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Suzuki AN650 2002, Service Manual

The Suzuki AN650 2002 Service Manual is essential for owners of this renowned scooter model. This comprehensive manual provides detailed instructions on maintenance, repairs, and troubleshooting, ensuring optimum performance. Download and access it for free at manualshive.com, your go-to source for user manuals.

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PERIODIC MAINTENANCE     2-11

(INTAKE SIDE)

MEASURED 

T

APPET 

CLEARANCE 

(mm)

SUFFIX

NO

.

120

125

130

135

140

145

150

155

160

165

170

175

180

185

190

195

200

205

210

215

220

PRESENT

SHIM SIZE

(mm)

1.20

1.25

1.30

1.35

1.40

1.45

1.50

1.55

1.60

1.65

1.70

1.75

1.80

1.85

1.90

1.95

2.00

2.05

2.10

2.15

2.20

0.00-0.04

1.20

1.25

1.30

1.35

1.40

1.45

1.50

1.55

1.60

1.65

1.70

1.75

1.80

1.85

1.90

1.95

2.00

2.05

2.10

0.05-0.09

1.20

1.25

1.30

1.35

1.40

1.45

1.50

1.55

1.60

1.65

1.70

1.75

1.80

1.85

1.90

1.95

2.00

2.05

2.10

2.15

0.10-0.20

SPECIFIED CLEARANCE/NO ADJUSTMENT REQ

UIRED

0.21-0.25

1.30

1.35

1.40

1.45

1.50

1.55

1.60

1.65

1.70

1.75

1.80

1.85

1.90

1.95

2.00

2.05

2.10

2.15

2.20

2.20

0.26-0.30

1.35

1.40

1.45

1.50

1.55

1.60

1.65

1.70

1.75

1.80

1.85

1.90

1.95

2.00

2.05

2.10

2.15

2.20

0.31-0.35

1.40

1.45

1.50

1.55

1.60

1.65

1.70

1.75

1.80

1.85

1.90

1.95

2.00

2.05

2.10

2.15

2.20

0.36-0.40

1.45

1.50

1.55

1.60

1.65

1.70

1.75

1.80

1.85

1.90

1.95

2.00

2.05

2.10

2.15

2.20

0.41-0.45

1.50

1.55

1.60

1.65

1.70

1.75

1.80

1.85

1.90

1.95

2.00

2.05

2.10

2.15

2.20

0.46-0.50

1.55

1.60

1.65

1.70

1.75

1.80

1.85

1.90

1.95

2.00

2.05

2.10

2.15

2.20

0.51-0.55

1.60

1.65

1.70

1.75

1.80

1.85

1.90

1.95

2.00

2.05

2.10

2.15

2.20

0.56-0.60

1.65

1.70

1.75

1.80

1.85

1.90

1.95

2.00

2.05

2.10

2.15

2.20

0.61-0.65

1.70

1.75

1.80

1.85

1.90

1.95

2.00

2.05

2.10

2.15

2.20

0.66-0.70

1.75

1.80

1.85

1.90

1.95

2.00

2.05

2.10

2.15

2.20

0.71-0.75

1.80

1.85

1.90

1.95

2.00

2.05

2.10

2.15

2.20

0.76-0.80

1.85

1.90

1.95

2.00

2.05

2.10

2.15

2.20

0.81-0.85

1.90

1.95

2.00

2.05

2.10

2.15

2.20

0.86-0.90

1.95

2.00

2.05

2.10

2.15

2.20

0.91-0.95

2.00

2.05

2.10

2.15

2.20

0.96-1.00

2.05

2.10

2.15

2.20

1.01-1.05

2.10

2.15

2.20

1.06-1.10

2.15

2.20

1.11-1.15

2.20

T

A

PPET SHIM SET (12800-05820)

HO

W T

O

 USE THIS 

CHAR

T

:

I.

Measure tappet clear

ance

. 

“ENGINE IS COLD”

II.

Measure present shim siz

e

.

III.

Match clear

ance in v

e

rtical column with present shim siz

e

in hor

iz

ontal column.

EXAMPLE

 

T

appet clear

ance is

0.23 mm

 

Present shim siz

e

1.70 mm

 

Shim siz

e to be used

1.80 mm

T

APPET SHIM SELECTION 

T

ABLE [INT

AKE]

T

APPET SHIM NO

. (12892-05C00-XXX)

Summary of Contents for AN650 2002

Page 1: ......

Page 2: ...ycle bet ter so that you can assure your customers of fast and reliable service 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 proc...

Page 3: ...n 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 1Brake disc 2Coller 3Dust seal 4Bearing 5Front tire 6Front wheel 7Spacer ...

Page 4: ...denum oil solution Mixture of engine oil and SUZUKl MOLY PASTE in a ratio of 1 1 Apply or use brake fluid Apply SUZUKI SUPER GREASE A 99000 25010 Measure in voltage range Apply SUZUKI MOLY PASTE 99000 25140 Measure in current range Apply SUZUKI BOND 1207B 99104 31140 USA Measure in resistance range Apply SUZUKI BOND 1215 99000 31110 Except USA Measure in diode test range Apply SUZUKI BOND 1216B 99...

Page 5: ...Control Unit D DC Direct Current DMC Dealer Mode Coupler DOHC Double Over Head Camshaft DRL Daytime Running Light E ECM Engine Control Module Engine Control Unit ECU FI Control Unit ECT Sensor Engine 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 Re...

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: ...Blue tracer R W Red with White tracer W B White with Black tracer W G White with Green tracer W Y White with Yellow tracer Y Bl Yellow with Blue tracer Y R Yellow with Red tracer B Br Black with Brown tracer B O Black with Orange tracer B W Black with White tracer Bl B Blue with Black tracer Bl R Blue with Red tracer Bl Y Blue with Yellow tracer Br W Brown with White tracer G Bl Green with Blue tr...

Page 8: ...NADA 1 4 FUEL FOR OTHER COUNTRIES 1 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 lN PROCEDURES 1 7 CYLINDER IDENTIFICATION 1 7 INFORMATION LABELS 1 8 SPECIFICATIONS 1 9 C...

Page 9: ...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 10: ... 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 11: ...uired 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 perm...

Page 12: ...tion 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...

Page 13: ...er to cooling system section page 8 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 14: ...rcised during its early life The general rules are as follows Keep to these break in engine speed limits Initial 800 km 500 miles Below 4 000 r min Up to 1 600 km 1 000 miles Below 6 000 r min Over 1 600 km 1 000 miles Below 8 500 r min Upon reaching an odometer reading of 1 600 km 1 000 miles you can subject the motorcycle to full throt tle operation However do not exceed 8 500 r min at any time ...

Page 15: ... label 2 Engine starting label 3 Screen warning label 4 Tire pressure label 5 Fuel caution label For E 02 24 6 Fuel information label 7 Front box loading capacity label 8 Trunk box loading capacity label 9 ID label For E 02 19 24 0 Noise label For E 24 A ICES CANADA label For E 28 B Information label For E 28 C Oil information label D Safety plate A ...

Page 16: ... element Starter system Electric starter Lubrication system Wet sump DRIVE TRAIN Clutch Wet multi plate automatic centrifugal type Gearshift pattern Automatic Manual shift Automatic transmission ratio Variable change 1 800 0 465 Final reduction ratio 1 580 32 31 31 32 34 31 49 34 Drive system Gear drive CHASSIS Front suspension Telescopic coil spring oil damped Rear suspension Swingarm type coil s...

Page 17: ...ght 12 V 1 4 W Turn signal indicator light 12 V 1 4 W Brake lock indicator light 12 V 1 4 W Fuel injector indicator light 12 V 1 4 W Engine coolant temperature indicator light 12 V 1 4 W Oil pressure indicator light 12 V 1 4 W Gear position indicator light 12 V 1 4 W 5 CAPACITIES Fuel tank including reserve 15 0 L 4 0 3 3 US Imp gal Engine oil oil change 2 600 ml 2 7 2 3 US Imp qt with filter chan...

Page 18: ...ON 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 24 E 28 E 33 U K U S A Except for California EU Australia Canada California U S A ...

Page 19: ...R 2 16 ENGINE IDLE SPEED 2 18 THROTTLE CABLE PLAY 2 18 THROTTLE VALVE SYNCHRONIZATION 2 19 PAIR AIR SUPPLY SYSTEM 2 19 COOLING SYSTEM 2 20 BRAKE 2 22 TIRE 2 25 STEERING 2 26 FRONT FORK 2 26 REAR SUSPENSION 2 27 EXHAUST PIPE BOLT AND MUFFLER MOUNTING BOLT 2 27 CHASSIS BOLT AND NUT 2 28 COMPRESSION PRESSURE CHECK 2 30 COMPRESSION TEST PROCEDURE 2 30 OIL PRESSURE CHECK 2 31 OIL PRESSURE TEST PROCEDUR...

Page 20: ... 4 000 7 500 11 000 14 500 months 1 6 12 18 24 Air cleaner I I R I Exhaust pipe bolts and muffler bolts T T T Tappet clearance I Spark plugs I R I R Fuel hose I I I I Replace every 4 years Engine oil R R R R R Engine oil filter R R Transmission oil R I R I R Final gear oil R R R CVT filter I I Idle speed I I I I I Throttle cable play I I I I I Throttle valve synchronization I I I E 33 only Evapora...

Page 21: ...ow 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 vRear brake lever holder vSide stand pivot and spring hook oThrottle cable vCenter stand pivot and spring hook vFront brake lever holder ...

Page 22: ...s AIR CLEANER Open the front box 1 Remove the air cleaner box lid 2 Remove the air cleaner element lid 3 Remove the air cleaner element 4 Inspect the air cleaner element and O ring for damage If any defects are found the air cleaner element and O ring must be replaced Inspect every 6 000 km 4 000 miles 6 months and replace every 18 000 km 11 000 miles 18 months ...

Page 23: ...ure on the throttle body side of the air cleaner element If air pressure is used on the other side dirt will be forced into the pores of the air cleaner element thus restricting air flow through the air cleaner element If driving under dusty condition clean the air cleaner element more frequently The surest way to accelerate engine wear is to use the engine without the element or to use a ruptured...

Page 24: ...oil plug caps 2 Remove the spark plugs with the spark plug wrench HEAT RANGE Check to see the heat range of the plug Inspect every 6 000 km 4 000 miles 6 months and replace every 12 000 km 7 500 miles 12 months The hot radiator and the hot engine can burn you Wait until the radiator and the engine are cool enough to touch Standard Cold type Hot type NGK CR8E CR9E CR7E DENSO U24ESR N U27ESR N U22ES...

Page 25: ...en insulator damaged thread SPARK PLUG INSTALLATION Install the spark plugs to the cylinder heads by finger tight and then tighten them to the specified torque Spark plug 11 N m 1 1 kgf m 8 0 lb ft TAPPET CLEARANCE Remove the front box 9 18 Remove the foot board 9 18 Remove the radiator 8 6 Remove the spark plugs 2 6 Remove the cylinder head cover 1 Confirm the thread size and reach when replacing...

Page 26: ... IN 0 10 0 20 mm 0 004 0 008 in EX 0 20 0 30 mm 0 008 0 012 in NOTE The clearance specification is for COLD state To turn the crankshaft for clearance checking be sure to use a wrench and rotate in the normal running direction All spark plugs should be removed Remove the valve timing inspection cap 2 Turn the crankshaft to bring the Top line on the starter clutch to the index mark and also to alig...

Page 27: ... ADJUSTMENT The clearance is adjusted by replacing the existing tappet shim by a thicker or thinner shim Remove the intake or exhaust camshafts 3 12 Remove the tappet 1 and shim 2 by fingers or magnetic hand Check the figures printed on the shim These figures indicate the thickness of the shim as illustrated Select a replacement shim that will provide a clearance within the specified range For the...

Page 28: ...the tappet is depressed fully This will squeeze out oil trapped between the shim and the tappet that could cause an incorrect measurement then check the clearance again to confirm that it is within the specified range After finishing the valve clearance adjustment reinstall the fol lowing items Page Cylinder head cover 3 74 Spark plug and plug cap 2 6 Valve timing inspection plug 2 8 Reinstall the...

Page 29: ... 2 05 2 10 2 15 2 20 0 41 0 45 1 50 1 55 1 60 1 65 1 70 1 75 1 80 1 85 1 90 1 95 2 00 2 05 2 10 2 15 2 20 0 46 0 50 1 55 1 60 1 65 1 70 1 75 1 80 1 85 1 90 1 95 2 00 2 05 2 10 2 15 2 20 0 51 0 55 1 60 1 65 1 70 1 75 1 80 1 85 1 90 1 95 2 00 2 05 2 10 2 15 2 20 0 56 0 60 1 65 1 70 1 75 1 80 1 85 1 90 1 95 2 00 2 05 2 10 2 15 2 20 0 61 0 65 1 70 1 75 1 80 1 85 1 90 1 95 2 00 2 05 2 10 2 15 2 20 0 66...

Page 30: ... 2 00 2 05 2 10 2 15 2 20 0 46 0 50 1 55 1 60 1 65 1 70 1 75 1 80 1 85 1 90 1 95 2 00 2 05 2 10 2 15 2 20 0 51 0 55 1 60 1 65 1 70 1 75 1 80 1 85 1 90 1 95 2 00 2 05 2 10 2 15 2 20 0 56 0 60 1 65 1 70 1 75 1 80 1 85 1 90 1 95 2 00 2 05 2 10 2 15 2 20 0 61 0 65 1 70 1 75 1 80 1 85 1 90 1 95 2 00 2 05 2 10 2 15 2 20 0 66 0 70 1 75 1 80 1 85 1 90 1 95 2 00 2 05 2 10 2 15 2 20 0 71 0 75 1 80 1 85 1 90...

Page 31: ... oil pan below the engine and drain oil by removing the drain plug 1 and filler cap 2 Tighten the drain plug 1 to the specified torque and pour fresh oil through the oil filler The engine will hold about 2 6 L 2 7 2 3 US Imp qt of oil Use an API classification of SF or SG oil with SAE 10W 40 viscosity Oil drain plug 23 N m 2 3 kgf m 16 5 lb ft Inspect every 6 000 km 4 000 miles 6 months Replace ev...

Page 32: ...at the fil ter gasket contacts the mounting surface Then tighten it 2 turns using the oil filter wrench 09915 40610 Oil filter wrench NOTE To properly tighten the filter use the special tool Never tighten the filter by hand Pour fresh engine oil and check the oil level in the same man ner of engine oil replacement procedure Engine oil capacity Oil change 2 6 L 2 7 2 3 US Imp qt Filter change 2 9 L...

Page 33: ...level plug 3 and filler plug 2 to the specified torque Oil level plug 12 N m 1 2 kgf m 8 5 lb ft Drain plug 12 N m 1 2 kgf m 8 5 lb ft Oil filler plug 12 N m 1 2 kgf m 8 5 lb ft NECESSARY AMOUNT OF TRANSMISSION OIL Oil change 360 ml 12 2 12 7 US lmp oz Overhaul 400 ml 13 5 14 1 US lmp oz FINAL GEAR OIL FINAL GEAR OIL REPLACEMENT Keep the motorcycle upright with the center stand Remove the final ge...

Page 34: ...t Tighten the oil level plug 3 to the specified torque Oil level plug 33 N m 3 3 kgf m 24 0 lb ft P Oil viscosity and classification Hypoid gear oil SAE 90 API grade GL 5 NECESSARY AMOUNT OF FINAL GEAR OIL Oil change 300 ml 10 1 10 6 US lmp oz Overhaul 430 ml 14 5 15 1 US lmp oz CVT FILTER Remove the leg side cover 9 12 Remove the CVT filter lid 1 hooked part Remove the CVT filter cover 2 Remove t...

Page 35: ...PERIODIC MAINTENANCE 2 17 Inspect the CVT filter for damage and dirt If any defects are found the CVT filter must be replaced ...

Page 36: ...play A should be 2 0 4 0 mm 0 08 0 16 in at the throttle grip Tighten the locknut 5 while holding the adjuster 6 Third step While holding the throttle grip at the fully closed position slowly turn out the adjuster 4 of the throttle returning cable 1 to feel resistance Tighten the locknut 3 while holding the adjuster 4 Throttle cable play A 2 0 4 0 mm 0 08 0 16 in NOTE Major adjustment can be made ...

Page 37: ... 0 08 0 16 in While holding the throttle grip at the fully closed position slowly turn the returning cable adjuster 3 to obtain a slack B of 1 0 mm 0 04 in Tighten the locknut 1 securely THROTTLE VALVE SYNCHRONIZATION Inspect the throttle valve synchronization periodically 7 24 PAIR AIR SUPPLY SYSTEM Inspect the PAIR air supply system periodically 12 6 After the adjustment is completed check that ...

Page 38: ...ve the maintenance lid 9 13 ENGINE COOLANT CHANGE Remove the lower leg shield 9 10 Remove the radiator cap 1 Drain engine coolant by removing the drain bolt A Inspect every 6 000 km 4 000 miles 6 months Replace engine coolant every 2 years Do not open the radiator cap when the engine is hot as you may be injured by escaping hot liquid or vapor Engine coolant may be harmful if swallowed or if it co...

Page 39: ...let Support the motorcycle upright with the center stand Slowly swing the motorcycle right and left to bleed the air trapped Add engine coolant up to the radiator inlet Start the engine and bleed air from the radiator inlet com pletely Add engine coolant up to the radiator inlet Repeat the above procedure until bleed no air from the radia tor inlet Close the radiator cap 1 securely After warming u...

Page 40: ...e brake fluid level by observing the lower limit lines on the front and rear brake fluid reservoirs When the level is below the lower limit line replenish with brake fluid that meets the following specification N Specification and Classification DOT 4 BRAKE Inspect initially at 1 000 km 600 miles 1 month and every 6 000 km 4 000 miles 6 months thereafter BRAKE HOSE AND BRAKE FLUID Inspect every 6 ...

Page 41: ... 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 Never re use brake fluid left over from the last servicing or stored for a long period Brake fluid if it leaks will interfere with safe running and immediately discolor painted surfaces Check the brake hoses and hose joints for cracks and fluid leak age bef...

Page 42: ...ee 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 it a quarter of a turn so that the brake fluid runs into the receptacle this will remove the tension of the ...

Page 43: ...essively worn tires will decrease riding stability and consequently invite a dangerous situation It is highly recommended to replace a tire when the remaining depth of tire tread reaches the following specification 09900 20805 Tire depth gauge Tire tread depth Service Limit FRONT 1 6 mm 0 06 in REAR 2 0 mm 0 08 in Inspect every 6 000 km 4 000 miles 6 months ...

Page 44: ...that the front wheel is off the ground with the wheel straight ahead and pull forward If play is found perform steering bearing adjustment as described in page 9 46 of this manual FRONT FORK Inspect the front forks for oil leakage scoring or scratches on the outer surface of the inner tubes Replace any defective parts if necessary 9 32 COLD INFLATION TIRE PRESSURE SOLO RINDING DUAL RIDING kPa kgf ...

Page 45: ...EXHAUST PIPE BOLT AND MUFFLER MOUNTING BOLT Tighten the exhaust pipe bolts muffler mounting bolts and nut to the specified torque Muffler mounting bolt nut A 23 N m 2 3 kgf m 16 5 lb ft Exhaust pipe bolt B 23 N m 2 3 kgf m 16 5 lb ft Inspect every 12 000 km 7 500 miles 12 months Tighten initially at 1 000 km 600 miles 1 month and every 12 000 km 7 500 miles 12 months thereafter ...

Page 46: ...wer clamp bolt 23 2 3 16 5 4 Front axle 65 6 5 47 0 5 Front axle pinch bolt 23 2 3 16 5 6 Handlebar clamp bolt 23 2 3 16 5 7 Front brake master cylinder mounting bolt 10 1 0 7 0 8 Front brake caliper mounting bolt 26 2 6 19 0 9 Brake hose union bolt 23 2 3 16 5 0 Air bleeder valve 7 5 0 75 5 5 A Brake disc bolt Front Rear 23 2 3 16 5 B Rear brake caliper mounting bolt 26 2 6 19 0 C Rear brake mast...

Page 47: ...PERIODIC MAINTENANCE 2 29 ...

Page 48: ... 213 psi even when they measure more than 1 200 kPa 12 kgf cm 171 psi COMPRESSION TEST PROCEDURE NOTE Before testing the engine for compression pressure make sure that the cylinder head bolts are tightened to the specified torque values and valves are properly adjusted Have the engine warmed up by idling before testing Be sure that the battery used is in fully charged condition Remove the parts co...

Page 49: ... check if the oil pressure indicator light is turned on If it keeps on lighting check the oil pressure indicator light circuit If it is in good condition check the oil pressure in the following manner Remove the main oil gallery plug 1 Install the oil pressure gauge with attachment in the position shown in the figure Warm up the engine as follows Summer 10 min at 2 000 r min Winter 20 min at 2 000...

Page 50: ...he engine to normal operating temperature Start the engine 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 1 500 2 100 r min 2 CLUTCH LOCK UP INSPECTION Perform this inspection to determine if the clutch is engaging fully and not slipping Start the en...

Page 51: ...AKE LOCK INSPECTION Inspect that the rear wheel is locked up when pulling the brake lock lever 4 to 6 notches and moving the motorcycle for ward to make sure that the brake lock acts enough Adjust the brake lock if necessary 9 85 ...

Page 52: ... SERVICE 3 22 CYLINDER HEAD COVER 3 22 CAMSHAFT 3 23 CAM CHAIN TENSION ADJUSTER 3 25 CAM CHAIN TENSIONER 3 25 CAM CHAIN GUIDE 3 25 CYLINDER HEAD 3 26 CYLINDER 3 34 PISTON AND PISTON RING 3 36 CLUTCH 3 38 STARTER CLUTCH 3 43 STARTER TORQUE LIMITER 3 44 OIL PUMP 3 44 OIL PRESSURE REGULATOR OIL SUMP FILTER 3 44 CRANK BALANCER 3 45 DRIVESHAFT 3 45 CONROD CRANKSHAFT 3 47 OIL JET 3 55 CRANKCASE 3 56 ENG...

Page 53: ...t 3 12 3 23 3 72 Starter motor 3 12 10 13 3 75 Cam chain tensioner adjuster 3 13 3 25 3 71 Cylinder head 3 13 3 26 3 71 Cylinder 3 13 3 34 3 70 Oil level switch 3 12 10 29 3 75 Piston 3 14 3 36 3 70 Oil filter Oil cooler 3 17 3 63 Cam position sensor 3 22 6 27 3 23 Engine coolant temperature switch 8 12 8 13 8 13 RIGHT OF ENGINE Starter clutch 3 16 3 43 3 64 Starter torque limiter 3 16 3 44 3 64 T...

Page 54: ...CVT unit EXTERNAL PARTS Remove the following parts 9 6 Lower leg shield Front leg shield cover Leg shield Front box Maintenance lid Lower frame cover Center frame cover Pil ion rider handle Trunk box cover Frame cover Foot board Trunk box Rear fender Leg side cover Remove the final gear case cover 10 48 Disconnect the battery terminals 10 3 Disconnect the joint hose 1 and breather hose 2 Remove th...

Page 55: ... hose 4 Loosen the throttle body clamp screws Remove the PAIR solenoid valve 5 Remove the air chamber 6 Disconnect the throttle cables 7 Disconnect the injector couplers 8 Disconnect the TP sensor coupler 9 and IAC valve coupler 0 Loosen the throttle body clamp screws Disconnect the fuel delivery hose Remove the throttle body ass y ...

Page 56: ...onnect the PAIR hose 1 and crankcase breather hose 2 Disconnect the engine coolant breather hose 3 and radiator hose 4 Disconnect the radiator inlet hose Disconnect the cooling fan switch coupler 5 Remove the radiator ...

Page 57: ...olution sensor lead wire coupler 4 and HO2 sensor lead wire coupler 5 Disconnect the starter motor lead wire Disconnect the ECT sensor coupler 6 Disconnect the side stand switch lead wire coupler 7 oil pressure switch lead wire coupler 8 oil level switch lead wire 9 CKP sensor coupler 0 and trunk light seat switch lead coupler A Disconnect the CMP sensor coupler B Remove the ignition coil spark pl...

Page 58: ...onnect the HO2 sensor coupler 2 Remove the muffler Remove the brake lock cable clamp Remove the rear brake hose clamp Remove the rear brake caliper bolts and remove the rear brake caliper 3 Remove the both sides of the rear shock absorber lower bolts 4 ...

Page 59: ...move the clamps Move the fuel feed hose not to interfere with the work Support the engine using an engine jack Remove the engine mounting bolts and nuts Remove the foot board bracket Remove the engine from the frame ...

Page 60: ...ENGINE 3 9 Remove the CVT assembly 5 2 Remove the swingarm 9 59 Remove the final gear case assembly 4 3 Remove the center stand Be careful not to allow the engine main body to fall down ...

Page 61: ...it 5 4 Installation of rear brake caliper 9 81 Pass through the engine mounting bolts from the right side of the frame Tighten the engine mounting nuts to the specified torque The engine mounting nut is the self lock type and can not be used repeatedly If the self lock effect is lost replace it with new one 55 N m 5 5 kgf m 55 N m 5 5 kgf m 55 N m 5 5 kgf m Front lower side Left Right Front upper ...

Page 62: ... 11 14 11 18 Supply a specified amount of engine oil and transmission oil 2 13 Supply a specified amount of cooling water 2 29 Adjust or inspect the following items Play of throttle cable 2 18 2 19 Idling rpm 2 18 Check the leakage of oil cooling water etc ITEM N m kgf m lb ft A 23 2 3 16 5 ...

Page 63: ...IL LEVEL SWITCH Remove the oil level switch 3 CYLINDER HEAD COVER Remove the cylinder head cover 4 NOTE Do not remove the dowel pin at the back side of the cylinder head cover since it is embedded CAMSHAFT Remove the valve timing inspection cap and bring the piston to the top dead center by turning the crankshaft 2 8 NOTE Take note of the tappet clearance 2 9 ...

Page 64: ...s 1 by removing the bolts Remove the camshafts 2 CYLINDER HEAD AND CYLINER Remove the cylinder head side bolt 1 Remove the cam chain tension adjuster bolts 2 Loosen the cylinder head bolts 3 Remove the cylinder head bolts diagonally Remove the cylinder head assembly Be sure to loosen the camshaft journal holder bolts evenly by shifting the wrench diagonally ...

Page 65: ... pins 6 PISTON Place a clean rag over the cylinder base so as not to drop the piston pin circlip into the crankcase Remove the piston pin circlip Remove the piston by driving out the piston pin NOTE Scribe the piston number on the head of the piston OIL HOSE Remove the oil hose 7 and oil return hose 8 GENERATOR COVER Remove the generator cover 9 ...

Page 66: ...e the generator rotor nut with the special tool 09930 40113 Rotor holder Remove the generator rotor 2 with the special tools 09930 40113 Rotor holder 09930 30450 Rotor remover Remove the generator stator 3 CKP sensor 4 and lead wire grommet 5 Remove the key ...

Page 67: ... clutch assembly 09930 40113 Rotor holder Remove the clutch shaft 3 Remove the driveshaft oil seal retainer 4 STARTER CLUTCH Remove the starter clutch cover 5 Remove the starter torque limiter shaft 6 starter torque lim iter 7 and washer Remove the starter idle gear shaft 8 and starter idle gear 9 ...

Page 68: ...ool 09920 34830 Starter clutch rotor holder CAM CHAIN Remove the cam chain tensioner 1 and cam chain 2 Remove the cam chain sprocket 3 WATER PUMP Remove the water pump assembly OIL FILTER Remove the oil filter 4 with the special tool 09915 40610 Oil filter wrench ...

Page 69: ...RANKCASE Untighten the crankcase tightening bolts diagonally Separate the crankcase into 2 parts right and left with the crankcase separating tool 09920 13120 Crankcase crankshft separator NOTE Pay attention when separating the crankcase so that it is kept horizontal with the mating surface ...

Page 70: ...and idle shaft 2 Remove the idle gear 3 Remove the circlip 4 and counter drive gear 5 Remove the counter drive gear shaft 6 BALANCER SHAFT Remove the upper balancer shaft 7 Remove the circlip 8 lower balancer shaft 9 oil pump gear 0 and oil pump drive chain ...

Page 71: ... PUMP Remove the pin 1 washer 2 and oil pump assembly 3 Remove the oil sump filter 4 OIL PRESSURE REGULATOR Remove the oil pressure regulator 5 PISTON COOLING NOZZLE Remove the piston cooling nozzle Remove the O ring ...

Page 72: ...e oil separator CRANKSHAFT Remove the crankshaft assembly 1 PRIMARY DRIVEN GEAR Remove the primary drive gear 2 RETURN OIL PUMP Remove the circlip 3 and return oil pump gear 4 Remove the pin 5 and return oil pump assembly 6 ...

Page 73: ... REASSEMBLY Apply THREAD LOCK 1342 to the thread and install the PAIR reed valve cover I 99000 32050 THREAD LOCK 1342 Check for stain and clogging in the breather and clean as required Assemble a new gasket and breather cover and tighten the part A together with the clamp Tightning torque 10 N m 1 0 kgf m 7 0 lb ft Identify the position of each removed part Organize the parts in their respective g...

Page 74: ...nched mark B Intake camshaft Punched mark A CAM FACE Check the sliding surface for extraordinary scratches or wear Measure the cam height H with a micrometer If the service limit has been exceeded replace the camshaft Cam height H Service Limit IN 35 1 mm 1 378 in EX 33 7 mm 1 339 in CAMSHAFT RUNOUT Measure the runout using the dial gauge Replace the camshaft if the runout exceeds the limit 09900 ...

Page 75: ...t 10 N m 1 0 kgf m 7 4 lb ft NOTE Do not rotate the camshaft with the plastigauge in place Remove the camshaft holders and read the width of the com pressed plastigauge with envelope scale This measurement should be taken at the widest part If the camshaft journal oil clearance measured exceeds the limit measure the inside diameter of the camshaft journal holder and outside diameter of the camshaf...

Page 76: ... If it does not slide smoothly replace the cam chain tension adjuster with a new one CAM CHAIN TENSIONER INSPECTION Check the contacting surface of the cam chain tensioner If it is worn or damaged replace it with a new one CAM CHAIN GUIDE INSPECTION Check the contacting surfaces of the cam chain guides If they are worn or damaged replace them with the new ones ...

Page 77: ...e other side Remove the oil seal 5 Remove the spring seat 6 CYLINDER HEAD DISTORTION Decarbonize the combustion chambers Check the gasket surface of the cylinder head for distortion with a straightedge and thickness gauge taking a clearance reading at several places indicated If the largest reading at any position of the straightedge exceeds the limit replace the cylinder head Cylinder head distor...

Page 78: ...ide be sure to recheck the deflec tion 09900 20205 Micrometer 0 25 mm Valve stem O D Standard IN 4 475 4 490 mm 0 1762 0 1768 in EX 4 455 4 470 mm 0 1754 0 1760 in NOTE If valve guides have to be removed for replacement after inspecting related parts carry out the steps shown in valve guide servicing VALVE STEM RUNOUT Support the valve using V blocks and check its runout using the dial gauge as sh...

Page 79: ...Weak ened spring result in reduced engine power output and often account for the chattering noise coming from the valve mecha nism Check the valve spring 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 range specified replace th...

Page 80: ...ial tool 09916 43210 Valve guide installer remover NOTE Install the valve guide until the attachment contacts with the cyl inder head 09916 43210 Valve guide remover installer 09916 44930 Valve guide installer attachment After installing the valve guides refinish their guiding bores using the reamer Clean and oil the guides after reaming 09916 33310 Valve guide reamer 09916 34542 Valve guide reame...

Page 81: ...the seat cutter Valve seat width W Standard 0 9 1 1 mm 0 035 0 043 in If the valve seat is out of specification recut the seat VALVE SEAT SERVICING The valve seats for both the intake and exhaust valves are machined to four different angles The seat contact surface is cut at 45 09916 21111 Valve seat cutter set 09916 20630 Valve seat cutter N 126 09916 20640 Solid pilot N 100 4 5 NOTE The valve se...

Page 82: ...r burned use the 45 cutter 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 camshaft TOP NARROWING CUT If the contact area W is too high on the valve or if it is too wide use the 15 for the exhaust side and the 30 for the intake side to lower and narrow the contact area 45 Too high or t...

Page 83: ...After servicing the valve seats be sure to check the tappet clearance after the cylinder head has been reinstalled 2 9 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 60 Too low or too narrow contact surface on va...

Page 84: ...all pitch portion B Large pitch portion Put on the valve spring retainer and using the valve lifter press down the springs fit the cotter halves to the stem end and release the lifter to allow the cotter 1 to wedge in between retainer and stem Be sure that the rounded lip A of the cotter fits snugly into the groove B in the stem end 09916 14510 Valve lifter 09916 14521 Valve lifter attachment 0991...

Page 85: ... 25010 SUZUKI SUPER GREASE A Others CYLINDER Disconnect the water pipe 1 and remove the O ring Untighten the thermostat case bolt Remove the thermostat 2 CYLINDER DISTORTION Check the gasket surface of the cylinder for distortion with a straightedge and thickess gauge taking a clearance reading at several places as indicated If the largest reading at any position of the straightedge exceeds the li...

Page 86: ...00 75 515 mm 2 9724 2 9730 in Service Limit 75 585 mm 2 9758 in Fit the O ring 1 to the water pipe and install the water pipe to the cylinder Coat the water pipe bolt with screw lock agent and tighten the water pipe with the bolt I 99000 32050 THREAD LOCK 1342 Install the thermostat to the cylinder Tighten the thermostat case bolt NOTE Position the thermostat jiggle valve as shown in the photo Use...

Page 87: ...exceeds the service limit replace the cylinder and the piston Piston to cylinder clearance Standard 0 045 0 055 mm 0 00177 0 00216 in Service Limit 0 120 mm 0 0047 in PISTON PINS AND PIN BORE Measure the piston pin bore inside diameter using the small bore gauge If the measurement is out of specification replace the piston 09900 20602 Dial gauge 1 1000 mm 09900 22401 Small bore gauge 10 18 mm Pist...

Page 88: ... Oil 2 01 2 03 mm 0 0791 0 0799 in Piston ring thickness Standard 1st 0 970 0 990 mm 0 03819 0 03898 in 2nd 0 970 0 990 mm 0 03819 0 03898 in PISTON RING FREE END GAP AND PISTON RING END GAP Measure the piston ring free end gap using vernier calipers Next fit the piston ring squarely into the cylinder and measure the piston ring end gap using the thickness gauge If any of the measurements exceed t...

Page 89: ...g compressor 09924 84510 Bearing installer set Remove the clutch hub 1 and spacer 1Circlip 2Spring seat 3Concaved washer 4Outer plate 5Driven plate No 2 6Clutch plate concaved washer 7Drive plate 8Driven plate No 1 9Clutch hub 0Spring AInner plate BRoller CClutch housing 5 5 N m 0 55 kgf m 4 0 lb ft ...

Page 90: ...Remove the rollers CLUTCH DRIVE PLATES CLUTCH DRIVEN PLATES NO 2 INSPECTION NOTE Wipe off engine oil from the clutch drive plates with a clean rag Measure the thickness of drive plates with a vernier calipers If each drive plate thickness is less than the limit replace it with a new one Drive plate thickness Service Limit 2 62 mm 0 095 in Driven plate No 2 thickness Service Limit 2 27 mm 0 0894 in...

Page 91: ... gauge CLUTCH SPRING FREE HEIGHT Measure the free length of the clutch spring with vernier cali pers If the length is below the service limit replace the spring Clutch spring free length Service Limit 13 2 mm 0 5197 in 09900 20102 Vernier calipers CLUTCH PLATE CONCAVED WASHER INSPECTION Measure the clutch plate concaved washer height A when applying the weight 9 8 N 1 kgf 2 2 lb as shown If clutch...

Page 92: ...n the reverse order of removal and dis assembly Pay attention to the following points Install the rollers Tighten the clutch spring bolts to the specified torque Clutch spring bolt 5 5 N m 0 55 kgf m 4 0 lb ft Install the spacer 1 and clutch sleeve hub ...

Page 93: ... washer outer plate concaved washer and spring seat Install the circlip with the special tools 09920 33530 Clutch spring compressor 09924 84510 Bearing installer set 1Driven plate No 2 2Driven plate No 1 3Drive plate Concaved washer Clutch plate concaved washer Outside Engine side Expanded view ...

Page 94: ...ovement Inspect that the gear turns one direction only If a large resistance is felt for rotation inspect the starter clutch bearing or the starter clutch contacting surface on the starter driven gear for wear and damage If they are found to be damaged replace them with new ones 1Washer 2Starter torque limiter 3Idle gear 4Wahser 5Starter clutch 55 N m 5 5 kgf m 40 0 lb ft ...

Page 95: ...ocket OIL PUMP INSPECTION Rotate the oil pump by hand and check that it moves smoothly If it does not move smoothly replace the oil pump assembly OIL PRESSURE REGULATOR OIL SUMP FILTER Inspect the operation of the oil pressure regulator by pushing on the piston with a proper bar If the piston dose not operate replace the oil pressure regula tor with a new one Check the oil sump filter for clogging...

Page 96: ... the following instructions Assemble the scissors gear with its punch mark side the out side When assembling align the balancer driven gear hole A with the scissors gear hole B Install the springs 5 Install the washer 6 and circlip 7 DRIVESHAFT DISASSEMBLY Remove the driveshaft nut Remove the washer 8 spring stopper 9 dumper cam spring 0 cam dog A final driven gear B and driveshaft oil seal C ...

Page 97: ...y taking care particularly about the following items Coat the spline area of the cam dog 2 with grease W 99000 25030 SUZUKI SUPER GREASE A USA 99000 25010 SUZUKI SUPER GREASE A Others Install the bushing 1 final drive gear 2 cam dog 3 dumper spring 4 spring stopper 5 washer 6 and nut 7 to the drive shaft Fix the driveshaft assembly to the vise and tighten the nut Driveshaft nut 105 N m 10 5 kgf m ...

Page 98: ... exceeds the limit remove the conrod and inspect the conrod big end width and the crank pin width If the width exceed the limit replace conrod or crankshaft Conrod big end side clearance Service Limit 0 30 mm 0 012 in 09900 20803 Thickness gauge Conrod big end width Standard 19 95 20 00 mm 0 7854 0 7874 in 09900 20205 Micrometer 0 25 mm Crank pin width Standard 20 10 20 15 mm 0 7913 0 7933 in 0990...

Page 99: ... the compressed plastigauge Conrod big end oil clearance Standard 0 032 0 056 mm 0 0013 0 0022 in Service Limit 0 080 mm 0 0031 in If the oil clearance exceeds the service limit select the speci fied bearings from the bearing selection table Check the corresponding conrod I D code number 1 or 2 A Check the corresponding crank pin O D code number 1 2 or 3 B Bearing selection table Apply engine oil ...

Page 100: ...ng surface O MOLYBDNUM OIL SOLUTION Code A I D specification 1 48 000 48 008 mm 1 8898 1 8901 in 2 48 008 48 016 mm 1 8901 1 8904 in Code B O D specification 1 44 992 45 000 mm 1 7713 1 7717 in 2 44 984 44 992 mm 1 7710 1 7713 in 3 44 976 47 984 mm 1 7707 1 7710 in Color Thickness Green 1 480 1 484 mm 0 0583 0 0584 in Black 1 484 1 488 mm 0 0584 0 0586 in Brown 1 488 1 492 mm 0 0586 0 0587 in Yell...

Page 101: ...he crankshaft journal bearings for any damage If any replace them with a specified set of bearings Inspect the crankshaft journal for any damage Measure the crankshaft journal O D with the special tool Crankshaft journal O D Standard 47 985 48 000 mm 1 8892 1 8898 in 09900 20202 Micrometer 25 50 mm CRANKCASE CRANKSHAFT BEARING SELECTION Select the specified bearings from the crankcase bore I D cod...

Page 102: ...tion from inside to outside of each crankcase half Gradually press out the bearing with the special tool by using the hand press NOTE Using the hand press is recommended to remove the crankshaft journal bearings However the crankshaft journal bearings can be removed by using with the following special tools 09913 60230 1 Jornal bearing remover installer 09924 84510 2 Bearing installer set 09924 74...

Page 103: ...6 5 lb ft Before setting the bearing apply enough engine oil to the special tool and bearings When setting the bearing align the bearing side with the engraved line A and also the bearing edge with the mating surface of the special tool Before installing the bearings lightly shave off the sharp edge part of the crankcase chamfer by using an oilstone and wash the crankcase bore with enough engine o...

Page 104: ...ool 3 1 09913 60210 Journal bearing remover installer Left crankcase 2 09913 60230 Journal bearing remover installer Right crankcase 3 09913 60241 Journal bearing installer holder Be sure the bearing protruded side A faces the crankcase bore Align the special tool mating surface with the line mark B on the crankcase Hand press or Bearing Bearing or 1Left crankcase 2Right crankcase Since the journa...

Page 105: ...earance Standard 0 10 0 15 mm 0 004 0 006 in If the thrust clearance is out of the standard range replace the shim so that the standard value is obtained To replace the shim remove the thrust shim and measure the thickness Select shims from the table below so that the stan dard value can be obtained Inspect the crankshaft thrust clearance again Unit mm in Match the hole center of the special tool ...

Page 106: ...the carved mark not to mistake the size NOTE The crankcase side of the oil jet is identified by letter 8 NOTE The cylinder head side of the oil jet is identified by letter 14 PISTON COOLING NOZZLE Check the piston cooling nozzle for clogging or deformation NOTE Before installing coat the O ring with engine oil Use a new O ring ...

Page 107: ... USA 99000 31140 SUZUKI BOND 1207B Others Remove the right crankcase cover 1 Remove the primary shaft cap 2 Install the right crankcase cover 1 and primary shaft cap 2 Right crankcase cover bolt 11 N m 1 1 kgf m 8 lb ft Primary shaft cap bolt 11 N m 1 1 kgf m 8 lb ft BEARING DISASSEMBLY Remove the bearings with the special tool 09921 20240 Bearing remover set 1 09941 54911 Bearing outer race remov...

Page 108: ...case Replace the bearing in the following procedure if there is any thing unusual BEARING REASSEMBLY Install the bearing into the crankcase with the special tool 09913 70210 Bearing installer set OIL SEAL DISASSEMBLY Remove the oil seal with the special tools 1 09913 70210 Bearing remover set 2 09913 85210 Bearing remover 09913 50121 Oil seal remover Play Play ...

Page 109: ... 99000 25010 SUZUKI SUPER GREASE A Others Install the oil seal with the special tool 09913 70210 Bearing installer set BUSHING INSTALLATION Replace the bushing with a new one if necessary Assemble the engine mount bushing as shown in the illustra tion Use a new Oil seal Bushing Crankcase 0 5 mm 0 0197 in ...

Page 110: ...asures should be taken NOTE Apply engine oil to each running and sliding part before reas sembling RETURN OIL PUMP Install the return oil pump and insert the pin 1 into the shaft Install the pin aligning to the groove of the return oil pump gear and fit a circlip PRIMARY DRIVEN GEAR CRANKSHAFT Install the primary driven gear 2 and crankshaft assembly 3 ...

Page 111: ... sump filter to the concave of the crankcase PISTON COOLING NOZZLE Coat the O ring with a small amount of grease and install the piston cooling nozzle 1 OIL PUMP OIL PRESSURE REGULATOR Install the oil pump 2 washer 3 and pin 4 Coat the O ring with grease and install the oil pressure regula tor 5 to the crankcase Use a new O ring ...

Page 112: ...ive chain to the oil pump gear and install the oil pump gear by aligning the groove and pin Install the circlip 5 DRIVESHAFT Install the counter drive gear shaft 6 from the outside install the counter drive gear 7 and fit the circlip Install the idle gear 8 idle shaft 9 and driveshaft assembly 0 Align the punched marks in line Check that the circlip is positively fitted ...

Page 113: ...e right crank case C 99104 31140 SUZUKI BOND 1207B USA D 99000 31110 SUZUKI BOND 1215 Others Assemble the crankcases with in few minutes and tighten the crankcase bolts diagonally and uniformly Right crankcase bolt M6 11 N m 1 1 kgf m 8 lb ft Left crankcase bolt M8 26 N m 2 6 kgf m 19 lb ft NOTE After tightening the crankcase bolts check that the crankshaft rotates smoothly Use a new O ring Coat t...

Page 114: ... union bolt 70 N m 7 0 kgf m 50 5 lb ft NOTE Use a new O ring WATER PUMP Install the water pump assembly CAM CHAIN Install the cam chain sprocket NOTE Align the punched mark on the crankshaft and that of the cam chain sprocket Install the washer 3 Coat the cam chain tensioner bolt with thread lock and tighten it I 99000 32050 THREAD LOCK 1342 Install the cam chain 4 ...

Page 115: ...k B of the crankshaft Install the starter clutch bolt together with the washer 2 Using the special tool tighten the bolt to the specified torque 09920 34830 Starter clutch rotor holder Starter clutch bolt 55 N m 5 5 kgf m 40 0 lb ft Install the starter torque limiter shaft 3 and washer 4 Install the starter torque limiter 5 starter idle gear shaft 6 and starter idle gear O MOLYBDENUM OIL Coat each...

Page 116: ...l the new gasket 1 and dowel pin Coat the starter clutch cover bearings with molybdenum oil O MOLYBDENUM OIL SOLUTION Install the starter clutch cover NOTE Tighten the starter clutch cover bolt A together with the clamp ...

Page 117: ...TCH Install the clutch shaft to the clutch assembly Coat the part A of the clutch shaft with SUZUKI MOLY PASTE Y 99000 25140 SUZUKI MOLY PASTE Install the clutch assembly washer 1 and clutch housing nut 2 to the left crankcase Using the special tool tighten the clutch housing nut to the specified torque 09930 40113 Rotor holder Clutch housing nut 70 N m 7 0 kgf m 5 lb ft Install the new gasket 3 a...

Page 118: ... and CKP sensor 2 Fit the grommet firmly Using the special tool tighten the generator rotor nut to the specified torque 09930 40113 Rotor holder Generator rotor bolt 160 N m 16 0 kgf m 115 5 lb ft Install the oil sump filter NOTE Set the projection of the oil sump filter to concave of the crank case Install the new gasket ...

Page 119: ...er with the clamp Fit the gasket washers 3 and union bolts to the oil hose 1 and oil return hose 2 NOTE Use a new gasket washer Connect the oil hose and oil return hose to the crankcase Oil hose union bolt 20 N m 2 0 kgf m 14 5 lb ft Oil return hose union bolt 28 N m 2 8 kgf m 20 0 lb ft ...

Page 120: ...er installing all the piston rings check that each ring rotates smoothly To prevent poor compression or oil leaking up to the cylinder inside position each ring end gap as shown in the right figure A Second ring side rail lower side B Side rail upper side C Top ring spacer When installing the spacer be careful so that the both edges are not overlapped When installing the piston ring be careful not...

Page 121: ...stall the pistons 1 Place a clean cloth under the piston and fit the circlip 2 CYLINDER Coat the conrod big end with oil Install the dowel pins 1 and new cylinder base gasket 2 Coat the cylinder inside surface and piston rings with engine oil and install the cylinder Use a new circlip Use a new gasket Keep the cam chain pulled out not to be caught between the sprocket and crankshaft ...

Page 122: ...linder head bolts 3 Cylinder head bolt M8 3 25 N m 2 5 kgf m 18 0 lb ft Unlock the ratchet of the cam chain tension adjuster and push and compress the adjuster rod Insert the special tool into the gap between the tension adjuster body and ratchet Install the cam chain tention adjuster bolts 4 and copper washers 5 09918 53810 Tensioner locking tool Cam chain tensioner adjust bolt 10 N m 1 0 kgf m 7...

Page 123: ...check that the tappet is properly installed The exhaust camshaft and intake camshaft are distinguished by the punched mark Exhaust camshaft B Intake camshaft A Match the arrow marked on the exhaust cam sprocket 1 to the cylinder head gasket surface Match the arrow marked on the intake cam sprocket 3 to the 15 roller pins counted from the exhaust cam sprocket 2 NOTE Do not move the crankshaft until...

Page 124: ...ENGINE 3 73 POSITION OF CAMSHAFTS AND SPROCKETS 15 1 1 2 2 3 3 ...

Page 125: ...ect positions according to the identification marks Intake camshaft IN Exhaust camshaft EX Unlock the cam chain tension adjuster CYLINDER HEAD COVER Assemble the new gasket to the cylinder head cover Coat the semicircular part of the gasket with sealing agent 99000 31230 SUZUKI BOND 1216B NOTE Do not remove the dowel pin at the backside of the cylinder head cover since it is embedded Install the c...

Page 126: ...OIL LEVEL SWITCH Install the oil level switch Oil level switch bolt 10 N m 1 0 kgf m 7 0 lb ft STARTER MOTOR Install the starter motor 1 Install the water bypass hose 2 Starter motor bolt 6 N m 0 6 kgf m 4 5 lb ft ...

Page 127: ...2 4 6 DRIVE TRAIN 4 1 CONTENTS DRIVE TRAIN DRIVE TRAIN 4 2 CONSTRUCTION 4 2 REMOVAL AND DISASSEMBLY 4 3 INSPECTION AND REPLACEMENT 4 4 REASSEMBLY AND REMOUNTING 4 7 ...

Page 128: ...gear 2No 1 gear 3No 2 gear 4No 3 gear 5Final driven gear 6Final gear case cover 7Final gear case 8Plate 9Final driven gear hub 0Right oil seal ALeft oil seal BOil seal CCirclip 10 N m 1 0 kgf m 7 0 lb ft 1 mm 0 04 in 2 mm 0 08 in 1 mm 0 04 in 1 mm 0 04 in ...

Page 129: ...er 9 12 Drain the final gear oil 2 15 Remove the rear wheel 9 48 Remove the swingarm 9 59 Remove the speedometer sensor 1 and harness guide 2 Remove the final gear case Remove the bearing from the engine Remove the dowel pins Remove the final gear case bolts in a crisscross pattern ...

Page 130: ... No 2 gear D No 3 gear E Final driven gear Remove the final drive gear hub 4 INSPECTION AND REPLACEMENT GEARS Inspect the gears for wear and damage If any defects are found replace the gear with a new one OIL SEALS Inspect the oil seals for wear and damage If any defects are found replace the seal with a new one ...

Page 131: ...f the bearing by hand while it is in the final gear case Rotate the inner race by hand to inspect for abnormal noise and smooth rotation If there is anything unusual replace the bearing with a new one Remove the bearing with the special tool 09921 20240 Bearing remover set To facilitate setting the special tool knock down the plate 1 that is at the No 2 gear bearing Remove the bearing with the spe...

Page 132: ...o the final gear case with the special tool 09913 70210 Bearing installer set Install the plate 2 into the final gear case cover at the No 2 gear and then install the bearing FINAL DRIVEN GEAR HUB Inspect the final driven gear hub for wear and damage If any defects are found replace the final driven gear hub with a new one Replace the removed bearing with a new one Install the plate 2 with the con...

Page 133: ...olt 10 N m 1 0 kgf m 7 0 lb ft Apply SUZUKI SUPER GREASE A to the bearing Install the bearing to the drive shaft W 99000 25010 SUZUKI SUPER GREASE A Install the final gear case assembly Tighten the rear shock absorber mounting bolt Rear shock absorber mounting bolt 29 N m 2 9 kgf m 21 0 lb ft Install the speedometer sensor 2 and harness guide 3 Tighten the speedometer sensor bolt to the specified ...

Page 134: ...lamp the breather hose 4 and speedometer sensor harness 5 Install the swingarm 9 61 Install the exhaust muffler 3 11 Install the rear wheel 9 56 Install the right left side leg shield covers Pour the final gear oil 2 16 ...

Page 135: ...T ASSEMBLY REMOVAL AND INSTALLATION 5 2 CVT ASSEMBLY REMOVAL 5 2 CVT ASSEMBLY INSTALLATION 5 4 CVT DISASSEMBLY AND REASSEMBLY 5 5 CVT DISASSEMBLY 5 6 CVT INSPECTION 5 11 CVT PRIMARY PULLEY SHIMS ADJUSTMENT 5 16 CVT REASSEMBLY 5 19 ...

Page 136: ...T CVT ASSEMBLY REMOVAL AND INSTALLATION CVT ASSEMBLY REMOVAL Remove the engine assembly ENGINE REMOVAL 3 3 Remove the bracket 1 Remove the bolts 2 and 3 Install the special tool as shown 09920 31050 CVT guide ...

Page 137: ...CVT 5 3 Remove the CVT mounting bolts Remove the CVT assembly ...

Page 138: ...primary driven gear shaft and clutch shaft 09920 31050 CVT guide Y99000 25140 SUZUKI MOLY PASTE Engage the spline and install the CVT assembly by turning the crankshaft slowly Install the bracket 2 Tighten the CVT mounting bolt to the specified torque CVT mounting bolt 50 N m 5 0 kgf m 36 0 lb ft Install the valve timing inspection cap 3 ENGINE INSTALLATION 3 10 ...

Page 139: ...e gear K Secondary pulley revolution sensor L CVT motor M CVT cover N CVT filter O Primary pulley stopper bolt P Pulley position sensor 1 Secondary pulley shaft nut 2 Secondary pulley shaft adaptor 3 O ring 4 Primary pulley shaft bolt 5 Primary pulley shaft adaptor 6 CVT casing 7 Bearing 8 O ring 9 CVT belt 0 Primary pulley assembly A Shim B O ring C Bearing ...

Page 140: ...5 6 CVT CVT DISASSEMBLY CVT CASING COVER Remove the pulley position sensor 1 Remove the secondary pulley revolution sensor 2 Remove the CVT motor Remove the CVT filter cover Remove the CVT filter ...

Page 141: ...t holder Remove the secondary shaft adaptor with a bearing puller Remove the primary pulley shaft bolt by holding the primary pulley shaft with the special tools 09920 31010 CVT primary pulley shaft holder 09920 31020 Extension handle Screw in the special tool and remove the primary pulley shaft adaptor 09920 31040 CVT primary pulley shaft adaptor remover ...

Page 142: ... fac ing downward After separating the CVT assembly remove the CVT casing with the special tool 09920 13120 Crankcase separater Remove the dowel pins The crankcase separator plate is parallel with the end face of the CVT crankcase When servicing the inside of the CVT assembly make sure to wear clean protective gloves ...

Page 143: ...ley idle gear clockwise and open the primary pulley fully Remove the primary slide pulley idle gear 2 and 3 Place a piece of clean rag on the primary pulley faces to pre vent them from scratches Remove the secondary pulley assembly Use caution not to cause scratches on the pulley sur faces dne to their contact ...

Page 144: ... belt from scratches Remove the CVT belt Mark the direction mark on the CVT belt PRIMARY PULLEY Remove the primary pulley stopper bolt A NOTE In the case of replacing the CVT belt only removing of the primary pulley is not necessary CVT BELT INSTALLATION 5 20 Remove the primary pulley assembly ...

Page 145: ... primary pulley assem bly with a new one Replace the O ring with a new one SECONDARY PULLEY INSPECTION Inspect the secondary pulley faces for any abnormal condi tions such as scratches or stepped wear If any damages are found replace the primary pulley assem bly with a new one Check that the secondary pulley faces are free from any greasy substance If the surface is found greasy make sure to degre...

Page 146: ... or damage Replace the bearing or secondary pulley fan if there is any thing unusual SECONDARY PULLEY DISASSEMBLY Remove the secondary pulley fan 1 Remove the snap ring 2 09900 06107 Snap ring pliers Remove the bearing with a bearing puller CVT MOTOR When replacing the CVT motor gear align the hole A with the hole of motor shaft to install the pin ...

Page 147: ...dary pulley fan bolts and tighten them I 99000 32050 THREAD LOCK 1342 CVT BELT INSPECTION Check that the drive belt is free from any greasy substance Inspect the CVT belt for cracks or uneven wear If any damages are found replace the CVT belt with a new one Replace the removed bearing with a new one Bearing If the CVT belt is found greasy replace it with a new one Do not spray a cleaning solvent d...

Page 148: ... if there is anything unusual Replace the O ring with a new one Apply SUZUKI SUPER GREASE A to the new O ring and install it W 99000 25030 SUZUKI SUPER GREASE A USA 99000 25010 SUZUKI SUPER GREASE A Others Thoroughly clean the case free from dirt and sealant CVT CASING COVER DISASSEMBLY Remove the bearing retainer 1 Replace the oil seal every time the CVT assembly is separated ...

Page 149: ...ther with the oil seal by using the special tool 09913 70210 Bearing installer set CVT CASING COVER REASSEMBLY Install the bearing with the special tool 09913 70210 Bearing installer set Install the bearing retainer 1 Install the oil seal and bearing with the special tool 09913 70210 Bearing installer set ...

Page 150: ...er mating face mea sure the depth D to the face A of the cover which the primary pulley assembly contacts using the vernier calipers Measure the depth D at three points and note the measured value D1 D2 and D3 09900 20102 Vernier calipers PRIMARY PULLEY HEIGHT MEASUREMENT Install the primary pulley assembly onto the CVT casing Install the primary pulley shaft adaptor with the special tool 09913 60...

Page 151: ...ey shaft holder 09920 31020 Extension handle Fix the CVT casing securely with its mating face positioned horizontally With the straightedge placed on the casing mating face mea sure the height H to the face B of the primary pulley assem bly using the vernier calipers Measure the height H at three points and note the measured value H1 H2 and H3 09900 20102 Vernier calipers D H ...

Page 152: ...131 0 138 in 0 52 mm 0 020 in 3 52 3 71 mm 0 139 0 146 in 0 72 mm 0 028 in 3 72 3 91 mm 0 147 0 154 in 0 92 mm 0 036 in 3 92 4 11 mm 0 155 0 162 in 1 12 mm 0 044 in 4 12 4 31 mm 0 163 0 170 in 1 32 mm 0 052 in 4 32 4 51 mm 0 171 0 178 in CVT cover depth D D1 125 35 mm 4 935 in D2 125 15 mm 4 927 in D3 125 25 mm 4 931 in Average depth Da 125 35 125 15 125 25 3 125 25 mm 4 931 in Primary pulley heig...

Page 153: ...he O ring 1 and shim 2 Turn the slide pulley gear and close the primary pulley Align the cutaway B of the screw shaft with the protrusion A Wear clean protective gloves If any of the primary pulley CVT casing or CVT cover has been replaced install the shim whose thickness has been adjusted in the shim adjustment procedure Degrease the primary pulley faces completely ...

Page 154: ...olt hole F of the CVT cover position the primary pulley assembly onto the CVT cover Make sure that the screw shaft is in proper position by check ing the location of cutaway B when viewed from the stopper bolt hole F Tighten the stopper bolt to the specified torque Primary pulley stopper bolt 36 N m 3 6 kgf m 26 0 lb ft CVT BELT INSTALLATION Install the primary slide pulley idle gear temporarily T...

Page 155: ...e a piece of clean rag on the primary pulley faces to pre vent them from scratches SECONDARY PULLEY ASSEMBLY Install the secondary pulley assembly Remove the rags Check that the secondary pulley is located inwardly relative to the primary pulley Never touch the side walls of the CVT belt Degrease the secondary pulley faces completely Use caution not to cause scratches on the pulley surfaces due to...

Page 156: ...VT cover mat ing face Install the primary slide pulley idle gear 1 and 2 Turn the idle gear until the primary pulley faces just touch the CVT belt Check the CVT belt movement for smooth rotation by turning the both pulleys Install the secondary pulley washer 3 ...

Page 157: ... Others Cover the secondary pulley shaft with a vinyl film to prevent oil seal damage Apply a small quantity of engine oil to the main lip B of the oil seal PENGINE OIL Apply SUZUKI BOND 1215 to the mating surface of the CVT casing D 99000 31110 SUZUKI BOND 1215 NOTE Make surfaces free from moisture oil dust and other foreign materials Spread on surfaces thinly to form an even layer and assemble t...

Page 158: ... GREASE A Others Install the primary pulley shaft adaptor with the special tool 09913 60910 Bearing puller or 09913 61110 Bearing puller or 09913 61510 Bearing puller Apply THREAD LOCK SUPER 1360 to the primary pulley shaft bolt J 99000 32130 THREAD LOCK SUPER 1360 Tighten the primary pulley shaft bolt to the specified torque with the special tools Primary pulley shaft bolt 64 N m 6 4 kgf m 46 5 l...

Page 159: ...ley shaft 09910 32850 Crankshaft installer attachment Press in the secondary pulley shaft adaptor with the special tool 09910 32812 Crankshaft installer Apply THREAD LOCK SUPER 1360 to the secondary pulley shaft nut J 99000 32130 THREAD LOCK SUPER 1360 Tighten the secondary pulley shaft nut to the specified torque with the special tools Secondary pulley shaft nut 226 N m 22 6 kgf m 163 5 lb ft 099...

Page 160: ...er by using compressed air Install the CVT filter Install the CVT filter cover Fit the clamp to the bolts A Install the CVT motor NOTE Pay attention to the direction of the CVT motor Install the secondary pulley revolution sensor ...

Page 161: ...EDURES It is necessary to allow the CVT belt to BRAKE IN before subjecting the CVT to maximum stresses Brake in engine speed Initial 800 km 500 miles Below 4 000 rpm NOTE When the CVT belt is new the engine rpm may jump briefly under hard acceleration due to the smoothness of the belt 35 35 30 30 30 30 30 30 30 30 CLAMP LOCATION ...

Page 162: ...ALFUNCTION 6 28 C13 IAP SENSOR CIRCUIT MALFUNCTION 6 29 C14 TP SENSOR CIRCUIT MALFUNCTION 6 31 C15 ECT SENSOR CIRCUIT MALFUNCTION 6 33 C16 SPEED SENSOR CIRCUIT MALFUNCTION 6 34 C21 IAT SENSOR CIRCUIT MALFUNCTION 6 36 C22 AP SENSOR CIRCUIT MALFUNCTION 6 37 C23 TO SENSOR CIRCUIT MALFUNCTION 6 39 C24 or C25 IGNITION SYSTEM MALFUNCTION 6 40 C32 or C33 FUEL INJECTOR CIRCUIT MALFUNCTION 6 40 C40 IAC VAL...

Page 163: ...sconnecting the coupler 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 I...

Page 164: ...xcessive 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 CVT CONTROL UNIT VARIOUS SENSORS Since each component is a high precision part great care should be taken not to apply any sharp i...

Page 165: ...lied to the ECM CVT control unit 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 CVT control unit when its coupler is disconnected Otherwise damage to ECM CVT control ...

Page 166: ...onnection 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...

Page 167: ... being checked voltage check can be used as circuit check With all connectors couplers connected and voltage applied to the circuit being checked measure voltage between each terminal and body ground If measurements were taken as shown in the figure at the right and results are as listed below it means that the circuit is open between terminals A and B Voltage Between C and body ground Approx 5 V ...

Page 168: ...s of those 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 sh...

Page 169: ...ti circuit 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 NOTE When connecting the multi circuit tester use a fine needle pointed probe or install fine copper wires O D is below 0 5 mm to the back s...

Page 170: ...e and various 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 Crankshaft Position Sensor CKP Sensor Throttle Position Sensor TP Sensor Various Sensors Injectors Intake air pressure signal Engine speed signal Various signals Injection signal Basic fuel injection time Co...

Page 171: ... ratio is lean and less fuel is supplied if 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 ENGINE RPM SIGNAL At high speed the injection time volume is increased STARTING SIGNAL When sta...

Page 172: ... PARTS LOCATION A Combination meter F Ignition coil IG COIL B ECM G Camshaft position sensor CMPS C PAIR control solenoid valve H Crankshaft position sensor CKPS D Fuel injector FI I Speed sensor E Engine coolant temperature sensor ECTS ...

Page 173: ... TOS K CVT control unit L Fuel pump relay FP RELAY M Atomospheric pressure sensor APS N Intake air pressure sensor IAPS O Intake air temperature sensor IATS P Throttle position sensor TPS Q IAC valve R Fuel pump FP S Heated oxygen sensor HO2S E 02 19 ...

Page 174: ...hrottle position sensor TPS Crankshaft position sensor CKPS ECM Engine coolant temperature sensor ECTS Intake air temperature sensor IATS Camshaft position sensor CMPS Fuel pump relay FP RELAY Tip over sensor TOS Engine stop switch Side stand relay Side stand switch Starter motor Ignition switch 15A 10A 10A 30A Starter relay Starter switch Brake switch Heated oxygen sensor HO2S E 02 19 ...

Page 175: ...nd CVT secondary pully revolution sensor Target CVT ratio is calculated on the basis of the target engine speed as determined by the speed sensor and the throttle position sensor Speed Sensor Throttle Position Sensor TP Sensor Vehicle speed Throttle position Target engine rpm Target CVT ratio Actual CVT ratio CVT motor Crankshaft Position Sensor CKP Sensor CVT Pulley Position Sensor CVT Secondary ...

Page 176: ...y revolution signal D Center stand voltage CVT secondary pulley revolution sensor Center stand switch B CVT motor operating voltage E Serial communication CVT motor F Throttle position voltage C CVT pulley position voltage Throttle position sensor CVT pulley position sensor ...

Page 177: ...6 16 FI SYSTEM CVT SYSTEM E Serial communication G Speed signal Speed sensor H Engine rpm Crankshaft position sensor ...

Page 178: ...de pul ley movement is controlled by the CVT motor revolution The secondary pulley squeezes the CVT belt with the spring force and the width of pulley adjusts itself in accordance with that of the primary pulley CVT motor CVT pulley position sensor Slide pulley Secondary pulley assembly CVT belt Clutch Primary pulley assembly ...

Page 179: ...relay signal or ignition switch signal is not sent to ECM In this case FI is indicated in the LCD panel Motorcycle does not run CHEC The LCD panel indicates CHEC when no communication signal from the ECM is received for 3 seconds For Example The ignition switch is turned ON and the engine stop switch is turned OFF In this case the speed ometer does not receive any signal from the ECM and the panel...

Page 180: ... devices 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...

Page 181: ...ke air pressure sensor IAPS Throttle position sensor TPS Engine coolant temp sensor ECTS Speed sensor Intake air temperature sensor IATS Atmospheric pressure sensor APS Tip over sensor TOS Ignition signal 1 IG coil 1 Ignition signal 2 IG coil 2 Fuel injector signal 1 Fuel injector signal 2 Idle air control valve IAC valve Fuel pump control system FP control system Ignition switch signal IG switch ...

Page 182: ...ing is also fixed YES YES Engine coolant temp sensor Engine coolant temperature value is fixed to 80 C YES YES Intake air temperature sensor Intake air temperature value is fixed to 40 C YES YES Atmospheric pressure sensor Atmospheric pressure is fixed to 760 mmHg YES YES Ignition signal 1 IG coil 1 1 Ignition off YES YES 2 cylinder can run Ignition signal 2 IG coil 2 2 Ignition off YES YES 1 cyli...

Page 183: ... 5th Malfunction indicator lamp condition 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 ...

Page 184: ...lways 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 Right hand co...

Page 185: ...o have good understanding as to what functions are available and how to use it Be sure to read PRECAUTIONS for Electrical Circuit Ser vice 6 2 before inspection and observe what is written there Lift the seat 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 ma...

Page 186: ...emperature sensor The sensor voltage should be the following 0 15 V sensor voltage 4 85 V Without the above range C15 is indicated Engine coolant temperature sensor wiring coupler connection C16 Speed sensor The speed sensor signal is not input for more than 3 sec during vehicle deceleration Speed sensor wiring coupler connection C21 Intake air temperature sensor The sensor voltage should be the f...

Page 187: ...rol unit to ECM for more than 5 sec after starting the engine Wiring coupler connection C51 CVT motor The CVT motor operating voltage is not supplied from CVT con trol unit CVT motor wiring coupler connection C52 CVT pulley position sensor The sensor should produce following voltage 0 06 sensor voltage 5 04 Without the above range C52 is indicated CVT pulley position sensor wiring coupler connecti...

Page 188: ...ess for open circuit and poor connection Turn the ignition switch OFF Check the CMP sensor coupler for loose or poor contacts If OK then measure the CMP sensor resistance Disconnect the CMP sensor coupler 1and measure the resistance CMP sensor resistance 0 9 1 7 kΩ B Y Brown If OK then check the continuity between each terminal and ground Disconnect the CMP sensor coupler Crank the engine a few se...

Page 189: ...sor coupler 1and measure the resistance CKP sensor resistance 150 300 Ω Blue Green If OK then check the continuity between each terminal and ground CKP sensor continuity Ω Infinity Blue Ground Green Ground z09900 25008 Multi circuit tester tTester knob indication Resistance Ω Disconnect the CKP sensor coupler Crank the engine a few seconds with the starter motor and measure the CKP sensor peak vol...

Page 190: ...easure the IAP sensor input voltage Disconnect the IAP sensor coupler Turn the ignition switch ON Measure the voltage at the Red wire and ground If OK then measure the voltage at the Red wire and B Br wire Connect the IAP sensor coupler Insert the copper wires to the lead wire coupler Start the engine at idle speed Measure the IAP sensor output voltage at the wire side coupler between Lg B and B B...

Page 191: ...e and connection are OK intermittent trouble or faulty ECM Recheck each terminal and wire harness for open circuit and poor connection Remove the IAP sensor Connect the vacuum pump gauge to the vacuum port of the IAP sensor Arrange 3 new 1 5 V batteries in series check that total voltage is 4 5 5 0 V and connect terminal to the ground terminal and terminal to the Vcc terminal Check the voltage bet...

Page 192: ...ce lid 9 13 1 2 Yes Yes No No Reset the TP sensor position correctly Replace the TP sensor with a new one TP sensor input voltage 4 5 5 5 V Red Ground Red B Br z09900 25008 Multi circuit tester uTester knob indication Voltage Loose or poor contacts on the ECM coupler Open or short circuit in the Red wire or B Br wire Turn the ignition switch OFF Disconnect the TP sensor coupler Check the continuit...

Page 193: ...ect it again Connect the TP sensor coupler Insert the copper wires to the lead wire coupler Turn the ignition switch ON Measure the TP sensor output voltage at the coupler be tween Yellow and Gr or R wires by turning the throttle grip TP sensor output voltage Throttle valve is closed Approx 1 1 V Throttle valve is opened Approx 4 3 V z09900 25008 Multi circuit tester u Tester knob indication Volta...

Page 194: ... tester tTester knob indication Resistance Ω Replace the ECT sensor with a new one Replace the ECM with a new one and inspect it again Turn the ignition switch OFF Check the ECT sensor coupler for loose or poor contacts If OK then measure the ECT sensor voltage at the wire side coupler Disconnect the coupler and turn the ignition switch ON Measure the voltage between B Bl wire terminal and ground ...

Page 195: ...nsor input voltage More than 7 V O R B W z 09900 25008 Multi circuit tester u Tester knob indication Voltage Loose or poor contacts on the ECM couplers Open or short circuit in the O R wire or B W wire Turn the ignition switch OFF Check the speed sensor lead wire coupler 1for loose or poor contacts If OK then measure the speed sensor input voltage Insert the copper wires to the lead wire coupler T...

Page 196: ...es to the lead wire caupler White Black White Turn the ignition switch ON Check that the voltage varies when a screwdriver is brought close to the pick up face of the speed sensor V OK NG Short circuit in the lead wire Replace the speed sensor with a new one Recheck ECM coupler for loose or poor contacts Replace ECM with a new one and inspect it again 3 3 ...

Page 197: ...ion Resistance Ω Replace the IAT sensor with a new one Replace the ECM with a new one and inspect it again Turn the ignition switch OFF Check the IAT sensor coupler for loose or poor contacts If OK then measure the IAT sensor voltage at the wire side coupler Disconnect the coupler and turn the ignition switch ON Measure the voltage between Dg wire terminal and ground If OK then measure the voltage...

Page 198: ...acts on the ECM coupler Open or short circuit in the Red wire or B Br wire AP sensor output voltage Approx 3 6 V at 760 mmHg 100 kPa G Y B Br z 09900 25008 Multi circuit tester u Tester knob indication Voltage Check the air passage for clogging Open or short circuit in the G Y wire Replace the AP sensor with a new one Turn the ignition switch OFF Check the AP sensor coupler for loose or poor conta...

Page 199: ...nd connection are OK intermittent trouble or faulty ECM Recheck each terminal and wire harness for open circuit and poor connection Remove the AP sensor Connect the vacuum pump gauge to the air passage port of the AP sensor Arrange 3 new 1 5 V batteries in series check that total voltage is 4 5 5 0 V and connect terminal to the ground terminal and terminal to the Vcc terminal Check the voltage bet...

Page 200: ...ion switch OFF Check the TO sensor coupler for loose or poor contacts If OK then measure the TO sensor resistance Disconnect the TO sensor coupler Measure the resistance between Red and B Br wire terminals TO sensor resistance 19 1 19 7 kΩ Red B Br z 09900 25008 Multi circuit tester t Tester knob indication Resistance Ω Connect the TO sensor coupler Insert the copper wires to the lead wire coupler...

Page 201: ... the ignition switch ON Measure the injector voltage between Y R wire and ground Injector voltage Battery voltage Y R Ground z09900 25008 Multi circuit tester u Tester knob indication Voltage Replace the ECM with a new one and inspect it again Injector resistance 11 13 Ω at 20 C 68 F Terminal Terminal Injector continuity Ω Infinity Terminal Ground z09900 25008 Multi circuit tester t Tester knob in...

Page 202: ...uel pump relay is turned OFF Fuel pump relay circuit open or short Fuel pump relay malfunction ECM malfunction 1 ECM couplers b 9 Remove the front box 9 18 1 Yes No Turn the ignition switch OFF Check the FP relay coupler for loose or poor contacts If OK then check the insulation and continuity Refer to page 10 28 for details Y G or O W wire open or shorted to ground or poor 9or b connection If wir...

Page 203: ...on 1 Turn the ignition switch OFF Check the HO2 sensor coupler for loose or poor contacts Insert the copper wires to the HO2 sensor lead wire coupler Warm up the engine enough Measure the HO2 sensor output voltage at the coupler between Black and Gray wires when idling condition Also measure the HO2 sensor output voltage while holding the engine speed at 3 000 r min No Yes Replace the HO2 sensor w...

Page 204: ... few seconds it is good condition NOTE Temperature of the sensor affects resistance value largely Make sure that the sensor heater is at correct tempera ture z09900 25008 Multi circuit tester set tTester knob indication Resistance Ω HO2 heater resistance 4 5 Ω at 23 C 73 4 F White White Heater voltage Battery voltage O W Ground NOTE Battery voltage can be detected only during few seconds after ign...

Page 205: ...er knob indication Voltage Loose or poor contacts on the CVT contol unit coupler Replace the CVT control unit with a new one Replace the ECM with a new one and inspect it again CVT control unit coupler CVT control unit coupler V V f ECM coupler Dark brown Turn the ignition switch OFF Check the ECM coupler and CVT control unit coupler for loose or poor contacts If OK check for existance of CVT seri...

Page 206: ... OK NG Replace the CVT motor Next page Turn the ignition switch OFF Check the CVT motor coupler 1for loose or poor contacts If OK then measure the CVT motor operating voltage Insert the copper wires to the coupler 1 Remove the center stand switch 2 Start the engine and shift to Automatic mode Check that there is a change of motor operating voltage as the engine speed is raised 2 Disconnect the CVT...

Page 207: ... ECM with a new one and inspect it again Remove the CVT motor Apply 12 volts to the terminals of the CVT motor lead wire coupler Check the CVT motor movement Then swap the wires supplied 12 volts and check the movement Check the CVT motor both way movements 12V 12V 3 3 ...

Page 208: ...rt in the Lbl O or R wire or B wire OK NG Replace the CVT control unit Next page Turn the ignition switch OFF Check the PPS coupler 1for loose or poor contacts If OK then measure the PPS input voltage Insert the copper wires to the coupler Turn the ignition switch ON and measure the PPS input voltage 2 Turn the ignition switch OFF Measure the PPS output voltage Insert the copper wires to the PPS c...

Page 209: ...ct it again Turn the ignition switch OFF Remove the PPS Measure the resistance each when the sensor is compressed and extended to the maximum between Lbl Y or Bl wire and B wire terminals Check the PPS smooth movement 8 Dor Jwire open or shorted to ground or poor connection If wire and connection are OK intermittent trouble or faulty ECM Recheck each terminal and wire harness for open circuit and ...

Page 210: ...eed sensor input voltage More than 7 V O R B W z 09900 25008 Multi circuit tester u Tester knob indication Voltage Loose or poor contacts on the CVT control unit couplers Open or short circuit in the O R wire or B W wire Turn the ignition switch OFF Check the speed sensor lead wire coupler 1for loose or poor contacts If OK then measure the speed sensor input voltage Insert the copper wires to the ...

Page 211: ...re caupler White Black White Turn the ignition switch ON Check that the voltage varies when a screwdriver is brought close to the pick up face of the speed sensor V OK NG Short circuit in the lead wire Replace the speed sensor with a new one Recheck the CVT control unit coupler for loose or poor contacts Replace the CVT control unit with a new one and inspect it again 3 3 ...

Page 212: ...cation Resistance Ω Revolution sensor peak voltage More than 5 0 V at idle speed Yellow White z 09900 25008 Multi circuit tester u Tester knob indication Voltage Replace the revolution sensor with a new one NG OK Loose or poor contacts on the CVT control unit coupler CVT control unit malfunction Turn the ignition switch OFF Check the CVT secondary pulley revolution sensor coupler 1for loose or poo...

Page 213: ...FI SYSTEM CVT SYSTEM 3 It C54 code is indicated replace the CVT control unit Remove the CVT assembly 5 2 Remove the CVT secondary pulley revolution sensor 2 Clean away metal particles or foreign material 3 3 ...

Page 214: ... V Br W Ground z 09900 25008 Multi circuit tester u Tester knob indication Voltage Short circuit in the Br W lead wire Loose or poor contacts ECM malfunction Check the ECM and CVT control unit couplers for loose or poor contacts If OK check the CVT engine revolution signal Insert the copper wire to the 3 Br W wire of the CVT control unit coupler Start the engine and measure the signal voltage betw...

Page 215: ...opend Approx 1 7 V z 09900 25008 Multi circuit tester u Tester knob indication Voltage Short circuit in the B R lead wire Loose or poor contacts ECM malfunction Check the ECM and CVT control unit couplers for loose or poor contacts If OK check the CVT throttle signal Insert the copper wire to the Brack Red E wire of the CVT control unit coupler Turn the ignition switch ON and measure the signal vo...

Page 216: ...m does not persist complete the inspection Turn the ignition switch OFF so that the malfunction code is reset Warm up the engine sufficiently and test drive to see if C58 code appears If C58 appears during test running proceed to stage 2 OK NG NG Replace the PPS with a new one Inspect the PPS 1 Remove the foot board 9 18 Remove the PPS 1and check the PPS for smooth movement 3 OK Complete the inspe...

Page 217: ...R The signal rotor is installed on the exhaust camshaft and the camshaft position sensor Pick up coil is installed on the cylin der head cover 6 27 CKP SENSOR The signal rotor is mounted on the generator rotor and the crankshaft position sensor Pick up coil is installed above the rotor 6 28 IAP SENSOR The intake air pressure sensor is located at the right side of the air chamber 6 29 ...

Page 218: ...nsor is installed on the cyl inder head 6 33 ECT sensor 18 N m 1 8 kgf m 13 0 lb ft SPEED SENSOR The speed sensor is installed on the final gear case 6 34 IAT SENSOR The intake air temperature sensor is installed on the right side of the air chamber 6 36 AP SENSOR The atmospheric pressure sensor is located at the right side of the leg shield brace 6 37 ...

Page 219: ...CVT PULLEY POSITION SENSOR The CVT pulley position sensor is mounted on the CVT cover 6 47 CVT SECONDARY PULLEY REVOLUTION SENSOR The secondary pulley revolution sensor is located underneath the CVT assembly 6 51 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 ...

Page 220: ...CLEANING 7 10 FUEL LEVEL GAUGE INSPECTION 7 10 FUEL PUMP FUEL LEVEL GAUGE REASSEMBLY AND INSTALLATION 7 11 THROTTLE BODY 7 14 THROTTLE BODY COMPONENTS 7 14 THROTTLE BODY REMOVAL 7 15 THROTTLE BODY DISASSEMBLY 7 17 THROTTLE BODY CLEANING AND INSPECTION 7 19 IAC VALVE INSPECTION 7 20 THROTTLE BODY REASSEMBLY 7 20 THROTTLE BODY INSTALLATION 7 22 THROTTLE CABLE ADJUSTMENT 7 23 TP SENSOR ADJUSTMENT 7 2...

Page 221: ...FUEL TANK COMPONENTS 1Fuel tank 2Seal ring 3Ring locknut 4Fuel tank pressure control valve Orange Black 5Fuel tank pressure control valve Gray Black 6Fuel tank inlet pipe 7Fuel tank inlet hose 8Fuel filler 9Fuel filler cap 33 N m 3 3 kgf m 24 lb ft ...

Page 222: ...e cover Center frame cover Helmet box cover Frame covers Helmet box Loosen the fuel tank inlet hose clamp Disconnect the fuel tank breather hose 1 Remove the fuel tank inlet hose 2 along with the fuel tank inlet pipe 3 Disconnect the fuel pump fuel level gauge coupler 4 Disconnect the fuel feed hose 5 Disconnect the fuel cut valve hose 6 Remove the fuel tank mounting bolts ...

Page 223: ...quipped in the fuel tank they can be distinguished by the color Fuel inlet side 1 Gray Black Fuel tank side 2 Orange Black Check FTPC valve if air can pass through smoothly when blown from the orange color side or gray color side and not from the other side Should any abnormal condition be found replace the valve with a new one Gasoline is highly flammable and explosive Keep heat spark and flame a...

Page 224: ...e hose Turn the ignition switch ON and check the fuel pressure Fuel pressure Approx 300 kPa 3 0 kgf cm2 43 psi If the fuel pressure is lower than the specification inspect the following items Fuel hose leakage Clogged fuel filter Pressure regulator Fuel pump If the fuel pressure is higher than the specification inspect the following items Fuel pump check valve Pressure regulator Before removing th...

Page 225: ... Yellow with red tracer 1 Apply 12 volts to the fuel pump for 30 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 discharge amount More than 900 ml 30 sec 30 4 31 7 US Imp oz 30 sec NOTE The battery must be in fully charged condition FUEL PUMP RELAY INSPECTION Fuel ...

Page 226: ...fuel pump fuel level gauge coupler 1 Disconnect the fuel feed hose 2 NOTE The fuel pump can be removed without removing the fuel tank 1Fuel pump assembly 2O ring 3Fuel filter cartridge assembly 4Fuel pressure regulator 5O ring 6Fuel level gauge 7Fuel pump upper cover 8Fuel pump lower cover 9Fuel feed hose 33 N m 3 3 kgf m 24 lb ft Align the marks in line ...

Page 227: ...cial tool 09941 51010 Ring locknut wrench Remove the fuel pump assembly Disconnect the fuel level gauge lead wire coupler Remove the fuel level gauge Disconnect the ground wire Remove the fuel pressure regulator Gasoline is highly flammable and explosive Keep heat spark and flame away ...

Page 228: ...ROTTLE BODY 7 9 Disconnect the fuel pump lead wire coupler and ground wire Remove the fuel pump lower case 1 Disconnect the fuel feed hose 2 Disconnect the fuel pump lead wire coupler Remove the fuel pump from its holder ...

Page 229: ...ith many sediment or rust replace the fuel filter cartridge with a new one FUEL LEVEL GAUGE INSPECTION Measure resistance between the terminals when the float is at the position listed below 09900 25008 Multi circuit tester If the resistance measured is out of the specification replace the gauge with a new one Fuel meter inspection 10 27 Fuel level position Resistance between terminals 130 mm F 11...

Page 230: ...of removal and disassembly and pay attention to the following points Install the new O rings to the fuel pump fuel pressure regula tor and fuel feed hose Apply thin coat of the engine oil to the O rings Install the fuel pump to its holder and connect the lead wire coupler Connect the fuel feed hose securely Use the new O rings to prevent fuel leakage ...

Page 231: ...ll the fuel pressure regulator and ground wire Install the fuel level gauge Connect the fuel pump lead wire coupler ground wire and fuel level gauge lead wire coupler Install the new seal ring 1 to the fuel tank Install the fuel pump assembly ...

Page 232: ...D THROTTLE BODY 7 13 Align the alignment marks A and B in line Using the special tool tighten the fuel pump ring locknut to the specified torque 09941 51010 Ring locknut wrench Ring locknut 33 N m 3 3 kgf m 24 lb ft ...

Page 233: ... 35 kgf m 2 5 lb ft 3 5 N m 0 35 kgf m 2 5 lb ft 1TP sensor 2O ring 3Fuel injector 4Fuel injector seal 5O ring 6Fuel delivery pipe 7Fuel delivery pipe joint 8O ring 9IAC hose connector 0O ring AIAC valve BO ring CThrottle stop screw DThrottle lever stopper screw EThrottle cable bracket FThrottle body GSynchronizing screw HO ring IVacuum hose ...

Page 234: ...ront box 9 18 Disconnect the PCV hose from the bottom side of the air cleaner box Remove the air cleaner box 1 Remove the IAP sensor 2 Disconnect the IAT sensor coupler 3 Remove the PAIR solenoid valve 4 Loosen the respective throttle body clamp screws air cham ber side ...

Page 235: ...IAC valve 9 FI Disconnect the fuel feed hose 0 Disconnect the throttle cables Loosen the respective throttle body clamp screws intake pipe side Remove the throttle body assembly After disconnecting the throttle cables do not snap the throttle valve from full open to full close It may cause damage to the throttle valve and throttle body ...

Page 236: ...ASSEMBLY Remove the IAC hose Remove the vacuum hoses Remove the fuel delivery pipe Remove the fuel injectors Remove the IAC valve Remove the TPS NOTE Prior to disassembly mark sensor s original position with a paint or scribe for accurate reinstallation ...

Page 237: ...TE Before removing the synchronizing 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 synchronizing screw to original position Never remove the throttle valve Avoid removing the throttle lever stopper screw A ...

Page 238: ... chemicals especially dip type soaking solutions are very corrosive and must be handled carefully Always follow the chemical manufacturer 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 cleaning solution and allow them to soak Always fol...

Page 239: ...w one Remove the IAC valve cover 1 Disconnect the IAC valve lead wire coupler Connect the 12 V battery to the IAC valve terminals for more than 3 minutes and check for change of the IAC valve temper ature from the cold condition If the IAC valve is not warmed up replace the IAC valve with a new one THROTTLE BODY REASSEMBLY Reassemble the throttle body in the reverse order of disassem bly Pay atten...

Page 240: ...ring Install the injector seal 1 and O ring 2 to each 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 each throt tle body Install the fuel delivery pipe assembly to the throttle body assembly Tighten the fuel delivery pipe mounting screws Fuel delivery pipe mounting screw 3 5 N m 0 35 kgf m 2 5 lb ft Replace the ...

Page 241: ...the engine oil to the new O ring THROTTLE BODY INSTALLATION Installation is in the reverse order of removal Pay attention to the following points Connect the throttle pulling cable and throttle returning cable to the throttle cable drum Adjust the throttle cable play with the cable adjusters Refer to page 2 19 for details THROTTLE BODY CLAMP POSITION Replace the O ring with a new one Replace the O...

Page 242: ... 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 box 9 18 Disconnect the injector couplers Remove the fuel delivery pipe assembly 7 17 Remove the fuel injectors No 1 and No 2 7 17 FUEL INJECTOR INSPECTION The fuel injector can be checked without removing it from the throttle body Refer to page 6 40 for deta...

Page 243: ...d start up the engine Bring the engine rpm to 1 200 rpm by the throttle stop screw Check the vacuum of the two cylinders and balance the two throttle valves with the synchronizing screw A NOTE During balancing the throttle valves always set the engine rpm at 1 200 rpm using throttle stop screw After balancing the two valves set the idle rpm to 1 200 rpm For vacuum balancer gauge 09913 13121 The va...

Page 244: ...OUNTING 8 9 COOLING FAN THERMO SWITCH 8 10 REMOVAL 8 10 INSPECTION 8 11 INSTALLATION 8 11 ENGINE COOLANT TEMPERATURE SENSOR 8 12 REMOVAL 8 12 INSPECTION 8 13 INSTALATION 8 13 THERMOSTAT 8 14 REMOVAL 8 14 INSPECTION 8 14 INSTALLATION 8 15 WATER PUMP 8 16 CONSTRUCTION 8 16 REMOVAL AND DISASSEMBLY 8 17 INSPECTION 8 19 REASSEMBLY AND INSTALLATION 8 21 LUBRICATION SYSTEM 8 25 OIL PRESSURE 8 25 OIL FILT...

Page 245: ... the radiator As the cool ant temperature rises to about 88 C 190 F the thermostat valve unseats and a normal coolant flow is established At about 100 C 212 F the thermostat becomes completely open and as a result heat is released to the atmosphere through the radiator core COOLING CIRCUIT OIL COOLER Oil cooler is setting on the place of oil filter The engine oil is cooled by engine coolant which ...

Page 246: ...ator anti leak additive Anti freeze 650 ml 1 4 1 1 US lmp pt Water 650 ml 1 4 1 1 US lmp pt Anti freeze density Freezing point 50 55 60 31 C 24 F 40 C 40 F 55 C 67 F 20 40 60 80 100 Density 0 10 20 30 40 50 60 70 32 14 4 22 40 58 76 94 Freezing point Fig 1 Engine coolant density freezing point curve C F 0 10 20 30 40 50 60 Density 150 140 130 120 110 100 Boiling point C F 302 284 266 248 230 212 E...

Page 247: ...er 1 Attach the radiator cap to the radiator tester as shown Slowly apply pressure to the radiator cap do not exceed 95 125 kPa 0 95 1 25 kgf cm 13 5 17 8 psi If the radiator cap does not hold the pressure for at least 10 seconds replace it with a new one Radiator cap release pressure 95 125 kPa 0 95 1 25 kgf cm 13 5 17 8 psi RADIATOR INSPECTION Check the radiator for dirt and other foreign materi...

Page 248: ...8 5 RADIATOR HOSE INSPECTION Remove the leg shield and footboard 9 10 9 18 Any radiator hose found in a cracked condition or flattened must be replaced Any leakage from the connecting section should be corrected by proper tightening ...

Page 249: ...e the leg shield and footboard 9 10 9 18 Drain engine coolant by removing the drain plug Disconnect the fan motor lead wire coupler 1 Disconnect the upper and lower radiator hoses Remove the three mounting bolts and radiator assembly Remove the radiator guard ...

Page 250: ...otor lead wire coupler Tighten the drain plug to the specified torque Drain plug 6 N m 0 6 kgf m 4 3 lb ft Pour engine coolant 2 21 Bleed air from the cooling circuit 2 21 RADIATOR RESERVOIR TANK REMOVAL REMOUNTING Remove the reservoir tank mounting bolt Disconnect the siphon hose from the reservoir tank and drain engine coolant Install the reservoir tank in the reverse order of removal Fill the r...

Page 251: ...ts to the motor With the motor with electric motor fan running at full speed the ammeter should be indicating not more than 5 amperes If the fan motor does not turn replace the motor assembly with a new one NOTE When making above test it is not necessary to remove the cool ing fan Connection Fan motor lead wire coupler BLUE Fan switch coupler BLACK fan motor side REMOVAL Remove the radiator 8 6 Di...

Page 252: ...ve the cooling fan REMOUNTING Remount the cooling fan in the reverse order of removal Pay attention to the following point Tighten the cooling fan mounting bolts to the specified torque Cooling fan mounting bolt 6 5 N m 0 65 kgf m 4 7 lb ft ...

Page 253: ...ting the cooling fan in motion REMOVAL Remove the leg shield and footboard 9 10 9 18 Drain engine coolant 2 20 Disconnect the cooling fan thermo switch lead wire coupler 1 Remove the cooling fan thermo switch 2 Ignition switch Fuse Fuse Main fuse Battery Fan relay Cooling fan motor Cooling fan thermoswitch CVT controller O G O B O B B R R B W Gr Y O G O B O B B R R B W Gr Y WIRE COLOR B O R B O B ...

Page 254: ... switch operating temperature Standard OFF ON Approx 98 C 208 F ON OFF Approx 92 C 198 F INSTALLATION Install the cooling fan thermo switch in the reverse order of removal Pay attention to the following points Apply engine coolant to the O ring Tighten the cooling fan thermo switch to the specified torque Cooling fan thermo switch 17 N m 1 7 kgf m 12 3 lb ft Pour engine coolant 2 21 Bleed air from...

Page 255: ...t the engine coolant temperature sensor lead wire coupler 1 Remove the engine coolant temperature sensor 2 Ignition switch Fuse Fuse Main fuse Battery Handle switch Water temp sensor Water temp warning ECU Speedometer O O W O G B Br B Br B Bl P W R O Y O Y B W O O W O G B Br B Bl P W R O Y B W WIRE COLOR O R B Br B Bl B W O G O Y O W P W Orange Red Black with Brown tracer Black with Blue tracer Bl...

Page 256: ...or specification If the resistance noted to show infinty or too much different resis tance value replace the temperature sensor with a new one INSTALATION Tighten the engine coolant temperature sensor to the speci fied torque Engine coolant temperature sensor 18 N m 1 8 kgf m 13 0 lb ft Temperature Standard resistance 20 C 68 F Approx 2 45 kΩ 50 C 122 F Approx 0 811 kΩ 80 C 176 F Approx 0 318 kΩ 1...

Page 257: ...immersed thermo stat is in suspension Heat the water by placing the beaker on a stove and observe the rising temperature on a thermometer 2 Read the thermometer just when opening the thermostat This reading which is the temperature level at which the thermo stat valve begins to open should satisfy the standard value Thermostat valve opening temperature Standard Approx 88 C 190 F Do not contact the...

Page 258: ...ver 0 31 in at 212 F A thermostat failing to satisfy either of the two requirements start to open temperature and valve lift must be replaced with a new one INSTALLATION Install the thermostat in the reverse order of removal Apply engine coolant to the rubber seal on the thermostat Install the thermostat NOTE The jiggle valve A of the thermostat faces upside Install the thermostat case Pour engine...

Page 259: ...ION 1Water pump cover 2O ring 3Impeller 4Mechanical seal 5Oil seal 6O ring 7Inner bearing 8Outer bearing 9E ring 0Circlip AO ring Oil pump drive chain Oil pump Oil pump driven sprocket Mechanical seal Impeller Inner bearing Outer bearing Impeller shaft Shaft ...

Page 260: ...ith impeller 2 Do not open the radiator cap when the engine is hot as you may be injured by escaping hot liquid or vapor The engine must be cool before servicing the cooling system Engine coolant may be harmful if swallowed or if it comes in contact with the skin or eyes If engine cool ant gets into the eyes or contacts the skin flush the eyes or wash the skin thoroughly with plenty of water If en...

Page 261: ...ing using the special tool 09921 20240 Bearing remover set NOTE If there is no abnormal noise bearing removal is not necessary Remove the circlip 1 Remove the inner bearing using the special tool 09921 20240 Bearing remover set NOTE If there is no abnormal noise bearing removal is not necessary The removed mechanical seal must be replaced with a new one The removed bearing must be replaced with a ...

Page 262: ...TION BEARING Inspect the play of the outer bearing and inner bearing by hand while it is in the water pump case Rotate the inner race by hand to inspect for abnormal noise and smooth rotation Replace the bearing if there is anything unusual MECHANICAL SEAL Visually inspect the mechanical seal for damage with particu lar attention given to the sealing face Replace the mechanical seal that shows ind...

Page 263: ...particular atten tion given to the lip Replace the oil seal that shows indications of leakage BEARING CASE MECHANICAL CASE Visually inspect the bearing case and mechanical case for damage Replace the water pump body if necessary IMPELLER Visually inspect the impeller and its shaft for damage ...

Page 264: ... Install the new outer bearing using the special tool 09913 70210 Bearing installer set Install the new oil seal using the special tool 09913 70210 Bearing installer set NOTE The stamped mark on the oil seal faces outside Apply a small quantity of the SUZUKI SUPER GREASE A to the oil seal lip W 99000 25030 SUZUKI SUPER GREASE A USA 99000 25010 SUZUKI SUPER GREASE A Others ...

Page 265: ...the oily or greasy matter from the mechanical seal ring install it into the impeller NOTE The paint marked side A of the mechanical seal ring faces the impeller Make sure the mechanical seal ring is fit into the impeller Apply grease to the impeller shaft W 99000 25030 SUZUKI SUPER GREASE A USA 99000 25010 SUZUKI SUPER GREASE A Others Install the impeller shaft to the water pump body Install the E...

Page 266: ...KI SUPER GREASE A Others Install the water pump body 1 with impeller 2 to the crank case Fit the cable clip NOTE Set the water pump shaft end A to the oil pump shaft B as shown in the figures Install the O ring to the water pump cover Apply engine coolant to the O ring Install the water pump cover Use the new O rings to prevent engine coolant leak age ...

Page 267: ...8 24 COOLING AND LUBRICATION SYSTEM Connect the radiator hose Pour engine coolant 2 21 Bleed air from the cooling circuit 2 21 Install the leg shield and footboard ...

Page 268: ...YSTEM 8 25 LUBRICATION SYSTEM OIL PRESSURE 2 31 OIL FILTER 2 14 OIL COOLER 3 17 3 63 OIL PRESSURE REGULATOR 3 44 OIL SUMP FILTER 3 44 OIL LEVEL SWITCH 10 29 OIL PRESSURE SWITCH 10 36 OIL PUMP 3 20 3 60 OIL RETURN PUMP 3 21 3 59 ...

Page 269: ... OIL PRESSURE SWITCH CRANKSHAFT PIN BEARING RH 2 PISTON PIN TAPPETS VALVES CAMSHAFT FLANGE WATER PUMP BEARING TO OIL PAN TO OIL PAN ORIFICE JET ORIFICE JET OIL RETURN HOSE 1 CYLINDER WALL CYLINDER HEAD 2 CYLINDER WALL CRANK JOURNAL BEARING LH 1 PISTON PIN CAMSHAFT FLANGE TAPPETS VALVES CLUTCH COVER CLUTCH CASE TRANSMISSION CASE DRIVESHAFT BEARING OIL SUMP FILTER COUNTER SHAFT GEAR IDLE SHAFT GEAR ...

Page 270: ...COOLING AND LUBRICATION SYSTEM 8 27 ENGINE LUBRICATION SYSTEM EXHAUST SIDE INTAKE SIDE OIL SUMP FILTER To oil pump MAIN GALLERY LUBRICATION OIL RETURNED OIL ...

Page 271: ... COOLING AND LUBRICATION SYSTEM OIL FILTER OIL COOLER To A From A OIL PRESSURE REGULATOR OIL PUMP OIL SUMP FILTER OIL RETURN PUMP ORIFICE JET OIL SUMP FILTER DRIVESHAFT BEARING LUBRICATION OIL RETURNED OIL ...

Page 272: ...ISASSEMBLY 9 33 INSPECTION 9 35 REASSEMBLY AND REMOUNTING 9 36 STEERING AND HANDLEBARS 9 40 CONSTRUCTION 9 40 REMOVAL 9 41 INSPECTION AND DISASSEMBLY 9 43 REASSEMBLY AND REMOUNTING 9 43 STEERING TENSION ADJUSTMENT 9 46 REAR WHEEL 9 47 CONSTRUCTION 9 47 REMOVAL 9 48 INSPECTION AND DISASSEMBLY 9 50 REASSEMBLY AND REMOUNTING 9 52 REAR SHOCK ABSORBER 9 57 CONSTRUCTION 9 57 REMOVAL 9 57 INSPECTION 9 58...

Page 273: ...CYLINDER REASSEMBLY AND REMOUNTING 9 71 REAR BRAKE 9 73 CONSTRUCTION 9 73 BRAKE PAD REPLACEMENT 9 74 BRAKE FLUID REPLACEMENT 9 76 CALIPER REMOVAL AND DISASSEMBLY 9 76 CALIPER INSPECTION 9 78 CALIPER REASSEMBLY AND REMOUNTING 9 79 BRAKE DISC INSPECTION 9 83 MASTER CYLINDER REMOVAL AND DISASSEMBLY 9 83 MASTER CYLINDER INSPECTION 9 83 MASTER CYLINDER REASSEMBLY AND REMOUNTING 9 83 BRAKE LOCK ADJUSTME...

Page 274: ...9 2 CHASSIS EXTERIOR PARTS CONSTRUCTION 1Front meter panel 2Leg shield brace 3Meter cover 4Front panel 5Leg shield 6Lower leg shield 7Floor mat 8Front box ...

Page 275: ...CHASSIS 9 3 1Maintenance lid 2Foot board 3Frame cover 4Leg side cover 5Center frame cover 6Lower frame cover 7Rear fender 8Floor mat 9Tray 0Packing For E 28 ...

Page 276: ...me Upper trunk box Lower trunk box Fuel tank Frame Frame cover Battery cover Foot board Trunk box cover A Max 1mm 0 04 in Both ends of weather strip should be butted at the front of the trunk box Outside Weather strip ...

Page 277: ...CHASSIS 9 5 1Front box 2Lid 3Cushion 4Cushion 5Front inner box 6Cushion FRONT BOX FOOT BOARD ASSEMBLY 1Foot board 2Louver 3Duct ...

Page 278: ...ter frame cover 9 15 JWind screen cover 9 7 KFront leg shield cover 9 11 LIgnition switch 9 19 MFloor mat right and left 9Seat 9 13 0Seat damper 9 14 APillion rider handle right and left 9 15 BTrunk box cover 9 16 CFrame cover right and left 9 16 DFoot board 9 18 EFront box 9 18 FRear fender 9 20 REMOVAL PROCEDURE FLOW CHART 1Wind screen JWind screen cover 5Lower leg shield KFront leg shield cover...

Page 279: ...CHASSIS 9 7 WIND SCREEN Remove the screws Remove the wind screen cover 1 hooked part Remove the wind screen Remove the wind screen brace 2 ...

Page 280: ...9 8 CHASSIS HANDLEBAR COVER Remove the handlebar rear cover 1 Remove the handlebar front cover 2 FRONT PANEL Remove the handlebar cover above Remove the screws Remove the front panel ...

Page 281: ... 9 8 Remove the front panel 9 8 Remove the bolts Disconnect the turn signal coupler which is located under the combination meter Remove the screws Insert the screw driver into the hole A Pry the turn signal light out 10 32 Disconnect the turn signal coupler ...

Page 282: ... of fastener Remove the screws Remove the lower leg shield 2 LEG SHIELD Remove the handlebar covers 9 8 Remove the front panel 9 8 Remove the lower leg shield above Remove the screws Remove the right left floor mat Remove the screws Detach the insertings of the leg side covers ...

Page 283: ...CHASSIS 9 11 Remove the front leg shield cover 1 hooked part Remove the screws Disconnect the headlight couplers ECM couplers and posi tion light couplers only E02 E19 Remove the leg shield ...

Page 284: ...the screws and fasteners Remove the right leg side cover by detaching the insertings LEFT LEG SIDE COVER Remove the floor mats Remove the screws and fasteners Remove the left side cover by detaching the insertings Foot board Leg side cover Foot board Leg side cover ...

Page 285: ...Cover the hatched areas in order to prevent the front box from getting damage SEAT Lift the seat up Remove the tool set Remove the battery cover 1 Remove the battery 10 3 Disconnect the trunk light coupler 2 Disconnect the seat damper 9 14 Remove the seat by removing the nuts at the seat hinge Foot board Maintenance lid ...

Page 286: ...9 14 CHASSIS SEAT DAMPER Remove the right frame cover 9 16 Remove the clip 1 washer 2 and mounting bolt 3 Remove the seat damper 4 Upward Seat Right Frame ...

Page 287: ...CHASSIS 9 15 PILLION RIDER HANDLE Lift the seat up Remove the lower frame cover 1 by removing the fasteners Remove the center frame cover 2 Remove the pillion rider handles 3 ...

Page 288: ...e starter relay 2 and coupler 3 from the battery cover Remove the battery 10 3 Remove the trunk box cover 4 FRAME COVER Remove the lower frame cover center frame cover and pillion rider handles 1 9 15 Remove the trunk box cover above Remove the bolt and the fasteners ...

Page 289: ...ashers from falling in the fuel inlet For E 28 Remove the fuel tank cap Remove the fuel inlet mounting screws and tray 2 NOTE When applying a tool to the mounting screw turn the lower part of cushion 3 over Remove the screws Remove the turn signal light socket and combination light socket Remove the frame covers Unclamp the harness in the back of the frame cover ...

Page 290: ... 9 16 Frame covers 9 16 Right left leg side covers 9 12 Front box 9 18 Remove the screws on the cooling duct Remove the foot board FRONT BOX Remove the following parts Maintenance lid 9 13 Handlebar covers 9 8 Front panel 9 8 Leg shield 9 10 Screws in the box Disconnect the power source coupler ...

Page 291: ...l the brake lock knob Remove the brake lock knob 1 Remove the inner box 2 Remove the ignition switch 3 by using the special tools 09930 11930 Torx bit JT30H 09930 11940 Bit holder Remove the screws Remove the front box ...

Page 292: ...s and bolts Remove the rear fender 2 Disconnect the license light coupler TRUNK BOX Remove the following parts Seat 9 13 Pillion rider handles 9 15 Right left frame covers 9 16 Rear fender above Foot board 9 18 Remove the rear frame brace 1 Remove the trunk light seat switch 2 ...

Page 293: ...CHASSIS 9 21 Remove the seat lock 3 Remove the trunk box screws Remove the muffler bracket 4 Remove the seat rail 5 Remove the trunk box 6 ...

Page 294: ...en brace 9 7 Remove the leg shield 9 10 Remove the front meter panel 1 and the combination meter assembly Remove the electrical parts from the leg shield brace Remove the mounting bolts NOTE It is possible to remove the leg shield brace without removing the front box ...

Page 295: ...ntion to the following points SEAT RAIL Apply THREAD LOCK SUPER 1360 to the seat rail mount ing bolts only M10 J 99000 32130 THREAD LOCK SUPER 1360 Tighten the seat rail mounting bolts to the specified torque Seat rail mounting bolt M8 23 N m 2 3 kgf m 16 5 lb ft M10 50 N m 5 0 kgf m 36 0 lb ft ...

Page 296: ...bar according to the clearance measured above NOTE When rotating the handlebar by 0 5 mm 0 02 in at the punch mark the clearance would be varied as follows A 4 7 mm 0 19 in at front end of handlebar cover B 7 3 mm 0 29 in at rear end of handlebar cover Tighten the handlebar clamp bolts to the specified torque Handlebar clamp bolt 23 N m 2 3 kgf m 16 5 lb ft Install the handlebar covers Inspect the...

Page 297: ...CHASSIS 9 25 FRONT WHEEL CONSTRUCTION 1Brake disc 2Coller 3Dust seal 4Bearing 5Front tire 6Front wheel 7Spacer 8Tire valve ADisc bolt BFront axle ITEM N m kgf m lb ft A 23 2 3 16 5 B 65 6 5 47 0 ...

Page 298: ...removing the caliper Loosen the axle pinch bolt Loosen the front axle with special tool 09900 18710 Hexagon socket 12 mm Rise the front wheel off the ground and support the motorcy cle with a jack or wooden block Remove the front axle and the front wheel Remove the collar 1 NOTE After removing the front wheel fit the calipers temporarily to the original positions Make sure that the motorcycle is s...

Page 299: ... exceeds the limit 09900 20607 Dial gauge 1 100 09900 20701 Magnetic stand 09900 21304 V block set 100 mm Axle shaft runout Service Limit 0 25 mm 0 010 in WHEEL Make sure that the wheel runout checked as shown does not exceed the service limit An excessive runout is usually due to worn or loosened wheel bearings and can be reduced by replac ing the bearings If bearing replacement fails to reduce t...

Page 300: ... in the wheel Rotate the inner race by finger to inspect for abnor mal noise and smooth rotation Replace the bearing in the following procedure if there is any thing unusual Remove the wheel bearings by using the special tool 09921 20240 Bearing remover set Do not reuse the removed bearings ...

Page 301: ...REMOUNTING Reassemble and remount the front wheel in the reverse order of removal and disassembly Pay attention to the following points 23 N m 2 3 kgf m 16 5 lb ft Right Left 23 N m 2 3 kgf m 16 5 lb ft 65 N m 6 5 kgf m 47 0 lb ft ...

Page 302: ...513 Bearing Steering race installer set 09913 70210 Bearing installer set BRAKE DISC Make sure that the brake disc is clean and free of any greasy matter Apply THREAD LOCK SUPER 1360 to the disc mounting bolts and tighten them to the specified torque Brake disc bolt 23 N m 2 3 kgf m 16 5 lb ft J 99000 32130 THREAD LOCK SUPER 1360 The sealed cover of the bearing must face outside Right Right Left L...

Page 303: ...on the left front fork leg move the front fork up and down 4 or 5 times without applying front brake Make sure that the arrow on the tire side wall points to the wheel rotation 9 93 Tighten axle pinch bolt on the left front fork leg to the specified torque Front axle pinch bolt 23 N m 2 3 kgf m 16 5 lb ft BRAKE CALIPER Tighten the brake caliper mounting bolts to the specified torque Front brake ca...

Page 304: ...ing 6Cylinder 7 Rebound spring 8 Inner tube 9 Dust seal 0 Stopper ring A Oil seal B Retainer C Guide metal D Slide metal E Oil lock piece F Fork cover G Outer tube H Gasket ITEM N m kgf m lb ft A 23 2 3 16 5 B 23 2 3 16 5 C 30 3 0 21 5 AFork cap bolt BAxle pinch bolt CCylinder bolt ...

Page 305: ... front fork upper clamp bolt 1 NOTE Slightly loosen the front fork cap bolt 2 before loosening the lower clamp bolts to facilitate later disassembly Loosen the front fork lower clamp bolts NOTE Hold the front fork by the hand to prevent sliding out of the steer ing stem Remove the front fork cap bolt 3 with the special tool 09940 30230 Socket hexagon 17 mm ...

Page 306: ...he fork inverted for a few minutes to drain oil Remove the cylinder bolt 7 NOTE If the cylinder turns together with the cylinder bolt temporarily install the fork spring spacer washer and cap bolt to prevent the cylinder from turning Remove the cylinder 8 and rebound spring 9 Remove the dust seal Remove the oil seal stopper ring ...

Page 307: ... Inspect the inner tube outer surface and the outer tube inner sur face for scratches If any defects are found replace them with the new ones FORK SPRING Measure the fork spring free length If it is shorter than the ser vice limit replace it with a new one Front fork spring free length Service limit 341 mm 13 42 in The slide metal guide metal oil seal and dust seal must be replaced with the new on...

Page 308: ...and as shown Apply fork oil to the oil seal lip lightly before installing it Assemble the following parts as shown 1 Oil seal 2 Oil seal retainer 3 Guide metal 4 Slide metal NOTE Stamped mark on the oil seal must face upward Install the spring 5 into the oil lock piece 6 securely Use special care to prevent damage to the Teflon coated surface of the guide metal when mounting it When installing the...

Page 309: ...ce into the inner tube by compressing the front fork fully Install the guide metal the retainer and the oil seal into the outer rube with special tool 09940 52861 Front fork oil seal installer Install the oil seal stopper ring 7 and the dust seal 8 A Dust seal B Oil seal stopper ring C Oil seal D Oil seal retainer E Guide metal CYLINDER BOLT Install the rebound spring to the cylinder Install the c...

Page 310: ...fully Pour the specified front fork oil into the front fork 99000 99044 10G SUZUKI FORK OIL 10 Front fork oil capacity each leg 482 ml 16 29 16 97 US Imp oz Move the inner tube up and down several strokes until no more bubbles come out from the oil Keep the front fork vertically and leave it during 5 6 minutes NOTE Take extreme attention to pump out air completely Hold the front fork vertically an...

Page 311: ...o the specified torque with the special tool Front fork cap bolt 23 N m 2 3 kgf m 16 5 lb ft 09940 30230 Socket hexagon 17 mm Align the top of the inner tube with the upper surface of the steering stem upper bracket Tighten the front fork upper and lower clamp bolts Front fork upper clamp bolt 23 N m 2 3 kgf m 16 5 lb ft Front fork lower clamp bolt 23 N m 2 3 kgf m 16 5 lb ft Install the front fen...

Page 312: ...2Steering stem upper bracket 3Dust seal 4Upper bearing 5Lower bearing 6Steering stem lower bracket 7Dust seal AHandlebar clamp bolt BUpper clamp bolt CLower clamp bolt DSteering stem head nut ITEM N m kgf m lb ft A 23 2 3 16 5 B 23 2 3 16 5 C 23 2 3 16 5 D 65 6 5 47 0 ...

Page 313: ...eft switch box 3 Disconnect the brake switch coupler Remove the rear brake master cylinder 4 Remove the handlebars STEERING STEM Remove the front panel 9 8 Remove the front fork 9 33 Remove the cable harness guide 1 Remove the brake hose clamp 2 NOTE Before removing the handlebars loosen the steering stem head nut to facilitate later disassembly Remove the steering stem lower cover ...

Page 314: ...Remove the steering stem nut with the special tool 09940 14911 Steering socket wrench Remove the steering stem lower bracket NOTE When loosing the stem nut hold the steering stem lower bracket to prevent it from falling Remove the dust cover 4 and bearing 5 Take care not to make air come in the front brake sys tem ...

Page 315: ...upper and lower bearing races using the special tools 09941 54911 Bearing outer race remover 09941 74911 Steering bearing installer REASSEMBLY AND REMOUNTING Reassemble and remount the steering stem in the reverse order of removal and disassembly Pay attention to the following points BEARING RACES Press in the upper and lower outer races using the special tool 09941 34513 Steering outer race insta...

Page 316: ...t and right so that the angular ball bearing will be seated properly Loosen the steering stem nut by turn NOTE This adjustment will vary from motorcycle to motorcycle Install the front fork to the steering stem lower bracket tempo rarily Install the steering stem upper bracket 1 Tighten the steering stem head nut 2 Steering stem head nut 65 N m 6 5 kgf m 47 0 lb ft Remount the front fork 9 39 HAND...

Page 317: ... tighten the bolts 2 Install the left switch box 3 to the handlebars by engaging the stopper D with the hole E on the handlebars Install the rear brake master cylinder 9 84 Install the right switch box 4 to the handlebars by engaging the stopper F with the hole G on the handlebars Install the front brake master cylinder 9 72 Install the handlebar covers and inspect the handlebar cover clearance 9 ...

Page 318: ...720 Spring scale If the initial force read on the scale when the handlebar starts turning is either too heavy or too light adjust it till it satisfies the specification 1 First loosen the front fork upper and lower clamp bolts steer ing stem head nut and steering stem nut and then adjust the steering stem nut by loosening or tightening it 2 Tighten the steering stem nut stem head nut and front for...

Page 319: ... N m kgf m lb ft A 23 2 3 16 5 B 100 10 0 72 5 1Washer 2Spacer 3Collar 4Dust seal 5Bearing 6Brake disc 7Rear tire 8Spacer 9Hub damper 0Washer ALock washer BO ring CRear hub driven joint DSpacer ERear axle FRear wheel ADisc bolt BRear axle nut ...

Page 320: ...r 1 Disconnect the brake lock cable 2 9 85 Remove the cotter pin For E 03 28 33 Loosen the rear axle nut Remove the caliper Remove the axle nut and draw out the rear axle Remove the spacer 3 Remove the rear wheel Remove the collars 4 Do not operate the brake lever while removing the rear wheel ...

Page 321: ...CHASSIS 9 49 Flatten the lock washers 5 Remove the bolts and washers 6 Remove the rear hub driven joint 7 Remove the O ring 8 Remove the brake disc Replace the removed O ring with a new one ...

Page 322: ...out Service Limit 0 25 mm 0 010 in 09900 20607 Dial gauge 1 100 mm 09900 20701 Magnetic stand 09900 21304 V block set 100 mm REAR HUB DAMPER Inspect the dampers for wear and damage Replace the damper if there is anything unusual Remove the dampers with the appropriate bar REAR HUB DRIVEN JOINT Inspect the rear hub driven joint for wear and damage If any defects are found replace it with a new one ...

Page 323: ...eal remover BEARING Inspect the play of the wheel bearings by hand while they are in the wheel Rotate the inner race by hand to inspect for abnormal noise and smooth rotation Replace the bearing if there is any thing unusual Remove the wheel bearings by using the special tool 09921 20240 Bearing remover set Do not reuse the removed dust seal The removed bearings must be replaced with the new ones ...

Page 324: ...Y AND REMOUNTING Reassemble and remount the rear wheel in the reverse order of removal and disassembly Pay attention to the following points 100 N m 10 0 kgf m 72 5 lb ft 23 N m 2 3 kgf m 16 5 lb ft Right Left For E 03 28 33 ...

Page 325: ...PER GREASE A First install the right wheel bearing then install the left wheel bearing and spacer using the special tool 09941 34513 Bearing Steering race installer set The sealed cover of the bearing must face outside Clearance Spacer Left Right Left Right Spacer Bearing Wheel hub Clearance ...

Page 326: ...mper before installing the hub damper in order to facilitate press fit BRAKE DISC Make sure that the brake disc is clean and free of any greasy matter Apply THREAD LOCK SUPER 1360 to the disc bolts and tighten them to the specified torque J 99000 32130 THREAD LOCK SUPER 1360 Brake disc bolt 23 N m 2 3 kgf m 16 5 lb ft REAR HUB DRIVEN JOINT Apply SUZUKI SUPER GREASE A to the O ring and wheel W 9900...

Page 327: ...tall the rear hub driven gear joint Install the washers 1 lock washers 2 Apply THREAD LOCK SUPER 1303 to the bolts and tighten them F 99000 32030 THREAD LOCK SUPER 1303 Bend the lock washers securely Install the collar ...

Page 328: ...n For E 03 28 33 Install the final gear case cover Install the caliper 9 81 Install the brake lock cable and brake lock arm 9 82 Adjust the brake lock 9 84 NOTE If the caliper pistons come out by operating the rear brake lever while removing the rear caliper it is impossible to push back the pistons into the caliper because of the brake lock system There fore remove the pads and turn the piston cl...

Page 329: ...ove the rear shock absorber mounting nut 1 Remove the rear shock absorber mounting bolt 2 Remove the rear shock absorber Right Left 1 Rear shock absorber 2 Frame 3 Swingarm 4 Final gear case 5Washer A Rear shock absorber nut B Rear shock absorber bolt ITEM N m kgf m lb ft A 29 2 9 21 0 B 29 2 9 21 0 ...

Page 330: ...sorber mounting bolt 29 N m 2 9 kgf m 21 0 lb ft SUSPENSION SETTING After installing the rear suspension adjust the spring pre load as follows SPRING PRE LOAD ADJUSTMENT The pre load is adjusted by turning the pre load adjuster Set the indicator a in the center of absorber lower bracket 1 Position 1 provides the softest spring pre load Position 5 provides the stiffest spring pre load STD position ...

Page 331: ...e rear wheel 9 48 Remove the rear brake hose guide 1 2 Remove the rear shock absorber bolt 3 1 Rear shock absorber 2 Swingarm 3 Bushing 4 Bearing 5 Dowel pin A Rear shock absorber mounting nut B Rear shock absorber mounting bolt C Pivot bolt D Locknut ITEM N m kgf m lb ft A 29 2 9 21 0 B 29 2 9 21 0 C 9 5 0 95 7 0 D 100 10 0 72 5 ...

Page 332: ... pivot locknut 5 washer and the swin garm pivot bolt 6 INSPECTION SWINGARM BEARING Insert the bearing and check smoothness of rotation If there is anything unusual replace the bearing with a new one Inspect the dust seal on the bearing for wear and damage If any defects are found replace the bearing with a new one ...

Page 333: ...lace it with a new one REMOUNTING Remount the swingarm in the reverse order of disassembly and removal and pay attention to the following points Apply SUZUKI SUPER GREASE A to the bearing and then install the bearing W 99000 25010 SUZUKI SUPER GREASE A Install the dowel pins 1 Install the swingarm Apply THREAD LOCK SUPER 1322 to the swingarm bolts Tighten the swingarm bolt G 99000 32110 THREAD LOC...

Page 334: ...lt 9 5 N m 0 95 kgf m 7 0 lb ft Tighten the swingarm pivot locknut 2 to the specified torque Swingarm pivot locknut 100 N m 10 0 kgf m 72 5 lb ft Install the rear wheel 9 56 Install the exhaust muffler 3 11 100 N m 10 0 kgf m 72 5 lb ft 9 5 N m 0 95 kgf m 7 0 lb ft Engine Washer Swingarm ...

Page 335: ...id 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 1Diaphragm 2Dust boot 3Piston cup set 4Brake hose 5Boot 6Caliper 7Brake pad sp...

Page 336: ...nting pin for wear If excessive wear is found replace the mounting pin with a new one Assemble the new brake pad 4 insulator 5 and shim 6 NOTE The pad fitted shim and insulator must be installed at piston side Install the brake pads Replace the brake pads as a set otherwise braking performance will be adversely affected ...

Page 337: ...kgf m 1 8 lb ft NOTE After replacing the brake pads pump the brake lever several times in order to operate the brake correctly and then check the brake fluid level BRAKE FLUID REPLACEMENT Place the motorcycle on a level surface and keep the handle bars straight Remove the brake fluid reservoir cap and diaphragm Suck up the old brake fluid as much as possible Fill the reservoir with the new brake f...

Page 338: ... Brake air bleeder valve 7 5 N m 0 75 kgf m 5 5 lb ft CALIPER REMOVAL AND DISASSEMBLY Drain the brake fluid 9 65 Disconnect the brake hoses by removing the brake hose union bolts Remove the brake calipers by removing the caliper mounting bolts Remove the brake pads 9 64 Remove the caliper holder 1 Remove the pad spring 2 Never reuse the brake fluid left over from previous servicing and which has b...

Page 339: ...ther damage If any damage is found replace the caliper with a new one BRAKE CALIPER PISTON Inspect the brake caliper piston surface for any scratches and other damage If any damage is found replace the caliper piston with a new one CALIPER HOLDER Inspect the caliper holder for damage If any damage is found replace it with a new one Do not use high pressure air to prevent piston dam age Do not reus...

Page 340: ...sification DOT 4 PISTON SEAL Install the piston seal and dust seal as shown in the illustra tion Install the piston to the caliper Wash the caliper components with fresh brake fluid before reassembly Never use cleaning solvent or gaso line to wash them Do not wipe the brake fluid off after washing the compo nents with a rag When washing the components use the specified brake fluid Never use differ...

Page 341: ...tall the brake pads 9 64 NOTE Before remounting the caliper push the piston all the way into the caliper Remount the brake caliper to the front fork Tighten each bolt to the specified torque Front brake caliper mounting bolt 4 26 N m 2 6 kgf m 19 0 lb ft Front brake hose union bolt 5 23 N m 2 3 kgf m 16 5 lb ft The seal washers should be replaced with the new ones to prevent fluid leakage Bleed ai...

Page 342: ...ge 1 100 mm 09900 20701 Magnetic stand Brake disc removal 9 27 Brake disc installation 9 30 MASTER CYLINDER REMOVAL AND DISAS SEMBLY Remove the handlebar cover 9 8 Drain the brake fluid 9 65 Disconnect the front brake light switch coupler 1 Place a rag underneath the union bolt on the master cylinder to catch any spilt brake fluid Remove the brake hose union bolt and disconnect the brake hose Remo...

Page 343: ... cup and dust boot for wear or damage If any defects are found replace them with new ones MASTER CYLINDER REASSEMBLY AND REMOUNTING Reassemble the master cylinder in the reverse order of removal and disassembly Pay attention to the following points N Specification and Classification DOT 4 Wash the master cylinder components with fresh brake fluid before reassembly Never use cleaning solvent or gas...

Page 344: ... holder s mating surface A with punch mark B on the handlebars and tighten the upper bolt 7 first Front brake master cylinder mounting bolt 10 N m 1 0 kgf m 7 0 lb ft After touching the brake hose union to the stopper tighten the brake hose union bolt to the specified torque Brake hose union bolt 23 N m 2 3 kgf m 16 5 lb ft The seal washers should be replaced with the new ones to prevent fluid lea...

Page 345: ...educes 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 them severly ITEM N m kgf m lb ft A 10 1 0 7 0 B 23 2 3 16 5 C 16 1 6 11 5 D 23 2 3 16 5 E 13 1 3 9 5 F 7 5 0 75 5 5 G 23 2 3 16 5 H 9 5 0 95 7 0 I 18 1 8 13 0 1...

Page 346: ... remove the brake pads Clean up the caliper especially around the pistons Inspect the pad mounting pins for wear If excessive wear is found replace the mounting pins with new ones Assemble the new pads 5 insulators 6 and shims 7 Do not operate the brake lever while dismounting the pads Replace the brake pads as a set otherwise braking performance will be adversely affected ...

Page 347: ...ng pin 18 N m 1 8 kgf m 13 0 lb ft Install the caliper Tighten the caliper mounting bolt to the specified torque Caliper mounting bolt 26 N m 2 6 kgf m 19 0 lb ft NOTE After replacing the brake pads pump the brake lever several times to check for proper brake operation and then check the brake fluid level Install the brake lock cable 9 86 Install the brake lock arm with the punch mark D aligned wi...

Page 348: ... until old brake fluid flows out of the bleeder system Close the caliper air bleeder valve and disconnect a clear hose Fill the reservoir with the new fluid to the upper mark of the reservoir Brake air bleeder valve 7 5 N m 0 75 kgf m 5 5 lb ft CALIPER REMOVAL AND DISASSEMBLY Drain the brake fluid above Disconnect the brake lock cable 9 85 Disconnect the brake hose Remove the caliper Remove the br...

Page 349: ...housing 3 Disassemble the parking brake Turn the piston counterclockwise fully Place a rag over the piston to prevent it from popping out and then force out the piston using compressed air Replace the removed O ring with a new one Do not use high pressure air to prevent piston dam age ...

Page 350: ...d replace the rear brake caliper BRAKE CALIPER PISTON Inspect the brake caliper pistons surface for any scratches and other damage Inspect the grooved piston for spring tension by pushing the retainer 1 If any damage is found replace the cali per piston with a new one Do not reuse the dust seal and piston seal to prevent fluid leakage Do not attempt to disassemble the brake lock bolt that is built...

Page 351: ...OUNTING Reassemble and remount the caliper in the reverse order of removal and disassembly Pay attention to the following points N Specification and Classification DOT 4 PISTON SEAL Install the piston seals as shown in the right illustration Install the pistons to the caliper Wash the caliper components with fresh brake fluid before reassembly Never use cleaning solvent or gasoline to wash them Ap...

Page 352: ... SUPER 1303 Tighten the sliding pins 1 2 to the specified torque Caliper sliding pin 1 23 N m 2 3 kgf m 16 5 lb ft Caliper sliding pin 2 13 N m 1 3 kgf m 9 5 lb ft Apply SUZUKI SILICONE GREASE to the sliding pin Z 99000 25100 SUZUKI SILICONE GREASE Install the caliper holder to the caliper Set the boot onto the sliding pin securely Install the brake pad 9 75 ...

Page 353: ...the brake lock housing to the cali per Apply THREAD LOCK SUPER 1360 to the brake lock bolts J 99000 32130 THREAD LOCK SUPER 1360 Tighten the brake lock housing bolts to the specified torque Brake lock housing bolt 23 N m 2 3 kgf m 16 5 lb ft Apply SUZUKI SILICONE GREASE to the O ring Z 99000 25100 SUZUKI SILICONE GREASE Install the O ring into the brake lock housing The seal washers should be repl...

Page 354: ...ke lock cable and E ring Install the brake lock adjust bolt 1 to the brake lock shaft Turn the brake lock shaft about 90 degree counterclockwise so that the punch mark D will face upward Install the brake lock arm 2 with the punch mark E aligned with the punch mark F on the brake lock arm 2 Hook the spring and connect the brake arm 2 with the brake lock cable NOTE Make sure that the spring end fac...

Page 355: ...R CYLINDER REASSEMBLY AND REMOUNTING Reassemble and remount the master cylinder in the reverse order of removal and disassembly Pay attention to the following points N Specification and Classification DOT 4 Apply brake fluid to the piston cup set Install the following parts to the master cylinder 1 Dust boot 2 Snap ring 3 Secondary cup 4 Piston 5 Primary cup 6 Return spring Wash the master cylinde...

Page 356: ... kgf m 16 5 lb ft BRAKE LOCK ADJUSTMENT Before adjusting the brake lock perform to bleed the air from the rear brake system Pull the brake lock lever by one step one notch NOTE The brake lock lever has eight steps eight notches when pull ing in full When pulling the brake lock lever first the brake lock switch makes sound then notch makes a sound Make a count of notch by sound except the brake loc...

Page 357: ...n the adjust bolt more than the given position or the adjust bolt may be damaged Inspect the brake lock 2 33 BRAKE LOCK CABLE REPLACEMENT Remove the right side leg shield 9 12 Remove the front box 9 18 Loosen the locknut 1 Disconnect the brake lock cable 2 Remove the brake hose clamp on the swingarm Remove the locknut 3 Remove the brake lock arm 4 from the caliper Disconnect the brake lock cable 5...

Page 358: ...ock lever assembly Tighten the locknut 9 securely Be sure to fit the boot 0 on the brake lock cable Connect the brake lock cable and install the E ring B Be sure to the dust boots C on the brake lock cable Install the brake lock arm D 9 82 NOTE The open end of spring E must face to the right side of vehicle Install the brake hose clamp Adjust the brake lock 9 84 Install the front box and right leg...

Page 359: ...n this bout the adjust bolt and adjust 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 returned by the return spring Caliper piston Brake calip...

Page 360: ...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 Clearance Caliper piston stroke A...

Page 361: ...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 362: ...e brake 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 ine...

Page 363: ... 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 runout 9...

Page 364: ...st be cleaned off Then install the valve 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 TIRE INSTALLATION Apply tire lubricant to the tire bead When installing the tire onto the wheel observe the following points Seal Be careful not to damage the lip of valve Valve hole Wheel Valve lip Valve Do not reuse the val...

Page 365: ...dicates that the bead is not properly seated If this is the case deflate the tire completely and unseat the bead for both sides Coat the bead with lubricant and fit the tire again When the bead has been fitted properly adjust the pressure to specification 2 26 As necessary adjust the tire balance BALANCER WEIGHT INSTALLATION When installing the balancer weights to the wheel set the two balancer we...

Page 366: ...ON 10 13 STARTER MOTOR REASSEMBLY 10 14 STARTER RELAY INSPECTION 10 15 SIDE STAND IGNITION INTERLOCK SYSTEM PARTS INSPECTION 10 16 IGNITION SYSTEM 10 18 TROUBLESHOOTING 10 18 INSPECTION 10 20 COMBINATION METER 10 23 PARTS NAMES 10 23 REMOVAL AND DISASSEMBLY 10 23 OPERATING PROCEDURE 10 24 INSPECTION 10 26 LAMP 10 31 HEADLIGHT 10 31 BRAKE LIGHT TAILLIGHT TURN SIGNAL LIGHT AND LICENSE LIGHT 10 32 RE...

Page 367: ... Inspect each terminal for corrosion and contamination CLAMPS Refer to the WIRING HARNESS ROUTING section for proper clamping procedures 11 14 to 11 17 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 or any substitutes for the band type clamp FUSES When a fuse blows always investigate the cause correct the problem and...

Page 368: ...t the battery lead wire first When connecting the battery lead wires be sure to connect the battery lead wire first If the terminal is corroded remove the battery pour warm water over it and clean it with a wire brush After connecting the battery apply a light coat of grease to the battery terminals Install the cover over the battery terminal WIRING PROCEDURE Properly route the wiring harness acco...

Page 369: ...6 7Intake air pressure sensor 6 29 8Brake lock switch 9Cooling fan motor relay 0Side stand relay or Fuel pump relay AFuel pump relay or Side stand relay BAtmospheric pressure sensor 6 37 CTO sensor 6 39 DCVT control unit EECM Engine Control Module FSolenoid 12 6 GHorn HCVT motor 6 45 IPulley position sensor 6 47 JCenter stand switch KHO2 sensor 6 42 LCVT secondary pulley revolution sensor 6 51 ...

Page 370: ...arter relay 8Trunk light 9Trunk light switch 0Fuse box ATurn signal relay BRegulator rectifier CSpeedometer sensor DIgnition coil plug cap 1 EIgnition coil plug cap 2 FGenerator GOil pressure switch HSide stand switch ICam position sensor 6 27 JFan motor 8 8 KCooling fan thermo switch 8 16 L CKP sensor 6 28 MOil level switch ...

Page 371: ...ed on next page Remove accessories Short circuit of wire harness Faulty electrical equipment Faulty battery Abnormal driving condition Battery runs down quickly Check accessories which use excessive amounts of electricity Check the battery for current leaks 10 8 Measure the charging voltage between the battery terminals 10 9 Correct Current leaks Accessories are installed ...

Page 372: ...0 9 Measure the generator no load voltage 10 10 Continuity Correct Inspect the regulator rectifier 10 10 Correct Inspect the wires Correct Incorrect No continuity Incorrect Incorrect Short circuit of wire harness Poor contact of coupler Faulty battery Battery overcharges Faulty regulator rectifier Faulty battery Poor contact of generator lead wire coupler Others ...

Page 373: ...ing the multi circuit tester If the reading exceeds the specified value leakage is evident 09900 25008 Multi circuit tester set Q Tester knob indication Current 20 mA Battery current leak Under 3 0 mA When checking to find the excessive current leakage remove the couplers and connectors one by one checking each part Because the current leak might be large turn the tester to the high range first to...

Page 374: ...aking this test be sure that the battery is in fully charged condition 09900 25008 Multi circuit tester set V Tester knob indication Voltage Regulated voltage 14 0 15 5 V at 5 000 r min GENERATOR COIL RESISTANCE Remove the left frame cover 9 16 Disconnect the generator coupler Measure the resistance between the three lead wires If the resistance is not specified value replace the stator coil with ...

Page 375: ...emove the left frame cover 9 16 Disconnect the regulator rectifier couplers 1 Measure the voltage between the terminals using the multi cir cuit tester as indicated in 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 More than 1 4 V tester s battery voltage NOTE If...

Page 376: ...f 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 Make sure the fuses are not blown and the battery is fully charged before diagnosing Measure the starter relay voltage at the starter relay connectors between Y G and Y B when the starter button is pushed No click Clicks Runs Voltage No voltage Faulty start...

Page 377: ...1 and remove the starter motor bolts 2 Remove the starter motor A from the crankcase Turn the starter motor B 180 to forward Remove the starter motor Faulty starter relay Correct Improper starter relay contact Check the starter relay 10 15 Incorrect Engine does not turn though the starter motor runs Faulty starter clutch Others ...

Page 378: ... and wipe it using a clean dry cloth If there is no undercut scrape out the insulator 1 with a saw blade ARMATURE COIL INSPECTION Check for continuity between each segment and between each segment and the armature shaft using the multi circuit tester If there is no continuity between the segments or there is conti nuity between the segments and shaft replace the armature with a new one 09900 25008...

Page 379: ...ay attention to the following points Apply SUZUKI SUPER GREASE A to the lip of the oil seal W 99000 25030 SUZUKI SUPER GREASE A USA 99000 25010 SUZUKI SUPER GREASE A Others Align the marks as shown Apply a small quantity of THREAD LOCK 1342 to the starter motor housing bolts I 99000 32050 THREAD LOCK 1342 Apply SUZUKI SUPER GREASE A to the O ring W 99000 25030 SUZUKI SUPER GREASE A USA 99000 25010...

Page 380: ...ler 3 Remove the starter relay with battery cover Apply 12 V to A and B lead wires and check for continuity between the positive and negative terminals using the multi cir cuit tester If the starter relay clicks and continuity is found the relay is ok 09900 25008 Multi circuit tester set Tester knob indication Continuity test Do not apply a battery voltage to the starter relay for more than five s...

Page 381: ...abnormality is found replace the component with a new one SIDE STAND SWITCH Remove the maintenance lid 9 13 Remove the left leg shield cover 9 12 Disconnect the side stand switch coupler and measure the voltage between Green and Black White lead wires 09900 25008 Multi circuit tester set Tester knob indication Diode test NOTE If the tester reads under 1 4 V when the tester probes are not connected...

Page 382: ...STARTER RELAY DIODE INSPECTION Remove left frame cover 9 16 Remove the diode Measure the voltage between the terminals using the multi cir cuit tester More than 1 4 V tester s battery voltage 09900 25008 Multi circuit tester set Tester knob indication Diode test NOTE If the tester reads under 1 4 V when the tester probes are not connected replace the batter of multi circuit tester Unit V Probe of ...

Page 383: ...ent circuit Engine coolant temp sensor Throttle position sensor CVT control unit Under no load the engine can run over 8 000 r min even if the ignition cut off circuit is effec tive and it may cause engine damage Do not run the engine without load over 8 000 r min at anytime No spark or poor spark Check the ignition system couplers for poor connections Correct Loose Improper coupler connection Con...

Page 384: ...multi circuit tester and the peak volt adaptor Inspect the ignition coil plug cap s 10 21 Correct Measure the CKP sensor peak voltage and its resistance 10 21 to 10 22 NOTE The CKP sensor peak voltage inspection is applicable only with the multi circuit tester and peak volt adaptor Correct Incorrect Correct Incorrect Correct Improper ignition coil plug cap s connection Faulty ignition switch Fault...

Page 385: ...d NOTE Do not disconnect the ignition coil plug cap lead wire couplers 09900 25008 Multi circuit tester set Set the side stand upright position and then turn the ignition switch to the ON position Pull 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 ...

Page 386: ...on Resistance Ω Ω Ω Ω Ignition coil plug cap resistance Primary 0 8 2 5 Ω Ω Ω Ω Terminal Terminal Secondary 8 18 kΩ Ω Ω Ω Plug cap Terminal Install the ignition coil plug cap CKP SENSOR PEAK VOLTAGE Remove the front panel 9 8 Disconnect the wire harness coupler 1 at the ECM Measure the CKP sensor peak voltage in the following proce dure Connect the multi circuit tester with the peak volt adaptor a...

Page 387: ...the CKP sensor lead wire coupler in the same manner as on the ECM coupler V Tester knob indication Voltage CKP sensor peak voltage More than 2 0 V If the peak voltage on the CKP sensor lead wire coupler is 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 generator must be replaced and re checked CKP SENSOR RESIST...

Page 388: ...eter 3Fuel meter 4Turn signal indicator light L 5Engine oil change indicator 6Engine oil level indicator 7Tachometer 8Speedometer 9Turn signal indicator light R 0Brake lock indicator light AFI indicator light BEngine oil pressure indicator light CHigh beam indicator light DClock hour adjust button EClock minute adjust button FClock GRiding mode indicator light HOdometer tripmeter A B ISelect butto...

Page 389: ... With each press of the SELECT button the display changes between odometer tripmeter A and tripmeter B as shown ODOMETER Displays the total distance travelled TRIPMETER Displays the distance travelled since the tripmeter was last reset NOTE The tripmeters A and B can be used independently Hold down the RESET button over two seconds to reset the trip meter CLOCK Displays the time hour and minutes o...

Page 390: ...aximum possible interval is 6 000 km 3 600 miles 4 Push the SELECT and RESET buttons together for more than two seconds NOTE The preset interval can be adjusted after the odometer reading has exceeded 1 000 km 600 miles Reset the indicator after engine oil replacement has been performed With the odometer reading past 1 000 km the oil change interval setting can be adjusted manually If the setting ...

Page 391: ...necting the engine cool ant temp sensor lead wire coupler make sure to turn OFF the ignition switch or electronic parts may get damaged Variable resister Engine coolant temp sensor Resistance More than 1 148 kΩ 1 148 0 587 kΩ 0 587 0 188 kΩ 0 188 0 140 kΩ Engine coolant temperature meter Engine coolant temperature indicator light Engine coolant temperature C H Under 39 C 40 59 C 60 99 C 100 111 C ...

Page 392: ...the combination meter with a new one FUEL GAUGE Remove the fuel pump 7 7 Measure the resistance at each fuel level gauge float position If the resistance is incorrect replace the fuel level gauge with a new one 09900 25008 Multi circuit tester set U Tester knob indication Resistance Ω Ω Ω Ω Resistance More than 112 Ω Less than 50 Ω 96 112 Ω 82 96 Ω 71 82 Ω 51 62 Ω Fuel level meter E F E F E F E F ...

Page 393: ...CATOR NOTE Before inspecting the oil pressure switch check the engine oil level Remove the leg side cover 9 12 Disconnect the oil pressure switch lead wire from the oil pres sure switch Turn the ignition switch ON position Check if the oil pressure indicator comes on when grounding the lead wire If the oil pressure indicator does not come on check the circuit connection or replace the bulb To oil ...

Page 394: ... OIL LEVEL SWITCH Remove the engine oil level switch 3 12 Check the continuity between the lead wine and switch body The relation between the position of the oil level gauge float in the oil level gauge and the continuity as shown below Install the oil level switch 3 74 SPEEDOMETER If the speedometer odometer or trip meter does not function properly inspect the speedometer sensor and connection of...

Page 395: ...Multi circuit tester set V Tester knob indication Voltage Under above condition if a suitable screwdriver touching the pick up surface of the speedometer sensor is moved the tester reading voltage changes 0 V 12 V or 12 V 0 V If the tester reading voltage does not change replace the speedome ter sensor with a new one NOTE The highest voltage reading in this test will be the same as that of battery...

Page 396: ...2 Remove the position light 3 Install the bulbs HEADLIGHT BEAM ADJUSUMENT Remove the front panel 9 8 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 02 E 19 ...

Page 397: ...screw 2 Insert the suitable screwdriver into the screw hole Remove the front turn signal light as shown Remove the socket 3 Remove the bulb 4 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 398: ...he reverse order of removal Brake light taillight Remove the center frame cover 9 15 Remove the socket holder plate 1 and socket 2 Remove the bulb 3 Install the brake light taillight in the reverse order of removal License light Remove the lower frame cover 9 15 Remove the lens 1 Remove the bulb 2 Install the license light in the reverse order of removal ...

Page 399: ...ignal relay may be faulty therefore replace the turn signal relay with a new one NOTE Make sure that the battery is fully charged COOLING FAN MOTOR RELAY Remove the cooling fan motor relay 10 4 First check the insulation between A and B terminals with the tester Then apply 12 V to terminals as shown and check the continuity between A and B If there is no continuity replace the side stand relay wit...

Page 400: ... B B W O G Br ON OFF LOCK P Color Position For Others W Y Y W HI LO Color Position DIMMER SWITCH Lg Lbl B L PUSH R Color Position TURN SIGNAL SWITCH B Lbl Lg OFF ON Color Position HAZARD SWITCH Except for E 24 and AN650L O B O W OFF À RUN Color Position ENGINE STOP SWITCH B BI Y G PUSH Color Position STARTER BUTTON B BI B W PUSH Color Position HORN BUTTON B R B BI OFF ON Color Position FRONT BRAKE...

Page 401: ...Gr Gray B Bl Black with Blue tracer B G Black with Green tracer B W Black with White tracer B R Black with Red tracer BI Y Blue with Yellow tracer Br W Brown with White tracer G Y Green with Yellow tracer O B Orange with Black tracer O Bl Orange with Blue tracer O G Orange with Green tracer O R Orange with Red tracer O W Orange with White tracer R W Red with White tracer Y G Yellow with Green trac...

Page 402: ... the electrolyte container After completely filling the battery with electrolyte use the caps 3 from the electrolyte container to seal the battery filler holes Insert the nozzles of the electrolyte container 5 into the elec trolyte filler holes of the battery Hold the electrolyte container firmly so that it does not fall Do not allow any of the electro lyte to spill Make sure the air bubbles 1 ris...

Page 403: ...p cover of the battery Measure the battery voltage using multi circuit tester The tester should indicate more than 12 5 12 6 V DC as shown in the Fig If the battery voltage is lower than the specification charge the battery with a battery charger Refer to the recharging oper ation NOTE Initial charging for a new battery is recommended if two years have elapsed since the date of manufacture Never u...

Page 404: ... hours or 6 A for 1 hour After recharging wait at least 30 minutes and then measure the battery voltage using the multi circuit tester If the battery voltage is less than 12 5 V recharge the battery again If the battery voltage is still less than 12 5 V after recharging replace the bat tery with a new one When a battery is left unused for a long time its voltage needs to be regularly measured When...

Page 405: ...3 WIRING HARNESS CABLE AND HOSE ROUTING 11 14 WIRING HARNESS ROUTING 11 14 CABLE ROUTING 11 18 THROTTLE BODY INSTALLATION HOSE ROUTING 11 20 FUEL TANK MOUNTING 11 21 FUEL TANK HOSE ROUTING 11 23 RADIATOR HOSE ROUTING 11 25 FRONT BRAKE HOSE ROUTING 11 26 REAR BRAKE HOSE ROUTING 11 27 SIDE STAND SET UP 11 28 CENTER STAND SET UP 11 28 SPECIAL TOOLS 11 29 TIGHTENING TORQUE 11 33 ENGINE 11 33 CVT 11 34...

Page 406: ...15 Engine coolant temperature sensor The sensor voltage should be the following 0 15 V sensor voltage 4 85 V Without the above range C15 is indicated Engine coolant temperature sensor wiring coupler connection C16 Speed sensor The speed sensor signal is not input for more than 3 sec during vehicle deceleration Speed sensor wiring coupler connection C21 Intake air temperature sensor The sensor volt...

Page 407: ...trol unit to ECM for more than 5 sec after starting the engine Wiring coupler connection C51 CVT motor The CVT motor operating voltage is not supplied from CVT control unit CVT motor wiring coupler connection C52 CVT pulley position sensor The sensor should produce following voltage 0 06 sensor voltage 5 04 Without the above range C52 is indicated CVT pulley position sensor wiring coupler connecti...

Page 408: ...t 2 Defective fuel pump 3 Defective fuel pressure regulator 4 Defective throttle position sensor 5 Defective crankshaft position sensor 6 Defective intake air pressure sensor 7 Defective atmospheric pressure sensor 8 Defective ECM 9 Defective engine coolant temp sensor 10 Defective intake air temp sensor Adjust Repair or replace Adjust Replace Replace See electrical section Retighten Clean Clean a...

Page 409: ...y or low battery voltage Control circuit or sensor improperly operating 1 Defective ECM 2 Defective fuel pressure regulator 3 Defective throttle position sensor 4 Defective intake air temp sensor 5 Defective camshaft position sensor 6 Defective crankshaft position sensor 7 Defective engine coolant temp sensor 8 Defective fuel pump relay Engine parts improperly operating 1 Fouled spark plugs 2 Defe...

Page 410: ...ing gears 2 Worn splines 3 Worn or rubbing primary gears 4 Worn bearings Noise seems to come from water pump 1 Too much play on pump shaft bearing 2 Worn or damaged impeller shaft 3 Worn or damaged mechanical seal 4 Contact between pump case and impeller Adjust Replace Replace Replace Replace Clean Replace Replace Replace Replace Repair or replace Replace Replace Replace Replace Replace the primar...

Page 411: ...kened valve springs 3 Valve timing out of adjustment 4 Worn piston rings or cylinders 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 Imbalanced throttle valve synchronization 12 Sucking air from throttle valve or vacuum hose 13 Too much engine oil 14 Defective fuel pump or ECM 15 ...

Page 412: ...g advance system engine coolant temp sensor gear position switch crankshaft position sensor and ECM Clean Add oil Replace or clean Retighten or replace Change See radiator section Repair or replace Repair or replace Repair or replace Replace Replace Replace Dirty or heavy exhaust smoke 1 Too much engine oil in the engine 2 Worn piston rings or cylinders 3 Worn valve guides 4 Scored or scuffed cyli...

Page 413: ...s 2 Defective sensors 3 CVT motor locking Replace Replace Replace Complaint Symptom and possible causes Remedy Engine overheats 1 Not enough engine coolant 2 Radiator core clogged with dirt or scale 3 Faulty cooling fan 4 Defective cooling fan thermo switch 5 Clogged water passage 6 Air trapped in the cooling circuit 7 Defective water pump 8 Use of incorrect engine coolant 9 Defective thermostat A...

Page 414: ...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 on suspension Replenish Retighten Wobbly rear wheel 1 Distorted wheel rim 2 Worn rear wheel bearing or swingarm bearings 3 Defe...

Page 415: ...e fluid 7 Clogged return port of master cylinder Repair surface with sandpa per 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 cor...

Page 416: ... circuited lead wires or loose lead con nections 2 Short circuited grounded or open generator coils 3 Short circuited or panctured regulator rectifiers Repair or replace or retighten Replace Replace Generator does charge but charging 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 stator coils or genera...

Page 417: ...ult of overcharging 3 Internal short circuit in the battery 4 Too low battery voltage 5 Too old battery Check the generator regula tor rectifier and circuit connec tions and make necessary adjustments to obtain specified charging operation Replace the battery and cor rect the charging system Replace the battery Recharge the battery fully Replace the battery Battery sulfation 1 Incorrect charging r...

Page 418: ...T revolution sensor Center stand switch HO2 sensor HO2 sensor CVT revolution sensor Center stand switch Throttle cable Position light R ECM Headlight R Front turn signal light R Handlebar switch R L Clamp Clamp TO sensor Set the front turn signal light L coupler ahead the wiring harness Wiring harness Front turn signal light L Clamp Clamp Front turn signal light L Set the TO sensor as shown TO sen...

Page 419: ...tery Battery terminal Battery terminal Set the lead wires to the front of the battery box Trunk light seat switch Set the lead wires under the fuel hose Wiring harness Set the battery lead wire coupler under the wiring harness Fuel hose Starter relay Fix the starter relay lead wire coupler to hole of the battery cover Battery lead wire coupler Trunk light switch Trunk light seat switch Clamp ...

Page 420: ...enerator Speedometer sensor Clamp Wiring harness Generator Starter motor Clamp Clamp Wiring harness Wiring harness Generator Starter motor Clamp Trunk light switch Wiring harness Clamp Clamp Speedometer sensor Regulator rectifier Oil level switch Oil pressure switch Clamp Oil pressure switch Fuel hose Side stand switch Oil level switch Clamp Wiring harness Clamp Ignition coil plug cap 1 Ignition c...

Page 421: ... VIEW D Oil pressure switch Battery ground wire E D Wirng harness clamp Oil level switch Forward B B C A Starter motor lead wire Starter motor Battery ground wire Oil level switch lead wire Oil pressure switch lead wire Oil pressure switch Oil level switch Clamp ...

Page 422: ... pulling Throttle cable returning Throttle cable pulling Throttle cable returning Throttle cable pulling Pass the throttle cables upper the wiring harness Handlebar switch RH Handlebar switch LH Front brake hose Rear brake hose Rear brake hose Rear brake lock cable Clamp Pass the throttle cables behind the brake hoses Guide Clamp Clamp Clamp Fix the clamp as shown Pass the rear brake lock cable be...

Page 423: ...SERVICING INFORMATION 11 19 Seat lock cable Seat lock cable Clamp Seat lock cable Clamp Clamp To the ignition switch A A VIEW A ...

Page 424: ...the PCV breather hose above the throttle cables VIEW OF B IAT sensor AP sensor PAIR control solenoid valve A downward A downward A backward PCV breather hose PAIR hose Throttle cables B top side B top side B top side IAC hose IAC hose A top side A top side VIEW OF A Vacuum hose Fuel feed hose IAC hose AP sensor IAT sensor 18 N m 1 8 kgf m 13 0 lb ft TP sensor Vacuum hose A The end of the clamp sho...

Page 425: ...SERVICING INFORMATION 11 21 FUEL TANK MOUNTING ...

Page 426: ...11 22 SERVICING INFORMATION FUEL TANK MOUNTING Only for E 28 ...

Page 427: ...SERVICING INFORMATION 11 23 FUEL TANK HOSE ROUTING Clamp Orange Black Gray Black 5 8 mm 5 8 mm 5 mm TPC valve TPC valve ...

Page 428: ...11 24 SERVICING INFORMATION FUEL TANK HOSE ROUTING Only for E 28 Clamp Orange Black TPC valve 5 8 mm 5 8 mm 5 mm TPC valve Black Gray ...

Page 429: ...om D Face the head of screw to the right E Face the head of screw to the back Yellow mar w mark Yellow mark Radiator Bypass hose Reservoir Reservoir inlet hose Reservoir overflow hose 0 20 White mark White mark Radiator outlet hose Oil cooler outlet hose Oil cooler inlet hose Yellow mark VIEW B Yellow mark Radiator outlet hose White mark White mark 14 10 Yellow mark VIEW A Air vent hose Reservoir ...

Page 430: ...se Brake hose guide B A 14 Fix the brake hose grommet to its hose clamp Fix the brake hose grommet to its hose clamp Washer VIEW B Stopper After touching the brake hose union to the stopper tighten the union bolt to the specified torque Brake hose Front brake caliper R Brake hose clamp 14 14 Washer 21 VIEW A Front brake master cylinder Rear brake pipe Throttle cable Front brake hose Brake hose gui...

Page 431: ...brake hose union to the stopper tighten the union bolt to the specified torque Stopper Rear brake caliper 28 G B B A C 14 E D D D F F F E E VIEW G VIEW C Fix the white mark on the brake pipe with the clamp Fix a non cover portion of brake pipe with the clamp Rear brake pipe Brake hose guide Rear brake hose Rear brake hose Rear brake pipe Washer 21 14 VIEW A VIEW B Stopper After touching the brake ...

Page 432: ... SERVICING INFORMATION SIDE STAND SET UP CENTER STAND SET UP 40 N m 4 0 kgf m 29 0 lb ft 50 N m 5 0 kgf m 36 0 lb ft Out side Spring position VIEW A A 29 N m 2 9 kgf m 21 0 lb ft 23 N m 2 3 kgf m 16 5 lb ft ...

Page 433: ... mm 09900 20605 Dial gauge 09900 20607 Dial gauge 1 100 mm 10 mm 09900 20701 Magnetic stand 09900 20803 09900 20806 Thickness gauge 09900 20805 Tire depth gauge 09900 21304 V block 100 mm 09900 22301 09900 22302 Plastigauge 09900 22401 Small bore gauge 10 18 mm 09900 25008 Multi circuit tester set 09910 32812 Crankshaft installer 09910 32850 Crankshaft installer attachment 09913 50121 Oil seal rem...

Page 434: ...Valve spring compressor 09916 14521 Valve spring com pressor attachment 09916 20630 Valve seat cutter head N 126 09916 20640 Solid pilot N 100 4 5 09916 21111 Valve seat cutter set 09916 33210 Valve guide reamer 4 5 mm 09916 34542 Reamer handle 09916 34561 Valve guide reamer 11 3 mm 09916 43210 Valve guide remover installer 09916 44930 Attachment 09916 84511 Tweezers 09917 23711 Ring nut wrench 09...

Page 435: ...ring remover set 09924 74570 Final drive gear bearing installer remover 09924 84510 Bearing installer set 09925 18011 Steering bearing installer 09930 11930 Torx bit JT30H 09930 11940 Bit holder 09930 30450 Rotor remover 09930 40113 Rotor holder 09930 73170 Starter torque limiter holder 09930 73120 Starter torque limiter socket 09930 82720 Mode selection switch 09940 14911 Steering stem nut wrench...

Page 436: ... or not 09940 40220 Fuel pressure gauge hose attachment 09940 52861 Front fork oil seal installer 09940 92720 Spring scale 09941 34513 Steering race installer 09941 51010 Ring locknut wrench 09941 54911 Bearing outer race remover 09943 74111 Fork oil level gauge 09941 74911 Steering bearing installer ...

Page 437: ...ver bolt 11 1 1 8 0 Primary shaft cap bolt 11 1 1 8 0 Breather cover bolt 10 1 0 7 3 Spark plug 11 1 1 8 0 Cam shaft holder bolt 10 1 0 7 3 Cylinder head side bolt 14 1 4 10 0 Cam position sensor bolt 10 1 0 7 3 Oil level switch bolt 10 1 0 7 3 Oil cooler union bolt 70 7 0 5 0 Engine mount bolt 55 5 5 40 0 Oil plug bolt M18 10 1 0 7 3 M10 16 1 6 11 5 M14 23 2 3 16 5 Exhaust pipe clamp bolt 23 2 3 ...

Page 438: ...ir bleeder valve Front and Rear 7 5 0 75 5 5 Brake caliper mounting bolt Front and Rear 26 2 6 19 0 Brake master cylinder mounting bolt Front and Rear 10 1 0 7 0 Front brake caliper holder pin 13 1 3 9 5 Front brake pad mounting pin plug 2 5 0 25 1 8 Brake pad mounting pin Front and Rear 18 1 8 13 0 Rear brake caliper holder sliding pin 13 1 3 9 5 23 2 3 16 5 Brake lock housing bolt 23 2 3 16 5 Br...

Page 439: ...nal 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 Conventional bolt 4 marked bolt 7 marked bolt A ...

Page 440: ... 060 0 0012 0 0024 Valve guide I D IN EX 4 500 4 515 0 1772 0 1778 Valve stem O D IN 4 475 4 490 0 1762 0 1768 EX 4 455 4 470 0 1754 0 1760 Valve stem deflection IN EX 0 35 0 014 Valve stem runout IN EX 0 05 0 002 Valve head thickness IN EX 0 5 0 02 Valve seat width IN EX 0 9 1 1 0 035 0 043 Valve head radial runout IN EX 0 03 0 001 Valve spring free length IN EX IN EX 40 6 1 60 Valve spring tensi...

Page 441: ...essure 1 500 1 900 kPa 15 0 19 0 kgf cm2 213 270 psi 1 200 kPa 12 kgf cm2 171 psi Compression pressure difference 200 kPa 2 0 kgf cm2 28 psi Piston to cylinder clearance 0 045 0 055 0 0018 0 0022 0 120 0 0047 Cylinder bore 75 500 75 515 2 9724 2 9730 75 585 2 9758 Piston diam 75 450 75 465 2 9705 2 9711 Measure at 15 mm 0 6 in from the skirt end 75 380 2 9677 Cylinder distortion 0 10 0 004 Piston ...

Page 442: ...04 0 008 0 30 0 012 Conrod big end width 19 950 20 000 0 7854 0 7874 Crank pin width 20 100 20 150 0 7913 0 7933 Conrod big end oil clearance 0 032 0 056 0 0013 0 0022 0 080 0 0031 Crank pin O D 44 976 45 000 1 7707 1 7717 Crankshaft journal oil clearance 0 018 0 045 0 0007 0 0018 0 080 0 0031 Crankshaft journal O D 47 985 48 000 1 8892 1 8898 Crankshaft thrust bearing thickness 2 025 2 175 0 0797...

Page 443: ...0 102 2 27 0 089 Driven plate No 1 distortion 0 10 0 004 Clutch spring free length 13 9 0 547 13 2 0 520 Clutch plate concaved washer height 3 1 0 12 Clutch engagement 1 500 2 100 r min Clutch lock up 3 200 3 800 r min ITEM SPECIFICATION NOTE Injector resistance 11 13 Ω at 20 C 68 F Fuel pump discharge amount More than 0 9 L 0 95 0 79 US Imp qt For 30 sec at 300 kPa 3 0 kgf cm2 43 psi Fuel pressur...

Page 444: ...0 C 68 F AP sensor input voltage 4 5 5 5 V AP sensor output voltage Approx 3 6 V at 760 mmHg 100 kPa TO sensor resistance 19 1 19 7 kΩ TO sensor output voltage Normal Less than 1 4 V Leaning Less than 3 7 V Injector voltage Battery voltage Ignition coil primary peak voltage More than 80 V When cranking 1 W Bl Ground 2 B Y Ground HO2 sensor resistance 4 5 Ω at 23 C 73 4 F HO2 sensor output voltage ...

Page 445: ...x 0 318 kΩ 110 C 230 F Approx 0 142 kΩ Radiator cap valve opening pres sure 110 kPa 1 1 kgf cm Eclectic fan thermo switch operat ing temperature ON 93 103 C OFF 87 97 C Engine coolant type Use an anti freeze coolant compatible with alumi num radiator mixed with distilled water only at the ratio of 50 50 Engine coolant including reserve Reverse tank side Approx 250 ml Engine side Approx 1 050 ml IT...

Page 446: ...0 A Ignition 15 A Turn signal 15 A Fan motor 10 A Main 40 A CVT 40 A ITEM STD SPEC E 02 19 E 03 24 28 33 Headlight HI 60 55 60 2 LO 55 55 2 Parking or position light 5 2 Brake light Taillight 21 5 2 Turn signal light 21 License light 5 Instrument panel light 1 4 2 Engine coolant temp indicator light 1 4 FI indicator light 1 4 Engine oil pressure indicator light 1 4 2 Brake lock indicator light 1 4...

Page 447: ...0 25 450 1 0000 1 0020 Rear 27 000 27 050 1 0630 1 0650 Brake caliper piston diameter Front 25 318 25 368 0 9968 0 9987 Rear 26 918 26 968 1 0598 1 0617 Brake fluid type DOT4 Wheel rim runout Axial 2 0 0 08 Radial 2 0 0 08 Wheel axle runout Front 0 25 0 010 Rear 0 25 0 010 Wheel rim size Front 15 M C MT3 50 Rear 14 M C MT4 50 ITEM STANDARD LIMIT Front fork stroke 105 4 1 Front fork spring free len...

Page 448: ...anol or less than 5 methanol with appropriate cosolvents and corro sion inhibitor is permissible E 03 28 33 Gasoline used should be graded 91 octane or higher An unleaded gasoline is recommended The others Fuel tank capacity Including reserve 15 0 L 4 0 3 3 US lmp gal Fuel meter mark flickering Approx 3 0 L 0 79 0 66 US lmp gal Fuel meter mark and LCD flickering Approx 1 5 L 0 40 0 33 US lmp gal E...

Page 449: ... SYSTEM 12 2 CRANKCASE EMISSION CONTROL SYSTEM 12 3 EXHAUST EMISSION CONTROL SYSTEM PAIR SYSTEM 12 4 NOISE EMISSION CONTROL SYSTEM 12 5 PAIR AIR SUPPLY SYSTEM INSPECTION 12 6 HOSE 12 6 PAIR REED VALVE 12 6 PAIR CONTROL SOLENOID VALVE 12 6 PAIR AIR SUPPLY SYSTEM HOSE ROUTING 12 8 HEATED OXGEN SENSOR HO2S INSPECTION 12 9 ...

Page 450: ...on level control This fuel injection system is precision designed manufactured and adjusted to comply with the applicable emission limits BEFORE PRESSURIZED FUEL RELIEVED FUEL PRESSURIZED FUEL Fuel filter For high pressure Fuel pump Fuel feed hose Fuel delivery pipe Fuel injector Fuel mesh filter For low pressure Fuel pressure regulator Throttle body ...

Page 451: ... The engine is equipped 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 FRESH AIR FUEL AIR MIXTURE BLOW BY GAS PAIR hose PCV hose ...

Page 452: ...Y CATALYST 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 ECM PAIR control solenoid valve PAIR reed valve HO2 sensor Three way catalyst FRESH AIR EXHAUST GAS FUEL AIR MIXTURE ...

Page 453: ...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 454: ... 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 Disconnect the PAIR control solenoid valve lead wire coupler Disconnect the PAIR hose Remove the PAIR control solenoid valve Check that air flows through the air inlet port to the air outlet port If air...

Page 455: ...ance 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 U 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 order of removal Connect the PAIR control solenoid valve lead wire coupler secure...

Page 456: ...12 8 EMISSION CONTROL INFORMATION PAIR AIR SUPPLY SYSTEM HOSE ROUTING 10 N m 1 0 kgf m 7 3 lb ft PAIR control solenoid valve 3 5 mm 0 1 0 2 in PAIR reed valve PAIR control solenoid valve ...

Page 457: ...the 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 fr...

Page 458: ...B R B Y Gr W Gr B Br B P G Bl Y Bl W Bl R G B R R B Bl R Bl Y O W B W G R Y B Br W R Bl W Bl B Bl G B W B W Y G Gr R R Bl B W W G B Y Y W Y R W Br B G W Y Dgr R P B Dg B Bl G Y B Br B Br Br W P W Lg B B O B B Br Bl W Bl B Bl G Bl R Bl Y R O W W R Gr R B W R Bl Y Bl Y G O Y B W O R P B W B W B P G R Bl O G B W O R P R B P W Br W Bl G Y Lg Y V O G B Bl W Y Y W B Bl B W Lg Lbl B O O G W B Lg Y R W Y ...

Page 459: ...W O Bl O Bl B W B W G O W O W B W B W Y B Y B Y G Y G O W O W Y R Y R R Bl R Bl O G O G Lbl Lbl G R G R G B G B Gr W Gr W Y R Y R Gr B Gr B Y R Y R O R O R Bl Bl B O B O RRR RRR RRR RRR B Y R Y R B W B W R B R B B W B W R P B P B B Br B Br B Br B Br Lg B Lg B R B Br B Br G Y G Y R R B R B R W R W O O Bl O Bl B Bl B Bl B Br B Br Dg Dg B Br B Br O W O W B Br B Br B G B G Y W Y W R B W B W B Y B Y Br...

Page 460: ... W O W W R W R Gr R Gr R B W B W O R O R P B W B W B W B W B O G O G R Bl R Bl O G O G B W B W O R O R P R B R B P W P W Br W Br W Bl Bl G Y G Y Lg Lg Y V O G O G B Bl B Bl O G O G W B W B Lg Y Lg Y R W R W Y B W B W G W G W O Bl O Bl B W B W G O W O W B W B W Y B Y B Y G Y G O W O W Y R Y R R Bl R Bl O G O G Lbl Lbl G R G R G B G B Gr W Gr W Y R Y R Gr B Gr B Y R Y R O R O R Bl Bl B O B O Y R Y R...

Page 461: ... R B O W B W Y Dgr R Y R G R B R W B B R B Y Gr W Gr B Br B P G Bl Y Bl W Bl R G B R R B Bl R Bl Y O W B W G R Y B Br W R Bl W Bl B Bl G B W B W Y G Gr R R Bl B W W G B Y Y W Y R W Br B G W Y Dgr R P B Dg B Bl G Y B Br B Br Br W P W Lg B B O B B Br Bl W Bl B Bl G Bl R Bl Y R O W W R Gr R B W O R W B W B W B P G R Bl O G B W O R W R B P W Br W Bl G Y Lg Y V O G B Bl W Y Y W O B Bl B W Lg Lbl B O O ...

Page 462: ...Prepared by July 2002 Part No 99500 36110 01E Printed in Japan 464 ...

Page 463: ......

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