Suzuki Burgman Series Owner'S Manual Download

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3-5

KEY

This motorcycle comes equipped
with a pair of identical ignition
keys. Keep the spare key in a safe
place.

The key number is stamped on a
plate provided with the keys. This
number is used when making
replacement keys. Please write
your key number in the box pro-
vided for your future reference.

IGNITION SWITCH

To open the ignition key-hole
shutter:

1. Match the ignition key head to

the square hole on the ignition
switch.

2. Turn the key to open and close

the key-hole shutter.

NOTE: Apply anti-freeze lubricant
when atmospheric temperature
drops below freezing to avoid igni-
tion key-hole shutter freezing.

Key No.:

Summary of Contents for Burgman Series

Page 1: ...ssenger vehicle or off road vehicle can expose you to chemicals including engine exhaust carbon monoxide phthalates and lead which are known to the State of California to cause cancer and birth defects or other reproductive harm To minimize exposure avoid breathing exhaust do not idle the engine except as necessary service your vehicle in a well ventilated area and wear gloves or wash your hands f...

Page 2: ...d in this manual By follow ing these instructions explicitly you will ensure a long trouble free operating life for your motorcycle This motorcycle also conforms to the U S Environmental Protection Agency emission regulations which apply to new motorcycles The proper adjustment of engine components is necessary for this motorcycle to comply with the EPA regulations Therefore please follow the main...

Page 3: ...our motorcycle Suzuki reserves the right to make production changes at any time without notice and without incur ring any obligation to make the same or similar changes to vehi cles previously built or sold Suzuki Motor Corporation believes in conservation and pro tection of Earth s natural resources To that end we encourage every vehicle owner to recycle trade in or properly dis pose of as approp...

Page 4: ...ENGINE OIL AND COOLANT RECOMMENDATIONS CONTROLS BREAK IN RUNNING IN AND INSPECTION BEFORE RIDING RIDING TIPS ACCESSORY USE AND MOTORCYCLE LOADING INSPECTION AND MAINTENANCE TROUBLESHOOTING STORAGE PROCEDURE AND MOTORCYCLE CLEANING CONSUMER INFORMATION SPECIFICATIONS INDEX ...

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Page 6: ...ETHING 1 3 SPECIAL SITUATIONS REQUIRE SPECIAL CARE 1 4 KNOW YOUR LIMITS 1 4 BE EXTRA SAFETY CONSCIOUS ON BAD WEATHER DAYS 1 4 PRACTICE AWAY FROM TRAFFIC 1 5 INSPECTION BEFORE RIDING 1 5 ACCESSORIES AND LOADING 1 5 CARRYING A PASSENGER 1 5 MOTORCYCLE SAFETY FOUNDATION S RIDING TIPS AND PRACTICE GUIDE HANDBOOK FOR OWNERS IN USA 1 5 BE STREET SMART 1 6 LABELS 1 6 CONCLUSION 1 6 ...

Page 7: ...Other drivers simply don t always notice motorcyclists Ride defensively Wise motorcy clists use a strategy of assuming they are invisible to other drivers even in broad daylight Pay care ful attention to other motorists especially at intersections because they may not be paying attention to you Select a lane position that gives you the best view of others and other motor ists the best view of you ...

Page 8: ...le of fingers over the lever when riding in traffic and near intersections to give their reaction time a head start Emergency stopping and swerv ing are techniques that you should practice and master before you find yourself in an emergency situation The best place to prac tice such techniques is in a con trolled environment such as the Motorcycle Safety Foundation s MSF rider training courses The...

Page 9: ...traffic visibility and road condi tions your motorcycle and your experience Riding a motorcycle safely requires that your mental and physical skills are fully part of the experience You should not attempt to operate a motor vehi cle especially one with two wheels if you are tired or under the influence of alcohol or other drugs Alcohol illegal drugs and even some prescription and over the counter ...

Page 10: ...might create hazards Aero dynamics handling balance and cornering clearance can suffer and the suspension and tires can be overloaded Read the ACCES SORY USE AND MOTORCYCLE LOADING section CARRYING A PASSENGER Carrying a passenger when done correctly is a great way to share the joy of motorcycling You will have to alter your riding style somewhat since the extra weight of a passenger will affect h...

Page 11: ...tors can best be dealt with by giving every ride your full attention Circumstances beyond your con trol could lead to an accident You need to prepare for the unex pected by wearing a helmet and other protective gear and learn ing emergency braking and swerving techniques to minimize the damage to you and your machine The best way to learn basic riding skills and evasive maneuvers or refresh your o...

Page 12: ...2 1 2 FUEL ENGINE OIL AND COOLANT RECOMMENDATIONS FUEL 2 2 ENGINE OIL 2 4 TRANSMISSION OIL 2 5 FINAL GEAR OIL 2 5 ENGINE COOLANT SOLUTION 2 6 ...

Page 13: ...te higher octane grade gasoline or another brand because there are differences between brands Oxygenated fuels which meet the minimum octane requirement and the requirements described below may be used in your motorcycle without jeopardizing the New Vehicle Limited Warranty or the Emission Control System War ranty NOTE Oxygenated fuels are fuels which contain oxygen carry ing additives such as alc...

Page 14: ...e meets these requirements check with the service station operator or the fuel supplier NOTE To help minimize air pollution Suzuki recommends that you use oxygenated fuels Be sure that any oxygenated fuel you use has octane rat ings of at least 87 pump octane R M 2 method If you are not satisfied with the drivability of your motorcycle when you are using an oxy genated fuel or if engine ping ing i...

Page 15: ...AR has been specially formulated for your SUZUKI product and contributes to the desired motorcycle perfor mance and ideal riding experi ence SAE Engine Oil Viscosity Suzuki recommends the use of SAE 10W 40 engine oil If SAE 10W 40 engine oil is not available select an alternative according to the following chart JASO T903 The JASO T903 standard is an index to select engine oils for 4 stroke motorc...

Page 16: ... clutch performance API SG SH SJ SL SM or SN Recommended API SH SJ SL or SM API SN Not recommended TRANSMISSION OIL Use a good quality SAE 10W 40 multi grade motor oil FINAL GEAR OIL Use an SAE90 hypoid gear oil which is rated GL 5 under the API classification system If you oper ate the motorcycle where ambient temperature is below 0 C 32 F use an SAE80 hypoid gear oil A PI SERVICE S J SAE 10W 40 ...

Page 17: ...ce and ideal riding experience WARNING Engine coolant is harmful or fatal if swallowed or inhaled Solution can be poisonous to animals Do not drink antifreeze or cool ant solution If swallowed do not induce vomiting Immedi ately contact a poison control center or a physician Avoid inhaling mist or hot vapors if inhaled remove to fresh air If coolant gets in eyes flush eyes with water and seek medi...

Page 18: ...ary to dilute SUZUKI SUPER LONG LIFE COOLANT when replacing coolant SUZUKI LONG LIFE COOLANT Green Water for Mixing Use distilled water only Water other than distilled water can cor rode and clog the aluminum radia tor Required amount of engine cool ant water solution capacity total 1600 ml 1 7 US qt NOTE This 50 mixture will protect the cooling system from freezing at temperatures above 31 C 24 F...

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Page 20: ...UMENT PANEL 3 8 LEFT HANDLEBAR 3 20 RIGHT HANDLEBAR 3 25 BRAKE LOCK LEVER 3 27 FUEL TANK CAP 3 28 FRONT TRUNK 3 29 FRONT SMALL BOX 3 30 TRUNK 3 31 HELMET HOLDER 3 31 BACKREST ADJUSTMENT 3 32 TRUNK BOX LIGHT SWITCH 3 32 STAND 3 33 REAR SUSPENSION 3 34 OUTPUT TERMINAL 3 34 ...

Page 21: ...switches 3Rear brake fluid reservoir 4Instrument panel 5Front brake fluid reservoir 6Right handlebar switches 7Throttle grip 8Front brake lever 9Grip heater switch 0Front small box AAir cleaner Fuses BIgnition switch CSeat heater switch DFront trunk EOutput terminal ...

Page 22: ...cap NSpark plugs OEngine coolant reservoir PEngine oil filler cap QEngine oil filter REngine oil drain plug SSide stand TEngine oil inspection window UTransmission oil drain plug VCenter stand WTransmission oil level plug XTransmission oil filler plug YFinal gear oil drain plug ZFinal gear oil level plug ...

Page 23: ...3 4 Main fuse CVT fuse CVT filter ...

Page 24: ...replacement keys Please write your key number in the box pro vided for your future reference IGNITION SWITCH To open the ignition key hole shutter 1 Match the ignition key head to the square hole on the ignition switch 2 Turn the key to open and close the key hole shutter NOTE Apply anti freeze lubricant when atmospheric temperature drops below freezing to avoid igni tion key hole shutter freezing...

Page 25: ...ll electrical circuits are cut off P Parking Position When parking the motorcycle lock the steering and turn the key to the P position The key can now be removed and the position light and taillight will remain lit and the steering will be locked This position is for night time roadside parking to increase visibility WARNING Turning the ignition switch to the P PARKING or LOCK position while the m...

Page 26: ...on The front seat will be warmed up OFF position The seat heater switch will be cut off F Front R Rear position Both the front and rear seats will be warmed up NOTE The seat heater uses bat tery power Turn off the seat heater switch when the engine is not running WARNING If the motorcycle falls down due to a slip or collision unex pected damage to the motorcy cle could cause the engine to keep run...

Page 27: ... will blink quickly to warn the rider of the existence of a prob lem BRAKE LOCK INDICATOR LIGHT 3 This light comes on when the parking brake is applied and the ignition switch is in the ON posi tion OIL PRESSURE INDICATOR LIGHT 4 This indicator comes on when the engine oil pressure is below the normal operating range This light should come on when the ignition switch is ON and the engine is not ru...

Page 28: ...ding the motorcycle with the oil pressure indicator light lit can damage the engine and transmission If the oil pressure indicator light comes on indicating low oil pressure stop the engine immediately Check the oil level and add oil if necessary If there is a proper amount of oil and the light still does not go out have your authorized Suzuki dealer or a qualified mechanic inspect your motor cycl...

Page 29: ...ADJUST but ton G to return to original read ing When the ambient air temperature is above 41 F 5 C the display will return to original reading automatically NOTE The thermometer will not indi cate the actual ambient air temperature when riding at low speed or when stopped The thermometer displays Lo when the ambient air tempera ture is below 14 F 10 C The thermometer displays HI when the ambient a...

Page 30: ... amount of fuel remaining in the fuel tank The fuel level indica tor displays all 5 segments when the fuel tank is full The mark blinks when the fuel level drops below 4 0 L 4 2 US qt The mark and segment blink when the fuel drops below 2 0 L 2 1 US qt NOTE The fuel level indicator will not indicate correctly when the motorcycle is placed on the side stand Turn the ignition switch to the ON positi...

Page 31: ...YSTEM INDICATOR LIGHT 9 If the fuel injection system or CVT system fails the malfunction indi cator light 9 comes on and the display I indicates FI in the odometer display area in following two modes A The display I in the odometer display area alternately indi cates FI and the odometer trip meter reading and the malfunction indicator light 9 comes on and remains lit B The display I in the odomete...

Page 32: ...t the engine stop switch is in the position If the display still indicates CHEC after above procedure inspect the ignition fuse and con nection of lead wire couplers NOTICE The malfunction and CVT indi cator light comes on to indi cate a problem with the fuel injection system or CVT sys tem Riding the motorcycle with the indicator lit can dam age the engine and CVT If the display indicates FI and ...

Page 33: ... stand with the engine running after riding the motorcycle and racing the engine the ABS indicator light can come on In such a case check if the ABS indicator light comes on by turning off and on the ignition switch After that check if the ABS indicator light goes out after the motorcycle speed exceeds 3 mph 5 km h If the ABS indicator light does not go out you should have the system checked by an...

Page 34: ...e clock can be adjusted when the ignition switch is in the ON position This clock is powered by the battery of the motorcycle If your motorcycle is to be left unused more than two months remove the battery from the motorcycle DRIVE MODE INDICATOR B Drive mode For normal riding and better fuel economy Power mode For sport riding and getting more power TACHOMETER C The tachometer indicates the engin...

Page 35: ...on F and turn the ignition switch to the ON position and hold the SELECT button F for 3 seconds 3 The oil change counter will reset and the OIL CHANGE indicator D blinks 3 times and goes off To preset the oil change interval 1 Set the meter to odometer then press and hold the ADJUST button G for 2 sec onds until the INTERVAL E and OIL CHANGE D indica tors blink 2 Push the SELECT button F to decrea...

Page 36: ... is below the normal operating range When the engine oil level indica tor comes on check the engine oil level through oil level inspection window described in this owner s manual Add engine oil if the oil level is below the specified range NOTE The engine oil level in the crankcase changes while riding Quick acceleration hard braking and hill climbing will change engine oil level This oil level ch...

Page 37: ...s been ridden The odometer ranges from 0 to 999999 NOTE The odometer display locks at 999999 when the total distance exceeds 999999 Trip meter The trip meter is a resettable odometer It can be used for indi cating the distance traveled on short trips or between fuel stops To reset a trip meter to zero push the ADJUST button G for 2 sec onds NOTE When the trip meter exceeds 9999 9 the trip meter wi...

Page 38: ...Drive mode but disabled when in the Manual mode The system monitors the motorcycle s real time fuel consumption rate and illuminates the Eco Drive Indi cator light when this rate is below predetermined fuel consumption rates The Eco Drive Indicator does not automatically improve fuel econ omy but may help riders refine their riding efficiency and improve fuel economy Fuel economy can be affected b...

Page 39: ...urn the adjuster to the desired position When changing the brake lever position always be sure the adjuster stops in the proper position a projection of the brake lever pivot should fit into the depression of the adjuster This motorcycle is delivered from the factory with its adjuster set on position 3 WARNING Adjusting the rear brake lever position while riding can be hazardous Removing a hand fr...

Page 40: ...switch will shift down the transmission The transmission will be shifted down automatically when the motorcycle speed is decreased NOTE Gear position indicator blinks 3 times when the shift change is not acceptable due to the desired gear being out of transmission speed range WARNING Riding the motorcycle with the rear view mirrors folded will be hazardous Extend both right and left rear view mirr...

Page 41: ...g more power NOTICE Sticking tape or placing objects in front of the headlight can obstruct headlight heat radiation This can result in headlight damage Do not stick tape on the head light or place objects in front of the headlight NOTICE Do not put objects in front of the headlight or taillight when they are on and do not cover with clothes when the motorcy cle is stopped This may cause melting o...

Page 42: ...mes lower at engine idling speed When the engine speed increases the auto matic switch turns on grip heater Pushing the switch will not turn on the grip heater when the engine speed is low Increase the engine speed and push the switch again to turn on the grip heater 1 100 LED indicator blinks 3 times 7 set 2 80 LED indicator blinks 2 times 7 set 3 60 LED indicator blinks 7 times OFF LED indicator...

Page 43: ...from DRIVE mode to MANUAL mode and vice versa DRIVE mode The drive mode indicator in the instrument panel shows D The transmission shifts automatically MANUAL mode The gear position indicator shows a numeral The transmission can be changed by pushing the shift switch 4 WARNING Failure to use the turn signals and failure to turn off the turn signals can be hazardous Other drivers may misjudge your ...

Page 44: ...t will be lit when the lever is squeezed inward Front Brake Lever Adjustment The distance between the throttle grip and the front brake lever is adjustable to 5 positions To change the position push the brake lever forward and turn the adjuster to the desired position When changing the brake lever position always be sure the adjuster stops in the proper posi tion a projection of the brake lever pi...

Page 45: ...fully up NOTE The headlight will go off when the electric starter switch is pushed POWER WINDSHIELD SWITCH 6 Windshield height can be adjusted by power windshield switch SCREEN NOTICE Engaging the starter motor for more than five seconds at a time can damage the starter motor and wiring harness from overheating Do not engage the starter motor for more than five sec onds at a time If the engine doe...

Page 46: ...lease it WARNING Riding the motorcycle with the brake lock lever engaged is hazardous The rear brake will overheat and it will reduce braking performance Use the brake lock lever only when parking and release the lever before riding WARNING Operating the brake lock lever while riding can be hazardous Removing a hand from the han dlebars can reduce your ability to control the motorcycle Operating t...

Page 47: ...fuel tank Do not use bad gas oline which is contaminated with dirt dust water or other liquid Be careful that dirt dust or water does not enter the fuel tank when refueling NOTE The fuel tank has a pres sure regulator around the fuel tank inlet to release pressure when the fuel tank becomes hot The fuel tank pressure regulator may whistle when it releases fuel tank pressure NOTE When refueling hol...

Page 48: ...e key 4 Pull the latch lever and check that the box lid is locked The box load capacity is 1 5 kg 3 0 lbs WARNING Failure to follow safety precau tions when refueling could result in a fire or cause you to breathe toxic fumes Refuel in a well ventilated area Make sure the engine is off and avoid spilling fuel on a hot engine Do not smoke and make sure there are no open flames or sparks in the area...

Page 49: ... is closed and locked securely WARNING Opening the box lid while riding can be hazardous Removing a hand from the han dlebars can reduce your ability to control the motorcycle Always keep both hands on the handlebars during operation WARNING Opening the box lid while riding can be hazardous Removing a hand from the han dlebars can reduce your ability to control the motorcycle Always keep both hand...

Page 50: ...torcycle unattended Do not put valuable items in the trunk because the trunk is not watertight Push down the rear end of the seat if the seat does not unlock with key operation Place helmets as shown or seat may not be completely locked HELMET HOLDER Use cable included and hook cable through helmet strap D rings and around helmet holder WARNING Overloading the motorcycle will decrease riding stabi...

Page 51: ...nt lever and slide the backrest forward or rearward Try to move the backrest forward and rearward to ensure that it is securely latched NOTE Return the adjustment lever by hand to lock the backrest TRUNK BOX LIGHT SWITCH ON position The trunk box light turns on OFF position The trunk box light turns off BACKREST ADJUST ON OFF OFF ...

Page 52: ...ide stand is down The side stand ignition interlock system works as follows If the side stand is down the engine can not be started If the engine is running and the side stand is put down the engine will stop running WARNING Riding with the side stand incompletely retracted can result in an accident when you turn left Check operation of the side stand ignition interlock sys tem before riding Alway...

Page 53: ...ry wattage should be less than 36W Check electrical accessory volt age and wattage before attaching accessories to the output termi nal NOTE The trunk lid may not latch closed if a long type plug is inserted into the output terminal WARNING Unequal suspension adjust ment can cause poor handling and instability Adjust the right and left shock absorbers to the same set tings NOTICE Using improper el...

Page 54: ...4 1 4 BREAK IN RUNNING IN AND INSPECTION BEFORE RIDING BREAK IN 4 2 INSPECTION BEFORE RIDING 4 3 ...

Page 55: ...per break in to assure maximum performance just as the engine does Wear in the tread surface by gradually increasing your cornering lean angles over the first 160 km 100 miles before attempting maximum performance Avoid hard acceleration hard cornering and hard braking for the first 160 km 100 miles AVOID CONSTANT LOW SPEED Operating the engine at constant low speed light load can cause parts to g...

Page 56: ...he 1000 km 600 miles service should be performed as outlined in the Maintenance Schedule section of this Owner s Manual Pay particular attention to the caution and warning mes sages in MAINTENANCE SCHEDULE section INSPECTION BEFORE RIDING WARNING Failure to inspect your motor cycle before riding and to prop erly maintain your motorcycle increases the chances of an accident or equipment dam age Alw...

Page 57: ...tle WHAT TO CHECK CHECK FOR Steering Smoothness No restriction of movement No play or looseness Brakes 3 20 3 25 3 27 7 29 Proper lever operation Fluid level in the reservoir to be above LOWER line No fluid leakage Brake pads not worn down to the limit line Correct lever play No sponginess No dragging Brake lock operation Tires 7 33 Proper pressure Adequate tread depth No cracks or cuts Fuel 3 11 ...

Page 58: ...5 5 1 RIDING TIPS STARTING THE ENGINE 5 2 STARTING OFF 5 4 RIDING ON HILLS MANUAL mode 5 5 STOPPING AND PARKING 5 5 ...

Page 59: ...ely and push the electric starter switch 3 After the engine starts let the engine run until the engine suf ficiently warms up When the Engine is Warm 1 Squeeze the front or rear brake lever 2 Close the throttle completely and push the electric starter switch 3 After the engine starts let the engine run until the engine suf ficiently warms up When a Warm Engine is Hard to Start 1 Squeeze the front ...

Page 60: ...the engine open ing the throttle or running the motorcycle with the oil pres sure indicator light turned on may adversely affect the engine Make sure that the oil pressure indicator light has turned off before operating the throttle or running the motorcycle NOTICE Running the engine too long without riding may cause the engine to overheat Overheat ing can result in damage to internal engine compo...

Page 61: ...d operating conditions and your skills and experience WARNING If you remove even one hand or foot from the motorcycle you can reduce your ability to con trol the motorcycle This could cause you to lose your balance and fall off the motorcycle If you remove a foot from a foot rest your foot or leg may come in contact with the rear wheel This could injure you or cause an accident Always keep both ha...

Page 62: ...ed to help prevent wheel lock up during hard braking or during braking on slippery sur faces while riding in a straight line The ABS will operate whenever it senses that the wheels are lock ing up You may feel the brake lever pulsate lightly while the ABS is operating Even though ABS helps prevent wheel lock up you must still be careful when braking in curves Hard braking while turning could cause...

Page 63: ...whether or not your motorcycle is equipped with ABS ABS can not control wheel side slips that occur when you brake hard while turning and the side slips could cause loss of control Slow down sufficiently in a straight line before you begin to turn and avoid other than slight braking while turning WARNING Failure to use good judgment with ABS can be hazardous ABS cannot make up for bad road conditi...

Page 64: ... con fuse the computer ABS does not work at very low speed less than 5 mph 8 km h and does not work with a dis charged battery Stopping and Parking 1 Twist the throttle grip away from yourself to close the throttle completely 2 Apply the front and rear brakes evenly and at the same time WARNING Inexperienced riders tend to underutilize the front brake This can cause excessive stop ping distance an...

Page 65: ...can lead to a collision As vehicle speeds increase stopping distance increases progressively Always maintain a safe stop ping distance between you and the vehicle in front of you NOTICE Holding the motorcycle stopped with throttle operation on inclines can damage the motorcycle s clutch Use the brakes when stopping the motorcycle on inclines CAUTION A hot muffler can cause severe burns The muffler...

Page 66: ...6 1 6 ACCESSORY USE AND MOTORCYCLE LOADING ACCESSORY USE 6 2 ACCESSORY INSTALLATION GUIDELINES 6 2 LOADING LIMIT 6 3 LOADING GUIDELINES 6 4 MODIFICATION 6 5 ...

Page 67: ...ground clearance and bank angle Inspect that the accessory does not interfere with the operation of the suspension steering or other control oper ations Accessories fitted to the han dlebars or the front fork area can create serious stability problems The extra weight will cause the motorcycle to be less responsive to your steer ing control The weight may also cause oscillations in the front end a...

Page 68: ...decar LOADING LIMIT Never exceed the GVWR Gross Vehicle Weight Rating of this motorcycle The GVWR is the combined weight of the machine accessories pay load rider and passenger When selecting your accesso ries keep in mind the weight of the riders as well as the weight of the accessories The addi tional weight of the accesso ries may not only create an unsafe riding condition but may also affect t...

Page 69: ...of the motor cycle Do not carry any items that protrude over the tail end of the motorcycle Check that both tires are prop erly inflated to the specified tire pressure for your loading conditions Refer to page 7 34 Improperly loading your motor cycle can reduce your ability to balance and steer the motor cycle You should ride at reduced speeds less than 130 km h 80 mph when you are carrying cargo ...

Page 70: ... carburetor s fuel injection system components the engine control module air suction system components the catalytic converter if equipped evaporative emission control sys tem components such as the car bon canister fuel tank fuel hoses and vapor hoses etc It is strictly prohibited to mod ify a vehicle by installing parts that can affect emissions con trol except in accordance with very specific U...

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Page 72: ...K PLUG 7 10 AIR CLEANER 7 13 ENGINE IDLE SPEED INSPECTION 7 16 THROTTLE CABLE PLAY 7 16 CVT FILTER 7 17 ENGINE COOLANT 7 19 ENGINE OIL 7 21 TRANSMISSION OIL AND FINAL GEAR OIL 7 26 BRAKES 7 29 TIRES 7 33 SIDE STAND IGNITION INTERLOCK SYSTEM 7 36 LIGHT BULB REPLACEMENT 7 37 FUSES 7 42 CATALYTIC CONVERTER 7 44 ...

Page 73: ...ility of the machine as explained in the maintenance section Your Suzuki dealer can provide you with fur ther guidelines Steering compo nents suspension and wheel components are key items and require very special and careful servicing For maximum safety we suggest that you have these items inspected and serviced by your authorized Suzuki dealer or quali fied service mechanic MAINTENANCE REPLACE ME...

Page 74: ... have mechanical experience If you are not sure how to do any of the jobs ask your Suzuki dealer to do the maintenance WARNING Exhaust gas contains carbon monoxide a dangerous gas that is difficult to detect because it is colorless and odorless Breathing carbon monoxide can cause death or severe injury Never start the engine or let it run indoors or where there is little or no ventilation NOTICE S...

Page 75: ...tle valve synchronization I CA only I I Evaporative emission control system California model only I I Replace vapor hose every 4 years PAIR air supply system I I CVT filter 7 17 I I Radiator hose 7 20 I I I I Replace every 4 years Engine coolant 7 19 SUZUKI SUPER LONG LIFE COOLANT Blue Replace every 4 years or 48000 km 29000 miles SUZUKI LONG LIFE COOLANT Green or an engine coolant other than SUZU...

Page 76: ...ly for the California model Interval months 2 12 24 36 48 km 1000 6000 12000 18000 24000 Item miles 600 4000 7500 11000 14500 Brakes 7 29 I I I I I Brake hose 7 29 I I I I Replace every 4 years Brake fluid 7 30 I I I I Replace every 2 years Steering I I I Front forks I I Rear suspension 3 34 I I Tires 7 33 I I I I Chassis bolts and nuts T T T T T Lubrication 7 6 Lubricate every 1000 km 600 miles ...

Page 77: ...working part of your motorcycle and also for safe riding It is a good practice to lubricate the motorcycle after a long rough ride and after getting it wet in the rain or after washing it Major lubrica tion points are indicated below NOTICE Lubricating electrical switches can damage the switches Do not apply grease or oil to electrical switches ...

Page 78: ...rate is 1 4A 5 to 10 hours and the max imum rate is 6A 1 hour Never exceed the maximum charging rate WARNING Battery posts terminals and related accessories contain lead and lead compounds Lead is harmful to your health if it gets into your blood stream Wash hands after handling any parts containing lead WARNING Diluted sulfuric acid from the battery can cause blindness or severe burns When workin...

Page 79: ...he reverse order of removal 2 Connect the battery terminals securely WARNING Batteries produce flammable hydrogen gas which can explode if exposed to flames or sparks Keep flames and sparks away from the battery Never smoke when working near the battery NOTICE Exceeding the maximum charging rate for the battery can shorten its life Never exceed the maximum charging rate for the battery WARNING Wip...

Page 80: ...f the battery The recycling of materials will help to conserve natural resources For more detailed information about dispos ing or recycling of the used bat tery consult your Suzuki dealer NOTICE Reversing the battery lead wires can damage the charging system and the battery Always attach the red lead to the positive terminal and the black or black with white tracer lead to the negative terminal W...

Page 81: ...er or not the standard spark plug is suitable for your type of usage A normally operating spark plug should be light brown or tan color If the spark plug is very white or glazed appearing then it has been operating much too hot This spark plug should be replaced with a colder plug NOTICE An improper spark plug may have an incorrect fit or inappro priate heat range for your engine This may cause se...

Page 82: ...rmance prob lems Use only the recommended spark plugs To remove the spark plug follow the procedure below 1 Remove the fasteners from the lower leg shield Unhook the hooks and remove the lower leg shield forward 1 NGK DENSO REMARKS CR7E U22ESR N If the standard plug is wet in appearance or very dark in color replace with this plug CR8E U24ESR N Standard CR9E U27ESR N If the standard plug is very w...

Page 83: ... NOTICE Improper installation of the spark plug can damage your motorcycle An overly tight or cross threaded spark plug will damage the aluminum threads of the cylinder head Carefully turn the spark plug by hand into the threads If the spark plug is new tighten it with a wrench about 1 2 turn past finger tight If you are reusing the old spark plug tighten it with a wrench about 1 8 turn past finge...

Page 84: ...back from the engine to the air intake box without the air cleaner element to stop it Severe engine damage can also occur if dirt enters the engine due to running the engine without the air cleaner element Never run the engine without the air cleaner element in place NOTICE Failure to inspect the air cleaner element frequently if the vehicle is used in dusty wet or muddy conditions can damage your...

Page 85: ...ust from the air cleaner ele ment NOTE Always apply air pressure to the mesh side of the air cleaner element only If you apply air pres sure to the fabric side dirt will be forced into the pores of the ele ment restricting the air flow through the element NOTICE A torn air cleaner element will allow dirt to enter the engine and can damage the engine Replace the air cleaner element with a new one i...

Page 86: ...AIR CLEANER DRAIN TUBES Remove the plugs and drain water and oil at the periodic mainte nance interval NOTICE Failure to position the air cleaner element properly can allow dirt to bypass the air cleaner element This will cause engine damage Be sure to properly install the air cleaner element ...

Page 87: ...TLE CABLE PLAY 2 0 4 0 mm 0 08 0 16 in To adjust the cable play 1 Remove the boot 1 2 Loosen the lock nut 2 3 Turn the adjuster 3 so that the throttle grip has 2 0 4 0 mm 0 08 0 16 in play 4 Tighten the lock nut 2 5 Reinstall the boot 1 WARNING Inadequate throttle cable play can cause engine speed to rise suddenly when you turn the handlebars This can lead to loss of control and an accident Adjust...

Page 88: ...ecurely Do not apply water directly to the boots when wash ing Wipe off dirt from the boots with a wet cloth when the boots are dirty CVT FILTER Right Side Leg Shield Removal 1 Remove the lower leg shield by referring to the SPARK PLUG section 2 Remove the floor mats 3 Remove the screws ...

Page 89: ... hooks and remove the right side leg shield 2 NOTE To remove the right side leg shield 2 push the hook 3 located inside the front side of leg shield and pull it towards you CVT Filter Replacement 1 Remove the screws 1 2 Unhook the hooks and move the CVT filter lid 2 3 Remove the bolts and CVT fil ter cover 3 ...

Page 90: ...e F FULL and the L LOW level lines in the reser voir tank at all times Inspect the level every time before riding with the motorcycle held vertically If the coolant is found lower than the L level line add specified engine coolant through the filler hole until it reaches the F line NOTE Check the coolant level when the engine is cold If the engine coolant reservoir is empty check the radiator cool...

Page 91: ...of coolant will be required when filling the radiator and reservoir tank Radiator Hose Inspection Inspect the radiator hoses for cracks damage or engine coolant leakage If any defects are found ask your Suzuki dealer to replace the radiator hose with a new one WARNING Engine coolant is harmful or fatal if swallowed or inhaled Solution can be poisonous to animals Do not drink antifreeze or coolant ...

Page 92: ...stand 2 Start the engine and run it for three minutes 3 Stop the engine and wait three minutes 4 Hold the motorcycle vertically and inspect the engine oil level through the engine oil level inspection window on the left side of the engine NOTICE Operating the motorcycle with too little or too much oil can damage the engine Place the motorcycle on level ground Check the oil level with the engine oi...

Page 93: ...nd Remove the maintenance lid 2 Remove the oil filler cap 1 3 Remove the drain plug 2 and gasket 3 from the bottom of the engine and drain the engine oil into a drain pan CAUTION Hot engine oil and exhaust pipes can burn you Wait until the engine oil drain plug and exhaust pipes cool before draining oil CAUTION A hot muffler can burn you The muffler will be hot enough to burn you for some time aft...

Page 94: ...d pets may be harmed by swallowing new or used oil Repeated prolonged contact with used engine oil may cause skin cancer Brief contact with oil may irritate skin Keep new and used oil and used oil filters away from chil dren and pets To minimize your exposure to used oil wear a long sleeve shirt and mois ture proof gloves such as dishwashing gloves when changing oil If oil contacts your skin wash ...

Page 95: ...r posi tion on the cap type filter wrench or on the oil filter Use an oil filter wrench to tighten the filter 2 turns or to specified torque Oil filter tightening torque 20 N m 2 0 kgf m 14 5 lbf ft NOTICE Failure to use an oil filter with the correct design and thread specifications can damage your motorcycle s engine Be sure to use a genuine Suzuki oil filter or an equiva lent one designed for y...

Page 96: ...e engine while the motorcycle is outside on level ground and allow it to idle for three minutes 11 Turn the engine off and wait approximately three minutes Recheck the oil level on the engine oil inspection window while holding the motorcycle vertically If it is lower than the L line add oil until the oil level is between the L line and the F line Inspect the area around the drain plug and oil fil...

Page 97: ...7 26 TRANSMISSION OIL AND FINAL GEAR OIL Left Side Leg Shield Removal 1 Remove the lower leg shield by referring to the SPARK PLUG section 2 Remove the floor mats 3 Remove the screws ...

Page 98: ...e motorcycle on level ground on the center stand Hold the motorcycle vertically and check the transmission oil 2 Remove the oil filler plug 1 3 Remove the drain plug 2 from the bottom of the engine and drain the transmission oil into a drain pan 4 Reinstall the drain plug 2 Tighten the plug securely with a wrench 5 Remove the oil level plug 3 and inspect the oil level If the level is below the lev...

Page 99: ...inal gear oil can cause the final drive unit to lock up and cause an accident Check for leaks and the correct level of final gear oil before each use Add oil if necessary Tighten the drain plug securely after changing the gear oil WARNING Children and pets may be harmed by swallowing new or used oil Repeated prolonged contact with used engine oil may cause skin cancer Brief contact with oil may ir...

Page 100: ...ppear ance The brake levers should have the proper stroke and be firm at all times Check the wear of the disk brake pads Brake Hose Inspection Inspect the brake hoses and hose joints for cracks damage or brake fluid leakage If any defects are found ask your Suzuki dealer to replace the brake hose with a new one WARNING Failure to properly inspect and maintain your motorcycle s brake systems can in...

Page 101: ...s the boiling point and can cause brake system including ABS malfunction due to corrosion of brake components Boiling brake fluid or brake system including ABS malfunction could result in an accident Replace the brake fluid every two years to maintain braking performance WARNING The use of any fluid except DOT4 brake fluid from a sealed container can damage the brake system and lead to an accident...

Page 102: ...ct with skin or eyes Solution can be poison ous to animals If brake fluid is swallowed do not induce vomiting Immedi ately contact a poison control center or a physician If brake fluid gets in eyes flush eyes with water and seek medical attention Wash thoroughly after handling Keep out of the reach of children and animals NOTICE Spilled brake fluid can damage painted surfaces and plastic parts Be ...

Page 103: ...he grooved wear limit line both front or both rear pads must be replaced with new ones by your authorized Suzuki dealer or a qualified ser vice mechanic WARNING Failure to inspect and maintain the brake pads and replace them when recommended can increase your chance of having an accident If you need to replace brake pads have your Suzuki dealer do this work Inspect and main tain the brake pads as ...

Page 104: ...e restored WARNING Replacing only one of the two brake pads can result in uneven braking action and can increase your chance of having an accident Always replace both pads together WARNING The tires on your motorcycle form the crucial link between your motorcycle and the road Failure to take the precautions below may result in an accident due to tire failure Check tire condition and pressure befor...

Page 105: ...mes Tire pressure should only be adjusted when the tires are cold Cold Inflation Tire Pressure WARNING Failure to perform break in of the tires could cause tire slip and loss of control which could result in an accident Use extra care when riding on new tires Perform proper break in of the tires referring to the BREAK IN section of this manual and avoid hard acceler ation hard cornering and hard b...

Page 106: ...hen you replace a tire be sure to replace it with a tire of the size listed below If you use a different size of tire motorcycle handling may be adversely affected possi bly resulting in loss of motorcycle control Be sure to balance the wheel after repairing a puncture or replacing the tire Proper wheel balance is important to avoid variable wheel to road contact and to avoid uneven tire wear FRON...

Page 107: ...ccident due to tire failure Tubeless tires require different service proce dures than tube tires Tubeless tires require an air tight seal between the tire bead and wheel rim Special tire irons and rim protectors or a special ized tire mounting machine must be used for removing and installing tires to prevent tire or rim damage which could result in an air leak Repair punctures in tubeless tires by...

Page 108: ...sition This may interfere with rider control during a left turn and could cause an accident Check the side stand ignition interlock system for proper operation before riding Check that the side stand is returned to its full up position before starting off NOTICE Failure to use a light bulb with the correct wattage rating can overload the electrical system of your motorcycle or cause the bulb to bu...

Page 109: ... and remove the rear handle cover 1 3 Remove the front handle cover 2 4 Open the right and left front small box Remove the screws and fasteners Unhook the hooks Pull the front panel 3 backward and remove it NOTE It is not necessary to dis connect the seat heater switch coupler 5 Disconnect the socket 4 from the headlight 6 Remove the rubber cap 5 ...

Page 110: ...ted both up and down or right and left if necessary To adjust the beam up and down Turn the adjuster 1 clockwise or counterclockwise To adjust the beam right and left Turn the adjuster 2 clockwise or counterclockwise NOTICE The headlight bulb s life may be shortened by oil from your fingers if you touch it When replacing the headlight bulb be careful not to touch the glass Grasp the new bulb with ...

Page 111: ... the bulb twisting it to the left and pull it out BRAKE LIGHT TAILLIGHT REAR TURN SIGNAL LIGHT AND LICENSE PLATE LIGHT BULB REPLACEMENT To replace the brake light taillight bulb rear turn signal light bulb and license plate light bulb follow the procedure below 1 Remove the fasteners 1 Unhook the hooks 2 Pull the under frame cover 3 back ward and remove it Brake Light Taillight Rear Turn Signal Li...

Page 112: ...wise and remove the socket 4 Push in on the burned out bulb turn it to the left and pull it out 5 To fit the replacement bulb push it in and turn it to the right while pushing License Plate Light 2 Turn the license plate lens counterclockwise and remove it 3 Pull off the bulb from the socket ...

Page 113: ...fuse 1 protects all electrical circuits 40A CVT fuse 2 protects CVT circuits Fuse box 3 is located under the air cleaner maintenance lid To access the fuse box remove the lid by referring to the AIR CLEANER section Fuse box 3 has HEAD HI HEAD LO FUEL ABS V ABS M and FAN fuses WARNING Replacing a fuse with a fuse that has an incorrect amperage rating or substitute e g alumi num foil or wire may cau...

Page 114: ...M oxygen sensor starter relay side stand relay fuel pump relay and canister purge solenoid California 15A SIGNAL fuse protects the horn turn signal lights stop light taillight cooling fan relay solenoid speedometer ECM and position light 15A FAN fuse protects the cooling fan motor 15A OUTLET fuse protects the output terminal and grip heater 15A ABS V fuse protects the ABS controller 20A ABS M fuse...

Page 115: ...mponents NOTICE Improper motorcycle opera tion can cause catalyst or other motorcycle damage To avoid damage to the catalyst or other related components you should take the following precautions Maintain the engine in the proper operating condition In the event of an engine mal function particularly one involving engine misfire or other apparent performance loss stop riding the motorcy cle and tur...

Page 116: ...ere there are combustible materi als such as dry grass or leaves these materials may come in contact with the catalytic con verter or other hot exhaust components This can cause a fire Avoid parking or operating your vehicle in areas with any combustible materials ...

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Page 118: ...8 1 8 TROUBLESHOOTING IGNITION SYSTEM CHECK 8 2 ...

Page 119: ...k the fuel supply in the fuel tank 2 Check the ignition system for intermittent spark 3 Check the idle speed NOTICE Improper repairs or adjust ments may damage the motor cycle instead of fixing it Such damage may not be covered under warranty If you are not sure about the proper action consult your Suzuki dealer about the prob lem WARNING Performing the spark test improperly can be hazardous You c...

Page 120: ...9 1 9 STORAGE PROCEDURE AND MOTORCYCLE CLEANING STORAGE PROCEDURE 9 2 PROCEDURE FOR RETURNING TO SERVICE 9 3 CORROSION PREVENTION 9 3 MOTORCYCLE CLEANING 9 4 INSPECTION AFTER CLEANING 9 7 ...

Page 121: ...y to the left and lock the steering and remove the ignition key FUEL Fill the fuel tank to the top with fuel mixed with the amount of gasoline stabilizer recommended by the stabilizer manufacturer BATTERY 1 Remove the battery from the motorcycle by referring to the BATTERY section 2 Clean the outside of the bat tery with a mild detergent and remove any corrosion from the terminals and wiring harne...

Page 122: ...d to reach areas Chipping scratches and any damage to treated or painted metal surfaces resulting from minor accidents or impacts from stones and gravel Road salt sea air industrial pollu tion and high humidity will all con tribute to corrosion How to Help Prevent Corrosion Wash your motorcycle fre quently at least once a month Keep your motorcycle as clean and dry as possible Remove foreign mater...

Page 123: ...ycle cover can help protect the finish from the harmful UV rays in sunlight and can reduce the amount of dust and air pollution reaching the surface Your Suzuki dealer can help you select the right cover for your motorcycle MOTORCYCLE CLEANING WASHING THE MOTORCYCLE When washing the motorcycle follow the instructions below 1 Remove dirt and mud from the motorcycle with cool running water You may u...

Page 124: ...torcy cle or riding in the rain Headlight fogging will be cleared gradually when the headlight is turned on When clearing the headlight lens fogging run the engine to avoid battery discharge NOTICE High pressure washers such as those found at coin operated car washes have enough pres sure to damage the parts of your motorcycle It may cause rust corrosion and increase wear Parts cleaner can also da...

Page 125: ...er protect and beautify the paint Only use waxes and polishes of good quality When using waxes and pol ishes observe the precautions specified by the manufactur ers SPECIAL CARE FOR MATTE FINISH PAINT Do not use polishing compounds or waxes that contain polishing compounds on surfaces which have a matte finish The use of polishing compounds will change the appearance of the matte fin ish Solid typ...

Page 126: ...eck your motorcycle for any problems that may have arisen during your last ride WARNING Operating the motorcycle with wet brakes can be hazardous Wet brakes may not provide as much stopping power as dry brakes This could lead to an accident Test your brakes after washing the motorcycle while riding at slow speed If necessary apply the brakes several times to let friction dry out the linings ...

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Page 128: ...WARRANTIES 10 2 EMISSION CONTROL SYSTEMS 10 3 REPORTING SAFETY DEFECTS 10 4 TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED 10 5 ON BOARD MOTORCYCLE COMPUTER DATA INFORMATION 10 6 SERIAL NUMBER LOCATION 10 7 LOCATION OF LABELS 10 8 ...

Page 129: ...n Control System Limited Warranty Applies ONLY to Suzuki street legal emission con trolled motorcycles certified for sale and registered in Califor nia Suzuki limited warranties and the Federal and California Emission Control System Limited Warranty may not cover damage caused by modifications that would change the original vehicle specifications including without limitation modi fications of any ...

Page 130: ...rs and electronic control units Evaporative Emission Control System if equipped The evaporative emission control system of your vehicle consists of the carbon canister fuel tank fuel hoses and fuel vapor hoses These parts incorporate technolo gies to control fuel evaporative emissions Servicing Requirements It is essential to have your vehicle serviced according to the mainte nance schedule in thi...

Page 131: ...between you your dealer or Suzuki Motor of America Inc To contact NHTSA you may either call the Vehicle Safety Hot Line toll free 1 888 327 4236 TTY 1 800 424 9153 go to http www safercar gov or write to Administrator NHTSA 1200 New Jersey Ave S E Washing ton DC 20590 You can also obtain other information about motor vehicle safety from http www safercar gov To contact Suzuki Motor of Amer ica Inc...

Page 132: ...y 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 compo nent which conducts exhaust gases Replacing the exhaust system or muffler with a system or muffler not marked with the same model specific code as the code listed on the Motorcy cle Noise Emission ...

Page 133: ...are monitored so that the ABS system can provide effective antilock braking Some information may be stored by the on board computer when malfunctions occur This stored information can assist techni cians in repairing the motorcycle To read the stored information special equipment is needed and access to the motorcycle or stor age device is required In addi tion once Suzuki collects or receives dat...

Page 134: ...ments for your motorcycle You also need these numbers to help your dealer when you order parts The frame number 1 is stamped on the frame as shown in the illus tration The engine serial number 2 is stamped on the engine Write down the serial numbers here for your future reference Frame No Engine No ...

Page 135: ...t remove them for any reason 1 2 WARNING To reduce the risk of injury Wear a helmet eye protection and protective clothing Read owner s manual carefully BRIDGESTONE kgf cm2 TYPE kPa psi TIRE SIZE FRONT REAR 120 70R15M C 56H TH01F TH01R M SOLO RIDING DUAL RIDING FRONT REAR COLD TIRE PRESSURE 225 280 2 25 2 80 33 41 kgf cm2 kPa psi 225 280 2 25 2 80 33 41 160 60R14M C 65H ...

Page 136: ...UTRAL ENGINE FAMILY EVAP FAMILY PERMEATION FAMILY EXHAUST EMISSION CONTROL SYSTEM VEHICLE EMISSION CONTROL INFORMATION SUZUKI MOTOR CORPORATION DISPLACEMENT cc The owner smanualcontainsimportant safety informationandinstructionswhichshouldbe read carefullybeforeoperatingthevehicle If the vehicle has been resold obtain the owner s manual from the previous owner or contact your local SUZUKI dealer f...

Page 137: ...ump DRIVE TRAIN Clutch Wet multi plate automatic centrifugal type Primary reduction ratio 1 333 88 66 Gearshift pattern Automatic and Manual shift Automatic transmission ratio Variable 1 800 0 465 Secondary reduction ratio 3 934 39 31 43 25 40 22 Final reduction ratio 1 580 32 31 31 32 34 31 49 34 Drive system Gear drive CHASSIS Front suspension Telescopic coil spring oil damped Rear suspension Sw...

Page 138: ... 12V 5W Turn signal light 12V 21W Instrument panel light LED Malfunction indicator light LED Oil pressure indicator light LED Brake lock indicator light LED High beam indicator light LED Turn signal indicator light LED Freeze indicator light LED ABS indicator light LED CAPACITIES Fuel tank 15 0 L 4 0 US gal Engine oil oil change 2600 ml 2 7 US qt With filter change 2900 ml 3 1 US qt Transmission o...

Page 139: ...T 1 6 BRAKE LOCK LEVER 3 27 BRAKES 7 29 BREAK IN 4 2 C CARRYING A PASSENGER 1 5 CATALYTIC CONVERTER 7 44 CONCLUSION 1 6 CORROSION PREVENTION 9 3 CVT FILTER 7 17 E EMISSION CONTROL SYSTEMS 10 3 ENGINE COOLANT 7 19 ENGINE COOLANT SOLUTION 2 6 ENGINE IDLE SPEED INSPECTION 7 16 ENGINE OIL 2 4 7 21 F FINAL GEAR OIL 2 5 FRONT SMALL BOX 3 30 FRONT TRUNK 3 29 FUEL 2 2 FUEL TANK CAP 3 28 FUSES 7 42 H HELME...

Page 140: ... LEFT HANDLEBAR 3 20 LIGHT BULB REPLACEMENT 7 37 LOADING GUIDELINES 6 4 LOADING LIMIT 6 3 LOCATION OF LABELS 10 8 LOCATION OF PARTS 3 2 LUBRICATION POINTS 7 6 M MAINTENANCE SCHEDULE 7 2 MODIFICATION 6 5 MOST ACCIDENTS CAN BE AVOIDED 1 2 MOTORCYCLE CLEANING 9 4 MOTORCYCLE SAFETY FOUNDATION S RIDING TIPS AND PRACTICE GUIDE HANDBOOK FOR OWNERS IN USA 1 5 O ON BOARD VEHICLE COMPUTER DATA INFORMATION 1...

Page 141: ...PLUG 7 10 SPECIAL SITUATIONS REQUIRE SPECIAL CARE 1 4 STAND 3 33 STARTING OFF 5 4 STARTING THE ENGINE 5 2 STOPPING AND PARKING 5 5 STORAGE PROCEDURE 9 2 T TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED 10 5 THROTTLE CABLE PLAY 7 16 TIRES 7 33 TOOLS 7 6 TRANSMISSION OIL 2 5 TRANSMISSION OIL AND FINAL GEAR OIL 7 26 TRUNK 3 31 TRUNK BOX LIGHT SWITCH 3 32 W WARRANTIES 10 2 Total page 140 ...

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Suzuki Burgman Series, Owner'S Manual

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