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Suzuki Burgman AN400, Service Manual

The Suzuki Burgman AN400 Service Manual is a comprehensive resource for owners of this popular scooter. This detailed manual contains important instructions and maintenance procedures to keep your Burgman running smoothly. Download it for free from manualshive.com and gain access to valuable information to enhance your riding experience.

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Table of Contents 0- i

0

Section 0

CONTENTS

General Information

General Information ................................ 0A-1

General Description .............................................0A-1

Symbols .............................................................. 0A-1
Abbreviations ...................................................... 0A-2
Vehicle Side View ............................................... 0A-3
Vehicle Identification Number ............................. 0A-3
Fuel / Oil / Engine Coolant Recommendation ..... 0A-3
Engine Coolant Recommendation ...................... 0A-4
BREAK-IN Procedures........................................ 0A-4
Country and Area Codes .................................... 0A-5
Wire Color Symbols ............................................ 0A-5
Warning, Caution and Information Labels 

Location ............................................................ 0A-6

Component Location ...........................................0A-7

Electrical Components Location ......................... 0A-7

Specifications.......................................................0A-9

Specifications...................................................... 0A-9

Special Tools and Equipment ...........................0A-11

Special Tool ......................................................0A-11

Maintenance and Lubrication................. 0B-1

Precautions...........................................................0B-1

Precautions for Maintenance .............................. 0B-1

General Description .............................................0B-1

Recommended Fluids and Lubricants................. 0B-1

Scheduled Maintenance ......................................0B-1

Periodic Maintenance Schedule Chart................ 0B-1
Lubrication Points ............................................... 0B-2

Repair Instructions ..............................................0B-2

Air Cleaner Element Removal and Installation .... 0B-2
Air Cleaner Element Inspection .......................... 0B-3
Spark Plug Removal and Installation .................. 0B-3
Spark Plug Inspection and Cleaning................... 0B-4
Valve Clearance Inspection and Adjustment ...... 0B-4
Fuel Line Inspection............................................ 0B-8
Evaporative Emission Control System (E-33 

Only) ................................................................. 0B-8

Engine Oil and Filter Change.............................. 0B-9

Final Reduction Gear Oil Replacement.............0B-10
Cooling Fan Filter Removal and Installation .....0B-10
Cooling Fan Filter Inspection and Cleaning ......0B-10
Drive V-belt Removal and Installation ...............0B-11
Drive V-belt Inspection ......................................0B-11
Throttle Cable Play Inspection and 

Adjustment ......................................................0B-11

Cooling System Inspection................................0B-11
Air Bleeding From the Cooling Circuit ...............0B-12
Radiator Hose Inspection..................................0B-13
Brake System Inspection ..................................0B-13
Brake Hose Replacement .................................0B-14
Air Bleeding from Brake Fluid Circuit ................0B-14
Brake Fluid Replacement..................................0B-14
Tire Inspection...................................................0B-15
Steering System Inspection ..............................0B-15
Front Fork Inspection ........................................0B-16
Rear Suspension Inspection .............................0B-16
Exhaust Pipe and Muffler Mounting 

Inspection........................................................0B-16

Chassis Bolt and Nut Inspection .......................0B-17
Compression Pressure Check ..........................0B-19
Oil Pressure Check ...........................................0B-19
SDS Check........................................................0B-19
Automatic Clutch Inspection..............................0B-19
Parking Brake (Brake-lock) Inspection..............0B-20
Parking Brake (Brake-lock) Adjustment ............0B-20

Specifications.....................................................0B-21

Tightening Torque Specifications......................0B-21

Special Tools and Equipment ...........................0B-21

Recommended Service Material .......................0B-21
Special Tool ......................................................0B-21

Service Data ............................................. 0C-1

Specifications.......................................................0C-1

Service Data........................................................0C-1
Tightening Torque Specifications........................0C-7

Summary of Contents for Burgman AN400

Page 1: ...9 9 5 0 0 3 4 1 0 0 0 1 E AN400 ...

Page 2: ...cations at the time of publication If modifi cations have been made since then differences may exist between the content of this manual and the actual motorcycle Illustrations in this manual are used to show the basic principles of operation and work procedures They may not represent the actual motorcycle exactly in detail This manual is written for persons who have enough knowledge skills and too...

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

Page 4: ......

Page 5: ...Table of Contents 00 i 00 Section 00 CONTENTS Precautions Precautions 00 1 Precautions 00 1 Warning Caution Note 00 1 General Precautions 00 1 Precautions for Electrical Circuit Service 00 2 ...

Page 6: ...tated you must use good judgement and basic mechanical safety principles If you are unsure about how to perform a particular service operation ask a more experienced mechanic for advice General Precautions B705H10000002 WARNING Proper service and repair procedures are important for the safety of the service mechanic and the safety and reliability of the motorcycle When 2 or more persons work toget...

Page 7: ...er material from the mating surfaces Never reuse a circlip When installing a new circlip take care not to expand the end gap larger than required to slip the circlip over the shaft After installing a circlip always ensure that it is completely seated in its groove and securely fitted Use a torque wrench to tighten bolts to the specified torque Wipe off grease and oil if a thread is smeared with th...

Page 8: ...to fit Check the male connector for bend and female connector for excessive opening Also check the coupler for locking looseness corrosion dust etc Fuse When a fuse blows always investigate the cause to correct it and then replace the fuse Do not use a fuse of a different capacity Do not use wire or any other substitute for the fuse Switch Never apply grease material to switch contact points to pr...

Page 9: ...ever to the ECM when its coupler is disconnected Otherwise damage to ECM may result Never connect an ohmmeter to the ECM with its coupler connected If attempted damage to ECM or sensors may result Be sure to use a specified voltmeter ohmmeter Otherwise accurate measurements may not be obtained and personal injury may result Electrical Circuit Inspection Procedures While there are various methods f...

Page 10: ...y foreign material which could impede proper terminal contact 4 Using continuity inspect or voltage check procedures as described below inspect the wire harness terminals for open circuit and poor connection Locate abnormality if any Continuity check 1 Measure resistance across coupler B between A and C in figure If no continuity is indicated infinity or over limit the circuit is open between term...

Page 11: ...ts which causes the voltage drop in the circuit between terminals A and B Voltage between A and body ground Approx 5 V B and body ground Approx 5 V 2 V voltage drop C and body ground 3 V 2 V voltage drop Short circuit check Wire harness to ground 1 Disconnect the cable from the battery 2 Disconnect the connectors couplers at both ends of the circuit to be checked NOTE If the circuit to be checked ...

Page 12: ...nt are not known make measurements using the highest range When measuring the resistance with the multi circuit tester 1 will be shown as 10 00 MΩ and 1 flashes in the display Check that no voltage is applied before making the measurement If voltage is applied the tester may be damaged After using the tester turn the power off Special tool 09900 25008 Multi circuit tester set NOTE When connecting ...

Page 13: ...ine Inspection 0B 8 Evaporative Emission Control System E 33 Only 0B 8 Engine Oil and Filter Change 0B 9 Final Reduction Gear Oil Replacement 0B 10 Cooling Fan Filter Removal and Installation 0B 10 Cooling Fan Filter Inspection and Cleaning 0B 10 Drive V belt Removal and Installation 0B 11 Drive V belt Inspection 0B 11 Throttle Cable Play Inspection and Adjustment 0B 11 Cooling System Inspection 0...

Page 14: ...PASTE in a ratio of 1 1 Apply SUZUKI SUPER GREASE A or equivalent 99000 25010 Apply SUZUKI MOLY PASTE or equivalent 99000 25140 Apply SUZUKI SILICONE GREASE or equivalent 99000 25100 Apply SUZUKI BOND 1207B or equivalent 99000 31140 Apply SUZUKI BOND 1215 or equivalent 99000 31110 Apply THREAD LOCK SUPER 1303 or equivalent 99000 32030 Apply THREAD LOCK SUPER 1322 or equivalent 99000 32110 Apply TH...

Page 15: ...ionCanister Canister F FI Fuel Injection Fuel Injector FP Fuel Pump FPR Fuel Pressure Regulator FP Relay Fuel Pump Relay FTPC Valve Fuel Tank Pressure Control Valve G GEN Generator GND Ground GP Switch Gear Position Switch H HC Hydrocarbons HO2S Heated Oxygen Sensor I IAP Sensor Intake Air Pressure Sensor IAPS IAT Sensor Intake Air Temperature Sensor IATS IG Ignition ISC Valve Idle Speed Control V...

Page 16: ...d especially for registering the machine and ordering spare parts Fuel Oil Engine Coolant Recommendation B705H10101005 Fuel For USA and Canada Use only unleaded gasoline of at least 87 pump octane R 2 M 2 or 91 octane or higher rated by the research method Gasoline containing MTBE Methyl Tertiary Butyl Ether less than 10 ethanol or less than 5 methanol with appropriate cosolvents and corrosion inh...

Page 17: ...er only Water other than distilled water can corrode and clog the aluminum radiator Anti freeze Engine coolant The engine coolant perform as a corrosion and rust inhibitor as well as anti freeze Therefore the engine coolant should be used at all times even though the atmospheric temperature in your area does not go down to freezing point Suzuki recommends the use of SUZUKI COOLANT anti freeze engi...

Page 18: ...W Blue White Bl Blue Bl Y Blue Yellow Br Brown Br B Brown Black Dbr Dark brown Br W Brown White Dg Dark green G B Green Black G Green G R Green Red Gr Gray G W Green White Lbl Light blue G Y Green Yellow Lg Light green Gr W Green White O Orange O B Orange Black P Pink O Bl Orange Blue R Red O G Orange Green V Violet O R Orange Red W White O W Orange White Y Yellow O Y Orange Yellow B Bl Black Blue...

Page 19: ...Fuel caution label For E 02 24 7 Manual notice label For E 03 33 8 Warning screen label For E 02 19 24 9 Warning screen label French For E 28 10 Tire information label For E 02 03 19 24 28 33 54 11 General warning label For E 02 03 19 24 28 33 54 12 General warning label French For E 28 13 Loading capacity label For E 02 03 19 24 28 33 54 14 Loading capacity label French For E 28 15 ICES Canada la...

Page 20: ...I705H1010005 04 1 Fuel injector 6 STVA 11 Ambient air temperature sensor 16 Generator 2 IAP sensor 7 Front brake switch 12 Brake lock relay 17 HO2 sensor 3 ISC valve 8 Right handlebar switch 13 Fuel pump relay 18 ECT sensor 4 TP sensor 9 Starter relay 14 IAT sensor 19 Starter motor 5 STP sensor 10 Mode select switch coupler 15 CKP sensor ...

Page 21: ... 31 32 I705H1010007 04 20 TO sensor 24 Left handlebar switch 28 Side stand switch 32 Regulator rectifier 21 Fuse box 25 Rear brake switch 29 Cooing fan thermo switch 22 Turn signal Side stand relay 26 Ignition coil 30 Cooing fan 23 ECM 27 Speed sensor 31 Horn ...

Page 22: ...n Compression ratio 10 6 1 E 03 28 33 11 2 1 Others Fuel system Fuel injection Air cleaner Paper element Starter system Electric Lubrication system Wet sump Idle speed 1450 100 r min Item Specification Remark Clutch Dry shoe automatic centrifugal type Gearshift pattern Automatic Final reduction ratio 5 904 31 14 x 40 15 Gear ratio 2 200 0 839 Variable change Drive system V belt drive Item Specific...

Page 23: ... Front turn signal light 12 V 27 8 W E 03 28 33 12 V 21 W Others Rear turn signal light 12 V 21 W Speedometer Tachometer light LED Coolant temperature meter light LED Fuel level meter light LED Turn signal indicator light LED x 2 High beam indicator light LED Brake lock indicator light LED Oil change indicator LCD Fuel injection warning light LED Immobilizer indicator light LED Except E 03 28 33 I...

Page 24: ...uge 1 1000 mm 1 mm Dial gauge 1 100 mm 10 mm Magnetic stand 09900 20803 09900 20805 09900 21303 09900 21304 Thickness gauge Tire depth gauge V block 75 mm V block 100 mm 09900 22301 09900 22403 09900 25008 09900 25009 Plastigauge 0 025 0 076 mm Small bore gauge 18 35 mm Multi circuit tester set Needle probe point set TT09900 06108 02 TT09900 18710 01 TT09900 20101 00 TT09900 20102 01 TT09900 20202...

Page 25: ...9915 74511 09915 74521 09915 74570 09915 77331 Compression gauge Oil pressure gauge hose Oil pressure gauge attachment Meter for high pressure 09916 10911 09916 14510 09916 14530 09916 33210 Valve lapper set Valve spring compressor Valve spring compressor attachment Valve guide reamer 4 5 mm TT09900 26006 00 TT09900 28630 00 TT09904 41010 00 TT09910 32812 01 TT09910 32870 00 TT09910 60611 01 TT099...

Page 26: ...aring puller Bearing installer set 09930 10121 09930 11950 09930 30104 09930 31921 Spark plug wrench set Torx wrench Rotor remover slide shaft Rotor remover 09930 40113 09930 82720 09940 11420 09940 11430 Rotor holder Mode select switch Steering stem nut socket Steering stem nut socket TT09916 34542 01 TT09916 34561 01 TT09916 43210 01 TT09916 53330 01 TT09916 84511 01 TT09917 47011 00 TT09919 286...

Page 27: ... installer Spring scale 09941 34513 09941 34513 09941 54911 09941 74911 Steering race installer Steering race installer Bearing outer race remover Steering bearing installer 09943 74111 99565 01010 008 Fork oil level gauge CD ROM Ver 8 TT09940 14911 01 TT09940 30230 01 TT09940 34520 00 TT09940 34531 00 TT09940 40211 01 TT09940 40230 00 TT09940 52861 01 TT09940 92720 01 TT09941 34513 01 TT09941 345...

Page 28: ...enance Periodic Maintenance Schedule Chart B705H10205001 NOTE I Inspect and clean adjust replace or lubricate as necessary R Replace T Tighten Item Interval km 1 000 6 000 12 000 18 000 24 000 miles 600 4 000 7 500 11 000 14 500 months 2 12 24 36 48 Air cleaner element I I R I Exhaust pipe bolts and muffler bolts T T T Valve clearance I Spark plug I R I R Fuel line I I I I Evaporative emission con...

Page 29: ... miles 12 months Replace air cleaner element Every 18 000 km 11 000 miles 36 months Removal 1 Remove the helmet box front cover 1 Refer to Helmet Box Front Cover Removal and Installation in Section 9D Page9D 16 2 Remove the air cleaner cover 2 and air cleaner element Installation Install air cleaner element in the reverse order of removal Pay attention to the following points When installing the a...

Page 30: ...lug Removal and Installation B705H10206003 Inspect spark plug Every 6 000 km 4 000 miles 12 months Replace spark plug Every 12 000 km 7 500 miles 24 months Removal WARNING The hot engine can burn you Wait until the engine is cool enough to touch 1 Remove the front frame cover Refer to Front Frame Cover Removal and Installation in Section 9D Page9D 17 2 Disconnect the plug cap 1 3 Remove the spark ...

Page 31: ...ad Valve Clearance Inspection and Adjustment B705H10206005 Inspect valve clearance Every 24 000 km 14 500 miles 48 months Inspection The valve clearance specification is different for intake and exhaust valves Valve clearance must be checked and adjusted a at the time of periodic inspection b when the valve mechanism is serviced and c when the camshafts are removed for servicing 1 Remove the air c...

Page 32: ... 1 Remove the intake or exhaust camshaft Refer to Engine Top Side Disassembly in Section 1D Page1D 16 2 Remove the tappet 1 and shim 2 by fingers or magnetic hand 3 Check the figures printed on the shim These figures indicate the thickness of the shim as illustrated 4 Select a replacement shim that will provide a clearance within the specified range For the purpose of this adjustment a total of 25...

Page 33: ...Maintenance and Lubrication 0B 6 INTAKE SIDE I310G1020024 02 ...

Page 34: ...0B 7 Maintenance and Lubrication EXHAUST SIDE I310G1020025 02 ...

Page 35: ...tion Page0B 3 10 Install other removed parts Fuel Line Inspection B705H10206006 Inspect fuel line Every 6 000 km 4 000 miles 12 months Inspect the fuel line in the following procedures 1 Remove the helmet box front cover Refer to Helmet Box Removal and Installation in Section 9D Page9D 21 2 Remove the front frame cover Refer to Front Frame Cover Removal and Installation in Section 9D Page9D 17 3 I...

Page 36: ... 2 3 kgf m 16 5 lb ft 4 Pour new oil through the oil filler When performing an oil change without oil filter replacement the engine will hold about 1 2 L 1 3 1 1 US Imp qt of oil Use SF SG or SH SJ in API with MA in JASO 5 Start the engine and allow it to run for three minutes at idling speed 6 Turn off the engine and wait about three minutes then check the oil level through the inspection window ...

Page 37: ...que Final reduction gear drain plug 12 N m 1 2 kgf m 8 5 lb ft 6 Pour new oil through the oil level check hole until the oil overflows from the hole 7 Tighten the oil level check plug to the specified torque Tightening torque Final reduction gear oil level check plug 16 N m 1 6 kgf m 11 5 lb ft OIL Engine Oil SAE 10W 40 API SF SG or SH SJ with JASO MA Necessary amount of final reduction gear oil O...

Page 38: ... Adjustment B705H10206031 Inspect throttle cable play Initially at 1 000 km 6 000 miles 2 month and every 6 000 km 4 000 miles 12 months thereafter Inspect and adjust the throttle cable play a as follows Throttle cable play a 2 0 4 0 mm 0 08 0 16 in 1 Loosen the lock nut 1 of the throttle pulling cable 2 2 Turn the adjuster 3 in or out until the throttle cable play a at the throttle grip is betwee...

Page 39: ...ator outlet hose 7 Pour the specified engine coolant up to the radiator inlet 8 Bleed air from the cooling circuit Air Bleeding From the Cooling Circuit B705H10206032 Bleed air from the cooling circuit in the following procedures 1 Remove the front panel Refer to Front Panel Removal and Installation in Section 9D Page9D 14 2 Remove the left footboard Refer to Footboard Removal and Installation in ...

Page 40: ...ect Brake System Initially at 1 000 km 600 miles 2 month and every 6 000 km 4 000 miles 12 months thereafter Inspect Brake Hose and Brake Fluid Every 6 000 km 4 000 miles 12 months Replace Brake Hose Every 4 years Replace Brake Fluid Every 2 years WARNING The brake system of this motorcycle is filled with a glycol based brake fluid Do not use or mix different types of fluid such as silicone based ...

Page 41: ...or crack damage or fluid leakage If any defects are found replace the brake hose with a new one Rear Brake Hose Inspection Inspect the rear brake hose for crack damage or fluid leakage If any defects are found replace the brake hose with a new one Brake Hose Replacement B705H10206035 Refer to Front Brake Hose Removal and Installation in Section 4A Page4A 6 and Rear Brake Hose Removal and Installat...

Page 42: ...S for front and 150 70 13M C for rear The use of tires other than those specified may cause instability It is highly recommended to use the specified tires Tire type BRIDGESTONE Front HOOP B03 G Rear HOOP B02 G Steering System Inspection B705H10206018 Inspect steering system Initially at 1 000 km 600 miles 2 month and every 12 000 km 7 500 miles 24 months thereafter Steering should be adjusted pro...

Page 43: ...or oil leakage and mounting rubbers for wear and damage Replace any defective parts if necessary Refer to Rear Shock Absorber Inspection in Section 2C Page2C 5 Exhaust Pipe and Muffler Mounting Inspection B705H10206021 Tighten exhaust pipe bolts and muffler bolts Initially at 1 000 km 600 miles 2 month and every 12 000 km 7 500 miles 24 months thereafter Check the exhaust pipe bolts muffler bolts ...

Page 44: ...lebar clamp bolt 23 N m 2 3 kgf m 16 5 lb ft a 1 I705H1020057 03 b 2 c 3 I705H1020059 01 d 4 I705H1020058 06 5 Brake master cylinder mounting bolt 10 N m 1 0 kgf m 7 0 lb ft 6 Front fork clamp bolt 23 N m 2 3 kgf m 16 5 lb ft 7 Front fork cap bolt 45 N m 4 5 kgf m 32 5 lb ft 8 Front axle 65 N m 6 5 kgf m 47 0 lb ft 9 Front axle pinch bolt 23 N m 2 3 kgf m 16 5 lb ft 10 Front brake caliper mounting...

Page 45: ...b ft l 12 I705H1020063 03 n 14 I705H1020064 01 o 15 p 16 p 16 I705H1020065 01 17 Engine mounting nut 93 N m 9 3 kgf m 67 0 lb ft 18 Crankcase bracket nut 85 N m 8 5 kgf m 61 5 lb ft 19 Rubber damper bolt 85 N m 8 5 kgf m 61 5 lb ft 20 Exhaust pipe bolt 23 N m 2 3 kgf m 16 5 lb ft 21 Muffler connecting bolt 23 N m 2 3 kgf m 16 5 lb ft 22 Muffler mounting bolt 23 N m 2 3 kgf m 16 5 lb ft s 19 r 18 q...

Page 46: ... to Front Frame Cover Removal and Installation in Section 9D Page9D 17 3 Connect the tachometer to the high tension cord 1 4 Seated on the motorcycle with the motorcycle on level ground increase the engine RPMs slowly and note the RPM at which the motorcycle begins to move forward Special tool 09900 26006 Engine tachometer solar cell type Engagement r min 2 100 2 700 r min 5 Disconnect the tachome...

Page 47: ...that the brake lock acts enough Parking Brake Brake lock Adjustment B705H10206041 Adjust the brake lock in the following procedures 1 Pull the brake lock lever by one step 1 notch NOTE The brake lock lever have 2 4 steps 2 4 notches when pulling in fully 2 With the lock nut 1 loosening adjust the adjuster bolt 2 in until the brake pad comes in contact with brake disc 3 Tighten the lock nut 1 4 Ret...

Page 48: ...0B 2 Special Tool B705H10208002 Fastening part Tightening torque Note N m kgf m lb ft Spark plug 11 1 1 8 0 Page0B 3 Oil drain plug 23 2 3 16 5 Page0B 9 Final reduction gear drain plug 12 1 2 8 5 Page0B 10 Final reduction gear oil level check plug 16 1 6 11 5 Page0B 10 Exhaust pipe bolt 23 2 3 16 5 Page0B 16 Muffler mounting bolt 23 2 3 16 5 Page0B 16 Muffler connecting bolt 23 2 3 16 5 Page0B 16 ...

Page 49: ...EX 0 35 0 014 Valve stem runout IN EX 0 05 0 002 Valve head thickness IN EX 0 5 0 02 Valve seat width 30 45 60 IN EX 0 9 1 1 0 035 0 043 Valve head radial runout IN EX 0 03 0 001 Valve spring free length IN EX 38 6 1 52 Valve spring tension IN EX 137 3 N 14 0 kgf 30 1 lbs at length 33 35 mm 1 313 in Item Standard Limit Cam height IN 36 61 36 66 1 441 1 443 36 31 1 430 EX 35 94 35 99 1 415 1 417 35...

Page 50: ... 0 007 0 5 0 02 Piston ring to groove clearance 1st 0 18 0 007 2nd 0 15 0 006 Piston ring groove width 1st 1 21 1 23 0 0476 0 0484 2nd 1 01 1 03 0 0398 0 0406 Oil 2 01 2 03 0 0791 0 0799 Piston ring thickness 1st 1 17 1 19 0 461 0 469 2nd 0 97 0 99 0 0382 0 0390 Piston pin bore 20 002 20 008 0 7874 0 7877 20 030 0 789 Piston pin O D 19 996 20 000 0 7872 0 7874 19 980 0 787 Item Standard Limit Conr...

Page 51: ...190 290 Ω CKP sensor peak voltage 4 5 V and more When cranking probe G W probe Bl IAP sensor input voltage 4 5 5 5 V IAP sensor output voltage Approx 1 5 3 5 V at idle speed TP sensor input voltage 4 5 5 5 V TP sensor output voltage Closed Approx 0 6 V Opened Approx 3 8 V ECT sensor input voltage 4 5 5 5 V ECT sensor resistance Approx 2 58 kΩ at 20 C 68 F IAT sensor input voltage 4 5 5 5 V IAT sen...

Page 52: ...mixed with distilled water only at the ratio of 50 50 Engine coolant including reserve Reserve tank side Approx 250 ml 0 3 0 2 US Imp oz Engine side Approx 1 700 ml 1 8 1 5 US Imp oz Item Standard Specification Note Spark plug Type NGK CR7E DENSO U22ESR N Gap 0 7 0 8 0 28 0 03 Spark performance Over 8 0 0 3 at 1 atm CKP sensor resistance 190 290 Ω G Bl CKP sensor peak voltage 4 5 V and more probe ...

Page 53: ...008 4 5 0 18 Brake disc runout 0 30 0 01 Master cylinder bore Front Rear 12 700 12 743 0 500 0 502 Master cylinder piston diameter Front Rear 12 657 12 684 0 498 0 499 Brake caliper cylinder bore Front 25 400 25 450 1 000 1 002 Rear 27 00 27 05 1 063 1 065 Brake caliper piston diameter Front 25 318 25 368 0 997 0 999 Rear 26 918 26 968 1 060 1 062 Brake fluid type DOT 4 Wheel rim runout Axial 2 0 ...

Page 54: ... 2 M 2 or higher rated by the research method Gasoline containing MTBE Methyl Tertiary Butyl Ether less than 10 ethanol or less than 5 methanol with appropriate cosolvents and corrosion inhibitor is permissible E 03 28 33 Gasoline used should be graded 91 octane or higher An unleaded gasoline type is recommended The others countries Fuel tank capacity Including reserve 13 5 L 3 6 3 0 US lmp gal Re...

Page 55: ...h cover bolt 11 1 1 8 0 Generator cover bolt 11 1 1 8 0 Oil filter cap bolt 10 1 0 7 0 Cylinder head bolt L130 25 2 5 18 0 L190 Initial 25 2 5 18 0 Final 42 4 2 30 5 Cam chain tension adjuster mounting bolt 10 1 0 7 0 Cam chain tension adjuster cap bolt 23 2 3 16 5 Cylinder head cover bolt 14 1 4 10 0 Starter motor mounting bolt 7 0 7 5 0 Starter motor lead wire bolt 3 0 3 2 0 Starter motor housin...

Page 56: ...ng bolt 10 1 0 7 0 Handlebar clamp bolt 23 2 3 16 5 Front fork cylinder bolt 30 3 0 21 5 Front fork clamp bolt 23 2 3 16 5 Front fork cap bolt 45 4 5 32 5 Steering stem nut 30 3 0 21 5 Steering stem lock nut 30 3 0 21 5 Handlebar holder set bolt 23 2 3 16 5 Handlebar holder clamp bolt 55 5 5 40 0 Rear axle nut 120 12 0 87 0 Rear brake caliper mounting bolt 23 2 3 16 5 Rear brake caliper pad pin 18...

Page 57: ...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 5 0 5 3 5 6 5 5 0 55 4 0 10 1 0 7 0 8 13 1 3 9 5 23 2 3 16 5 10 29 2 9 21 0 50 5 0 36 0 12 45 4 5 32 5 85 8 5 61 5 14 65 6 5 47 0 135 13 5 97 5 16 105 10 5 76 0 210 21 0 152 0 18 160 16 0 115 5 240 24 0 173 5 3 2 1 a a a I649G1030001 03 1 Conventional bolt 2 4 marked bolt 3 7 marked bolt ...

Page 58: ...0C 10 Service Data ...

Page 59: ...alfunction 1A 39 DTC C23 P1651 H L TO Sensor Circuit Malfunction 1A 42 DTC C24 P0351 Ignition System Malfunction 1A 45 DTC C28 P1655 Secondary Throttle Valve Actuator STVA Malfunction 1A 45 DTC C29 P1654 H L Secondary Throttle Position Sensor STPS 1A 49 DTC C32 P0201 Fuel Injector Circuit Malfunction 1A 52 DTC C40 P0505 P0506 or P0507 ISC Valve Circuit Malfunction 1A 55 DTC C41 P0230 H L FP Relay ...

Page 60: ...ning 1D 15 Engine Top Side Disassembly 1D 16 Engine Top Side Assembly 1D 18 Camshaft Inspection 1D 22 Cam Chain Tension Adjuster Inspection 1D 24 Cam Chain Guide Inspection 1D 25 Cylinder Head Disassembly and Reassembly 1D 25 Cylinder Head Related Parts Inspection 1D 29 Valve Guide Replacement 1D 32 Valve Seat Repair 1D 33 Cylinder Disassembly and Assembly 1D 33 Cylinder Inspection 1D 34 Piston Ri...

Page 61: ...G 10 Fuel Pressure Inspection 1G 12 Fuel Pump Relay Inspection 1G 13 Fuel Mesh Filter Inspection 1G 13 Fuel Level Gauge Inspection 1G 13 Fuel Pump Inspection 1G 14 Fuel Injector Inspection 1G 14 Fuel Injector Removal and Installation 1G 14 Specifications 1G 15 Service Data 1G 15 Tightening Torque Specifications 1G 15 Special Tools and Equipment 1G 16 Special Tool 1G 16 Ignition System 1H 1 General...

Page 62: ...nspection 1J 5 Generator No load Performance Inspection 1J 5 Regulator Rectifier Inspection 1J 5 Generator Removal and Installation 1J 6 Battery Components 1J 8 Battery Initial Charging 1J 8 Battery Visual Inspection 1J 9 Battery Recharging 1J 10 Battery Removal and Installation 1J 10 Specifications 1J 11 Service Data 1J 11 Tightening Torque Specifications 1J 11 Special Tools and Equipment 1J 11 S...

Page 63: ...Precautions 1 1 Precautions Precautions Precautions for Engine B705H11000001 Refer to General Precautions in Section 00 Page00 1 and Precautions for Electrical Circuit Service in Section 00 Page00 2 ...

Page 64: ...Injection Volume The factors to determine the injection time include the basic fuel injection time which is calculated on the basis of the intake air pressure engine speed and throttle opening angle and various compensations These compensations are determined according to the signals from various sensors that detect the engine and driving conditions I705H1110001 01 ...

Page 65: ...Descriptions ENGINE COOLANT TEMPERATURE SENSOR SIGNAL When engine coolant temperature is low injection time volume is increased INTAKE AIR TEMPERATURE SENSOR SIGNAL When intake air temperature is low injection time volume is increased HEATED OXYGEN SENSOR SIGNAL Air fuel ratio is compensated to the theoretical ratio from density of oxygen in exhaust gasses The compensation occurs in such a way tha...

Page 66: ...n not be checked The defective function is memorized in the computer Use the special tool s coupler to connect to the dealer mode coupler A The memorized malfunction code is displayed on LCD DISPLAY panel Malfunction means that the ECM does not receive signal from the devices These affected devices are indicated in the code form Special tool A 09930 82720 Mode select switch Malfunction LCD Display...

Page 67: ...tarter button B Throttle position sensor TPS K Fuel pump relay FP relay T Brake light switch C Intake air pressure sensor IAPS L Ignition coil U Brake relay D Secondary throttle position sensor STPS M Speed sensor V Side stand switch E Engine coolant temperature sensor ECTS N Idle speed control valve ISC valve W Starter relay F Intake air temperature sensor IATS O Secondary throttle valve actuator...

Page 68: ...r signal HO2 29 STP sensor signal STP 8 ECM ground E1 30 Starter relay 9 CKP sensor signal CKP 31 SDS 10 32 Mode select switch 11 Power source for fuel injector VM 33 Speed sensor 12 STVA signal STVA 1A 34 ISC valve motor signal ISCA 1B 13 STVA signal STVA 1B 35 ISC valve motor signal ISCA 1A 14 Power source for sensors Vcc 36 ISC valve motor signal ISCA 2B 15 ISC valve motor signal ISCA 2A 37 Met...

Page 69: ... I705H1110131 01 A ECM G Intake air temperature IATS B Fuel injector FI H Fuel pump FP C Idle speed control valve ISC valve I Crankshaft position sensor CKPS D Throttle position sensor TPS J Heated oxygen sensor HO2S E Secondary throttle position sensor STPS K Fuel pump relay FP relay F Secondary throttle valve actuator STVA ...

Page 70: ...ow Valve clearance out of adjustment Adjust Worn valve guides or poor seating of valves Repair or replace Mistimed valves Adjust Excessively worn piston rings Replace Worn down cylinder bore Replace Starter motor cranks too slowly Refer to Starting System Diagram in Section 1I Page1I 1 Poor seating of spark plug Retighten Engine will not start or is hard to start Plugs not sparking Fouled spark pl...

Page 71: ...tive ISC valve Replace Engine stalls often Incorrect fuel air mixture Defective IAP sensor or circuit Repair or replace Clogged fuel filter Clean or replace Defective fuel pump Replace Defective fuel pressure regulator Replace Damaged or cracked vacuum hose Replace Defective ECT sensor Replace Defective thermostat Replace Defective IAT sensor Replace Engine stalls often Fuel injector improperly op...

Page 72: ...e internal electrical parts Weakened valve springs Replace Worn camshafts Replace Valve timing out of adjustment Adjust Too narrow spark plug gap Adjust Ignition not advanced sufficiently due to poorly working timing advance circuit Replace ECM Defective ignition coil Replace Defective CKP sensor Replace Defective ECM Replace Clogged air cleaner element Clean Clogged fuel hose resulting in inadequ...

Page 73: ...ve fuel tank pressure control valve Replace Engine overheats Defective engine internal parts Heavy carbon deposit on piston crown Clean Not enough oil in the engine Add oil Defective oil pump or clogged oil circuit Replace or clean Use of incorrect engine oil Change Sucking air from intake pipe Retighten or replace Defective cooling system Refer to Engine Cooling System Warning in Section 1F Page1...

Page 74: ...sor CKPS Pick up coil signal signal generator C13 Intake air pressure sensor IAPS C14 Throttle position sensor TPS 1 C15 Engine coolant temperature sensor ECTS C16 Speed sensor Speed sensor signal for FI system C21 Intake air temperature sensor IATS C23 Tip over sensor TOS C24 Ignition signal IG coil C28 Secondary throttle valve actuator STVA C29 Secondary throttle position sensor STPS C32 Fuel in...

Page 75: ...tarting Poor Driveability No cranking Hesitation on acceleration No initial combustion Back fire After fire No combustion Lack of power Poor starting at Surging cold warm always Abnormal knocking Other Engine rpm jumps briefly Poor Idling Engine Stall when Poor fast Idle Immediately after start Abnormal idling speed Throttle valve is opened High Low r min Throttle valve is closed Unstable Load is ...

Page 76: ...nd noise Refer to Exhaust System Inspection in Section 1K Page1K 4 Each coupler disconnection Refer to Precautions for Electrical Circuit Service in Section 00 Page00 2 Self Diagnostic Procedures B705H11104012 NOTE Do not disconnect coupler from ECM battery cable from battery ECM ground wire harness from engine or main fuse before confirming DTC Diagnostic Trouble Code stored in memory Such discon...

Page 77: ...in fuse before confirming DTC Diagnostic Trouble Code stored in memory Such disconnection will erase the memorized information in ECM memory DTC stored in ECM memory can be checked by the SDS Be sure to read Precautions for Electrical Circuit Service in Section 00 Page00 2 before inspection and observe what is written there 1 Remove the upper meter panel Refer to Upper Meter Panel Removal and Inst...

Page 78: ...remains stored in the ECM 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 coupler has been disconnected at the time of diagnosis erase the stored malfunction history code using SDS 6 Click Clear 2 to delete history code Past DTC 7 Follow the displaye...

Page 79: ...g or stopped 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 to store each show data when trouble for two different malfunctions in the order as the malfunction is detected Utilizing this function it is possible to know the order of malfunctions that...

Page 80: ...ved or filed can allow the specific engine failure to be determined Remove the upper meter panel Refer to Upper Meter Panel Removal and Installation in Section 9D Page9D 13 Set up the SDS tool Refer to Use of SDS Diagnostic Procedures Page1A 14 Special tool 09904 41010 SDS set 99565 01010 008 CD ROM Ver 8 NOTE Before taking the sample of data check and clear the Past DTC A number of different data...

Page 81: ... 000 r min under no load Data at the time of racing Check the manifold absolute pressure XX kPa 3 000 r min I705H1110127 02 Throttle Quick wide open Throttle Slowly open Secondary throttle valve opens closes in according with the engine r min I705H1110128 04 ...

Page 82: ...agnosis Data of intake negative pressure during idling 100 C Data of secondary throttle valve operation at the time of starting Check the manifold absolute pressure Approx XX kPa I705H1110129 03 Closes fully in approx XX sec I705H1110130 02 ...

Page 83: ...tage 4 9 V In other than the above range C15 P0115 is indicated ECT sensor lead wire coupler connection P0115 H Sensor voltage is higher than specified value ECT sensor circuit open or ground circuit open L Sensor voltage is lower than specified value ECT sensor circuit shorted to ground C16 Speed sensor The speed sensor signal is not input for more than 3 sec during the engine is running at 5 000...

Page 84: ...an the desired idle speed ISC valve is fixed ISC valve pre set position is incorrect 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 lead wire coupler connection power source to fuel pump relay and fuel injectors P0230 H Voltage is applied to fuel pump although...

Page 85: ...ssible Cause Although the intake pressure is fluctuated the signal does not reach for 3 sec or more NOTE If SDS is used P0355 is indicated Metal particles or foreign material being attached on the CKP sensor and rotor tip CKP sensor circuit open or short CKP sensor malfunction ECM malfunction Generator ECM CKP sensor CKP To regulator rectifier CKP 3 9 G W BI Bl G I705H1110012 02 ...

Page 86: ... resistance 3 Disconnect the CKP sensor coupler 1 and measure the resistance CKP sensor resistance 190 290 Ω Bl G Special tool A 09900 25008 Multi circuit tester set Tester knob indication Resistance Ω If OK then check the continuity between each terminal and ground CKP sensor continuity Ω Infinity Bl Ground G Ground Special tool A 09900 25008 Multi circuit tester set Tester knob indication Contin...

Page 87: ... G W or Bl wire open or shorted to ground Loose or poor contacts on the CKP sensor coupler or ECM coupler terminal 2 or 9 Refer to Terminal Alignment of ECM Coupler Harness Side Page1A 5 If wire and connection are OK intermittent trouble 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 Inspect that ...

Page 88: ...indicated when sensor voltage is higher than specified value If SDS is used P0105 L is indicated when sensor voltage is lower than specified value Clogged vacuum passage between throttle body and IAP sensor Air being drawn from vacuum passage between throttle body and IAP sensor IAP sensor circuit open or shorted to ground IAP sensor malfunction ECM malfunction NOTE When P0105 H is displayed it is...

Page 89: ...age1A 15 Step Action Yes No 1 1 Turn the ignition switch OFF 2 Remove the helmet box front cover Refer to Helmet Box Front Cover Removal and Installation in Section 9D Page9D 16 3 Check the IAP sensor coupler 1 for loose or poor contacts If OK then measure the IAP sensor input voltage 4 Disconnect the IAP sensor coupler 5 Turn the ignition switch ON Go to Step 2 Loose or poor contacts on the ECM c...

Page 90: ... Negative terminal Ground Positive terminal R Negative terminal B Br Special tool A 09900 25008 Multi circuit tester set Tester knob indication Voltage Is the voltage OK Go to Step 2 Loose or poor contacts on the ECM coupler terminal 14 or 4 Refer to Terminal Alignment of ECM Coupler Harness Side Page1A 5 Open or short circuit in the R wire or B Br wire Step Action Yes No A I705H1110135 01 A I705H...

Page 91: ...side coupler between G B and B Br wires IAP sensor output voltage Approx 1 5 3 5 V at idle speed Positive terminal G B Negative terminal B Br Special tool A 09900 25008 Multi circuit tester set B 09900 25009 Needle pointed probe set Tester knob indication Voltage Is the voltage OK Go to Step 3 Open or short circuit in the G B wire If the wire is OK replace the IAP sensor with a new one Step Action...

Page 92: ...ob indication Voltage Is the voltage OK R G B or B Br wire open or shorted to ground or poor 4 6 or 14 connection Refer to Terminal Alignment of ECM Coupler Harness Side Page1A 5 If wire and connection are OK intermittent trouble 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 again If check result is not s...

Page 93: ...age is not within the following range Difference between actual throttle opening and opening calculated by ECM is larger than specified value 0 35 V Sensor voltage 4 90 V NOTE If SDS is used P0120 H is indicated when sensor voltage is higher than specified value If SDS is used P0120 L is indicated when sensor voltage is lower than specified value TP sensor maladjusted TP sensor circuit open or sho...

Page 94: ...tion switch ON 6 Measure the voltage at the R wire and ground If OK then measure the voltage at the R wire and B Br wire TP sensor input voltage 4 5 5 5 V Positive terminal R Negative terminal Ground Positive terminal R Negative terminal B Br Special tool A 09900 25008 Multi circuit tester set Tester knob indication Voltage Is the voltage OK Go to Step 2 Loose or poor contacts on the ECM coupler t...

Page 95: ...s opened Approx 3 8 V Special tool A 09900 25008 Multi circuit tester set Tester knob indication Voltage Is the voltage OK R or B Br wire open or shorted to ground or poor 4 5 or 14 connection Refer to Terminal Alignment of ECM Coupler Harness Side Page1A 5 If wire and connection are OK intermittent trouble or faulty ECM Recheck each terminal and wire harness for open circuit and poor connection R...

Page 96: ... SDS is used P0115 H is indicated when sensor voltage is higher than specified value If SDS is used P0115 L is indicated when sensor voltage is lower than specified value ECT sensor circuit open or short ECT sensor malfunction ECM malfunction NOTE When P0115 H is displayed it is possible that ECT sensor circuit is open or ground circuit is open When P0115 L is displayed it is possible that ECT sen...

Page 97: ...n the ignition switch OFF 2 Remove the air cleaner box Refer to Air Cleaner Box Removal and Installation in Section 1D Page1D 9 3 Connect the couplers disconnected in the air cleaner box removal 4 Check the ECT sensor coupler 1 for loose or poor contacts If OK then measure the ECT sensor voltage at the wire side coupler 5 Disconnect the ECT coupler and turn the ignition switch ON 6 Measure the vol...

Page 98: ...sure the ECT sensor resistance ECT sensor resistance Approx 2 58 kΩ at 20 C 68 F Terminal Terminal Special tool A 09900 25008 Multi circuit tester set Tester knob indication Resistance Ω Is the resistance OK Dg or B Br wire open or shorted to ground or poor 24 or 4 connection Refer to Terminal Alignment of ECM Coupler Harness Side Page1A 5 If wire and connection are OK intermittent trouble or faul...

Page 99: ...e clear the DTC using SDS tool Refer to Use of SDS Diagnosis Reset Procedures Page1A 15 Refer to Use of SDS Diagnosis Reset Procedures Page1A 15 Detected Condition Possible Cause The speed sensor signal is not input to ECM for more than 3 sec during the engine is running at 5 000 r min or more NOTE If SDS is used P0500 is indicated Speed sensor circuit open or short Metal particles or foreign mate...

Page 100: ...lead wire coupler 5 Turn the ignition switch ON 6 Measure the speed sensor input voltage at the couplers between positive terminal O R and negative terminal B W wire Speed sensor input voltage Battery voltage Positive terminal O R Negative terminal B W Special tool A 09900 25008 Multi circuit tester set B 09900 25009 Needle pointed probe set Tester knob indication Voltage Is the voltage OK Remove ...

Page 101: ...t voltage varies when a screwdriver is brought close to the pick up face of the speed sensor Special tool A 09900 25008 Multi circuit tester set B 09900 25009 Needle pointed probe set Tester knob indication Voltage Is the voltage OK Recheck ECM coupler for loose or poor contacts Replace ECM with a new one and inspect again Short circuit in the lead wire Replace the speed sensor with a new one Step...

Page 102: ...ethod is the same way as that of the ECT sensor Refer to IAT Sensor Inspection in Section 1C Page1C 4 for details Detected Condition Possible Cause Output voltage is not with in the following range 0 2 V Sensor voltage 4 9 V NOTE If SDS is used P0110 H is indicated when sensor voltage is higher than specified value If SDS is used P0110 L is indicated when sensor voltage is lower than specified val...

Page 103: ...ure the voltage between B Bl wire terminal and ground 6 If OK then measure the voltage between B Bl wire terminal and B Br wire terminal IAT sensor voltage 4 5 5 5 V Positive terminal B Bl Negative terminal Ground Positive terminal B Bl Negative terminal B Br Special tool A 09900 25008 Multi circuit tester set Tester knob indication Voltage Is the voltage OK Go to Step 2 Loose or poor contacts on ...

Page 104: ...en or shorted to ground or poor 25 or 4 connection Refer to Terminal Alignment of ECM Coupler Harness Side Page1A 5 If wire and connection are OK intermittent trouble 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 again Replace the IAT sensor with a new one Step Action Yes No A I705H1110027 03 Intake Air T...

Page 105: ...f SDS is used P1651 H is indicated when sensor voltage is higher than specified value If SDS is used P1651 L is indicated when sensor voltage is lower than specified value TO sensor circuit open or short TO sensor malfunction ECM malfunction NOTE When P1651 H is displayed it is possible that TO sensor circuit is shorted to Vcc or ground circuit is open When P1651 L is displayed it is possible that...

Page 106: ...No 1 1 Turn the ignition switch OFF 2 Remove the meter panel Refer to Meter Panel Removal and Installation in Section 9D Page9D 14 3 Check the TO sensor coupler 1 for loose or poor contacts If OK then measure the TO sensor resistance 4 Disconnect the TO sensor coupler 5 Measure the resistance between R and B Br wire terminals TO sensor resistance 16 5 22 3 kΩ R terminal B Br terminal Special tool ...

Page 107: ...eft and right from the horizontal level TO sensor voltage Leaning 3 7 4 4 V Positive terminal Br W Negative terminal B Br Special tool A 09900 25008 Multi circuit tester set Tester knob indication Voltage Is the voltage OK R Br W or B Br wire open or shorted to ground or poor 28 or 29 connection Refer to Terminal Alignment of ECM Coupler Harness Side Page1A 5 If wire and connection are OK intermit...

Page 108: ...TVA Malfunction B705H11104034 Detected Condition and Possible Cause Wiring Diagram Detected Condition Possible Cause The operation voltage does not reach the STVA ECM does not receive communication signal from the STVA NOTE If SDS is used P1655 is indicated STVA malfunction STVA circuit open or short STVA motor malfunction 13 12 16 17 ECM STVA 2B STVA 1A STVA 1B STVA B P G W Bl P B B O W G G R STV...

Page 109: ... front cover and frame front cover Refer to Helmet Box Front Cover Removal and Installation in Section 9D Page9D 16 and Front Frame Cover Removal and Installation in Section 9D Page9D 17 2 Check the STVA lead wire coupler 1 for loose or poor contacts 3 Remove the air cleaner outlet tube 2 4 Turn the ignition switch ON to check the STV operation STV operating order Full open 95 open Is the operatio...

Page 110: ...rminal B Ground P Terminal G Ground W B Special tool A 09900 25008 Multi circuit tester set Tester knob indication Resistance Ω Is the resistance OK B O P B G R or W G wire open or shorted to ground or poor 13 12 16 and 17 connection Refer to Terminal Alignment of ECM Coupler Harness Side Page1A 5 If wire and connection are OK intermittent trouble or faulty ECM Recheck each terminal and wire harne...

Page 111: ...up the SDS tool Refer to the SDS operation manual for further details 2 Turn the ignition switch ON 3 Click Secondary throttle operating control 4 Click each button 1 At this time if an operation sound is heard from the STVA the function is normal I705H1110064 02 1 I705H1110065 02 ...

Page 112: ...ltage 4 90 V NOTE If SDS is used P1654 H is indicated when sensor voltage is higher than specified value If SDS is used P1654 L is indicated when sensor voltage is lower than specified value STP sensor maladjusted STP sensor circuit open or short STP sensor malfunction ECM malfunction NOTE When P1654 H is displayed it is possible that STP sensor circuit is shorted to Vcc or ground circuit is open ...

Page 113: ... poor contacts If OK then measure the STP sensor input voltage 4 Disconnect the STP sensor coupler Black 5 Turn the ignition switch ON 6 Measure the voltage at the R wire and ground 7 If OK then measure the voltage at the R wire and B Br wire STP sensor input voltage 4 5 5 5 V Positive terminal R Negative terminal Ground Positive terminal R Negative terminal B Br Special tool A 09900 25008 Multi c...

Page 114: ...x 0 5 V Secondary Throttle valve is opened Approx 3 9 V Special tool 09900 28630 TPS test wire harness Tester knob indication Voltage Is the voltage OK R Y G or B Br wire open or shorted to ground or poor 14 29 or 4 connection Refer to Terminal Alignment of ECM Coupler Harness Side Page1A 5 If wire and connection are OK intermittent trouble or faulty ECM Recheck each terminal and wire harness for ...

Page 115: ...dition and Possible Cause Wiring Diagram Detected Condition Possible Cause No injector signal is detected for 0 8 sec NOTE If SDS is used P0201 is indicated Injector circuit open or short Injector malfunction ECM malfunction ECM Fuel pump relay Fuel injector Y R Gr W To engine stop switch 20 Fuel injector I705H1110080 01 ...

Page 116: ... Action Yes No 1 1 Turn the ignition switch OFF 2 Remove the helmet box front cover Refer to Helmet Box Front Cover Removal and Installation in Section 9D Page9D 16 3 Check the injector coupler 1 for loose or poor contacts If OK then measure the injector resistance 4 Disconnect the coupler and measure the resistance between terminals Injector resistance Approx 10 3 Ω at 20 C 68 F Terminal Terminal...

Page 117: ...injector voltage between Y R wire and ground Injector voltage Battery voltage Positive terminal Y R Negative terminal Ground Special tool A 09900 25008 Multi circuit tester set Tester knob indication Voltage Is the voltage OK Gr W wire open or shorted to ground or poor 20 connection Refer to Terminal Alignment of ECM Coupler Harness Side Page1A 5 If wire and connection are OK intermittent trouble ...

Page 118: ...ecified value NOTE If SDS is used P0505 is indicated ISC valve circuit open or shorted to ground Power source circuit open Air passage clogged ISC valve is fixed ISC valve pre set position is incorrect Idle speed is lower than the desired idle speed NOTE If SDS is used P0506 is indicated Idle speed is higher than the desired idle speed NOTE If SDS is used P0507 is indicated ECM IS1A IS1B IS2A IS2B...

Page 119: ...oupler with a needle pointed tester probe to prevent the terminal damage or terminal bend NOTE After repairing the trouble clear the DTC using SDS tool Refer to Use of SDS Diagnosis Reset Procedures Page1A 15 Step Action Yes No 1 1 Turn the ignition switch OFF 2 Remove the helmet box front cover Refer to Helmet Box Front Cover Removal and Installation in Section 9D Page9D 16 3 Check the ISC valve ...

Page 120: ...W and 15 terminals B Lg and 35 ISC valve wire continuity Continuity Special tool 09900 25008 Multi circuit tester set 09900 25009 Needle pointed probe set Tester knob indication Continuity test Is the continuity OK Go to Step 2 G W B P W or B Lg wire open Step Action Yes No G W B P W B Lg I705H1110087 01 15 36 35 34 I705H1110088 01 ...

Page 121: ...ignition switch OFF 2 Measure the resistance between terminal B Lg and terminal G and between terminal P W and terminal W B ISC valve resistance Approx 80 Ω at 68 C Terminal B Lg Terminal G Terminal P W Terminal W B Special tool A 09900 25008 Multi circuit tester set Tester knob indication Resistance Ω Is the resistance up If wire is OK intermittent trouble or faulty ECM Replace the ISC valve with...

Page 122: ...pm slowly 2 Check that the Desired idle speed 2 is nearly equal to the Spec 1 At the same time check that the number of steps 4 in the ISC valve position decreases 3 Click the button 5 and increase the Spec 1 slowly 4 Check that the Desired idle speed 2 is nearly equal to the Spec 1 Also check that the number of steps 4 in the ISC valve position increases 1 I705H1110092 03 2 I705H1110093 04 1 3 5 ...

Page 123: ...se the Spec 1 to 1 795 rpm 2 Check that the Desired idle speed 2 is approx 1 795 rpm 3 Check that the Engine speed 6 is close to 1 795 rpm NOTE Be careful not to increase the Spec to 1 800 rpm or the Engine speed may reach the upper limit If the ISC valve does not function properly replace the ISC valve or inspect the ISC valve Refer to Throttle Body Disassembly and Assembly in Section 1D Page1D 1...

Page 124: ...ay is turned OFF If SDS is used P0230 L is indicated when No voltage is applied to fuel pump although fuel pump relay is turned ON Fuel pump relay circuit open or short Fuel pump relay malfunction ECM malfunction NOTE When P0230 H is displayed it is possible that fuel pump relay switch circuit is shorted to power source or fuel pump switch side is faulty When P0230 L is displayed it is possible th...

Page 125: ...stallation in Section 9D Page9D 14 3 Check the FP relay coupler 1 for loose or poor contacts If OK then check the FP relay Refer to Fuel Pump Relay Inspection in Section 1G Page1G 13 Is the FP relay OK B or O W wire open or short or poor 19 connection Refer to Terminal Alignment of ECM Coupler Harness Side Page1A 5 Y R or R Bl wire open shorted or poor 11 connection Refer to Terminal Alignment of ...

Page 126: ...Page9B 11 for details Detected Condition Possible Cause Ignition switch signal is not input in the ECM NOTE If SDS is used P1650 is indicated Ignition system circuit open or short ECM malfunction When the ID agreement is not verified ECM does not receive communication signal from the immobilizer antenna For E 02 19 24 54 NOTE If SDS is used P1650 is indicated Immobilizer system malfunction For E 0...

Page 127: ...ct temperature After repairing the trouble clear the DTC using SDS tool Refer to Use of SDS Diagnosis Reset Procedures Page1A 15 Detected Condition Possible Cause HO2 sensor output voltage is not input to ECM during engine operation and running condition NOTE If SDS is used P0130 is indicated HO2 sensor circuit open or shorted to ground Fuel system malfunction ECM malfunction NOTE When P0135 H is ...

Page 128: ... and B Br wire when idling condition 6 Measure the HO2 sensor output voltage while holding the engine speed at 3 000 r min HO2 sensor output voltage at idle speed 0 3 V and less Positive terminal B Y Negative terminal B Br HO2 sensor output voltage at 3 000 r min 0 7 V and more Positive terminal B Y Negative terminal B Br Special tool A 09900 25008 Multi circuit tester set B 09900 25009 Needle poi...

Page 129: ...K Go to step 3 Replace the HO2 sensor with a new one 3 1 Turn the ignition switch OFF 2 Disconnect the HO2 sensor coupler 3 Measure the resistance between the terminals W W of the HO2 sensor HO2 sensor resistance 11 5 14 5 Ω at 23 C 73 F W W Special tool A 09900 25008 Multi circuit tester set Tester knob indication Resistance Ω Is the voltage OK Gr or W wire open or shorted to ground or poor 7 4 2...

Page 130: ... 0 6 V Opened Approx 3 8 V ECT sensor input voltage 4 5 5 5 V ECT sensor resistance Approx 2 58 kΩ at 20 C 68 F IAT sensor input voltage 4 5 5 5 V IAT sensor resistance Approx 2 58 kΩ at 20 C 68 F TO sensor resistance 16 5 22 3 kΩ TO sensor output voltage Normal 0 4 1 4 V Leaning 3 7 4 4 V Injector voltage Battery voltage Ignition coil primary peak voltage 150 V and more When cranking probe W prob...

Page 131: ...35 Page1A 37 Page1A 38 Page1A 40 Page1A 41 Page1A 43 Page1A 44 Page1A 44 Page1A 47 Page1A 47 Page1A 50 Page1A 53 Page1A 54 Page1A 54 Page1A 57 Page1A 58 Page1A 65 Page1A 66 Page1A 66 Page1A 28 Page1A 37 Page1A 38 Page1A 57 Page1A 65 Page1A 66 09900 28630 09904 41010 TPS test wire harness SDS set Page1A 51 Page1A 14 Page1A 17 09917 47010 09930 82720 Vacuum pump gauge Mode select switch Page1A 29 Pa...

Page 132: ...l injection volumes are stringently controlled with the programmed injection maps in the ECM by varying engine conditions Adjusting interfering with improper replacement or resetting of any of the fuel injection components may adversely affect injection performance and cause the motorcycle to exceed the exhaust emission level limits If unable to effect repairs contact the distributor s representat...

Page 133: ...The engine is equipped with a PCV system Blow by gas in the engine is constantly drawn into the crankcase which is returned to the combustion chamber through the PCV breather hose air cleaner and throttle body A B C D I705H1120005 01 A Fresh air B Fuel Air mixture C Exhaust gas D Blow by gas ...

Page 134: ...mate purchaser or while it is in use The use of the vehicle after such device or element of design has been removed or rendered inoperative by any person Among Those Acts Presumed to Constitute Tampering Are the Acts Listed Below Removing or puncturing the muffler baffles header pipes screen type spark arrester if equipped or any other component which conducts exhaust gases Removing or puncturing ...

Page 135: ... the sensor air holes Install the HO2 sensor in the reverse order of removal Pay attention to the following point Tighten the HO2 sensor to the specified torque Tightening torque HO2 sensor 48 N m 4 8 kgf m 34 5 lb ft Heated Oxygen Sensor HO2S Inspection B705H11206002 Inspect the HO2 sensor in the following procedures 1 Inspect the HO2 sensor and its circuit referring to flow table of the malfunct...

Page 136: ...istance Ω 4 Connect the HO2 sensor coupler securely CAUTION Do not apply oil or other materials to the sensor air hole PCV Hose Inspection B705H11206003 Inspect the PCV hose 1 for wear and damage If it is worn or damaged replace the PCV hose with a new one Check that the PCV hose 1 is securely connected PCV Hose Removal and Installation B705H11206005 Removal 1 Remove the PCV hose 1 Installation In...

Page 137: ...ications in Section 0C Page0C 7 Special Tools and Equipment Special Tool B705H11208001 Item Specification Note HO2 sensor resistance 11 5 14 5 Ω at 23 C 73 4 F HO2 sensor output voltage Idle speed 0 3 V and less 3 000 r min 0 7 V and more Item Standard Specification Note Spark plug Type NGK CR7E DENSO U22ESR N Gap 0 7 0 8 0 28 0 03 Fastening part Tightening torque Note N m kgf m lb ft HO2 sensor 4...

Page 138: ...tion in Section 9D Page9D 14 3 Pull out the ECM 1 from the front box and disconnect the ECM coupler 2 Installation Install the ECM in the reverse order of removal CKP Sensor Inspection B705H11306003 Refer to DTC C12 P0335 CKP Sensor Circuit Malfunction in Section 1A Page1A 22 CKP Sensor Removal and Installation B705H11306004 Removal 1 Drain engine oil Refer to Engine Oil and Filter Change in Secti...

Page 139: ...or in the reverse order of removal TP Sensor Inspection B705H11306007 Refer to DTC C14 P0120 H L TP Sensor Circuit Malfunction in Section 1A Page1A 30 TP Sensor Adjustment B705H11306008 Adjust the TP sensor in the following procedures 1 Warm up the engine 2 Remove the helmet box front cover Refer to Helmet Box Front Cover Removal and Installation in Section 9D Page9D 16 3 Remove the upper meter pa...

Page 140: ...f the ECT sensor ohmic valve does not change in the proportion indicated replace it with a new one Temperature sensor specification CAUTION Take special care when handling the ECT sensor It may cause damage if it gets a sharp impact Do not contact the ECT sensor and the column thermometer with a pan 4 Install the ECT sensor Refer to ECT Sensor Removal and Installation Page1C 3 ECT Sensor Removal a...

Page 141: ...he IAT sensor with a new one NOTE IAT sensor resistance measurement method is the same way as that of ECT sensor Refer to ECT Sensor Inspection Page1C 3 3 Install the IAT sensor Refer to IAT Sensor Removal and Installation Page1C 4 IAT Sensor Removal and Installation B705H11306015 Removal 1 Remove the air cleaner box Refer to Air Cleaner Box Removal and Installation in Section 1D Page1D 9 2 Remove...

Page 142: ... in Section 1A Page1A 49 STP Sensor Adjustment B705H11306025 Adjust the STP sensor in the following procedures 1 Remove the helmet box front cover Refer to Helmet Box Front Cover Removal and Installation in Section 9D Page9D 16 2 Remove the air cleaner box outlet tube 1 3 Disconnect the STVA lead wire coupler 2 4 Turn the ignition switch ON 5 Insert the needle pointed probes to the STP sensor coup...

Page 143: ...lation B705H11306028 Removal 1 Remove the helmet box front cover Refer to Helmet Box Front Cover Removal and Installation in Section 9D Page9D 16 2 Disconnect the coupler and screw 3 Remove the ISC valve 1 Installation Install the ISC valve in the reverse order of removal ISC valve pre set When removing or replacing the ISC valve set the ISC valve to the following procedures Procedure 1 Turn the i...

Page 144: ...ening Torque Specifications B705H11307003 Reference For the tightening torque of fastener not specified in this section refer to Tightening Torque Specifications in Section 0C Page0C 7 Special Tools and Equipment Special Tool B705H11308001 Item Specification Note ECT sensor resistance Approx 2 58 kΩ at 20 C 68 F IAT sensor resistance Approx 2 58 kΩ at 20 C 68 F Fastening part Tightening torque Not...

Page 145: ...recautions for Engine Mechanical B705H11400001 Refer to General Precautions in Section 00 Page00 1 Schematic and Routing Diagram Camshaft and Sprocket Assembly Diagram B705H11402001 a b I705H1140174 02 23 N m 2 3 kgf m 16 5 lb ft 10 N m 1 0 kgf m 7 0 lb ft ...

Page 146: ...er motor lead wire and seat lock cable together 2 Wire harness C Pass the throttle cables through inside of the frame Bind the parking brake cable starter motor lead wire and seat lock cable together 3 Throttle cable No 1 D Pass the throttle cables through inside of the frame 4 Throttle cable No 2 E Pass the throttle cables through inside of the frames A Pass the throttle cables through inside of ...

Page 147: ...Page0B 3 3 Install the compression gauge and adaptor in the spark plug hole Make sure that the connection is tight Special tool A 09915 64512 Compression gauge B 09913 10750 Compression gauge adapter 4 Keep the throttle grip in the fully opened position 5 Press the starter button and crank the engine for a few seconds Record the maximum gauge reading as the cylinder compression Compression pressur...

Page 148: ...ug Refer to Spark Plug Removal and Installation in Section 0B Page0B 3 Refer to Spark Plug Inspection and Cleaning in Section 0B Page0B 4 Refer to Spark Plug Removal and Installation in Section 0B Page0B 3 Cylinder head cover Refer to Valve Clearance Inspection and Adjustment in Section 0B Page0B 4 Refer to Engine Top Side Assembly Page1D 18 Camshaft Refer to Engine Top Side Disassembly Page1D 16 ...

Page 149: ...il and Filter Change in Section 0B Page0B 9 Rear axle shaft Refer to Final Gear Disassembly and Assembly in Section 3A Page3A 4 Refer to Final Gear Disassembly and Assembly in Section 3A Page3A 4 Idle shaft Refer to Final Gear Disassembly and Assembly in Section 3A Page3A 4 Refer to Final Gear Disassembly and Assembly in Section 3A Page3A 4 Driveshaft Refer to Final Gear Disassembly and Assembly i...

Page 150: ...footboards Refer to Footboard Removal and Installation in Section 9D Page9D 21 6 Remove the air cleaner box Refer to Air Cleaner Box Removal and Installation Page1D 9 7 Remove the throttle body 1 from the intake pipe 8 Disconnect the radiator hoses 1 and 2 9 Disconnect the ignition coil lead wires 3 10 Disconnect the ECT sensor coupler 4 and remove the wire harness 5 for the ignition coil ECT sens...

Page 151: ...mps and rear brake caliper from the swingarm 18 Remove the rear axle nut 14 and collar 15 19 Remove the swingarm 16 20 Remove the collar 17 and rear wheel 21 Support the engine using an engine jack 22 Remove the cushion rod bolt nut 18 and engine mounting bolt nut 19 23 Remove the engine from the frame 13 12 I705H1140184 01 I705H1140185 02 I705H1140186 01 15 14 16 I705H1140187 02 17 I705H1140188 0...

Page 152: ...ke sure that the thread of axle shaft is clean from any greasy matter Install the rear wheel Refer to Rear Wheel Assembly Removal and Installation in Section 2D Page2D 9 Tighten the rear axle nut to the specified torque Tightening torque Rear axle nut 120 N m 12 0 kgf m 87 0 lb ft Install the exhaust pipe muffler Refer to Exhaust Pipe Muffler Removal and Installation in Section 1K Page1K 2 1 2 2 a...

Page 153: ... Refer to Front Frame Cover Removal and Installation in Section 9D Page9D 17 3 Remove the left footboard Refer to Footboard Removal and Installation in Section 9D Page9D 21 4 Disconnect the PCV hose 1 5 Remove the wire harness clamp bolt 2 6 Disconnect the following couplers Injector coupler 3 IAP sensor coupler 4 ISC valve coupler 5 TP sensor coupler 6 STP sensor coupler 7 STVA coupler 8 ECTS IAT...

Page 154: ...5 4 Visually inspect the drain plugs 1 and 2 5 Drain water if necessary by removing the plug 6 Install the removed parts Throttle Cable Removal and Installation B705H11406069 Removal 1 Remove the handlebar covers Refer to Handlebar Cover Removal and Installation in Section 9D Page9D 13 2 Remove the front box Refer to Front Box Removal and Installation in Section 9D Page9D 18 3 Remove the front fra...

Page 155: ...al 1D 11 Throttle Body Components B705H11406072 2 1 3 3 3 3 3 3 5 6 7 8 9 4 FWD FWD I705H1140207 05 1 Throttle body 4 STP sensor 7 Insulator 2 TP sensor 5 ISC valve 8 Fuel injector 3 O ring 6 IAP sensor 9 Cushion seal ...

Page 156: ...nsor A Triangle mark must point downward 3 ISC valve B Tighten the bracket with the cylinder head bolt L130 4 Fuel injector C Tighten each bolt in temporary and final stages in numerical order on bolt Refer to Fuel Pump Disassembly and Assembly in Section 1G Page1G 10 5 TP sensor 12 N m 1 2 kgf m 8 5 lb ft 6 STP sensor 10 N m 1 0 kgf m 7 0 lb ft 7 STVA 10 N m 1 0 kgf m 7 0 lb ft ...

Page 157: ...body to the intake pipe fit the projection on the throttle body to the depression of the intake pipe Connect the throttle cables properly Refer to Throttle Cable Removal and Installation Page1D 10 Adjust the throttle cable play Refer to Throttle Cable Play Inspection and Adjustment in Section 0B Page0B 11 Throttle Body Disassembly and Assembly B705H11406073 Disassembly 1 Remove the throttle body R...

Page 158: ...the O ring NOTE Align the secondary throttle shaft end A with the groove B of STP sensor Apply grease to the secondary throttle shaft end A Grease 99000 25010 SUZUKI SUPER GREASE A or equivalent NOTE Make sure the STP valve open or close smoothly If the STP sensor adjustment is necessary refer to STP Sensor Adjustment in Section 1C Page1C 5 With the throttle valve fully closed install the TP senso...

Page 159: ...handled carefully Always follow the chemical manufacturer s instructions on proper use handling and storage Clean passageways with a spray type carburetor cleaner and blow dry with compressed air CAUTION Do not use wire to clean passageways Wire can damage passageways If the components cannot be cleaned with a spray cleaner it may be necessary to use a dip type cleaning solution and allow them to ...

Page 160: ...racket 2 3 Remove the cylinder head cover 3 Camshaft 1 Remove the spark plug Refer to Spark Plug Removal and Installation in Section 0B Page0B 3 2 Remove the cooling fan cover 1 and cooling fan filter 2 3 Remove the generator cover plug 3 and bring the piston to TDC on the compression stroke by turning the crankshaft until the line A on the generator rotor aligns with the slit B in the generator c...

Page 161: ...at shield 2 3 Remove the cylinder head 3 NOTE Be sure to loosen the cylinder head bolts evenly and in a crisscross pattern 4 Remove the dowel pins and gasket 5 Remove the cam chain guide No 1 4 6 Remove the cylinder 5 7 Remove the dowel pins and gasket 8 9 I705H1140008 01 1 I705H1140009 01 2 I705H1140010 02 3 I705H1140011 02 I705H1140012 01 4 5 I705H1140013 02 I705H1140014 01 ...

Page 162: ...n installing the piston face the dent mark A on its head to the exhaust side of the cylinder NOTE Place a clean rag over the cylinder base so as not to drop the piston pin circlip into the crankcase CAUTION Use new piston pin circlips Cylinder Install the dowel pins 1 and a new gasket 2 to the crankcase Coat the cylinder wall and piston surface with engine oil CAUTION Replace the gasket with a new...

Page 163: ...es 1 Apply engine oil to the bolt threads and both sides of washers 2 Tighten the bolts 1 and 2 diagonally and evenly to the specified torque Tightening torque Cylinder head bolt L190 Initial a 25 N m 2 5 kgf m 18 0 lb ft Cylinder head bolt L130 b 25 N m 2 5 kgf m 18 0 lb ft 3 Additionally tighten the bolts A to the specified torque Tightening torque Cylinder head bolt L190 Final a 42 N m 4 2 kgf ...

Page 164: ...e embossed letters EX or IN The exhaust camshaft sprocket has an arrow marked 1 Turn the exhaust camshaft so that the arrow is aligned with the gasket surface of the cylinder head Engage the cam chain with the exhaust camshaft sprocket The other arrow marked 2 should now be pointing upward Starting from the roller pin that is directly above the arrow marked 2 count out 15 roller pins from the exha...

Page 165: ...g of the ratchet mechanism 1 and push the push rod all the way in Fit a new gasket 2 on the cylinder head Position the cam chain tension adjuster so the UP mark A points upward Tighten the cam chain tension adjuster bolts to the specified torque CAUTION Replace the gasket with a new one Tightening torque Cam chain tension adjuster bolt 10 N m 1 0 kgf m 7 0 lb ft Install the gasket washer 3 spring ...

Page 166: ...e gaskets with new ones and apply engine oil to both sides of them Tighten the bolts to the specified torque Tightening torque Cylinder head cover bolt a 14 N m 1 4 kgf m 10 0 lb ft Install the spark plug Tightening torque Spark plug 11 N m 1 1 kgf m 8 0 lb ft Camshaft Inspection B705H11406046 Refer to Engine Top Side Disassembly Page1D 16 Refer to Engine Top Side Assembly Page1D 18 Camshaft Ident...

Page 167: ...e 2 Use the plastigauge to read the clearance at the widest portion which is specified as follows Special tool A 09900 22301 Plastigauge 0 025 0 076 mm 3 Install the camshaft journal holder Refer to Engine Top Side Assembly Page1D 18 NOTE Do not rotate the camshafts with the plastigauge in place Tightening torque Camshaft journal holder bolt 10 N m 1 0 kgf m 7 0 lb ft 4 Remove the camshaft journal...

Page 168: ...Automatic Decomp Check that automatic decomp cam 1 moves smoothly and pin 2 rotates together If any abnormal condition are found replace the camshaft Cam Chain Tension Adjuster Inspection B705H11406047 The cam chain tension adjuster is maintained at the proper tension by an automatically adjusted 1 Remove the cam chain tension adjuster Refer to Engine Top Side Disassembly Page1D 16 2 Unlock the ra...

Page 169: ...pet 1 and shim 2 by fingers or magnetic hand CAUTION Identify the position of each removed part 2 Install the protector 3 between the valve spring and cylinder head 3 Using the special tools compress the valve spring and remove the two cotter halves from the valve stem Special tool A 09916 14510 Valve spring compressor B 09916 14530 Valve spring compressor attachment C 09919 28610 Sleeve protector...

Page 170: ...move the oil jet for cam chain tension adjuster 13 13 Remove the oil gallery plug cylinder head 14 Assembly Assembly is in the reverse order of disassembly Pay attention to the following points Tighten the oil gallery plug cylinder head 1 to the specified torque Tightening torque Oil gallery plug cylinder head 10 N m 1 0 kgf m 7 0 lb ft CAUTION Replace the gasket with a new one 7 8 I705H1140050 02...

Page 171: ...UTION Replace the O ring with a new one Tightening torque Intake pipe bolt a 10 N m 1 0 kgf m 7 0 lb ft Install the thermostat Refer to Thermostat Removal and Installation in Section 1F Page1F 11 Install the valve spring seat Apply MOLYBDENUM OIL SOLUTION to the oil seal 2 and press fit it into position M O Molybdenum oil MOLYBDENUM OIL SOLUTION CAUTION Do not reuse the removed oil seal Insert the...

Page 172: ... rounded lip F of the cotter fits snugly into the groove G in the stem end Install the other valves and springs in the same manner as described previously CAUTION Be sure to restore each spring and valve to their original positions Be careful not to damage the valve and valve stem when handling it Install the tappet shims and the tappets to their original positions NOTE Apply engine oil to the ste...

Page 173: ...1 Magnetic stand C 09900 21304 V block 100 mm Valve stem runout Service limit 0 05 mm 0 002 in Valve Head Radial Runout Place the dial gauge at a right angle to the valve head face and measure the valve head radial runout If it measures more than the service limit replace the valve Special tool A 09900 20606 Dial gauge 1 100 mm B 09900 20701 Magnetic stand C 09900 21304 V block 100 mm Valve head r...

Page 174: ... 475 4 490 mm 0 1762 0 1768 in Standard EX 4 455 4 470 mm 0 1754 0 1760 in NOTE If valve guides have to be removed for replacement after inspecting related parts carry out the steps shown in valve guide replacement Refer to Valve Guide Replacement Page1D 32 Valve Springs The force of the coil spring keeps the valve seat tight Weak ened spring result in reduced engine power output and often account...

Page 175: ...at using the seat cutter Refer to Valve Seat Repair Page1D 33 Valve seat width a Standard 0 9 1 1 mm 0 035 0 043 in Valve Seat Sealing Condition 1 Clean and assemble the cylinder head and valve components 2 Fill the intake and exhaust port with gasoline to check for leaks If any leaks occur inspect the valve seat and face for burrs or other things that could prevent the valve from sealing Refer to...

Page 176: ...reamer 11 3 mm C 09916 34542 Reamer handle 5 Cool down the new valve guides in a freezer for about one hour and heat the cylinder head to 100 150 C 212 302 F with a hot plate CAUTION Do not use a burner to heat the valve guide hole to prevent cylinder head distortion 6 Apply engine oil to each valve guide 1 and valve guide hole 7 Drive the guide into the guide hole using the valve guide installer ...

Page 177: ...ly polished or shiny finish This will provide a soft surface for the final seating of the valve which will occur during the first few seconds of engine operation NOTE After servicing the valve seats be sure to check the valve clearance after the cylinder head has been reinstalled Refer to Valve Clearance Inspection and Adjustment in Section 0B Page0B 4 Cylinder Disassembly and Assembly B705H114060...

Page 178: ... Refer to Piston and Related Parts Inspection Page1D 35 Piston Ring Removal and Installation B705H11406055 Removal 1 Draw out the piston pin and remove the piston Refer to Engine Top Side Disassembly Page1D 16 2 Carefully spread the ring opening with your thumbs and then push up the opposite side of the 1st ring 1 to remove it NOTE Do not expand the piston ring excessively since it is apt to be br...

Page 179: ...n Refer to Engine Top Side Assembly Page1D 18 Piston and Related Parts Inspection B705H11406056 Refer to Engine Top Side Disassembly Page1D 16 Piston Diameter Measure the piston diameter using the micrometer at 15 mm 0 6 in from the skirt end If the piston diameter is less than the service limit replace the piston Special tool A 09900 20204 Micrometer 75 100 mm Piston diameter Service limit 80 880...

Page 180: ...andard 1st 1 21 1 23 mm 0 0476 0 0484 in Standard 2nd 1 01 1 03 mm 0 0398 0 0406 in Standard Oil 2 01 2 03 mm 0 0791 0 0799 in Piston ring thickness Standard 1st 1 17 1 19 mm 0 0461 0 0469 in Standard 2nd 0 97 0 99 mm 0 0382 0 0396 in Piston Ring Free End Gap and Piston Ring End Gap Measure the piston ring free end gap using vernier calipers Next fit the piston ring squarely into the cylinder and ...

Page 181: ...he piston pin Special tool C 09900 20205 Micrometer 0 25 mm Piston pin O D Service limit 19 980 mm 0 7866 in Engine Bottom Side Disassembly B705H11406057 CAUTION Identify the position of each removed part Organize the parts in their respective groups e g intake exhaust so that they can be reinstalled in their original positions NOTE The crankcase must be separated to service the crankshaft oil pum...

Page 182: ...e dowel pins and gasket 2 Outer Clutch Cover Remove the outer clutch cover 1 Oil Filter 1 Remove the oil filter cap 1 2 Remove the oil filter 2 and O ring 3 Transmission Breather Hose Remove the transmission breather hose 1 1 I705H1140069 01 1 I705H1140073 03 1 I705H1140070 04 2 I705H1140071 02 1 I705H1140072 01 1 I705H1140074 01 2 3 I705H1140075 02 1 I705H1140076 04 ...

Page 183: ...the special tool remove the clutch housing nut and concaved washer 6 Remove the clutch housing 3 Special tool A 09930 40113 Rotor holder 7 Remove the drive V belt 4 and clutch shoe movable driven face assembly 5 8 Remove the movable drive face assembly 6 with the spacer 7 9 Remove the final gear assembly Refer to Final Gear Assembly Removal and Installation in Section 3A Page3A 3 1 I705H1140077 01...

Page 184: ... 31921 Rotor remover Starter Drive Gear Remove the key 1 and starter driven gear 2 Cam Chain and Starter Idle Gear 1 Remove the cam chain 1 starter idle gear shaft 2 spacer 3 and starter idle gear 4 Cam Chain Tensioner 1 Remove the cam chain tensioner 1 2 Remove the cam chain guide bolt 2 I705H1140087 01 A 1 I705H1140088 02 1 2 I705H1140089 02 2 3 4 1 I705H1140090 02 1 2 I705H1140091 01 ...

Page 185: ...riven gear nut 1 and washer 3 Remove the balancer driven gear 2 along with the scissors gear behind 4 Remove the key 3 Oil Pump Drive Gear 1 Remove the oil pump drive gear cover 1 2 Remove the oil pump drive gear nut 2 3 Remove the oil pump drive gear 3 4 Remove the pin 4 and spacer 5 A A B I705H1140092 02 1 I705H1140093 01 2 I705H1140094 01 3 I705H1140095 01 1 I705H1140096 01 2 3 I705H1140097 01 ...

Page 186: ... diameter crankcase bolts first and then larger ones diagonally and evenly 6 Separate the crankcase using the special tool Special tool B 09920 13120 Crankcase separating tool NOTE Set the special tool so that the tool arms are in parallel with the end face of crankcase The crankshaft should remain in the left crankcase half 7 Remove the O rings 4 and dowel pins A I705H1140099 01 1 2 3 I705H114010...

Page 187: ... 1 2 Remove the oil pump assembly 2 3 Remove the oil pump drive shaft 3 and chain 4 Crankshaft Remove the crankshaft using the spacial tool Special tool A 09920 13120 Crankcase separating tool NOTE Set the special tool so that the tool arms are in parallel with the end face of crankcase 1 I705H1140105 01 1 2 I705H1140106 03 1 I705H1140107 04 2 I705H1140108 01 3 4 I705H1140109 01 A I705H1140110 02 ...

Page 188: ...ankshaft installer B 09910 32870 Crankshaft installer attachment C 09913 70210 Bearing installer set CAUTION Do not hit the crankshaft with a plastic hammer or the like to install the crankshaft into the crankcase Make sure that the direction of conrod is turned toward the cylinder hole Oil Pump Install the oil pump drive shaft 1 and oil pump drive chain 2 to the bearing Install the oil pump assem...

Page 189: ...he dowel pins CAUTION Replace the O rings with the new ones Clean and degrees the crankcase mating surfaces both surfaces with a cleaning solvent Apply bond to the right crankcase Sealant 99000 31140 SUZUKI BOND No 1207B or equivalent CAUTION Coat the sealant evenly without break Application of sealant must be performed within a short period of time Take extreme care not to let sealant enter into ...

Page 190: ...n the slot of the balancer drive gear with the pin Set the washer with its convex side facing outside Insert a proper steel rod A into the crankcase hole and pass it through the crankshaft wed holes in order to prevent the crankshaft from turning Using the special tool tighten the balancer drive gear nut to the specified torque Special tool 09922 21410 Long socket 46 mm Tightening torque Balancer ...

Page 191: ...r No 2 8 align the punch mark C on the balancer drive gear with the punch mark D on the balancer driven gear No 1 Insert a steel rod through the driven gear holes and let the balancer driven gear No 1 teeth mesh with the balancer drive gear teeth CAUTION Make sure that the punch mark C on the balancer drive gear is aligned with the punch mark D on the balancer driven gear No 1 Install the washer a...

Page 192: ...rter driven gear 1 and key 2 Apply engine oil to the starter clutch mating surface Generator Rotor Degrease the tapered portion A of generator rotor and also the crankshaft B Use nonflammable cleaning solvent to wipe off oily or greasy matter and make these surfaces completely off oily or greasy matter and make these surfaces completely dry Install the generator rotor 1 NOTE Make sure to engage th...

Page 193: ...moval and Installation in Section 3A Page3A 3 Install the clutch and movable driven face Refer to V belt Type Continuously Variable Automatic Transmission Removal and Installation in Section 5A Page5A 3 Water Pump Refer to Water Pump Removal and Installation in Section 1F Page1F 14 Speed Sensor Install the speed sensor 1 Tightening torque Speed Sensor 10 N m 1 0 kgf m 7 0 lb ft Final Reducation Ge...

Page 194: ... with a new one Tightening torque Oil filter cap bolt 10 N m 1 0 kgf m 7 0 lb ft Outer Clutch Cover Refer to V belt Type Continuously Variable Automatic Transmission Removal and Installation in Section 5A Page5A 3 Ignition Coil Install the ignition coil 1 Starter Motor Install the O ring 1 to the starter motor CAUTION Replace the O ring with a new one Apply grease to the O ring 1 Grease 99000 2501...

Page 195: ... 20 040 mm 0 789 in Special tool A 09900 20605 Dial calipers 1 100 mm 10 34 mm Conrod Big End Side Clearance Inspect the conrod side clearance using the thickness gauge If the clearance exceeds the limit inspect the conrod big end width and crank pin width If the width exceed the limit replace conrod or crankshaft Conrod big end side clearance Limit 1 00 mm 0 04 in Special tool A 09900 20803 Thick...

Page 196: ...59 9 60 1 mm 2 358 2 366 in Bearing Inspection B705H11406061 Inspect the bearing in the following procedures 1 Separate the crankcase Refer to Engine Bottom Side Assembly Page1D 44 2 Rotate the bearing inner race by finger to inspect for abnormal play noise and smooth rotation while the bearings are in the crankcase if there is anything unusual replace the bearing Refer to Bearing Removal and Inst...

Page 197: ...l C 09921 20240 Bearing remover set Remove the bearing 6 using the special tool Special tool D 09921 20240 Bearing remover set Installation Install the bearing 1 2 and 3 using the special tool Special tool 09913 70210 Bearing installer set Install the bearing 4 5 and 6 using the special tool Special tool 09913 70210 Bearing installer set A I705H1140152 01 4 B I705H1140153 02 5 C I705H1140154 02 6 ...

Page 198: ...age1D 44 2 Using appropriate size steel tubes 1 and vise remove the rear suspension mounting bushing 2 LH and RH Installation 1 Using an appropriate side steel tube and vise press in the busing into the crankcase LH and RH CAUTION Bushing end A must be flush with the crankcase surface 2 Assemble the crankcase Refer to Engine Bottom Side Disassembly Page1D 37 and Engine Bottom Side Assembly Page1D ...

Page 199: ...0 35 0 014 Valve stem runout IN EX 0 05 0 002 Valve head thickness IN EX 0 5 0 02 Valve seat width 30 45 60 IN EX 0 9 1 1 0 035 0 043 Valve head radial runout IN EX 0 03 0 001 Valve spring free length IN EX 38 6 1 52 Valve spring tension IN EX 137 3 N 14 0 kgf 30 1 lbs at length 33 35 mm 1 313 in Item Standard Limit Cam height IN 36 61 36 66 1 441 1 443 36 31 1 430 EX 35 94 35 99 1 415 1 417 35 64...

Page 200: ... 1st 0 06 0 21 0 002 0 008 0 5 0 02 2nd 0 06 0 18 0 002 0 007 0 5 0 02 Piston ring to groove clearance 1st 0 18 0 007 2nd 0 15 0 006 Piston ring groove width 1st 1 21 1 23 0 0476 0 0484 2nd 1 01 1 03 0 0398 0 0406 Oil 2 01 2 03 0 0791 0 0799 Piston ring thickness 1st 1 17 1 19 0 461 0 469 2nd 0 97 0 99 0 0382 0 0390 Piston pin bore 20 002 20 008 0 7874 0 7877 20 030 0 789 Piston pin O D 19 996 20 ...

Page 201: ...aft journal holder bolt 10 1 0 0 7 Page1D 21 Cam chain tension adjuster bolt 10 1 0 7 0 Page1D 21 Spring holder bolt 23 2 3 16 5 Page1D 22 Cylinder head cover bolt 14 1 4 10 0 Page1D 22 Spark plug 11 1 1 8 0 Page1D 22 Camshaft journal holder bolt 10 1 0 7 0 Page1D 23 Oil gallery plug cylinder head 10 1 0 7 0 Page1D 26 ECT sensor 12 1 2 8 5 Page1D 27 Intake pipe bolt 10 1 0 7 0 Page1D 27 Water inle...

Page 202: ...ZUKI Bond 1207B or equivalent P No 99000 31140 Page1D 22 Thread lock cement THREAD LOCK CEMENT 1342 or equivalent P No 99000 32050 Page1D 27 09900 20102 09900 20202 Vernier calipers 1 20 mm 200 mm Micrometer 1 100 mm 25 50 mm Page1D 29 Page1D 30 Page1D 36 Page1D 22 09900 20204 09900 20205 Micrometer 75 100 mm Micrometer 0 25 mm Page1D 35 Page1D 24 Page1D 30 Page1D 36 Page1D 37 09900 20508 09900 20...

Page 203: ... 37 Page1D 44 09910 32870 09913 10750 Crankshaft installer attachment Compression gauge adapter Page1D 44 Page1D 3 09913 50121 09913 70210 Oil seal remover Bearing installer set Page1D 53 Page1D 44 Page1D 52 Page1D 53 Page1D 53 Page1D 53 Page1D 54 09915 64512 09916 10911 Compression gauge Valve lapper set Page1D 3 Page1D 31 09916 14510 09916 14530 Valve spring compressor Valve spring compressor at...

Page 204: ...330 09916 84511 Attachment Tweezers Page1D 32 Page1D 25 Page1D 28 09919 28610 09920 13120 Sleeve protector Crankcase separating tool Page1D 25 Page1D 28 Page1D 42 Page1D 43 09921 20240 09922 21410 Bearing remover set Long socket 46 mm Page1D 53 Page1D 53 Page1D 42 Page1D 46 09930 31921 09930 40113 Rotor remover Rotor holder Page1D 40 Page1D 39 ...

Page 205: ... Lubrication System Chart Diagram B705H11502001 OIL SUMP FILTER OIL PUMP BY PASS OIL FILTER GENERATOR COVER MAIN GALLERY GENERATOR ROTOR CRANKSHAFT PISTON COOLING NOZZLE STARTER CLUTCH CYLINDER OIL JET CAMCHAIN TENSION ADJUSTER CYLINDER HEAD CRANK PIN BEARING CAM CHAIN CAM FACES TAPPETS CAM FACES TAPPETS INTAKE CAMSHAFT EXHAUST CAMSHAFT INTAKE CAMSHAFT JOURNAL EXHAUST CAMSHAFT JOURNAL PISTON OIL P...

Page 206: ...1E 2 Engine Lubrication System Engine Lubrication Circuit Diagram B705H11502002 2 1 3 A B I705H1150012 01 1 Oil sump filter 3 Oil filter B Returned oil 2 Oil pump A Lubrication oil ...

Page 207: ...15 74570 Oil pressure gauge attachment C 09915 77331 Meter for high pressure 3 Warm up the engine as follows Summer 10 min at 2 000 r min Winter 20 min at 2 000 r min 4 After warm up increase the engine speed to 3 000 r min Observe the tachometer and read the oil pressure gauge If the oil pressure is lower or higher than the specification the following causes may be considered Oil pressure specifi...

Page 208: ...t crankcase Refer to Engine Bottom Side Disassembly in Section 1D Page1D 37 Installation Install the oil sump filter in the reverse order of removal Pay attention to the following points Install the oil sump filter 1 CAUTION The lip A of the oil sump filter should be positioned downward The shorter side B of the oil sump filter should be positioned inside Oil Sump Filter Cleaning B705H11506009 Cle...

Page 209: ...pump mounting bolts to the specified torque Tightening torque Oil pump mounting bolt 10 N m 1 0 kgf m 7 0 lb ft Oil Pump Inspection B705H11506016 Inspect the oil pump in the following procedures 1 Remove the oil pump Refer to Oil Pump Removal and Installation Page1E 5 2 Rotate the oil pump shaft by hand and check that it moves smoothly If it does not move smoothly replace the oil pump with a new o...

Page 210: ...ogged clean its oil passage with a proper wire or compressed air 3 Install the piston cooling nozzle Refer to Piston Cooling Nozzle Removal and Installation Page1E 5 Specifications Service Data B705H11507002 Oil Pump Tightening Torque Specifications B705H11507003 Reference For the tightening torque of fastener not specified in this section refer to Tightening Torque Specifications in Section 0C Pa...

Page 211: ...cation System 1E 7 Special Tools and Equipment Special Tool B705H11508001 09915 74521 09915 74570 Oil pressure gauge hose Oil pressure gauge attachment Page1E 3 Page1E 3 09915 77331 Meter for high pressure Page1E 3 ...

Page 212: ... engine coolant through the radiator As the coolant temperature rises to about 88 C 190 F the thermostat valve unseats and a normal coolant flow is established At about 100 C 212 F the thermostat becomes completely open and as a result heat is released to the atmosphere through the radiator core Engine Coolant Description B705H11601002 At the time of manufacture the cooling system is filled with a...

Page 213: ...tomatically controlled by the thermo switch The thermo switch remains open when the temperature of the engine coolant is low but closes when the temperature reaches approximately 98 C 208 F setting the cooling fan in motion I310G1160001 01 I310G1160002 01 Ignition switch Fuse O Y R R Main fuse Battery Bl Cooling fan thermo switch B W Cooling fan motor I705H1160001 02 Bl Blue R Red O Y Orange with ...

Page 214: ...nsor in contact with coolant and engine coolant temperature meter Battery Main fuse Fuse Fuse Speedometer ECM R R R O O O Dg O B O W O W B Br B G O G O G B W B G ECT Ignition switch I705H1160060 03 Dg Dark green B Br Black with Brown tracer O G Orange with Green tracer O Orange B G Black with Green tracer O W Orange with White tracer R Red O B Orange with Black tracer P W Pink with White tracer ...

Page 215: ...ler 1 is located inside the crankcase The engine oil is cooled by engine coolant which is circulated through inside core of oil cooler OIL COOLER THERMOSTAT BY PASS CRANKCASE CYLINDER CYLINDER HEAD ECT SENSOR COOLING FAN THERMO SWITCH RADIATOR RESERVOIR TANK WATER PUMP I705H1160059 04 1 I705H1160002 03 ...

Page 216: ... B D G 4 C E F I705H1160056 02 1 Reservoir tank inlet hose 9 Cooling fan thermo switch 2 Conduction hose A Yellow making 3 Reservoir tank overflow hose B White marking 4 Radiator inlet hose C Pink marking 5 Radiator outlet hose D The clamp end should face to engine side 6 Thermostat E The clamp end should face forward 7 Water by pass hose F The clamp end should face downward 8 Reservoir tank G The...

Page 217: ...sure for at least 10 seconds check the entire cooling system for leaks and replace the damaged part 6 Install the front panel Refer to Front Panel Removal and Installation in Section 9D Page9D 14 7 Install the handlebar covers Refer to Handlebar Cover Removal and Installation in Section 9D Page9D 13 CAUTION Do not exceed the radiator cap release pressure or the radiator cap and subsequently the ra...

Page 218: ... 9D Page9D 16 2 Remove the left and right footboards Refer to Footboard Removal and Installation in Section 9D Page9D 21 3 Drain engine coolant Refer to Cooling System Inspection in Section 0B Page0B 11 4 Remove the radiator outlet hose 1 5 Disconnect the cooling fan motor coupler 2 and radiator heat shields 3 6 Disconnect the conduction hose 4 and remove the radiator mounting bolts 7 Disconnect t...

Page 219: ...9 Inspect the radiator hoses in the following procedures 1 Remove the left footboard Refer to Footboard Removal and Installation in Section 9D Page9D 21 2 Remove the air cleaner box Refer to Air Cleaner Box Removal and Installation in Section 1D Page1D 9 3 Remove the radiator mounting bolts Refer to Radiator Removal and Installation Page1F 7 4 Inspect the radiator hoses for crack or flat and leaka...

Page 220: ...07 Removal 1 Remove the front leg shield Refer to Front Leg Shield Removal and Installation in Section 9D Page9D 14 2 Remove the reservoir tank bracket bolt 3 Disconnect the hoses and remove the reservoir tank 1 4 Remove the bracket 2 Installation Install radiator reservoir tank in the reverse order of removal Pay attention to the following point Fill the reservoir tank to the upper level Cooling ...

Page 221: ...bolt 7 N m 0 7 kgf m 5 0 lb ft Cooling Fan Thermo Switch Removal and Installation B705H11606011 Removal 1 Remove the left footboard Refer to Footboard Removal and Installation in Section 9D Page9D 21 2 Remove the under cover Refer to Under Cover Removal and Installation in Section 9D Page9D 16 3 Drain engine coolant Refer to Cooling System Inspection in Section 0B Page0B 11 4 Disconnect the coolin...

Page 222: ... raise its temperature slowly and read the column thermometer 2 when the switch closes or opens Special tool 09900 25008 Multi circuit tester set Tester knob indication Continuity test Cooling fan thermo switch operating temperature Standard OFF ON Approx 98 C 208 F Standard ON OFF Approx 92 C 198 F ECT Sensor Removal and Installation B705H11606014 Refer to ECT Sensor Removal and Installation in S...

Page 223: ...stat with its valve open even slightly under normal temperature must be replaced 4 Immerse the thermostat 1 in the water contained in a beaker and note that the immersed thermostat is in suspension 5 Heat the water by placing the beaker on a stove and observe the rising temperature on a thermometer 2 6 Read the thermometer just when opening the thermostat If this reading which is the temperature l...

Page 224: ...ling System Water Pump Components B705H11606020 2 2 2 1 3 5 6 4 I705H1160057 02 1 Water pump cover 4 Mechanical seal Apply grease 2 O ring 5 Oil seal Apply engine coolant 3 Impeller 6 Mechanical seal ring Do not reuse ...

Page 225: ... pomp assembly 1 Installation Install the water pump assembly in the reverse order of removal Pay attention to the following points CAUTION Replace the O rings with the new ones Apply grease to the O ring 1 Grease 99000 25010 SUZUKI SUPER GREASE A or equivalent Apply engine coolant to the O rings 2 Install the water pump assembly with the slot on the pump shaft end A securely engaged with the flat...

Page 226: ...1 Water Pump Disassembly and Assembly B705H11606022 Refer to Water Pump Removal and Installation Page1F 14 Disassembly 1 Remove the water pump cover 1 2 Remove the O rings and E ring 2 3 Remove the impeller 3 together with the water pump shaft 4 Remove the mechanical seal ring 4 and the rubber seal 5 from the impeller 5 Remove the mechanical seal using the special tool NOTE If there is no abnormal...

Page 227: ...using the special tool Special tool A 09913 70210 Bearing installer set NOTE The stamped mark on the oil seal faces mechanical seal side Apply a small quantity of the super grease to the oil seal lip Grease 99000 25010 SUZUKI SUPER GREASE A or equivalent Install a new mechanical seal using a suitable size socket wrench A CAUTION The removed mechanical seal must be replaced with a new one NOTE On t...

Page 228: ...lent Water Pump Related Parts Inspection B705H11606023 Refer to Water Pump Disassembly and Assembly Page1F 15 Mechanical Seal Visually inspect the mechanical seal for damage with particular attention given to the sealing face Replace the mechanical seal that shows indications of leakage Oil Seal Visually inspect the oil seal for damage with particular attention given to the lip Replace the oil sea...

Page 229: ...perature sensor resistance 20 C 68 F Approx 2 58 kΩ 50 C 122 F Approx 0 77 kΩ 80 C 176 F Approx 0 28 kΩ 110 C 230 F Approx 0 12 kΩ Radiator cap valve opening pressure 93 3 122 7 kPa 0 93 1 23 kgf cm2 13 3 17 4 psi Cooling fan thermo switch operating temperature OFF ON Approx 98 C 208 F ON OFF Approx 92 C 198 F Engine coolant type Use an anti freeze coolant compatible with aluminum radiator mixed w...

Page 230: ...cial Tool B705H11608002 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or equivalent P No 99000 25010 Page1F 14 Page1F 16 Page1F 17 09900 25008 09913 70210 Multi circuit tester set Bearing installer set Page1F 11 Page1F 16 09921 20240 Bearing remover set Page1F 15 ...

Page 231: ...care to minimize spillage of gasoline Spilled gasoline should be wiped off immediately Work in a well ventilated area CAUTION To prevent the fuel system fuel tank fuel hose etc from contamination with foreign particles blind all openings After removing the throttle body tape the cylinder intake section to prevent foreign particles from entering ...

Page 232: ...hose through into the ring part of the tray C Orange 4 Check valve 10 Molding Adhere both ends and center area for approx 10 mm 1 4 in using adhesive 5 Cushion 11 Water drain hose Pass the water drain hose through into the slit located on rear left side end of under cover 6 Clamp Cut off the clamp after tightening 3 5 N m 0 35 kgf m 2 5 lb ft A B 3 4 10 9 3 a 1 2 1 2 4 5 7 6 2 7 5 2 8 11 C I705H11...

Page 233: ...epair or replace Lead wire disconnection or shorted Repair or replace Battery failure or voltage too low Replace or recharge Engine is likely to stop Control circuit or sensor function failure ECM failure Replace Fuel pressure regulator failure Replace Throttle position sensor failure Replace Fuel pump relay failure Replace Engine is likely to stop Engine parts function failure Fuel hose clogging ...

Page 234: ...lure Fuel pressure too low Repair or replace Throttle position failure Replace ECM failure Replace Throttle position sensor synchronization failure Adjust Engine overheats Fuel mixture too lean Fuel injector failure Replace Condition Possible cause Correction Reference Item ...

Page 235: ...Fuel System 1G 5 Repair Instructions Fuel System Components B705H11706001 2 4 3 1 a I705H1170040 01 1 Brake lock cable 3 Check valve a 5 mm 0 2 in 2 Water drain hose 4 Breather hose ...

Page 236: ...valve 2 Installation Install the fuel cut valve in the reverse order of removal Pay attention the following points Install the fuel cut valve with its protrusions A engaged with cutaway B on the gasket CAUTION Replace the gasket with a new one 2 2 1 1 B A I705H1170041 01 1 Fuel tank A Match the upper end of the fuel tank heat shield with the flange base 2 Fuel tank heat shield B Match the fuel tan...

Page 237: ... Removal and Installation in Section 1D Page1D 6 3 Remove the cushion lever mounting nut Refer to Rear Shock Absorber and Rear Shock Absorber Assembly Removal and Installation in Section 2C Page2C 4 4 Remove the clamp 5 Disconnect the fuel pump coupler 6 Remove the fuel tank filler cap 1 and fuel drain tray 2 from the fuel inlet CAUTION After removing the fuel drain tray 2 refit the fuel tank fill...

Page 238: ...e fuel hose 1 CAUTION After the fuel hose 1 has been disconnected fit a blind plug to the opening 4 Remove the fuel pump assembly 2 CAUTION When removing the fuel pump assembly take care not to cause damage to it If such a possibility is thought to exist remove the fuel tank from the body Refer to Fuel Tank Removal and Installation Page1G 7 WARNING Use caution to minimize spillage of gasoline Spil...

Page 239: ...Removal and Installation in Section 9D Page9D 18 2 Remove the fuel tank filler cap 1 fuel drain tray 2 from the fuel tank CAUTION After the fuel drain tray has been removed the fuel cap should be fitted to the fuel tank 3 Disconnect the hose 3 from the fuel cut valve 4 Remove the FTPC valve 4 from the fuel drain tray Installation Install the fuel drain tray and FTPC valve in the reverse order of r...

Page 240: ... the fuel cut valve Refer to Fuel Drain Tray and FTPC Valve Removal and Installation Page1G 9 FTPC Valve Inspection B705H11706023 Inspect the FTPC valve in the following procedures 1 Remove the FTPC valve Refer to Fuel Drain Tray and FTPC Valve Removal and Installation Page1G 9 2 Check that air passes easily when blown from the orange paint side of the FTPC valve and that resistance exists when bl...

Page 241: ...embly Pay attention to the following points CAUTION To prevent fuel leakage each O ring must be replaced with a new one Apply engine oil lightly to each of the O rings Connect all wiring couplers securely so as not to cause contact failure With the engine oil lightly applied to the O ring install the fuel pump to the fuel tank After the fuel pump mounting bolts have been tightened temporarily tigh...

Page 242: ...5 74521 Oil pressure gauge hose 4 Turn the ignition ON and check for fuel pressure Fuel pressure Approx 300 kPa 3 0 kgf cm2 43 5 psi If the fuel pressure is lower than the specification check for the followings Hose leakage Filter clogging Pressure regulator Fuel pump If the fuel pressure is higher than the specification check for the followings Pump check valve Pressure regulator CAUTION Prior to...

Page 243: ...es it hinders smooth gasoline flow resulting in loss of engine power Such a filter should be cleaned by blowing with compressed air NOTE When the fuel mesh filter is dirtied excessively replace the fuel filter cartridge with a new one 3 After finishing the fuel mesh filter inspection reinstall the fuel mesh filter Refer to Fuel Mesh Filter Inspection Page1G 13 Fuel Level Gauge Inspection B705H1170...

Page 244: ...ve the meter panel Refer to Meter Panel Removal and Installation in Section 9D Page9D 14 5 Disconnect the ECM lead wire coupler 6 With 12 V voltage applied to the power source lead wire Y R measure the volume of gasoline discharged within 10 seconds 7 If the discharge amount is out of the specification the probable cause may be failure of the fuel pump or clogged fuel filter Fuel discharge amount ...

Page 245: ... operating set pressure Approx 300 kPa 3 0 kgf cm2 43 psi Item Specification Note Fuel type Use only unleaded gasoline of at least 87 pump octane or 91 octane R 2 M 2 or higher rated by the research method Gasoline containing MTBE Methyl Tertiary Butyl Ether less than 10 ethanol or less than 5 methanol with appropriate cosolvents and corrosion inhibitor is permissible E 03 28 33 Gasoline used shou...

Page 246: ...25008 09915 74521 Multi circuit tester set Oil pressure gauge hose Page1G 13 Page1G 12 09915 77331 09917 47011 Meter for high pressure Vacuum pump gauge Page1G 12 Page1G 10 09940 40211 09940 40230 Fuel pressure gauge adapter Fuel pressure gauge hose attachment Page1G 12 Page1G 12 ...

Page 247: ...er transmits the key ID signal to ECM so that ECM can make comparison with its own ID and if it matches the engine is made ready to start Also when the ignition switch is turned ON the indicator light flashes as many as the number of IDs registered in ECM Thereafter if the IDs are in agreement the indicator light turns on for two seconds to notify of completion in successful communication If the i...

Page 248: ...is case the indicator light operation starts immediately after the starter operation NOTE In the case that the LED flashes fast remains lit or unlit the probable cause of such a failure may be due to abnormal condition in the key key cylinder wiring harness or ECM If such a failure exists contact your distributor or dealer Schematic and Routing Diagram Ignition System Diagram B705H11802001 1 I705H...

Page 249: ... replace Defective CKP sensor Replace Defective ECM Replace Spark plug is wet or quickly becomes fouled with carbon Excessively rich air fuel mixture Consult FI system Incorrect gasoline Change Dirty air cleaner element Replace Incorrect spark plug Cold type Change to hot type spark plug Spark plug quickly becomes fouled with oil or carbon Worn piston ring Replace Worn piston Replace Worn cylinder...

Page 250: ...ouplers 3 Measure the ignition coil primary peak voltage Refer to Ignition Coil Inspection Page1H 5 NOTE This ignition coil primary peak voltage inspection method is applicable only with the multi circuit tester and the peak volt adaptor Is the peak voltage OK Go to step 4 Go to step 5 4 Inspect the spark plug Refer to Spark Plug Inspection and Cleaning in Section 0B Page0B 4 Is the spark plug OK ...

Page 251: ...plug 1 to the spark plug cap and ground it on the cylinder NOTE Be sure that the spark plug is connected properly and the battery used is in fully charged condition 4 Connect the multi circuit tester with the peak voltage adaptor as follows WARNING Do not touch the tester probes and spark plug to prevent an electric shock while testing NOTE Do not disconnect the ignition coil lead wires Special to...

Page 252: ...nob indication Resistance Ω 5 After measure the ignition coil resistance reinstall the removed parts Ignition Coil Assembly Removal and Installation B705H11806010 Refer to Electrical Components Location in Section 0A Page0A 7 Removal 1 Remove the front frame cover and left footboard Refer to Footboard Removal and Installation in Section 9D Page9D 21 2 Disconnect the spark plug cap 3 Disconnect the...

Page 253: ...asure the highest CKP sensor peak voltage CKP sensor peak voltage 4 5 V and more G W Bl 6 If the peak voltage measured on the ECM coupler is lower than the standard value measure the peak voltage on the CKP sensor coupler as follows a Disconnect the CKP sensor coupler 2 b Connect the multi circuit tester with the peak voltage adaptor Special tool A 09900 25008 Multi circuit tester set Tester knob ...

Page 254: ...sistance Ω CKP sensor resistance Approx 190 290 Ω G Bl Ω G Ground 3 After measuring the CKP sensor resistance reinstall the removed parts CKP Sensor Removal and Installation B705H11806014 Refer to CKP Sensor Removal and Installation in Section 1C Page1C 1 Engine Stop Switch Inspection B705H11806015 Refer to Engine Stop Switch Inspection in Section 9B Page9B 10 Ignition Switch Inspection B705H11806...

Page 255: ... B705H11808001 2 3 I705H1180028 01 Item Standard Specification Note Spark performance Over 8 0 0 3 at 1 atm CKP sensor resistance 190 290 Ω G Bl CKP sensor peak voltage 4 5 V and more probe G W probe Bl Ignition coil resistance Primary 1 2 3 5 Ω Secondary 15 30 kΩ Ignition coil primary peak voltage 150 V and more When cranking probe W probe Ground 09900 25008 Multi circuit tester set Page1H 5 Page...

Page 256: ...ponents Location B705H11903001 Refer to Electrical Components Location in Section 0A Page0A 7 Starter motor Starter relay Safety relay Starter button Front brake switch Rear brake switch To ignition coil Engine stop switch Turn signal side stand relay Side stand switch Signal fuse lgnition fuse lgnition switch Main fuse Battery I705H1190026 01 ...

Page 257: ...ter motor runs when its terminal is connected to positive battery terminal Do not use a thin wire because a large amount of current flows Does the starter motor run Faulty starter relay Loose or disconnected starter motor lead wire Faulty starter motor 3 1 Measure the starter relay voltage at the starter relay connectors between positive terminal Y G and negative terminal B W when the starter butt...

Page 258: ...1 3 8 9 4 5 a 10 b 11 c 12 7 6 2 2 I705H1190016 02 1 Housing end Outside 8 Washer 7 N m 0 7 kgf m 5 0 lb ft 2 O ring 9 Shim Apply grease to sliding surface 3 Starter motor case 10 Starter motor housing bolt Apply moly paste to sliding surface 4 Armature 11 Starter motor lead wire bolt Apply thread lock to thread part 5 Housing end Inside 12 Starter motor mounting bolt Do not reuse 6 O ring 4 N m 0...

Page 259: ...assembly Disassemble the starter Refer to Starter Motor Components Page1I 3 Assembly Reassemble the starter motor in the reverse order of removal Pay attention to the following points CAUTION Replace the O rings with the new ones to prevent oil leakage and moisture Apply grease to the lip of the oil seal Grease 99000 25010 SUZUKI SUPER GREASE A or equivalent Fit the washer 1 to the housing end wit...

Page 260: ...brush holder set with a new one Brush length a Service limit 3 5 mm 0 14 in Special tool 09900 20102 Vernire calipers Commutator Inspect the commutator for discoloration abnormal wear or undercut A If the commutator is abnormally worn replace the armature If the commutator surface is discolored polish it with 400 sandpaper and wipe it using a clean dry cloth If there is no undercut scrape out the ...

Page 261: ...e the starter relay 5 Installation Install the starter relay in the reverse order of removal Starter Relay Inspection B705H11906005 Inspect the starter relay in the following procedures 1 Remove the starter relay Refer to Starter Relay Removal and Installation Page1I 6 2 Apply 12 V to A and B terminals and check for continuity between the and terminals using the multi circuit tester If the starter...

Page 262: ... of removal Side stand Ignition Interlock System Parts Inspection B705H11906007 Refer to Electrical Components Location in Section 0A Page0A 7 Check the interlock system for proper operation 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 1 Remove the left footboard...

Page 263: ...900 25008 Multi circuit tester set Tester knob indication Continuity test 4 Install the turn signal side stand relay Refer to Turn Signal Side stand Relay Removal and Installation Page1I 7 Diode inspection 1 Remove the turn signal side stand relay Refer to Turn Signal Side stand Relay Removal and Installation Page1I 7 2 Measure the voltage between the terminals using the multi circuit tester Speci...

Page 264: ...mbly in Section 1D Page1D 37 Installation Install the starter clutch in the reverse order of removal Pay attention to the following points Install the generator rotor Refer to Engine Bottom Side Assembly in Section 1D Page1D 44 Replace the generator cover gasket with a new one Install the muffler Refer to Exhaust Pipe Muffler Removal and Installation in Section 1K Page1K 2 Pour engine oil Refer to...

Page 265: ... to be damaged replace them with the new ones 2 Inspect the starter driven gear bearing for any damages Starter Clutch Disassembly and Assembly B705H11906011 Disassembly 1 With the rotor held with a wrench loosen the starter clutch bolts 2 Remove the one way clutch guide 1 and one way clutch 2 from the rotor Reassembly Reassemble the starter clutch in the reverse order of disassembly Pay attention...

Page 266: ...htening Torque Specifications B705H11907003 NOTE The specified tightening torque is also described in the following Starter Motor Components Page1I 3 Starter Clutch Component Page1I 9 Reference For the tightening torque of fastener not specified in this section refer to Tightening Torque Specifications in Section 0C Page0C 7 I705H1190027 01 Item Standard Specification Note Starter relay resistance...

Page 267: ...908002 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or equivalent P No 99000 25010 Page1I 4 Page1I 4 Moly paste SUZUKI Moly paste or equivalent P No 99000 25140 Page1I 4 Thread lock cement Thread Lock Cement 1342 or equivalent P No 99000 32050 Page1I 5 Page1I 11 09900 20102 09900 25008 Vernier calipers 1 20 mm 200 mm Multi circuit tester set Page1I 5 Page1...

Page 268: ...iagram Charging System Diagram B705H11A02001 Component Location Charging System Components Location B705H11A03001 Refer to Electrical Components Location in Section 0A Page0A 7 lgnition switch Main fuse Battery Load Regulator Rectifier Generator I705H11A0001 02 ...

Page 269: ...und connection Unstable charging Lead wire insulation frayed due to vibration resulting in intermittent short circuiting Repair or replace Internally short circuited generator Replace Defective regulator rectifier Replace Sulfation acidic white powdery substance or spots on surfaces of cell plates Cracked battery case Replace the battery Battery has been left in a run down condition for a long tim...

Page 270: ...inals Refer to Regulated Voltage Inspection Page1J 4 Is the battery charging of voltage OK Faulty battery Abnormal driving condition Go to step 4 4 1 Measure the resistance of the generator coil Refer to Generator Coil Resistance Inspection Page1J 5 Is the resistance of generator coil OK Go to step 5 Faulty generator coil or disconnected lead wires 5 1 Measure the generator no load voltage Refer t...

Page 271: ...ot turn the ignition switch to the ON position when measuring current 5 Reinstall the removed parts Regulated Voltage Inspection B705H11A06002 Inspect the regulated voltage in the following procedures 1 Remove the battery cover 1 2 Start the engine and keep it running at 5 000 r min with the dimmer switch turned HI position 3 Measure the DC voltage between the and battery terminals using the multi...

Page 272: ...H11A06005 Inspect the generator no load performance in the following procedures 1 Disconnect the generator coupler 1 2 Start the engine and run it at 5 000 r min 3 Using the multi circuit tester measure the voltage between three lead wires If the tester reads under the specified value replace the generator with a new one Special tool 09900 25008 Multi circuit tester set Tester knob indication Volt...

Page 273: ...on 9D Page9D 14 Generator Removal and Installation B705H11A06003 Removal 1 Drain engine oil 2 Remove the side leg shield Refer to Side Leg Shield Removal and Installation in Section 9D Page9D 15 3 Remove the generator cover Refer to CKP Sensor Removal and Installation in Section 1C Page1C 1 4 Remove the generator stator 1 CKP sensor 2 and lead wire guide 3 5 Remove the snap ring 4 6 Remove the bea...

Page 274: ...o the generator cover CAUTION Engage the convex part A on the starter into the notch B on the generator cover Tighten the generator stator bolts 3 to the specified torque Tightening torque Generator stator bolt a 11 N m 1 1 kgf m 8 0 lb ft Tighten the CKP sensor bolts 4 to the specified torque Tightening torque CKP sensor bolt b 6 N m 0 6 kgf m 4 5 lb ft Install the generator cover CAUTION Replace...

Page 275: ... Hold the electrolyte container firmly so that it does not fall 5 Do not allow any of the electrolyte to spill 6 Make sure the air bubbles 6 rise to the top of each electrolyte container and leave the electrolyte container in this position for more than 20 minutes NOTE If air bubbles do not rise from any one of the filler ports tap the bottom of the electrolyte container two or three times Never r...

Page 276: ...he figure 3 If the battery voltage is lower than the specification charge the battery with a battery charger Refer to Battery Recharging Page1J 10 CAUTION Do not remove the caps on the battery top while charging NOTE Initial charging for a new battery is recommended if two years have elapsed since the date of manufacture Battery Visual Inspection B705H11A06008 Inspect the battery visual in the fol...

Page 277: ...ge the battery again 5 If the battery voltage is still less than 12 5 V after recharging replace the battery with a new one 6 When a battery is left unused for a long time its voltage needs to be regularly measured 7 When the motorcycle is not used for more than one month especially during the winter season measure the battery voltage at least once a month Battery Removal and Installation B705H11A...

Page 278: ... Generator no load voltage When engine is cold 55 V and more at 5 000 r min Generator Max output Approx 400 W at 5 000 r min Starter motor brush length 7 0 28 3 5 0 14 Regulated voltage 14 0 15 5 V at 5 000 r min Battery Type designation FTZ9 BS Capacity 12 V 32 4 kC 9 Ah 10 HR Fastening part Tightening torque Note N m kgf m lb ft Generator stator bolt 11 1 1 8 0 Page1J 7 CKP sensor bolt 6 0 6 4 5...

Page 279: ...ubber parts and plastic parts to avoid melting After installing the exhaust pipe and muffler check the exhaust pipe connection and muffler connection for exhaust gas leakage Repair Instructions Exhaust System Components B705H11B06001 2 a 3 b 4 c 5 d 6 d 6 1 I705H11B0012 04 1 Exhaust pipe gasket 5 Exhaust pipe connecting bolt 23 N m 2 3 kgf m 16 5 lb ft 2 Muffler connector 6 Muffler mounting bolt 2...

Page 280: ...ire coupler 1 2 Loosen the exhaust pipe connecting bolt 2 3 Remove the muffler mounting bolts 3 and remove the muffler 4 4 Remove the HO2 sensor 5 5 Remove the exhaust pipe 6 6 Remove the exhaust pipe gasket 7 1 I705H11B0001 01 2 I705H11B0002 01 3 4 I705H11B0003 01 5 I705H11B0004 01 6 I705H11B0005 01 7 I705H11B0006 01 ...

Page 281: ...34 5 lb ft CAUTION Be careful not to expose it to excessive shock Do not use an impact wrench while installing the HO2 sensor Be careful not to twist or damage the sensor lead wires Do not apply oil or other materials to the sensor air hole Apply thread lock to the exhaust pipe joint bolt and muffler mounting bolts Thread lock cement 99000 32050 THREAD LOCK CEMENT 1342 or equivalent Tighten the ex...

Page 282: ...ne Check the exhaust pipe bolts exhaust pipe connecting bolt and muffler mounting bolts are tightened to their specified torque Tightening torque Exhaust pipe bolt a 23 N m 2 3 kgf m 16 5 lb ft Exhaust pipe connecting bolt b 23 N m 2 3 kgf m 16 5 lb ft Muffler mounting bolt c 23 N m 2 3 kgf m 16 5 lb ft HO2 Sensor Inspection B705H11B06006 Refer to HO2 Sensor Inspection in Section 1C Page1C 6 a 3 I...

Page 283: ...s and Equipment Recommended Service Material B705H11B08001 NOTE Required service material is also described in the following Exhaust System Components Page1K 1 Fastening part Tightening torque Note N m kgf m lb ft Exhaust pipe bolt 23 2 3 16 5 Page1K 3 Page1K 4 HO2 sensor 48 4 8 34 5 Page1K 3 Exhaust pipe connecting bolt 23 2 3 16 5 Page1K 3 Page1K 4 Muffler mounting bolt 23 2 3 16 5 Page1K 3 Page...

Page 284: ...1K 6 Exhaust System ...

Page 285: ...r Swingarm Dust Seal Bearing Removal and Installation 2C 8 Cushion Lever and Cushion Rod Inspection 2C 9 Cushion Lever Bearing Removal and Installation 2C 10 Crankcase Bracket Construction 2C 11 Crankcase Bracket Removal and Installation 2C 12 Crankcase Bracket Related Parts Inspection 2C 12 Crankcase Bracket Bearing Removal and Installation 2C 13 Specifications 2C 14 Service Data 2C 14 Tightening...

Page 286: ...nsions bolts and nuts are an important part in that it could affect the performance of vital parts They must be tightened to the specified torque periodically and if the suspension effect is lost replace it with a new one CAUTION Never attempt to heat quench or straighten any suspension part Replace it with a new one or damage to the part may result ...

Page 287: ...lace Noisy front suspension Not enough fork oil Replenish Loose bolts on suspension Retighten Wobbly rear wheel Distorted wheel rim Replace Worn rear swingarm bearing Replace Defective or incorrect tire Replace Worn rear suspension bushing Replace Loose bolts on rear suspension and rear swingarm Retighten Loose rear axle nut Retighten Rear suspension too soft Weakened spring of shock absorber Repl...

Page 288: ...und spring 13 Oil seal retainer 19 Front axle pinch bolt 2 O ring 8 Inner tube 14 Guide metal 45 N m 4 5 kgf m 32 5 lb ft 3 Washer 9 Inner tube slide metal 15 Oil lock piece 30 N m 3 0 kgf m 21 5 lb ft 4 Front fork spring 10 Dust seal 16 Outer tube Apply thread lock to thread part 5 Cylinder ring 11 Oil seal stopper ring 17 Gasket Apply fork oil 6 Cylinder 12 Oil seal 18 Cylinder bolt Do not reuse...

Page 289: ...he front fork cap bolt 4 and washer using the special tool CAUTION Use caution when removing the front fork cap bolt since the spring force is applied to the cap bolt Special tool A 09940 30230 Socket hexagon 17 mm 7 Loose the front fork clamp bolts 5 and remove the front fork 6 NOTE Hold the front fork by the hand to prevent sliding out of the steering stem Installation 1 Insert the front fork in...

Page 290: ...der 6 Tighten the brake hose clamp bolt 7 Connect the brake hose clamp to the front fender 8 Install the front wheel assembly Refer to Front Wheel Assembly Removal and Installation in Section 2D Page2D 4 WARNING After remounting the brake caliper pump the brake lever until the pistons push the pads correctly NOTE Before tightening the front axle and front axle pinch bolts move the front fork up an...

Page 291: ...ent A 5 Remove the cylinder 3 rebound spring 4 and cylinder ring 5 6 Remove the dust seal 6 and oil seal stopper ring 7 7 Pull the outer tube out of the inner tube NOTE Be careful not to damage the inner tube 8 Remove the following parts Oil seal 8 Oil seal retainer 9 Guide metal 10 Slide metal 11 Oil lock piece 12 I649G1220012 01 A B I705H1220008 01 2 I705H1220009 01 3 5 4 I705H1220010 02 6 7 I70...

Page 292: ...lide metal surfaces since the surfaces are teflon coated Oil lock piece Install the spring 1 into the oil lock piece 2 securely Inner tube Apply fork oil to the guide metal and oil seal lip Fork Oil 99000 99044 10G FORK OIL or equivalent Install the following parts onto the inner tube Oil seal 1 Oil seal retainer 2 Guide metal 3 CAUTION When installing the oil seal to inner tube be careful not to ...

Page 293: ...pecial tool A 09940 52861 Front fork oil seal installer Install the oil seal stopper ring 4 and the dust seal 5 Dust seal 5 Oil seal stopper ring 4 Oil seal 1 Oil seal retainer 2 Guide metal 3 Cylinder Rebound spring Cylinder ring Install the rebound spring and the cylinder ring to the cylinder and install them together to the inner tube NOTE The cylinder ring should be installed onto the cylinder...

Page 294: ... A Tightening torque Cylinder bolt 30 N m 3 0 kgf m 21 5 lb ft Front fork oil Place the front fork vertically without spring Compress the front fork fully Pour the specified front fork oil into the front fork Fork Oil 99000 99044 10G FORK OIL or equivalent Front fork oil capacity each leg 301 ml 10 17 10 60 US Imp oz Move the inner tube up and down slowly several strokes until no more bubbles come...

Page 295: ...5H12206009 Refer to Front Fork Disassembly and Assembly Page2B 3 Inspect the following parts Inner Outer Tubes Inspect the inner tube sliding surface and outer tube sliding surface for scuffing If any defects are found replace them with the new ones Fork Spring Measure the fork spring free length If it is shorter than the service limit replace it with a new one Front fork spring free length a 347 ...

Page 296: ... to Tightening Torque Specifications in Section 0C Page0C 7 Item Standard Item Front fork stroke 110 4 33 Front fork spring free length 347 6 13 69 340 Front fork oil type G 10 Front fork oil capacity each leg 301 ml 10 17 10 60 US lmp oz Front fork oil level 87 3 43 without spring inner outer tube fully pressed Front fork inner tube O D 41 1 61 Fastening part Tightening torque Note N m kgf m lb f...

Page 297: ...commended product or Specification Note Fork Oil FORK OIL or equivalent P No 99000 99044 10G Page2B 2 Page2B 5 Page2B 5 Page2B 7 Thread lock cement Thread Lock Cement 1342 or equivalent P No 99000 32050 Page2B 7 09940 30230 09940 34520 Socket hexagon 17 mm T handle Page2B 2 Page2B 3 Page2B 4 Page2B 7 09940 34531 09940 52861 Attachment A Front fork oil seal installer Page2B 4 Page2B 7 Page2B 6 0994...

Page 298: ...Cushion lever 50 N m 5 0 kgf m 36 0 lb ft 2 Rear shock absorber 9 Cushion lever nut 50 N m 5 0 kgf m 36 0 lb ft 3 Cushion lever bolt 10 Cushion lever rod bolt 80 N m 8 0 kgf m 58 0 lb ft 4 Cushion lever nut 11 Cushion lever rod nut 50 N m 5 0 kgf m 36 0 lb ft 5 Cushion lever bolt 12 Cushion lever rod 50 N m 5 0 kgf m 36 0 lb ft 6 Spacer 13 Cushion lever rod bolt 7 Bearing 14 Cushion lever rod nut ...

Page 299: ...b 3 2 1 3 5 4 A FWD I705H1230041 04 1 Rear shock absorber mounting bolt 5 Cushion rod mounting nut 80 N m 8 0 kgf m 58 0 lb ft 2 Cushion lever nut A Assemble the rear shock absorber with dent side up Apply grease 3 Cushion lever mounting nut a 1 mm 0 04 in 4 Cushion rod nut 50 N m 5 0 kgf m 36 0 lb ft ...

Page 300: ...ar Suspension Rear Swingarm Components B705H12306027 1 a 2 3 4 5 FWD FWD I705H1230035 01 1 Rear swingarm 3 Dust seal 5 Dust seal Do not reuse 2 Rear swingarm mounting bolt 4 Bearing 50 N m 5 0 kgf m 36 0 lb ft ...

Page 301: ...Install the rear shock absorber assembly in the reverse order of removal Pay attention to the following points Tighten the cushion lever nuts 1 and cushion rod nut 2 to the specified torque Tightening torque Cushion lever nut a 50 N m 5 0 kgf m 36 0 lb ft Cushion rod nut b 50 N m 5 0 kgf m 36 0 lb ft Install the rear shock absorber assembly and tighten the rear shock absorber bolt 3 rear cushion r...

Page 302: ...705H12306017 Refer to Rear Shock Absorber and Rear Shock Absorber Assembly Removal and Installation Page2C 4 WARNING The rear shock absorber unit contains high pressure nitrogen gas Mishandling can cause explosion Keep away from fire and heat High gas pressure caused by heat can cause an explosion Release gas pressure before disposing Gas Pressure Release Make sure to observe the following precaut...

Page 303: ...g tension and position 7 provides the stiffest STD position Position 3 Rear Swingarm Removal and Installation B705H12306024 Removal 1 Raise the rear wheel resting center stand and using jack CAUTION Fix the frame to be stabilized 2 Remove the muffler Refer to Exhaust Pipe Muffler Removal and Installation in Section 1K Page1K 2 3 Loosen the rear axle nut 1 while depressing the rear brake pedal 4 Re...

Page 304: ...oint bolt and muffler mounting bolt to the specified torque CAUTION Replace the exhaust pipe connector with a new one Tightening torque Exhaust pipe connecting bolt 23 N m 2 3 kgf m 16 5 lb ft Muffler mounting bolt 23 N m 2 3 kgf m 16 5 lb ft WARNING After remounting the rear wheel pump the rear brake lever several times to check for proper brake operation Rear Swingarm Related Parts Inspection B7...

Page 305: ... collar for wear or damage If any defects are found replace it with a new one Rear Swingarm Dust Seal Bearing Removal and Installation B705H12306026 Refer to Rear Suspension Assembly Construction Page2C 2 Removal 1 Remove the rear swingarm Refer to Rear Swingarm Removal and Installation Page2C 6 2 Remove the dust seals 1 and 2 using the special tool Special tool A 09913 50121 Oil seal remover 3 Re...

Page 306: ...g stamped mark on the bearing must face outside Install the oil seal using the special tool Special tool 09913 70210 Bearing installer set Apply grease to the oil seal lip Grease 99000 25010 SUZUKI SUPER GREASE A or equivalent Cushion Lever and Cushion Rod Inspection B705H12306018 Refer to Rear Shock Absorber and Rear Shock Absorber Assembly Removal and Installation Page2C 4 Inspect the following ...

Page 307: ... Cushion Lever Bearing Removal and Installation Page2C 10 Cushion Rod Inspect the cushion rod for damage and bend If any defects are found replace the cushion rod with a new one Cushion Lever Bearing Removal and Installation B705H12306019 Removal 1 Remove the cushion lever Refer to Rear Shock Absorber and Rear Shock Absorber Assembly Removal and Installation Page2C 4 2 Remove the cushion lever bea...

Page 308: ... Special tool A 09941 34513 Steering race installer Apply grease to the bearings Grease 99000 25010 SUZUKI SUPER GREASE A or equivalent Install the cushion lever Refer to Rear Shock Absorber and Rear Shock Absorber Assembly Removal and Installation Page2C 4 Crankcase Bracket Construction B705H12306020 A I705H1230013 01 I705H1230014 01 4 3 2 2 2 3 4 1 3 2 2 3 b 6 a 5 I705H1230042 01 1 Crankcase bra...

Page 309: ...case bracket held immovable tighten the crankcase bracket nut 1 to the specified torque Tightening torque Crankcase bracket nut a 85 N m 8 5 kgf m 61 5 lb ft 5 Remove the rubber damper bolts 2 L R after tightening the crankcase bracket nut 1 6 Install the rubber dampers 3 L R and tighten the rubber damper bolts 2 L R to the specified torque Tightening torque Rubber damper bolt b 85 N m 8 5 kgf m 6...

Page 310: ...5H12306023 Removal 1 Remove the crankcase bracket Refer to Crankcase Bracket Removal and Installation Page2C 12 2 Remove the bearing 1 using the special tools Special tool A 09923 74511 Bearing puller B 09930 30104 Sliding shaft Installation CAUTION The removed bearings must be replaced with the new ones 1 Install the bearing using the special tool Special tool A 09924 84521 Bearing installer set ...

Page 311: ... in Section 0C Page0C 7 Item Standard Item Rear wheel travel 100 3 94 Rear shock absorber spring adjuster 3rd position Fastening part Tightening torque Note N m kgf m lb ft Cushion lever nut 50 5 0 36 0 Page2C 4 Cushion rod nut 50 5 0 36 0 Page2C 4 Rear shock absorber bolt 50 5 0 36 0 Page2C 4 Rear cushion rod nut 50 5 0 36 0 Page2C 4 Cushion lever mounting nut 80 8 0 58 0 Page2C 4 Rear brake cali...

Page 312: ...12308002 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or equivalent P No 99000 25010 Page2C 9 Page2C 9 Page2C 11 09913 50121 09913 70210 Oil seal remover Bearing installer set Page2C 8 Page2C 8 Page2C 9 09923 73210 09923 74511 Bearing remover Bearing puller Page2C 10 Page2C 13 09924 84521 09930 30104 Bearing installer set Rotor remover slide shaft Page2C 1...

Page 313: ...aller amount of tire in contact with the road which can contribute to skidding and loss of control Replace the wheel when wheel runout exceed the service limit or if find damage such as distortion crack nick or scratch When tire replacement is necessary the original equipment type tire should be used Do not mix different types of tires on the same vehicle such as radial and bias belted tires excep...

Page 314: ...3 4 1 10 b 8 4 9 11 2 3 6 7 7 I705H1240028 05 1 Front wheel 7 Brake disc 23 N m 2 3 kgf m 16 5 lb ft 2 Spacer 8 Brake disc bolt Apply grease 3 Bearing 9 Tire Apply thread lock to thread part 4 Dust seal 10 Air valve Do not reuse 5 Front axle 11 Wheel balancer 6 Collar 65 N m 6 5 kgf m 47 0 lb ft ...

Page 315: ...019 b 2 c 3 b 2 a 1 c 3 a Left Right I705H1240030 02 1 Front axle a Clearance 23 N m 2 3 kgf m 16 5 lb ft 2 Front brake caliper mounting bolt 65 N m 6 5 kgf m 47 0 lb ft Apply grease 3 Front brake disc bolt 35 N m 3 5 kgf m 25 5 lb ft Apply thread lock to thread part ...

Page 316: ...wooden block CAUTION Do not carry out the work with the motorcycle resting on the side stand Do not support the motorcycle with the fuel tank and the radiator Make sure that the motorcycle is supported securely 6 Draw out the front axle and remove the front wheel NOTE After removing the front wheel install the calipers temporarily to the original positions 7 Remove the collar 3 Installation 1 Inst...

Page 317: ...hten the axle pinch bolt 4 on the right front fork leg to the specified torque Tightening torque Front axle pinch bolt c 23 N m 2 3 kgf m 16 5 lb ft Front Wheel Related Parts Inspection B705H12406021 Refer to Front Wheel Assembly Removal and Installation Page2D 4 Inspect the following parts Tire Refer to Tire Inspection in Section 0B Page0B 15 Front Brake Disc Refer to Front Brake Disc Inspection ...

Page 318: ...out replace the wheel Wheel runout Service limit Axial and Radial 2 0 mm 0 08 in Wheel Bearing Inspect the play of the wheel bearings by finger while they are in the wheel Rotate the inner race by finger to inspect for abnormal noise and smooth rotation Replace the bearing in the following procedures if there is anything unusual Refer to Front Wheel Dust Seal Bearing Removal and Installation Page2...

Page 319: ...s 1 Apply grease to the wheel bearings Grease 99000 25010 SUZUKI SUPER GREASE A or equivalent 2 First install the right wheel bearing then install the spacer 1 and left wheel bearing Special tool A 09941 34513 Steering race installer CAUTION The sealed cover of the bearing must face outside B 2 I705H1240010 01 3 I705H1240011 01 I649G1240019 01 1 Spacer a Clearance A I649G1240020 02 A A 1 a Left Ri...

Page 320: ...heel assembly Refer to Front Wheel Assembly Removal and Installation Page2D 4 Rear Wheel Components B705H12406024 B I705H1240012 01 I705H1240013 01 2 1 5 6 8 10 4 a 3 b 7 9 FWD FWD I705H1240029 02 1 Rear wheel 6 Collar 23 N m 2 3 kgf m 16 5 lb ft 2 Brake disc 7 Rear axle nut 120 N m 12 0 kgf m 87 0 lb ft 3 Brake disc bolt 8 Tire Apply grease 4 O ring 9 Air valve Apply thread lock to thread part 5 ...

Page 321: ...tion in Section 9D Page9D 16 2 Disconnect the HO2 sensor lead wire coupler 1 3 Remove the exhaust pipe connecting bolt 2 4 Remove the muffler 3 5 Remove the rear brake hose clamps 4 and rear brake caliper 5 6 Remove the rear swingarm mounting bolts 6 rear axle nut 7 and remove the rear swing arm 8 7 Remove the inner color 9 and the rear wheel 10 CAUTION Do not operate the brake lever while removin...

Page 322: ...ear wheel nut b 120 N m 12 0 kgf m 87 0 lb ft Tighten the rear brake caliper mounting bolts 3 to the specified torque Tightening torque Rear brake caliper mounting bolt c 23 N m 2 3 kgf m 16 5 lb ft CAUTION Replace the exhaust pipe connector 4 with a new one Insert the exhaust pipe connecting bolt and the muffler mounting bolt temporarily Tighten the exhaust pipe connecting bolts 5 to the specifie...

Page 323: ...f bearing replacement fails to reduce the runout replace the wheel Wheel runout Service limit Axial and Radial 2 0 mm 0 08 in Wheel clean and check Refer to Wheel Tire Air Valve Inspection and Cleaning Page2D 13 Tire Removal and Installation B705H12406027 Removal The most critical factor of a tubeless tire is the seal between the wheel rim and the tire bead For this reason it is recommended to use...

Page 324: ...hould point to the direction of wheel rotation Align the chalk mark put on the tire at the time of removal with the valve position 3 Bounce the tire several times while rotating This makes the tire bead expand outward to contact the wheel thereby facilitating air inflation 4 Install the valve core and inflate the tire WARNING Do not inflate the tire to more than 400 kPa 4 0 kgf cm2 If inflated bey...

Page 325: ... seating area Wheel rim runout Refer to Front Wheel Assembly Removal and Installation Page2D 4 and Rear Wheel Assembly Removal and Installation Page2D 9 Tire Tire must be checked for the following points Nick and rupture on side wall Tire tread depth Refer to Tire Inspection in Section 0B Page0B 15 Tread separation Abnormal uneven wear on tread Surface damage on bead Localized tread wear due to sk...

Page 326: ...valve hole apply a special tire lubricant or neutral soapy liquid to the valve Wheel Balance Check and Adjustment B705H12406030 Check and adjust the wheel balance in the following procedures 1 Removal the wheel assembly Refer to Front Wheel Assembly Removal and Installation Page2D 4 and Rear Wheel Assembly Removal and Installation Page2D 9 2 Check the wheel balance using the balancer and adjust th...

Page 327: ...00 Item Standard Limit Cold inflation tire pressure Solo riding Front 175 kPa 1 75 kgf cm2 25 psi Rear 200 kPa 2 00 kgf cm2 29 psi Dual riding Front 175 kPa 1 75 kgf cm2 25 psi Rear 250 kPa 2 50 kgf cm2 36 psi Tire size Front 120 80 14M C 58S Rear 150 70 13M C 64S Tire type Front BRIDGESTONE HOOP B03G Rear BRIDGESTONE HOOP B02G Tire tread depth Recommended depth Front 1 6 mm 0 06 in Rear 2 0 mm 0 ...

Page 328: ...l B705H12408002 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or equivalent P No 99000 25010 Page2D 7 Page2D 8 09900 18710 09900 20607 Hexagon socket 12 mm Dial gauge 1 100 mm 10 mm Page2D 5 Page2D 6 09900 20701 09900 21304 Magnetic stand V block 100 mm Page2D 6 Page2D 6 09913 50121 09913 70210 Oil seal remover Bearing installer set Page2D 6 Page2D 8 09921 ...

Page 329: ...d Procedures 3A 1 Drive Chain and Sprocket Symptom Diagnosis 3A 1 Repair Instructions 3A 2 Final Gear Components 3A 2 Final Gear Assembly Removal and Installation 3A 3 Final Gear Disassembly and Assembly 3A 4 Final Drive Gear Bearing Inspection 3A 8 Specifications 3A 9 Tightening Torque Specifications 3A 9 Special Tools and Equipment 3A 9 Recommended Service Material 3A 9 Special Tool 3A 9 ...

Page 330: ...3 1 Precautions Precautions Precautions Precautions for Driveline Axle B705H13000001 Refer to General Precautions in Section 00 Page00 1 ...

Page 331: ... Diagnostic Information and Procedures Drive Chain and Sprocket Symptom Diagnosis B705H13104001 Condition Possible cause Correction Reference Item Noisy drive chain Noise seems to come from final gear case Worn or rubbing gears Replace Worn splines Replace Worn bearing Replace ...

Page 332: ...11 Bearing 21 Oil drain bolt 2 Bearing 12 Drive shaft 23 N m 2 3 kgf m 16 5 lb ft 3 Oil seal 13 Bearing 16 N m 1 6 kgf m 11 5 lb ft 4 Rear axle shaft 14 Oil seal 12 N m 1 2 kgf m 8 5 lb ft 5 Bearing 15 O ring 22 N m 2 2 kgf m 16 0 lb ft 6 Bearing 16 Dowel pin Apply oil 7 Snap ring 17 Final gear cover Apply grease 8 Washer 18 Gasket Do not reuse 9 Idle shaft 19 Oil filler bolt 10 Bearing 20 Oil lev...

Page 333: ...rive shaft 4 7 Remove the dowel pins 5 and washer 6 8 Remove the final driven gear 7 and rear axle shaft 8 9 Remove the idle shaft 9 10 Remove the washer 10 Installation Install the final gear assembly in the reverse order of removal Pay attention to the following points CAUTION Apply engine oil to each gears and shaft part Install the dowel pin to the case side Install the final gear cover and dr...

Page 334: ... torque Oil drain plug b 12 N m 1 2 kgf m 8 5 lb ft Oil level bolt c 16 N m 1 6 kgf m 11 5 lb ft Final gear capacity when replacing 190 ml Final Gear Disassembly and Assembly B705H13106003 Refer to Final Gear Assembly Removal and Installation Page3A 3 Disassembly Final gear cover 1 Remove the drive shaft 1 and O ring 2 from the final gear cover 3 2 Remove the oil seal 4 using the special tool Spec...

Page 335: ... gear Idle shaft 1 Remove the washers 1 snap ring 2 and idle gear 3 2 Remove the snap ring 4 and idle shaft 5 Final driven gear Rear axle shaft 1 Remove the snap ring 1 and final driven gear 2 2 Remove the snap ring 3 from the rear axle shaft 4 7 C I705H1310014 05 8 I705H1310015 01 3 2 1 I705H1310018 01 5 4 I705H1310019 02 2 1 I705H1310016 01 3 4 I705H1310034 04 ...

Page 336: ...using the special tool Special tool 09921 20240 Bearing remover set Assembly Assemble the final gear assembly in the reverse order of disassembly Pay attention to the following points Final gear case Install the bearings 1 and 2 using the special tool CAUTION Replace the bearings with the new ones Install the bearing so that its stamped mark faces outside Special tool 09913 70210 Bearing installer...

Page 337: ...ent Install the bearing retainer 5 Final gear cover Install the bearings 1 2 and 3 using the special tool CAUTION Replace the bearing with a new one Install the bearing so that its stamped mark faces outside Special tool A 09913 70210 Bearing installer set Install the oil seal 4 using the special tool CAUTION Replace the oil seal with a new one Special tool A 09913 70210 Bearing installer set Appl...

Page 338: ...isassembly and Assembly Page3A 4 Inspect the following items Final gear case side Inspect the play of the bearings by hand while they are in the case Rotate the inner race by hand to inspect for abnormal noise and smooth rotation Replace the bearing if there is anything unusual Refer to Final Gear Assembly Removal and Installation Page3A 3 Final gear cover side Inspect the play of the bearings by ...

Page 339: ... described in the following Final Gear Components Page3A 2 Special Tool B705H13108002 Fastening part Tightening torque Note N m kgf m lb ft Final gear cover bolt 22 2 2 16 0 Page3A 4 Page3A 8 Oil drain plug 12 1 2 8 5 Page3A 4 Oil level bolt 16 1 6 11 5 Page3A 4 Page3A 8 Oil filler bolt 23 2 3 16 5 Page3A 8 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or e...

Page 340: ...3A 10 Drive Chain Drive Train Drive Shaft ...

Page 341: ...14 Special Tool 4A 14 Front Brakes 4B 1 Repair Instructions 4B 1 Front Brake Components 4B 1 Front Brake Pad Inspection 4B 2 Front Brake Pad Replacement 4B 2 Front Brake Caliper Removal and Installation 4B 3 Front Brake Caliper Disassembly and Assembly 4B 4 Front Brake Caliper Parts Inspection 4B 5 Front Brake Disc Removal and Installation 4B 6 Front Brake Disc Inspection 4B 6 Specifications 4B 7 ...

Page 342: ...ble of Contents Parking Brake System Brake lock System Disassembly and Assembly 4D 7 Parking Brake Cable Brake lock Cable Removal and Installation 4D 7 Specifications 4D 8 Tightening Torque Specifications 4D 8 ...

Page 343: ...rvicing or which has been stored for long periods of time When storing brake fluid seal the container completely and keep it away from children When replenishing brake fluid take care not to get dust into the fluid When washing brake components use new brake fluid Never use cleaning solvent A contaminated brake disc or brake pad reduces braking performance Discard contaminated pads and clean the d...

Page 344: ...ake hose B After touching the clamp to the stopper tighten the clamp bolt 2 Front brake hose C Insert the clamp to the hole of the front fender fully 3 Brake hose guide D After touching the brake hose union to the stopper tighten the union bolt to the specified torque 4 Rear brake pipe E Do not bend the brake hose to frame head pipe side 5 Front brake caliper a 28 A Fix the brake hose grommet to i...

Page 345: ... pipe B After positioning the clamp with the stopper on the swingarm tighten the clamp bolt 2 Rear brake hose C After touching the brake hose union to the stopper tighten the union bolt to the specified torque 3 Front cowling plate D Clamp the brake hose firmly 4 E ring a 28 5 Rear brake caliper b 14 A Clamp the rear brake pipe at white mark position ...

Page 346: ...orn pads Replace Oil adhesion on friction surface of pads Clean disc and pads Worn disc Replace Air in hydraulic system Bleed air Not enough brake fluid in the reservoir Replenish Brake squeaking Carbon adhesion on pad surface Repair surface with sandpaper Tilted pad Correct pad fitting or replace Damaged wheel bearing Replace Loose front wheel axle or rear wheel axle Tighten to specified torque W...

Page 347: ...n the brake fluid circuit be purged of air in the following manner CAUTION Handle brake fluid with care the fluid reacts chemically with paint plastic rubber materials etc Front Brake 1 Fill the master cylinder reservoir to the top of the inspection window Place the reservoir cap to prevent dirt from entering 2 Attach a hose to the air bleeder valve and insert the free end of the hose into a recep...

Page 348: ...106020 CAUTION Handle brake fluid with care the fluid reacts chemically with paint plastic rubber materials etc Front Brake 1 Place the motorcycle on a level surface and keep the handlebars straight 2 Remove the brake fluid reservoir cap and diaphragm 3 Suck up the old brake fluid as much as possible 4 Fill the reservoir with new brake fluid BF Brake fluid DOT 4 5 Connect a clear hose to the air b...

Page 349: ...ON The seal washers should be replaced with the new ones to prevent fluid leakage 1 Install the front brake hose Refer to Front Brake Hose Routing Diagram Page4A 1 2 Bleed air from the front brake system Refer to Air Bleeding from Brake Fluid Circuit Page4A 4 3 Reinstalled remove the parts Rear Brake Hose Removal and Installation B705H14106022 Removal 1 Remove the right foot board Refer to Footboa...

Page 350: ...er Cylinder Components B705H14106023 a 2 1 3 5 4 b 6 FWD FWD I705H1410026 06 1 Reservoir cap 4 Master cylinder 10 N m 1 0 kgf m 7 0 lb ft Do not reuse 2 Plate 5 Piston Cup set 23 N m 2 3 kgf m 16 5 lb ft 3 Diaphragm 6 Brake hose union bolt Apply brake fluid ...

Page 351: ... hose union bolt and disconnect the brake hose 6 Remove the master cylinder assembly Installation Install the front brake master cylinder in the reverse order of removal Pay attention to the following points When installing the master cylinder 1 onto the handlebars 2 align the master cylinder holder s mating surface A with the punch mark B on the handlebars 2 and tighten the upper holder bolt firs...

Page 352: ...ront Master Cylinder Brake Lever Disassembly and Assembly B705H14106024 Refer to Front Brake Master Cylinder Assembly Removal and Installation Page4A 8 Disassembly 1 Remove the dust cover 1 brake lever 2 and brake light switch 3 2 Remove the reservoir cap 4 plate 5 and diaphragm 6 3 Pull out the dust boot 7 and remove the snap ring 8 using the special tool Special tool 09900 06108 Snap ring pliers...

Page 353: ...with the hole in the master cylinder Apply grease to the brake lever pivot bolt Apply grease to the contact point between piston and brake lever Grease 99000 25100 SUZUKI Silicone Grease or equivalent Tightening torque Brake lever pivot bolt 1 0 N m 0 1 kgf m 0 72 lb ft Brake lever pivot bolt lock nut 6 0 N m 0 6 kgf m 4 5 lb ft Front Master Cylinder Parts Inspection B705H14106025 Refer to Front M...

Page 354: ...er Cylinder Components B705H14106026 a 2 1 3 4 5 b 6 FWD FWD I705H1410027 04 1 Reservoir cap 4 Master cylinder 10 N m 1 0 kgf m 7 0 lb ft Do not reuse 2 Plate 5 Piston Cup set 23 N m 2 3 kgf m 16 5 lb ft 3 Diaphragm 6 Brake hose union bolt Apply brake fluid ...

Page 355: ...e union bolt to the specified torque CAUTION The seal washers should be replaced with the new ones to prevent fluid leakage Tightening torque Brake hose union bolt b 23 N m 2 3 kgf m 16 5 lb ft Bleed air from the brake system Refer to Air Bleeding from Brake Fluid Circuit Page4A 4 Rear Master Cylinder Brake Lever Disassembly and Assembly B705H14106028 Refer to Rear Brake Master Cylinder Assembly R...

Page 356: ...Tightening Torque Specifications in Section 0C Page0C 7 Item Standard Limit Master cylinder bore Front Rear 12 700 12 743 0 500 0 502 Master cylinder piston diameter Front Rear 12 657 12 684 0 498 0 499 Brake fluid type DOT 4 Fastening part Tightening torque Note N m kgf m lb ft Air bleeder valve Front brake 6 0 0 6 4 5 Page4A 5 Page4A 6 Air bleeder valve Rear brake 6 0 0 6 4 5 Page4A 5 Page4A 6 M...

Page 357: ...ing Front Brake Master Cylinder Components Page4A 7 Rear Brake Master Cylinder Components Page4A 11 Special Tool B705H14108002 Material SUZUKI recommended product or Specification Note Brake fluid DOT 4 Page4A 5 Page4A 10 Grease SUZUKI Silicone Grease or equivalent P No 99000 25100 Page4A 10 09900 06108 09900 25008 Snap ring pliers Multi circuit tester set Page4A 9 Page4A 3 ...

Page 358: ...r valve 8 Pin bolt 18 N m 1 8 kgf m 13 0 lb ft 2 Pad mounting pin 9 Washer 35 N m 3 5 kgf m 25 5 lb ft 3 Brake pad spring 10 Bracket 23 N m 2 3 kgf m 16 5 lb ft 4 Piston seal 11 Front brake pad set Apply thread lock to thread part 5 Dust seal 12 Front brake disc Apply brake fluid 6 Piston 6 N m 0 6 kgf m 4 5 lb ft Do not reuse 7 Boot 18 N m 1 8 kgf m 13 0 lb ft ...

Page 359: ...in the following procedures CAUTION Do not operate the brake lever while removing the caliper 1 Loosen the front brake pad mounting pins 1 2 Remove the front brake caliper mounting bolts 2 3 Remove the front brake caliper 4 Remove the front brake pad mounting pins 5 Remove the front brake pads 6 Disassemble the shims from the front brake pads 7 Clean up the caliper especially around the caliper pi...

Page 360: ...2 Remove the brake hose from the caliper by removing the union bolt 1 and catch the brake fluid in a suitable receptacle NOTE Place a rag underneath the union bolt on the brake caliper to catch any spilt brake fluid Slightly loosen the brake pad mounting pins 2 to facilitate later disassembly if necessary 3 Remove the brake caliper by removing the caliper mounting bolts 3 4 Remove the front brake ...

Page 361: ... painted surfaces Check the brake hose and hose joints for cracks and fluid leakage Front Brake Caliper Disassembly and Assembly B705H14206013 Refer to Front Brake Caliper Removal and Installation Page4B 3 Disassembly 1 Remove the front brake pads Refer to Front Brake Caliper Removal and Installation Page4B 3 2 Remove the front brake pad spring 3 Place a rag over the pistons to prevent it from pop...

Page 362: ...se the specified brake fluid Never use different types of fluid or cleaning solvent such as gasoline kerosine or the others Apply the brake fluid to piston seals 1 and dust seals 2 CAUTION Replace the piston seals 1 and dust seals 2 with the new ones BF Brake fluid DOT 4 Install the piston seals as shown in the figure Tightening torque Pin bolt a 18 N m 1 8 kgf m 13 0 lb ft Front Brake Caliper Par...

Page 363: ...sure that the brake discs are clean and free of any grease Apply thread lock to the brake disc bolts and tighten them to the specified torque Thread lock cement 99000 32130 Thread Lock Cement Super 1360 or equivalent Tightening torque Brake disc bolt a 23 N m 2 3 kgf m 16 5 lb ft Front Brake Disc Inspection B705H14206002 Brake Disc Thickness Check the brake disc for damage or cracks and measure th...

Page 364: ...ed in the following Front Brake Components Page4B 1 Reference For the tightening torque of fastener not specified in this section refer to Tightening Torque Specifications in Section 0C Page0C 7 A I649G1420020 02 Item Standard Limit Brake disc thickness Front 4 5 0 2 0 18 0 008 4 0 0 16 Rear 5 0 0 2 0 20 0 008 4 5 0 18 Brake disc runout 0 30 0 01 Brake caliper cylinder bore Front 25 400 25 450 1 0...

Page 365: ...t Brake Components Page4B 1 Special Tool B705H14208002 Material SUZUKI recommended product or Specification Note Brake fluid DOT 4 Page4B 5 Page4B 5 Thread lock cement Thread Lock Cement Super 1360 or equivalent P No 99000 32130 Page4B 6 09900 20205 09900 20607 Micrometer 0 25 mm Dial gauge 1 100 mm 10 mm Page4B 6 Page4B 7 09900 20701 Magnetic stand Page4B 7 ...

Page 366: ...D I705H1430001 02 1 Lock nut 12 Bracket 23 Brake pad 2 Arm 13 Pad mounting pin 22 N m 2 2 kgf m 16 0 lb ft 3 Adjuster 14 Piston Upper side 23 N m 2 3 kgf m 16 5 lb ft 4 Brake lock shaft 15 Dust seal 18 N m 1 8 kgf m 13 0 lb ft 5 O ring 16 Piston seal 23 N m 2 3 kgf m 16 5 lb ft 6 Brake lock housing bolt 17 Piston Lower side Apply silicone grease to sliding surface ...

Page 367: ...g the caliper Refer to Rear Brake Components Page4C 1 1 Remove the caliper mounting bolts 1 2 Remove the pad pins 2 and brake pads 3 3 Clean up the caliper especially around the pistons 4 With the caliper piston front side pushed back into the caliper force the other caliper piston rear side also into the caliper by turning it clockwise CAUTION When pushing on the caliper piston rear side keep hol...

Page 368: ... lb ft NOTE After replacing the brake pads pump the brake lever several times in order to operate the brake correctly and then check the brake fluid level Rear Brake Caliper Removal and Installation B705H14306006 Removal 1 Drain the brake fluid Refer to Brake Fluid Replacement in Section 4A Page4A 5 2 Remove the brake hose from the caliper by removing the union bolt 1 and catch the brake fluid in ...

Page 369: ...er Refer to Brake System Inspection in Section 0B Page0B 13 Check the brake fluid leakage and brake operation WARNING Brake fluid if it leaks will interfere with safe running and discolor painted surfaces Check the brake hose and hose joints for cracks and fluid leakage Rear Brake Caliper Disassembly and Assembly B705H14306007 Refer to Rear Brake Caliper Removal and Installation Page4C 3 1 Remove ...

Page 370: ...ter 7 arm 8 and brake lock shaft 9 Assembly Assemble the caliper in the reverse order of disassembly Pay attention to the following points Assemble the gasket 1 CAUTION Replace the gasket with a new one Apply thread lock to the brake lock housing bolts 2 and tighten them to the specified torque Thread lock cement 99000 32130 THREAD LOCK CEMENT SUPER 1360 or equivalent Tightening torque Brake lock ...

Page 371: ...lock nut and spring temporarily Grease 99000 25100 SUZUKI Silicone Grease or equivalent Wash the bore and piston of the caliper with specified brake fluid Particularly wash the dust seal groove and piston seal groove BF Brake fluid DOT 4 CAUTION Wash the caliper components with fresh brake fluid before reassembly Never use cleaning solvent or gasoline to wash them Do not wipe the brake fluid off a...

Page 372: ... grease to inside of the boot and caliper bracket pins and install them Grease 99000 25100 SUZUKI Silicone Grease or equivalent Brake Caliper Piston Disassembly and Assembly B705H14306012 Refer to Rear Brake Caliper Disassembly and Assembly Page4C 4 Disassembly 1 Remove the snap ring 1 CAUTION Use caution when removing the snap ring as the parts inside may fly out of position 2 Remove the spring 2...

Page 373: ...inder Inspect the brake caliper cylinder sliding face and oil seal groove for wear or other damage If any damage is found replace the caliper with a new one Brake Caliper Piston Inspect the brake caliper piston sliding face for any scratches or other damage If any damage is found replace the piston with a new one Brake Caliper Piston Inspect the brake caliper piston sliding face and oil seal groov...

Page 374: ... Rear Brake Disc Inspection B705H14306002 Brake Disc Thickness Check the brake disc for damage or cracks and measure the thickness using the micrometer Replace the brake disc if the thickness is less than the service limit or if defect is found Special tool A 09900 20205 Micrometer 0 25 mm Brake disc thickness Service limit Rear 4 5 mm 0 18 in Brake Disc Runout 1 Remove the rear brake caliper Refe...

Page 375: ...pecial Tool B705H14308002 Fastening part Tightening torque Note N m kgf m lb ft Pad mounting pin 18 1 8 13 0 Page4C 3 Caliper mounting bolt 23 2 3 16 5 Page4C 3 Page4C 4 Brake hose union bolt 23 2 3 16 5 Page4C 4 Brake lock housing bolt 22 2 2 16 0 Page4C 5 Brake disc bolt 23 2 3 16 5 Page4C 9 Material SUZUKI recommended product or Specification Note Brake fluid DOT 4 Page4C 6 Page4C 7 Grease SUZU...

Page 376: ...automatically from sleeve piston to adjust bolt The adjust bolt presses brake pad to brake disk through the adjust nut caliper piston In this bout the adjust bolt and adjust nut move together with the relation as shown in the figure When releasing the brake lock lever each part return to home position the caliper piston will be returned by an elasticity transform of piston seal the adjust bolt wil...

Page 377: ...5 4 6 8 9 A 7 10 11 B I705H1440011 04 4 Brake pad 9 Sleeve piston 5 Caliper piston 10 Brake lock adjuster 6 Adjust nut 11 Brake lock arm 7 Adjust bolt A Thread 8 Adjust bolt spring B The adjust bolt presses the adjust nut ...

Page 378: ...ce between brake pad and brake disk Operation Normal Condition Braking The hydraulic pressure by brake lever operation acts on the adjust nut caliper piston The adjust bolt threads and adjust nut threads have a clearance The piston stroke when braking is shorter than clearance thus the braking operation will finish without automatic brake lock adjuster system operation 2 1 3 A B I705H1440012 03 1 ...

Page 379: ... adjust bolt and adjust nut Only the adjust bolt turns C because the caliper piston adjust nut is fixed to the brake pad with caliper piston groove and pad boss at D Thus the adjust bolt keeps original position with rotating as well as the caliper piston adjust nut moves outside The adjust bolt stops rotating once the brake pad to disc clearance become zero so the automatic adjuster operation is c...

Page 380: ...a force D after that The adjust bolt stops after the adjust bolt nut clearance becomes zero On this account the caliper piston adjust nut can not return back E using the elasticity transform of piston seal when releasing the brake lever It is the over adjust condition 2 1 3 4 5 A B C E D I705H1440014 02 1 Caliper piston A Rapid braking 2 Piston seal B Rapid rotation 3 Hydraulic pressure C Sudden s...

Page 381: ... and Routing Diagram Parking Brake Cable Brake lock Cable Routing Diagram B705H14402001 6 F H I G I705H1440015 02 6 Spring G Spring compresses I Rotate F Rapid braking H Spring tensions adjuster nut moves 2 1 1 D C A B I705H1440007 03 1 Clamp B Pass the throttle cables through under and inside of the frame Bind the brake lock cable starter motor lead wire and seat lock cable together 2 Wire harnes...

Page 382: ...er to Parking Brake Cable Brake lock Cable Routing Diagram Page4D 6 Removal 1 Remove the front box Refer to Front Box Removal and Installation in Section 9D Page9D 18 2 Loosen the brake lock nut 1 remove the brake lock cable 2 3 Remove the brake hose clamp 4 Remove the lock nut 3 and remove the brake lock arm 4 5 Remove the brake lock cable Refer to Parking Brake Cable Brake lock Cable Routing Dia...

Page 383: ...he front box Refer to Front Box Removal and Installation in Section 9D Page9D 18 8 After installing adjust the brake lock Refer to Brake System Inspection in Section 0B Page0B 13 Specifications Tightening Torque Specifications B705H14407001 Reference For the tightening torque of fastener not specified in this section refer to Tightening Torque Specifications in Section 0C Page0C 7 4 6 5 a 7 I705H1...

Page 384: ...4D 9 Parking Brake ...

Page 385: ...l and Installation 5A 3 Drive V belt Inspection 5A 6 Cooling Fan Filter Inspection 5A 6 Inner Clutch Cover Bearing Inspection 5A 7 Inner Clutch Cover Bering Removal and Installation 5A 7 Movable Drive Face Component 5A 8 Movable Drive Face Disassembly and Assembly 5A 8 Movable Drive Face Parts Inspection 5A 9 Oil Seal Removal and Installation 5A 10 Clutch Shoe Movable Driven Face Components 5A 11 ...

Page 386: ...5 1 Precautions Precautions Precautions Precautions for Transmission Transaxle B705H15000001 Refer to General Precautions in Section 00 Page00 1 ...

Page 387: ...e Train System B705H15102001 2 3 5 6 7 8 9 11 12 10 4 1 A I705H1510001 07 1 Crankshaft 6 Fixed driven face 11 Final gear 2 Movable drive face 7 Driveshaft 12 Rear axle shaft 3 Fixed drive face 8 Clutch shoe A Drive Train route 4 V belt 9 Clutch housing 5 Movable driven face 10 Idle gear ...

Page 388: ... or abnormal contact Replace Spline worn Replace Bearing worn or burned Replace V belt slipping V belt slipping Replace Pulley face worn Replace Clutch slipping Clutch shoe worn Replace Centrifugal weight operation failure Repair or replace V belt worn Replace Clutch dragging Clutch shoe spring fatigued Replace Movable driven face distorted Replace 1 a a 1 a a I705H1510068 02 1 Cushion Stick top o...

Page 389: ... drive face 1 Hold the fixed drive face using the special tools and remove the fixed drive face nut and washer WARNING To prevent the fin from breakage or injury from occurring due to inadvertent slipping engage the tool end with the side of pulley securely and make sure the contact is on a center area of the fin Remove the drive face nut with pressing the special tool to the drive face Special to...

Page 390: ...ously variable automatic transmission in the reverse order of the removal Pay attention to the following points Clutch and movable driven face 1 Assemble the clutch shoe movable driven face assembly and V belt CAUTION Position the V belt so that its arrow points to the engine rotational direction Degrees the V belt contact surface pulley face 2 Fit the V belt by compressing it and pushing open the...

Page 391: ... that the parts are properly fitted with the spline When installing the fixed drive face check that the V belt has a play and the fixed drive face contacts the end of the spacer When installing the fixed drive face nut check that the V belt is not caught in the movable drive face assembly 4 Hold the fixed drive face using the special tools and tighten the fixed drive face nut 4 to the specified to...

Page 392: ...contacted by the face Measure drive V belt width using the vernier calipers Special tool A 09900 20101 Vernier calipers 1 15 mm 150 mm Drive V belt width Standard 25 1 mm 0 99 in Service limit 24 1 mm 0 95 in 3 After inspection install the drive V belt Refer to V belt Type Continuously Variable Automatic Transmission Removal and Installation Page5A 3 Cooling Fan Filter Inspection B705H15106004 Per...

Page 393: ...riable Automatic Transmission Removal and Installation Page5A 3 2 Remove the bearing retainers 1 3 Remove the bearing 2 using the special tool Special tool A 09921 20240 Bearing remover set Installation Install the bearing in the reverse order of removal Pay attention to the following points CAUTION The removed bearing must be replaced with the new ones Apply grease to the bearing and inner clutch...

Page 394: ... Movable Drive Face Component Page5A 8 Disassembly 1 Remove the spacer 1 2 Remove the movable drive face cover 2 3 Remove the movable drive plate 3 and dampers 4 4 Remove the rollers 5 1 Oil seal 6 Damper 2 Movable drive face 7 Movable drive face cover 3 Roller Apply grease 4 Spacer Do not reuse 5 Movable drive plate 2 3 5 4 7 1 1 6 FWD FWD I705H1510016 03 1 I705H1510017 01 2 I705H1510018 04 4 3 I...

Page 395: ...se 99000 25010 SUZUKI SUPER GREASE A or equivalent CAUTION Excess grease should be wiped off 5 Assemble the movable drive plate 4 to movable drive face 2 6 Assemble the movable drive face cover 5 7 Assemble the spacer 6 Movable Drive Face Parts Inspection B705H15106007 Refer to Movable Drive Face Disassembly and Assembly Page5A 8 Inspect the following parts Movable Face Inspect the movable face fo...

Page 396: ... 2 Remove the roller 3 Remove the oil seals 1 and 2 using the special tool Special tool 09913 50121 Oil seal remover CAUTION Care should be used when removing the drive face so as not to cause scratch or other damage on its surface Installation 1 Install the oil seal using the special tool Special tool 09913 70210 Bearing installer set CAUTION Care should be used when installing the drive face so ...

Page 397: ...iven face 15 Clutch housing 2 Snap ring 9 Oil seal 16 Clutch housing nut 3 Bearing 10 O ring 17 Inner clutch cover bearing 4 Fixed driven face 11 Movable driven face seat 105 N m 10 5 kgf m 76 0 lb ft 5 Oil seal 12 Movable driven face spring 85 N m 8 5 kgf m 61 5 lb ft 6 Movable driven pin 13 Clutch shoe assembly Apply grease 7 Movable driven pin spacer 14 Clutch shoe nut Do not reuse ...

Page 398: ...pring compressor B 09920 31020 Extension handle CAUTION Since a high spring force applies to the clutch shoe assembly care must be used so as not to cause the clutch shoe assembly and movable driven face to come off abruptly 3 Remove the clutch shoe plate 2 and spring 3 by loosening the special tool handle slowly CAUTION The clutch shoe cannot be disassembled 4 Remove the movable driven face seat ...

Page 399: ...pecial tool D 09913 70210 Bearing installer set Assembly Refer to Clutch Shoe and Movable Driven Face Parts Inspection Page5A 16 1 Install the bearing 1 to the fixed driven face 2 using a spacer the size being appropriate for outside diameter of the bearing CAUTION Use a new bearing 2 Install the snap ring CAUTION Use a new snap ring 9 8 I705H1510041 01 10 I705H1510042 01 11 C I705H1510043 03 I705...

Page 400: ...on the needle bearing Grease 99000 25010 SUZUKI SUPER GREASE A or equivalent 5 Install the oil seal 4 and O ring 5 to the movable driven face CAUTION Use a new oil seal and O ring 6 Apply the grease both to the lip of oil seal and O ring Grease 99000 25010 SUZUKI SUPER GREASE A or equivalent 7 Apply the grease in the grease groove of movable driven face 6 and sliding face Grease 99000 25010 SUZUKI...

Page 401: ...e of the clutch shoe plate Special tool A 09922 31440 Clutch spring compressor 14 While the special tool handle is being turned in slowly engage two flats D on the end of movable driven face with the same shaped hole E on the clutch shoe plate 15 Check that the pawl on the special tool is securely fitted into the hole on the clutch shoe plate and tighten the clutch shoe nut 11 to the specified tor...

Page 402: ...condition is found replace the part with a new one Play damage operation etc for the center area and the centrifugal weight fulcrum Existence of damage or oil sticking on the clutch shoe Measure the thickness of clutch shoe center area by using vernier calipers Special tool 09900 20101 Vernier calipers 1 15 mm 150 mm Thickness of clutch shoe a Service limit 2 0 mm 0 08 in Movable Driven Face Sprin...

Page 403: ...or the tightening torque of fastener not specified in this section refer to Tightening Torque Specifications in Section 0C Page0C 7 I705H1510060 01 I705H1510061 01 Item Standard Limit Clutch wheel I D 160 0 160 2 6 30 6 31 160 5 6 32 Clutch shoe thickness 3 0 0 12 2 0 0 08 Item Specification Note Primary reduction ratio 1 000 Reduction ratio 2 200 0 839 Secondary reduction ratio 2 214 Final reduct...

Page 404: ...E A or equivalent P No 99000 25010 Page5A 5 Page5A 7 Page5A 9 Page5A 10 Page5A 14 Page5A 14 Page5A 14 Page5A 15 09900 20101 09913 50121 Vernier calipers 1 15 mm 150 mm Oil seal remover Page5A 6 Page5A 16 Page5A 16 Page5A 16 Page5A 10 09913 70210 09920 31020 Bearing installer set Extension handle Page5A 7 Page5A 10 Page5A 13 Page5A 3 Page5A 5 Page5A 12 Page5A 15 09920 53740 09921 20240 Clutch sleev...

Page 405: ...B 1 Handlebars Components 6B 1 Handlebars Removal and Installation 6B 2 Handlebars Inspection 6B 4 Steering Components 6B 5 Steering Removal and Installation 6B 6 Steering Related Parts Inspection 6B 9 Steering System Inspection 6B 9 Steering Stem Bearing Removal and Installation 6B 9 Steering Tension Adjustment 6B 10 Specifications 6B 11 Tightening Torque Specifications 6B 11 Special Tools and Eq...

Page 406: ...6 1 Precautions Precautions Precautions Precautions for Steering B705H16000001 Refer to General Precautions in Section 00 Page00 1 ...

Page 407: ...djust Wobbly Handlebars Loss of balance between right and left front forks Replace fork or adjust fork oil level or replace spring Distorted front fork Repair or replace Distorted front axle or crooked tire Replace Loose steering stem nut Adjust Worn or incorrect tire or wrong tire pressure Adjust or replace Worn bearing race in steering stem Replace Wobbly front wheel Distorted wheel rim Replace ...

Page 408: ...WD FWD FWD FWD I705H1620033 05 1 Throttle grip 6 Handle cover A Apply handle grip bond 2 Rubber grip 7 Handlebar holder Apply thread lock to thread part 3 Handlebar switch box RH 8 Handlebar 23 N m 2 3 kgf m 16 5 lb ft 4 Handlebar switch box LH 9 Handle expander 10 N m 1 0 kgf m 7 0 lb ft 5 Rear view mirror 10 Handle balancer expander ...

Page 409: ...bar balancer 5 6 Remove the grip rubber 6 Right side 1 Remove the rear view mirror 1 2 Disconnect the front brake light switch lead wire couplers 2 3 Remove the front brake master cylinder 3 CAUTION Do not turn the front brake master cylinder upside down 4 Remove the right handlebar switch box 4 5 Remove the handlebar balancer 5 6 Remove the throttle grip 6 Handlebar holder 1 Remove the handlebar ...

Page 410: ...ed before driving Cable routing Refer to Throttle Cable Routing Diagram in Section 1D Page1D 2 Throttle cable play Refer to Throttle Cable Play Inspection and Adjustment in Section 0B Page0B 11 Right side Install the right handlebar switch box 1 to the handlebars by engaging the stopper A with the hole B on the handlebars Adjust the throttle cable play Refer to Throttle Cable Play Inspection and A...

Page 411: ...hten both the bolts to the specified torque Tightening torque Master cylinder bolt a 10 N m 1 0 kgf m 7 0 lb ft Connect the rear brake light switch lead wire couplers Apply a handle grip bond D onto the left handlebar before installing the handlebar grip Handle grip bond Handle grip bond commercial available Handlebars Inspection B705H16206009 Refer to Handlebars Removal and Installation Page6B 2 ...

Page 412: ...per bearing 55 N m 5 5 kgf m 40 0 lb ft 2 Handlebar holder set bolt 8 Lower bearing 30 N m 3 0 kgf m 21 5 lb ft 3 Handlebar holder clamp bolt 9 Steering stem 30 N m 3 0 kgf m 21 5 lb ft 4 Steering stem lock nut 10 Lower inner race Apply grease 5 Steering stem nut 11 Front brake hose cramp Do not reuse 6 Dust seal 23 N m 2 3 kgf m 16 5 lb ft ...

Page 413: ...in Section 2B Page2B 2 4 Remove the front brake hose clamp bolts 1 and remove the cable guide 2 5 Remove the front brake hose clamp 3 6 Remove the front brake hose clamp 4 from the steering stem CAUTION Take care not to make air come in to the front brake system Be careful not to drop the front brake caliper components 7 Loosen the handlebar holder clamp bolts 5 and remove the clamp 6 8 Remove the...

Page 414: ...ling Bearing Apply grease to the bearings races and dust seals before remounting the steering stem Grease 99000 25010 SUZUKI SUPER GREASE A or equivalent Steering stem nut Washer Lock nut Tighten the steering stem nut 1 to the specified torque using the special tools Special tool A 09940 14911 Steering stem nut wrench B 09940 11430 Steering stem nut socket Tightening torque Steering stem nut a 30 ...

Page 415: ...e Lock nut b 30 N m 3 0 kgf m 21 5 lb ft Handlebar holder Install the handlebar holder with the handlebars and tighten the handlebar holder set bolt 1 to the specified torque CAUTION This operation must be performed without causing undue stress to the brake hoses lead wires and throttle cables Tightening torque Handlebar holder set bolt a 23 N m 2 3 kgf m 16 5 lb ft Install the clamp and tighten t...

Page 416: ...h the new ones Steering System Inspection B705H16206013 Refer to Steering System Inspection in Section 0B Page0B 15 Steering Stem Bearing Removal and Installation B705H16206014 Refer to Steering Components Page6B 5 Removal 1 Remove the steering stem Refer to Steering Removal and Installation Page6B 6 2 Remove the dust seal 1 and steering stem upper bearing 2 3 Remove the steering stem lower bearin...

Page 417: ... the steering stem Grease 99000 25010 SUZUKI SUPER GREASE A or equivalent Instal the steering Refer to Steering Removal and Installation Page6B 6 Steering Tension Adjustment B705H16206015 Check the steering movement in the following procedures 1 By supporting the motorcycle with a jack lift the front wheel unit is off the floor 20 30 mm 0 8 1 2 in 2 Check to make sure that the cables and wire harn...

Page 418: ...d range adjustment has been completed NOTE Hold the front fork legs move them back and forth and make sure that the steering is not loose Specifications Tightening Torque Specifications B705H16207001 NOTE The specified tightening torque is also described in the following Handlebars Components Page6B 1 Steering Components Page6B 5 Reference For the tightening torque of fastener not specified in thi...

Page 419: ...o 99000 25010 Page6B 7 Page6B 10 Handle grip bond Handle grip bond commercial available Page6B 4 Thread lock cement Thread Lock Cement Super 1303 or equivalent P No 99000 32030 Page6B 3 09940 11420 09940 11430 Steering stem nut socket Steering stem nut socket Page6B 7 Page6B 8 Page6B 7 Page6B 7 09940 14911 09940 92720 Steering stem nut wrench Spring scale Page6B 7 Page6B 7 Page6B 7 Page6B 8 Page6B...

Page 420: ...6B 13 Steering Handlebar ...

Page 421: ...rake lock Switch Inspection 9B 11 Trunk Box Switch Inspection 9B 11 Specifications 9B 12 Service Data 9B 12 Special Tools and Equipment 9B 12 Special Tool 9B 12 Combination Meter Fuel Meter Horn 9C 1 Repair Instructions 9C 1 Combination Meter Components 9C 1 Combination Meter Removal and Installation 9C 1 Combination Meter Disassembly and Assembly 9C 1 Combination Meter Inspection 9C 2 Fuel Level ...

Page 422: ...stallation 9D 19 Frame Cover Removal and Installation 9D 20 Helmet Box Removal and Installation 9D 21 Footboard Removal and Installation 9D 21 Special Tools and Equipment 9D 22 Recommended Service Material 9D 22 Body Structure 9E 1 Repair Instructions 9E 1 Body Frame Construction 9E 1 Engine Mounting Bracket Bushing Replacement 9E 2 Engine Mounting Bushing Replacement 9E 2 Side stand Construction ...

Page 423: ...System B705H19000001 Refer to General Precautions in Section 00 Page00 1 and Precautions for Electrical Circuit Service in Section 00 Page00 2 Component Location Electrical Components Location B705H19003001 Refer to Electrical Components Location in Section 0A Page0A 7 ...

Page 424: ...9A 1 Wiring Systems Wiring Systems Schematic and Routing Diagram Wiring Diagram B705H19102002 Refer to Wire Color Symbols in Section 0A Page0A 5 ...

Page 425: ...W W R Gr B W B Lg P W G W B G B W G B W B W B B W R B W B B R Bl Y R B W B Lg O B O W Y B O Y W O G W B B Lg Lbl Gr P O B O W Y G O R Y W B R B Bl O G B W B Bl O G B Bl B W Lg Lbl B Y W B Bl B W Dg P Dbr Lg Lbl B O R W Y W B O G B Y B Y B B B B B Y W Y W W R Bl O Y O O G O Bl G O Y O B BR Lbl B W O Y Y Bl B W G Y O Y Y B G R Y R Gr W R Br W B Br W Gr B W O W B Br B Y Y W B Br G B R Bl G W Y Y Y Y ...

Page 426: ...R O W W R Gr B W Br B B W B W O Y G B W G B W B W B B W R B W B B R Bl Y R B W B Lg O B O W Y B O Y W O G W B B Lg Lbl Gr P O B O W Y G O R Y W B R B Bl O G B W B Bl O G B Bl B W Lg Lbl B Y W B Bl B W Dg P Dbr Lg Lbl B O R W Y W B O G B Y B Y Y W Y W W R Bl O Y O O G O Bl G O Y O B Br Lbl B W O Y Y R Gr W R Br W B Br W Gr B W O W B Br B Y Y W B Br G B R Bl G W Y Y Y Y Y Y R B W B W Y G B W B W P B...

Page 427: ...ator lead wires and HO2 sensor lead wire with no slack 5 ECM 16 ISC valve A Cut the surplus of clamp 6 White tape 17 Fuel injector B Pass the lead wires through inside the cable guide 7 Regulator rectifier read wire 18 IAP sensor C Pass the lead wires through outside the hoses 8 Clamp Clamp the wiring harness and battery lead wire 19 IAT sensor D To IAT sensor 9 Clamp Clamp the left and right hand...

Page 428: ...e starter motor lead wire and wiring harness 6 Ignition coil C To main harness 3 Clamp Clamp the starter motor lead wire and brake lock cable 7 Air cleaner D To license light 4 Clamp Clamp the rear brake hose brake lock cable and starter motor lead wire A Pass the wiring harness through front of seat lock cable a 2 3 mm 0 08 0 12 in ...

Page 429: ...or 5 Outer clutch cover 11 N m 1 1 kgf m 8 0 lb ft 2 Generator cover 6 Speed sensor 160 N m 16 0 kgf m 111 5 lb ft 3 Battery lead wire Tighten the rear side bolt first 3 N m 0 3 kgf m 2 0 lb ft 4 Starter motor lead wire 6 N m 0 6 kgf m 4 5 lb ft 10 N m 1 0 kgf m 7 0 lb ft ...

Page 430: ...9A 7 Wiring Systems 2 1 3 I705H1910904 01 1 Ambient air temperature sensor 3 Coupler Do not attempt to disconnect the coupler from the sensor 2 Clamp ...

Page 431: ...ing torque is also described in the following Wiring Harness Routing Diagram Page9A 4 Reference For the tightening torque of fastener not specified in this section refer to Tightening Torque Specifications in Section 0C Page0C 7 Item Standard Specification Note Fuse size Headlight HI 10 A LO 10 A Meter 15 A Ignition 10 A Signal 15 A Fan motor 10 A Main 30 A ...

Page 432: ...t Components B705H19206001 8 6 9 7 3 4 10 6 7 9 8 2 1 10 5 FWD FWD I705H1920011 03 1 Front combination light RH 5 Headlight high beam bulb 9 Socket 2 Front combination light LH 6 Position light bulb 10 Cover 3 Headlight low beam bulb 7 Socket 4 Adapter 8 Front turn signal light bulb ...

Page 433: ...inspect the headlight beam Refer to Headlight Beam Adjustment Page9B 4 Headlight Bulb Turn Signal Light Bulb Position Light Bulb Replacement B705H19206015 Refer to Front Combination Light Components Page9B 1 CAUTION A fouled glass can cause damage to the bulb when lit If the bulb is contacted with bare a hand wipe clean with a cloth damped with alcohol or detergent Do not use the bulb of a wattage...

Page 434: ...n in Section 9D Page9D 14 2 Remove the socket 1 by turning it counter clockwise 3 Replace the front turn signal light bulb 2 4 After finishing the front turn signal light bulb replacement reinstall the removed parts Position Light Bulb Replace the position light bulb in the following procedures NOTE To replace the positioning light bulb the same procedures is applicable to both the right and left ...

Page 435: ...adjust the headlight beam adjust the beam horizontally first then adjust vertically Rear Reflector Rear Combination Light License Light Components B705H19206016 1 Horizontal adjuster 2 Vertical adjuster 2 1 I705H1920043 01 3 2 3 2 1 5 6 4 FWD FWD I705H1920017 01 1 Rear combination light 3 Rear turn signal light bulb 5 License light bulb 2 Brake light taillight bulb 4 License light lens 6 Socket ...

Page 436: ... Page9D 20 2 Remove the rear combination light NOTE Care should be used not to cause scratch or damage to the frame cover and rear combination light Installation Install the rear combination light in the reverse order of removal License Light Removal 1 Remove the lower frame cover Refer to Lower Frame Cover Removal and Installation in Section 9D Page9D 19 2 Remove the license plate light cover 1 3...

Page 437: ...illight bulb in the following procedures 1 Remove the lower frame cover Refer to Lower Frame Cover Removal and Installation in Section 9D Page9D 19 2 Remove the socket 1 by turning it counter clockwise 3 Replace the brake light taillight bulb 4 After finishing the brake light and taillight bulb replacement reinstall the removed parts Rear Turn Signal Light Bulb Replace the rear turn signal light b...

Page 438: ...e bulb turn signal switch and circuit connection are OK the turn signal relay may be faulty therefore replace the turn signal side stand relay with a new one Refer to Turn Signal Side stand Relay Removal and Installation Page9B 7 Turn Signal Side stand Relay Removal and Installation B705H19206020 Removal 1 Remove the meter panel Refer to Meter Panel Removal and Installation in Section 9D Page9D 14...

Page 439: ... and Installation in Section 6B Page6B 2 Special tool 09900 25008 Multi circuit tester set Tester knob indication Continuity 4 After finishing the turn signal switch inspection reinstall the removed parts Passing Light Switch Inspection B705H19206024 Inspect the passing light switch in the following procedures 1 Remove the meter panel Refer to Meter Panel Removal and Installation in Section 9D Pag...

Page 440: ...nt Brake Light Switch Inspection B705H19206029 Refer to Brake Light Switch Inspection in Section 4A Page4A 3 Hazard Switch Inspection B705H19206031 Inspect the hazard switch in the following procedures 1 Remove the meter panel Refer to Meter Panel Removal and Installation in Section 9D Page9D 14 2 Disconnect the right handlebar switch coupler 1 and 2 3 Inspect the hazard switch for continuity with...

Page 441: ...stop switch inspection reinstall the removed parts Starter Button Inspection B705H19206026 Inspect the starter button in the following procedures 1 Remove the meter panel Refer to Meter Panel Removal and Installation in Section 9D Page9D 14 2 Disconnect the right handlebar switch coupler 1 and 2 3 Inspect the starter button for continuity with the tester If any abnormality is found replace the rig...

Page 442: ...s 1 3 Inspect the brake lock switch for continuity with the tester If any abnormality is found replace the brake lock switch assembly with a new one Special tool 09900 25008 Multi circuit tester set Tester knob indication Continuity 4 After finishing the brake lock switch inspection reinstall the removed parts Trunk Box Switch Inspection B705H19206027 Inspect the trunk box switch in the following ...

Page 443: ...fication E 02 19 24 54 E 03 28 33 Headlight HI 60 55 LO 55 Parking position light 5 x 2 Brake light Taillight 21 5 x 2 Turn signal light 21 x 2 Front 21 x 2 Rear 27 8 x 2 Front 21 x 2 Rear License plate light 5 Trunk light 5 09900 25008 Multi circuit tester set Page9B 8 Page9B 8 Page9B 8 Page9B 9 Page9B 9 Page9B 10 Page9B 10 Page9B 11 Page9B 11 Page9B 11 ...

Page 444: ...mbination meter assembly 1 Installation Install the combination meter in the reverse order of the removal Combination Meter Disassembly and Assembly B705H19306002 Refer to Combination Meter Removal and Installation Page9C 1 Disassembly Disassemble the combination meter Refer to Combination Meter Components Page9C 1 Assembly Assemble the combination meter Refer to Combination Meter Components Page9...

Page 445: ...es not light up inspect the wiring harness and connectors If no abnormal condition is found replace the combination meter Fuel Level Meter Inspection B705H19306016 Inspect the fuel level meter in the following procedures 1 Remove the foot board and fuel pump coupler 1 Refer to Footboard Removal and Installation in Section 9D Page9D 21 2 Check that the fuel level meter operates properly when a resi...

Page 446: ...tion in Section 9B Page9B 11 Ignition Switch Removal and Installation B705H19306022 Refer to Ignition Switch Removal and Installation in Section 1H Page1H 8 Horn Inspection B705H19306023 Horn Button Inspection NOTE If the horn sound condition is normal it is not necessary to inspect the horn button continuity Refer to Horn Button Inspection in Section 9B Page9B 9 Horn Inspection Inspect the horn i...

Page 447: ...Specification E 02 19 24 54 E 03 28 33 Speedometer tachometer light LED Engine coolant temp gauge light LED Fuel level gauge light LED Immobilizer indicator light LED Oil change indicator LCD FI indicator light LED Brake lock indicator light LED High beam indicator light LED Turn signal indicator light LED x 2 ...

Page 448: ...ock cable No 1 2 Seat lock cable No 2 B Pass the seat lock cable No 1 through inside of the frame 3 Brake lock cable C Pass the cables through inner side of the frame 4 Starter motor lead wire D Pass the cables through bottom and inner side of the frame 5 Clamp Clamp the brake lock cable starter motor lead wire and seat lock cable E Seat lock cable set position 6 Seat lock cable F Change set posit...

Page 449: ...over 13 Center frame cover 19 Rear handlebar cover 2 Front leg shield cover 8 Front frame cover 14 Lower frame cover 20 Front panel 3 Front leg shield 9 Center leg cover 15 Frame cover 21 Front box 4 Lower leg shield 10 Footboard 16 Meter panel 22 Side leg shield 5 Helmet box 11 Under cover 17 Upper meter panel 6 Pillion rider handle 12 Pillion rider handle cover 18 Front handlebar cover ...

Page 450: ... 15 Frame cover Rear combination light 10 Footboard 5 Helmet box assembly 9 Center leg cover 21 Front box assembly 2 Front leg sheild cover 1 Wind screen 20 Front panel 16 Meter panel assembly 3 Front leg shield 4 Lower leg shield 13 Center frame cover 14 Lower frame cover 22 Side leg shield Speedometer 11 Under cover 18 Rear handlebar cover 19 Front handlebar cover I705H1940049 05 ...

Page 451: ...uctions Exterior Parts Components B705H19406002 1 2 3 4 5 7 6 8 I705H1940053 02 1 Wind screen 3 Meter panel assembly 5 Front leg shield cover 7 Front box assembly 2 Upper meter panel 4 Front panel 6 Front leg shield 8 Lower leg shield ...

Page 452: ... 12 I705H1940052 01 1 Frame cover RH 4 Side leg shield RH 7 Frame cover LH 10 Footboard LH 2 Footboard RH 5 Center frame cover 8 Lower frame cover 11 Side leg shield LH 3 Center leg cover RH 6 Front frame cover 9 Center leg cover 12 Under cover ...

Page 453: ... 02 1 Front reflex reflector For E 03 28 33 B Set the reflector to the edge of front leg shield A Adhere the front reflex reflector on to the front leg shield C Align the projection of reflector with the joint part of meter panel and front box ...

Page 454: ... 7 9 8 10 6 a b c I705H1940055 04 1 Fuel lid 6 Cushion a 0 mm 2 Front box inner cover LH 7 Fuel lid b 0 3 mm 0 0 12 in 3 Battery cover 8 Inner cushion c 4 mm 0 16 in 4 Front box inner cover RH 9 Cushion 5 Front box 10 Front box lid ...

Page 455: ...Exterior Parts 9D 8 1 2 2 3 A a 2 I705H1940060 01 1 Front panel box lid a 2 mm 0 08 in 2 Cushion A Do not exchange the right one and left one 3 Front panel box Apply silicone grease ...

Page 456: ...9D 9 Exterior Parts 1 2 A I705H1940056 03 1 Pillion rider handle 2 Pillion rider handle cover A To frame ...

Page 457: ... 12 6 11 I705H1940061 02 1 Seat molding 6 Mat 11 Lower helmet box 2 Helmet box front cover 7 Frame 12 License plate light cover 3 Helmet box lid LH 8 Seat a 0 1 mm 0 0 04 in 4 Helmet box lid RH 9 Tool band A Outside 5 Upper helmet box 10 Seat damper ...

Page 458: ... 1 FWD 1 A B 1 FWD 1 C 2 I705H1940063 02 1 Fuel tray mudguard sheet B Face the clamp locking part inside and clamp end backward 2 Frame C Clamp the seat with the wiring harness A The seat must be assembled behind the horn ...

Page 459: ...Exterior Parts 9D 12 Inner Cover Construction B705H19406025 1 2 2 2 2 2 1 I705H1940062 01 1 Inner cover 2 Clamp Clamp ends should face inside The clamps are not fastened too much ...

Page 460: ...stallation B705H19406004 Removal Pull out the upper meter panel 1 Installation Push in the upper meter panel 1 Front Leg Shield Cover Removal and Installation B705H19406005 Removal 1 Remove the upper meter panel Refer to Upper Meter Panel Removal and Installation Page9D 13 2 Remove the screws 3 Remove the front leg shield cover 1 Installation Install the front leg shield cover in the reverse order...

Page 461: ... reverse order of removal Meter Panel Removal and Installation B705H19406008 Removal 1 Remove the wind screen Refer to Wind Screen Removal and Installation Page9D 14 2 Remove the screws and detach the meter panel assembly 1 forward 3 Disconnect the meter coupler 2 and remove the meter panel Installation Install the meter panel in the reverse order of removal Front Leg Shield Removal and Installati...

Page 462: ... Side Leg Shield Removal and Installation B705H19406010 Removal 1 Remove the left and right rear floor mats 1 fasteners and screws 2 Remove the left and right side leg shields 2 Installation Install each of the side leg shield in the reverse order of removal I705H1940014 01 I705H1940015 01 3 4 4 6 5 5 I705H1940016 02 1 I705H1940017 01 I705H1940018 01 2 I705H1940019 04 2 I705H1940020 04 ...

Page 463: ...r Leg Shield Removal and Installation B705H19406012 Removal 1 Remove the front leg shield Refer to Front Leg Shield Removal and Installation Page9D 14 2 Remove the fasteners 3 Remove the lower leg shield 1 Helmet Box Front Cover Removal and Installation B705H19406013 Removal 1 Open the seat 2 Remove the helmet box front cover 1 Installation Install the helmet box front cover in the reverse order o...

Page 464: ... Page9D 17 2 Disconnect the helmet box light coupler 1 3 Disengage the seat damper 2 4 Remove the seat by removing the nuts 3 Installation Install the seat in the reverse order of removal Center Leg Cover Removal and Installation B705H19406016 Removal 1 Remove the front frame cover Refer to Front Frame Cover Removal and Installation Page9D 17 2 Remove the left and right center leg cover 1 CAUTION ...

Page 465: ... and Installation Page9D 17 2 Remove the ambient temperature sensor 1 from the front box 3 Remove the ECM 2 from the front box 4 Remove the front box inner cover 3 and disconnect the power terminal coupler 4 5 Remove the front box 5 by removing the screws and bolts Installation Install the front box in the reverse order of removal 1 I705H1940030 02 2 I705H1940032 02 4 3 I705H1940033 02 I705H194003...

Page 466: ...l and Installation Page9D 19 2 Remove the pillion rider handle 1 Installation Install the pillion rider handle in the reverse order of removal Center Frame Cover Removal and Installation B705H19406020 Removal Pull out the center frame cover 1 Installation Install the center frame cover in the reverse order of removal Lower Frame Cover Removal and Installation B705H19406021 Removal Pull out the low...

Page 467: ... Cover Removal and Installation Page9D 19 and Lower Frame Cover Removal and Installation Page9D 19 2 Remove the fasteners and remove the footboard cover 1 LH only 3 Disconnect the rear combination light coupler 2 4 Remove the license plate light cover 3 and remove the left and right frame covers along with the rear combination light assembly 5 Remove the frame covers 4 from the rear combination li...

Page 468: ...x in the reverse order of removal Footboard Removal and Installation B705H19406024 Removal 1 Remove the side leg shields front box and frame covers Refer to Side Leg Shield Removal and Installation Page9D 15 Front Box Removal and Installation Page9D 18 and Frame Cover Removal and Installation Page9D 20 2 Remove the left and right footboards Installation Install the footboard in the reverse order o...

Page 469: ...Exterior Parts 9D 22 Special Tools and Equipment Recommended Service Material B705H19408001 NOTE Required service material is also described in the following Exterior Parts Components Page9D 4 ...

Page 470: ... 3 3 5 5 6 7 10 11 11 12 12 4 4 a 8 b 9 FWD FWD I705H1950003 02 1 Frame 6 Collar 11 Bearing 2 Crankcase bracket bolt 7 Crankcase bracket 12 Collar 3 Bushing 8 Crankcase bracket nut 102 N m 10 2 kgf m 73 5 lb ft 4 Bearing 9 Rubber damper bolt 102 N m 10 2 kgf m 73 5 lb ft 5 Spacer 10 Rubber damper ...

Page 471: ...f necessary Refer to Body Frame Construction Page9E 1 Engine Mounting Bushing Replacement B705H19506012 Replace the engine mounting bushing if necessary Refer to Body Frame Construction Page9E 1 Side stand Construction B705H19506015 1 2 a I705H1950001 03 1 Outer spring 2 Inner spring 50N m 5 0 kgf m 36 0 lb ft Apply grease ...

Page 472: ...ion Page9E 2 Installation Install the side stand Refer to Side stand Construction Page9E 2 Center Stand Construction B705H19506017 a a b c d 1 3 2 4 5 I705H1950002 03 1 Center stand 5 Cushion d 57 mm 2 24 in 2 Center stand inner spring a 60 mm 2 36 in 50 N m 5 0 kgf m 36 0 lb ft 3 Center stand outer spring b 57 mm 2 24 in Apply grease to sliding surface 4 Frame c 60 mm 2 36 in ...

Page 473: ... Torque Specifications B705H19507001 NOTE The specified tightening torque is also described in the following Body Frame Construction Page9E 1 Side stand Construction Page9E 2 Center Stand Construction Page9E 3 Reference For the tightening torque of fastener not specified in this section refer to Tightening Torque Specifications in Section 0C Page0C 7 Special Tools and Equipment Recommended Service...

Page 474: ...Prepared by April 2006 Part No 99500 34100 01E Printed in Japan 476 ...

Page 475: ...Printed in Japan K7 ...

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