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Suzuki Boulevard M50, Service Manual

The Suzuki Boulevard M50 Service Manual is an essential resource for owners looking to maintain and repair their motorcycle. You can easily download this manual for free from manualshive.com, ensuring you have all the information you need to keep your bike running smoothly.

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12

WIRING DIAGRAM

E-02, 19, 24

Wiring diagrams wire color, refer to section “WIRE COLOR”.

O/RO/R

P

B/WB/W

O/R

P

B/W

W

B/WB/W

Br/BBr/B

B

Y

G

B/YB/Y

Gr/WGr/W

Gr/BGr/B

B/WB/W

P/WP/W

W/BW/B

B/LgB/Lg

Bl/RBl/R

Bl/YBl/Y

Gr/RGr/R

B/GB/G

W/RW/R

G/YG/Y

BlBl

Y/GY/G

B/BrB/Br

B/BrB/Br

G/BG/B

Bl/BBl/B

Br/WBr/W

B/BlB/Bl

O/YO/Y

Bl/WBl/W

Bl/BBl/B

Bl/GBl/G

B/BrB/Br

B/WB/W

R/BlR/Bl

O/GO/G

Y/RY/R

BrBr

Y/BY/B

W/BlW/Bl

R

Y/WY/W

G/WG/W

DgDg

P

W

B/W

Br/B

B

Y

G

B/Y

Gr/W

Gr/B

B/W

P/W

W/B

B/Lg

Bl/R

Bl/Y

Gr/R

B/G

W/R

G/Y

Bl

Y/G

B/Br

B/Br

G/B

Bl/B

Br/W

B/Bl

O/Y

Bl/W

Bl/B

Bl/G

B/Br

B/W

R/Bl

O/G

Y/R

Br

Y/B

W/Bl

R

Y/W

G/W

Dg

P

B/BrB/Br

Bl/WBl/W

Bl/BBl/B

Bl/GBl/G

Bl/RBl/R

Bl/YBl/Y

R

B/Br

Bl/W

Bl/B

Bl/G

Bl/R

Bl/Y

R

O/GO/G

W/RW/R

Gr/RGr/R

B/WB/W

O/G

W/R

Gr/R

B/W

Y/BY/B

Y/GY/G

R

R

Y/B

Y/G

R

R

BrBr

G/YG/Y

B

B

B

Br

G/Y

B

B

B

B/LgB/Lg

P/WP/W

G

B

R

Y/WY/W

B/BrB/Br

B/Lg

P/W

G

B

R

Y/W

B/Br

DgDg

B/BrB/Br

Dg

B/Br

B/BlB/Bl

B/BrB/Br

B/Bl

B/Br

O/WO/W

Br/BBr/B

O/W

Br/B

B

B

B

B

Gr/BGr/B

Y/RY/R

Gr/B

Y/R

R

W

Y

Y/BlY/Bl

W/BlW/Bl

R/BlR/Bl

O/YO/Y

O/GO/G

O

O/BlO/Bl

Bl/BBl/B

BlBl

G

O/YO/Y

O/BO/B

BrBr

LblLbl

R

W

Y

Y/Bl

W/Bl

R/Bl

O/Y

O/G

O

O/Bl

Bl/B

Bl

G

O/Y

O/B

Br

Lbl

Gr/WGr/W

Y/RY/R

Gr/W

Y/R

B/BrB/Br

G/BG/B

R

B/Br

G/B

R

B/BrB/Br

G/WG/W

R

B/Br

G/W

R

G/YG/Y

BlBl

P

B/WB/W

G

G/Y

Bl

P

B/W

G

G/YG/Y

BlBl

P

B/WB/W

G

G/Y

Bl

P

B/W

G

R

O

O/YO/Y

BrBr

R

O

O/Y

Br

B/BlB/Bl

O/GO/G

B/Bl

O/G

B/RB/R

B/WB/W

B/R

B/W

B/RB/R

O/YO/Y

B/R

O/Y

B

BlBl

B

Bl

R

O

O/YO/Y

BrBr

R

O

O/Y

Br

B/BlB/Bl

B/WB/W

LgLg

LblLbl

B

Y/WY/W

W/BlW/Bl

Y/BlY/Bl

Y/WY/W

B/WB/W

Y/BY/B

B/Bl

B/W

Lg

Lbl

B

Y/W

W/Bl

Y/Bl

Y/W

B/W

Y/B

B/BlB/Bl

B/WB/W

LgLg

LblLbl

B

O/RO/R

W

Y

Y/WY/W

B/YB/Y

B/YB/Y

B/Bl

B/W

Lg

Lbl

B

O/R

W

Y

Y/W

B/Y

B/Y

B

B

B

R

R

B/WB/W

B/WB/W

B

B

B

R

R

B/W

B/W

B/WB/W

B/W

B/WB/W

B/W

B

B

B

B

B

B

B

B

B

B

Lg

Lg
Br

Br

B/W

B/W
W/B

W/B

B

Lg
Br

B/W
W/B

B

Lg

Lg

B/W

B/W

Lg

B/W

B/W

B/W

B

B/W

B

Gr

Gr

B/W

B/W

Gr

B/W

Br

Br

B/W

B/W

Br

B/W

Br

Br

B/W

B/W

Br

B/W

Y

B/W

B/W

W

Y

B/W

W

B

B/W

B/W

B

B/W

B

B/W

B/W

B

B/W

Lg

Lg

B/W

B/W

Lg

B/W

B

B/W

B/W

B

B/W

Y/BY/B

B/LgB/Lg

B/YB/Y

G/YG/Y

B/WB/W

B/GB/G

O/GO/G

R/BlR/Bl

Y/B

B/Lg

B/Y

G/Y

B/W

B/G

O/G

R/Bl

Y/BY/B

B/LgB/Lg

B

G/YG/Y

B/WB/W

B/GB/G

O/GO/G

R

Y/B

B/Lg

B

G/Y

B/W

B/G

O/G

R

B

LblLbl

LgLg

O/BO/B

O/WO/W

O/GO/G

W/BW/B

Y/GY/G

Y/WY/W

O

B

Lbl

Lg

O/B

O/W

O/G

W/B

Y/G

Y/W

O

B

LblLbl

LgLg

O/BO/B

O/WO/W

B/RB/R

B/BlB/Bl

Y/GY/G

Y/WY/W

O/RO/R

B

Lbl

Lg

O/B

O/W

B/R

B/Bl

Y/G

Y/W

O/R

B/WB/W

O/BlO/Bl

B/W

O/Bl

O/WO/W

W

O/W

W

O/WO/W

B/YB/Y

O/W

B/Y

O/GO/G

W/BW/B

O/G

W/B

B/WB/W

O/GO/G

B/YB/Y

Y

Bl/BBl/B

LgLg

B

B/W

O/G

B/Y

Y

Bl/B

Lg

B

B/WB/W

O/GO/G

Y

B/YB/Y

BlBl

LgLg

B

B/W

O/G

Y

B/Y

Bl

Lg

B

R

Bl/BBl/B

B/BrB/Br

R

Bl/B

B/Br

O/WO/W

B/BrB/Br

W/BlW/Bl

W/BW/B

O/W

B/Br

W/Bl

W/B

Y

O/WO/W

R/BlR/Bl

Y/RY/R

Y

O/W

R/Bl

Y/R

R

Br/WBr/W

B/BrB/Br

R

Br/W

B/Br

Y/RY/R

B/WB/W

B/LgB/Lg

Y/BY/B

Y/R

B/W

B/Lg

Y/B

B Bl

B

B

B

B/RB/R

B/RB/R

B/WB/W

B/WB/W

B

B

B

B/R

B/R

B/W

B/W

BlBl

G

Y

Y

Y

Bl

G

Y

Y

Y

BlBl

Y

B

Bl

Y

B

W

GrGr

B

W

W

Gr

B

W

Y/RY/R

B/WB/W

B/LgB/Lg

R/BR/B

Y/R

B/W

B/Lg

R/B

B/WB/W

G

B/W

G

Gr

Gr

B/W

B/W
W/B

W/B

Gr

B/W
W/B

P

LOCK
OFF

ON

OFF

ON

ON

OFF

M

PUSH
FREE

ON

OFF

ON

OFF

PUSH

FREE

L

PUSH

R

HI

LO

PUSH

HANDLEBAR SWITCH (R)

REAR BRAKE
SWITCH

IGNITION
COIL (F)

IGNITION
COIL (R)

IGNITION SWITCH

ENGINE 
STOP
SWITCH

HAZARD 
SWITCH

FRONT BRAKE
SWITCH

STARTER
BUTTON

HO2
SENSOR

ECM

FUEL
PUMP

TP
SENSOR

PILOT LAMP

TO
SENSOR

FUEL PUMP
RELAY

BRAKE LIGHT/
TAILLIGHT

REAR TURN 
SIGNAL LIGHT (R)

REAR TURN 
SIGNAL LIGHT (L)

LICENSE LIGHT

BATTERY

1: MAIN (30 A) 

STARTER 
MOTOR

STARTER 
RELAY

1

FUSE BOX

1. HEAD HI
2. HEAD LO
3. FUEL
4. IGNITION
5. SIGNAL
6. POWER SOURCE

10 A
10 A
10 A
15 A
10 A
10 A

REGULATOR/
RECTIFIER

SIDE STAND
SWITCH

OIL PRESSURE 
SWITCH

GP 
SWITCH

IAT
SENSOR

CKP
SENSOR

ECT
SENSOR

1

2

3

4

5

6

IAP
SENSOR
(F)

IAP
SENSOR
(R)

INJECTOR (R)

INJECTOR (F)

COOLING
FAN
MOTOR

COOLING
FAN 
THERMO-
SWITCH

PAIR
SOLENOID

CLUTCH
SWITCH

DIMMER
SWITCH

TURN SIGNAL
LIGHT SWITCH

PASSING
LIGHT
SWITCH

HORN
BUTTON

HANDLEBAR SWITCH (L)

HORN

OPTION

HEADLIGHT

FRONT TURN  SIGNAL
LIGHT (R)

FRONT TURN  SIGNAL
LIGHT (L)

POSITION LIGHT
(E-02,19 ONLY)

: ENGINE COOLANT TEMP. WARNING LIGHT
: FI LIGHT
: FUEL WARNING LIGHT 
: TURN SIGNAL INDICATOR LIGHT
: HI-BEAM INDICATOR LIGHT
: NEUTRAL INDICATOR LIGHT
: OIL INDICATOR LIGHT

TEMP
FI
F
TU
HI
NU
OIL

SPEED
SENSOR

STV 
ACTUATOR

STP 
SENSOR

GENERATOR

OFF
RUN

PUSH

OFF
RUN

B

P

G

W/BW/B

BlBl

Y

B

B

P

G

W/Bl

Bl

Y

B

SPEEDOMETER

SA

MP

LE

Summary of Contents for Boulevard M50

Page 1: ...VZ800 9 9 5 0 0 3 8 0 5 0 0 1 E...

Page 2: ...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 s...

Page 3: ...irst 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...

Page 4: ...e of engine oil and SUZUKl MOLY PASTE in a ratio of 1 1 Use fork oil 99000 99044 L01 Apply SUZUKI SUPER GREASE A 99000 25030 USA 99000 25010 Others Apply or use brake fluid Apply SUZUKI MOLY PASTE 990...

Page 5: ...irect 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 EOT Sensor Engine Oil Temperature Sen...

Page 6: ...ntilation Crankcase Breather R RH Right Hand ROM Read Only Memory S SAE Society of Automotive Engineers SDS Suzuki Diagnosis System STC System Secondary Throttle Control System STCS STP Sensor Seconda...

Page 7: ...Brown with White tracer G B Green with Black tracer G W Green with White tracer G Y Green with Yellow tracer Gr B Gray with Black tracer Gr R Gray with Red tracer Gr W Gray with White tracer Lg G Lig...

Page 8: ...ANTI FREEZE ENGINE COOLANT 1 5 LIQUID AMOUNT OF WATER ENGINE COOLANT 1 5 BREAK lN PROCEDURES 1 6 CYLINDER IDENTIFICATION 1 6 INFORMATION LABELS 1 7 SPECIFICATIONS 1 8 COUNTRY AND AREA CODES The follow...

Page 9: ...e 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 serv...

Page 10: ...uts 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 r...

Page 11: ...e These num bers are required 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...

Page 12: ...to freezing point Suzuki recommends the use of SUZUKI COOLANT anti freeze engine coolant If this is not available use an equivalent which is compatible with an aluminum radiator LIQUID AMOUNT OF WATE...

Page 13: ...d during its early life Refer to the following break in engine speed recommendations Keep to these break in throttle positions during the break in period Break in throttle operation Initial 800 km 500...

Page 14: ...33 3 Vacuum hose routing label A For E 33 4 Manual notice label A For E 03 33 5 Fuel caution label A For E 02 24 6 Tire information label A 7 General warning label A 8 ICES Canada label A For E 28 9...

Page 15: ...e 83 0 mm 3 268 in Stroke 74 4 mm 2 929 in Displacement 805 cm 49 1 cu in Compression ratio 9 4 1 Fuel system Fuel injection Air cleaner Non woven fabric element Starter system Electric Lubrication sy...

Page 16: ...Fuse 10 10 10 10 10 15 A Headlight 12 V 60 55 W H4 Parking or city light 12 V 5 W For E 02 19 Front turn signal light 12 V 21 5 W For E 03 28 33 12 V 21 W For the others Rear turn signal light 12 V 21...

Page 17: ...CHRONIZATION 2 15 EVAPORATIVE EMISSON CONTROL SYSTEM FOR E 33 ONLY 2 15 PAIR AIR SUPPLY SYSTEM 2 15 CLUTCH 2 16 COOLING SYSTEM 2 17 FINAL GEAR OIL 2 19 BRAKE 2 19 TIRE 2 23 STEERING 2 23 FRONT FORK 2...

Page 18: ...0 24 000 miles 600 4 000 7 500 11 000 14 500 months 2 12 24 36 48 Air cleaner element I I R I Exhaust pipe bolts and muffler bolts T T T Valve clearance I I I Spark plugs I R I R Fuel hose I I I I Eng...

Page 19: ...efore 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...

Page 20: ...miles 12 months and replace every 18 000 km 11 000 miles 36 months Always use air pressure on the engine side of the air cleaner element If air pressure is used on the other side dirt will be forced...

Page 21: ...seats 8 3 Remove the fuel tank 6 3 Remove the right frame cover 1 Hooked part Remove the spark plug cap Remove the spark plug with a spark plug wrench 09930 14530 Universal joint Inspect every 6 000...

Page 22: ...AP Measure the plug gap with a thickness gauge If out of specifi cation adjust it to the following gap 09900 20803 Thickness gauge Spark plug gap A Standard 0 8 0 9 mm 0 031 0 035 in ELECTRODES CONDIT...

Page 23: ...08 0 13 mm 0 003 0 005 in EX 0 17 0 22 mm 0 007 0 009 in NOTE The clearance specification is for COLD state Both intake and exhaust valves must be checked and adjusted when the piston is at Top Dead...

Page 24: ...2 8 PERIODIC MAINTENANCE Remove the cylinder head cover caps 1 2 Remove the PAIR pipe Remove the gasket 3 Do not reuse the removed gasket SAMPLE...

Page 25: ...stroke Rotate the rotor until the R I T line on the rotor is aligned with the center of hole on the generator cover To inspect the No 1 engine s valve clearance insert the thick ness gauge to the clea...

Page 26: ...clearance as the same manner above NOTE Use the thickness gauge from the arrow marks as shown in the illustration FUEL HOSE Inspect the fuel feed hose for damage and fuel leakage If any defects are f...

Page 27: ...will hold about 3 0 L 3 2 2 6 US Imp qt of oil Use of API SF SG or SH SJ with JASO MA Oil drain plug 21 N m 2 1 kgf m 15 0 lb ft Start up the engine and allow it to run for several minutes at idling...

Page 28: ...rench 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 En...

Page 29: ...i circuit tester to the high tension cord Start up the engine and set its idle speed to the specified range by turning the throttle stop screw 1 Engine idle speed 1 100 100 r min 09900 25008 Multi cir...

Page 30: ...e lock nut 4 while holding the adjuster 6 Third step While holding the throttle grip at the fully closed position slowly turn out the adjuster 3 of the throttle returning cable 2 to feel resistance Ti...

Page 31: ...ed position slowly turn the returning cable adjuster 2 to obtain a slack of 1 0 mm 0 04 in Tighten the lock nut 1 securely THROTTLE VALVE SYNCHRONIZATION Inspect the throttle valve synchronization per...

Page 32: ...two or three rotations From that position slowly turn in the adjusting screw 4 to feel resistance From this position turn out the adjusting screw 4 1 4 rota tions and tighten the lock nut 3 Loosen th...

Page 33: ...g the radiator hose 2 from the pump Flush the radiator with fresh water if necessary Connect the radiator hose 2 securely Pour the specified engine coolant up to the radiator inlet Bleed the air from...

Page 34: ...e until bleed no air from the radia tor inlet Close the radiator cap securely After warming up and cooling down the engine several times add the engine coolant up to the full level of the reservoir En...

Page 35: ...specification Specification and classification DOT 4 Replace initially at 1 000 km 600 miles 2 months and inspect every 12 000 km 7 500 miles 24 months thereafter BRAKE Inspect initially at 1 000 km...

Page 36: ...e pad When the wear exceeds the grooved limit replace the pads with new ones 8 52 REAR BRAKE PEDAL HEIGHT Loosen the lock nut 1 Adjust the brake pedal height A by turning the adjuster 2 Rear brake ped...

Page 37: ...brake lining wear perform the following steps Make sure that the rear brake is properly adjusted Depress the rear brake pedal Make sure that the index mark 1 is within the range 2 embossed on the bra...

Page 38: ...r valve and insert the free end of the pipe into a receptacle Squeeze and release the brake lever several times in rapid succession and squeeze the lever fully without releasing it Loosen the bleeder...

Page 39: ...h turning of han dlebars and safe running Overtighten steering prevents smooth turning of the handlebars and too loose steering will cause poor stability Check that there is no play in the steering st...

Page 40: ...PIPE BOLT Tighten the exhaust pipe bolts and muffler mounting bolts to the specified torque Muffler mounting bolt and exhaust pipe bolt A 23 N m 2 3 kgf m 16 5 lb ft Muffler mounting nut B 23 N m 2 3...

Page 41: ...16 5 6 Front axle 65 6 5 47 0 7 Front axle pinch bolt 23 2 3 16 5 8 Handlebar holder set nut 45 4 5 32 5 9 Handlebar clamp bolt 23 2 3 16 5 0 Front brake master cylinder mounting bolt 10 1 0 7 0 A Fro...

Page 42: ...2 26 PERIODIC MAINTENANCE SAMPLE...

Page 43: ...essure are below 1 100 kPa 11 kgf cm2 156 psi even when they measure more than 1 300 kPa 13 kgf cm2 185 psi COMPRESSION TEST PROCEDURE NOTE Before testing the engine for compression pressure make sure...

Page 44: ...l 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...

Page 45: ...er 8 3 Set up the SDS tool 5 24 09904 41010 SDS set tool 99565 01010 CD ROM Ver 5 A number of different data under a fixed condition as shown below should be saved or filed as sample SAMPLE Data sampl...

Page 46: ...Quic Quick wide open k wide open Throttle Quick wide open Chec Check the manif k the manifold absolute pressure old absolute pressure in according with the throttle v in according with the throttle va...

Page 47: ...SASSEMBLY 3 11 ENGINE COMPONENTS INSPECTION AND SERVICING 3 27 CYLINDER HEAD COVER 3 27 CAMSHAFT 3 28 CAM CHAIN TENSIONER AND GUIDE 3 30 CYLINDER HEAD 3 30 CYLINDER 3 40 PISTON 3 41 CONROD CRANKSHAFT...

Page 48: ...NGINE LEFT SIDE ENGINE RIGHT SIDE PARTS REMOVAL INSTALLATION Inspection cap PAIR pipe Starter motor Oil filter 3 12 3 11 9 14 3 21 3 85 3 86 9 14 3 72 PARTS REMOVAL INSTALLATION Neutral switch Generat...

Page 49: ...Reinstall the engine by reversing the removal procedure Drain engine oil 2 11 Drain engine coolant 2 17 Remove the seats 8 3 Remove the fuel tank 6 3 Disconnect the battery lead wire and starter moto...

Page 50: ...ide stand switch lead wire coupler 4 Disconnect the neutral switch lead wire coupler 5 Disconnect the generator lead wire coupler 6 and the signal generator lead wire coupler 7 Remove the clutch relea...

Page 51: ...IR SUPPLY cover Remove the PAIR mounting bolts Disconnect the PAIR hoses B and lead wire coupler C Remove the air cleaner box D and air intake pipe E 5 47 Remove the air cleaner box bracket Remove the...

Page 52: ...sensor lead wire coupler G Disconnect the spark plug caps Remove the right frame cover 8 4 Disconnect the HO2 sensor lead wire coupler H For E 02 19 24 Remove the No 1 muffler I Remove the exhaust pip...

Page 53: ...he horn lead wire coupler L and rear brake switch lead wire coupler M Remove the cooling fan N 7 8 Remove the engine frame mounting bolt O Remove the ground lead wire P Support the engine with an engi...

Page 54: ...nt NOTE Be sure to face the short portion A backward when installing it Install the boot NOTE Make sure that the UP mark B faces up Gradually raise the engine and then engage the secondary driven gear...

Page 55: ...and tighten them to the specified torque Install the gearshift lever and the footrest in the correct posi tion Gearshift lever height A Standard 85 95 mm 3 3 3 7 in 79 N m 7 9 kgf m 57 0 lb ft 79 N m...

Page 56: ...SE A USA 99000 25010 SUZUKI SUPER GREASE A Others Clutch release screw Standard 1 4 turn back CLUTCH CABLE ADJUSTMENT 2 16 Install the new gaskets Install the exhaust pipes and mufflers Apply gas seal...

Page 57: ...SEMBLY Remove the PAIR pipes Remove the spark plugs 09930 10121 Spark plug wrench set Remove the gaskets Remove the cylinder head cover caps 1 2 Remove the water outlet union 3 Remove the breather cov...

Page 58: ...ve the intake pipes 6 F R CYLINDER HEAD COVER Remove the valve timing inspection plug 1 and the generator cover cap 2 Position R I T line on the generator with the center of the valve timing inspectio...

Page 59: ...and 1 4 turns and align the F I T line on the generator with the center of the valve timing inspection hole Remove the cylinder head cover Front Remove the dowel pins and camshaft end cap 4 CAMSHAFT...

Page 60: ...olts Front cylinder After unlocking the ratchet push the cam chain tension adjuster rod fully Insert the special tool between the ratchet and the adjuster body 09918 53810 Chain tensioner lock tool Re...

Page 61: ...der Remove the cam chain guide 4 Remove the dowel pins and gasket 5 Remove the cylinder head bolts Rear cylinder Push the cam chain tension adjuster rod and insert the spe cial tool 09918 53810 Chain...

Page 62: ...guide 8 Remove the water hose and pipe Remove the cylinder 9 Rear cylinder Remove the dowel pins and gasket 0 PISTON Place a clean rag under the piston to prevent any parts from falling into the cran...

Page 63: ...on pin 2 and remove the pistons 3 F R NOTE Scribe the cylinder position on the head STARTER MOTOR Remove the starter motor cover 1 Remove the starter motor 2 CLUTCH Remove the clutch cover Remove the...

Page 64: ...mounting bolts and springs diago nally Remove the pressure plate 2 Remove the thrust washer 3 bearing 4 push piece 5 and push rod 6 Remove the clutch drive and driven plates 7 Remove the spring washe...

Page 65: ...9920 53740 Clutch sleeve hub holder Remove the washer 0 and the clutch sleeve hub A Remove the thrust washer B spacer C and needle roller bearing D Remove the primary driven gear assembly E and the oi...

Page 66: ...and washer 2 Remove the oil pump 3 GEARSHIFT Draw out the gearshift shaft 1 Remove the cam guide and the pawl lifter Remove the cam driven gear assembly 2 by removing the gearshift cam stopper bolt R...

Page 67: ...ilter with the special tool 09915 40610 Oil filter wrench DRIVESHAFT BOLT SECONDARY DRIVEN GEAR SHAFT NUT Install the universal joint on the secondary driven gear shaft While holding the universal joi...

Page 68: ...ressure switch lead wire Remove the neutral switch assembly Remove the neutral switch contacts 1 and spring 2 GENERATOR Remove the generator cover Remove the dowel pins and gasket 1 Remove the starter...

Page 69: ...olt is used in conjunction with the rotor remover when removing the rotor Remove the generator rotor assembly with the special tool 09930 33730 Rotor remover Remove the starter gear 3 and key 4 Remove...

Page 70: ...bly and gasket 1 SECONDARY DRIVEN GEAR Remove the secondary driven gear housing bolts Remove the secondary driven gear case Remove the secondary driven gear assembly 1 and shims 2 Remove the bearing 3...

Page 71: ...NE 3 25 OIL JET Remove the oil jets CRANKCASE Remove the crankcase bolts Separate the crankcase into two parts with the special tool 09920 13120 Crankcase separator Remove the dowel pins and O ring SA...

Page 72: ...emove the gearshift fork shafts 3 gearshift forks 4 and gearshift cam 5 Remove the transmission Remove the washer SECONDARY DRIVE BEVEL GEAR Remove the over driving gear 1 and bush 2 Remove the second...

Page 73: ...s the limit replace the cylinder head cover ROCKER ARM SHAFT O D Measure diameter of rocker arm shaft Rocker arm shaft O D IN EX Standard 11 977 11 995 mm 0 4715 0 4722 in 09900 20205 Micrometer 0 25...

Page 74: ...ld be caused by a worn camshafts The camshaft can be distinguished by the embossed letters F and R on the camshaft F Front No 2 camshaft R Rear No 1 camshaft CAMSHAFT CAM WEAR Worn down cams are often...

Page 75: ...10 N m 1 0 kgf m 7 0 lb ft M8 24 5 N m 2 45 kgf m 18 0 lb ft NOTE Do not rotate the camshafts with the plastigauge in place Remove the cylinder head cover and read the width of the com pressed plasti...

Page 76: ...ioners F Front No 2 cam chain tensioner R Rear No 1 cam chain tensioner CAM CHAIN GUIDE Check the contacting surface of the cam chain guide for wear and damage If it is found to be damaged replace it...

Page 77: ...dge exceeds the limit replace the cylin der head Cylinder head distortion Service Limit 0 05 mm 0 002 in 09900 20803 Thickness gauge VALVE FACE WEAR Visually inspect each valve for wear of its seating...

Page 78: ...a new one Valve stem deflection IN EX Service Limit 0 35 mm 0 14 in 09900 20607 Dial gauge 1 100 mm 09900 20701 Magnetic stand VALVE STEM WEAR If the valve stem is worn down to the limit as measured w...

Page 79: ...reamer Be sure to clean and oil the guide after ream ing 09916 34550 Valve guide reamer 09916 34542 Reamer handle NOTE Be sure to cool down the cylinder head to ambient air tempera ture Insert the rea...

Page 80: ...ve lapper set If either requirement is not met correct the seat by servicing it as follows VALVE SEAT SERVICING The valve seats for intake and exhaust valves are machined to four different angles The...

Page 81: ...cut If the valve seat is pitted or 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 beco...

Page 82: ...eat position and width is achieved use the 45 cutter very lightly to clean up any burrs caused by the pre vious cutting operations NOTE After servicing the valve seats be sure to check the valve clear...

Page 83: ...the valve seat tight 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 springs for proper strength by m...

Page 84: ...on A facing cylinder head B Large pitch portion Put on the valve spring retainer using the valve spring com pressor press down the springs fit the two cotter halves to the stem end and release the com...

Page 85: ...ENGINE 3 39 NOTE When installing the water union to the cylinder head apply grease to the new O rings 99000 25030 SUZUKI SUPER GREASE A USA 99000 25010 SUZUKI SUPER GREASE A Others SAMPLE...

Page 86: ...bore diameter at six places If any one of the measurements exceeds the limit overhaul the cylinder and replace the piston with an oversize or replace the cylinder Once the reboring is done on any one...

Page 87: ...iston to cylinder clearance Service Limit 0 120 mm 0 0047 in Piston oversize 0 5 1 0 mm PISTON RING TO GROOVE CLEARANCE Using a thickness gauge measure the side clearances of the 1st and 2nd rings If...

Page 88: ...70 mm 0 028 in 09900 20102 Vernier calipers 09900 20803 Thickness gauge Oversize piston ring The following two types of oversize piston rings are used They bear the following identification numbers Ov...

Page 89: ...tside diameter at three positions Piston pin O D Service Limit 19 980 mm 0 7866 in 09900 20205 Micrometer 0 25 mm PISTON RING REASSEMBLY Install the piston rings in the order of oil ring 2nd ring and...

Page 90: ...eter Conrod small end I D Service Limit 20 040 mm 0 7890 in 09900 20602 Dial gauge 1 1 000 mm 1 mm 09900 22403 Small bore gauge 18 35 mm If the conrod small end inside diameter exceeds the above men t...

Page 91: ...bearings NOTE Never try to remove or loosen the conrod cap bolts due to their possible loosening in the rod Once displaced the bearing cap will not be fitted properly Place plastigauge axially on the...

Page 92: ...orresponding crank pin O D code number 2 1 2 or 3 The crank pin O D code number 2 1 2 or 3 which are stamped on the left crank web Bearing selection table Conrod I D specification Crank pin O D specif...

Page 93: ...conrod fitting nuts with specified torque after applying engine oil to the nut thread Conrod nut Initial tightening torque 25 N m 2 5 kgf m 18 0 lb ft Final tightening torque 51 N m 5 1 kgf m 37 0 lb...

Page 94: ...cial tool Crankshaft journal bearing I D 2 Standard 48 000 48 015 mm 1 8898 1 8904 in 09900 20508 Cylinder gauge set If each crankshaft journal bearing I D is not within the stan dard range replace th...

Page 95: ...ve the crankshaft journal bearings in only one direction from inside to outside of each crankcase half Gradually press out the bearing with the special tool by using the hand press Color Part No Thick...

Page 96: ...41 Journal bearing remover installer Tighten the special tool bolt to the specified torque Special tool bolt 23 N m 2 3 kgf m 16 5 lb ft Bearing Before setting the bearing apply enough engine oil to t...

Page 97: ...l tool carefully Gradually press in the bearing into the main journal bore by using the hand press until the special tool 2 stops the special tool 3 09913 60230 Journal bearing remover installer 09900...

Page 98: ...right crankcase half after installing the thrust shim on the crankshaft NOTE The oil grooved face A of thrust shim 1 is faced to crankshaft web side Place the thrust washer camshaft drive sprocket an...

Page 99: ...thin the standard range replace it with a new one Clutch drive plate thickness Standard No 1 2 92 3 08 mm 0 115 0 121 in No 2 3 42 3 58 mm 0 135 0 141 in 09900 20102 Vernier calipers Measure the claw...

Page 100: ...gth Service Limit 46 8 mm 1 84 in 09900 20102 Vernier calipers CLUTCH BEARING Inspect the clutch release bearing for any abnormality particu larly cracks upon removal from the clutch to decide whether...

Page 101: ...he starter clutch contacting surface of the starter driven gear for wear or damage If they are found to be damaged replace them with new ones STARTER DRIVEN GEAR BEARING INSPECTION Inspect the starter...

Page 102: ...ed torque while holding the rotor with off set wrench 99000 32030 THREAD LOCK SUPER 1303 Starter clutch securing bolt 26 N m 2 6 kgf m 19 0 lb ft OIL PUMP Rotate the oil pump by hand and check that it...

Page 103: ...veshaft bolt 8 2nd driven gear 2 Over driving gear 9 Countershaft 1st drive gear 3 1st driven gear 0 4th drive gear 4 4th driven gear A 3rd drive gear 5 3rd driven gear B 5th drive gear 6 Driveshaft C...

Page 104: ...gear onto the driveshaft install the lock washer No 2 1 onto the driveshaft and turn and fit it into the groove Then fit the lock washer No 1 2 in the lock washer No 2 1 Never reuse a circlip After a...

Page 105: ...ENGINE 3 59 TRANSMISSION GEARS AND RELATED PARTS When installing the 1st and 3rd driven gear bushings align the bushing oil hole C with the driveshaft oil hole D SAMPLE...

Page 106: ...Gearshift fork to groove clearance Standard 0 10 0 30 mm 0 004 0 012 in Service Limit 0 50 mm 0 020 in 09900 20803 Thickness gauge 09900 20102 Vernier calipers Shift fork groove width Standard No 1 5...

Page 107: ...mp filter cover Remove the oil sump filter Clean the oil sump filter using compressed air When installing the new O ring apply grease to it 99000 25030 SUZUKI SUPER GREASE A USA 99000 25010 SUZUKI SUP...

Page 108: ...ove the oil pressure regulator Check the operation of the oil pressure regulator by pushing on the piston with an appropriately shaped tool If the piston does not operate replace the oil pressure regu...

Page 109: ...h the special tool NOTE The stamped mark side of the bearing faces 1 2 4 out side The stamped mark side of the bearing faces 3 5 6 inside 09913 70210 Bearing installer set Apply a small quantity of th...

Page 110: ...99000 31140 SUZUKI BOND 1207B OIL SEAL Remove the oil seal with the special tool 09913 70210 Bearing installer set Install the oil seal with the special tool Apply grease to the oil seal lip 99000 250...

Page 111: ...GEAR Install the secondary drive bevel gear shim s SHIM SELECTION 4 7 Install the secondary drive bevel gear assembly and tighten the retainer bolts to the specified torque NOTE Apply THREAD LOCK SUP...

Page 112: ...face A of thrust shim 1 faces to crankshaft web side The thrust shim is selected by the crankshaft thrust clearance 3 52 Install the crankshaft into the left crankcase half NOTE Coat lightly moly pas...

Page 113: ...BOND 1207B to the oil hole oil groove and bearing Apply to distorted surfaces as it forms a comparatively thick film Fit the gaskets to the bolts A Fit the lead wire to the bolt B When securing the r...

Page 114: ...crankcase and the second ary gear case Apply SUZUKI BOND 1207B to the mating surface of the secondary gear case 99000 31140 SUZUKI BOND 1207B NOTE Make surfaces free from moisture oil dust and other f...

Page 115: ...oint on the secondary driven gear shaft While holding the universal joint with a adjustable wrench tighten the secondary drive gear shaft nut 1 and driveshaft bolt 2 to the specified torque Secondary...

Page 116: ...2 spacer 3 and cam chain Cam chain tensioner bolt 10 N m 1 0 kgf m 7 0 lb ft 1 For front cylinder 2 For rear cylinder NOTE The No 2 cam chain For front cylinder is a little longer than the No 1 cam c...

Page 117: ...N m 16 0 kgf m 115 5 lb ft Install the starter driven gear and the idle gear Install the new gasket 3 and dowel pins Install the generator cover NOTE Fit the new gaskets to the bolts A NEUTRAL SWITCH...

Page 118: ...ns using the oil filter wrench 20 N m 2 0 kgf m 14 5 lb ft 09915 40610 Oil filter wrench PRIMARY DRIVE GEAR Install the thrust washer 1 onto the crankshaft NOTE The chamfer side A of thrust washer 1 f...

Page 119: ...the gearshift cam stopper plate after aligning the gear shift cam pins A with the gearshift cam stopper plate holes B Install the washer 2 Apply a small quantity of THREAD LOCK 1342 to the gear shift...

Page 120: ...riven gear OIL PUMP Install the oil pump Oil pump mounting bolt 11 N m 1 1 kgf m 8 lb ft NOTE Set the oil pump shaft end A to the water pump shaft B Install the washer 1 and pin 2 Install the oil pump...

Page 121: ...gear bearing 3 and install it Install the spacer 4 and thrust washer 5 Install the clutch sleeve hub 6 and washer 7 NOTE The convex side of the washer 7 faces outside Tighten the clutch sleeve hub nu...

Page 122: ...e plate Thickness 3 0 mm 0 12 in 6 pcs a Driven plate 6 pcs Install the wave washer seat 8 and the wave washer 9 95 N m 9 5 kgf m 68 5 lb ft 60 N m 6 0 kgf m 43 5 lb ft Clutch drive plate No 2 Clutch...

Page 123: ...clutch push piece 0 bearing A and thrust washer B Apply engine oil to the bearing Install the springs and tighten the clutch spring set bolts diag onally to the specified torque Clutch spring set bolt...

Page 124: ...the new O ring and install the oil jets PISTON Apply a light coat of SUZUKI MOLY PASTE to the piston pins 99000 25140 SUZUKI MOLY PASTE When installing the piston the arrow mark on the piston head is...

Page 125: ...chain tension adjuster mounting bolt 10 N m 1 0 kgf m 7 0 lb ft Coat SUZUKI BOND 1207B lightly to the mating surfaces among the crankcase mating surfaces 99000 31140 SUZUKI BOND 1207B Fit the dowel pi...

Page 126: ...r head bolts diagonally to the specified torque Rear cylinder Cylinder head bolt M10 Initial 25 N m 2 5 kgf m 18 0 lb ft Final 38 N m 3 8 kgf m 27 5 lb ft NOTE Bolt A 165 mm 6 5 in Bolt B 155 mm 6 1 i...

Page 127: ...T Position R I T mark on the generator rotor with the center of the valve timing inspection hole Before installing the camshafts onto each cylinder head apply SUZUKI MOLY PASTE onto the camshaft journ...

Page 128: ...R I T mark on the generator rotor arrow mark on the No 1 Rear camshaft and arrow mark on the No 2 Front camshaft Install the lock washer so that it is covering the locating pin Apply THREAD LOCK SUPE...

Page 129: ...99000 25010 SUZUKI SUPER GREASE A Others Lightly tighten the cylinder head cover bolts diagonally and then if everything is satisfactory tighten securely with a torque wrench to the specified torque...

Page 130: ...t to the bolt 3 Remove the tensioner lock tools NOTE Click sound is heard when the cam chain tension adjuster is released FRONT REAR FWD L 40 L 25 L 20 L 30 L 20 L 30 L 250 L 80 L 250 L Length Unit mm...

Page 131: ...00 25010 SUZUKI SUPER GREASE A Others Install the gasket and the breather cover Apply grease to the new O rings and install the valve inspec tion caps 99000 25030 SUZUKI SUPER GREASE A USA 99000 25010...

Page 132: ...3 86 ENGINE Install the new gaskets Install the PAIR pipes Install the spark plugs 09930 10121 Spark plug wrench set SAMPLE...

Page 133: ...EMBLY 4 4 INSPECTION 4 5 SECONDARY GEAR SHIMS ADJUSTMENT 4 6 REASSEMBLY 4 10 INSTALLATION 4 10 FINAL BEVEL GEARS 4 11 CONSTRUCTION 4 11 FINAL GEAR CASE REMOVAL 4 13 FINAL GEAR CASE DISASSEMBLY 4 13 FI...

Page 134: ...ven bevel gear bearing D Bearing stopper 3 Circlip 9 O ring E Universal joint 4 Output cam dog 0 Shims 5 kinds A Secondary drive gear shaft nut 5 Damper spring A O ring B Secondary drive bevel gear be...

Page 135: ...lable as a set 24935 38810 Part number Thickness 24945 05A 0A0 0 30 mm 0 012 in 24945 05A 0B0 0 35 mm 0 014 in 24945 05A 0C0 0 40 mm 0 016 in 24945 05A 0D0 0 50 mm 0 020 in 24945 05A 0E0 0 60 mm 0 024...

Page 136: ...ust be removed in the described order before removing the secondary driven bevel gear NOTE Refer to the following pages for the details of each step Remove the rear wheel 8 33 Remove the swingarm 8 40...

Page 137: ...rmalities Drive and driven bevel gears damage or wear Improper tooth contact Abnormal noise of bearings Bearing damage or wear Oil seal damage or wear Output cam dog wear or damage Universal joint spl...

Page 138: ...econdary driven bevel gear assembly with removed shims the driven bevel gear bearing and secondary gear case NOTE Do not install the O ring on the driven gear housing at this stage O ring is installed...

Page 139: ...ion the shims Driven bevel gear side must be changed and the backlash should be re checked until correct Refer to the chart for appropriate changes NOTE When changing the shims Driven bevel gear side...

Page 140: ...act pattern made in the dye or paste Compare the tooth contact pattern to the examples as shown in 1 2 and 3 If tooth contact is found to be incorrect the shims of the sec ondary drive bevel gear and...

Page 141: ...as a set 24945 35810 Part No Shim thickness 24935 38A01 030 0 30 mm 0 012 in 24935 38A01 035 0 35 mm 0 014 in 24935 38A01 040 0 40 mm 0 016 in 24935 38A01 050 0 50 mm 0 020 in 24935 38A01 060 0 60 mm...

Page 142: ...lip pay attention to the direction of the snap ring Fit the snap ring to the side where the thrust is as shown in the illustration The rounded side should be against the output cam dog surface INSTALL...

Page 143: ...ng O Propeller shaft 6 Shims 4 kinds F Final drive bevel gear P Universal joint 7 Final driven bevel gear G Final drive bevel gear bearing A Final gear case bolt 8 Shims 8 kinds H Oil seal B Final dri...

Page 144: ...14 in 27327 34210 0 40 mm 0 016 in 27445 38A00 040 0 40 mm 0 016 in 27327 34220 0 50 mm 0 020 in 27445 38A00 050 0 50 mm 0 020 in 27327 34230 0 60 mm 0 024 in 27445 38A00 060 0 60 mm 0 024 in The shim...

Page 145: ...r to the following pages for the details of each step Drain final gear oil 2 19 Remove the rear wheel 8 33 Remove the final gear case FINAL GEAR CASE DISASSEMBLY Remove the plate 1 Remove the oil seal...

Page 146: ...coupling nut with the spe cial tool 09924 62430 22 mm Long socket 09924 64510 Final drive gear coupling holder Remove the washer 7 and the final drive coupling 8 Remove the bearing stopper by with the...

Page 147: ...essary Remove the final gear bearing case bolts Remove the final gear bearing case from the final gear case by using two 5 mm screws Remove the final driven bevel gear A and shims B Remove the oil sea...

Page 148: ...NOTE If no abnormal noise the bearing removal is not necessary Remove the oil seal E and O ring F from the bearing stopper NOTE If no oil leakage the oil seal removal is not necessary INSPECTION Inspe...

Page 149: ...E It is not necessary to apply SUZUKI BOND 1207B to the matching surface at this stage Measure the clearance between the shims and bearing If it is not within the specification the shims must be chang...

Page 150: ...ot to change the clearance between final driven bevel gear and bearing the total thickness of the shims installed after a change is made must equal the original total thickness of shims If backlash is...

Page 151: ...o 5 mm screws 4 15 Do not misplace the shims Remove the final driven bevel gear Clean and de grease several teeth on the final driven bevel gear Coat these teeth with machinist s dye or paste prefera...

Page 152: ...e shim must be installed and the tooth contact pat tern rechecked by repeating the tooth coating procedure above NOTE If it is necessary to adjust the shim 4 thickness between final drive bevel gear b...

Page 153: ...for the final drive bevel gear into the final gear case with the special tool 09913 75821 Bearing installer Install the oil seal into the final gear case with the special tool 09913 70210 Bearing inst...

Page 154: ...CK 1342 Bearing retainer screw 9 N m 0 9 kgf m 6 5 lb ft Install a new oil seal to the final gear bearing case Apply grease to the lip of the oil seal 99000 25030 SUZUKI SUPER GREASE A USA 99000 25010...

Page 155: ...al tool 09924 62410 Final drive gear bearing holder wrench Final drive bevel gear bearing stopper 110 N m 11 0 kgf m 79 5 lb ft Install the final drive coupling 4 and washer 5 Apply a small quantity o...

Page 156: ...ny hitch or bearing noise 09900 06108 Snap ring pliers Install the oil seal with the special tool 09940 51410 Steering bearing installer 09925 18011 Bearing installer Apply grease to the lip of the oi...

Page 157: ...e order of removal NOTE Refer to the following pages for the details of each step Install the final gear case Tighten the final gear case bolts to the specified torque Final gear case nut 40 N m 4 0 k...

Page 158: ...ION 5 22 SELF DIAGNOSTIC PROCEDURES 5 23 SELF DIAGNOSIS RESET PROCEDURE 5 23 USE OF SDS DIAGNOSTIC PROCEDURES 5 24 USE OF SDS DIAGNOSIS RESET PROCEDURE 5 25 SHOW DATA WHEN TROUBLE DISPLAING DATA AT TH...

Page 159: ...5 IAP SENSOR INSPECTION 5 75 IAP SENSOR REMOVAL INSTALLATION 5 75 TP SENSOR INSPECTION 5 75 TP SENSOR REMOVAL INSTALLATION 5 75 STP SENSOR INSPECTION 5 76 STP SENSOR REMOVAL INSTALLATION 5 76 CKP SENS...

Page 160: ...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 mus...

Page 161: ...for excessive opening Also check the coupler for locking loose ness corrosion dust etc 1 Coupler 2 Probe 3 Where male terminal fits FUSE When a fuse blows always investigate the cause to correct it a...

Page 162: ...be applied to the ECM which may result in serious damage Before measuring voltage at each terminal check to make sure that battery voltage is 11 V or higher Terminal voltage check with a low voltage...

Page 163: ...check for condition of the coupler lock if equipped 1 Check for loose connection Using a test male terminal check the female terminals of the circuit being checked for contact tension Check each term...

Page 164: ...ked 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 measurem...

Page 165: ...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 be...

Page 166: ...he multi circuit tester will be shown as 10 00 M and 1 flashes in the display Check that no voltage is applied before making the measure ment If voltage is applied the tester may be damaged After usin...

Page 167: ...ious 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 Posit...

Page 168: ...CM 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 i...

Page 169: ...sition switch B Starter relay I Crankshaft position sensor CKPS C Starter motor J Fuel injector 2 FI D Intake air pressure sensor 1 IAPS K Fuel injector 1 FI E Fuel pump relay FP RELAY L Ignition coil...

Page 170: ...Intake air temperature sensor IATS O Secondary throttle position sensor STPS S Ignition coil 2 IG COIL P Throttle position sensor TPS T Engine coolant temperature sensor ECTS Q Secondary throttle val...

Page 171: ...Clutch lever position switch Starter motor Starter relay 10 A 10 A 30 A 15 A Side stand switch Side stand relay Engine stop switch Starter switch Fuel pump relay Ignition switch Neutral indicator ligh...

Page 172: ...CKP sensor signal CKP P Neutral switch NT 0 Power source for fuel injector VM Q CKP sensor signal CKP A Power source B 1 R B Power source for back up B 2 S Blank C ECM ground E1 T Blank D Sensors gro...

Page 173: ...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...

Page 174: ...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...

Page 175: ...is case C28 and C29 are indicated alternately CODE MALFUNCTION PART REMARKS C00 C12 C13 C14 C15 C17 C21 C23 C24 C25 C28 C29 C31 C32 C33 C41 C42 C44 C49 None Crankshaft position sensor CKPS Intake air...

Page 176: ...screws 5 47 5 Move the inlet pipe 1 6 Loosen the screw with a torx wrench T25 and turn the throt tle position sensor 2 and bring the line to the middle 7 Then tighten the screw to fix the throttle pos...

Page 177: ...throttle opening is fixed to full open position Ignition timing is also fixed YES YES ECT sensor Engine coolant temperature value is fixed to 80 C 176 F YES YES IAT sensor Intake air temperature value...

Page 178: ...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...

Page 179: ...9 Each warning light operation 9 29 Speedometer operation 9 31 Exhaust gas leakage and noise 2 24 Each coupler disconnection Clogged radiator core 7 5 Engine coolant level and leakage 7 6 MOTORCYCLE E...

Page 180: ...nnect 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 malfunction c...

Page 181: ...ERVICING 5 3 before inspection and observe what is written there Remove the right frame cover 8 4 Set up the SDS tool Refer to the SDS operation manual for further details Read the DTC Diagnostic Trou...

Page 182: ...Therefore erase the history code memorized in the ECM using SDS tool NOTE The malfunction code is memorized in the ECM also when the wire coupler of any sensor is disconnected Therefore when a wire c...

Page 183: ...ed when a malfunction was detected by checking the show data when trouble This show data when trouble function can record the maximum of two Diagnostic Trouble Codes in the ECM Also ECM has a function...

Page 184: ...should produce following voltage 0 1 V sensor voltage 4 8 V In other than the above range C14 P0120 is indicated TP sensor lead wire coupler connection P0120 H Sensor voltage is higher than specified...

Page 185: ...fied value TO sensor circuit shorted to ground or VCC circuit open C24 C25 Ignition sig nal CKP sensor pick up coil signal is pro duced but signal from ignition coil is interrupted 8 times or more con...

Page 186: ...P0201 P0202 C41 Fuel pump relay No voltage is applied to the fuel pump although fuel pump relay is turned ON or voltage is applied to fuel pump although fuel pump relay is turned OFF Fuel pump relay...

Page 187: ...e the tool box cover 2 DETECTED CONDITION POSSIBLE CAUSE The signal does not reach ECM for 3 sec or more after receiving the starter signal Metal particles or foreign material being stuck on the CKP s...

Page 188: ...e resis tance CKP sensor resistance 184 276 Green Blue 8 If OK then check the continuity between each terminal and ground CKP sensor continuity Infinity Blue Ground Green Ground 09900 25008 Multi circ...

Page 189: ...uble clear the DTC using SDS tool 5 25 YES G Y or Brown wire open or shorted to ground Loose or poor contacts on the CKP sensor cou pler or ECM coupler terminal 9 or Q If wire and connection are OK in...

Page 190: ...ound 7 Also measure the voltage at the Red wire 3 and B Br wire 4 IAP sensor input voltage 4 5 5 5 V Red Ground Red B Br 09900 25008 Multi circuit tester set Tester knob indication Voltage DETECTED CO...

Page 191: ...Approx 2 6 V at idle speed Front cylinder side G B B Br Rear cylinder side G W B Br 09900 25008 Multi circuit tester set 09900 25009 Needle pointed probe set Tester knob indication Voltage Is the volt...

Page 192: ...acuum pump gauge 09900 25008 Multi circuit tester set Tester knob indication Voltage Is the voltage OK 6 After repairing the trouble clear the DTC using SDS tool 5 25 YES Red B Br or G B wire open or...

Page 193: ...0 30 C 68 86 F ALTITUDE Reference ATMOSPHERIC PRESSURE OUTPUT VOLTAGE ft m mmHg kPa V 0 2 000 0 610 760 707 100 94 3 4 4 0 2 001 5 000 611 1 524 707 634 94 85 2 8 3 7 5 001 8 000 1 525 2 438 634 567 8...

Page 194: ...ester knob indication Voltage Is the voltage OK DETECTED CONDITION POSSIBLE CAUSE C14 Output voltage is not within the following range Difference between actual throttle open ing and opening calculate...

Page 195: ...ster the circuit condition is OK 6 Remove the right frame cover 8 4 ECM bracket 1 and disconnect the ECM coupler 7 Check the continuity between BI B wire A and terminal K 8 Also check the continuity b...

Page 196: ...er the circuit condi tion is OK 7 Remove the right frame cover 8 4 ECM bracket 5 38 and disconnect the ECM coupler 8 Check the continuity between BI B wire A and terminal K 9 Also check the continuity...

Page 197: ...ce TP sensor resistance Throttle valve is closed Approx 1 1 k Throttle valve is opened Approx 4 4 k 6 If OK then measure the TP sensor resistance at the termi nals between Blue wire and Black wire TP...

Page 198: ...25008 Multi circuit tester set 09900 25009 Needle pointed probe set Tester knob indication Voltage Is the voltage OK 5 After repairing the trouble clear the DTC using SDS tool 5 25 V 3 YES R B Br or B...

Page 199: ...l 2 ECT sensor input voltage 4 5 5 5 V B Bl Ground B Bl B Br 09900 25008 Multi circuit tester set Tester knob indication Voltage Is the voltage OK DETECTED CONDITION POSSIBLE CAUSE C15 Output voltage...

Page 200: ...er 6 Remove the ECM bracket 5 38 and ECM coupler 7 Check the continuity between B Bl wire A and terminal I 8 Also check the continuity between B Br wire B and terminal D ECTS lead wire continuity Cont...

Page 201: ...d is not heard from the tester the circuit condition is OK Tester knob indication Continuity test 7 Connect the ECT sensor coupler 8 Turn the ignition switch ON 9 Measure the voltage between B Bl wire...

Page 202: ...After repairing the trouble clear the DTC using SDS tool 5 25 ECT sensor specification 2 2 YES B Bl or B Br wire open or shorted to ground or poor D or I connection If wire and connection are OK inte...

Page 203: ...not change in the propor tion indicated replace it with a new one ECT sensor specification 09900 25008 Multi circuit tester set Tester knob indication Resistance If the resistance is noted to show inf...

Page 204: ...e wire side coupler 5 Disconnect the IAT sensor coupler and turn the ignition switch ON DETECTED CONDITION POSSIBLE CAUSE C21 Output voltage is not within the following range 0 1 Sensor voltage 4 6 V...

Page 205: ...e terminal 3 and B Br wire terminal 4 IAT sensor input voltage 4 5 5 5 V Dg Ground Dg B Br 09900 25008 Multi circuit tester set Tester knob indication Voltage Is the voltage OK 1 V YES Go to Step 2 NO...

Page 206: ...the IAT sensor coupler 7 Remove the ECM bracket 5 38 and ECM coupler 8 Check the continuity between Dg wire A and terminal 2 9 Also check the continuity between B Br wire B and terminal D IATS lead wi...

Page 207: ...ound is not heard from the tester the circuit condition is OK Tester knob indication Continuity test 7 Connect the IAT sensor coupler and turn the ignition switch ON 8 Measure the voltage between Dg w...

Page 208: ...f the ECT sensor Refer to 5 46 for details 4 After repairing the trouble clear the DTC using SDS tool 5 25 2 YES Dg or B Br wire open or shorted to ground or poor 2 or D connection If wire and connect...

Page 209: ...circuit tester set Tester knob indication Resistance Is the resistance OK DETECTED CONDITION POSSIBLE CAUSE C23 The sensor voltage should be the follow ing for 2 sec and more after ignition switch is...

Page 210: ...ester the circuit condition is OK 6 Remove the ECM bracket 5 38 and disconnect the ECM coupler 7 Check the continuity between Br W wire B and terminal J 8 Also check the continuity between B Br wire C...

Page 211: ...not heard from the tester the circuit condi tion is OK 7 Remove the ECM bracket 5 38 and disconnect the ECM coupler 8 Check the continuity between Red wire A and terminal 6 9 Also then check the cont...

Page 212: ...009 Needle pointed probe set Tester knob indication Voltage Is the voltage OK 6 After repairing the trouble clear the DTC using SDS tool 5 25 C24 P0351 or C25 P0352 IGNITION SYSTEM MALFUNCTION When in...

Page 213: ...ull open 95 open Is the operating OK 6 After repairing the trouble clear the DTC using SDS tool 5 25 DETECTED CONDITION POSSIBLE CAUSE The operation voltage does not reach the STVA ECM does not receiv...

Page 214: ...D 09900 25008 Multi circuit tester set Tester knob indication Resistance Is the resistance OK 5 After repairing the trouble clear the DTC using SDS tool 5 25 2 2 YES B Lg P W Green and Black wire open...

Page 215: ...e SDS tool Refer to the SDS operation manual for further details 2 Turn the ignition switch ON 3 Click Secondary throttle operating control 1 4 Click each button 2 At this time if an operation sound i...

Page 216: ...on Voltage Is the voltage OK DETECTED CONDITION POSSIBLE CAUSE C29 Signal voltage is not within the following range Difference between actual throttle open ing and opening calculated by ECM is larger...

Page 217: ...dition is OK 6 Remove the right frame cover 8 4 7 Remove the ECM bracket 5 38 and disconnect the ECM coupler 8 Check the continuity between Y W wire C and terminal 4 9 Also check the continuity betwee...

Page 218: ...e circuit condi tion is OK 7 Remove the right frame cover 8 4 8 Remove the ECM bracket 5 38 and disconnect the ECM coupler 9 Check the continuity between Y W wire C and terminal 4 10 Also check the co...

Page 219: ...and measure the valve closing and opening resistance STP sensor resistance Secondary throttle valve is closed Approx 0 5 k Secondary throttle valve is opened Approx 3 9 k Yellow A Black B 7 If OK the...

Page 220: ...y throttle valve is closed Approx 0 5 V Secondary throttle valve is opened Approx 3 9 V 09900 25008 Multi circuit tester set 09900 25009 Needle pointed probe set Tester knob indication Voltage Is the...

Page 221: ...9 Measure the voltage at the wire side coupler between Pink wire A and B W wire B when shifting the gearshift lever from 1st to Top GP switch voltage 0 6 V and more P A B W B 09900 25008 Multi circui...

Page 222: ...mittent trou ble or faulty ECM Recheck each terminal and wire harness for open circuit and poor connection Replace the ECM with a known good one and inspect it again NO P or B W wire open or Pink wire...

Page 223: ...e 1 or Rear cyl inder side 2 for loose or poor contacts If OK then measure the injector resistance 5 Disconnect the injector coupler and measure the resistance between terminals Injector resistance Ap...

Page 224: ...nds after ignition switch is turned ON 09900 25008 Multi circuit tester set Tester knob indication Voltage Is the voltage OK 3 After repairing the trouble clear the DTC using SDS tool 5 25 YES Go to S...

Page 225: ...d to fuel pump although fuel pump relay is turned OFF Fuel pump relay circuit open or short Fuel pump relay malfunction ECM malfunction ECM Side stand relay Engine stop switch Fuel pump relay Fuel pum...

Page 226: ...is not heard from the tester the circuit condi tion is OK 09900 25008 Multi circuit tester set Tester knob indication Continuity test DETECTED CONDITION POSSIBLE CAUSE C44 P0130 HO2 sensor output volt...

Page 227: ...coupler 4 Measure the HO2 sensor output voltage between W Bl wire A and B Br wire B when idling condition HO2 sensor output voltage at idle speed 0 2 V and less W Bl A B Br B 5 If OK then pinch the PA...

Page 228: ...affects resistance value largely Make sure that the sensor heater is at correct temperature 09900 25008 Multi circuit tester set Tester knob indication Resistance Is the voltage OK 5 After repairing t...

Page 229: ...09900 25008 Multi circuit tester set 09900 25009 Needle pointed probe set Tester knob indication Voltage Is the voltage OK 5 After repairing the trouble clear the DTC using SDS tool 5 25 YES O W or W...

Page 230: ...5008 Multi circuit tester set Tester knob indication Resistance 5 If OK then check the continuity between each terminal and ground PAIR valve resistance Infinity Terminal Ground Tester knob indication...

Page 231: ...eration manual for further details 2 Turn the ignition switch ON 3 Click PAIR Sol operating control 1 4 Click each button 2 At this time if an operation sound is heard from the PAIR control solenoid v...

Page 232: ...oses 3 Installation is in the reverse order of removal TP SENSOR INSPECTION The throttle position sensor is installed on the No 2 throttle body 5 37 TP SENSOR REMOVAL INSTALLATION Remove the fuel tank...

Page 233: ...a torx wrench T25 and STP sensor 2 Install the STP sensor to the No 2 throttle body 6 18 STP sensor setting procedure 6 21 CKP SENSOR INSPECTION The signal rotor is mounted on the generator rotor and...

Page 234: ...led at the No 2 cylinder head cover 5 42 ECT SENSOR REMOVAL INSTALLATION Remove the fuel tank 6 3 Disconnect the ECT sensor coupler 1 and remove the ECT sensor 2 Installation is in the reverse order o...

Page 235: ...in the reverse order of removal Tighten the sensor unit to the specified torque HO2 SENSOR 25 N m 2 5 kgf m 18 0 lb ft Route the HO2 sensor lead wire properly Do not remove the HO2 sensor while it is...

Page 236: ...ON 6 11 THROTTLE BODY 6 12 CONSTRUCTION 6 12 AIR CLEANER BOX REMOVAL 6 13 AIR CLEANER BOX INSTALLATION 6 13 THROTTLE BODY REMOVAL 6 13 THROTTLE BODY DISASSEMBLY 6 14 THROTTLE BODY CLEANING 6 17 INSPEC...

Page 237: ...e regulator As the fuel pressure applied to the fuel injector the fuel pressure in the fuel delivery pipe is always kept at absolute fuel pressure of 3 0 kgf cm 300 kPa 43 psi the fuel is injected int...

Page 238: ...ll be twisted Remove the pilot lamp coupler 1 Disconnect the fuel pump lead wire coupler 2 Place a rag under the fuel feed hose and remove the fuel feed hose 3 Remove the fuel tank FUEL TANK INSTALLAT...

Page 239: ...switch ON and check the fuel pressure Fuel pressure Approx 300 kPa 3 0 kgf cm 43 psi If the fuel pressure is lower than the specification inspect the following items Clogged fuel filter Pressure regul...

Page 240: ...e Disconnect the fuel pump lead wire coupler 2 Place the measuring cylinder and insert the fuel feed hose end into the measuring cylinder Connect a proper lead wire into the fuel pump lead wire cou pl...

Page 241: ...ear case cover Remove the secondary gear case cover 2 16 Remove the fuel pump relay First check the insulation between A and B terminals with pocket tester Then apply 12 volts to C and D terminals to...

Page 242: ...DY 6 7 FUEL PUMP REMOVAL AND DISASSEMBLY CONSTRUCTION 1 Thermistor 6 O ring 2 Fuel pump 7 Cover 3 Vessel 8 Fuel mesh filter ITEM N m kgf m lb ft 4 Rubber cushion A Fuel pump mounting bolt A 10 1 0 7 0...

Page 243: ...th the recessed section A of the delivery pipe positioned at the edge of the tank opening as shown in the photograph turn the pump assembly 90 counterclockwise Remove the high pressure filter 2 from t...

Page 244: ...fuel pump wiring coupler 3 out of the tank opening while taking care not to cause it to interfere with the tank opening Remove the thermistor 4 from the tank opening Remove the fuel pump assembly 1 al...

Page 245: ...AND THROTTLE BODY Remove the thermistor 7 Disconnect fuel pump coupler 8 Remove the fuel pump 9 Remove the rubber cushion 0 and vessel A Remove the fuel pump holder B Remove the cover C and fuel mesh...

Page 246: ...pump Be sure to connect the wires to the proper terminals A Thermistor HIGH B Thermistor LOW C Positive terminal for fuel pump Install a new O ring and apply SUZUKI SUPER GREASE A to it 99000 25030 S...

Page 247: ...or E 33 2 TP sensor 0 Hose For E 33 3 IAP sensor A Vacuum hoses 4 STVA B Throttle stop screw 5 Fuel delivery pipe C Idle adjusting screw 6 O ring A STP sensor mounting screw ITEM N m kgf m lb ft 7 Fue...

Page 248: ...cleaner box AIR CLEANER BOX INSTALLATION Installation is in the reverse order of removal THROTTLE BODY REMOVAL Remove the air cleaner box Above Remove the IAP sensors Front cylinder side 1 and Rear cy...

Page 249: ...clamp screw at the intake pipe side Disconnect the throttle cables from their drum THROTTLE BODY DISASSEMBLY Remove the vacuum hose 1 and fuel feed hose 2 Remove the clamp 3 After disconnecting the th...

Page 250: ...pipes 5 Remove the fuel injectors 6 Remove the TP sensor 7 and STP sensor 8 with the special tool 09930 11950 Torx wrench NOTE Prior to disassembly mark each sensor s original position with a paint o...

Page 251: ...pes E Do not loosen the nut 0 The fast idle screw A is factory adjusted at the time of delivery and therefore avoid removing or turning it unless otherwise necessary Do not turn the screw B Never remo...

Page 252: ...he new O rings Some carburetor cleaning chemicals especially dip type soaking solutions are very corrosive and must be handled carefully Always follow the chemical manufacturer s instructions for prop...

Page 253: ...moothly If the STP sensor adjustment is necessary refer to page 6 20 for STP sensor setting procedure With the throttle valve fully closed install the TP sensor 2 and tighten the TP sensor mounting sc...

Page 254: ...he groove F of the delivery pipe Install the fuel delivery pipes 5 to the throttle body assembly Tighten the fuel delivery pipe mounting screws to the speci fied torque Fuel delivery pipe mounting scr...

Page 255: ...he throttle pulling cable 2 and throttle returning cable 3 to the throttle cable drum Loosen each throttle cable lock nut Turn in each throttle cable adjuster fully and locate each outer cable so that...

Page 256: ...tage If the STP sensor voltage is out of specification loosen the STP sensor mounting screw and adjust the STP sensor volt age to specification Tighten the STP sensor mounting screw 09930 11950 Torx w...

Page 257: ...re ambient temperature and lapsed time the fast idle is cancelled allowing the engine to resume idle speed FAST IDLE ADJUSTMENT Lift and support the fuel tank 6 3 Start up the engine and run it in idl...

Page 258: ...s 0 08 V TP sensor output voltage variation 0 064 0 096 V If the voltage variation is out of specification loosen the lock nut 2 and turn in or out the fast idle adjust screw 3 to adjust the voltage t...

Page 259: ...ee way joint 13681 39F00 225 Hose 1 To vacuum nipple 2 To vacuum hose 3 To vacuum balancer gauge hose Connect a tachometer Start up the engine and keep it running at 1 100 rpm by turn ing throttle sto...

Page 260: ...the following points The vacuum gauge is positioned vertical level and in this posi tion the two balls should be within one ball dia If the difference is larger than one ball turn the balance adjustin...

Page 261: ...ION 7 7 REMOVAL 7 7 INSTALLATION 7 8 COOLING FAN THERMO SWITCH 7 9 REMOVAL 7 9 INSPECTION 7 9 INSTALLATION 7 9 ENGINE COOLANT TEMPERATURE SENSOR 7 10 REMOVAL 7 10 INSPECTION 7 10 INSTALLATION 7 11 THE...

Page 262: ...r anti leak additive Anti freeze 750 ml 1 6 1 3 US lmp pt Water 750 ml 1 6 1 3 US lmp pt Anti freeze density Freezing point 50 55 60 30 C 24 F 40 C 44 F 55 C 67 F 20 40 60 80 100 Density 0 10 20 30 40...

Page 263: ...he pressure should fall during this 10 second interval it means that there is a leaking point in the system In such a case inspect the entire system and replace the leaking com ponent or part WATER PU...

Page 264: ...HOSES RADIATOR REMOVAL Remove the fuel tank 6 3 Remove the frame head covers 3 3 Drain the engine coolant 2 17 Remove the radiator cover 1 Remove the radiator mounting bolts Disconnect the ECT sensor...

Page 265: ...nd not to satisfy either of these two requirements Radiator cap valve opening pressure Standard 95 125 kPa 0 95 1 25 kgf cm 13 5 17 8 psi RADIATOR INSPECTION AND CLEANING Road dirt or trash stuck to t...

Page 266: ...ve the fuel tank 6 3 Remove the secondary gear case cover 8 40 Remove the frame head covers 3 3 Any water hose and reservoir tank 1 found in a cracked con dition or flattened must be replaced Any leak...

Page 267: ...is for making sure that the battery applies 12 volts to the motor With the motor with electric motor fan run ning at full speed the ammeter should be indicating not 5 amperes and more If the fan motor...

Page 268: ...the cooling fan in the reverse order of removal Pay atten tion to the following points Put the cooling fan 1 between the down tube and the engine Temporary tighten the down tube mounting bolts 3 9 Tig...

Page 269: ...mperature slowly and read the col umn thermometer when the switch closes or opens 09900 25008 Multi circuit tester set Tester knob indication Continuity test Cooling fan thermo switch operating temper...

Page 270: ...aced on a stove Heat the oil to raise its temperature slowly and read the col umn thermometer 2 and the ohmmeter If the temperature sensor ohmic value does not change in the proportion indicated repla...

Page 271: ...rder of removal Pay attention to the following points 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 Take special...

Page 272: ...Pass a string 1 between flange of thermostat 2 as shown Immerse the thermostat in the water contained in a beaker as shown in the illustration Note that the immersed thermostat is in suspension Heat...

Page 273: ...nd over at 90 C 0 24 in and over at 194 F A thermostat failing to satisfy either of the two requirements start to open temperature and valve lift must be replaced INSTALLATION Install the thermostat i...

Page 274: ...e between the water pump and crankcase If engine oil is leaking visually inspect the oil seal and O ring If engine coolant is leaking visually inspect the mechanical seal and seal washer 7 16 Turn the...

Page 275: ...l is not necessary INSPECTION BEARING Inspect the play of the bearing by hand while it is in the water pump case Rotate the inner race by hand to inspect for abnormal noise and smooth rotation Replace...

Page 276: ...isually inspect the bearing case for damage Replace the water pump body if necessary REASSEMBLY AND INSTALLATION Install the oil seal with the special tool 09913 70210 Bearing installer set NOTE The s...

Page 277: ...e stamped mark on the bearing faces crankcase side Apply SUZUKI SUPER GREASE A to the impeller shaft 99000 25030 SUZUKI SUPER GREASE A USA 99000 25010 SUZUKI SUPER GREASE A Others Install the impeller...

Page 278: ...EASE A Others Install the new gasket 6 Apply grease to the O ring Set the water pump shaft end C to the oil pump shaft D 99000 25030 SUZUKI SUPER GREASE A USA 99000 25010 SUZUKI SUPER GREASE A Others...

Page 279: ...COOLING AND LUBRICATION SYSTEM 7 19 LUBRICATION SYSTEM OIL PRESSURE 2 28 OIL FILTER 2 12 OIL PRESSURE REGULATOR 3 62 OIL STRAINER 3 61 OIL JET 3 60 OIL PUMP 3 56 OIL PRESSURE SWITCH 3 63 SAMPLE...

Page 280: ...MAIN GALLERY STARTER CLUTCH BEARING R CRANK JOURNAL OIL JET REAR CYLINDER CYLINDER HEAD CAMSHAFT R JOURNAL CYLINDER WALL PISTON AND PISTON PIN NO 2 CONROD BIG END CAM CHAIN CAMSHAFT ROCKER ARM IN VAL...

Page 281: ...SEMBLY 8 22 REASSEMBLY AND REMOUNTING 8 22 STEERING 8 24 CONSTRUCTION 8 24 REMOVAL AND DISASSEMBLY 8 25 INSPECTION AND DISASSEMBLY 8 27 REASSEMBLY AND REMOUNTING 8 27 STEERING TENSION ADJUSTMENT 8 30...

Page 282: ...8 56 MASTER CYLINDER REMOVAL AND DISASSEMBLY 8 57 MASTER CYLINDER INSPECTION 8 58 MASTER CYLINDER REASSEMBLY AND REMOUNTING 8 59 REAR BRAKE 8 61 CONSTRUCTION 8 61 REMOVAL AND DISASSEMBLY 8 62 INSPECTI...

Page 283: ...t by removing the bolt Remove the rear seat grip band by removing the bolts Remove the seat FRAME COVER Remove the left frame cover 1 with the ignition key Hooked part Be careful not to scratch the re...

Page 284: ...of THREAD LOCK to its mounting bolts and tighten them to the specified torque Hooked part 99000 32030 THREAD LOCK SUPER 1303 Frame handle grip mounting bolt A M10 50 N m 5 0 kgf m 36 0 lb ft Hooked p...

Page 285: ...HASSIS 8 5 FRONT WHEEL CONSTRUCTION 1 Bearing R 5 Brake disc 2 Front wheel 6 Spacer ITEM N m kgf m lb ft 3 Spacer A Front axle A 65 6 5 47 0 4 Bearing L B Brake disc mounting bolt B 23 2 3 16 5 SAMPLE...

Page 286: ...8 6 CHASSIS A Front axle B Brake disc bolt ITEM N m kgf m lb ft A 65 6 5 47 0 B 23 2 3 16 5 Left Right SAMPLE...

Page 287: ...e with the special tool 09900 18710 Hexagon socket 12 mm Raise the front wheel off the ground with a jack or a wooden block Remove the front axle 2 spacer 3 and front wheel Remove the brake disc by re...

Page 288: ...al tool A or B 09921 20240 A Bearing remover set 17 mm or 09941 50111 B Wheel bearing remover FRONT WHEEL Make sure that the wheel runout axial and radial does not exceed the service limit when checke...

Page 289: ...e order of removal and disassembly Pay special attention to the following points WHEEL BEARING Apply SUZUKI SUPER GREASE A to the bearings before installing 99000 25030 SUZUKI SUPER GREASE A USA 99000...

Page 290: ...PEED SENSOR Apply SUZUKI SUPER GREASE A to the speed sensor dust seal 99000 25030 SUZUKI SUPER GREASE A USA 99000 25010 SUZUKI SUPER GREASE A Others Align the grooves 1 on the speed sensor with the lu...

Page 291: ...e 65 N m 6 5 kgf m 47 0 lb ft Front axle pinch bolt 23 N m 2 3 kgf m 16 5 lb ft 09900 18710 Hexagon socket 12 mm NOTE Before tightening the front axle pinch bolt 3 move the front fork up and down four...

Page 292: ...Oil seal stopper ring B Inner rod lock nut 3 Spring 8 Dust seal C Front axle pinch bolt 4 Outer tube 9 Inner rod Damper rod cartridge D Caliper rod bolt 5 Oil seal retainer 0 Inner tube ITEM N m kgf m...

Page 293: ...efore loosening the lower clamp bolts to facilitate later disassembly Loosen the turn signal light clamp screws and front fork lower clamp bolts Remove the front forks Separate the front fork cap bolt...

Page 294: ...and spring 4 Invert the front fork and stroke the inner rod several times to let out fork oil Under the inverted condition of front fork drain oil completely by holding the fork for a while Remove the...

Page 295: ...reful not to damage the ANTI FRICTION metals Remove the dust seal 6 Remove the oil seal stopper ring 7 Remove the oil seal 8 with the special tool 09913 50121 Oil seal remover Remove the oil seal reta...

Page 296: ...them with a new one FORK SPRING Measure the fork spring free length If it is shorter than the service limit replace it with a new one Front fork spring free length Service Limit 372 mm 14 6 in DAMPER...

Page 297: ...ront fork oil seal installer NOTE Stamped mark on the oil seal should face outside DAMPER ROD BOLT Insert the inner rod damper rod cartridge into the inner tube with the gasket 1 fitted apply the damp...

Page 298: ...ner rod holder NOTE Refill front fork oil up to the top of the outer tube so that bubbles are visible while bleeding air Refill specified front fork oil up to the top level of the outer tube again Mov...

Page 299: ...the spacer 09940 52841 Inner rod holder A 09940 94930 Front fork spacer holder B 09940 94922 Stopper plate C Slowly turn the cap bolt 1 until the inner rod is lightly seated Hold the cap bolt 1 and t...

Page 300: ...clamp bolts 4 slightly tighten the front fork cap bolt 3 to the specified torque Front fork cap bolt 3 23 N m 2 3 kgf m 16 5 lb ft Tighten the front fork upper clamp bolts 4 to the specified torque F...

Page 301: ...CHASSIS 8 21 HANDLEBAR CONSTRUCTION FW D FW D 1 Handlebars 3 Left handle grip 5 Right handle grip 2 Handlebar balancer 4 Left handle switch 6 Right handle switch SAMPLE...

Page 302: ...er bolt 7 Remove the left handlebar balancer 8 and the left handlebar switch 9 Remove the handlebar clamp bolt caps handlebar clamp bolts and handlebar clamps Remove the speedometer by removing the sp...

Page 303: ...aps Apply the SUZUKI SUPER GREASE A to the throttle cables and their holder 99000 25030 SUZUKI SUPER GREASE A USA 99000 25010 SUZUKI SUPER GREASE A Others When remounting the right and left handle swi...

Page 304: ...mp holder 7 Steering stem lower bearing D Handlebar holder nut 3 Steering stem upper bracket 8 Steering stem E Front fork lower clamp bolt 4 Steering stem nut A Handlebar set bolt 5 Dust seal B Steeri...

Page 305: ...the clamps Remove the handlebar 8 22 Remove the steering stem head nut 2 and washer Remove the steering stem upper bracket 3 Remove the speed sensor lead wire coupler 9 31 Remove the cable guide 4 Rem...

Page 306: ...lower bracket NOTE Hold the steering stem lower bracket to prevent it from falling Remove the dust seal 5 steering stem upper bearing inner race 6 and bearing 7 Remove the steering stem lower bearing...

Page 307: ...ter races upper and lower using the steel rod REASSEMBLY AND REMOUNTING Reassemble and remount the steering stem in the reverse order of removal and disassembly Pay attention to the following points O...

Page 308: ...eering stem Install the steering stem nut as shown NOTE The flange side A of the steering stem must face down Tighten the steering stem nut to the specified torque with the special tool 09940 14911 St...

Page 309: ...Install the steering stem upper bracket washer and steering stem head nut Install the front forks 8 20 Tighten the steering stem head nut 1 to the specified torque Steering stem head nut 1 90 N m 9 0...

Page 310: ...he initial force read on the scale when the handlebar starts turning is either too heavy or too light adjust it till it satisfies the specification 1 First loosen the front fork upper clamp bolts hand...

Page 311: ...Cotter pin For E 03 28 33 3 Lock washer 0 Bearing RH A Driven joint stopper bolt 4 Driven joint stopper A Rear wheel B Rear brake cam lever bolt 5 Driven joint B Brake shoe C Rear axle nut 6 Damper C...

Page 312: ...Rear axle nut B Brake cam lever nut ITEM N m kgf m lb ft ITEM N m kgf m lb ft C Rear torque link nut F A 65 6 5 47 0 C 35 3 5 25 5 D Rear torque link nut R B 10 1 0 7 0 D 25 2 5 18 0 Right Left For E...

Page 313: ...motorcy cle with a jack or wooden block Remove the rear brake rod 1 Remove the torque link rod 2 Remove the left frame cover 8 3 Remove the left frame lower cover 3 Hooked part Remove the rear swinga...

Page 314: ...t of motorcycle can be lifted high enough to take the rear wheel out smoothly DISASSEMBLY Flatten the lock washers Remove the fitting bolts washers and plates Pull off the driven joint 1 Remove the O...

Page 315: ...unusual Remove the wheel bearings by with the special tool 09921 20240 Bearing remover set 17 mm REAR AXLE Using a dial gauge check the rear axle for runout If the runout exceeds the limit replace the...

Page 316: ...0 25030 SUZUKI SUPER GREASE A USA 99000 25010 SUZUKI SUPER GREASE A Others Install the wheel bearings with the special tool 09941 34513 Bearing installer set WHEEL DAMPER Install the dampers NOTE If s...

Page 317: ...sher to lock the bolts REAR WHEEL Install the spacer 1 Apply grease to the final gear spline before installing the rear wheel 99000 25030 SUZUKI SUPER GREASE A USA 99000 25010 SUZUKI SUPER GREASE A Ot...

Page 318: ...unting nut 3 Spacer 8 Swingarm D Rear swingarm pivot bolt lock nut 4 Rear cushion lever bearing 9 Boot E Rear swingarm pivot bolt Right 5 Rear cushion lever A Rear shock absorber mounting nut F Rear s...

Page 319: ...CHASSIS 8 39 Left Right 50 N m 5 0 kgf m 43 5 lb ft 78 N m 7 8 kgf m 56 5 lb ft 100 N m 10 0 kgf m 72 5 lb ft 100 N m 10 0 kgf m 72 5 lb ft 1 mm 1 mm 1 mm 1 mm 9 5 N m 0 95 kgf m 7 0 lb ft SAMPLE...

Page 320: ...tank 6 3 Remove the battery 1 and disconnect the coupler 2 Remove the set mounting bracket 3 Disconnect the starter motor lead wire 4 and starter relay coupler 5 Remove the battery case 6 Remove the f...

Page 321: ...he right frame lower cover 8 clutch rear cover 9 Hooked part Remove the tool box cover 0 Remove the tool box Remove the fuse box and relay stay Remove the cushion lever mounting bolt and nut and cushi...

Page 322: ...he left and right side swingarm pivot bolts D NOTE Slightly loosen the cushion rod mounting nuts and the shock absorber lower mounting nut before removing the swingarm to facilitate later disassembly...

Page 323: ...pivot bearing its race and dust seal for wear or damage If any defects are found replace the bearing with a new one Remove the swingarm pivot right side bearing plate 1 and bearing races 2 by using a...

Page 324: ...mm Remove the cushion lever mounting bearing 2 and shock absorber lower side bearing 3 by using the special tool 09913 70210 Bearing installer set SHOCK ABSORBER Inspect the shock absorber body and bu...

Page 325: ...ioned right side Install the swingarm cushion rod upper side bearings with the special tool 8 39 09924 84510 Bearing installer set NOTE When reinstalling the bearings stamped mark of bearing must face...

Page 326: ...NOTE Make sure that the UP mark A on the boot faces up Install the swingarm assembly its pivot bearings and bolts 1 2 NOTE Apply grease to the swingarm pivot bearings 99000 25030 SUZUKI SUPER GREASE...

Page 327: ...k absorber upper mounting nut 1 to the specified torque Shock absorber mounting nut 50 N m 5 0 kgf m 36 0 lb ft Tighten the cushion rod nuts 2 to the specified torque Cushion rod mounting nut 78 N m 7...

Page 328: ...ot front and the universal joint back Engage the universal joint to the propel ler shaft first and then engage it to the secondary driven bevel gear shaft Tighten the final gear case mounting nuts to...

Page 329: ...USPENSION SETTING After installing the rear suspension adjust the spring pre load as follows The rear shock unit contains high pressure nitrogen gas Mishandling can cause explosion Keep away from fire...

Page 330: ...lator 2 Diaphragm 7 Caliper A Master cylinder mounting bolt 3 Master cylinder 8 Pad set B Brake hose union bolt 4 Piston set 9 Piston C Brake caliper mounting bolt 5 Brake hose 0 Piston and dust seal...

Page 331: ...or which has been stored for a long period of time When storing brake fluid be sure to seal the container completely and keep it out of the reach of children When replenishing brake fluid be sure not...

Page 332: ...ke caliper mounting bolts to the specified torque Brake caliper mounting bolts 39 N m 3 9 kgf m 28 lb ft Install the reflex reflector 1 For E 03 28 33 NOTE After replacing the brake pads pump the brak...

Page 333: ...hose Fill the reservoir with new brake fluid to the upper end of the inspection window BRAKE CALIPER REMOVAL AND DISASSEMBLY Remove the reflex reflector 1 For E 03 28 33 Disconnect the brake hose from...

Page 334: ...CTION BRAKE CALIPER Inspect each brake caliper cylinder wall for nicks scratches or other damage If any damages are found replace the brake cal iper with a new one BRAKE CALIPER PISTONS Inspect the br...

Page 335: ...iston seal grooves Specification and classification DOT 4 PISTON SEALS Install the piston seals 1 and dust seals 2 as shown Wash the brake caliper components with new brake fluid before reassembly Do...

Page 336: ...m 2 3 kgf m 16 5 lb ft For assembly procedure of brake hose 10 21 Install the reflex reflector 3 For E 03 28 33 NOTE Before remounting the brake caliper push the brake caliper pis tons all the way int...

Page 337: ...MOVAL AND DISAS SEMBLY Place a rag underneath the brake hose union bolt on the mas ter cylinder to catch any spilt brake fluid Remove the brake hose union bolt and disconnect the brake hose Disconnect...

Page 338: ...YLINDER Inspect the master cylinder bore for any scratches or damage If any damages are found replace the master cylinder with a new one PISTON AND RUBBER PARTS Inspect the piston surface primary seco...

Page 339: ...aster cylinder Apply SUZUKI SUPER GREASE A to the bolt 99000 25030 SUZUKI SUPER GREASE A USA 99000 25010 SUZUKI SUPER GREASE A Others Wash the master cylinder components with new brake fluid before re...

Page 340: ...upper clamp bolt first Master cylinder mount bolt 10 N m 1 0 kgf m 7 0 lb ft Tighten the brake hose union bolt to the specified torque For assembly procedure of brake hose 10 21 Brake hose union bolt...

Page 341: ...REAR BRAKE CONSTRUCTION 1 Brake shoe 2 Brake camshaft ITEM N m kgf m lb ft 3 Brake panel A 65 6 5 47 0 4 Brake cam lever B 10 1 0 7 0 5 Cotter pin For E 03 28 33 A Rear axle nut B Rear brake cam lever...

Page 342: ...ve the washer 4 spring 5 and O ring 6 Remove the rear brake cam 7 INSPECTION BRAKE DRUM Inspect the brake drum and measure the brake drum I D to determine the extent of wear Replace the brake drum if...

Page 343: ...s with spring hooks faced inside BRAKE CAM LEVER Install the new O ring and washer Install the brake cam lever to the brake camshaft as shown Tighten the brake cam lever bolt to the specified torque B...

Page 344: ...ove the right frame lower cover 1 clutch rear cover 2 Hooked part Remove the rear brake switch spring 3 Remove the rear brake pedal 4 Remove the cotter pin 5 Remove the rear brake pedal shaft 6 Remove...

Page 345: ...r brake link pivot bolt 29 N m 2 9 kgf m 21 lb ft Apply grease to the rear brake pedal shaft 99000 25030 SUZUKI SUPER GREASE A USA 99000 25010 SUZUKI SUPER GREASE A Others Tighten the rear brake pedal...

Page 346: ...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...

Page 347: ...shows no abnormal con dition removing of the valve is not necessary If the seal has abnormal deformation replace the valve with a new one Any dust or rust around the valve hole B must be cleaned off...

Page 348: ...the tire changer manufacturer Bounce the tire several times while rotating This makes the tire bead expand outward to contact the wheel thereby facili tating air inflation Inflate the tire Do not reus...

Page 349: ...e tire again When the bead has been fitted properly adjust the pressure to specification As necessary adjust the tire balance Cold inflation tire pressure BALANCER WEIGHT INSTALLATION When installing...

Page 350: ...OUBLESHOOTING 9 12 STARTER MOTOR REMOVAL AND DISASSEMBLY 9 14 STARTER MOTOR INSPECTION 9 15 STARTER MOTOR REASSEMBLY 9 15 STARTER RELAY INSPECTION 9 16 SIDE STAND IGNITION INTERLOCK SYSTEM PARTS INSPE...

Page 351: ...ELECTRICAL SYSTEM CONTENTS 9 2 ELECTRICAL SYSTEM SWITCHES 9 35 BATTERY 9 37 SPECIFICATIONS 9 37 INITIAL CHARGING 9 37 SERVICING 9 39 RECHARGING OPERATION 9 39 SAMPLE...

Page 352: ...res Inspect each terminal on the coupler for being loose or bent Inspect each terminal for corrosion and contamination CLAMP Clamp the wire harness at such positions as indicated in WIRE HARNESS ROUTI...

Page 353: ...ttery Be sure to recharge the battery in a well ventilated and open area Note that the charging system for the MF battery is different from that of a conventional battery Do not replace the MF battery...

Page 354: ...If voltage is applied the tester will be damaged After using the tester be sure to turn the switch to the OFF position 09900 25008 Multi circuit tester set NOTE When connecting the multi circuit teste...

Page 355: ...33 A TO sensor 5 52 3 Fuel injector 1 5 66 B Starter motor 4 ECM Engine Control Module C Ignition switch 5 Speed sensor D Horn 6 Ignition coil 2 E Cooling fan thermo switch 7 9 7 IAT sensor 5 47 F Coo...

Page 356: ...2 Fuel pump 6 5 0 Turn signal Side stand relay 3 Battery A Regulator Rectifier 4 ECT sensor 5 42 B Oil pressure switch 5 Fuse box C Generator 6 Ignition coil 1 D CKP sensor 5 30 7 Fuel pump relay 6 6...

Page 357: ...egulated voltage between the battery terminals 9 10 Is the regulated voltage OK Step 4 1 Measure the resistance of the generator coil 9 10 Is the resistance of generator coil OK YES Remove accessories...

Page 358: ...and the bat tery lead wire using the multi circuit tester If the reading exceeds the specified value leakage is evident Battery current leak Under 1 mA 09900 25008 Multi circuit tester set Tester kno...

Page 359: ...ged condition Regulated voltage Charging output 13 5 15 0 V at 5 000 r min 09900 25008 Multi circuit tester set Tester knob indication Voltage GENERATOR COIL RESISTANCE Remove the tool box 8 41 Discon...

Page 360: ...e the voltage between the lead wires using the multi cir cuit tester as indicated in the table below If the voltage is not within the specified value replace the regulator rectifier with a new one 099...

Page 361: ...runs when its terminal is connected to the battery terminal Do not use thin wire because a large amount of current flows Does the starter motor run YES Go to Step 2 NO Go to Step 3 YES Faulty starter...

Page 362: ...neutral with the side stand up 2 Check the side stand switch 9 17 Is the side stand switch OK Step 2 1 Check the starter clutch Is the starter clutch OK YES Go to Step 4 NO Faulty engine stop switch F...

Page 363: ...emove the mufflers and exhaust pipe 3 6 Remove the engine coolant pipe 1 Remove the starter motor cover 2 Remove the water union 3 Remove the starter motor 4 Disassemble the starter motor as shown in...

Page 364: ...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 nu...

Page 365: ...the threaded parts 5 on the housing end Apply a small quantity of THREAD LOCK to the starter motor housing bolts 99000 32050 THREAD LOCK 1342 Apply SUZUKI SUPER GREASE A to the O ring 99000 25030 SUZ...

Page 366: ...eration If the interlock system does not operate properly check each component for damage or abnormalities If any abnormality is found replace the component with a new one SIDE STAND SWITCH Remove the...

Page 367: ...osition Insert the needle pointed probes to the gear position switch coupler Measure the voltage between Pink and Black White lead wires using the multi circuit tester when shifting the gearshift leve...

Page 368: ...d E If there is no continuity replace the turn signal side stand relay with a new one 09900 25008 Multi circuit tester set Tester knob indication Continuity test DIODE INSPECTION Measure the voltage b...

Page 369: ...neutral and the engine stop switch is in the RUN position Grasp the clutch lever Check that the fuse is not blown and the battery is fully charged before diagnosing Step 1 1 Check the ignition system...

Page 370: ...23 Are the ignition coils OK Step 6 1 Measure the CKP sensor peak voltage and its resistance 9 23 to 24 NOTE The CKP peak voltage inspection is applicable only with the multi circuit tester and peak v...

Page 371: ...ct the ignition coil primary wire coupler 09900 25008 Multi circuit tester set Shift the transmission into neutral and turn ignition switch ON Pull the clutch lever Crank the engine a few seconds with...

Page 372: ...esistance CKP SENSOR PEAK VOLTAGE Remove the right frame cover 8 4 NOTE Be sure that all couplers are connected properly and the battery used is in fully charged condition Disconnect the ECM coupler 1...

Page 373: ...t the multi circuit tester with the peak volt adaptor Blue Probe Green Probe Measure the CKP sensor peak voltage at the CKP sensor lead wire coupler Tester knob indication Voltage CKP sensor peak volt...

Page 374: ...s not a malfunction This condition implies that combination meter receives no signal from the ECM In that case they are restored to normal indication by turning the engine stop switch to RUN position...

Page 375: ...headlight Disconnect the speedometer lead wire couplers Remove the speedometer cover 1 Hooked part Remove the speedometer When disconnecting and reconnecting the speedome ter coupler make sure to tur...

Page 376: ...ELECTRICAL SYSTEM 9 27 Disassemble the speedometer as follows Do not attempt to disassemble the speedometer unit 1 Speedometer cover 2 Speedometer unit 3 Speedometer case SAMPLE...

Page 377: ...ift and support the fuel tank 6 3 Remove the coupler 1 Remove the fuel tank upper cover 2 Remove the pilot lamp box When disconnecting and reconnecting the pilot lamp box coupler make sure to turn OFF...

Page 378: ...edometer unit with a new one after checking its wire har ness coupler NOTE The pointer may not return to the proper position even turning the ignition switch on under low temperature condition In that...

Page 379: ...EL INDICATOR SWITCH INSPECTION Remove and disassemble the fuel pump assembly 6 8 Connect 12 V battery and test bulb 12 V 3 4 W to the fuel level indicator switch as shown in the right illustration The...

Page 380: ...ler If the fuel level indicator switch and its lead wire coupler are functioning properly replace the combination meter with a new one SPEED SENSOR INSPECTION If the speedometer odometer or tripmeter...

Page 381: ...V 0 V If the tester reading voltage does not change replace the speed sensor with a new one NOTE The highest tester reading voltage 12 V while testing is same as battery voltage OIL PRESSURE INDICATOR...

Page 382: ...W POSITION LIGHT 12 V 5 W E 02 19 BRAKE LIGHT TAILLIGHT LED LICENCE PLATE LIGHT 4 12 V 5 W TURN SIGNAL LIGHT 5 Front 12 V 21 5 W E 03 28 33 12 V 21 W E 02 19 24 Rear 12 V 21 W If you have touched and...

Page 383: ...CTRICAL SYSTEM HEADLIGHT BEAM ADJUSTMENT Adjust the headlight beam A Vertical adjuster B Horizontal adjuster NOTE To adjust the headlight beam adjust the beam horizontally first then adjust vertically...

Page 384: ...n this case replace the turn sig nal side stand relay with a new one NOTE Make sure that the battery is fully charged Refer to the page 9 16 for the side stand relay and diode inspection STARTER RELAY...

Page 385: ...BRAKE SWITCH REAR BRAKE SWITCH CLUTCH LEVER POSITION SWITCH OIL PRESSURE SWITCH WIRE COLOR B Black Lbl Light blue R Red Br Brown Lg Light green Y Yellow Gr Gray O Orange W White G Green B BI Black wit...

Page 386: ...t the nozzles of the electrolyte container into the battery s electrolyte filler holes holding the container firmly so that it does not fall Take precaution not to allow any of the fluid to spill Make...

Page 387: ...e caps do not protrude above the upper surface of the battery s top cover For initial charging use the charger specially designed for MF battery Never use anything except the specified battery Once th...

Page 388: ...r 5 to 10 hours After recharging wait for more than 30 minutes and check the battery voltage with a multi circuit tester If the battery voltage is less than the 12 5 V recharge the bat tery again If b...

Page 389: ...IGNAL LEAD WIRE ROUTING 10 23 MUFFLER EXHAUST PIPE INSTALLATION 10 23 HANDLEBAR BALANCER 10 24 BATTERY PROTECTOR 10 24 LUBRICATION POINTS 10 25 FUEL TANK INSTALLATION 10 26 REAR COMBINATION LAMP INSTA...

Page 390: ...sensor The sensor should produce following voltage 0 1 V sensor voltage 4 8 V In other than the above range C14 P0120 is indicated TP sensor lead wire coupler connection P0120 H Sensor voltage is hig...

Page 391: ...specified value TO sensor circuit shorted to ground or VCC circuit open C24 C25 Ignition sig nal CKP sensor pick up coil signal is pro duced but signal from ignition coil is interrupted 8 times or mo...

Page 392: ...ay is turned ON or voltage is applied to fuel pump although fuel pump relay is turned OFF Fuel pump relay lead wire cou pler connection power source to the fuel pump relay and fuel injectors P0230 C42...

Page 393: ...ching the intake manifold 1 Clogged fuel filter or fuel hose 2 Defective fuel pump 3 Defective fuel pressure regulator 4 Defective fuel injector 5 Defective fuel pump relay 6 Defective ECM 7 Open circ...

Page 394: ...Defective ECT sensor 6 Defective thermostat 7 Defective IAT sensor 8 Damaged or cracked vacuum hose Improperly working fuel injector 1 Defective fuel injector 2 No injection signal from ECM 3 Open or...

Page 395: ...clutch plates driven and drive 4 Worn clutch release bearing 5 Weakened clutch dampers Noise seems to come from crankshaft 1 Due to wear rattling bearings 2 Worn and burnt crank pin bearings 3 Worn a...

Page 396: ...STV actuator Defective air flow system 1 Clogged air cleaner element 2 Defective throttle valve 3 Defective secondary throttle valve 4 Sucking air from throttle body joint 5 Defective ECM 6 Imbalancin...

Page 397: ...r 10 Defective EXCV actuator Adjust Replace Adjust Replace Repair Clean or replace Adjust or replace Clean Adjust Clean Adjust Retighten or replace Drain out excess oil Replace Replace Repair or repla...

Page 398: ...wl Replace Replace Replace Transmission will not shift back 1 Broken return spring on shift shaft 2 Rubbing or stickily shift shaft 3 Distorted or worn gearshift forks Replace Repair or replace Replac...

Page 399: ...lace Adjust Adjust Front suspension too stiff 1 Too viscous fork oil 2 Too much fork oil 3 Improperly set front fork spring adjuster 4 Improperly set front fork damping force adjuster 5 Bent front axl...

Page 400: ...disc 5 Air in hydraulic system 6 Not enough brake fluid in the reservoir Repair or replace Replace Clean disc and pads Replace Bleed air Replenish Brake squeaking 1 Carbon adhesion on pad surface 2 T...

Page 401: ...lead wires or loose lead connec tions 2 Shorted grounded or open generator coils 3 Shorted or punctured regulator rectifier Repair or replace or retighten Replace Replace Generator does charge but ch...

Page 402: ...of overcharging 3 Internal short circuit in the battery 4 Too low battery voltage 5 Too old battery Check the generator regu lator rectifier and circuit connections and make nec essary adjustments to...

Page 403: ...eadwire 3 Clamp Speedometer 5 mm Clamp Handlebar switch R Clamp Handlebar switch L Clamp Cushion Clamp To generator To generator To wiring harness To wiring harness To horn Wiring harness Solenoid bra...

Page 404: ...he frame Tapping clamp Frame Harness Tapping clamp IAT sensor Battery harness Horn Frame Wiring harness Radiator FWD Shuroud Tapping clamp Turn down Set under the starter relay 1 TO sensor Set inside...

Page 405: ...SERVICING INFORMATION 10 17 Starter motor Oil pressure switch Starter motor lead wire 80 110 30 60 90 Crankcase R Clamp Clamp Clamp Generator lead wire 20 45 SAMPLE...

Page 406: ...ch cable attach to the cushion 6 Clamp inside the bar Clutch cable 3 Guide Throttle cable No 1 Throttle cable No 2 Clip White tape Clutch cable Clutch cable 0 2 m m 0 2 m m Solenoid harness High tensi...

Page 407: ...linder 8 Purge hose E 33 only ITEM N m kgf m lb ft 3 PCV Breather hose 1 Match mark 5 18 1 8 13 0 4 Fuel feed hose 2 Pass through the PCV Breather hose upper the fuel hose 5 ECT sensor 3 Install intak...

Page 408: ...left side left side left side Set the white mark Set the white mark left side out side Set the white mark left side Set the yellow mark Clearance Match mark Set the yellow mark Clamp from left side Se...

Page 409: ...FRONT BRAKE ROUTING 1 After the brake hose union touching to the stop per tighten the union bolt 3 Clamp the sleeve firmly 2 Pass through the brake hose firmly 4 Set the clamp with stopper before tig...

Page 410: ...1 Pass through the speed sensor harness in front of the brake hose and guide 5 Clamp 2 Pass through the speed sensor harness in front of the brake hose 6 Clip 3 Do not catch the speed sensor harness...

Page 411: ...MUFFLER EXHAUST PIPE INSTALLATION 1 Cut after clamping Clamp 1 Left handle switch harness Brake hose guide Right front turn signal Clamp Right front turn signal Speed sensor Wiring harness Left front...

Page 412: ...lebar 4 Handle balancer expander 2 Nut 5 Handlebar balancer 3 Throttle grip 6 Screw 1 Stick protectors to upper end of this surface 4 60 mm 2 36 in 2 90 mm 3 54 in 5 65 mm 2 56 in 3 30 mm 1 18 in 5 5...

Page 413: ...SERVICING INFORMATION 10 25 LUBRICATION POINTS 5 3 mm 2 1 in SAMPLE...

Page 414: ...10 26 SERVICING INFORMATION FUEL TANK INSTALLATION 1 Cut after clamping 2 Frame Inside SAMPLE...

Page 415: ...Pass through the left turn signal harness 4 Reflex reflector 2 Reflex reflector 5 Right reflex reflector For E 03 28 33 3 License plate bracket For E 02 19 24 6 Left reflex reflector For E 03 28 33 1...

Page 416: ...FRAME HEAD COVER CUSHION INSTALLATION LEFT SIDE COVER CUSHION INSTALLATION 1 Cushion 4 5 mm 0 20 in 7 10 mm 0 39 in 2 3 mm 0 12 in 5 15 mm 0 59 in 3 12 mm 0 47 in 6 20 mm 0 79 in 1 Cushion 2 27 mm 1 0...

Page 417: ...SERVICING INFORMATION 10 29 REAR FENDER CUSHION INSTALLATION 7 mm 0 28 in 13 5 mm 0 5 3 in SAMPLE...

Page 418: ...10 30 SERVICING INFORMATION LEFT SIDE COVER INSTALLATION SAMPLE...

Page 419: ...SERVICING INFORMATION 10 31 LID CUSHION INSTSALLATION 1 Cushion 2 10 mm 0 39 in 3 45 mm 1 77 in SAMPLE...

Page 420: ...Clamp 1 Pass through the tail lamp harness and left turn signal harness over the right side mounting boss 3 Pass through the wiring harness outside of cushions 2 Assemble to the rear fender 4 Pass th...

Page 421: ...SERVICING INFORMATION 10 33 PAIR AIR SUPPLY SYSTEM DIAGRAM 3 1 2 1 PAIR control solenoid valve 1 From air cleaner 2 PAIR reed valve 2 To 1 cylinders A FRESH AIR 3 To 2 cylinders SAMPLE...

Page 422: ...3 5 4 1 PAIR control solenoid valve 2 Matching mark 2 Throttle body 3 Do not contact the hose and throttle cable drum 3 Bolt 4 The sealant side should face PAIR pipe side 1 To air cleaner box 5 With...

Page 423: ...der gauge set 09900 20602 Dial gauge 1 1000 mm 1 mm 09900 20605 Dial calipers 1 100 mm 10 34 mm 09900 20607 Dial gauge 1 100 mm 10 mm 09900 20701 Magnetic stand 09900 20803 09900 20806 Thickness gauge...

Page 424: ...ressure gauge hose 09915 74532 Oil pressure gauge adaptor 09915 64512 Compression gauge set 09915 77331 Meter for high pressure 09916 10911 Valve lapper set 09916 14510 Valve lifter 09916 14910 Valve...

Page 425: ...50 09924 62410 Final drive gear bearing holder wrench 09924 62430 22 mm Long socket 09924 64510 Final drive gear coupring holder 09924 74570 Final drive gear bearing remover installer 09924 84510 Bea...

Page 426: ...re gauge hose attachment 09940 50120 Front fork inner rod holder 09940 51410 Bearing installer 09940 52841 Inner rod holder 09940 52861 Front fork oil seal installer 09940 92720 Spring scale 09940 949...

Page 427: ...se bolt Initial 15 1 5 11 0 Final 22 2 2 16 0 Generator rotor bolt 160 16 0 115 5 Starter clutch allen bolt 26 2 6 19 0 Crankcase bolt 6 mm 11 1 1 8 0 8 mm Initial 15 1 5 11 0 Final 22 2 2 16 0 Conrod...

Page 428: ...nut 100 10 0 72 5 Final drive bevel gear bearing stopper 110 11 0 79 5 Final gear case oil drain plug 23 2 3 16 5 Final gear case bolt 8 mm 23 2 3 16 5 10 mm 50 5 0 36 0 Final driven bevel gear beari...

Page 429: ...5 Handlebar set bolt 23 2 3 16 5 Handlebar holder nut 45 4 5 32 5 Front footrest bracket mounting bolt 55 5 5 40 0 Frame down tube mounting bolt M8 23 2 3 16 5 Frame down tube mounting bolt M10 50 5...

Page 430: ...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...

Page 431: ...Valve stem O D IN 5 475 5 490 0 2156 0 2161 EX 5 455 5 470 0 2148 0 2154 Valve stem deflection IN EX 0 35 0 014 Valve stem runout IN EX 0 05 0 002 Valve head thickness IN EX 0 5 0 02 Valve stem end l...

Page 432: ...12 018 0 4724 0 4731 Rocker arm shaft O D IN EX 11 977 11 995 0 4715 0 4722 Cylinder head distortion 0 05 0 002 Cylinder head cover distortion 0 05 0 002 ITEM STANDARD LIMIT Compression pressure 1 30...

Page 433: ...8 0 7881 20 040 0 7890 Conrod big end side clearance 0 10 0 20 0 004 0 008 0 30 0 012 Conrod big end width 21 95 22 00 0 864 0 866 Crank pin width 22 10 22 15 0 870 0 872 Conrod big end oil clearance...

Page 434: ...MIT Primary reduction ratio 1 690 71 42 Secondary reduction ratio 1 000 30 30 Final reduction ratio 3 503 17 15 34 11 Gear ratios Low 2 461 32 13 2nd 1 631 31 19 3rd 1 227 27 22 4th 1 000 25 25 Top 0...

Page 435: ...or cap valve opening pressure 95 125 kPa 0 95 1 25 kgf cm 13 5 17 8 psi Cooling fan thermo switch operating temperature OFF ON Approx 105 C 221 F ON OFF Approx 100 C 212 F Engine coolant type Use an a...

Page 436: ...8 F TO sensor resistance 19 1 19 7 k TO sensor voltage Normal 0 4 1 4 V Leaning 3 7 4 4 V When leaning 65 GP switch voltage 0 6 V and more From 1st to Top Injector voltage Battery voltage STP sensor i...

Page 437: ...al Ignition coil primary peak voltage 205 V and more 1 W Ground 2 B Y Ground Generator coil resistance 0 2 1 5 Generator no load voltage when engine is cold 70 V AC and more at 5 000 r min Y Y Regulat...

Page 438: ...cator light LED ITEM STANDARD LIMIT Rear brake pedal free travel 20 30 0 8 1 2 Rear brake pedal height 75 85 3 0 3 3 Brake drum I D Rear 180 7 7 11 Brake disc thickness Front 4 8 5 2 0 19 0 21 4 5 0 1...

Page 439: ...80 15 M C 77H Tire type Front IRC GS 23F A Rear IRC GS 23R A Tire tread depth Front 1 6 0 06 Rear 2 0 0 08 ITEM STANDARD LIMIT Front fork stroke 140 5 5 Front fork spring free length 380 4 14 98 372...

Page 440: ...r higher An unleaded gasoline is recommended Others Fuel tank capacity Including reserve 15 0 L 4 0 3 3 US lmp gal E 33 Including reserve 15 5 L 4 1 3 4 US lmp gal Others Fuel level indicator light li...

Page 441: ...EVAPORATIVE EMISSION CONTROL SYSTEM Only for E 33 11 4 PAIR AIR SUPPLY SYSTEM INSPECTION 11 5 HOSES 11 5 PAIR REED VALVE 11 5 PAIR CONTROL SOLENOID VALVE 11 6 PAIR AIR SUPPLY SYSTEM HOSE ROUTING 11 7...

Page 442: ...rol This fuel injection system is precision designed manufactured and adjusted to comply with the applicable emission limits 1 Fuel tank 7 Fuel mesh filter For low pressure 2 Fuel filter For high pres...

Page 443: ...r is drawn into the exhaust port with the PAIR control solenoid valve and PAIR reed valve The PAIR control solenoid valve is operated by the ECM and the fresh air flow is con trolled according to the...

Page 444: ...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 co...

Page 445: ...re connection PAIR REED VALVE Remove the PAIR control solenoid valve 3 5 Remove the reed valve case 1 and PAIR reed valve 2 Inspect the reed valve for the carbon deposit If the carbon deposit is found...

Page 446: ...k the air flow If air does not flow out the solenoid valve is in normal condi tion Check the resistance between the terminals of the PAIR con trol solenoid valve Resistance 20 24 at 20 30 C 68 86 F 09...

Page 447: ...2 1 3 5 4 1 PAIR control solenoid valve 2 Matching mark 2 Throttle body 3 Do not contact the hose and throttle cable drum 3 Bolt 4 The sealant side should face PAIR pipe side 1 To air cleaner box 5 Wi...

Page 448: ...ite White 09900 25008 Multi circuit tester set Tester knob indication Resistance If the resistance is not within the standard range replace the HO2 sensor with a new one NOTE Temperature of the sensor...

Page 449: ...PECTION Only for E 33 Remove the seats 1 8 3 Remove the fuel tank 2 6 3 Remove the right frame cover 3 8 4 HOSES EVAP hose Inspect the hoses for wear or damage Make sure that the hoses are securely co...

Page 450: ...1 Three way joint 2 White paint mark should face upside 2 Wiring harness 3 To three way joint 3 Fuel shut off valve 4 Face the clamp end right side 4 EVAP canister 5 Face the clamp end right side 1 P...

Page 451: ...Y B W B W B G B G O G O G R Bl R Bl Y B B Lg B Y G Y B W B G O G R Bl Y B Y B B Lg B Lg B G Y G Y B W B W B G B G O G O G R Y B B Lg B G Y B W B G O G R B Lbl Lbl Lg Lg O B O B O W O W O G O G W B W B...

Page 452: ...Y B Y G Y G Y B W B W B G B G O G O G R Bl R Bl Y B B Lg B Y G Y B W B G O G R Bl Y B Y B B Lg B Lg B G Y G Y B W B W B G B G O G O G R Y B B Lg B G Y B W B G O G R B Lbl Lbl Lg Lg O B O B O W O W O G...

Page 453: ...Prepared by December 2004 Part No 99500 38050 01E Printed in Japan 456 SAMPLE...

Page 454: ......

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