Suzuki gw250F Owner'S Manual Download Page 81

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6-31

BRAKE PADS

FRONT

REAR

Inspect the front and rear brake pads

to see if they are worn down to the

grooved wear limit line

. If a front or

rear pad is worn to the grooved wear

limit line

, both front or both rear

pads must be replaced with new

ones. After replacing either the front

or rear brake pads, the brake lever or

pedal must be pumped several times.

This will extend the pads to their

proper position.

WARNING

Failure to inspect and maintain the

brake pads and replace them

when recommended can increase

your chance of having an acci-

dent.

If you need to replace brake pads,

have your Suzuki dealer do this

work. Inspect and maintain the

brake pads as recommended.

FRONT

REAR

Summary of Contents for gw250F

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Page 3: ...ant that you avoid operating the engine in a manner which could expose the engine parts to excessive heat Please refer to the BREAK IN RUN NING IN section for specific break in recommendations WARNING CAUTION NOTICE NOTE Please read this manual and follow its instructions carefully To emphasize special information the symbol and the words WARNING CAUTION NOTICE and NOTE have special meanings Pay p...

Page 4: ...nced technicians that are trained to provide your motorcycle with the best possible service with the right tools and equip ment All information illustrations and speci fications contained in this manual are based on the latest product informa tion available at the time of publica tion Due to improvements or other changes there may be some discrep ancies between information in this manual and your ...

Page 5: ...NSUMER INFORMATION CONTROLS FUEL ENGINE OIL AND COOLANT RECOMMENDATIONS BREAK IN RUNNING IN AND INSPECTION BEFORE RIDING RIDING TIPS INSPECTION AND MAINTENANCE TROUBLESHOOTING STORAGE PROCEDURE AND MOTORCYCLE CLEANING SPECIFICATIONS INDEX ...

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Page 7: ...ONSUMER INFORMATION ACCESSORY USE AND MOTORCYCLE LOADING 1 2 MODIFICATION 1 4 SAFE RIDING RECOMMENDATION FOR MOTORCYCLE RIDERS 1 4 LABELS 1 5 SERIAL NUMBER LOCATION 1 6 NOISE CONTROL SYSTEM AUSTRALIA ONLY 1 6 ...

Page 8: ...ity problems The extra weight will cause the motor cycle to be less responsive to your steering control The weight may also cause oscillations in the front end and lead to instability prob lems Accessories added to the handlebars or front fork of the machine should be as light as possible and kept to a minimum Certain accessories displace the rider from his or her normal riding position This limit...

Page 9: ...eight low and close to the center of the motorcycle as possible Do not attach large or heavy items to the handlebars front forks or rear fender Do not install a luggage carrier or a luggage box protruding over the tail end of the motorcycle Do not carry any items that pro trude over the tail end of the motorcycle Check that both tires are properly inflated to the specified tire pres sure for your ...

Page 10: ...e INSPECTION BEFORE RIDING section of this manual Do not forget to perform an entire safety inspection to ensure the safety of the rider and its passenger FAMILIARIZE YOURSELF WITH THE MOTORCYCLE Your riding skill and your mechanical knowledge form the foundation for safe riding practices We suggest that you practice riding your motorcycle in a non traffic situation until you are thoroughly famili...

Page 11: ... strategy of assuming they are invisible to other drivers even in broad day light Wear bright reflecting clothing Turn on the headlight and taillight every time even on a bright sunny day to attract driver s attention Do not ride in another driver s blind spot LABELS Read and follow all the labels on the motorcycle Make sure you under stand all of the labels Do not remove any labels from the motor...

Page 12: ...our future reference NOISE CONTROL SYSTEM AUSTRALIA ONLY TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED Owners are warned that the law may prohibit a The removal or rendering inopera tive by any person other than for purposes of maintenance repair or replacement of any device or element of design incorporated into any new vehicle for the pur pose of noise control prior to its sale or delivery to t...

Page 13: ...RTS 2 2 KEY 2 5 IGNITION SWITCH 2 5 INSTRUMENT PANEL 2 6 LEFT HANDLEBAR 2 14 RIGHT HANDLEBAR 2 15 FUEL TANK CAP 2 17 GEARSHIFT LEVER 2 18 REAR BRAKE PEDAL 2 19 SEAT LOCK AND HELMET HOLDERS 2 19 SIDE STAND 2 20 REAR SUSPENSION 2 21 ...

Page 14: ...ROLS LOCATION OF PARTS 1 Clutch lever 2 Left handlebar switches 3 Instrument panel 4 Front brake fluid reservoir 5 Right handlebar switches 6 Throttle grip 7 Front brake lever 8 Ignition switch 9 Fuel tank cap ...

Page 15: ...2 3 0 Fuse A Battery B Tools C Main fuse D Helmet holder E Seat lock F Passenger grab handle G Engine oil filter H Engine oil drain plug I Side stand J Gearshift lever K Footrests L Passenger footrests ...

Page 16: ...2 4 M Rear brake fluid reservoir N Air cleaner O Rear brake light switch P Rear brake pedal Q Engine oil inspection window R Engine oil filler cap ...

Page 17: ...the igni tion switch in this position LOCK POSITION To lock the steering turn the handle bar all the way to the left Push down and turn the key to the LOCK posi tion and remove the key All electrical circuits are cut off P Parking POSITION EU When parking the motorcycle lock the steering and turn the key to the P position The key can now be removed and the position light and taillight will remain ...

Page 18: ...ition WARNING Turning the ignition switch to the P PARKING or LOCK posi tion while the motorcycle is mov ing can be hazardous Moving the motorcycle while the steering is locked can be hazardous You could lose your balance and fall or you could drop the motorcycle Stop the motorcycle and place it on the side stand before locking the steering Never attempt to move the motorcycle when the steering is...

Page 19: ...HT 2 This indicator comes on when the engine oil pressure is below the nor mal operating range This should come on when the ignition switch is ON and the engine is not running As soon as the engine starts this should go out NOTICE Riding the motorcycle with the coolant temperature indicator lit can cause serious engine damage due to overheating If the engine coolant temperature indicator light com...

Page 20: ...tently and the red indicator light comes on and remains lit keep the engine running and bring your motorcycle to an authorized Suzuki dealer If the engine stalls try restarting the engine after turn ing the ignition switch off and on If the display indicates FI contin uously and the red indicator light blinks the engine will not start NOTICE The fuel injection indicator light comes on to indicate ...

Page 21: ...ht 7 will light or blink when the engine speed reaches a preset engine rpm LIGHT BLINK NO LIGHT Mode Selection 1 To enter the selection mode turn on the ignition switch and press and hold the SEL button D for more than 2 seconds to change the mode 2 Push the ADJ button B to change the lighting mode The mode changes as follows LIGHT BLINK NO LIGHT LIGHT The engine rpm indicator light 7 comes on ste...

Page 22: ...l tank The fuel meter displays all 5 segments when the fuel tank is full The mark blinks when the fuel drops below 4 0 L 4 2 3 5 US Imp qt The mark and segment blink when the fuel drops below 2 0 L 2 1 1 8 US Imp qt NOTE The fuel meter will not indicate correctly when the motorcycle is placed with the side stand Turn the ignition switch to the ON position when the motorcycle is held upright WARNIN...

Page 23: ...NANCE display blinks 3 times and goes off NOTE Reset the display after initial engine oil replacement To preset the interval 1 Press and hold the ADJ button B for 2 seconds until MAINTE NANCE display blinks when the display shows the odometer 2 Push the SEL button D to decrease interval from 5000 km 2500 miles to 500 km 300 miles in 500 km 300 miles steps 3 Push the ADJ button B to increase interv...

Page 24: ...ch is turned on again NOTE EU Australia Canada Set the meter to odometer then press and hold the ADJ button B and SEL button D for 3 seconds to switch between km and mile At this time speedometer will be changed between km h and mph Select km h or mph as appropri ate to comply with traffic regula tions Check km h and mph display after adjusting the instrument panel dis play To change the display p...

Page 25: ... and start counting again Clock The clock has a 12 hour display Fol low the procedure below to adjust the clock 1 Push the SEL button D and ADJ button B simultaneously for 2 seconds until the minute display blinks when the display shows the clock 2 Adjust the minute display by push ing the ADJ button B NOTE When the ADJ button B is held in the display advances continu ously 3 Push the SEL button D...

Page 26: ...lding the dimmer switch between the and posi tion will light both the high and low headlight beam This improper operation can damage the motor cycle s headlight Use the dimmer switch to select only the or position NOTICE Sticking tape or placing objects in front of the headlight can obstruct headlight heat radiation This can result in headlight damage Do not stick tape on the headlight or place ob...

Page 27: ...a traffic hazard RIGHT HANDLEBAR ENGINE STOP SWITCH 1 position The ignition circuit is off The engine cannot start or run position The ignition circuit is on and the engine can run FRONT BRAKE LEVER 2 The front brake is applied by squeez ing the brake lever gently toward the throttle grip This motorcycle is equipped with a disk brake system and excessive pressure is not required to slow the motorc...

Page 28: ...rter motor With the ignition switch in the ON position the engine stop switch in the transmission in neutral squeeze the clutch lever push the electric starter switch to operate the starter motor and start the engine NOTE This motorcycle is equipped with interlock switches for the ignition circuit and the starter circuit The engine can only be started if The transmission is in neutral and the clut...

Page 29: ...e key and open the fuel tank cap To close the fuel tank cap push the cap down firmly with the key in the cap lock until you hear it click 1 Fuel level 2 Filler neck NOTICE Engaging the starter motor for more than five seconds at a time can damage the starter motor and wiring harness from overheating Do not engage the starter motor for more than five seconds at a time If the engine does not start a...

Page 30: ...ely in neutral Reduce the motorcycle speed before down shifting When down shifting the engine speed should be increased before the clutch is engaged This will prevent unneces sary wear on the drive train compo nents and the rear tire WARNING If you overfill the fuel tank fuel may overflow when it expands due to engine heat or heating by the sun Fuel that overflows can catch fire Stop adding fuel w...

Page 31: ...t will be illuminated when the rear brake is operated SEAT LOCK AND HELMET HOLDERS To unlock the seat lock insert the ignition key into the lock and turn it clockwise To lock the seat slide the seat hooks into the seat hook retain ers and push down firmly until the seat snaps into the locked position ...

Page 32: ...engine can not be started If the engine is running and the transmission is shifted into gear with the side stand down the engine will stop running If the engine is running and the side stand is put down with the transmission in gear the engine will stop running WARNING Failure to install the seat properly could allow the seat to move and cause loss of rider control Latch the seat securely in its p...

Page 33: ...ffest This motorcycle is delivered from the factory with its adjuster set on position 3 WARNING Riding with the side stand incom pletely retracted can result in an accident when you turn left Check operation of the side stand ignition interlock system before riding Always retract the side stand completely before starting off NOTICE If you do not take proper precau tions when parking the motorcy cl...

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Page 35: ...3 1 3 FUEL ENGINE OIL AND COOLANT RECOMMENDATIONS FUEL OCTANE RATING 3 2 OXYGENATED FUEL RECOMMENDATION Canada and EU 3 2 ENGINE OIL 3 3 COOLANT 3 5 ...

Page 36: ...tain oxygen carrying addi tives such as MTBE or alcohol Gasoline Containing MTBE Unleaded gasoline containing MTBE Methyl Tertiary Butyl Ether may be used in your motorcycle if the MTBE content is not greater than 15 This oxygenated fuel does not contain alcohol Gasoline Ethanol Blends Blends of unleaded gasoline and eth anol grain alcohol also known as GASOHOL may be used in your motorcycle if th...

Page 37: ...engine pinging is experienced substitute another brand as there are differences between brands ENGINE OIL Use Suzuki genuine engine oil or equivalent If Suzuki genuine engine oil is not available select a proper engine oil according to the following guideline Oil quality is a major contributor to your engine s performance and life Always select good quality engine oil Use oil with an API American ...

Page 38: ...fica tion as follows 1 Code number of oil sales company 2 Oil classification Energy Conserving Suzuki does not recommend the use of ENERGY CONSERVING or RESOURCE CONSERVING oils Some engine oils which have an API classification of SH or higher have an ENERGY CONSERVING or RESOURCE CONSERVING indica tion in the API classification donut mark These oils can affect engine life and clutch performance E...

Page 39: ...oper ratio Add only SUZUKI SUPER LONG LIFE COOLANT if coolant level drops It is not necessary to dilute SUZUKI SUPER LONG LIFE COOL ANT when replacing coolant WARNING Engine coolant is harmful or fatal if swallowed or inhaled Solution can be poisonous to animals Do not drink antifreeze or coolant solution If swallowed do not induce vomiting Immediately con tact a poison control center or a physici...

Page 40: ...Solution capacity total 1350 ml 1 4 1 2 US Imp qt NOTE This 50 mixture will protect the cooling system from freezing at temperatures above 31 C If the motorcycle is to be exposed to tem perature below 31 C this mixing ratio should be increased up to 55 40 C or 60 55 C coolant The mixing ratio should not exceed 60 coolant 50 Water 675 ml 0 7 0 6 US Imp qt Coolant 675 ml 0 7 0 6 US Imp qt ...

Page 41: ... MAXIMUM ENGINE SPEED RECOMMENDATION 4 2 VARY THE ENGINE SPEED 4 2 BREAKING IN THE NEW TIRES 4 2 AVOID CONSTANT LOW SPEED 4 2 ALLOW THE ENGINE OIL TO CIRCULATE BEFORE RIDING 4 3 OBSERVE YOUR FIRST AND MOST CRITICAL SERVICE 4 3 INSPECTION BEFORE RIDING 4 3 ...

Page 42: ... in to assure maximum performance just as the engine does Wear in the tread surface by gradually increasing your cornering lean angles over the first 160 km 100 miles before attempting maximum performance Avoid hard acceleration hard cornering and hard braking for the first 160 km 100 miles AVOID CONSTANT LOW SPEED Operating the engine at constant low speed light load can cause parts to glaze and ...

Page 43: ...ormance from the engine NOTE The 1000 km 600 miles ser vice should be performed as outlined in the INSPECTION AND MAINTE NANCE section of this Owner s Man ual Pay particular attention to the CAUTION and WARNING in that sec tion INSPECTION BEFORE RIDING WARNING Failure to inspect your motorcy cle before riding and to properly maintain your motorcycle increases the chances of an acci dent or equipme...

Page 44: ...ay in the throttle cable Smooth operation and positive return of the throttle grip to the closed position Clutch 6 23 Correct play in the cable Smooth and sure action of clutch lever Brakes 6 29 Proper pedal and lever operation Fluid level in the reservoir to be above LOWER line Correct pedal and lever play No sponginess No fluid leakage Brake pads not to be worn down to the limit line Suspensions...

Page 45: ...5 1 5 RIDING TIPS STARTING THE ENGINE 5 2 STARTING OFF 5 3 USING THE TRANSMISSION 5 4 RIDING ON HILLS 5 5 STOPPING AND PARKING 5 5 ...

Page 46: ...ciently warms up When a Cold Engine is Hard to Start 1 Open the throttle approximately 1 8 turn and push the electric starter switch 2 After the engine starts let the engine run until the engine suffi ciently warms up When the Engine is Warm Close the throttle completely and push the electric starter switch When a Warm Engine is Hard to Start Open the throttle approximately 1 8 turn and push the e...

Page 47: ... side stand is down the engine will stop running WARNING Riding at excessive speeds increases your chances of losing control of the motorcycle which can result in an accident Always ride at a speed that is proper for the terrain visibility and operating conditions and your skills and experience WARNING If you remove even one hand or foot from the motorcycle you can reduce your ability to control t...

Page 48: ...0 12 2nd 3rd 30 19 3rd 4th 40 25 4th 5th 50 31 5th 6th 60 37 Gear position km h miles h 6th 5th 50 31 5th 4th 40 25 4th 3rd 30 19 WARNING Downshifting when engine speed is too high can cause the rear wheel to skid and lose traction due to increased engine braking resulting in an accident or force the engine to overrev in the lower gear resulting in engine damage Reduce speed before downshift ing W...

Page 49: ...NG 1 Turn the throttle grip away from you to close the throttle com pletely 2 Apply the front and rear brakes evenly and at the same time 3 Downshift through the gears as road speed decreases 4 Select neutral with the clutch lever squeezed toward the grip disen gaged position just before the motorcycle stops The neutral position can be confirmed by observing the neutral indicator light WARNING Ine...

Page 50: ...to remove anti theft lock before moving the motorcycle WARNING Hard braking on wet loose rough or other slippery surfaces can cause wheel skid and loss of con trol Brake lightly and with care on slip pery or irregular surfaces WARNING Following another vehicle too closely can lead to a collision As vehicle speeds increase stop ping distance increases progres sively Always maintain a safe stopping ...

Page 51: ... 6 12 SPARK PLUGS 6 15 FUEL HOSE 6 17 ENGINE OIL 6 17 ENGINE IDLE SPEED INSPECTION 6 22 THROTTLE CABLE ADJUSTMENT 6 22 CLUTCH 6 23 COOLANT 6 24 DRIVE CHAIN 6 26 BRAKES 6 29 TIRES 6 33 SIDE STAND IGNITION INTERLOCK SWITCH 6 36 FRONT WHEEL REMOVAL 6 37 REAR WHEEL REMOVAL 6 40 LIGHT BULB REPLACEMENT 6 42 FUSES 6 46 CATALYTIC CONVERTER 6 48 ...

Page 52: ...m safety we sug gest that you have these items inspected and serviced by your authorized Suzuki dealer or a quali fied service mechanic WARNING Improper maintenance or failure to perform recommended mainte nance can lead to an accident Keep your motorcycle in good condition Ask your Suzuki dealer or a qualified mechanic to perform the maintenance items marked with an asterisk You may per form the ...

Page 53: ...a qualified mechanic NOTICE Servicing electric parts with the ignition switch in the ON posi tion can damage the electric parts when the electric circuit is shorted Turn off the ignition switch before servicing the electric parts to avoid short circuit damage NOTICE Poorly made replacement parts can cause your motorcycle to wear more quickly and may shorten its useful life When replacing parts on ...

Page 54: ...oil 6 17 R R R R Engine oil filter 6 18 R R Idle speed I I I I Throttle cable play 6 22 I I I I Secondary air supply system I I Engine coolant 6 24 SUZUKI SUPER LONG LIFE COOLANT Blue Replace every 16000 km 9600 miles or 48 months SUZUKI LONG LIFE COOLANT Green or other than SUZUKI SUPER LONG LIFE COOLANT Blue Replace every 8000 km 5000 miles or 24 months Radiator hose 6 25 I I I Clutch cable play...

Page 55: ...ycle on the side stand and remove the seat Drain fuel from the fuel tank 2 Remove the screw 1 Then remove the frame cover 2 NOTE To remove the frame cover 2 hold the rear part of the frame cover 2 then pull the front part of the frame cover 2 to unhook the hooks 3 Then slide the frame cover 2 forward to unhook the hook 4 ...

Page 56: ...emove the under cowling 9 by unhooking the hooks 0 5 Remove the two screws A and fasteners B Then remove the meter cover C 6 Remove the two screws D and fastener E Then unhooking the hooks F and remove the side cowling G 7 Release the coupler lock and dis connect the couplers H and I left side only 8 Remove the two screws J Then remove the fuel tank center cover K ...

Page 57: ...g the fuel hose 11 Disconnect the fuel pump coupler M 12 Disconnect the fuel hose by pinch ing the retainer N 13 Remove the fuel tank The fuel tank can be difficult to handle during removal It is rec ommended that the work be done by two persons Do not lift the fuel tank or bend the fuel hose by force to prevent the fuel hose from being folded Be careful not to damage the hose end when disconnecti...

Page 58: ...n parti cles from entering into the hose when installing the fuel hose Face the clip end towards you when connecting the hose Can ada NOTE Check that the fuel tank drain hose and breather hose are not bent before reinstalling the fuel tank WARNING Fuel spilled from the fuel hose can catch on fire Stop the engine before discon necting the fuel hose Keep flames sparks and heat sources away Do not sm...

Page 59: ...ride and after get ting it wet in the rain or after washing it Major lubrication points are indi cated below 0 Grease Drive chain lubricant 1 Clutch lever pivot 2 Side stand pivot and spring hook 3 Gearshift lever pivot and footrest pivot 4 Drive chain 5 Brake lever pivot 6 Brake pedal pivot and footrest pivot NOTICE Lubricating electrical switches can damage the switches Do not apply grease and o...

Page 60: ... battery can cause blindness or severe burns When working near the battery use proper eye protection and gloves Flush eyes or body with ample water and get medical care immediately if you suffer injury Keep batteries out of reach of chil dren WARNING Batteries produce flammable hydrogen gas which can explode if exposed to flames or sparks Keep flames and sparks away from the battery Never smoke wh...

Page 61: ... Recharge the battery once a month if the motorcycle is not used for a long time NOTICE Reversing the battery lead wires can damage the charging system and the battery Always attach the red lead to the positive terminal and the black or black with white tracer lead to the negative terminal WARNING Batteries contain toxic sub stances including sulfuric acid and lead They could cause injury to human...

Page 62: ... cleaner is located under the fuel tank If the elements have become clogged with dust intake resistance will increase with a result ant decrease in power output and an increase in fuel consumption If you use your motorcycle under normal low stress conditions you should ser vice the air cleaner at the intervals specified If you ride in dusty wet or muddy conditions you will need to inspect the air ...

Page 63: ...E Failure to inspect the air cleaner element frequently if the vehicle is used in dusty wet or muddy con ditions can damage your motorcy cle The air cleaner element can become clogged under these con ditions and engine damage may result Always inspect the air cleaner ele ment after riding in severe condi tions Clean or replace the element as necessary If water gets in the air cleaner case imme dia...

Page 64: ...he fuel tank NOTE Check that the fuel tank drain hose and breather hose are not bent before reinstalling the fuel tank Air Cleaner Drain Plug Remove the plug 1 and drain water and oil at the periodic maintenance interval The air cleaner drain plug is located inside the left frame cover NOTICE Failure to position the air cleaner element properly can allow dirt to bypass the air cleaner element This...

Page 65: ...erve the oper ational color of each spark plug s por celain tip This color tells you whether or not the standard spark plug is suit able for your type of usage A nor mally operating spark plug should be very light brown in color If the spark plug is very white or glazed appear ing it has been operating much too hot This spark plug should be replaced with the colder plug Consult your Suzuki dealer ...

Page 66: ...range for your engine This may cause severe engine damage which may not be covered under warranty Use one of the spark plugs listed or their equivalent Consult your Suzuki dealer if you are not sure which spark plug is correct for your type of usage NGK DENSO REMARKS CR7E U22ESR N Standard NOTICE Improper installation of the spark plug can damage your motorcycle An overly tight or cross threaded s...

Page 67: ...dic changing of the oil Daily oil level checks and periodic changes are two of the most important mainte nance items to be performed ENGINE OIL LEVEL CHECK Follow the procedure below to inspect the engine oil level 1 Place the motorcycle on level ground on the side stand 2 Start the engine and run it for three minutes 3 Stop the engine and wait three minutes 4 Hold the motorcycle vertically and in...

Page 68: ...stand 2 Remove the oil filler cap 1 3 Place a drain pan under the drain plug 2 4 Remove the drain plug 2 and gasket 3 with a wrench and drain out the engine oil while holding the motorcycle vertically NOTICE Operating the motorcycle with too little or too much oil can damage the engine Place the motorcycle on level ground Check the oil level with the engine oil inspection window before each use of...

Page 69: ...e the L low line and not higher than the F full line CAUTION Hot engine oil and exhaust pipes can burn you Wait until the oil drain plug and exhaust pipes cool before drain ing oil WARNING Children and pets may be harmed by swallowing new or used oil Repeated prolonged contact with used engine oil may cause skin cancer Brief contact with oil may irritate skin Keep new and used oil and used oil fil...

Page 70: ... wrench Part No 09915 40620 9 Wipe off the mounting surface 7 on the engine where the new oil fil ter will be seated with a clean rag 10 Smear a little engine oil around the filter gasket 8 of the new oil filter 11 Screw the new oil filter by hand until the filter gasket contacts the mounting surface a small resis tance will be felt NOTICE Failure to use an oil filter with the correct design and t...

Page 71: ...be required when changing oil only 14 With the engine running look carefully for leaks at the oil filter and drain plug Run the engine at various speeds for three minutes 15 Stop the engine and wait three minutes Check the oil level again Engine oil level can be inspected through the inspection window while holding the motorcycle verti cally If the oil level is lower than the L line add new oil un...

Page 72: ...rew is posi tioned at the best setting THROTTLE CABLE ADJUSTMENT To adjust the cable play 1 Slide the boot 1 2 Loosen the lock nut 2 3 Turn the adjuster 3 so that the throttle grip has 2 0 4 0 mm 0 08 0 16 in play 4 Tighten the lock nut 2 5 Reinstall the boot 1 WARNING Inadequate throttle cable play can cause engine speed to rise sud denly when you turn the handle bar This can lead to loss of ride...

Page 73: ...are dirty CLUTCH The play of the clutch lever should be 10 15 mm 0 4 0 6 in as mea sured at the clutch lever end If you find the play of the clutch incorrect adjust it in the following way Minor Adjustment 1 Slide the boot 1 2 Loosen the clutch cable adjuster lock nut 2 3 Turn the clutch cable adjuster 3 to provide the specified play 4 Tighten the lock nut 2 5 Reinstall the boot 1 Boots 10 15 mm 0...

Page 74: ...ent should be performed by your Suzuki dealer 6 Reinstall the boot 4 7 Reinstall the left under cowling COOLANT COOLANT LEVEL The coolant should be kept between the F FULL and L LOW level lines in the reservoir tank at all times Inspect the level every time before riding with the motorcycle is held ver tically If the coolant is found lower than the L level line add specified engine coolant in the ...

Page 75: ... 2 US Imp qt of coolant will required when filling the radiator and reservoir tank RADIATOR HOSE INSPECTION Inspect the radiator hoses for cracks damage or engine coolant leakage If any defects are found ask your Suzuki dealer to replace the radiator hose with a new one WARNING Engine coolant is harmful or fatal if swallowed or inhaled Solution can be poisonous to animals Do not drink antifreeze o...

Page 76: ... Damage to the drive chain means that the sprockets may also be dam aged Inspect the sprockets for the following Excessively worn teeth Broken or damaged teeth Loose sprocket mounting nuts If you find any of these problems with your sprocket consult your Suzuki dealer or a qualified mechanic NOTE The two sprockets should be inspected for wear when a new chain is installed and replace them if neces...

Page 77: ...osity oil 80 90 6 Lubricate both front and back plates of the drive chain 7 Wipe off excess lubricant after lubricating all around of the drive chain NOTICE Cleaning the drive chain improp erly can damage seal rings and ruin the drive chain Do not use a volatile solvent such as paint thinner kerosene and gasoline Do not use high pressure cleaner to clean the drive chain Do not use wire brush to cl...

Page 78: ...ist you in perform ing this procedure there are refer ence marks 3 on the chain adjusters which are to be aligned with the hole of the swingarm and to be used as a reference from one side to the other 4 Tighten the axle nut 1 securely 5 Recheck the chain slack after tightening and readjust if neces sary Rear axle nut tightening torque 65 N m 6 5 kgf m 47 0 lbf ft WARNING Too much chain slack can c...

Page 79: ...ked appearance The brake lever and pedal should have the proper stroke and be firm at all times Check the wear of the disk brake pads BRAKE HOSE INSPECTION Inspect the brake hoses and hose joints for cracks damage or brake fluid leakage If any defects are found ask your Suzuki dealer to replace the brake hose with a new one WARNING Failure to properly inspect and maintain your motorcycle s brake s...

Page 80: ...erent types of brake fluid UPPER LOWER WARNING Brake fluid is harmful or fatal if swallowed and harmful if it comes in contact with skin or eyes Solu tion can be poisonous to animals If brake fluid is swallowed do not induce vomiting Immediately con tact a poison control center or a physician If brake fluid gets in eyes flush eyes with water and seek medical attention Wash thor oughly after handli...

Page 81: ...ith new ones After replacing either the front or rear brake pads the brake lever or pedal must be pumped several times This will extend the pads to their proper position WARNING Failure to inspect and maintain the brake pads and replace them when recommended can increase your chance of having an acci dent If you need to replace brake pads have your Suzuki dealer do this work Inspect and maintain t...

Page 82: ...d 2 in the proper position WARNING If you ride this motorcycle after brake system repair or brake pad replacement without pumping the brake lever pedal you may get poor braking performance which could result in an accident After brake system repair or brake pad replacement pump the brake lever pedal several times until brake pads are pressed against the brake disks and proper lever pedal stroke an...

Page 83: ...ure before each ride and adjust pressure if necessary Avoid overloading your motor cycle Replace a tire when worn to the specified limit or if you find damage such as cuts or cracks Always use the size and type of tires specified in this owner s manual Balance the wheel after tire installation Read this section of the owner s manual carefully WARNING Failure to perform break in of the tires could ...

Page 84: ...on Pressure NOTE When you detect drops in tire pressure check the tire for nails or other punctures or a damaged wheel rim Tubeless tires sometimes lose pressure gradually when punctured TIRE CONDITION AND TYPE Proper tire condition and proper tire type affect vehicle performance Cuts or cracks in the tires can lead to tire failure and loss of vehicle control Worn tires are susceptible to puncture...

Page 85: ...after repairing a puncture or replacing the tire Proper wheel balance is impor tant to avoid variable wheel to road contact and to avoid uneven tire wear FRONT REAR SIZE 110 80 17M C 57H 140 70 17M C 66H TYPE IRC RX 01F D ROAD WINNER IRC RX 01R ROAD WINNER Triangle mark Wear bar WARNING An improperly repaired installed or balanced tire can cause loss of control and an accident or can wear out soon...

Page 86: ...tires may result in an accident due to tire failure Tubeless tires require dif ferent service procedures than tube tires Tubeless tires require an air tight seal between the tire bead and wheel rim Special tire irons and rim protectors or a special ized tire mounting machine must be used for removing and installing tires to prevent tire or rim damage which could result in an air leak Repair punctu...

Page 87: ...back into the caliper assembly and brake fluid leakage may result WARNING If the side stand ignition interlock system is not working properly it is possible to ride the motorcycle with the side stand in the down position This may interfere with rider control during a left turn and could cause an accident Check the side stand ignition interlock system for proper opera tion before riding Check that ...

Page 88: ...ully position a jack under the engine and raise until the front wheel is slightly off the ground 7 Turn the axle shaft counterclock wise and draw it out 8 Slide the front wheel forward 9 To reinstall the wheel assembly reverse the sequence described above 10 After installing the wheel apply the front brake several times to restore the proper lever stroke NOTICE Improper jacking may cause dam age t...

Page 89: ...restored Also check that the wheel rotates freely WARNING Installing the front wheel in the reverse direction can be hazard ous The tire for this motorcycle is directional Therefore the motor cycle may have unusual handling if the wheel is installed incorrectly Install the front wheel so that the tire rotates in the specified direc tion as indicated by the arrow on the sidewall of the tire WARNING...

Page 90: ...aw out the axle shaft 6 With the wheel moved forward remove the chain from the sprocket CAUTION A hot muffler can burn you Wait until the muffler cools before removing the axle nut NOTICE Removing the rear wheel without use of an accessory stand can result in your motorcycle falling over and being damaged Do not attempt roadside removal of the rear wheel Only remove the rear wheel at a properly eq...

Page 91: ...ust the drive chain and failure to torque axle nut prop erly could lead to an accident Adjust the drive chain as described in DRIVE CHAIN ADJUSTMENT section after installing the rear wheel Torque axle nut to the proper specifications If you are not sure of the proper procedure have your authorized Suzuki dealer or a qualified mechanic do this WARNING Failure to extend brake pads after installing t...

Page 92: ...nd position light bulb perform the follow ing step Headlight bulb 1 Disconnect the coupler 1 and remove the rubber cap 2 2 Unhook the bulb holder spring 3 and pull out the bulb 4 NOTICE Failure to use a light bulb with the correct wattage rating can over load the electrical system of your motorcycle or cause the bulb to burn out sooner Use only the light bulbs shown in the chart as replacement bul...

Page 93: ... if necessary To adjust the beam up and down 1 Remove the two screws 1 and fasteners 2 Then remove the meter cover 3 2 Turn the adjuster 4 clockwise or counterclockwise NOTICE The headlight bulb s life may be shortened by oil from your fingers if you touch it When replacing the headlight bulb be careful not to touch the glass Grasp the new bulb with a clean cloth ...

Page 94: ...g it to the left and pull it out 3 To fit the replacement bulb push it in and twist it to the right while pushing FRONT TURN SIGNAL LIGHT To replace the front turn signal light bulb follow these directions 1 Turn the socket counterclockwise and remove it 2 Push in on the bulb twisting it to the left and pull it out 3 To fit the replacement bulb push it in and twist it to the right while pushing ...

Page 95: ... the lens 2 Remove the screws 2 and take off the socket 3 Push in on the bulb twisting it to the left and pull it out 4 To fit the replacement bulb push it in and twist it to the right while pushing NOTICE Overtightening the screws when reinstalling the lens may cause the lens to crack Tighten the screws only until they are snug ...

Page 96: ...ad by fuses in the circuits If a blown fuse is found then the elec trical problem must be inspected and repaired before replacing the blown fuse with a new fuse Consult your Suzuki dealer for the electrical system check and repair WARNING Replacing a fuse with incorrect amperage rating or substitute e g aluminum foil or wire may cause serious damage to the electrical system and possibly fire Alway...

Page 97: ...ne 10A and one 15A are provided inside the fuse boxes FUSE LIST 30A MAIN fuse protects all electri cal circuits 15A HEAD fuse protects the headlight high beam headlight low beam position lights taillight stop light and license light 10A IGNITION fuse protects the cooling fan relay ignition coils starter relay fuel pump relay oxy gen sensor solenoid and canister purge solenoid 10A SIGNAL fuse prote...

Page 98: ...o nents NOTICE Improper motorcycle operation can cause catalyst or other motor cycle damage To avoid damage to the catalyst or other related components you should take the following precau tions Maintain the engine in the proper operating condition In the event of an engine mal function particularly one involv ing engine misfire or other apparent performance loss stop riding the motorcycle and tur...

Page 99: ...ere there are com bustible materials such as dry grass or leaves these materials may come in contact with the cat alytic converter or other hot exhaust components This can cause a fire Avoid parking or operating your vehicle in areas with any combus tible materials ...

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Page 101: ...7 1 7 TROUBLESHOOTING FUEL SUPPLY CHECK 7 2 IGNITION SYSTEM CHECK 7 3 ENGINE STALLING 7 3 ...

Page 102: ...indicator displays FI showing signs of trouble in the fuel injection system take your motor cycle to an authorized Suzuki dealer Refer to the INSTRUMENT PANEL section for an explanation of fuel injection system indicator NOTICE Improper repairs or adjustments may damage the motorcycle instead of fixing it Such damage may not be covered under war ranty If you are not sure about the proper action co...

Page 103: ... 2 If the fuel injection indicator dis plays FI showing signs of trou ble in the fuel injection system take your motorcycle to an autho rized Suzuki dealer Refer to the INSTRUMENT PANEL section for an explanation of fuel injection system indicator 3 Check the ignition system for intermittent spark 4 Check the idle speed The correct idle speed is 1300 1500 r min WARNING Performing the spark test im...

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Page 105: ...8 1 8 STORAGE PROCEDURE AND MOTORCYCLE CLEANING STORAGE PROCEDURE 8 2 PROCEDURE FOR RETURNING TO SERVICE 8 3 CORROSION PREVENTION 8 3 MOTORCYCLE CLEANING 8 4 INSPECTION AFTER CLEANING 8 6 ...

Page 106: ...ngine for a few minutes until the stabilized gasoline fills the fuel injection system ENGINE 1 Pour one tablespoon of motor oil into each spark plug hole Rein stall the spark plugs and crank the engine a few times 2 Drain the engine oil thoroughly and refill the crankcase with fresh engine oil all the way up to the filler hole 3 Cover the air cleaner intake and the muffler outlet with oily rags to...

Page 107: ...rs to come Important Information About Corrosion Common causes of corrosion Accumulation of road salt dirt moisture or chemicals in hard to reach areas Chipping scratches and any damage to treated or painted metal surfaces resulting from minor accidents or impacts from stones and gravel Road salt sea air industrial pollution and high humidity will all contribute to corrosion How to Help Prevent Co...

Page 108: ...cycle cover can help protect the finish from the harmful UV rays in sunlight and can reduce the amount of dust and air pollution reaching the surface Your Suzuki dealer can help you select the right cover for your motorcycle MOTORCYCLE CLEANING Washing the Motorcycle When washing the motorcycle follow the instructions below 1 Remove dirt and mud from the motorcycle with cool running water You may ...

Page 109: ... motorcycle or riding in a rain Headlight fogging will be cleared gradually when the headlight is turned on To clear the headlight lens fogging run the engine to avoid battery discharge NOTICE High pressure washers such as those found at coin operated car washes have enough pressure to damage the parts of your motorcy cle It may cause rust corrosion and increase wear Parts cleaner can also damage ...

Page 110: ...s on surfaces which have a matte finish The use of polishing compounds will change the appear ance of the matte finish Solid type waxes may be difficult to remove from surfaces with a matte finish Friction while riding excessive rub bing or polishing of a surface with a matte finish will change its appear ance INSPECTION AFTER CLEANING For extended life of your motorcycle lubricate according to LU...

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Page 112: ...sump DRIVE TRAIN Clutch Wet multi plate type Transmission 6 speed constant mesh Gearshift pattern 1 down 5 up Primary reduction ratio 3 238 68 21 Gear ratios Low 2 416 29 12 2nd 1 529 26 17 3rd 1 181 26 22 4th 1 043 24 23 5th 0 909 20 22 Top 0 807 21 26 Final reduction ratio 3 285 46 14 Drive chain DID 520VF or RK 520KRO 116 links CHASSIS Front suspension Telescopic coil spring oil damped Rear sus...

Page 113: ...W License plate light 12V 5W Speedometer light LED Tachometer light LED Neutral indicator light LED High beam indicator light LED Turn signal indicator light LED Oil pressure indicator light LED Coolant temperature indicator light LED Engine RPM indicator light LED Fuel injection system indicator light LED CAPACITIES Fuel tank 13 3 L 3 5 2 9 US lmp gal Engine oil without oil filter change 2100 ml ...

Page 114: ...STALLING 7 3 F FRONT WHEEL REMOVAL 6 37 FUEL HOSE 6 17 FUEL OCTANE RATING 3 2 FUEL SUPPLY CHECK 7 2 FUEL TANK CAP 2 17 FUEL TANK REMOVAL 6 5 FUSES 6 46 G GEARSHIFT LEVER 2 18 I IGNITION SWITCH 2 5 IGNITION SYSTEM CHECK 7 3 INSPECTION AFTER CLEANING 8 6 INSPECTION BEFORE RIDING 4 3 INSTRUMENT PANEL 2 6 K KEY 2 5 L LABELS 1 5 LEFT HANDLEBAR 2 14 LIGHT BULB REPLACEMENT 6 42 LOCATION OF PARTS 2 2 LUBR...

Page 115: ... 5 RIGHT HANDLEBAR 2 15 S SAFE RIDING RECOMMENDATION FOR MOTORCYCLE RIDERS 1 4 SEAT LOCK AND HELMET HOLDERS 2 19 SERIAL NUMBER LOCATION 1 6 SIDE STAND 2 20 SIDE STAND IGNITION INTERLOCK SWITCH 6 36 SPARK PLUGS 6 15 STARTING OFF 5 3 STARTING THE ENGINE 5 2 STOPPING AND PARKING 5 5 STORAGE PROCEDURE 8 2 T THROTTLE CABLE ADJUSTMENT 6 22 TIRES 6 33 TOOLS 6 5 U USING THE TRANSMISSION 5 4 V VARY THE ENG...

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