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Suzuki GW250, Service Manual

The Suzuki GW250 Service Manual is essential for maintaining and repairing your motorcycle. Get your free download of this comprehensive manual from manualshive.com today. This manual provides detailed instructions and diagrams to help you keep your Suzuki GW250 running smoothly for years to come.

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CHASSIS

CONTENTS

8-2     CHASSIS

INSALLATION .......................................................................................  8-44
SUSPENSION SETTING .......................................................................  8-44

REAR SUSPENSION ...................................................................................  8-45

CONSTRUCTION ..................................................................................  8-45
REMOVAL .............................................................................................  8-46
INSPECTION AND DISASSEMBLY .....................................................  8-47
REASSEMBLY ......................................................................................  8-49
INSTALLATION.....................................................................................  8-50

FRONT BRAKE............................................................................................  8-51

CONSTRUCTION ..................................................................................  8-51
BRAKE PAD REPLACEMENT .............................................................  8-52
BRAKE FLUID REPLACEMENT ..........................................................  8-54
CALIPER REMOVAL ............................................................................  8-54
CALIPER DISASSEMBLY ....................................................................  8-55
CALIPER INSPECTION ........................................................................  8-56
CALIPER REASSEMBLY .....................................................................  8-57
CALIPER INSTALLATION ....................................................................  8-58
BRAKE DISC INSPECTION..................................................................  8-58
MASTER CYLINDER REMOVAL AND DISASSEMBLY ......................  8-59
MASTER CYLINDER INSPECTION......................................................  8-60
MASTER CYLINDER REASSEMBLY AND INSTALLATION ..............  8-61

REAR BRAKE..............................................................................................  8-63

CONSTRUCTION ........................................................................................ 8-63

BRAKE PAD REPLACEMENT .............................................................  8-64
BRAKE FLUID REPLACEMENT ..........................................................  8-65
CALIPER REMOVAL ............................................................................  8-66
CALIPER DISASSEMBLY ....................................................................  8-66
CALIPER INSPECTION ........................................................................  8-67
CALIPER REASSEMBLY .....................................................................  8-68
CALIPER INSTALLATION ....................................................................  8-69
BRAKE DISC INSPECTION..................................................................  8-69
MASTER CYLINDER REMOVAL AND DISASSEMBLY ......................  8-69
MASTER CYLINDER INSPECTION......................................................  8-71
MASTER CYLINDER REASSEMBLY AND INSTALLATION ..............  8-71

TIRE AND WHEEL.......................................................................................  8-73

TIRE REMOVAL ....................................................................................  8-73
INSPECTION .........................................................................................  8-73
TIRE INSTALLATION............................................................................  8-75
BALANCER WEIGHT INSTALLATION ................................................  8-76

DRIVE CHAIN ..............................................................................................  8-77

DRIVE CHAIN CUTTING .......................................................................  8-77
DRIVE CHAIN CONNECTING...............................................................  8-78

Summary of Contents for GW250

Page 1: ...SERVICE MANUAL GW250 9 9 5 0 0 3 2 1 7 0 0 1 E...

Page 2: ...stomers of fast and reliable service COPYRIGHT SUZUKI MOTOR CORPORATION 2012 This manual has been prepared on the basis of the latest specifications at the time of publi cation If modifications have b...

Page 3: ...sted on the first page of each section 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 is its exploded view Work instructions and...

Page 4: ...oil solution Mixture of engine oil and SUZUKI MOLY PASTE in a ratio of 1 1 Apply or use brake fluid Apply SUZUKI SUPER GREASE A or equivalent 99000 25010 Measure in voltage range Apply SUZUKI SILICONE...

Page 5: ...ntrol Unit ECT Sensor Engine Coolant Temperature Sensor ECTS Water Temp Sensor WTS F FI Fuel Injection Fuel Injector FP Fuel Pump FPR Fuel Pressure Regulator FP Relay Fuel Pump Relay FWD Forward G GEN...

Page 6: ...lack with Blue tracer O BI Orange with Blue tracer B Br Black with Brown tracer O R Orange with Red tracer B G Black with Green tracer O W Orange with White tracer B R Black with Red tracer O Y Orange...

Page 7: ...COOLANT RECOMMENDATION 1 6 BREAK IN PROCEDURES 1 7 CYLINDER IDENTIFICATION 1 7 INFORMATION LABELS 1 8 SPECIFICATIONS 1 9 DIMENSIONS AND CURB MASS 1 9 ENGINE 1 9 DRIVE TRAIN 1 9 CHASSIS 1 10 ELECTRICAL...

Page 8: ...s relating to the servicing or lack of servicing of the motorcycle In addition to the WARN INGS CAUTIONS and NOTICES stated you must use good judgement and basic mechanical safety princi ples If you a...

Page 9: ...negative cable from the battery When tightening the cylinder head or case bolts and nuts tighten the larger sizes first Always tighten the bolts and nuts diagonally from the inside toward outside and...

Page 10: ...markets SERIAL NUMBER LOCATION The frame serial number or V I N Vehicle Identification Number 1 is stamped on the right side of the steering head pipe The engine serial number 2 is located on the left...

Page 11: ...JASO classification of MA Suzuki recommends the use of SAE 10W 40 engine oil If SAE 10W 40 engine oil is not available select an alternative according to the right chart Suzuki does not recommend the...

Page 12: ...SUZUKI super long life coolant is the latter type and SUZUKI long life coolant is the former type WATER FOR MIXING Use distilled water only Water other than distilled water can corrode and clog the a...

Page 13: ...cised during its early life The general rules are as follows Keep to these break in engine speed limits Initial 800 km 500 miles Below 5 500 r min Up to 1 600 km 1 000 miles Below 8 250 r min Over to...

Page 14: ...INFORMATION LABELS NO LABEL or PLATE NAME 1 I D Plate For P21 24 71 2 Tire information label 3 General warning label 4 Brake Approval Label For P21 24 5 Fuel limitation label For P12 6 Noise label For...

Page 15: ...2 106 in Stroke 55 2 mm 2 173 in Displacement 248 cm 15 1 cu in Compression ratio 11 5 1 Fuel system Fuel injection Air cleaner Non woven fabric element Starter system Electric Lubrication system Wet...

Page 16: ...SR N Battery 12 V 36 0 kC 8 Ah 10 HR Generator Three phase A C generator Main fuse 30 A Fuse 10 10 10 15 A Headlight 12 V 60 55 W Position light 12 V 5 W 2 Turn signal light 12 V 10 W License plate li...

Page 17: ...OLTS 2 5 SPARK PLUGS 2 6 VALVE CLEARANCE 2 8 ENGINE OIL AND OIL FILTER 2 11 FUEL LINE 2 12 PAIR AIR SUPPLY SYSTEM 2 13 THROTTLE CABLE PLAY 2 13 ENGINE IDLE SPEED 2 13 CLUTCH CABLE PLAY 2 14 COOLING SY...

Page 18: ...m months 3 15 30 45 Air cleaner element I I R Exhaust pipe bolts and muffler bolts T T Valve clearance I I I I Spark plugs I R I Fuel line I I I Engine oil R R R R Engine oil filter R R Throttle cable...

Page 19: ...spots and wipe off any grease oil dirt or grime Lubricate exposed parts which are subject to rust with a rust preventative spray whenever the motorcycle has been operated under wet or rainy conditions...

Page 20: ...ment If air pressure is used on the other side dirt will be forced into the pores of the air cleaner element thus restrict ing air flow through the air cleaner element Install the cleaned element or n...

Page 21: ...bolt and exhaust connecting bolts to the specified torque Tighten initially at 1 000 km 600 miles 3 months and every 10 000 km 6 000 miles 30 months thereafter A Exhaust pipe bolt B Muffler support b...

Page 22: ...ed appearing replace the spark plug with colder type one CARBON DEPOSITS Check carbon deposits on the spark plug If carbon is deposited remove it using a spark plug cleaner machine SPARK PLUG GAP Meas...

Page 23: ...ad with fingers and then tighten them to the specified torque Spark plug 11 N m 1 1 kgf m 8 0 Ibf ft 09930 10121 Spark plug wrench set Connect the spark plug caps Confirm the thread size and reach whe...

Page 24: ...eriodic inspection 2 when the valve mecha nism is serviced and 3 when the camshafts are removed for servicing Valve clearance when cold Standard IN 0 05 0 10 mm 0 002 0 004 in EX 0 17 0 22 mm 0 007 0...

Page 25: ...B of valve timing inspection hole and also bring the notch C on the left end of camshaft to the position as shown D Intake side To inspect the 2 Right cylinder valve clearance use a thickness gauge be...

Page 26: ...pect the 1 Left cylinder valve clearance as the same manner of 2 Right cylinder and adjust the clearance if nec essary Valve clearance adjuster lock nut 10 N m 1 0 kgf m 7 0 Ibf ft 09900 20803 Thickne...

Page 27: ...rain plug 23 N m 2 3 kgf m 16 5 lbf ft Tighten the filler cap 1 Start up the engine and allow it to run for several minutes at idling speed Turn off the engine and wait about three minutes Hold the mo...

Page 28: ...o properly tighten the oil filter use the special tool Never tighten the oil filter by hand Oil filter 20 N m 2 0 kgf m 14 5 lbf ft Add new engine oil and check the oil level is as described in the en...

Page 29: ...in ENGINE IDLE SPEED Warm up the engine Inspect the engine idle speed If the engine idle speed is not within the specified range check the ISC system 4 60 Engine idle speed 1 400 100 r min Inspect in...

Page 30: ...terclockwise 1 rotation and tighten the lock nut 7 while holding the release screw 8 Clutch release adjuster lock nut 7 5 5 N m 0 55 kgf m 4 0 lbf ft Reinstall the clutch cover and pour engine oil 3 8...

Page 31: ...the water pump inlet and outlet hoses 2 securely 10 21 Pour the specified engine coolant up to the radiator inlet Engine coolant capacity excluding reservoir 1 100 ml 1 2 1 0 US lmp qt Bleed the air...

Page 32: ...oolant flows out 10 Tighten the water pump air bleeder bolt to the specified torque Water pump air bleeder bolt 6 N m 0 6 kgf m 4 5 lbf ft 11 Close the radiator cap securely 12 After warming up and co...

Page 33: ...is DID520VF 116 L Suzuki recom mends to use this standard drive chain as a replacement CHECKING AND ADJUSTING Support the motorcycle with a jack for P 21 24 71 Place the motorcycle on the center stan...

Page 34: ...rgent Lubricate with a motorcycle sealed drive chain lubricant or high viscosity oil Lubricate both front and back plates of the drive chain Wipe off excess lubricant after lubricating all around of t...

Page 35: ...5 months thereafter BRAKE HOSE AND BRAKE FLUID Inspect every 5 000 km 3 000 miles 15 months Replace hoses every 4 years Replace fluid every 2 years The brake system of this motorcycle is filled with a...

Page 36: ...e pads with the new ones 8 52 Rear brake The extent of brake pad wear can be checked by observing the grooved limit line A on the pad When the wear exceeds the grooved limit line replace the pads with...

Page 37: ...pped in the brake fluid circuit acts like a cushion to absorb a large proportion of the pressure developed by the master cylinder and thus interferes with the full braking perfor mance of the brake ca...

Page 38: ...rip Then close the air bleeder valve pump and squeeze the lever and open the valve Repeat this process until fluid flowing into the receptacle contains no air bubbles NOTE While bleeding the brake sys...

Page 39: ...adversely affected and tire wear will increase Therefore main tain the correct tire pressure for good roadability or shorter tire life will result Cold inflation tire pressure is as follows Cold infl...

Page 40: ...fork tubes near the axle and pull forward If play is found readjust the steering 8 26 FRONT FORKS Inspect the front forks for oil leakage scoring or scratches on the outer surface of the inner tubes R...

Page 41: ...16 5 6 Handlebar clamp bolt 16 1 6 11 5 7 Front brake master cylinder holder bolt 10 1 0 7 0 8 Front brake caliper mounting bolt 26 2 6 19 0 9 Brake hose union bolt 23 2 3 16 5 0 Air bleeder valve Fr...

Page 42: ...2 26 PERIODIC MAINTENANCE...

Page 43: ...and more All compression pressure readings are below 1 300 kPa 13 kgf cm2 185 psi even when they measure 1 000 kPa 10 kgf cm2 142 psi and more COMPRESSION TEST PROCEDURE NOTE Before testing the engin...

Page 44: ...d check if the oil pressure indicator light is turned on If the light stays on check the oil pressure indicator light circuit If the circuit is OK check the oil pressure in the fol lowing manner Remov...

Page 45: ...he case of a customer vehicle which is not periodically brought in for service with no past data value having been saved if the data value of a good vehicle condition have been already saved as a mast...

Page 46: ...ta at the time of racing Approx 3 000 r min Check the manifold absolute pressure XX kPa Check the engine coolant temperature XX C PAIR control solenoid valve ON OFF in accordance with the throttle val...

Page 47: ...gative pressure during idling 100 C Data of manifold absolute pressure operation at the time of starting Check the manifold absolute pressure XX kPa Check the engine coolant temperature Approx 100 C C...

Page 48: ...t data that have been saved under the same condition then you may determine how changes have occurred with the passing of time and identify what problem is currently occurring With DTC not output if t...

Page 49: ...ER HEAD 3 27 CAMSHAFT 3 34 CAM CHAIN TENSION ADJUSTER 3 36 CAM CHAIN TENSIONER AND CAM CHAIN GUIDE 3 36 CYLINDER 3 36 PISTON 3 37 CLUTCH 3 40 OIL PUMP 3 41 STARTER CLUTCH 3 42 GENERATOR 3 44 WATER PUM...

Page 50: ...e body 5 12 5 15 5 17 Cam chain tension adjuster 3 13 3 36 3 92 Cylinder head cover 3 12 3 25 3 93 Camshafts 3 12 3 34 3 89 Rocker arms 3 26 3 26 3 26 Cylinder head 3 14 3 28 3 87 Cylinder 3 15 3 36 3...

Page 51: ...GINE REMOVAL AND INSTALLATION ENGINE REMOVAL Drain engine oil 2 11 Drain engine coolant 2 15 Remove the seat 8 5 Disconnect the battery lead wire Remove the fuel tank 1 5 2 Remove the throttle body as...

Page 52: ...e spark plug cap 2 4 PCV hose 5 starter motor lead wire 6 and battery lead wire 7 Disconnect the clamps 8 GP switch coupler 9 generator coupler 0 CKP sensor coupler A and side stand switch cou pler B...

Page 53: ...gine sprocket cover F Loosen the clutch cable nuts G and clutch cable adjuster H Remove the clutch release arm I along with the clutch cable J Remove the clutch release camshaft retainer K Disconnect...

Page 54: ...sor rotor Q by removing it bolt while depressing the rear brake pedal Remove the engine sprocket nut R while depressing the rear brake pedal Remove the washer S Loosen the rear axle nut T and left and...

Page 55: ...ift shaft before removing Remove the bolts X and washers Y Move the right footrest bracket assembly Z Remove the bolts and washers Remove the left footrest bracket Support the engine using an engine j...

Page 56: ...locking Once the nuts have been removed they are no longer of any use Insert the two engine mounting bolts from left side and tighten their nuts Install the frame down tube 1 and engine mounting brac...

Page 57: ...all the engine sprocket 4 with drive chain 5 Apply engine oil to the driveshaft thread portion Tighten the engine sprocket nut 6 to the specified torque Engine sprocket nut 120 N m 12 0 kgf m 87 0 lbf...

Page 58: ...of clutch release cam shaft Tighten the engine sprocket cover bolts B to the specified torque Engine sprocket cover bolt 10 N m 1 0 kgf m 7 0 lbf ft Tighten the oil pressure switch lead wire bolt C to...

Page 59: ...allation check the following items Wiring harness cables and hoses routing 10 14 to 10 22 and 10 25 Throttle cable play 2 13 Clutch cable play 2 14 Drive chain slack 2 18 Engine oil 2 11 Engine coolan...

Page 60: ...DER HEAD COVER Remove the cylinder head cover 1 and its gasket Remove the dowel pins 2 CAMSHAFT Remove the valve timing inspection cap 1 and generator cover plug 2 Identify the position of each remove...

Page 61: ...f compression stroke and also the engraved lines B on the camshafts are par allel with the mating surface of the cylinder head cover Remove the cam chain tension adjuster cap bolt 3 spring 4 and O rin...

Page 62: ...ft A Disengage the cam chain B from the camshaft sprocket 0 Remove the camshaft A and camshaft sprocket 0 Remove the C ring C NOTE Do not drop the C ring C into the cylinder head CYLINDER HEAD Loosen...

Page 63: ...r does not come off lightly tap it with a plastic ham mer Remove the gasket 9 and dowel pins 0 PISTON Place a clean rag over the cylinder base so as not to drop the piston pin circlip into the crankca...

Page 64: ...nd clutch springs NOTE Loosen the clutch spring set bolts little by little and diagonally Remove the clutch pressure plate 1 Remove the clutch drive plates 2 and driven plates 3 NOTE Prior to removal...

Page 65: ...push rod 9 NOTE If it is difficult to pull out the push rod 9 use a magnetic hand or a wire Flatten the lock washer 0 of the clutch sleeve hub nut Remove the clutch sleeve hub nut A with the special...

Page 66: ...1 washer 2 and oil pump driven sprocket 3 0990 06107 Snap ring pliers Open type NOTE Do not drop the snap ring 1 and washer 2 into the crankcase Remove the oil pump drive sprocket 4 along with the oil...

Page 67: ...90 06107 Snap ring pliers Open type Remove the gearshift shaft assembly 3 and washer 4 Remove the gearshift cam stopper plate bolt 5 and gearshift cam stopper plate 6 Remove the gearshift cam stopper...

Page 68: ...washer 2 Hold the generator rotor and remove the primary drive gear nut 3 09930 44521 Rotor holder NOTE The primary drive gear nut 3 has left hand threads Remove the spring washer 4 washer 5 and prim...

Page 69: ...sen the generator rotor bolt 1 do not remove it The generator rotor bolt is used in conjunction with the generator rotor remover when removing the generator rotor Remove the generator rotor 2 with the...

Page 70: ...PRESSURE SWITCH Remove the oil filter 1 with the special tool 09915 40620 Oil filter wrench Remove the oil pressure switch 2 ENGINE SPROCKET SPACER Remove the engine sprocket spacer 1 and oil seal re...

Page 71: ...s M6 Remove the upper and lower crankcase bolts M8 NOTE Loosen the crankcase bolts diagonally and the smaller sizes first Make sure that all of the bolts are removed Then tap the sides of the lower cr...

Page 72: ...driveshaft assembly 2 and countershaft assem bly 3 Remove the C rings 4 and pins 5 CRANK BALANCER AND CRANKSHAFT Remove the crank balancer assembly 1 Remove the crankshaft assembly 2 and thrust beari...

Page 73: ...reed valve for the carbon deposit If the carbon deposit is found in the reed valve replace the PAIR reed valve with a new one INSTALLATION Install the PAIR reed valve and PAIR reed valve cover 10 25...

Page 74: ...20205 Micrometer 0 25 mm ROCKER ARM INSIDE DIAMETER INSPECTION Measure the inside diameter of the rocker arm and check the wear of the camshaft contacting surface If the diameter exceeds the limit or...

Page 75: ...the special tools 09916 14510 Valve lifter 09916 14910 Valve lifter attachment Remove the two cotter halves 4 09916 84511 Tweezer Remove the valve spring retainer 5 inner valve spring 6 and outer val...

Page 76: ...0 20803 Thickness gauge VALVE FACE WEAR Visually inspect each valve face for wear Replace any valve with an abnormally worn face The thickness of the valve face decreases as the face wears Measure the...

Page 77: ...35 mm 0 014 in 09900 20607 Dial gauge 09900 20701 Dial gauge chuck VALVE STEM WEAR If the valve stem is worn down to the limit when measured with the micrometer and the clearance is found to be in ex...

Page 78: ...haust ports with gasoline to check for leaks If any leaks occur inspect the valve seat and face for burrs or other things that could prevent the valve from sealing INTAKE EXHAUST Seat angle 30 45 15 4...

Page 79: ...r strength by measuring their free length and also by the force required to compress them If the spring length is less than the service limit or if the force required to compress the spring does not f...

Page 80: ...nt Install the cotter halves 3 NOTE To facilitate assembly apply a little grease to the valve cotter when fitting into the valve stem groove 09916 84511 Tweezer Fit the new gasket 4 to each oil galler...

Page 81: ...pe 6 Tighten the water outlet pipe bolt 7 to the specified torque Cylinder head water outlet pipe bolt 10 N m 1 0 kgf m 7 0 lbf ft Apply grease to the new O rings of the intake pipes 8 99000 25010 SUZ...

Page 82: ...e clearance at the widest portion which is specified as follows Camshaft journal oil clearance Service Limit 0 150 mm 0 0059 in 09900 22301 Plastigage 0 025 0 076 mm 09900 22302 Plastigage 0 051 0 152...

Page 83: ...mm 0 8666 0 8671 in 09900 20602 Dial gauge 09900 22403 Small bore gauge 18 35 mm Camshaft jouranal O D Standard 21 959 21 980 mm 0 8645 0 8654 in 09900 20205 Micrometer 0 25 mm CAMSHAFT RUNOUT Measur...

Page 84: ...SPECTION Check the contacting surface of the cam chain tensioner 1 and cam chain guide 2 If it is worn or damaged replace it with a new one CYLINDER CYLINDER DISTORTION Check the gasket surface of the...

Page 85: ...de diameter at 10 mm 0 4 in A from the piston skirt end If the measurement is less than the limit replace the piston Piston diameter Service Limit 53 380 mm 2 1016 in at 10 mm 0 4 in from the skirt en...

Page 86: ...vice Limit 14 980 mm 0 5898 in 09900 20205 Micrometer 0 25 mm PISTON RING TO GROOVE CLEARANCE Measure the side clearances of the 1st and 2nd piston rings using the thickness gauge If any of the cleara...

Page 87: ...3 6 mm 0 14 in 09900 20101 Vernier calipers 150 mm Piston ring end gap Service Limit 1st 0 50 mm 0 020 in 2nd 0 50 mm 0 020 in 09900 20803 Thickness gauge OVERSIZE RINGS Oversize piston ring The foll...

Page 88: ...he limit Drive plate claw width Service Limit 15 2 mm 0 598 in 09900 20102 Vernier calipers 200 mm CLUTCH DRIVEN PLATE INSPECTION NOTE Wipe off engine oil from the clutch driven plates with a clean ra...

Page 89: ...EMBLY Inspect the slot of the clutch sleeve hub 1 and primary driven gear assembly 2 for damage or wear caused by the clutch plates If necessary replace it with a new one CLUTCH PUSH ROD Inspect the c...

Page 90: ...elt to rotation inspect the starter clutch for damage or inspect the starter clutch contacting surface of the starter driven gear for wear or damage I they are found to be damaged replace them with ne...

Page 91: ...at the flange A of the one way clutch 1 to the guide 2 When installing the guide 2 to the generator rotor 3 face the groove B of the guide 2 inside Apply thread lock to the bolts 4 and then tighten th...

Page 92: ...rib B GENERATOR INSPECTION 9 10 to 11 REASSEMBLY When replacing the generator coil 1 or CKP sensor 2 apply thread lock to the generator starter set bolts 3 and CKP sen sor mounting bolts 4 and tighten...

Page 93: ...or wear or bend Inspect the return springs for damage or fatigue Replace the gearshift shaft or springs if there is anything unusual GEARSHIFT SHAFT REASSEMBLY Reassembly the gearshift shaft in the re...

Page 94: ...e camshaft in the reverse order of disassembly Pay attention to the following points Apply engine oil to the new bearing 1 Apply grease to the camshaft sliding surface of the clutch release camshaft 1...

Page 95: ...essure regulator by pushing on the piston with a proper bar If the piston does not operate replace the oil pressure regulator with a new one OIL STRAINER Clean the oil strainer if necessary Inspect th...

Page 96: ...t Organize the parts in their respective groups i e drive or driven so that they can be reinstalled in their original positions FWD 1 Countershaft 1st drive gear 7 2nd driven gear 2 5th drive gear 8 6...

Page 97: ...eal apply grease to it When installing a new snap ring do not expand the end gap larger than required to slip the snap ring over the shaft After installing a snap ring make sure that it is completely...

Page 98: ...3 50 ENGINE TRANSMISSION PARTS LOCATION 1 Countershaft 2 Driveshaft...

Page 99: ...t cam 6 and its bearing 7 Remove the gearshift arm stopper 8 GEARSHIFT FORK TO GROOVE CLEARANCE Using a thickness gauge check the gearshift fork clearance in the groove of its gear The clearance for e...

Page 100: ...g the vernier calipers Shift fork thickness Standard 4 8 4 9 mm 0 189 0 193 in 09900 20101 Vernier calipers 150 mm GEARSHIFT CAM BEARING AND GEARSHIFT SHAFT BEARING Bearing inspection Inspect the gear...

Page 101: ...ith the special tools 09921 20210 Bearing remover 12 mm 09930 30104 Rotor remover sliding shaft Bearing installation Install the new bearings with the special tool 09913 70210 Bearing installing set 1...

Page 102: ...g 3 fitted NOTE The stamped mark side of the gearshift cam bearing faces out side Install the gearshift forks and their shafts as shown 4 For 3rd 4th drive gears 5 For 5th driven gear 6 For 6th driven...

Page 103: ...cooling oil jets 3 from the upper crank case Remove the oil jet 4 for transmission from the lower crank case Inspection and cleaning Make sure that the oil jets are not clogged If they are clogged cle...

Page 104: ...Apply engine oil to the new O rings Install the oil jet cylinder head 2 and each piston cooling jet 3 When fitting the crankshaft journal bearings 4 to the upper crankcase be sure to fix the stopper...

Page 105: ...to the gearshift fork shaft plugs 3 and oil gallery plug 4 99000 32110 THREAD LOCK CEMENT SUPER 1322 or equivalent Fit the gearshift fork shaft plugs 3 and oil gallery plug 4 as shown in illustration...

Page 106: ...replace the defec tive part Measure the free length of each balancer spring If any spring length is less than the service limit replace all of the spring Balancer spring free length Service Limit 10...

Page 107: ...ncer when a piece of plastigage is installed Crankshaft journal bolt M 8 Initial 15 N m 1 5 kgf m 11 0 lbf ft Final 26 N m 2 6 kgf m 19 0 lbf ft Crankcase bolt M 6 11 N m 1 1 kgf m 8 0 lbf ft Remove t...

Page 108: ...rings on upper and lower crank cases are the same Crank balancer journal O D B Code A B C Crankcase I D A A Green Black Brown B Black Brown Yellow Code I D specification A 31 000 31 008 mm 1 2205 1 22...

Page 109: ...urnals resting on the blocks Set up the dial gauge as shown Rotate the crankshaft slowly to read the runout Replace the crankshaft if the runout exceeds the limit Crankshaft runout Service Limit 0 05...

Page 110: ...dard 19 95 20 00 mm 0 7854 0 7874 in 09900 20205 Micrometer 0 25 mm Crank pin width Standard 20 10 20 15 mm 0 7913 0 7933 in 09900 20605 Dial calipers 10 34 mm CONROD CRANK PIN BEARING INSPECTION Loos...

Page 111: ...pe scale This measure ment should be taken at the widest part of the compressed plastigage Conrod big end oil clearance Standard 0 032 0 056 mm 0 0013 0 0022 in Service Limit 0 080 mm 0 0031 in If the...

Page 112: ...to each crank pin and bearing surface MOLYBDENUM OIL SOLUTION When fitting the conrod cap make sure that I D code B on each conrod faces intake side Code O D specification 1 30 992 31 000 mm 1 2202 1...

Page 113: ...two steps Conrod cap bolt 15 N m 1 5 kgf m 11 0 lbf ft then turn 90 1 4 turn clockwise CRANKSHAFT JOURNAL BEARING INSPECTION Inspect each bearing of upper and lower crankcases for any damage SELECTIO...

Page 114: ...age Crankshaft journal oil clearance Standard 0 016 0 040 mm 0 0006 0 0016 in Service Limit 0 080 mm 0 0031 in If the oil clearance exceeds the service limit select the speci fied bearings from the be...

Page 115: ...ress in the other opposite side of the bearing NOTE Do not touch the bearing surfaces with your hands Grasp by the edge of the bearing shell Code O D specification A 29 992 30 000 mm 1 1808 1 1811 in...

Page 116: ...hrust bearing Measure the thickness of the left side thrust bearing using the micrometer If the thickness of the left side thrust bearing is below stan dard replace it with a new one and once again pe...

Page 117: ...mm 0 1055 0 1063 in None 12228 17E00 0L0 2 600 2 625 mm 0 1024 0 1033 in 0 055 0 100 mm 0 0022 0 0039 in 2 655 2 680 mm 0 1045 0 1055 in Purple 12228 17E00 0K0 2 575 2 600 mm 0 1014 0 1024 in 0 050 0...

Page 118: ...L SOLUTION Apply engine oil to the conrod big end side surfaces Check the conrod movement for smooth turning Install the crankshaft assembly along with the cam chain into the upper crankcase Insert th...

Page 119: ...E Align the C ring with the groove of bearing and the bearing pin with the indent on the bearing Install the driveshaft assembly to the upper crankcase NOTE Align the C ring with the groove of bearing...

Page 120: ...quivalent NOTE Use of SUZUKI bond is as follows Make surfaces free from moisture oil dust and other foreign materials Spread the sealant on surfaces thinly to form an even layer and assemble the crank...

Page 121: ...d to these bolts Tighten each bolt a little at a time to equalize the pressure in the following two steps Crankshaft journal bolt M 8 Initial 15 N m 1 5 kgf m 11 0 lbf ft Final 26 N m 2 6 kgf m 19 0 l...

Page 122: ...k to the oil pressure regulator and tighten it to the specified torque 99000 32110 THREAD LOCK CEMENT SUPER 1322 or equivalent Oil pressure regulator 28 N m 2 8 kgf m 20 0 lbf ft OIL STRAINER Apply gr...

Page 123: ...seal lip 99000 25010 SUZUKI SUPER GREASE A or equivalent Install the engine sprocket spacer 1 NOTE The grooved A side of the engine sprocket spacer 1 must face crankcase side CRANKCASE BREATHER COVER...

Page 124: ...SWITCH Apply grease to the new O ring 1 99000 25010 SUZUKI SUPER GREASE A or equivalent Apply thread lock to the gear position switch mounting bolts 2 and tighten them to the specified torque 99000 3...

Page 125: ...ft Hold the generator rotor with the special tool and tighten its bolt to the specified torque 09930 44521 Rotor holder Generator rotor bolt 130 N m 13 0 kgf m 94 0 lbf ft STARTER IDLE GEAR Apply engi...

Page 126: ...0 5 lbf ft Hold the primary drive gear nut 5 and tighten the crank bal ancer bolt 6 to the specified torque Crank balancer bolt 50 N m 5 0 kgf m 36 0 lbf ft GENERATOR COVER Apply engine oil to the sta...

Page 127: ...return spring end A to the gearshift cam stopper 1 Check the gearshift cam stopper 1 moves smoothly Locate the gearshift cam in the neutral position Install the gearshift cam stopper plate 5 NOTE Alig...

Page 128: ...When install the oil pump 1 fit the convex part A of the oil pump shaft onto the concave part B of the water pump shaft Apply thread lock to the oil pump mounting bolts 2 and tighten them to the spec...

Page 129: ...clutch side Install the washer 8 and new snap ring 9 09900 06107 Snap ring pliers Open type NOTE Be careful not to drop any parts into the crankcase CLUTCH 1 Primary driven gear assembly 2 Clutch sle...

Page 130: ...he primary driven gear assembly 2 onto the countershaft NOTE Be sure to engage the oil pump drive sprocket with the primary driven gear sprocket When engaging the primary drive gear and primary driven...

Page 131: ...5 0 kgf m 36 0 lbf ft Bend the lock washer 5 securely Install the clutch push rod 6 into the countershaft Apply engine oil to the bearing 8 Install the clutch push piece 7 bearing 8 and thrust washer...

Page 132: ...13 Flywheel rotor holoder Tighten the clutch spring bolts securely in diagonal Loosen the clutch release adjuster nut C and turn in the clutch release screw D to feel resistance From this position tur...

Page 133: ...f oil ring 2nd ring and 1st ring The first member to go into the oil ring groove is a spacer 1 After placing the spacer fit the two side rails 2 NOTE Side designations top and bottom are not applied t...

Page 134: ...check that the gaps are so located C 2nd ring and lower side rail D Upper side rail E 1st ring and Spacer PISTON Apply a small quantity of molybdenum oil solution onto each piston pins 1 MOLYBDENUM O...

Page 135: ...tion to the slid ing surface of the pistons piston ring sets and cylinder walls MOLYBDENUM OIL SOLUTION Hold the piston rings in proper position and insert each of the pistons into the respective cyli...

Page 136: ...upside Tighten the cylinder head bolts to the specified torque and diagonally Cylinder head bolt 25 N m 2 5 kgf m 18 0 lbf ft Tighten the cylinder side bolts 5 to the specified torque Cylinder side b...

Page 137: ...lybde num oil solution to their journals and cam faces MOLYBDENUM OIL SOLUTION Apply a engine oil to the camshaft journal holders Install the C ring 1 NOTE Be careful not to drop the C ring 1 into the...

Page 138: ...older R 7 evenly by tightening the camshaft journal holder bolts lightly in the ascending order of numbers NOTE Each camshaft journal holder is identified with a embossed let ters Land R 3 91 The asce...

Page 139: ...cified torque Camshaft journal holder bolt 10 N m 1 0 kgf m 7 0 lbf ft The camshaft journal holder bolts are made of a spe cial material and much superior in strength compared with other types of high...

Page 140: ...t 7 to the specified torque Cam chain tension adjuster cap bolt 8 N m 0 8 kgf m 6 0 lbf ft After installing the cam chain tension adjuster rotate the crankshaft some turns and recheck the positions of...

Page 141: ...head Apply engine oil to both sides of the new gaskets 2 Fit a new gasket 2 to each head cover bolt Tighten the cylinder head cover bolts to the specified torque Cylinder head cover bolt Initial 10 N...

Page 142: ...SUAL INSPECTION 4 22 SELF DIAGNOSTIC PROCEDURES 4 23 SELF DIAGNOSIS RESET PROCEDURE 4 23 USE OF SDS DIAGNOSTIC PROCEDURES 4 24 USE OF SDS DIAGNOSIS RESET PROCEDURE 4 25 SHOW FAILURE DATA DISPLAYING DA...

Page 143: ...IT MALFUNCTION 4 85 DTC C65 P0506 P0507 IDLE SPEED MALFUNCTION 4 89 SENSORS 4 91 CKP SENSOR INSPECTION 4 91 CKP SENSOR REMOVAL AND INSTALLATION 4 91 IAP SENSOR INSPECTION 4 91 IAP SENSOR REMOVAL AND I...

Page 144: ...pler body and do not pull the lead wires Inspect each terminal on the connector coupler for looseness or bending Push in the coupler straightly An angled or skewed insertion may cause the terminal to...

Page 145: ...pening of female ter minal Never push in the probe where male terminal is supposed to fit Check the male connector for bend and female connector for excessive opening Also check the coupler for lockin...

Page 146: ...necting and connecting the coupler make sure to turn OFF the ignition switch or electronic parts may get damaged BATTERY Battery connection in reverse polarity is strictly prohibited Such a wrong conn...

Page 147: ...cal circuit inspection described here is a general method to check for open and short circuit using an ohmmeter and a voltmeter OPEN CIRCUIT CHECK Possible causes for the open circuits are as follows...

Page 148: ...and removing 2 Check each terminal for bend and proper alignment Using continuity inspect or voltage check procedure as described below inspect the wire harness terminals for open circuit and poor con...

Page 149: ...resistance abnormality exists which causes the voltage drop in the circuit between terminals A and B Voltage Between A and body ground Approx 5 V B and body ground Approx 5 V 2 V voltage drop C and b...

Page 150: ...not known make measure ments using the highest range When measuring the resistance with the multi circuit tester 1 will be shown as 10 00 M and 1 flashes in the display Check that no voltage is applie...

Page 151: ...rious compensations These compensations are determined according to the signals from various sensors that detect the engine and driving conditions Intake Air Pressure Sensor IAP Sensor Intake air pres...

Page 152: ...ection time volume is increased STARTING SIGNAL When starting engine additional fuel is injected during cranking engine ACCELERATION SIGNAL DECELERATION SIGNAL During acceleration the fuel injection t...

Page 153: ...A ECM F Heated oxygen sensor HO2S B Ignition coil 2 IG coil 2 G Tip over sensor TOS C Engine coolant temperature sensor ECTS H Intake air pressure sensor 2 IAPS 2 D Fuel injector 2 I PAIR control sol...

Page 154: ...ter Q Speed sensor K Ignition coil 1 IG coil 1 R Fuel pump relay FP relay L Fuel injector 1 S Cooling fan relay M Throttle position sensor TPS T Fuel pump FP N Intake air temperature sensor IATS U Coo...

Page 155: ...r Y Bl P Y G B Y W R B R W B Lbl B G Dg Cooling fan motor Cooling fan relay 10 A 10 A 10 A 30 A Fuel injector FP relay Ignition switch 1 2 Engine stop switch Neutral indicator light Battery Starter bu...

Page 156: ...signal TPS T Fuel pump relay FP relay 9 U HO2 sensor heater HO2SH 0 V PAIR control solenoid PAIR A Power source for sensors VCC W Fuel injector 2 2 B CKP sensor CKPS X Fuel injector 1 1 C Power sourc...

Page 157: ...he LCD panel Motorcycle does not run CHEC The LCD panel indicates CHEC when no communication signal from the ECM is received for 3 seconds For Example The ignition switch is turned ON and the engine s...

Page 158: ...e affected devices are indicated in the code form 09930 82720 Mode selection switch NOTE Before checking the malfunction code do not disconnect the ECM lead wire coupler If the coupler from the ECM is...

Page 159: ...C41 C42 C44 C49 C60 C65 None Crankshaft position sensor CKPS Intake air pressure sensor 2 IAPS 2 Throttle position sensor TPS Engine coolant temperature sensor ECTS Intake air pressure sensor 1 IAPS 1...

Page 160: ...position of the bar in the left of C code displayed on the LCD panel A Incorrect position B Correct position 5 If the TP sensor adjustment is necessary remove the left frame front cover 8 4 6 Loosen...

Page 161: ...G ABILITY RUNNING ABILITY IAP sensor Intake air pressure is fixed to 101 kPa 760 mmHg YES YES TP sensor The throttle opening is fixed to full open position Ignition timing is also fixed YES YES ECT se...

Page 162: ...tor lamp condition LED Always ON Sometimes ON Always OFF Good condition Malfunction display code LCD User mode No display Malfunction display Dealer mode No code Malfunction code PROBLEM SYMPTOMS Diff...

Page 163: ...on Broken fuse FI indicator light operation 4 16 Each warning light operation 9 26 Combination meter operation 9 26 Exhaust gas leakage and noise 6 3 Each coupler disconnection Clogged radiator fins 7...

Page 164: ...there Remove the right frame cover 8 4 Connect the special tool to the mode select coupler 1 and start the engine or crank the engine for more than 4 seconds Turn the special tool s switch ON and che...

Page 165: ...s 4 24 and refer to the SDS operation manual for further details Click the DTC inspection button 4 25 Start the engine or crank the engine for more than 4 seconds and check the DTC to determine the ma...

Page 166: ...orized in the ECM using SDS tool NOTE The malfunction code is memorized in the ECM also when the wire coupler of any sensor is disconnected Therefore when a wire coupler has been disconnected at the t...

Page 167: ...nning or stopped when a malfunction was detected by checking the show fail ure data This show failure data function can record the maximum of two Diagnostic Trouble Codes in the ECM Also ECM has a fun...

Page 168: ...other than the above range C14 P0120 is indicated TP sensor lead wire coupler connection P0120 H Sensor voltage is higher than specified value TP sensor signal circuit shorted to VCC or ground circui...

Page 169: ...33 Fuel injector CKP sensor pickup coil signal is pro duced but fuel injector signal is inter rupted 4 times or more continuously In this case the code C32 P0201 or C33 P0202 is indicated Fuel injecto...

Page 170: ...R control solenoid valve voltage is not input to ECM PAIR control solenoid valve lead wire coupler P1656 C60 Cooling fan relay Cooling fan relay signal is not input to ECM Cooling fan relay lead wire...

Page 171: ...etal particles or foreign material being stuck on the CKP sensor and rotor tip CKP sensor circuit open or short CKP sensor malfunction ECM malfunction When using the multi circuit tester do not strong...

Page 172: ...ouplers 2 4 Check for proper terminal connection to the CKP sensor cou pler and ECM couplers 5 If connections are OK check the following points Resistance 09900 25008 Multi circuit tester set 09900 25...

Page 173: ...ep 2 CKP sensor check 1 Measure the CKP sensor resistance 09900 25008 Multi circuit tester set Tester knob indication Resistance CKP sensor resistance 150 230 2 Check the continuity between each termi...

Page 174: ...eck 1 Connect the ECM couplers 2 Crank the engine several seconds with the starter motor and measure the CKP sensor peak voltage at the coupler 09900 25008 Multi circuit tester set Tester knob indicat...

Page 175: ...g drawn from vacuum passage between throttle body and IAP sensor IAP sensor circuit open or shorted to ground IAP sensor malfunction ECM malfunction P1750 P0105 H Sensor voltage is higher than specifi...

Page 176: ...ircuit tester set Tester knob indication Voltage IAP sensor power supply voltage 4 5 5 5 V terminal R terminal B Br Is check result OK Step 2 IAP sensor ground circuit check 1 Measure the voltage betw...

Page 177: ...wire 2 of IAP sensor coupler and ECM coupler less than 1 Between Bl W wire 1 or W R wire 2 and ground infinity Bl W wire 1 or W R wire 2 terminal and other terminal at IAP sensor connector infinity V...

Page 178: ...ort of the IAP sensor 4 Arrange 3 new 1 5 V batteries 1 in series check that total voltage is 4 5 5 0 V and connect terminal to the ground terminal B and terminal to the VCC terminal A 5 Check the vol...

Page 179: ...tion ECM malfunction P0120 H Sensor voltage is higher than specified value TP sensor signal circuit is shorted to VCC or ground circuit open TP sensor signal circuit is open or shorted to ground or VC...

Page 180: ...R wire and B Br wire 09900 25008 Multi circuit tester set Tester knob indication Voltage TP sensor power supply voltage 4 5 5 5 V terminal R terminal B Br Is check result OK Step 2 TP sensor ground c...

Page 181: ...nnection to the ECM couplers 5 If connections are OK check the following points Resistance 09900 25008 Multi circuit tester set 09900 25009 Needle point prove set Tester knob indication Resistance Bet...

Page 182: ...ion switch ON 5 Measure the TP sensor output voltage between the V wire terminal and B Br wire terminal with turning the throttle grip open and close 09900 25008 Multi circuit tester set 09900 25009 N...

Page 183: ...t ECT sensor malfunction ECM malfunction P0115 H Sensor voltage is higher than specified value ECT sensor circuit open or ground circuit open ECT sensor circuit shorted to ground L Sensor voltage is l...

Page 184: ...ulti circuit tester set Tester knob indication Voltage ECT sensor input voltage 4 5 5 5 V terminal B Bl terminal Ground terminal B Bl terminal B Br Is check result OK Step 2 ECT sensor circuit check 1...

Page 185: ...ECT sensor coupler infinity Voltage 09900 25008 Multi circuit tester set Tester knob indication Voltage Between B Bl wire or B Br wire and ground approx 0 V When ignition switch is ON Is check result...

Page 186: ...r 2 4 Measure the ECT sensor resistance NOTE Refer to ECT SENSOR INSPECTION for details 7 10 09900 25008 Multi circuit tester set Tester knob indication Resistance ECT sensor resistance Approx 2 45 k...

Page 187: ...rt IAT sensor malfunction ECM malfunction P0110 H Sensor voltage is higher than specified value IAT sensor circuit open or ground circuit open IAT sensor circuit shorted to ground L Sensor voltage is...

Page 188: ...4 If connections are OK turn the ignition switch ON 5 Measure the input voltage between the Y R wire and ground 6 If OK measure the input voltage between the Y R wire and B Br wire 09900 25008 Multi c...

Page 189: ...ECM couplers 5 If connections are OK check the following points Resistance 09900 25008 Multi circuit tester set 09900 25009 Needle point probe set Tester knob indication Resistance Between Y R wire a...

Page 190: ...E IAT sensor resistance measurement method is the same way as that of the ECT sensor Refer to page 7 10 for details 09900 25008 Multi circuit tester set Tester knob indication Resistance IAT sensor re...

Page 191: ...TO sensor malfunction ECM malfunction P1651 H Sensor voltage is higher than specified value TO sensor signal circuit is open or ground circuit open TO sensor signal circuit is open or shorted to grou...

Page 192: ...n the R wire and B Br wire 09900 25008 Multi circuit tester set Tester knob indication Voltage TO sensor power supply voltage 4 5 5 5 V terminal R terminal B Br Is check result OK Step 2 TO sensor gro...

Page 193: ...rcuit tester set 09900 25009 Needle point probe set Tester knob indication Resistance Between Br wire of TO sensor coupler and ECM coupler less than 1 Between Br wire and ground infinity Between Br wi...

Page 194: ...sensor voltage Normal 0 4 1 4 V terminal Br terminal B Br 6 Measure the voltage when it is leaned 65 and more left and right from the horizontal level 09900 25008 Multi circuit tester set 09900 25009...

Page 195: ...P switch voltage is not within the following range GP switch voltage 0 6 V GP switch circuit open or short GP switch malfunction ECM malfunction When using the multi circuit tester do not strongly tou...

Page 196: ...rminal P terminal Ground terminal P terminal B W Is check result OK Step 2 GP switch circuit check 1 Turn the ignition switch OFF 2 Remove the seat 8 5 3 Disconnect the ECM couplers 1 4 Check for prop...

Page 197: ...on switch OFF 2 Measure the resistance between the P wire and B W wire when shifting the gearshift lever from 1st to Top 09900 25008 Multi circuit tester set Tester knob indication Resistance GP switc...

Page 198: ...or 2 cylinder 2 DETECTED CONDITION POSSIBLE CAUSE CKP signal is produced but fuel injector signal is interrupted by 4 times or more continuity Injector circuit open or short Injector malfunction ECM...

Page 199: ...ltage terminal O Bl terminal Ground Is check result OK Step 2 Injector drive circuit check 1 Turn the ignition switch OFF 2 Disconnect the ECM couplers 1 3 Check for proper terminal connection to the...

Page 200: ...ion switch OFF 2 Measure the injector resistance between terminals 09900 25008 Multi circuit tester set Tester knob indication Resistance Injector resistance 11 5 12 5 at 20 C 68 F Terminal Terminal 3...

Page 201: ...tion switch is turned to OFF If the ECM coupler or ISC valve coupler is disconnected within 5 seconds after ignition switch is turned to OFF there is a possibility of an unusual value being written in...

Page 202: ...oper terminal connection to the ISC valve coupler and ECM couplers 5 If connections are OK check the following points Resistance 09900 25008 Multi circuit tester set 09900 25009 Needle point probe set...

Page 203: ...nal at ISC valve coupler infinity Between B R wire terminal and other terminal at ISC valve coupler infinity Between W B wire terminal and other terminal at ISC valve coupler infinity Between Lbl wire...

Page 204: ...ulti circuit tester set Tester knob indication Resistance ISC valve continuity Infinity Terminal Ground 3 If OK measure the resistance between the W R wire termi nal A and B R wire terminal B and betw...

Page 205: ...eck that the Desired idle rpm 3 is within the specified idle rpm Check 2 1 Click the button 4 and decrease the Command value 2 to 1 300 rpm slowly 2 Check that the Desired idle rpm 3 is nearly equal t...

Page 206: ...in the ISC valve position increases Check 4 1 Click the button 6 and increase the Command value 2 to 1 900 rpm slowly 2 Check that the Desired idle rpm 3 is approx 1 900 rpm 3 Check that the Engine s...

Page 207: ...ch circuit is shorted to power source Faulty FP relay switch side L No voltage is applied to fuel pump although FP relay is turned ON FP relay coil circuit open or short Faulty FP relay coil side When...

Page 208: ...ck the following points Voltage between O W wire and ground is battery voltage Voltage between R Y wire and ground is battery voltage 09900 25008 Multi circuit tester set Tester knob indication Voltag...

Page 209: ...09900 25009 Needle point probe set Tester knob indication Resistance Between O Bl wire and Y wire of FP relay coupler and ECM coupler less than 1 Between O Bl or Y wire and ground infinity Voltage 09...

Page 210: ...ection of ECM terminal to fuel fuse Fuel fuse When using the multi circuit tester do not strongly touch the terminal of the ECM coupler with a needle point tester probe to prevent terminal damage ECM...

Page 211: ...er knob indication Voltage ECM input voltage Battery voltage terminal R Y terminal Ground Is check result OK DTC C42 P1650 IG SWITCH CIRCUIT MALFUNCTION DETECTED CONDITION AND POSSIBLE CAUSE TROUBLESH...

Page 212: ...heater operation voltage is not supplied to the oxygen heater circuit Oxygen heater circuit is open or shorted to ground Battery voltage is not supplied to the HO2 sensor P0135 When using the multi c...

Page 213: ...s are OK turn the ignition switch ON 5 Measure the voltage between O W wire and ground 09900 25008 Multi circuit tester set Tester knob indication Voltage HO2 sensor heater power supply voltage Batter...

Page 214: ...obe set Tester knob indication Resistance Between W B and B Br wires of HO2 sensor coupler and ECM coupler less than 1 Between each of W B and B Br wires and ground infinity Between W wire terminal an...

Page 215: ...esistance between terminals NOTE Temperature of the HO2 sensor affects resistance value largely Make sure that the HO2 sensor heater is in atmospheric tem perature 09900 25008 Multi circuit tester set...

Page 216: ...25009 Needle point probe set Tester knob indication Voltage HO2 sensor output voltage at idle speed 0 4 V or less terminal B terminal B Br 5 If OK lift and support the fuel tank 5 2 and pinch the PAI...

Page 217: ...onnection to the HO2 sensor cou pler and the ECM couplers 5 If connections are OK check the following points Resistance 09900 25008 Multi circuit tester set 09900 25009 Needle point probe set Tester k...

Page 218: ...2 sensor coupler 2 Warm up the engine enough 3 Insert the needle point probes to the lead wire coupler 4 Measure the HO2 sensor output voltage between the B wire and B Br wire in idling condition 0990...

Page 219: ...t the HO2 sensor coupler 1 4 93 3 Check for proper terminal connection to the HO2 sensor cou pler 4 If connections are OK turn the ignition switch ON 5 Measure the voltage between O W wire and ground...

Page 220: ...Multi circuit tester set 09900 25009 Needle point probe set Tester knob indication Resistance Between W wire of HO2 sensor coupler and ECM coupler less than 1 Between W wire and ground infinity Betwee...

Page 221: ...istance value largely Make sure that the HO2 sensor heater is in atmospheric tem perature 09900 25008 Multi circuit tester set Tester knob indication Resistance HO2 sensor heater resistance 6 7 9 5 at...

Page 222: ...control solenoid valve circuit open or short PAIR control solenoid valve malfunction ECM malfunction When using the multi circuit tester do not strongly touch the terminal of the ECM coupler with a ne...

Page 223: ...ndication Voltage PAIR control solenoid valve power supply voltage Battery voltage terminal O W terminal Ground Is check result OK Step 2 PAIR control solenoid valve drive circuit check 1 Turn the ign...

Page 224: ...trol solenoid valve check 1 Turn the ignition switch OFF 2 Remove the PAIR control solenoid valve 11 4 3 Measure the PAIR control solenoid valve resistance between terminals 09900 25008 Multi circuit...

Page 225: ...ols 4 24 and refer to the SDS opera tion manual for further details 2 Turn the ignition switch ON 3 Click PAIR control solenoid drive control 1 4 Click each button 2 At this time if an operation sound...

Page 226: ...oling fan relay circuit open or short Cooling fan relay ECM malfunction When using the multi circuit tester do not strongly touch the terminal of the ECM coupler with a needle point tester probe to pr...

Page 227: ...pler 5 If connections are OK turn the ignition switch ON 6 Measure the voltage between O W wire and ground 09900 25008 Multi circuit tester set Tester knob indication Voltage Cooling fan relay power s...

Page 228: ...ti circuit tester set 09900 25009 Needle point probe set Tester knob indication Resistance Between Y W wire of cooling fan relay coupler and ECM coupler less than 1 Between Y W wire and ground infinit...

Page 229: ...l at any engine coolant temperature until reaching 100 C 212 F 5 Click the Stop 3 to check the operation properly 6 Click the Off 4 to check the cooling fan relay and cooling fan motor operation NOTE...

Page 230: ...y closed position Is check result OK DETECTED CONDITION POSSIBLE CAUSE C65 Idle speed rose higher than or dropped lower than desired idle speed by more than specified range Air passage clogged ISC val...

Page 231: ...Step 4 Engine mechanical systems check 1 Check the following points related to engine mechanical sys tem Engine compression 2 27 Fuel pressure 5 3 Is check result OK YES Go to Step 4 NO Repair or rep...

Page 232: ...MOVAL AND INSTALLATION Remove the fuel tank 5 2 Disconnect the IAP sensor couplers 2 Remove the IAP sensors 1 from the bracket Disconnect the vacuum hoses 3 Install the IAP sensors in the reverse orde...

Page 233: ...6 IAT SENSOR REMOVAL AND INSTALLATION Disconnect the IAT sensor coupler 2 and remove the IAT sensor 1 Install the IAT sensor in the reverse order of removal TO SENSOR INSPECTION The TO sensor 1 is loc...

Page 234: ...8 5 Remove the reservoir tank mounting bolt 1 and radiator mounting bolts 2 Remove the clamps 3 and disconnect the HO2 sensor cou pler 4 Remove the HO2 sensor 5 Do not remove the HO2 sensor while it i...

Page 235: ...the HO2 sensor 5 to the specified torque HO2 sensor 25 N m 2 5 kgf m 18 0 lbf ft Clamp the HO2 sensor lead wire 10 14 Apply thread lock to the reservoir tank mounting bolt 6 and tighten it to the spe...

Page 236: ...HROTTLE BODY CLEANING 5 15 INSPECTION 5 15 THROTTLE BODY REASSEMBLY 5 16 THROTTLE BODY INSTALLATION 5 17 FUEL INJECTOR REMOVAL 5 18 FUEL INJECTOR INSPECTION 5 18 FUEL INJECTOR INSTALLATION 5 18 ISC VA...

Page 237: ...hose 3 will be bent or twisted Disconnect the fuel pump lead wire coupler 2 Place a rag under the fuel feed hose 3 and disconnect the fuel feed hose 3 NOTE When removing the fuel tank do not leave th...

Page 238: ...pump and fuel deliv ery pipe 09940 40211 Fuel pressure gauge adapter 09940 40220 Fuel pressure gauge attachment 09915 77331 Oil pressure gauge 1 000 kPa 09915 74521 Adapter hose Turn the ignition swi...

Page 239: ...r sensor and fuel pump circuit con nections are OK the fuel pump may be faulty replace the fuel pump with a new one FUEL DISCHARGE AMOUNT INSPECTION Lift and support the fuel tank 5 2 Place a rag unde...

Page 240: ...scharge amount 97 2 ml 3 3 3 4 US Imp oz or more 10 sec NOTE The battery must be in fully charged condition FUEL PUMP RELAY INSPECTION Fuel pump relay is located to inside of the left frame upper cove...

Page 241: ...E BODY FUEL PUMP AND FUEL LEVEL GAUGE REMOVAL CONSTRUCTION FWD 1 Fuel pressure regulator assembly 5 Fuel mesh filter 2 Joint 6 Dust cover ITEM N m kgf m lbf ft 3 Fuel pump A Fuel pump mounting bolt A...

Page 242: ...onnect the fuel level gauge lead wire coupler 2 and remove the fuel pump assembly 1 Remove the fuel level gauge 3 while pushing the pawl end A FUEL LEVEL GAUGE INSPECTION 9 32 Keep away from fire or s...

Page 243: ...pump assembly 5 7 Disconnect the lead wires 1 and lead wire coupler 2 Remove the dust cover 3 Remove the screw 4 Remove the fuel pump 5 Remove the cover 6 and fuel pressure regulator assembly 7 Remove...

Page 244: ...asoline flow resulting in loss of engine power NOTE When the fuel mesh filter is dirtied excessively replace the fuel mesh filter with a new one FUEL PUMP AND FUEL LEVEL GAUGE REASSEMBLY AND INSTALLAT...

Page 245: ...NOTE Push the lock position C fully until the clicking sound heard Install a new O ring 5 and apply grease to it 99000 25010 SUZUKI SUPER GREASE A or equivalent Connect the fuel level gauge lead wire...

Page 246: ...DY 5 11 THROTTLE BODY CONSTRUCTION FWD FWD 1 TP sensor 6 ISC valve 2 Fuel delivery pipe 7 ISC valve hose 3 O ring 8 Air screw 4 Fuel injector A Fuel delivery pipe mounting screw ITEM N m kgf m lbf ft...

Page 247: ...the TP sensor coupler 4 ISC valve hose 5 fuel feed hose 6 IAP sensor hose 1 7 and IAT sensor coupler 8 Disconnect the IAP sensor hose 2 9 and ignition coil clamp 0 Disconnect the throttle cables A fro...

Page 248: ...backward Remove the throttle body assembly THROTTLE BODY DISASSEMBLY NOTE Identify the position of each removed part Organize the parts in their respective groups so that they can be reinstalled in t...

Page 249: ...xR wrench T25H NOTE Prior to disassembly mark the TP sensor original position with a paint or scribe for accurate reinstallation NOTE Never remove the throttle valves 6 NOTE The adjusting screw 7 are...

Page 250: ...eum solvent directly to the throttle valve and ISC bypass passage The cleaner if splayed would work its way into the inside of the ISC valve and attack the insulation film of the coil there causing a...

Page 251: ...0 11950 TorxR wrench T25H Make sure the throttle valves smoothly open and close NOTE Don t push the throttle lever to TP sensor side Throttle valve operating angle fully opened fully closed Apply thin...

Page 252: ...ounting bolts to the specified torque 10 18 Air cleaner upper mounting bolt A 10 N m 1 0 kgf m 7 0 lbf ft Air cleaner lower mounting bolt B 5 5 N m 0 55 kgf m 4 0 lbf ft 5 Connect the throttle pulling...

Page 253: ...ON Check fuel injector filter for evidence of dirt and contamination If present clean and check for presence of dirt in the fuel lines and fuel tank FUEL INJECTOR INSTALLATION Install the fuel injecto...

Page 254: ...r cleaner box 3 backward Disconnect the fuel feed hose 4 Disconnect the fuel injector lead wire couplers 5 Remove the fuel delivery pipe mounting screws 6 Remove the fuel delivery pipe assembly 7 with...

Page 255: ...gine oil to the new cushion seals 2 Install the fuel delivery pipe assembly to the throttle body NOTE Never turn the injector while pushing it Tighten the fuel delivery pipe mounting screws 3 to the s...

Page 256: ...S tool 4 24 2 Turn the ignition switch ON 3 Click Active control 4 Click ISC aperture learned value reset 1 5 Click Reset button 2 to clear the ISC learned value NOTE The learned value of the ISC valv...

Page 257: ...up the SDS tool 4 24 2 Turn the ignition switch ON 3 Click Active control 4 Click TP fully closed learned value reset 1 5 Click Reset button 2 to clear the TP fully closed learned value NOTE The learn...

Page 258: ...cylinders Step 1 Lift up support the fuel tank 5 2 Disconnect the respective vacuum hoses 1 from each vac uum nipples on the throttle body Connect the respective vacuum tester hoses 2 to the vac uum n...

Page 259: ...m from 1 and 2 cyl inders Equalize the vacuum of the cylinders by turning each air screws 3 and keep it running at idling speed NOTE Always set the engine speed at idle speed If the adjustment is not...

Page 260: ...en air screws were cleaned Close the SDS tool and turn the ignition switch OFF Disconnect the vacuum tester and reinstall the removed parts After completing the throttle valve synchronization clear th...

Page 261: ...EXHAUST SYSTEM 6 1 EXHAUST SYSTEM CONTENTS 6 EXHAUST SYSTEM 6 2 REMOVAL 6 2 INSPECTION 6 3 INSTALLATION 6 3...

Page 262: ...lamp 2 and disconnect the HO2 sensor coupler 3 To avoid the risk of being burned do not touch the exhaust system when the system is hot Any service on the exhaust system should be performed when the s...

Page 263: ...the exhaust pipe connection muffler connection and HO2 sensor for exhaust gas leakage and mounting condition If any defect is found replace the defect part with a new one Check the exhaust pipe bolts...

Page 264: ...ADIATOR INSPECTION AND CLEANING 7 8 COOLING FAN 7 8 INSPECTION 7 8 COOLING FAN RELAY INSPECTION 7 9 ECT SENSOR 7 9 REMOVAL 7 9 INSPECTION 7 10 INSTALLATION 7 10 THERMOSTAT 7 11 REMOVAL 7 11 INSPECTION...

Page 265: ...the optimum corrosion protection and excellent heat protection and will protect the cool ing system from freezing at temperatures above 31 C 24 F If the vehicle is to be exposed to tempera tures below...

Page 266: ...lant density freezing point curve C F 0 10 20 30 40 50 60 Density 150 140 130 120 110 100 Boiling point C F 302 284 266 248 230 212 Engine coolant density boiling point curve Fig 2 kgf cm 1 5 0 9 0 5...

Page 267: ...f the pressure should fall during this 10 second interval it means that there is a leaking point in the system In such a case inspect the entire system and replace the leaking com ponent or part Do no...

Page 268: ...in the engine coolant 2 15 Disconnect the reservoir tank over flow hose 1 and reservoir tank inlet hose 2 Remove the reservoir tank 3 Disconnect the clamp 4 and cooling fan motor coupler 5 Disconnect...

Page 269: ...e order of removal Pay attention to the following points Tighten the cooling fan motor assembly mounting bolts 1 to the specified torque Cooling fan motor assembly mounting bolt 7 N m 0 7 kgf m 5 0 lb...

Page 270: ...ng circuit 2 16 WATER HOSE INSPECTION Remove the left and right fuel tank covers 8 5 Check the water hoses for crack damage or engine coolant leakage If any defect is found replace the water hose with...

Page 271: ...engine coolant Disconnect the clamp 1 and cooling fan motor coupler 2 Test the cooling fan motor 3 for load current with an ammeter 4 connected as shown in the figure If the fan motor does not turn re...

Page 272: ...n apply 12 volts to C and D terminals to C and to D and check the continuity between A and B If there is no continuity replace it with a new one 09900 25008 Multi circuit tester set Tester knob indica...

Page 273: ...ON OFF Approx 100 C 212 F If the resistance is noted to show infinity or too much different resistance value replace the ECT sensor with a new one INSTALLATION Install the new gasket washer 1 Tighten...

Page 274: ...that the immersed thermostat is in suspension Heat the water 4 by placing the pan on a electric stove 5 and observe the rising temperature on a thermometer 6 Read the thermometer just when opening the...

Page 275: ...A Standard 4 5 mm and over at 100 C 0 18 in and over at 212 F A thermostat failing to satisfy either of the two requirements start to open temperature and valve lift must be replaced INSTALLATION Inst...

Page 276: ...over 7 O ring 2 O ring 8 Impeller shaft ITEM N m kgf m lbf ft 3 Impeller A Water pump air bleeder bolt A 6 0 6 4 5 4 Mechanical seal B Impeller securing bolt B 8 0 8 6 0 5 Oil seal C Water pump cover...

Page 277: ...If engine oil is leaking visually inspect the oil seal and O ring If engine coolant is leaking visually inspect the mechanical seal and seal ring 7 16 Drain the engine coolant 2 15 Drain the engine o...

Page 278: ...ring 9 and rubber seal 0 from the impeller Remove the impeller shaft A and washer B Remove the mechanical seal with the special tool 09921 20240 Bearing remover set NOTE If there is no abnormal condi...

Page 279: ...for damage with particular atten tion given to the lip Replace the oil seal that shows indications of leakage IMPELLER SHAFT JOURNAL Visually inspect the journal for damage or scratch Replace the wat...

Page 280: ...cal seal side Apply a small quantity of the grease to the oil seal lip 99000 25010 SUZUKI SUPER GREASE A or equivalent Install the new mechanical seal using a suitable size socket wrench NOTE On the n...

Page 281: ...uring bolt NOTE The metal side C of seal washer and the curved side D of washer face the impeller securing bolt head Install the impeller 8 Tighten the impeller securing bolt 9 to the specified torque...

Page 282: ...p mounting bolt 10 N m 1 0 kgf m 7 0 lbf ft Install the dowel pins E and speed sensor bracket F Tighten the speed sensor bracket bolts to the specified torque Speed sensor bracket bolt 10 N m 1 0 kgf...

Page 283: ...OLING AND LUBRICATION SYSTEM LUBRICATION SYSTEM OIL PRESSURE 2 28 OIL FILTER 2 12 OIL PRESSURE REGULATOR 3 23 and 3 47 OIL STRAINER 3 23 and 3 47 OIL JET 3 55 OIL PUMP 3 18 and 3 41 OIL PRESSURE SWITC...

Page 284: ...PIN BEARING OIL JET OIL FILTER OIL PUMP OIL STRAINER OIL PRESSUER REGULATOR COUNTERSHAFT LEFT SIDE BEARING COUNTERSHAFT GEARS AND BUSHINGS DRIVESHAFT GEARS AND BUSHINGS CLUTCH PUSH PIECE CLUTCH PLATES...

Page 285: ...ION 8 15 REMOVAL AND DISASSEMBLY 8 16 INSPECTION 8 18 REASSEMBLY AND INSTALLATION 8 19 STEERING 8 23 CONSTRUCTION 8 23 REMOVAL 8 24 INSPECTION AND DISASSEMBLY 8 25 REASSEMBLY 8 26 INSTALLATION 8 26 ST...

Page 286: ...L AND DISASSEMBLY 8 59 MASTER CYLINDER INSPECTION 8 60 MASTER CYLINDER REASSEMBLY AND INSTALLATION 8 61 REAR BRAKE 8 63 CONSTRUCTION 8 63 BRAKE PAD REPLACEMENT 8 64 BRAKE FLUID REPLACEMENT 8 65 CALIPE...

Page 287: ...tallation Let the center piece stick out toward the head so that the pawls 2 close Insert the fastener into the installation hole NOTE To prevent the pawl 2 from damage insert the fastener all the way...

Page 288: ...the reverse order of removal FRAME FRONT COVER REMOVAL NOTE The left and right side frame front covers are installed symmetri cally and therefore the removal procedure for one side is the same as that...

Page 289: ...tank center cover 8 4 Pull the front part of fuel tank cover 1 by removing the screws 2 A Guide Hooked point Disconnect the front turn signal light coupler 3 and remove the fuel tank cover 4 INSTALLA...

Page 290: ...nect the clamp 1 and seat lock cable 2 Remove the screws 3 and fasteners 4 Remove the frame upper cover assembly 5 INSTALLATION Install the frame upper cover in the reverse order of removal PILLION RI...

Page 291: ...CHASSIS 8 7 FRONT WHEEL CONSTRUCTION FWD 1 Front axle 5 Front wheel 2 Brake disc 6 Spacer ITEM N m kgf m lbf ft 3 Dust seal 7 Collar 1 65 6 5 47 0 4 Bearing A Brake disc bolt A 18 1 8 13 0...

Page 292: ...he ground and support the motorcy cle with a jack or a wooden block Draw out the front axle 2 and remove the front wheel 3 Remove the collar 4 LH only INSPECTION AND DISASSEMBLY TIRE 2 23 8 73 BRAKE D...

Page 293: ...Dial gauge 09900 20701 Dial gauge chuck 09900 21304 V blocks Wheel axle runout Service Limit 0 25 mm 0 010 in WHEEL Make sure that the wheel runout checked as shown does not exceed the service limit...

Page 294: ...n the wheel Rotate the inner race by finger to inspect for abnormal noise and smooth rotation Replace the bearing in the following procedure if there is any thing unusual Remove the wheel bearings 1 o...

Page 295: ...embly Pay attention to the following points WHEEL BEARING Apply grease to the new wheel bearings 99000 25010 SUZUKI SUPER GREASE A or equivalent A LH B RH a Clearance 2 5 mm 0 08 0 20 in 2 5 mm 0 08 0...

Page 296: ...ller set NOTE The sealed cover of the bearing must face outside Remove the removed wheel bearings 4 DUST SEAL Install the new dust seals using the special tool 09913 70210 Bearing installing set 10 75...

Page 297: ...THREAD LOCK CEMENT SUPER 1360 or equivalent Brake disc bolt Front 18 N m 1 8 kgf m 13 0 lbf ft FRONT AXLE Install the front axle in the following procedure Tighten the front axle 1 using the special t...

Page 298: ...axle pinch bolt 3 to the specified torque Front axle pinch bolt 23 N m 2 3 kgf m 16 5 lbf ft Then tighten the front stabilizer bolts 2 After installing the front wheel pump the brake lever until the p...

Page 299: ...l 4 Spring D Spacer 5 Damper rod ring E Outlet tube slide bushing 6 Rebound spring F Outer tube RH 7 Damper rod G Outer tube LH ITEM N m kgf m lbf ft 8 Oil lock piece A Front fork cap bolt A 23 2 3 16...

Page 300: ...flectors only for P 24 Remove the front stabilizer 4 and front fender 5 Loosen the front fork upper clamp bolt 6 and handlebar holder bolt 7 NOTE Slightly loosen the front fork cap bolt 8 to facilitat...

Page 301: ...t fork oil Hold the front fork in the inverted position for a few minutes to allow the fork oil to fully drain Remove the damper rod bolt D using the wrench and special tools 09940 34520 T type handle...

Page 302: ...cer K Oil seal INSPECTION INNER AND OUTER TUBES Inspect the inner tube sliding surface and outer tube sliding sur face for any scuffing and damage If any defects are found replace them with new ones F...

Page 303: ...ark on the oil seal must face upward Apply fork oil to the inner tube slide bushing 1 outer tube slide bushing 2 and the lip of oil seal 4 99000 99044 10G SUZUKI FORK OIL G 10 or equivalent Insert the...

Page 304: ...et 2 Apply thread lock to the damper rod bolt and tighten it to the specified torque using the special tools 99000 32050 THREAD LOCK 1342 or equivalent 09940 34520 T type handle 09940 34581 Front fork...

Page 305: ...oil level compress the inner tube fully without the fork spring Fork oil level 136 mm 5 4 in 09943 74111 Front fork oil level gauge FORK SPRING Install the fork spring into the inner tube NOTE The sma...

Page 306: ...fork cap bolt 2 and front fork upper clamp bolt 3 to the specified torque Front fork cap bolt 23 N m 2 3 kgf m 16 5 lbf ft Front fork upper clamp bolt 23 N m 2 3 kgf m 16 5 lbf ft Install the handleba...

Page 307: ...aring inner race 0 Steering stem lower bracket A 65 6 5 47 0 4 Steering stem upper bearing A Steering stem head nut B 23 N m 2 3 kgf m 16 5 lbf ft then turn counterclockwise 0 1 4 5 Upper bearing oute...

Page 308: ...icence plate only for P 12 Remove the headlight bracket 5 Remove the steering stem head nut 6 and washer Remove the steering stem upper bracket 7 Remove the steering stem nut 8 using the special tool...

Page 309: ...damage Abnormal bearing noise Race wear or damage Dust seal wear or damage If any abnormal points are found replace defective parts with new ones Remove the steering stem lower bearing inner race 1 an...

Page 310: ...ly grease to the bearings and dust seal 99000 25010 SUZUKI SUPER GREASE A or equivalent STEM NUT Tighten the steering stem nut 1 to the specified torque 23 N m 2 3 kgf m 16 5 lbf ft using the special...

Page 311: ...te hitch the spring scale special tool on one handlebar grip end as shown in the figure and read the graduation when the handle bar starts moving Do the same on the other grip end Initial force 200 50...

Page 312: ...ndlebar holder bolt 2 Rear view mirror 6 Handlebar holders ITEM N m kgf m lbf ft 3 Handlebar balancer 7 Right handlebar switch box B Handlebar clamp bolt A 23 2 3 16 5 4 Left handlebar grip 8 Left han...

Page 313: ...olt 6 HANDLEBAR RIGHT SIDE PARTS Remove the rear view mirror 1 Remove the handlebar switch box screws 2 Remove the front brake master cylinder 3 Disconnect the brake light switch lead wires 4 Remove t...

Page 314: ...he handlebar holder bolts 1 to the specified torque Handlebar holder bolt 23 N m 2 3 kgf m 16 5 lbf ft Insert the throttle grip 2 onto the right handlebar Insert the clutch lever holder 3 onto the lef...

Page 315: ...rk G on the left handlebars Tighten the clutch lever holder bolt 5 to the specified torque Clutch lever holder bolt 10 N m 1 0 kgf m 7 0 lbf ft Apply a handle grip bond onto the left handlebar before...

Page 316: ...t 2 Brake disc A Retainer 3 Collar B Bearing 4 Dust seal C Dust seal 5 Bearing D Spacer 6 Rear wheel A Brake disc bolt ITEM N m kgf m lbf ft 7 Wheel damper B Rear sprocket nut A 23 2 3 16 5 8 Spacer C...

Page 317: ...from the sprocket 5 Remove the rear brake caliper assembly 6 by moving it rear ward Pull the rear wheel 3 rearward NOTE Do not operate the brake pedal with the rear wheel removed Remove the collar 7...

Page 318: ...front wheel specifications and procedure DUST SEAL Inspect the wheel and sprocket mounting drum dust seal for wear or damage If any damage is found replace the dust seal with a new one Remove each du...

Page 319: ...nspect the play wheel bearing and sprocket mounting drum bearing by hand while they are installed in place Rotate the inner race by hand to inspect for abnormal noise and smooth rotation Replace the b...

Page 320: ...he reverse order of removal and disassembly Pay attention to the following points A LH B RH a Clearance 1 Insert the protrusion on the wheel damper firmly 49 N m 4 9 kgf m 35 5 lbf ft 2 5 mm 0 08 0 20...

Page 321: ...ing installing set 10 75 First install the right wheel bearing 1 then install the spacer 2 and left wheel bearing 3 using the special tool and removed wheel bearings 4 09924 84510 Bearing installer se...

Page 322: ...e protrusion on the wheel damper firmly 8 36 REAR SPROCKET AND SPROCKET MOUNTING DRUM Apply grease to the retainer 1 before installing the rear sprocket mounting drum 99000 25010 SUZUKI SUPER GREASE A...

Page 323: ...ighten them to the specified torque 99000 32130 THREAD LOCK CEMENT SUPER 1360 or equivalent Brake disc bolt Rear 23 N m 2 3 kgf m 16 5 lbf ft Install the collar 1 REAR AXLE Install the rear wheel with...

Page 324: ...40 CHASSIS REAR SHOCK ABSORBER CONSTRUCTION FWD 1 Rear shock absorber B Rear shock absorber mounting nut Lower ITEM N m kgf m lbf ft A Rear shock absorber mounting nut Upper A 50 5 0 36 0 B 84 8 4 61...

Page 325: ...Take out the rear shock absorber INSPECTION Inspect the shock absorber for damage and oil leakage and absorber bushing for wear and damage If any defects are found replace the shock absorber with a n...

Page 326: ...hock absorber bearing 2 using the special tools 09923 73210 Bearing remover 09930 30104 Rotor remover sliding shaft Press the new bearing using the special tool 09924 84510 Bearing installer set Apply...

Page 327: ...needle 4 The rear shock unit contains high pressure nitrogen gas Mishandling can cause explosion Keep away from fire and heat High gas pressure caused by heat can cause an explosion Release gas press...

Page 328: ...k absorber mounting nut Lower 84 N m 8 4 kgf m 61 0 lbf ft Tighten the front footrest bracket mounting bolts to the speci fied torque Front footrest bracket mounting bolt 23 N m 2 3 kgf m 16 5 lbf ft...

Page 329: ...5 REAR SUSPENSION CONSTRUCTION FWD 1 Swingarm pivot shaft 6 Spacer 2 Chain buffer 7 Swingarm 3 Dust cover 8 Chain case 4 Spacer 9 Chain adjuster ITEM N m kgf m lbf ft 5 Bearing A Swingarm pivot nut A...

Page 330: ...ith a jack to be no load for the swin garm Remove the rear wheel 8 33 Open the brake hose guides 1 Remove the rear shock absorber lower mounting bolt and nut Remove the swingarm pivot nut Draw out the...

Page 331: ...CTION AND DISASSEMBLY SPACER Remove the spacers from swingarm Inspect the spacers for wear and damage If any defects are found replace the spacer with a new one SWINGARM BEARING Insert the spacers int...

Page 332: ...T SHAFT Using a dial gauge check the pivot shaft runout and replace it if the runout exceeds the limit Swingarm pivot shaft runout Service limit 0 3 mm 0 01 in 09900 20607 Dial gauge 09900 20701 Dial...

Page 333: ...e order of disassembly Pay attention to the following points 1 Washer B RH ITEM N m kgf m lbf ft 2 Dust cover C Rear shock absorber mounting nut Upper C 50 5 0 36 0 3 Spacer D Rear shock absorber moun...

Page 334: ...erse order of removal Pay attention to the following points Insert the swingarm pivot shaft and tighten swingarm pivot nut to the specified torque Swingarm pivot nut 65 N m 6 5 kgf m 47 0 lbf ft Tight...

Page 335: ...e B 2 5 0 25 2 0 4 Piston seal E Brake caliper sliding pin A C 18 1 8 13 0 5 Dust seal F Brake caliper sliding pin B D 6 0 6 4 5 6 Brake caliper piston G Brake caliper mounting bolt E 23 2 3 16 5 7 Br...

Page 336: ...been stored for a long period of time When storing the brake fluid seal the container completely and keep away from children When replenishing brake fluid take care not to get dust into fluid When wa...

Page 337: ...set otherwise braking perfor mance will be adversely affected Make sure that the detent A of the pad is seated onto the pad guide on the caliper bracket Tighten the brake caliper mounting bolts 3 pad...

Page 338: ...ake lever until old brake fluid flows out of the bleeder system Close the caliper air bleeder valve and disconnect a clear hose Fill the reservoir with new fluid to the upper mark of the reservoir Spe...

Page 339: ...lean rag over the pistons to prevent it from popping out and then force out the pistons using compressed air Remove the dust seals 4 and piston seals 5 Fingers can get caught between piston and calipe...

Page 340: ...or any scratches and other damage If any damage is found replace the pistons with a new set BRAKE CALIPER SLIDING PIN Inspect the brake caliper sliding pins for wear and other dam age If any damage is...

Page 341: ...nd classification DOT 4 Install the each seal as shown in the illustration 1 Piston seal 2 Dust seal 3 Caliper body Apply grease to the brake caliper sliding pins 99000 25100 SUZUKI SILICONE GREASE or...

Page 342: ...r 2 21 to 22 BRAKE DISC INSPECTION Visually check the brake disc for damage or cracks Measure the thickness with a micrometer Replace the disc if the thickness is less than the service limit or if dam...

Page 343: ...split brake fluid Remove the brake hose union bolt 2 and disconnect the brake hose Remove the master cylinder assembly 3 and disconnect the brake light switch lead wires 4 Remove the reservoir cap 5 p...

Page 344: ...INDER Inspect the master cylinder bore for any scratches or other dam age If any damage is found replace the master cylinder with a new one PISTON Inspect the piston surface for any scratches or other...

Page 345: ...ston and brake lever 99000 25100 SUZUKI SILICONE GREASE or equivalent Tighten the brake lever pivot bolt 1 and lock nut 2 to the specified torque Front brake lever pivot bolt 1 N m 0 1 kgf m 0 5 lbf f...

Page 346: ...n the upper holder bolt first Front brake Master cylinder holder bolt Upper and Lower 10 N m 1 0 kgf m 7 0 lbf ft 3 Master cylinder 4 Handlebar A Mating surface B Punch mark C UP mark a Clearance Inst...

Page 347: ...in A 23 2 3 16 5 4 Caliper piston C Brake pad mounting pin plug B 18 1 8 13 0 5 Dust seal D Brake caliper sliding pin C 2 5 0 25 2 0 6 Piston seal E Brake caliper air bleeder valve D 27 2 7 19 5 7 Bra...

Page 348: ...om the last servicing or which has been stored for a long period of time When storing the brake fluid seal the container completely and keep away from children When replenishing brake fluid take care...

Page 349: ...brake caliper mounting bolt 23 N m 2 3 kgf m 16 5 lbf ft Rear brake pad mounting pin 18 N m 1 8 kgf m 13 0 lbf ft Rear brake pad pin plug 2 5 N m 0 25 kgf m 2 0 lbf ft After replacing the brake pads...

Page 350: ...4 Remove the brake caliper from the caliper bracket CALIPER DISASSEMBLY Remove the brake pad spring 1 Remove the spacer 2 and rubber boot 3 Place a clean rag over the piston to prevent it from popping...

Page 351: ...s and other damage If any damage is found replace the piston with a new one BRAKE CALIPER SLIDING PIN Inspect the brake caliper sliding pin for wear and other damage If any damage is found replace it...

Page 352: ...ssification DOT 4 Install the each seal as shown in the illustration 1 Piston seal 2 Dust seal 3 Caliper body Apply grease to the inside of boot Apply grease to the brake caliper sliding pin 99000 251...

Page 353: ...olt 2 to the specified torque Brake hose union bolt 23 N m 2 3 kgf m 16 5 lbf ft Bleed air from the brake system after installing the caliper 2 21 to 22 BRAKE DISC INSPECTION Inspect the rear brake di...

Page 354: ...aster cylinder along with the reservoir by turn ing the push rod 5 Remove the reservoir tank 6 and reservoir hose 7 Remove the connector 8 by removing the snap ring 9 Remove the O ring 0 09900 06108 S...

Page 355: ...ny defects are found replace it with a new one MASTER CYLINDER REASSEMBLY AND INSTALLATION Reassemble and install the master cylinder in the reverse order of removal and disassembly Pay attention to t...

Page 356: ...kgf m 7 0 lbf ft Rear brake master cylinder rod lock nut 18 N m 1 8 kgf m 13 0 lbf ft Install the brake hose with union bolt and new seal washers After setting the brake hose union to the stopper tig...

Page 357: ...the tire is refitted to the original position after repairing puncture the tire may have to be balanced again since such a repair can cause imbalance INSPECTION WHEEL Wipe the wheel clean and check fo...

Page 358: ...ows no abnormal con dition removing of the valve is not necessary If the seal has abnormal deformation replace the valve with a new one Any dust or rust around the valve hole B must be cleaned off The...

Page 359: ...ow the instructions given by the tire changer manufacturer Bounce the tire several times while rotating This makes the tire bead expand outward to contact the wheel thereby facili tating air inflation...

Page 360: ...sides Coat the bead with lubricant and fit the tire again When the bead has been fitted properly adjust the pressure to specification As necessary adjust the tire balance Cold inflation tire pressure...

Page 361: ...eaded parts of the special tool DRIVE CHAIN CUTTING Set up the special tool as shown in the illustration 1 Tool body 2 Grip handle 3 Pressure bolt A 4 Pressure bolt B 5 Bar 6 Adjuster bolt with throug...

Page 362: ...out of the chain After the joint pin 9 is removed loosen the pressure bolt B 4 and then pressure bolt A 3 Remove the joint pin 9 of the other side of joint plate DRIVE CHAIN CONNECTING JOINT PLATE IN...

Page 363: ...using the bar 7 to press the joint plate over the joint pins Continue pressing the joint plate until the distance between the two joint plates come to the specification Joint plate distance specificat...

Page 364: ...cified dimension After joining of the chain has been completed check to make sure that the link is smooth and no abnormal condition is found Pin end diameter specification A Adjust the drive chain aft...

Page 365: ...TING 9 8 INSPECTION 9 9 STARTER SYSTEM 9 12 TROUBLESHOOTING 9 12 STARTER MOTOR REMOVAL 9 13 STARTER MOTOR DISASSEMBLY 9 14 STARTER MOTOR INSPECTION 9 14 STARTER MOTOR REASSEMBLY 9 15 STARTER RELAY INS...

Page 366: ...ION 9 42 STARTER RELAY INSPECTION 9 42 FUEL PUMP RELAY INSPECTION 9 42 COOLING FAN RELAY INSPECTION 9 42 SWITCHES 9 42 IGNITION SWITCH REMOVAL AND INSTALLATION 9 42 SWITCHES INSPECTION 9 43 BATTERY 9...

Page 367: ...tion The terminals must be clean and free of any foreign material which could impede proper terminal contact Before refitting the sealed coupler make sure its seal rubber is positioned properly The se...

Page 368: ...rt circuit nearby when charging the battery Be sure to recharge the battery in a well ventilated and open area Note that the charging system for the MF battery is different from that of a conventional...

Page 369: ...ure to turn the switch OFF 09900 25008 Multi circuit tester set NOTE When connecting the multi circuit tester use the nee dle pointed probe to the back side of the lead wire coupler and connect the pr...

Page 370: ...IAT sensor 4 46 0 TO sensor 4 50 G Speed sensor 9 33 to 34 4 Starter motor A Fuel pump relay 5 5 H GP switch 4 54 5 Turn signal relay 9 42 B Cooling fan relay 7 9 I Ignition coil 1 9 23 to 24 6 IAP se...

Page 371: ...10 6 Horn A HO2 sensor 4 71 2 Fuse box 7 Oil pressure switch 9 34 B Mode select coupler 3 Fuel pump 5 4 8 Ignition coil 2 9 23 to 24 C Side stand diode 9 19 4 Fuel level gauge 9 32 9 Fuel injector 2 4...

Page 372: ...e the regulated voltage between the battery terminals 9 10 Is the regulated voltage OK Step 4 1 Measure the resistance of the generator coil 9 10 Is the resistance of generator coil OK YES Remove acce...

Page 373: ...t 8 5 Disconnect the battery lead wire Measure the current between battery terminal and the battery lead wire using the multi circuit tester If the reading exceeds the specified value leakage is evide...

Page 374: ...the battery is in fully charged condition 09900 25008 Multi circuit tester set Tester knob indication Voltage Regulated voltage Charging output 14 0 15 5 V at 5 000 r min GENERATOR COIL RESISTANCE Re...

Page 375: ...move the right frame cover 8 4 Disconnect the regulator rectifier couplers 1 Measure the voltage between the terminals using the multi circuit testers as indicated in the following table If the voltag...

Page 376: ...al Do not use thin wire because a large amount of current flows Does the starter motor run YES Go to Step 2 NO Go to Step 3 YES Faulty starter relay Loose or disconnected starter motor lead wire Loose...

Page 377: ...the side stand switch OK Step 2 1 Check the starter clutch Is the starter clutch OK STARTER MOTOR REMOVAL Remove the seat 8 5 Disconnect the battery lead wire Disconnect the starter motor lead wire 1...

Page 378: ...replace the brush with a new one Starter motor brush length Service Limit 6 5 mm 0 26 in COMMUTATOR Inspect the commutator for discoloration abnormal wear or undercut A If the commutator is abnormall...

Page 379: ...spect the oil seal lip for damage or leakage Inspect the bearing for abnormal noise and smooth movement If any defects are found replace the housing end inside BUSHING Inspect the bushing for wear and...

Page 380: ...starter motor case with the match mark on the housing end inside Apply grease to the new O ring 2 99000 25010 SUZUKI SUPER GREASE A or equivalent Tighten the starter motor mounting bolt 3 with the bat...

Page 381: ...e multi circuit tester If the starter relay clicks and continuity is found the relay is OK 09900 25008 Multi circuit tester set Tester knob indication Continuity test Measure the relay coil resistance...

Page 382: ...side stand switch 09900 25008 Multi circuit tester set Tester knob indication Diode test NOTE If the tester reads under 1 4 V when the tester probes are not connected replace its battery SIDE STAND RE...

Page 383: ...minals using the multi cir cuit tester 09900 25008 Multi circuit tester set Tester knob indication Diode test NOTE If the multi circuit tester reads 1 4 V and below when the tester probes are not conn...

Page 384: ...ignition switch ON and side stand to upright position Measure the voltage between P and B W lead wires using the multi circuit tester when shifting the gearshift lever from low to top 09900 25008 Mul...

Page 385: ...oor connections Is there connection in the ignition system couplers Step 2 1 Measure the battery voltage between input lead wires at the ECM with the ignition switch in ON position O R and B W Is the...

Page 386: ...sure the CKP sensor peak voltage and its resistance 9 25 NOTE The CKP sensor peak voltage inspection is applicable only with the multi circuit tester and peak volt adaptor Is the peak voltage and resi...

Page 387: ...wire 09900 25008 Multi circuit tester set NOTE Before using the multi circuit tester and peak volt adaptor be sure to refer to the appropriate instruction manual Shift the transmission into neutral tu...

Page 388: ...nition coil resistance in both the primary and secondary windings If the resistance is not within the stan dard range replace the ignition coil with a new one 09900 25008 Multi circuit tester set Test...

Page 389: ...ank for a few seconds and then measure the CKP sensor peak volt age Repeat the above test procedure a several times and mea sure the highest peak voltage Tester knob indication Voltage CKP sensor peak...

Page 390: ...maintenance free LED is less electric power consuming and stronger to vibration resistance com pared to the bulb 1 ADJ button Trip 1 Trip 2 Clock Eco Norm Maintenance 9 LCD Maintenance 2 Tachometer 0...

Page 391: ...sconnect the boot 3 and combination meter assembly cou pler 4 Remove the combination meter assembly 2 Disassemble the combination meter assembly as follows Reinstall the removed parts NOTE Fix the boo...

Page 392: ...replace the combination meter unit with a new one after checking its wire har ness coupler NOTE The pointer may not return to the proper position even turning the ignition switch ON under low tempera...

Page 393: ...changes in the order below 3 Push the SEL button 1 to fix the selected mode While in the mode selection if the motorcycle reaches speed of more than 10 km h or the ignition switch is turned to OFF th...

Page 394: ...for 3 seconds until MAINTE NANCE display 3 blinks 3 time sand goes off NOTE Reset the display after initial engine oil replacement To preset the interval 1 Press and hold the ADJ button 2 for 2 secon...

Page 395: ...ss Turn the ignition switch to the ON position when the motor cycle is held upright Check the display of fuel level indicator as shown below If any abnormality is found replace the combination meter u...

Page 396: ...each fuel level gauge float position If the resistance is incorrect replace the fuel level gauge with a new one 09900 25008 Multi circuit tester set Tester knob indication Resistance Float position Re...

Page 397: ...inspect the speed sensor and the coupler connections If the speed sensor and coupler connection are OK replace the combination meter unit with a new one 9 27 SPEED SENSOR Remove the right frame cover...

Page 398: ...d sensor bolt to the specified torque Speed sensor bolt 4 5 N m 0 45 kgf m 3 3 lbf ft OIL PRESSURE INDICATOR NOTE Before inspecting the oil pressure switch check if the engine oil level is correct 2 1...

Page 399: ...than those with predetermined wattage Remove the bulb when it gets cool since it may be heated to an extremely high temperature when the headlight is turned ON FWD FWD FWD FWD For P12 For P21 24 71 W...

Page 400: ...coupler 3 NOTE When removing the headlight assembly 4 disconnect the posi tion light coupler 5 Remove the rubber cap 6 Remove the headlight bulb 7 by unhooking the bulb holder spring 8 Replace the he...

Page 401: ...EPLACEMENT NOTE The right and left position light bulbs are installed symmetrically and therefore the replacement procedure for one side is the same as that for the other side Remove the combination m...

Page 402: ...termined wattage LICENSE PLATE LIGHT BULB REPLACEMENT Disconnect the clamp 1 Remove the license plate light nuts 2 Remove the lens cover 3 Replace the license plate light bulb 4 When you touch the bul...

Page 403: ...wattage BRAKE TAIL LIGHT BULB REPLACEMENT Remove the lens 1 Push in on the brake tail light bulb 2 turn it counterclockwise and pull it out Replace the brake tail light bulb 2 When you touch the bulb...

Page 404: ...and therefore the replacement procedure for one side is the same as that for the other side Remove the fuel tank cover 8 5 Remove the bulb socket 1 by turning it counterclockwise Push in on the front...

Page 405: ...ght bulbs are installed sym metrically and therefore the replacement procedure for one side is the same as that for the other side Remove the lens assembly 1 Remove the socket 2 Push in on the rear tu...

Page 406: ...ay be faulty replace it with a new one NOTE When making this test be sure that the battery is fully charged STARTER RELAY INSPECTION 9 17 FUEL PUMP RELAY INSPECTION 5 5 COOLING FAN RELAY INSPECTION 7...

Page 407: ...W Orange with White tracer O Y Orange withYellow tracer W B White with Black tracer Y G Yellow with Green tracer Y W Yellow with White tracer HORN BUTTON FRONT BRAKE LIGHT SWITCH REAR BRAKE LIGHT SWI...

Page 408: ...und Remove the caps 2 NOTE After filling the electrolyte completely use the removed cap 2 as sealing caps of battery filler holes Do not remove or pierce the sealed areas 3 of the electrolyte containe...

Page 409: ...caps do not protrude above the upper surface of the battery s top cover For initial charging use the charger specially designed for MF battery Never use anything except the specified battery Once the...

Page 410: ...er Remove the battery from the motorcycle A Charging period B Stop charging Recharging time 0 9 A for 5 to 10 hours or 4 A for 1 hour After recharging wait for 30 minutes and more and check the batter...

Page 411: ...HOSE ROUTING 10 23 REAR BRAKE HOSE ROUTING 10 24 PAIR AIR SUPPLY SYSTEM HOSE ROUTING 10 25 FUEL TANK INSTALLATION 10 26 MUFFLER EXHAUST PIPE INSTALLATION 10 27 SEAT LOCK CABLE ROUTING 10 28 FRONT FEND...

Page 412: ...RVICING INFORMATION REGULATOR RECTIFIER INSTALLATION 10 40 SPECIAL TOOLS 10 41 TIGHTENING TORQUE 10 44 ENGINE 10 44 FI SYSTEM AND INTAKE AIR SYSTEM 10 46 COOLING SYSTEM 10 46 CHASSIS 10 46 TIGHTENING...

Page 413: ...rds No fuel reaching the intake manifold 1 Clogged fuel filter or fuel hose 2 Defective fuel pump 3 Defective fuel pressure regulator 4 Defective fuel injector 5 Defective fuel pump relay 6 Defective...

Page 414: ...sensor 6 Defective thermostat 7 Defective IAT sensor 8 Damaged or cracked vacuum hose 9 Damaged or clogged ISC valve Fuel injector improperly operating 1 Defective fuel injectors 2 No injection signal...

Page 415: ...d clutch plates driven and drive 4 Worn clutch release bearing Noise seems to come from crankshaft 1 Rattling bearings due to wear 2 Worn and burnt big end bearings 3 Worn and burnt journal bearings 4...

Page 416: ...fuel pump 12 Defective TP sensor Defective air flow system 1 Clogged air cleaner element 2 Defective throttle valve 3 Sucking air from throttle body joint 4 Defective ECM 5 Imbalanced throttle valve s...

Page 417: ...valve synchronization Adjust Replace Adjust Replace Repair Clean or replace Replace Replace Adjust Clean or replace Adjust Repair or replace Drain out excess oil Replace Replace Repair or replace Repl...

Page 418: ...Replace Replace Replace Adjust Dragging clutch 1 Some clutch spring weakened while others are not 2 Distorted pressure plate or clutch plates 3 Clutch release screw out of adjustment Replace Replace...

Page 419: ...age 8 Air trapped in the cooling circuit 9 Defective water pump 10 Use incorrect coolant 11 Defective thermostat 12 Damaged ISC valve 13 ISC bad learning Add coolant Clean Repair or replace Repair or...

Page 420: ...nough fork oil 3 Wrong weight fork oil Replace Replenish Replace Front suspension too stiff 1 Too viscous fork oil 2 Too much fork oil 3 Bent front axle Replace Drain excess oil Replace Noisy front su...

Page 421: ...oreign material in brake fluid 7 Clogged return port of master cylinder Repair surface with sandpaper Correct pad fitting or replace Replace Tighten to specified torque Replace Replace brake fluid Dis...

Page 422: ...ead wires or loose lead connections 2 Short circuited grounded or open generator coil 3 Short circuited or punctured regulator rectifier Repair or replace or retighten Replace Replace Generator does c...

Page 423: ...lt of overcharging 3 Internal short circuit in the battery 4 Too low battery voltage 5 Too old battery Check the generator regu lator rectifier and circuit connections and make nec essary adjustments...

Page 424: ...itch Fixed clamp ECM TO sensor Fixed clamp Fixed clamp Pass the HO2 sensor lead wire to left side of the oil filter Clamp the wiring harness at white tape position Face the lock part of clamp inside P...

Page 425: ...Fixed clamp Horn Cooling fan motor Clamp the wiring harness at white tape position Ignition coil 1 Starter motor Fuel pump relay Cooling fan relay TO sensor Fixed clamp Starter relay cap Starter rela...

Page 426: ...not contact the clamp to the crankcase Generator cover Lead wire CKP sensor 11 N m 1 1 kgf m 8 0 lbf ft 5 5 N m 0 55 kgf m 4 0 lbf ft CKP sensor Grommet VIEW A VIEW C Do not slacken Gear position swi...

Page 427: ...Pass the throttle cables over the water bypass hose 5 4 Cable guide 2 Pass the throttle cables to the right side of head pipe 5 Water bypass hose 3 Pass the clutch cable to the left side of head pipe...

Page 428: ...White mark ITEM N m kgf m lbf ft 3 Intake pipe clamp 2 Clamp end should face left side A 10 1 0 7 0 4 Outlet tube clamp 3 Pass the IAP sensor hose 1 between the fuel feed hose 5 5 5 0 55 4 0 5 Air cle...

Page 429: ...to the narrow side of 3 way joint 5 3 Fuel tank breather hose No 2 4 Pass the fuel tank breather hose No 2 to left side of the fuel tank water drain hose 4 Fuel tank breather hose No 3 5 Align the whi...

Page 430: ...should face forward Do not contact the clamp screw and bracket The clamp screw head should face right side The clamp end should face upward The clamp end should face downward White mark The clamp scre...

Page 431: ...should face backward The clamp screw head should face backward The clamp screw head should face forward Yellow mark Fuel tank water drain hose Left side Front side Fuel tank water drain hose Clamp Wh...

Page 432: ...1 Pass the high tension cord behind the throt tle cable guide 2 Ignition coil 2 ITEM N m kgf m lbf ft 3 Spark plug cap 2 Pass the high tension cord under the fuel hose A 6 5 0 65 4 5 4 High tension co...

Page 433: ...HOSE ROUTING 1 Brake hose 3 After the brake hose union has contacted the stopper tighten the union bolt 1 Pass the brake hose as shown ITEM N m kgf m lbf ft 2 Clamp the brake hose firmly A 23 2 3 16 5...

Page 434: ...reservoir tank hose to the union firmly ITEM N m kgf m lbf ft 3 Rear brake reservoir tank hose A 23 2 3 16 5 3 White paint faces outside before binding the clamp B 27 2 7 19 5 4 Pin C 6 0 6 4 5 5 Rea...

Page 435: ...PAIR control solenoid valve 2 The clamp end should face downward 2 PAIR reed valve 3 The clamp end should face left side ITEM N m kgf m lbf ft 3 Air cleaner box 4 The clamp end should face upward A 10...

Page 436: ...irmly 2 Fuel tank center cover 3 Clean the surface before attaching the cushion 3 Fuel tank cover 4 Keep clearance 2 4 mm 0 08 0 16 in between the fuel tank and fuel tank covers 2 3 4 4 Fuel tank fron...

Page 437: ...lbf ft 3 Rear muffler cover 3 Contact the connector 4 to the stopper A 23 2 3 16 5 4 Connector 4 Install the connector 4 to the exhaust pipe 5 and then install the muffler 2 B 25 2 5 18 0 5 Exhaust p...

Page 438: ...ck cable 2 The tip of the cable is cylindrical shaped 2 Clamp 3 The tip of the cable is spherical shaped 3 Flame 4 Set the cable firmly 1 The lock part of clamp over the frame 5 Align the lib of seat...

Page 439: ...FRONT FENDER INSTALLATION FRONT LICENSE PLATE INSTALLATION Only for P 12 1 Front fender 3 Washer RH only 2 Front stabilizer 1 The embossed lettering of the front stabilizer must face lower side 1 Fro...

Page 440: ...10 30 SERVICING INFORMATION FRONT SIDE REFLEX REFLECTOR INSTALLATION Only for P 24 1 Reflex reflector 3 Washer ITEM N m kgf m lbf ft 2 Reflector bolt 4 Front fork A 4 5 0 45 3 5 B 1 8 0 18 1 5...

Page 441: ...ear fender 3 Frame upper cover CENTER A Pillion rider handle 4 Frame front cover LH 1 To footrest bracket 5 Frame front cover RH 2 To air cleaner box 6 Frame cover LH 3 To frame 7 Frame cover RH 4 To...

Page 442: ...FRAME INSTALLATION SIDE STAND INSTALLATION 1 Frame down tube ITEM N m kgf m lbf ft 2 Frame A 60 6 0 43 5 3 Engine mounting bracket B 50 5 0 36 0 1 Install the spring as shown ITEM N m kgf m lbf ft A...

Page 443: ...FORMATION 10 33 CENTER STAND INSTALLATION For P 12 1 Center stand 3 Center stand cushion ITEM N m kgf m lbf ft 2 Center stand spring 1 Do not apply grease to the flange and thread part A 60 6 0 43 5 T...

Page 444: ...ATION 1 Brake pedal 6 Rear brake master cylinder 2 Footrest bracket 7 Circlip ITEM N m kgf m lbf ft 3 Brake pedal spring 8 Washer A 10 1 0 7 0 4 Brake switch spring 1 Measuring position B 18 1 8 13 0...

Page 445: ...nt brake master cylinder with punch mark B 6 0 6 4 5 C 10 1 0 7 0 4 Guide 4 Align the matching surface of clutch lever holder with punch mark D 6 5 0 65 4 5 E 23 2 3 16 5 5 Front brake hose F 1 0 1 0...

Page 446: ...10 36 SERVICING INFORMATION HEADLIGHT COVER INSTALLATION 1 Headlight lower cover 4 Headlight side cover RH 2 Headlight upper cover 5 Headlight housing brace 3 Headlight side cover LH 6 Cushion...

Page 447: ...N 1 Headlight unit 4 Headlight side cover LH 2 Combination meter assembly 5 Headlight side cover RH ITEM N m kgf m lbf ft 3 Headlight upper cover 6 Headlight housing brace A 6 0 6 4 5 K L F I K L E H...

Page 448: ...SIGNAL LIGHT INSTALLATION 1 Front turn signal light RH 3 Radiator reservoir tank 2 Pass the front turn signal lead wire behind the front turn signal light 2 Front turn signal light LH 1 Coupler positi...

Page 449: ...se plate light lead wire pass the lead wires inside the hole of the rear fender Do not slacken 2 Rear fender 3 Rear frame center cover 4 License plate light 2 When installing the TO sensor do not dama...

Page 450: ...LATION 1 Regulator Rectifier 4 Clamp 2 Pass the regulator rectifier lead wire along the frame Do not slacken 2 Bracket 5 ECM 3 Clamp the regulator rectifier lead wire at root of the connector 3 Clamp...

Page 451: ...Cylinder gauge set 09900 20602 Dial gauge 09900 20605 Dial calipers 10 34 mm 09900 20607 Dial gauge 09900 20701 Dial gauge chuck 09900 20803 Thickness gauge 09900 20805 Tire depth gauge 09900 21304 V...

Page 452: ...attachment 09916 84511 Tweezer 09917 14910 Tappet adjust driver 09917 47011 Vacuum pump gauge set 09920 53740 Clutch sleeve hub holder 09921 20210 Bearing remover 12 mm 09921 20240 Bearing remover se...

Page 453: ...ering stem nut socket wrench 09940 34520 T type handle 09940 34581 Front fork assembling attachment F 09940 40211 Fuel pressure gauge adapter 09940 40220 Fuel pressure gauge attachment 09940 52861 Fro...

Page 454: ...0 Engine mounting nut 55 5 5 40 0 Engine mounting bracket nut 60 6 0 43 5 Crank balancer bolt 50 5 0 36 0 Valve clearance adjuster lock nut 10 1 0 7 0 Camshaft sprocket bolt 15 1 5 11 0 Spark plug 11...

Page 455: ...0 7 0 Ignition coil nut 6 5 0 65 4 5 Gearshift lever shaft 40 4 0 29 0 Gearshift link arm bolt 10 1 0 7 0 Crankshaft journal bolt M 8 Initial 15 1 5 11 0 Final 26 2 6 19 0 Crankcase bolt M 6 11 1 1 8...

Page 456: ...bolt 6 0 6 4 5 Water jacket plug 25 2 5 18 0 Cooling fan motor assembly mounting bolt 7 0 7 5 0 Cooling fan mounting nut 1 1 0 11 1 0 ECT sensor 18 1 8 13 0 Cooling fan motor mounting screw 2 7 0 27...

Page 457: ...liding pin 27 2 7 19 5 Rear brake pad mounting pin 18 1 8 13 0 Rear brake pad pin plug 2 5 0 25 2 0 Rear brake master cylinder mounting bolt 10 1 0 7 0 Rear brake master cylinder rod lock nut 18 1 8 1...

Page 458: ...5 160 kgf m 0 15 0 3 0 55 1 3 2 9 4 5 6 5 10 5 16 0 lbf ft 1 0 2 0 4 0 9 5 21 0 32 5 47 0 76 0 115 5 A equivalent of 4T strength fastener with flange N m 1 7 3 3 6 14 32 50 72 116 176 kgf m 0 17 0 33...

Page 459: ...Valve stem O D IN 4 975 4 990 0 1959 0 1965 EX 4 955 4 970 0 1951 0 1957 Valve stem deflection IN EX 0 35 0 014 Valve stem runout IN EX 0 05 0 002 Valve head thickness IN EX 0 5 0 02 Valve stem end le...

Page 460: ...03 32 75 1 289 Camshaft journal oil clearance 0 032 0 066 0 0013 0 0026 0 150 0 0059 Camshaft journal holder I D 22 012 22 025 0 8666 0 8671 Camshaft journal O D 21 959 21 980 0 8645 0 8654 Camshaft r...

Page 461: ...n from the skirt end 53 380 2 1016 Cylinder distortion 0 10 0 004 Piston ring free end gap 1st 1R Approx 5 3 0 21 4 2 0 17 2nd 2R Approx 4 6 0 18 3 6 0 14 Piston ring end gap 1st 0 20 0 32 0 008 0 013...

Page 462: ...000 1 2195 1 2205 Crankshaft journal oil clearance 0 016 0 040 0 0006 0 0016 0 080 0 0031 Crankshaft journal O D 29 976 30 000 1 1802 1 1811 Crankshaft thrust bearing thickness Right side 2 450 2 625...

Page 463: ...9 0 632 15 2 0 598 Driven plate distortion No 1 2 and 3 0 10 0 004 Clutch spring free length 38 5 1 528 36 6 1 441 ITEM STANDARD LIMIT Primary reduction ratio 3 238 68 21 Final reduction ratio 3 286 4...

Page 464: ...ening pres sure 93 123 kPa 0 93 1 23 kgf cm 13 2 17 5 psi Cooling fan operating temperature OFF ON Approx 105 C 221 F ON OFF Approx 100 C 212 F Engine coolant type Use an antifreeze coolant compatible...

Page 465: ...resistance 25 0 26 0 k TO sensor voltage Normal 0 4 1 4 V Leaning 3 7 4 4 V When leaning 65 GP switch voltage 0 6 V or more From 1st to Top GP switch resistance Approx 500 or more Injector voltage Bat...

Page 466: ...60 V AC or more at 5 000 r min Starter motor brush length Standard 10 0 39 Limit 6 5 0 26 Regulated voltage 14 0 15 5 V at 5 000 r min Starter relay resistance 3 6 GP switch voltage 0 6 V or more From...

Page 467: ...Rear Approx 38 2 1 50 Brake fluid type DOT 4 Wheel rim runout Axial 2 0 0 08 Radial 2 0 0 08 Wheel rim size Front 17 M C MT 3 00 Rear 17 M C MT 4 00 Wheel axle runout Front 0 25 0 010 Rear 0 25 0 010...

Page 468: ...nt fork inner tube O D 37 1 46 Rear shock absorber spring adjuster 3rd position Rear wheel travel 120 4 7 Swingarm pivot shaft runout 0 3 0 01 ITEM SPECIFICATION NOTE Fuel type Gasoline used should be...

Page 469: ...11 2 NOISE EMISSION CONTROL SYSTEM 11 2 HO2 SENSOR INSPECTION 11 2 HO2 SENSOR REMOVAL AND INSTALLATION 11 2 PAIR AIR SUPPLY SYSTEM AND EMISSION CONTROL SYSTEM INSPECTION 11 3 PAIR HOSES 11 3 PAIR REED...

Page 470: ...of the vehicle after such device or element of design has been removed or rendered inoperative by any person AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW Removing or pu...

Page 471: ...e left fuel tank cover 8 5 Remove the PAIR reed valve cover 1 and PAIR read valve 2 Inspect the reed valve for the carbon deposit If the carbon deposit is found in the PAIR reed valve replace the PAIR...

Page 472: ...IR control solenoid valve coupler 2 Disconnect the PAIR hose 3 Remove the PAIR control solenoid valve 4 from the bracket INSPECTION Check that air flows through the air inlet port to the air outlet po...

Page 473: ...ve PAIR control solenoid valve resistance 18 22 at 20 C 68 F 09900 25008 Multi circuit tester set Tester knob indication Resistance INSTALLATION Installation is in the reverse order of removal Pay att...

Page 474: ...3 2 2 4 MIN 10 mm 0 4 in MIN 10 mm 0 4 in 1 1 PAIR control solenoid valve 2 The clamp end should face downward 2 PAIR reed valve 3 The clamp end should face left side ITEM N m kgf m lbf ft 3 Air clea...

Page 475: ...0A 4 IGNITION 10A SPARE 15A SPARE 10A PAIR CONTROL SOLENOID VALVE IAP SENSOR IAT SENSOR ECT SENSOR 1 2 TP SENSOR ISC VALVE STARTER BUTTON ECM CKP SENSOR PUSH FREE SIDE STAND SWITCH SIDE STAND RELAY DI...

Page 476: ...A SPARE 10A PAIR CONTROL SOLENOID VALVE IAP SENSOR IAT SENSOR ECT SENSOR 1 2 TP SENSOR ISC VALVE STARTER BUTTON ECM CKP SENSOR PUSH FREE SIDE STAND SWITCH SIDE STAND RELAY DIODE FUEL INJECTOR IAP SENS...

Page 477: ...Prepared by Supplied by April 2012 Part No 99500 32170 01E Printed in Japan 480 CHANGZHOU HAOJUE SUZUKI MOTORCYCLE CO LTD...

Page 478: ...Printed in Japan L3 CHANGZHOU HAOJUE SUZUKI MOTORCYCLE CO LTD...

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