the items with asterisk in the CONTENTS below refer to the same section of the service manual mentioned in the FOREWORD of this manual ...

Page 6: ... positioned correctly NOTE If all of the connections are not properly connected the ABS may not operate correctly For connector and coupler precautions Refer to Precautions for Electrical Circuit Service in related manual 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 impacts or allow them to be dropped The ABS contr...

Page 7: ...Valve Clearance Inspection and Adjustment 0B Fuel Line Inspection 0B Evaporative Emission Control System E 33 Only 0B Engine Oil and Filter Change 0B Final Reduction Gear Oil Replacement 0B Cooling Fan Filter Removal and Installation 0B Cooling Fan Filter Inspection and Cleaning 0B Drive V belt Removal and Installation 0B Drive V belt Inspection 0B Throttle Cable Play Inspection and Adjustment 0B ...

Page 8: ...other abbreviations which are not given in this manual A ABS Anti lock Brake System Vehicle Side View AN400 A ZAK9 B905H10101013 NOTE Difference between illustration and actual motorcycles may exist depending on the markets SUZUKI AN400 2009 model Right Side Left Side SUZUKI AN400A 2009 model Right Side Left Side I905H1010001 01 I905H1010002 02 I905H1010003 01 I905H1010004 02 ...

Page 9: ... for California JS1CK44A 92100001 E 19 E U JS1CG111100135961 E 24 Australia JS1CG111300100360 E 28 Canada JS1CK44A 92100001 E 33 California JS1CK44A 92100001 E 51 Korea JS1CG111590100001 E 54 Israel JS1CG111490100001 AN400A K9 E 02 U K JS1CG113200100001 E 03 U S A Except for California JS1CK44B 92100001 E 19 E U JS1CG113100100001 E 24 Australia JS1CG113300100001 E 28 Canada JS1CK44B 92100001 E 33 ...

Page 10: ...the AN400K9 09 model and AN400AK9 09 model in specifications are indicated with an asterisk mark Dimensions and Curb Mass Item Specification Remark Overall length 2 270 mm 89 4 in Overall width 760 mm 29 9 in Overall height 1 385 mm 54 5 in Wheelbase 1 585 mm 62 4 in Ground clearance 125 mm 4 9 in Seat height 710 mm 28 0 in Curb mass 216 kg 476 lbs Item Specification Remark Overall length 2 270 mm...

Page 11: ...12 V 60 55 W H4 x 2 E 03 28 33 Position Parking light 12 V 5 W x 2 E 02 19 24 54 Position light 12 V 5 W x 2 E 03 28 33 Brake light Taillight 12 V 21 5 W x 2 License plate light 12 V 5 W Helmet box light 12 V 5 W Front turn signal light 12 V 27 8 W E 03 28 33 12 V 21 W Others Rear turn signal light 12 V 21 W Speedometer Tachometer light LED Coolant temperature meter light LED Fuel level meter ligh...

Page 12: ...pecial Tool B905H10108002 09900 20803 Thickness gauge 09900 20806 Thickness gauge 09900 25008 Multi circuit tester set 09900 25009 Needle point probe set 09904 41010 SUZUKI Diagnostic system set 09930 82710 Mode select switch 99565 01010 020 CD ROM Ver 20 ...

Page 13: ... 2 0 0 08 Engage r min 2 600 3 200 r min Lock up r min 4 000 5 000 r min Item Specification Note Primary reduction ratio 1 000 Reduction ratio 2 200 0 839 Secondary reduction ratio 2 214 Final reduction ratio 2 666 Drive V belt width 25 1 0 99 24 1 0 95 Movable driven face spring free length 145 0 5 7 137 8 5 43 Movable drive face roller O D 26 00 26 16 1 024 1 030 Drive driven face ware 0 4 0 02 ...

Page 14: ...A E 03 28 33 LO 10 A E 02 19 24 54 15 A E 03 28 33 Meter 10 A Ignition 15 A Signal 15 A Power source 10 A Main 30 A ABS motor 20 A ABS valve 15 A Item Standard Specification E 02 19 24 54 E 03 28 33 Speedometer tachometer light LED Engine coolant temp gauge light LED Fuel level gauge light LED Immobilizer indicator light LED Oil change indicator LCD FI indicator light LED Brake lock indicator ligh...

Page 15: ...00 0 502 Master cylinder piston diameter Front 13 957 13 984 0 549 0 551 Rear 12 657 12 684 0 498 0 499 Brake caliper cylinder bore Front 25 400 25 450 1 000 1 002 Rear 27 00 27 05 1 063 1 065 Brake caliper piston diameter Front 25 318 25 368 0 997 0 999 Rear 26 918 26 968 1 060 1 062 Brake fluid type DOT 4 Wheel rim runout Axial 2 0 0 08 Radial 2 0 0 08 Wheel axle runout Front 0 25 0 01 Rear 0 25...

Page 16: ...0C 4 Service Data ...

Page 17: ...C C24 P0351 Ignition System Malfunction 1A DTC C28 P1655 Secondary Throttle Valve Actuator STVA Malfunction 1A DTC C29 P1654 H L Secondary Throttle Position Sensor STPS 1A DTC C32 P0201 Fuel Injector Circuit Malfunction 1A DTC C40 P0505 P0506 or P0507 ISC Valve Circuit Malfunction 1A DTC C41 P0230 H L FP Relay Circuit Malfunction 1A DTC 42 P1650 IG Switch Circuit Malfunction 1A DTC C44 P0130 P0135...

Page 18: ...omponents 1D Throttle Body Construction 1D Throttle Body Removal and Installation 1D Throttle Body Disassembly and Assembly 1D Throttle Body Inspection and Cleaning 1D Engine Top Side Disassembly 1D Engine Top Side Assembly 1D Camshaft Inspection 1D Cam Chain Tension Adjuster Inspection 1D Cam Chain Guide Inspection 1D Cylinder Head Disassembly and Reassembly 1D Cylinder Head and Related Parts Ins...

Page 19: ...Removal and Installation 1G Fuel Drain Tray and FTPC Valve Removal and Installation 1G Fuel Cut Valve Inspection 1G FTPC Valve Inspection 1G Fuel Pump Disassembly and Assembly 1G Fuel Pressure Inspection 1G Fuel Pump Relay Inspection 1G Fuel Mesh Filter Inspection 1G Fuel Level Gauge Inspection 1G Fuel Pump Inspection 1G Fuel Injector Inspection 1G Fuel Injector Removal and Installation 1G Fuel Pu...

Page 20: ...nt Leakage Inspection 1J Regulated Voltage Inspection 1J Generator Coil Resistance Inspection 1J Generator No load Performance Inspection 1J Regulator Rectifier Inspection Except AN400K8 E 03 28 33 1J Regulator Rectifier Inspection AN400K8 E 03 28 33 only 1J Generator Removal and Installation 1J Battery Components 1J Battery Initial Charging 1J Battery Visual Inspection 1J Battery Recharging 1J Ba...

Page 21: ...mp Bind the parking brake cable and starter motor lead wire with the clamp 9 Clamp Clamp the throttle cable at white taping point 3 Seat lock cable A Pass the parking brake cable into the guide 4 Parking brake cable B Pass the parking brake cable inside of the brake hose 5 Starter motor lead wire C Pass the parking brake cable under the brake pipe Do not slacken the parking brake cable 6 Brake pip...

Page 22: ...Install the oil breather separator 3 to the left crankcase Clean and degrees the crankcase mating surfaces both surfaces with a cleaning solvent Apply bond to the right crankcase and part a of the left crankcase Sealant 99000 31140 SUZUKI BOND No 1207B or equivalent CAUTION Coat the sealant evenly without break Application of sealant must be performed within a short period of time Take extreme car...

Page 23: ...y Specifications Tightening Torque Specifications B905H11407002 Reference For the tightening torque of fastener not specified in this section refer to Tightening Torque List in Section 0C in related manual Special Tools and Equipment Recommended Service Material B905H11408001 I705H1140102 01 I705H1140101 01 Fastening part Tightening torque Note N m kgf m lbf ft Crankcase bolt M6 11 1 1 8 0 Page 1D...

Page 24: ...nts AN400 A ZAK9 B905H11706017 1 Fuel level gauge 5 Fuel pump 9 Fuel pump mounting bolt 2 O ring 6 Fuel mesh filter 10 N m 1 0 kgf m 7 0 lbf ft 3 Fuel pressure regulator assembly 7 Dust cover Apply engine oil 4 O ring 8 O ring Do not reuse 1 2 3 5 6 7 8 4 a 9 I905H1170003 01 ...

Page 25: ...sembly Refer to Fuel Pump Disassembly and Assembly in related manual Specifications Tightening Torque Specifications B905H11707002 NOTE The specified tightening torque is described in the following Fuel Pump Components AN400 A ZAK9 Page 1G 1 Reference For the tightening torque of fastener not specified in this section refer to Tightening Torque List in Section 0C in related manual Special Tools an...

Page 26: ...1G 3 Fuel System ...

Page 27: ...e Bracket Construction 2C Crankcase Bracket Removal and Installation 2C Crankcase Bracket Related Parts Inspection 2C Crankcase Bracket Bearing Removal and Installation 2C Rear Swingarm Construction AN400 A ZAK9 2C 1 Specifications 2C Service Data 2C Tightening Torque Specifications 2C Special Tools and Equipment 2C Recommended Service Material 2C Special Tool 2C Wheels and Tires 2D 1 Precautions ...

Page 28: ...2 ii Table of Contents Specifications 2D 7 Service Data 2D Tightening Torque Specifications 2D 7 Special Tools and Equipment 2D 7 Recommended Service Material 2D 7 Special Tool 2D 7 ...

Page 29: ...on Rear Suspension Repair Instructions Rear Swingarm Construction AN400 A ZAK9 B905H12306018 1 2 3 5 4 I905H1230001 01 1 Rear swingarm 3 Swingarm cushion No 2 5 Swingarm cushion cover 2 Swingarm cushion No 3 4 Swingarm cushion No 1 ...

Page 30: ... FWD FWD I905H1240001 02 1 Front wheel 6 Collar 11 Wheel balancer 6 N m 0 6 kgf m 4 5 lbf ft 2 Spacer 7 Brake disk 12 Wheel speed sensor rotor Apply grease 3 Bearing 8 Brake disk bolt 13 Wheel speed sensor rotor bolt Apply thread lock to thread part 4 Dust seal 9 Tire 65 N m 6 5 kgf m 47 0 lbf ft Do not reuse 5 Front axle 10 Air valve 23 N m 2 3 kgf m 16 5 lbf ft ...

Page 31: ...1240010 02 1 Front axle a Clearance 23 N m 2 3 kfg m 16 5 lbf ft 2 Front brake caliper mounting bolt b 0 36 1 62 mm 0 014 0 064 in 6 N m 0 6 kfg m 4 5 lbf ft 3 Front brake disc bolt 65 N m 6 5 kfg m 47 0 lbf ft Apply grease 4 Front wheel speed sensor rotor bolt 35 N m 3 5 kfg m 25 5 lbf ft Apply thread lock to thread part ...

Page 32: ... to Front Wheel Speed Sensor Rotor Removal and Installation AN400A ZAK9 in Section 4E Page 4E 73 Installation Refer to Front Wheel Related Parts Inspection in related manual Refer to Wheel Speed Sensor and Sensor Rotor Inspection AN400A ZAK9 in Section 4E Page 4E 74 Install the front wheel assembly in the reverse order of removal Pay attention to the following points Install the front wheel assemb...

Page 33: ...1 Rear axle 7 Rear axle nut 23 N m 2 3 kgf m 16 5 lbf ft 2 Brake disc 8 Tire 120 N m 12 0 kgf m 87 0 lbf ft 3 Brake disc bolt 9 Air valve 6 N m 0 6 kgf m 4 5 lbf ft 4 O ring 10 Wheel balancer Apply grease 5 Collar 11 Wheel speed sensor rotor Apply thread lock to thread part 6 Collar 12 Wheel speed sensor rotor bolt Do not reuse ...

Page 34: ... 5 Rear wheel speed sensor rotor bolt 6 N m 0 6 kgf m 4 5 lbf ft 2 Rear brake caliper mounting bolt a 0 16 1 62 mm 0 006 0 064 in Apply grease 3 Rear brake disc bolt 120 N m 12 0 kgf m 87 0 lbf ft Apply thread lock to thread part 4 Rear wheel speed sensor bracket mounting bolt 23 N m 2 3 kgf m 16 5 lbf ft Apply thread lock to thread part ...

Page 35: ...ssary Refer to Rear Wheel Speed Sensor Rotor Removal and Installation AN400A ZAK9 in Section 4E Page 4E 73 Installation Refer to Rear Wheel Related Parts Inspection in related manual Refer to Wheel Speed Sensor and Sensor Rotor Inspection AN400A ZAK9 in Section 4E Page 4E 74 Install the rear wheel assembly in the reverse order of removal Pay attention to the following points Install the rear wheel...

Page 36: ...ning torque of fastener not specified in this section refer to Tightening Torque List in Section 0C in related manual Special Tools and Equipment Recommended Service Material B905H12408001 NOTE Required service material is also described in the following Front Wheel Components AN400A ZAK9 Page 2D 1 Front Wheel Assembly Construction AN400A ZAK9 Page 2D 2 Rear Wheel Components AN400A ZAK9 Page 2D 4 ...

Page 37: ...00A ZAK9 4A 3 Specifications 4A 4 Service Data 4A Tightening Torque Specifications 4A 4 Special Tools and Equipment 4A Recommended Service Material 4A Special Tool 4A Front Brakes 4B Repair Instructions 4B Front Brake Components 4B Front Brake Pad Inspection 4B Front Brake Pad Replacement 4B Front Brake Caliper Removal and Installation 4B Front Brake Caliper Disassembly and Assembly 4B Front Brake...

Page 38: ...3 C1613 Wheel Speed Sensor Rotor Malfunction F AN400A ZAK9 4E 32 DTC 14 C1614 Wheel Speed Sensor Rotor Malfunction R AN400A ZAK9 4E 34 DTC 22 C1622 ABS Actuator Circuit Malfunction F AN400A ZAK9 4E 36 DTC 23 C1623 ABS Actuator Circuit Malfunction R AN400A ZAK9 4E 38 DTC 25 C1625 Wheel Speed Sensor Related Malfunction AN400A ZAK9 4E 40 DTC 35 C1635 ABS Motor Malfunction AN400A ZAK9 4E 42 DTC 41 C16...

Page 39: ...n has contacted the stopper tighten the union bolt 11 Clamp Insert the brake hose clamp to the hole of front fender properly 4 Stopper After the brake pipe protector has contacted the stopper tighten the brake pipe flare nut A Fix the brake hose protector to its hose clamp 5 Rear brake hose No 1 B After the clamp has contacted the stopper tighten the clamp mounting bolt 6 Front brake hose No 1 23 ...

Page 40: ...1 Rear brake pipe No 2 B Fix the brake hose to its hose clamp 2 Rear brake hose No 2 C After positioning the clamp with the stopper on the swingarm tighten the clamp bolt 3 E ring 23 N m 2 3 kgf m 16 5 lbf ft 4 Stopper After the brake hose union has contacted the stopper tighten the union bolt a 28 A Clamp the brake pipe at white marking point b 14 ...

Page 41: ...N400A ZAK9 Page 4A 1 2 Bleed air from the front brake system Refer to Air Bleeding from Brake Fluid Circuit in related manual 3 Reinstall the removed parts Rear Brake Hose Removal and Instaltion AN400A ZAK9 B905H14106017 CAUTION This brake system is filled with an etylene glycol based DOT 4 brake fluid Do not mix different types of fluid such as silicone based or petroleum based Do not use any bra...

Page 42: ...e specified tightening torque is described in the following Front Brake Hose Routing Diagram AN400A ZAK9 Page 4A 1 Rear Brake Hose Routing Diagram AN400A ZAK9 Page 4A 2 Reference For the tightening torque of fastener not specified in this section refer to Tightening Torque List in Section 0C in related manual ...

Page 43: ...n the motorcycle s braking distance When riding down slopes or on wet or bumpy roads the braking distance is lengthened as compared to a motorcycle without ABS In addition braking distance increases more when the road is slippery The ABS does not control slides which may occur when braking while turning As with a motorcycle that does not have ABS it is best not apply the brakes while turning The b...

Page 44: ...1 2 I905H1450003 01 ABS contorl unit HU ABS contorl unit Main CPU ABS indicator light Motor M Front IN V Rear OUT V Rear IN V Front OUT V Ignition Battery Front wheel speed sensor Rear wheel speed sensor Brake light switch Mode selection switch Input interface Wheel speed sensor circuit Switch input circuit SDS Communication circuit Power unit Output interface Indicator light circuit Solenoid valv...

Page 45: ...BS and a diagnostic trouble code is stored Normal calculating process Calculating process when a malfunction occurs Ignition switch turned to ON ABS control unit initialization Self diagnosis while inmotion Wheel speed sensor signal enters ABS control processing Hydraulic unit control signal output 1 cycle 10 1 000 seconds ABS indicator light lights up Is ABS under control Diagnostic trouble code ...

Page 46: ...te components for the front and the rear except for the pump drive motor which is shared by both systems Rear brake light switch Rear wheel speed sensor Front wheel speed sensor Rear system Front system ABS indicator light Front brake light switch One way valve One way valve Damper Reservoir Reservoir Solenoid valve OUT Solenoid valve OUT Solenoid valve IN Solenoid valve IN Motor Rear brake calipe...

Page 47: ...dicator light keeps lighting up NOTE When a malfunction has occurred in the ABS connect the special tool to the mode select coupler to display the diagnostic trouble code on the ABS indicator light Refer to DTC Diagnostic Trouble Code Output AN400A ZAK9 Page 4E 22 Special tool A 09930 82710 Mode select switch ABS Operation and ABS Indicator Light The ABS indicator light shows the ABS operating con...

Page 48: ...ion Description AN400A ZAK9 B905H14501007 If malfunction occurs in the ABS electric system this sets fail safe relay OFF Consequently motor relay will be set OFF and the indicator light ON and no current will be applied to motor solenoid valve inactivating ABS and turning ABS indicator light ON In this case it functions as the normal brake However if malfunctions occurs while ABS is being activate...

Page 49: ... W R Bl Gr B W R B O Y B W B W W B B R W R B Y W Y Br W B O B R W R B Y W Y Br W B O B R W R B Y W Y W Bl W Bl R O R O 7 8 COMBINATION METER FRONT BRAKE SWITCH IGNITION SWITCH Gr B W W B Gr B W W B 7 ABS MOTOR 20A 8 ABS VALVE 15A FUSE BOX BATTERY 1 MAIN FUSE 30 A STARTER RELAY 1 HEAD HI 10 A 2 HEAD LO 10 A 3 METER 10 A 4 IGNITION 15 A 5 SIGNAL 15 A 6 P SOURCE 10 A FUSE BOX ABS INDICATOR SDS COUPLE...

Page 50: ...r Rear wheel speed sensor Mode select coupler ABS control unit Indicator M Ground 24 25 2 2 3 3 12 12 12 13 13 13 18 18 18 10 10 10 4 4 11 11 21 16 16 16 8 9 2 3 4 10 21 12 13 16 18 24 8 9 25 Motor ground SDS coupler O Y Br W B R Bl R B B W B W W Y B Y B R O Gr W R ABS motor fuse 20 A ABS valve fuse 15 A A B C D E F G I905H1450008 01 A Rear brake solenoid OUT C Front brake solenoid OUT E Fail safe...

Page 51: ... point of sensor lead wire and the brake hose sleeve 3 Front wheel speed sensor F Clamp the protector of sensor lead wire and the brake hose sleeve A Pass the sensor lead wire inside of leg shield brace G Cut off the excess end of clamp B Clamp the white taping point of sensor lead wire and the brake hose H Outside marking C Pass the sensor lead wire between front fender and front fork Pass the se...

Page 52: ...speed sensor B Pass the rear wheel speed sensor lead wire along the speed sensor lead wire 2 Sensor bracket pin C Outside marking 3 Sensor bracket D Pass the rear wheel speed sensor lead wire along the depression of left crankcase 4 Clamp Apply thread lock to thread part A Fit the clamp between bolt and rear wheel speed sensor ...

Page 53: ...ts Location AN400A ZAK9 B905H14503001 1 2 3 4 5 6 7 I905H1450011 03 1 ABS control unit HU 3 Mode select coupler 5 Front wheel speed sensor rotor 7 Rear wheel speed sensor rotor 2 SDS coupler 4 Front wheel speed sensor 6 Rear wheel speed sensor ...

Page 54: ...00A ZAK9 Page 4E 14 3 Inspect the ABS indicator light Refer to ABS Indicator Light Inspection AN400A ZAK9 Page 4E 16 4 Output the DTCs stored in the ABS control unit Refer to DTC Diagnostic Trouble Code Output AN400A ZAK9 Page 4E 22 5 Perform appropriate troubleshooting procedures according to the DTCs output Refer to DTC Table AN400A ZAK9 Page 4E 31 If troubleshooting procedures cannot be perform...

Page 55: ...sary to ask certain important questions concerning the malfunction Therefore a questionnaire has been created to improve the information gathering procedure EXAMPLE CUSTOMER PROBLEM INSPECTION FORM NOTE This form is a standard sample The form should be modified according to conditions and characteristic of each market User name Model VIN Date of issue Date Reg Date of problem Mileage PROBLEM SYMPT...

Page 56: ...t and 150 70 13M C 64S for rear The use of tires other than those specified may cause instability It is highly recommended to use a SUZUKI Genuine Tire Replace the tire as a set otherwise the DTC 25 C1625 may be stored Wheel Refer to Front Wheel Related Parts Inspection in Section 2D in related manual and Rear Wheel Related Parts Inspection in Section 2D in related manual Battery Battery voltage i...

Page 57: ...nt box and remove the battery cover Refer to Battery Removal and Installation in Section 1J in related manual 3 Disconnect the battery lead wire 1 4 Disconnect the ABS control unit coupler 2 Refer to ABS Control Unit Coupler Disconnect and Connect AN400A ZAK9 Page 4E 71 5 Check for continuity between 24 B W at the coupler and the battery terminal also 25 B W at the coupler and the battery terminal...

Page 58: ...rning the ignition switch ON Does the ABS indicator light up Go to Step 2 Go to Step 3 2 The ABS indicator light lights up 1 Ride the motorcycle at more than 10 km h 6 2 mile h Does the ABS indicator light go off Normal No DTC exists DTC output Refer to DTC Diagnostic Trouble Code Output AN400A ZAK9 Page 4E 22 If DTC can not be output the ABS indicator light does not flash go to Step 7 I905H145001...

Page 59: ...sconnect the ABS control unit coupler Refer to ABS Control Unit Coupler Disconnect and Connect AN400A ZAK9 Page 4E 71 3 Turn the ignition switch ON with the ABS control unit coupler disconnected measure the voltage between 16 O Y and 24 B W at the coupler Special tool A 09900 25008 Multi circuit tester set Tester knob indication Voltage Normal value 16 24 Battery voltage 12 0 V and more ABS contro...

Page 60: ...the wire harness Faulty indicator light wire Signal fuse or indicator light is blown 6 1 Turn the ignition switch OFF 2 Check for continuity between 24 B W at the coupler and body ground also 25 B W at the coupler and body ground Special tool A 09900 25008 Multi circuit tester set Tester knob indication Continuity ABS control unit coupler Harness side Are there continuity between 24 25 and body gr...

Page 61: ...switch OFF 2 Disconnect the ABS control unit coupler Refer to ABS Control Unit Coupler Disconnect and Connect AN400A ZAK9 Page 4E 71 3 Turn the ignition switch ON with the ABS control unit coupler disconnected measure the voltage between 16 O Y and 24 B W at the coupler Special tool A 09900 25008 Multi circuit tester set Tester knob indication Voltage Normal value 16 24 Battery voltage 12 0 V and ...

Page 62: ... and 24 B W at the coupler Special tool A 09900 25008 Multi circuit tester set Tester knob indication Voltage Normal value 21 24 8 0 V and more ABS control unit coupler Harness side Is the voltage between 21 and 24 normal Go to Step 10 Inspect the wire harness Faulty indicator light wire Step Action Yes No 24 25 ޓ 18 10 12 13 16 2 3 4 21 ޓ 8 9 A I718H1450037 02 ...

Page 63: ...tween 13 O and 24 B W at the coupler Special tool A 09900 25008 Multi circuit tester set Tester knob indication Continuity ABS control unit coupler Harness side Is there continuity between 13 and 24 Replace the ABS control unit HU Inspect the wire harness Faulty mode select switch wire Step Action Yes No O B W A I905H1450020 01 24 25 ޓ 18 10 12 13 16 2 3 4 21 ޓ 8 9 A A I718H1450043 02 ...

Page 64: ...in fuse before confirming the malfunction code self diagnostic trouble code stored in memory Such disconnection will erase the memorized information in ABS HU memory Be sure to read Precautions for Electrical Circuit Service Refer to Precautions for Electrical Circuit Service in Section 00 in related manual and Precautions for ABS AN400A ZAK9 Page 4E 1 before inspection and observe what is written...

Page 65: ...hts up in interval of 0 4 seconds and the separation between the tens and ones are indicated by the light staying off for 1 6 seconds In addition the separation between the start code and the DTC is indicated by the light being off for 3 6 seconds After the start code is displayed DTCs appear from the smallest number code If no DTCs are memorized the ABS indicator light keeps lighting up I905H1450...

Page 66: ...written there 1 Remove the upper meter panel Refer to Upper Meter Panel Removal and Installation in Section 9D in related manual 2 Set up the SDS tool Refer to the SDS operation manual for further details Special tool A 09904 41010 SUZUKI Diagnostic system set B 99565 01010 020 CD ROM Ver 20 3 Read the DTC Diagnostic Trouble Code and show data when trouble displaying data at the time of DTC accord...

Page 67: ... deletion mode is started after the switch is set to OFF 5 In the DTC deletion mode switch the ABS test switch from OFF to ON three times each time leaving it at ON for more than 1 second NOTE The DTC deletion can be made within 12 5 seconds after the switch is turned ON DTC Deleting Diagram I905H1450023 01 A I905H1450006 01 I718H1450050 01 I718H1450051 01 DTC indicated DTC erasing enabled ABS ind...

Page 68: ...mile h and quickly apply the brakes to check that the ABS activates correctly Use of SDS 1 Remove the upper meter panel Refer to Upper Meter Panel Removal and Installation in Section 9D in related manual 2 After repairing the trouble turn OFF the ignition switch and turn ON again 3 Set up the SDS tool Refer to the SDS operation manual for further details Special tool 09904 41010 SUZUKI Diagnostic ...

Page 69: ...periodically with changes over time or failure conditions of the motorcycle For example when a motorcycle is brought in for service but the troubleshooting is difficult comparison with the normal data that have been saved or filed can allow the specific ABS failure to be determined 1 Remove the upper meter panel Refer to Upper Meter Panel Removal and Installation in Section 9D in related manual 2 ...

Page 70: ...Set up the SDS tool Refer to the SDS operation manual for further details Special tool 09904 41010 SUZUKI Diagnostic system set 99565 01010 020 CD ROM Ver 20 3 Click ABS 1 Check the front wheel speed Check the front wheel speed XX XX km h km h Check the front wheel speed XX km h Check the rear wheel speed XX km h Check the battery voltage XX V Check the brake switch ON and OFF I718H1450048 03 1 I9...

Page 71: ...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 d ABS HU operating 4 7 e ABS HU operating 5 7 f ABS HU operating 6 7 2 I718H1450058 01 3 I718H1450059 01 Return Next Cancel Help I905H1450025 01 Return Next Cancel Help I905H1450026 01 Return Next Cancel Help I905H1450027 01 Return Next Cancel Help I905H1450028 01 Cance...

Page 72: ...e ABS HU motor operates for 6 seconds and then stops automatically g ABS HU operating 7 7 NOTE Inspect the rear brake in the same manner of front brake If the ABS does not function the cause may lie in the ABS control unit HU 7 Close the SDS tool and turn the ignition switch OFF 8 Disconnect the SDS tool and reinstall the removed parts Return Finish Cancel Help I905H1450031 01 ...

Page 73: ...nsor related malfunction ON Refer to DTC 25 C1625 Wheel Speed Sensor Related Malfunction AN400A ZAK9 Page 4E 40 35 C1635 ABS motor malfunction ON Refer to DTC 35 C1635 ABS Motor Malfunction AN400A ZAK9 Page 4E 42 41 C1641 Wheel speed sensor signal malfunction F 2 ON Refer to DTC 41 C1641 Wheel Speed Sensor Signal Malfunction F AN400A ZAK9 Page 4E 44 42 C1642 Wheel speed sensor circuit open F 2 ON ...

Page 74: ...ossible Cause Front wheel speed sensor rotor distortion Faulty front wheel speed sensor or wiring discontinuity etc Step Action Yes No 1 1 Inspect the clearance between the front wheel speed sensor and sensor rotor using the thickness gauge Special tool A 09900 20803 Thickness gauge B 09900 20806 Thickness gauge Wheel speed sensor Sensor rotor clearance 0 36 1 62 mm 0 014 0 064 in Is the clearance...

Page 75: ...tion in Section 2D in related manual Tire type and size BRIDGESTONE HOOP B03 G 120 80 14M C 58S Cold inflation tire pressure Solo riding 175 kPa 1 75 kgf cm2 25 psi Cold inflation tire pressure Dual riding 175 kPa 1 75 kgf cm2 25 psi Wheel runout Service limit axial and radial 2 0 mm 0 08 in Are the front tire type tire pressure and wheel runout OK Replace the ABS control unit HU Adjust or replace...

Page 76: ... Step Action Yes No 1 1 Inspect the clearance between the rear wheel speed sensor and sensor rotor using the thickness gauge Special tool A 09900 20803 Thickness gauge B 09900 20806 Thickness gauge Wheel speed sensor Sensor rotor clearance 0 16 1 62 mm 0 006 0 064 in Is the clearance OK Go to Step 2 Adjust the clearance 2 1 Inspect the rear wheel speed sensor rotor for damage and check that no for...

Page 77: ...ated Parts Inspection in Section 2D in related manual Tire type and size BRIDGESTONE HOOP B02 G 150 70 13 M C 64S Cold inflation tire pressure Solo riding 200 kPa 2 00 kgf cm2 29 psi Cold inflation tire pressure Dual riding 250 kPa 2 50 kgf cm2 36 psi Wheel runout Service limit axial and radial 2 0 mm 0 08 in Are the rear tire type tire pressure and wheel runout OK Replace the ABS control unit HU ...

Page 78: ...round and support the motorcycle with a jack or wooden block 2 Inspect the dragging of the front brake Is there any dragging in the front brake Inspect the front brake master cylinder and the calipers Go to step 2 2 1 Inspect the clearance between the front wheel speed sensor and sensor rotor using the thickness gauge Special tool A 09900 20803 Thickness gauge B 09900 20806 Thickness gauge Wheel s...

Page 79: ...ABS 4E 37 3 1 Check that the front wheel speed sensor is mounted securely Is the sensor mounted securely Replace the ABS control unit HU Tighten the mounting bolts Step Action Yes No I905H1450032 01 ...

Page 80: ...otorcycle with its center stand 2 Inspect the dragging of the rear brake Is there any dragging in the rear brake Inspect the rear brake master cylinder caliper and parking brake cable Go to step 2 2 1 Inspect the clearance between the rear wheel speed sensor and sensor rotor using the thickness gauge Special tool A 09900 20803 Thickness gauge B 09900 20806 Thickness gauge Wheel speed sensor Sensor...

Page 81: ...eck that the rear wheel speed sensor is mounted securely Is the sensor mounted securely Replace the ABS control unit HU Tighten the mounting bolts or replace the bracket if necessary Step Action Yes No I905H1450035 01 ...

Page 82: ...GESTONE HOOP B02 G 150 70 13M C 64S Are the tires OK Go to Step 2 Use the specified tires 2 1 Make sure the tire pressure for each tire Refer to Tire Inspection in Section 0B in related manual Cold inflation tire pressure Solo riding Front 175 kPa 1 75 kgf cm2 25 psi Rear 200 kPa 2 00 kgf cm2 29 psi Cold inflation tire pressure Dual riding Front 175 kPa 1 75 kgf cm2 25 psi Rear 250 kPa 2 50 kgf cm...

Page 83: ... the front and rear wheel speed sensor sensor rotor using the thickness gauge Special tool A 09900 20803 Thickness gauge B 09900 20806 Thickness gauge Wheel speed sensor Sensor rotor clearance Front 0 36 1 62 mm 0 014 0 064 in Rear 0 16 1 62 mm 0 006 0 064 in Front Rear Are the clearances OK Replace the ABS control unit HU Adjust the clearance Step Action Yes No I905H1450049 01 A B I905H1240005 02...

Page 84: ...p motor makes turning noise by setting the ignition switch to ON from OFF when the vehicle stands still Does the pump motor make any turning noise Faulty HU motor Replace the ABS control unit HU Go to Step 2 2 1 Remove the upper meter panel Refer to Upper Meter Panel Removal and Installation in Section 9D in related manual 2 Inspect the ABS motor fuse 1 CAUTION If a fuse is blown find the cause of...

Page 85: ...r Disconnect and Connect AN400A ZAK9 Page 4E 71 4 Measure the voltage between 9 R B and 25 B W at the coupler Special tool A 09900 25008 Multi circuit tester set Tester knob indication Voltage Normal value 9 25 Battery voltage 12 0 V and more ABS control unit coupler Harness side Is the voltage between 9 and 25 normal Replace the ABS control unit HU Inspect the wire harness Faulty motor power supp...

Page 86: ...Action Yes No 1 1 Inspect the clearance between the front wheel speed sensor and sensor rotor using the thickness gauge Special tool A 09900 20803 Thickness gauge B 09900 20806 Thickness gauge Wheel speed sensor Sensor rotor clearance 0 36 1 62 mm 0 014 0 064 in Is the clearance OK Go to Step 2 Adjust the clearance 2 1 Inspect the front wheel speed sensor rotor for damage and check that no foreign...

Page 87: ...ont wheel speed sensor is mounted securely Is the sensor mounted securely Go to DTC 42 C1642 Refer to DTC 42 C1642 Wheel Speed Sensor Circuit Open F AN400A ZAK9 Page 4E 46 Tighten the mounting bolts Step Action Yes No I905H1450032 01 ...

Page 88: ... Refer to ABS Unit Diagram AN400A ZAK9 Page 4E 8 Troubleshooting NOTE After repairing the trouble clear the DTC using SDS tool Refer to DTC Diagnostic Trouble Code Deleting AN400A ZAK9 Page 4E 25 Possible Cause Poor contact in the front wheel speed sensor coupler Faulty front wheel speed sensor etc ...

Page 89: ...t coupler Refer to ABS Control Unit Coupler Disconnect and Connect AN400A ZAK9 Page 4E 71 4 Measure the resistance between 12 B R and ground at the ABS control unit coupler Special tool A 09900 25008 Multi circuit tester set B 09900 25009 Needle point probe set Tester knob indication Resistance Ω Normal value 12 Ground Ω Infinity Is the resistance between 12 and ground OK Go to Step 3 Go to Step 2...

Page 90: ...ct the wire harness Faulty B R wire Faulty front wheel speed sensor 3 1 Measure the resistance between 3 W R and ground at the ABS control unit coupler Special tool A 09900 25008 Multi circuit tester set B 09900 25009 Needle point probe set Tester knob indication Resistance Ω Normal value 3 Ground Ω Infinity Is the resistance between 3 and ground OK Go to Step 5 Go to Step 4 Step Action Yes No A A...

Page 91: ...ensor 5 1 Check for continuity between 12 B R on the ABS control unit coupler and C B R on the front wheel speed sensor coupler Special tool A 09900 25008 Multi circuit tester set B 09900 25009 Needle point probe set Tester knob indication Continuity test Normal value 12 C Continuity Is there continuity between 12 and C Go to Step 6 Inspect the wire harness Faulty B R wire Step Action Yes No B A S...

Page 92: ...0 25008 Multi circuit tester set B 09900 25009 Needle point probe set Tester knob indication Continuity test Normal value 3 D Continuity Is there continuity between 3 and D Go to Step 7 Inspect the wire harness Faulty W R wire Step Action Yes No B A D 12 18 10 13 2 4 16 8 9 24 25 21 3 Harness side ABS control unit coupler Harness side I905H1450044 01 ...

Page 93: ...ction in reverse polarity is strictly prohibited Such a wrong connection will damage the wheel speed sensor when reverse power is applied Special tool A 09900 25008 Multi circuit tester set B 09900 25009 Needle point probe set Tester knob indication Current 20 mA Normal value 5 17 mA Is the current OK Replace the ABS control unit HU Faulty front wheel speed sensor Step Action Yes No 12 DCmA ABS co...

Page 94: ...ve the meter panel Refer to Meter Panel Removal and Installation in Section 9D in related manual 3 Check the ABS control unit coupler for loose or poor contacts If OK then disconnect the ABS control unit coupler Refer to ABS Control Unit Coupler Disconnect and Connect AN400A ZAK9 Page 4E 71 4 Check for continuity between 3 W R and 12 B R at the coupler Special tool A 09900 25008 Multi circuit test...

Page 95: ...nition switch ON with the ABS control unit coupler disconnected measure the voltage between 3 W R and 24 B W at the coupler Special tool A 09900 25008 Multi circuit tester set Tester knob indication Voltage Normal value 3 24 0 V ABS control unit coupler Harness side Is the voltage between 3 and 24 normal value Replace the ABS control unit HU Inspect the wire harness Faulty sensor signal or power s...

Page 96: ...Action Yes No 1 1 Inspect the clearance between the rear wheel speed sensor and sensor rotor using the thickness gauge Special tool A 09900 20803 Thickness gauge B 09900 20806 Thickness gauge Wheel speed sensor Sensor rotor clearance 0 16 1 62 mm 0 006 0 064 in Is the clearance OK Go to Step 2 Adjust the clearance 2 1 Inspect the rear wheel speed sensor rotor for damage and check that no foreign o...

Page 97: ...sor is mounted securely Is the sensor mounted securely Go to DTC 45 C1645 Refer to DTC 45 C1645 Wheel Speed Sensor Circuit Open R AN400A ZAK9 Page 4E 56 Tighten the mounting bolts or replace the bracket if necessary Step Action Yes No I905H1450035 01 ...

Page 98: ...heel speed sensor etc Step Action Yes No 1 1 Turn the ignition switch OFF 2 Remove the helmet box front cover Refer to Helmet Box Front Cover Removal and Installation in Section 9D in related manual 3 Remove the meter panel Refer to Meter Panel Removal and Installation in Section 9D in related manual 4 Check the ABS control unit coupler and rear wheel speed sensor coupler for loose or poor contact...

Page 99: ... 2 1 Disconnect the rear wheel speed sensor coupler 2 Measure the resistance between A W and ground at the rear wheel speed sensor coupler Special tool A 09900 25008 Multi circuit tester set Tester knob indication Resistance Ω Normal value A Ground Ω Infinity Is the resistance between A and ground OK Inspect the wire harness Faulty B Y wire Replace the rear wheel speed sensor Step Action Yes No 12...

Page 100: ...Go to Step 5 Go to Step 4 4 1 Measure the resistance between B Bl and ground at the rear wheel speed sensor coupler Special tool A 09900 25008 Multi circuit tester set Tester knob indication Resistance Ω Normal value B Ground Ω Infinity Is the resistance between B and ground OK Inspect the wire harness Faulty W Y wire Replace the rear wheel speed sensor Step Action Yes No 10 18 12 13 2 4 16 8 9 24...

Page 101: ...he continuity between 18 W Y on the ABS control unit coupler and D W Y on the rear wheel speed sensor coupler Special tool A 09900 25008 Multi circuit tester set B 09900 25009 Needle point probe set Tester knob indication Continuity test Normal value 18 D Continuity Is the resistance between 18 and D Go to Step 7 Inspect the wire harness Faulty W Y wire Step Action Yes No B A C 12 18 10 13 2 4 16 ...

Page 102: ...on in reverse polarity is strictly prohibited Such a wrong connection will damage the wheel speed sensor when reverse power is applied Special tool A 09900 25008 Multi circuit tester set B 09900 25009 Needle point probe set Tester knob indication Current 20 mA Normal value 5 17 mA Is the current OK Replace the ABS control unit HU Replace the rear wheel speed sensor Step Action Yes No 2 DCmA ABS co...

Page 103: ...e the meter panel Refer to Meter Panel Removal and Installation in Section 9D in related manual 3 Check the ABS control unit coupler for loose or poor contacts If OK then disconnect the ABS control unit coupler Refer to ABS Control Unit Coupler Disconnect and Connect AN400A ZAK9 Page 4E 71 4 Check for continuity between 2 B Y and 18 W Y at the coupler Special tool A 09900 25008 Multi circuit teste...

Page 104: ... ignition switch ON with the ABS control unit coupler disconnected measure the voltage between 2 B Y and 24 B W at the coupler Special tool A 09900 25008 Multi circuit tester set Tester knob indication Voltage Normal value 2 24 0 V ABS control unit coupler Harness side Is the voltage between 2 and 24 0 V Replace the ABS control unit HU Inspect the wire harness Faulty sensor signal or power supply ...

Page 105: ...ween the and battery terminals using the multi circuit tester Special tool A 09900 25008 Multi circuit tester set Tester knob indication Voltage Battery voltage 12 0 V and more Is the voltage over 12 V Go to Step 2 Charge or replace the battery 2 1 Start the engine at 5 000 r min with the dimmer switch set to HI 2 Measure the voltage between the and battery terminals Special tool A 09900 25008 Mul...

Page 106: ...ler Refer to ABS Control Unit Coupler Disconnect and Connect AN400A ZAK9 Page 4E 71 5 Start the engine at 5 000 r min with the dimmer switch set to HI 6 Measure the voltage between 16 O Y and 24 B W at the coupler Special tool A 09900 25008 Multi circuit tester set Tester knob indication Voltage Is the voltage same as Step 2 Replace the ABS control unit HU Inspect the wire harness Faulty ignition ...

Page 107: ...tor rectifier Faulty ABS control unit Faulty wire harness etc Step Action Yes No 1 1 Turn the ignition switch OFF 2 Open the front box and remove the battery cover Refer to Battery Removal and Installation in Section 1J in related manual 3 Measure the voltage between the and battery terminals using the multi circuit tester Special tool A 09900 25008 Multi circuit tester set Tester knob indication ...

Page 108: ...al 3 1 Turn the ignition switch OFF 2 Remove the meter panel Refer to Meter Panel Removal and Installation in Section 9D in related manual 3 Install the combination meter 4 Check the ABS control unit coupler for loose or poor contacts If OK then disconnect the ABS control unit coupler Refer to ABS Control Unit Coupler Disconnect and Connect AN400A ZAK9 Page 4E 71 5 Start the engine at 5 000 r min ...

Page 109: ...e Faulty ABS control unit Step Action Yes No 1 1 Inspect the clearances of the front and rear wheel speed sensor sensor rotor using the thickness gauge Special tool A 09900 20803 Thickness gauge B 09900 20806 Thickness gauge Wheel speed sensor Sensor rotor clearance Front 0 36 1 62 mm 0 014 0 064 in Rear 0 16 1 62 mm 0 006 0 064 in Front Rear Are the clearances OK Go to Step 2 Adjust the clearance...

Page 110: ...nted securely Are the sensors mounted securely Go to Step 4 Tighten the mounting bolts or replace the bracket if necessary 4 1 Delete DTCs and repeat the code output procedure Refer to DTC Diagnostic Trouble Code Deleting AN400A ZAK9 Page 4E 25 and DTC Diagnostic Trouble Code Output AN400A ZAK9 Page 4E 22 Is the DTC 55 C1655 output again Replace the ABS control unit HU Intermittent trouble Step Ac...

Page 111: ...use Faulty solenoid valve or relay Step Action Yes No 1 1 Turn the ignition switch OFF 2 Remove the upper meter panel Refer to Upper Meter Panel Removal and Installation in Section 9D in related manual 3 Inspect the ABS valve fuse 1 CAUTION If a fuse is blown find the cause of the problem and correct it before replacing the fuse ABS valve fuse 15 A Is the ABS valve fuse OK Go to Step 2 Replace the...

Page 112: ...t and Connect AN400A ZAK9 Page 4E 71 3 Measure the voltage between 8 R Bl and 24 B W at the coupler Special tool A 09900 25008 Multi circuit tester set Tester knob indication Voltage Normal value 8 24 Battery voltage 12 0 V and more ABS control unit coupler Harness side Is the voltage between 8 and 24 normal Replace the ABS control unit HU Inspect the wire harness Faulty solenoid or ground wire St...

Page 113: ...ion 9D in related manual 3 Disconnect the front wheel speed sensor coupler 1 4 Remove the front wheel speed sensor mounting bolts 5 Remove the front wheel speed sensor as shown in the front wheel speed sensor routing diagram Refer to Front Wheel Speed Sensor Routing Diagram AN400A ZAK9 Page 4E 9 Installation Refer to Wheel Speed Sensor and Sensor Rotor Inspection AN400A ZAK9 Page 4E 74 Install the...

Page 114: ...ear wheel speed sensor coupler 1 6 Remove the rear wheel speed sensor bracket mounting bolt 7 Remove the rear wheel speed sensor as shown in the rear wheel speed sensor routing diagram Refer to Rear Wheel Speed Sensor Routing Diagram AN400A ZAK9 Page 4E 10 8 Remove the rear wheel speed sensor 2 from the bracket 3 Installation Refer to Wheel Speed Sensor and Sensor Rotor Inspection AN400A ZAK9 Page...

Page 115: ...Front wheel speed sensor rotor bolt a 6 N m 0 6 kgf m 4 5 lbf ft Install the front wheel assembly Refer to Front Wheel Assembly Removal and Installation AN400A ZAK9 in Section 2D Page 2D 3 Check the clearance between the front wheel speed sensor and sensor rotor using the thickness gauge Special tool A 09900 20803 Thickness gauge B 09900 20806 Thickness gauge Wheel speed sensor Sensor rotor cleara...

Page 116: ...otor clearance 0 16 1 62 mm 0 006 0 064 in Wheel Speed Sensor and Sensor Rotor Inspection AN400A ZAK9 B905H14506008 Wheel Speed Sensor 1 Remove the wheel speed sensor Refer to Front Wheel Speed Sensor Removal and Installation AN400A ZAK9 Page 4E 71 and Rear Wheel Speed Sensor Removal and Installation AN400A ZAK9 Page 4E 72 2 Inspect the wheel speed sensor for damage Clean the sensor if any metal p...

Page 117: ...uid reacts chemically with paint plastics rubber materials etc and will damage then severely The ABS is made up of many precision parts never subject it to strong impacts or allow it to become dirty or dusty The ABS control unit HU cannot be disassembled 1 Turn the ignition switch OFF 2 Remove the front leg shield Refer to Front Leg Shield Removal and Installation in Section 9D in related manual 3...

Page 118: ...ram AN400A ZAK9 in Section 4A Page 4A 1 or Rear Brake Hose Routing Diagram AN400A ZAK9 in Section 4A Page 4A 2 Make sure to hold the brake pipe when tightening the flare nut or it may be misaligned Tighten the brake pipe flare nuts to the specified torque Tightening torque Brake pipe flare nut a 16 N m 1 6 kgf m 11 5 lbf ft Bleed air from the brake fluid circuit Refer to Air Bleeding from Brake Fl...

Page 119: ...A ZAK9 Page 4E 10 Special Tool B905H14508002 Fastening part Tightening torque Note N m kgf m lbf ft Front wheel speed sensor rotor bolt 6 0 6 4 5 Page 4E 73 Rear wheel speed sensor rotor bolt 6 0 6 4 5 Page 4E 74 Brake pipe flare nut 16 1 6 11 5 Page 4E 76 09900 20803 09900 20806 Thickness gauge Thickness gauge Page 4E 15 Page 4E 32 Page 4E 34 Page 4E 36 Page 4E 38 Page 4E 41 Page 4E 44 Page 4E 54...

Page 120: ... 57 Page 4E 58 Page 4E 58 Page 4E 59 Page 4E 59 Page 4E 60 Page 4E 61 Page 4E 62 Page 4E 62 Page 4E 63 Page 4E 63 Page 4E 64 Page 4E 65 Page 4E 66 Page 4E 66 Page 4E 70 Page 4E 47 Page 4E 48 Page 4E 49 Page 4E 50 Page 4E 51 Page 4E 57 Page 4E 58 Page 4E 59 Page 4E 59 Page 4E 60 09904 41010 09930 82710 SUZUKI Diagnostic system set Mode select switch Page 4E 24 Page 4E 26 Page 4E 27 Page 4E 28 Page ...

Page 121: ... Movable Drive Face Component 5A Movable Drive Face Disassembly and Assembly 5A Movable Drive Face Parts Inspection 5A Oil Seal Removal and Installation 5A Clutch Shoe Movable Driven Face Components 5A Clutch Shoe Movable Driven Face Disassembly and Assembly 5A Clutch Shoe and Movable Driven Face Parts Inspection 5A Outer Clutch Cover Cushion Construction AN400 A ZAK9 5A 1 Belt Cooling Duct Hose C...

Page 122: ... a a a a b I905H1510001 01 1 Clutch outer cover cushion No 1 6 Clutch outer cover cushion No 6 2 Clutch outer cover cushion No 2 7 Belt cooling duct cushion No 1 3 Clutch outer cover cushion No 3 A Stick top of cushion 0 5 mm 0 0 2 in inside of the clutch outer cover 4 Clutch outer cover cushion No 4 a 5 10 mm 0 2 0 4 in 5 Clutch outer cover cushion No 5 b 4 6 mm 0 16 0 24 in ...

Page 123: ...ose Construction AN400 A ZAK9 B905H15106017 A 2 1 2 B I905H1510003 03 1 Belt cooling duct A Clamp the belt cooling duct hose at this position 2 Belt cooling duct hose B Mach the groove part of belt cooling duct hose to the edge of belt cooling duct ...

Page 124: ...se properly Refer to Belt Cooling Duct Hose Construction AN400 A ZAK9 Page 5A 2 Tighten the belt cooling duct hose clamp screw Tightening torque Belt cooling duct hose clamp screw 1 5 N m 0 15 kgf m 1 0 lbf ft Specifications Service Data AN400K9 B905H15107003 Refer to Service Data AN400K9 in Section 0C Page 0C 1 Service Data AN400A ZAK9 B905H15107004 Refer to Service Data AN400A ZAK9 in Section 0C...

Page 125: ...Grip Heater Diagram AN400ZK7 6B Grip Heater DIagram AN400ZK8 6B Knuckle cover Construction AN400ZK7 K8 6B Knuckle cover Removal and Installation AN400ZK7 K8 6B Steering Components 6B Steering Removal and Installation 6B Steering Related Parts Inspection 6B Steering System Inspection 6B Steering Stem Bearing Removal and Installation 6B Steering Tension Adjustment 6B Grip Heater Removal and Installa...

Page 126: ...the grip heater lead wire RH and handlebar switch lead wire RH with the clamp Cut off the excess end of clamp B Align the master cylinder holder s mating surface with the white taping point of lead wire 4 Clamp Bind the grip heater lead wire RH with the clamp Cut off the excess end of clamp C Do not pinch the lead wire between the handlebar covers Clamp the lead wire between the handlebar switch a...

Page 127: ...H16206017 1 Disconnect the grip heater lead wire couplers Refer to Grip Heater Removal and Installation AN400ZK7 K8 in related manual 2 Measure the grip heater resistance between the lead wires If the resistance is not within the specified value replace the grip heater with a new one Special tool 09900 25008 Multi circuit tester set Tester knob indication Resistance Ω Grip heater resistance LH 4 5...

Page 128: ...6B 3 Steering Handlebar Special Tools and Equipment Special Tool B905H16208002 09900 25008 Multi circuit tester set Page 6B 2 ...

Page 129: ...h Inspection 9B Engine Stop Switch Inspection 9B Starter Button Inspection 9B Ignition Switch Inspection 9B Parking Brake Switch Brake lock Switch Inspection 9B Trunk Box Switch Inspection 9B Specifications 9B Service Data 9B Special Tools and Equipment 9B Special Tool 9B Combination Meter Fuel Meter Horn 9C 1 Repair Instructions 9C 1 Combination Meter Components 9C Combination Meter Removal and I...

Page 130: ...der Handle Removal and Installation 9D Center Frame Cover Removal and Installation 9D Lower Frame Cover Removal and Installation 9D Frame Cover Removal and Installation 9D Helmet Box Removal and Installation 9D Footboard Removal and Installation 9D Pillion Rider Backrest Removal and Installation AN400ZK7 K8 9D Side Leg Shield Cover LH Componets AN400 Z A ZAK9 9D 1 Special Tools and Equipment 9D Re...

Page 131: ...Wiring Systems 9A 1 Body and Accessories Wiring Systems Schematic and Routing Diagram Wiring Diagram AN400A ZAK9 B905H19102005 Refer to Wire Color Symbols in Section 0A in related manual ...

Page 132: ... B R W R Bl 7 8 Bl B B O Y B W SPEED SENSOR COMBINATION METER POWER SOURCE HAZARD SWITCH ENGINE STOP SWITCH HANDLEBAR SWITCH R STARTER BUTTON FRONT BRAKE SWITCH IGNITION COIL ECT SENSOR IAT SENSOR FUEL PUMP Y R B W B Lg SAFETY RELAY FUEL PUMP RELAY TP SENSOR SIDE STAND SWITCH HELMET BOX SEAT SWITCH HELMET BOX LIGHT SWITCH HELMET BOX LIGHT ECM IGNITION SWITCH Gr B W W B Gr B W W B Lg B W Gr B W B W...

Page 133: ...Gr B W R B O Y B W Lg Br B W W B B B R W R B Y W Y Br W B O B R W R B Y W Y W Bl W Bl R O O Y B W O G Br R O O Y B W O G Br R R B R W R Bl 7 8 Bl B B O Y B W SPEED SENSOR POWER SOURCE HAZARD SWITCH ENGINE STOP SWITCH HANDLEBAR SWITCH R STARTER BUTTON FRONT BRAKE SWITCH IGNITION COIL ECT SENSOR IAT SENSOR FUEL PUMP Y R B W B Lg SAFETY RELAY FUEL PUMP RELAY TP SENSOR SIDE STAND SWITCH HELMET BOX SEA...

Page 134: ...grip heater switch lead wire AN400ZA only and grip heater lead wire LH AN400ZA only with the clamp Cut off the excess end of clamp C Align the master cylinder holder s mating surface with the white taping point of lead wire 3 Clamp Bind the grip heater lead wire RH with the clamp Cut off the excess end of clamp D Pass the parking brake switch lead wire over the cushion 4 Clamp Bind the grip heater...

Page 135: ...f clamp with the air cleaner box The tip of clamp should face outside of the motorcycle B Pass the wiring harness in front of the seat lock cable 7 Clamp Bind the starter motor lead wire and parking brake cable with the clamp C Do not pinch the lead wire and wiring harness between front leg shield and brace 8 Clamp Bind the starter motor lead wire and wiring harness with the clamp D Black tape 9 C...

Page 136: ...the wiring harness stopper 9 Clamp Bind the generator lead wire and HO2 sensor lead wire with the clamp G To rear combination light 10 Wiring harness stopper H Pass the wiring harness in front of the frame 11 Clamp Bind the speed sensor lead wire and rear wheel speed sensor lead wire with the clamp I Pass the lead wire outside of the hoses 12 Clamp Bind the wiring harness speed sensor lead wire ge...

Page 137: ...Systems 9A 7 Specifications Service Data AN400K9 B905H1910S003 NOTE The service data is the same as the K8 model Service Data AN400A ZAK9 B905H1910S004 Refer to Service Data AN400A ZAK9 in Section 0C Page 0C 2 ...

Page 138: ...ning the ignition switch ON If the ABS indicator does not light up replace the combination meter assembly with a new one after checking its wire harness coupler Refer to ABS Indicator Light Inspection AN400A ZAK9 in Section 4E Page 4E 16 Specifications Service Data AN400K9 B905H19307002 NOTE The service data is the same as the K8 model Service Data AN400A ZAK9 B905H19307003 Refer to Service Data A...

Page 139: ...rts 9D 1 Body and Accessories Exterior Parts Repair Instructions Side Leg Shield Cover LH Componets AN400 Z A ZAK9 B905H19406028 3 1 2 I905H1940001 01 1 Side leg shield cover LH 2 Screw 3 Side leg shield cover LH ...

Page 140: ... AN400 Z A ZAK9 B905H19506008 a a b b A 5 1 2 3 4 a I905H1950001 01 1 Center stand A Do not apply grease to the thread portion of the bolts 2 Center stand inner spring a 60 mm 2 4 in 3 Center stand outer spring b 57 mm 2 2 in 4 Frame 50 Nm 5 0 kgf m 36 0 lbf ft 5 Cushion Apply grease to sliding surface ...

Page 141: ...nstruction AN400 Z A ZAK9 Page 9E 1 Reference For the tightening torque of fastener not specified in this section refer to Tightening Torque List in Section 0C in related manual Special Tools and Equipment Recommended Service Material B905H19508001 NOTE Required service material is also described in the following Center Stand Construction AN400 Z A ZAK9 Page 9E 1 ...

Page 142: ...Prepared by April 2009 Part No 99501 34170 01E Printed in Japan 140 ...

Page 143: ...Printed in Japan K9 ...

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