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Suzuki FL2, Setup Manual

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Suzuki FL2 Setup Manual Download Page 1

L2

© COPYRIGHT SUZUKI MANUFACTURING OF AMERICA CORPORATION 

Aug. ’11 (CLA) 28

99505-01042-01E

EN

FOREWORD

This vehicle has been designed and produced utilizing Suzuki’s most modern tech-
nology. The finest product, however, cannot perform properly unless it is correctly
assembled and serviced. This set-up manual has been produced to aid you in prop-
erly assembling and servicing this vehicle.

Please read this manual and follow its instructions carefully. To emphasize special
information, the symbol 

 and the words WARNING,  CAUTION, 

NOTICE

 and

NOTE

 have special meanings. Pay particular attention to messages highlighted by

these signal words:

Indicates a potential hazard that could result in death or serious injury

Indicates a potential hazard that could result in minor or moderate injury.

Indicates a potential hazard that could result in vehicle or equipment damage.

NOTE:
Indicates special information to make maintenance easier or instructions clearer.

This set-up manual is based on a vehicle of standard specification. Some minor dif-
ferences from this manual may be found in other specifications.

Summary of Contents for FL2

Page 1: ...ly To emphasize special information the symbol and the words WARNING CAUTION NOTICE and NOTE have special meanings Pay particular attention to messages highlighted by these signal words Indicates a potential hazard that could result in death or serious injury Indicates a potential hazard that could result in minor or moderate injury Indicates a potential hazard that could result in vehicle or equi...

Page 2: ...Place the packed vehicle on a level floor where it is clean and spacious CAUTION Assembling the vehicle without proper clothes and protective gear can be hazardous You can be injured if you do not wear proper clothes and protective gear Be sure to wear proper clothes and shoes for assembling and wear protective glasses mask or gloves as necessary ...

Page 3: ...f crate CAUTION Crate has nails and may have sharp splinters that could cause injury Wear proper protective clothes and gear CAUTION Careless use of cutter can injure a person Wear proper protective clothes and gear Use a cutter with the proper method CAUTION Careless crate separation can injure a person Lift the top part with two persons Wear proper protective clothes and gear ...

Page 4: ...eless use of cutter can injure a person Wear proper protective clothes and gear Use a cutter with the proper method NOTE Cut the carton from the top to the bottom along the perforated lines on both sides at each end Be careful not to damage the vehicle CAUTION Careless inappropriate handling of the disman tled crate can injure a person Wear proper protective clothes and gear ...

Page 5: ...move the battery electrolyte container stored in the front grip A Component parts box B Battery electrolyte container 1 Lift the vehicle with a hoist then balance the vehi cle 2 Pull the crate base forward 3 Place the vehicle in a clean working area and remove the hoist and hooks NOTE The J hook nut cardboard washer and rubber are not necessary to assemble the machine ...

Page 6: ...rear fender 2 Right and Left Fastener 10 Screw 2 5 20 mm Screw 2 5 25 mm Washer 4 OD 20 0 ID 5 5 Rubber cushion with nut 4 5 mm L 21 0 Item Part Name Q ty Remarks D Reflex reflector 2 For E 17 Flange nut 2 5 mm E Warning label set 1 For E 17 F DVD 1 For E 17 G Battery electrolyte container 1 H Owner s manual 1 NOTE Item B and H are located in the box under the seat H For E 24 28 The parts shown as...

Page 7: ...6 COMPONENT PARTS Check that the component parts are in the box A Owner s manual For E 24 28 B Battery holder kit C Box ...

Page 8: ... customer ASSEMBLY REMOVING THE WRAP FILM Remove the wrap film from the front and rear fenders A Wrap film MUD GUARD FRONT FENDER FOR E 17 24 Remove screws washers and rubber cushions with nuts A Screw washer rubber cushion with nut Align the mud guard front fender to the front fender A Mud guard front fender B Front fender NOTE The screws washers and rubber cushions with nuts are not necessary to...

Page 9: ...EFLECTOR FOR E 17 Align the boss of reflex reflector to the hole of mud guard rear fender Install the reflex reflector to the mud guard rear fender A Mud guard rear fender B Reflex reflector C Boss D Hole E 5 mm flange nut MUD GUARD REAR FENDER FOR E 17 E 24 Align the mud guard rear fender to the rear fender A Mud guard rear fender B Rear fender NOTE To install the fastener pull the center pin as ...

Page 10: ... Align the parts and secure them with the screw A A 5 x 20 mm screw B Washer OD 20 0 mm ID 5 5 mm C Rubber cushion with nut 5 mm L 21 0 mm D Mud guard rear fender E Extension bracket WARNING LABEL FOR E 17 Select the appropriate language label for your country NOTE To install the fastener pull the center pin as C and fix the fastener by pushing the center pin as D Arrows show direction of fastener...

Page 11: ...ng label General warning B Warning label Tire information C Warning label Age 16 D Warning label Gear shifting For French only E Warning label Trailer tow F Front fender Right G Rear fender Right REAR RIGHT Stick the label E Warning label Trailer tow For French only ...

Page 12: ... the seat Pull the seat lock lever and remove the seat A Seat B Seat lock lever Pull the clips up and remove the cover A Cover B Clip C Hook Check the Owner s manual stored in the box Take out the battery holder kit from the box Reinstall the box cover D Owner s manual For E 24 28 E Battery holder kit F Box ...

Page 13: ...F G Rear brake switch lead wire H Parking brake switch lead wire I Front brake switch lead wire J Horn switch lead wire For E 17 24 K Emergency switch lead wire For E 17 NOTE The line drawings on page 28 29 30 and 31 show the proper routing of the control cables hose and wirings Refer to them in addition to following the instruc tions carefully ...

Page 14: ...ium tape sealing the battery elec trolyte filler holes A Aluminium tape B Electrolyte filler hole Remove the caps from the electrolyte container A Caps B Sealed area NOTE Use the removed caps as the sealing cap of bat tery filler holes Do not remove or pierce the sealed areas of the electrolyte container ...

Page 15: ...firmly so that it does not fall Take precaution not to allow any of the fluid to spill A Electrolyte containers Make sure air bubbles are coming up in each electro lyte container and leave in this position for about 20 minutes A Air bubbles NOTE If no air bubbles are coming up from a filler port tap the bottom of the container two or three times Never remove the container from the battery ...

Page 16: ...y make sure to use the charger specially designed for MF battery Other wise the battery may be overcharged resulting in shortened service life Do not remove the cap during charging Position the battery with the cap facing upward during charging NOTICE Connecting the battery lead wires with the igni tion switch ON can damage the motorcycle Turn off the ignition switch before connecting or disconnec...

Page 17: ...with rubber boot 4 Connect the lead to the negative terminal of the battery A lead B lead C Rubber boot Install the battery holder A Battery holder B 6 16 mm flange bolt Reinstall the seat Insert the seat hook into the seat hook retainer and push the seat down firmly A Seat assembly B Seat hook C Seat hook retainer D Boss E Hole ...

Page 18: ...o the con tainer so that the end of the clear hose is sub merged and cannot draw any additional air back into the circuit during the air bleeding servicing 3 Close the valve pump and squeeze the lever and open the valve while squeezing brake lever 4 Repeat this process until the fluid flowing into the receptacle no longer contains air bubbles 5 After bleeding the brake circuit tighten the bleeder ...

Page 19: ...ee play is available and that the cable housing is properly seated in the adjuster A 4 Tighten the lock nut B while holding the adjuster A 5 Place the rubber boot C REAR PARKING BRAKE Adjust the rear brake by adjusting the brake pedal first and then adjust the brake lever WARNING Inadequate throttle cable play can cause engine speed to rise suddenly when you turn the han dlebars This can lead to l...

Page 20: ...urn in the adjuster A as far as possible 2 Turn the adjuster C to obtain the correct play 3 Minor adjustments can now be made with the brake lever adjuster A 4 Tighten the lock nut B while holding the adjuster A 5 Place the lever cover D 6 After adjusting the play check that the rear wheels roll freely with the brake disengaged the transmis sion in neutral and the rear wheels off the ground 7 Set ...

Page 21: ...e lock nut F and turn out the adjuster G slowly until resistance is felt Then turn the adjuster G one more turn out from that position 4 Tighten the lock nut F while holding the adjuster G 5 Place the rubber boot H 6 Reinstall the steering head cover D E 2WD 4WD selection cable F Lock nut G Adjuster H Rubber boot TIRE PRESSURE Using an accurate air gauge check the air pressure of the front and rea...

Page 22: ...hten them securely A Oil filler plug B Oil level bolt FINAL GEAR OIL Place the vehicle on a level ground Check the final gear oil levels as follows Remove the oil level bolt If the oil level is below the level hole add the gear oil through the filler hole until the oil flows out from the level hole Reinstall the oil level bolt and the oil filler plug Tighten them securely A Oil filler plug B Oil l...

Page 23: ... oil level 7 If the level is below the L Low line add fresh oil from the filler hole If the level is above the F Full line drain oil from the drain hole 8 Reinstall the drain plug and engine oil filler plug Tighten them securely 9 Reinstall the footrest guard lid A Engine oil filler plug B Engine oil dipstick NOTE This vehicle is shipped from factory with the engine filled with engine oil NOTICE O...

Page 24: ...il container shows the classification as shown A Code number of oil sales company B Oil classification Energy Conserving Suzuki does not recommend the use of ENERGY CONSERVING oils Some engine oils which have an API classification of SH or higher have an ENERGY CONSERVING indi cation in the API classification doughnut mark These oils can affect engine life and clutch perform ance SAE API JASO 10W ...

Page 25: ...e fastener To remove the fastener C turn the center pin counter clockwise while holding outer and pull out the fastener NOTE The engine idle should be adjusted with engine warmed up NOTE Use only unleaded gasoline with an octane rating of 91 or higher Research method or Use only unleaded gasoline of at least 87 pump octane R 2 M 2 method Unleaded gasoline can extend spark plug life and exhaust com...

Page 26: ...affic reg ulations Check km h and mph display after adjusting the instru ment panel display A Function change button B Speedometer display km h mph Test ride the vehicle checking all mechanical functions Tighten all nuts bolts and miscellaneous mounting parts to the proper torque specs Confirm that all cables and wiring harnesses are con nected and routed correctly ...

Page 27: ...mounting bolt upper 55 5 5 F Front shock absorber mounting bolt lower 60 6 0 G Front brake master cylinder mounting bolt 10 1 0 H Front brake caliper mounting bolt 26 2 6 I Front suspension arm pivot nut 65 6 5 Item Part Name N m kgf m REAR SUSPENSION AND REAR BRAKE J Rear shock absorber mounting nut upper 35 3 5 K Rear shock absorber mounting nut lower 60 6 0 L Rear hub nut 121 12 1 M Rear wheel ...

Page 28: ...32 3 2 23 0 12 50 5 0 36 0 14 72 7 2 52 0 16 116 11 6 84 0 A equivalent of 4T strength bolt with flange 18 176 17 6 127 5 Bolt type Thread diameter Nominal diameter A mm Unit N m kgf m lbf ft 4 2 3 0 23 1 5 5 4 5 0 45 3 5 6 10 1 0 7 0 8 23 2 3 16 5 10 50 5 0 36 0 12 85 8 5 61 5 14 135 13 5 97 5 A equivalent of 7T strength bolt without flange and small crown shape bolt 1 16 210 21 0 152 0 18 240 24...

Page 29: ...ttle cable Front brake switch lead wire Washer Cotter pin Transfer cable LT A400F Clamp Clamp Clamp Throttle cable Rear brake cable Pass the breather hose outside of the cable Rear brake cable Rear brake cable Pin Parking brake cable Parking brake cable Parking brake cable Front brake switch lead wire Pass the starter cable in front of the wiring harness Throttle cable Front brake hose Pass the th...

Page 30: ...rottle cable Throttle cable Throttle cable Parking brake cable Pass the throttle cable and parking brake cable through the guide Clamp Starter cable Wiring harness Wiring harness guide E 28 Frame Clamp Starter cable Wiring harness Frame INSIDE INSIDE Clamp Starter cable Wiring harness Wiring harness Clamp Starter cable Frame INSIDE ...

Page 31: ...ng harness guide E 28 Mud protector E 24 Clamp Wiring harness Wiring harness Wiring harness guide E 28 Starter cable Starter cable Cooling fan motor lead wire Pass over the bridge Pass the starter motor lead wire under the hose Mud protector E 24 Clamp Back lamp lead wire E 17 Back lamp relay lead wire E 17 Rear combination light lead wire Clamp Horn switch lead wire E 17 24 ...

Page 32: ...Fuel cut sensor lead wire Gear in start switch lead wire Speedometer lead wire Stop lamp switch lead wire Horn switch lead wire E 17 24 Clamp Handlebar switch lead wire L Gear in start switch lead wire Horn switch lead wire E 17 24 Stop lamp switch lead wire Clamp Headlight lead wire L Horn switch lead wire E 17 24 Speed sensor lead wire Mud protector E 24 Throttle cable Stop lamp switch Speed sen...

Page 33: ...g and cable Routing Operation Wiring connectors Clean Tight Suspensions Check Tighten all nuts and bolts Torque those listed in this manual Cotter pins circlip and fasteners Check Paint and chrome Inspect Wash and polish Warning label For E 17 Select Stick TIRE PRESSURE FRONT REAR 32 5 kPa 0 325 kgf cm2 4 7 psi 30 kPa 0 30 kgf cm2 4 4 psi ITEM CHECK FOR Light Lighting Adjust Headlight high low bea...

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