Suzuki AN400 2003 Service Manual Download Page 1

Page: 1 / 384

Summary of Contents for AN400 2003

Page 1: ......

Page 2: ...liable service COPYRIGHT SUZUKI MOTOR CORPORATION 2002 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 and the actual motorcycle Illustrations in this manual are used to show the basic principles of operation and work procedures They may not repre...

Page 3: ...ed on the first page of each section to help you find the item and page you need COMPONENT PARTS AND WORK TO BE DONE Under the name of each system or unit is its exploded view Work instructions and other service information such as the tightening torque lubricating points and locking agent points are provided Example Front wheel 1Wheel bearing 2Front tire 3Front wheel 4Spacer 5Brake disc 6Dust sea...

Page 4: ...SUZUKI MOLY PASTE in a ratio of 1 1 Use fork oil 99000 99044 10G Apply SUZUKI SUPER GREASE A 99000 25010 Others 99000 25030 USA Apply or use brake fluid Apply SUZUKI MOLY PASTE 99000 25140 Measure in voltage range Apply SUZUKI SILICONE GREASE 99000 25100 Measure in current range Apply SUZUKI BOND 1215 99000 31110 Except USA Measure in resistance range Apply SUZUKI BOND 1207B 99104 31140 USA Measur...

Page 5: ... DOHC Double Over Head Camshaft DRL Daytime Running Light E ECM Engine Control Module Engine Control Unit ECU FI Control Unit ECT Sensor Engine Coolant Temperature Sensor ECTS Water Temp Sensor WTS EVAP Evaporative Emission EVAP Canister Evaporative Emission Canister Canister F FI Fuel Injection Fuel Injector FP Fuel Pump FPR Fuel Pressure Regulator FP Relay Fuel Pump Relay FTPC Valve Fuel Tank Pr...

Page 6: ...nimum N NOX Nitrogen Oxides O OHC Over Head Camshaft OLS Oil Level Switch OPS Oil Pressure Switch P PCV Positive Crankcase Ventilation Crankcase Breather R RH Right Hand ROM Read Only Memory S SAE Society of Automotive Engineers T TO Sensor Tip Over Sensor TOS TP Sensor Throttle Position Sensor TPS ...

Page 7: ...4 ENGINE OIL AND TRANSMISSION OIL FOR USA 1 5 ENGINE OIL AND TRANSMISSION OIL FOR OTHER COUNTRIES 1 5 FINAL GEAR OIL 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 5 LIQUID AMOUNT OF WATER ENGINE COOLANT 1 6 BREAK IN PROCEDURES 1 7 INFORMATION LABELS 1 8 SPECIFICATIONS 1 9 DIMENSIONS AND DRY MASS 1 9 ENGINE 1 9 DRIVE TRAIN 1 9 CHASSIS 1 ...

Page 8: ...st use good judgement and basic mechanical safety principles If you are unsure about how to perform a particular service operation ask a more experienced mechanic for advice GENERAL PRECAUTIONS Proper service and repair procedures are important for the safety of the service mechanic and the safety and reliability of the motorcycle When 2 or more persons work together pay attention to the safety of...

Page 9: ... nuts tighten the larger sizes first Always tighten the bolts and nuts diagonally from the inside toward outside and to the speci fied tightening torque Whenever you remove oil seals gaskets packing O rings locking washers self locking nuts cotter pins circlips and certain other parts as specified be sure to replace them with new ones Also before installing these new parts be sure to remove any le...

Page 10: ...d especially for registering 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 the research method Gasoline containing MTBE Methyl Tertiary Butyl Ether less than 10 ethanol or less than 5 methanol with appropriate cosolvents and corrosion inhibitor is permissi...

Page 11: ... and classification DOT 4 FRONT FORK OIL Use fork oil 10 or an equivalent fork oil ENGINE COOLANT Use an anti freeze engine coolant compatible with an aluminum radiator mixed with distilled water only WATER FOR MIXING Use distilled water only Water other than distilled water can corrode and clog the aluminum radiator ANTI FREEZE ENGINE COOLANT The engine coolant perform as a corrosion and rust inh...

Page 12: ...refer to cooling system section page 6 3 Mixing of anti freeze engine coolant should be limited to 60 Mixing beyond it would reduce its efficiency If the anti freeze engine coolant mixing ratio is below 50 rust inhabiting perfor mance is greatly reduced Be sure to mix it above 50 even though the atmospheric tempera ture does not go down to the freezing point ...

Page 13: ... BREAK IN before subjecting the engine to maximum stresses The future performance and reliability of the engine depends on the care and restraint exercised during its early life The general rules are as follows Keep to these break in engine speed limits Initial 800 km Below 4 000 r min Up to 1600 km Below 6 000 r min Upon reaching an odometer reading of 1600 km you can subject the motorcycle to fu...

Page 14: ...arning label 4 Tire pressure label 6 Loading capacity label 7 ID label 8 Information label For E 03 28 33 9 Noise label For E 03 33 5 Fuel caution label For E 02 E 03 33 Front box Stick the label on the frame tube Stick the label on the front trunk box cover Stick the label on the trunk box cover E 28 ...

Page 15: ...rethane foam element Starter system Electric Lubrication system Wet sump Idle speed 1 400 100 r min DRIVE TRAIN Clutch Dry shoe automatic centrifugal type Gearshift pattern Automatic Final reduction ratio 6 168 31 14 39 14 Gear ratio 2 203 0 854 variable change Drive system V belt drive CHASSIS Front suspension Telescopic coil spring oil damped Rear suspension Link type coil spring oil damped Fron...

Page 16: ...7 W Coolant temperature gauge light 12 V 1 7 W Fuel level gauge light 12 V 1 7 W Turn signal indicator light 12 V 1 7 W 2 High beam indicator light 12 V 1 7 W Brake lock indicator light 12 V 1 7 W Oil change indicator light 12 V 1 7 W Fuel injection warning light 12 V 1 7 W CAPACITIES Fuel tank including reserve 13 0 L 3 4 2 9 US lmp gal Engine oil oil change 1 900 ml 2 0 1 7 US Imp qt with filter...

Page 17: ...TION 1 11 COUNTRY AND AREA CODES The following codes stand for the applicable country ies and area s CODE COUNTRY or AREA E 02 E 03 E 19 E 28 E 33 E 54 U K U S A Except for California EU Canada California U S A Israel ...

Page 18: ...R OIL 2 10 IDLE SPEED 2 11 THROTTLE CABLE PLAY 2 12 COOLING FAN FILTER 2 13 COOLING SYSTEM 2 13 DRIVE V BELT INSPECTION 2 15 PAIR AIR SUPPLY SYSTEM 2 15 BRAKE SYSTEM 2 16 STEERING 2 20 FRONT FORK 2 21 REAR SUSPENSION 2 21 TIRE 2 22 CHASSIS BOLT AND NUT 2 23 COMPRESSION PRESSURE CHECK 2 25 COMPRESSION TEST PROCEDURE 2 25 OIL PRESSURE CHECK 2 26 OIL PRESSURE TEST PROCEDURE 2 26 AUTOMATIC CLUTCH INSP...

Page 19: ... Item months 1 6 12 18 24 Air cleaner element Clean every 3 000 km 1 800 miles Exhaust pipe bolts and muffler bolts T T T T T Valve clearance I I I I I Spark plug I R I R Fuel line I I I I Replace every 4 years Engine oil R R R R R Engine oil filter R R Final gear oil R R Idle speed I I I I I Throttle cable play I I I I I Cooling fan filter Clean every 3 000 km 1 800 miles Radiator hose I I I I Re...

Page 20: ... NOTE Before lubricating each part clean off any rusty spots and wipe off any grease oil dirt or grime Lubricate exposed parts which are subject to rust with a rust preventative spray whenever the motorcycle has been operated under wet or rainy conditions Combination brake lever folder Side stand pivot and spring hook Center stand pivot and spring hook Throttle cables Front brake lever holder ...

Page 21: ...4 Immerse the element in the cleaning sol vent and wash it Gently squeeze the element to remove the excess solvent do not twist or wring the element or it will develop tears Immerse the element in motor oil 5 and squeeze out the excess oil The element should be wet but not dripping Reinstall the cleaned or new air cleaner element in the reverse order of removal Clean every 3 000 km 1 800 miles Ins...

Page 22: ...joint nut 30 N m 3 0 kgf m 21 5 lb ft Muffler mounting nut 23 N m 2 3 kgf m 16 5 lb ft VALVE CLEARANCE Remove the trunk box 7 18 Remove the air cleaner box and throttle body 5 14 Remove the cooling fan cover 3 11 Remove the cooling fan filter 3 11 Remove the cylinder head cover 1 Tighten initially at 1 000 km 600 miles 1 months and every 6 000 km 4 000 miles 6 months thereafter Inspect initially a...

Page 23: ...e clear ance The clearance specification is for COLD state To turn the crankshaft for clearance checking and rotate in the normal running direction The spark plug should be removed Turn crankshaft to bring the TDC line A on the rotor to the index mark B on the generator stator case Check that the engrave line C locates parallel with the mating face between the cylinder head cover when viewed from ...

Page 24: ...e following gap Spark plug gap Standard 0 7 0 8 mm 0 028 0 031 in 09900 20803 Thickness gauge ELECTRODE S CONDITION Inspect to see the worn or burnt condition of the electrodes If it is extremely worn or burnt replace the plug And also replace the plug if it has a broken insulator damaged thread etc Inspect at 6 000 km 4 000 miles 6 months and repla ce every 12 000 km 7 000 miles 12 months thereaf...

Page 25: ...the engine oil change ENGINE OIL REPLACEMENT Keep the motorcycle upright with the center stand Place an oil pan below the engine and drain the oil by remov ing the filler cap 1 and oil drain plug 2 Before using a spark plug wrench carefeuuly turn the spark plug by finger into the threads of the cylinder head to prevent damage the aluminum threads Inspect initially at 6 000 km 4 000 miles 6 months ...

Page 26: ...rcycle on the center stand Start up the engine and allow it to run for several minutes at idling speed Turn off the engine and wait about one minute then check the oil level by removing the filler cap 4 If the level is below mark L add oil to F level If the level is above mark F drain oil to F level OIL FILTER REPLACEMENT Drain engine oil in the same manner of engine oil replacement procedure Remo...

Page 27: ...e the left side leg shield 7 15 Remove the clutch cover 1 3 16 Place an oil pan below the mission case Remove the oil level plug 2 and inspect the oil level If the level is below the level hole add oil until oil flows from the level hole Oil viscosity and classification SAE 10 W 40 with SF or SG Tighten the oil level plug 2 to the specified torque Oil level plug 12 N m 1 2 kgf m 8 5 lb ft NOTE If ...

Page 28: ...he left side leg shield 7 15 Connect an electric tachometer Start up the engine and set its speed at anywhere between 1400 and 1600 r min by turning idle adjust screw 1 Engine idle speed Standard 1400 100 r min 09900 26006 Tachometer Inspect initially at 1 000 km 600 miles 1 months and every 6 000 km 4 000 miles 6 months thereafter ...

Page 29: ...at the throttle grip Tighten the lock nut 4 while holding the 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 2 to feel resistance Tighten the lock nut 1 while holding the adjuster 3 Throttle cable play A 2 0 4 0 mm 0 08 0 16 in Inspect initially at 1 000 km 600 miles 1 months and every 6 000 km 4 000...

Page 30: ...rse order of removal COOLING SYSTEM RADIATOR HOSES Check to see the radiator hoses for crack damage or engine coolant leakage If any defects are found replace the radiator hoses with new ones Clean every 3 000 km 1 800 miles Do not apply oil or water to the fan filter RADIATOR HOSE Inspect every 6 000 km 4 000 miles 6 months Replace radiator hoses every 4 years ENGINE COOLANT Replace engine coolan...

Page 31: ...n engine coolant by disconnecting the water hoses 2 and 3 Flush the radiator with fresh water if necessary Pour the specified engine coolant up to the radiator inlet Bleed the air from the engine coolant circuit as following pro cedure NOTE For engine coolant information refer to page 6 3 Do not open the radiator cap when the engine is hot as you may be injured by escaping hot liquid or vapor Engi...

Page 32: ... cooling down the engine several times add the engine coolant up to the full level of the reserve tank Engine coolant capacity Approx 1 300 ml 43 9 45 8 US lmp oz DRIVE V BELT INSPECTION Remove the left side leg shield 7 15 Remove the clutch cover 3 16 Remove the clutch inner cover 3 16 Check the contact surface for crack or other damage Measure the width of the belt if necessary 3 55 If any abnor...

Page 33: ...0 km 4 000 miles 6 months thereafter BRAKE HOSE AND BRAKE FLUID Inspect every 6 000 km 4 000 miles 6 months Replace hoses every 4 years Replace fluid every 2 years The brake system of this motorcycle is filled with a glycol based brake fluid Do not use or mix different types of fluid such as silicone based or petro leum based Do not use any brake fluid taken from old used or unsealed containers Ne...

Page 34: ...KE PAD REPLACEMENT Front brake pad 7 26 Rear brake pad 7 52 FRONT BRAKE FLUID REPLACEMENT Place the motorcycle on a level surface and keep the handle bar straight Remove the master cylinder reservoir cap and diaphragm Suck up the old brake fluid as much as possible Fill the reservoir with new brake fluid Specification and classification DOT4 Replace the brake pad as a set otherwise braking per for...

Page 35: ...aight Remove the rear brake caliper cover 1 Remove the master cylinder reservoir cap and diaphragm Suck up the old brake fluid as much as possible Fill the reservoir with new brake fluid Specification and classification DOT4 Connect a clear hose 1 to the air bleeder valve and insert the other end of the hose into a receptacle Loosen the air bleeder valve and pump the brake lever until the old brak...

Page 36: ... the reservoir cap to prevent entry of dirt Connect a clear hose 1 to the air bleeder valve and insert the free end of the pipe into a receptacle Air bleeder valve 7 5 N m 0 75 kgf m 5 5 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 Loosen the bleeder valve by turning...

Page 37: ... from the rear side first and then the front side 2 Clear hose for rear brake 3 Clear hose for front brake STEERING Steering should be adjusted properly for smooth turning of handlebars and safe running Overtight steering prevents smooth turning of the handlebars and too loose steering will cause poor stability Handle brake fluid with care the fluid reacts chemi cally with paint plastics rubber ma...

Page 38: ...on the outer surface of the inner tubes Replace any defective parts if necessary 7 35 REAR SUSPENSION Inspect the rear shock absorber for oil leakage and mounting rubbers including engine mounting for wear and damage Replace any defective parts if necessary REAR SHOCK ABSORBER ADJUSTMENT Turn the adjuster handle adjust the rear shock absorber spring pre load Rear shock absorber spring pre load Adj...

Page 39: ...cted and tire wear increased Therefore main tain the correct tire pressure for good roadability or shorter tire life will result Cold inflation tire pressure is as follows TIRE TYPE BRIDGESTONE Front HOOP B03 Rear HOOP B02 Inspect initially at 1 000 km 600 miles 1 months and every 6 000 km 4 000 miles 6 months thereafter COLD INFLATION TIRE PRESSURE SOLD RIDING DUAL RIDING kPa kgf cm psi kPa kgf c...

Page 40: ... 2 Pinch bolt 23 2 3 16 5 3 Lock nut 30 3 0 21 5 4 Handlebar holder clamp bolt 55 5 5 40 0 5 Handlebar holder set bolt 23 2 3 16 5 6 Handlebar clamp bolt 23 2 3 16 5 7 Front fork cap bolt 45 4 5 32 5 8 Front fork clamp bolt 23 2 3 16 5 9 Master cylinder bolt 10 1 0 7 0 0 Union bolt 23 2 3 16 5 A Caliper mounting bolt 25 2 5 18 0 B Air bleeder valve 7 5 0 75 5 5 C Brake disc bolt 23 2 3 16 5 D Rear...

Page 41: ...2 24 PERIODIC MAINTENANCE ...

Page 42: ... engine for compression pressure make sure that the cylinder head bolts are tightened to the specified torque values and valves are properly adjusted Have the engine warmed up by idling before testing Be sure that the battery used is in fully charged condition Remove the parts concerned and test the compression pres sure in the following manner Support the motorcycle with the center stand Remove t...

Page 43: ...ination of the above items OIL PRESSURE TEST PROCEDURE Check the oil pressure in the following manner Support the motorcycle with the center stand Remove the main gallery plug 1 Install the oil pressure gauge with adaptor in the position shown in the figure Connect the tachometer Warm up the engine as follows Summer 10 min at 2 000 r min Winter 20 min at 2 000 r min After warming up increase the e...

Page 44: ...ng temperature Remove the left side leg shield 7 15 Connect the tachometer to the high tension cord 1 Seated on the motorcycle with the motorcycle on level ground increase the engine RPMs slowly and note the RPM at which the motorcycle begins to move forward 09900 26006 Tachometer Engagement r min 2 300 2 900 r min 2 CLUTCH LOCK UP INSPECTION Perform this inspection to determine if the clutch is e...

Page 45: ...le forward to make sure that the brake lock acts enough ADJUSTMENT Pull the brake lock lever by one step one notch NOTE The brake lock lever have 8 steps 8 notchs when pulling in full Remove the rear brake caliper cover 1 With the lock nut 2 loosening adjust the adjuster bolt 3 in until the brake pad comes in contact with brake disc Tighten the lock nut 2 ...

Page 46: ...PERIODIC MAINTENANCE 2 29 Return the brake lock lever to original position and inspect the brake lock After the brake lock adjustment inspect the brake fluid level of combination brake ...

Page 47: ...6 CYLINDER 3 38 PISTON 3 38 CONROD AND CRANKSHAFT 3 40 MOVABLE DRIVE FACE ASSEMBLY 3 42 CLUTCH SHOE MOVABLE DRIVEN FACE 3 44 TRANSMISSION COVER 3 50 IDLE GEAR 3 52 FINAL DRIVEN GEAR 3 53 SCISSORS GEAR 3 53 CLUTCH INNER COVER 3 54 STARTER CLUTCH 3 56 GENERATOR 3 57 OIL SUMP FILTER 3 59 OIL PUMP 3 59 CRANKCASE 3 59 ENGINE REASSEMBLY 3 65 CRANKSHAFT 3 65 BALANCER SHAFT 3 65 CRANKCASE 3 65 BALANCER GE...

Page 48: ...RIVEN FACE ASSEMBLY 3 72 MOVABLE DRIVE FACE ASSEMBLY 3 74 CLUTCH INNER COVER 3 74 GENERATOR COVER 3 75 WATER PUMP 3 75 OIL FILTER 3 76 PISTON RING 3 76 PISTON 3 77 CYLINDER 3 78 CAM CHAIN GUIDE 3 78 CYLINDER HEAD 3 78 CAMSHAFT 3 79 CAM CHAIN TENSION ADJUSTER 3 81 CYLINDER HEAD COVER 3 81 STARTER MOTOR 3 82 ...

Page 49: ...Spark plug 3 10 2 7 Cylinder head cover 3 11 3 81 Camshaft 3 13 3 79 Cam sprocket 3 13 3 79 Valve 3 25 3 34 Cylinder 3 14 3 78 Piston 3 14 3 77 ITEM REMOVAL INSTALLATION Fixed drive face 3 17 3 74 Movable drive face 3 17 3 74 Clutch housing 3 17 3 73 Clutch shoe movable driven face assembly 3 17 3 72 Drive V belt 3 17 3 72 Transmission cover 3 17 3 72 Oil sump filter 3 18 3 70 Rear axle shaft 3 18...

Page 50: ... 2 10 Disconnect the breather hose 1 Remove the IAP sensor coupler 2 Disconnect the fuel injector coupler 3 Disconnect the ECT sensor ignition coil coupler 4 Disconnect the IAT sensor coupler 5 Remove the hose 6 Loosen the air cleaner hose clamp screw 7 Remove the air cleaner mounting bolts 8 Disengage the hooks on the bottom of the air cleaner box and then remove the air cleaner box 9 ...

Page 51: ...ts and then remove the intake pipe 2 along with the throttle body 3 Remove the O rings 4 and insulator 5 Disconnect the starter motor lead wire 6 and engine ground lead wire 7 Disconnect the generator coupler 8 and CKP sensor coupler 9 Disconnect the clamps 0 A ...

Page 52: ...hoses 1 and 2 Remove the exhaust pipe bolts 3 Remove the muffler mounting nuts and then remove the muf fler 4 Remove the gasket Remove the muffler bracket 5 Remove the rear wheel nuts Remove the rear wheel 6 Remove the axle nut 7 ...

Page 53: ... caliper mounting bolts 3 Remove the rear brake caliper 4 Remove the rear brake disc 5 Remove the rear hub 6 Support the engine using an engine jack Remove the cushion rod bolt and nut 7 located on the front lower part of the engine Remove the engine mounting bolt and nut 8 Remove the engine from the frame ...

Page 54: ...rs and needle roller bearings 99000 25010 SUZUKI SUPER GREASE A Others 99000 25030 SUZUKI SUPER GREASE A USA Tighten the rear cushion rod nut 2 to the specified torque Rear cushion rod nut 2 50 N m 5 0 kgf m 36 0 lb ft Tighten the engine mounting nut 3 to the specified torque Engine mounting nut 3 93 N m 9 3 kgf m 67 5 lb ft Crankcase bracket Bearing Crankcase 85 N m 8 5 kgf m 61 5 lb ft 93 N m 9 ...

Page 55: ...nting top After the engine has been mounted install the lead wires cables and hoses securely Pour the specified amount of final gear oil 2 10 Pour the specified amount of engine oil 2 9 Pour the specified amount of engine coolant 2 14 Perform the following adjustments Throttle cable 2 12 Brake lock 2 28 Check for leakage of the transmission oil engine oil and engine coolant 23 N m 2 3 kgf m 16 5 l...

Page 56: ...Remove the ECT sensor coupler 3 and ignition coil 4 Remove the starter motor 5 Remove the spark plug 6 09930 10121 Spark plug wrench set Put the removed parts from the engine in order of each component part Be careful not to cause damage on the removed parts when handling ...

Page 57: ...3 11 Remove the water hose 1 Remove the cylinder head cover 2 Remove the dowel pin 3 Remove the cooling fan cover 4 Remove the cooling fan filter 5 Remove the camshaft journal holder 6 Remove the dowel pins 7 ...

Page 58: ...e cam chain tension adjuster 3 Remove the generator cover plug 4 Bring the piston to TDC on the compression stroke by turning the crankshaft until T mark B on the generator rotor aligns with the mark C on the generator cover Slide the cam sprocket 5 to the engine right side Remove the camshaft journal holder 6 Remove the cam chain 7 from the cam sprocket ...

Page 59: ...el pins 3 and C ring 4 Remove the 6 mm cylinder head nuts 5 and clamp 6 Remove the 8 mm cylinder head nuts 7 Remove the 10 mm cylinder head bolts 8 along with the cop per washers Remove the cylinder head 9 The cylinder head bolts must be loosened diagonally and evenly ...

Page 60: ... 2 Remove the cam chain guide 3 Remove the cylinder nuts 4 Remove the cylinder 5 Remove the cylinder gasket 6 and dowel pins 7 Remove the piston pin circlip 8 Remove the piston pin 9 Remove the piston 0 Use care not to drop the removed circlip into the crankcase ...

Page 61: ...ENGINE 3 15 Remove the oil filter cap 1 Remove the O ring 2 Remove the oil filter 3 Remove the O ring 4 Remove the water pump 5 Remove the O ring 6 Remove the generator cover 7 ...

Page 62: ...3 16 ENGINE Remove the gasket 1 Remove the dowel pins 2 Remove the clutch cover 3 Remove the clutch inner cover 4 Remove the dowel pins 5 ...

Page 63: ...he clutch housing held immovable using the special tool loosen the clutch housing nut 2 Remove the clutch housing 3 09930 40113 Rotor holder Remove the drive V belt 4 and clutch shoe movable driven face assembly 5 Remove the movable drive face assembly 6 with the spacer 7 Remove the driveshaft 8 together with the transmission cover 9 ...

Page 64: ... dowel pins 1 and washers 2 3 Remove the final driven gear 4 together with the rear axle shaft 5 Remove the idle shaft 6 Remove the washer 7 Remove the oil sump filter cap 8 Remove the O ring 9 Pull out the oil sump filter 0 ...

Page 65: ... loosen the genera tor rotor nut 1 Remove the generator rotor 2 using the special tool 09930 31921 Rotor remover Remove the key 3 and starter driven gear 4 Remove the oil pump 5 Remove the oil pump chain 6 Remove the circlip 7 Remove the oil pump gear 8 ...

Page 66: ... 4 and starter idle gear 5 Insert a proper steel rod 6 into the crankcase hole A and pass through the crankshaft web holes B in order to prevent the crankshaft from turning Remove the balancer driven gear nut 7 and washer 8 Remove the balancer driven gear 9 together with the scis sors gear ...

Page 67: ...n the balancer drive gear nut 2 09920 21410 Long socket 46 mm Remove the washer 3 and balancer drive gear 4 Remove the pin 5 Remove the 6 mm crankcase bolts 6 Remove the 8 mm crankcase bolts 7 Loosen the smaller diameter crankcase bolts first and then thicker ones diagonally and evenly ...

Page 68: ...crankshaft separator NOTE The crankcase separator plate is parallel with the end face of the crankcase Remove the O ring 1 and dowel pins 2 Remove the balancer shaft 3 Remove the crankshaft using the spacial tool 09920 13120 Crankcase crankshaft separator The crankshaft must remain in the left crankcase half ...

Page 69: ...ket 3 INSPECTION 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 REASSEMBLY Reassembly the cylinder head cover in the reverse order of disassembly Pay attention to the following points Install the cylinder head cover gasket 1 Replace the removed cylinder head cover gasket with a new one ...

Page 70: ...tandard value replace the shaft Rocker arm shaft O D IN EX Standard 11 973 11 984 mm 0 471 0 472 in 09900 20205 Micrometer 0 25 mm ROCKER ARM SHAFT INSIDE DIAMETER INSPECTION Measure the rocker arm inside diameter in two directions at right angle to each other If the inside diameter measured exceeds the standard value replace the shaft Rocker arm shaft I D IN EX Standard 12 000 12 018 mm 0 472 0 4...

Page 71: ...ter 09916 14910 Attachment Remove the cotter halves 2 09916 84511 Tweezers Remove the valve spring retainer 3 Remove the spring 4 Remove the valve 5 from the other side Remove the valve stem seal 6 Remove the spring seat 7 Remove the cam chain tensioner bolt 8 and gasket washer 9 Remove the cam chain tensioner 0 ...

Page 72: ... replace the cyl inder head Cylinder head distortion Service Limit 0 05 mm 0 002 in 09900 20803 Thickness gauge VALVE FACE WEAR Visually inspect each valve face for wear Replace any valve with an abnormally worn face The thickness of the valve face decreases as the face wears Measure the valve face T If it is out of specification replace the valve with a new one Valve head thickness T Service Limi...

Page 73: ... as shown and check its runout with a dial gauge If the service limit is exceeded or abnormal condition exists replace the valve Valve stem runout Service Limit 0 05 mm 0 002 in 09900 20607 Dialgauge 1 100 mm 09900 20701 Magnetic stand 09900 21304 V block 100 mm ...

Page 74: ...00 20607 Dial gauge 1 100 mm 09900 20701 Magnetic stand VALVE STEM DIAMETER If the valve stem deflection exceeds the service limit measure the valve stem outside diameter If the diameter measured is within the standard range replace the valve guide For each of upper middle and lower sections within the slid ing range two measurements each in crosswise direction must be taken Valve stem O D Standar...

Page 75: ... their guiding bores using the reamer Be sure to clean and oil the guides after reaming 09916 34550 Valve guide reamer 5 5 mm 09916 54542 Valve guide reamer handle NOTE Insert the reamer from the combustion chamber and always turn the reamer handle clockwise VALVE SEAT WIDTH INSPECTION Visually check for valve seat width on each valve face If the valve face has worn abnomally replace the valve Coa...

Page 76: ...ned to three different angles The seat contact surface is cut at 45 09916 21111 Valve seat cutter set 09916 20610 Valve seat cutter N 121 09916 20620 Valve seat cutter N 122 09916 24935 Valve seat cutter N 608 09916 24311 Solid pilot N 100 5 0 09916 22410 Solid pilot N 140 5 0 NOTE Use the solid pilot along with the valve seat cutter N 121 and 122 When installing the solid pilot rotate is slightly...

Page 77: ... to con dition the seat some more NOTE Cut only the minimum amount necessary from the seat to pre vent the possibility of the valve stem becoming too close to the rocker arm for correct valve contact angle TOP NARROWING CUT Measure the valve seat width If the contact area W is too high on the valve or if it is too wide use the 15 cutter to lower and narrow the contact area Use the 15 cutter 45 Con...

Page 78: ...ION Clean and assemble the head and valve 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 Do not use lapping compound after the final cut is made The finished valve seat should have a velvety smooth finish but not a highly polished or shiny fin ish Th...

Page 79: ...ing for proper strength by measuring its free length and also by the force required to compress it If the spring length is less than the service limit or if the force required to compress the spring does not fall within the speci fied range replace the spring 09900 20102 Vernier calipers Valve spring free length IN EX Service Limit 38 8 mm 1 53 in Valve spring tension IN EX Standard 182 210N 18 2 ...

Page 80: ...ge pitch portion Compress the valve spring 1 using the special tools 09916 14510 Valve lifter 09916 14910 Attachment 09916 84511 Tweezers Install the valve cotter halves 2 NOTE To facilitate assembly apply a little grease to the valve cotter when fitting into the valve stem groove Replace the stem seal with a new one When installing the valve insert the stem slowly while rotating and taking care n...

Page 81: ...between the camshaft 1 and camshaft holder and tighten the camshaft holder bolt to the specified torque 09900 22301 Plastigauge 09900 22302 Plastigauge Camshaft holder bolt 10 N m 1 0 kgf m 7 0 lb ft NOTE Do not rotate the camshaft after the camshaft holder has been tightened with the plastigauge in place Remove the camshaft holders and read the width of the com pressed plastigauge with envelope s...

Page 82: ...nder head with new ones Camshaft jouranal O D Standard 22 21 959 21 980 mm 0 8645 0 8653 in 17 5 17 466 17 484 mm 0 6876 0 6883 in 09900 20205 Micrometer 0 25 mm CAMSHAFT RUNOUT Inspect the camshaft surface for scrach With the camshaft held on the V blocks measure the runout with a dial gauge If the runout exceeds the service limit replace the camshaft Camshaft runout Service Limit 0 10 mm 0 004 i...

Page 83: ...age If it is found to be damaged replace it with a new one CAM CHAIN TENSIONER INSPECTION Check the contacting surface 1 of the cam chain tensioner If it is worn or damaged replace it with a new one CAM CHAIN TENSIONER REMOUNTING Install the cam chain tensioner 1 in the cylinder head Install the gasket washer 2 to the bolt 3 and then tighten it to the specified torque Cam chain tensioner bolt 13 N...

Page 84: ...e the bore diameter At each position take two measurements one par allel with and the other perpendicular to the crankshaft axis Cylinder bore Service Limit 83 085 mm 3 27 in 09900 20508 Cylinder gauge set PISTON PISTON DIAMETER INSPECTION Measure the piston outside diameter in the direction perpen dicular to the piston pin axis at the height from the skirt as shown in the illustration using a mic...

Page 85: ...602 Dial gauge 1 1 000 mm 1 mm 09900 22403 Small bore gauge 18 35 mm PISTON PIN DIAMETER INSPECTION Using a micrometer measure the piston pin outside diameter at three positions both the ends and the center If any of the measurements is found less than the service limit replace the pin Piston pin O D Service Limit 19 980 mm 0 787 in 09900 20205 Micrometer 0 25 mm PISTON RING END GAP INSPECTION Ins...

Page 86: ... a thickness gauge Piston ring to Groove clearance Service Limit 1st 0 18 mm 0 007 in 2nd 0 15 mm 0 006 in Piston ring groove width Standard 1st 1 01 1 04 mm 0 0398 0 0409 in 2nd 1 01 1 04 mm 0 0398 0 0409 in Oil 2 01 2 03 mm 0 0791 0 0799 in Piston ring thickness Standard 1st 0 97 0 99 mm 0 0382 0 0390 in 2nd 0 97 0 99 mm 0 0382 0 0390 in 09900 20803 Thickness gauge 09900 20205 Micrometer 0 25 mm...

Page 87: ... holding the big end immovable in thrust direction Measure the amount of deflection Turn the conrod and see if it moves smoothly without play and noise This method can check the extent of wear on the parts of the conrod s big end Conrod deflection Service Limit 3 0 mm 0 12 in 09900 20607 Dial gauge 1 100 mm 09900 20701 Magnetic stand 09900 21304 V block CRANKSHAFT RUNOUT INSPECTION With the right ...

Page 88: ...Remove the spacer 1 Check the lip of oil seal for any damage If any defects are found replace the oil seal with a new one Check the drive face for any abnormal condition such as stepped wear or discoloration caused by burning If any defeets are found replace the movable drive face with a new one DISASSEMBLY Remove the movable drive face cover 1 Remove the movable drive face plate 2 Remove the damp...

Page 89: ...ly the movable drive face in the reverse order of disassembly Pay attention to the following points Install the oil seal Apply sufficient SUZUKI SUPER GREASE to the sliding sec tions of the movable drive face Apply a small amount of SUZUKI SUPER GREASE to the bore and oil seal lip 99000 25010 SUZUKI SUPER GREASE A Others 99000 25030 SUZUKI SUPER GREASE A USA Position the eight rollers 1 on the mov...

Page 90: ...ompress the clutch shoe movable driven face assembly by turning in the special tool handle Remove the clutch shoe nut 2 09922 31420 Clutch spring compressor Replace the oil seal with a new one Press down the movable drive face plate so as not to cause the roller to come out of the position when inserting the spacer Do not remove the clutch shoe nut before attaching the clutch spring compressor Sin...

Page 91: ...shoe assembly To remove the movable driven face seat 3 use a thin brade screwdriver Remove three pins 4 together with rollers Remove the rollers 5 from the pins Remove the movable driven face 6 from the fixed driven face Do not attempt to disassemble the clutch shoe assem bly ...

Page 92: ...ler bearing 0 using a steel rod NOTE If abnormal noise does not occur it is not necessary to remove the bearing Remove the circlip A Remove the bearing B using the special tool 09913 70210 Bearing installer set 30 mm NOTE If abnormal noise does not occur it is not necessary to remove the bearing ...

Page 93: ...00 20102 Vernier calipers MOVABLE DRIVEN FACE SPRING INSPECTION Measure the spring free length using the vernier calipers If the length is shorter than the service limit replace the spring with a new one Movable driven face spring free length Service Limit 118 7 mm 4 67 in 09900 20102 Vernier calipers REASSEMBLY Reassembly the clutch shoe movable driven face in the reverse order of disassembly Pay...

Page 94: ...m Install the oil seal 7 09913 70210 Bearing installer set 62 68 mm 99000 25010 SUZUKI SUPER GREASE A Others 99000 25030 SUZUKI SUPER GREASE A USA Position the needle bearing with its punch mark out side Apply sufficient grease both to the grease groove and needle bearing inside the fixed driven face Replace the oil seal with a new one Position the oil seal so that the stamped code toward outside ...

Page 95: ...e 99000 25010 SUZUKI SUPER GREASE A Others 99000 25030 SUZUKI SUPER GREASE A USA Install the movable driven face seat D Install the spring E and clutch shoe assembly F onto the movable driven face G and attach the special tool 09922 31420 Clutch spring compressor To prevent the oil seal lip from damaged during instal lation slide the lip using a piece of 0 1 mm 0 004 in thick steel sheet as a guid...

Page 96: ... face assembly Hold the clutch shoe with the special tool and tighten the clutch shoe nut using the special tool to the specified torque 09940 92440 Wrench set 09930 40131 Attachment 09930 40113 Rotor holder Clutch shoe nut 105 N m 10 5 kgf m 76 lb ft TRANSMISSION COVER DISASSEMBLY Remove the driveshaft 1 from the transmission cover 2 and washer 3 Remove the O ring 4 Remove the oil seal 5 using th...

Page 97: ...he special tool 09921 20240 Bearing remover set 7 20 mm 8 25 mm Remove the bearing 9 using the special tool 09913 70210 Bearing installer set 32 35 mm Remove the magnet 0 Clean the magnet with a cleaning solvent Remove the drain plug A oil level plug B and oil filler plug C ...

Page 98: ... 1 2 kgf m 8 5 lb ft Oil filler bolt 12 N m 1 2 kgf m 8 5 lb ft Install the bearing 4 using the special tool 09913 70210 Bearing installer set 35 mm Install the bearings 5 6 using the special tool 09913 70210 Bearing installer set 5 62 68 mm 6 32 35 mm Install the oil seal 7 using the special tool 09913 70210 Bearing installer set 37 40 mm IDLE GEAR DISASSEMBLY Remove the circlip 1 Replace the bea...

Page 99: ...ide out the final driven gear 2 Remove the circlip 3 from the rear axle shaft 4 REASSEMBLY Reassemble the final driven gear in the reverse order of dis assembly Pay attention to the following points Assemble the final driven gear 1 with the thicker flange side A facing outside SCISSORS GEAR DISASSEMBLY Remove the circlip 1 and washer 2 Remove the spring washer 3 Remove the washer 4 ...

Page 100: ...ole B with the scissors gear hole C Install the springs 1 Install the washers 2 3 and spring washer 4 Install the circlip 5 CLUTCH HOUSING INSPECTION Check for any abnormal surface damage Measure the inside diameter of the clutch housing If the measurement exceeds the service limit replace the housing with a new one Clutch housing I D Service Limit 135 5 mm 5 33 in CLUTCH INNER COVER DISASSEMBLY R...

Page 101: ...r set 62 68 mm DRIVE V BELT INSPECTION Check that the drive V belt is free from any greasy substance Check the contact surface for crack or other damage Measure the width A of the belt using the vernier calipers If the measurement exceeds the service limit or crack or other damage exists replace the belt with a new one Dride V belt width Service Limit 20 85 mm 0 82 in 09900 20102 Vernier Calipers ...

Page 102: ...e starter driven gear sliding surface for wear or damage If any abnormal condition is found replace the starter clutch with a new one DISASSEMBLY With the rotor held with a wrench loosen the strater clutch bolt Remove the one way clutch guide 1 and one way clutch 2 from the rotor REASSEMBLY Reassemble the starter clutch in the reverse order of disas sembly Pay attention to the following points Whe...

Page 103: ...0 THREAD LOCK SUPER 1322 Others 99000 32050 THREAD LOCK 1342 USA GENERATOR DISASSEMBLY Remove the generator stator 1 CKP sensor 2 and lead wire guide 3 Remove the circlip 4 Remove the bearing 5 using the special tool 09921 20240 Bearing remover set 12 mm Remove the oil seal 6 After installing the starter driven gear check that the clutch functions properly ...

Page 104: ... into the generator cover Tighten the generator stator bolts 3 to the sepecified torque Generator stator bolt 10 N m 1 0 kgf m 7 0 lb ft Tighten the CKP sensor bolts 4 to the specified torque CKP sensor bolt 5 N m 0 5 kgf m 3 7 lb ft Tighten the lead wire guide bolt 5 to the specified torque Lead wire guide bolt 10 N m 1 0 kgf m 7 0 lb ft Install the oil seal with the marked code toward out side R...

Page 105: ...moves smoothly If it does not move smoothly replace the oil pump assembly CRANKCASE OIL NOZZLE REMOVAL Remove the oil nozzle 1 OIL NOZZLE INSPECTION Check the oil nozzle for clogging and damage If any fault is detected replace with a new one OIL NOZZLE REMOUNTING Install the O ring 1 to the oil nozzle 2 Install the oil nozzle 1 to the crankcase Replace the O ring with a new one ...

Page 106: ...nkcase Replace the bearing in the following procedure if there is any thing unusual NOTE If abnormal noise does not occur it is not necessary to remove the bearing BEARING REMOVAL Remove the bearing 1 using the special tool 09913 70210 Bearing installer set 30 mm Remove the bearing 2 using the special tool 09913 70210 Bearing installer set 42 47 mm Play Play ...

Page 107: ...move the bushing 4 use an appropriate size steel tube 5 such as a spacer Remove the oil seal 6 using the special tool 09913 50121 Oil seal remover Remove the bearing 7 using the special tool 09913 70210 Bearing installer set 42 47 mm Remove the bearing 8 09921 20240 Bearing remover set 20 mm Crankcase ...

Page 108: ...er 9 Remove the bearing 0 using the special tool 09913 75830 Bearing installer Remove the oil seal A using the special tool 09913 50121 Oil seal remover Remove the circlip B Remove the two bearings C D 09921 20240 Bearing remover set 20 mm ...

Page 109: ...ip 99000 25010 SUZUKI SUPER GREASE A Others 99000 25030 SUZUKI SUPER GREASE A USA Install the bearings 6 7 using the special tool 09913 70210 Bearing installer set 6 32 35 mm 7 52 55 mm Install the oil seal 8 using the special tool 09913 70210 Bearing installer set 52 55 mm Apply SUZUKI SUPER GREASE to the oil seal lip 99000 25010 SUZUKI SUPER GREASE A Others 99000 25030 SUZUKI SUPER GREASE A USA ...

Page 110: ...earing retainer toward the upper side A of the engine Using a vice and a tube of appropriate size for outside diame ter of the mounting bushing A press in the bushing 09924 84521 Bearing installer set Replace the bearing with a new one Press in the mounting bushing so that the end of out side A shell becomes flush with the inside face B of crankcase ...

Page 111: ...10 32812 Crankshaft installer 09910 32870 Attachment BALANCER SHAFT Install the balancer shaft 1 CRANKCASE Install the O ring 1 Make sure to coat the rotating and sliding sections with engine oil Care must be taken so that the drive belt drive face and driven face are completely free from oil and grease Do not hit the crankshaft with a plastic hammer or the like to install it into the crankcase Be...

Page 112: ...I BOND 1207B USA Assemble the crankcases with in few minutes Fit the gasket washer to the right crankcase bolts A Fit the gasket washers to the left crankcase bolts B Coat the sealant evenly without break Application of sealant must be performed within a short period of time Take extreme care not to let sealant enter into the oil hole or bearing Others USA Replace the copper washer with a new one ...

Page 113: ...ncer drive gear 2 Insert a proper steel rod into the crankcase hole A and pass through the crankshaft wed holes B in order to prevent the crankshaft from turning Install the wave washer Using the special tool tighten the balancer drive gear nut to the specified torque 09922 21410 Long socket 46 mm Balancer drive gear nut 150 N m 15 kgf m 11 lb ft 3 Balancer drive gear 4 Wave washer 5 Balancer driv...

Page 114: ...balancer driven gear teeth mesh with the balancer drive gear teeth Install the washer 9 and balancer driven gear nut 0 Lock the crankshaft by inserting a steel rod and tighten the balancer driven gear nut to the specified torque Balancer driven gear nut 50 N m 5 0 kgf m 36 0 lb ft STARTER IDLE GEAR Install the starter idle gear 1 onto the starter idle gear shaft 2 Make sure that the punch mark E o...

Page 115: ... pump Install the oil pump gear 3 Install the circlip 4 Engage the chain 5 with the oil pump gear With the other side of the chain 6 engaged with the crank shaft gear 7 install the oil pump on the crankcace Tighten the oil pump bolts to the specified torque Oil pump bolt 10 N m 1 0 kgf m 7 0 lb ft ...

Page 116: ...or rotor nut With the generator rotor locked tighten the generator rotor nut to the specified torque Generator rotor nut 160 N m 16 0 kgf m 115 5 lb ft OIL SUMP FILTER Install the O ring 1 to the oil sump filter cap 2 Insert the oil sump filter 3 Replace the O ring with a new one The lip A of the oil sump filter should be positioned downward The thinner side B of the oil sump filter should be posi...

Page 117: ...INE 3 71 Install the oil sump filter cap 4 IDLE SHAFT Fit the washer 1 Install the idle shaft 2 REAR AXLE SHAFT Install the rear axle shaft 1 Install the washers 2 3 Apply engine oil to each gear and shaft ...

Page 118: ...ABLE DRIVEN FACE ASSEMBLY With the clutch shoe spring compressed by pulling the mov able driven face toward the clutch install the drive V belt 1 to the movable driven face 2 Replace the O ring with a new one Be careful not to drop the driveshaft washer inside during assembly Also take care not to allow the O ring to be pinched Position the drive belt so that the arrow A points the engine rotating...

Page 119: ...ng the special tool and tighten the clutch housing nut to the specified torque 09930 40113 Rotor holder Clutch housing nut 85 N m 8 5 kgf m 61 5 lb ft Pull the center area B of upper and lower belt lines to be close to each other to prevent the belt from expanding Degrease the inner surface of the clutch housing Pay attention to the direction of the spring washer ...

Page 120: ...105 N m 10 5 kgf m 76 0 lb ft To obtain proper contact of the drive V belt 5 turn the fixed drive face 6 until the fixed drive face and the movable driven face 7 can rotate synchronously CLUTCH INNER COVER Install the dowel pins 1 2 The assembly work should be carefully performed so as not to allow the roller to dislocate Degrease the drive belt contact surface pulley face Check that the fixed dri...

Page 121: ... the generator cover bolts to the specified torque Generator cover bolt 11 N m 1 1 kgf m 8 0 lb ft WATER PUMP Install the O rings 1 2 to the water pump Apply a small amount of engine oil to the O rings Install the water pump 3 Replace the gasket with a new one Fit the gasket washer to the bolts A Replace the gaskets with new ones Replace the O rings with new ones Align the flats A of the water pum...

Page 122: ... Tighten the oil filter cap bolts to the specified torque Oil filter cap bolt 10 N m 1 0 kgf m 7 0 lb ft PISTON RING Install the piston rings in the order of oil ring 2nd ring and top ring To install the oil ring fit the spacer 1 first and then the side rails 2 Replace the O ring with a new one Position the oil filter so that the valve A comes out side Position the triangle mark B of oil filter ca...

Page 123: ... right figure A Second ring side rail lower side B Side rail upper side C Top ring spacer PISTON Lightly coat the piston pin with SUZUKI MOLY PASTE when inserting 99000 25140 SUZUKI MOLY PASTE When installing the piston turn the concaved part A on the piston head to exhaust side When installing the spacer be careful so that the both edges are not overlapped When installing the piston ring be caref...

Page 124: ...t 2 on the crank case Replace the circlip with a new one Place a piece of rag under the piston when installing the circlip to prevent it from falling into the crank case The circlip end gap must be positioned so as not to coincide with the piston pin bore cutaway Replace the gasket with a new one When inserting the piston into the cylinder use care not to break the piston ring When installing the ...

Page 125: ...t Final tightening 41 N m 4 1 kgf m 29 5 lb ft Cylinder head nut M8 25 N m 2 5 kgf m 18 0 lb ft Cylinder head nut M6 10 N m 1 0 kgf m 7 0 lb ft Cylinder nut 10 N m 1 0 kgf m 7 0 lb ft CAMSHAFT With the cam chain held by hand turn the crankshaft in nor mal direction and align T mark on the generator rotor with the triangle mark A on the generator cover Install the C ring Position the camshaft 1 cam...

Page 126: ...procket bolts to the specified torque Cam sprocket bolt 15 N m 1 5 kgf m 11 0 lb ft Bend up the lock washer to lock the bolts Install the dowel pins 5 Apply MOLYBDENUM OIL SOLUTION on the cam faces MOLYBDENUM OIL SOLUTION Install the camshaft holder 6 then tighten the camshaft holder bolts to the specified torque Camshaft holder bolt 10 N m 1 0 kgf m 7 0 lb ft Install the dowel pins 7 Install the ...

Page 127: ... holder bolt 6 Tighten the spring holder bolts to the specified torque Spring holder bolt 8 N m 0 8 kgf m 5 7 lb ft Inspect the valve clearance 2 5 CYLINDER HEAD COVER Install the gasket to the cylinder head cover 1 Apply SUZUKI BOND to the cam end cap 0 99000 31160 SUZUKI BOND 1216 Replace the gasket with a new one Replace the O ring with a new one When the cam chain tension adjuster has been ins...

Page 128: ... the specified torque Cylinder head cover bolt 14 N m 1 4 kgf m 10 lb ft Install the spark plug 2 7 STARTER MOTOR Install the O ring 1 to the starter motor Apply SUZUKI SUPER GREASE to the O ring 1 99000 25010 SUZUKI SUPER GREASE A Others 99000 25030 SUZUKI SUPER GREASE A USA Replace the gasket with a new one Replace the O ring with a new one ...

Page 129: ...17 FI SYSTEM TROUBLESHOOTING 4 18 CUSTOMER COMPLAINT ANALYSIS 4 18 SELF DIAGNOSTIC PROCEDURES 4 20 SELF 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 C15 ECT SENSOR CIRCUIT MALFUNCTION 4 31 C21 IAT SENSOR CIRCUIT MALFUNCTION 4 33 C23 TO SENSOR CIRCUI...

Page 130: ...pler be sure to hold the coupler body and do not pull the lead wires Inspect each terminal on the connector coupler for looseness or bending Inspect each terminal for corrosion and contamination The terminals must be clean and free of any foreign material which could impede proper terminal contact Inspect each lead wire circuit for poor connection by shaking it by hand lightly If any abnormal cond...

Page 131: ...ctor for excessive opening Also check the coupler for locking loose ness corrosion dust etc FUSE When a fuse blows always investigate the cause correct it and then replace the fuse Do not use a fuse of a different capacity Do not use wire or any other substitute for the fuse ECM VARIOUS SENSORS Since each component is a high precision part great care should be taken not to apply any sharp impacts ...

Page 132: ...rce will be applied to the ECM which may result in serious damage Before measuring voltage at each terminal check to make sure that battery voltage is 11 V or higher Terminal voltage check at low battery voltage will lead to erroneous diagnosis Never connect any tester voltmeter ohmmeter or whatever to the ECM when its coupler is disconnected Otherwise damage to ECM may result Never connect an ohm...

Page 133: ...tion Also check for condition of the coupler lock if equipped Using a test male terminal check the female terminals of the circuit being checked for contact tension Check each terminal visually for poor contact possibly caused by dirt corrosion rust entry of foreign object etc At the same time check to make sure that each terminal is fully inserted in the coupler and locked If contact tension is n...

Page 134: ...eing checked voltage check can be used as circuit check With all connectors couplers connected and voltage applied to the circuit being checked measure voltage between each terminal and body ground If measurements were taken as shown in the figure at the right and results are as listed below it means that the circuit is open between terminals A and B Voltage Between C and body ground Approx 5V B a...

Page 135: ...hose parts Otherwise diagnosis 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 and C Disconnect the connector coupler included in circuit coupler B and measure resistance between terminal A and body ground If continuity is indicated the circuit is shorted ...

Page 136: ...rcuit tester will be shown as 10 00 MΩ and 1 flashes in the display Check that no voltage is applied before making the measure ment If voltage is applied the tester may be damaged After using the tester turn the power off 09900 25008 Multi circuit tester set NOTE When connecting the multi circuit tester use a fine needle pointed probe or install fine copper wires O D is below 0 5mm to the back sid...

Page 137: ...arious compensations 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 Engine speed signal Throttle opening signal Crankshaft Position Sensor CKP Sensor Throttle Position Sensor TP Sensor Various Sensors Various signals Injection signal Injector ECM Basic fu...

Page 138: ...it is rich BATTERY VOLTAGE SIGNAL ECM operates on the battery voltage and at the same time it monitors the voltage signal for compensation of the fuel injection time volume A longer injection time is needed to adjust injection volume in the case of low voltage STARTING SIGNAL When starting engine additional fuel is injected during cranking engine ACCELERATION SIGNAL DECELETATION SIGNAL During acce...

Page 139: ...FI SYSTEM 4 11 FI SYSTEM PARTS LOCATION A ECM B Engine coolant temperature sensor ECTS C Ignition coil IG COIL ...

Page 140: ... E Fuel pump relay FP RELAY F Fuel pump FP G Fuel injector FI H Intake air pressure sensor IAPS I Idle air control valve IAC J PAIR control solenoid K Throttle position sensor TPS L Intake air temperature sensor IATS M Speed sensor N HO2 sensor ...

Page 141: ...sor TO sensor Combination meter ECM Fuel injector Speed sensor Fuel pump relay Fuel pump Engine stop switch Main switch Side stand relay Side stand switch Starter motor Starter relay Brake switch 15A 10A 10A 30A Ignition coil IAC valve PAIR control solenoid valve Starter switch Brake relay M ...

Page 142: ...nal or ignition switch signal is not sent to ECM In this case FI is indicated in the LCD panel Motorcycle does not run CHEC The LCD panel indicates CHEC when no communication signal from the ECM is received for 5 seconds For Example The ignition switch is turned ON and the engine stop switch is turned OFF In this case the speed ometer does not receive any signal from ECM and the panel indicates CH...

Page 143: ...es These affected devices are indicated in the code form 09930 82720 Mode select switch Before checking the malfunction code do not disconnect the ECM lead wire couplers If the couplers from the ECM are disconnected the malfunction code memory is erased and the malfunction code can not be checked MALFUNCTION LCD DISPLAY INDICATION FI LIGHT INDICATION INDICATION MODE NO C00 FI light turns OFF YES C...

Page 144: ...he screw to fix the throttle position sensor CODE MALFUNCTION PART REMARKS C00 C12 C13 C14 C15 C21 C23 C24 C32 C40 C41 C42 C44 None Crankshaft position sensor CKPS Intake air position sensor IAPS Throttle position sensor TPS Engine coolant temperature sensor ECTS Intake air temperature sensor IATS Tip over sensor TOS Ignition signal IG coil Fuel injector signal Idle air control valve IAC valve Fue...

Page 145: ...e it is nec essary to bring the motorcycle to the workshop for complete repair ITEM FAIL SAFE MODE STARTING ABILTY RUNNING ABILITY Intake air pressure sensor Intake air pressure is fixed to 760 mmHg YES YES Throttle position sensor The throttle opening is fixed to full open position Ignition timing is also fixed YES YES Engine coolant temperature sensor Engine coolant temperature value is fixed to...

Page 146: ...ition LED Always ON 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 Driveability No cranking Hesitation on acceleration No initial combustion Back fire After fire No combustion Lack of power Poor starting at cold warm always Surging Abnormal knocking Other Engi...

Page 147: ...old F C Always Always 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 phase Warmed up Always Other at starting Immediately after start Racing without load Engine speed r min Motorcycle con dition During driving Constant speed Accelerating Decelerating Righ...

Page 148: ... as to what functions are available and how to use it Be sure to read PRECAUTIONS for Electrical Circuit Ser vice 4 2 before inspection and observe what is written there Remove the front leg shield cover Connect the special tool to the dealer mode coupler A at the wiring harness and start the engine or crank the engine for more than 4 seconds Turn the special tool s switch ON and check the malfunc...

Page 149: ...the above range C21 is indicated Intake air temperature sensor wiring coupler connection C23 Tip over sensor The sensor voltage should be the following for more than 2 sec after ignition switch turns ON 0 40 V sensor voltage 4 60 V Without the above value C23 is indicated Tip over sensor wiring coupler connection C24 Ignition signal Crankshaft position sensor pick up coil signal is produced but si...

Page 150: ...O2 feedback control O2 sensor voltage is higher than the specification or lower than the specification No signal is detected during engine operation or no electrical power is supplied from battery HO2S lead wire coupler connection Battery voltage supply to the HO2S ...

Page 151: ...check the continuity between each terminal and ground CKP sensor continuity Ω Ω Ω Ω Infinity Blue Ground Green Ground 09900 25008 Multi circuit tester set Tester knob indication Resistance Ω Ω Ω Ω Are the resistance and continuity OK DETECTED CONDITION POSSIBLE CAUSE No CKP sensor signal for more than 2 seconds after receiving the starter signal Metal particles or foreign materiel being attached o...

Page 152: ...tage If OK then measure the CKP sensor peak voltage at the ECM terminals 1 2 09900 25008 Multi circuit tester set Tester knob indication voltage Is the voltage OK YES BIue or Green wire open or shorted to ground or poor 1 or 2 connection If wire and connection are OK intermittent trou ble or faulty ECM Recheck each terminal and wire harness for open circuit and poor connection NO Loose or poor con...

Page 153: ...5008 Multi circuit tester set Tester knob indication Voltage Is the voltage OK DETECTED CONDITION POSSIBLE CAUSE IAP sensor voltage low or high 0 30 V Sensor voltage 4 45 V without the above range NOTE Note that atmospheric pressure varies depending on weather conditions as well as altitude Take that into consideration when inspecting volt age Clogged vacuum passage between throttle body and IAP s...

Page 154: ...l and terminal to the Vcc terminal Check the voltage between Vout and ground Also check if voltage reduces when vacuum is applied up to 400 mmHg by using vacuum pump gauge 4 27 09917 47010 Vacuum pump gauge 09900 25008 Multi circuit tester set Tester knob indication Voltage Is the voltage OK YES Go to Step 3 NO Check the vacuum hose for crack or damage Open or short circuit in the G B wire Replace...

Page 155: ...mp 20 30 C 68 86 F ALTITUDE Reference ATMOSPHERIC PRESSURE OUTPUT VOLTAGE ft m mmHg kPa V 0 2 000 0 610 760 707 100 94 3 4 3 6 2 001 5 000 611 1 524 707 634 94 85 3 2 3 4 5 001 8 000 1 524 2 438 634 567 85 76 2 9 3 2 8 001 10 000 2 439 3 048 567 526 76 70 2 7 2 9 ...

Page 156: ...ground 7 If OK 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 DETECTED CONDITION POSSIBLE CAUSE Output voltage low or high 0 45 Sensor voltage 4 80 V without the above range TP sensor maladjusted TP sensor circuit open or short TP sensor malfunction EC...

Page 157: ...or resistance at the coupler between Yellow and B Br wires 5 Turn the throttle grip and measure the resistance TP sensor resistance Throttle valve is closed Approx 0 6 kΩ Ω Ω Ω Throttle valve is opened Approx 3 8 kΩ Ω Ω Ω 09900 25008 Multi circuit tester set Tester knob indication Resistance Ω Ω Ω Ω Are the resistance and continuity OK YES Go to Step 3 NO Reset the TP sensor position correctly Rep...

Page 158: ...le valve is closed Approx 0 6 V Throttle valve is opened Approx 3 8 V 09900 25008 Multi circuit tester set Tester knob indication Voltage Is the voltage OK YES Red Yellow or B Br wire open or shorted to ground or poor A D or R connection If wire and connection are OK intermittent trou ble or faulty ECM Recheck each terminal and wire harness for open circuit and poor connection NO If check result i...

Page 159: ...wire terminal and ground 6 If OK then measure the voltage between Dg wire terminal and B Br wire terminal ETC sensor voltage 4 5 5 5 V Dg Ground Dg B Br 09900 25008 Multi circuit tester set Tester knob indication Voltage Is the voltage OK DETECTED CONDITION POSSIBLE CAUSE Output voltage low or high 0 20 Sensor voltage 4 80 V without the above range ECT sensor circuit open or short ECT sensor malfu...

Page 160: ... to page 6 9 for details Is the resistance OK YES Dg or B Br wire open or shorted to ground or poor 4 or A connection If wire and connection are OK intermittent trou ble or faulty ECM Recheck each terminal and wire harness for open circuit and poor connection NO Replace the ECT sensor with a new one Engine Coolant Temp Resistance 20 C 68 F Approx 2 58 kΩ 40 C 104 F Approx 1 14 kΩ 80 C 176 F Approx...

Page 161: ... Bl wire terminal and ground 6 If OK then measure the voltage between B Bl wire terminal and B Br wire terminal IAT sensor voltage 4 5 5 5 V B Bl Ground B Bl B Br 09900 25008 Multi circuit tester set Tester knob indication Voltage Is the voltage OK DETECTED CONDITION POSSIBLE CAUSE Output voltage low or high 0 20 Sensor voltage 4 80 V without the above range IAT sensor circuit open or short IAT se...

Page 162: ... measurement method is the same way as that of the ECT sensor Refer to page 6 9 for details YES B Bl or B Br wire open or shorted to ground or poor A or C connection If wire and connection are OK intermittent trou ble or faulty ECM Recheck each terminal and wire harness for open circuit and poor connection NO Replace the IAT sensor with a new one Intake Air Temp Resistance 20 C 68 F Approx 2 58 kΩ...

Page 163: ... coupler 5 Measure the resistance between Red wire and B Br wire terminals TO sensor resistance 19 1 19 7 kΩ Ω Ω Ω Red B Br 09900 25008 Multi circuit tester set Tester knob indication Resistance Ω Ω Ω Ω Is the resistance OK DETECTED CONDITION POSSIBLE CAUSE Output voltage low or high 0 40 Sensor voltage 4 60 V without the above range TO sensor circuit open or short TO sensor malfunction ECM malfun...

Page 164: ...ore than 70 left and right from the horizontal level TO sensor voltage 3 8 V and more Br W B Br 09900 25008 Multi circuit tester set Tester knob indication Voltage Is the voltage OK C24 IGINTION SYSTEM MALFUNCTION Refer to the IGNITION SYSTEM for details 8 23 YES Red Br W or B Br wire open or shorted to ground or poor R or S connection If wire and connection are OK intermittent trou ble or faulty ...

Page 165: ...istance 10 18 Ω Ω Ω Ω at 20 C 68 F Terminal Terminal 5 If OK then check the continuity between each terminal and ground Injector continuity Ω Ω Ω Ω Infinity Terminal Ground 09900 25008 Multi circuit tester set Tester knob indication Resistance Ω Ω Ω Ω Is the resistance OK DETECTED CONDITION POSSIBLE CAUSE CKP signals produced but fuel injector signal is interrupted continuous by 2 times or more In...

Page 166: ...ted only 3 seconds after ignition switch is turned ON 09900 25008 Multi circuit tester set Tester knob indication Voltage Is the voltage OK YES Gr W wire open or shorted to ground or poor N or W connection If wire and connection are OK intermittent trou ble or faulty ECM Recheck each terminal and wire harness for open circuit and poor connection NO Open circuit in the Y R wire ECM Coupler ...

Page 167: ...25008 Multi circuit tester set Tester knob indication Resistance Ω Ω Ω Ω Is the resistance OK Step 2 1 Remove the IAC valve cover 1 2 Connect the 12 V battery to the IAC valve terminals for more than 3 minutes and check for change of the IAC valve tem perature from the cold condition Is the IAC valve warm up DETECTED CONDITION POSSIBLE CAUSE No IAC valve voltage is supplied after starting the engi...

Page 168: ... Ground 09900 25008 Multi circuit tester set Tester knob indication Voltage Is the voltage OK YES Open circuit in the B Y wire NO O W or B Y wire open or shorted to ground or poor P or V connection If wire and connection are OK intermittent trou ble or faulty ECM Recheck each terminal and wire harness for open circuit and poor connection ECM Coupler ...

Page 169: ...o voltage is applied to fuel pump although fuel pump relay is turned ON or voltage is applied to fuel pump although fuel pump relay is turned OFF Fuel pump relay circuit open or short Fuel pump relay malfunction ECM malfunction YES Y G or O W wire open or shorted to ground or poor G or P connection If wire and connection are OK intermittent trou ble or faulty ECM Recheck each terminal and wire har...

Page 170: ...gine speed at 3 000 r min HO2 sensor output voltage at idle speed 0 4 V and less B G Y W HO2 sensor output voltage at 3 000 r min 0 6 V and more B G Y W 09900 25008 Multi circuit tester set Tester knob indication Voltage Is the voltage OK DETECTED CONDITION POSSIBLE CAUSE During O2 feedback control O2 sensor voltage is higher than the specification or lower than the speci fication Without the abov...

Page 171: ... HO2 sensor coupler 3 Check the resistance between the terminals White White of the HO2 sensor HO2 heater resistance 11 5 14 5 Ω Ω Ω Ω at 23 C 73 4 F White White NOTE Temperature of the sensor affects resistance value largely Make sure that the sensor heater is at correct temperature 09900 25008 Multi circuit tester set Tester knob indication Resistance Ω Ω Ω Ω Is the resistance OK YES Go to Step ...

Page 172: ...r case 4 25 TP SENSOR INSPECTION The throttle position sensor is installed at the right side of the throttle body 4 28 TPS SETTING PROCEDURE 5 21 ECT SENSOR INSPECTION The engine coolant temperature sensor is installed on the cylin der head 4 31 ECT sensor 18 N m 1 8 kgf m 13 0 lb ft IAT SENSOR INSPECTION The intake air temperature sensor is installed beneath the air chamber 4 33 IAT sensor 3 N m ...

Page 173: ...9 The heated oxygen sensor is installed on the exhaust pipe 4 42 HO2 SENSOR 47 5 N m 4 75 kgf m 34 3 lb ft Do not remove the HO2 sensor while it is hot Be careful not to expose it to excessive shock Do not use an impact wrench while removing or installing the HO2 sensor unit Be careful not to twist or damage the sensor lead wire Do not apply oil or other materials to the sensor air hole ...

Page 174: ...ASSEMBLY 5 9 FUEL MESH FILTER INSPECTION AND CLEANING 5 10 FUEL LEVEL GAUGE INSPECTION 5 11 FUEL PUMP AND FUEL LEVEL GAUGE REASSEMBLY 5 12 THROTTLE BODY 5 13 REMOVAL 5 14 DISASSEMBLY 5 16 CLEANING AND INSPECTION 5 18 REASSEMBLY 5 19 INSTALLATION 5 20 THROTTLE CABLE ADJUSTMENT 5 20 TP SENSOR ADJUSTMENT 5 21 FUEL INJECTOR REMOVAL 5 21 FUEL INJECTOR INSPECTION 5 21 FUEL INJECTOR INSTALLATION 5 21 Gas...

Page 175: ...t A 3 5 0 35 2 5 B 4 5 0 45 3 3 1Fuel tank filler cap 2Fuel drain tray 3Fuel cut valve 4Gasket 5Fuel tank 6O ring 7O ring 8Fuel pressure regulator 9Fuel level gauge 0O ring AFuel mesh filter BFuel pump CClamp DFuel filter AFuel cut valve bolt BFuel pump mounting bolt ...

Page 176: ...t fender 7 20 36 Remove the radiator 6 4 Disconnect the fuel level gauge coupler 1 Remove the fuel feed hose 2 Remove the bracket 3 Remove the clamps 4 Remove the fuel tank bolts Remove the fuel tank 5 forward After disconnecting the fuel feed hose 2 insert a blind plug into the end to stop fuel leakage As gasoline leakage may occur in this operation keep away from fire and sparks ...

Page 177: ... and fuel drain tray 7 Remove the FTPC valve 8 Remove the fuel pump assembly 9 Remove the fuel cut valve 0 Fit the fuel filler cap 6 to the fuel tank after the fuel drain tray 7 has been removed Gasoline is highly flammable and explosive Keep heat spark and flame away ...

Page 178: ...ply vacuum to the fuel cut valve 4 and check that the gauge indicator hand deflects 09917 47011 Vacuum pump gauges Check that resistance is felt when blowing air in the fuel cut valve Replace if any abnormal condition is found FTPC VALVE Check FTPC valve if air can pass trough smoothly when blown from the orange painted side and not from the other side Should any abnormal condition be found replac...

Page 179: ...ighten the fuel cut valve bolt to the specified torque Fuel cut valve bolt 3 5 N m 0 35 kgf m 2 5 lb ft Apply thin coat of the engine oil to the O ring 4 Install the O ring to the fuel tank When installing the fuel pump assembly first tighten all the fuel pump assembly mounting bolts lightly in the ascending order of numbers and then tighten them to the specified torque in the above tightening ord...

Page 180: ...fuel tank Install the special tools to the fuel tank 09940 40211 Fuel pressure gauge adaptor 09940 40230 Fuel pressure gauge hose attachment 09915 77331 Oil pressure gauge 09915 74521 Oil pressure gauge hose Turn the ignition switch ON and check the fuel 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 hos...

Page 181: ...nd into the measuring cylinder Disconnect the ECM lead wire coupler With the lead wire s fastener A unlocked pull out the power source lead wire Yellow with red tracer 1 Apply 12 volts to the fuel pump for 10 seconds and measure the amount of fuel discharged If the pump does not discharge the amount specified it means that the fuel pump is defective or that the fuel filter is clogged Fuel discharg...

Page 182: ...insulation between 1 and 2 terminals with pocket tester Then apply 12 volts to 3 and 4 terminals 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 LEVEL GAUGE DIS ASSEMBLY Remove the fuel pump assembly 5 6 Remove the ground lead wire 1 and clamp 2 Remove the fuel pump 3 Remove the fuel pressure regulator 4 ...

Page 183: ... CLEANING If the fuel mesh filter is clogged with sediment or rust fuel will not flow smoothly and loss in engine power may result Blow the fuel mesh filter with compressed air NOTE If the fuel mesh filter is clogged with many sediment or rust replace the fuel filter cartridge with a new one ...

Page 184: ...If the resistance measured is out of the specification replace the gauge with a new one Fuel level meter inspection 8 28 Fuel float position Resistance between terminals F 98 4 mm 3 87 in from tank mating face Approx 4 10 Ω 1 2 176 1 mm 6 93 in from tank mating face Approx 40 50 Ω E 244 7 mm 9 63 in from tank mating face Approx 90 100 Ω F 98 4mm 3 87in E 244 7mm 9 63in 176 1mm 6 93in 1 2 ...

Page 185: ... filter 1 Apply thin coat of the engine oil to the O ring Install the O ring 2 to the fuel tank When installing the fuel pump assembly first tighten all the fuel pump assembly mounting bolts lightly in the ascending order to numbers and then tighten them to the specified torque in the above tightening order Fuel tank bolt 4 5 N m 0 45 kgf m 3 3 lb ft Use the new O ring to prevent fuel leakage Inst...

Page 186: ...t A 3 5 0 35 2 5 1Idle adjust screw 2O ring 3Throttle body 4O ring 5IAC valve 6IAC valve cap 7TP sensor 8O ring 9O ring 0Insulator AO ring BIntake pipe CO ring DFuel injector seal EFuel injector FO ring GInsulator HThrottle lever stopper screw ATP sensor mounting screw ...

Page 187: ...sor coupler 3 Disconnect the PAIR control solenoid valve hoses 4 Disconnect the ECT sensor ignition coil coupler 5 Disconnect the PCV hose 6 Remove the air cleaner box 7 Disconnect the fuel injector coupler 8 Disconnect the IAP sensor coupler 9 Disconnect the IAC valve coupler 0 Disconnect the TP sensor coupler A Disconnect the PAIR control solenoid valve coupler B ...

Page 188: ...isconnect the throttle cables 2 Disconnect the fuel feed hose 3 Remove the throttle body assembly 4 insulator 5 and two O rings After disconnecting the throttle cables do not snap the throttle valve from full open to full close It may cause damage to the throttle valve and throttle body ...

Page 189: ...e cap 1 Remove the IAC valve 2 Remove the TP sensor 3 NOTE Prior to disassembly mark sensor s original position A with a paint or scribe for accurate reinstallation Remove the IAP sensor 4 Disconnect the vacuum hose 5 Remove the insulator 6 Remove the fuel injector 7 ...

Page 190: ...E Before removing the idle adjust screw determine the setting by slowly turning it clockwise and count the number of turns required to lightly seat the screw This counted number is impor tant when reassembling idle adjust screw to original position Never remove the throttle valve 4 Avoid removing the throttle lever stopper screw A ...

Page 191: ...spect the IAC valve 4 39 Some carburetor cleaning chemicals especially dip type soaking solutions are very corrosive and must be handled carefully Always follow the chemical manufacture s instructions on proper use handling and storage Do not use wire to clean passageways Wire can dam age passageways If the components cannot be cleaned with a spray cleaner it may be necessary to use a dip type cle...

Page 192: ... 2 to the throttle body Install the injector seal 3 and O ring 4 to fuel injector Apply thin coat of the engine oil to the new O ring and new seal Install the fuel injectors by pushing them straight to throttle body Apply a small quantity of SUZUKI SUPER GREASE to the shaft end and seal lip 99000 25010 SUZUKI SUPER GREASE A Others 99000 25030 SUZUKI SUPER GREASE A USA Replace the O ring with a new...

Page 193: ...oil to the new O ring INSTALLATION Installation is in the reverse order of removal Pay attention to the following points With THREAD LOCK applied to the mounting bolts install the PAIR control solenoid valve 99000 32050 THREAD LOCK 1342 Insert the protrusions A of air cleaner box into the holes B of its bracket THROTTLE CABLE ADJUSTMENT Adjustment can be made by the throttle grip side adjuster 2 1...

Page 194: ... TP sensor adjustment is necessary loosen the TP sen sor mounting screw Turn the TP sensor and bring the line to middle Tighten the TP sensor mounting screw TP sensor mounting screw 3 5 N m 0 35 kgf m 2 5 lb ft FUEL INJECTOR REMOVAL Remove the front frame cover 7 17 Disconnect the injector coupler Remove the fuel feed hose 5 15 Remove the fuel injector 5 16 FUEL INJECTOR INSPECTION The fuel inject...

Page 195: ...AND REMOUNTING 6 6 COOLING FAN THERMO SWITCH 6 7 REMOVAL 6 8 INSPECTION 6 8 INISTALLATION 6 8 ENGINE COOLANT TEMPERATURE SENSOR 6 9 REMOVAL 6 9 INSPECTION 6 9 INSTALLATION 6 9 THERMOSTAT 6 10 REMOVAL 6 10 INSPECTION 6 10 INSTALLTATION 6 11 WATER PUMP 6 12 REMOVAL AND DISASSEMBLY 6 12 INSPECTION 6 13 REASSEMBLY AND REMOUNTING 6 13 LUBRICATION SYSTEM 6 16 OIL PRESSURE 6 16 OIL FILTER 6 16 OIL SUMP F...

Page 196: ...ght and good heat dissipation A wax pellet type thermostat is used to regulate the flow of engine coolant through the radiator As the cool ant temperature rises to about 82 C 180 F the thermostat valve unseats and a normal coolant flow is established At about 95 C 203 F the thermostat becomes completely open and as a result heat is released to the atmosphere through the radiator core COOLING CIRCU...

Page 197: ...ve the radiator cap Disconnect the radiator hose 1 to let coolant drain off Remove the hose 2 and drain coolant remaining inside the engine Coolant used should be of a high quality ethyleneg lycol base mixed with distilled water Do not use an alcohol base coolant The mixture ratio should not be higher than 60 and lower than 50 Do not use sealing additives in cooling solution Density Density 20 40 ...

Page 198: ... RADIATOR Remove the front box 7 14 Drain the engine coolant 6 3 Disconnect the radiator inlet hose 1 and radiator cap hose 2 Disconnect the cooling fan coupler 3 Remove the radiator 4 Disconnect the cooling fan thermo switch coupler 5 Remove the cooling fan 6 ...

Page 199: ...or leaks from the joint and if found retighten the clamp COOLING FAN Remove the front box 7 14 Disconnect the cooling fan coupler 1 Disconnect the cooling fan thermo switch coupler 2 and short circuit it with a jumper wire Connect an ammeter as shown in the right diagram and mea sure load current NOTE Removing the cooling fan from the motorcycle is not necessary in the above test 09900 25008 Multi...

Page 200: ...ollowing points Tighten the cooling fan mounting bolts to the specified torque Cooling fan mounting bolt 10 N m 1 0 kgf m 7 0 lb ft Tighten the radiator mounting bolt to the specified torque Radiator mounting bolt 10 N m 1 0 kgf m 7 0 lb ft Install the hoses 9 25 After the radiator has been installed fill coolant and perform air bleeding 2 15 Check for leakage of the engine coolant ...

Page 201: ...tch The thermo switch remains open when the temperature of the engine coolant is low but closes when the temperature reaches approximately 93 C 199 F setting the cooling fan in motion Ignition switch Fuse O Y R R Main fuse Battery Bl Cooling fan thermo switch B W Cooling fan motor WIRE COLOR Bl Blue O Orange R Red B W Black with White tracer O Y Orange with Yellow tracer ...

Page 202: ... one 09900 25008 Multi circuit tester set Cooling fan thermo switch operating temperature Standard OFF ON 93 103 C 199 217 F ON OFF 87 97 C 189 207 F INISTALLATION Install the O ring 1 Tighten the cooling fan thermo switch to the specified torque Cooling fan thermo switch 18 N m 1 8 kgf m 13 0 lb ft After the cooling fan thermo switch has been installed fill coolant and perform air bleeding 2 15 H...

Page 203: ...read the column thermometer 2 when the switch closes or opens 09900 25008 Multi circuit tester set Cooling fan thermo switch operating temperature Standard 20 C 68 F Approx 2 58 kΩ Ω Ω Ω 40 C 104 F Approx 1 14 kΩ Ω Ω Ω 80 C 176 F Approx 0 28 kΩ Ω Ω Ω 100 C 212 F Approx 0 16 kΩ Ω Ω Ω INSTALLATION Install the O ring 1 Tighten the engine coolant temperature sensor to the speci fied torque Engine cool...

Page 204: ...ter is heated gradually If the thermostat valve opening temperature is not within the specified range replace the thermostat with a new one Thermostat valve start to open temperature Approx 82 C 180 F Do not allow the thermostat 1 and thermometer 2 to come in contact with the bottom of the pan As the thermostat operating response to water tem perature change is gradual do not raise water tem perat...

Page 205: ...pecifica tion replace the thermostat with a new one Thermostat valve lift 3 0 mm 0 12 in INSTALLTATION Position the thermostat with the air bleeder hole A upside Install the thermostat case 1 Thermostat case bolt 10 N m 1 0 kgf m 7 0 lb ft NOTE Tighten the bolt together with the clamp 2 and secure the high tension cord with the clamp After the thermostat has been installed fill coolant and per for...

Page 206: ...Y Drain engine coolant 6 3 Disconnect the water hose 1 Remove the water pump 2 Remove the water pump cover 3 Remove the E ring 4 Remove the impeller together with the water pump shaft Remove the mechanical seal 5 using the special tool 09921 20240 Bearing remover set 12 ...

Page 207: ...amage care fully If any sign of leakage is noted replace the mechanical seal and as necessary together with the oil seal and bearing REASSEMBLY AND REMOUNTING Install the bearing 1 09925 98221 Bearing installer Prior to installing the oil seal apply SUZUKI SUPER GRE ASE to the lip NOTE Press fit the oil seal 2 with the stamped mark side to face the mechanical seal side 99000 25010 SUZUKI SUPER GRE...

Page 208: ...e water pump cover to the water pump with the O ring 4 fitted and grease coated 99000 25010 SUZUKI SUPER GREASE A Others 99000 25030 SUZUKI SUPER GREASE A USA Apply SUZUKI SUPER GREASE to the O rings 5 6 and install the water pump case on the engine 99000 25010 SUZUKI SUPER GREASE A Others 99000 25030 SUZUKI SUPER GREASE A USA Install the water pump with the flats on the pump shaft end A securely ...

Page 209: ...Tighten the water pump case bolts to the specified torque and install the water hose 9 25 Water pump case bolt 10 N m 1 0 kgf m 7 0 lb ft Pour coolant into the cooling system 2 13 Start the engine and check for leakage of coolant and oil ...

Page 210: ...YSTEM CHART OIL PAN OIL SUMP FILTER OIL PUMP BY PASS OIL FILTER STARTER IDLE GEAR GENERATOR COVER MAIN GALLERY OIL RE TURN PASSAGE OIL NOZZLE PISTON CRANKSHAFT STARTER DRIVEN GEAR CYLINDER CYLINDER HEAD CRANK PIN BEARING INTAKE ROCKER ARM INTAKE ROCKER ARM SHAFT CAMSHAFT CAM FACE CAM CHAIN EXHAUST ROCKER ARM EXHAUST ROCKER ARM SHAFT CAMSHAFT JOURNAL ...

Page 211: ...COOLING AND LUBRICATION SYSTEM 6 17 ENGINE LUBRICATION SYSTEM EXHAUST ROCKER ARM CAMSHAFT INTAKE ROCKER ARM OIL SUMP FILTER OIL PUMP OIL FILTER LUBRICATION OIL RETURNED OIL ...

Page 212: ...MASTER CYLINDER REMOVAL AND DISASSEMBLY 7 29 MASTER CYLINDER INSPECTION 7 30 MASTER CYLINDER REASSEMBLY AND REMOUNTING 7 31 HANDLEBARS 7 33 REMOVAL 7 33 REASSEMBLY 7 34 FRONT FORK 7 35 REMOVAL AND DISASSEMBLY 7 35 FRONT FORK SPRING INSPECTION 7 38 INNER TUBE AND OUTER TUBE INSPECTION 7 38 CYLINDER INSPECTION 7 38 REASSEMBLY AND REMOUNTING 7 39 STEERING 7 43 REMOVAL AND DISASSEMBLY 7 43 INSPECTION ...

Page 213: ...1 DELAY VALVE REMOVAL 7 62 DELAY VALVE REMOUNTING 7 62 BRAKE LOCK CABLE REPLACEMENT 7 62 BRAKE SYSTEM 7 65 REAR SUSPENSION 7 69 REMOVAL AND DISASSEMBLY 7 69 INSPECTION 7 70 REAR SHOCK ABSORBER DISPOSAL 7 71 REASSEMBLY AND REMOUNTING 7 73 CRANKCASE BRACKET 7 75 REMOVAL AND DISASSEMBLY 7 75 INSPECTION 7 75 BEARING REPLACEMENT 7 76 REASSEMBLY AND REMOUNTING 7 77 TIRE AND WHEEL 7 78 TIRE REMOVAL 7 78 ...

Page 214: ...SIS 7 3 EXTERIOR PARTS CONSTRUCTION 1 Front leg shield cover 2 Front leg shield 3 Wind screen 4 Lower leg shield 5 Front meter panel 6 Rear meter panel 7 Front panel 8 Front box 9 Front floor mat left right ...

Page 215: ...7 4 CHASSIS 1 Front box 2 Front box inner cover 3 Battery box lid 4 Front box lid 5 Cushion 6 Fuel lid ...

Page 216: ...CHASSIS 7 5 1 Front frame cover 2 Frame cover left right 3 Foot board left right 4 Rear floor mat left right 5 Lower frame cover left right 6 Under cover 7 Frame cover center 8 Lower leg shield ...

Page 217: ...7 6 CHASSIS FRONT PANEL BOX ...

Page 218: ...CHASSIS 7 7 TRUNK BOX Clip Frame Vehicle left side Washer Upper 1 Front trunk box cover 2 Upper trunk box 3 Lower trunk box 4 Tool holder Frame Weather strip Forward A Max 1mm ...

Page 219: ...7 8 CHASSIS PILLION RIDER HANDLE 1 Pillion rider handle left right 2 Rear pillion rider handle cover 3 Center pillion rider handle 4 Back rest 5 Front pillion rider handle cover ...

Page 220: ...r leg shield K Left foot board L Trunk box M Right foot board J Frame cover center left right I Lower frame cover H Pillion rider handle left right G Center pillion rider handle E Front frame cover C Front trunk box cover B Side leg shield left right D Seat F Front pillion rider handle cover 9 Front box REMOVAL PROCEDURE FLOW CHART 1 Also remove front floor mats A B A Under cover ...

Page 221: ...ner INSTALLATION Let the center piece stick out toward the head so that the pawls 2 close Insert the fastener into the installation hole NOTE To prevent the pawl 2 from damage insert the fastener all the way into the installation hole Push in the head of center piece until it becomes flush with the fastener outside face ...

Page 222: ...ndle cover 1 Remove the front handle cover 2 Remove the front panel 3 FRONT LEG SHIELD COVER Remove the screws Remove the front leg shield cover 1 Hooked part WIND SCREEN Remove the front leg shield cover 7 11 Remove the screws and wind screen 1 ...

Page 223: ...reen 7 11 Remove the side leg shield 7 15 Remove the screws and fastener Disconnect the front combination light couplers 1 Disconnect the headlight couplers 2 Disconnect the position light coupler 3 Except for E 03 28 33 Remove the front leg shield 4 ...

Page 224: ...g shield 7 12 Remove the lower leg shield 1 METER PANEL Remove the handle cover 7 11 Remove the front leg shield 7 12 Remove the screws Disconnect the speedometer coupler Remove the screw 2 Remove the front meter panel 3 Remove the rear meter panel 4 ...

Page 225: ...eter panel 7 13 Remove the battery 8 36 Remove the front frame cover 7 17 Remove the brake lock knob 1 Remove the accessories socket coupler 2 and ECM coupler 3 Remove the bolts and screws Remove the front box 4 UNDER COVER Remove the fasteners Remove the under cover 1 ...

Page 226: ...D Remove the under cover 7 14 Remove the front floor mats 1 Remove the rear floor mats 2 Remove the fasteners and screws Remove the left side leg shield 3 Remove the right side leg shield 4 LOWER FRAME COVER Remove the fasteners ...

Page 227: ...emove the lower frame cover 1 Hooked part SEAT Uplift the seat Remove the screws Remove the front trunk box cover 1 Disconnect the seat damper 2 Remove the trunk box light coupler 3 Remove the nuts Remove the seat 4 ...

Page 228: ... front frame cover 1 PILLION RIDER HANDLE Remove the rear pillion rider handle cover 1 Remove the screw 2 With the hooks drawn out remove the back rest 3 Hooked part Remove the front pillion rider handle cover 4 Disconnect the seat lock cable 5 Remove the center pillion rider handle 6 ...

Page 229: ...Remove the front frame cover 7 17 Remove the pillion rider handle 7 17 Disconnect the licence light coupler 1 and rear brake light coupler 2 Remove the four fasteners in the trunk box Remove the screws Remove the frame cover 3 with the center left and right TRUNK BOX Remove the mat 1 Remove the bolts and nuts Remove the trunk box 2 ...

Page 230: ...t foot board 2 INSTALLATION Install the exterior parts in the revers order of removal Pay attention to the following points PILLION RIDER HANDLE Apply THREAD LOCK to the pillion rider handle left right bolts 99000 32050 THREAD LOCK 1342 Tighten the pillion rider handle bolts to the specified torque Pillion rider handle bolt 23 N m 2 3 kgf m 16 5 lb ft ...

Page 231: ... clamp bolt 3 should be removed so as not to cause the speed sensor lead wires to be pulled tight Draw out the front axle and remove the front wheel When using a jack take care not to cause scratches on the chassis 1 Wheel bearing 2 Front tire 3 Front wheel 4 Spacer 5 Brake disc 6 Dust seal 7 Spacer A Front axle B Brake disc bolt ITEM N m kgf m Ib ft A 65 6 5 47 0 B 23 2 3 16 5 ...

Page 232: ...nt wheel runout Radial and Axial 2 0 mm 0 08 in WHEEL BEARING The wheel bearing inspection must be performed with the bearing installed in the wheel Turn the bearing inner race by hand to see if there is no abnormal play or noise Also check for smoothness of turning If any abnormal condition is found replace the bearing with a new one WHEEL BEARING REPLACEMENT Remove the wheel bearings using the s...

Page 233: ...e Limit 0 25 mm 0 010 in 09900 20607 Dial gauge 1 100 mm 09900 20701 Magnetic stand 09900 21304 V block TIRE Tire inspection 7 78 REASSEMBLY AND REMOUNTING Reassemble and remount the front wheel in the reverse order of removal and disassembly Pay attention to the following points Left Right 18 N m 1 8kgf m 13 0 lb ft 23 N m 2 3kgf m 16 5 lb ft 65 N m 6 5kgf m 47 0 lb ft ...

Page 234: ...E A Others 99000 25030 SUZUKI SUPER GREASE A USA Using the special tool press fit the left bearing Fit the spacer and press fit the right bearing 09924 84521 Bearing installer set Position the sealed side of bearing facing outside Use care not to allow the spacer to skew Left Right Left Right spacer clearance ...

Page 235: ...R GREASE A Others 99000 25030 SUZUKI SUPER GREASE A USA WHEEL Apply SUZUKI SUPER GREASE to the convex parts of wheel 99000 25010 SUZUKI SUPER GREASE A Others 99000 25030 SUZUKI SUPER GREASE A USA With the recesses on the wheel engaged with the drive lugs on the speed sensor position the wheel to the front fork while also aligning the speed sensor with the fork stopper Tighten the front axle 1 to t...

Page 236: ... brake fluid taken from old used or unsealed containers Never reuse brake fluid left over from the last 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 washing brake components use fresh brake fluid Never use cleaning solvent A contaminated brake disc ...

Page 237: ...te the brake correctly and then check the brake fluid level CALIPER REMOVAL AND DISASSEMBLY Drain brake fluid of both the front brake side and the combina tion brake side 2 18 Remove the union bolts 1 and caliper mounting bolts 2 Remove the brake pad 7 26 Remove the caliper housing bolts 3 NOTE Slightly loosen the caliper housing bolts 3 before removing the caliper mounting bolts to facilitate lat...

Page 238: ...D REMOUNTING Reassemble and remount the caliper in the reverse order of disassembly and removal Pay attention to the following points Specification and classification DOT 4 Do not use high pressure air to prevent piston dam age Use care not to cause scratch on the cylinder bore Do not reuse the piston seal and dust seal that have been removed Wash the caliper components with fresh brake fluid befo...

Page 239: ...iper housing bolt 23 N m 2 3 kgf m 16 5 lb ft 99000 32130 THREAD LOCK SUPER 1360 Tighten the caliper mounting bolts 5 to the specified torque With the hose ends contacted to the stoppers tighten the union bolts 6 to the specified torque 5 Caliper mounting bolt 25 N m 2 5 kgf m 18 0 lb ft 6 Union bolt 23 N m 2 3 kgf m 16 5 lb ft For assembly procedure of brake hose 9 23 Fill the system with brake f...

Page 240: ...ness Service Limit 4 0 mm 0 16 in 09900 20205 Micrometer 0 25 mm Measure the runout with a dial gauge Replace the disc if the runout exceeds the service limit Brake disc runout Service Limit 0 30 mm 0 012 in 09900 20607 Dial gauge 1 100 mm 09900 20701 Magnetic stand MASTER CYLINDER REMOVAL AND DISASSEMBLY Remove the handle covers 7 11 Drain brake fluid from the front brake side reservoir 2 17 Remo...

Page 241: ...ver 6 Remove the boot 7 and remove the snap ring 8 Remove the piston cup set 9 and spring 0 MASTER CYLINDER INSPECTION Inspect the cylinder wall piston cup set and spring for scratch corrosion or other damages If any abnormal condition is noted replace the inner parts or master cylinder ...

Page 242: ...ylinder assemble the brake light switch When remounting the brake master cylinder onto the handle bars align the master cylinder holder s mating surface with punch mark C on the handlebars Tighten the upper bolt first temporarily to provide clearance on the lower side and then tighten both the bolts to the speci fication Master cylinder bolt 10 N m 1 0 kgf m 7 0 lb ft Wash each component with fres...

Page 243: ...tall the brake hose and tighten the union bolt 1 9 23 Union bolt 23 N m 2 3 kgf m 16 5 lb ft Fill the system with brake fluid and bleed air 2 19 Perform the front brake inspection after assembly has been completed 2 16 ...

Page 244: ...ve the master cylinder 4 7 60 Remove the handlebar balancer 5 and grip 6 Remove the rear view mirror 7 Remove the right handlebar switches 8 Disconnect the brake light switch lead wires 9 and remove the master cylinder 0 7 29 Remove the handlebar balancer A and grip B Remove the bolts and remove the handlebar holders C Remove the handlebars D 1 Handleber balancer 2 Handlebars 3 Grip ...

Page 245: ...AD LOCK SUPER 1303 Handlebar clamp bolt 23 N m 2 3 kgf m 16 5 lb ft With the stopper B engaged with the handlebar hole C assemble the handlebar switch When remounting the brake master cylinder onto the handle bars align the master cylinder holder s mating surface with punch mark D on the handlebars Tighten the upper bolt first temporarily to provide clearance on the lower side and then tighten bot...

Page 246: ...e caliper 1 and disconnect the brake hose clamp 2 1 Dust seal 2 Oil seal stopper ring 3 Oil seal 4 Oil seal retainer 5 Guide metal 6 Oil lock piece 7 Outer tube 8 Cylinder 9 Rebound spring 0 Inner tube A Slide metal B Washer C Front fork spring A Cylinder bolt B Front fork cap bolt ITEM N m kgf m Ib ft A 30 3 0 21 5 B 45 4 5 32 5 ...

Page 247: ...lt 2 and washer using the spe cial tool 09940 30230 Hexagon socket 17 mm Loosen the front fork clamp bolts and remove the front fork 3 Remove the front fork spring 4 and drain the front fork oil Use caution when removing the front fork cap bolt since the spring force is applied to the cap bolt ...

Page 248: ...ment A Remove the cylinder 2 and rebound spring 3 Remove the dust seal 4 and oil seal stopper ring 5 Pull the inner tube out of the outer tube Remove the oil lock piece 6 Remove the oil seal 7 oil seal retainer 8 guide metal 9 and slide metal 0 from the inner tube Be careful not to damage the outer tube ...

Page 249: ...e spring Front fork spring free length Service limit 324 mm 12 8 in INNER TUBE AND OUTER TUBE INSPEC TION Inspect the sliding surface of the inner tube outer tube and cylinder for scratch wear bending or other abnormal condi tion CYLINDER INSPECTION Inspect the surface of the cylinder for scratch and wear If any defects are found replace it with a new one ...

Page 250: ...ce Thoroughly wash all the component parts being assembled Insufficient washing can result in oil leakage or pre mature wear of the parts When reassembling the front fork use new fork oil Use the specified fork oil for the front fork When reassembling replace the slide metals oil seal dust seal and damper rod bolt gasket with new ones Use care not to cause damage to the slide metal sur faces since...

Page 251: ...g the special tool 99000 25010 SUZUKI SUPER GREASE A Others 99000 25030 SUZUKI SUPER GREASE A USA 09940 52861 Front fork oil seal installer set Fit the stopper ring 3 and dust seal 4 2 Oil seal 3 Oil seal stopper ring 4 Dust seal 5 Oil seal retainer 6 Guide metal Install the rebound spring 7 on the cylinder 8 and install them together to the inner tube Wach clean the front fork oil seal installer ...

Page 252: ...ront fork Front fork oil capacity each leg 284 ml 9 6 1 00 US lmp OZ 99000 99044 10G SUZUKI FORK OIL 10 With the front fork held in vertical position compress the inner tube all the way Wait until the fluid level stabilizes measure and adjust the level to specification using the special tool Front fork oil level without spring 96 mm 3 78 in 09943 74111 Front fork oil level gauge Install the front ...

Page 253: ... the washer and temporarily tighten the front fork cap bolt Tighten the front fork clamp bolts 1 to the specified torque Front fork clamp bolt 23 N m 2 3 kgf m 16 5 lb ft Tighten the front fork cap bolt 2 to the specified torque using the special tool 09940 30230 Hexagon socket 17 mm Front fork cap bolt 45 N m 4 5 kgf m 32 5 lb ft Perform the following inspections after assembly has been completed...

Page 254: ... fork disassembly work is requied Remove the front brake hose clamp bolts 1 Remove the clamp 2 and cable guide 3 1 Steering stem 2 Washer 3 Steering stem nut 4 Dust cover 5 Upper inner race 6 Upper bearing 7 Lower bearing A Handlebar holder clamp bolt B Handlebar holder set bolt C Lock nut D Handlebar clamp bolt ITEM N m kgf m Ib ft A 55 5 5 40 0 B 23 2 3 16 5 C 30 3 0 21 5 D 23 2 3 16 5 ...

Page 255: ...4 and steering stem nut 5 using the special tools and draw out the steering stem 09940 14911 Steering socket wrench 09940 11420 Steering stem nut socket 09940 11430 Steering stem nut socket Remove the dust cover 6 upper inner race 7 and upper bearing 8 Remove the lower bearing 9 This operation must be performed without causing undue stress to the brake hose and wire ...

Page 256: ... head for any damage Inspect the bearing and race for corrosion nick or other dam age REASSEMBLY AND REMOUNTING Reassemble and remount the steering in the reverse order of removal and disassembly Pay attention to the following points Press in the upper and lower outer race using the special tool 09941 34513 Steering race installer Unless corrosion damage or other abnormal condi tion is found the b...

Page 257: ...ue using the special tools 09940 14911 Steering socket wrench 09940 11430 Steering stem nut socket Steering stem nut 30 N m 3 0 kgf m 21 5 lb ft Turn the steering stem right and left 5 6 times to break in the bearing Return the steering stem nut 3 by 1 4 to 1 2 of a turn In this condition check that the steering stem can turn smoothly with no rattle and stiffness If there is a rattle or heavy move...

Page 258: ...teering stem nut adjust ment Therefore after tightening the lock nut check the steering movement again and adjust if necessary Tighten the handlebar holder set bolt 1 to the specified torque Handlebar holder set bolt 23 N m 2 3 kgf m 16 5 lb ft Tighten the handlebar holder clamp bolts 2 to the specified torque Handlebar holder clamp bolt 55 N m 5 5 kgf m 40 0 lb ft Perform the steering inspection ...

Page 259: ...CHASSIS REAR WHEEL REMOVAL Remove the under cover Remove the exhaust pipe joint nut Remove the muffler 1 1 Rear tire 2 Rear wheel 3 Rear wheel nut A Axle nut ITEM N m kgf m Ib ft A 55 5 5 40 0 B 23 2 3 16 5 ...

Page 260: ...out using a dial gauge If the runout measured exceeds the service limit overhaul the rear axle and check for the cause 3 18 71 Rear wheel runout Radial and Axial Service Limit 2 0 mm 0 08 in REMOUNTING Remount the rear wheel in the reverse order of removal Pay attention to the following points Install the rear wheel and tighten the rear wheel nuts 1 to the specified torque Rear wheel nut 50 N m 5 ...

Page 261: ...bolts from the muffler side and assemble the muffler 3 muffler bracket 4 washers and muffler mounting nuts in that order Tighten the muffler mounting nuts to the specified torque Muffler mounting nut 23 N m 2 3 kgf m 16 5 lb ft Tighten the exhaust pipe joint nuts to the specified torque Exhaust pipe joint nut 23 N m 2 3 kgf m 16 5 ft ...

Page 262: ...ponents use fresh brake fluid Never use cleaning solvent A contaminated brake disc or brake pad reduces braking performance Discard contaminated pads and clean the disc with high quality brake cleaner or neutral detergent Handle brake fluid with care the fluid reacts chemically with paint plastics rubber materials etc and will damage then severly 1 Brake hose 2 Master cylinder 3 Piston cup set 4 S...

Page 263: ...2 and remove the brake pad 3 Pad mounting pin 18 N m 1 8 kgf m 13 0 lb ft Push and return the front piston 4 to the caliper Push and return the rear piston 5 with turning clockwise to the caliper NOTE Keep back the front caliper piston 4 not to be push out when installing the rear caliper piston 5 When tightening the caliper mounting bolts make sure that the brake disc is slid on the axle all the ...

Page 264: ...rake 2 16 Inspection for brake lock 2 28 CALIPER REMOVAL AND DISASSEMBLY Drain brake fluid from the combination brake reservoir 2 18 Remove the rear wheel 7 48 Remove the rear brak caliper cover 1 Remove the brake hose union bolt and caliper mounting bolts With the brake lock cable 2 disconnected detach the brake caliper 3 Make sure that the convex A of brake pad fits into the groove of caliper pi...

Page 265: ...ing compressed air Remove the rear piston 6 with turning counterclockwise Remove the dust seals 7 and piston seals 8 from the cylin der Remove the brake lock housing bolts and remove the brake lock housing 9 Do not use high pressure air to prevent piston dam age Use care not to cause scratch on the cylinder bore Do not reuse the piston seal and dust seal that have been removed ...

Page 266: ...per pistons surface for nicks scratches and other damage If any damage is found replace the rear brake caliper with a new one CALIPER REASSEMBLY AND REMOUNTING Reassemble and remount the brake caliper in the reverse order of removal and disassembly Pay attention to the following points Install the new gasket 1 Apply THREAD LOCK to the brake lock housing bolts 2 and tighten them to the specified to...

Page 267: ...ch mark A may position between both notch B of housing when tightening turning counterclockwise the brake lock shaft Align the punch mark C on the brake lock shaft with the punch mark D on the brake lock arm Apply SUZUKI SILICONE GREASE to the tip and thread of brake lock adjuster assemble the lock nut and spring tempo rarily 99000 25100 SUZUKI SILICONE GREASE ...

Page 268: ...aliper with turning clockwise Apply SUZUKI SILICONE GREASE to the caliper axles 9 99000 25100 SUZUKI SILICONE GREASE Install the pad spring Install the brake pad 7 52 Wash the caliper components with fresh brake fluid before reassembly Do not wipe off brake fluid after washing the components Replace the piston seal and dust seal with new ones with brake fluid applied ...

Page 269: ...ctions after the caliper assembly has been completed Adjustment of brake lock cable 2 28 Brake inspection 2 16 Replacing brake fluid 2 18 BRAKE DISC REMOVAL Remove the rear wheel 7 48 Remove the rear brake caliper cover 1 Remove the caliper mounting bolts and remove the caliper 2 NOTE Hold the caliper so as not to cause undue stress on the brake hose When tightening the caliper mounting bolts make...

Page 270: ...fitting an appropriate nut to the wheel bolt Measure the runout with a dial gauge Replace the disc if the runout exceeds the service limit Brake disc runout Service Limit 0 30 mm 0 012 in 09900 20607 Dial gauge 1 100 mm 09900 20701 Magnetic stand BRAKE DISC REASSEMBLY Reassemble the brake disc in the reverse order of removal Pay attention to the following points Install the brake disk 1 to the rea...

Page 271: ...mbination brake reservoir 2 18 Disconnect the brake light switch lead wires Remove the union bolt 2 Remove the master cylinder 3 Remove the brake light switch 4 and brake lever 5 Remove the boot 6 and remove the snap ring 7 Remove the piston cup set 8 and spring 9 Place a rag under the union bolt so that brake fluid may not contact the parts ...

Page 272: ...ten the upper bolt first temporarily to provide clearance on the lower side and then tighten both the bolts to the speci fication Master cylinder bolt 10 N m 1 0 kgf m 7 0 lb ft Install the brake hose and tighten the union bolt to the speci fied torque 9 23 Union bolt 23 N m 2 3 kgf m 16 5 lb ft 2 Master cylinder bolt 3 Handlebars 4 Master cylinder 5 Punch mark 6 Clearance Fill the system with bra...

Page 273: ... the following points Tighten the delay valve mounting bolt 1 together with the clamp Delay valve mounting bolt 10 N m 1 0 kgf m 7 0 lb ft With the brake hose end contacted to the stopper tighten the union bolt to the specified torque Union bolt 23 N m 2 3 kgf m 16 5 lb ft Tighten the brake pipe joint bolt 2 to the specified torque Brake pipe joint bolt 16 N m 1 6 kgf m 11 5 lb ft BRAKE LOCK CABLE...

Page 274: ... cable 6 Install the brake lock cable 9 19 Turn the nut 7 until the clearance is 0mm 0 in Install the brake lock cable to the brake lock lever 8 and tighten the nut 9 Install the brake lock arm A 7 56 NOTE The open end of spring must face to the left side of vehicle as shown Clearance Check that the boot 0 is fitted securely ...

Page 275: ...7 64 CHASSIS Install the brake lock cable Adjust the brake lock 2 28 Install the front box ...

Page 276: ...to brake disk through the adjust nut caliper piston In this bout the adjust bolt and asjust nut move together with the relation as shown in the illustration When releasing the brake lock lever each parts return to home position the caliper piston will be returned by an elasticity transform of piston seal the adjust bolt will be returned by the adjust bolt spring the brake lock adjuster will be ret...

Page 277: ...tween brake pad and brake disk OPERATION Normal condition Braking The hydraulic pressure by brake lever operation acts on the adjust nut caliper piston The adjust bolt threads and adjust nut threads have a clearance The piston stroke when braking is shorter than clearance thus the braking operation will finish without automatic brake lock adjuster system operation Adjust bolt Hydraulic pressure Ad...

Page 278: ...d to rotary movement and acts on the adjust bolt and adjust nut Only the adjust bolt turns 3 because the caliper piston adjust nut is fixed to the brake pad with caliper piston groove and pad boss at A Thus the adjust bolt keeps original position with rotating as well as the caliper piston adjust nut moves outside The adjust bolt stops rotating once the brake pad to disc clearance become zero so t...

Page 279: ...ake lever It is the over adjust condition The spring is equipped between the caliper piston and the adjust nut for preventing the over adjust serves damper interm of rapid caliper piston movement The spring compress 2 as soon as the caliper piston moves exponentially 1 the adjust nut moves 3 4 behind time Here with it is possible to make correct clearance of the adjust bolt nut because the inertia...

Page 280: ...ame cover 7 18 Remove the trunk box 7 18 Remove the rear shock absorber adjuster 2 1 Cushion lever 2 Rear shock absorber 3 Spacer 4 Bearing A Rear shock absorber bolt B Cushion lever mounting nut C Rear cushion rod nut D Rear shock absorber adjuster bolt ITEM N m kgf m Ib ft A 50 5 0 36 0 B 78 7 8 56 5 C 50 5 0 36 0 D 10 1 0 7 0 ...

Page 281: ...inkage Remove the cushion lever bearings using the special tools 09930 30104 Sliding shaft 09923 73210 Bearing remover INSPECTION CUSHION LEVER Inspect the cushion lever body for crack break or other abnormal condition Attempt to move the spacer laterally to see that no play exists Also check the spacer for smooth turning If any abnormal condition is noted in the spacer movement replace the bearin...

Page 282: ...her dam age If any defects are found replace the shock absorber with a new one REAR SHOCK ABSORBER DISPOSAL REAR SHOCK ABSORBER GAS EVACUATION Remove the valve cap 1 Handle the rear shock absorber with caution since a high pressure nitrogen gas is contained Avoid incineration exposure to high pressure or overhauling In the case of scrapping the rear shock absorber evacuate gas in the following pro...

Page 283: ...7 72 CHASSIS Evacuate gas through the valve hole 2 Keep your face away from the valve hole ...

Page 284: ...unt the rear suspension in the reverse order of removal and disassembly Pay attention to the following points Left Right 50 N m 5 0 kgf m 36 0 lb ft 78 N m 7 8 kgf m 56 5 lb ft 50 N m 5 0 kgf m 36 0 lb ft 50 N m 5 0 kgf m 36 0 lb ft 50 N m 5 0 kgf m 36 0 lb ft ...

Page 285: ...s and nuts referring to the illustration in the previous page 7 73 NOTE Pass the cushion lever mounting bolt after all other bolts have been inserted Install the rear shock absorber adjuster 1 Rear shock absorber adjuster hose routing 9 22 Tighten the rear shock absorber adjuster bolts 2 to the spec ified torque Rear shock absorber adjuster bolt 10 N m 1 0 N m 7 0 lb ft SPRING PRE LOAD ADJUSTMENT ...

Page 286: ...t and remove the crank case bracket nut 5 and rubber damper bolts 6 Remove the crankcase bracket 7 rubber dampers 8 and spacers 9 INSPECTION With the spacers 1 inserted in the bearings 2 Inspect that the spacer turns smoothly without vertical and horizontal play Replace the component if any abnormal condition is noted Inspect the rubber damper and bushing for crack and damage and replace if such a...

Page 287: ...930 30104 Sliding shaft Press in the bearing using the special tool 09924 84521 Bearing installer set NOTE When press fitting the bearing the bearing should be positioned so that its stamped mark side contacts the tool 85 N m 8 5 kgf m 61 5 lb ft 93 N m 9 3 kgf m 67 5 lb ft Crankcase bracket Crankcase Bearing ...

Page 288: ...kcase bracket in the direction shown by the arrow to provide clearance of 2mm between the rubber damper hole and the washer hold the bracket in that position and tighten the crankcase bracket nut 1 to specification Crankcase bracket nut 85 N m 8 5 kgf m 61 5 lb ft Insert a steel rod 3 into the crankcase bracket and move the bracket to the direction shown by the arrow Install the rubber damper 4 an...

Page 289: ...mark the tire with a chalk 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 repair can cause imbalance INSPECTION WHEEL Wipe the wheel clean and check for the following Distortion and crack Any flaws and scratches at the bead seating area Wheel rim runo...

Page 290: ...valve shows no abnormal con dition removing of the valve is not necessary If the seal has abnormal deformation replace the valve with a new one Any dust or rust around the valve hole B must be cleaned off Then install the valve C in the rim NOTE To properly install the valve into the valve hole apply a special tire lubricant or neutral soapy liquid to the valve Be careful not to damage the lip C o...

Page 291: ...n by the tire changer manufacturer Bounce the tire several times while rotating This makes the tire bead expand outward to contact the wheel thereby facili tating air inflation Inflate the tire Do not reuse the valve which has been once removed Never use oil grease or gasoline on the tire bead in place of tire lubricant Do not inflate the tire to more than 400 kPa 4 0 kgf cm 57 psi If inflated bey...

Page 292: ...t the tire again When the bead has been fitted properly adjust the pressure to specification As necessary adjust the tire balance Cold inflation tire pressure BALANCER WEIGHT INSTALLATION When installing the balancer weights to the wheel set the two balancer weights B on both sides of wheel rim Do not run with a repaired tire at a high speed Front Rear Solo riding 175 kPa 1 75 kgf cm 25 psi 200 kP...

Page 293: ...TING 8 13 STARTER MOTOR REMOVAL AND DISASSEMBLY 8 14 STARTER MOTOR INSPECTION 8 15 STARTER MOTOR REASSEMBLY AND INSTALLATION 8 16 STARTER RELAY INSPECTION 8 18 SIDE STAND IGNITION INTERLOCK SYSTEM PARTS INSPECTION 8 18 IGNITION SYSTEM 8 21 TROUBLESHOOTING 8 21 IGNITION SYSTEM INSPECTION 8 23 COMBINATION METER 8 26 REMOVAL AND DISASSEMBLY 8 26 INSPECTION 8 27 FUEL LEVEL METER INSPECTION 8 28 LAMP 8...

Page 294: ...8 2 ELECTRICAL SYSTEM ELECTRICAL SYSTEM CONTENTS SPECIFICATIONS 8 34 INITIAL CHARGING 8 34 SERVICING 8 35 RECHARGING OPERATION 8 36 BATTERY REMOVAL 8 36 ...

Page 295: ...coupler be sure to hold the coupler do not pull the lead wires Inspect each terminal on the coupler for looseness or bends Inspect each terminal for corrosion and contamination CLAMPS Refer to the WIRING HARNESS ROUTING section for proper clamping procedures 9 17 to 9 18 Bend the clamp properly as shown in the illustration When clamping the wire harness do not allow it to hang down Do not use wire...

Page 296: ... the battery Be sure to recharge the battery in a well ventilated and open area Note that the charging system for the MF battery is different from that of a conventional battery Do not replace the MF battery with a conventional battery CONNECTING THE BATTERY When disconnecting terminals from the battery for disas sem bly or servicing be sure to disconnect the battery lead wire first When connectin...

Page 297: ...cle and tester If the voltage and current values are not known begin mea suring in the highest range When measuring the resistance make sure no voltage is applied If voltage is applied the tester will be damaged After using the tester be sure to turn the switch to the OFF position Before using the multi circuit tester read its instruc tion manual ...

Page 298: ...ter relay 2 Fuse box 3 Turn signal Side stand relay 4 Left handlebar switch 5 Left brake switch 6 Trunk light seat switch 7 Trunk light switch 8 Trunk light 9 Regulator rectifier 0 TO sensor 4 35 A Side stand switch B Starter motor C ECT sensor 6 9 D Ignition coil ...

Page 299: ... J PAIR control solenoid valve 10 6 K Fuel pump 5 8 L Right handle switch M Right brake switch N Battery O Ignition switch P ECM Engine Control Module Q Fuel pump relay R Safety relay S Speed sensor T Brake lock switch U Horn V Cooling fan switch W Cooling fan X HO2 sensor 4 42 Y Generator Z CKP sensor 4 23 ...

Page 300: ...attery for current leaks 8 10 Is the battery for current leaks OK Step3 1 Measure the charging voltage between the battery terminals 8 10 Is the battery charging of voltage OK YES Remove accessories NO Go to Step2 YES Go to Step3 NO Short circuit of wire harness Faulty electrical equipment YES Faulty battery Abnormal NO Go to Step4 lgnition switch Main fuse Battery Load Regulator rectifier Generat...

Page 301: ...tor rectifier 8 12 Is the 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 Step5 NO Faulty generator coil Disconnected lead wires YES Go to Step6 NO Faulty generator YES Go to Step7 NO Faulty regulator rectifier YES Faulty battery NO Short circuit of wir...

Page 302: ...ATED VOLTAGE INSPECTION Remove the battery cover 8 36 Remove the left side leg shield 7 15 Start the engine turn the ignition switch and the dimmer switch to HI and run the engine at 5 000 r min Measure the DC voltage between the and battery termi nals using the multi circuit tester NOTE When making this test be sure that the battery is in fullycharged condition If the voltage in not within the sp...

Page 303: ...e Ω Ω Ω Ω Generator coil resistance 0 2 0 6 Ω Ω Ω Ω Yellow Yellow Ω Ω Ω Ω Yellow Ground GENERATOR NO LOAD PERFORMANCE INSPECTION Remove the front box 7 14 Disconnect the generator coupler Start the engine and run it at 5 000 r min Measure the AC voltage between the lead wires of the generator using the multi circuit tester If the voltage is under the specified value replace the AC gener ator with ...

Page 304: ... the table below If the voltage is not within the specified value replace the regu lator 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 the tester reads under 1 4 V when the tester probes are not connected replace the battery of multi circuit tester Tester prove Tester prove A B C D E A 0 4 0 7 ...

Page 305: ...sound heard Step2 1 Check if the starter motor runs when its terminal is connected to the battery terminal Do not use a thin wire because a large amount of current flows Does the starter motor run YES Go to Step2 NO Go to Step3 YES Faulty starter relay Loose or disconnected starter motor lead wire Loose or disconnected between starter relay and battery terminal NO Faulty starter motor Starter moto...

Page 306: ...tch STARTER MOTOR REMOVAL AND DISAS SEMBLY Remove the trunk box 7 18 Remove the air cleaner box 3 4 Disconnect the starter motor lead wire 1 Remove the starter motor 2 YES Go to Step4 NO Faulty safety relay Faulty starter button Faulty engine stop switch Faulty turn signal side stand relay Faulty ignition switch Faulty front brake switch and rear brake switch Faulty side stand switch Improper conn...

Page 307: ...normal wear or undercut A If abnormal wear is found replace the armature with a new one If the commutator surfaced is discolored polish it with 400 sandpaper and wipe it using a clean dry cloth If there is no undercut scrape out the insulator 1 with saw blade 1 Housing end outside 2 O ring 3 Starter motor case 4 Armature 5 Hausing end inside 6 O ring 7 Oil seal 8 Washer 9 Shim A Starter motor lead...

Page 308: ...L SEAL INSPECTION Check the oil seal lip for damage or leakage If any damage is found replace the housing end BEARING INSPECTION Check the bearing of housing end for damage If any damage is found replace the housing end STARTER MOTOR REASSEMBLY AND INSTALLATION Reassemble the starter motor in the reverse order of disassem bly Pay attention to the following points Apply SUZUKI SUPER GREASE to the l...

Page 309: ...mark A on the housing with the line B on the hous ing end Fit the O rings to the starter motor housing bolts and tighten the bolts Starter motor housing bolt 3 7 N m 0 37 kgf m 2 7 lb ft Apply SUZUKI SUPER GREASE to the O ring 3 99000 25010 SUZUKI SUPER GREASE A Others 99000 25030 SUZUKI SUPER GREASE A USA Install the starter motor Starter motor mounting bolt 7 N m 0 7 Kgf m 5 0 lb ft To prevent o...

Page 310: ...y test Measure the relay coil resistance between the terminals using the multi circuit tester If the resistance is not within the speci fied value replace the starter relay with a new one 09900 25008 Multi circuit tester set Tester knob indication Resistance Ω Ω Ω Ω Starter relay resistance 3 6 Ω Ω Ω Ω SIDE STAND IGNITION INTERLOCK SYS TEM PARTS INSPECTION Check the interlock system for proper ope...

Page 311: ...d replace its battery SAFETY RELAY INSPECTION Remove the front box 7 14 Remove the safety relay 1 Check that no continuity exists between the terminals A and B If continuity is found replace the relay 09900 25008 Multi circuit tester set Tester knob indication Continuity test Check there is continuity between the terminals A and B when 12V battery voltage is applied positive to the terminal C and ...

Page 312: ...nect the turn signal side stand relay First check the insulation between B and C terminals with the tester Then apply 12 V to terminals B and A to B and to A and check the continuity between B and C If there is no continuity replace the turn signal side stand relay with a new one 09900 25008 Multi circuit tester set Tester knob indication Continuity test SIDE STAND RELAY DIODE TURN SIGNAL RELAY ...

Page 313: ... and the battery is fully charged before diagnosing Step1 1 Check ignition system couplers for poor connections Is there connection in the ignition switch couplers YES Go to Step2 NO Improper coupler connection ECM CKP Sensor Wave from arrangement circuit TP Sensor CPU WT Sensor Power source circuit lgnition coil Engine stop switch Turn signal side stand relay lgnition fuse lgnition switch Main fu...

Page 314: ...on coil 8 24 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 adaptor Is the peak voltage and resistance OK YES Go to Step3 NO Faulty ignition switch Faulty turn signal side stand switch relay Faulty ignition switch Broken wire harness or poor connection ...

Page 315: ...08 Multi circuit tester set Set the side stand upright position and then turn the ignition switch to the ON position Grasp the front or rear brake lever Press the starter button and allow the engine to crank for a few seconds and then measure the ignition coil primary peak voltage Repeat the above procedure a few times and measure the highest ignition coil primary peak voltage Tester knob indicati...

Page 316: ...fastener A un locked pull out the lead wire G W Bl Connect the multi circuit tester with the peak voltage adaptor as follows Probe Green White lead wire Probe Blue lead wire 09900 25008 Multi circuit tester set Set the side stand upright position and then turn the ignition switch to the ON position Grasp the front or rear brake Pull the starter button and allow the engine to crank for a few second...

Page 317: ...s ok but on the ECM coupler is out of specification the wire harness must be replaced If both peak voltages are out of specification the CKP sensor must be replaced and re checked CKP SENSOR RESISTANCE INSPECTION Remove the front box 7 14 Disconnect the CKP sensor coupler Measure the resistance between the lead wires and ground If the resistance is not specified value the CKP sensor must be replac...

Page 318: ...8 26 ELECTRICAL SYSTEM COMBINATION METER REMOVAL AND DISASSEMBLY Remove the front meter panel 7 13 Disassembly the combination meter as shown ...

Page 319: ...TION If the speedometer odometer or trip meter does not function properly inspect the speedometer sensor and connection of coupler If the speedometer sensor and connection are all right replace the meter with a new one SPEED SENSOR INSPECTION Disconnect the speed sensor coupler Connect 12 V battery 10 kΩ resistance and the tester to the speed sensor lead coupler as shown 09900 25008 Multi circuit ...

Page 320: ...pler termi nals If the indication excessively deviators from the standard value replace the meter with a new one NOTE Prior to this inspection check that the fuel gauge is functioning properly When reading the meter indication wait at least for 20 sec onds after the resistor has been connected FUEL LEVELGAUGE INSPECTION For the inspection procedure 5 11 Resistor Meter indication Approx 95 Ω 1 Appr...

Page 321: ...ing 2 Install the headlight in the revers order of removal HEADLIGHT BEAM ADJUSUMENT Adjust the headlight beam both vertical and horizontal A Vertical adjuster using a screw driver B Horizontal adjuster using a screw driver If you touch the bulb with your bare hands clean the bulb with a cloth moistened with alcohol or soapy water to prevent premature bulb failure E 03 28 33 E 02 19 54 ...

Page 322: ...ACEMENT Remove the front leg shield 7 12 Remove the socket 1 Remove the bulb Install the turn signal light in the reverse order of removal If you touch the bulb with your bare hands clean the bulb with a cloth moistened with alcohol or soapy water to prevent premature bulb failure ...

Page 323: ...emove the bulb Install the turn signal light in the reverse order of removal BRAKE LIGHT TAILLIGHT REPLACEMENT Remove the lower frame cover 7 15 Remove the socket 1 Remove the bulb Install the brake light in the reverse order of removal If you touch the bulb with your bare hands clean the bulb with a cloth moistened with alcohol or soapy water to prevent premature bulb failure ...

Page 324: ...all the license light in the reverse order of removal SWITCHES IGNITION SWITCH REMOVAL AND REMOUNTING Remove the front box 7 14 Disconnect the coupler Loosen the nut 1 and torx bolt 2 09930 11930 Torx bit JT30H 09930 11940 Bit holder Remount the ignition switch in the reverse order of removal Bolt nut 10 N m 1 0 kgf m 7 0 lb ft ...

Page 325: ...H HORN BUTTON FRONT BRAKE SWITCH REAR BRAKE SWITCH BRAKE LOCK SWITCH HAZARD SWITCH Except for E 03 28 33 Position Color Position Color Position Color Position Color O R Y W Lg O R O B O W B B W Y G O W Y Lbl B B Bl B W B Bl B R B R B O G V Lbl Lg B G HI L LO PUSH PUSH Position Color PUSH Position Color PUSH OFF RUN R Position Color Position OFF ON Color Position OFF ON Color Position OFF ON Color ...

Page 326: ...te completely use the removed caps 3 as the sealed caps of battery filler holes Do not remove or pierce the sealed areas 4 of the electrolyte container Insert the nozzles of the electrolyte container 5 into the bat tery s electrolyte filler holes holding the container firmly so that it does not fall Take precaution not to allow any of the fluid to spill Make sure air bubbles 6 are coming up each e...

Page 327: ...RVICING Visually inspect the surface of the battery container If any signs of cracking or electrolyte leakage from the sides of the battery have occurred replace the battery with a new one If the battery terminals are found to be coated with rust or an acidic white powdery substance clean the battery terminals with sandpaper Never use anything except the specified battery Once install the caps to ...

Page 328: ...ill less than 12 5 V after recharging replace the battery with a new one When a battery is left unused for a long time its voltage needs to be regularly measured When the motorcycle is not used for more than one month especially during the winter season measure the battery voltage at least once a month BATTERY REMOVAL Open the front trunk Remove the battery cover 1 Disconnect the battery lead 2 fi...

Page 329: ...ROUTING 9 19 SPEEDOMETER CABLE ROUTING 9 20 SEAT LOCK CABLE ROUTING 9 21 REAR SHOCK ABSORBER HOSE ROUTING 9 22 FRONT BRAKE HOSE ROUTING 9 23 REAR BRAKE ROUTING 9 24 RADIATOR HOSE ROUTING 9 25 FUEL TANK FUEL TANK LOWER COVER MOUNTING 9 26 THROTTLE BODY INSTALLATION HOSE ROUTING 9 27 SIDE STAND SET UP 9 28 CENTER STAND SET UP 9 28 TIGHTENING TORQUE 9 29 ENGINE 9 29 FI SYSTEM AND INTAKE AIR SYSTEM 9 ...

Page 330: ...8 V Without the above range C21 is indicated Intake air temperature sensor wiring coupler connection C23 Tip over sensor The sensor voltage should be the following for more than 2 sec after ignition switch turns ON 0 4 V sensor voltage 4 6 V Without the above value C23 is indicated Tip over sensor wiring coupler connection C24 Ignition signal Crankshart position sensor pick up coil signal is produ...

Page 331: ...ing O2 feedback control O2 sensor voltage is higher than the specification or lower than the specification No signal is detected during engine operation or no electrical power is supplied from battery HO2S lead wire coupler connection Battery voltage supply to the HO2S ...

Page 332: ...ld 1 Clogged fuel filter or fuel hose 2 Defective fuel pump 3 Defective fuel pressure regulator 4 Defective fuel injector 5 Defective fuel pump relay 6 Defective ECM 7 Open circuited wiring connections Incorrect fuel air mixture 1 Throttle position sensor out of adjustment 2 Defective fuel pump 3 Defective fuel pressure regulator 4 Defective throttle position sensor 5 Defective crankshaft position...

Page 333: ...ve engine coolant temperature sensor 7 Defective thermostat 8 Defective intake air temperature sensor Fuel injector improperly operating 1 Defective fuel injector 2 No injection signal from ECM 3 Open or short circuited wiring connection 4 Defective battery or low battery voltage Control circuit or sensor improperly operating 1 Difective ECM 2 Defective fuel pressure regulator 3 Defective throttle...

Page 334: ...rom water pump 1 Too much play on water pump shaft bearing 2 Worn or damaged impeller shaft 3 Worn or damaged mechanical seal 4 Contact between water pump case and impeller Adjust Replace Replace Replace Replace Clean Replace Replace Replace Replace Repair or replace Replace Replace Replace bearing Replace Replace Replace Replace Replace Replace Replace Engine runs poorly in high speed range Defec...

Page 335: ...rnal electrical parts 1 Loss of valve clearance 2 Weakened valve springs 3 Valve timing out of adjustment 4 Worn piston rings or cylinder 5 Poor seating of valves 6 Fouled spark plug 7 Incorrect spark plug 8 Clogged injector 9 Throttle position sensor out of adjustment 10 Clogged air cleaner element 11 Sucking air from throttle valve or vacuum hose 12 Too much engine oil 13 Defective fuel pump or ...

Page 336: ...eplace Repair or replace Repair or replace Replace Replace Replace Dirty or heavy exhaust smoke 1 Too much engine oil in the engine 2 Worn piston rings or cylinder 3 Worn valve guides 4 Scored or scuffed cylinder walls 5 Worn valves stems 6 Defective stem seals 7 Worn oil ring side rails Check with inspection win dow Drain excess oil Replace Replace Replace Replace Replace Replace Slipping clutch ...

Page 337: ... Front suspension too soft 1 Weakened springs 2 Not enough fork oil 3 Wrong viscous fork oil Replace Replenish Replace Front suspension too stiff 1 Too viscous fork oil 2 Too much fork oil 3 Bent front axle Replace Drain excess oil Replace Noisy front suspen sion 1 Not enough fork oil 2 Loose bolts of suspension Replenish Retighten Wobbly rear wheel 1 Distorted wheel rim 2 Defective or incorrect t...

Page 338: ...luid 7 Clogged return port of master cylinder Repair surface with sand paper Correct pad fitting or replace Replace Tighten to specified torque Replace Replace brake fluid Disassemble and clean master cylinder Excessive brake lever stroke 1 Air in hydraulic system 2 Insufficient brake fluid 3 Improper quality of brake fluid Bleed air Replenish fluid to specified level bleed air Replace with correc...

Page 339: ...ort circuited lead wires or loose lead connections 2 Short circuited grounded or open generator coil 3 Short circuited or panctured regulator rectifier Repair or replace or retighten Replace Replace Generator does charge but charg ing rate is below the specification 1 Lead wires tend to get short or open circuited or loosely connected at terminals 2 Grounded or open circuited startor coil or gener...

Page 340: ...as a result of overcharging 3 Internal short circuit in the battery 4 Too low battery voltage 5 Too old battery Check the generator regu lator rectifier and circuit connections and make nec essary adjustments to obtain specified charging operation Replace the battery and correct the charging sys tem Replace the battery Recharge the battery fully Replace the battery Battery sulfation 1 Incorrect ch...

Page 341: ...1 Magnetic stand 09900 20803 09900 20806 Thickness gauge 09900 20805 Tire depth gauge 09900 21304 V block 100 mm 09900 22301 09900 22302 Plastigauge 09900 22403 Small bore gauge 18 35 mm 09900 25008 Multi circuit tester set 09900 26006 Tachometer 09910 32812 Crankshaft installer 09910 32870 Attachment 09910 60611 Universal clamp wrench 09913 50121 Oil seal remover 09913 70210 Bearing installer set...

Page 342: ... Solid pilot N 100 5 0 09916 24935 Valve seat cutter N 608 09916 34542 Valve guide reamer handle 09916 34550 Valve guide reamer 5 5 mm 09916 34580 Valve guide reamer 10 8 mm 09916 57330 Valve guide installer 09916 57340 Valve guide installer attachment 09916 84511 Tweezers 09917 14920 Valve clearance adjusting driver 09917 47011 Vacuum pump gauge 09920 13120 Crankcase crankshaft separator 09921 20...

Page 343: ...r remover 09930 40113 Rotor holder 09930 40130 Attachment 09930 82720 Mode select switch 09940 11420 Steering stem nut socket 09940 11430 Steering stem nut socket 09940 14911 Steering socket wrench 09940 30230 Hexagon socket 17 mm 09940 34520 T Handle 09940 34531 Attachment A 09940 40230 Fuel pressure gauge hose attachment 09940 52861 Front fork oil seal installer set 09940 92440 Wrench set 09941 ...

Page 344: ...9 16 SERVICING INFORMATION NOTE When ordering a special tool please confirm whether it is available or not 09943 74111 Front fork oil level gauge 09951 16080 Bearing installer ...

Page 345: ...P sensor Clamp Wiring herness IAC valve Brake hose PAIR control solenoid TP sensor Generator Battery terminal Battery terminal Battery terminal Clamp together at their marking Rear brake light Starter motor Starter motor Clamp Clamp Clamp Clamp Clamp Side stand switch Side stand switch Wiring harness Wiring harness Generator Clamp together at their marking Clamp provided on wiring harness Starter ...

Page 346: ...ler R Headlight Clamp Handlebar switch L Handlebar switch R Brake hose Throttle cable Handlebar switch R Handlebar switch L Clamp Speedometer coupler Fuse box Clamp Wiring harness Starter relay License light Clamp Accessories socket Fl control unit Brake lock Switch Route to inside of conduction hose Clamp together at their marking Engine ground Clamp ...

Page 347: ...ble with its white tape located below brake hose guide Handlebar switch L Clamp Handlebar switch R Route throttle cable in front of F R brake switch and right handlebar switch leads Brake lock lever assembly Brake lock cable Brake lock cable Throttle cable Route brake lock cable to inside of guide Clamp Brake lock cable Clamp approximate center of sponge protector of brake lock cable ...

Page 348: ...m 100mm 100mm 70mm Cut off at base No looseness of hose or cable exists in section below clamp Route meter cable between brake hoses Install so that loop faces rearward Clamp lead wire at white mark position White mark Clamp lead wire at white mark position No sagging should exist in this section ...

Page 349: ...SERVICING INFORMATION 9 21 SEAT LOCK CABLE ROUTING Seat lock cable Clamp Seat lock cable Clamp Clamp To ignition switch Route on outside of frame ...

Page 350: ...ER HOSE ROUTING Clamp Clamp Wiring harness Rear shock absorber adjuster hose Left Right Clamp Clamp the marking position Route rear shock absorber adjuster hose in front of trunk box Torsion of rear shock absorber adjuster hose must be within 180 ...

Page 351: ...ction Route in front of handlebar cover reinforcement Stopper should be contacted Route in front of rear brake hose Brake hose guide Hose cable and wiring harness are bound together Clamp Stopper should contact master cylinder Stopper should be contacted 3 5 m m Stopper should be contacted Clamp Install with white mark tacing forward Pass through guide Install with white mark facing forward Combin...

Page 352: ...VICING INFORMATION REAR BRAKE ROUTING Delay valve Rear brake pipe lever Rear brake caliper Clamp Fit rear brake hose E ring from above Brake lock cable Secure hose and cable so as not to contact with each other ...

Page 353: ...ellow Clamp from below Alignment mark White Direct pawl downward Clamp from left side Alignment mark White Clamp from right side Alignment mark Yellow Alignment mark White Alignment mark White Alignment mark Yellow Direct pawl downward Clamp from left side Route to inside of thorottle cable Do not pinch when installing front box Clamp from left side ...

Page 354: ...9 26 SERVICING INFORMATION FUEL TANK FUEL TANK LOWER COVER MOUNTING ...

Page 355: ...SERVICING INFORMATION 9 27 THROTTLE BODY INSTALLATION HOSE ROUTING ...

Page 356: ...9 28 SERVICING INFORMATION SIDE STAND SET UP CENTER STAND SET UP ...

Page 357: ...nut 160 16 0 115 5 Transmission cover bolt 22 2 2 16 0 Clutch housing nut 85 8 5 61 5 Clutch shoe nut 105 10 5 76 0 Fixed drive face nut 105 10 5 76 0 Clutch inner cover bolt 11 1 1 8 0 Generator cover bolt 11 1 1 8 0 Water pump bolt 10 1 0 7 0 Oil filter cap bolt 10 1 0 7 0 Cylinder head bolt Tighten lightly 25 2 5 18 0 Tighten firmly 41 4 1 29 5 Cylinder head nut M8 25 2 5 18 0 Cylinder head nut...

Page 358: ...0 Cooling fan thermo switch 18 1 8 13 0 Water temperature sensor 12 1 2 8 5 Thermostat case bolt 10 1 0 7 0 Water pump case bolt 10 1 0 7 0 Starter moter housing bolt 3 7 0 37 2 7 Starter moter mounting bolt 7 0 7 5 0 ITEM N m kgf m lb ft Fuel cut valve bolt 3 5 0 35 2 5 Fuel pump mounting bolt 4 5 0 45 3 3 Fuel tank bolt 10 1 0 7 0 TPS screw 3 5 0 35 2 5 IAT sensor 3 0 3 2 0 ...

Page 359: ...2 5 Steering stem nut 30 3 0 21 5 Lock nut 30 3 0 21 5 Handlebar holder set bolt 23 2 3 16 5 Handlebar holder clamp bolt 55 5 5 40 0 Rear wheel nut 50 5 0 36 0 Caliper mounting bolt 25 2 5 18 0 Pad pin 18 1 8 13 0 Brake lock housing bolt 23 2 3 16 5 Union bolt 23 2 3 16 5 Master cylinder bolt 10 1 0 7 0 Delay valve mounting bolt 10 1 0 7 0 Brake pipe joint bolt 16 1 6 11 5 Crank case bracket nut 8...

Page 360: ...l or 4 marked bolt 7 marked 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 14 65 6 5 47 0 135 13 5 97 5 16 105 10 5 76 0 210 21 0 152 0 18 160 16 0 115 5 240 24 0 173 5 4 marked bolt Conventional bolt 7 marked bolt ...

Page 361: ...SERVICING INFORMATION 9 33 WIRING DIAGRAM E 02 19 54 ...

Page 362: ...9 34 SERVICING INFORMATION E 03 28 33 ...

Page 363: ...022 Valve guide I D IN EX 5 000 5 012 0 1969 0 1973 Valve stem O D IN 4 975 4 990 0 1959 0 1965 EX 4 955 4 970 0 1951 0 1957 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 stem end length IN EX 1 7 0 07 Valve seat width IN EX 0 9 1 1 0 035 0 043 Valve head radial runout IN EX 0 03 0 001 Valve spring free length IN EX 38 8 1 53 Va...

Page 364: ...32 0 066 0 001 0 003 0 15 0 006 17 5 0 028 0 059 0 001 0 002 0 15 0 006 Camshaft journal holder I D 22 22 012 22 025 0 8666 0 8671 17 5 17 512 17 525 0 689 0 690 Camshaft journal O D 22 21 959 21 980 0 8645 0 8654 17 5 17 466 17 484 0 6876 0 6883 Camshaft runout 0 10 0 004 Rocker arm shaft I D IN EX 12 000 12 018 0 472 0 473 Rocker arm shaft O D IN EX 11 973 11 984 0 471 0 472 Cylinder head distor...

Page 365: ...880 3 263 Cylinder distortion 0 05 0 002 Piston ring free end gap 1st R Approx 11 3 0 44 9 0 0 35 2nd R Approx 7 7 0 30 6 2 0 24 Piston ring end gap 1st 0 20 0 35 0 008 0 014 0 70 0 03 2nd 0 35 0 50 0 014 0 020 1 0 0 04 Piston ring to groove clearance 1st 0 18 0 007 2nd 0 15 0 006 Piston ring groove width 1st 1 01 1 03 0 0398 0 0406 2nd 1 01 1 03 0 0398 0 0406 Oil 2 01 2 03 0 0791 0 0799 Piston ri...

Page 366: ...0 030 1 0 0 04 Conrod big end width 21 95 22 00 0 864 0 866 Width between crankshaft webs 59 9 60 1 2 358 2 366 Crankshaft runout 0 08 0 003 ITEM STANDARD LIMIT Oil pressure at 60 C 140 F Above 80 kPa 0 8 kgf cm 11 psi Below160 kPa 1 6 kgf cm 23 psi at 3 000 r min ITEM STANDARD LIMIT Clutch wheel I D 150 0 150 2 5 906 5 913 150 5 5 925 Clutch shoe thickness 3 0 0 12 2 0 0 08 Engagement r min 2 300...

Page 367: ...on ratio 2 785 Drive V belt width 21 85 0 86 20 85 0 82 Movable driven face spring free length 125 4 92 118 7 4 67 Movable drive face roller O D 23 72 23 88 0 93 0 94 Drive Driven face wear 0 4 0 02 ITEM SPECIFICATION NOTE Injector resistance 10 18 Ω at 20 C 68 F Fuel pump discharge amount 35 ml and more For 10 sec at 300 kPa 3 0 kgf cm 43 psi Fuel pressure regulator operating set pressure Approx ...

Page 368: ... Opened Approx 3 8 V ECT sensor input voltage 4 5 5 5 V ECT sensor resistance Approx 1 14 kΩ at 40 C 104 F IAT sensor input voltage 4 5 5 5 V IAT sensor resistance Approx 1 14 kΩ at 40 C 104 F TO sensor resistance 19 1 19 7 kΩ TO sensor output voltage Normal 1 3 V and less Leaning 3 8 V and more Injector voltage Battery voltage Ignition coil primary peak voltage 150 V and more when cranking W Grou...

Page 369: ...1 5 Thermostat valve lift Over3 0 mm at 95 C 203 F Engine coolant temperature sensor resistance 20 C 68 F Approx 2 58 kΩ 40 C 104 F Approx 1 14 kΩ 80 C 176 F Approx 0 28 kΩ 100 C 212 F Approx 0 16 kΩ Radiator cap valve opening pressure 107 9 137 3 kPa 1 1 1 4 kgf cm 16 20 psi Cooling fan thermo switch operating temperature ON 93 103 C 199 217 F OFF 87 97 C 189 207 F Engine coolant type Use an anti...

Page 370: ...nce Primary 3 5 Ω Secondary 17 30 kΩ Ignition coil primary peak voltage 150 and more W Ground Generator coil resistance Charging 0 2 0 6 Ω Y Y Generator no load voltage When cold 55 V and more at 5 000 r min Generator Max output Approx 375 W at 5 000 r min Regulated voltage 14 0 15 5 V at 5 000 r min Starter relay resistance 3 6 Ω Battery Type designation FT12A BS Capasity 12 V36 kC 10 Ah 10 HR Fu...

Page 371: ...I 35 2 LO 35 2 Parking or position light 5 2 Brake light Taillight 21 5 2 Turn signal light 21 4 License light 5 Instrument panel light 1 7 3 Oil change indicator light 1 7 FI indicator light 1 7 Brake lock indicator light 1 7 High beam indicator light 1 7 Turn signal indicator light 1 7 2 Trunk light 5 ...

Page 372: ...er cylinder piston diameter Front 10 957 10 984 0 431 0 432 Rear 13 957 13 984 0 549 0 551 Brake caliper cylinder bore Front 33 960 34 010 22 650 22 700 1 337 1 339 0 892 0 894 Rear 25 400 25 450 1 000 1 002 Brake caliper piston diameter Front 33 878 33 928 22 568 22 618 1 334 1 336 0 889 0 890 Rear 25 318 25 368 0 997 0 999 Wheel rim runout Axial 2 0 0 08 Radial 2 0 0 08 Wheel axle runout Front 0...

Page 373: ...75 kPa 1 75 kgf cm 25 psi Rear 225 kPa 2 25 kgf cm 32 psi Tire size Front 110 90 13 M C 55 P Rear 130 70 13 M C 63 P Tire type Front BRIDGESTONE HOOP B03G Rear BRIDGESTONE HOOP B02G Tire tread depth Recommended depth Front 1 6 mm 0 06 in Rear 2 0 mm 0 08 in ITEM SPECIFICATION NOTE Fuel type Gasoline used should be graded 91 octane or higher An unleaded gasoline is recommended Fuel tank capacity In...

Page 374: ... SYSTEM 10 2 CRANKCASE EMISSION CONTROL SYSTEM 10 3 EXHAUST EMISSION CONTROL SYSTEM PAIR SYSTEM 10 4 NOISE EMISSION CONTROL SYSTEM 10 5 PAIR AIR SUPPLY SYSTEM INSPECTION 10 6 HOSE 10 6 PAIR REED VALVE 10 6 PAIR CONTROL SOLENOID VALVE 10 6 PAIR AIR SUPPLY SYSTEM HOSE ROUTING 10 8 HEATED OXGEN SENSOR HO2S INSPECTION 10 9 ...

Page 375: ...for emission level control This fuel injection system is precision designed manufactured and adjusted to comply with the applicable emission limits Fuel mesh filter For low pressure Fuel pump Fuel filter For high pressure Fuel pressure regulator Fuel feed hose Fuel injector Throttle body PRESSURIZED FUEL BEFORE PRESSURIZED FUEL RELIEVED FUEL ...

Page 376: ... with a PCV system Blow by gas in the engine is constantly drawn into the crank case which is returned to the combustion chamber through the PCV breather hose air cleaner and throttle body PAIR control solenoid valve PAIR reed valve PCV hose FRESH AIR FUEL AIR MIXTURE EXHAUST GAS BLOW BY GAS ...

Page 377: ...ST sys tem The fresh air is drawn into the exhaust port with the PAIR solenoid valve and PAIR reed valve The PAIR solenoid valve is operated by the ECM and the fresh air flow is controlled according to the TPS ECTS IATS IAPS and CKPS PAIR control solenoid valve PAIR reed valve HO2 sensor Except for E 28 FRESH AIR FUEL AIR MIXTURE EXHAUST GAS ECM Three way catalyst ...

Page 378: ...is in use or 2 The use of the vehicle after such device or element of design has been removed or rendered inoperative by any person AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW Removing or puncturing the muffler baffles header pipes screen type spark arrester if equipped or any other component which conducts exhaust gases Removing or puncturing the air cleaner case a...

Page 379: ...Remove the PAIR reed valve cover 1 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 PAIR CONTROL SOLENOID VALVE Remove the trunk box 7 18 Remove the air cleaner box 3 4 Disconnect the PAIR control solenoid valve coupler 1 Disconnect the PAIR hose 2 Remove the PAI...

Page 380: ...f 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 Ω Ω Ω Ω at 20 C 68 F 09900 25008 Multi circuit tester set Tester knob indication Resistance Ω Ω Ω Ω If the resistance is not within the standard range replace the PAIR control solenoid valve with a new one Installation is in the reverse ...

Page 381: ...10 8 EMISSION CONTROL INFORMATION PAIR AIR SUPPLY SYSTEM HOSE ROUTING PAIR reed valve PAIR control solenoid valve Clamp the IAT sensor lead wire Matching mark Yellow Matching mark White ...

Page 382: ...e standard range replace the HO2 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 in the reverse order of removal Tighten the sensor unit to the specified torque HO2 SENSOR 47 5 N m 4 75 kgf m 34 3 lb ft Route the HO2 sensor lead wire into the fram...

Page 383: ...Prepared by November 2002 Part No 99500 34080 01E Printed in Japan 390 ...

Page 384: ...Printed in Japan K3 ...

Search results

Summary of Contents for AN400 2003

Reviews:

Suzuki AN400 2003, Service Manual, Page: 1 / 384

Search results

Summary of Contents for AN400 2003

Reviews: