Suzuki drz 400 2000 Service Manual Download Page 1

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SUZUKI

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DR-Z400

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M.Y 2000-2007

SERVICE MANUAL

http://www.motorcycle.in.th

Summary of Contents for drz 400 2000

Page 1: ...SUZUKI DR Z400 M Y 2000 2007 SERVICE MANUAL http www motorcycle in th...

Page 2: ...tion to help you find the item and page you need COMPONENT PARTS AND WORK TO BE DONE Under the name of each system or unit there is an exploded view which provides work instructions and other service...

Page 3: ...n resistance range mixture of engine oil and SUZUKI MOLY PASTE in a ratio of 1 1 Apply SUZUKI SUPER GREASE A Measure in current range 99000 25030 For USA 99000 25010 For the other countries Apply SUZU...

Page 4: ...UZUKI DR Z400SY 2000 MODEL 1 4 SERIAL NUMBER LOCATION 1 4 FUEL OIL AND ENGINE COOLANT RECOMMENDATIONS 1 4 FUEL 1 4 ENGINE OIL 1 5 BRAKE FLUID 1 5 FRONT FORK OIL 1 5 ENGINE COOLANT 1 5 BREAK IN PROCEDU...

Page 5: ...gement 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 A WARNING Proper serv...

Page 6: ...nd bolts tighten the larger sizes first Always tighten the nuts and bolts from the inside working out diagonally and to the specified torque Whenever you remove oil seals gaskets packing O rings self...

Page 7: ...t _ _ I _ _ _ __ __ _ 1 II oo __ rUCL OIL AND CNGINE COOLANT AECOMMI NDATIONS FUEL FOR USA AND CANADA r Ch hid SUlIJI C _0 ___ _ 0 __ 1 Iae ll CCM r mIf PoW a t IIU E I Iae II or _ CCM 0 _ f n _ _ CO_...

Page 8: ...e last servicing or which has been stored for a long period of time FRONT FORK OIL Use SUZUKI FORK OIL SS 05 or an equivalent fork oil ENGINE COOLANT Since antifreeze also has corrosion and rust inhib...

Page 9: ...ility of the engine depends on the care and restraint exercised during its early life Refer to the following break in engine speed recommendations Keep to these brake in throttle positions during the...

Page 10: ...3 E S4 CD Engine starting label 0 0 0 0 0 0 Noise label 0 0 Inlormatlon label 0 0 ICES Canada label 0 Fuel caution label 0 Manual notice label 0 0 J Tire air pressure label 0 0 0 0 0 0 Warning safety...

Page 11: ...mm 3 543 in Stroke 62 6 mm 2 465 In Piston displacement 398 cm 24 3 cu in Compression ratio 11 3 1 Carburetor MIKUNI BSR36 Air cleaner Polyurethane foam element Starter system Electric Lubrication sy...

Page 12: ...nic iQnition CDI Ignition timing 7 BTDC at 1 500 r min Spark plug NGK CR8E Generator Fuse DENSO U24ESR N Three phase A C generator 20 A Battery 12 V 23 4 kC 6 5 Ah l0 HR Headlight Position light Brake...

Page 13: ...INFORMATION COUNTRY AND AREA CODES The following are codes and their applicable country or area CODE COUNTRY OR AREA E 02 UK E 03 USA E 19 EU E 28 Canada E 33 California USA E 54 Israel http www moto...

Page 14: ...___ __ __ __ __ 2 14 ENGINE COOLANT ______ __ ____ __ __ ______ __ ______ ____ __ ___ 2 14 RADIATOR HOSES _ __ __ _________ __________ __ ____________________ __ __ __ _______ __ __ ______ 2 15 CLUTCH...

Page 15: ...ug I R I Spark arrester For E 03 28 33 C C C Fuel line I I I Replace every four years Enoine oil R R R R Engine oil filter R R Engine oil hoses I I I I Carburetor I I I I Engine coolant Replace every...

Page 16: ...with a nonflammable cleaning solvent Immerse the air cleaner element in the cleaning sol vent and wash it Press the air cleaner element between the palms of both hands to remove the excess solvent do...

Page 17: ...r Remove the right frame cover c r 6 2 Tiohten the exhaust pipe n t j p xh rirp hnlt 2 muffl connection bolt 0 muffler mounting bolt 0 and muffler mount ing nut to the specified torque Exhaust pipe nu...

Page 18: ...erviced and 3 when the camshafts are removed for servic ing NOTE Tile J luII IIlu 1 ue dllu J uedu I ellle TOe UII lIe I ulrlpres sion stroke in order to check or adjust the tappet clearance The tappe...

Page 19: ...o apply molybdenum oil solution to the top and bot tom faces of the tappet shim When installing the tappet shim make sure that the side with the numbers face towards the tappet ACAUTION I Install the...

Page 20: ...340 34 350 350 345 350 3 50 3 50 350 350 TAPPET SHIM SET NO 12800 41810 1 I 270 275 280 285 290 295 300 30 3 320 32 330 3 0 3 350 2 70 275 0 285 290 1295 300 305 3 320 325 330 335 3 40 34 350 2 60 2...

Page 21: ...00 I 3 10 I 315 1320 I 325 13 30 I 335 I 340 I 345 I 3 50 3 50 o5 l6 061 6 o66 0 7C 071 ln o76 1 8 0 81 l 0 86 09 t 091 l9 0 96 1 1 01 1 106 11 1 11 1 I 116 12C 1 21 1 2 126 13 1 31 1 3 136 14 C 141...

Page 22: ...re the spark plug gap using a thickness gauge If the spark plug gap IS out Of speCification adlust me gap Spark plug gap Standard 0 7 0 8 mm 0 028 0 031 in Gil 09900 20803 Thickness gauge ELECTRODE Ch...

Page 23: ...lSpark plug 11 N m 1 1 kgf m 8 0 Ib It SPARK ARRESTER FOR E 03 28 33 Clean every 6 000 km 4 000 miles 6 months Remove the spark arrester Remove the carbon deposits from spark arrester and muffler Tig...

Page 24: ...will hold about 1 7 L 1 8 US qt 1 5 Imp qt of oil Use an engine oil that meets Arl service classifications SF or SG and that has a viscosity rating of SAE 10W 40 Engine oil drain plug on the crankcas...

Page 25: ...check the oil level as described in the engine oil replacement procedure _ Engine oil capacity Oil change Oil and filter change Engine overhaul ACAUTION 1 7 L 1 8 US qt 1 51mp qt 1 8 L 1 9 US qt 1 6...

Page 26: ...ssary adjust the thread length in the following way Loosen the locknut Turn the nut 8 to obtain the thread length of 3 mm 0 12 in Tighten the locknut G securely PULLING CABLE PLAY The pulling cable sh...

Page 27: ...ather hose Therefore the engine coolant level may decrease while riding Check the engine coolant level before every ride Removl thl riahl ide cover c r 6 2 Loosen the stopper screw CD Remove the radia...

Page 28: ...5 4 Air bleeding the engine coolant circuit Bleed air from the air bleeder bolt Tighten the air bleeder bolt to the specified torque Air bleeder bolt 5 5 N m 0 55 kgf m 4 0 Ib ft Add engine coolant u...

Page 29: ...k or wooden block and turn the rear wheel slowly by hand Visually inspect the drive chain for the possible damages listed below Loose pins Damaged rollers Rusted links Missino O rino p I Twisted or se...

Page 30: ...hain slack 40 50 mm 1 6 2 0 in After adjusting the drive chain tighten the rear axle nut to the specified torque Rear axle nut 100 N m 10 0 kgf m 72 5 Ib ft For E 03 28 33 110 N m 11 0 kgf m 79 5 Ib f...

Page 31: ...ace the brake pads as a set otherwise braking per formance will be adversely affected BRAKE LEVER PLAY Loosen the locknut CD Adjust the brake lever play by turning tile adju51 uilUI II lever is 0 1 0...

Page 32: ...he reach of child ren When replenishing brake fluid be sure not to get any dust or other foreign materials in the fluid Brake fluid if it leaks will interfere with safe running and immediately discolo...

Page 33: ...JJluc et until the fluid flowing into the receptacle no longer contains air bubbles NOTE While bleeding the brake system replenish the brake fluid in the reservoir as necessary Make sure that there is...

Page 34: ...s 6 months TIRE TREAD CONDITION Operating the motorcycle with excessively worn tires will de crease riding stability and consequenlly invite a dangerous situ ation It is highly recommended to replace...

Page 35: ...Dual riding Front 125 kPa 1 25 kgf cm 18 pc Rear 175 kPa 1 75 kgf cm 25 psi L ACAUTIO The standard tire fitted on this motorcycle is a 80 100 21 51 P for the front and a 120 90 18 65P for the rear Th...

Page 36: ...djust the steering 0 6 22 FRONT FORK Inspect every 12 000 km 7 500 miles 12 months Inspect the front forks for oil leakage scoring or scratches on the outer surface of the inner tubes If any damages a...

Page 37: ...pad mountino pin 1R 1 B 13 0 Brake hose union bolt front rear 23 2 3 16 5 Brake air bleeder valve front rear 7 5 0 75 5 5 Brak e di5C rnuulllir ry Gull huill rectr 10 U 7 0 Swingarm pivot nut 77 7 7 5...

Page 38: ...PERIODIC MAINTENANCE 2 25 http www motorcycle in th...

Page 39: ...le Speedometer gearbox Q Sidestand pivot and spring hook Drive chain Swingarm Pivot Brake pedal Pivot o Brake lever holder Clutch lever holder Before lubricating each part remove any rust and wipe off...

Page 40: ...asket NOTE When the compression pressure goes below specification check the engine for conditions listed above COMPRESSION TEST PROCEDURE NOTE Before testing the engine for compression pressure make s...

Page 41: ...g Defective oil pump Combination of the above items HIGH OIL PRESSURE Engine oil viscosity is too high Clogged oil passage CUllllJinaUon Of the above Items OIL PRESSURE TEST PROCEDURE Connect a tachom...

Page 42: ...43 OIL SEALS 3 46 OIL CHECK VALVE 3 47 ENGINE REASSEMBLY 3 48 CRANKSHAFT 3 48 GEARSHIFT CAM AND FORK 3 49 CRANKCASE 3 50 STARTER CLUTCH AND GENERATOR ROTOR 3 51 BALANCER SHAFT J J PRIMARY DRIVE GEAR...

Page 43: ...L INSTALLATION Exhaust pipe muffler 3 5 3 10 Oil filter 3 14 Clutch pressure plate drive plates and driven plates 3 16 3 56 Clutch sleeve hub 3 16 3 56 Primary driven gear assembly 3 17 3 56 Oil rump...

Page 44: ...steps Remove the seat side covers and frame covers c r 6 2 Drain the engine oil c r 2 11 Remove the carburetor c r 4 6 Remove the radialor c r 5 6 and 5 7 Disconnecllhe 8 baltery lead wire and enqine...

Page 45: ...emove the engine coolant overflow tank mounting bolt Disconnect the spark plug cap j engine oil breather hose g engine oil hose and remove the engine oil tank Remove the clutch relea e rm nri rAmove t...

Page 46: ...Remove the exhaust pipe CD and muffler g Disconnect the engine oil pipe and engine oil hose union bOlt ENGINE 3 5 http www motorcycle in th...

Page 47: ...ket cover Flatten the washer CD and remove the engine sprocket nut while pressing down on the rear brake pedal Remove the engine spror kp t Remove the cotter pins and brake pedal I ACAUTION Replace th...

Page 48: ...Disconnect the horn coupler CD and remove the horn CD Remove the PAIR air supply valve assembly For E 02 19 54 Remove the engine from the frame ENGINE 3 7 http www motorcycle in th...

Page 49: ...ed it is no longer of any use I ACAUTION Replace the ens line mounting nuts with new ones Hold the bolthead with a wrench and then tighten the engine mounting nuts to the specified torque I H y ______...

Page 50: ...ne sprocket with side of the sprocket facing toward the engine Tighten the engine sprocket nut to the specified torque Engi sprock t nut 110 N m 11 0 kgf m 79 5 Ib ft NOTE When tightening the engine s...

Page 51: ...2 3 kgf m 16 5 Ib ft Pour 1 9 L 2 0 US qt 1 7 Imp qt of an API service classified SF or SG engine oil that has a viscosity rating of SAE 10W 40 i lu II It uil lill I ule located In the frame alter ove...

Page 52: ...or until the T line on the generator ro tor is aligned with the center of the hole in the generator cover NOTE When removing the cylinder head cover the piston must be at TOG of the compression stroke...

Page 53: ...2 NOTE Do not drop the dowel pins into the crankcase Remove the cylinder head side bolt NOTE Do not drop the cam chain into the crankcase Remove the fOllr r ylinrlp r hp rl holt in diagonal stag s NO...

Page 54: ...chain guide Remove the cylinder base nuts and then remove the cylin der NOTE If the cylinder does not come off easily lightly tap it using a plas tic mallet Remove the cylinder gasket and dow 1 pins...

Page 55: ...over CD and starter drive gear Remove the generator rotor cover Remove the starter driven gear dowel pins 0 and gasket Remove the neutral switch witr h r ontA t CD and springs Remove the oil filter ca...

Page 56: ...he clutch cover Remove the right crankcase cover Remove the dowel pins CD and gasket 2 Loosen the clutch spring set bolts working in diagonal stages and then remove them when they are fully loosened E...

Page 57: ...emove the push rod spring washer and spring washer St dl Flatten the clutch sleeve hub washer Hold the clutch sleeve hub usino thp r r i l 1001 and then remove the clutch sleeve hub nut S 09920 53740...

Page 58: ...emove the retainer and spacer Remove the oil pump idle gear and oil pump driven gear Remove the pin and oil pump assembly IACAUTION I Do not remove the circlip before separating the cr mkc e to preven...

Page 59: ...aft CD by removing the circlip ev Remove the gearshift arm stopper Remove the gearshift pawl lifter G and gearshift cam driven gear Remove the gearshift cam stopper arm Remove the gearshift cam ririvp...

Page 60: ...tor using a 26 mm offset wrench and then remove the generator rotor nut Remove the generator rotor using the special tool ditJ 09930 31921 Rotor remover N OTE Do not use the rotor remover attachment t...

Page 61: ...case using the special tool 09920 13120 Crankcase separating tnol NOTE Fit the crankcase separating tool to the right side so that the tool plate is paralleled with the end face of the crankcase Remov...

Page 62: ...bly CD and driveshaft assem bly Remove the balancer shaft Remove the crankshaft from the crankcase using the special tool r5tJ 09920 13120 Crankcase separating tool Remove the oil sump filtgr ENGINE 3...

Page 63: ...inal posi tions Remove Ihe intake pipe Remove Ihe thermostat housing and thermostat Remove the tappets D and shims by hand or by using a magnet Compress thp VRlvp sprinos nd then remove the valvQ cot...

Page 64: ...and thickness gauge Take clearance read ings at several places If any clearance reading exceeds the ser vice limit replace the cylinder head with a new one S 09900 20803 Thickness gauge _ Cylinder he...

Page 65: ...ECTION Lift the valve about 10 mm 0 39 in from the valve seat Mea sure the valve stem deflection in two directions X and Y per pendicular to each other Position the dial gauge as shown If the deflecti...

Page 66: ...Reamer handle Oil the stem hole of each valve guide and drive the guide into the guide hole using the valve guide installer and attachment S 09916 44310 Valve guide removerlinstaller 09916 53360 Valve...

Page 67: ...valve seat is out of specification re cut the seat VALVE SEAT SERVICING The valve seats for both the intake and exhaust valves are ma chined to three different angle T he seat contact surfact j L ut a...

Page 68: ...p the seat using the 45 cutter Rotate the cutter one or two turns Measure the valve seat width after every cut If the valve s eat i pitted or burned use the 45 Gutter to con dition the seat some more...

Page 69: ...hieved use the 60 cutter very lightly to clean up any burrs caused by the previous cutting operations A CAUTION I DO NOT use a lapping compound after the final cut is made The finished valve seat shou...

Page 70: ...ts for the chattering noise coming from the valve mechanism Check the valve springs for proper strength by measuring their free length and also by the force required to compress them If the spring len...

Page 71: ...tall the valve spring with the smaller pitch facing the cylinder head Larger pitch Down Inst lll thp v lvp c pring retainer by prQssing down the spring using the valve lifter Fit the cotter halves to...

Page 72: ...he automatic decompression weight does not operate smoothly replace it with a new one CAM WEAR Worn down cams are often the cause of mistimed valve opera tion resulting in reduced power output Measure...

Page 73: ...tile carnshan Journal 011 clearance exceedS the service limit measure the inside diameter of the camshaft journal holder and outside diameter of the camshaft journal Replace the camshaft or the cylind...

Page 74: ...RE Inspect the cylinder wall for any scratches nicks or other dam age Measure the cylinder bore diameter at six places S 09900 20508 Cylinder gauge set _ Cylinder bore Standard 90 000 90 015 mm 3 5433...

Page 75: ...03 mm 0 0791 0 0799 in Piston ring thickness Stanaara 1st 0 71 0 76 mm 0 0280 0 0299 in 1 08 1 10 mm 0 0425 0 0433 in 2nd 0 77 0 79 mm 0 0303 0 0311 in PISTON RING FREE END GAP AND PISTON RING END GAP...

Page 76: ...ne S 09900 20605 Dial calipers Conrad small end 1 0 Service Limit 20 040 mm 0 7890 in CONROD DEFLECTION AND BIG END SIDE CLEARANCE w ear on the big end 01 the conrOd can be estimated by checking the m...

Page 77: ...in STARTER CLUTCH Hold the rotor with 0 26 mm offset wrench and remove the hexagon bolts Install the starter clutch in the proper direction as shown NOTE When installing the starter clutch onto the ro...

Page 78: ...ng the spe cial tools and vise as shown if the slip torque is not within the specified torque replace the starter torque limiter with a new nne mm 09930 73170 Starter torque limiter holder 09930 73180...

Page 79: ...DRIVEN PLATES Measure each clutch driven plate for distortion using the thick ness gauge If a clutch driven platei not within the ser vil t lirllil replace the clutch plates as a set tEl 09900 20803...

Page 80: ...e groove of its respec tive gear using the thickness gauge If the clearance exceeds specification replace the fork its re spective gear or both S 09900 20803 Thickness gauge 09900 20101 vernier calipe...

Page 81: ...dnve gear Circilp 3rd drive gear Circhp 4th drive gear J 2nd drive gear Circlip 9 1 Rp arina OW Bearing Onveshaft Washer 2nd dnv m 9Qar Qoj Spacer Bearing Oil seal 4th driven gear 3rd driven gear l Wa...

Page 82: ...p larger than required to slip the circlip over the shaft After installing a new circlip make sure that it is com pletely seated in its groove and securely fitted NOTE When reassembling the transmissi...

Page 83: ...3 42 ENGINE cp Dnveshaft C1l Counlershait 1 8 cJ J ct g I IJ http www motorcycle in th...

Page 84: ...ing with a new one Install the right countershaft bearings using the special tool S 09913 70210 Bearing installer set Apply a small quantity of THREAD LOCK 1342 or THREAD LOCK SUPER 1322 to tho boarin...

Page 85: ...t CRANKSHAFT BEARINGS Remove the right and left crankshaft bearings using the spe cial tool am 09921 20220 Bearing remover set A CAUTION I Replace the removed bearings with new ones Install the right...

Page 86: ...N Replace the removed bearing with a new one Install the right balancer shaft bearing using the special tool Gil 09913 70210 BGaring install r s t LEFT BALANCEn SHAFT BEARING Remove the left balancer...

Page 87: ...ver Pay attention to the fOllowing points ACAUTION I Replace the removed oil seals with new ones Apply SUZUKI SUPER GREASE A to the lip of the oil seals For USA 99000 25030 SUZUKI SUPER GREASE A For t...

Page 88: ...TION Replace the removed oil seal with a new one Install the gearshift shaft oil seal into the left crankcase slowly using the special tool S 09913 70210 Bearing installer set OIL CHECK VALVE Remove t...

Page 89: ...he wcbo referring to the figure when rebuilding the crankshaft llL lrJ Crank web to crank web width Standard 62 0 0 1 mm 2 441 0 004 in When mounting the crankshaft in the crankcase it is neces sary t...

Page 90: ...arshift fork shaft Install the gearshift forks into the gearshifting grooves in the correct posilion and direclion Install the gearshift fork shafts N OTE After the gearshift fork shaft and gearshift...

Page 91: ...p filter wash the sump filter with clean ing solvent and then blow compressed air through it to dry it off Install the dowel pins to the left crankcase Apply engine oil to the conrod big end and to th...

Page 92: ...stance IS leI to rotation try to free me snafts by tapping them with a plastic mallet STARTER CLUTCH AND GENERATOR ROTOR Remove the grease from the tapered portion 01 tne cranK shaft and the generator...

Page 93: ...installing the balancer drive gear align the pin CD with the groove When installing the bal mr p r irivgn gear align the pin with the groove Install the balancer driven gear by aligning the matching...

Page 94: ...arshift cam driven gear bolt to thc specified torque Gearshift cam driven gear bolt 24 N m 2 4 kgf m 17 5 Ib ft Install each pawl lifter into the oearshift cam driven oear The large shoulder must face...

Page 95: ...rolor inner rotor and shaft When installing the inner rotor align the pin ill with the groove Apply a small quanlity of THREAD LOCK 1342 or THREAD LOCK SUPER 1322 to the threaded parts of the oil pum...

Page 96: ...lutcn release camsnan l Boll Spring retainer j Spring Pressure plate Drive plate 7 pes J Driven plate 7 pes Drive plale 1 pc Beanng Push piece Washer Spring washer Spring washer seat Clutch sleeve hub...

Page 97: ...o the clutch sleeve hub correctly In t rt the clutch drive plates and drivQn plates ong by one into the clutch sleeve hub in the prescribed order NOTE Be sure to install the drive plate with an inside...

Page 98: ...crankcase cover bolt as shown CLUTCH COVER Tighten the clutch cover boltG Gccurely NOTE Install the new gasket onto the clutch cover bolt A as shown GENERATOR ROTOR COVER Install the starter driven ge...

Page 99: ...ews securely PISTON RING Install the oil ring first the 2nd ring cecond and the 131 ring last NOTE The 1st CD and 2nd 0 piston rings differ in shape The 1st piston ring should be installed with the gr...

Page 100: ...Upper side rail 1st ring and spacer PISTON AND CYLINDER Install the piston and cylinder in the reverse order of removal NOTE Install the piston with the punch mark on the piston head facing toward the...

Page 101: ...r after attaching the camshaft drive chain keep me camSharr orlve chain taut Ihe camshaft Onve chain must not be caught between the cam drive chain sprocket and crankcase when the crankshaft is rotate...

Page 102: ...and cylinder nuts to the speci fied torque r Cylinder head bolt 10 N m 1 0 kgf m 7 0 Ib ft Cylinder nut 10 N m 1 0 kgf m 7 0 Ib ft Tighten the cylinder head side bait to the specified torque Cylinrt h...

Page 103: ...amshaft sprocket has an arrow marked 1 D 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...

Page 104: ...Apply SUZUKI BON D 1207B to the end caps of the cylinder head cover gasket as shown For USA o jiEJ991 04 31140 SUZUKI BOND 1207B For the other countries o jiEJ99000 31140 SUZUKI BOND 1207B NOTE When...

Page 105: ...r body lACAUTION I I Use a new gasket to prevent oil leakage Install the cam chain tension adjuster body to the cylinder and then tighten the two Allen bolts to the specified torque J Cam chain tensio...

Page 106: ...l Remove the PAIR air supply pipe from the cylinder head Remove the PAIR air supply valve assembly Remove the PAIR air supply pip and air cl an r hos CD INSPECTION HOSE AND PIPE Inspect each hose and...

Page 107: ...in the photograph Apply negative pressure sluwly tu II PAIR air supply valve and inspect the air flow If air does not Ilow out within the specified range the PAIR air supply valve is in normal conditi...

Page 108: ...ALVE 4 3 REMOVAL AND INSPECTION 4 3 FUEL STRAINER 4 3 REMOUNTING 4 3 CARBURETOR 4 4 CONSTRUCTION 4 4 SPECIFICATIONS 4 5 1 0 NO LOCATION 4 5 REMOVAL 4 6 DISASSEMBLY 4 6 CLEANING 4 10 INSPECTION 4 10 RE...

Page 109: ...r 6 2 Turn the fuel valve to the OFF position Disconnect the fuel hose A WARNING Gasoline is highly flammable and eYl lo ive Keep heat sparks and flames away from gasoline Remove the fuel tank REMOUNT...

Page 110: ...ew one to pre vent fuel leakage Tighten the fuel valve mounting bolts to the specified torque C Fuel valve mounting bolt 4 4 N m 0 44 kgf m 3 2 Ib ft FUEL STRAINER II me luel strainer Is dirty with se...

Page 111: ...raom Piston valve O ring Pilot air Jel Carburetor body Coasting richer pump assembly Starter plunger assembly Q Pilot screw Starter jet Q Needle Jel Qfl Piiol Jet Valve seal loodlo VQllvo Main Jel Flo...

Page 112: ...eight 13 0 1 0 mm 0 51 0 04 in Main jet M J 142 5 1 12 5 Jot noodlo J N 5DH362nd 5DH37 Needle jet N J P OM P OM Pilot jet PJ 22 5 22 5 Pilot air jet PA J 165 135 Pilot screw PS 3 turns out PRESET Thro...

Page 113: ...throttle position sensor coupler CD and piston valve control solenoid coupler Except for E 03 28 33 Disconnect the throttle cables Disconnect the air vent hose 0 and vacuum hose Loosen the carburetor...

Page 114: ...valve conlrol solenoid CD and joint pipe Except for E 03 28 33 Remove the throttle position sensor Remove the coasting richer pump assembly Remove the top cap FUEL AND LUBRICATION SYSTEM 4 7 http www...

Page 115: ...needle stopper 0 a ring spring wash amJjet needle assembly 0 Remove the float chamber and throttle stop screw ACAUTIONJ Replace the removed O ring with a new one to prevent fuel leakage Remove the th...

Page 116: ...e a 1 8 size drill bit with a drill stop to remove the pilot screw plug Set the drill stop 6 mm from the end of the bit to prevent drilling into the pilot screw Carefully drill through the plug Thread...

Page 117: ...or body using compressed air _A CAUTION Do not use wire to clean the passageways valve seat and jets If the GUIIIJJulI nl s c nnot be cleaned with a spray type cleaner it may be necessary to soak them...

Page 118: ...IS Just contacting the needle valve using vernier calipers Bend the tongue as necessary to bring the float height to the specified level S 09900 20101 Vernier calipers B Float height 13 0 1 0 mm 0 51...

Page 119: ...tle position sen sor terminals as shown in the illustration Throttle positiOn sensor resistance 3 5 6 5 IUl Measure the resistance between the throttle position sen sor terminals ac chown in the illus...

Page 120: ...HT CRANKSHAFT t t I OIL HOSE I PISTON JET I OIL JET I CRANKSHAFT RIGHT END 1 t RIGIIT CRANKCASC I I OIL PIPC 1 1 I RIGHT H OIL PUMP f OIL CHECK rl OIL FILTER CLUTCH COVER I CRANKCASF VALVF 1 BY PASS I...

Page 121: ...REMOVAL 5 6 REMOUNTING 5 7 COOLING FAN THERMOSWITCH 5 8 REMOVAL 5 8 INSPECTION 5 9 INSTALLATlON 5 9 ENGINE COOLANT TEMPERATURE THERMOSWITCH 5 10 REMOVAL 5 10 INSPECTION 5 10 INSTALLATION 5 10 THERMOST...

Page 122: ...gine coolant through the radiator As the coolant temperature rises to about 75 C 16 oF the thermostat valve unseats and a normal coolant flow is established At about 90 C 194 F the thermostat becomes...

Page 123: ...nk AIr bleeder bolt Cooling fan thermoswitch Engine coolant temperature Ihermoswilch ITEM N m kgf m 5 5 13 13 CD Circlip Water pump driven gear j Pin o Waohcr Clrclip Bearing o Q ring Oil oal Mechanic...

Page 124: ...ange the coolant s frost pro tection and rust inhibiting capabilities will be re duced Always keep the antifreeze content above 50 even if the atmospheric temperature does not go be low the freezing p...

Page 125: ...filler to prevent the enQine coolant from spray ing out IACAUTIONl Do not exceed the radiator cap release pressure or the radiator cap and subsequently the radiator can be damaged Check the radiator c...

Page 126: ...k c r 4 2 Drain the engine coolant c T 2 15 A WARNING Do not open the radiator cap when the engine is hot as you may be injured by escaping hot liquid or va por The engine must be cool before servicin...

Page 127: ...diator covers Remove the radiators Remove the cooling fan REMOUNTING Remount the radiator in the reverse order of removal After remount ing the radiator be lure to add engine coolant c r 2 15 COOLING...

Page 128: ...is low but closes when the temperature reaches approximately 96 C 205 F setting the cooling fan in motion R O fM B R I Fuse Ignition switch Cooling fan Cooling fan 1 motor thermoswitch Battery REMOVA...

Page 129: ...cooling fan lhern10 5vvitch in the levelse OIdel of 11 moval Pay attention to the following points Apply SUZUKI SUPER GREASE A to the O ring For USA 99000 25030 SUZUKI SUPER GREASE A For the other cou...

Page 130: ...gine coolant temperature thermoswitch specifica tion OFF ON Approximately 117 C 243 F ON OFF Approximately 100 C 212 F INSTALLATION Install the engine coolant temperature thermoswitch in the re verse...

Page 131: ...the eyes or contacts the skin flush the eyes or wash the skin thoroughly with plenty of water If engine coolant is swallowed induce vomit ing and call a physician immediately Disconnect the thermosta...

Page 132: ...ed at least 6 0 mm 0 24 in Thermostat valve lift over 6 0 mm at 90 C over 0 24 in at 194 F If the thermostat is faulty in either of these two checks re place it INSTALLATION Install the thermostat in...

Page 133: ...rmful if swallowed or if it comes in contact with the skin or eyes If engine cool ant gets into the eyes or contacts the skin flush the eyes or wash the skin thoroughly with plenty of wa ter If engine...

Page 134: ...and lock it into the slit of the bearing remover attachment Drive out the water pump bearing by knocking the wedge bar S 09941 50111 Bearing remover A CAUTION Replace the removed bearing with a new on...

Page 135: ...I SUPER GREASE A For the other countries 099000 25010 SUZUKI SUPER GREASE A When installing the water pump driven gear align the pin ill with the groove ev After installing the water pump be sure to a...

Page 136: ...RBER DAMPING FORCE ADJUSTMENT 6 35 nEAn SWINCAnM AND CUSHION LEVEn nEMOVAL 6 36 INSPECTION AND DISASSEMBLY 6 37 REASSEMBLY AND REMOUNTING 6 39 FINAL INSPECTION AND ADJUSTMENT 6 40 FRONT BRAKE 6 41 CON...

Page 137: ...D SIDE COVERS Remove the left and right side covers CD FRAME COVERS Remove the left frame cover CD and right frame cover BATTERY COVER Remove the battery cover CD REMOUNTING Remount the seat side cove...

Page 138: ...peedometer gearbox 0 Boaflng IRl l4 Front wheel C0 Spacer Beaflng ILl CD Dust seal Brake disc Spacer i 1 Q Washer A Front axle nul B Brake disc mounting bolt J ITEM N m kgf m 42 4 2 10 1 0 CHASSIS 6 3...

Page 139: ...6 4 CHASSIS c Righi r J Left J o Riohl Leh 0 r i g ht http www motorcycle in th...

Page 140: ...axle nut G and loosen the front axle pinch bolts 0 Support the motorcycle with a jack or wooden block and re move the front axle and front wheel I ACAUTION J Do not operate the brake lever during or a...

Page 141: ...seal with a new one Remove the wheel hub dust seal using Ihe special tool 09913 50121 Oil seal remover IA CAUTION Replace the removed dust seal with a new one WHEEL BEARINGS Inspect the play of Ihe w...

Page 142: ...limit when checkeu 0 5 11QWr1 All excessive amount of runout is usually due to worn or loose wheel bearings and can be corrected by replacing the bearings If bearing re placement fails to reduce the...

Page 143: ...WHEEL HUB DUST SEAL Apply SUZUKI SUPER GREASE A to the lip of dust seal For USA 0 99000 25030 SUZUKI SUPER GREASE A For the other countries 0 99000 25010 SUZUKI SUPER GREASE A Install the wheel hub d...

Page 144: ...Installed as snown Tighten the front axle nut to 20 N m 2 0 kgf m 14 5 Ib ft by holding the front axle using the special tools mm 09940 34520 T handle 09940 34581 Attachment F Tighten the front axle p...

Page 145: ...l CD Siopper ring 0 1 seal 011 seal retainer 0 Inner tube anllfnctlOn metal Inner tube Outer tube antifrichOn metal Clamp Bool Clamp Oil lock piece Holder Outer tube O ring End plale 3 O flng Front fo...

Page 146: ...per clamp bolts and lower clamp bolts NOTE Slightly loosen the front fork cap bolt to facilitate later disas sembly Remove the boot A CAUTION Replace the removed lower boot clamp with a new one_ Remov...

Page 147: ...ront fork brake caliper bracket using the vise A CAUTION I Do not over tighten the vise or the outer tube will be damaged Remove the damper rod bolt using the special tool em 09940 54821 Front fork in...

Page 148: ...fork spring free length is shorter than the service limit replace the fork spring with a new one Front fork spring free length Service limit 561 mm 22 1 in INNER AND OUTER TUBE Inspect the inner tube...

Page 149: ...metal when mounting the inner tube Apply fork oil to the inner and outer tube antifriction motals Apply front fork oil to the lip of oil seal lightly before installing it oG D 99000 99001 555 5UZUKI F...

Page 150: ...g 709 ml 24 0 US OZ 25 0 Imp oz Move the inner tube slowly several times Hold the front fork in a vertical position and adjust the fork oil level using the special tool Sl 09943 74111 Fork oil level g...

Page 151: ...t fork cap bolt 23 N m 2 3 kgf m 16 5 Ib It FRONT WHEEL c 6 9 NOTE Before tightening the front axle nut and front axle pinch bolts move the front fork up and down four or five times SUSPENSION SETTING...

Page 152: ...51 upper bracket f9 em nut o Bearrng Steering stem Beanng I Headlight cover bracket Handlebarclampboll B Steenng 51 F em head nut rant fork up r Fronllork 10 pe clamp boll wer clamp boll t l ITEM N m...

Page 153: ...t Disconnect the speedometer cable CD indicator lights cou pler 6 and speedometer coupler Remove the speedometer assembly ni r nnnect the left and right turn signal light couplers CD and remove the le...

Page 154: ...ht handlebar switch V and throttle cables 0 Remove the throttle grip Remove the clamp left handlebar switch and left rear view mirror Disconnect the clutch cable Remove the front fender CHASSIS 6 19 h...

Page 155: ...upper bracket Remove the step rinD stp m nllt Iising the special tools rim 09940 14911 Steering nut socket wrench 09940 14960 Steering nut wrench socket Remove the steering stem lower bracket NOTE Ho...

Page 156: ...m upper and lower bearing races using the special tools Gil 09941 54911 Bearing outer race remover 09941 74910 Bearing installer REASSEMBLY AND REMOUNTING Reassemble and remount the steering stem in t...

Page 157: ...illY 1 IIul 1 4 1 2 of a turn NOTE This adjustment will vary from motorcycle to motorcycle TiohtF n thp tAp ring stem head nut to the specified torque Steering stem head nut 90 N m 9 0 kgf m 65 0 Ib...

Page 158: ...AND HOSE ROUTING c r 8 12 10 8 20 NOTE Hold the front fork legs move them back and forth and make sure that the steering is not loose ACAUTION I After performing the adjustment and installing the hand...

Page 159: ...Brake disc Spacer Dust seal Q Bearing Rear wheel Rear sprocket l Spacer Bearing Bearing Dust seal Spacer Rear axle Rear axle nul Brake disc mounting bolt Rear sprocket nul I ITEM N m kgf m E J3zo 3J...

Page 160: ...CHASSIS 6 25 LeN J Right Except E 03 28 33 LeN J c Right Left J c Right Clearance http www motorcycle in th...

Page 161: ...Replace the removed cotter pin with a new one Support the motorcycle with a jack or wooden block and re move me rear axle Q and rear wheel A CAUTION Do not operate the brake pedal during or after rea...

Page 162: ...e order of removal and disassembly Pay special attention to the following points WHEEL BEARINGS Apply SUZUKI SUPER GREASE A to the left wheel bear ing For USA 0 99000 2 1030 SUZUKI SUPER GREASE A For...

Page 163: ...ase Apply THREAD LOCK SUPER 3bU to me braKe diSC mount ing boits and then tighten them to the specified torque 99000 32130 THREAD LOCK SUPER 1360 lBrake disc mounting bolt 10 N m 1 0 kgf m 7 0 Ib ft R...

Page 164: ...Rear axle nut 100 N m 10 0 kgf m 72 5 Ib ft For E 03 28 33 110 N m 11 0 kgf m 79 5 Ib ft For the other countries NOTe After installing the rear axle nut insert a new cotter pin into the rear axle For...

Page 165: ...hion lever Swmgarm pivot shaft SWlngarm Chain gUide CD Chain buffer Chain case J Rear shock absorber nul Cushion rod mounting nut Cushion lever mounllng nut Q Cushion lever mounting nut l J SWlngarm p...

Page 166: ...CHASSIS 6 31 A c ITEM N m kgf m Ib ft E 55 5 5 40 0 55 5 5 40 0 100 10 0 72 5 100 10 0 72 5 100 10 0 72 5 77 7 7 55 5 F http www motorcycle in th...

Page 167: ...r j Disconnect the brake lighVtaillight coupler left and right tum iyllallight couplers starter relay coupler and starter relay lead wires Disconnect the air cleaner breather hoses and loosen the car...

Page 168: ...caused by heat can cause an explosion Release gas pressure before disposing GAS PRESSURE RELEASE Remove the valve cap Press the valve with a screwdriver to bleed out the nitrogen gas A WARNING Releasi...

Page 169: ...259 5 mm 247 5 mm 10 16 in J 10 22 in 9 74 in A CAUTION Do not set the spring less than 247 5 mm 9 74 in Tighten the rear shock absorber upper and lower mounting nut to the specified torque Rear shock...

Page 170: ...just the compression damping force as follows Fully turn the damping adjuster clockwise to the hard setting position and then turn it out to the standard setting position Standard setting position Com...

Page 171: ...the rear brake caliper c 7 6 53 Remove the drive chain guide CD and chain case Disconnect the brake hose from the brake hose guide Remove the cushion lever mounting bolt and nut Rp mnVA thA wingarm p...

Page 172: ...FFER Inspect the chain buffer for wear and damage If any damages are lound replace the cnaln butter With a new one SWINGARM NEEDLE BEARINGS Insert the spacers into the needle bearings move the spacer...

Page 173: ...g remover 09930 30102 Sliding hammer IA CAUTIQI j Replace the removed needle bearings with new ones CUSHION LEVER AND CUSHION LEVER RODS Inspect the cushion lever and cushion lever rods for damage If...

Page 174: ...o the swingarm pivot using the special tool S 09941 34513 Steering outer race installer CUSHION LEVER NEEDLE BEARINGS Apply SUZUKI SUPER GREASE A to the spacers and needle bearings For USA 0 99000 250...

Page 175: ...55 5 Ib ft Tighten the cushion lever mounting nut to the specified torque J Cushion lever mounting nut 100 N m 10 0 kgf m 72 5 Ib ft FINAL INSPECTION AND ADJUSTMENT Aftor inctalling the rear wheel adj...

Page 176: ...e brake system otherwise serious damage to the brake system will result Do not use any brake fluid taken from old used or unsealed containers Do not reuse brake fluid left over from the last servicing...

Page 177: ...dversely affected Install the new brake pads A WARNING Make sure that the brake pad is properly engaged with the guide plate as shown in the photograph Tiohten thf hr kf p rI mnl Intina pin to thE spE...

Page 178: ...servoir with new brake fluid to the upper end of the in spection window ACAUTIONj Bleed air from the brake system c r 2 19 and 2 20 BRAKE CALIPER REMOVAL AND DISASSEMBLY Disconnect the brake hose trom...

Page 179: ...mage to the pistons will result Remove the dust seals and piston ssals ACAUTION I Do not reuse the dust se l and piston seals to pre vent fluid leakage BRAKE CALIPER INSPECTION BRAKE CALIPEn Inspect e...

Page 180: ...ponents with new brake fluid before reassembly Do not wipe the brake fluid off after washing the com ponents When washing the components use the specified brake fluid Never use different types of flui...

Page 181: ...nd 2 20 BRAKE DISC INSPECTION Check the brake disc for cracks or dan1dyt allU 111t C1 1ure ti le thickness using the micrometer If any damages are found or if the thickness is less than the service li...

Page 182: ...ting any part of the motorcycle The brake fluid reacts chemically with paint plastics rubber materials etc and will damage them severely Disconnect the front brake light switch lead wires CD Remove th...

Page 183: ...OUNTING Reassemble and remount the master cylinder In the reverse or der of removal and disassembly Pay special attention to the fol lowing points A AUTION Wash the master cylinder components with new...

Page 184: ...olt first Master cylinder clamp bolt 10 N m 1 0 kgf m 7 0 Ib ft Master cylinder Master cylinder upper clamp bolt H mrllp h u Clearance Tighten the brake hose union bolt to the specified torque Brake h...

Page 185: ...refilling the brake system otherwise serious damage to the brake system will result Do not use any brake fluid taken from old used or unsealed containers Do not reuse brake fluid left over from the l...

Page 186: ...affected Install the new brake pads A WARNING Make sure that the brake pad is properly engaged with the guide plate as shown in the photograph Tighten the brake pad mounting pin to the specified torq...

Page 187: ...eservoir cover CD and reservoir tank mounting bolt Remove the reservoir cap and diaphragm ReiJlac e Ihe brake flulO t J 6 43 Specification and classification DOT 4 A CAUTION Bleed air from the brake s...

Page 188: ...if it leaks will interfere with safe running and discolor painted surfaces Check the brake hose and hose joints for cracks and oil leakage Remove the brake pads c 7 6 51 Remove the brake caliper hold...

Page 189: ...4 L ACAUTiOi Wash the brake caliper components with new brake fluid before reassembly Do not wipe the brake fluid off after washing the com ponents When washing the components use the specified brake...

Page 190: ...BRAKE DISC c r 6 46 MASTER CYLINDER REMOVAL AND DISASSEMBLY Remove the reservoir cover eJ 6 52 Remove the reservoir mounting bolt Place a rag underneath the brake hose union boll on the master cylinde...

Page 191: ...linder as sembly Remove Ihe circlip and reservoir assembly Q Pull Ihe dust boot out and remove the circlip Remove the push rod and piston assembly D MASTER CYLINDER INSPECTION MASTER CYLINDER c r 6 48...

Page 192: ...d or clean ing solvents such as gasoline kerosine etc Apply brake fluid to the master cylinder bore and all of the master cylinder components before reassem bly i i Speclticatlon ana ClaSSIfication UO...

Page 193: ...OTOR REMOVAL AND DiSASSEMBLy 7 13 STARTER MOTOR INSPECTION 7 14 STARTER MOTOR REASSEMBLY AND REMOUNTING 7 15 STARTER RELAY INSPECTION 7 16 SIDE STANDIIGNITION INTERLOCK SYSTEM PARTS INSPECTION 7 17 IG...

Page 194: ...inal for corrosion and contamination CLAMPS Ref tu tile WIRE HARNESS CABLE AND HOSE ROUT ING section for proper clamping procedures c r 8 12 to 8 18 Bend the clamp properly as shown in the illustratio...

Page 195: ...r the MF battery is different from that of a conventional battery Do not replace the MF battery with a conventional battery CONNECTING THE BATTERY When dlsCOnneC lng ermlnals from me banery for disass...

Page 196: ...ge and current values are not known begin mea suring in the highest range When measuring the resistance make sure that no voltage is applied If voltage is applied the tester will be damaged After usin...

Page 197: ...S Q COl umt Slarier relay engine cooleant tcmpereoture therm03wilch 4 Horn Ignition sWitch Speedometer o FrU1l1Ulct1o 1 1 hylll tnll Q Right handlebar SWitch 0 Rear brake light SWitch ELECTRICAL SYSTE...

Page 198: ...ing fan thermoswltch Cooling fan molor 1 1 Ignition coil Q Battery ifP Fuse box SIde stand SWitch t o9ulntor roc ll cr O W Generator W Starter molor C r Neutral sWitch Throttle position sensor Turn si...

Page 199: ...regulator rectifier is one unit with two functions The regulator prevents overcharging of the battery by grounding the excessive AC current The rectifier changes the AC current which is produced by th...

Page 200: ...ct the regulator rectifier J 7 11 I Correct Correct Accessories r are installed Remove accessories Current leaks Short circuit of the wire harness Correct No continuity Loose or disconnected wires Fau...

Page 201: ...nition switch to the ON position when measuring tho curront When checking to find the excessive current leakage remove Ihe rnllrl r nrl r nnn r lnr nn hy nn r h r kinO r h r 1 REGULATED VOLTAGE Remove...

Page 202: ...tion Resistance 0 Stator coil resistance Standard 0 50 1 25 n Yellow Yellow n Yellow Ground AC GENERATOR NO LOAD PERFORMANCE Remove the left frame cover c 7 6 2 Disconnect the tdlul cuil It i 1u wire...

Page 203: ...08 Multi circuit tester set Tester knob indication Diode test e Tesler probe R 81W y y w R 0 5 1 2 0 4 0 7 0 4 0 7 e 81W 1 4 1 5 1 4 1 5 1 4 1 5 y 1 4 1 5 0 4 0 7 1 4 1 5 CD y 1 4 1 5 0 4 0 7 1 4 1 5...

Page 204: ...h lever Engine stop Ignition sWitch sWitch position switch r O R R Y G OIW Neutral l J switch Starter T Battery I Turn cigno l cidc stand relay switch TROUBLESHOOTING Starter motor will not run The tr...

Page 205: ...ter relay contact Tlltj tilCiILt 1 1I1UlUI IUllti wlu HI lilt llaJIt irllititiiurJ it ill leullal tJut jue I1U t rUll wtlen tile lrCiflt imit i iurl is in any position other than neutral with the side...

Page 206: ...ce the armature with a new one If the commutator surface is discolored polish it with 400 sand paper and wipe it using a clean dry cloth If there is no undercut scrape out the insulator CD with a saw...

Page 207: ...SUPER GREASE A to the lip of the oil seal For USA 99000 25030 SUZUKI SUPER GREASE A For the other countries 99000 25010 SUZUKI SUPER GREASE A Arrly m 11 l ntity nf 1171 IKI MOl Y PA TF tn thl rm ture...

Page 208: ...uity is found the relay is ok S 09900 25008 Multi circuit tester set Tester knob indication Continuity test oIl ACAUTION J Do not apply battery voltage to the starter relay for more than five seconds...

Page 209: ...d BlacklWhite lead wires with the transmission in neutral Blue BlacklWhite ON in neutral 0 0 OFF not in neutral SIDE STAND SWITCH The side stand switch coupler is located under the seat Remove the sea...

Page 210: ...continuity between ter minals and If there is no continuity replace the turn signal side stand relay with a new one em 09900 25008 Multi circuit tester set Tester knob indication Continuity test _11...

Page 211: ..._a_r_ k_o r p _o _o _r_s _p _a_r_ k____ I Check the ignition system couplers for poor connections I Correct Measure the battery voltage between input lead wires O W and B w at the COl unit with the ig...

Page 212: ...Faulty spark pluo Inspect the ignition coil CY 7 22 Correct Measure the pickup coil and signal coil peak voltage and resistance CY7 22 and 7 23 Improper spark plug connection Incorrect Faulty ignitio...

Page 213: ...rimary wire 09900 25008 Multi circuit tester set IAGAUTION I Before using the multi circuit tester and peak volt adap tor be sure to refer to the appropriate instruction manual Shift the transmission...

Page 214: ...re the pickup coil and signal coil peak voltage in the fol lowing procedure Connect the multi circuit tester with the peak volt adaptor as follows Pickup coil Blue 8 probe Green 8 probe Signal coil Bl...

Page 215: ...lead wires using the multi circuit tester If the resistance is not within the specified value the pickup coil and signal coil must be replaced miiib 09900 50011 Multi circuit tester set Tester knob i...

Page 216: ...r hghl assembly Speedometer assembly Speedometer cable REMOVAL Remove the headlight assembly c 7 7 29 nisconnect the speedometer cable CD speedometor coupler and indicator lights coupler Remove the sp...

Page 217: ...NGING THE DISPLAY MODE With each press of the MODE TRIP button the display changes between tripmeter A tripmeter B and the odometer as shown below 8 9 ELECTRICAL SYSTEM 7 25 Q Turn signal Indicator li...

Page 218: ...tton for three seconds to change the display as snown below ror I U U3 33 A WARNING To avoid riding with only one hand do not operate the buttons while riding NOTE Make sure not to press more than one...

Page 219: ...P button to reset the tripmeter lIo AE 5P Make addition or subtrac tion calculations Displays the distance with a calibration coefficient 70 130 applied Hold down the SETTIMEfTRIP button for three sec...

Page 220: ...onds to reset the stopwatc TIMER This 24 hour timer or countdown timer displays me minutes seconds and 1 100 seconds up to one hour After one hour the hours minutes and seconds are displayed li j b s...

Page 221: ...LB REPLACEMENT Remove the headlight cover G and headlighl bracket mount ing bolt g Remove the position light coupler For E 02 19 54 Remove Ihe turn signal side stand relay ffi Disconnect the headlight...

Page 222: ...ulb failure FRONT AND REAR TURN SIGNAL LIGHT Turn signal light 12 V 21 W FRONT AND REAR TURN SIGNAL LIGHT BULB REPLACEMENT Remove the front turn signal light lens CD and rear turn signal light lens a...

Page 223: ...CEMENT Remove Ihe brake light taillight lens Remove the brake light laillight bulb A CAUTION I If you touch the bulb w ith your bare hands elean the bulb with a cloth moistened with alcohol or soapy w...

Page 224: ...PECTION Before removing the turn signal side stand relay check the op eration of the turn signal light If the turn signal light does not illuminate inspect the bulb turn signal switch and circuit conn...

Page 225: ...03 28 33 Color t Posltion oln PUSH 0 Gr Y w n J W Y 0 0 Lbt B C D 0 O W 0 Y 0 STARTER BUTTON r Position O W Y G PUSH 0 HORN BUTTON Position BIBI B w PUSH 0 FRONT BRAKE LIGHT SWITCH r Position B B R Ur...

Page 226: ...4 12 V 23 4 kC 6 5 Ah 10 HR SERVICING Visually inspect the surface of the battery container If any signs Of cracking or electrolyte leakage from me Sides Of me banery have occurred replace the batter...

Page 227: ...t 30 minutes and then measure the battery voltage using the multi circuit tester If the battery voltage is less than 12 6 V recharge the battery again If the battery voltage is still less than 12 6 V...

Page 228: ...L INFORMATION 9 1 EMISSION CONTROL INFORMATION CONTENTS EMISSION CONTROL CARBURETOR COMPONENTS 9 2 EVAPORATIVE EMISSION CONTROL SYSTEM FOR E 33 9 3 CANISTER HOSE ROUTING 9 4 INSPECTION 9 5 http www mo...

Page 229: ...it witn a jet needle of me same type SUZUKI recommends mat Genuine uzuKI I arts be utilized whenever possible for the best possible periormance and durability Conventional figures used on 1 2 3 4 5 6...

Page 230: ...SSION CONTROL SYSTEM FOR E 33 Fuel filler cap Fuelliller pipe ellank Fuel vapor separator I I Vacuum hose Fuel valve FUEL Fuel hose 4 FRESH AIR HCVAPOR J VACUUM Purge port Purge hose Roll over valve C...

Page 231: ...r hose Fuel valve Fuel hose Purge hose Aoll over valve G Set the formed side of the hose to the fuel tank and face the exhaust end of the hose to the left e Pass the purge hose under the frame air cle...

Page 232: ...ES Inspect me noses tor wear or damage It any damages are tound replace the hoses with new ones Make sure that the hoses are properly connected CANISTER Inspect the canister body for damage If any dam...

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Suzuki drz 400 2000, Service Manual

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