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Suzuki Intruder VZ1500, Owner'S Manual

The Suzuki Intruder VZ1500 Owner's Manual is a comprehensive guide to help you get the most out of your motorcycle. This manual is available for free download on our website, ensuring hassle-free access to all the information you need to maintain, operate, and enjoy your VZ1500.

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 7

INSPECTION AND MAINTENANCE

NOTICE ....................................................................................................................................................... 7-2
MAINTENANCE SCHEDULE  ..................................................................................................................... 7-2
TOOLS ........................................................................................................................................................ 7-7
GENERAL LUBRICATION  ......................................................................................................................... 7-7
BATTERY .................................................................................................................................................... 7-9
AIR CLEANER  .......................................................................................................................................... 7-11
SPARK PLUG  ........................................................................................................................................... 7-18
ENGINE OIL .............................................................................................................................................. 7-23
THROTTLE CABLE ADJUSTMENT  ........................................................................................................ 7-31
ENGINE IDLE SPEED INSPECTION ....................................................................................................... 7-32
FUEL HOSE  .............................................................................................................................................. 7-32
CLUTCH ADJUSTMENT  .......................................................................................................................... 7-34
ENGINE COOLANT  .................................................................................................................................. 7-36
FINAL GEAR OIL ...................................................................................................................................... 7-38
BRAKES ................................................................................................................................................... 7-40
TIRES ........................................................................................................................................................ 7-47
SIDE STAND/IGNITION INTERLOCK SYSTEM ...................................................................................... 7-52
FRONT WHEEL REMOVAL  ..................................................................................................................... 7-54
REAR WHEEL REMOVAL  ....................................................................................................................... 7-58
LIGHT BULB REPLACEMENT  ................................................................................................................ 7-62
FUSES ....................................................................................................................................................... 7-68

Summary of Contents for Intruder VZ1500

Page 1: ...p p VZ1500 Part No 99011 40H50 03A July 2008 EN TK OWNER S MANUAL This owner s manual contains important safety information Please read it carefully ...

Page 2: ... cancer and birth defects or other reproductive harm This manual should be considered a permanent part of the motorcycle and should remain with the motorcycle when resold or otherwise transferred to a new owner or operator The manual contains important safety information and instructions which should be read carefully before operating the motorcycle California Proposition 65 Warning ...

Page 3: ... words NOTE Indicates special information to make maintenance easier or instruc tions clearer WARNINGs and CAUTIONs are arranged like this WARNING Indicates a potential hazard that could result in death or injury CAUTION Indicates a potential hazard that could result in motorcycle damage WARNING or CAUTION The first part will describe a POTENTIAL HAZARD and WHAT CAN HAPPEN if you ignore the WARNIN...

Page 4: ...ill ensure a long trouble free operating life for your motorcycle This motorcycle also con forms to the U S Environmental Protec tion Agency emission regulations which apply to new motorcycles The proper adjustment of engine components is necessary for this motorcycle to comply with the EPA regulations Therefore please follow the maintenance instruc tions closely to ensure emission compli ance You...

Page 5: ... reserves the right to make production changes at any time without notice and without incurring any obligation to make the same or similar changes to vehicles previously built or sold Suzuki Motor Corporation believes in conservation and protection of Earth s Natural resources To that end we encourage every vehicle owner to recy cle trade in or properly dispose of as appropriate used motor oil eng...

Page 6: ......

Page 7: ...AND COOLANT RECOMMENDATIONS CONTROLS EQUIPMENT AND ADJUSTMENTS BREAK IN AND INSPECTION BEFORE RIDING RIDING TIPS ACCESSORY USE AND MOTORCYCLE LOADING INSPECTION AND MAINTENANCE TROUBLESHOOTING STORAGE PROCEDURE AND MOTORCYCLE CLEANING CONSUMER INFORMATION SPECIFICATIONS INDEX ...

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Page 9: ...O SOMETHING 1 4 SPECIAL SITUATIONS REQUIRE SPECIAL CARE 1 5 KNOW YOUR LIMITS 1 5 BE EXTRA SAFETY CONSCIOUS ON BAD WEATHER DAYS 1 6 PRACTICE AWAY FROM TRAFFIC 1 7 INSPECTION BEFORE RIDING 1 7 ACCESSORIES AND LOADING 1 8 CARRYING A PASSENGER 1 8 MOTORCYCLE SAFETY FOUNDATION S RIDING TIPS AND PRACTICE GUIDE HANDBOOK FOR OWNERS IN USA 1 9 BE STREET SMART 1 9 CONCLUSION 1 10 ...

Page 10: ...a motorcyclist or how experi enced you are you will eventually face some challenging situations In preparing for these challenges you will be fine tuning your coordination concentration and attitude Learning the skills and strategies associated with motorcycling is the basis for safely par ticipating in this sport Many motorcy clists find that as they become better riders they also get more enjoym...

Page 11: ...nd other motorists the best view of you Wear bright reflective clothing Put reflective strips on your helmet IF YOU DON T HAVE A HELMET BUY A HELMET AND WEAR IT EVERY TIME YOU RIDE Most accidents occur within a few miles of home and almost half occur at speeds of less than 30 mph So even if you re just going on a quick errand be prepared strap on your helmet before you take off Helmets do not redu...

Page 12: ...e of fingers over the lever when riding in traffic and near intersec tions to give their reaction time a head start Emergency stopping and swerving are techniques that you should practice and master before you find yourself in an emergency situation The best place to practice such techniques is in a con trolled environment such as the Motor cycle Safety Foundation s MSF rider training courses The ...

Page 13: ...Over braking when traction is limited will cause your tires to skid pos sibly resulting in loss of directional con trol or causing you and your motorcycle to fall over KNOW YOUR LIMITS Always ride within the boundaries of your own skills Knowing these limits and staying within them will help you avoid accidents A major cause of accidents involving only a motorcycle and no cars is going too fast th...

Page 14: ... or under the influence of alcohol or other drugs PLEASE DO NOT RIDE your motorcy cle BE EXTRA SAFETY CONSCIOUS ON BAD WEATHER DAYS Riding on bad weather days especially wet ones requires extra caution Brak ing distances increase on a rainy day Stay off the painted surface marks manhole covers and greasy appearing areas as they can be especially slip pery Use extra caution at railway cross ings an...

Page 15: ...the MSF s Rider Courses Even experts will be pleased with the caliber of the infor mation presented in these courses As the MSF says The more you know the better it gets INSPECTION BEFORE RIDING Review the instructions in the INSPEC TION BEFORE RIDING section of this manual Perform an entire pre ride inspection before you head out on the road Spending a few minutes preparing your machine for a rid...

Page 16: ...a great way to share the joy of motorcycling You will have to alter your riding style somewhat since the extra weight of a passenger will affect han dling and braking You may also need to adjust tire pressures and suspension please refer to the Tire Pressure and Loading section and the Suspension section for more details A passenger needs the same protection that you do including a helmet and prop...

Page 17: ...ual contains a variety of safety tips helpful hints and practice exercises This manual can increase your riding enjoyment and safety You should read it thoroughly BE STREET SMART Always heed speed limits local laws and the basic rules of the road Set a good example for others by demonstrat ing a courteous attitude and a responsi ble riding style ...

Page 18: ... by wearing a helmet and other protective gear and learning emergency braking and swerv ing techniques to minimize the damage to you and your machine The best way to learn basic riding skills and evasive maneuvers or refresh your own riding skills is to take one of the courses offered by the Motorcycle Safety Foundation Your authorized Suzuki dealer can help you locate the fundamental or advanced ...

Page 19: ...2 1 2 FUEL OIL AND COOLANT RECOMMENDATIONS FUEL 2 2 ENGINE OIL 2 5 FINAL GEAR OIL 2 7 ENGINE COOLANT SOLUTION 2 7 ...

Page 20: ...r dizing the New Vehicle Limited War ranty or the Emission Control System Warranty NOTE Oxygenated fuels are fuels which contain oxygen carrying additives 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 alco hol Gasoline Etha...

Page 21: ...icle Limited Warranty or the Emission Control Sys tem Warranty Fuel Pump Labeling In some states pumps that dispense oxygenated fuels are required to be labeled for the type and percentage of oxygenate and whether important addi tives are present Such labels may pro vide enough information for you to determine if a particular blend of fuel meets the requirements listed above In other states pumps ...

Page 22: ... not satisfied with the drive ability of your motorcycle when you are using an oxygenated fuel or if engine pinging is experienced sub stitute another brand as there are differences between brands CAUTION Spilled gasoline containing alcohol can harm your motorcycle Alcohol can damage painted surfaces Be careful not to spill any fuel when filling the fuel tank Wipe spilled gas oline up immediately ...

Page 23: ... oil with an API American Petroleum Institute classifi cation of SF SG or SH SJ or with a JASO classification of MA API American Petroleum Institute JASO Japanese Automobile Standards Organization SAE Engine Oil Viscosity Suzuki recommends the use of SAE 10W 40 engine oil If SAE 10W 40 engine oil is not available select an alternative according to the following chart SAE API JASO 10W 40 SF or SG 1...

Page 24: ...es MA and MB The oil container shows the classifica tion as follows 1 Code number of oil sales company 2 Oil classification Energy Conserving Suzuki does not recommend the use of ENERGY CONSERVING oils Some engine oils which have an API classifi cation of SH or higher have an ENERGY CONSERVING indication in the API classification doughnut mark These oils can affect engine life and clutch performan...

Page 25: ...h an aluminum radiator mixed with distilled water at a 50 50 mixture ratio for engine coolant solution An engine coolant mixture other than 50 50 can affect cooling efficiency or rust inhibiting performance Engine Coolant Engine coolant should be used at all times in your motorcycle s radiator even if the temperature in your area does not go down to the freezing point Engine coolant acts as a rust...

Page 26: ...nduce vomiting Immediately contact a poi son control center or a physician Avoid inhaling mist or hot vapors if inhaled remove to fresh air If cool ant gets in eyes flush eyes with water and seek medical attention Wash thoroughly after handling Solution can be poisonous to ani mals Keep out of the reach of chil dren and animals CAUTION Spilled engine coolant can damage painted surfaces Do not spil...

Page 27: ...ARTS 3 2 KEY 3 5 IGNITION SWITCH 3 6 STEERING LOCK 3 7 INSTRUMENT PANEL 3 8 LEFT HANDLEBAR 3 21 RIGHT HANDLEBAR 3 24 FUEL TANK CAP 3 28 GEARSHIFT LEVER 3 30 REAR BRAKE PEDAL 3 31 SEAT LOCK 3 31 HELMET HOLDER 3 34 SIDE STAND 3 35 SUSPENSION ADJUSTMENT 3 37 ...

Page 28: ...T AND ADJUSTMENTS LOCATION OF PARTS 1 Clutch lever 2 Left handlebar switches 3 Instrument panel 4 Indicator lights 5 Front brake fluid reservoir 6 Right handlebar switches 7 Throttle grip 8 Front brake lever 9 Fuel tank cap ...

Page 29: ...nition switch C Battery and Main fuse D Tools E Helmet holder F Gearshift lever G Engine oil filter H Footrests I Engine oil filler cap J Engine oil drain plug K Speed sensor L Side stand M Engine coolant reservoir N Passenger footrests ...

Page 30: ...3 4 O Fuses P Rear brake fluid reservoir Q Steering lock R Seat lock S Rear brake light switch T Rear brake pedal ...

Page 31: ...s motorcycle Keep the spare key in a safe place An identifying number is stamped on the plate Use this number when making a replacement key Please write down your key number in the box provided for your future refer ence Key number ...

Page 32: ...t front turn signal light and taillight will automatically turn on The key cannot be removed in this position NOTE Start the engine promptly after turning the key to the ON position or the battery will lose power due to con sumption by the headlight and taillight P PARKING position The taillight will come on to increase visibility for temporary road side parking at night Push down the key and turn...

Page 33: ... into the steer ing lock and turn it counterclockwise to lock the steering WARNING Moving the motorcycle while the steering is locked can be hazardous You could lose your balance and fall or you could drop the motorcycle Never attempt to move the motorcy cle when the steering is locked ...

Page 34: ... to confirm their function when the ignition switch is turned to the ON position The coolant temperature indicator light 3 oil pressure indicator light 4 and fuel injection system indica tor light 8 come on for 3 seconds The speedometer needle moves to the full scale position and returns to the home position All LCD segments will have appear action and then show normal dis play ...

Page 35: ...the button 9 for 3 5 seconds 3 Release the button 9 Rap the but ton 9 twice NOTE Reset procedure from step 1 to step 3 should be performed within 10 seconds COMBINATION SYSTEM DISPLAY 2 The display in the speedometer has five functions odometer two trip meters clock and fuel meter When the ignition switch is turned to the ON position the test pattern shown below is dis played To change the display...

Page 36: ...3 10 F ODO E F TRIP 1 E F TRIP 2 E F E Odometer Trip meter 2 Trip meter 1 Clock ...

Page 37: ...tance and trip meter 2 can regis ter the distance between fuel stops To reset a trip meter to zero push the button 9 for two seconds while the dis play indicates the trip meter 1 or 2 you want to reset NOTE When the trip meter exceeds 9999 9 the trip meter will return to 0 0 and start counting again WARNING Operating the display while riding can be hazardous Removing a hand from the handlebars can...

Page 38: ...3 12 Clock F E 2 seconds 2 seconds 2 seconds Push ...

Page 39: ...seconds to highlight 10 minutes dis play 5 Adjust the 10 minutes display by pushing the button 9 6 Press and hold the button 9 for 2 seconds to highlight minute display 7 Adjust the minute display by pushing the button 9 8 Press and hold the button 9 for 2 seconds to return to the clock mode WARNING Operating the display while riding can be hazardous Removing a hand from the handlebars can reduce ...

Page 40: ... fuel tank The fuel meter displays all 5 segments when the fuel tank is full The mark flickers when the fuel level drops below 3 5 L 3 7 US qt The segment flicker when the fuel drops below 1 5 L 1 6 US qt Fuel tank Fuel gauge Approximately 1 5 L Full Flicker Approximately 3 5 L ...

Page 41: ...T TEMPERATURE INDICATOR LIGHT 3 This indicator comes on when the cool ant temperature is too high CAUTION Running the engine with high engine coolant temperature can cause seri ous engine damage If the engine coolant temperature indicator light comes on stop the engine to let it cool Do not run the engine until the cool ant temperature indicator light goes out ...

Page 42: ...HT 4 This indicator comes on when the engine oil pressure is below the normal 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 indicator should go out ...

Page 43: ...ently than normal to notify the rider of the existence of a failure CAUTION Riding the motorcycle with the oil pressure indicator light lit can dam age the engine and transmission Whenever the oil pressure indicator lights up indicating low oil pressure stop the engine immediately Check the oil level and determine if the proper amount of oil is in the engine If the light still does not go out have...

Page 44: ...blue indicator light will come on when the headlight high beam is turned on NEUTRAL INDICATOR LIGHT N 7 The green light will come on when the transmission is in neutral The light will go out when you shift into any gear other than neutral ...

Page 45: ...dicates FI continu ously and the red indicator light 8 blinks while cranking the engine The engine may continue to run in mode A but the engine will not run in mode B CAUTION Riding the motorcycle with the dis play indicating a problem with the fuel injection system and with the indicator light lit can damage the engine Whenever the red indicator light is lit and the display indicates FI have your...

Page 46: ...p the engine running and bring your motorcycle to an authorized Suzuki dealer If the engine stalls try restarting the engine after turning the ignition switch off and on If the display 2 indicates FI contin uously and the red indicator light blinks the engine will not start ...

Page 47: ...the display still indicates CHEC after checking the above items inspect the ignition fuse and the connection of the lead wire couplers LEFT HANDLEBAR Clutch Lever 1 The clutch lever is used for disengaging the drive to the rear wheel when start ing the engine or shifting transmission gears Squeezing the lever disengages the clutch Headlight Flasher Switch 2 Press the switch to flash the headlight ...

Page 48: ...turns on CAUTION Holding the dimmer switch between and position will light both and headlight beam This operation can damage the motorcycle Use the dimmer switch only at or position CAUTION Sticking some tape or placing objects in front of the headlight can damage the headlight Do not stick any tapes to the head light Do not place objects in front of the headlight ...

Page 49: ...cators will flash simultaneously when the switch is turned on with the ignition switch in the ON or P position Use the hazard warning lights to warn other traffic during emergency parking or when your vehicle could otherwise become a traffic hazard WARNING Failure to use the turn signals and failure to turn off the turn signals can be hazardous Other drivers may misjudge your course and this may r...

Page 50: ...ition circuit is off The engine cannot start or run position The ignition circuit is on and the engine can run Front Brake Lever 2 Apply the front brake by squeezing the front brake lever toward the grip The brake light will come on when the lever is squeezed ...

Page 51: ... the adjuster stops in the proper position a projection of the brake lever holder should fit into the depression of the adjuster This motorcycle is deliv ered from the factory with its adjuster set on position 3 WARNING Adjusting the front brake lever posi tion while riding can be hazardous Removing a hand from the handle bars can reduce your ability to con trol the motorcycle Always keep both han...

Page 52: ...h lever and push the electric starter button to start the engine NOTE This motorcycle has a starter interlock system for the ignition and starter circuit The engine can only be started if The transmission is in neutral and the clutch is disengaged or The transmission is in gear the side stand is fully up and the clutch is dis engaged NOTE The headlight will go off when the electric starter button ...

Page 53: ...engine speed Turn it away from you to decrease engine speed CAUTION To prevent electrical system damage do not operate the starter motor longer than five seconds at a time If the engine does not start after sev eral attempts check the fuel supply and ignition system Refer to the TROUBLESHOOTING section in this manual ...

Page 54: ...nsert the ignition key into the lock and turn it clockwise With the key inserted lift the cap up with key To close the fuel tank cap push the cap down firmly with the key in the cap lock Face the arrow mark forward when refit ting the fuel tank cap ...

Page 55: ... on fire Never fill the fuel above the bottom of the filler neck WARNING Fuel and fuel vapor are highly flam mable and toxic You can be burned or poisoned when refueling Stop the engine and keep flames sparks and heat sources away Refuel only outdoors or in a well ventilated area Do not smoke Wipe up spills immediately Avoid breathing fuel vapor Keep children and pets away ...

Page 56: ... to upshift Depress the front end of the gearshift lever to downshift Neutral is located between 1st and 2nd gear When neu tral is desired depress or lift the lever halfway between 1st and 2nd gear NOTE When the transmission is in neutral the green indicator light on the instrument panel will be lit However even though the light is lit cautiously and slowly release the clutch lever to make sure th...

Page 57: ...31 REAR BRAKE PEDAL Pressing the rear brake pedal will apply the rear brake The brake light will come on when the rear brake is operated SEAT LOCK 1 Unhook the hooks and remove the right side frame cover ...

Page 58: ...3 32 2 To remove the seat insert the igni tion key into the lock and turn it clockwise 3 Raise the rear end of the seat and slide it backward ...

Page 59: ... into the seat hook retainer and push down firmly until the seat snaps into the locked position 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 proper position ...

Page 60: ...nd turn it clock wise to open the latch Hook your helmet fastener ring to the latch and turn the key back to lock the holder WARNING Riding with a helmet fastened to the helmet holder can interfere with rider control Never carry a helmet fastened to the helmet holder Fix the helmet securely atop the seat if you must carry it ...

Page 61: ...he ignition circuit when the side stand is down and the transmission is in any gear other than neutral The side stand ignition interlock sys tem works as follows If the side stand is down and the transmission is in gear the engine cannot 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 t...

Page 62: ...tion interlock system before riding Always retract the side stand com pletely before starting off CAUTION Park the motorcycle on firm level ground to help prevent it from falling over If you must park on an incline aim the front of the motorcycle uphill and put the transmission into 1st gear to reduce the possibility of rolling off the side stand ...

Page 63: ...SUSPENSION ADJUSTMENT REAR SUSPENSION Spring Pre load Adjustment 1 Place the motorcycle on the side stand 2 Unhook the hooks and remove the left side frame cover 3 Remove the bolts and left side lower cover ...

Page 64: ...4 This adjustment can be performed by changing the adjuster ring posi tion However Suzuki recommends that this adjustment be done by your authorized Suzuki dealer since a special tool is needed for this job ...

Page 65: ......

Page 66: ......

Page 67: ...4 1 4 BREAK IN AND INSPECTION BEFORE RIDING BREAK IN 4 2 INSPECTION BEFORE RIDING 4 5 ...

Page 68: ...le Opening Recommendation The table below shows the maximum throttle opening recommendation dur ing the break in period Vary the Engine Speed Vary the engine speed during the break in period This allows the parts to load aiding the mating process and then unload allowing the parts to cool Although it is essential to place some stress on the engine components during break in you must be careful not...

Page 69: ... miles before attempting maximum performance Avoid hard acceleration hard cornering and hard braking for the first 160 km 100 miles WARNING Failure to perform break in of the tires could cause tire slip and loss of control Use extra care when riding on new tires Perform proper break in of the tires as described in this section and avoid hard acceleration hard corner ing and hard braking for the fi...

Page 70: ...d Most Critical Service The initial service 1000 km mainte nance is the most important service your motorcycle will receive During break in operation all of the engine components will have mated together and seated Maintenance required as part of the initial service includes cor rection of all adjustments tightening of all fasteners and replacement of dirty oil Timely performance of this service w...

Page 71: ...mage Always perform a pre ride inspection before each ride Refer to the table or page 4 4 for check items For further details refer to the INSPECTION AND MAINTENANCE section WARNING Using worn improperly inflated or incorrect tires will reduce stability and can cause an accident Follow all instructions in the TIRES section in this owner s manual ...

Page 72: ...ms Be sure your motor cycle is in good condition for the per sonal safety of the rider passenger and protection of the motorcycle WARNING Checking maintenance items when the engine is running can be hazard ous You could be severely injured if your hands or clothing gets caught in moving parts Shut the engine off when performing maintenance checks except when checking the engine stop switch and thr...

Page 73: ...rn signals License plate light Indicator lights Proper operation of all lights Oil pressure Coolant High beam Neutral Turn signals FI Engine stop switch Proper operation Horn Correct function Engine oil Correct level Cooling system Proper coolant level No leaks or damage Gear oil Correct level Throttle Proper play Smooth response Quick return to idle position Gearshift lever No damage Smooth opera...

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Page 75: ...5 1 5 RIDING TIPS STARTING THE ENGINE 5 2 STARTING OFF AND SHIFTING 5 4 USING THE TRANSMISSION 5 6 RIDING ON HILLS 5 8 STOPPING AND PARKING 5 8 CARRYING A PASSENGER 5 11 ...

Page 76: ...an only be started if The transmission is in neutral and the clutch is disengaged or The transmission is in gear the side stand is fully up and the clutch is disengaged When the Engine is Cold 1 Close the throttle completely 2 Squeeze the clutch lever and push the electric starter button 3 After the engine starts let the engine run until the engine suffi ciently warms up When the Engine is Warm Cl...

Page 77: ...tains carbon monoxide a gas that is colorless and odorless and can cause death or severe injury Only run the engine outdoors where there is fresh air CAUTION Running the engine too long without riding may cause the engine to over heat Overheating can result in dam age to internal engine components and discoloration of exhaust pipes Shut the engine off if you cannot begin your ride promptly ...

Page 78: ... limits of your skills your motorcycle and the riding conditions WARNING Removing your hands from the han dlebars or feet from the footrests during operation can be hazardous If you remove even one hand or foot from the motorcycle you can reduce your ability to control the motorcy cle Always keep both hands on the han dlebars and both feet on the foot rests of your motorcycle during operation ...

Page 79: ...tly then close the throttle and pull the clutch lever in simultaneously Lift the gearshift lever upward to select the next gear and release the clutch lever as you open the throttle again Select higher gears in this manner until top gear is reached NOTE This motorcycle has a side stand ignition interlock switch If you shift the transmission into gear when the side stand is down the engine will sto...

Page 80: ...e prevailing conditions Never slip the clutch to con trol road speed but rather downshift to allow the engine to run within its normal operational range The table below shows the approximate speed range for each gear Shifting up schedule Shifting down schedule Disengage the clutch when the motor cycle speed drops below 20 km h 12 miles h Gear position miles h km h 1st 2nd 12 20 2nd 3rd 19 30 3rd 4...

Page 81: ...d engine braking resulting in an accident or force the engine to overrev in the lower gear resulting in engine damage Reduce speed before downshifting WARNING Downshifting while the motorcycle is leaned over in a corner may cause rear wheel skid and loss of control Reduce your speed and downshift before entering a corner ...

Page 82: ...gine may be used for braking by shifting to a lower gear Be careful however not to allow the engine to overrev STOPPING AND PARKING 1 Turn the throttle grip away from you to close the throttle completely 2 Apply the front and rear brakes evenly and at the same time 3 Downshift through the gears as motorcycle speed decreases 4 Select neutral with the clutch lever squeezed toward the grip disen gage...

Page 83: ...hile turning may cause wheel skid and loss of control Brake before you begin to turn WARNING Hard braking on wet loose rough or other slippery surfaces can cause wheel skid and loss of control Brake 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 stopping distance increases progressively Be su...

Page 84: ...ecurity 8 Remove the keys NOTE If an optional anti theft lock such as U shape lock brake disk lock and chain is used to avoid theft be sure to remove anti theft lock before moving the motorcycle WARNING A hot muffler can burn you The muf fler will be hot enough to burn you for some time after stopping the engine Park the motorcycle where pedestri ans or children are not likely to touch the muffler...

Page 85: ... of this manual The passenger should always hold onto your waist or hips or onto the seat strap or grab bar as equipped Ask your pas senger not to make any sudden move ments When you lean going around a corner the passenger should lean with you The passenger should always keep his or her feet on the footrests even when you are stopped at a light To help prevent burn injuries warn your passenger no...

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Page 87: ...6 1 6 ACCESSORY USE AND MOTORCYCLE LOADING ACCESSORY USE 6 2 ACCESSORY INSTALLATION GUIDELINE 6 3 LOADING LIMIT 6 4 LOADING GUIDELINES 6 5 MODIFICATION 6 6 ...

Page 88: ...er your dealer can assist you in selecting quality accessories and installing them correctly Use extreme caution when selecting and installing the accessories on your motorcycle and consult your Suzuki dealer if you have any questions WARNING Improper accessory installation can make your motorcycle unsafe and can lead to an accident Use Suzuki genuine accessories or equivalent designed and tested ...

Page 89: ...with the operation of the suspension steer ing or other control operations Accessories fitted to the handlebars or the front fork area can create seri ous stability problems The extra weight will cause the motorcycle to be less responsive to your steering control The weight may also cause oscillations in the front end and lead to instability problems Accessories added to the handlebars or front fo...

Page 90: ...ceed the GVWR Gross Vehicle Weight Rating of this motorcycle The GVWR is the combined weight of the machine accessories payload rider and passenger When selecting your accessories keep in mind the weight of the riders as well as the weight of the accessories The additional weight of the accessories may not only create an unsafe riding condition but may also affect the steering ease WARNING Overloa...

Page 91: ...assenger Follow the guidelines below to carry a passenger or cargo Balance the load between the left and right side of the motorcycle and fasten it securely Place cargo weight as close to the center of the motorcycle as possible Do not attach large or heavy items to the handlebars front forks or rear fender Check that both tires are properly inflated to the specified tire pressure for your loading...

Page 92: ...e at reduced speeds less than 130 km h 80 mph when you are carrying cargo or have added accessories Adjust suspension settings as nec essary MODIFICATION Modification of the motorcycle or removal of original equipment may ren der the vehicle unsafe or illegal Obey all applicable equipment regulations in your area ...

Page 93: ...11 SPARK PLUG 7 18 ENGINE OIL 7 23 THROTTLE CABLE ADJUSTMENT 7 31 ENGINE IDLE SPEED INSPECTION 7 32 FUEL HOSE 7 32 CLUTCH ADJUSTMENT 7 34 ENGINE COOLANT 7 36 FINAL GEAR OIL 7 38 BRAKES 7 40 TIRES 7 47 SIDE STAND IGNITION INTERLOCK SYSTEM 7 52 FRONT WHEEL REMOVAL 7 54 REAR WHEEL REMOVAL 7 58 LIGHT BULB REPLACEMENT 7 62 FUSES 7 68 ...

Page 94: ...een periodic services in kilometers miles and months are shown At the end of each interval be sure to perform the maintenance listed MAINTENANCE REPLACEMENT OR REPAIR OF THE EMISSION CONTROL DEVICES AND SYS TEMS MAY BE PERFORMED BY ANY MOTORCYCLE REPAIR ESTABLISHMENT OR INDIVIDUAL USING ANY MOTORCYCLE PART WHICH HAS BEEN CERTIFIED UNDER THE PROVISIONS IN THE CLEAN AIR ACT Sec 207 a 2 ...

Page 95: ...ollow the inspection and maintenance recommendations and schedules in this owner s manual Ask your SUZUKI dealer or a quali fied mechanic to do the maintenance items marked with an asterisk You may perform the unmarked maintenance items by referring to the instructions in this section if you have mechanical experience If you are not sure how to do any of the jobs have your SUZUKI dealer or a quali...

Page 96: ...7 4 CAUTION Using poor quality replacement parts can cause your motorcycle to wear more quickly and may shorten its useful life Use only genuine SUZUKI replace ment parts or their equivalent ...

Page 97: ... 48 Air cleaner element I I R I Exhaust pipe bolts and muffler bolts T T T Valve clearance I I I Spark plugs I R I R Fuel line I I I I Evaporative emission control system California model only I I Engine oil R R R R R Engine oil filter R R Final gear oil R I I Throttle cable play I I I I I PAIR air supply system I I Throttle valve synchronization I CA only I I Engine coolant Replace every 2 years ...

Page 98: ...rval is to be applied only for the California model Interval km 1000 6000 12000 18000 24000 mile 600 4000 7500 11000 14500 Element months 2 12 24 36 48 Clutch cable play I I I I Brakes I I I I I Brake hose I I I I Replace every 4 years Brake fluid I I I I Replace every 2 years Tires I I I I Steering I I I Front forks I I Rear suspension I I Chassis bolts and nuts T T T T T ...

Page 99: ...n is important for safe smooth operation and a long life for your motorcycle Be sure that all lubri cation is performed during periodic maintenance on the motorcycle Increase frequency when you use your motorcycle in severe conditions CAUTION Lubricating switches can damage the switches Do not apply grease and oil to the switches ...

Page 100: ...7 8 Grease 1Clutch lever holder 2Gearshift link pivots 3Side stand pivot and spring hook 4Brake lever holder 5Brake pedal pivot ...

Page 101: ...terminals and related accessories contain lead and lead compounds Wash hands after handling WARNING Hydrogen gas produced by batteries can explode if exposed to flames or sparks Keep flames and sparks away from the battery Never smoke when work ing near the battery CAUTION Exceeding the maximum charging rate for the battery can shorten its life Never exceed the maximum charging rate ...

Page 102: ...E Remove the negative terminal first and then remove the positive termi nal 4 To reinstall the battery reverse the procedure above CAUTION Reversing the battery lead wires can damage the charging system and the battery The red lead must go to the positive terminal and the black or black with white tracer lead must go to the negative terminal ...

Page 103: ... or muddy conditions you will need to inspect the air cleaner element much more frequently Use the following pro cedure to remove the element and inspect it WARNING Operating the engine without the air cleaner element in place could allow a flame to spit back from the engine to the air cleaner or could allow dirt to enter the engine This could cause a fire or severe engine damage Never run the eng...

Page 104: ...r replace the air cleaner ele ment frequently if the motorcycle is used in dusty wet or muddy condi tions The air cleaner element will clog under these conditions and this may cause engine damage poor per formance and poor fuel economy Clean the air cleaner case and inspect the element immediately if water gets in the air cleaner case ...

Page 105: ...7 13 3 Loosen the clamp screw 3 and remove the air cleaner 4 4 Disconnect the tubes 5 and coupler 6 ...

Page 106: ...7 14 5 Remove the screws Remove the air cleaner case 7 6 Remove the screws Remove the air cleaner element 8 ...

Page 107: ...Replace the air cleaner ele ment periodically CAUTION A torn air cleaner element will allow dirt to enter the engine and can dam age the engine Carefully examine the air cleaner ele ment for tears during cleaning Replace it with a new one if it is torn ...

Page 108: ...air cleaner element is securely in position and is properly sealed Air Cleaner Drain Plug RIGHT CAUTION Failure to position the air cleaner ele ment properly can allow dirt to bypass the air cleaner element This will cause engine damage Be sure to properly install the air cleaner element ...

Page 109: ...7 17 LEFT Remove the plug and drain water and oil at the periodic maintenance interval The air cleaner drain plugs are located inside the air cleaner box and air cleaner left chamber side ...

Page 110: ...ates that the engine may need adjustment or another plug type may be needed Consult your authorized Suzuki dealer or a qualified mechanic if your plug insulator is not a light brown color CAUTION An improper spark plug may have an incorrect fit or heat range for your engine This may cause severe engine damage which will not be covered under warranty Use one of the spark plugs listed below or equiv...

Page 111: ...ug to avoid jamming elec tronic parts Improper spark plug selec tion may cause electronic interference with your motorcycle s ignition system resulting in motorcycle performance problems Use only the recommended spark plugs NGK DENSO REMARKS CR6E U20ESR N Standard CR7E U22ESR N If the standard plug is apt to overheat replace with this plug ...

Page 112: ...7 20 Spark Plug Removal 1 Place the motorcycle on the side stand FRONT REAR ...

Page 113: ...caps 4 Remove the spark plugs with a spark plug wrench Spark Plug Cleaning 0 7 0 8 mm 0 028 0 031 in To maintain a hot strong spark keep the plugs free from carbon Adjust the gap to 0 7 0 8 mm 0 028 0 031 in for good ignition Use a thickness feeler gauge to check the gap ...

Page 114: ...are reusing the old spark plug tighten it with a wrench about 1 8 turn past finger tight CAUTION A crossthreaded or overtightened spark plug will damage the aluminum threads of the cylinder head Follow the procedure below to tighten the spark plug properly CAUTION Dirt can damage your engine if it enters an open spark plug hole Cover the spark plug hole whenever the spark plug is removed ...

Page 115: ...r with the oil filler cap as shown The level on the dipstick should be between the L Low and F Full lines The engine oil level inspection should be performed under the following condi tions 1 Place the motorcycle on the side stand 2 Start the engine and allow it to idle for about three minutes If the engine is cold warm up the engine suffi ciently 3 Stop the engine and wait approxi mately three mi...

Page 116: ...hange the engine oil and oil filter at the scheduled times The engine should always be warm when the engine oil is changed so the engine oil will drain eas ily The procedure is as follows 1 Place the motorcycle on level ground on the side stand 2 Remove the oil filler cap CAUTION The engine oil level must be between the L Low line and F Full line or engine damage may occur Check the oil level with...

Page 117: ... tom of the engine and drain the engine oil into a drain pan WARNING Engine oil and exhaust pipes can be hot enough to burn you Wait until the engine oil drain plug and exhaust pipes are cool enough to touch with bare hands before draining oil ...

Page 118: ...ardous Children and pets may be harmed by swallowing new or used oil Repeated prolonged contact with used engine oil may cause skin can cer Brief contact with used oil may irritate skin Keep new and used oil away from children and pets Wear a long sleeve shirt and water proof gloves Wash with soap if oil contacts your skin ...

Page 119: ...filter with a Suzuki cap type oil filter wrench or a strap type filter wrench of the proper size and remove the oil filter 5 Wipe off the mounting surface on the engine where the new filter will be seated with a clean rag ...

Page 120: ...resistance will be felt NOTE To tighten the oil filter properly it is important to accurately identify the position at which the filter gasket first contacts the mounting surface CAUTION Using an oil filter with the wrong design or thread specifications can cause oil leaks or engine damage Use a genuine SUZUKI oil filter or an equivalent filter designed for your motorcycle ...

Page 121: ...er 2 turns or to speci fied torque Oil filter tightening torque 20 N m 2 0 kgf m 14 5 lbf ft 9 Reinstall the drain plug and gasket Tighten the plug securely with a wrench Mark top dead center Oil filter wrench In the position at which the filter gasket first contacts the mounting surface Tighten the filter 2 turns or to specified torque ...

Page 122: ... About 3000 ml 3 2 US qt of oil will be required when changing oil only 11 Check the oil level according to Oil Level Check procedure NOTE Check to see that no oil is leak ing from the oil filter cover CAUTION Engine damage may occur if you use oil that does not meet SUZUKI s specifications Use the oil specified in the FUEL OIL AND COOLANT RECOMMENDA TIONS section ...

Page 123: ...so that the throt tle grip has 2 0 4 0 mm 0 08 0 16 in play 3 Tighten the lock nut 1 WARNING Inadequate throttle cable play can cause engine speed to rise suddenly when you turn the handlebars This can lead to loss of rider control Adjust the throttle cable play so that engine idle speed does not rise due to handlebar movement ...

Page 124: ...If the engine idle speed is not within the specified range ask your Suzuki dealer or a qualified mechanic to inspect and repair the motorcycle FUEL HOSE Fuel Tank Lift 1 Place the motorcycle on the side stand Remove the seat by referring to the SEAT LOCK section 2 Remove the bolt 1 Raise the rear end of the fuel tank and slide it back ward ...

Page 125: ...ts are found the fuel hose must be replaced NOTE Lifting up the fuel tank too much can result in the fuel hose becoming bent or twisted Lift the fuel tank as little as possible and disconnect the fuel hose The fuel tank in the above illustra tion is lifted to show the fuel hose and coupler clearly ...

Page 126: ...measured at the clutch lever end Adjust clutch cable play according to the following procedure Minor Adjustment 10 15 mm 0 4 0 6 in Loosen the lock nut 2 Turn the clutch cable adjuster 1 to provide the speci fied play Major Adjustment 1 Remove the 3 bolts Remove the cover ...

Page 127: ...ith the clutch lever side adjuster 1 4 Tighten the lock nuts 2 and 3 NOTE Check that the clearance between the clutch cable and gearshift rod is more than 6 mm 0 2 in before tightening the lock nuts 3 NOTE Any maintenance of the clutch other than the clutch cable play adjust ment should be performed by your Suzuki dealer ...

Page 128: ... the level is lower than L low level line bring it up to F full level by adding a 50 50 mixture of distilled water and engine coolant To add mixed coolant 1 Place the motorcycle on the side stand 2 Remove the cover by referring to the SUSPENSION ADJUSTMENT sec tion 3 Remove the filler cap and add prop erly mixed coolant through the filler hole F L ...

Page 129: ...haled Do not drink antifreeze or coolant solution If swallowed do not induce vomiting Immediately contact a poi son control center or a physician Avoid inhaling mist or hot vapors if inhaled remove to fresh air If cool ant gets in eyes flush eyes with water and seek medical attention Wash thoroughly after handling Solution can be poisonous to ani mals Keep out of the reach of chil dren and animals...

Page 130: ...nto a suitable container from the bottom of the final gear case 4 Reinstall the drain plug and tighten it securely after all the oil has been drained out Hold the motorcycle vertically and pour fresh oil through the filler hole until the oil level reaches the oil filler hole Approxi mately 200 220 ml 6 8 7 4 US oz of oil will be required 5 Reinstall the oil filler cap ...

Page 131: ...h use Add oil if necessary Tighten the drain plug securely after changing the gear oil WARNING New and used oil can be hazardous Children and pets may be harmed by swallowing new or used oil Repeated prolonged contact with used engine oil may cause skin can cer Brief contact with used oil may irritate skin Keep new and used oil away from children and pets Wear a long sleeve shirt and water proof g...

Page 132: ... these conditions the brakes must be inspected more often than recommended in the MAIN TENANCE SCHEDULE Brake Fluid FRONT WARNING Failure to inspect and properly main tain the brakes increases your chance of having an accident Inspect the brake system before each use according to the INSPEC TION BEFORE RIDING section Fol low the MAINTENANCE SCHEDULE section to maintain your brake sys tem ...

Page 133: ...er voir full with proper brake fluid can be hazardous The brakes may not work correctly without the proper amount and type of brake fluid This could lead to an accident Inspect the brake fluid level before each use Use only DOT4 brake fluid from a sealed container Never use or mix different types of brake fluid If there is frequent loss of fluid take your motorcycle to a SUZUKI dealer or a qualifi...

Page 134: ...n control center or a physician If brake fluid gets in eyes flush eyes with water and seek medical attention Wash thoroughly after handling Solution can be poisonous to animals Keep out of the reach of children and ani mals CAUTION Spilled brake fluid can damage painted surfaces and plastic parts Avoid spilling any fluid when filling the reservoir Wipe up spills immedi ately ...

Page 135: ... to the grooved wear limit lines 1 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 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 ...

Page 136: ...f having an accident Inspect brake pad wear before each use Ask your SUZUKI dealer or a qualified mechanic to replace brake pads if any pad is worn to the limit WARNING Failure to extend brake pads after repair or replacement can cause poor braking performance and may result in an accident Before riding pump the brake lever pedal repeatedly until brake pads are pressed against the brake disk and p...

Page 137: ...b against the disk causing damage to the pads and to the disk surface Adjust the brake pedal position in the following manner 1 Remove the front footrest mounting bolts 1 WARNING A hot muffler can burn you The muf fler will be hot enough to burn you for some time after stopping the engine Wait until the muffler cools to avoid burns ...

Page 138: ...ten the lock nut 2 to secure the push rod 3 in the proper posi tion NOTE Apply a drop of SUZUKI THREAD LOCK 1322 to the front foot rest mounting bolt 1 CAUTION An incorrectly adjusted brake pedal may force brake pads to rub against the disk at all times causing damage to the pads and disk Follow the steps in this section to adjust the brake pedal properly ...

Page 139: ...RNING Failure to follow these warnings may result in an accident due to tire failure The tires on your motorcycle form the crucial link between your motorcycle and the road Follow these instructions Check tire condition and pressure and adjust pressure before each ride Avoid overloading your motorcycle Replace a tire when worn to the speci fied limit or if you find damage such as cuts or cracks Al...

Page 140: ... tires and lead to higher inflation pressure readings WARNING Failure to perform break in of the tires could cause tire slip and loss of control Use extra care when riding on new tires Perform proper break in of the tires referring to the BREAK IN sec tion and avoid hard acceleration hard cornering and hard braking for the first 160 km 100 miles LOAD SOLO RIDING WITH LIGHT OR LITTLE CARGO LOAD DUA...

Page 141: ...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 Tire condition and tire type affect motor cycle performance Cuts or cracks in the tires can lead to tire failure and loss of motorcycle control Worn tires are susceptible to puncture failures and subsequent loss of motorcycle control Tire wear a...

Page 142: ...t indicates that the tire wear limit has been reached Whenever you replace a tire use a tire of the size and type listed below If you use a different size or type of tire motorcycle handling may be adversely affected possibly resulting in loss of motorcycle control Always balance the wheel after repair ing a puncture or replacing the tire Proper wheel balance is important to avoid variable wheel t...

Page 143: ... each tire WARNING Failure to follow these instructions about tubeless tires may result in an accident due to tire failure Tubeless tires require different service proce dures 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 specialized tire mounting machine must be used for removing and installing tires to pre ...

Page 144: ...position Do not use an external repair plug to repair a puncture since the plug may work loose as a result of the corner ing forces experienced by a motor cycle tire After repairing a tire do not exceed 80 km h 50 mph for the first 24 hours 130 km h 80 mph thereafter This is to avoid excessive heat build up which could result in a tire repair failure and tire deflation Replace the tire if it is pu...

Page 145: ...king properly Have your motorcycle inspected by an authorized Suzuki dealer or some other qualified service mechanic 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 Check the side stand ignition inter lock system for proper operation be...

Page 146: ...h of the cal ipers NOTE Never squeeze the front brake lever with the caliper removed It is very difficult to force the pads back into the caliper assembly and brake fluid leak age may result 3 Loosen the axle holder bolts 2 Loosen the axle 3 temporarily NOTE A special tool is necessary to loosen the axle The special tool is avail able from a Suzuki dealer ...

Page 147: ...efully position a jack under the engine or chassis tubes and raise the jack until the front wheel is slightly off the ground 5 Turn the axle counterclockwise and draw it out CAUTION Improper jacking may cause damage to the oil filter Do not apply the jack head to the oil filter when jacking up the motorcy cle ...

Page 148: ...cribed above 8 After installing the wheel apply the front brake several times to restore the proper lever stroke WARNING Failure to extend brake pads after installing the wheel can cause poor braking performance and may result in an accident Before riding pump the brake repeatedly until the brake pads are pressed against the brake disks and proper lever stroke and firm feel are restored Also check...

Page 149: ...zardous The tire for this motorcycle is direc tional Therefore the motorcycle may have unusual handling if the wheel is installed incorrectly Install the front wheel in the speci fied direction as indicated by the arrow on the sidewall of the tire WARNING Failure to torque bolts and nuts prop erly could lead to an accident Torque bolts and nuts to the proper specifications If you are not sure of t...

Page 150: ...e axle nut 1 WARNING Removing the rear wheel without use of an accessory stand can result in your motorcycle falling over and being damaged Do not attempt road side removal of the rear wheel Only remove the rear wheel at a properly equipped servic ing facility using an accessory ser vice stand ...

Page 151: ...alent under the swingarm or chassis tubes to stabilize the rear end 5 Draw out the axle WARNING A hot muffler can burn you The muf fler will be hot enough to burn you for some time after stopping the engine Wait until the muffler cools to avoid burns ...

Page 152: ...ounting bolt 2 Remove the brake caliper assembly 3 7 Remove the wheel from the splined drive gear and set the wheel assem bly on the ground 8 Pull the wheel assembly rearward 9 To replace the wheel reverse the complete sequence described above ...

Page 153: ... to the rear brake caliper bracket mounting bolt 2 WARNING Failure to torque bolts and nuts prop erly and to properly apply thread lock to specified bolts and nuts could lead to an accident Torque bolts and nuts to the proper specifications Properly apply thread lock to specified bolts If you are not sure of the proper procedure have your authorized SUZUKI dealer or a qualified mechanic do this ...

Page 154: ...replace the headlight bulb perform the following steps 1 Disconnect the socket 1 from the headlight and remove the rubber cap 2 CAUTION Using a light bulb with the wrong wattage rating can cause electrical system damage or shorten bulb life Always use the specified light bulb Headlight 12V 60 55W H4 Turn signal light Front 12V 21 5W Rear 12V 21W License plate light 12V 5W ...

Page 155: ... bulb holder spring 3 and pull out the bulb 4 3 To replace the headlight bulb reverse the above sequence CAUTION Oil from your skin may damage the headlight bulb or shorten its life Grasp the new bulb with a clean cloth ...

Page 156: ... down or right and left if necessary To adjust the beam up and down Insert 5 mm hexagon wrench as shown and turn the adjuster clockwise or coun terclockwise To adjust the beam right and left Insert 5 mm hexagon wrench as shown and turn the adjuster clockwise or coun terclockwise ...

Page 157: ...gnal light bulbs follow these directions 1 Remove the screw 1 2 Turn the lens counterclockwise and remove it 3 Push in on the bulb 2 turn it to the left and pull it out 4 To fit the replacement bulb push it in and turn it to the right while pushing ...

Page 158: ...ght To replace the license plate light bulb follow the procedure steps 1 Remove the nuts 1 CAUTION Overtightening the screws when reinstalling the lens may cause the lens to crack Tighten the screws only until they are snug ...

Page 159: ...7 2 Remove the screws 2 and take off the cover with the lens 3 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 ...

Page 160: ... FUSES MAIN FUSE The main fuse is located under the seat One 30A spare fuse is located in the fuse box FUSES The fuses are located under the seat Two spare fuses 10A and one 15A are provided in the fuse box ...

Page 161: ...GNITION fuse protects the headlight relay fan motor relay side stand relay de comp solenoids ECU oxygen sensor fuel pump relay starter relay and ignition coils 10A SIGNAL fuse protects the run ning light horn speedometer turn signal light license light stop lamp and taillight 15A FAN fuse protects the cooling fan motor CAUTION Installing a fuse of incorrect rating or using aluminum foil or wire in...

Page 162: ......

Page 163: ...8 1 8 TROUBLESHOOTING FUEL SUPPLY CHECK 8 2 IGNITION SYSTEM CHECK 8 3 ...

Page 164: ...ion for an explanation of fuel injection system indicator If the indicator does not dis play FI make sure there is enough fuel in the fuel tank If the indicator does not display FI and there is enough fuel the ignition system should be checked CAUTION Failure to troubleshoot a problem correctly can damage your motorcy cle Improper repairs or adjustments may damage the motorcycle instead of fixing ...

Page 165: ... position and the ignition switch in the ON position While holding the spark plug with its base firmly against the engine push the electric starter button If the ignition system is operating properly a blue spark should jump across the spark plug gap If there is still no spark take your motorcycle to an authorized Suzuki dealer ...

Page 166: ... for an explanation of fuel injection system indicator 3 Check the ignition system for inter mittent spark 4 Check the idle speed The correct idle speed is 900 1100 r min WARNING Performing the spark test improperly can cause a high voltage electrical shock or an explosion Avoid performing this check if you are not familiar with this procedure or if you have a heart condition or wear a pacemaker K...

Page 167: ...9 1 9 STORAGE PROCEDURE AND MOTORCYCLE CLEANING STORAGE PROCEDURE 9 2 PROCEDURE FOR RETURNING TO SERVICE 9 4 CORROSION PREVENTION 9 4 MOTORCYCLE CLEANING 9 6 INSPECTION AFTER CLEANING 9 8 ...

Page 168: ...to your authorized Suzuki dealer If you wish to service the machine for storage your self follow the general guidelines below MOTORCYCLE Clean the entire motorcycle Place the motorcycle on the side stand on a firm flat surface where it will not fall over FUEL 1 Fill the fuel tank to the top with fuel mixed with the amount of gasoline stabilizer recommended by the sta bilizer manufacturer 2 Run the...

Page 169: ...om entering BATTERY 1 Remove the battery from the motor cycle 2 Clean the outside of the battery with a mild soap and remove corrosion from the terminals and wiring har ness 3 Store the battery in a room above freezing TIRES Inflate the tires to the normal specifica tions EXTERNAL Spray all vinyl and rubber parts with rubber preservative Spray the unpainted surfaces with rust preventative Coat the...

Page 170: ...m the INSPECTION BEFORE RIDING as listed in this manual 8 Start the motorcycle as outlined in this manual CORROSION PREVENTION It is important to take good care of your motorcycle to protect it from corrosion and keep it looking new for years to come Important Information About Corrosion Common causes of corrosion Accumulation of road salt dirt mois ture or chemicals in hard to reach areas Chippin...

Page 171: ...rer s directions when using these special cleaners Repair finish damage as soon as possible Carefully examine your motorcycle for damage to the painted surfaces Should you find any chips or scratches in the paint touch them up immediately to pre vent corrosion from starting If the chips or scratches have gone through to the bare metal have a Suzuki dealer make the repair Store your motorcycle in a...

Page 172: ...on 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 running water You may use a soft sponge or brush Do not use hard materials which can scratch the paint 2 Wash the entire motorcycle with mild detergent o...

Page 173: ...tergent with running water 4 After rinsing wipe off the motorcycle with a wet chamois or cloth and allow it to dry in the shade CAUTION Radiator fins can be damaged by spraying high pressure water on them Do not spray high pressure water on the radiator CAUTION High pressure washers and parts cleaner can damage your motorcy cle Do not use high pressure washers to clean your motorcycle Do not use p...

Page 174: ...ION section Follow the procedures in the INSPEC TION BEFORE RIDING section to check your motorcycle for any problems that may have arisen during your last ride CAUTION Cleaning with any alkaline or strong acid cleaner gasoline brake fluid or any other solvent will damage the motorcycle parts Clean only with soft cloth and warm water with mild detergent WARNING Wet brakes can cause poor braking per...

Page 175: ...RMATION EMISSION CONTROL WARRANTY 10 2 TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED 10 3 ON BOARD MOTORCYCLE COMPUTER DATA INFORMATION 10 4 SERIAL NUMBER LOCATION 10 5 REPORTING SAFETY DEFECTS 10 6 LOCATION OF LABELS 10 7 ...

Page 176: ...ot to meet these standards within its useful life Useful life is defined for each class of motorcycle as 5 years or the corre sponding number of kilometers miles shown in the chart below whichever occurs first Failures other than those resulting from defects in material or workmanship which arise solely as a result of owner abuse and or lack of proper mainte nance are not covered by the warranty V...

Page 177: ... any person Among those acts presumed to consti tute tampering are the acts listed below removing or puncturing the muffler baffles header pipes screen type spark arrester if equipped or any other component which conducts exhaust gases replacing the exhaust system or muffler with a system or muffler not marked with the same model spe cific code as the code listed on the Motorcycle Noise Emission C...

Page 178: ...n may be stored by the on board computer when malfunctions occur This stored information can assist technicians in repairing the motorcycle To read the stored informa tion special equipment is needed and access to the motorcycle or storage device is required In addition once SUZUKI collects or receives data SUZUKI may use the data for research conducted by SUZUKI make the data available for outsid...

Page 179: ...rcycle You also need these numbers to help your authorized Suzuki dealer when you order parts The frame number 1 is stamped on the steering head as shown in the illustra tion The engine serial number 2 is stamped on the crankcase assembly Write down the serial numbers here for your future reference Frame No Engine No ...

Page 180: ...tween you your authorized Suzuki dealer or American Suzuki Motor Corp To contact NHTSA you may either call the Vehicle Safety Hot Line toll free 1 888 327 4236 TTY 1 800 424 9153 go to http www safercar gov or write to Administrator NHTSA 400 Seventh Street SW Washington DC 20590 You can also obtain other information about motor vehicle safety from http www NHTSA gov To contact American Suzuki own...

Page 181: ...ur motorcycle Do not remove them for any reason 1 WARNING Failure to follow these safety precautions may increase your risk of injury Wear a helmet eye protection and bright protective clothing Don t ride after consuming alcohol or other drugs Slow down on slippery surfaces unfamiliar terrain or when visibility is reduced Read owner s manual carefully ...

Page 182: ...ainsimportantsafety informationandinstructionswhichshouldbe readcarefullybeforeoperatingthevehicle If the vehicle has been resold obtain the owner s manual from the previous owner or contact your local SUZUKI dealer for assistance ...

Page 183: ...W G853 G G852 G SOLO RIDING DUAL RIDING FRONT REAR COLD TIRE PRESSURE 250 250 2 50 2 50 36 36 Check tire condition wear and cold tire pressure before each ride Replace only with TUBELESS tires of listed size and type Read owner s manual for more information kgf cm2 kPa psi 250 290 2 50 2 90 36 42 ...

Page 184: ...clearance 145 mm 5 7 in Seat height 716 mm 28 2 in Curb mass 328 kg 723 lbs ENGINE Type Four stroke liquid cooled SOHC 54 degree V twin Number of cylinders 2 Bore 96 0 mm 3 780 in Stroke 101 0 mm 3 976 in Displacement 1462 cm3 89 2 cu in Compression ratio 9 5 1 Fuel system Fuel injection Air cleaner Paper element Starter system Electric Lubrication system Wet sump ...

Page 185: ...atio 3 137 20 17 32 12 Drive system Shaft drive CHASSIS Front suspension Inverted telescopic coil spring oil damped Rear suspension Link type coil spring oil damped Front fork stroke 130 mm 5 1 in Rear wheel travel 108 mm 4 3 in Caster 32 Trail 129 mm 5 1 in Steering angle 37 right left Turning radius 3 3 m 10 8 ft Front brake Disk brake twin Rear brake Disk brake Front tire size 120 70ZR18M C 59W...

Page 186: ...e 10 10 10 10 15 15A Headlight 12V 60 55W H4 Brake light Taillight LED Front turn signal light 12V 21 5W Rear turn signal light 12V 21W License plate light 12V 5W Speedometer light LED High beam indicator light LED Neutral indicator light LED Turn signal indicator light LED Coolant temperature indicator light LED Oil pressure indicator light LED Fuel injection indicator light LED ...

Page 187: ...CAPACITIES Fuel tank 18 0 L 4 8 US gal Engine oil without filter change 3000 ml 3 2 US qt With filter change 3200 ml 3 4 US qt Final gear oil 200 220 ml 6 8 7 4 US oz Engine coolant 2 7 L 2 9 US qt ...

Page 188: ...T 1 9 BRAKES 7 40 BREAK IN 4 2 C CARRYING A PASSENGER 1 8 5 11 CLUTCH ADJUSTMENT 7 34 CONCLUSION 1 10 CORROSION PREVENTION 9 4 E EMISSION CONTROL WARRANTY 10 2 ENGINE COOLANT 7 36 ENGINE COOLANT SOLUTION 2 7 ENGINE IDLE SPEED INSPECTION 7 32 ENGINE OIL 2 5 7 23 F FINAL GEAR OIL 2 7 7 38 FRONT WHEEL REMOVAL 7 54 FUEL 2 2 FUEL HOSE 7 32 FUEL SUPPLY CHECK 8 2 FUEL TANK CAP 3 28 FUSES 7 68 ...

Page 189: ...Y A HELMET AND WEAR IT EVERY TIME YOU RIDE 1 3 IGNITION SWITCH 3 6 IGNITION SYSTEM CHECK 8 3 INSPECTION AFTER CLEANING 9 8 INSPECTION BEFORE RIDING 1 7 4 5 INSTRUMENT PANEL 3 8 K KEY 3 5 KNOW YOUR LIMITS 1 5 L LEFT HANDLEBAR 3 21 LIGHT BULB REPLACEMENT 7 62 LOADING GUIDELINES 6 5 LOADING LIMIT 6 4 LOCATION OF LABELS 10 7 LOCATION OF PARTS 3 2 ...

Page 190: ...ATION S RIDING TIPS AND PRACTICE GUIDE HANDBOOK FOR OWNERS IN USA 1 9 N NOTICE 7 2 O ON BOARD MOTORCYCLE COMPUTER DATA INFORMATION 10 4 P PRACTICE AWAY FROM TRAFFIC 1 7 PROCEDURE FOR RETURNING TO SERVICE 9 4 R REAR BRAKE PEDAL 3 31 REAR WHEEL REMOVAL 7 58 REPORTING SAFETY DEFECTS 10 6 RIDING ON HILLS 5 8 RIGHT HANDLEBAR 3 24 ...

Page 191: ...ITUATIONS REQUIRE SPECIAL CARE 1 5 STARTING OFF AND SHIFTING 5 4 STARTING THE ENGINE 5 2 STEERING LOCK 3 7 STOPPING AND PARKING 5 8 STORAGE PROCEDURE 9 2 SUSPENSION ADJUSTMENT 3 37 T TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED 10 3 THROTTLE CABLE ADJUSTMENT 7 31 TIRES 7 47 TOOLS 7 7 U USING THE TRANSMISSION 5 6 Total page 192 ...

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Page 195: ...ncrease your risk of injury Wear a helmet eye protec tion and bright protective clothing Don t ride after consuming alcohol or other drugs Slow down on slippery sur faces unfamiliar terrain or when visibility is reduced Read owner s manual care fully WARNING Failure to follow these safety precautions may increase your ...

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