Suzuki GSX1300BK B-King Owner'S Manual Download Page 82 | Manualshive

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3-6

COOLANT

Use an anti-freeze compatible with alumin-
ium radiator mixed with distilled water only
at the ratio of 50:50.



WARNING

Engine coolant is harmful or fatal if swal-
lowed or inhaled.

Do not drink antifreeze or coolant solu-
tion. If swallowed, do not induce vomit-
ing. Immediately 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
medical attention. Wash thoroughly after
handling. Solution can be poisonous to
animals. Keep out of the reach of chil-
dren and animals.

CAUTION

Spilled engine coolant can damage
painted surfaces.

Do not spill any fluid when filling the
radiator. Wipe spilled engine coolant up
immediately.

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Summary of Contents for GSX1300BK B-King

Page 1: ...p p GSX1300BK OWNER S MANUAL Part No 99011 23H50 01A June 2007 EN TK...

Page 2: ...t of the motorcycle and should remain with the motorcycle when resold or otherwise transferred to a new owner or operator The manual contains important safety information and instructions which should...

Page 3: ...quality mate rials and machined parts are finished to close tolerances Proper break in operation allows the machined surfaces to polish each other and mate smoothly Motorcycle reliability and perform...

Page 4: ...n this Owner s Manual before riding the motorcycle The proper care and maintenance that your motorcycle requires is outlined in this man ual By following these instructions explicitly you will ensure...

Page 5: ...anges there may be some discrepancies between information in this manual and your motorcycle Suzuki reserves the right to make changes at any time Please note that this manual applies to all specifica...

Page 6: ......

Page 7: ...SUMER INFORMATION CONTROLS FUEL ENGINE OIL AND COOLANT RECOMMENDATIONS BREAK IN RUNNING IN AND INSPECTION BEFORE RIDING RIDING TIPS INSPECTION AND MAINTENANCE TROUBLESHOOTING MOTORCYCLE CLEANING AND S...

Page 8: ......

Page 9: ...1 1 1 CONSUMER INFORMATION ACCESSORY USE AND MOTORCYCLE LOADING 1 2 SAFE RIDING RECOMMENDATION FOR MOTORCYCLE RIDERS 1 7 SERIAL NUMBER LOCATION 1 9 NOISE CONTROL SYSTEM AUSTRALIA ONLY 1 10...

Page 10: ...es however your dealer can assist you in selecting quality accesso ries and installing them correctly Use extreme caution when selecting and install ing the accessories on your motorcycle and consult...

Page 11: ...to the handlebars or the front fork area can create serious stability problems This extra weight will cause the motorcycle to be less respon sive to your steering control The weight may also cause os...

Page 12: ...as the weight of the accessories The additional weight of the accessories may not only create an unsafe riding condition but may also affect the riding stability G V W 460 kg 1010 lbs at the tire pre...

Page 13: ...erly inflated to the specified tire pressure for your loading conditions Refer to page 6 53 Improperly loading your motorcycle can reduce your ability to balance and steer the motorcycle You should ri...

Page 14: ...t ing condition and subsequent accident Suzuki will not be responsible in any way for personal injury or damage to the motorcycle caused by frame modifications Bolt on accessories that do not modify t...

Page 15: ...se fancy clothing can be uncomfortable and unsafe when riding your motorcycle Choose good quality motorcycle riding apparel when riding your motorcycle INSPECTION BEFORE RIDING Review thoroughly the i...

Page 16: ...especially slippery Use extreme caution at railway crossings and on metal gratings and bridges Whenever in doubt about road con dition slow down RIDE DEFENSIVELY The most common type of motorcycle ac...

Page 17: ...d to assist your dealer when order ing parts or referring to special service infor mation The frame number 1 is stamped on the steering head tube The engine serial number 2 is stamped on the crankcase...

Page 18: ...ny person other than for purposes of maintenance repair or replacement of any device or element of design incorpo rated into any new vehicle for the pur pose of noise control prior to its sale or deli...

Page 19: ...6 IGNITION SWITCH 2 7 INSTRUMENT PANEL 2 10 SUZUKI DRIVE MODE SELECTOR 2 32 LEFT HANDLEBAR 2 34 RIGHT HANDLEBAR 2 38 FUEL TANK CAP 2 42 GEARSHIFT LEVER 2 44 REAR BRAKE PEDAL 2 45 SEAT LOCK AND HELMET...

Page 20: ...ront brake lever 2 Left handlebar switches 9 INFO switch 3 Clutch fluid reservoir 0 SET switch 4 Instrument panel A Ignition switch 5 Front brake fluid reservoir B Fuel tank cap 6 Right handlebar swit...

Page 21: ...2 3 D Helmet holder E Tools F Seat lock G Side stand H Gearshift lever...

Page 22: ...2 4 I Rear brake pedal...

Page 23: ...ference NOTE Attaching key holder or some chain to the ignition key can damage plated parts and painted parts around the ignition switch Use only the ignition key or a soft key holder to avoid plating...

Page 24: ...ys are lost the ECM should be replaced NOTE Attaching key holder or some chain to the ignition key can damage plated parts and painted parts around the ignition switch Use only the ignition key or a s...

Page 25: ...cles with immobi lizer keys keep those keys away from the ignition switch when using your motorcycle or they may interfere with your motorcycle immobilizer system Two keys are originally registered to...

Page 26: ...be removed from the ignition switch in this position NOTE Start the engine promptly after turn ing the key to the ON position or the bat tery will lose power due to consumption by the headlight and t...

Page 27: ...ncrease visi bility The key hole can be covered by turning the lid WARNING Turning the ignition switch to the P PARKING or LOCK position while the motorcycle is moving can be hazardous Moving the moto...

Page 28: ...ENT PANEL The fuel injection system indicator light 3 coolant temperature indicator light 4 oil pressure indicator light D LCD and meter needle work as follows to confirm their func tion when the igni...

Page 29: ...needle does not point to zero follow the procedure below to reset the meter 1 Press and hold the ADJ button 0 and turn on the ignition switch 2 Hold the ADJ button 0 for 3 seconds TURN SIGNAL INDICATO...

Page 30: ...ANT TEMPERATURE METER 5 The coolant temperature meter indicates engine coolant temperature When the cool ant temperature becomes high the indicator light 4 comes on 3 2 4 5 6 7 8 9 10 11 12 1 0 x1000r...

Page 31: ...r minute r min CAUTION Running the engine with high engine coolant temperature can cause serious engine damage If the engine coolant temperature indicator light comes on stop the engine to let it cool...

Page 32: ...r modes 1 clock odometer trip meter and fuel injection system indicator 2 maintenance interval 3 running time 4 average speed The infor mation display will be changed by pushing the INFO switch on the...

Page 33: ...2 15 The display will be changed as shown above when the INFO switch is pushed NOTE Clock and trip meter can be adjusted only when the clock and odometer trip meter is displayed...

Page 34: ...DJ button 0 simultaneously for 2 seconds until return to the clock mode Odometer Trip Meter Fuel Injection System Indicator The indicator displays odometer trip meter under normal condition The indica...

Page 35: ...meter then press and hold ADJ button 0 for 3 seconds to change between km h and mph Except for Canada and Australia Select km h or mph as appropriate to comply with traffic regulations Check the km h...

Page 36: ...distance and trip meter 2 can register the distance between fuel stops To reset the meter to zero push the ADJ button 0 for 2 seconds while the display indicates the trip meter 1 or 2 you want to res...

Page 37: ...he red indicator light 3 comes on and remains lit B The display 7 indicates FI continu ously and the red indicator light 3 blinks The engine may continue to run in mode A but the engine will not run i...

Page 38: ...s lit keep the engine running and bring your motorcycle to an authorized Suzuki dealer If the engine stalls try restarting the engine after turning the ignition switch off and on If the display indica...

Page 39: ...lowing items Make sure that the engine stop switch is in the position Make sure that the transmission is in neutral or the side stand is fully up If the display still indicates CHEC after checking th...

Page 40: ...2 22 Maintenance Interval The maintenance interval display comes on to notify maintenance timing Initial preset maintenance interval is 1000 km 600 miles 3 2 4 5 6 7 8 9 10 11 12 1 0 x1000r min km h...

Page 41: ...alternately when maintenance interval meter comes zero Reset the display to turn off the M mark To reset the maintenance interval 1 Turn off the ignition switch 2 Push SET switch and turn on the igni...

Page 42: ...nd negative S mark Display shows preset interval value 3 Push SET switch to decrease from 6000 km 3600 miles to 500 km 300 miles in 500 km 300 miles steps 4 Push INFO switch to increase from 500 km 30...

Page 43: ...ing time 1 Push SET switch to turn on the running timer mark will start blinking 2 Push the SET switch to stop counting mark goes off 3 Push the SET switch to restart counting mark starts blinking To...

Page 44: ...ignition switch is turned on To turn on off average speed 1 Push SET switch to turn on the average speed counter mark will start blink ing 2 Push the SET switch to stop counting mark goes off 3 Push...

Page 45: ...ning in the fuel tank The fuel meter displays all 6 segments when the fuel tank is full The mark flickers when the fuel level drops below 3 3 L 3 5 2 9 US Imp qt The mark and segment flicker when the...

Page 46: ...hen indicator comes on 2 seconds and goes off Immobilizer system is designed to help pre vent motorcycle theft by electronically dis abling the engine starting system The engine can be started only wi...

Page 47: ...ndicator blinks numbers of registered key when the ignition switch is turned on The indicator blinks for 24 hours after the ignition switch is turned off If your own spare key or other vehicle s immob...

Page 48: ...light should go off 3 2 4 5 6 7 8 9 10 11 12 1 0 x1000r min km h CAUTION Riding the motorcycle when the oil pres sure indicator light is lit can damage the engine and transmission Whenever the oil pr...

Page 49: ...drive mode indicator displays drive mode A or B Refer to the SUZUKI DRIVE MODE SELECTOR section for detail GEAR POSITION INDICATOR F The gear position indicator indicates gear position This indicator...

Page 50: ...Mode Selector Operation Drive mode is preset at A mode when the ignition switch and the engine stop switch are turned on Follow the procedure below to operate the suzuki drive mode selector 1 Turn on...

Page 51: ...e change operation is failed Turning off the ignition switch or the engine stop switch will return the drive mode to A mode Start the engine and reset the drive mode Drive Mode Engine power Throttle o...

Page 52: ...ueezing the lever disengages the clutch HEADLIGHT FLASHER SWITCH 2 Press the switch to flash the headlight high beam The headlight high beam will be lit when the dimmer switch is in LO position DIMMER...

Page 53: ...arking or when your vehicle could other wise become a traffic hazard CAUTION Holding the dimmer switch between HI and LO position will light both HI and LO headlight beam This operation can dam age th...

Page 54: ...ancel turn signal opera tion push the switch in HORN SWITCH 6 Press the switch to sound the horn WARNING Failure to use the turn signals and fail ure to turn off the turn signals can be hazardous Othe...

Page 55: ...on always be sure the adjuster stops in the proper position a projection of the clutch lever holder should fit into the depres sion of the adjuster This motorcycle is deliv ered from the factory with...

Page 56: ...circuit is on and the engine can run FRONT BRAKE LEVER 2 The front brake is applied by squeezing the brake lever gently toward the throttle grip This motorcycle is equipped with a disk brake system an...

Page 57: ...position always be sure the adjuster stops in the proper position a pro jection of the brake lever holder should fit into the depression of the adjuster This motorcycle is delivered from the factory w...

Page 58: ...on to operate the starter motor and start the engine NOTE This motorcycle is equipped with interlock switches for the ignition circuit and the starter circuit The engine can only be started if The tra...

Page 59: ...engine speed Turn it away from you to decrease engine speed CAUTION To prevent electrical system damage do not operate the starter motor more than 5 seconds at a time If the engine does not start aft...

Page 60: ...cap insert the ignition key into the lock and turn it clockwise With the key inserted lift up with the key and open the fuel tank cap To close the fuel tank cap push the cap down firmly with the key i...

Page 61: ...fill the fuel above the bottom of the filler neck WARNING Fuel and fuel vapor are highly flammable and toxic You can be burned or poi soned when refueling Stop the engine and keep flames sparks and he...

Page 62: ...red depress or lift the lever halfway between 1st and 2nd gear NOTE When the transmission is in neutral the green indicator light on the instrument panel will be lit However even though the light is i...

Page 63: ...the rear disk brake The brake light will be illuminated when the rear brake is operated SEAT LOCK AND HELMET HOLDER Front Seat To remove the front seat insert the ignition key into the lock and turn i...

Page 64: ...at snaps into locked posi tion Helmet Holder This motorcycle has helmet holder under the front seat Hook your helmet to the helmet holder and lock the seat WARNING Failure to install the seat properly...

Page 65: ...wn to hook passenger s helmet WARNING Riding with a helmet fastened to the hel met holder can interfere with rider con trol Never carry a helmet fastened to the hel met holder Fix the helmet securely...

Page 66: ...2 48 Rear Seat The seat lock is located under the front seat To remove the rear seat pull the seat lock wire Raise the front end of the seat and slide it forward...

Page 67: ...t snaps into the locked position Seat Tail Cover A seat tail cover for solo riding can be attached by using the same procedure as for installing the rear seat WARNING Failure to install the seat prope...

Page 68: ...raps from the hooks and reinstall the rear seat with the straps out Hook bands to the straps to fix luggage on the rear seat SIDE STAND An interlock switch is provided to cut off the ignition circuit...

Page 69: ...ransmission in gear 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 igni tion inte...

Page 70: ...d rear suspensions are selected to meet various riding conditions such as low to high motor cycle speed and light to heavy load on the motorcycle The suspension settings can be adjusted for your prefe...

Page 71: ...uster counterclockwise will decrease the spring pre load There are 5 grooved lines on the side of the adjuster 1 for reference Position 5 provides the minimum spring pre load and position 0 provides t...

Page 72: ...ust the damping force set the adjuster to the standard setting first and then adjust the adjuster to the desired position To set the rebound damping force adjuster to the standard position turn the ad...

Page 73: ...stiffen the damping force Turn the adjuster counterclockwise to soften the damping force The damping force should be adjusted gradually 1 click at a time to fine tune the suspension NOTE Do not loose...

Page 74: ...is job Damping Force Adjustment The rebound and compression damping force can be individually adjusted by turning the respective adjusters The rebound damping force adjuster 1 is located at the bottom...

Page 75: ...unch marks align If the two punch marks do not align by turning out 2 turns turn in or out the adjuster until two punch marks align Turn the adjuster clockwise from the stan dard position to stiffen t...

Page 76: ...punch marks align If the two punch marks do not align by turning out 2 turns turn in or out the adjuster until two punch marks align Turn the adjuster clockwise from the stan dard position to stiffen...

Page 77: ...3 1 3 FUEL ENGINE OIL AND COOLANT RECOMMENDATIONS FUEL 3 2 ENGINE OIL 3 4 COOLANT 3 6...

Page 78: ...our motor cycle without jeopardizing the New Vehicle Limited Warranty or the Emission Control System Warranty NOTE The GSX1300BK engine is designed to use premium unleaded gasoline only Use premium un...

Page 79: ...ty or the Emis sion Control System Warranty NOTE To help minimize air pollution Suzuki recommends that you use oxygenated fuels Be sure that any oxygenated fuel you use has octane ratings of at least...

Page 80: ...e classifica tion of SF SG or SH SJ or with a JASO classification of MA API American Petroleum Institute JASO Japanese Automobile Standards Organization SAE Engine Oil Viscosity Suzuki recommends the...

Page 81: ...MA and MB The oil container shows the classification as fol lows 1 Code number of oil sales company 2 Oil classification Energy Conserving Suzuki does not recommend the use of ENERGY CONSERVING oils...

Page 82: ...ing Immediately 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 medical attention...

Page 83: ...the atmospheric temper ature in your area does not go down to freezing point Required amount of water coolant Solution capacity total 2900 ml 3 1 2 6 US Imp qt NOTE This 50 mixture will protect the co...

Page 84: ......

Page 85: ...MAXIMUM ENGINE SPEED RECOMMENDATION 4 2 VARY THE ENGINE SPEED 4 2 BREAKING IN THE NEW TIRES 4 3 AVOID CONSTANT LOW SPEED 4 3 ALLOW THE ENGINE OIL TO CIRCULATE BEFORE RIDING 4 4 OBSERVE YOUR FIRST AND...

Page 86: ...ng the break in period VARY THE ENGINE SPEED The engine speed should be varied and not held at a constant speed This allows the parts to be loaded with pressure and then unloaded allowing the parts to...

Page 87: ...LOW SPEED Operating the engine at constant low speed light load can cause parts to glaze and not seat in Allow the engine to accelerate freely through the gears without exceeding the recommended maxi...

Page 88: ...will receive During break in operation all of the engine components will have mated together and seated Maintenance required as part of the initial service includes correc tion of all adjustments tigh...

Page 89: ...ge Always perform a pre ride inspection before each ride Refer to the table on page 4 6 for check items For further details refer to the INSPECTION AND MAINTENANCE section WARNING Using worn improperl...

Page 90: ...e stop switch and throttle WHAT TO CHECK CHECK FOR Steering Smoothness No restriction of movement No play or looseness Throttle Correct play in the throttle cable Smooth operation and positive return...

Page 91: ...Correct pressure Adequate tread depth No cracks or cuts Engine oil Correct level Cooling system Proper coolant level No coolant leakage Lighting Operation of all lights and indicators Horn Correct fun...

Page 92: ......

Page 93: ...5 1 5 RIDING TIPS STARTING THE ENGINE 5 2 STARTING OFF 5 4 USING THE TRANSMISSION 5 6 RIDING ON HILLS 5 8 STOPPING AND PARKING 5 8 CARRYING A PASSENGER 5 11...

Page 94: ...and the clutch is disen gaged When the Engine is Cold 1 Close the throttle completely and push the electric starter button 2 After the engine starts let the engine run until the engine sufficiently w...

Page 95: ...rless and can cause death or severe injury Only run the engine outdoors where there is fresh air CAUTION Running the engine too long without riding may cause the engine to overheat Overheating can res...

Page 96: ...of your skills your motorcycle and the riding conditions WARNING Removing your hands from the handle bars or feet from the footrests during operation can be hazardous If you remove even one hand or f...

Page 97: ...lose the throttle and squeeze the clutch lever simultaneously Lift the gear shift lever upward to select the next gear release the clutch lever and open the throttle again Select higher gears in this...

Page 98: ...ions Never slip the clutch to control road speed but rather downshift to allow the engine to run within its normal operational range For Canada The table below shows the approximate speed range for ea...

Page 99: ...rev in the lower gear resulting in engine dam age Reduce speed before downshifting WARNING Downshifting while the motorcycle is leaned over in a corner may cause rear wheel skid and loss of control Re...

Page 100: ...fting to a lower gear Con tinuous brake application can overheat the brakes and reduce their effective ness Be careful however not to allow the engine to over rev STOPPING AND PARKING 1 Twist the thro...

Page 101: ...hile turning may cause wheel skid and loss of control Brake before you begin to turn WARNING Hard braking on wet loose rough or other slippery surfaces can cause wheel skid and loss of control Brake l...

Page 102: ...neutral before starting engine 6 Turn the ignition key to the OFF posi tion 7 Turn the handlebars all the way to the left and lock the steering for security 8 Remove the ignition key NOTE If an optio...

Page 103: ...ur passenger not to make any sudden move ments When you lean going around a cor ner the passenger should lean with you The passenger should always keep his or her feet on the footrests even when you a...

Page 104: ......

Page 105: ...ERY 6 9 AIR CLEANER 6 11 SPARK PLUGS 6 21 FUEL HOSE 6 25 ENGINE OIL 6 26 ENGINE IDLE SPEED INSPECTION 6 34 THROTTLE CABLE PLAY 6 34 CLUTCH 6 35 COOLANT 6 37 DRIVE CHAIN 6 39 BRAKES 6 45 TIRES 6 51 SID...

Page 106: ...wheel com ponents are key items and require very spe cial and careful servicing For maximum safety we suggest that you have these items inspected and serviced by your authorized Suzuki dealer or a qua...

Page 107: ...ur SUZUKI dealer or a qualified mechanic WARNING Running the engine indoors or in a garage can be hazardous Exhaust gas contains carbon monoxide a gas that is colorless and odorless and can cause deat...

Page 108: ...hs 2 12 24 36 48 Air cleaner element I I R I Exhaust pipe bolts and muffler bolts T T T Exhaust control valve I I I Valve clearance I Spark plugs I R I R Fuel hose I I I I Engine oil R R R R R Engine...

Page 109: ...0 11000 14500 Element months 2 12 24 36 48 Clutch hose I I I I Replace every 4 years Drive chain I I I I I Clean and lubricate every 1000 km 600 miles Brakes I I I I I Brake fluid I I I I Replace ever...

Page 110: ...6 6 TOOLS A tool kit is supplied and located inside the left frame cover...

Page 111: ...confuse the grease like residue on the steering damper s shaft with an oil leak Collection of this residue is normal and is from oil seal lubricant used in the damper You may also notice a sound as t...

Page 112: ...ur motorcycle and also for safe riding It is a good practice to lubricate the motorcy cle after a long rough ride and after getting it wet it in the rain or after washing it Major lubrication points a...

Page 113: ...rest pivot BATTERY The battery is located under the front seat Remove the front seat by referring to the SEAT LOCK AND HELMET HOLDER sec tion This battery is a sealed type battery and requires no main...

Page 114: ...king near the battery CAUTION Exceeding the maximum charging rate for the battery can shorten its life Never exceed the maximum charging rate CAUTION Reversing the battery lead wires can damage the ch...

Page 115: ...e WARNING Operating the engine without the air cleaner element in place could allow a flame to spit back from the engine to the air cleaner or could allow dirt to enter the engine This could cause a f...

Page 116: ...front seat by referring to the SEAT LOCK AND HELMET HOLDER section 3 Remove the right and left side frame covers 1 by unhooking the side frame covers 4 Remove the screws and fasteners Remove the righ...

Page 117: ...and fasteners Remove the right and left fuel tank cover 3 by unhooking the fuel tank covers 6 Turn the ignition cover 4 clockwise and remove it 7 Remove the bolts Remove the fuel tank cap cover 5 with...

Page 118: ...connect the couplers NOTE Drain the fuel from the fuel tank before tilting up the fuel tank if the fuel tank is full 9 Remove the fasteners from both right and left side 10 Remove the fuel tank fittin...

Page 119: ...6 15 11 To open the tool box pull out the prop stay 8 12 Lift the front end of the fuel tank and prop it up as shown above Put the circle end of the prop stay onto the steering lock assembly...

Page 120: ...6 16 13 Remove the fastener 9 14 Loosen the right and left bolts 0...

Page 121: ...6 17 15 Disconnect the coupler A Pull out the tube B Disconnect the air cleaner sen sor assembly C 16 Pull out the tubes D E 17 Remove the air cleaner box...

Page 122: ...6 18 18 Remove the 11 screws F 19 Remove the cover G 20 Remove the air cleaner element H...

Page 123: ...the air cleaner element condition Replace the air cleaner element periodically Remove the plug and drain water and oil at the periodic maintenance interval The air cleaner drain plug is located benea...

Page 124: ...N A torn air cleaner element will allow dirt to enter the engine and can damage the engine Carefully examine the air cleaner ele ment for tears during cleaning Replace it with a new one if it is torn...

Page 125: ...the air cleaner box by referring to the AIR CLEANER section 2 Release the connector locks and discon nect the connectors from the ignition coils 3 Pull off the ignition coils CAUTION Improper removal...

Page 126: ...the 1 0 mm 0 04 in wire type feeler gauge does not insert between the spark plug gap A If the gauge is inserted into the gap replace the plug with a new one CAUTION Dirt can damage your engine if it...

Page 127: ...g is very white or glazed appearing it has been oper ating much too hot This spark plug should be replaced with the colder plug SPARK PLUG REPLACEMENT GUIDE CAUTION An improper spark plug may have an...

Page 128: ...inger tight 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 finger tight NGK DENSO...

Page 129: ...l FUEL HOSE Inspect the fuel hose for damage and fuel leakage If any defects are found the fuel hose must be replaced CAUTION Improper installation of ignition coils can damage the ignition coils Inst...

Page 130: ...nce items to be performed ENGINE OIL LEVEL CHECK Follow the procedure below to inspect the engine oil level 1 Place the motorcycle on level ground on the side stand 2 Start the engine and run it for a...

Page 131: ...that the oil will drain thoroughly from the engine The pro cedure is as follows 1 Place the motorcycle on the side stand 2 Remove the oil filler cap 1 CAUTION The engine oil level must be between the...

Page 132: ...2 4 Remove the drain plug with a wrench and drain out the engine oil WARNING Engine oil and exhaust pipes can be hot enough to burn you Wait until the oil drain plug and exhaust pipes are cool enough...

Page 133: ...aler Oil filter wrench Part No 09915 40610 WARNING New and used oil can be hazardous Children and pets may be harmed by swallowing new or used oil Repeated prolonged contact with used engine oil may c...

Page 134: ...r 4 counterclockwise and remove it with a Suzuki cap type oil filter wrench or a strap type filter wrench of the proper size 8 Wipe off the mounting surface 5 on the engine where the new filter will b...

Page 135: ...resistance will be felt NOTE To tighten the oil filter properly it is important to accurately identify the position at which the filter gasket first contacts the mounting surface CAUTION Using an oil...

Page 136: ...9 US Imp qt of new engine oil through the filler hole and install the filler cap Be sure to always use the specified engine oil described in the FUEL ENGINE OIL AND COOLANT RECOMMENDATIONS section NO...

Page 137: ...hrough the inspection window while holding the motorcycle vertically If the oil level is lower than the F line add new oil until it reaches the F line Check for leaks again NOTE If you do not have a p...

Page 138: ...speed The engine idle speed should be 1050 1250 r min when the engine is warm NOTE If the engine idle speed is not within the specified range ask your Suzuki dealer or a qualified mechanic to inspect...

Page 139: ...djustment needed on the clutch release system because the system is self adjusting However inspect the following each time before driving to make sure that the system is in good condition and function...

Page 140: ...Wash thoroughly after handling Solution can be poisonous to animals Keep out of the reach of chil dren and animals WARNING Failure to keep the clutch fluid reservoir full with the proper brake fluid c...

Page 141: ...cycle held vertically If the coolant is found lower than the L level line add properly mixed coolant in the following way 1 Place the motorcycle on the side stand 2 Remove the side frame cover by refe...

Page 142: ...gine coolant and water WARNING Engine coolant is harmful or fatal if swal lowed or inhaled Do not drink antifreeze or coolant solu tion If swallowed do not induce vomit ing Immediately contact a poiso...

Page 143: ...k We recommend that you take your motorcycle to an authorized Suzuki dealer or a qualified mechanic if the drive chain needs to be replaced The condition and adjustment of the drive chain should be ch...

Page 144: ...w how If necessary con sult your authorized Suzuki dealer or a qual ified mechanic Damage to the drive chain means that the sprockets may also be damaged Inspect the sprockets for the following Excess...

Page 145: ...ncompletely riv eted master link or a joint clip type mas ter link may come apart and cause an accident or severe engine damage Do not use a joint clip type chain Chain replacement requires a special...

Page 146: ...the chain with gasoline or com mercial cleaning solvents can damage O rings and ruin the chain Clean the drive chain with kerosene only CAUTION Some drive chain lubricants contain sol vents and additi...

Page 147: ...lace the motorcycle on the side stand 2 Loosen the axle nut 1 3 Loosen the right and left lock nut 2 WARNING A hot muffler can burn you The muffler will be hot enough to burn you for some time after s...

Page 148: ...ce marks 4 on the swingarm and each chain adjuster which are to be aligned with each other and to be used as a refer ence from one side to the other 5 Tighten the right and left lock nut 2 6 Tighten t...

Page 149: ...ect the front and rear brake system for signs of fluid leakage Inspect the brake hose for leakage or a cracked appearance The brake lever and pedal should have the proper stroke and be firm at all tim...

Page 150: ...fatal if swal lowed and harmful if it comes in contact with skin or eyes If swallowed do not induce vomiting Immediately contact a poison control center or a physician If brake fluid gets in eyes flus...

Page 151: ...nt Inspect the brake fluid level before each use Use only DOT4 brake fluid from a sealed container Never use or mix differ ent types of brake fluid If there is fre quent loss of fluid take your motorc...

Page 152: ...ads by not ing whether or not the friction pads are worn down to the grooved limit line 1 If a front or rear pad is worn to the grooved limit line both front or both rear pads must be replaced with ne...

Page 153: ...ore each use Ask your SUZUKI dealer or a qualified mechanic to replace brake pads if any pad is worn to the limit WARNING Failure to extend brake pads after repair or replacement can cause poor brakin...

Page 154: ...on in the follow ing manner 1 Loosen the lock nut 1 and rotate the push rod 2 to locate the pedal 55 65 mm 2 2 2 6 in below the top face of the footrest 2 Retighten the lock nut 1 to secure the push r...

Page 155: ...lure The tires on your motorcycle form the crucial link between your motorcycle and the road Follow these instructions Check tire condition and pressure and adjust pressure before each ride Avoid over...

Page 156: ...ll heat up the tires and lead to higher inflation pressure readings Under inflated tires make smooth cornering difficult and can result in rapid tire wear Over inflated tires cause a smaller amount of...

Page 157: ...loss of vehicle control Worn tires are susceptible to puncture failures and subsequent loss of vehicle control Tire wear also affects the tire profile changing vehicle handling character istics Check...

Page 158: ...a puncture or replacing the tire Proper wheel balance is important to avoid variable wheel to road contact and to avoid uneven tire wear FRONT REAR SIZE 120 70ZR17M C 58W 200 50ZR17M C 75W TYPE DUNLO...

Page 159: ...ult in an air leak Repair punctures in tubeless tires by removing the tire and applying an internal patch Do not use an external repair plug to repair a puncture since the plug may work loose as a res...

Page 160: ...continuing to hold the clutch in move the side stand to the down posi tion If the engine stops running when the side stand is moved to the down position then the side stand ignition interlock switch i...

Page 161: ...force the pads back into the caliper assem bly and brake fluid leakage may result WARNING If the side stand ignition interlock sys tem is not working properly it is possi ble to ride the motorcycle w...

Page 162: ...s 3 5 Loosen the axle holder bolts 4 6 Place an accessory service stand or an equivalent stand under the swingarm to help stabilize the rear end 7 Carefully position a jack under the exhaust pipe and...

Page 163: ...0 Put the new wheel in place and insert the axle shaft 11 Remove the jack and service stand CAUTION Improper jacking may cause damage to the fairing or oil filter Do not apply the jack head to the fai...

Page 164: ...lder bolts 6 to the specified torque 14 Move the steering up and down several times to seat the axle shaft 15 Tighten the axle holder bolts 7 to the specified torque 16 Reinstall the brake calipers 17...

Page 165: ...e brake disks and proper lever stroke and firm feel are restored Also check that the wheel rotates freely WARNING Installing the front wheel in the reverse direction can be hazardous The tire for this...

Page 166: ...R WHEEL REMOVAL WARNING Failure to torque bolts and nuts properly could lead to an accident Torque bolts and nuts to the proper specifications If you are not sure of the proper procedure have your aut...

Page 167: ...axle nut 1 3 Place an accessory service stand or an equivalent stand under the swing arm to lift the rear wheel slightly off the ground 4 Loosen the right and left lock nut 2 Turn the right and left...

Page 168: ...epress the rear brake pedal with the rear wheel removed It is very diffi cult to force the pads back into the caliper assembly 8 To replace the wheel reverse the com plete sequence listed 9 Adjust the...

Page 169: ...Torque bolts and nuts to the proper specifications If you are not sure of the proper procedure have your authorized SUZUKI dealer or a quali fied mechanic do this WARNING Failure to extend brake pads...

Page 170: ...ctrical sys tem or premature failure of a bulb HEADLIGHT To replace the headlight bulb perform the following steps 1 Remove the bolts 1 Tilt up the rear end of the instrument panel CAUTION Using a lig...

Page 171: ...nect the socket 2 from the headlight and remove the rubber cap 3 3 Unhook the bulb holder spring 4 and pull out the bulb 5 CAUTION Oil from your skin may damage the head light bulb or shorten its life...

Page 172: ...light beam To adjust the beam vertically Turn the adjuster 1 clockwise or counter clockwise To adjust the beam horizontally Turn the adjuster 2 clockwise or counter clockwise Position Light 1 Tilt up...

Page 173: ...6 69 3 Remove the screws Remove the head light lower cover 2 by unhooking the headlight lower cover 4 Pull out the socket 3 5 Pull off the bulb from the socket...

Page 174: ...these directions 1 Remove the fuel tank covers by referring to the AIR CLEANER section 2 Turn the socket counterclockwise and remove it 3 Push in on the bulb turn it to the left and pull it out 4 To f...

Page 175: ...LIGHT To replace the turn signal light bulb follow these directions 1 Remove the screw 1 CAUTION Overtightening the screws when rein stalling the lens may cause the lens to crack Tighten the screws on...

Page 176: ...6 72 2 Pull out the lens Remove the screw 2 3 Push in on the bulb turn it to the left and pull it out 4 To fit the replacement bulb push it in and twist it to the right while pushing...

Page 177: ...e plate light bulb follow the procedure steps 1 Remove the bolts and screws Remove the rear fender cover 1 CAUTION Overtightening the screws when rein stalling the lens may cause the lens to crack Tig...

Page 178: ...6 74 2 Remove the nuts 2 3 Remove the screws 3 and take off the lens 4...

Page 179: ...the left and pull it out 5 To fit the replacement bulb push it in and twist it to the right while pushing CAUTION Overtightening the screws when rein stalling the lens may cause the lens to crack Tig...

Page 180: ...e is located under the center lid To access the fuse remove the seat by referring to the SEAT LOCK AND HELMET HOLDER section Remove the fasteners Remove the center lid One 30A spare fuse is located in...

Page 181: ...uit overload exists in individual electrical system circuits If any electrical system fails to operate then the fuses must be checked CAUTION Installing a fuse of incorrect rating or using aluminum fo...

Page 182: ...n relay ignition coils starter relay fuel pump relay solenoid ECU oxygen sen sor side stand relay and Immobilizer 10A SIGNAL fuse protects the turn sig nal lights position lights taillight stop lamp l...

Page 183: ...7 1 7 TROUBLESHOOTING FUEL SUPPLY CHECK 7 2 IGNITION SYSTEM CHECK 7 3 ENGINE STALLING 7 4...

Page 184: ...NSTRUMENT PANEL section for an explanation of fuel injection system indicator If the indicator does not display FI make sure there is enough fuel in the fuel tank If the indicator does not display FI...

Page 185: ...in the ON position the engine stop switch in the position the trans mission in neutral and the clutch disen gaged If the ignition system is operating properly a blue spark should jump across the spark...

Page 186: ...for an explanation of the fuel injection system indicator 3 Check the ignition system for intermittent spark 4 Check that the engine idles smoothly and steadily WARNING Performing the spark test impr...

Page 187: ...8 1 8 MOTORCYCLE CLEANING AND STORAGE PROCEDURE MOTORCYCLE CLEANING 8 2 STORAGE PROCEDURE 8 5 PROCEDURE DURING STORAGE 8 7 PROCEDURE FOR RETURNING TO SERVICE 8 7...

Page 188: ...he paint 2 Wash the entire motorcycle with a mild detergent or car wash soap using a sponge or soft cloth The sponge or cloth should be frequently soaked in the soap solution NOTE Avoid spraying or al...

Page 189: ...ll damaged spots and allow them to dry b Stir the paint and touch up the dam aged spots lightly with a small brush c Allow the paint to dry completely CAUTION High pressure washers and parts cleaner c...

Page 190: ...ning For extended life of your motorcycle lubri cate according to LUBRICATION POINTS section Follow the procedures in the INSPECTION BEFORE RIDING section to check your motorcycle for any problems tha...

Page 191: ...MOTORCYCLE Clean the entire motorcycle Place the motorcycle on the side stand on a firm flat surface where it will not fall over FUEL 1 Fill the fuel tank to the top with fuel mixed with the amount o...

Page 192: ...battery with a mild detergent and remove any corro sion from the terminals and wiring har ness connections 3 Store the battery in a room above freez ing TIRES Inflate the tires to the normal specific...

Page 193: ...al first then connect the negative termi nal Remove the spark plugs Turn the engine a few times by putting the trans mission in top gear and turning the rear wheel Reinstall the spark plugs Drain the...

Page 194: ...mm 60 0 in Ground clearance 120 mm 4 7 in Seat height 805 mm 31 7 in Dry mass 235 kg 518 lbs ENGINE Type Four stroke liquid cooled DOHC Number of cylinders 4 Bore 81 0 mm 3 189 in Stroke 65 0 mm 2 55...

Page 195: ...ratio 2 388 43 18 Drive chain RK GB50GSV Z4 118 links CHASSIS Front suspension Inverted telescopic coil spring oil damped Rear suspension Link type coil spring oil damped Front fork stroke 120 mm 4 7...

Page 196: ...aillight LED Position light 12V 5W 2 Speedometer light LED Tachometer light LED Neutral indicator light LED High beam indicator light LED Turn signal indicator light LED Coolant temperature indicator...

Page 197: ......

Page 198: ...EW TIRES 4 3 C CARRYING A PASSENGER 5 11 CLUTCH 6 35 COOLANT 3 6 6 37 D DRIVE CHAIN 6 39 E ENGINE IDLE SPEED INSPECTION 6 34 ENGINE OIL 3 4 6 26 ENGINE STALLING 7 4 F FRONT WHEEL REMOVAL 6 57 FUEL 3 2...

Page 199: ...S 2 50 M MAINTENANCE SCHEDULE 6 2 MAXIMUM ENGINE SPEED RECOMMENDATION 4 2 MOTORCYCLE CLEANING 8 2 N NOISE CONTROL SYSTEM AUSTRALIA ONLY 1 10 O OBSERVE YOUR FIRST AND MOST CRITICAL SERVICE 4 4 P PROCED...

Page 200: ...NITION INTERLOCK SWITCH 6 56 SPARK PLUGS 6 21 STARTING OFF 5 4 STARTING THE ENGINE 5 2 STEERING DAMPER MAINTENANCE 6 7 STOPPING AND PARKING 5 8 STORAGE PROCEDURE 8 5 SUSPENSION ADJUSTMENT 2 52 SUZUKI...

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Page 203: ...T T K8 Printed in Japan 300 TAKATSUKA MINAMI HAMAMATSU JAPAN...

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