Suzuki Intruder VZ1500 Service Manual Download Page 571

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Exterior Parts: 9D-2

Repair Instructions

Exterior Parts Construction

B940H29406001

I940H1940014-03

1. Frame head cover

5. Frame head cover

2. Frame lower cover (RH)

6. Regulator/Rectifier

3. Frame side cover (RH)

7. Frame lower cover (LH)

4. Frame side lower cover (RH)

8. Frame side cover (LH)

Summary of Contents for Intruder VZ1500

Page 1: ...ications at the time of publication If modifi cations have been made since then differences may exist between the content of this manual and the actual motorcycle Illustrations in this manual are used to show the basic principles of operation and work procedures They may not represent the actual motorcycle exactly in detail This manual is written for persons who have enough knowledge skills and to...

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Page 3: ... Suspension 2 i Precautions 2 1 Suspension General Diagnosis 2A 1 Front Suspension 2B 1 Rear Suspension 2C 1 Wheels and Tires 2D 1 Driveline Axle 3 i Precautions 3 1 Drive Chain Drive Train Drive Shaft 3A 1 Brake 4 i Precautions 4 1 Brake Control System and Diagnosis 4A 1 Front Brakes 4B 1 Rear Brakes 4C 1 Transmission Transaxle 5 i Precautions 5 1 Manual Transmission 5B 1 Clutch 5C 1 Steering 6 i...

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Page 5: ... i 00 Section 00 CONTENTS Precautions Precautions 00 1 Precautions 00 1 Warning Caution Note 00 1 General Precautions 00 1 Precautions for Electrical Circuit Service 00 2 Special Tools and Equipment 00 8 Special Tool 00 8 ...

Page 6: ...do not touch the engine engine oil radiator and exhaust system until they have cooled After servicing the fuel oil water exhaust or brake systems check all lines and fittings related to the system for leaks CAUTION If parts replacement is necessary replace the parts with Suzuki Genuine Parts or their equivalent When removing parts that are to be reused keep them arranged in an orderly manner so th...

Page 7: ... fully to engage the lock when connecting When disconnecting the coupler be sure to hold the coupler body and do not pull the lead wires Inspect each terminal on the connector coupler for looseness or bending Push in the coupler straightly An angled or skewed insertion may cause the terminal to be deformed possibly resulting in poor electrical contact Inspect each terminal for corrosion and contam...

Page 8: ...age 9A 5 Bend the clamp properly so that the wire harness is clamped securely In clamping the wire harness use care not to allow it to hang down Do not use wire or any other substitute for the band type clamp Fuse When a fuse is blown always investigate the cause to correct it and then replace the fuse Do not use a fuse of different capacity Do not use wire or any other substitute for the fuse Swi...

Page 9: ...it when its coupler is disconnected Otherwise damage to electronic unit may result Never connect an ohmmeter to the electronic unit with its coupler connected If attempted damage to ECM or sensors may result Be sure to use a specified voltmeter ohmmeter Otherwise accurate measurements may not be obtained and personal injury may result Electrical Circuit Inspection Procedure While there are various...

Page 10: ... any foreign material which could impede proper terminal contact 4 Using continuity inspect or voltage check procedure as described below inspect the wire harness terminals for open circuit and poor connection Locate abnormality if any Continuity check 1 Measure resistance across coupler B between A and C in the figure If no continuity is indicated infinity or over limit the circuit is open betwee...

Page 11: ...es the voltage drop in the circuit between terminals A and B Voltage between A and body ground Approx 5 V B and body ground Approx 5 V 2 V voltage drop C and body ground 3 V 2 V voltage drop Short circuit check Wire harness to ground 1 Disconnect the negative cable from the battery 2 Disconnect the connectors couplers at both ends of the circuit to be checked NOTE If the circuit to be checked bran...

Page 12: ...ance with the multi circuit tester 1 will be shown as 10 00 MΩ and 1 flashes in the display Check that no voltage is applied before making the measurement If voltage is applied the tester may be damaged After using the tester turn the power off Special tool 09900 25008 Multi circuit tester set NOTE When connecting the multi circuit tester use the needle pointed probe to the back side of the lead w...

Page 13: ...Precautions 00 8 Special Tools and Equipment Special Tool B940H20008001 09900 25008 09900 25009 Multi circuit tester set Needle pointed probe set Page 00 7 Page 00 7 Page 00 7 ...

Page 14: ...00 9 Precautions ...

Page 15: ...Cleaner Element Replacement 0B 2 Air Cleaner Element Inspection 0B 2 Exhaust Pipe Bolt and Muffler Bolt Inspection 0B 3 Valve Clearance Inspection and Adjustment 0B 3 Spark Plug Replacement 0B 6 Spark Plug Inspection and Cleaning 0B 7 Fuel Line Inspection 0B 7 Evaporative Emission Control System Inspection E 33 Only 0B 8 Engine Oil and Filter Replacement 0B 8 Final Gear Oil Replacement 0B 10 Throt...

Page 16: ...M Engine Control Module Engine Control Unit ECU FI Control Unit ECT Sensor Engine Coolant Temperature Sensor ECTS Water Temp Sensor WTS EVAP Evaporative Emission F FI Fuel Injection Fuel Injector FP Fuel pump FPR Fuel Pressure Regulator Symbol Definition Torque control required Data beside it indicate specified torque Apply oil Use engine oil unless otherwise specified Apply molybdenum oil solutio...

Page 17: ...L Air Cleaner Air Cleaner Box B Battery Positive Voltage B Battery Voltage B C Crankshaft Position Sensor CKP Sensor Crankshaft Position Sensor CKPS Crank Angle D Data Link Connector DLC Dealer Mode Coupler Diagnostic Test Mode DTM Diagnostic Trouble Code DTC Diagnostic Code Malfunction Code E Electronic Ignition EI Engine Control Module ECM Engine Control Module ECM Fl Control Unit Engine Control...

Page 18: ...ial number B is located on the right side of the crankcase These numbers are required especially for registering the machine and ordering spare parts Fuel and Oil Recommendation B940H20101005 Fuel For USA and Canada Use only unleaded gasoline of at least 90 pump octane R 2 M 2 Gasoline containing MTBE Methyl Tertiary Butyl Ether less than 10 ethanol or less than 5 methanol with appropriate cosolve...

Page 19: ...ing point Suzuki recommends the use of SUZUKI COOLANT anti freeze engine coolant If this is not available use an equivalent which is compatible with an aluminum radiator Liquid amount of water Engine coolant Solution capacity total 2 650 ml 2 8 2 3 US Imp qt For engine coolant mixture information refer to Engine Coolant Description in Section 1F Page 1F 1 CAUTION Mixing of anti freeze engine coola...

Page 20: ... tracer Gr Gray Gr W Gray with White tracer Lbl Light blue Gr Y Gray with Yellow tracer Lg Light green O G Orange with Green tracer O Orange O R Orange with Red tracer P Pink O W Orange with White tracer R Red O Y Orange with Yellow tracer W White P B Pink with Black tracer Y Yellow P W Pink with White tracer B Bl Black with Blue tracer R B Red with Black tracer B Br Black with Brown tracer R Bl R...

Page 21: ...el For E 28 3 Information label For E 03 28 33 12 I D plate For E 02 19 24 4 Vacuum hose routing label For E 33 13 Safety plate For E 03 28 33 5 Manual notice label For E 03 33 14 Gearshift label 6 Tire information label English For E 03 33 A Frame head Right side 7 Tire information label French German English For E 02 19 24 28 B Frame head Left side 8 General warning label English For E 02 03 24 ...

Page 22: ... 33 17 ISC valve 2 IAP sensor 1 10 Horn 18 ECM Engine Control Module 3 Ignition coil 1 11 Turn signal Side stand relay 19 Fuse box 4 IAT sensor 12 Fuel pump relay 20 Starter relay Main fuse 5 STP sensor 13 Headlight relay 21 Battery 6 STV actuator 14 Cooling fan 22 Mode select switch coupler 7 TP sensor 15 Rear brake switch 23 EVAP system purge control solenoid valve For E 33 8 Starter motor 16 EC...

Page 23: ...l injector 1 32 Generator 25 Fuel injector 2 33 CKP sensor 26 Fuel level gauge 34 Speedometer sensor 27 Fuel pump 35 Side stand switch 28 Ignition coil 2 36 TO sensor 29 Ignition switch 37 Cooling fan relay 30 Regulator Rectifier 38 GP sensor 31 Oil pressure switch 39 PAIR control solenoid valve ...

Page 24: ...ystem Fuel injection Air cleaner Paper element Starter system Electric Lubrication system Wet sump Idle speed 1000 100 r min Item Specification Remark Clutch Wet multi plate type Transmission 5 speed constant mesh Gearshift pattern 1 down 4 up Primary reduction ratio 1 407 76 54 Gear ratios Low 2 187 35 16 2nd 1 400 28 20 3rd 1 038 27 26 4th 0 875 28 32 Top 0 787 26 33 Final reduction ratio 3 137 ...

Page 25: ...urn signal light Position light 12 V 21 5 W E 03 28 33 Rear turn signal light 12 V 21 W Brake light Taillight LED License plate light 12 V 5 W Speedometer light LED Neutral indicator light LED High beam indicator light LED Turn signal indicator light LED Coolant temperature indicator light LED Oil pressure indicator light LED FI indicator light LED Item Specification Remark Fuel tank 18 L 4 8 4 0 ...

Page 26: ...3 Micrometer 1 100 mm 50 75 mm 09900 20204 Micrometer 75 100 mm 09900 20205 Micrometer 0 25 mm 09900 20530 Cylinder gauge set 09900 20602 Dial gauge 1 1000 mm 1 mm 09900 20605 Dial calipers 1 100 mm 10 34 mm 09900 20607 Dial gauge 1 100 mm 10 mm 09900 20701 Magnetic stand 09900 20702 Micrometer stand 09900 20803 Thickness gauge 09900 20805 Tire depth gauge 09900 21304 V block 100 mm 09900 22301 Pl...

Page 27: ...9913 70210 Bearing installer set 09913 75821 Bearing installer 09913 76010 Bearing installer 09913 84510 Bearing installer 09915 40620 Oil filter wrench 09915 64512 Compression gauge 09915 74521 Oil pressure gauge hose 09915 74533 Oil pressure gauge attachment 09915 77331 Meter for high pressure 09916 10911 Valve lapper set 09916 14510 Valve lifter 09916 14910 Valve spring compressor attachment 09...

Page 28: ...g remover 09923 74511 Bearing remover 09924 34510 Backlash measuring tool φ27 50 09924 41830 Bearing retainer wrench 09924 62410 Final drive gear bearing holder wrench 09924 62430 Long socket 22 mm 09924 64510 Final driving gear coupling holder 09924 74520 Oil seal installer remover 09924 84510 Bearing installer set 09924 84521 Bearing installer set 09925 18011 Steering bearing installer 09930 101...

Page 29: ...ent 09940 51410 Bearing installer 09940 52841 Front fork inner rod holder 09940 52861 Front fork oil seal installer 09940 92720 Spring scale 09940 94922 Front fork spring stopper plate 09940 94930 Front fork spacer holder 09941 34513 Steering race installer 09941 54911 Bearing outer race remover 09941 64511 Bearing remover 09941 74911 Steering bearing installer 09943 74111 Fork oil level gauge 099...

Page 30: ...vere conditions General Description Recommended Fluids and Lubricants B940H20201001 Refer to Fuel and Oil Recommendation in Section 0A Page 0A 3 and Engine Coolant Recommendation in Section 0A Page 0A 4 Scheduled Maintenance Periodic Maintenance Schedule Chart B940H20205001 NOTE I Inspect and clean adjust replace or lubricate as necessary R Replace T Tighten Item Interval km 1 000 6 000 12 000 18 ...

Page 31: ...r element Every 18 000 km 11 000 miles 36 months Refer to Air Cleaner Element Removal and Installation in Section 1D Page 1D 6 Air Cleaner Element Inspection B940H20206002 Inspect air cleaner element Every 6 000 km 4 000 miles 12 months Inspection 1 Remove the air cleaner element Refer to Air Cleaner Element Removal and Installation in Section 1D Page 1D 6 Tires I I I I Steering I I I Front fork I...

Page 32: ...ereafter Check the exhaust pipe bolts muffler bolts and nut to the specified torque Tightening torque Exhaust pipe bolt a 23 N m 2 3 kgf m 16 5 lbf ft Muffler connecting bolt b 26 N m 2 6 kgf m 19 0 lbf ft Muffler joint bolt c 26 N m 2 6 kgf m 19 0 lbf ft Muffler support bolt d 26 N m 2 6 kgf m 19 0 lbf ft Muffler support nut e 26 N m 2 6 kgf m 19 0 lbf ft Valve Clearance Inspection and Adjustment...

Page 33: ...and Installation in Section 1H Page 1H 4 6 Remove the cylinder head inspection covers 2 and 3 1 Cylinder 2 Cylinder NOTE The valve clearance specification is different for both intake and exhaust valves Valve clearance When cold IN 0 08 0 13 mm 0 003 0 005 in EX 0 17 0 22 mm 0 007 0 009 in 7 Remove the generator cover plug 4 and valve timing inspection plug 5 I940H1020006 01 I940H1020007 01 1 2 2 ...

Page 34: ... the clearance is out of the specification bring it into the specified range by using the special tool Special tool A 09900 20803 Thickness gauge B 09917 10410 Valve adjuster driver Tightening torque Valve clearance adjuster lock nut 15 N m 1 5 kgf m 11 0 lbf ft 11 Turn the crankshaft 486 degrees 1 1 3 turns to set the 2 Front cylinder at TDC of compression stroke Align the F T line of G on the ge...

Page 35: ... equivalent CAUTION Use a new O rings to prevent oil leakage 14 Tighten the valve timing inspection cap bolts to the specified torque Tightening torque Valve timing inspection cap bolt a 10 N m 1 0 kgf m 7 0 lbf ft 15 Tighten the generator cover cap and valve timing inspection plug to the specified torque Tightening torque Generator cover cap b 11 N m 1 1 kgf m 8 0 lbf ft Valve timing inspection p...

Page 36: ...g a thickness gauge Adjust the spark plug gap if necessary Spark plug gap 0 7 0 8 mm 0 028 0 030 in 3 After finishing the spark plug inspection reinstall the removed parts Electrodes Condition 1 Remove the spark plugs Refer to Spark Plug Cap and Spark Plug Removal and Installation in Section 1H Page 1H 4 2 Check to see the worn or burnt condition of the electrodes If it is extremely worn or burnt ...

Page 37: ...done together with the engine oil change Engine Oil Replacement 1 Keep the motorcycle upright with a jack or wooden block 2 Place an oil pan below the engine and drain engine oil by removing the oil drain plug 1 and filler cap 2 3 Tighten the oil drain plug 1 to the specified torque CAUTION Replace the gasket washers with new one Tightening torque Oil drain plug a 23 N m 2 3 kgf m 16 5 lbf ft 4 Po...

Page 38: ...L FILTER Other manufacturer s oil filters may differ in thread specifications thread diameter and pitch filtering performance and durability which may lead to engine damage or oil leaks Also do not use a genuine Suzuki automobile oil filter on this motorcycle 4 Install a new oil filter Turn it by hand until you feel that the oil filter O ring contacts the oil filter mounting surface Then tighten t...

Page 39: ...mp oz 5 Tighten the filler cap 1 CAUTION Use a new O ring to prevent oil leakage Throttle Cable Play Inspection and Adjustment B940H20206011 Inspect throttle cable play Initially at 1 000 km 600 miles 2 months and every 6 000 km 4 000 miles 12 months thereafter Inspect and adjust the throttle cable play a as follows Throttle cable play a 2 0 4 0 mm 0 08 0 16 in 1 Loosen the lock nut 1 of the throt...

Page 40: ...ine Coolant Description in Section 1F Page 1F 1 WARNING Do not open the radiator cap when the engine is hot as you may be injured by escaping hot liquid or vapor Engine coolant may be harmful if swallowed or if it comes in contact with skin or eyes If engine coolant gets into the eyes or in contact with the skin flush thoroughly with plenty of water If swallowed induce vomiting and call physician ...

Page 41: ... filled with engine coolant up to the reservoir full level 12 Reinstall the removed parts Radiator Hose Inspection Check the radiator hoses for crack damage or engine coolant leakage If any defect is found replace the radiator hose with a new one Clutch Cable Play Inspection and Adjustment B940H20206015 Inspect clutch cable play Every 6 000 km 4 000 miles 12 months Inspect and adjust the clutch ca...

Page 42: ...muffler Refer to Clutch Installation in Section 5C Page 5C 8 and Exhaust Pipe Muffler Removal and Installation in Section 1K Page 1K 2 g Pour engine oil Refer to Engine Oil and Filter Replacement Page 0B 8 5 Install the clutch cable holder 1 6 Loosen the lock nut 4 7 Turn in the adjuster 5 until 3 5 mm 0 1 0 2 in b as shown in the figure 8 Loosen the lock nut 6 and turn the cable adjuster 7 to obt...

Page 43: ...ks will interfere with safe running and immediately discolor painted surfaces Check the brake hoses and hose joints for cracks and oil leakage before riding Brake Fluid Level Check 1 Keep the motorcycle upright and place the handlebars straight 2 Check the brake fluid level by observing the lower limit lines on the front and rear brake fluid reservoirs When the brake fluid level is below the lower...

Page 44: ...ke Hose Removal and Installation in Section 4A Page 4A 8 3 Reinstall the removed parts Brake Pedal Height Inspection and Adjustment WARNING Do not adjust the brake pedal height when exhaust pipe is hot 1 Inspect the brake pedal height a between the pedal top face and footrest Adjust the brake pedal height if necessary Brake pedal height a Standard 60 70 mm 2 4 2 8 in 2 Remove the right footrest br...

Page 45: ...t Replace brake fluid Every 2 years Refer to Brake Fluid Replacement in Section 4A Page 4A 6 Air Bleeding from Brake Fluid Circuit Refer to Air Bleeding from Brake Fluid Circuit in Section 4A Page 4A 4 Rear Brake Light Switch Adjustment Refer to Rear Brake Light Switch Inspection and Adjustment in Section 4A Page 4A 4 Tire Inspection B940H20206017 Inspect tire Every 6 000 km 4 000 miles 12 months ...

Page 46: ...teering should be adjusted properly for smooth turning of handlebars and safe running Overtighten steering prevents smooth turning of the handlebars and too loose steering will cause poor stability 1 Check that there is no play in the front fork 2 Support the motorcycle so that the front wheel is off the ground with the wheel facing straight ahead grasp the lower fork tubes near the axle and pull ...

Page 47: ...iles 2 months and every 6 000 km 4 000 miles 12 months thereafter Check that all chassis bolts and nuts are tightened to their specified torque 1 Steering stem head nut 90 N m 9 0 kgf m 65 0 lbf ft 2 Handlebar clamp bolt 23 N m 2 3 kgf m 16 5 lbf ft I940H1020050 01 I940H1020051 01 b 2 a 1 I940H1020052 01 3 Front fork lower clamp bolt 23 N m 2 3 kgf m 16 5 lbf ft 4 Handlebar holder bolt 45 N m 4 5 ...

Page 48: ...iper mounting bolt 39 N m 3 9 kgf m 28 0 lbf ft 17 Air bleeder valve 7 5 N m 0 75 kgf m 5 5 lbf ft e 9 f 11 f 10 e 9 I940H1020056 02 g 12 I940H1020057 05 b 14 h 16 b 15 g 13 b 8 i 17 I940H1020058 03 8 Brake hose union bolt 23 N m 2 3 kgf m 16 5 lbf ft 17 Air bleeder valve 7 5 N m 0 75 kgf m 5 5 lbf ft 18 Rear brake caliper mounting bolt 54 N m 5 4 kgf m 39 0 lbf ft 19 Rear brake caliper bracket mo...

Page 49: ...ke master cylinder rod lock nut 18 N m 1 8 kgf m 13 0 lbf ft d 23 b 8 m 24 I940H1020062 04 25 Rear brake pedal boss bolt 16 N m 1 6 kgf m 11 5 lbf ft n 25 I940H1020069 02 Fastening part Tightening torque Note N m kgf m lbf ft Exhaust pipe bolt 23 2 3 16 5 Page 0B 3 Muffler connecting bolt 26 2 6 19 0 Page 0B 3 Muffler joint bolt 26 2 6 19 0 Page 0B 3 Muffler support bolt 26 2 6 19 0 Page 0B 3 Muff...

Page 50: ...UZUKI recommended product or Specification Note Brake fluid DOT 4 Page 0B 14 Grease SUZUKI SUPER GREASE A or equivalent P No 99000 25010 Page 0B 6 Thread lock cement THREAD LOCK CEMENT SUPER 1322 or equivalent P No 99000 32110 Page 0B 16 09900 20803 09900 20805 Thickness gauge Tire depth gauge Page 0B 5 Page 0B 5 Page 0B 6 Page 0B 16 09915 40620 09917 10410 Oil filter wrench Valve adjuster driver ...

Page 51: ...N EX 0 9 1 1 0 035 0 043 Valve head radial runout IN EX 0 03 0 001 Valve spring free length Inner 34 4 1 35 Outer 38 1 1 50 Valve spring tension Inner 58 66 N 5 9 6 7 kgf 13 1 15 0 lbs at length 27 56 mm 1 09 in Outer 135 155 N 13 5 15 5 kgf 30 4 34 9 lbs at length 31 06 mm 1 23 in Item Standard Limit Cam height IN 33 060 33 110 1 3016 1 3035 32 760 1 2898 EX 33 110 33 160 1 304 1 306 32 810 1 291...

Page 52: ...g groove width 1st 1 21 1 23 0 0476 0 0484 2nd 1 01 1 03 0 0398 0 0402 Oil 2 51 2 53 0 0988 0 0996 Piston ring thickness 1st 1 17 1 19 0 046 0 047 2nd 0 97 0 99 0 038 0 039 Piston pin bore I D 22 002 22 008 0 8662 0 8665 22 030 0 8673 Piston pin O D 21 993 22 000 0 8658 0 8661 21 980 0 8654 Item Standard Limit Conrod small end I D 22 010 22 018 0 8665 0 8668 22 040 0 8677 Conrod big end side clear...

Page 53: ...20 C 68 F Approx 2 45 kΩ 50 C 122 F Approx 0 811 kΩ 80 C 176 F Approx 0 318 kΩ 110 C 230 F Approx 0 142 kΩ Radiator cap valve opening pressure 108 137 kPa 1 1 1 4 kgf cm2 15 6 19 5 psi Cooling fan operating temperature OFF ON Approx 105 C 221 F ON OFF Approx 99 C 210 F Engine coolant type Use an antifreeze coolant compatible with aluminum radiator mixed with distilled water only at the ratio of 50...

Page 54: ...age 4 5 5 5 V TP sensor resistance Closed Approx 1 1 kΩ Opened Approx 4 3 kΩ TP sensor output voltage Closed Approx 1 1 V Opened Approx 4 3 V ECT sensor input voltage 4 5 5 5 V ECT sensor output voltage 0 1 4 85 V ECT sensor resistance Approx 2 45 kΩ at 20 C 68 F IAT sensor input voltage 4 5 5 5 V IAT sensor output voltage 0 1 4 6 V IAT sensor resistance Approx 2 5 kΩ at 20 C 68 F TO sensor resist...

Page 55: ...ance Primary 1 5 Ω Secondary 25 40 kΩ Ignition coil primary peak voltage 150 V and more 2 B Ground 1 W Bl Ground Generator coil resistance 0 2 0 6 Ω Generator maximum output Approx 425 W at 5 000 r min Generator no load voltage When engine is cold 80 V AC and more at 5 000 r min Regulated voltage 13 5 15 5 V at 5 000 r min Starter relay resistance 3 6 Ω Battery Type designation FTZ16 BS Capacity 1...

Page 56: ...Item Standard Limit Rear brake pedal height 60 70 2 4 2 8 Brake disc thickness Front 4 3 4 7 0 169 0 185 4 0 0 16 Rear 6 6 7 0 0 260 0 276 6 3 0 25 Brake disc runout Front Rear 0 30 0 012 Master cylinder bore Front 15 870 15 913 0 6248 0 6265 Rear 15 870 15 913 0 6248 0 6265 Master cylinder piston diam Front 15 827 15 854 0 6231 0 6242 Rear 15 827 15 854 0 6231 0 6242 Brake caliper cylinder bore F...

Page 57: ... kPa 2 50 kgf cm2 36 psi Rear 290 kPa 2 90 kgf cm2 42 psi Tire size Front 120 70ZR 18M C 59W tubeless Rear 200 50ZR 17M C 75W tubeless Tire type Front BRIDGESTONE G853 G Rear BRIDGESTONE G852 G Tire tread depth Recommended depth Front 1 6 mm 0 06 in Rear 2 0 mm 0 08 in Item Specification Note Fuel type Use only unleaded gasoline of at least 90 pump octane R 2 M 2 Gasoline containing MTBE Methyl Te...

Page 58: ... Oil drain plug 23 2 3 16 5 Crankcase bolt M6 Initial 6 0 6 4 5 Final 11 1 1 8 0 M8 Initial 15 1 5 11 0 Final 26 2 6 19 0 Oil gallery plug M8 18 1 8 13 0 M14 23 2 3 16 5 M16 35 3 5 25 5 Oil gallery plug Transmission oil jet M10 18 1 8 13 0 Oil pressure switch 14 1 4 10 0 Oil pressure switch lead wire bolt 1 5 0 15 1 0 Oil pump cover screw 1 3 0 13 1 0 Clutch sleeve hub nut 95 9 5 68 5 Clutch sprin...

Page 59: ...nal drive bevel gear bearing stopper 110 11 0 79 5 Final gear case bolt M8 23 2 3 16 5 M10 50 5 0 36 0 Final gear oil drain plug 23 2 3 16 5 Item N m kgf m lbf ft CKP sensor mounting bolt 5 5 0 55 4 0 Fuel pump mounting bolt 10 1 0 7 0 GP switch mounting bolt 6 5 0 65 4 5 TP sensor mounting screw 3 5 0 35 2 5 STP sensor mounting screw 3 5 0 35 2 5 IAT sensor mounting screw 1 3 0 13 1 0 ISC valve m...

Page 60: ...leeder valve Rear brake 7 5 0 75 5 5 Brake hose union bolt Front Rear 23 2 3 16 5 Brake lever pivot bolt 1 0 1 0 7 Brake lever pivot bolt lock nut 6 0 6 4 5 Front brake master cylinder holder bolt 10 1 0 7 0 Rear brake master cylinder mounting bolt 10 1 0 7 0 Rear master cylinder rod lock nut 18 1 8 13 0 Rear brake pedal boss bolt 16 1 6 11 5 Frame down tube bolt 50 5 0 36 0 Rear frame bolt 50 5 0...

Page 61: ...rked bolt N m kgf m lbf ft N m kgf m lbf ft 4 1 5 0 15 1 0 2 3 0 23 1 5 5 3 0 3 2 0 4 5 0 45 3 0 6 5 5 0 55 4 0 10 1 0 7 0 8 13 1 3 9 5 23 2 3 16 5 10 29 2 9 21 0 50 5 0 36 0 12 45 4 5 32 5 85 8 5 61 5 14 65 6 5 47 0 135 13 5 97 5 16 105 10 5 76 0 210 21 0 152 0 18 160 16 0 115 5 240 24 0 173 5 3 2 1 a a a I649G1030001 04 1 Conventional bolt 2 4 marked bolt 3 7 marked bolt ...

Page 62: ...0C 12 Service Data ...

Page 63: ...ve Actuator STVA Malfunction 1A 58 DTC C29 P1654 H L Secondary Throttle Position Sensor STPS Circuit Malfunction 1A 62 DTC C31 P0705 GP Switch Circuit Malfunction 1A 69 DTC C32 P0201 C33 P0202 Fuel Injector Circuit Malfunction 1A 71 DTC C40 P0505 P0506 P0507 ISC Valve Circuit Malfunction 1A 74 DTC C41 P0230 FP Relay Circuit Malfunction 1A 78 DTC C42 P1650 IG Switch Circuit Malfunction 1A 79 DTC C4...

Page 64: ...e Material 1C 11 Special Tool 1C 11 Engine Mechanical 1D 1 Schematic and Routing Diagram 1D 1 Throttle Cable Routing Diagram 1D 2 Diagnostic Information and Procedures 1D 3 Engine Mechanical Symptom Diagnosis 1D 3 Compression Pressure Check 1D 3 Repair Instructions 1D 4 Engine Components Removable with the Engine in Place 1D 4 Air Cleaner Element Removal and Installation 1D 6 Air Cleaner Element I...

Page 65: ... 1F 8 ECT Sensor Removal and Installation 1F 9 ECT Sensor Inspection 1F 9 Thermostat Removal and Installation 1F 9 Thermostat Inspection 1F 10 Water pump Components 1F 11 Water Pump Removal and Installation 1F 11 Water Pump Disassembly and Assembly 1F 13 Water Pump Related Parts Inspection 1F 15 Specifications 1F 16 Service Data 1F 16 Tightening Torque Specifications 1F 17 Special Tools and Equipm...

Page 66: ...Starter Torque Limiter Starter Clutch Removal and Installation 1I 10 Starter Torque Limiter Inspection 1I 12 Starter Clutch Inspection 1I 12 Starter Button Inspection 1I 13 Specifications 1I 14 Service Data 1I 14 Tightening Torque Specifications 1I 14 Special Tools and Equipment 1I 14 Recommended Service Material 1I 14 Special Tool 1I 15 Charging System 1J 1 Schematic and Routing Diagram 1J 1 Char...

Page 67: ...cautions 1 1 Engine Precautions Precautions Precautions for Engine B940H21000001 Refer to General Precautions in Section 00 Page 00 1 and Precautions for Electrical Circuit Service in Section 00 Page 00 2 ...

Page 68: ...erature is low injection time volume is increased INTAKE AIR TEMPERATURE SENSOR SIGNAL When intake air temperature is low injection time volume is increased HEATED OXYGEN SENSOR SIGNAL Air fuel ratio is compensated to the theoretical ratio from density of oxygen in exhaust gasses The compensation occurs in such a way that more fuel is supplied if detected air fuel ratio is lean and less fuel is su...

Page 69: ...n the LCD panel Motorcycle does not run CHEC The LCD panel indicates CHEC when no communication signal from the ECM is received for 3 seconds and more Signal Descriptions TIP OVER SENSOR SIGNAL FUEL SHUT OFF When the motorcycle tips over the tip over sensor sends a signal to the ECM Then this signal cuts OFF current supplied to the fuel pump fuel injectors and ignition coils OVER REV LIMITER SIGNA...

Page 70: ...Dealer Mode The defective function is memorized in the computer Use the special tool s coupler to connect to the mode select switch The memorized malfunction code is displayed on LCD DISPLAY panel Malfunction means that the ECM does not receive signal from the devices These affected devices are indicated in the code form CAUTION Before checking the malfunction code do not disconnect the ECM couple...

Page 71: ...2 3 4 5 GP switch ISC valve STVA Clutch lever position switch Headlight relay Starter relay Headlight Starter motor 10 A M Battery Side stand switch Neutral indicator light 15 A 15 A 15 A Side stand relay 30 A IG switch 10 A Engine stop switch Starter button ECM 27 24 10 42 51 34 36 11 18 21 31 9 5 4 3 2 22 12 20 17 6 19 G W B G B W G R Gr W O W Gr B Y R Dbr 43 W Bl 52 B 45 25 26 1 7 47 40 49 38 3...

Page 72: ...lenoid SOLP For E 33 10 Power source for back up 37 STVA signal STVA 1A 11 Power source 38 ISC valve signal ISC 2B 12 Sensor ground E2 39 13 ECM ground E1 40 ISC valve signal ISC 1B 14 41 General power ground E01 15 42 Fuel injector 1 16 43 Ignition coil 1 17 HO2 sensor heater HO2SH For E 02 19 24 33 44 STVA signal STVA 2B 18 Ignition switch signal 45 PAIR control solenoid valve PAIR 19 ECT sensor...

Page 73: ...nsor D Intake air temperature sensor IATS I Ignition coil 1 IG coil 1 N Gear position switch GP switch E PAIR control solenoid valve PAIR valve J Tip over sensor TOS O Ignition coil 2 IG coil 2 P R T Y V Z W S Q U A X I940H1110006 02 A ECM U Fuel pump relay P ISC valve ISCV V Fuel pump Q Intake air pressure sensor 2 IAPS W HO2 sensor HO2S For E 02 19 24 33 R Secondary throttle position sensor STPS...

Page 74: ...filter or fuel hose Clean or replace Defective fuel pump Replace Defective fuel pressure regulator Replace Defective fuel injectors Replace Defective fuel pump relay Replace Defective ECM Replace Open circuited wiring connection Check and repair Engine will not start or is hard to start Incorrect fuel air mixture TP sensor out of adjustment Adjust Defective fuel pump Replace Defective fuel pressur...

Page 75: ...ean Valve clearance out of adjustment Adjust Noisy engine Excessive valve chatter Too large valve clearance Adjust Weakened or broken valve springs Replace Worn tappet or cam surface Replace Worn or burnt camshaft journal Replace Noisy engine Noise seems to come from piston Worn down pistons or cylinders Replace Combustion chamber fouled with carbon Clean Worn piston pins or piston pin bore Replac...

Page 76: ... valve Adjust or replace Sucking air from throttle body joint Repair or replace Defective ECM Replace Imbalancing throttle valve synchronization Adjust Defective STP sensor or STVA Replace Engine runs poorly in high speed range Defective control circuit or sensor Low fuel pressure Repair or replace Defective TP sensor Replace Defective IAT sensors Replace Defective CKP sensor Replace Defective GP ...

Page 77: ... cooling system See radiator section Engine overheats Lean fuel air mixture Short circuited IAP sensors lead wires Repair or replace Short circuited IAT sensor lead wire Repair or replace Sucking air from intake pipe joint Repair or replace Defective fuel injectors Replace Defective ECT sensor Replace Engine overheats Other factors Ignition timing is too advanced due to defective timing advance sy...

Page 78: ...9D 5 2 Connect the special tool to the mode select switch coupler at the wiring harness Special tool A 09930 82720 Mode select switch 3 Start the engine or crank the engine for more than 4 seconds 4 Turn the special tool s switch ON 5 Check the DTC to determine the malfunction part Refer to DTC Table Page 1A 20 Special tool A 09930 82720 Mode select switch 6 After repairing the trouble turn OFF th...

Page 79: ...d in ECM memory can be checked by SDS Be sure to read Precautions for Electrical Circuit Service in Section 00 Page 00 2 before inspection and observe what is written there 1 Remove the right frame side cover Refer to Exterior Parts Removal and Installation in Section 9D Page 9D 5 2 Set up the SDS tools Refer to the SDS operation manual for further details Special tool A 09904 41010 SDS Set B 9956...

Page 80: ...the ignition switch OFF 8 Disconnect the SDS tool and install the right frame side cover Use of SDS Diagnosis Reset Procedures B940H21104003 NOTE The malfunction code is memorized in the ECM also when the lead wire coupler of any sensor is disconnected Therefore when a lead wire coupler has been disconnected at the time of diagnosis erase the stored malfunction history code using SDS 1 After repai...

Page 81: ...ions e g whether the engine was warm or not where the motorcycle was running or stopped when a malfunction was detected by checking the show data when trouble This show data when trouble function can record the maximum of two Diagnostic Trouble Codes in the ECM Also ECM has a function to store each show data when trouble for two different malfunctions in the order of occurrence as the malfunction ...

Page 82: ... Engine General Information and Diagnosis 1 Click Show data when trouble 1 to display the data 2 Click the drop down button 2 either Failure 1 or Failure 2 can be selected 1 I718H1110269 02 2 I718H1110270 01 ...

Page 83: ...vehicle which is not periodically brought in for service with no past data value having been saved if the data value of a good vehicle condition have been already saved as a master STD comparison between the same models helps to facilitate the troubleshooting 1 Remove the right frame side cover Refer to Exterior Parts Removal and Installation in Section 9D Page 9D 5 2 Set up the SDS tool Refer to ...

Page 84: ...temperature XX C Approx 3 000 r min Check the manifold absolute pressure XXX kPa I940H1110096 01 Throttle Slowly open Throttle Quick wide open Secondary throttle valve opens closes in according with the throttle valve opening PAIR control solenoid valve ON OFF in according with the throttle valve opens closes I940H1110097 02 ...

Page 85: ...dling 100 C Data of manifold absolute pressure operation at the time of starting Check the engine coolant temperature XX C Check the manifold absolute pressure XXX kPa Check the manifold absolute pressure XXX kPa I940H1110098 02 Check the manifold absolute pressure XXX kPa I940H1110099 01 ...

Page 86: ...etermine how changes have occurred with the passing of time and identify what problem is currently occurring NOTE With DTC not output if the manifold absolute pressure 2 and ISC valve stepping position are found to be abnormal than the data saved previously the possible cause may probably lie in the hardware side such as ISC valve air inlet hose 1 cylinder side crumple bend etc No DTC output Abnor...

Page 87: ...ant temperature sensor ECTS C17 P0105 Page 1A 29 Intake air pressure sensor 1 IAPS For 1 cylinder C21 P0110 H L Page 1A 46 Intake air temperature sensor IATS C23 P1651 H L Page 1A 51 Tip over sensor TOS C24 P0351 Page 1A 58 Ignition signal 1 IG coil 1 For 1 cylinder C25 P0352 Page 1A 58 Ignition signal 2 IG coil 2 For 2 cylinder C28 P1655 Page 1A 58 Secondary throttle valve actuator STVA C29 P1654...

Page 88: ...ed to 101 kPa 760 mmHg YES YES TP sensor The throttle opening value is fixed to full open position YES YES ECT sensor Engine coolant temperature value is fixed to 70 C 158 F Cooling fan is fixed on position YES YES IAT sensor Intake air temperature value is fixed to 25 C 77 F YES YES Ignition signal 1 fuel cut YES YES 2 cylinder can run 2 fuel cut YES YES 1 cylinder can run STV actuator When motor...

Page 89: ...Hesitation on acceleration No initial combustion Back fire After fire No combustion Lack of power Poor starting at Surging cold warm always Abnormal knocking Other Engine rpm jumps briefly Other Poor Idling Engine Stall when Poor fast Idle Immediately after start Abnormal idling speed Throttle valve is opened High Low r min Throttle valve is closed Unstable Load is applied Hunting r min to r min O...

Page 90: ...unction Code Detected Item Detected Failure Condition Check For C00 NO FAULT C12 CKP sensor The signal does not reach ECM for 3 sec or more after receiving the starter signal CKP sensor wiring and mechanical parts CKP sensor lead wire coupler connection P0335 C13 C17 IAP sensor The sensor should produce following voltage 0 1 V Sensor voltage 4 8 V In other than the above range C13 P0170 or C17 P01...

Page 91: ...s lower than specified value STP sensor circuit open or shorted to ground or VCC circuit open C31 Gear position signal When gear position switch voltage is as follows GP switch voltage 0 2 V for 6 sec and more When gear position switch voltage is neutral and switch voltage is as follows GP switch voltage 4 55 V for 6 sec and more If lower than the above value C31 P0705 is indicated GP switch wirin...

Page 92: ...r operation voltage is not supply to the oxgen heater circuit C44 P0135 is indicated HO2 sensor circuit open or shorted to the ground Battery voltage supply to the HO2 sensor C49 PAIR control solenoid valve PAIR control solenoid valve voltage is not input to ECM PAIR control solenoid valve lead wire coupler connection P1656 C60 Cooling fan relay Cooling fan relay signal is not input to ECM Cooling...

Page 93: ... DTC using SDS tool Refer to Use of SDS Diagnosis Reset Procedures Page 1A 13 Detected Condition Possible Cause The signal does not reach ECM for 3 sec or more after receiving the starter signal Metal particles or foreign material being stuck on the CKP sensor and rotor tip CKP sensor circuit open or short CKP sensor malfunction ECM malfunction Generator ECM CKP sensor E1 To the regulator rectifie...

Page 94: ...Exterior Parts Removal and Installation in Section 9D Page 9D 5 4 Check the CKP sensor coupler 1 for loose or poor contacts If OK then measure the CKP sensor resistance 5 Disconnect the CKP sensor coupler and measure the CKP sensor resistance Special tool A 09900 25008 Multi circuit tester set Tester knob indication Resistance Ω CKP sensor resistance 170 260 Ω Bl G Go to Step 2 Replace the CKP sen...

Page 95: ...mes and measure the highest peak voltage Is the voltage OK G W or B W wire of the harness side open or shorted to ground Loose or poor contacts on the CKP sensor coupler or ECM coupler Terminal 27 or 13 If the wires and connection are OK intermittent trouble or faulty ECM Recheck each terminal and wire harness for open circuit and poor connection Replace the ECM with a known good one and inspect i...

Page 96: ... IAP sensor voltage is not within the following range 0 1 V Sensor voltage 4 8 V NOTE Note that atmospheric pressure varies depending on weather conditions as well as altitude Take that into consideration when inspecting voltage Clogged vacuum passage between throttle body and IAP sensor Air being drawn from vacuum passage between throttle body and IAP sensor IAP sensor circuit open or shorted to ...

Page 97: ...ect the IAP sensor coupler 5 Turn the ignition switch ON 6 Measure the voltage between the R wire and ground If OK then measure the voltage between the R wire and B Br wire Special tool A 09900 25008 Multi circuit tester set Tester knob indication Voltage IAP sensor input voltage 4 5 5 5 V terminal R terminal Ground terminal R terminal B Br Is the voltage OK Go to Step 2 Loose or poor contacts on ...

Page 98: ...de coupler 2 Between P B and B Br wires 1 Between G B and B Br wires Special tool A 09900 25008 Multi circuit tester set B 09900 25009 Needle pointed probe set Tester knob indication Voltage IAP sensor output voltage Approx 2 6 V at idle speed 2 terminal P B terminal B Br 1 terminal G B terminal B Br IAP sensor 2 IAP sensor 1 Is the voltage OK Go to Step 3 Check the vacuum hose for crack or damage...

Page 99: ... Multi circuit tester set Tester knob indication Voltage Is the voltage OK R P B or B Br wire open or shorted to ground or poor 5 3 or 12 connection 2 R G B or B Br wire open or shorted to ground or poor 5 22 or 12 connection 1 If wire and connection are OK intermittent trouble or faulty ECM Recheck each terminal and wire harness for open circuit and poor connection Replace the ECM with a known go...

Page 100: ...tput voltage is not within the following range Difference between actual throttle opening and opening calculated by ECM is larger than specified value 0 1 V Sensor voltage 4 8 V TP sensor maladjusted TP sensor circuit open or short TP sensor malfunction ECM malfunction P0120 H Sensor voltage is higher than specified value TP sensor circuit is shorted to VCC or ground circuit is open L Sensor volta...

Page 101: ...ut voltage 4 Disconnect the TP sensor coupler 5 Turn the ignition switch ON 6 Measure the input voltage between the R wire and ground If OK then measure the input voltage between the R wire and B Br wire Special tool A 09900 25008 Multi circuit tester set Tester knob indication Voltage TP sensor input voltage 4 5 5 5 V terminal R terminal Ground terminal R terminal B Br Is the voltage OK Go to Ste...

Page 102: ...If OK then check the TP sensor lead wire continuity 4 Disconnect the TP sensor coupler 5 Check the continuity between the P B wire and R wire If the sound is not heard from the tester the circuit condition is OK Special tool A 09900 25008 Multi circuit tester set Tester knob indication Continuity 6 Disconnect the ECM coupler Refer to ECM Removal and Installation in Section 1C Page 1C 1 Go to Step ...

Page 103: ... continuity between the B Br wire B and terminal 12 Special tool A 09900 25008 Multi circuit tester set B 09900 25009 Needle pointed probe set Tester knob indication Continuity ECM coupler Harness side Is the continuity OK Go to Step 3 P B wire shorted to VCC or B Br wire open Step Action Yes No A B A B 12 21 I940H1110026 02 ...

Page 104: ...d wire continuity 4 Disconnect the TP sensor coupler 5 Check the continuity between the P B wire and ground Also check the continuity between the P B wire and B Br wire If the sound is not heard from the tester the circuit condition is OK Special tool A 09900 25008 Multi circuit tester set Tester knob indication Continuity 6 Disconnect the ECM coupler Refer to ECM Removal and Installation in Secti...

Page 105: ...tep 2 R and P B wire open or P B wire shorted to ground 3 1 Connect the ECM coupler 2 Turn the ignition switch ON 3 Measure the input voltage between the R wire and ground If OK the measure the input voltage between the R wire and B Br wire Special tool A 09900 25008 Multi circuit tester set Tester knob indication Voltage TP sensor input voltage 4 5 5 5 V terminal R terminal Ground terminal R term...

Page 106: ... 28630 TPS test wire harness TP sensor continuity Ω Infinity Terminal A Ground 5 If OK then measure the TP sensor resistance at the test harness terminals 6 Turn the throttle grip and measure the resistance TP sensor resistance Throttle valve is closed Approx 1 1 kΩ Throttle valve is opened Approx 4 3 kΩ Go to Step 3 Reset the TP sensor position correctly Replace the TP sensor with a new one Step ...

Page 107: ...l with turning the throttle grip open and close Special tool C 09900 28630 TPS test wire harness 09900 25008 Multi circuit tester set Tester knob indication Voltage TP sensor output voltage Throttle valve is closed Approx 1 1 V Throttle valve is opened Approx 4 3 V terminal P B terminal B Br Is the voltage OK P B R or B Br wire open or shorted to ground or poor 21 5 or 12 connection If wire and co...

Page 108: ... of SDS Diagnosis Reset Procedures Page 1A 13 Detected Condition Possible Cause C15 Output voltage is not with in the following range 0 1 V Sensor voltage 4 85 V ECT sensor circuit open or short ECT sensor malfunction ECM malfunction P0115 H Sensor voltage is higher than specified value ECT sensor circuit is open or ground circuit open L Sensor voltage is lower than specified value ECT sensor circ...

Page 109: ...nput voltage 4 Disconnect the ECT coupler and turn the ignition switch ON 5 Measure the input voltage between the B Bl wire and ground If OK then measure the input voltage between the B Bl wire and B Br wire Special tool A 09900 25008 Multi circuit tester set Tester knob indication Voltage ECT sensor input voltage 4 5 5 5 V terminal B Bl terminal Ground terminal B Bl terminal B Br Is the voltage O...

Page 110: ...T sensor coupler 5 Disconnect the ECM coupler Refer to ECM Removal and Installation in Section 1C Page 1C 1 6 Insert the needle pointed probes to the lead wire coupler 7 Check the continuity between the B Bl wire A and terminal 19 Also check the continuity between the B Br wire B and terminal 12 Special tool A 09900 25008 Multi circuit tester set B 09900 25009 Needle pointed probe set Tester knob ...

Page 111: ...the ECT sensor lead wire continuity 4 Disconnect the ECT sensor coupler 5 Check the continuity between the B Bl wire and ground If the sound is not heard from the tester the circuit condition is OK Special tool A 09900 25008 Multi circuit tester set Tester knob indication Continuity 6 Connect the ECT sensor coupler 7 Insert the needle pointed probes to the lead wire coupler 8 Turn the ignition swi...

Page 112: ... A 09900 25008 Multi circuit tester set Tester knob indication Resistance Ω ECT sensor resistance Approx 2 45 kΩ at 20 C 68 F Terminal Terminal NOTE Refer to ECT Sensor Inspection in Section 1C Page 1C 5 for details Is the resistance OK B Bl or B Br wire open or shorted to ground or poor 19 or 12 connection If wire and connection are OK intermittent trouble or faulty ECM Recheck each terminal and ...

Page 113: ... Use of SDS Diagnosis Reset Procedures Page 1A 13 Detected Condition Possible Cause C21 Output voltage is not with in the following range 0 1 V Sensor voltage 4 6 V IAT sensor circuit open or short IAT sensor malfunction ECM malfunction P0110 H Sensor voltage is higher than specified value IAT sensor circuit open or ground circuit open L Sensor voltage is lower than specified value IAT sensor circ...

Page 114: ...ct the IAT sensor coupler and turn the ignition switch ON 5 Measure the input voltage between the Dg wire terminal and ground If OK then measure the input voltage between the Dg wire terminal and B Br wire terminal Special tool A 09900 25008 Multi circuit tester set Tester knob indication Voltage IAT sensor input voltage 4 5 5 5 V terminal Dg terminal Ground terminal Dg terminal B Br Is the voltag...

Page 115: ... 5 Disconnect the ECM coupler Refer to ECM Removal and Installation in Section 1C Page 1C 1 6 Insert the needle pointed probes to the lead wire coupler 7 Check the continuity between the Dg wire A and terminal 2 Also check the continuity between the B Br wire B and terminal 12 Special tool A 09900 25008 Multi circuit tester set B 09900 25009 Needle pointed probe set Tester knob indication Continui...

Page 116: ...ensor lead wire continuity 4 Disconnect the IAT sensor coupler 5 Check the continuity between the Dg wire and ground If the sound is not heard from the tester the circuit condition is OK Special tool A 09900 25008 Multi circuit tester set Tester knob indication Continuity 6 Connect the IAT sensor coupler 7 Turn the ignition switch ON 8 Insert the needle pointed probes to the lead wire coupler Go t...

Page 117: ...er knob indication Resistance Ω IAT sensor resistance Approx 2 5 kΩ at 20 C 68 F Terminal Terminal NOTE IAT sensor resistance measurement method is the same way as that of the ECT sensor Refer to ECT Sensor Inspection in Section 1C Page 1C 5 Is the resistance OK Dg or B Br wire open or shorted to ground or poor 2 or 12 connection If wire and connection are OK intermittent trouble or faulty ECM Rec...

Page 118: ... 1A 13 Detected Condition Possible Cause C23 The sensor voltage should be the following for 2 sec and more after ignition switch is turned ON 0 2 V Sensor voltage 4 6 V TO sensor circuit open or short TO sensor malfunction ECM malfunction P1651 H Sensor voltage is higher than specified value TO sensor circuit is open or ground circuit open L Sensor voltage is lower than specified value TO sensor c...

Page 119: ... for loose or poor contacts If OK then measure the TO sensor resistance 4 Measure the resistance between terminal A and terminal B Special tool A 09900 25008 Multi circuit tester set Tester knob indication Resistance Ω TO sensor resistance 16 5 22 3 kΩ Terminal A Terminal B Is the resistance OK Go to Step 2 Replace the TO sensor with a new one Refer to TO Sensor Removal and Installation in Section...

Page 120: ...re continuity 4 Disconnect the TO sensor coupler 5 Check the continuity between the R wire A and Br wire B If the sound is not heard from the tester the circuit condition is OK Special tool A 09900 25008 Multi circuit tester set Tester knob indication Continuity 6 Disconnect the ECM coupler Refer to ECM Removal and Installation in Section 1C Page 1C 1 7 Insert the needle pointed probes to the lead...

Page 121: ...he continuity between B Br wire C and terminal 12 Special tool A 09900 25008 Multi circuit tester set B 09900 25009 Needle pointed probe set Tester knob indication Continuity ECM coupler Harness side Is the continuity OK Go to Step 2 Br wire shorted to VCC or B Br wire open Step Action Yes No A B C B 12 20 I940H1110043 03 ...

Page 122: ...sensor coupler 5 Check the continuity between the Br wire A and ground Also check the continuity between the Br wire A and B Br wire B If the sound is not heard from the tester the circuit condition is OK Special tool A 09900 25008 Multi circuit tester set Tester knob indication Continuity 6 Disconnect the ECM coupler Refer to ECM Removal and Installation in Section 1C Page 1C 1 7 Insert the needl...

Page 123: ...he continuity between Br wire A and terminal 20 Special tool A 09900 25008 Multi circuit tester set B 09900 25009 Needle pointed probe set Tester knob indication Continuity ECM coupler Harness side Is the continuity OK Go to Step 2 R or Br wire open or Br wire shorted to ground Step Action Yes No A A C 5 20 B I940H1110044 02 ...

Page 124: ...sure the voltage when it is leaned 65 and more to left and right from the horizontal level TO sensor voltage Leaning 3 7 4 4 V terminal Br terminal B Br Is the voltage OK R Br or B Br wire open or shorted to ground or poor 5 20 or 12 connection If wire and connection are OK intermittent trouble or faulty ECM Recheck each terminal and wire harness for open circuit and poor connection Replace the EC...

Page 125: ...he terminal of the ECM coupler with a needle pointed tester probe to prevent terminal damage NOTE After repairing the trouble clear the DTC using SDS tool Refer to Use of SDS Diagnosis Reset Procedures Page 1A 13 Detected Condition Possible Cause The operation voltage does not reach the STVA ECM does not receive communication signal from the STVA STVA can not operate properly STVA malfunction STVA...

Page 126: ...n 1D Page 1D 7 2 Check the STVA lead wire coupler 1 for loose or poor contacts 3 Turn the ignition switch ON to check the STV operation STVA operating order Full open Is the operation OK Go to Step 2 Loose or poor contacts on the coupler Open or short circuit in the B Lg P W W B or G wire If wire and connection are OK go to Step 2 1 I940H1110048 02 I705H1110063 01 ...

Page 127: ... indication Resistance Ω STVA resistance Approx 7 Ω Terminal A Terminal B Terminal C Terminal D Is the resistance OK B Lg P W G and W B wire open or shorted to ground or poor 35 37 44 and 46 connection If wire and connection are OK intermittent trouble or faulty ECM Recheck each terminal and wire harness for open circuit and poor connection Replace the ECM with a known good one and inspect it agai...

Page 128: ...the SDS tool Refer to the SDS operation manual for further details 2 Turn the ignition switch ON 3 Click Secondary throttle operating control 1 4 Click each button 2 At this time if an operation sound is heard from the STVA the function is normal 1 I940H1110094 02 2 2 I940H1110101 02 ...

Page 129: ...ible Cause C29 Output voltage is not within the following range Difference between actual throttle opening and opening calculated by ECM is larger than specified value 0 1 V Sensor voltage 4 83 V STP sensor maladjusted STP sensor circuit open or short STP sensor malfunction ECM malfunction STP sensor circuit shorted to VCC or ground circuit open P1654 H Sensor voltage is higher than specified valu...

Page 130: ...poor contacts If OK then measure the STP sensor input voltage 5 Disconnect the STP sensor coupler 6 Turn the ignition switch ON 7 Measure the input voltage between the R wire A and ground Also measure the voltage between the R wire A and B Br wire B Special tool A 09900 25008 Multi circuit tester set Tester knob indication Voltage STP sensor input voltage 4 5 5 5 V terminal R terminal Ground termi...

Page 131: ...K then check the STP sensor lead wire continuity 4 Disconnect the STP sensor coupler 5 Check the continuity between the Y W wire A and R wire B If the sound is not heard from the tester the circuit condition is OK Special tool A 09900 25008 Multi circuit tester set Tester knob indication Continuity 6 Disconnect the ECM coupler Refer to ECM Removal and Installation in Section 1C Page 1C 1 Go to Ste...

Page 132: ... continuity between the B Br wire C and terminal 12 Special tool A 09900 25008 Multi circuit tester set B 09900 25009 Needle pointed probe set Tester knob indication Continuity ECM couplers Harness side Is the continuity OK Go to Step 3 Y W wire shorted to VCC or B Br wire open Step Action Yes No A C A 4 12 B I940H1110053 01 ...

Page 133: ...re continuity 4 Disconnect the STP sensor coupler 5 Check the continuity between the Y W wire A and ground Also check the continuity between the Y W wire A and B Br wire B If the sound is not heard from the tester the circuit condition is OK Special tool A 09900 25008 Multi circuit tester set Tester knob indication Continuity 6 Disconnect the ECM coupler Refer to ECM Removal and Installation in Se...

Page 134: ...ep 2 R or Y W wire open or Y W wire shorted to ground 3 1 Connect the ECM coupler 2 Turn the ignition switch ON 3 Measure the input voltage between the R wire C and ground Also measure the input voltage between the R wire C and B Br wire B Special tool A 09900 25008 Multi circuit tester set Tester knob indication Voltage STP sensor input voltage 4 5 5 5 V terminal R terminal Ground terminal R term...

Page 135: ...ion 1C Page 1C 6 Special tool B 09900 25008 Multi circuit tester set Tester knob indication Voltage STP sensor output voltage Secondary throttle valve is closed Approx 0 6 V Secondary throttle valve is opened Approx 4 2 V terminal Y W terminal B BW Is the voltage OK R Y W or B Br wire open or shorted to ground or poor 5 14 or 12 connection If wire and connection are OK intermittent trouble or faul...

Page 136: ...Condition Possible Cause No Gear Position switch voltage GP switch voltage is not within the following range GP switch voltage 0 2 V for 6 sec and more When gear position switch voltage is neutral and switch voltage is as follows GP switch voltage 4 55 V for 6 sec and more GP switch circuit open or short GP switch malfunction ECM malfunction 1 5 4 2 3 ECM GP E1 B W Br B Bl P B W GP switch Side sta...

Page 137: ...arshift lever from 1st to Top Special tool A 09900 25008 Multi circuit tester set B 09900 25009 Needle pointed probe set Tester knob indication Voltage GP switch voltage 0 6 V and more terminal P terminal B W Is the voltage OK P wire open or shorted to ground If wire and connection are OK intermittent trouble or faulty ECM Recheck each terminal and wire harness for open circuit and poor connection...

Page 138: ...epairing the trouble clear the DTC using SDS tool Refer to Use of SDS Diagnosis Reset Procedures Page 1A 13 Detected Condition Possible Cause CKP signal is produced but fuel injector signal is interrupted by 8 times or more continuity Injector circuit open or short Injector malfunction ECM malfunction ECM Fuel pump relay Fuel injector 2 cylinder 1 cylinder Y R 2 1 42 51 To the engine stop switch G...

Page 139: ... for loose or poor contacts If OK then measure the injector resistance 4 Disconnect the injector coupler and measure the resistance between terminals Special tool A 09900 25008 Multi circuit tester set Tester knob indication Resistance Ω Injector resistance 11 13 Ω at 23 C 73 F Terminal Terminal Go to Step 2 Replace the injector with a new one Refer to Throttle Body Disassembly and Assembly in Sec...

Page 140: ... for 3 seconds after ignition switch is turned ON Special tool A 09900 25008 Multi circuit tester set Tester knob indication Voltage Injector voltage Battery voltage terminal Y R terminal Ground Is the voltage OK Gr W wire open or shorted to ground or poor 42 connection 1 cylinder Gr B wire open or shorted to ground or poor 51 connection 2 cylinder If wire and connection are OK intermittent troubl...

Page 141: ...edle pointed tester probe to prevent terminal damage NOTE After repairing the trouble clear the DTC using SDS tool Refer to Use of SDS Diagnosis Reset Procedures Page 1A 13 Detected Condition Possible Cause C40 P0505 The circuit voltage of motor drive is unusual ISC valve circuit open or shorted to the ground C40 P0506 Idle speed is lower than the desired idle speed Air passage clogged ISC valve i...

Page 142: ... ECM coupler Refer to ECM Removal and Installation in Section 1C Page 1C 1 4 Check the continuity between terminal A and 47 terminal B and 49 terminal C and 40 terminal D and 38 Special tool A 09900 25008 Multi circuit tester set B 09900 25009 Needle pointed probe set Tester knob indication Continuity ECM couplers Harness side Is the continuity OK Go to Step 2 B R B Bl B G or Dg wire open 1 I940H1...

Page 143: ...erminal Ground 3 If OK then measure the resistance between the B R wire A and B Bl wire B and between the B G wire C and Lg wire D ISC valve resistance Approx 20 Ω at 20 C 68 F Terminal A Terminal B Terminal C Terminal D Is the resistance OK If wire is OK intermittent trouble or faulty ECM Replace the ISC valve with a new one Refer to Throttle Body Disassembly and Assembly in Section 1D Page 1D 14...

Page 144: ...e the Spec 2 slowly 4 Check that the Desired idle speed 3 is nearly equal to the Spec 2 Also check that the number of steps 5 in the ISC valve position increases Check 3 1 Click the button 6 and increase the Spec 2 to 1 300 rpm slowly 2 Check that the Desired idle speed 3 is nearly equal to the Spec 2 Also check that the number of steps 5 in the ISC valve position increases NOTE Be careful not to ...

Page 145: ...ring the trouble clear the DTC using SDS tool Refer to Use of SDS Diagnosis Reset Procedures Page 1A 13 Detected Condition Possible Cause No voltage is applied to fuel pump Fuel pump relay circuit open or short Fuel pump relay malfunction ECM malfunction ECM Side stand relay Engine stop switch Fuel pump relay Fuel pump Ignition switch M Y R VM FP relay R BI O W Y B To the side stand switch 9 34 I9...

Page 146: ...e FP relay coupler 1 for loose or poor contacts If OK then check the FP relay Refer to Fuel Pump Relay Inspection in Section 1G Page 1G 6 Is the FP relay OK Y B or O W wire open or shorted or poor 34 connection Y R or R Bl wire open shorted or poor 9 connection If wire and connection are OK intermittent trouble or faulty ECM Recheck each terminal and wire harness for open circuit and poor connecti...

Page 147: ...etected Condition Possible Cause C44 P0130 HO2 sensor output voltage is not input to ECM during engine operation and running condition Sensor voltage 0 55 V HO2 sensor circuit is open or shorted to the power source C44 P0135 The heater can not operate so that heater operation voltage is not supplied to the oxygen heater circuit Heated circuit is open or shorted to the ground Battery voltage is not...

Page 148: ... continuity 4 Disconnect the HO2 sensor coupler 5 Check the continuity between the Br wire and ground Also check the continuity between Br wire and B Br wire If the sound is not hard from the tester the circuit condition is OK Special tool A 09900 25008 Multi circuit tester set Tester knob indication Continuity 6 Disconnect the ECM coupler Refer to ECM Removal and Installation in Section 1C Page 1...

Page 149: ...inuity between the B Br wire A and terminal 12 Special tool A 09900 25008 Multi circuit tester set B 09900 25009 Needle pointed probe set Tester knob indication Continuity ECM couplers Harness side Is the continuity OK Go to Step 2 W G wire shorted to ground or Br or B Br wire open Step Action Yes No A B A B 6 12 I940H1110075 02 ...

Page 150: ...Section 9D Page 9D 5 Next pinch the PAIR hose 1 with a proper hose clamps 6 Measure the HO2 sensor output voltage while holding the engine speed at 4 000 r min HO2 sensor output voltage at 4 000 r min 0 6 V and more terminal Br terminal B Br Is the voltage OK Br or B Br wire open or shorted to the power source or poor 6 or 12 connection If wire and connection are OK intermittent trouble or faulty ...

Page 151: ...r for loose or poor contacts If OK then measure the HO2 sensor resistance 4 Disconnect the HO2 sensor coupler and measure the resistance between terminals CAUTION Temperature of the sensor affects resistance value largely Make sure that the sensor heater is in correct temperature Special tool A 09900 25008 Multi circuit tester set Tester knob indication Resistance Ω HO2 heater resistance 4 0 5 0 Ω...

Page 152: ...B 09900 25009 Needle pointed probe set Tester knob indication Voltage Heater voltage Battery voltage terminal B R terminal Ground Is the voltage OK B G or B R wire open or shorted to the ground or poor 17 connection Recheck each terminal and wire harness for open circuit and poor connection If wire and connection are OK intermittent trouble or faulty ECM Replace the ECM with a known good one and i...

Page 153: ...e trouble clear the DTC using SDS tool Refer to Use of SDS Diagnosis Reset Procedures Page 1A 13 Detected Condition Possible Cause PAIR control solenoid valve ampere is not input to ECM PAIR control solenoid valve circuit open or short PAIR control solenoid valve malfunction ECM malfunction ECM Side stand relay Ignition switch Engine stop switch R Y To the side stand switch SOL 45 O B PAIR control...

Page 154: ...rake reservoir tank 1 by removing the mounting bolt 4 Check the PAIR control solenoid valve coupler 2 for loose or poor contacts If OK then measure the PAIR control solenoid valve resistance 5 Disconnect the PAIR control solenoid valve coupler Go to Step 2 Replace the PAIR control solenoid with a new one Refer to PAIR Control Solenoid Valve Removal and Installation in Section 1B Page 1B 9 1 I940H1...

Page 155: ...ch ON 2 Measure the voltage between the R Y wire and ground Special tool A 09900 25008 Multi circuit tester set Tester knob indication Voltage PAIR control solenoid valve voltage Battery voltage terminal O B terminal Ground Is the voltage OK R Y wire open or shorted to ground or poor 45 connection failure If wire and connection are OK intermittent trouble or faulty ECM Recheck each terminal and wi...

Page 156: ...S tool Refer to the SDS operation manual for further details 2 Turn the ignition switch ON 3 Click PAIR Sol operating control 1 4 Click each button 2 At this time if an operating sound is heard from the PAIR control solenoid valve the function is normal 1 I940H1110110 02 2 I940H1110111 04 ...

Page 157: ...nal damage NOTE After repairing the trouble clear the DTC using SDS tool Refer to Use of SDS Diagnosis Reset Procedures Page 1A 13 Detected Condition Possible Cause Cooling fan relay signal is not input to ECM Cooling fan relay circuit open or short ECM malfunction ECM Side stand relay Ignition switch FAR 24 G R O B Cooling fan relay Cooling fan motor To the side stand switch I940H1110117 01 1 18 ...

Page 158: ...eck the cooling fan relay 1 coupler for loose or poor contacts If OK then inspection the cooling fan relay Refer to Cooling Fan Inspection in Section 1F Page 1F 8 Is the cooling fan relay OK O B and G R wire open or shorted to ground or poor 24 connection If wire and connection are OK intermittent trouble or faulty ECM Recheck each terminal and wire harness for open circuit and poor connection Rep...

Page 159: ... cooling fan relay and cooling fan motors are operated the function is normal NOTE Cooling fan relay and cooling fan motor operation can be checked until the engine coolant temperature is less than 100 C 212 F after starting the engine 5 Click the Stop 3 to check the operation properly 2 I940H1110113 02 3 I940H1110114 03 ...

Page 160: ...airing the trouble clear the DTC using SDS tool Refer to Use of SDS Diagnosis Reset Procedures Page 1A 13 Detected Condition Possible Cause EVAP system purge control valve voltage is not input to ECM EVAP system purge control valve circuit open or short EVAP system purge control valve malfunction ECM malfunction ECM SOLP Dbr O W Engine stop switch Ignition switch To the side stand switch Side stan...

Page 161: ...valve resistance 4 Disconnect the EVAP system purge control valve coupler 5 Measure the resistance between terminals Special tool A 09900 25008 Multi circuit tester set Tester knob indication Resistance Ω EVAP system purge control valve resistance Approx 32 Ω at 20 C 68 F Terminal Terminal Is the resistance OK Go to Step 2 Replace the EVAP system purge control with a new one Refer to Evaporative E...

Page 162: ...et Tester knob indication Voltage EVAP system purge control valve voltage Battery voltage terminal O W terminal Ground Is the voltage OK W Y wire open or shorted to ground or poor 36 connection failure If wire and connection are OK intermittent trouble or faulty ECM Recheck each terminal and wire harness for open circuit and poor connection Replace the ECM with a known good one and inspect it agai...

Page 163: ...T sensor output voltage 0 1 4 85 V ECT sensor resistance Approx 2 45 kΩ at 20 C 68 F IAT sensor input voltage 4 5 5 5 V IAT sensor output voltage 0 1 4 6 V IAT sensor resistance Approx 2 5 kΩ at 20 C 68 F TO sensor resistance 16 5 22 3 kΩ TO sensor voltage Normal 0 4 1 4 V Leaning 3 7 4 4 V When leaning 65 GP switch voltage 0 6 V and more From 1st to Top Injector voltage Battery voltage Ignition c...

Page 164: ... 1A 35 Page 1A 36 Page 1A 37 Page 1A 38 Page 1A 38 Page 1A 39 Page 1A 40 Page 1A 40 Page 1A 42 Page 1A 43 Page 1A 44 Page 1A 45 Page 1A 45 Page 1A 47 Page 1A 48 Page 1A 49 Page 1A 50 Page 1A 50 Page 1A 52 Page 1A 53 Page 1A 54 Page 1A 55 Page 1A 56 Page 1A 57 Page 1A 31 Page 1A 36 Page 1A 38 Page 1A 43 Page 1A 45 Page 1A 48 Page 1A 50 Page 1A 54 Page 1A 56 Page 1A 57 Page 1A 65 Page 1A 67 Page 1A ...

Page 165: ...applicable emission limits With varying engine conditions all of the fuel injection volumes are precisely controlled by the programmed injection maps in the ECM to reduce CO NOX and HC Adjusting interfering with improper replacement or resetting of any of the fuel injection components may adversely affect injection performance and cause the motorcycle to exceed the exhaust emission level limits 1 ...

Page 166: ...ankcase emissions into the atmosphere Blow by gas in the engine is constantly drawn into the crankcase which is returned to the combustion chamber through the PCV breather hose air cleaner chamber and throttle body C D E A B 2 1 I940H1120019 01 1 PAIR control solenoid valve A Fresh air C Exhaust gas E Return oil 2 PCV hose B Fuel Air mixture D Blow by gas ...

Page 167: ... is operated by the ECM which is controlled according to the signals from TPS ECTS IATS IAPS and CKPS ISC valve adjusts the bypass air volume of the throttle body to control engine idling speed with various sensor signals by varying engine running conditions and the idling control contributes to reduce exhaust emission level A B 7 7 6 8 3 1 2 2 4 5 I940H1120020 03 1 PAIR control solenoid valve 6 H...

Page 168: ...chaser or while it is in use or The use of the vehicle after such device or element of design has been removed or rendered inoperative by any person Among Those Acts Presumed to Constitute Tampering are the Acts Listed Below Removing or puncturing the muffler baffles header pipes screen type spark arrester if equipped or any other component which conducts exhaust gases Removing or puncturing the a...

Page 169: ...1005 1 2 3 4 5 6 7 8 9 12 10 11 C D A B I940H1120018 01 1 Fuel vapor separator 7 EVAP canister A Fuel 2 Fuel tank 8 Purge hose B HC vapor 3 Fuel pump 9 EVAP purge control valve C Fresh air 4 Fuel feed hose 10 Throttle body D Vacuum 5 Surge hose 11 IAP sensor 6 Fuel shut off valve 12 3 way connector ...

Page 170: ...agram B940H21202001 a a a a a 1 2 3 4 B A 2 5 A A FWD FWD FWD 1 3 2 I940H1120001 03 1 PAIR control solenoid valve 5 PAIR reed valve 2 PAIR hose Rear Pass the PAIR hose Rear under the fuel hose and wiring harness A Matching mark White 3 Fuel hose B Matching mark Yellow 4 Wiring harness a 0 ...

Page 171: ... 1 EVAP canister A Face the white mark on the hose to backward 2 Fuel shut off valve B Face the tip of the clip to backward 3 Purge control valve C Face the white mark on the hose to upper 4 Surge hose D Face the white mark on the hose to outside 5 Purge hose E Face the tip of the clip to outside 6 Cap F Face the tip of the clip to downward ...

Page 172: ...xygen Sensor HO2S Inspection B940H21206002 Refer to DTC C44 P0130 P0135 HO2 Sensor HO2S Circuit Malfunction For E 02 19 24 33 in Section 1A Page 1A 80 PAIR Reed Valve Removal and Installation B940H21206003 Removal 1 Remove the fuel tank Refer to Fuel Tank Removal and Installation in Section 1G Page 1G 9 2 Remove the air cleaner chamber Refer to Air Cleaner Chamber Removal and Installation in Secti...

Page 173: ...on B940H21206005 PAIR Hose 1 Remove the fuel tank Refer to Fuel Tank Removal and Installation in Section 1G Page 1G 9 2 Remove the air cleaner chamber Refer to Air Cleaner Chamber Removal and Installation in Section 1D Page 1D 7 3 Inspect the PAIR hoses 1 for wear or damage If it is worn or damaged replace the PAIR hose with a new one Refer to PAIR System Hose Routing Diagram Page 1B 6 4 Reinstall...

Page 174: ...sistance between the terminals of the PAIR control solenoid valve Special tool 09900 25008 Multi circuit tester set Tester knob indication Resistance Ω PAIR control solenoid valve resistance 18 22 Ω at 20 30 C 68 86 F 5 Reinstall the PAIR control solenoid valve Refer to PAIR Control Solenoid Valve Removal and Installation Page 1B 9 Crankcase Breather PCV Hose Inspection B940H21206006 Inspect the c...

Page 175: ...the EVAP hose as shown in the EVAP canister hose routing diagram Refer to EVAP Canister Hose Routing Diagram Only for E 33 Page 1B 7 Installation 1 Install the EVAP hose as shown in the EVAP canister hose routing diagram Refer to EVAP Canister Hose Routing Diagram Only for E 33 Page 1B 7 2 Reinstall the removed parts EVAP Canister Removal 1 Remove the right frame side cover Refer to Exterior Parts...

Page 176: ...Installation Only for E 33 Page 1B 11 3 Disconnect the surge hoses 2 4 Remove the fuel shut off valve 3 Installation 1 Install the fuel shut off valve as shown in the EVAP canister hose routing diagram Refer to EVAP Canister Hose Routing Diagram Only for E 33 Page 1B 7 2 Reinstall the removed parts Evaporative Emission Control System Inspection For E 33 only B940H21206009 Refer to Evaporative Emis...

Page 177: ... air flows out the solenoid valve is in normal condition 3 Check the resistance between the terminals of the EVAP system purge control solenoid valve If the resistance is not within the standard range replace the EVAP system purge control solenoid valve with a new one Special tool A 09900 25008 Multi circuit tester set Tester knob indication Resistance Ω EVAP system purge control solenoid valve re...

Page 178: ...n this section refer to Tightening Torque List in Section 0C Page 0C 8 Special Tools and Equipment Recommended Service Material B940H21208001 Special Tool B940H21208002 A I823H1120038 02 Item Specification Note HO2 sensor output voltage 0 4 V and less at idle speed 0 6 V and more at 3 000 r min PAIR solenoid valve resistance 18 22 Ω at 20 30 C 68 86 F EVAP system purge control solenoid valve resis...

Page 179: ...fer to Exterior Parts Removal and Installation in Section 9D Page 9D 5 2 Remove the battery lead wire 3 Disconnect the ECM couplers 1 and remove the ECM 2 Installation Install the ECM in the reverse order of removal CKP Sensor Inspection B940H21306002 Refer to CKP Sensor Inspection in Section 1H Page 1H 8 CKP Sensor Removal and Installation B940H21306003 Removal 1 Remove the generator cover Refer ...

Page 180: ...move the TP sensor 2 with the special tool NOTE Prior to disassembly mark each sensor s original position with a paint or scribe for accurate reinstallation Special tool 09930 11950 Torx wrench Installation 1 Apply thin coat of the engine oil to the O ring CAUTION Replace the O ring with a new one 2 With the throttle valve fully closed install the TP sensor 1 and tighten the TP sensor mounting scr...

Page 181: ...screw to the specified torque Tightening torque TP sensor mounting screw 3 5 N m 0 35 kgf m 2 5 lbf ft 6 Turn off the engine and install the right air cleaner box Refer to Air Cleaner Element Removal and Installation in Section 1D Page 1D 6 IAT Sensor Removal and Installation B940H21306009 Removal 1 Remove the fuel tank Refer to Fuel Tank Removal and Installation in Section 1G Page 1G 9 2 Disconne...

Page 182: ...mostat case 3 along with the water hose 6 Remove the ECT sensor 4 CAUTION Take special care when handling the ECT sensor It may cause damage if it gets an excessive impact Installation Install the ECT sensor in the reverse order of removal Pay attention to the following points Tighten the ECT sensor 1 to the specified torque CAUTION Use the new gasket washer 2 to prevent engine coolant leakage Tig...

Page 183: ...r If the ECT sensor ohmic valve does not change in the proportion indicated replace it with a new one CAUTION Take special care when handling the ECT sensor It may cause damage if it gets an excessive sharp impact Do not contact the ECT sensor and the column thermometer with a pan Special tool A 09900 25008 Multi circuit tester set Tester knob indication Resistance Ω Temperature sensor specificati...

Page 184: ...4 Refer to DTC C29 P1654 H L Secondary Throttle Position Sensor STPS Circuit Malfunction in Section 1A Page 1A 62 STP Sensor Adjustment B940H21306015 Adjust the STP sensor in the following procedures 1 Move the each air cleaner box and lift and support the air cleaner chamber Refer to STP Sensor Removal and Installation Page 1C 7 NOTE It is unnecessary to remove the sensors and hoses 2 Disconnect ...

Page 185: ...TP sensor mounting screw 3 5 N m 0 35 kgf m 2 5 lbf ft 8 Disconnect the special tool and reinstall the removed parts STP Sensor Removal and Installation B940H21306016 Removal 1 Turn the ignition switch OFF 2 Move the each air cleaner box and lift and support the air cleaner chamber Refer to Air Cleaner Chamber Removal and Installation in Section 1D Page 1D 7 NOTE It is unnecessary to remove the se...

Page 186: ...Inspection B940H21306017 Refer to DTC C28 P1655 Secondary Throttle Valve Actuator STVA Malfunction in Section 1A Page 1A 58 STV Actuator Removal and Installation B940H21306018 Refer to Throttle Body Disassembly and Assembly in Section 1D Page 1D 14 CAUTION Never remove the STVA from the throttle body The STVA and throttle body are available only as an assembly ISC Valve Inspection B940H21306019 Re...

Page 187: ...40H21306022 Refer to DTC C44 P0130 P0135 HO2 Sensor HO2S Circuit Malfunction For E 02 19 24 33 in Section 1A Page 1A 80 HO2 Sensor Removal and Installation B940H21306023 Refer to Heated Oxygen Sensor HO2S Removal and Installation in Section 1B Page 1B 8 GP Switch Inspection B940H21306024 Refer to Side stand Ignition Interlock System Parts Inspection in Section 1I Page 1I 8 GP Switch Removal and In...

Page 188: ...utput voltage 0 1 4 6 V IAT sensor resistance Approx 2 5 kΩ at 20 C 68 F TO sensor resistance 16 5 22 3 kΩ TO sensor voltage Normal 0 4 1 4 V Leaning 3 7 4 4 V When leaning 65 GP switch voltage 0 6 V and more From 1st to Top Injector voltage Battery voltage STP sensor input voltage 4 5 5 5 V STP sensor output voltage Closed Approx 0 6 V Opened Approx 4 2 V STV actuator resistance Approx 7 Ω HO2 se...

Page 189: ...recommended product or Specification Note Grease SUZUKI SUPER GREASE A or equivalent P No 99000 25010 Page 1C 2 Page 1C 8 09900 25008 09900 28630 Multi circuit tester set TPS test wire harness Page 1C 5 Page 1C 7 Page 1C 7 09930 11950 09930 82720 Torx wrench Mode select switch Page 1C 2 Page 1C 2 Page 1C 3 Page 1C 7 Page 1C 7 Page 1C 8 Page 1C 3 ...

Page 190: ...1D 1 Engine Mechanical Engine Engine Mechanical Schematic and Routing Diagram ...

Page 191: ...left 3 Front brake hose C Pass the throttle cables between the frame bridge and radiator conduction hose 4 Clutch cable D Pass the clutch cable behind the frame down tube 5 Cable guide E Pass the clutch cable inside the engine mounting plate 6 Gearshift rod F Adjust the clutch cable play on engine side adjuster with the lever side adjuster thread 3 5 mm 0 12 0 20 in left a 1 mm 0 04 in 4 5 N m 0 4...

Page 192: ... battery is in fully charged condition 1 Warm up the engine 2 Lift and support for 1 cylinder the fuel tank Refer to Fuel Tank Removal and Installation in Section 1G Page 1G 9 3 Remove the right frame head cover for 2 cylinder Refer to Exterior Parts Removal and Installation in Section 9D Page 9D 5 4 Remove the all spark plug caps and spark plug 1 Refer to Spark Plug Cap and Spark Plug Removal and...

Page 193: ...lement Removal and Installation Page 1D 6 Oil filter Refer to Engine Oil and Filter Replacement in Section 0B Page 0B 8 Refer to Engine Oil and Filter Replacement in Section 0B Page 0B 8 Oil pump Refer to Oil Pump Removal and Installation in Section 1E Page 1E 9 Refer to Oil Pump Inspection in Section 1E Page 1E 10 Refer to Oil Pump Removal and Installation in Section 1E Page 1E 9 Throttle body Re...

Page 194: ...e 1E 4 Refer to Oil Pressure Regulator Removal and Installation in Section 1E Page 1E 3 Oil pump drive gear Refer to Oil Pump Removal and Installation in Section 1E Page 1E 9 Refer to Oil Pump Removal and Installation in Section 1E Page 1E 9 Gearshift shaft Refer to Gearshift Shaft Gearshift Cam Plate Removal and Installation in Section 5B Page 5B 13 Refer to Gearshift Linkage Inspection in Sectio...

Page 195: ...val Pay attention following points Install the ISC valve Refer to ISC Valve Removal and Installation Page 1D 12 Align the mark A of the air cleaner case and convex part B of the joint tube Gear position switch Refer to Gear Position GP Switch Removal and Installation in Section 5B Page 5B 10 Refer to Gear Position GP Switch Inspection in Section 5B Page 5B 10 Refer to Gear Position GP Switch Remov...

Page 196: ...004 Removal 1 Remove the fuel tank Refer to Fuel Tank Removal and Installation in Section 1G Page 1G 9 2 Remove the air cleaner box 1 Refer to Air Cleaner Element Removal and Installation Page 1D 6 3 Disconnect the joint tube 2 left and right 4 Remove the following parts from the air cleaner chamber a IAP sensor 3 b IAT sensor coupler 4 c PCV hose 5 5 Remove the air cleaner chamber 6 from the thro...

Page 197: ...te the hoses properly Refer to Throttle Body Construction Page 1D 10 Connect the IAP sensor coupler and IAT sensor coupler Align the mark A of the air cleaner case and convex part B of the joint tube Connect the ISC hoses 1 and ISC connector 2 Install the joint tube to the air cleaner chamber Refer to Throttle Body Construction Page 1D 10 Tighten the clamp screws 3 A B I940H1140012 01 1 2 I940H114...

Page 198: ...livery pipe mounting screw 3 5 N m 0 35 kgf m 2 5 lbf ft 2 STP sensor 8 Cushion seal 14 STP sensor mounting screw 4 5 N m 0 45 kgf m 3 0 lbf ft 3 STVA 9 ISC valve 15 TP sensor mounting screw Apply engine oil 4 Fuel delivery pipe 10 Vacuum hose 16 ISC valve mounting bolt Do not reuse 5 IAP sensor 11 Vacuum hose E 33 only 17 ISC hose 6 O ring 12 EVAP purge control valve 5 N m 0 5 kgf m 3 5 lbf ft ...

Page 199: ...WD RH 2 Cylinder 1 Cylinder a C C E B 1 B 4 3 UP FWD FWD 2 2 A A 2 A D FWD b I940H1140337 04 1 PCV hose A White mark E Face the lip right side of motorcycle 2 ISC hose B Yellow mark a 20 3 PAIR hose C Up mark b 15 4 Clamp Face the tip of the clip to outside D Match mark ...

Page 200: ...Engine Mechanical 1 4 2 3 2 C 5 A FWD B I940H1140338 04 1 Canister E 33 only 4 PCV hose C Face the tip of the clip to outside 2 Canister purge valve E 33 only A White mark 3 Purge hose E 33 only B Match mark ...

Page 201: ... Page 1D 6 2 Remove the ISC valve 1 Installation Install the ISC valve in the reverse order of removal Pay attention to the following points Install the ISC valve 1 CAUTION Use a new O ring 2 Tighten the ISC valve mounting bolts to the specified torque Tightening torque ISC valve mounting bolt a 4 5 N m 0 45 kgf m 3 0 lbf ft Throttle Body Removal and Installation B940H21406008 Removal 1 Disconnect...

Page 202: ...ull close It may cause damage to the throttle valve and throttle body 8 Disconnect the EVAP hoses 5 For E 33 Installation Install the throttle body in the reverse order of removal Pay attention to the following points Connect the throttle pulling cable 1 and throttle returning cable 2 to the throttle body Tighten the throttle body clamp screws Refer to Throttle Body Construction Page 1D 10 Loosen ...

Page 203: ...er to Throttle Body Removal and Installation Page 1D 12 Disassembly CAUTION Identify the position of each removed part Organize the parts in their respective groups so that they can be reinstalled in their original positions 1 Disconnect the IAP sensor vacuum hoses 1 ISC valve hoses 2 and fuel feed hose 3 2 Remove the fuel delivery pipes 4 CAUTION Be careful not to twist the fuel delivery pipe whe...

Page 204: ...ssary Assembly Assembly is the throttle body in the reverse order of removal Pay attention to the following points Apply thin coat of the engine oil to the O ring CAUTION Replace the O ring with a new one With the STV fully closed install the STP sensor 1 and tighten the STP sensor mounting screw to the specified torque NOTE Align the secondary throttle shaft end A with the groove B of the STP sen...

Page 205: ...TE Align the throttle shaft end C with the groove D of the TP sensor Apply grease to the throttle shaft end C if necessary Special tool 09930 11950 Torx wrench Tightening torque TP sensor mounting screw 3 5 N m 0 35 kgf m 2 5 lbf ft NOTE Make sure the throttle valve open or close smoothly If the TP sensor adjustment is necessary refer to TP Sensor Adjustment in Section 1C Page 1C 3 Apply thin coat...

Page 206: ...hemical manufacturer s instructions on proper use handling and storage Clean passageways with a spray type carburetor cleaner and blow dry with compressed air CAUTION Never clean the main bore of throttle body to prevent come off molybdenum from the throttle valve Do not use wire to clean passageways Wire can damage passageways If the components cannot be cleaned with a spray cleaner it may be nec...

Page 207: ... air cleaner box along with the joint tube Refer to Air Cleaner Chamber Removal and Installation Page 1D 7 3 Disconnect the IAP sensor hoses 1 4 Connect the respective vacuum hoses to each vacuum nipple on the throttle body 5 Set up the SDS tool Refer to the SDS operation manual for further details 6 Reinstall the left air cleaner box and joint tube Refer to Air Cleaner Chamber Removal and Install...

Page 208: ... and clean them with a spray type carburetor cleaner and blow dry with a compressed air Also clean the air screw passageways NOTE Slowly turn the air screw in clockwise and count the number of turns until the screw is lightly seated Make a note of how many turns were made so the screw can be reset correctly after cleaning 17 Repeat the procedures of 7 to 15 18 Close the SDS tool and turn the ignit...

Page 209: ...tarted after the ignition switch is turned OFF Engine Assembly Removal B940H21406013 CAUTION Make sure that the motorcycle is supported securely Before taking the engine out of the frame wash the engine using a stream cleaner Engine removal is sequentially explained in the following steps 1 Drain engine oil Refer to Engine Oil and Filter Replacement in Section 0B Page 0B 8 2 Remove the front seat ...

Page 210: ...emoval and Installation Page 1D 12 10 Disconnect the PAIR hoses 5 11 Remove the ignition coils plug caps Refer to Spark Plug Cap and Spark Plug Removal and Installation in Section 1H Page 1H 4 1 Cylinder 2 Cylinder 12 Remove the exhaust pipes and mufflers Refer to Exhaust Pipe Muffler Removal and Installation in Section 1K Page 1K 2 1 I940H1140341 01 2 I940H1140342 01 3 I940H1140343 01 4 I940H1140...

Page 211: ...ft frame lower cover Refer to Exterior Parts Removal and Installation in Section 9D Page 9D 5 18 Remove the regulator rectifier 10 19 Disconnect the generator lead wire coupler 11 regulator rectifier lead wire coupler 12 and CKP sensor lead wire coupler 13 20 Release the lead wires from the clamp 14 21 Disconnect the side stand switch lead wire coupler 15 and speedometer sensor lead wire coupler 1...

Page 212: ... 25 Remove the swing arm pivot cover 21 26 Remove the right frame lower cover 22 27 Remove the rear brake pipe 23 from the down tube 28 Remove the rear brake hose clamp 24 29 Support the engine with a proper jack 17 I940H1140351 01 18 19 I940H1140352 01 20 I940H1140353 02 21 I940H1140354 01 22 I940H1140312 02 23 I940H1140355 02 24 I940H1140356 01 I940H1140357 01 ...

Page 213: ... not to drop the engine accidentally when the engine mounting bolts and nuts are removed Engine Assembly Installation B940H21406014 Reinstall the engine in the reverse order of engine removal Pay attention to the following points Install the driven bevel gear coupling to the universal joint NOTE When installing the driven bevel gear coupling align the splines by turning the rear wheel slowly by ha...

Page 214: ...own tube nuts are self locking Once the nuts have been removed they are no longer of any use Tightening torque Frame down tube bolt a 50 N m 5 0 kgf m 36 0 lbf ft Tighten all engine mounting bolts and nuts to the specified torque as shown in the following illustration 1 I940H1140365 01 a a 2 I940H1140366 01 a I940H1140367 01 LH RH LH RH LH RH 3 a b b b 5 a 4 b I940H1140313 03 3 Engine mounting bol...

Page 215: ...tallation in Section 1K Page 1K 2 Connect the water hoses Refer to Water Hose Routing Diagram in Section 1F Page 1F 3 Install the throttle body Refer to Throttle Body Removal and Installation Page 1D 12 Install the air cleaner chamber Refer to Air Cleaner Chamber Removal and Installation Page 1D 7 Tighten the radiator heat shield mounting bolts 8 to the specified torque Tightening torque Radiator ...

Page 216: ...ginal positions Intake Pipe Remove the front and rear intake pipes 1 Thermostat Remove the thermostat assembly 1 and disconnect the water hoses 2 Cylinder Head Cover 1 Cylinder 1 Remove the spark plugs Refer to Spark Plug Cap and Spark Plug Removal and Installation in Section 1H Page 1H 4 2 Remove the rear cylinder head cover 1 and its gasket Camshaft 1 Cylinder 1 Remove the valve timing inspectio...

Page 217: ...ng 10 9 Remove the camshaft 11 10 Remove the camshaft C ring 12 Rocker Arm 1 Cylinder CAUTION Be sure to identify each removed part as to its location and lay the parts out in groups designated as Exhaust Intake so that each will be restored to the original location during assembly 1 Remove the rocker arm shaft 1 2 Remove the each rocker arm 2 and wave washer 3 3 3 4 I940H1140333 02 5 6 I940H11400...

Page 218: ... with a plastic hammer 2 Remove the rear cylinder gasket 3 and dowel pins Rear Piston 1 Cylinder 1 Place a clean rag over the cylinder base so as not to drop the piston pin circlips into the crankcase 2 Remove the piston pin circlip 1 3 Draw out the piston pin 2 and remove the piston 3 NOTE Scribe the cylinder number on the piston head Cylinder Head Cover 2 Cylinder 1 Remove the spark plugs Refer ...

Page 219: ...washer 2 3 Remove the cam chain tension adjuster cap bolt 3 washer and spring 4 Remove the front cam chain tension adjuster 4 and gasket 5 Remove the cam chain sprocket 5 6 Remove the camshaft journal holder 6 7 Remove the dowel pins 7 and O ring 8 8 Remove the camshaft 9 9 Remove the camshaft C ring 10 I940H1140057 04 1 1 2 I940H1140331 01 3 4 I940H1140060 02 5 I940H1140332 01 6 I940H1140061 04 7...

Page 220: ...t cylinder head NOTE Loosen the cylinder head bolts little by little diagonally with the smaller sizes first 2 Remove the front cylinder head gasket 1 and dowel pins Front Cylinder 2 Cylinder 1 Remove the cam chain guide 1 and front cylinder 2 NOTE Firmly grip the cylinder at both ends and lift it straight up If the cylinder does not come off lightly tap on the finless portions of the cylinder wit...

Page 221: ...hen installing the piston pins apply molybdenum oil solution onto each piston pins M O Molybdenum oil MOLYBDENUM OIL SOLUTION NOTE When installing the pistons the indent A on the piston head must be faced to each exhaust side Front Rear Place a clean rag over the cylinder base so as not to drop the piston pin circlips 1 into the crankcase Install the piston pin circlips 1 CAUTION Use new piston pi...

Page 222: ...pins Cylinder Install the new gaskets 1 front and rear CAUTION Use a new gaskets 1 to prevent oil leakage Apply molybdenum oil solution to the sliding surface of the pistons and cylinder walls M O Molybdenum oil MOLYBDENUM OIL SOLUTION Hold the piston rings in proper positions and insert each of the pistons into the respective cylinders NOTE The cylinders can be distinguished by the embossed lette...

Page 223: ...r head keep the cam chain taut Apply engine oil to the both side of the washers and thread portion of the bolts before installing the cylinder head bolts Tighten the cylinder head bolts L190 to the specified two step torque with a torque wrench sequentially and diagonally Tightening torque Cylinder head bolt L190 Initial 25 N m 2 5 kgf m 18 0 lbf ft Cylinder head bolt L190 Final 42 N m 4 2 kgf m 3...

Page 224: ...sure to align R I T line A with the index mark B and hold this position when installing the camshafts Install the C rings The camshafts are identified by the embossed letters Before replacing the camshafts on cylinder head apply molybdenum oil solution to their journals and cam faces Apply molybdenum oil solution to the camshaft journal holders M O Molybdenum oil MOLYBDENUM OIL SOLUTION Rear Front...

Page 225: ...n Apply THREAD LOCK SUPER 1303 to the bolts and tighten them to the specified torque Tightening torque Cam chain sprocket bolt a 15 N m 1 5 kgf m 11 5 lbf ft Thread lock cement 99000 32030 THREAD LOCK CEMENT SUPER 1303 or equivalent Bend up the washer tongue positively to lock the bolts After tightening the bolt align the R I T line A on the generator with the index marks B of the timing inspectio...

Page 226: ...er arm shafts 1 Install the rocker arm shafts wave washer and rocker arms CAUTION Align the groove A of the rocker arm shafts and holes B of the camshaft journal Tighten the rear camshaft journal holder bolts to the specified torque Tightening torque Camshaft journal holder bolt 10 N m 1 0 kgf m 7 0 lbf ft I940H1140110 01 I940H1140111 01 1 1 I940H1140114 02 C Wave washer position D Cam chain sproc...

Page 227: ... is installed Tighten the cam chain tension adjuster cap bolt 7 to the specified torque Tightening torque Cam chain tension adjuster cap bolt b 23 N m 2 3 kgf m 16 5 lbf ft CAUTION After installing the cam chain tension adjuster check to be sure that the adjuster works properly by checking the slack of cam chain Turn the crankshaft clockwise approx 1 1 3 turns 486 and align the F I T line A on the...

Page 228: ...er cap bolt is installed Tighten the cam chain tension adjuster cap bolt 13 to the specified torque Tightening torque Cam chain tension adjuster cap bolt d 23 N m 2 3 kgf m 16 5 lbf ft CAUTION After installing the cam chain tension adjuster check to be sure that the adjuster works properly by checking the slack of cam chain After installing the camshaft journal holder rotate the crankshaft some tu...

Page 229: ...ening torque Cylinder head cover bolt 14 N m 1 4 kgf m 10 0 lbf ft Spark Plug Install the spark plugs Refer to Spark Plug Cap and Spark Plug Removal and Installation in Section 1H Page 1H 4 Thermostat Apply engine coolant to the O ring CAUTION Use a new O ring to prevent engine coolant leakage Connect the water hoses Refer to Water Hose Routing Diagram in Section 1F Page 1F 3 Intake Pipe When repl...

Page 230: ...valve gasket mating surfaces B of the cylinder head cover If it is damaged replace the cylinder head covers with a new one 3 Install the cylinder head covers Refer to Engine Top Side Assembly Page 1D 32 Camshaft Inspection B940H21406019 Refer to Engine Top Side Disassembly Page 1D 27 Refer to Engine Top Side Assembly Page 1D 32 Camshaft Identification The camshafts can be identified by the engrave...

Page 231: ...camshaft journal holder and measure the width of the compressed plastigauge using the envelope scale 5 This measurement should be taken at the widest part of the compressed plastigauge Camshaft journal oil clearance IN EX Service limit 0 150 mm 0 0059 in 6 If the camshaft journal oil clearance exceeds the limit measure the inside diameter of the camshaft journal holder and the outside diameter of ...

Page 232: ...y If it does not operate smoothly replace the camshaft automatic decompression assembly with a new one CAUTION Do not attempt to disassemble the cam sprockets and automatic decomp assembly They are unserviceable Install the front and rear camshafts Refer to Engine Top Side Assembly Page 1D 32 Cam Chain Tension Adjuster Inspection B940H21406021 The cam chain tensions are maintained at the proper ca...

Page 233: ...ings 1 with new ones Grease 99000 25010 SUZUKI SUPER GREASE A or equivalent 2 Install the valve timing inspection caps and tighten the bolts 2 to the specified torque Tightening torque Valve timing inspection cap bolt a 10 N m 1 0 kgf m 7 0 lbf ft 3 Install the PAIR read valve and PAIR read valve cover 4 Apply thread lock to the bolts and tighten them Thread lock cement 99000 32110 THREAD LOCK CEM...

Page 234: ...s i e intake exhaust No 1 or No 2 so that they can be installed in their original locations Disassembly Water jacket pipe Remove the water jacket pipe 1 for rear cylinder Water jacket plug Cylinder head Remove the water jacket plug 1 for front and rear cylinder Valve Valve spring 1 Using the special tools compress the valve spring and remove the two cotter halves 1 and valve spring retainer 2 from...

Page 235: ... the oil seal M O Molybdenum oil MOLYBDENUM OIL SOLUTION Install the valve springs with the small pitch portion A facing cylinder head Put on the valve spring retainer 3 and using the special tools press down the spring fit the cotter halves to the stem end and release the lifter to allow the cotter 4 halves to wedge in between retainer and stem CAUTION Be sure to restore each spring and valve to ...

Page 236: ...he rocker arm shafts from the cylinder head cover Refer to Cylinder Head Cover Disassembly and Assembly Page 1D 44 2 Measure each rocker arm shaft out side diameter using the micrometer If the diameter exceeds the limit replace the rocker arm shaft with a new one Special tool A 09900 20205 Micrometer 0 25 mm Rocker arm shaft O D IN EX Standard 11 973 11 984 mm 0 4714 0 4718 in 3 Reinstall the remo...

Page 237: ...ace the cylinder head Special tool 09900 20803 Thickness gauge Cylinder head distortion Service limit 0 05 mm 0 002 in Valve Stem Runout Support the valve using V blocks and check its runout using the dial gauge as shown in the figure If the runout exceeds the service limit replace the valve Special tool A 09900 20607 Dial gauge 1 100 mm 10 mm B 09900 20701 Magnetic stand C 09900 21304 V block 100...

Page 238: ...n replace the guide After replacing valve or guide be sure to recheck the deflection Special tool A 09900 20205 Micrometer 0 25 mm Valve stem O D Standard IN 5 475 5 490 mm 0 2156 0 2161 in Standard EX 5 455 5 470 mm 0 2148 0 2154 in NOTE If valve guides have to be removed for replacement after inspecting related parts carry out the steps shown in valve guide replacement Refer to Valve Guide Repla...

Page 239: ...d prevent the valve from sealing Refer to Valve Seat Repair Page 1D 52 WARNING Always use extreme caution when handling gasoline NOTE After servicing the valve seats be sure to check the valve clearance after the cylinder head has been reinstalled Refer to Valve Clearance Inspection and Adjustment in Section 0B Page 0B 3 Valve Guide Replacement B940H21406026 1 Remove the cylinder head Refer to Eng...

Page 240: ...installer and attachment NOTE Install the valve guide until the attachment contacts the cylinder head CAUTION Failure to oil the valve guide hole before driving the new guide into place may result in a damaged guide or head Special tool A 09916 44910 Valve guide remover installer D 09916 44920 Valve guide installer attachment 8 After installing the valve guides refinish their guiding bores using t...

Page 241: ...he coil spring keeps the valve seat tight Weakened spring results in reduced engine power output and often accounts for the chattering noise coming from the valve mechanism Check the valve springs for proper strength by measuring its free length and also by the force required to compress it If the spring length is less than the service limit or if the force required to compress the spring does not...

Page 242: ...clearance reading at several places as indicated If the largest reading at any position of the straightedge exceeds the limit replace the cylinder Special tool 09900 20803 Thickness gauge Cylinder distortion Service limit 0 05 mm 0 002 in Cylinder Bore Check the cylinder wall for any scratches nicks or other damage Cylinder bore Standard 96 000 96 015 mm 3 7795 3 7801 in Piston Ring Removal and In...

Page 243: ...ll the 2nd ring 3 and 1st ring 4 to piston NOTE 1st ring has letters IT marked on the side Be sure to bring the marked side to the top when fitting it to the position 2nd ring has letters T marked on the side Be sure to bring the marked side to the top when fitting it to the piston 2 Position the gaps of the three rings and side rails as shown Before inserting piston into the cylinder check that t...

Page 244: ...the piston Piston to cylinder clearance Service limit 0 120 mm 0 0047 in Piston Ring to groove Clearance Measure the side clearances of the 1st and 2nd piston rings using the thickness gauge If any of the clearances exceed the limit replace both the piston and piston rings Special tool A 09900 20803 Thickness gauge B 09900 20205 Micrometer 0 25 mm Piston ring to groove clearance Service limit 1st ...

Page 245: ...iston pin bore inside diameter using the small bore gauge If measurement is out of specification replace the piston Special tool A 09900 20602 Dial gauge 1 1000 mm 1 mm B 09900 22403 Small bore gauge 18 35 mm Piston pin bore I D Service limit 22 030 mm 0 8673 in Measure the piston pin outside diameter at three positions using the micrometer If any of the measurements are out of specification repla...

Page 246: ... hose 3 Generator Remove the generator component parts 1 Refer to Generator Removal and Installation in Section 1J Page 1J 5 Starter Driven Gear Starter Torque Limiter Starter Idle Gear Remove the key 1 and starter driven gear 2 Remove the starter torque limiter 3 and starter idle gear 4 Front Cam Chain 1 Remove the front cam chain tensioner 1 2 Remove the cam chain 2 and cams 3 Remove the cam cha...

Page 247: ...r 4 Hold the clutch sleeve hub 4 with the special tool Special tool A 09920 53740 Clutch sleeve hub holder 09920 31020 Extension handle 5 Loosen the secondary drive gear bolt 5 and remove the secondary drive gear 6 and shim 7 6 Unlock the clutch hub nut 7 Loosen the clutch hub nut and remove the clutch sleeve hub 4 along with the clutch drive cam 8 and driven cam 9 8 Remove the washer 10 and prima...

Page 248: ...ioner 1 2 Remove the cam chain 2 3 Remove the cam chain guide bolt 3 4 Remove the cam chain drive sprocket 4 Oil Pump Drive Gear Oil Pressure Regulator 1 Remove the oil pressure regulator 1 2 Remove the snap ring 2 and oil pump driven gear 3 NOTE Do not drop the snap ring 2 into the crankcase Special tool 09900 06107 Snap ring pliers 3 Remove the pin 4 and washer 5 Gearshift System 1 Remove the sn...

Page 249: ...t arm stopper 8 Gear Position Switch Remove the gear position switch 1 Oil Filter Remove the oil filter with the special tool Special tool A 09915 40620 Oil filter wrench Oil Pressure Switch 1 Remove the oil pressure switch 1 Oil Separator Plate 1 Remove the oil separator plate 1 3 4 I940H1140189 01 5 8 6 7 I940H1140190 02 1 I940H1140193 01 A I940H1140293 01 1 I940H1140195 01 1 I940H1140196 01 ...

Page 250: ...ght crankcase halves and then lift the right crankcase off of the left crankcase NOTE The crankshaft and transmission components should remain in the left crankcase half 3 Remove the O rings 1 and dowel pins 2 Transmission Gearshift Cam Remove the gearshift cam 1 driveshaft assembly 2 and countershaft assembly 3 Crankshaft 1 Remove the crankshaft 1 I940H1140197 01 I940H1140198 01 I940H1140199 01 1...

Page 251: ...on 1E Page 1E 4 Engine Mount Bushing Remove the upper and lower crankcase engine mount bushings 1 if necessary Oil Jet 1 Remove the piston cooling jets 1 and oil jet secondary gear 2 from the each crankcase 2 Remove the oil gallery plug 3 3 Remove the oil jet transmission 4 with the suitable bar 1 2 I940H1140204 01 1 I940H1140205 01 1 I940H1140206 01 1 I940H1140207 01 2 I940H1140208 01 3 I940H1140...

Page 252: ... crankcase and the crankshaft journal bearings Do not touch the bearing surfaces with your hands Grasp the bearings by their edges NOTE Do not remove the crankshaft journal bearings unless absolutely necessary Make a note of where the crankshaft journal bearings are removed from so that they can be reinstalled in their original positions Bearing Remove the bearings from the crankcase if necessary ...

Page 253: ...specified torque Tightening torque Oil gallery plug M16 a 35 N m 3 5 kgf m 25 5 lbf ft Oil gallery plug M14 b 23 N m 2 3 kgf m 16 5 lbf ft Oil gallery plug M8 c 18 N m 1 8 kgf m 13 0 lbf ft Oil Jet CAUTION Use the new O rings to prevent oil pressure leak Apply engine oil to the new O ring 1 Apply thread lock to the oil gallery plug 2 and tighten it to the specified torque CAUTION Use the new gaske...

Page 254: ...num oil solution to the thrust bearing M O Molybdenum oil MOLYBDENUM OIL SOLUTION Insert the thrust bearing with oil groove A facing the crank web Install the crankshaft assembly to the left crankcase Transmission Gearshift Cam Install the driveshaft assembly 1 countershaft assembly 2 and gearshift cam 3 Refer to Transmission Removal and Installation in Section 5B Page 5B 3 3 I940H1140215 02 4 5 I...

Page 255: ...Make surfaces free from moisture oil dust and other foreign materials Spread on surfaces thinly to form an even layer and assemble the crankcases within few minutes Take extreme care not to apply any bond to the oil hole oil groove and bearing Apply to distorted surfaces as it forms a comparatively thick film Apply sealant to both mating surface of crankcases at hatched parts Sealant 99000 31110 S...

Page 256: ...d countershaft rotate smoothly Oil Separator Plate Install the oil separator plate 1 Oil Pressure Switch Apply bond to the thread part of the oil pressure switch 1 and tighten the oil pressure switch 1 to the specified torque NOTE Be careful not to apply bond to the hole of thread end Sealant 99000 31140 SUZUKI BOND No 1207B or equivalent Tightening torque Oil pressure switch a 14 N m 1 4 kgf m 10...

Page 257: ...mp Driven Gear Oil Pressure Regulator Install the washer 1 and pin 2 Install the oil pump driven gear 3 and snap ring 4 NOTE Never reuse a snap ring Special tool 09900 06107 Snap ring pliers Apply grease to the O rings and pass in the oil pressure regulator 5 to the lower crankcase CAUTION Use the new O rings to prevent oil leakage Grease 99000 25010 SUZUKI SUPER GREASE A or equivalent A B I940H11...

Page 258: ...alent NOTE Hook the return spring end A to the stopper 1 Tightening torque Gearshift cam stopper bolt b 10 N m 1 0 kgf m 7 0 lbf ft Check the gearshift cam stopper moves smoothly Locate the gearshift cam in the neutral position Install the gearshift cam stopper plate 6 NOTE Align the gearshift cam pin B with the gearshift cam stopper plate hole C Apply thread lock to the gearshift cam stopper plat...

Page 259: ... tensioner 3 Apply thread lock to the bolts and tighten its to the specified torque Thread lock cement 99000 32030 THREAD LOCK CEMENT SUPER 1303 or equivalent Tightening torque Cam chain guide bolt a 23 N m 2 3 kgf m 16 5 lbf ft Rear cam chain tensioner bolt b 23 N m 2 3 kgf m 16 5 lbf ft Primary Drive Gear Install the primary drive gear assembly 1 Refer to Primary Drive Gear Removal and Installat...

Page 260: ...cement 99000 32130 THREAD LOCK CEMENT SUPER 1360 or equivalent Tightening torque Secondary drive gear bolt a 160 N m 16 0 kgf m 115 5 lbf ft Install the clutch drive plates driven plates push rod push pease and pressure plate Refer to Clutch Installation in Section 5C Page 5C 8 Front Cam Chain Front Cam Chain Tensioner Install the front cam chain 1 and cam chain tensioner 2 Apply thread lock to th...

Page 261: ...rator Install the generator component parts 1 Refer to Generator Removal and Installation in Section 1J Page 1J 5 Water Pump Apply grease to the O ring CAUTION Use a new O ring to prevent oil leakage NOTE When install the water pump fit the convex part A of the oil pump shaft onto the concave part B of the water pump shaft Grease 99000 25010 SUZUKI SUPER GREASE A or equivalent Tighten the water pu...

Page 262: ...e specified torque Tightening torque Starter motor mounting bolt a 10 N m 1 0 kgf m 7 0 lbf ft Engine Top Side Assembly the engine top side Refer to Engine Top Side Assembly Page 1D 32 Cam Chain Tensioner Inspection B940H21406034 Inspect the cam chain tensioner in the following procedures 1 Remove the cam chain tensioner Refer to Engine Bottom Side Disassembly Page 1D 56 and Engine Bottom Side Ass...

Page 263: ...r original positions CAUTION When removing the bearings be careful not to scratch the conrods and the bearings Installation 1 When installing the bearings into the conrod cap and conrod be sure to fix the stopper part A first and then press in the opposite side of the bearing NOTE Inspect and select the conrod crank pin bearing if necessary Refer to Conrod Crank Pin Bearing Inspection and Selectio...

Page 264: ...l gauge 1 1000 mm 1 mm B 09900 22403 Small bore gauge 18 35 mm Conrod small end I D Service limit 22 040 mm 0 8677 in Conrod Big End Side Clearance 1 Check the conrod big end side clearance using the thickness gauge Special tool A 09900 20803 Thickness gauge Conrod big end side clearance Service limit 0 30 mm 0 012 in 2 If the clearance exceeds the limit remove the conrod and measure the conrod bi...

Page 265: ...ver rotate the crankshaft or conrod when a piece of plastigauge is installed Tightening torque Conrod cap bolt 35 N m 3 5 kgf m 25 5 Ib ft then turn in 1 4 90 turn 4 Remove the conrod caps and measure the width of the compressed plastigauge using the envelope scale This measurement should be taken at the widest part of the compressed plastigauge If the oil clearance exceeds the service limit selec...

Page 266: ...940H21406038 Refer to Engine Bottom Side Disassembly Page 1D 56 and Engine Bottom Side Assembly Page 1D 64 Inspection 1 Inspect the crankshaft bearings for any damage Code B O D specification 1 54 992 55 000 mm 2 1650 2 1654 in 2 54 984 54 992 mm 2 1647 2 1650 in 3 54 976 54 984 mm 2 1644 2 1647 in B I940H1140322 04 A I940H1140269 01 Conrod I D A Code 1 2 1 Green Black 2 Black Brown 3 Brown Yellow...

Page 267: ...nal bearings with new ones CAUTION Bearing must be replaced as a seat Selection Select the specified bearings from the crankcase bore I D code Bearing selection table Crankshaft Bearing Replacement B940H21406039 Use the special tool to replace the crankshaft journal bearings The replacement procedure is as follows Special tool A 09913 60250 Journal bearing remover installer Set the special tool as...

Page 268: ...A 09913 60250 Journal bearing remover installer Tighten the special tool bolt to the specified torque Tightening torque Special tool bolt a 23 N m 2 3 kgf m 16 5 lbf ft CAUTION Before installing the bearings lightly shave off the sharp edge B part of the crankcase chamber by using an oilstone and wash the crankcase bore with enough engine oil Set the bearings installed in the special tool to the c...

Page 269: ...ring 1 After installing the bearings check the bearing surface for any scratch or damage Crankshaft Thrust Clearance Inspection and Adjustment B940H21406040 Refer to Engine Bottom Side Disassembly Page 1D 56 Refer to Engine Bottom Side Assembly Page 1D 64 Inspection 1 Install the crankshaft in the right crankcase half after installing the thrust shim 1 on the crankshaft NOTE The oil grooved face A...

Page 270: ...e standard range adjust the thrust clearance NOTE Pull the crankshaft to the right Primary driven gear side so that there is no clearance on the thrust bearing Special tool A 09900 20803 Thickness gauge Crankshaft thrust clearance Standard 0 100 0 150 mm 0 0039 0 0059 in Selection 1 Remove the thrust bearing and measure its thickness using the micrometer If the thickness of the thrust bearing is b...

Page 271: ...mm 0 0040 0 0059 in 12228 40H00 0F0 2 050 2 075 mm 0 0807 0 0817 in 0 100 0 150 mm 0 0040 0 0059 in Item Standard Limit Valve diam IN 33 1 30 EX 30 1 18 Tappet clearance When cold IN 0 08 0 13 0 003 0 005 EX 0 17 0 22 0 007 0 009 Valve guide to valve stem clearance IN 0 010 0 037 0 0004 0 0015 EX 0 030 0 057 0 0012 0 0022 Valve guide I D IN EX 5 500 5 512 0 2165 0 2170 Valve stem O D IN 5 475 5 49...

Page 272: ...diam 95 970 95 985 3 7783 3 7789 Measure at 15 mm 0 6 in from the skirt end 95 88 3 7748 Cylinder distortion 0 05 0 002 Piston ring free end gap 1st Approx 11 0 43 8 8 0 35 2nd Approx 11 0 43 8 8 0 35 Piston ring end gap 1st 0 10 0 25 0 004 0 010 0 5 0 020 2nd 0 10 0 25 0 004 0 010 0 5 0 020 Piston ring to groove clearance 1st 0 180 0 0071 2nd 0 150 0 0059 Piston ring groove width 1st 1 21 1 23 0 ...

Page 273: ...aft journal holder bolt 10 1 0 7 0 Page 1D 37 Page 1D 38 Page 1D 42 Cam chain tension adjuster bolt 10 1 0 7 0 Page 1D 38 Page 1D 39 Cam chain tension adjuster cap bolt 23 2 3 16 5 Page 1D 38 Page 1D 39 Cylinder head cover bolt 14 1 4 10 0 Page 1D 40 Valve timing inspection cap bolt 10 1 0 7 0 Page 1D 44 Cylinder head cover bracket bolt 10 1 0 7 0 Page 1D 45 Water jacket plug Cylinder head 26 2 6 ...

Page 274: ...72 Page 1D 73 Molybdenum oil MOLYBDENUM OIL SOLUTION Page 1D 32 Page 1D 33 Page 1D 33 Page 1D 35 Page 1D 46 Page 1D 46 Page 1D 65 Page 1D 65 Page 1D 74 Sealant SUZUKI BOND No 1215 or equivalent P No 99000 31110 Page 1D 33 Page 1D 66 SUZUKI BOND No 1207B or equivalent P No 99000 31140 Page 1D 40 Page 1D 67 Thread lock cement THREAD LOCK CEMENT SUPER 1303 or equivalent P No 99000 32030 Page 1D 36 Pa...

Page 275: ...09900 20205 09900 20530 Micrometer 0 25 mm Cylinder gauge set Page 1D 47 Page 1D 49 Page 1D 55 Page 1D 56 Page 1D 75 Page 1D 81 Page 1D 42 Page 1D 78 09900 20602 09900 20605 Dial gauge 1 1000 mm 1 mm Dial calipers 1 100 mm 10 34 mm Page 1D 42 Page 1D 56 Page 1D 75 Page 1D 48 Page 1D 75 09900 20607 09900 20701 Dial gauge 1 100 mm 10 mm Magnetic stand Page 1D 43 Page 1D 48 Page 1D 48 Page 1D 49 Page...

Page 276: ...19 Page 1D 3 09913 60250 09915 40620 Journal bearing remover installer Oil filter wrench Page 1D 78 Page 1D 79 Page 1D 80 Page 1D 60 Page 1D 67 09915 64512 09916 10911 Compression gauge Valve lapper set Page 1D 3 Page 1D 50 09916 14510 09916 14910 Valve lifter Valve spring compressor attachment Page 1D 45 Page 1D 46 Page 1D 45 Page 1D 46 09916 34542 09916 34550 Reamer handle Valve guide reamer 5 5...

Page 277: ...511 Valve guide installer attachment Tweezers Page 1D 51 Page 1D 45 Page 1D 46 09920 31020 09920 53740 Extension handle Clutch sleeve hub holder Page 1D 58 Page 1D 71 Page 1D 58 Page 1D 71 09930 11950 Torx wrench Page 1D 15 Page 1D 15 Page 1D 16 ...

Page 278: ...M CHAIN 1 PISTON AND CYLINDER WALL 1 PISTON COOLING OIL JET 1 PISTON PIN BEARING SECONDARY BEVEL GEARS AND BEARING SECONDARY DRIVEN BEVEL SHAFT SECONDARY DRIVEN GEAR BEARING COUNTERSHAFT GEARS AND BUSHINGS CLUTCH PUSH PIECE COUNTERSHAFT LEFT SIDE BEARING CLUTCH PLATES 2 CYLINDER HEAD 2 CYLINDER 2 CAMSHAFT JOURNAL HOLDER 2 CAMSHAFT ROCKER ARM IN ROCKER ARM EX OIL JET OIL JET 2 CAM CHAIN TENSION ADJ...

Page 279: ...n oil pan bellow the engine and remove the main oil gallery plug 1 3 Install the oil pressure gauge and attachment into the main oil gallery Special tool A 09915 74521 Oil pressure gauge hose B 09915 74533 Oil pressure gauge attachment C 09915 77331 Meter for high pressure 4 Connect the tachometer to the high tension cord Special tool D 09900 26006 Engine tachometer solar cell type 5 Warm up the e...

Page 280: ...efer to Engine Oil and Filter Replacement in Section 0B Page 0B 8 Engine Oil Level Inspection B940H21506002 Refer to Engine Oil and Filter Replacement in Section 0B Page 0B 8 Oil Pressure Regulator Removal and Installation B940H21506003 Removal 1 Drain engine oil Refer to Engine Oil and Filter Replacement in Section 0B Page 0B 8 2 Remove the clutch cover Refer to Clutch Removal in Section 5C Page ...

Page 281: ...should be positioned downward The shorter side B of the oil sump filter should be positioned inside Oil Pressure Regulator Oil Sump Filter Inspection B940H21506005 Refer to Oil Pressure Regulator Removal and Installation Page 1E 3 and Oil Sump Filter Removal and Installation Page 1E 4 Oil pressure regulator Inspect the operation of the oil pressure regulator by pushing on the piston with a proper ...

Page 282: ... a 14 N m 1 4 kgf m 10 0 lbf ft 2 Connect the oil pressure switch lead wire securely Refer to Wiring Harness Routing Diagram in Section 9A Page 9A 5 Tightening torque Oil pressure switch lead wire bolt b 1 5 N m 0 15 kgf m 1 0 lbf ft 3 Pour engine oil Refer to Engine Oil and Filter Replacement in Section 0B Page 0B 8 Oil Pressure Switch Inspection B940H21506007 Refer to Oil Pressure Indicator Insp...

Page 283: ...e Assembly in Section 1D Page 1D 32 Oil Jet For Piston Cooling Removal 1 Remove the engine assembly Refer to Engine Bottom Side Disassembly in Section 1D Page 1D 56 2 Separate the crankcases left and right Refer to Engine Bottom Side Disassembly in Section 1D Page 1D 56 3 Remove the crankshaft assembly Refer to Engine Bottom Side Disassembly in Section 1D Page 1D 56 4 Remove the piston cooling oil...

Page 284: ...h a suitable bar Installation Installation is in the reverse order of removal Pay attention to the following points Apply engine oil to the O ring CAUTION Use a new O ring to prevent oil leakage Apply thread lock to the thread part and tighten the oil gallery plug 1 to the specified torque CAUTION Use a new gasket to prevent oil leakage Thread lock cement 99000 32030 THREAD LOCK CEMENT SUPER 1303 ...

Page 285: ...lation in Section 3A Page 3A 3 2 Remove the oil jet 1 Installation Installation is in the reverse order of removal Pay attention to the following points Apply engine oil to the O ring CAUTION Use a new O ring to prevent oil leakage Oil Jet Inspection B940H21506009 Refer to Oil Jet Removal and Installation Page 1E 5 Make sure that the oil jets are not clogged If they are clogged clean their oil pas...

Page 286: ...ce of the oil pump inner rotor 1 and shaft When installing the inner rotor 1 align the pin A with the groove B of the inner rotor Apply engine oil to the oil pump sliding surface of the oil pump outer rotor 2 Check the punch marks C of the rotors faces outside Before mounting the oil pump apply engine oil to the sliding surfaces of the outer rotor inner rotor and shaft Tighten the screw 3 to the s...

Page 287: ...oil pump assembly The oil pump is available only as an assembly 3 Install the oil pump Refer to Oil Pump Removal and Installation Page 1E 9 Outer Inner Rotor Inspect the outer rotor 1 and inner rotor 2 for any scratches or other damage If any damages are found replace them with new ones Specifications Service Data B940H21507001 Oil Pump Oil I940H1150039 01 I940H1150040 01 1 2 I822H1150039 01 Item ...

Page 288: ...switch lead wire bolt 1 5 0 15 1 0 Page 1E 5 Oil gallery plug M10 18 1 8 13 0 Page 1E 7 Oil gallery plug M8 18 1 8 13 0 Page 1E 8 Oil pump cover screw 1 3 0 13 1 0 Page 1E 9 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or equivalent P No 99000 25010 Page 1E 3 Sealant SUZUKI BOND No 1207B or equivalent P No 99000 31140 Page 1E 5 Thread lock cement THREAD LO...

Page 289: ...ion Engine Coolant Description B940H21601001 CAUTION Use a high quality ethylene glycol base anti freeze mixed with distilled water Do not mix an alcohol base anti freeze and different brands of anti freeze Do not put in more than 60 anti freeze or less than 50 Refer to Fig 1 and 2 At the time of manufacture the cooling system is filled with a 50 50 mixture of distilled water and ethylene glycol a...

Page 290: ...ngine Cooling System Schematic and Routing Diagram Cooling Circuit Diagram B940H21602001 WATER PUMP RADIATOR ENGINE COOLANT TEMPERATURE SENSOR CYLINDER HEAD CYLINDER THERMOSTAT RESERVOIR TANK I822H1160053 01 ...

Page 291: ...tank inlet hose between the frame and radiator outlet hose C Red marking J Clamp screw head should face forward left side 3 Clamp D White marking K Insert the hose to the stopper 4 Protection tape E Clamp screw head should face upward L Clamp end should face upward 5 Clamp Clamp the reservoir tank inlet hose with the clamp F Clamp screw head should face left side M Clamp end should face backward 6...

Page 292: ...0 seconds CAUTION Do not exceed the radiator cap release pressure or the radiator cap and subsequently the radiator can be damaged 4 After finishing the cooling circuit inspection reinstall the removed parts Condition Possible cause Correction Reference Item Engine overheats Not enough engine coolant Add engine coolant Radiator core clogged with dirt or scale Clean Faulty cooling fan Repair or rep...

Page 293: ...nspect the radiator for water leaks If any defects are found replace the radiator with a new one If the fins are bent or dented repair them by carefully straightening them with the blade of a small screwdriver Radiator Cleaning Blow out any foreign matter that is stuck in the radiator fins using compressed air CAUTION Make sure not to bend the fins when using compressed air Always apply compressed...

Page 294: ...Refer to Water Hose Routing Diagram Page 1F 3 Tightening torque Water hose clamp screw 1 5 N m 0 15 kgf m 1 0 lbf ft Pour engine coolant Refer to Cooling System Inspection in Section 0B Page 0B 11 Bleed air from the cooling circuit Refer to Cooling System Inspection in Section 0B Page 0B 11 Water Hose Inspection B940H21606005 Inspect the water hoses in the following procedures 1 Move the fuel tank...

Page 295: ...uting Diagram Page 1F 3 2 Pour engine coolant and bleed air from the cooling circuit Refer to Cooling System Inspection in Section 0B Page 0B 11 3 Reinstall the fuel tank Refer to Fuel Tank Removal and Installation in Section 1G Page 1G 9 Radiator Reservoir Tank Inspection B940H21606007 Inspect the radiator reservoir tank in the following procedures 1 Remove the left frame lower cover and secondar...

Page 296: ... assembly with a new one Refer to Radiator Cooling Fan Motor Removal and Installation Page 1F 5 NOTE When making this test it is not necessary to remove the cooling fan Make sure that the battery has a capacity enough to supply the motor with 12 V With the motor running at full speed the ammeter should indicate an amperage not higher than 6 0 A 3 Connect the cooling fan motor coupler Cooling Fan R...

Page 297: ...B940H21606013 Removal 1 Drain a small amount of engine coolant Refer to Cooling System Inspection in Section 0B Page 0B 11 2 Remove the left air cleaner cover Refer to Air Cleaner Element Removal and Installation in Section 1D Page 1D 6 3 Disconnect the radiator inlet hose 1 4 Remove the connector cap 2 5 Remove the thermostat 3 Installation Install the thermostat in the reverse order of removal P...

Page 298: ... Heat the water by placing the beaker on a stove and observe the rising temperature on a thermometer 2 6 Read the thermometer just when opening the thermostat If this reading which is the temperature level at which the thermostat valve begins to open is out of the standard value replace the thermostat with a new one Thermostat valve opening temperature Standard Approx 88 C 190 F 7 Keep on heating ...

Page 299: ... to Engine Oil and Filter Replacement in Section 0B Page 0B 8 and Cooling System Inspection in Section 0B Page 0B 11 2 Remove the left frame lower cover and secondary gear case cover Refer to Exterior Parts Removal and Installation in Section 9D Page 9D 5 3 Remove the clutch release assembly Refer to Clutch Release Assembly Push Rod Removal and Installation in Section 5C Page 5C 2 4 Disconnect the...

Page 300: ...mp assembly with the slot on the pump shaft end A securely engaged with the flat B on the oil pump shaft Tighten the water pump mounting bolts 1 Apply engine coolant to the O ring CAUTION Use a new O ring to prevent engine coolant leakage Connect the water hoses securely Refer to Water Hose Routing Diagram Page 1F 3 Pour engine oil and coolant Refer to Engine Oil and Filter Replacement in Section ...

Page 301: ...he impeller assembly 7 6 Remove the mechanical seal ring 8 and rubber seal 9 from the impeller assembly 7 Remove the mechanical seal with the special tool NOTE If there is no abnormal condition the mechanical seal removal is not necessary Special tool A 09921 20240 Bearing remover set 8 Remove the oil seal NOTE If there is no abnormal condition the oil seal removal is not necessary 1 2 I940H116002...

Page 302: ... SUPER GREASE A or equivalent 3 Install a new mechanical seal using a suitable size socket wrench CAUTION Replace the mechanical seal with a new one NOTE On the new mechanical seal the sealer A has been applied 4 Install the rubber seal 1 into the impeller 5 After wiping off the oily or greasy matter from the mechanical seal ring 2 install it into the impeller NOTE The paint marked side B of mecha...

Page 303: ...mp case screw a 5 5 N m 0 55 kgf m 4 0 lbf ft Water Pump Related Parts Inspection B940H21606018 Refer to Water Pump Disassembly and Assembly Page 1F 13 Mechanical Seal Visually inspect the mechanical seal for damage with particular attention given to the sealing face Replace the mechanical seal that shows indications of leakage Oil Seal Visually inspect the oil seal for damage with particular atte...

Page 304: ...ure Approx 88 C 190 F Thermostat valve lift Over 8 mm 0 31 in at 100 C 212 F ECT sensor resistance 20 C 68 F Approx 2 45 kΩ 50 C 122 F Approx 0 811 kΩ 80 C 176 F Approx 0 318 kΩ 110 C 230 F Approx 0 142 kΩ Radiator cap valve opening pressure 108 137 kPa 1 1 1 4 kgf cm2 15 6 19 5 psi Cooling fan operating temperature OFF ON Approx 105 C 221 F ON OFF Approx 100 C 212 F Engine coolant type Use an ant...

Page 305: ...Components Page 1F 11 Special Tool B940H21608002 Fastening part Tightening torque Note N m kgf m lbf ft Cooling fan mounting bolt 6 5 0 65 4 5 Page 1F 6 Water hose clamp screw 1 5 0 15 1 0 Page 1F 6 Water pump case screw 5 5 0 55 4 0 Page 1F 15 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or equivalent P No 99000 25010 Page 1F 12 Page 1F 14 Molybdenum oil ...

Page 306: ...use care to minimize spillage of gasoline Spilled gasoline should be wiped off immediately Work in a well ventilated area CAUTION To prevent the fuel system fuel tank fuel hose etc from contamination with foreign particles blind all openings After removing the throttle body tape the cylinder intake section to prevent foreign particles from entering ...

Page 307: ...is regulated by the fuel pressure regulator 5 As the fuel pressure applied to the fuel injector 7 the fuel pressure in the fuel delivery pipe is always kept at absolute fuel pressure of 300 kPa 3 0 kgf cm2 43 psi the fuel is injected into the throttle body in conic dispersion when the injector 7 opens according to the injection signal from the ECM The fuel relieved by the fuel pressure regulator 5...

Page 308: ...m B940H21702001 1 2 1 2 1 3 1 B B A C Inside Outside 1 D 5 4 I940H1170036 01 1 Fuel tank breather hose A White mark 2 Fuel tank breather valve B Face the tip of the clip lower 3 3 way joint C Face the tip of the clip forward 4 Frame D To the fuel tank 5 Coolant reservoir tank inlet hose ...

Page 309: ...Defective fuel pressure regulator Replace Damaged or cracked vacuum hose Replace Defective ECT sensor Replace Defective thermostat Replace Defective IAT sensor Replace Engine stalls often Fuel injector improperly operating Defective fuel injectors Replace No injection signal from ECM Repair or replace Open or short circuited wiring connection Repair or replace Defective battery or low battery volt...

Page 310: ... followings Fuel hose leakage Clogged fuel filter Pressure regulator Fuel pump If the fuel pressure is higher than the specification check for the followings Fuel pump Pressure regulator 5 Remove the special tools WARNING Before removing the special tools turn the ignition switch OFF and release the fuel pressure slowly 6 Reinstall the fuel tank Refer to Fuel Tank Removal and Installation Page 1G ...

Page 311: ...12 V to the fuel pump between R wire and B wire for 10 seconds and measure the amount of fuel discharged If the discharge amount is out of the specification the probable cause may be failure of the fuel pump or clogged fuel filter NOTE The battery must be in fully charged condition Fuel discharge amount 168 ml 5 7 5 9 US lmp oz and more 10 seconds 7 After finishing the fuel discharge inspection re...

Page 312: ...set Tester knob indication Continuity test Fuel Hose Inspection B940H21706005 Refer to Fuel Line Inspection in Section 0B Page 0B 7 Fuel Level Gauge Inspection B940H21706006 Refer to Fuel Level Gauge Inspection in Section 9C Page 9C 7 Fuel Level Indicator Inspection B940H21706007 Refer to Fuel Level Indicator Inspection in Section 9C Page 9C 6 Fuel Level Indicator Switch Thermistor Inspection B940...

Page 313: ...uel System 1G 8 Fuel Tank Construction B940H21706009 a 1 2 3 4 6 5 7 OUTSIDE I940H1170032 06 1 Clamp 4 Wiring harness 7 Cushion 2 Fuel tank 5 Fuel tank bracket a 45 5 3 Fuel tank cap 6 Fuel tank cushion ...

Page 314: ... Page 9D 5 2 Remove the fuel tank mounting bolt 3 Lift and support the fuel tank 4 Place a rag under the fuel feed hose and disconnect the fuel feed hose 1 CAUTION When removing the fuel tank do not leave the fuel feed hose 1 on the fuel pump side 5 Disconnect the fuel tank breather hose 2 6 Disconnect the fuel pump lead wire coupler 3 7 Disconnect the pilot lamp lead wire coupler 4 I940H1170008 0...

Page 315: ...oval Pay attention to the following points CAUTION Be careful not to bend the hoses When installing the fuel tank be careful not to scratch the radiator cap Connect the fuel feed hose 1 until it locks securely a click is heard When installing the fuel tank pass the fuel pump coupler 2 to under of the frame bridge 3 1 I940H1170037 01 2 3 2 I940H1170040 02 ...

Page 316: ...0H21706011 FWD FWD 7 a 5 4 3 2 1 6 I940H1170035 02 1 Filter cover 5 Fuel pressure regulator assembly Apply engine oil 2 Fuel mesh filter 6 Fuel level gauge Apply grease 3 Fuel pump 7 O ring Do not reuse 4 Thermistor 10 N m 1 0 kgf m 7 0 lbf ft ...

Page 317: ...the fuel pump assembly 1 and disconnect the fuel level gauge lead wire coupler 2 4 Remove the O ring 3 5 Remove the fuel level gauge 4 while pushing the pawl end A CAUTION Do not pull the lead wire when removing the fuel gauge Installation Install the fuel pump assembly in the reverse order of removal Pay attention to the following points Install the fuel level gauge 1 into the fuel tank NOTE Push...

Page 318: ... 0 kgf m 7 0 lbf ft Fuel Pump Disassembly and Assembly B940H21706013 Refer to Fuel Pump Assembly Fuel Level Gauge Removal and Installation Page 1G 12 Disassembly 1 Disconnect the fuel pump coupler 1 2 Remove the hose 2 clamp 3 and filter cover 4 3 Remove the fuel mesh filter 5 4 Remove the band 6 5 Remove the fuel pump 7 6 Remove the following parts from the adapter 8 Pressure regulator 9 Joint 10...

Page 319: ...h filter in the following procedures 1 Remove the fuel mesh filter Refer to Fuel Pump Disassembly and Assembly Page 1G 13 2 If the fuel mesh filter is clogged with foreign particles it hinders smooth gasoline flow resulting in loss of engine power NOTE When the fuel mesh filter is dirtied excessively replace the fuel mesh filter with a new one 3 Reinstall the fuel mesh filter Refer to Fuel Pump Di...

Page 320: ...all the fuel shut off valve as shown in the Fuel tank breather hose routing diagram Refer to Fuel Tank Breather Hose Routing Diagram Page 1G 3 2 Reinstall the removed parts Fuel Tank Breather Inspection B940H21706018 Inspect the fuel tank breather valve body for damage Inspect the fuel tank breather valve operation in the following procedures 1 When air is blown into the fuel tank breather valve w...

Page 321: ... 168 ml and more 5 7 5 9 US lmp oz for 10 seconds at 300 kPa 3 0 kgf cm2 43 psi Fuel pressure regulator operating set pressure Approx 300 kPa 3 0 kgf cm2 43 psi Item Specification Note Fuel type Use only unleaded gasoline of at least 90 pump octane R 2 M 2 Gasoline containing MTBE Methyl Tertiary Butyl Ether less than 10 ethanol or less than 5 methanol with appropriate cosolvents and corrosion inh...

Page 322: ... Tool B940H21708002 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or equivalent P No 99000 25010 Page 1G 13 09900 25008 09915 74521 Multi circuit tester set Oil pressure gauge hose Page 1G 7 Page 1G 5 09915 77331 09940 40211 Meter for high pressure Fuel pressure gauge adapter Page 1G 5 Page 1G 5 09940 40220 Fuel pressure gauge hose attachment Page 1G 5 ...

Page 323: ...bols in Section 0A Page 0A 5 Ignition System Components Location B940H21802002 Refer to Electrical Components Location in Section 0A Page 0A 7 ECM TP sensor ECT sensor GP switch Engine stop switch Fuse Fuse Ignition switch Battery CPU CKP sensor 1 R 2 F Side stand relay Power source circuit Waveform arrangement circuit I940H1180016 03 ...

Page 324: ... or replace Defective CKP sensor Replace Defective ECM Replace Spark plug is wet or quickly becomes fouled with carbon Excessively rich air fuel mixture Inspect FI system Excessively high idling speed Inspect FI system Incorrect gasoline Change Dirty air cleaner element Clean or replace Incorrect spark plug Cold type Change to hot type spark plug Spark plug quickly becomes fouled with oil or carbo...

Page 325: ...on coil primary peak voltage Refer to Ignition Coil and Plug Cap Inspection Page 1H 7 NOTE This inspection method is applicable only with the multi circuit tester and the peak volt adaptor Is the peak voltage OK Go to Step 4 Go to Step 5 4 Inspect the spark plugs Refer to Spark Plug Inspection and Cleaning in Section 0B Page 0B 7 Is the spark plug s OK Go to Step 5 Faulty spark plug s 5 Inspect th...

Page 326: ...121 Spark plug wrench set Installation Install the spark plugs and spark plug caps in the reverse order of removal Pay attention to the following points Screw the spark plugs into the cylinder head with fingers and then tighten them to the specified torque CAUTION Do not cross thread or over tighten the spark plug or such an operation will damage the aluminum threads of the cylinder head Special t...

Page 327: ...on B940H21806002 1 3 4 a 3 2 2 FWD I940H1180017 01 1 Clamp Clamp the high tension code so it does not contact to the cylinder head cover cap 4 Cushion Align both edges of cushion when adhering it 2 2 ignition coil a 50 mm 1 97 in 3 1 ignition coil ...

Page 328: ... Tank Removal and Installation in Section 1G Page 1G 9 2 Remove the left and right frame head cover Refer to Exterior Parts Removal and Installation in Section 9D Page 9D 5 3 Move the rear brake reservoir tank 1 by removing the mounting bolt 4 Disconnect the 2 ignition coil lead wire coupler 2 5 Remove the clamp 3 and ignition coil 4 Installation Install the ignition coils as shown in the ignition...

Page 329: ...propriate instruction manual Tester knob indication Voltage 3 Inspect the ignition coil primary peak voltage in the following procedures WARNING Do not touch the tester probes and spark plugs to prevent an electric shock while testing a Shift the transmission into neutral turn the ignition switch ON and grasp the clutch lever b Press the starter button and allow the engine to crank for a few secon...

Page 330: ...9D 5 3 Disconnect the CKP sensor lead wire coupler 1 and connect the multi circuit tester with the peak volt adaptor NOTE Be sure that all of the couplers are connected properly and the battery is fully charged 4 Connect the multi circuit tester with the peak volt adaptor as follows CAUTION Before using the multi circuit tester and peak voltage adaptor refer to the appropriate instruction manual S...

Page 331: ...al and Installation B940H21806007 Refer to Generator Removal and Installation in Section 1J Page 1J 5 Engine Stop Switch Inspection B940H21806008 Inspect the engine stop switch in the following procedures 1 Turn the ignition switch OFF 2 Remove the headlight Refer to Headlight Removal and Installation in Section 9B Page 9B 2 3 Disconnect the right handlebar switch coupler 1 4 Inspect the engine st...

Page 332: ...e Specifications B940H21807002 Reference For the tightening torque of fastener not specified in this section refer to Tightening Torque List in Section 0C Page 0C 8 1 2 I940H1180015 02 Item Specification Note Firing order 1 2 Spark plug Type NGK CR6E DENSO U20ESR N Gap 0 6 0 7 0 024 0 028 Spark performance Over 8 0 3 at 1 atm CKP sensor resistance 170 260 Ω Ignition coil resistance Primary 1 5 Ω S...

Page 333: ...ial Tools and Equipment Special Tool B940H21808001 09900 25008 09900 25009 Multi circuit tester set Needle pointed probe set Page 1H 7 Page 1H 8 Page 1H 8 Page 1H 9 Page 1H 7 09930 10121 Spark plug wrench set Page 1H 4 Page 1H 4 ...

Page 334: ... To the ignition coil O W Y G Clutch switch B Y Starter button Engine stop switch O B Turn signal Side stand relay G Ignition switch R Fuse 30 A GP switch Neutral Fuse 15 A Battery Bl Side stand switch O I822H1190001 01 Condition Possible cause Correction Reference Item Engine does not turn though the starter motor runs Faulty starter clutch Replace Starter button is not effective Run down battery...

Page 335: ...y starter relay Loose or disconnected starter motor lead wire Loose or disconnected between starter relay and battery terminal Faulty starter motor 3 Measure the starter relay voltage at the starter relay connectors between Y G and B Y when the starter button is pushed Is the voltage OK Go to Step 4 Faulty ignition switch Faulty engine stop switch Faulty clutch lever position switch Faulty gear po...

Page 336: ...emove the radiator heat shield 1 FWD FWD a 7 b 8 1 2 3 3 3 4 d 10 5 6 c 9 I940H1190038 01 1 O ring 7 Starter motor lead wire mounting nut 10 N m 1 0 kgf m 7 0 lbf ft 2 Housing end Inside 8 Brush holder nut 5 N m 0 5 kgf m 3 5 lbf ft 3 Starter motor case 9 Starter motor mounting bolt Apply grease 4 Armature 10 Starter motor housing bolt Apply moly paste to sliding surface 5 Brush holder 6 N m 0 6 k...

Page 337: ... O ring Grease 99000 25010 SUZUKI SUPER GREASE A or equivalent CAUTION Replace the O ring with a new one Connect the starter motor lead wire Tightening torque Starter motor lead wire mounting nut a 6 N m 0 6 kgf m 4 5 lbf ft Tighten the starter motor mounting bolt 1 to the specified torque Tightening torque Starter motor mounting bolt b 10 N m 1 0 kgf m 7 0 lbf ft 2 I940H1190002 01 3 I940H1190003 ...

Page 338: ...otor in the reverse order of removal Pay attention to the following points CAUTION Replace the O ring with new ones to prevent oil leakage and moisture Apply grease to the lip of the oil seal Grease 99000 25010 SUZUKI SUPER GREASE A or equivalent Apply a small quantity of moly paste to the armature shaft Moly paste 99000 25140 SUZUKI Moly paste or equivalent Align the projection A on the brush hol...

Page 339: ...s 1 20 mm 200 mm Commutator Inspect the commutator for discoloration abnormal wear or undercut A If the commutator is abnormally worn replace the armature If the commutator surface is discolored polish it with 400 sandpaper and wipe it using a clean dry cloth If there is no undercut scrape out the insulator 1 with a saw blade Armature Coil Measure for continuity between each segment Measure for co...

Page 340: ...in the reverse order of removal Starter Relay Inspection B940H21906006 Inspect the starter relay in the following procedures 1 Remove the starter relay Refer to Starter Relay Removal and Installation Page 1I 7 2 Apply 12 V to A and B terminals and check for continuity between the positive and negative terminals using the multi circuit tester If the starter relay clicks and continuity is found the ...

Page 341: ... Check the interlock system for proper operation If the interlock system does not operate properly check each component for damage or abnormalities If any abnormality is found replace the component with a new one Side stand Switch 1 Turn the ignition switch OFF 2 Remove the left frame side cover Refer to Exterior Parts Removal and Installation in Section 9D Page 9D 5 3 Disconnect the side stand sw...

Page 342: ... relay Refer to Turn Signal Side stand Relay Removal and Installation Page 1I 8 Diode inspection 1 Remove the turn signal side stand relay Refer to Turn Signal Side stand Relay Removal and Installation Page 1I 8 2 Measure the voltage between the A B and C terminals using the multi circuit tester Special tool 09900 25008 Multi circuit tester set Tester knob indication Diode test NOTE If the multi c...

Page 343: ...ack White lead wires using the multi circuit tester when shifting the gearshift lever from low to top Special tool A 09900 25008 Multi circuit tester set B 09900 25009 Needle pointed probe set Tester knob indication Voltage Gear position switch voltage Except neutral position 0 6 V and more P B 8 Turn the ignition switch OFF 9 Install the right frame side cover Refer to Exterior Parts Removal and ...

Page 344: ...de 2 NOTE Be sure to seat the flange A of the one way clutch 1 to the guide 2 Install the guide 2 to the generator rotor NOTE The arrow mark B must face to the generator rotor side Apply thread lock to the bolts and then tighten them to the specified torque with the special tool Thread lock cement 99000 32030 THREAD LOCK CEMENT SUPER 1303 or equivalent Tightening torque Starter clutch bolt a 25 N ...

Page 345: ...torque limiter socket 2 Turn the starter torque limiter with a torque wrench and check the slip torque If the slip torque is not within the specification replace the starter torque limiter with a new one Starter torque limiter slip torque Standard 19 6 39 2 N m 1 96 3 92 kgf m 14 0 28 5 lbf ft Starter Clutch Inspection B940H21906011 Refer to Starter Torque Limiter Starter Clutch Removal and Instal...

Page 346: ...B 2 2 Disconnect the right handlebar switch coupler 1 3 Inspect the starter button for continuity with a tester If any abnormality is found replace the right handle switch assembly with a new one Refer to Handlebars Removal and Installation in Section 6B Page 6B 1 Special tool 09900 25008 Multi circuit tester set Tester knob indication Continuity 4 After finishing the starter button inspection rei...

Page 347: ...dard 19 6 39 2 N m 1 96 3 92 kgf m 14 0 28 5 lbf ft Starter relay resistance 3 6 Ω Fastening part Tightening torque Note N m kgf m lbf ft Starter motor lead wire mounting nut 6 0 6 4 5 Page 1I 4 Starter motor mounting bolt 10 1 0 7 0 Page 1I 4 Radiator heat shield mounting bolt Left side 5 5 0 55 4 0 Page 1I 5 Radiator heat shield mounting bolt Right side 10 1 0 7 0 Page 1I 5 Brush holder nut 11 1...

Page 348: ...20 mm 200 mm Multi circuit tester set Page 1I 6 Page 1I 6 Page 1I 7 Page 1I 8 Page 1I 8 Page 1I 9 Page 1I 9 Page 1I 10 Page 1I 10 Page 1I 13 09900 25009 09930 73140 Needle pointed probe set Starter torque limiter socket Page 1I 10 Page 1I 12 09930 73170 Starter torque limiter holder Page 1I 12 ...

Page 349: ...ing Diagram Charging System Diagram B940H21A02001 Component Location Charging System Components Location B940H21A03001 Refer to Electrical Components Location in Section 0A Page 0A 7 Generator Regulator Rectifier IC SCR Battery Load Ignition switch I940H11A0026 03 ...

Page 350: ...sulting in intermittent short circuiting Repair or replace Internally short circuited generator Replace Defective regulator rectifier Replace Battery overcharges Faulty regulator rectifier Replace Faulty battery Replace Poor contact of generator lead wire coupler Repair Battery runs down quickly Trouble in charging system Check the generator regulator rectifier and circuit connections and make nec...

Page 351: ... of electricity Are accessories being installed Remove accessories Go to Step 2 2 Check the battery for current leakage Refer to Battery Current Leakage Inspection Page 1J 3 Is the battery for current leakage OK Go to Step 3 Short circuit of wire harness Faulty electrical equipment 3 Measure the regulated voltage between the battery terminals Refer to Regulated Voltage Inspection Page 1J 4 Is the ...

Page 352: ...ion Special tool 09900 25008 Multi circuit tester set Tester knob indication Voltage Regulated voltage Charging output Standard 13 5 15 5 V at 5 000 r min 5 Install the seat Refer to Exterior Parts Removal and Installation in Section 9D Page 9D 5 Generator Inspection B940H21A06003 Generator Coil Resistance 1 Remove the left frame lower cover Refer to Exterior Parts Removal and Installation in Sect...

Page 353: ...he battery lead wire Refer to Battery Battery Holder Removal and Installation Page 1J 11 2 Drain engine oil Refer to Engine Oil and Filter Replacement in Section 0B Page 0B 8 3 Remove the left frame lower cover and secondary gear case cover Refer to Exterior Parts Removal and Installation in Section 9D Page 9D 5 4 Remove the left foot rest 1 along with the gearshift lever 5 Remove the clutch relea...

Page 354: ...ool A 09930 30721 Rotor remover 11 Remove the key 6 12 Remove the generator stator 7 along with the CKP sensor 8 Installation Install the generator in the reverse order of removal Pay attention to the following points Tighten the generator starter set bolts 1 and CKP sensor mounting bolts 2 to the specified torque NOTE Be sure the grommet 3 is set to the generator cover Tightening torque Generator...

Page 355: ...erator rotor bolt c 160 N m 16 0 kgf m 115 5 lbf ft Apply molybdenum oil solution to the idle gear shaft holes M O Molybdenum oil MOLYBDENUM OIL SOLUTION Install the dowel pins and new gasket 5 CAUTION Use a new gasket to prevent oil leakage Install the generator cover and tighten the generator cover bolts WARNING Be careful not to pinch the finger between the generator cover and the crankcase Ins...

Page 356: ...tester as indicated in the following table If the voltage is not within the specified value replace the regulator rectifier with a new one NOTE If the tester reads 1 4 V and below when the tester probes are not connected replace its battery Special tool 09900 25008 Multi circuit tester set Tester knob indication Diode test Unit V 6 Connect the regulator rectifier couplers and bind the clamp 1 I940...

Page 357: ...completely use the removed cap 2 as sealing caps of battery filler holes 3 Insert the nozzles of the electrolyte container 3 into the electrolyte filler holes of the battery 4 Hold the electrolyte container firmly so that it does not fall NOTE Do not allow any of the electrolyte to spill 5 Make sure that air bubbles 4 rise to the top of each electrolyte container and leave in this position for abo...

Page 358: ...e caps with a hammer when installing them Charging For initial charging use the charger specially designed for MF battery CAUTION For charging the battery make sure to use the charger specially designed for MF battery Otherwise the battery may be overcharged resulting in shortened service life Do not remove the cap during charging Position the battery with the cap facing upward during charging Bat...

Page 359: ... to Battery Battery Holder Removal and Installation Page 1J 11 Battery Battery Holder Removal and Installation B940H21A06008 Removal 1 Remove the seat Refer to Exterior Parts Removal and Installation in Section 9D Page 9D 5 2 Disconnect the battery lead wire 1 3 Disconnect the battery lead wire 2 NOTE Be sure to disconnect the battery lead wire 1 first then disconnect the battery lead wire 2 4 Rem...

Page 360: ... wire mounting bolts securely Battery Visual Inspection B940H21A06009 Inspect the battery in the following procedures 1 Remove the seat Refer to Exterior Parts Removal and Installation in Section 9D Page 9D 5 2 Visually inspect the surface of the battery container If any signs of cracking or electrolyte leakage from the sides of the battery have occurred replace the battery with a new one If the b...

Page 361: ...pprox 425 W at 5 000 r min Generator no load voltage When engine is cold 80 V AC and more at 5 000 r min Regulated voltage 13 5 15 5 V at 5 000 r min Battery Type designation FTZ16 BS Capacity 12 V 64 8 kC 18 Ah 10 HR Fastening part Tightening torque Note N m kgf m lbf ft Generator stator set bolt 11 1 1 8 0 Page 1J 6 CKP sensor mounting bolt 5 5 0 55 4 0 Page 1J 6 Generator rotor bolt 160 16 0 11...

Page 362: ...ffler have enough clearance from the rubber parts and plastic parts to avoid melting Repair Instructions Exhaust System Construction B940H21B06001 CAUTION Replace the gaskets and connectors with new ones when reassembling a 2 1 a 1 c 2 b b d 3 b b b b I940H11B0017 01 1 Gasket 10 N m 1 0 kgf m 7 0 lbf ft 2 Connector Chamfer side should face muffler side 48 N m 4 8 kgf m 34 5 lbf ft 3 HO2 sensor For...

Page 363: ...t the HO2 sensor lead wire coupler 1 and remove the clamp 2 3 Remove the rear muffler upper cover 3 4 Loosen the muffler connecting bolt 4 5 Remove the muffler joint bolts 5 6 Remove the rear muffler 6 7 Remove the muffler support bolt and nut 7 8 Remove the exhaust pipe bolts 8 1 2 I940H11B0002 02 3 I940H11B0003 01 4 I940H11B0004 01 5 I940H11B0005 01 6 I940H11B0006 01 7 I940H11B0007 01 8 8 I940H1...

Page 364: ...tion to the following points Tighten the HO2 sensor to the specified torque Tightening torque HO2 sensor a 48 N m 4 8 kgf m 34 5 lbf ft CAUTION Be careful not to expose it to an excessive shock Do not use an impact wrench when installing the HO2 sensor Be careful not to twist or damage the sensor lead wires Do not apply oil or other materials to the sensor air hole Install the exhaust pipe gaskets...

Page 365: ...r joint bolts and exhaust pipe bolt and tighten them to the specified torque Thread lock cement 99000 32130 THREAD LOCK CEMENT SUPER 1360 or equivalent Tightening torque Muffler joint bolt h 26 N m 2 6 kgf m 19 0 lbf ft Route the HO2 sensor lead wire Refer to Throttle Body Construction in Section 1D Page 1D 10 and Wiring Harness Routing Diagram in Section 9A Page 9A 5 Exhaust System Inspection B94...

Page 366: ...o described in the following Exhaust System Construction Page 1K 1 Fastening part Tightening torque Note N m kgf m lbf ft HO2 sensor 48 4 8 34 5 Page 1K 3 Muffler connecting bolt Front 26 2 6 19 0 Page 1K 4 Exhaust pipe bolt 23 2 3 16 5 Page 1K 4 Muffler support nut 26 2 6 19 0 Page 1K 4 Muffler connecting bolt Rear 26 2 6 19 0 Page 1K 4 Rear muffler upper cover mounting bolt 10 1 0 7 0 Page 1K 4 ...

Page 367: ...stallation 2C 7 Cushion Lever Inspection 2C 7 Cushion Lever Bearing Removal and Installation 2C 8 Swingarm Related Parts Inspection 2C 9 Swingarm Bearing Removal and Installation 2C 11 Specifications 2C 12 Service Data 2C 12 Tightening Torque Specifications 2C 12 Special Tools and Equipment 2C 12 Recommended Service Material 2C 12 Special Tool 2C 13 Wheels and Tires 2D 1 Precautions 2D 1 Precautio...

Page 368: ... suspensions bolts and nuts are an important part in that it could affect the performance of vital parts They must be tightened to the specified torque periodically and if the suspension effect is lost replace it with a new one CAUTION Never attempt to heat quench or straighten any suspension part Replace it with a new one or damage to the part may result ...

Page 369: ...ive fork oil Check level and drain Bent front axle Replace Front suspension too noisy Insufficient fork oil Check level and add Loose front suspension fastener Tighten Wobbly rear wheel Distorted wheel rim Replace Worn rear wheel bearing Replace Defective or incorrect tire Replace Worn swingarm bearing Replace Worn rear suspension bearing Replace Loose rear suspension fastener Tighten Rear suspens...

Page 370: ...ing 15 Front fork cap bolt 2 Spacer 9 Inner rod lock nut 15 N m 1 5 kgf m 11 0 lbf ft 3 Outer tube 10 Inner rod Damper rod cartridge 23 N m 2 3 kgf m 16 5 lbf ft 4 Oil seal retainer 11 Inner tube 30 N m 3 0 kgf m 21 5 lbf ft 5 Oil seal 12 Gasket Apply thread lock to the thread part 6 Oil seal stopper ring 13 Damper rod bolt Apply fork oil 7 Dust seal 14 Front axle pinch bolt Do not reuse ...

Page 371: ...cilitate later disassembly 4 Loosen the front fork lower clamp bolts 3 and remove the front fork NOTE Hold the front fork by the hand to prevent sliding out of the steering stem Installation 1 Set the front fork to the front fork lower bracket temporarily by tightening the lower clamp bolts 1 2 Tighten the front fork cap bolt 2 to the specified torque Tightening torque Front fork cap bolt a 23 N m...

Page 372: ...NOTE The right and left front forks are installed symmetrically and therefore the disassembly procedure for one side is the same as that for the other side Disassembly 1 Compress the front fork spring with the special tool A and insert the special tool B between the lock nut and the spacer Special tool A 09940 94930 Front fork spacer holder B 09940 94922 Front fork spring stopper plate 2 Remove th...

Page 373: ...the damper rod bolt using the special tools Special tool C 09940 30221 Front fork assembling tool 9 Remove the inner rod damper rod cartridge 6 CAUTION Do not disassemble the inner rod damper rod cartridge 10 Remove the outer tube from the inner tube 11 Remove the dust seal 7 and oil seal stopper ring 8 3 4 I940H1220010 01 I823H1220018 01 5 I940H1220011 01 C I940H1220012 01 6 I940H1220013 02 I940H...

Page 374: ... 3 Oil seal retainer 4 CAUTION The oil seal and dust seal must be replaced with new ones when assembling front fork When installing the oil seal to inner tube be careful not to damage the oil seal lip Apply fork oil to the oil seal lip Fork Oil 99000 99044 L01 SUZUKI FORK OIL L01 or equivalent Install the oil seal 3 into the outer tube using the special tool Special tool A 09940 52861 Front fork o...

Page 375: ...r equivalent Tightening torque Damper rod bolt a 30 N m 3 0 kgf m 21 5 lbf ft Fork oil Place the front fork vertically without spring Compress it fully Pour specified front fork oil to the inner tube Fork Oil 99000 99044 L01 SUZUKI FORK OIL L01 or equivalent Capacity each leg 636 ml 21 5 22 4 US lmp oz Move the inner rod slowly with the special tool more than ten times until bubbles do not come ou...

Page 376: ...g and compress the inner tube fully Special tool B 09943 74111 Fork oil level gauge Fork oil level a 121 mm 4 8 in Front fork inner rod lock nut Loosen the lock nut 1 to the bottom of inner rod threads Fork spring Install the fork spring as shown in the figure NOTE The smaller pitch a should face to the bottom side of the front fork Front fork cap bolt Pull up the inner rod with the special tool S...

Page 377: ...mbly and Assembly Page 2B 3 Inner and Outer Tubes Inspect the inner tube outer surface and outer tube inner surface for scratches Inspect the ANTI FRICTION metal surfaces for scratches If any defects are found replace them with the new ones CAUTION Do not remove the ANTI FRICTION metals A and B Fork Spring Measure the fork spring free length If it is shorter than the service limit replace it with ...

Page 378: ...ork spring free length 338 13 3 331 13 0 Front fork inner tube O D 43 1 7 Front fork oil level Without spring inner tube fully compressed 121 4 8 Front fork oil type SUZUKI FORK OIL L01 or an equivalent fork oil Front fork oil capacity Each leg 636 ml 21 5 22 4 US lmp oz Fastening part Tightening torque Note N m kgf m lbf ft Front fork cap bolt 23 2 3 16 5 Page 2B 2 Front fork lower clamp bolt 23 ...

Page 379: ... 09940 34531 T handle Attachment A Page 2B 6 Page 2B 6 09940 52841 09940 52861 Front fork inner rod holder Front fork oil seal installer Page 2B 6 Page 2B 7 Page 2B 5 09940 94922 09940 94930 Front fork spring stopper plate Front fork spacer holder Page 2B 3 Page 2B 3 Page 2B 7 Page 2B 3 Page 2B 3 Page 2B 7 09943 74111 Fork oil level gauge Page 2B 7 ...

Page 380: ... absorber 8 Swingarm pivot shaft nut 65 N m 6 5 kgf m 47 0 lbf ft 2 Rear cushion rod 9 Swingarm pivot bearing 132 N m 13 2 kgf m 95 5 lbf ft 3 Spacer 10 Boot 100 N m 10 0 kgf m 72 5 lbf ft 4 Rear cushion lever bearing 11 Rear cushion rod bearing Apply grease to the bearing 5 Rear cushion lever seal 12 Rear cushion rod seal Do not reuse 6 Rear cushion lever 13 Swingarm pivot cover 7 Swingarm pivot ...

Page 381: ...t Lower b 5 0 mm 0 20 in 3 Cushion rod mounting nut Upper c 0 5 mm 0 02 in 4 Cushion rod mounting nut Lower d 5 5 mm 0 22 in 5 Cushion lever mounting nut 65 N m 6 5 kgf m 47 0 lbf ft 6 Cushion rod The stamped mark side of the cushion rod should face outside 132 N m 13 2 kgf m 95 5 lbf ft 7 Cushion lever The stamped mark 40H side of the cushion lever should face right side 100 N m 10 0 kgf m 72 5 l...

Page 382: ... Remove the right frame lower cover Refer to Exterior Parts Removal and Installation in Section 9D Page 9D 5 4 Remove the rear brake hose 1 and bracket 2 5 Remove the rear brake pipe 3 by removing brake pipe clamps 6 Remove the final gear assembly 4 Refer to Final Gear Assembly Removal and Installation in Section 3A Page 3A 12 7 Remove the rear shock absorber upper bolt spacer and nut 8 Remove the...

Page 383: ...Bearing remover 09930 30104 Rotor remover sliding shaft Installation Install the swingarm in the reverse order of removal Pay attention in the following points CAUTION The removed bearings and cushion rod seals must be replaced with new ones Install the cushion rod bearing 1 with the special tool as shown in the rear suspension assembly construction Refer to Rear Suspension Assembly Construction P...

Page 384: ...rear shock absorber mounting nut to the specified torque Tightening torque Rear shock absorber mounting nut Lower b 65 N m 6 5 kgf m 47 0 lbf ft Install the swingarm assembly and tighten the swingarm pivot shaft nut 4 to the specified torque with the special tool NOTE After tightening the swingarm pivot shaft nut be sure to check the swingarm operation Tightening torque Swingarm pivot shaft nut c ...

Page 385: ...val and Installation Page 2C 6 2 Inspect the rear shock absorber for damage and oil leakage and absorber bushing for wear and damage If any defect is found replace the rear shock absorber with a new one CAUTION Do not attempt to disassemble the rear shock absorber It is unserviceable 3 Install the rear shock absorber Refer to Swingarm Assembly Removal and Installation Page 2C 3 Rear Suspension Adj...

Page 386: ...ear shock absorber 1 with a vinyl bag 2 and fix it on a vise as shown in the figure 3 Drill a 2 3 mm 0 08 0 12 in hole at the marked drill center using a drilling machine and let out gas while taking care not to get the vinyl bag entangled with the drill bit WARNING Be sure to wear protective glasses since drilling chips and oil may fly off with blowing gas when the drill bit has penetrated throug...

Page 387: ... cushion lever for damage If any defect is found replace the cushion lever with a new one Cushion Lever Bearing Removal and Installation B940H22306011 Refer to Swingarm Assembly Removal and Installation Page 2C 3 Removal 1 Remove the cushion lever seal 1 2 Remove the cushion lever bearings using the special tools Special tool A 09921 20240 Bearing remover set B 09913 70210 Bearing installer set I9...

Page 388: ...nstall the cushion lever seal with the special tool Special tool C 09913 70210 Bearing installer set 3 Install the bearings 1 and 2 with the special tool Special tool C 09924 84521 Bearing installer set 4 Apply grease to the bearings and cushion lever seal Grease 99000 25010 SUZUKI SUPER GREASE A or equivalent Swingarm Related Parts Inspection B940H22306012 Refer to Swingarm Assembly Removal and I...

Page 389: ... down If excessive play is noted replace the bearing with a new one Refer to Swingarm Assembly Removal and Installation Page 2C 3 Cushion Rod Inspect the cushion rods for damage and bend If any defects are found replace the cushion rods with new ones Swingarm Pivot Shaft Measure the swingarm pivot shaft runout using the dial gauge If the runout exceeds the service limit replace the pivot shaft Spe...

Page 390: ...enter spacer 2 Installation 1 Install the center spacer 2 Press the bearings into the swingarm pivot with the special tool NOTE When installing the bearing stamped mark on the bearing must face outside Special tool A 09941 34513 Steering race installer 3 Apply grease to the bearings Grease 99000 25010 SUZUKI SUPER GREASE A or equivalent 4 Install the swingarm Refer to Cushion Lever Removal and Ins...

Page 391: ...terial is also described in the following Rear Suspension Components Page 2C 1 Rear Suspension Assembly Construction Page 2C 2 Item Standard Limit Rear shock absorber spring pre set length 192 7 56 Rear wheel travel 108 4 3 Swingarm pivot shaft runout 0 3 0 01 Fastening part Tightening torque Note N m kgf m lbf ft Cushion rod nut 132 13 2 95 5 Page 2C 5 Rear shock absorber mounting nut Lower 65 6 ...

Page 392: ...0 09910 60611 09913 70210 Universal clamp wrench Bearing installer set Page 2C 6 Page 2C 5 Page 2C 8 Page 2C 9 09921 20240 09923 73210 Bearing remover set Bearing remover Page 2C 8 Page 2C 11 Page 2C 4 09924 84510 09924 84521 Bearing installer set Bearing installer set Page 2C 4 Page 2C 9 Page 2C 9 09930 30104 09941 34513 Rotor remover sliding shaft Steering race installer Page 2C 4 Page 2C 4 Page...

Page 393: ...s Over inflation reduces tire s area of road contact and thus results in skidding and loss of control Do not interchange tires between wheels on the same motorcycle Do not use tires of sizes and types different from the originally installed tires Rotation of tires or use of such different tires may adversely affect handling of the motorcycle and can result in loss of control Replace the wheel if i...

Page 394: ... 6 3 2 9 a 5 6 FWD FWD I940H1240047 02 1 Front axle 7 Front wheel 100 N m 10 0 kgf m 72 5 lbf ft 2 Dust seal 8 Front tire Apply grease 3 Bearing 9 Collar Apply thread lock to the thread part 4 Spacer 10 Wheel balancer Do not reuse 5 Brake disc bolt 11 Air valve 6 Brake disc 23 N m 2 3 kgf m 16 5 lbf ft ...

Page 395: ...stand Make sure that the motorcycle is supported securely 2 Remove the brake calipers Refer to Front Brake Caliper Removal and Installation in Section 4B Page 4B 3 CAUTION Do not operate the brake lever while removing the caliper b a LH RH a 3 a 1 c 2 a 1 I940H1240042 05 1 Brake disc bolt a Clearance 39 N m 3 9 kgf m 28 0 lbf ft 2 Brake caliper mounting bolt 23 N m 2 3 kgf m 16 5 lbf ft Apply grea...

Page 396: ...000 25010 SUZUKI SUPER GREASE A or equivalent 2 Install the front wheel with the front axle and tighten the front axle temporarily WARNING The directional arrow on the tire should point to the wheel rotation when remounting the wheel 3 Tighten the front brake caliper mounting bolts 2 to the specified torque Tightening torque Front brake caliper mounting bolt a 39 N m 3 9 kgf m 28 0 lbf ft WARNING ...

Page 397: ...n Page 2D 3 Tire Refer to Tire Inspection in Section 0B Page 0B 16 Front Brake Disc Refer to Front Brake Disc Inspection in Section 4B Page 4B 7 Dust Seal Inspect the dust seal lips for wear or damage If any defects are found replace the dust seal with the new ones Refer to Front Wheel Dust Seal Bearing Removal and Installation Page 2D 6 Wheel Axle Using a dial gauge check the wheel axle for runou...

Page 398: ... the play of the wheel bearings by finger while they are in the wheel Rotate the inner race by finger to inspect for abnormal noise and smooth rotation Replace the bearing in the following procedure if there is anything unusual Refer to Front Wheel Dust Seal Bearing Removal and Installation Page 2D 6 Front Wheel Dust Seal Bearing Removal and Installation B940H22406005 Removal 1 Remove the front wh...

Page 399: ... bearing then install the spacer 1 and left wheel bearing with the special tool Special tool A 09941 34513 Steering race installer B 09924 84510 Bearing installer set CAUTION The sealed cover of the bearing must face outside 3 Install the dust seals with the special tool Special tool C 09913 70210 Bearing installer set I649G1240019 02 A B I940H1240018 02 1 Spacer a Clearance LH RH LH RH a A B A B ...

Page 400: ...ires 4 Apply grease to the lip of the dust seals Grease 99000 25010 SUZUKI SUPER GREASE A or equivalent 5 Install the front wheel assembly Refer to Front Wheel Assembly Removal and Installation Page 2D 3 I940H1240021 01 ...

Page 401: ...cer 17 Wheel balancer 2 Spacer 10 Rear wheel 18 Air valve 3 Bearing 11 Rear tire 23 N m 2 3 kgf m 16 5 lbf ft 4 Lock washer 12 Dust seal 100 N m 10 0 kgf m 72 5 lbf ft 5 Driven joint stopper 13 Collar Apply grease 6 Driven joint 14 Brake disc Apply thread lock to the thread part 7 Wheel damper 15 Brake disc bolt Do not reuse 8 O ring 16 Rear axle nut ...

Page 402: ...moval and Installation in Section 4C Page 4C 3 CAUTION Do not operate the brake pedal while removing the caliper NOTE It is unnecessary to disengage the brake hose from the caliper 3 Remove the brake caliper bracket mounting bolt 1 b a LH RH a 1 I940H1240044 04 1 Brake disc bolt 100 N m 10 0 kgf m 72 5 lbf ft Apply grease a Clearance Apply thread lock to the thread part 23 N m 2 3 kgf m 16 5 lbf f...

Page 403: ...r wheel assembly 7 and collar 8 Installation 1 Apply grease to the final gear spline Grease 99000 25010 SUZUKI SUPER GREASE A or equivalent 2 Install the rear wheel with the front axle and tighten the front axle temporarily WARNING The directional arrow on the tire should point to the wheel rotation when remounting the wheel 2 I940H1240023 01 A 3 4 I940H1240024 01 5 I940H1240025 01 6 I940H1240026 ...

Page 404: ...rear axle with the special tool and tighten the rear axle nut 4 to the specified torque Tightening torque Rear axle nut b 100 N m 10 0 kgf m 72 5 lbf ft Special tool A 09944 28320 Hexagon socket 19 mm 9 Install the cap 5 10 Install the brake caliper Refer to Rear Brake Caliper Removal and Installation in Section 4C Page 4C 3 Rear Wheel Related Parts Inspection B940H22406009 Refer to Rear Wheel Ass...

Page 405: ...n or loosened wheel bearings and can be reduced by replacing the bearings If bearing replacement fails to reduce the runout replace the wheel 3 Install the brake pads Refer to Rear Brake Pad Replacement in Section 4C Page 4C 2 Wheel rim runout Service limit Axial and Radial 2 0 mm 0 08 in Bearing Inspect the play of the wheel bearings by hand while they are in the wheel Rotate the inner race by ha...

Page 406: ... wheel bearings Grease 99000 25010 SUZUKI SUPER GREASE A or equivalent 2 First install the right wheel bearing then install the spacer 1 and left wheel bearings with the special tools Special tool A 09941 34513 Steering race installer B 09924 84510 Bearing installer set CAUTION The sealed cover of the bearing must face outside B 2 I940H1240036 01 3 I940H1240037 01 I649G1240019 02 1 Spacer a Cleara...

Page 407: ... requirement and can make the operation efficient as well as functional CAUTION For operating procedures refer to the instructions supplied by the tire changer manufacturer NOTE When removing the tire in case of repair or inspection mark the tire with a chalk to indicate the tire position relative to the valve position Even though the tire is refitted to the original position after repairing punct...

Page 408: ...around 6 If the distance between the rim line and wheel rim varies this indicates that the bead is not properly seated If this is the case deflate the tire completely and unseat the bead for both sides Coat the bead with lubricant and fit the tire again 7 When the bead has been fitted properly adjust the pressure to specification 8 As necessary adjust the tire balance Refer to Wheel Balance Check ...

Page 409: ...r wear and damage If any defect is found replace the valve core with a new one Refer to Air Valve Removal and Installation Page 2D 17 Air Valve Removal and Installation B940H22406013 Removal 1 Remove the wheel assembly Refer to Front Wheel Assembly Removal and Installation Page 2D 3 and Rear Wheel Assembly Removal and Installation Page 2D 10 2 Remove the tire Refer to Tire Removal and Installation...

Page 410: ... wheel balance using the balancer and adjust the wheel balance if necessary CAUTION For operating procedures refer to the instructions supplied by the wheel balancer manufacturer 3 When installing the balancer weight to the wheel set the balancer weight on center rib of the wheel 4 Recheck the wheel balance 5 Install the wheel assembly Refer to Front Wheel Assembly Removal and Installation Page 2D...

Page 411: ...lo riding Front 250 kPa 2 50 kgf cm2 36 psi Rear 250 kPa 2 50 kgf cm2 36 psi Cold inflation tire pressure Dual riding Front 250 kPa 2 50 kgf cm2 36 psi Rear 290 kPa 2 90 kgf cm2 42 psi Tire size Front 120 70ZR 18M C 59W tubeless Rear 200 50ZR 17M C 75W tubeless Tire type Front BRIDGESTONE G853 G Rear BRIDGESTONE G852 G Tire tread depth Recommended depth Front 1 6 mm 0 06 in Rear 2 0 mm 0 08 in Fas...

Page 412: ...etic stand V block 100 mm Page 2D 5 Page 2D 13 Page 2D 5 Page 2D 13 09913 50121 09913 70210 Oil seal remover Bearing installer set Page 2D 6 Page 2D 13 Page 2D 7 Page 2D 15 09921 20240 09924 84510 Bearing remover set Bearing installer set Page 2D 6 Page 2D 14 Page 2D 7 Page 2D 14 09941 34513 09944 28320 Steering race installer Hexagon socket 19 mm Page 2D 7 Page 2D 14 Page 2D 11 Page 2D 12 ...

Page 413: ...ondary Driven Gear Related Parts Inspection 3A 8 Secondary Gear Shim Inspection and Adjustment 3A 9 Final Bevel Gear Components 3A 11 Final Gear Construction 3A 12 Final Gear Assembly Removal and Installation 3A 12 Final Gear Disassembly and Assembly 3A 14 Final Gear Parts Inspection 3A 21 Universal Joint Removal and Installation 3A 21 Universal Joint Inspection 3A 22 Rear Wheel Dumper Removal and...

Page 414: ...le Precautions Precautions Precautions for Driveline Axle B940H23000001 Refer to General Precautions in Section 00 Page 00 1 WARNING Support the motorcycle with a jack or wooden block when servicing the driveshafts and drive train ...

Page 415: ...bevel gear and final bevel gear assemblies Oil level too low Refill Check oil jet Replace oil seal Drive and driven bevel gears damaged or worn Replace Excessive backlash Adjust Improper tooth contact Adjust Damage to bearings Replace Noisy shaft drive Noise seems to come from propeller shaft area Propeller shaft universal joint damaged Replace Propeller shaft splines damaged or worn Replace Insuf...

Page 416: ...kgf m 68 5 lbf ft 3 Driven bevel gear coupling 11 Secondary driven bearing stopper 55 N m 5 5 kgf m 40 0 lbf ft 4 O ring 12 Secondary driven bevel gear spacer 160 N m 16 0 kgf m 115 5 lbf ft 5 Secondary shaft spacer 13 Secondary driven bevel gear Apply grease 6 Oil seal 14 Secondary driven gear shaft Apply thread lock to the thread part 7 Bearing housing 15 Bearing Apply thread lock to the thread ...

Page 417: ... in Section 9C Page 9C 7 3 Remove the clutch release assembly Refer to Clutch Release Assembly Push Rod Removal and Installation in Section 5C Page 5C 2 4 Remove the secondary gear case 1 5 Remove the dowel pins 2 and secondary driven gear assembly 3 1 Shims 4 Secondary driven gear Apply grease 2 Shims 95 N m 9 5 kgf m 68 5 lbf ft Apply thread lock to the thread part 3 Secondary drive gear 55 N m ...

Page 418: ...ing Sealant 99000 31110 SUZUKI BOND No 1215 or equivalent Install the secondary gear case and temporarily tighten the bolts to the specified torque Tightening torque Secondary gear case bolt Initial a 15 N m 1 5 kgf m 11 0 lbf ft Apply a small quantity of the thread lock to the bearing housing bolts and tighten them to the specified torque Thread lock cement 99000 32030 THREAD LOCK CEMENT SUPER 13...

Page 419: ... gear coupling holder 4 Remove the washer 2 and driven bevel gear coupling 3 5 Remove the following parts from the shaft 4 Secondary shaft spacer 5 Bearing housing 6 Secondary driven bevel gear spacer 7 Secondary driven bevel gear 8 6 Remove the oil seal 9 7 Unlock the secondary driven bearing stopper 10 8 Remove the secondary driven bearing stopper 10 with the special tool Special tool B 09924 41...

Page 420: ...ring with the special tool CAUTION The removed bearing must be replaced with a new one NOTE When installing the bearing stamped mark on the bearing must face outside Special tool A 09913 70210 Bearing installer set 2 Install the oil seal with the special tool CAUTION The removed oil seal must be replaced with a new one Special tool A 09913 70210 Bearing installer set B 09924 74520 Oil seal install...

Page 421: ...4 41830 Bearing retainer wrench Tightening torque Secondary driven bevel gear bearing stopper a 105 N m 10 5 kgf m 76 0 lbf ft 5 Lock the bearing stopper 3 with a center punch 6 Install the secondary driven bevel gear 4 secondary driven bevel gear spacer 5 and bearing housing 3 to the shaft 6 7 Apply grease to the lip of oil seal and O ring and install the secondary shaft spacer 7 CAUTION Replace ...

Page 422: ...5 Refer to Secondary Driven Gear Disassembly and Assembly Page 3A 5 Driven Bevel Gear Inspect the driven bevel gear for wear or damage If any defects are found replace the gear with a new one Driven Bevel Gear Shaft Inspect the driven bevel gear shaft for wear or damage If any defects are found replace the driven bevel gear shaft with a new one Bearing Inspect the secondary bevel gear bearings lef...

Page 423: ... so that it touches the backlash measuring tool arm at the mark hold the secondary drive bevel gear securely and turn the secondary driven bevel gear coupling slightly in each direction reading the total backlash on the dial gauge Secondary gear backlash Standard 0 03 0 15 mm 0 001 0 006 in If the backlash is not within specification the shims driven bevel gear side must be changed and the backlas...

Page 424: ... is made the backlash must be rechecked as it may change Refer to the backlash checking sub section and readjust until both backlash and tooth contact are correct Contact Position List of shims For drive bevel gear side 1 List of shims For driven bevel gear side 2 1 Shim Drive bevel gear side 2 Shim Driven bevel gear side Backlash Shim adjustment Contact at tooth top A Decrease thickness of shims ...

Page 425: ...f m 36 0 lbf ft 5 Final driven bevel gear 19 Spring 110 N m 11 0 kgf m 79 5 lbf ft 6 Shims 20 Snap ring 40 N m 4 0 kgf m 29 0 lbf ft 7 Final driven gear bearing 21 Oil seal 100 N m 10 0 kgf m 72 5 lbf ft 8 Oil seal 22 Propeller shaft Apply grease 9 Final gear case 23 Universal joint Apply moly paste 10 Final drive gear bearing 24 Final gear case bolt M8 Apply bond to mating surface 11 Final drive ...

Page 426: ...ction 2D Page 2D 10 3 Remove the swingarm pivot cover 1 4 Remove the final gear case pivot bolt 2 and swing arm cover 3 5 Remove the final gear case nut and washer 6 Remove the final gear case 4 backward a 4 2 5 3 b FWD 1 I822H1310041 05 1 Shims 5 Final driven bevel gear Apply bond to matching surface 2 Shims 40 N m 4 0 kgf m 29 0 lbf ft Apply bond to matching surface 3 Shims 100 N m 10 0 kgf m 72...

Page 427: ... the universal joint 1 to the rear propeller shaft 2 and install the final gear assembly NOTE To install the final gear case easily move the dust boot front and the universal joint turn into the propeller shaft 4 Install the washers 3 and tighten the final gear case nut 4 to the specified torque NOTE The conical side of the washer 3 faces outside Tightening torque Final gear case nut a 40 N m 4 0 ...

Page 428: ...the stopper plate 1 2 Remove the dust seal 2 3 Remove the snap ring 3 with the special tool Special tool 09900 06108 Snap ring pliers 4 Remove the propeller shaft 4 and spring 5 5 Unlock the final drive gear coupling nut with a chisel 6 Remove the final drive gear coupling nut with the special tools Special tool A 09924 62430 Long socket 22 mm Special tool B 09924 64510 Final driving gear coupling...

Page 429: ...ng remover NOTE If no abnormal noise the bearing removal is not necessary 11 Remove the washer 10 12 Remove the inner race with the special tool Special tool D 09913 60910 Bearing remover CAUTION When replacing the drive bevel gear replace the driven bevel gear also as they must be replaced together 13 Remove the final gear case bolts 14 Remove the final gear bearing case 11 from the final gear ca...

Page 430: ...h the special tool Special tool E 09913 50121 Oil seal remover 19 Remove the final driven gear bearing 16 and oil seal 17 with the special tools Special tool F 09941 64511 Bearing remover G 09930 30104 Rotor remover sliding shaft 20 Remove the final drive gear bearing 18 with the special tools Special tool H 09923 74511 Bearing remover G 09930 30104 Rotor remover sliding shaft 12 13 I822H1310059 0...

Page 431: ... 75821 Bearing installer Install the oil seal into the final gear case with the special tool Special tool B 09913 76010 Bearing installer CAUTION Use a new oil seal to prevent oil leakage The lip and spring of the oil seal A should face to the driven bevel gear side Apply grease to the oil seal lip Grease 99000 25010 SUZUKI SUPER GREASE A or equivalent Install the final driven gear bearing into th...

Page 432: ...iven bevel gear and install the gear to the final gear case Apply bond to the mating surface of the final gear case and final gear bearing case CAUTION Do not block the breather passage when applying bond Sealant 99000 31140 SUZUKI BOND No 1207B or equivalent Apply thread lock to the final gear case bolts 5 and 6 and tighten them to the specified torque Thread lock cement 99000 32110 THREAD LOCK C...

Page 433: ... a new oil seal and O ring to prevent oil leakage Grease 99000 25010 SUZUKI SUPER GREASE A or equivalent Tighten the bearing stopper 12 to the specified torque with the special tool Special tool G 09924 62410 Final drive gear bearing holder wrench Tightening torque Final drive bevel gear bearing stopper c 110 N m 11 0 kgf m 79 5 lbf ft Install the final drive gear coupling 13 and washer 14 Apply a...

Page 434: ...Install the spring 15 and propeller shaft 16 Moly paste 99000 25140 SUZUKI MOLY PASTE or equivalent Install the snap ring 17 After installing the propeller shaft with a new snap ring make sure that the propeller shaft turns smoothly without any hitch or bearing noise Special tool 09900 06108 Snap ring pliers Apply grease to the lip of the dust seal CAUTION Use a new dust seal to prevent oil leakag...

Page 435: ...al Refer to Final Gear Disassembly and Assembly Page 3A 14 Spring Inspect the spring damage or fatigue If any defects are found replace the spring with a new one Oil Seal Inspect the oil seal for wear and damage If any defects are found replace the oil seal with a new one Universal Joint Removal and Installation B940H23106012 Removal 1 Remove the swingarm Refer to Swingarm Assembly Removal and Ins...

Page 436: ...excessive play is noted replace it with a new one CAUTION Do not attempt to disassemble the universal joint Rear Wheel Dumper Removal and Installation B940H23106014 Removal 1 Remove the rear wheel assembly Refer to Rear Wheel Assembly Removal and Installation in Section 2D Page 2D 10 2 Flatten the lock washers 3 Remove the bolts washers and plates 4 Remove the driven hub joint 1 with the special t...

Page 437: ...one Grease 99000 25010 SUZUKI SUPER GREASE A or equivalent When install the driven hub joint align the driven hub joint flat surface A with the screw holes B of the wheel Apply thread lock to the driven hub joint bolts Thread lock cement 99000 32030 THREAD LOCK CEMENT SUPER 1303 or equivalent Tighten the driven hub joint bolts securely Bend up washers to lock the bolts Wheel Dumper Inspection B940...

Page 438: ... the shims 1 and bearing If it is not within the specification the must be changed Final gear case shim clearance Standard 0 1 mm 0 04 in List of shims For final gear case side Backlash After assembling the final gear case measure the final bevel gear backlash as follows Install the backlash measuring tool on the drive bevel gear coupling and set up a dial gauge as shown in the figure Special tool...

Page 439: ...al driven bevel gear and final gear case Increase thickness of the shims 2 between the final driven bevel gear bearing and bearing case by an amount equal to decrease above Backlash is too small Install a thicker shim pack 1 between the final driven bevel gear and final gear case Decrease thickness of the shims 2 between the final driven gear bearing and bearing case by an amount equal to increase...

Page 440: ... shims in place positioning the coated teeth so that they are centered on the final drive bevel gear Reinstall the final gear bearing case and bolts and tighten to specification Tightening torque Final gear case bolt M8 a 23 N m 2 3 kgf m 16 5 lbf ft Final gear case bolt M10 b 50 N m 5 0 kgf m 36 0 lbf ft Using a socket and handle on the final drive bevel gear coupling nut rotate the final drive b...

Page 441: ...r backlash may change and should be rechecked according to the procedure outlined under the Backlash Measurement sub section Both adjustments may be needed until both backlash and tooth contact are correct Contact Position List of shims 4 A Incorrect Contact at tooth top B Correct C Incorrect Contact at tooth root A B C I822H1310039 06 Part number Shim thickness 27445 24810 Shim set 5 pcs 27445 24...

Page 442: ...y reduction ratio 1 407 76 54 Final reduction ratio 3 137 20 17 x 32 12 Fastening part Tightening torque Note N m kgf m lbf ft Secondary gear case bolt Initial 15 1 5 11 0 Page 3A 4 Page 3A 9 Secondary driven gear bearing housing bolt 55 5 5 40 0 Page 3A 4 Secondary gear case bolt Final 26 2 6 19 0 Page 3A 4 Page 3A 9 Secondary driven bevel gear bearing stopper 105 10 5 76 0 Page 3A 7 Secondary be...

Page 443: ... 99000 25140 Page 3A 13 Page 3A 20 Sealant SUZUKI BOND No 1215 or equivalent P No 99000 31110 Page 3A 4 Page 3A 13 SUZUKI BOND No 1207B or equivalent P No 99000 31140 Page 3A 18 Thread lock cement THREAD LOCK CEMENT SUPER 1303 or equivalent P No 99000 32030 Page 3A 4 Page 3A 19 Page 3A 23 THREAD LOCK CEMENT SUPER 1322 or equivalent P No 99000 32110 Page 3A 18 09900 06108 09900 20607 Snap ring plie...

Page 444: ... socket 22 mm Page 3A 15 Page 3A 19 Page 3A 14 Page 3A 20 09924 64510 09924 74520 Final driving gear coupling holder Oil seal installer remover Page 3A 5 Page 3A 8 Page 3A 14 Page 3A 20 Page 3A 6 09925 18011 09930 30104 Steering bearing installer Rotor remover sliding shaft Page 3A 20 Page 3A 16 Page 3A 16 09940 51410 09941 64511 Bearing installer Bearing remover Page 3A 20 Page 3A 16 09951 16080 ...

Page 445: ...e Master Cylinder Disassembly and Assembly 4A 16 Rear Brake Master Cylinder Parts Inspection 4A 17 Rear Brake Pedal Removal and Installation 4A 17 Specifications 4A 18 Service Data 4A 18 Tightening Torque Specifications 4A 19 Special Tools and Equipment 4A 19 Recommended Service Material 4A 19 Special Tool 4A 19 Front Brakes 4B 1 Repair Instructions 4B 1 Front Brake Components 4B 1 Front Brake Pad...

Page 446: ... servicing or which has been stored for a long period of time When storing brake fluid seal the container completely and keep it away from children When replenishing brake fluid take care not to get dust into the fluid When washing brake components use new brake fluid Never use cleaning solvent A contaminated brake disc or brake pad reduces braking performance Discard contaminated pads and clean t...

Page 447: ...a A B B B C D C a 1 B 1 a 1 C D I940H1410081 05 1 Stopper Position the brake hose union with the stopper before tightening the bolt D Position the brake hose clamp with the stopper before tightening the bolt A Pass the brake hose outside the throttle cables a 42 B Set the brake hose in the guide firmly b 14 C Clamp the brake hose firmly 23 N m 2 3 kgf m 16 5 lbf ft ...

Page 448: ... brake hose union with the stopper before tightening the bolt B Yellow marking H Position the clamp with the hole of the swingarm C Clamp end should face inside a 84 D Clamp end should face upward b 49 E Position the clamp end with the stopper before tightening the bolt 23 N m 2 3 kgf m 16 5 lbf ft F Set the heat shield above the clamp 16 N m 1 6 kgf m 11 5 lbf ft ...

Page 449: ...nd disc Replace Oil adhesion on friction surface of pads Clean disc and pads Air in hydraulic system Bleed air Not enough brake fluid in the reservoir Replenish Brake squeaking Carbon adhesion on pad surface Repair surface with sandpaper Tilted pad Correct pad fitting or replace Damaged wheel bearing Replace Loose front wheel axle or rear wheel axle Tighten to specified torque Worn pads and disc R...

Page 450: ...ection 0B Page 0B 14 Brake Hose Inspection B940H24106006 Refer to Brake System Inspection in Section 0B Page 0B 14 Air Bleeding from Brake Fluid Circuit B940H24106007 Air trapped in the brake fluid circuit acts like a cushion to absorb a large proportion of the pressure developed by the master cylinder and thus interferes with the full braking performance of the brake caliper The presence of air i...

Page 451: ...eceptacle no longer contains air bubbles NOTE While bleeding the brake system replenish the brake fluid in the reservoir as necessary Make sure that there is always some fluid visible in the reservoir 7 Close the air bleeder valve and disconnect the hose Tightening torque Air bleeder valve Front brake 7 5 N m 0 75 kgf m 5 5 lbf ft 8 Fill the reservoir with brake fluid to the upper mark of the rese...

Page 452: ...d reservoir cap and diaphragm 3 Suck up the old brake fluid as much as possible 4 Fill the reservoir with new brake fluid BF Brake fluid DOT 4 5 Connect a clear hose to the air bleeder valve and insert the other end of the hose into a receptacle 6 Loosen the air bleeder valve and pump the brake lever until the old brake fluid flows out of the brake system 7 Close the air bleeder valve 1 and discon...

Page 453: ...gm 4 Suck up the old brake fluid as much as possible 5 Fill the reservoir with new brake fluid BF Brake fluid DOT 4 6 Connect a clear hose to the air bleeder valve and insert the other end of the hose into a receptacle 7 Loosen the air bleeder valve and pump the brake pedal until the old brake fluid flows out of the brake system 8 Close the air bleeder valve 1 and disconnect the clear hose Tighten...

Page 454: ...eeding from Brake Fluid Circuit Page 4A 4 Rear Brake Hose Removal and Installation B940H24106010 Removal 1 Remove the fuel tank Refer to Fuel Tank Removal and Installation in Section 1G Page 1G 9 2 Remove the frame head cover Refer to Exterior Parts Removal and Installation in Section 9D Page 9D 5 3 Drain brake fluid Refer to Brake Fluid Replacement Page 4A 6 4 Remove the rear brake hoses as shown...

Page 455: ...H1410088 02 1 Reservoir cap 7 Brake lever 10 N m 1 0 kgf m 7 0 lbf ft 2 Plate 8 Brake lever pivot bolt Apply brake fluid 3 Diaphragm 9 Brake lever pivot bolt lock nut Apply silicone grease 4 Master cylinder 23 N m 2 3 kgf m 16 5 lbf ft Do not reuse 5 Piston Cup set 1 N m 0 1 kgf m 0 7 lbf ft 6 Brake hose union bolt 6 N m 0 6 kgf m 4 5 lbf ft ...

Page 456: ... following points When installing the master cylinder 1 onto the handlebars 2 align the master cylinder holder s mating surface A with the punch mark B on the handlebars 2 and tighten the upper holder bolt first Tightening torque Front brake master cylinder holder bolt Upper and Lower a 10 N m 1 0 kgf m 7 0 lbf ft After setting the brake hose union to the stopper tighten the union bolt 3 to the sp...

Page 457: ...econdary cup 9 Primary cup 10 Spring 11 Assembly Assemble the master cylinder in the reverse order of disassembly Pay attention to the following points CAUTION Wash the master cylinder components with new brake fluid before reassembly Do not wipe the brake fluid off after washing the components When washing the components use the specified brake fluid Never use different types of fluid or cleaning...

Page 458: ... 4 5 lbf ft When installing the brake light switch align the projection on the switch with the hole in the master cylinder Front Brake Master Cylinder Parts Inspection B940H24106014 Refer to Front Brake Master Cylinder Brake Lever Disassembly and Assembly Page 4A 11 Master Cylinder Inspect the master cylinder bore for any scratches or other damage Piston Inspect the piston surface for any scratche...

Page 459: ...er to Brake Fluid Replacement Page 4A 6 2 Disconnect the rear brake light switch coupler 1 1 b 2 a 3 5 6 c 4 I940H1410089 02 1 Reservoir tank 4 Master cylinder 10 N m 1 0 kgf m 7 0 lbf ft Apply silicone grease 2 Brake hose union bolt 5 Piston Cup set 23 N m 2 3 kgf m 16 5 lbf ft Apply brake fluid 3 Brake hose connector 6 Push rod 18 N m 1 8 kgf m 13 0 lbf ft Do not reuse 1 I940H1410056 01 ...

Page 460: ...th reservoir hose 10 Installation Install the rear brake master cylinder in the reverse order of removal Pay attention to the following points Install the reservoir hose 1 to the clamp 2 Install the master cylinder 3 and tighten the master cylinder mounting bolts 4 to the specified torque Tightening torque Rear brake master cylinder mounting bolt a 10 N m 1 0 kgf m 7 0 lbf ft 3 2 I940H1410058 02 4...

Page 461: ... or equivalent Tightening torque Front footrest bracket bolt c 50 N m 5 0 kgf m 36 0 lbf ft Tighten the brake hose union bolt 8 to the specified torque CAUTION The seal washers should be replaced with the new ones to prevent fluid leakage Tightening torque Brake hose union bolt d 23 N m 2 3 kgf m 16 5 lbf ft Connect the rear reservoir tank hose and rear brake light switch coupler properly Bleed ai...

Page 462: ...in the reverse order of disassembly Pay attention to the following points CAUTION Wash the master cylinder components with new brake fluid before reassembly Do not wipe the brake fluid off after washing the components When washing the components use the specified brake fluid Never use different types of fluid or cleaning solvents such as gasoline kerosine etc Apply brake fluid to the master cylind...

Page 463: ...bore for any scratches or other damage Cup Set Inspect the cup set for other damage Piston Inspect the piston surface for any scratches or other damage Rubber Parts Inspect the primary cup secondary cup and dust boot for wear or damage Rear Brake Pedal Removal and Installation B940H24106019 Removal 1 Remove the right footrest bracket bolts 1 2 Move and support the right footrest bracket and remove...

Page 464: ...valent Tightening torque Front footrest bracket bolt b 50 N m 5 0 kgf m 36 0 lbf ft Specifications Service Data B940H24107001 Brake Unit mm in a 1 A B I940H1410085 01 b 2 I940H1410086 01 Item Standard Limit Rear brake pedal height 60 70 2 4 2 8 Brake disc thickness Front 4 3 4 7 0 169 0 185 4 0 0 16 Rear 6 6 7 0 0 260 0 276 6 3 0 25 Brake disc runout Front Rear 0 30 0 012 Master cylinder bore Fron...

Page 465: ...valve Front brake 7 5 0 75 5 5 Page 4A 5 Page 4A 6 Air bleeder valve Rear brake 7 5 0 75 5 5 Page 4A 5 Page 4A 7 Front brake master cylinder holder bolt Upper and Lower 10 1 0 7 0 Page 4A 10 Brake hose union bolt 23 2 3 16 5 Page 4A 10 Page 4A 15 Brake lever pivot bolt 1 0 1 0 7 Page 4A 12 Brake lever pivot bolt lock nut 6 0 6 4 5 Page 4A 12 Rear brake master cylinder mounting bolt 10 1 0 7 0 Page...

Page 466: ...nes Refer to Front Brake Pad Replacement Page 4B 2 CAUTION Replace the brake pad as a set otherwise braking performance will be adversely affected 1 2 3 b c 7 a 4 5 6 FWD FWD I940H1420024 02 1 Front brake caliper 6 Brake disc Apply silicone grease 2 Piston 7 Front brake pad set Apply thread lock to the thread part 3 Oil seal Dust seal 7 5 N m 0 75 kgf m 5 5 lbf ft Apply brake fluid 4 Caliper holde...

Page 467: ... pads as a set otherwise braking performance will be adversely affected 4 Install the new brake pads 5 Insert the pad set pin 4 and pad set pin clip 3 as shown in the figure 6 Tighten the brake caliper mounting bolts 1 to the specified torque Tightening torque Front brake caliper mounting bolt a 39 N m 3 9 kgf m 28 0 lbf ft NOTE After replacing the brake pads pump the brake lever several times to ...

Page 468: ... the brake hose union to the stopper tighten the union bolts to the specified torque CAUTION The seal washers should be replaced with new ones to prevent fluid leakage Tightening torque Brake hose union bolt b 23 N m 2 3 kgf m 16 5 lbf ft Bleed air from the brake system after installing the caliper Refer to Air Bleeding from Brake Fluid Circuit in Section 4A Page 4A 4 Check the brake fluid leakage...

Page 469: ...e high pressure air to prevent piston damage 5 Remove the dust seals 5 and piston seals 6 Brake caliper carrier Remove the pad guide 1 Assembly Assemble the caliper in the reverse order of disassembly Pay attention to the following points Brake caliper carrier Install the pad guide 1 3 2 I940H1420010 01 I940H1420011 01 4 I940H1420012 01 6 5 I940H1420013 01 1 I940H1420014 01 1 I940H1420014 01 ...

Page 470: ... dust seals 2 with new ones BF Brake fluid DOT 4 Install the piston seals as shown in the figure Apply grease to the two pins Grease 99000 25100 SUZUKI SILICONE GREASE or equivalent Install the brake caliper carrier 3 to the brake caliper Install the brake pads Refer to Front Brake Pad Replacement Page 4B 2 Install the brake caliper and brake hose Refer to Front Brake Caliper Removal and Installat...

Page 471: ...r damage and excessive bend If any defects are found replace the brake pad spring with a new one Brake Pad Guide Inspect the brake pad guide for damage and excessive bend If any defects are found replace the brake pad guide with a new one Boots Inspect the boots for damage or wear If defects are found replace them new ones Brake Caliper Carrier Inspect the brake caliper carrier for damage If any d...

Page 472: ...spection B940H24206008 Brake Disc Thickness Check the brake disc for damage or cracks and measure the thickness using the micrometer Replace the brake disc if the thickness is less than the service limit or if defect is found Special tool A 09900 20205 Micrometer 0 25 mm Brake disc thickness Service limit Front 4 0 mm 0 16 in Brake Disc Runout 1 Dismount the front brake caliper Refer to Front Brak...

Page 473: ...4B 1 Item Standard Limit Brake disc thickness Front 4 3 4 7 0 169 0 185 4 0 0 16 Brake disc runout Front Rear 0 30 0 012 Brake caliper cylinder bore Front 30 230 30 306 1 1902 1 1931 Brake caliper piston diam Front 30 150 30 200 1 1870 1 1890 Brake fluid type DOT 4 Fastening part Tightening torque Note N m kgf m lbf ft Front brake caliper mounting bolt 39 3 9 28 0 Page 4B 2 Page 4B 3 Brake hose un...

Page 474: ...4B 9 Front Brakes Special Tool B940H24208002 09900 20205 09900 20607 Micrometer 0 25 mm Dial gauge 1 100 mm 10 mm Page 4B 7 Page 4B 7 09900 20701 Magnetic stand Page 4B 7 ...

Page 475: ...iper bracket Apply thread lock to the thread part 2 Piston seal Dust seal 8 Brake disc Apply thread lock to the thread part 3 Piston 7 5 N m 0 75 kgf m 5 5 lbf ft Apply silicone grease to sliding surface 4 Caliper holder 54 N m 5 4 kgf m 39 0 lbf ft Apply brake fluid 5 Pad set pin 94 N m 9 4 kgf m 68 0 lbf ft Do not reuse 6 Rear brake pad set 23 N m 2 3 kgf m 16 5 lbf ft ...

Page 476: ...ill be adversely affected Rear Brake Pad Replacement B940H24306003 1 Remove the caliper mounting bolts 1 CAUTION Do not operate the brake pedal while dismounting the pads 2 Remove the pads mounting pin 2 by removing the clip 3 3 Remove the brake pads 4 4 Clean up the caliper especially around the caliper piston 5 Aseemble the new brake pads 4 and shim 5 CAUTION Replace the brake pads as a set othe...

Page 477: ... the brake hose from the caliper by removing the union bolt 1 and catch the brake fluid in a suitable receptacle NOTE Place a rag underneath the union bolt on the brake caliper to catch any spilt brake fluid 3 Remove the brake caliper and brake pads Refer to Rear Brake Pad Replacement Page 4C 2 Installation Install the brake caliper in the reverse order of removal Pay attention to the following po...

Page 478: ...luid leakage Rear Brake Caliper Disassembly and Assembly B940H24306005 Refer to Rear Brake Caliper Removal and Installation Page 4C 3 Disassembly Brake caliper 1 Remove the pad spring 1 2 Remove the caliper holder 2 and rubber boots 3 3 Place a rag over the piston to prevent it from popping out and then force out the pistons 4 using compressed air CAUTION Do not use high pressure air to prevent pi...

Page 479: ...the components use the specified brake fluid Never use different types of fluid or cleaning solvent such as gasoline kerosine or the others Apply the brake fluid to piston seal 1 and dust seal 2 CAUTION Replace the piston seal 1 and dust seal 2 with new ones BF Brake fluid DOT 4 Install the piston seals as shown in the figure Apply grease to the two pins Grease 99000 25100 SUZUKI Silicone Grease o...

Page 480: ...w ones Brake Pad Set Pin Clip Inspect the brake pad set pin and clip for wear and other damage If any damage is found replace defective parts with a new one Boot Inspect the boots for damage and wear If any defects are found replace them with new ones Brake Pad Spring Inspect the brake pad spring for damage and excessive bend If any defects are found replace the brake pad spring with a new one Bra...

Page 481: ...e brake discs are clean and free of any grease Apply thread lock to the brake disc bolts 1 and tighten them to the specified torque Thread lock cement 99000 32130 Thread Lock Cement Super 1360 or equivalent Tightening torque Brake disc bolt a 23 N m 2 3 kgf m 16 5 lbf ft Rear Brake Disc Inspection B940H24306008 Brake Disc Thickness Check the brake disc for damage or cracks and measure the thicknes...

Page 482: ...940H24307002 NOTE The specified tightening torque is described in the following Rear Brake Components Page 4C 1 Reference For the tightening torque of fastener not specified in this section refer to Tightening Torque List in Section 0C Page 0C 8 A I649G1430028 03 Item Standard Limit Rear brake pedal height 60 70 2 4 2 8 Brake disc thickness Rear 6 6 7 0 0 260 0 276 6 3 0 25 Brake disc runout Front...

Page 483: ...ommended product or Specification Note Brake fluid DOT 4 Page 4C 5 Page 4C 5 Grease SUZUKI Silicone Grease or equivalent P No 99000 25100 Page 4C 5 Thread lock cement THREAD LOCK CEMENT SUPER 1303 or equivalent P No 99000 32030 Page 4C 3 Thread Lock Cement Super 1360 or equivalent P No 99000 32130 Page 4C 7 09900 20205 09900 20607 Micrometer 0 25 mm Dial gauge 1 100 mm 10 mm Page 4C 7 Page 4C 8 09...

Page 484: ...4C 10 Rear Brakes ...

Page 485: ...ation 5B 13 Gearshift Linkage Inspection 5B 16 Gearshift Shaft Oil Seal Bearing Removal and Installation 5B 16 Specifications 5B 17 Service Data 5B 17 Tightening Torque Specifications 5B 18 Special Tools and Equipment 5B 18 Recommended Service Material 5B 18 Special Tool 5B 19 Clutch 5C 1 Precautions 5C 1 Precautions for Clutch System 5C 1 Schematic and Routing Diagram 5C 1 Clutch Cable Routing Di...

Page 486: ...5 1 Precautions Transmission Transaxle Precautions Precautions Precautions for Transmission Transaxle B940H25000001 Refer to General Precautions in Section 00 Page 00 1 ...

Page 487: ...eplace driveshaft Worn or rubbing primary gear Replace Worn bearing Replace Transmission will not shift Broken gearshift cam Replace Distorted gearshift fork Replace Worn gearshift pawl Replace Transmission will not shift back Broken gearshift shaft return spring Replace Rubbing or stuck gearshift shaft Repair or replace Worn or distorted gearshift fork Replace Transmission jumps out of gear Worn ...

Page 488: ...drive gear 6 Driveshaft 11 1st driven gear 6 5 N m 0 65 kgf m 4 5 lbf ft 2 5th drive gear 7 2nd driven gear 12 Gearshift cam Apply oil 3 4th drive gear 8 3rd driven gear 13 Gear position switch Apply grease 4 3rd drive gear 9 4th driven gear 14 Gearshift fork Apply thread lock to the thread part 5 2nd drive gear 10 5th driven gear 15 Gearshift fork shaft Do not reuse ...

Page 489: ...arshift forks 4 6 Remove the countershaft assembly 5 as shown 7 Remove the driveshaft 6 8 Remove the bearings from the crankcase Refer to Engine Bottom Side Disassembly in Section 1D Page 1D 56 Installation Install the transfer in the reverse order of removal Pay attention to the following points CAUTION Apply engine oil to each gears and shafts Replace the removed bearing with a new one Install t...

Page 490: ...fer to Engine Bottom Side Assembly in Section 1D Page 1D 64 Remount engine assembly Refer to Engine Assembly Installation in Section 1D Page 1D 24 and Engine Top Side Assembly in Section 1D Page 1D 32 Transmission Construction B940H25206003 3 I940H1520007 02 5 5 6 3 4 I940H1520009 03 3 3 3 3 1 2 I940H1520026 01 1 Countershaft 2 Driveshaft 3 Snap ring Assemble the snap ring with sharp edge side out...

Page 491: ...lowing points Driveshaft Open the 3rd drive gear snap ring 1 with the special tool from its groove and slide it towards the 4th drive gear side Special tool 09900 06104 Snap ring pliers Slide the 3rd 4 and 2nd 3 drive gears toward the 4th drive gear side then remove the circlip 2 Remove the 3rd drive gear bushing 5 washer 6 snap ring 7 and 4th drive gear 8 Remove the snap ring 9 with the special t...

Page 492: ... snap rings has been removed from a shaft it should be discarded and a new snap rings must be installed When installing a new snap rings do not expand the end gap larger than required to slip the snap rings over the shaft After installing snap rings make sure that they are completely seated in their groove and securely fitted NOTE Rotate the bearing by hand to inspect if there are any abnormal noi...

Page 493: ...oval and Installation B940H25206005 Removal 1 Remove the countershaft assembly and driveshaft assembly Refer to Transmission Removal and Installation Page 5B 3 2 Remove the left gearshift cam bearing 1 with the special tool Special tool A 09923 74511 Bearing remover B 09930 30104 Rotor remover sliding shaft 3 Remove the left countershaft bearing 2 with the special tool Special tool C 09921 20240 B...

Page 494: ...one Except for right gearshift cam bearing Install the right driveshaft bearings 1 and countershaft bearing 2 with the special tool and install the right gearshift cam bearing 3 by hand CAUTION Use the special tool suitable size for each bearing to prevent damage NOTE The sealed side A of right driveshaft bearing 1 faces outside of crankcase The stamped mark side of the bearing faces inside of cra...

Page 495: ...earing faces inside of crankcase Special tool 09913 70210 Bearing installer set Transmission Related Parts Inspection B940H25206006 Refer to Transmission Removal and Installation Page 5B 3 and Countershaft Gear Driveshaft Gear Disassembly and Assembly Page 5B 5 Gearshift Fork to Groove Clearance NOTE The clearance for each gearshift fork plays an important role in the smoothness and positiveness o...

Page 496: ...rotation Replace the bearing if there is anything unusual Refer to Bearing Removal and Installation Page 5B 7 Gear Position GP Switch Inspection B940H25206007 Refer to Side stand Ignition Interlock System Parts Inspection in Section 1I Page 1I 8 Gear Position GP Switch Removal and Installation B940H25206008 Removal 1 Turn the ignition switch OFF 2 Remove the right frame side cover secondary gear c...

Page 497: ...ction 9A Page 9A 5 Install the clutch cover Refer to Clutch Installation in Section 5C Page 5C 8 Gearshift Lever Construction B940H25206009 Gearshift Lever Removal and Installation B940H25206010 Removal 1 Remove the frame lower cover and secondary gear case cover Refer to Exterior Parts Removal and Installation in Section 9D Page 9D 5 2 Disengage the gearshift link arm by removing the bolt NOTE Ma...

Page 498: ...ift Lever Height Inspection and Adjustment Page 5B 12 Gearshift Lever Height Inspection and Adjustment B940H25206011 Inspect and adjust the gearshift lever height in the following procedures 1 Inspect the gearshift lever height a between the pedal top face and footrest Adjust the gearshift lever height if necessary Gearshift lever height a Standard 95 105 3 7 4 1 in 2 Remove the secondary gear cas...

Page 499: ...hift shaft assembly 4 5 Remove the following parts from the gearshift shaft 4 Washer 5 Snap ring 6 Gearshift return spring 7 Gearshift cam drive plate 8 Plate return spring 9 Washer 10 Snap ring 11 Special tool 09900 06107 Snap ring pliers 1 Gearshift shaft 2 Gearshift cam drive plate 3 Gearshift cam plate 4 Gearshift cam stopper 10 N m 1 0 kgf m 7 0 lbf ft 19 N m 1 9 kgf m 13 5 lbf ft Apply threa...

Page 500: ...n it to the specified torque Thread lock cement 99000 32030 THREAD LOCK CEMENT SUPER 1303 or equivalent Tightening torque Gearshift arm stopper a 19 N m 1 9 kgf m 13 5 lbf ft Install the gearshift cam stopper 2 bolt 3 washer 4 and return spring 5 Apply thread lock to the gearshift cam stopper bolt 3 and tighten it to the specified torque Thread lock cement 99000 32110 THREAD LOCK CEMENT SUPER 1322...

Page 501: ...LOCK CEMENT SUPER 1322 or equivalent Tightening torque Gearshift cam stopper plate bolt c 10 N m 1 0 kgf m 7 0 lbf ft When installing the gearshift shaft return spring position the stopper D of the gearshift arm between shaft return spring ends E Apply grease to the lip of the oil seal and install the gearshift shaft 8 Grease 99000 25010 SUZUKI SUPER GREASE A or equivalent Install the washer 9 and...

Page 502: ...l Seal Inspect the gearshift shaft oil seal lip for wear or damage If any defect is found replace the oil seal with a new one Gearshift Shaft Bearing Inspect the gearshift shaft bearing for abnormal noise and smooth rotation Replace the bearing if there is anything unusual Gearshift Shaft Oil Seal Bearing Removal and Installation B940H25206015 Removal 1 Remove the gearshift shaft Refer to Gearshif...

Page 503: ...Special tool A 09913 70210 Bearing installer set Apply grease to the oil seal lip Grease 99000 25010 SUZUKI SUPER GREASE A or equivalent Specifications Service Data B940H25207001 Drive Train Unit mm in Except ratio A I940H1520070 01 A I940H1520071 02 Item Standard Limit Primary reduction ratio 1 407 76 54 Final reduction ratio 3 137 20 17 x 32 12 Gear ratios 1st 2 187 35 16 2nd 1 400 28 20 3rd 1 0...

Page 504: ...truction Page 5B 11 Gearshift Shaft Gearshift Cam Plate Components Page 5B 13 Fastening part Tightening torque Note N m kgf m lbf ft GP switch mounting bolt 6 5 0 65 4 5 Page 5B 11 Front footrest bracket bolt 50 5 0 36 Page 5B 12 Gearshift arm stopper 19 1 9 13 5 Page 5B 14 Gearshift cam stopper bolt 10 1 0 7 0 Page 5B 14 Gearshift cam stopper plate bolt 10 1 0 7 0 Page 5B 15 Material SUZUKI recom...

Page 505: ...m 200 mm Thickness gauge Page 5B 10 Page 5B 10 Page 5B 9 09913 70210 09920 13120 Bearing installer set Crankcase separating tool Page 5B 8 Page 5B 8 Page 5B 9 Page 5B 9 Page 5B 17 Page 5B 17 Page 5B 3 09921 20210 09921 20240 Bearing remover Bearing remover set Page 5B 16 Page 5B 7 Page 5B 8 09923 74511 09930 30104 Bearing remover Rotor remover sliding shaft Page 5B 7 Page 5B 7 Page 5B 16 ...

Page 506: ...tem Noise seems to come from clutch Worn splines of countershaft or hub Replace Worn teeth of clutch plates Replace Distorted clutch plates driven and drive Replace Worn clutch release bearing Replace Weakened clutch dampers Replace the primary driven gear Slipping clutch Weakened clutch springs Replace Worn or distorted clutch pressure plates Replace Distorted clutch plates or pressure plates Rep...

Page 507: ... cover Refer to Exterior Parts Removal and Installation in Section 9D Page 9D 5 3 Remove the clutch cable as shown in the throttle cable diagram Refer to Throttle Cable Routing Diagram in Section 1D Page 1D 2 Installation 1 Install the clutch cable as shown in the throttle cable diagram Refer to Throttle Cable Routing Diagram in Section 1D Page 1D 2 2 Adjust the clutch cable play Refer to Clutch C...

Page 508: ... in the reverse order of removal Pay attention to the following points Apply grease to the each oil seal lip CAUTION The removed oil seal must be replaced with a new one Grease 99000 25010 SUZUKI SUPER GREASE A or equivalent Install the clutch release arm NOTE Align the release arm punch mark A with the notch mark B on the release camshaft 3 I940H1530004 01 4 I940H1530005 01 5 6 7 I940H1530067 01 ...

Page 509: ...Assembly Push Rod Removal and Installation Page 5C 2 2 Inspect the oil seal for wear and damage If any defects are found replace the oil seal with a new one Clutch Push Rod Left Inspection B940H25306005 Inspect the push rod in the following procedures 1 Remove the clutch push rod Refer to Clutch Release Assembly Push Rod Removal and Installation Page 5C 2 2 Inspect the push rod for wear or bend If...

Page 510: ...piece 9 Clutch sleeve hub 150 N m 15 0 kgf m 108 5 lbf ft 3 Drive plate No 3 10 Primary driven gear assembly 23 N m 2 3 kgf m 16 5 lbf ft 4 Driven plate No 1 11 Clutch push rod Apply thread lock to the thread part 5 Drive plate No 1 12 Primary drive gear assembly Apply engine oil 6 Drive plate No 2 13 Clutch spring stopper bolt Do not reuse 7 Clutch cam set 10 N m 1 0 kgf m 7 0 lbf ft ...

Page 511: ...t 2 and dowel pins 5 Remove the clutch spring set bolts clutch springs and pressure plate 3 NOTE Loosen the clutch spring set bolts little by little and diagonally 6 Remove the clutch push piece 4 thrust washer 5 and bearing 6 7 Remove the clutch push rod 7 8 Remove the clutch drive plates 8 and driven plates 9 9 Remove the spring washer 10 and its seat 11 1 I940H1530008 01 2 I940H1530009 01 3 I94...

Page 512: ...nut 13 Remove the clutch drive cam 12 and clutch driven cam 13 14 Remove the clutch sleeve hub 14 15 Remove the washer 15 and primary driven gear 16 NOTE If it is difficult to remove the primary driven gear 16 rotate the crankshaft 16 Remove the needle roller bearing 17 spacer 18 and washer 19 I940H1530014 01 A I940H1530015 01 12 13 I940H1530016 01 14 I940H1530017 01 15 16 I940H1530018 01 17 18 19...

Page 513: ...er 2 onto the countershaft NOTE The chamfer side A of washer should face the crankcase side 3 Install the spacer 3 and bearing 4 and apply engine oil to them 4 Install the primary driven gear assembly 5 and thrust washer 6 A Primary driven gear side 18 I940H1530020 01 1 I940H1530021 01 1 A I940H1530022 03 A 2 I940H1530023 01 3 4 I940H1530024 01 6 5 I940H1530025 01 ...

Page 514: ...ock and tighten them to the specified torque Thread lock cement 99000 32030 THREAD LOCK CEMENT SUPER 1303 or equivalent Tightening torque Clutch spring support bolt a 23 N m 2 3 kgf m 16 5 lbf ft 6 Install the clutch sleeve hub 9 and spring washer 11 NOTE The conical curve side of spring washer 11 faces outside 7 Hold the clutch sleeve hub with the special tools Special tool A 09920 53740 Clutch s...

Page 515: ... clutch drive plates and driven plates one by one into the clutch sleeve hub in the prescribed order NOTE Insert the outermost No 2 drive plate claws D to the other slits E of clutch housing as shown in the figure b 12 A I940H1530029 03 I940H1530014 01 13 14 I940H1530028 02 15 No 3 drive plate 16 No 1 drive plate 17 No 2 drive plate 18 No 2 driven plate 0 2 pcs The No 1 and No 2 driven plates are ...

Page 516: ...clutch push rod 20 13 Install the clutch push piece 21 bearing 22 and thrust washer 23 to the countershaft NOTE Tighten the washer 23 is located between the pressure plate and bearing 22 14 Install the pressure plate and clutch springs 15 Tighten the clutch spring set bolts to the specified torque NOTE Tighten the clutch spring set bolts diagonally Tightening torque Clutch spring set bolt 10 N m 1...

Page 517: ...and driven plates with a vernier calipers If each plate thickness is found to have reached the limit replace it with a new one Special tool A 09900 20102 Vernier calipers 1 20 mm 200 mm Clutch drive plate thickness Service limit No 1 No 2 and No 3 drive plate 3 42 mm 0 103 in Measure the claw width of the driven plates with a vernier calipers Replace the drive plates found to have worn down to the...

Page 518: ... engagement and disengagement of the clutch depends on the condition of this bearing Push Rod Right Inspect the push rod for wear and damage If any defects are found replace the push rod with a new one Clutch Sleeve Hub Primary Driven Gear Assembly Inspect the slot of the clutch sleeve hub and primary driven gear assembly for damage or wear caused by the clutch plates If necessary replace it with ...

Page 519: ... to the specified torque NOTE The primary drive gear bolt 2 has left hand threads Tightening torque Primary drive gear bolt a 150 N m 15 0 kgf m 108 5 lbf ft Special tool A 09930 40113 Rotor holder Specifications Service Data B940H25307001 Clutch Unit mm in A 2 I940H1530041 01 A B 1 I940H1530042 01 A a 2 1 I940H1530043 01 Item Standard Limit Clutch cable play 10 15 0 4 0 6 Clutch release arm play ...

Page 520: ...t Gearshift lever height 95 105 3 7 4 1 Fastening part Tightening torque Note N m kgf m lbf ft Clutch spring support bolt 23 2 3 16 5 Page 5C 9 Clutch sleeve hub nut 95 9 5 68 5 Page 5C 10 Clutch spring set bolt 10 1 0 7 0 Page 5C 11 Primary drive gear bolt 150 15 0 108 5 Page 5C 14 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or equivalent P No 99000 2501...

Page 521: ...Clutch 5C 16 09920 53740 09930 40113 Clutch sleeve hub holder Rotor holder Page 5C 7 Page 5C 9 Page 5C 14 Page 5C 14 ...

Page 522: ...5C 17 Clutch ...

Page 523: ... 6B 1 Handlebars Components 6B 1 Handlebars Removal and Installation 6B 1 Handlebars Inspection 6B 3 Steering Components 6B 4 Steering Removal and Installation 6B 4 Steering Related Parts Inspection 6B 7 Steering System Inspection 6B 7 Steering Stem Bearing Removal and Installation 6B 7 Steering Tension Adjustment 6B 8 Specifications 6B 9 Tightening Torque Specifications 6B 9 Special Tools and Equ...

Page 524: ...6 1 Precautions Steering Precautions Precautions Precautions for Steering B940H26000001 Refer to General Precautions in Section 00 Page 00 1 ...

Page 525: ...Broken bearing in steering stem Replace Distorted steering stem Replace Not enough pressure in tires Adjust Wobbly Handlebars Loss of balance between right and left front forks Replace fork or adjust fork oil level or replace spring Distorted front fork Repair or replace Distorted front axle or crooked tire Replace Loose steering stem nut Adjust Worn or incorrect tire or wrong tire pressure Adjust...

Page 526: ...the left handlebar a Clutch lever 1 b Left handlebar switch box 2 c Grip end cap 3 d Handlebar grip 4 FWD FWD 7 4 6 5 1 7 b a 3 2 A FWD FWD I940H1620023 01 1 Throttle grip 5 Right handlebar switch box 23 N m 2 3 kgf m 16 5 lbf ft 2 Handlebars 6 Left handlebar switch box 10 N m 1 0 kgf m 7 0 lbf ft 3 Handlebar clamp 7 Grip end cap 4 Left handlebar grip A Apply handle grip bond 1 2 3 4 I940H1620001 ...

Page 527: ...ark A aligns with the mating surface of the left handlebar holder Tighten the handlebar clamp bolts 1 to the specified torque NOTE First tighten the handlebar clamp bolts front ones Tightening torque Handlebar clamp bolt a 23 N m 2 3 kgf m 16 5 lbf ft Install the clutch lever holder align the holder s mating surface B with punched mark C on the handlebars Apply a handle grip bond D onto the left h...

Page 528: ...10 Insert the projection H of the left handlebar switch box into the hole of the handlebars After installing the steering the following adjustments are required before driving Cable routing Refer to Throttle Cable Routing Diagram in Section 1D Page 1D 2 Throttle cable play Refer to Throttle Cable Play Inspection and Adjustment in Section 0B Page 0B 10 Clutch cable play Refer to Clutch Cable Play I...

Page 529: ... Meter Removal and Installation in Section 9C Page 9C 2 5 Remove the front turn signal left and right and turn signal cover Refer to Front Turn Signal Light Removal and Installation in Section 9B Page 9B 8 FWD FWD a 1 2 3 6 7 8 9 10 a c 11 a 5 b 4 I940H1620024 02 1 Handlebar clamp bolt 7 Dust seal 90 N m 9 0 kgf m 65 0 lbf ft 2 Handlebar clamp 8 Steering stem upper bearing 45 N m 4 5 kgf m 32 5 lb...

Page 530: ...forks Refer to Front Fork Removal and Installation in Section 2B Page 2B 2 10 Remove the steering stem upper bracket 2 11 Remove the steering stem nut using the special tool NOTE When loosening the stem nuts hold the steering stem lower bracket to prevent it from falling Special tool A 09940 14911 Steering stem nut wrench 12 Remove the steering stem lower bracket 13 Remove the dust seal 3 and stee...

Page 531: ...f m 32 5 lbf ft then turn back 1 2 1 4 Turn the steering stem lower bracket about five or six times to the left and right so that the taper roller bearings seat properly Loosen the steering stem nut 1 4 1 2 turn a NOTE This adjustment will vary from motorcycle to motorcycle Steering stem upper bracket Install the front forks and steering stem upper bracket in the following steps 1 Install the stee...

Page 532: ...malities Distortion of the steering stem Bearing wear or damage Abnormal bearing noise Race wear or damage Bearing lower seal damage Rubber seat and damper bushing wear or damage If any abnormal points are found replace defective parts with new ones Steering System Inspection B940H26206007 Refer to Steering System Inspection in Section 0B Page 0B 17 Steering Stem Bearing Removal and Installation B...

Page 533: ... tool and install the bearing Special tool A 09941 74911 Steering bearing installer Install the steering Refer to Steering Removal and Installation Page 6B 4 Steering Tension Adjustment B940H26206009 Check the steering movement in the following procedures 1 By supporting the motorcycle with a jack lift the front wheel until it is off the floor 20 30 mm 0 8 1 2 in 2 Check to make sure that the cabl...

Page 534: ...ications Tightening Torque Specifications B940H26207001 NOTE The specified tightening torque is described in the following Handlebars Components Page 6B 1 Steering Components Page 6B 4 Reference For the tightening torque of fastener not specified in this section refer to Tightening Torque List in Section 0C Page 0C 8 Special Tools and Equipment Recommended Service Material B940H26208001 NOTE Requi...

Page 535: ...002 09940 14911 09940 92720 Steering stem nut wrench Spring scale Page 6B 5 Page 6B 6 Page 6B 8 09941 34513 09941 54911 Steering race installer Bearing outer race remover Page 6B 8 Page 6B 8 09941 74911 Steering bearing installer Page 6B 8 Page 6B 8 ...

Page 536: ...6B 11 Steering Handlebar ...

Page 537: ... 11 Service Data 9B 11 Tightening Torque Specifications 9B 12 Special Tools and Equipment 9B 12 Special Tool 9B 12 Combination Meter Fuel Meter Horn 9C 1 General Description 9C 1 Combination Meter System Description 9C 1 Repair Instructions 9C 2 Combination Meter Components 9C 2 Combination Meter Removal and Installation 9C 2 Combination Meter Disassembly and Assembly 9C 3 Combination Meter Inspec...

Page 538: ...ervice Material 9D 7 Body Structure 9E 1 Repair Instructions 9E 1 Body Frame Construction 9E 1 Steering Lock Bracket Construction 9E 2 Side stand Construction 9E 2 Side stand Removal and Installation 9E 3 Specifications 9E 3 Tightening Torque Specifications 9E 3 Special Tools and Equipment 9E 3 Recommended Service Material 9E 3 ...

Page 539: ...ectrical System B940H29000001 Refer to General Precautions in Section 00 Page 00 1 and Precautions for Electrical Circuit Service in Section 00 Page 00 2 Component Location Electrical Components Location B940H29003001 Refer to Electrical Components Location in Section 0A Page 0A 7 ...

Page 540: ...9A 1 Wiring Systems Body and Accessories Wiring Systems Schematic and Routing Diagram Wiring Diagram B940H29102001 Refer to Wire Color Symbols in Section 0A Page 0A 5 ...

Page 541: ...ELAY TO SENSOR FUEL PUMP REGULATOR RECTIFIER 1 MAIN 30A TP SENSOR STV ACTUATOR COOLING FAN MOTOR FREE CLUTCH LEVER POSITION SWITCH Lg B W Gr B W W B Gr B W B W B Lg Br B W W B B Y B O W Y R R Bl Br B B W B B B B B B R B Y Dbr R R R B W B W G W B W B W ISC VALVE Bl G B B B B B B B R B W B G B W B B W B B W Br B W Br B W Lg B W Y B W W B Lg P W G W B R Y W B Br B Br P B R B Br G B R R P B B Br Dg B ...

Page 542: ...H INJECTOR RELAY TO SENSOR FUEL PUMP REGULATOR RECTIFIER 1 MAIN 30A TP SENSOR STV ACTUATOR COOLING FAN MOTOR FREE CLUTCH LEVER POSITION SWITCH Lg B W Gr B W W B Gr B W B W B Lg Br B W W B B Y B O W Y R R Bl Br B B R B Y Dbr R R R B W B W G W B W B W ISC VALVE Bl G B B B B B B B R B W Y B W B G B W O G B B W O G B B W Gr B B W Gr W B Lg P W G W B R Y W B Br B Br P B R B Br G B R R P B B Br Dg B Br ...

Page 543: ... REGULATOR RECTIFIER 1 MAIN 30A TP SENSOR STV ACTUATOR COOLING FAN MOTOR FREE CLUTCH LEVER POSITION SWITCH EVAP SYSTEM PURGE CONTROL SOLENOID VALVE Lg B W Gr B W W B Gr B W B W B Lg Br B W W B B Y B O W Y R R Bl Br B B W B R B Y Dbr R R R B W B W G W B W B W ISC VALVE Bl G B B B B B B B R B W Y B W B G B W O G B B W O G B B W Gr B B W Gr W B Lg P W G W B R Y W B Br B Br P B R B Br G B R R P B B Br...

Page 544: ... Bind the wiring harness with the clamp B Pass the handlebar switch L lead wire in front of the guide 4 Clamp Bind the handlebar switch harness L R and wiring harness with the clamp C Pass the wiring harness inside of the seat lock cable 5 Clamp Bind the handlebar switch harness L R with the clamp D Set the coupler between fuel feed hose and air cleaner tube 6 Clamp a 15 25 mm 0 6 1 0 in 7 Clamp B...

Page 545: ...D Pass the wiring harness between the clutch release assembly and generator cover 4 Conduction hose E Pass the wiring harness in front of the hose 5 Clamp F Pass the starter motor lead wire between the hose and battery holder 6 Clamp Bind the generator lead wire and side stand switch lead wire with the clamp a 0 20 mm 0 0 8 in 7 Clamp Bind the GP switch and clutch release assembly with the clamp b...

Page 546: ...A 7 Wiring Systems Specifications Service Data B940H2910S001 Electrical Unit mm in Item Specification Note Fuse size Headlight HI 10 A LO 10 A Fuel 10 A Ignition 15 A Signal 10 A Fan motor 15 A Main 30 A ...

Page 547: ... Lighting Systems Repair Instructions Front Lighting System Construction B940H29206001 1 2 3 4 a a I940H1920033 04 1 Headlight housing brace 3 Headlight cover plate 8 5 N m 0 85 kgf m 6 0 lbf ft 2 Front turn signal cover 4 Headlight front cover ...

Page 548: ...oupler 1 2 Disconnect the position light coupler 2 For E 02 19 24 3 Protect the speedometer assembly and headlight cover with a tape to prevent damage 4 Remove the headlight assembly 3 1 2 FWD FWD I940H1920045 02 1 Headlight unit 2 Headlight bulb 12 V 60 55 W H4 1 2 I940H1920001 02 A Protect point A I940H1920037 03 A A 3 3 A A I940H1920038 04 ...

Page 549: ...bolts 1 to the specified torque Tightening torque Headlight cover mounting bolt a 8 5 N m 0 85 kgf m 6 0 lbf ft After installing be sure to inspect the headlight beam Refer to Headlight Beam Adjustment Page 9B 4 Headlight Bulb Replacement B940H29206004 CAUTION When you touch the bulb with your bare hands clean the bulb with a cloth moistened with alcohol or soap water to prevent premature bulb fai...

Page 550: ...spect the headlight relay in the following procedures 1 Remove the front seat Refer to Exterior Parts Removal and Installation in Section 9D Page 9D 5 2 Remove the headlight relay 1 3 First check for continuity with the tester between terminals A and B Next check for continuity between A and B with 12 V voltage applied positive to terminal C and negative to terminal D If the continuity is found wh...

Page 551: ...ve the rear fender assembly Refer to Exterior Parts Removal and Installation in Section 9D Page 9D 5 2 Disconnect the rear combination light coupler 1 1 2 a 3 4 5 I940H1920034 01 1 Rear fender extension 3 License plate bracket E 02 19 24 only 5 Brake light Tail light 2 License plate light 4 Rear fender 5 N m 0 5 kgf m 3 5 lbf ft 1 I940H1920010 01 ...

Page 552: ...in the reverse order of removal License Plate Light Components B940H29206009 License Plate Light Removal and Installation B940H29206010 Removal 1 Remove the rear fender extension Refer to Exterior Parts Removal and Installation in Section 9D Page 9D 5 2 Disconnect the licence plate light coupler 1 2 I940H1920012 02 1 2 3 FWD FWD I940H1920046 01 1 License plate light bulb 12 V 5 W 2 Lens 3 Lens cov...

Page 553: ...icense plate light in the reverse order of removal License Plate Light Bulb Replacement B940H29206011 1 Remove the license plate light by removing the nuts 2 Remove the lens by removing the screws 3 Replace the bulb 1 4 Reinstall the lens I940H1920014 01 I940H1920015 01 I940H1920016 01 1 I940H1920017 01 ...

Page 554: ...the turn signal light couplers 1 3 Remove the turn signal light 2 by removing the mounting bolt 3 left and right Installation Install the front turn signal light in the reverse order of removal 1 2 3 3 FWD FWD I940H1920048 02 1 Front turn signal light bulb 12 V 21 5 W x 2 for E 03 28 33 Front turn signal light bulb 12 V 21 W x 2 for E 02 19 24 3 Lens 2 Rear turn signal light bulb 12 V 21 W x 2 1 1...

Page 555: ... LH Gray 1 4 Remove the clamps 2 5 Remove the rear turn signal 3 Installation Install the rear turn signal light in the reverse order of removal Turn Signal Light Bulb Replacement B940H29206015 CAUTION When you touch the bulb with your bare hands clean the bulb with a cloth moistened with alcohol or soap water to prevent premature bulb failure 1 Remove the screw 1 2 Remove the rear turn signal len...

Page 556: ...40H29206018 Inspect the hazard switch in the following procedures 1 Disconnect the left handlebar switch coupler 1 2 Inspect the hazard switch for continuity with a tester If any abnormality is found replace the left handlebar switch assembly with a new one Refer to Handlebars Removal and Installation in Section 6B Page 6B 1 Special tool 09900 25008 Multi circuit tester set Tester knob indication ...

Page 557: ...h in the following procedures 1 Disconnect the left handlebar switch coupler 1 2 Inspect the dimmer switch for continuity with a tester If any abnormality is found replace the left handlebar switch assembly with a new one Refer to Handlebars Removal and Installation in Section 6B Page 6B 1 Special tool 09900 25008 Multi circuit tester set Tester knob indication Continuity 3 After finishing the dim...

Page 558: ...struction Page 9B 5 Reference For the tightening torque of fastener not specified in this section refer to Tightening Torque List in Section 0C Page 0C 8 Special Tools and Equipment Special Tool B940H29208001 Fastening part Tightening torque Note N m kgf m lbf ft Headlight cover mounting bolt 8 5 0 85 6 0 Page 9B 3 09900 25008 Multi circuit tester set Page 9B 4 Page 9B 10 Page 9B 10 Page 9B 11 Pag...

Page 559: ...l level indicator and Clock FI DTC respectively LED Light Emitting Diode LED is used for the illumination light and each indicator light LED is maintenance free LED is less power consuming and more resistant to vibration resistance compared to the bulb 1 2 3 5 4 6 6 7 8 9 I940H1930001 02 1 Adjust switch Odo Trip Clock 6 LED Turn signal indicator light 2 LED Coolant temperature indicator 7 LED High...

Page 560: ...llation B940H29306002 Removal 1 Remove the headlight assembly Refer to Headlight Removal and Installation in Section 9B Page 9B 2 2 Disconnect the combination meter coupler 1 3 Remove the bolt 2 FWD FWD 1 2 3 4 5 I940H1930032 01 1 Upper cover 3 Combination meter 5 Pilot lamp assembly 2 Upper case assembly 4 Lower case 1 2 I940H1930002 01 ...

Page 561: ...Tightening torque Combination meter mounting bolt a 10 N m 1 0 kgf m 7 0 lbf ft Combination Meter Disassembly and Assembly B940H29306003 Refer to Combination Meter Removal and Installation Page 9C 2 Disassembly Disassemble the combination meter as shown in the combination meter components Refer to Combination Meter Components Page 9C 2 Assembly Assemble the combination meter as shown in the combin...

Page 562: ...r position even turning the ignition switch on under low temperature condition In that case you can reset the pointer to the proper position by the following instruction Complete the operation within 10 seconds after the ignition switch has been turned ON 2 With the adjuster switch 1 pressed turn the ignition switch ON 3 Hold the adjuster switch 1 3 to 5 seconds after turning the ignition switch O...

Page 563: ...or coupler 1 3 Connect the variable resistor 2 between the terminals 4 Turn the ignition switch ON 5 Check the LED operations when the resistance is adjusted to the specified values If either one or all indications are abnormal replace the combination meter with a new one Refer to Combination Meter Removal and Installation Page 9C 2 6 Connect the ECT sensor coupler Engine Coolant Temperature Remov...

Page 564: ...g it 7 Connect the fuel level gauge coupler and reinstall the fuel tank Refer to Fuel Tank Removal and Installation in Section 1G Page 1G 9 Fuel Level Indicator Switch Thermistor Inspection B940H29306009 Inspect the fuel level indicator switch in the following procedures 1 Remove the fuel pump Refer to Fuel Pump Assembly Fuel Level Gauge Removal and Installation in Section 1G Page 1G 12 2 Remove t...

Page 565: ... indication Resistance Ω 3 Install the fuel level gauge Refer to Fuel Pump Assembly Fuel Level Gauge Removal and Installation in Section 1G Page 1G 12 Speedometer Inspection B940H29306011 If the speedometer odometer or tripmeter does not function properly inspect the speed sensor and the coupler connections If the speed sensor and coupler connections are OK replace the combination meter unit with ...

Page 566: ...ester probe to B R as shown in the figure Special tool 09900 25008 Multi circuit tester set Tester knob indication Voltage 3 Move a screwdriver back and forth across the pick up surface of the speed sensor The voltage readings should cycle as follows 0 V 12 V or 12 V 0 V If the voltage reading does not change replace the speed sensor with a new one NOTE While testing the highest voltage reading sh...

Page 567: ...s Removal and Installation in Section 9D Page 9D 5 2 Disconnect the ignition switch coupler 1 3 Inspect the ignition switch for continuity with a tester If any abnormality is found replace the ignition switch with a new one Special tool 09900 25008 Multi circuit tester set Tester knob indication Continuity 4 After finishing the ignition switch inspection reinstall the removed parts Ignition Switch...

Page 568: ...ntinuity Horn Inspection 1 Disconnect the horn couplers 1 2 Connect a 12 V battery to terminal A and terminal B If the sound is not heard from the horn replace the horn with a new one 3 Connect the horn coupler Horn Removal and Installation B940H29306019 Removal 1 Disconnect the horn couplers 1 2 Remove the horn by removing the mounting bolts 2 Installation Install the horn in the reverse order of...

Page 569: ... Item Specification Brake light Taillight LED Speedometer light LED Turn signal indicator light LED High beam indicator light LED Neutral position indicator light LED Coolant temperature indicator light LED Oil pressure indicator light LED FI indicator light LED Fastening part Tightening torque Note N m kgf m lbf ft Combination meter mounting bolt 10 1 0 7 0 Page 9C 3 Material SUZUKI recommended p...

Page 570: ...Routing Diagram Seat Lock Cable Routing Diagram B940H29402001 1 2 3 1 2 A 6 2 4 3 2 3 A A 1 2 5 I940H1940018 03 1 Frame 3 Seat lock 5 Clamp Clamp the seat lock cable only A White tape 2 Seat lock cable 4 ECM 6 Clamp Clamp the seat lock cable at the white tape A E 33 only ...

Page 571: ...r Parts Construction B940H29406001 1 2 3 3 4 4 7 8 6 5 I940H1940014 03 1 Frame head cover 5 Frame head cover 2 Frame lower cover RH 6 Regulator Rectifier 3 Frame side cover RH 7 Frame lower cover LH 4 Frame side lower cover RH 8 Frame side cover LH ...

Page 572: ... Cover Cushion Construction B940H29406002 1 1 2 1 1 3 I940H1940015 02 1 Cushion When sticking the cushion on the frame head cover align the cushion edge with the extension of stopping line 3 Frame head cover RH 2 Frame head cover LH ...

Page 573: ...ar frame 6 Rear fender 2 Rear fender brace ABC After temporary tightening tighten the bolts to the specified torque in order of A B C 3 Rear frame plate 50 N m 5 0 kgf m 36 0 lbf ft 4 Rear fender extension 1 8 N m 0 18 kgf m 1 3 lbf ft 5 Rear reflex refractor For E 03 28 33 Apply thread lock to the thread part ...

Page 574: ...e seat hooks into the seat hook retainers on the frame and tighten the bolts securely Rear Seat Seat Tail Cover Removal 1 Remove the front seat 2 Remove the rear seat by removing the bolts 1 Installation 1 Slide the hook into the seat hook retainer 2 Tighten the bolts 1 securely Frame Side Cover Removal Remove the frame cover 1 I940H1940001 01 I940H1940002 02 1 I940H1940003 01 A Hooked point I940H...

Page 575: ...der extension and rear fender as shown rear fender construction Refer to Rear Fender Construction Page 9D 4 Installation Install the rear fender in the reverse order of removal Front Fender Removal Remove the front fender mounting bolts Remove the front fender Installation Install the front fender in the reverse order of removal Frame Head Cover Removal 1 Move the fuel tank backward Refer to Fuel ...

Page 576: ...lowing point Apply thread lock to the right frame lower cover mounting screws Thread lock cement 99000 32110 THREAD LOCK CEMENT SUPER 1322 or equivalent Specifications Tightening Torque Specifications B940H29407001 NOTE The specified tightening torque is described in the following Rear Fender Construction Page 9D 4 Reference For the tightening torque of fastener not specified in this section refer...

Page 577: ...truction B940H29506001 1 2 a 4 3 a B 3 a C a A a 4 FWD FWD I940H1950003 02 1 Frame ABC After temporary tightening tighten the bolts to the specified torque in order of A B C 2 Frame down tube 50 N m 5 0 kgf m 36 0 lbf ft 3 Rear frame Apply thread lock to the thread part 4 Frame down tube bolt ...

Page 578: ...003 1 Frame 3 Steering lock bracket bolt Do not reuse 2 Steering lock bracket 26 N m 2 6 kgf m 19 0 lbf ft 1 a 3 2 I940H1950001 02 1 2 a 3 b 4 I940H1950002 01 1 Side stand 3 Side stand bolt 50 N m 5 0 kgf m 36 0 lbf ft Apply grease to sliding surface 2 Spring 4 Side stand nut 40 N m 4 0 kgf m 29 0 lbf ft ...

Page 579: ...ions Tightening Torque Specifications B940H29507001 NOTE The specified tightening torque is described in the following Body Frame Construction Page 9E 1 Steering Lock Bracket Construction Page 9E 2 Side stand Construction Page 9E 2 Reference For the tightening torque of fastener not specified in this section refer to Tightening Torque List in Section 0C Page 0C 8 Special Tools and Equipment Recomm...

Page 580: ...Prepared by September 2008 Part No 99500 39370 03E Printed in U S A 580 ...

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Suzuki Intruder VZ1500, Service Manual

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