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Suzuki Intruder VZR1800, Service Manual

The Suzuki Intruder VZR1800 is a powerful cruiser motorcycle that demands attention on the road. For those looking to maintain their ride, a Service Manual is essential. Download the manual for free from manualshive.com to ensure your Intruder stays in top condition for every ride.

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SYMBOL

Listed in the table below are the symbols indicating instructions and other information necessary for servic-
ing. The meaning of each symbol is also included in the table.

SYMBOL

DEFINITION

SYMBOL

DEFINITION

Torque control required.
Data beside it indicates specified 
torque.

Apply THREAD LOCK SUPER “1360” or 
equivalent.
99000-32130

Apply oil. 
Use engine oil unless otherwise speci-
fied.

Use engine coolant or equivalent.
99000-99032-11X

Apply molybdenum oil solution.
(Mixture of engine oil and SUZUKI 
MOLY PASTE in a ratio of 1:1)

Use fork oil or equivalent.
99000-99044-L01

Apply SUZUKI SUPER GREASE “A” or 
equivalent.
99000-25010

Apply or use brake fluid.

Apply SUZUKI MOLY PASTE or equiva-
lent.
99000-25140

Measure in voltage range.

Apply SUZUKI SILICON GREASE or 
equivalent.
99000-25100

Measure in current range.

Apply SUZUKI BOND “1215” or equiva-
lent.
99000-31110

Measure in resistance range.

Apply SUZUKI BOND “1207B” or equiv-
alent.
99000-31140

Measure in diode test range.

Apply THREAD LOCK SUPER “1303” 
or equivalent.
99000-32030

Measure in continuity test range.

Apply THREAD LOCK SUPER “1322” 
or equivalent.
99000-32110

Use special tool.

Apply THREAD LOCK “1342” or equiv-
alent.
99000-32050

Indication of service data.

Summary of Contents for Intruder VZR1800

Page 1: ...9 9 5 0 0 3 9 2 9 0 0 1 E VZR1800...

Page 2: ...re your customers of fast and reliable service COPYRIGHT SUZUKI MOTOR CORPORATION 2006 This manual has been prepared on the basis of the latest specifications at the time of publi cation If modificati...

Page 3: ...isted on the first page of each section to help you find the item and page you need COMPONENT PARTS AND WORK TO BE DONE Under the name of each system or unit is its exploded view Work instructions and...

Page 4: ...MOLY PASTE in a ratio of 1 1 Use fork oil or equivalent 99000 99044 L01 Apply SUZUKI SUPER GREASE A or equivalent 99000 25010 Apply or use brake fluid Apply SUZUKI MOLY PASTE or equiva lent 99000 2514...

Page 5: ...rol Unit ECT Sensor Engine Coolant Temperature Sensor ECTS Water Temp Sensor WTS EVAP Evaporative Emission EVAP Canister Evaporative Emission Canister Canister EXC System Exhaust Control System EXCS E...

Page 6: ...Memory S SAE Society of Automotive Engineers SDS Suzuki Diagnosis System STC System Secondary Throttle Control System STCS STP Sensor Secondary Throttle Position Sensor STPS ST Valve Secondary Throttl...

Page 7: ...Blue tracer G B Green with Black tracer G W Green with White tracer G R Green with Red tracer Gr B Gray with Black tracer G Y Green with Yellow tracer Gr W Gray with White tracer O B Orange with Blac...

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

Page 9: ...t use good judgement and basic mechanical safety principles If you are unsure about how to perform a particular service operation ask a more experienced mechanic for advice GENERAL PRECAUTIONS Proper...

Page 10: ...nd nuts tighten the larger sizes first Always tighten the bolts and nuts diagonally from the inside toward outside and to the speci fied tightening torque Whenever you remove oil seals gaskets packing...

Page 11: ...kets SERIAL NUMBER LOCATION The frame serial number or V I N Vehicle Identification Number 1 is stamped on the right side of the steering head pipe The engine serial number 2 is located on the right s...

Page 12: ...lowing chart ENGINE OIL FOR OTHER COUNTRIES Oil quality is a major contributor to your engine s performance and life Always select good quality engine oil Use of API SF SG or SH SJ with JASO MA Suzuki...

Page 13: ...mperature in your area does not go down to freezing 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...

Page 14: ...exercised during its early life The general rules are as follows Keep to these break in engine speed limits Initial 800 km 500 miles Below 3 500 r min Up to 1 600 km 1 000 miles Below 5 500 r min Ove...

Page 15: ...el A A 6 Manual notice label A For E 03 33 7 Tire information label A A 8 General warning label A A 9 ICES Canada label A For E 28 0 I D plate A Except E 02 19 24 A A E 19 I D label A B Safety plate A...

Page 16: ...r of cylinders 2 Bore 112 0 mm 4 409 in Stroke 90 5 mm 3 563 in Displacement 1 783 cm 108 8 cu in Compression ratio 10 5 1 Fuel system Fuel injection Air cleaner Non woven fabric element Starter syste...

Page 17: ...Headlight 12 V 60 55 W H4 Position light 12 V 5 W For E 02 19 24 Front turn signal position light 12 V 21 5 W For E 03 28 33 Front turn signal light 12 V 21 W For the others Rear turn signal light 12...

Page 18: ...ANCE 2 8 SPARK PLUG 2 13 FUEL LINE 2 16 EVAPORATIVE EMISSION CONTROL SYSTEM E 33 ONLY 2 16 ENGINE OIL AND OIL FILTER 2 17 FINAL GEAR OIL 2 19 THROTTLE CABLE PLAY 2 19 PAIR AIR SUPPLY SYSTEM 2 19 THROT...

Page 19: ...12 000 18 000 24 000 miles 600 4 000 7 500 11 000 14 500 Item months 2 12 24 36 48 Air cleaner element I I R I Exhaust pipe bolts and muffler bolts T T T Exhaust control valve I I I Valve clearance I...

Page 20: ...below NOTE Before lubricating each part clean off any rusty spots and wipe off any grease oil dirt or grime Lubricate exposed parts which are subject to rust with a rust preventative spray whenever t...

Page 21: ...irements AIR CLEANER Remove the right and left air cleaner box bolts NOTE indicates hook location Loosen the air cleaner box clamp screw and disconnect the drain tube 1 Remove the air cleaner box Remo...

Page 22: ...ne depends largely on this component Install the cleaned or new air cleaner element in the reverse order of removal NOTE When cleaning the air cleaner element drain water from the air cleaner by remov...

Page 23: ...s muffler mounting bolt and nut to the specified torque Tighten initially at 1 000 km 600 miles 2 months and every 12 000 km 7 500 miles 24 months thereafter 1 Gasket 2 Exhaust pipe connector ITEM N m...

Page 24: ...k exhaust valve actuator electrical circuit and exhaust valve carbon sticking Check the exhaust control cable play 7 12 Remove the two bolts and cover Check the lock nuts tightness If the lock nuts ar...

Page 25: ...e must be checked and adjusted 1 at the time of periodic inspection 2 when the valve mecha nism is serviced and 3 when the camshafts are removed for servicing Valve clearance when cold Standard IN 0 0...

Page 26: ...Rear cylinder tappet clearance use a thickness gauge between the tappet and the cam If the clear ance is out of specification adjust it into the specified range 09900 20803 Thickness gauge Turn the c...

Page 27: ...to check shim size with micrometer to ensure its size Refer to the tappet shim selection table 2 11 and 12 for details NOTE Be sure to apply engine oil to tappet shim top and bottom faces When seating...

Page 28: ...00 3 05 3 10 3 15 3 20 3 25 3 30 3 35 3 40 3 45 3 50 2 70 2 75 2 80 2 85 2 90 2 95 3 00 3 05 3 10 3 15 3 20 3 25 3 30 3 35 3 40 3 45 3 50 2 75 2 80 2 85 2 90 2 95 3 00 3 05 3 10 3 15 3 20 3 25 3 30 3...

Page 29: ...2 90 2 95 3 00 3 05 3 10 3 15 3 20 3 25 3 30 3 35 3 40 3 45 3 50 3 50 2 70 2 75 2 80 2 85 2 90 2 95 3 00 3 05 3 10 3 15 3 20 3 25 3 30 3 35 3 40 3 45 3 50 3 50 2 75 2 80 2 85 2 90 2 95 3 00 3 05 3 10...

Page 30: ...nch Remove the right cylinder head cover cap 3 NOTE indicates hook location Remove the spark plug cap 4 Remove the spark plug with a spark plug wrench Inspect every 6 000 km 4 000 miles 12 months repl...

Page 31: ...plug wrench Remove the left cylinder head cover cap 3 NOTE indicates hook location Remove the spark plug cap 4 Remove the spark plug with a spark plug wrench Disconnect the lead wire coupler before r...

Page 32: ...lug cleaner machine or carefully use a tool with a pointed end SPARK PLUG GAP Measure the spark plug gap with a thickness gauge Adjust the spark plug gap if necessary Spark plug gap A Standard 0 6 0 7...

Page 33: ...cts are found the fuel feed hose must be replaced EVAPORATIVE EMISSION CONTROL SYSTEM E 33 ONLY Inspect the evaporative emission control system periodically Do not cross thread or over tighten the spa...

Page 34: ...upright while pouring engine oil Motorcycle on the side stand position Tighten the drain plugs 1 Pour fresh oil 3 0 L Tighten the filler cap 2 Start up the engine and allow it to run few minutes at i...

Page 35: ...the special tool Never tighten the oil filter by hand Oil filter 20 N m 2 0 kgf m 14 5 lb ft Add new engine oil and check the oil level is as described in the engine oil replacement procedure NECESSAR...

Page 36: ...n the lock nut 2 of the throttle pulling cable 1 Turn the adjuster 3 in or out until the throttle cable play at the throttle grip A is between 2 0 4 0 mm 0 08 0 16 in Tighten the lock nut 2 while hold...

Page 37: ...is below the lower line remove the fuel tank 6 3 left frame head cover and left radiator cover 9 6 and add engine coolant to the full line from the engine coolant reservoir filler ENGINE COOLANT CHAN...

Page 38: ...t Start up the engine and bleed air from the radiator inlet com pletely Add engine coolant up to the radiator inlet Repeat the above procedure until bleed no air from the radia tor inlet Close the rad...

Page 39: ...ts are found replace the radiator hoses with new ones CLUTCH CABLE PLAY Loosen the lock nut 1 Turn in the adjuster 2 all the way into the clutch lever assem bly Remove the secondary gear case cover 3...

Page 40: ...months thereafter BRAKE HOSE AND BRAKE FLUID Inspect every 6 000 km 4 000 miles 12 months Replace hoses every 4 years Replace fluid every 2 years The brake system of this motorcycle is filled with a...

Page 41: ...e pads with the new ones 9 52 Rear brake The extent of brake pad wear can be checked by observing the grooved limit line A on the pad When the wear exceeds the grooved limit line replace the pads with...

Page 42: ...in A below the top of the footrest Tighten the lock nut 1 securely Rear brake master cylinder rod lock nut 18 N m 1 8 kgf m 13 0 Ib ft Brake pedal height A Standard 25 35 mm 1 0 1 4 in BRAKE LIGHT SW...

Page 43: ...bleeder valve and insert the free end of the hose into a receptacle Squeeze and release the brake lever several times in rapid succession and squeeze the lever fully without releasing it Loosen the a...

Page 44: ...nder is actuated by a pedal TIRES TIRE TREAD CONDITION Operating the motorcycle with excessively worn tires will decrease riding stability and consequently invite a dangerous situation It is highly re...

Page 45: ...of the handlebars and too loose steering will cause poor stability Check that there is no play in the front fork Support the motorcycle so that the front wheel is off the ground With the wheel facing...

Page 46: ...nt axle pinch bolt 23 2 3 16 5 7 Handlebar clamp bolt 23 2 3 16 5 8 Front brake master cylinder mounting bolt 10 1 0 7 0 9 Front brake caliper mounting bolt 39 3 9 28 0 0 Brake hose union bolt Front R...

Page 47: ...2 30 PERIODIC MAINTENANCE...

Page 48: ...compression pressure readings are below 1 100 kPa 11 0 kgf cm2 156 psi even when they measure 800 kPa 8 0 kgf cm2 114 psi and more COMPRESSION TEST PROCEDURE NOTE Before testing the engine for compres...

Page 49: ...light is turned on If the light stays on check the oil pressure indicator light circuit If the circuit is OK check the oil pressure in the fol lowing manner Remove the boot 1 and oil pressure switch...

Page 50: ...ubleshooting is difficult comparison with the normal data that have been saved or filed can allow the specific engine failure to be determined Remove the left frame side cover 9 5 Set up the SDS tool...

Page 51: ...000 r min under no load Data at the time of racing Approx 3 000 r min Check the manifold absolute pressure 1 XX mmHg Check the water temperature XX C Check the manifold absolute pressure 1 in accordi...

Page 52: ...idling 100 C Data of manifold absolute pressure operation at the time of starting Check the manifold absolute pressure 1 XX mmHg Check the water temperature Approx 100 C Check the manifold absolute p...

Page 53: ...CHAIN TENSIONER 3 32 CAM CHAIN GUIDE 3 32 CYLINDER HEAD AND VALVE 3 32 CYLINDER 3 41 PISTON AND PISTON RING 3 42 CLUTCH 3 44 GEARSHIFT COVER 3 46 STARTER CLUTCH 3 47 OIL PUMP 3 48 STARTER TORQUE LIMIT...

Page 54: ...pressure regulator 3 27 3 53 3 84 Oil pressure switch 3 26 10 42 3 86 ITEM REMOVAL INSPECTION INSTALLATION Exhaust pipe and muffler 7 8 7 10 Cam chain tension adjuster 3 15 17 3 32 3 107 108 Starter m...

Page 55: ...the following steps Reinstall the engine by reversing the removal procedure Drain engine oil 2 17 Drain engine coolant 2 20 Remove the frame side covers 9 5 Remove the fuel tank 6 3 Remove the frame h...

Page 56: ...s 2 13 and 14 Disconnect the radiator inlet hose 5 Remove the rear brake fluid reservoir mounting bolt 6 Remove the master cylinder cover 7 Do not remove the ignition coil plug cap before dis connecti...

Page 57: ...ENGINE 3 5 Remove the right footrest 8 Disconnect the starter motor lead wire 9 Disconnect the oil cooler hose 0 Remove the oil pressure switch lead wire A...

Page 58: ...side cover D Remove the secondary gear case cover E Disconnect the generator lead wire coupler F Disconnect the CKP sensor lead wire coupler G Disconnect the regulator rectifier lead wire coupler H D...

Page 59: ...e clutch cable K Support the engine with an engine jack Remove the left footrest L and gearshift lever M Remove the ground lead wire N Disconnect the GP switch lead wire coupler O Remove the engine mo...

Page 60: ...Slightly move the frame down tube by removing its bolts P bolts and nuts Q Remove the caps Remove the engine mounting bracket bolts R Remove the engine mounting bolts and nuts S Remove the the engine...

Page 61: ...e and then engage the secondary driven gear shaft to the universal joint Properly fit the boot onto the engine and the swingarm Install the engine mounting bracket 1 and tighten it bolts to the specif...

Page 62: ...d nuts 3 to the specified torque NOTE The frame down tube nuts are self locking Once the nuts have been removed they are no longer of any use Frame down tube bolt 50 N m 5 0 kgf m 36 0 lb ft Install t...

Page 63: ...Install the gearshift lever and tighten the mounting bolts to the specified torque Left front footrest bolt 50 N m 5 0 kgf m 36 0 lb ft Footrest in the correct position Gearshift lever height A Standa...

Page 64: ...5 lb ft Install the rear brake master cylinder cover 4 9 72 Install the throttle body 6 21 Install the exhaust pipe and muffler 7 10 Perform service and adjustment in the following items Engine oil 2...

Page 65: ...or 1 INTAKE PIPE Remove the front and rear intake pipes 1 THERMOSTAT Remove the thermostat assembly 1 and disconnect the water hoses 2 3 Identify the position of each removed part Organize the parts i...

Page 66: ...EAD COVER Remove the right and left head cover brackets 1 Remove the rear cylinder head cover 2 and its gasket REAR CAMSHAFT Remove the generator cover cap 1 Remove the valve timing inspection plug 2...

Page 67: ...s A on the camshafts are parallel with the mating surface of the cylinder head cover Remove the cam chain tension adjuster cap bolt 4 and spring Remove the rear cam chain tension adjuster No 2 5 and g...

Page 68: ...sket Remove the cylinder nuts Remove the cylinder 5 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 cyli...

Page 69: ...to the index mark of the valve inspection hole and also to bring the cams to the position as shown NOTE At the above condition the front cylinder is at TDC on expansion stroke and also the engraved l...

Page 70: ...d bolts and washers NOTE Loosen the cylinder head bolts little by little diagonally with the smaller sizes first Remove the cylinder head 1 FRONT CYLINDER Remove the cylinder head gasket 1 dowel pins...

Page 71: ...and dowel pins FRONT PISTON Place a clean rag over the cylinder base so as not to drop the piston pin circlip into the crankcase Remove the piston pin circlip Remove the piston pin and piston NOTE Scr...

Page 72: ...it is difficult to pull out the push rod 5 and ball 6 use a long bar Unlock the clutch sleeve hub nut Hold the generator rotor with a 41 mm offset wrench Remove the clutch sleeve hub nut Remove the sp...

Page 73: ...N ADJUSTER Unlock the ratchet 1 and insert the special tool 09917 62430 Chain tensioner lock tool Remove the rear cam chain tensioner No 1 assy 2 Remove the cam chain guide No 1 3 and rear cam chain t...

Page 74: ...ove the rear cam chain drive sprocket bolt Remove the rear cam chain drive sprocket 1 STARTER TORQUE LIMITER STARTER IDLE GEAR Remove the washer 1 starter torque limiter 2 and washer Remove the shaft...

Page 75: ...the rotor Remove the generator rotor assembly with the special tool 09930 30721 Rotor remover Remove the key 1 FRONT CAM CHAIN IDLER SPROCKET Loosen the front cam chain tensioner No 1 mounting bolt 1...

Page 76: ...cket 8 and cam chain No 1 9 Remove the front cam chain tension adjuster No 1 0 SECONDARY DRIVEN GEAR Remove the secondary driven gear assembly 1 and shims SECONDARY DRIVEN GEAR INSPECTION 4 6 GEARSHIF...

Page 77: ...rive gear 1 removal 3 28 SECONDARY DRIVE GEAR SERVICING 4 10 PRIMARY DRIVEN GEAR Hold the primary driven gear with the special tool and remove the primary driven gear bolt 09930 44541 Rotor holder Rem...

Page 78: ...filter with the special tool 09915 40610 Oil filter wrench OIL COOLER OIL PRESSURE SWITCH Disconnect the water hose 1 Remove the oil cooler 2 by removing the union bolt Remove the oil pressure switch...

Page 79: ...O rings 3 UPPER CRANKCASE Remove the breather cover 1 Remove the upper crankcase bolts LOWER CRANKCASE Remove the lower crankcase bolts Make sure that all of the bolts are removed Then tap the sides o...

Page 80: ...ts and nuts to the crankcase by separating the upper and lower crankcase halves as shown in the illustration TRANSMISSION Remove the driveshaft assembly 1 and countershaft assem bly 2 Remove the O rin...

Page 81: ...tall the PAIR reed valve and PAIR reed valve cover Apply THREAD LOCK to the bolts and tighten them 99000 32050 THREAD LOCK 1342 or equivalent CAMSHAFT CAMSHAFT IDENTIFICATION The camshafts can be iden...

Page 82: ...est portion which is specified as follows Camshaft journal oil clearance Service Limit IN EX 0 150 mm 0 0059 in 09900 22301 Plastigauge 09900 22302 Plastigauge NOTE Install camshaft journal holder to...

Page 83: ...d IN EX 23 959 23 980 mm 0 9433 0 9441 in 09900 20205 Micrometer 0 25 mm CAMSHAFT RUNOUT Measure the runout using the dial gauge Replace the camshaft if the runout exceeds the limit Camshaft runout Se...

Page 84: ...1 2 Front cam chain tension adjuster No 2 3 Rear cam chain tension adjuster No 1 4 Rear cam chain tension adjuster No 2 CAM CHAIN TENSIONER INSPECTION Check the contacting surface of the cam chain ten...

Page 85: ...imit 0 05 mm 0 002 in 09900 20803 Thickness gauge VALVE AND VALVE SPRING DISASSEMBLY Remove the tappet 1 and shim 2 by fingers or magnetic hand Install the special tool between the valve spring and cy...

Page 86: ...imit 0 05 mm 0 002 in 09900 20607 Dial gauge 1 100 mm 09900 20701 Magnetic stand 09900 21304 V block set 100 mm VALVE HEAD RADIAL RUNOUT Place the dial gauge at a right angle to the valve head face an...

Page 87: ...the guide should be replaced with a new one Valve stem deflection IN EX Service Limit 0 35 mm 0 014 in 09900 20607 Dial gauge 1 100 mm 09900 20701 Magnetic stand VALVE STEM WEAR If the valve stem is w...

Page 88: ...guide installer 1 and attachment 2 09916 46020 Valve guide installer remover 1 09916 44940 Attachment 2 NOTE Install the valve guide until the attachment contacts the cylinder head 3 After installing...

Page 89: ...the seat VALVE SEAT SERVICING The valve seats 1 for both the intake valve 2 and exhaust valve 3 are machined to three different angles The seat con tact surface is cut at 45 NOTE After servicing the v...

Page 90: ...the service limit or if the force required to compress the spring does not fall within the range specified replace the spring Valve spring free length Service limit IN EX 40 5 mm 1 60 in 09900 20102...

Page 91: ...16 84511 Tweezers 09919 28610 Sleeve protector Be sure that the rounded lip E of the cotter fits snugly into the groove F in the stem end Install the other valves and springs in the same manner as des...

Page 92: ...ne Install the cam chain tensioner 1 washers 2 and nuts 3 Tighten the cam chain tensioner nuts to the specified torque Cam chain tensioner nut 10 N m 1 0 kgf m 7 0 lb ft WATER JACKET PLUG Remove the w...

Page 93: ...ng at any position of the straightedge exceeds the limit replace the cylinder Cylinder distortion Service Limit 0 05 mm 0 002 in 09900 20803 Thickness gauge CYLINDER BORE Inspect the cylinder wall for...

Page 94: ...arance exceeds the service limit replace the cylinder or the piston or both Piston to cylinder clearance Service Limit 0 120 mm 0 0047 in PISTON PIN AND PIN BORE Measure the piston pin bore diameter u...

Page 95: ...in Oil 2 51 2 53 mm 0 0988 0 0996 in Piston ring thickness Standard 1st 0 86 0 91 mm 0 034 0 036 in 1 38 1 40 mm 0 054 0 055 in 2nd 1 17 1 19 mm 0 046 0 047 in PISTON RING FREE END GAP AND PISTON RIN...

Page 96: ...e the driven plates found to have worn down to the limit Driven plate claw width Service limit No 1 No 2 7 16 mm 0 282 in 09900 20102 Vernier calipers CLUTCH PLATE DISTORTION NOTE Wipe off engine oil...

Page 97: ...utch push rod for damage and bend If neces sary replace it with a new one CLUTCH PUSH ROD RELEASE BALL Inspect the push rod release ball for damage or wear If nec essary replace it with a new one CLUT...

Page 98: ...the gearshift shaft oil seal 1 Remove the bearing with the special tools 09921 20210 Bearing remover 09930 30104 Sliding shaft REASSEMBLY Install the bearing 1 and oil seal 2 with the special tool 099...

Page 99: ...ter driven gear bushing for any damage If necessary replace it with a new one DISASSEMBLY Remove the starter clutch securing bolts Remove the one way clutch 1 and guide 2 from the genera tor rotor REA...

Page 100: ...return pump DISASSEMBLY Remove the oil return pump outer rotor 1 inner rotor 2 and pin 3 INSPECTION Rotate the oil pump by hand and check that it moves smoothly If it does not move smoothly replace th...

Page 101: ...talling the inner rotor 1 align the pin 2 with the groove 3 When installing the inner rotor and outer rotor face the punched marks A on the rotors to the outside INSTALLATION Before mounting the oil p...

Page 102: ...ply a small quantity of THREAD LOCK to the startor bolt Tighten the generator stator bolts 1 clamp bolt 2 and CKP sensor bolts 3 99000 32050 THREAD LOCK 1342 or equivalent Generator stator bolt 1 11 N...

Page 103: ...seal 8 REASSEMBLY Apply SUZUKI SUPER GREASE A the release camshaft 1 new bearing 2 and oil seal 3 before installing 99000 25010 SUZUKI SUPER GREASE A or equivalent Install the clutch release arm and...

Page 104: ...shaft gearshift arm for wear or bend Inspect the return springs for damage or fatigue Replace the arm or spring if there is anything unusual GEARSHIFT SHAFT GEARSHIFT ARM REASSEMBLY Install the follow...

Page 105: ...essure regulator by pushing on the piston with a proper bar If the piston does not operate replace the oil pressure regula tor with a new one OIL STRAINER Clean the oil strainer if necessary Inspect t...

Page 106: ...SSION CONSTRUCTION 1 Countershaft 1st drive gear 7 2nd driven gear 2 5th drive gear 8 3rd driven gear 3 4th drive gear 9 4th driven gear 4 3rd drive gear 0 5th driven gear 5 2nd drive gear A 1st drive...

Page 107: ...ve gears toward the 4th drive gear 4 side then remove the 2nd drive gear circlip 7 Remove the 2nd drive gear 8 and 3rd drive gear 9 Remove the 3rd drive gear bushing 0 washer A snap ring B and 4th dri...

Page 108: ...ar bushing G Driveshaft Remove the bearing 1 washer 2 and 1st driven gear 3 Remove the 1st driven gear bushing 4 washer 5 and 5th driven gear 6 Remove the snap ring 7 washer 8 and 4th driven gear 9 Re...

Page 109: ...ASE A or equivalent NOTE When reassembling the transmission attention must be given to the locations and positions of washers and snap rings The cross sectional view shows the correct position of the...

Page 110: ...Fit it to the side where the thrust is as shown in the illustration A Thrust B Sharp edge When installing the gear bushing onto the counter shaft 1 and driveshaft 2 align the shaft oil hole 3 with th...

Page 111: ...ENGINE 3 59 TRANSMISSION PARTS LOCATION 1 Countershaft 2 Driveshaft...

Page 112: ...the gearshift cam 5 and its bearing 6 GEARSHIFT FORK TO GROOVE CLEARANCE Using a thickness gauge check the gearshift fork clearance in the groove of its gear The clearance for each gearshift fork play...

Page 113: ...193 in 09900 20102 Vernier calipers GEARSHIFT CAM BEARING AND GEARSHIFT SHAFT BEARING Bearing inspection Inspect the gearshift cam bearing for abnormal noise and smooth rotation Replace the bearings i...

Page 114: ...913 70210 Bearing installer set 1 20 2 32 NOTE The stamped mark side of the gearshift shaft bearing 1 and gearshift cam bearing 2 faces outside Install the gearshift cam 3 with the bearing 4 NOTE The...

Page 115: ...ft retainer plug 0 to the specified torque 99000 32050 THREAD LOCK 1342 or equivalent 99000 32030 THREAD LOCK SUPER 1303 or equivalent Gearshift arm stopper bolt 19 N m 1 9 kgf m 13 5 lb ft Gearshift...

Page 116: ...1 to each piston cooling oil jet and apply engine oil to them Install each piston cooling oil jet with the bolt NOTE Apply a small quantity of THREAD LOCK to the bolts and tighten them 99000 32050 TH...

Page 117: ...ENGINE 3 65 Remove the oil gallery plugs 2 for upper crankcase side Remove the oil gallery plugs 3 for lower crankcase side Remove the oil gallery plugs 4 for oil pan...

Page 118: ...er removed oil gallery plugs Tighten each plug to the specified torque Water jacket plug cylinder head 1 26 N m 2 6 kgf m 19 0 lb ft Oil gallery plug lower crankcase 2 35 N m 3 5 kgf m 25 5 lb ft 6 25...

Page 119: ...l 09913 70210 Bearing installer set Hold the balancer drivengear with the special tool 09920 53740 Clutch sleeve hub holder Remove the balancer driven gear No 1 bolts 1 and No 2 bolts 2 Remove the spa...

Page 120: ...OCK SUPER 1303 or equivalent Tighten the bolts 5 6 to the specified torque Balancer driven gear No 1 bolt 5 10 N m 1 0 kgf m 7 0 lb ft Balancer driven gear No 2 bolt 6 25 N m 2 5 kgf m 18 0 lb ft Set...

Page 121: ...g a thickness gauge If the clearance exceeds the limit remove the conrod and inspect the conrod big end width and the crank pin width If the width exceed the limit replace conrod or crankshaft Conrod...

Page 122: ...fied torque in two stages 3 73 The number faces the intake side 1 Remove the bearing caps and measure the width of the com pressed plastigauge using the envelope scale This measure ment should be take...

Page 123: ...k the corresponding crank pin O D code number 1 2 or 3 B Bearing selection table Conrod I D Crank pin O D B Code 1 2 3 Conrod I D A 1 Green Black Brown 2 Black Brown Yellow Code I D specification 1 58...

Page 124: ...rod cap make sure that I D code B on each conrod faces intake side Code 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 Co...

Page 125: ...4 of a turn 90 Check the conrod movement for smooth turning CRANKSHAFT JOURNAL BEARING INSPECTION Inspect each bearing of upper and lower crankcases for any damage SELECTION Place the plastigauge axi...

Page 126: ...ied bearings from the bearing selection table Check the corresponding crankcase journal I D code number A A B or C which is stamped on the rear of upper crankcase Check the corresponding crankshaft jo...

Page 127: ...ther end Code O D specification A 54 994 55 000 mm 2 1651 2 1654 in B 54 988 54 994 mm 2 1649 2 1651 in C 54 982 54 988 mm 2 1646 2 1649 in Color Part No Thickness Green 12229 48G00 0A0 1 989 1 992 mm...

Page 128: ...ust the thrust clearance by the following procedures CRANKSHAFT THRUST CLEARANCE ADJUSTMENT Remove the thrust bearing and measure its thickness with a micrometer If the thickness of the thrust bearing...

Page 129: ...300 2 350 mm 0 0906 0 0925 in 0 100 0 200 mm 0 0039 0 0079 in 2 500 2 550 mm 0 0984 0 1004 in Blue 12228 48G00 0C0 2 350 2 400 mm 0 0925 0 0945 in 0 100 0 200 mm 0 0039 0 0079 in 2 550 2 600 mm 0 100...

Page 130: ...crankshaft assembly to the upper crankcase Apply a MOLYBDENUM OIL SOLUTION to each crankshaft journal and bearing lightly MOLYBDENUM OIL SOLUTION Insert the thrust bearing with oil groove A facing the...

Page 131: ...he upper crankcase NOTE Align the C ring with the groove of bearing and the bearing pin with the indent on the bearing Install the driveshaft assembly on the upper crankcase NOTE Align the C ring with...

Page 132: ...3 80 ENGINE Install the O rings 1 Apply SUZUKI SUPER GREASE A to the O rings 99000 25010 SUZUKI SUPER GREASE A or equivalent Install the dowel pins 2 Use a new O ring to prevent oil leakage...

Page 133: ...her 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 Appl...

Page 134: ...washers to the crankcase bolts B Fit the new gasket washers to the crankcase bolts C Crankcase bolt M6 11 N m 1 1 kgf m 8 0 lb ft M8 26 N m 2 6 kgf m 19 0 lb ft M10 Initial 30 N m 3 0 kgf m 21 5 lb ft...

Page 135: ...is as follows Make surfaces free from moisture oil dust and other foreign materials Spread on surfaces thinly to form an even layer and assemble the breater cover within few minutes Apply to distorte...

Page 136: ...the O rings 99000 25010 SUZUKI SUPER GREASE A or equivalent NOTE Align the oil strainer C with the lower crankcase hole D OIL PRESSURE REGULATOR Apply SUZUKI SUPER GREASE A to the O rings and press in...

Page 137: ...pan NOTE Fit the new gasket washers to the oil pan bolts A Fit the clamp B and stay C to the bolts Tighten the oil pan bolts diagonally WATER PUMP Apply SUZUKI SUPER GREASE A to the O ring 99000 25010...

Page 138: ...ressure switch 14 N m 1 4 kgf m 10 0 lb ft NOTE Be careful not to apply SUZUKI BOND to the hole of thread end OIL COOLER Apply engine oil to the O ring NOTE When install the oil cooler fit the convex...

Page 139: ...WITCH Apply SUZUKI SUPER GREASE A to the O ring NOTE Align the gear position switch pin A with the gearshift cam hole B 99000 25010 SUZUKI SUPER GREASE A or equivalent Install the gear position switch...

Page 140: ...n spring end A to the stopper 5 Check the gearshift cam stopper moves smoothly Install the gearshift cam stopper plate 6 NOTE Align the gearshift cam pin B with the gearshift cam stopper plate hole C...

Page 141: ...gear bolt and tighten its to the specified torque 99000 32030 THREAD LOCK SUPER 1303 or equivalent Secondary drive gear bolt 160 N m 16 0 kgf m 115 5 lb ft GEARSHIFT COVER Install the dowel pins and g...

Page 142: ...26 N m 2 6 kgf m 19 0 lb ft NO 1 FRONT CAM CHAIN TENSION ADJUSTER After unlocking the ratchet push the cam chain tension adjuster rod Insert the special tool between the ratchet and the adjuster body...

Page 143: ...SUPER 1303 or equivalent Front chain tensioner No 1 bolt 18 N m 1 8 kgf m 13 0 lb ft Engage the cam chain No 1 onto the cam drive idler sprocket and install it to the upper crankcase Align the groove...

Page 144: ...e nonflammable cleaning solvent to wipe off the oily or greasy matter to make these surfaces completely dry Install the key 1 Install the generator rotor assembly Tighten the generator rotor bolt to t...

Page 145: ...OIL SOLUTION Fit the washers 4 onto the starter torque limiter 5 Install the starter torque limiter 5 to the crankcase REAR CAM CHAIN IDLER SPROCKET Engage the cam chain No 1 onto the cam drive idler...

Page 146: ...ster No 1 bolt 10 N m 1 0 kgf m 7 0 lb ft Install the cam chain guide No 1 1 rear cam chain tensioner No 1 assy 2 Apply a small quantity of THREAD LOCK SUPER to the bolts and tighten its to the specif...

Page 147: ...ft Install the thrust washer 4 Install the clutch sleeve hub assembly 5 onto the counter shaft Install the spring washer 6 NOTE The conical curve side of spring washer 6 faces outside Hold the generat...

Page 148: ...c C Wave washer D Wave washer seat DRIVEN PLATE a Driven plate No 1 4 pcs b Driven plate No 2 2 pcs 2 9 mm 0 11 in 2 9 mm 0 11 in 3 4 mm 0 13 in 3 6 mm 0 14 in 2 6 mm 0 10 in 2 0 mm 0 08 in a Driven p...

Page 149: ...he conical curve side of spring washer 8 faces outside Insert the clutch drive plates and driven plates one by one to the clutch sleeve hub after applying engine oil to the them Install the clutch pus...

Page 150: ...2 NOTE Side designations top and bottom are not applied to the spacer and side rails you can position each either way A INCORRECT B CORRECT Install the 2nd ring 3 and the 1st ring 4 to the piston NOT...

Page 151: ...ON Assemble the pistons and conrods front and rear NOTE When installing the pistons front and rear the indents A on the piston heads must be located to each exhaust side Place a clean rag over the cyl...

Page 152: ...FR Front 2 cylinder RR Rear 1 cylinder Hold the piston rings in proper position and insert each of the pistons into the respective cylinders Tighten the cylinder nuts temporarily CYLINDER HEAD Pull t...

Page 153: ...lts M10 to the specified two step torque with a torque wrench sequentially and diagonally Cylinder head bolt M10 Initial 25 N m 2 5 kgf m 18 0 lb ft Final 42 N m 4 2 kgf m 30 5 lb ft Tighten the other...

Page 154: ...identified by the embossed letters Before replacing the camshafts on cylinder head apply MOLYBDENUM OIL SOLUTION to their journals and cam faces Apply a MOLYBDENUM OIL SOLUTION to the camshaft jour n...

Page 155: ...procket Starting from the roller pin that is directly above the arrow marked 2 D count out 18 roller pins from the exhaust cam shaft side going towards the intake camshaft side Engage the 18th roller...

Page 156: ...haft journal holders are not drawn down evenly Each camshaft journal holder is identified with a cast on letter F IN EX The ascending order of numbers are indicated on the cam shaft journal holder Tig...

Page 157: ...the camshafts on cylinder head apply MOLYBDENUM OIL SOLUTION to their journals and cam faces Apply a MOLYBDENUM OIL SOLUTION to the camshaft jour nal holders MOLYBDENUM OIL SOLUTION NOTE Before instal...

Page 158: ...D should now be pointing straight up Starting from the roller pin that is directly above the arrow marked 2 D count out 18 roller pins from the intake cam shaft side going towards the exhaust camshaft...

Page 159: ...older Tighten the camshaft journal holder bolts in ascending order of numbers to the specified torque 3 104 Camshaft journal holder bolt 11 N m 1 1 kgf m 8 0 lb ft REAR CAM CHAIN TENSION ADJUSTER The...

Page 160: ...AM CHAIN TENSION ADJUSTER The cam chain tension adjuster are identified by the embossed letters F UP Retract the push rod by pushing the stopper 1 Install a new gasket 2 Install the cam chain tension...

Page 161: ...ts 3 106 FRONT AND REAR CYLINDER HEAD COVER Pour engine oil in each oil pocket in the cylinder heads NOTE Be sure to check the valve clearance 2 8 Install the new gaskets to the cylinder head covers A...

Page 162: ...ue Head cover bolt Front and Rear 11 N m 1 1 kgf m 8 0 lb ft GENERATOR COVER Install the dowel pins and gasket 1 Install the generator cover and tighten its bolts NOTE Fit the new gasket washers to th...

Page 163: ...b ft Valve timing inspection plug 23 N m 2 3 kgf m 16 5 lb ft Install the generator cover cap 4 CLUTCH COVER Loosen the lock nut 1 and turn in the release screw 2 to feel resistance From that position...

Page 164: ...the water hoses 2 Tighten the thermostat assembly bolt INTAKE PIPE Apply SUZUKI SUPER GREASE A to the O ring 99000 25010 SUZUKI SUPER GREASE A or equivalent Install the intake pipes NOTE Face the UP...

Page 165: ...OR Apply SUZUKI SUPER GREASE A to the O ring 99000 25010 SUZUKI SUPER GREASE A or equivalent Tighten the starter motor 1 bolts to the specified torque Starter motor bolt 6 N m 0 6 kgf m 4 5 lb ft Inst...

Page 166: ...MOVAL 4 4 DISASSEMBLY 4 4 INSPECTION 4 6 REASSEMBLY 4 8 SECONDARY GEAR SHIMS ADJUSTMENT 4 10 FINAL BEVEL GEARS 4 13 CONSTRUCTION 4 13 FINAL GEAR CASE REMOVAL 4 15 FINAL GEAR CASE DISASSEMBLY 4 15 FINA...

Page 167: ...condary driven bearing stopper 4 Bearing housing set A Output cam dog C Secondary driven bearing housing bolt 5 O ring B Damper spring D Secondary drive gear bolt 6 Shims C Spring cam stopper E Second...

Page 168: ...035 0 35 mm 0 014 in 24945 26D00 040 0 40 mm 0 016 in 24945 26D00 050 0 50 mm 0 020 in 24945 26D00 060 0 60 mm 0 024 in Part number Thickness 24935 48G00 040 0 40 mm 0 016 in 24935 48G00 045 0 45 mm 0...

Page 169: ...he engine removal and the engine disas sembly sections for secondary bevel gear assembly removal Engine removal 3 3 DISASSEMBLY SECONDARY DRIVE BEVEL GEAR 3 28 SECONDARY DRIVEN BEVEL GEAR Remove the s...

Page 170: ...the driven bevel gear coupling nut with the special tool 09924 64510 Final drive gear coupling holder Remove the washer 6 and the driven bevel gear coupling 7 Using a chisel unlock the nut Remove the...

Page 171: ...Improper tooth contact Output cam dog wear or damage Shaft damage or wear Universal joint spline damage or wear BEARING OIL SEAL Rotate the bearing inner race by finger to inspect for abnormal play n...

Page 172: ...oil seal housing 3 with the special tools 09921 20240 Bearing remover set 30 mm 09941 64511 Bearing remover 09930 30104 Sliding shaft DAMPER SPRING Measure the free length of the damper spring If the...

Page 173: ...e bearing with the special tool 09913 70210 Bearing installer set 42 mm NOTE When installing the bearing stamped mark on the bearing must face outside Apply SUZUKI BOND to the mating surface of the be...

Page 174: ...og Tighten the bearing stopper to the specified torque with spe cial tool Secondary driven gear bearing stopper 105 N m 10 5 kgf m 76 0 lb ft 09924 41830 Bearing retainer wrench Lock the bearing stopp...

Page 175: ...sing at this stage O ring is installed after backlash and tooth contact are correct Tighten the secondary driven gear case bolts to the specified torque Secondary driven gear case bolt 26 N m 2 6 kgf...

Page 176: ...ndary gear case 4 4 Clean and degrease the secondary drive bevel gear teeth and apply a coating of machinist s layout dye or paste to sev eral teeth Reinstall the secondary gear case with removed shim...

Page 177: ...d readjust until both backlash and tooth contact are correct Tooth contact Shim adjustment Contact at tooth top 1 Decrease thickness of shims 4 or 5 Contact at tooth root 3 Increase thickness of shims...

Page 178: ...g A Final gear case bolt M8 5 Final driven bevel gear E Oil seal B Final gear case bolt M10 6 Shims F O ring C Oil drain plug 7 Final driven gear bearing G Stopper plate D Final gear case nut 8 Oil se...

Page 179: ...327 38B00 040 0 40 mm 0 016 in 27445 24A01 040 0 40 mm 0 016 in 27327 38B00 050 0 50 mm 0 020 in 27445 24A01 050 0 50 mm 0 020 in 27327 38B00 060 0 60 mm 0 024 in 27445 24A01 060 0 60 mm 0 024 in The...

Page 180: ...emoved in the described order before removing the final gear case Drain final gear oil 2 19 Remove the rear wheel 9 34 Remove the final gear case nut spring washer and final gear case 1 FINAL GEAR CAS...

Page 181: ...pling nut with the special tool 09924 62430 22 mm Long socket 09924 64510 Final drive gear coupling holder Remove the washer 6 and the final drive gear coupling 7 Remove the bearing stopper with the s...

Page 182: ...not necessary Remove the washer 0 Remove the inner race with the special tool 09913 60910 Bearing puller Remove the final gear bearing case bolts Remove the final gear bearing case from the final gea...

Page 183: ...ble bars remove the final driven bevel gear bearing from the bevel gear NOTE If no abnormal noise the bearing removal is not necessary Remove the oil seal with the special tool 09913 50121 Oil seal re...

Page 184: ...ssary Remove the oil seal F and O ring G from the bearing stopper INSPECTION Inspect the removed parts for the following abnormalities Drive and driven bevel gear damage or wear Improper tooth contact...

Page 185: ...It is not necessary to apply SUZUKI BOND 1207B and THREAD LOCK to the matching surface and bolts at this stage Measure the clearance between the shims and bearing If it is not within the specification...

Page 186: ...order not to change the clearance between final driven bevel gear and bearing the total thickness of the shims installed after a change is made must equal the original total thickness of shims If back...

Page 187: ...ot misplace the shims Remove the final driven bevel gear Clean and de grease several teeth on the final driven bevel gear Coat these teeth with machinist s dye or paste prefera bly of a light color Re...

Page 188: ...priate shim must be installed and the tooth contact pat tern rechecked by repeating the tooth coating procedure above NOTE If it is necessary to adjust the shim 4 thickness between final drive bevel g...

Page 189: ...installer Install the oil seal into the final gear case with the special tool 09913 76010 Bearing installer set Apply SUZUKI SUPER GREASE A to the oil seal lip 99000 25010 SUZUKI SUPER GREASE A or eq...

Page 190: ...g installer Install correct shims 3 4 to the both sides of the final driven bevel gear and install the gear to the final gear case Shim adjustment 4 20 Apply SUZUKI BOND to the mating surface of the f...

Page 191: ...GREASE A to the O ring and the lip of oil seal Install the bearing stopper 0 99000 25010 SUZUKI SUPER GREASE A or equivalent Tighten the bearing stopper to the specified torque with the special tool...

Page 192: ...shaft splines and final drive bevel gear cou pling Install the spring C and propeller shaft D Install the snap ring E After installing the propeller shaft with a new snap ring make sure that the prop...

Page 193: ...e proper position Apply SUZUKI BOND to the mating surface of swingarm 99000 31140 SUZUKI BOND 1207B or equivalent Apply Lithium Base Molybdenum grease NLGI 2 to the pro peller shaft spline FINAL GEAR...

Page 194: ...VELINE AXLE 4 29 Install the final gear case Tighten the final gear case bolts to the specified torque Final gear case nut 40 N m 4 0 kgf m 29 0 lb ft Install the rear wheel 9 39 Pour final gear oil 2...

Page 195: ...ISUAL INSPECTION 5 23 SELF DIAGNOSTIC PROCEDURES 5 24 SELF DIAGNOSIS RESET PROCEDURE 5 24 USE OF SDS DIAGNOSTIC PROCEDURES 5 25 USE OF SDS DIAGNOSIS RESET PROCEDURE 5 26 SHOW DATA WHEN TROUBLE DISPLAI...

Page 196: ...CTION 5 92 C60 P0480 COOLING FAN RELAY CIRCUIT MALFUNCTION 5 94 SENSORS 5 97 IAP SENSOR INSPECTION 5 97 IAP SENSOR REMOVAL AND INSTALLATION 5 97 TP SENSOR INSPECTION 5 97 TP SENSOR REMOVAL AND INSTALL...

Page 197: ...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 Inspect each terminal for corrosion and contamination Th...

Page 198: ...onnector for excessive opening Also check the coupler for locking loose ness corrosion dust etc 1 Coupler 2 Probe 3 Where male terminal fits FUSE When a fuse blows always investigate the cause to corr...

Page 199: ...motive force will be applied to the ECM which may result in serious damage Before measuring voltage at each terminal check to make sure that battery voltage is 11 V or higher Terminal voltage check wi...

Page 200: ...so check for condition of the coupler lock if equipped 1 Sensor 2 ECM 1 Check for loose connection Using a test male terminal check the female terminals of the circuit being checked for contact tensio...

Page 201: ...circuit being checked voltage check can be used as circuit check With all connectors couplers connected and voltage applied to the circuit being checked measure voltage between each terminal and body...

Page 202: ...se parts Otherwise diagnosis will be misled Measure resistance between terminal at one end of circuit A terminal in figure and body ground If continuity is indicated there is a short circuit to ground...

Page 203: ...en measuring the resistance with the multi circuit tester 1 will be shown as 10 00 M and 1 flashes in the display Check that no voltage is applied before making the measure ment If voltage is applied...

Page 204: ...nd various compensations These compensations are determined according to the signals from various sensors that detect the engine and driving conditions Intake Air Pressure Sensor IAP Sensor Intake air...

Page 205: ...SIGNAL ECM operates on the battery voltage and at the same time it monitors the voltage signal for compensation of the fuel injection time volume A longer injection time is needed to adjust injection...

Page 206: ...1 IG COIL E Secondary throttle position sensor STPS F Throttle position sensor TPS G Secondary throttle valve actuator STVA H PAIR control solenoid valve For E 02 19 24 I Ignition coil plug cap 2 J HO...

Page 207: ...injector 1 E Fuel injector 2 F Intake air pressure sensor 1 IAPS G Fuel pump H Ignition coil plug cap 1 I Tip over sensor TOS J Fuel pump relay FP RELAY K Cooling fan relay L Engine coolant temperatu...

Page 208: ...osition sensor CKPS 2 1 Speedometer Tachometer Fan relay Fuel pump Fuel pump relay Ignition coil PAIR solenoid valve Gear position switch 1 1 2 2 Cooling fan motor Fuel injector 5 S L Q P 9 J A 8 U X...

Page 209: ...speedometer M GP switch signal GP 7 Blank N Blank 8 TP sensor signal TP O Blank 9 IAP sensor signal 1 IAP 1 P IAP sensor signal 2 IAP 2 0 ECT sensor signal ECT Q IAT sensor signal IAT A Power source f...

Page 210: ...H r Mode select switch b Starter relay s Neutral switch c Cooling fan relay FAR t Clutch position switch d Rear cylinder PAIR control solenoid 1 valve PAIR 1 u e Blank v f Blank w PAIR control solenoi...

Page 211: ...signal or ignition switch signal is not sent to ECM In this case FI is indicated in the LCD panel Motorcycle does not run CHEC The LCD panel indicates CHEC when no communication signal from the ECM is...

Page 212: ...se affected devices are indicated in the code form 09930 82720 Mode select switch Before checking the malfunction code do not disconnect the ECM lead wire couplers If the couplers from the ECM are dis...

Page 213: ...49 C60 C61 C64 None Crankshaft position sensor CKPS Intake air pressure sensor 2 IAPS 2 Throttle position sensor TPS Engine coolant temp sensor ECTS Intake air pressure sensor 1 IAPS 1 Intake air temp...

Page 214: ...e the right air cleaner box 6 13 5 If the throttle position sensor adjustment is necessary loosen the screw and turn the throttle position sensor and bring the line to the middle 6 Then tighten the sc...

Page 215: ...t temperature value is fixed to 80 C 176 F YES YES IAT sensor Intake air temperature value is fixed to 40 C 104 F YES YES Ignition signal 1 1 or 1 2 Ignition off YES YES 1 cylinder can run 2 1 or 2 2...

Page 216: ...condition LED Always ON Sometimes ON Always OFF Good condition Malfunction display code LCD User mode No display Malfunction display Dealer mode No code Malfunction code PROBLEM SYMPTOMS Difficult St...

Page 217: ...ection Broken fuse FI light operation 5 17 and 10 33 Each warning light operation 10 33 Speedometer operation 10 37 Exhaust gas leakage and noise 2 6 Each coupler disconnection Clogged radiator fins 8...

Page 218: ...de cover 3 6 Connect the special tool to the dealer mode coupler at the wir ing harness and start the engine or crank the engine for more than 4 seconds Turn the special tool s switch ON and check the...

Page 219: ...IN SERVICING 5 3 before inspection and observe what is written there Remove the left frame lower side cover 3 6 Set up the SDS tool Refer to the SDS operation manual for further details Read the DTC D...

Page 220: ...n the ECM Therefore erase the history code memorized in the ECM using SDS tool NOTE The malfunction code is memorized in the ECM also when the wire coupler of any sensor is disconnected Therefore when...

Page 221: ...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...

Page 222: ...than the above range C14 P0120 is indicated TP sensor lead wire coupler connection P0120 P0120 H Sensor voltage is higher than specified value TP sensor circuit shorted to VCC or ground circuit open L...

Page 223: ...upplied from the ECM communica tion signal does not reach ECM or operation voltage does not reach STVA motor C28 P1655 is indicated STVA can not operate STVA motor STVA lead wire coupler P1655 C29 STP...

Page 224: ...re cou pler connection power source to fuel pump relay and fuel injec tors P0230 P0230 H Voltage is applied to fuel pump although fuel pump relay is turned OFF Fuel pump relay switch circuit shorted t...

Page 225: ...pecified value EXCVA position sensor circuit shorted to VCC or ground circuit open L EXCVA position sensor voltage is lower than specified value EXCVA position sensor circuit open or shorted to ground...

Page 226: ...sure the CKP sensor resistance 5 Disconnect the CKP sensor coupler and measure the resis tance CKP sensor resistance 190 290 Green Blue DETECTED CONDITION POSSIBLE CAUSE The signal does not reach ECM...

Page 227: ...olt adaptor 09900 25008 Multi circuit tester set Tester knob indication Voltage Is the voltage OK 3 After repairing the trouble clear the DTC using SDS tool 5 26 YES Go to step 2 NO Replace the CKP se...

Page 228: ...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 bei...

Page 229: ...tart the engine at idle speed and measure the IAP sensor output voltage at the wire side coupler 2 between P B and B Br wires 1 between G B and B Br wires IAP sensor output voltage Approx 2 6 V at idl...

Page 230: ...p gauge 5 40 09917 47011 Vacuum pump gauge 09900 25008 Multi circuit tester set Tester knob indication Voltage Is the voltage OK 6 After repairing the trouble clear the DTC using SDS tool 5 26 YES Red...

Page 231: ...IAP sensor coupler for loose or poor contacts If OK then check the IAP sensor lead wire continuity 4 Disconnect the IAP sensor coupler 5 Check the continuity between Red wire A and P B 2 1 or G B 1 2...

Page 232: ...sensor 1 1 Turn the ignition switch OFF 2 Remove the fuel tank 6 3 3 Check the IAP sensor coupler for loose or poor contacts If OK then check the IAP sensor lead wire continuity 4 Disconnect the IAP...

Page 233: ...t 09900 25009 Needle pointed probe set Tester knob indication Continuity test Is the continuity OK 10 After repairing the trouble clear the DTC using SDS tool 5 26 When using the multi circuit tester...

Page 234: ...9 Needle pointed probe set Tester knob indication Voltage Is the voltage OK 5 After repairing the trouble clear the DTC using SDS tool 5 26 Step 3 5 36 Output voltage VCC voltage 4 5 5 0 V ambient tem...

Page 235: ...knob indication Voltage Is the voltage OK DETECTED CONDITION POSSIBLE CAUSE C14 Output voltage is not within the following range Difference between actual throttle open ing and opening calculated by E...

Page 236: ...k the continuity between P B wire A and terminal 8 8 Also check the continuity between B Br wire C and terminal S TPS lead wire continuity Continuity 09900 25008 Multi circuit tester set 09900 25009 N...

Page 237: ...5 37 8 Check the continuity between P B wire A and terminal 8 9 Also check the continuity between Red wire B and terminal A TPS lead wire continuity Continuity 09900 25008 Multi circuit tester set 09...

Page 238: ...nce TP sensor resistance Throttle valve is closed Approx 1 1 k Throttle valve is opened Approx 4 3 k 7 If OK then measure the TP sensor resistance at the test har ness terminals between terminal C and...

Page 239: ...uit tester set Tester knob indication Voltage Is the voltage OK 4 After repairing the trouble clear the DTC using SDS tool 5 26 V 3 ECM TPS P B R B Br 3 YES P B Red or B Br wire open or shorted to gro...

Page 240: ...e terminal B ECT sensor voltage 4 5 5 5 V B Bl Ground B Bl B Br 09900 25008 Multi circuit tester set Tester knob indication Voltage Is the voltage OK DETECTED CONDITION POSSIBLE CAUSE C15 Output volta...

Page 241: ...6 Also check the continuity between B Br wire B and terminal S ECTS lead wire continuity Continuity 09900 25008 Multi circuit tester set 09900 25009 Needle pointed probe set Tester knob indication Con...

Page 242: ...from the tester the circuit condition is OK Tester knob indication Continuity test 6 Connect the ECT sensor coupler and turn the ignition switch ON 7 Measure the voltage between B Bl wire A and groun...

Page 243: ...uble clear the DTC using SDS tool 5 26 ECT sensor specification YES B Bl or B Br wire open or shorted to ground or poor 0 or S connection If wire and connection are OK intermittent trou ble or faulty...

Page 244: ...nal B IAT sensor input voltage 4 5 5 5 V Dg Ground Dg B Br 09900 25008 Multi circuit tester set Tester knob indication Voltage Is the voltage OK DETECTED CONDITION POSSIBLE CAUSE C21 Output voltage is...

Page 245: ...eck the continuity between B Br wire B and terminal S IATS lead wire continuity Continuity 09900 25008 Multi circuit tester set 09900 25009 Needle pointed probe set Tester knob indication Continuity t...

Page 246: ...ard from the tester the circuit condition is OK Tester knob indication Continuity test 6 Connect the IAT sensor coupler and turn the ignition switch ON 7 Measure the voltage between Dg wire A and grou...

Page 247: ...is the same way as that of the ECT sensor Refer to page 8 9 for details 2 YES Dg or B Br wire open or shorted to ground or poor Q or S connection If wire and connection are OK intermittent trou ble or...

Page 248: ...i circuit tester set Tester knob indication Resistance Is the resistance OK DETECTED CONDITION POSSIBLE CAUSE C23 The sensor voltage should be the follow ing for 2 sec and more after ignition switch i...

Page 249: ...the continuity between Black wire B and terminal L 8 Also check the continuity between B Br wire C and terminal S TOS lead wire continuity Continuity 09900 25008 Multi circuit tester set 09900 25009...

Page 250: ...CM coupler 5 37 8 Check the continuity between Red wire A and terminal A 9 Also then check the continuity between Black wire B and terminal L TOS lead wire continuity Continuity 09900 25008 Multi circ...

Page 251: ...edle pointed probe set Tester knob indication Voltage Is the voltage OK 6 After repairing the trouble clear the DTC using SDS tool 5 26 C24 P0351 C25 P0352 C26 P0353 or C27 P0354 IGNITION SYSTEM MALFU...

Page 252: ...ng OK 4 After repairing the trouble clear the DTC using SDS tool 5 26 DETECTED CONDITION POSSIBLE CAUSE The operation voltage does not reach the STVA ECM does not receive communication signal from the...

Page 253: ...D 09900 25008 Multi circuit tester set Tester knob indication Resistance Is the resistance OK 5 After repairing the trouble clear the DTC using SDS tool 5 26 2 2 YES W B P W Green and B Lg wire open...

Page 254: ...Set up 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 operatio...

Page 255: ...Tester knob indication Voltage Is the voltage OK DETECTED CONDITION POSSIBLE CAUSE C29 Signal voltage is not within the following range Difference between actual throttle open ing and opening calculat...

Page 256: ...e ECM coupler 5 37 7 Check the continuity between Y W wire A and terminal J 8 Also check the continuity between B Br wire C and terminal S STPS lead wire continuity Continuity 09900 25008 Multi circui...

Page 257: ...7 Disconnect the ECM coupler 5 37 8 Check the continuity between Y W wire A and terminal J 9 Also check the continuity between Red wire B and terminal A STPS lead wire continuity Continuity 09900 2500...

Page 258: ...ure the valve closing and opening resistance STP sensor resistance Secondary throttle valve is closed Approx 0 6 k Secondary throttle valve is opened Approx 4 2 k Y W A B Br C 7 If OK then measure the...

Page 259: ...pprox 0 6 V Secondary throttle valve is opened Approx 4 2 V 09900 25008 Multi circuit tester set 09900 28630 TPS test wire harness Tester knob indication Voltage Is the voltage OK After repairing the...

Page 260: ...switch ON 9 Measure the voltage at the wire side coupler between Pink wire and B W wire when shifting the gearshift lever from 1st to Top GP switch voltage 0 6 V and more Pink B W 09900 25008 Multi c...

Page 261: ...ittent trou ble 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 again NO Pink or B W wire open or Pink wi...

Page 262: ...yl inder side 2 for loose or poor contacts If OK then measure the injector resistance 4 Disconnect the injector coupler and measure the resistance between terminals Injector resistance 11 13 at 23 C 7...

Page 263: ...conds after ignition switch is turned ON 09900 25008 Multi circuit tester set Tester knob indication Voltage Is the voltage OK 3 After repairing the trouble clear the DTC using SDS tool 5 26 YES Go to...

Page 264: ...is lower than the desired idle speed W Y or Lg wire open or short ISC valve is fixed Air curcuit clogged P0507 Idle speed is higher than the desired idle speed W Y or Dgr wire open or short Disconnect...

Page 265: ...inals D and l terminals E and F and terminals F and Y ISC valve wire continuity Continuity 09900 25008 Multi circuit tester set 09900 25009 Needle pointed probe set Tester knob indication Continuity t...

Page 266: ...ty Terminal 1 Terminal 3 Terminal 2 Terminal 4 4 If OK then measure the resistance between terminals 1 and 2 terminals 3 and 4 ISC valve resistance Approx 30 1 2 at 20 C 68 F Terminal 1 Terminal 2 Ter...

Page 267: ...ROL Check 1 1 Set up the SDS tool Refer to the SDS operation manual for further details 2 Check that the engine is running 3 Click the Active control 4 Click the ISC rpm control 1 5 Check that the Spe...

Page 268: ...idle speed 3 is nearly equal to the Spec 2 At the same time check that the number of steps in the ISC valve position decreases 3 Click the button 4 and increase the Spec 2 slowly 4 Check that the Desi...

Page 269: ...eases Check 4 1 Increase the Spec 1 to 1 400 rpm 2 Check that the Desired idle speed 2 is approx 1 400 rpm 3 Check that the Engine speed 3 is close to 1 400 rpm If the ISC valve does not function prop...

Page 270: ...although fuel pump relay is turned OFF Fuel pump relay switch circuit shorted to power source Faulty fuel pump relay switch side L No voltage is applied to fuel pump although fuel pump relay is turned...

Page 271: ...ol 5 26 1 YES Y R wire shorted to power source Y B wire shorted to ground If wire and connection are OK intermittent trou ble or faulty ECM Recheck each terminal and wire harness for open circuit and...

Page 272: ...IG SWITCH CIRCUIT MALFUNCTION INSPECTION Refer to the IGNITION SWITCH INSPECTION for details 10 42 DETECTED CONDITION POSSIBLE CAUSE Ignition switch signal is not input to the ECM Ignition system cir...

Page 273: ...from the tester the circuit condition is OK 09900 25008 Multi circuit tester set Tester knob indication Continuity test DETECTED CONDITION POSSIBLE CAUSE C44 C64 P0156 P0130 HO2 sensor output voltage...

Page 274: ...ng condition HO2 sensor output voltage at idle speed 0 4 V and less W G or W Bl B Br 4 If OK then pinch the PAIR hose 1 with a proper hose clamp 5 Remove the fuel tank 6 3 and frame head covers 9 6 6...

Page 275: ...the sensor affects resistance value largely Make sure that the sensor heater is at correct temperature 09900 25008 Multi circuit tester set Tester knob indication Resistance Is the voltage OK 4 After...

Page 276: ...00 25008 Multi circuit tester set 09900 25009 Needle pointed probe set Tester knob indication Voltage Is the voltage OK 5 After repairing the trouble clear the DTC using SDS tool 5 26 YES W B wire ope...

Page 277: ...the EXCV actuator EXCVA position sensor voltage low or high 0 1 V Sensor voltage 4 9 V without the above range EXCVA maladjusted EXCVA circuit open or short EXCVA motor malfunction EXCVA position sen...

Page 278: ...coupler 5 37 7 Check the continuity between Yellow wire A and terminal 5 8 Also check the continuity between B Br wire B and terminal S EXCVA lead wire continuity Continuity 09900 25008 Multi circuit...

Page 279: ...isconnect the ECM coupler 5 37 8 Check the continuity between Yellow wire A and terminal 5 9 Also check the continuity between Red wire C and terminal A EXCVA lead wire continuity Continuity 09900 250...

Page 280: ...nsor lead wire coupler 4 Turn the ignition switch ON 5 Measure the voltage between the Red wire terminal 1 and ground 6 If OK then measure the voltage between the Red wire terminal 1 and B Br wire ter...

Page 281: ...Connect the position sensor coupler 5 Set the EXCVA to adjustment position 7 2 6 Disconnect the position sensor coupler and measure the resistance between Yellow and White wires Position sensor resis...

Page 282: ...the ignition switch ON 8 Measure the position sensor output voltage at fully close posi tion 9 Then to set the EXCV to fully open position apply 12 volts to B and A terminals Positive wire B Gray wir...

Page 283: ...output voltage to specified by turning out the No 2 cable adjuster 2 Repeat the above procedure Step 4 until the output voltage is within the specified value Position sensor output voltage EXCV is fu...

Page 284: ...eration OK 5 After repairing the trouble clear the DTC using SDS tool 5 26 6 6 12 V 6 12 V YES Loose or poor contacts on the EXCVA or ECM coupler terminal 3 or 4 Open or short circuit in the B R wire...

Page 285: ...1 Set up the SDS tool Refer to the SDS operation manual for further details 2 Turn the ignition switch ON 3 Click Exhaust valve operating control 1 4 Click each button 2 At this time if an operation s...

Page 286: ...nals PAIR valve resistance 18 22 at 20 30 C 68 86 F Terminal Terminal 09900 25008 Multi circuit tester set Tester knob indication Resistance Is the resistance OK 5 After repairing the trouble clear th...

Page 287: ...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 operation sound is heard from the PAIR control solenoid valve the...

Page 288: ...ION 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 O R O B Cooling fan motor Cooling fan r...

Page 289: ...an relay control 1 4 Click the operate button 2 At this time if an operation sound is heard from the cooling fan relay and cooling fan motor is operated the function is normal NOTE Cooling fan relay a...

Page 290: ...erature is below 50 C 122 F Check that the cooling fan relay operates for a few seconds as the engine coolant temperature arrives each at 50 C 122 F 70 C 158 F and 90 C 194 F above 4 000 r min It is c...

Page 291: ...the air cleaner chamber Install the IAP sensors in the reverse order of removal TP SENSOR INSPECTION The throttle position sensor is installed on the No 2 throttle body 5 41 TP SENSOR REMOVAL AND INS...

Page 292: ...connect the coupler 1 09930 11950 Torx wrench Install the STP sensor to the No 2 throttle body 6 19 STP SENSOR ADJUSTMENT Adjust the STP sensor 6 22 CKP SENSOR INSPECTION The signal rotor is mounted o...

Page 293: ...sensor is installed at the ther mostat body 5 46 ECT SENSOR REMOVAL AND INSTALLATION Remove the right air cleaner box 6 13 Remove the ECT sensor from the thermostat body Install the ECT sensor in the...

Page 294: ...HO2 sensor in the reverse order of removal Tighten the sensor unit to the specified torque HO2 SENSOR 48 N m 4 8 kgf m 34 5 lb ft Do not remove the HO2 sensor while it is hot Be careful not to expose...

Page 295: ...ROTTLE BODY 6 12 CONSTRUCTION 6 12 AIR CLEANER BOX REMOVAL 6 13 AIR CLEANER BOX INSTALLATION 6 13 AIR CLEANER CHAMBER AND THROTTLE BODY REMOVAL 6 13 THROTTLE BODY DISASSEMBLY 6 15 THROTTLE BODY CLEANI...

Page 296: ...sure regulator As the fuel pressure applied to the fuel injector the fuel pressure in the fuel delivery pipe is always kept at absolute fuel pressure of 3 0 kgf cm2 300 kPa 43 psi the fuel is injected...

Page 297: ...re than about 10 cm 3 94 in or hoses will be twisted Disconnect the fuel pump lead wire coupler 1 Place a rag under the fuel feed hose and disconnect the fuel feed hose 2 Disconnect the speedometer co...

Page 298: ...tch ON and check the fuel pressure Fuel pressure Approx 300 kPa 3 0 kgf cm2 43 psi If the fuel pressure is lower than the specification inspect the following items Clogged fuel filter Pressure regulat...

Page 299: ...rom the fuel delivery pipe Place the measuring cylinder and insert the fuel feed hose end into the measuring cylinder Disconnect the fuel pump lead wire coupler 2 Connect a proper lead wire into the f...

Page 300: ...de frame cover 9 5 Remove the fuel pump relay 1 First check the insulation between A and B terminals with tester Then apply 12 V to C and D terminals to C and to D and check the continuity between A a...

Page 301: ...THROTTLE BODY 6 7 FUEL PUMP AND FUEL LEVEL GAUGE REMOVAL CONSTRUCTION 1 Thermistor 5 O ring 2 Fuel pump 6 Fuel level gauge ITEM N m kgf m lb ft 3 Fuel mesh filter A Fuel pump mounting bolt A 10 1 0 7...

Page 302: ...y 2 mounting bolts diago nally Remove the fuel pump assembly and disconnect the fuel gauge lead wire coupler 3 Remove the fuel level gauge 4 while pushing the pawl end A FUEL LEVEL GAUGE INSPECTION 10...

Page 303: ...Disconnect the fuel pump coupler 1 Remove the band 2 and clamp 3 Remove the hose 4 and filter cover 5 Remove the clamp 6 and thermistor 7 Remove the fuel mesh filter 8 Remove the fuel pump 9 Remove t...

Page 304: ...ge in the reverse order of removal and disassembly Pay attention to the following points Apply thin coat of engine oil to the new bushing and install if to the fuel joint pipe Install the new O ring t...

Page 305: ...UPER GREASE A to it 99000 25010 SUZUKI SUPER GREASE A or equivalent When installing the fuel pump assembly first tighten all the fuel pump mounting bolts lightly and then to the specified torque as sh...

Page 306: ...8 Cushion seal 2 STP sensor 9 Air screw 3 STVA 0 ISC valve 4 Fuel delivery pipe A Vacuum hose ITEM N m kgf m lb ft 5 IAP sensor A Fuel delivery pipe mounting screw A 5 0 5 3 5 6 O ring B STP sensor m...

Page 307: ...screw 4 Remove the left air cleaner box AIR CLEANER BOX INSTALLATION Installation is in the reverse order of removal AIR CLEANER CHAMBER AND THROTTLE BODY REMOVAL Remove the air cleaner box above Rem...

Page 308: ...ottle body clamp screws at the air cleaner chamber side Disconnect the PAIR lead wire couplers 9 and hoses 0 Remove the air cleaner chamber For E 03 28 33 For the others Disconnect the STVA lead wire...

Page 309: ...le cables from their drum Remove the throttle body assembly THROTTLE BODY DISASSEMBLY Disconnect the IAP sensor vacuum hoses 1 ISC valve hoses 2 and fuel feed hoses 3 Remove the fuel delivery pipes an...

Page 310: ...TE Prior to disassembly mark each sensor s original position with a paint or scribe for accurate reinstallation Never remove the STVA 8 from the throttle body This screw 9 is factory adjusted at the t...

Page 311: ...motor assembly with a new one Some carburetor cleaning chemicals especially dip type soaking solutions are very corrosive and must be handled carefully Always follow the chemical manufacturer s instru...

Page 312: ...Y ISC VALVE REMOVAL Disconnect the hoses and remove the ISC valve 1 INSPECTION Check the ISC valve for wear or damage replace it with a new one if necessary ISC VALVE INSTALLATION Install the ISC valv...

Page 313: ...950 Torx wrench STP sensor mounting screw 3 5 N m 0 35 kgf m 2 5 lb ft NOTE Make sure the STP valve open or close smoothly If the STP sensor adjustment is necessary refer to page 6 22 for STP sensor s...

Page 314: ...E of injector with boss F of the delivery pipe Install the fuel delivery pipes and hose assembly 7 to the throttle body assembly Tighten the fuel delivery pipe mounting screws to the speci fied torqu...

Page 315: ...e coupler 3 and STP sensor lead wire coupler 4 TP sensor lead wire coupler 3 Gray Connect the throttle pulling cable 5 and throttle returning cable 6 to the throttle cable drum Loosen each throttle ca...

Page 316: ...ndication Voltage If the STP sensor voltage is out of specification loosen the STP sensor mounting screw and adjust the STP sensor volt age to specification Tighten the STP sensor mounting screw 09930...

Page 317: ...pushing it 6 20 THROTTLE VALVE SYNCHRONIZATION Check and adjust the throttle valve synchronization among two cylinders Step 1 Remove the fuel tank 6 3 Remove the ISC valve 6 18 Connect the ISC valve...

Page 318: ...yet correct remove each air screw 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 clockwis...

Page 319: ...CONTROL VALVE ACTUATOR AND EXCV EXHAUST CONTROL VALVE 7 2 EXCVA AND EXCV REMOVAL 7 2 EXCVA INSPECTION 7 3 EXCV INSPECTION 7 3 CABLE INSPECTION 7 3 EXCVA AND EXCV INSTALLATION 7 3 EXCVA ADJUSTMENT 7 5...

Page 320: ...heck the cable slots A of the EXCVA pulley face backward adjustment position as shown Turn the ignition switch OFF Remove the exhaust pipe and muffler 7 8 Remove the EXCVA cover 2 Hold the EXCVA pulle...

Page 321: ...check that it moves smoothly If it does not move smoothly replace the EXCV together with the muffler body Decarbonize the EXCV if necessary CABLE INSPECTION Inspect the cables for wear or bend if it...

Page 322: ...rn the No 1 cable adjuster 1 in or out until the inner cable length B becomes 42 43 mm 1 65 1 69 in After adjusting the inner cable length B tighten the lock nut 2 No 1 cable 11276 48G0 Make the No 2...

Page 323: ...No 2 cable 0 loosen the lock nut A and turn the adjuster B in or out until 8 5 9 5 mm 0 33 0 37 in of the thread length F on the cable adjuster cam be provided and tighten the lock nut A NOTE Install...

Page 324: ...ON If C46 is not indicated on the LCD DISPLAY the adjustment is correctly completed In this case it is unnecessary to pro ceed to 3rd step If C46 is indicated repeat the adjustment procedure from 3rd...

Page 325: ...rn out the No 1 cable adjuster 3 Repeat the above procedure until the output voltage becomes specified value Position sensor output voltage EXCV is fully close 0 5 output voltage 1 5 V To next step NO...

Page 326: ...ster 1 Repeat the above procedure until the output voltage comes within the specified value Position sensor output voltage EXCV is fully open 3 5 output voltage 4 5 V After adjusting the EXCV cables p...

Page 327: ...T SYSTEM 7 9 Disconnect the front and rear HO2 sensor lead wire couplers For E 02 19 24 Remove the muffler cover 3 Remove the No 1 muffler 4 Remove the right frame lower cover 5 NOTE indicates hook lo...

Page 328: ...st pipes 1 with the No 2 muffler 2 Tighten the exhaust pipe bolts and No 2 muffler bolts and nut to the specified torque Exhaust pipe bolt 23 N m 2 3 kgf m 16 5 lb ft Muffler mounting bolt and nut 23...

Page 329: ...EXHAUST SYSTEM 7 11 Install the No 1 muffler 3 Tighten the No 1 muffler bolts and muffler connecting bolts Muffler mounting bolt 23 N m 2 3 kgf m 16 5 lb ft...

Page 330: ...16 in and more No 1 No 2 58 59 mm 2 28 2 32 in 42 43 mm 1 65 1 69 in 4 0 mm 0 16 in and more 8 5 9 5 mm 0 33 0 73 in No 1 No 2 23 N m 2 3 kgf m 16 5 lb ft 23 N m 2 3 kgf m 16 5 lb ft HO2 sensor For E...

Page 331: ...P INSPECTION 8 5 RADIATOR INSPECTION AND CLEANING 8 6 RADIATOR REASSEMBLY 8 6 RADIATOR INSTALLATION 8 6 WATER HOSE INSPECTION 8 7 COOLING FAN 8 8 INSPECTION 8 8 COOLING FAN RELAY INSPECTION 8 8 ECT SE...

Page 332: ...more anti freeze or 50 and less Refer to below figure Do not use a radiator anti leak additive Anti freeze 1 350 ml 2 9 2 4 US lmp pt Water 1 350 ml 2 9 2 4 US lmp pt 20 40 60 80 100 Density 0 10 20...

Page 333: ...ds this pressure for 10 seconds If the pressure should fall during this 10 second interval it means that there is a leaking point in the system In such a case inspect the entire system and replace the...

Page 334: ...he frame head covers and radiator covers 9 6 Drain the engine coolant 2 20 Disconnect the reservoir hose 1 and cooling fan lead wire coupler 2 Disconnect the oil cooler water outlet hose 3 and remove...

Page 335: ...Build up pressure slowly by operating the tester Make sure that the pressure build up stops at 93 123 kPa 0 93 1 23 kgf cm2 13 2 17 5 psi and that with the tester held stand still the cap is capable...

Page 336: ...n be repaired by straightening them with the blade of a small screwdriver RADIATOR REASSEMBLY Reassemble the radiator in the reverse order of disassembly Pay attention to the following points Install...

Page 337: ...the frame head covers and radiator covers 9 6 Remove the left and right air cleaner boxs 6 13 Remove the secondary gear case cover 3 6 Any water hose found in a cracked condition or flattened must be...

Page 338: ...should be indicating not 8 5 amperes and more If the fan motor does not turn replace the motor assembly with a new one 8 5 NOTE When making above test it is not necessary to remove the cool ing fan C...

Page 339: ...ve Heat the oil to raise its temperature slowly and read the col umn thermometer 3 and the ohmmeter If the ECT sensor ohmic value does not change in the propor tion indicated replace it with a new one...

Page 340: ...m 1 8 kgf m 13 0 lb ft Install the rear intake pipe and thermostat assembly 3 112 Install the air cleaner chamber and throttle body 6 21 Pour engine coolant 2 21 Take special care when handling the EC...

Page 341: ...ring 1 between flange 2 of thermostat as shown Immerse the thermostat in the water contained in a beaker as shown in the illustration Note that the immersed thermostat is in suspension Heat the water...

Page 342: ...stat valve lift A Standard 8 0 mm and over at 100 C 0 31 in and over at 212 F A thermostat failing to satisfy either of the two requirements start to open temperature and valve lift must be replaced I...

Page 343: ...crankcase If engine oil is leaking visually inspect the oil seal and O ring If engine coolant is leaking visually inspect the mechanical seal and seal washer 8 15 Remove the secondary gear case cover...

Page 344: ...emove the mechanical seal ring 4 and rubber seal 5 from the impeller Remove the impeller shaft 6 washer 7 and O ring 8 Remove the mechanical seal with the special tool 09921 20240 Bearing remover set...

Page 345: ...e Also replace the seal ring if necessary OIL SEAL Visually inspect the oil seal for damage with particular atten tion given to the lip Replace the oil seal that shows indications of leakage IMPELLER...

Page 346: ...h the special tool 09913 70210 Bearing installer set 22 NOTE The stamped mark on the oil seal faces mechanical seal side Apply a small quantity of the SUZUKI SUPER GREASE A to the oil seal lip 99000 2...

Page 347: ...de B of mechanical seal ring faces the rub ber seal Install the washer 5 and seal washer 6 onto the impeller securing bolt 7 NOTE The metal side C of seal washer and the curved side D of washer face t...

Page 348: ...shaft end E to the oil pump shaft F as shown Connect the water hose 0 Tighten the water pump mounting bolts to the specified torque Water pump mounting bolt 10 N m 1 0 kgf m 7 0 lb ft Connect the wate...

Page 349: ...XHAUST CAMSHAFT JOURNAL HOLDER 1 PISTON AND CYLINDER WALL OIL PIPE OIL JET OIL JET COUNTERSHAFT GEARS AND BUSHINGS BALANCER SHAFT LEFT SIDE BEARING DRIVESHAFT RIGHT SIDE BEARING DRIVESHAFT GEARS AND B...

Page 350: ...REMOVAL AND DISASSEMBLY 9 15 INSPECTION 9 18 REASSEMBLY 9 19 INSTALLATION 9 22 STEERING 9 23 CONSTRUCTION 9 23 REMOVAL 9 24 INSPECTION AND DISASSEMBLY 9 25 REASSEMBLY 9 26 INSTALLATION 9 26 STEERING...

Page 351: ...INSPECTION 9 60 MASTER CYLINDER REASSEMBLY 9 60 MASTER CYLINDER INSTALLATION 9 61 REAR BRAKE 9 62 CONSTRUCTION 9 62 BRAKE PAD REPLACEMENT 9 63 BRAKE FLUID REPLACEMENT 9 64 CALIPER REMOVAL 9 65 CALIPE...

Page 352: ...k out toward the head so that the pawls 2 close Insert the fastener into the installation hole NOTE To prevent the pawl 2 from damage insert the fastener all the way into the installation hole Push in...

Page 353: ...installation hole NOTE To prevent the pawl 2 from damage insert the fastener all the way into the installation hole Push in the head of center piece FRONT AND REAR SEAT REMOVAL Remove the front seat...

Page 354: ...location Disconnect the seat lock cable 2 Remove the right frame side cover 3 NOTE indicates hook location REAR FRAME COVER REMOVAL Remove the left and right frame side covers above Remove the rear s...

Page 355: ...e right frame head cover 1 and left frame head cover 2 Remove the right radiator cover 3 by removing the bolt 4 and fastener 5 NOTE indicates hook location Remove the left radiator cover 6 by removing...

Page 356: ...s and radiator covers in the reverse order of removal Pay attention to the following points Install the radiator bottom cover 1 NOTE Pass the breather hose A in the hole B of a radiator bottom cover F...

Page 357: ...9 8 CHASSIS FRONT WHEEL CONSTRUCTION 1 Brake disc 5 Collar 2 Dust seal 6 Front wheel ITEM N m kgf m lb ft 3 Bearing A Front axle A 100 10 0 72 5 4 Spacer B Brake disc bolt B 23 23 0 16 5...

Page 358: ...e the front wheel NOTE After removing the front wheel fit the calipers temporarily to the original positions Remove the collar 3 INSPECTION AND DISASSEMBLY WHEEL 9 73 TIRE 2 27 and 9 73 BRAKE DISC 9 5...

Page 359: ...HEEL BEARINGS Inspect 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...

Page 360: ...reverse order of removal and disassembly Pay attention to the following points WHEEL BEARING Apply SUZUKI SUPER GREASE A to the wheel bearings 99000 25010 SUZUKI SUPER GREASE A or equivalent 23 N m 2...

Page 361: ...seal lip 99000 25010 SUZUKI SUPER GREASE A or equivalent BRAKE DISC Make sure that the brake disc is clean and free of any greasy matter Apply THREAD LOCK SUPER to the disc mounting bolts and tighten...

Page 362: ...he brake caliper mounting bolts left and right to the specified torque Front brake caliper mounting bolt 39 N m 3 9 kgf m 28 0 lb ft Move the front fork up and down 4 or 5 times Tighten two axle pinch...

Page 363: ...bolt 2 Spacer 7 Dust seal B Inner rod lock nut 3 Outer tube 8 Spring C Damper rod bolt 4 Oil seal retainer 9 Inner rod Damper rod cartridge D Front axle pinch bolt 5 Oil seal 0 Inner tube ITEM N m kg...

Page 364: ...cap bolts 4 before loosening the lower clamp bolts to facilitate later disassembly Loosen the front fork lower clamp bolts Remove the front fork NOTE Hold the front fork by the hand to prevent sliding...

Page 365: ...front fork and stroke the inner rod several times to let out fork oil Under the inverted condition of front fork drain oil completely by holding the fork for a while Remove the damper rod bolt with th...

Page 366: ...careful not to damage the ANTI FRICTION metals Remove the dust seal 9 and oil seal stopper ring 0 Remove the oil seal with the special tool 09913 50121 Oil seal remover Remove the oil seal retainer A...

Page 367: ...found replace them with a new one FORK SPRING Measure the fork spring free length If it is shorter than the service limit replace it with a new one Front fork spring free length Service Limit 391 mm...

Page 368: ...09940 52861 Front fork oil seal installer NOTE Stamped mark on the oil seal should face outside DAMPER ROD BOLT Insert the inner rod damper rod cartridge into the inner tube Apply THREAD LOCK SUPER t...

Page 369: ...ll front fork oil up to the top of the outer tube so that bubbles are visible while bleeding air Refill specified front fork oil up to the top level of the outer tube again Move the outer tube up and...

Page 370: ...and then insert the special tool C between the lock nut and the spacer 09940 52841 Inner rod holder A 09940 94930 Front fork spacer holder B 09940 94922 Stopper plate C 11 mm Slowly turn the cap bolt...

Page 371: ...er bracket and tighten the front fork lower clamp bolts 1 to the specified torque Front fork lower clamp bolt 23 N m 2 3 kgf m 16 5 lb ft Tighten the front fork cap bolt 2 to the specified torque and...

Page 372: ...m head nut 3 Handlebar holder bracket 8 Steering stem lower bearing D Front fork upper clamp bolt 4 Steering stem upper bracket 9 Steering stem E Handlebar holder bolt 5 Steering stem nut A Handlebar...

Page 373: ...lt 3 Remove the steering stem head nut 4 and washer Remove the steering stem upper bracket 5 Remove the steering stem nut with the special tool 09940 14911 Steering stem nut wrench Draw out the steeri...

Page 374: ...es Handlebars distortion Distortion of the steering stem Bearing wear or damage Abnormal noise of bearing If any abnormal points are found replace defective parts with the new ones Remove the steering...

Page 375: ...ace installer set INNER RACE Press in the lower bearing with the special tool 09925 18011 Steering bearing installer INSTALLATION Install the steering stem in the reverse order of removal Pay attentio...

Page 376: ...FORK AND STEERING STEM UPPER BRACKET Install the handlebar holder 1 and handlebar holder bracket 2 Temporarily tighten the handlebar holder bolts and handlebar holder bracket bolts Install the steerin...

Page 377: ...ith the front wheel in the straight ahead state hitch the spring scale special tool on one handlebar grip end as shown in the figure and read the graduation when the handle bar starts moving Do the sa...

Page 378: ...CHASSIS 9 29 HANDLEBARS CONSTRUCTION 1 Handlebars 3 Left handlebar grip 5 Right handlebar grip 2 Grip end cap 4 Left handlebar switch 6 Right handlebar switch...

Page 379: ...isconnect the throttle cable by removing the throttle grip 6 Remove the left handlebar switch 7 and disconnect the clutch lever switch lead wire coupler 8 Remove the left handlebar grip end cap 9 and...

Page 380: ...amp mating surface as shown First tighten the handlebar clamp bolts 1 to the half of speci fied torque and then tighten the handlebar clamp bolts 1 and 2 to the specified torque Handlebar clamp bolt 2...

Page 381: ...cables and their holder 99000 25010 SUZUKI SUPER GREASE A or equivalent When remounting the right and left handlebar switches engage the stopper with the handlebar hole After installing the handlebars...

Page 382: ...ing D Brake disc 3 Bearing 9 Spacer E Cotter pin For E 03 28 33 4 Lock washer 0 Bearing A Rear brake disc bolt 5 Driven joint stopper A Rear wheel B Rear axle nut 6 Driven joint B Dust seal ITEM N m k...

Page 383: ...agon socket Raise the rear wheel off the ground and support the motorcy cle with a jack or wooden block Draw out the rear axle and coller 4 Remove the rear wheel DISASSEMBLY Flatten the lock washers R...

Page 384: ...27 and 9 73 BRAKE DISC 9 69 Remove the brake disc 1 WHEEL BEARINGS Inspect the play of the wheel bearings by finger while they are in the wheel Rotate the inner race by finger to inspect for abnormal...

Page 385: ...BLY AND INSTALLATION Reassemble and install the rear wheel in the reverse order of removal and disassembly Pay attention to the following points The removed bearings should be replaced with new ones L...

Page 386: ...ng Steering race installer set 09924 84510 Bearing installer set Install the dust seal with the special tool 09913 70210 Bearing installer set 52 mm Apply SUZUKI SUPER GREASE A to the dust seal lip 99...

Page 387: ...pplied around the damper it makes the job easier DRIVEN HUB JOINT Install the new O ring 1 and driven hub joint 2 NOTE Apply SUZUKI SUPER GREASE A to the O ring and the final gear spline before instal...

Page 388: ...Install the brake caliper with the caliper bracket Tighten the rear axle nut 1 to the specified torque with the special tool 09944 28320 Hexagon socket Rear axle nut For E 03 28 33 100 N m 10 0 kgf m...

Page 389: ...ear cushion rod 7 Swingarm pivot bearing C Rear cushion lever mounting nut 3 Spacer 8 Swingarm D Swingarm pivot shaft 4 Rear cushion lever bearing 9 Boot 5 Rear cushion lever A Rear shock absorber mou...

Page 390: ...the regulator rectifier 2 Remove the rear shock absorber front mounting bolt and nut Remove the rear shock absorber rear mounting bolt and nut Remove the rear shock absorber 3 Remove the cushion rod m...

Page 391: ...r 7 Remove the rear fender 8 INSPECTION AND DISASSEMBLY SPACER Remove the spacers from frame Remove the spacers from the cushion lever Remove the spacers from the cushion rod Inspect the spacers for a...

Page 392: ...excessive play is noted replace the bearings with a new one Remove the dust seals 1 Remove the cushion lever upper bearings with the special tool 09913 70210 Bearing installer set 25 mm Draw out the c...

Page 393: ...LEVER RODS Inspect the cushion lever and cushion lever rods for damage If any defects are found replace it with a new one SWINGARM Inspect the swingarm for damage If any defects are found replace the...

Page 394: ...aking care not to get the vinyl bag entangled with the drill bit The rear shock absorber unit contains high pressure nitrogen gas Mishandling can cause explosion Keep away from fire and heat High gas...

Page 395: ...s NOTE Tightening order are E to F LH RH 1 1 0 mm 0 04 in C Rear cushion lever lower nut 2 4 5 mm 0 17 in D Rear cushion rod nut ITEM N m kgf m lb ft A Rear shock absorber nut E Swingarm pivot shaft A...

Page 396: ...depth from the cushion lever edge 9 46 Press the cushion lever lower bearings with the special tool 09924 84521 Bearing installer set NOTE When installing the bearing stamped mark on the bearing must...

Page 397: ...9 48 CHASSIS Apply SUZUKI SUPER GREASE A to the spacers 99000 25010 SUZUKI SUPER GREASE A or equivalent...

Page 398: ...lever 2 onto the swin garm temporarily SWINGARM Before installing the swingarm install the boot and the univer sal joint NOTE Make sure that the UP mark A on the boot faces to up Tighten the swingarm...

Page 399: ...ion rod mounting nut 110 N m 11 0 kgf m 79 5 lb ft Tighten the cushion lever mounting nuts 2 and 3 to the specified torque Cushion lever mounting nut 2 110 N m 11 0 kgf m 79 5 lb ft 3 85 N m 8 5 kgf m...

Page 400: ...b ft 3 Cap A Master cylinder mounting bolt A 10 1 0 7 0 4 Diaphrapm B Brake caliper mounting bolt B 39 3 9 28 0 5 Master cylinder C Brake caliper air bleeder valve C 7 5 0 75 5 5 6 Piston seal D Brake...

Page 401: ...as silicone based or petroleum based Do not use any brake fluid taken from old used or unsealed containers Never reuse brake fluid left over from the last servicing or stored for long periods When st...

Page 402: ...ied torque Pad mounting pin 1 15 N m 1 5 kgf m 11 0 lb ft Front brake caliper mounting bolt 2 39 N m 3 9 kgf m 28 0 lb ft NOTE After replacing the brake pads pump the brake lever a few times to check...

Page 403: ...and classification DOT 4 CALIPER REMOVAL Remove the brake hose from the caliper by removing the union bolt 1 and catch the brake fluid in a suitable recepta cle NOTE Place a rag underneath the union...

Page 404: ...09930 11920 Torx bit JT40H 09930 11940 Bit holder Remove the O ring 4 Place a rag over the pistons to prevent it from popping out and then force out the pistons using compressed air Remove the dust se...

Page 405: ...e order of disassembly Pay attention to the following points Clean the caliper bores and pistons with specified brake fluid especially the dust seal grooves and piston seal grooves Specification and c...

Page 406: ...emporarily tighten the air bleeder valve 2 Tighten each bolt to the specified torque Front brake caliper housing bolt 3 22 N m 2 2 kgf m 16 0 lb ft 09930 11920 Torx bit JT40H 09930 11940 Bit holder In...

Page 407: ...s is less than the service limit or if damage is found Front disc thickness Service Limit 4 5 mm 0 18 in 09900 20205 Micrometer 0 25 mm Remove the brake calipers 9 52 and 63 Measure the runout with a...

Page 408: ...emove the union bolt and disconnect the brake hose Remove the right rear view mirror 3 and master cylinder assembly 4 Remove the front brake light switch 5 Remove the nut and bolt 6 and brake lever 7...

Page 409: ...d return spring for wear or damage MASTER CYLINDER REASSEMBLY Reassemble the master cylinder in the reverse order of disas sembly Pay special attention to the following points Specification and classi...

Page 410: ...en remounting the master cylinder onto the handlebars align the master cylinder holder s mating surface with the punch mark A on the handlebars and tighten the upper clamp bolt first Master cylinder m...

Page 411: ...et 7 Dust seal 2 Reservoir hose 8 Brake pad spring ITEM N m kgf m lb ft 3 Brake hose A Caliper air bleeder valve A 7 5 0 75 5 5 4 Brake pad B Brake hose union bolt B 23 2 3 16 5 5 Piston C Brake maste...

Page 412: ...id taken from old used or unsealed containers Never reuse brake fluid left over from the last servicing or stored for long periods When storing the brake fluid seal the container completely and keep a...

Page 413: ...rake caliper mounting bolt 39 N m 3 9 kgf m 28 0 lb ft NOTE After replacing the brake pads pump the brake pedal a few times to check for proper brake operation and then check the brake fluid level BRA...

Page 414: ...the brake hose from the caliper by removing the union bolt 1 and catch the brake fluid in a suitable recepta cle NOTE Place a rag underneath the union bolt on the brake caliper to catch any split brak...

Page 415: ...nspect each brake caliper cylinder wall for nicks scratches or other damage If any defects are found replace the brake cal iper with a new one BRAKE CALIPER PISTONS Inspect the brake caliper pistons f...

Page 416: ...ts are found replace the holder with a new one RUBBER BOOT Inspect the rubber boot for damage and wear If any defects are found replace the boots with new ones BRAKE PAD SPRING Inspect the brake pad s...

Page 417: ...CON GREASE to the brake caliper holder 99000 25100 SUZUKI SILICONE GREASE or equivalent Clean the caliper components with fresh brake fluid before reassembly Never use cleaning solvent or gasoline to...

Page 418: ...23 N m 2 3 kgf m 16 5 lb ft BRAKE DISK INSPECTION 9 58 Rear disc thickness Service Limit 6 3 mm 0 25 in MASTER CYLINDER REMOVAL Remove the right frame head cover and right radiator cover 9 6 Remove th...

Page 419: ...ster cylinder by turning the master cylinder rod 6 MASTER CYLINDER DISASSEMBLY Remove the reservoir cap 1 and diaphragm 2 Remove the snap ring 3 connector 4 and O ring 5 09900 06108 Snap ring pliers P...

Page 420: ...DER REASSEMBLY Reassemble the master cylinder in the reverse order of disas sembly Pay attention to the following points Specification and classification DOT 4 Clean the master cylinder components wit...

Page 421: ...1 40 Master cylinder rod lock nut 1 18 N m 1 8 kgf m 13 0 lb ft Brake hose union bolt 2 23 N m 2 3 kgf m 16 5 lb ft Remove the master cylinder mounting bolts Apply THREAD LOCK SUPER to the master cyli...

Page 422: ...he 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 puncture the tire may have to be balanced ag...

Page 423: ...alve shows no abnormal con dition removing of the valve is not necessary If the seal has abnormal deformation replace the valve with a new one Any dust or rust around the valve hole B must be cleaned...

Page 424: ...by the tire changer manufacturer Bounce the tire several times while rotating This makes the tire bead expand outward to contact the wheel thereby facili tating air inflation Inflate the tire Do not...

Page 425: ...the tire again When the bead has been fitted properly adjust the pressure to specification As necessary adjust the tire balance Cold inflation tire pressure BALANCER WEIGHT INSTALLATION When installi...

Page 426: ...ING 10 8 INSPECTION 10 9 STARTER SYSTEM AND SIDE STAND IGNITION INTERLOCK SYSTEM 10 12 TROUBLESHOOTING 10 12 STARTER MOTOR REMOVAL 10 14 STARTER MOTOR DISASSEMBLY 10 15 STARTER MOTOR INSPECTION 10 15...

Page 427: ...LIGHT AND TURN SIGNAL LIGHT 10 39 HEADLIGHT RELAY INSPECTION 10 40 RELAYS 10 41 TURN SIGNAL SIDE STAND RELAY 10 41 STARTER RELAY 10 41 FUEL PUMP RELAY 10 41 COOLING FAN RELAY 10 41 SWITCHES INSPECTION...

Page 428: ...es Inspect each terminal on the coupler for being loose or bent Inspect each terminal for corrosion and contamination CLAMP Clamp the wire harness at such positions as indicated in WIRING HARNESS ROUT...

Page 429: ...tery Be sure to recharge the battery in a well ventilated and open area Note that the charging system for the MF battery is different from that of a conventional battery Do not replace the MF battery...

Page 430: ...ied If voltage is applied the tester will be damaged After using the tester be sure to turn the switch to the OFF position 09900 25008 Multi circuit tester set NOTE When connecting the multi circuit t...

Page 431: ...coil 1 6 IAT sensor 5 50 7 Ignition coil Plug cap 2 8 STP sensor 5 61 9 STV actuator 5 58 0 TP sensor 5 41 A TO sensor 5 54 B Starter motor C Horn D Turn signal Side stand relay E Fuel pump relay 6 6...

Page 432: ...dule 5 Fuse box 6 Ignition coil 2 7 Mode selection switch coupler 5 24 8 Ignition switch 9 Starter relay Main fuse 0 PAIR control solenoid valve 12 6 A Regulator Rectifier B Oil pressure switch C Gene...

Page 433: ...egulated voltage between the battery terminals 10 10 Is the regulated voltage OK Step 4 1 Measure the resistance of the generator coil 10 10 Is the resistance of generator coil OK YES Remove accessori...

Page 434: ...move the battery cover Disconnect the battery lead wire Measure the current between battery terminal and the battery lead wire using the multi circuit tester If the reading exceeds the specified value...

Page 435: ...r set Tester knob indication Voltage Regulated voltage Charging output 14 0 15 5 V at 5 000 r min GENERATOR COIL RESISTANCE Remove the fuel tank 6 3 Remove the left frame side cover 9 5 Remove the lef...

Page 436: ...move the left frame side cover 9 5 Remove the left frame lower side cover 3 6 Disconnect the regulator rectifier couplers 1 Measure the voltage between the lead wires using the multi circuit tester as...

Page 437: ...hed Is a click sound heard Step 2 1 Check if the starter motor runs when its terminal is connected to the battery terminal Do not use thin wire because a large amount of current flows Does the starter...

Page 438: ...on other than neutral with the side stand up 2 Check the side stand switch 10 19 Is the side stand switch OK Step 2 1 Check the starter clutch Is the starter clutch OK YES Go to Step 4 NO Faulty engin...

Page 439: ...R MOTOR REMOVAL Remove the right frame side cover 9 5 Remove the exhaust pipe and muffler 7 8 Remove the master cylinder cover 1 Disconnect the battery lead wire Disconnect the starter motor lead wire...

Page 440: ...emble the starter motor as shown in the illustration 1 O ring 5 Brush holder 2 Housing end inside 6 Housing end outside ITEM N m kgf m lb ft 3 Armature A Starter motor lead wire nut A 6 0 6 4 5 4 Star...

Page 441: ...th a new one If the commutator surface is discolored polish it with 400 sand paper and wipe it using a clean dry cloth If there is no undercut scrape out the insulator with a saw blade 1 Insulator 2 S...

Page 442: ...9000 25010 SUZUKI SUPER GREASE A or equivalent Align the projection 1 on the brush holder with the groove 2 on the starter motor case Tighten the brush holder nut to the specified torque Brush holder...

Page 443: ...ve the starter relay 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 f...

Page 444: ...nent with a new one SIDE STAND SWITCH Remove the left frame side cover 9 5 Disconnect the side stand switch coupler and measure the voltage between Green and Black White lead wires 09900 25008 Multi c...

Page 445: ...easure the voltage between Pink and Black White lead wires using the multi circuit tester when shifting the gearshift lever from low to top 09900 25008 Multi circuit tester set 09900 25009 Needle poin...

Page 446: ...nd E If there is no continuity replace the turn signal side stand relay with a new one 09900 25008 Multi circuit tester set Tester knob indication Continuity test DIODE INSPECTION Measure the voltage...

Page 447: ...he gear position is neutral this circuit cuts off fuel when engine speed reaches 7 100 r min Under no load the engine can run over 7 100 r min though the fuel cut off circuit is effective which may po...

Page 448: ...ith the ignition switch in the ON position E 02 19 24 O G and B W E 03 28 33 O W and B W Is the voltage OK Step 3 1 Measure the ignition coil primary peak voltage 10 25 to 27 NOTE This inspection meth...

Page 449: ...on sensor peak voltage inspection is applicable only with the multi circuit tester and peak volt adaptor Is the peak voltage and resistance OK YES Go to Step 6 NO Poor connection of the ignition coil...

Page 450: ...and plug caps Connect all the ignition coil plug cap lead wire couplers to the ignition coil plug caps respectively and ground them on the cylinder head each spark plug hole Connect new spark plugs t...

Page 451: ...sion into neutral and turn ignition switch ON Pull the clutch lever Crank the engine a few seconds with the starter motor by depressing starter button and check the ignition coil primary peak voltage...

Page 452: ...age Ignition coil primary peak voltage 250 V and more If the peak voltage is lower than the specified values inspect the ignition coil 10 28 IGNITION COIL PLUG CAP RESISTANCE Disconnect the ignition c...

Page 453: ...een Probe Measure the CKP sensor peak voltage at the CKP sensor lead wire coupler Shift the transmission into the neutral and turn ignition switch ON Crank the engine a few seconds with the starter mo...

Page 454: ...een the lead wires and ground If the resistance is not within the standard range replace the CKP sensor with a new one 09900 25008 Multi circuit tester set Tester knob indication Resistance CKP sensor...

Page 455: ...ch indicator light LED is maintenance free LED is less electric power consuming and stronger to vibration resistance com pared to the bulb Tachometer indicator lamp The tachometer light up for 1 0 sec...

Page 456: ...e speedometer 1 NOTE 2 indicates hook location Disassemble the speedometer as follows When disconnecting and reconnecting the speedome ter coupler make sure to turn OFF the ignition switch or electron...

Page 457: ...leber 9 30 Remove the head light 9 15 Remove the screws 1 Disconnect the tachometer lead wire coupler and remove the tachometer 2 Disassemble the tachometer as follows Do not attempt to disassemble th...

Page 458: ...new one after checking its wire har ness coupler NOTE The pointer may not return to the proper position even turning the ignition switch on under low temperature condition In that case you can reset...

Page 459: ...r all indications are abnormal replace the combi nation meter with a new one NOTE If the engine stop switch is turned OFF or side stand ignition inter lock system is not working while the ignition swi...

Page 460: ...condition the bulb should go out If the bulb remains lit replace the unit with a new one FUEL LEVEL INDICATOR LIGHT INSPECTION If the fuel level indicator light does not function properly check the fu...

Page 461: ...tion when inspecting it FUEL LEVEL GAUGE INSPECTION Remove the fuel level gauge assembly 6 8 Measure the resistance at each fuel level gauge float position If the resistance is incorrect replace the f...

Page 462: ...uit tester as shown in the right illustration O R Orange with Red tracer B W Black with White tracer P Pink 09900 25008 Multi circuit tester set Tester knob indication Voltage Under above condition if...

Page 463: ...e oil pressure switch lead wire from the oil pres sure switch Turn the ignition switch ON Check if the oil pressure indicator A and LCD B will light when grounding the lead wire If any indications are...

Page 464: ...ION LIGHT E 02 19 24 12 V 5 W BRAKE LIGHT TAILLIGHT LED LICENCE PLATE LIGHT 12 V 5 W 2 TURN SIGNAL POSITION LIGHT E 03 28 33 12 V 21 W 5 W 2 3 12 V 21 W 2 4 TURN SIGNAL LIGHT E 02 19 24 12 V 21 W 4 5...

Page 465: ...with tester Then apply 12 volts to C and D terminals to C and to D and check the continuity between A and B If there is no continuity replace it with a new one 09900 25008 Multi circuit tester set Tes...

Page 466: ...nal light does not illuminate inspect the bulb turn signal switch and circuit connection If the bulb turn signal switch and circuit connection are OK the turn signal relay may be faulty In this case r...

Page 467: ...R BRAKE SWITCH CLUTCH LEVER POSITION SWITCH OIL PRESSURE SWITCH WIRE COLOR B Black Lbl Light blue R Red Br Brown Lg Light green W White Gr Gray O Orange Y Yellow B BI Black with Blue tracer B R Black...

Page 468: ...ground Remove the caps 2 NOTE After filling the electrolyte completely use the removed cap 2 as sealing caps of battery filler holes Do not remove or pierce the sealed areas 3 of the electrolyte conta...

Page 469: ...e caps do not protrude above the upper surface of the battery s top cover For initial charging use the charger specially designed for MF battery Never use anything except the specified battery Once th...

Page 470: ...period B Stop charging Recharging time 9 A for 1 hour or 1 8 A for 5 to 10 hours After recharging wait for 30 minutes and more and check the battery voltage with a multi circuit tester If the battery...

Page 471: ...HARNESS CABLE AND HOSE ROUTING 11 35 WIRING HARNESS ROUTING 11 35 ENGINE ELECTRICAL PARTS LEAD WIRE ROUTING 11 37 CABLE ROUTING 11 38 FRONT BRAKE HOSE ROUTING 11 39 REAR BRAKE HOSE ROUTING 11 40 THRO...

Page 472: ...ORMATION IGNITION COIL INSTALLATION 11 51 SIDE STAND INSTALLATION 11 51 REAR TURN SIGNAL LIGHT LICENSE LIGHT WIRE ROUTING 11 52 SEAT LOCK CABLE ROUTING 11 52 LICENSE LIGHT AND LICENSE PLATE INSTALLATI...

Page 473: ...80 V In other than the above range C14 P0120 is indicated TP sensor lead wire coupler connection P0120 P0120 H Sensor voltage is higher than specified value TP sensor circuit shorted to VCC or ground...

Page 474: ...supplied from the ECM communica tion signal does not reach ECM or operation voltage does not reach STVA motor C28 P1655 is indicated STVA can not operate STVA motor STVA lead wire coupler P1655 C29 ST...

Page 475: ...ire cou pler connection power source to fuel pump relay and fuel injec tors P0230 P0230 H Voltage is applied to fuel pump although fuel pump relay is turned OFF Fuel pump relay switch circuit shorted...

Page 476: ...specified value EXCVA position sensor circuit shorted to VCC or ground circuit open L EXCVA position sensor voltage is lower than specified value EXCVA position sensor circuit open or shorted to groun...

Page 477: ...cords No fuel reaching the intake manifold 1 Clogged fuel filter or fuel hose 2 Defective fuel pump 3 Defective fuel pressure regulator 4 Defective fuel injector 5 Defective fuel pump relay 6 Defecti...

Page 478: ...l pressure regulator 5 Defective ECT sensor 6 Defective thermostat 7 Defective IAT sensor 8 Damaged or cracked vacuum hose Fuel injector improperly operating 1 Defective fuel injectors 2 No injection...

Page 479: ...Worn clutch release bearing 5 Weakened clutch dampers Noise seems to come from crankshaft 1 Rattling bearings due to wear 2 Worn and burnt big end bearings 3 Worn and burnt journal bearings 4 Too lar...

Page 480: ...STVA Defective air flow system 1 Clogged air cleaner element 2 Defective throttle valve 3 Defective secondary throttle valve 4 Sucking air from throttle body joint 5 Defective ECM 6 Imbalancing thrott...

Page 481: ...ose 13 Too much engine oil 14 Defective fuel pump or ECM 15 Defective CKP sensor and ignition coils Defective control circuit or sensor 1 Low fuel pressure 2 Defective TP sensor 3 Defective IAT sensor...

Page 482: ...guides 4 Scored or scuffed cylinder walls 5 Worn valves stems 6 Defective stem seal 7 Worn oil ring side rails Check with inspection window drain out excess oil Replace Replace Replace Replace Replac...

Page 483: ...ive ECT sensor 7 Clogged water passage 8 Air trapped in the cooling circuit 9 Defective water pump 10 Use incorrect coolant 11 Defective thermostat Add coolant Clean Repair or replace Repair or replac...

Page 484: ...kened springs 2 Not enough fork oil 3 Wrong weight fork oil Replace Replenish Replace Front suspension too stiff 1 Too viscous fork oil 2 Too much fork oil 3 Bent front axle Replace Drain excess oil R...

Page 485: ...n disc 5 Air in hydraulic system 6 Not enough brake fluid in the reservoir Repair or replace Replace Clean disc and pads Replace Bleed air Replenish Brake squeaking 1 Carbon adhesion on pad surface 2...

Page 486: ...not charge 1 Open or short circuited lead wires or loose lead connections 2 Short circuited grounded or open generator coil 3 Short circuited or punctured regulator rectifier Repair or replace or ret...

Page 487: ...lt of overcharging 3 Internal short circuit in the battery 4 Too low battery voltage 5 Too old battery Check the generator regu lator rectifier and circuit connections and make nec essary adjustments...

Page 488: ...0 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 20803 09900 20806 Thickness gauge 09900 20805 Tire depth gauge 09900 21304...

Page 489: ...l filter wrench 09915 64512 Compression gauge set 09915 74511 09915 74521 Oil pressure gauge hose 09915 77331 Meter for high pressure 09916 10911 Valve lapper set 09916 14510 Valve lifter 09916 14910...

Page 490: ...measur ing tool 27 50 09924 41830 Bearing retainer wrench 09924 62410 Final drive gear bearing holder wrench 09924 62430 22 mm Long socket 09924 64510 Final drive gear coupring holder 09924 84510 Bear...

Page 491: ...el pressure gauge hose attachment 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...

Page 492: ...Cam chain guide No 1 bolt 18 1 8 13 0 Exhaust pipe bolt 23 2 3 16 5 Muffler mounting bolt and nut 23 2 3 16 5 Oxygen sensor For E 02 19 24 1 2 48 4 8 34 5 Spark plug 11 1 1 8 0 Primary driven gear bo...

Page 493: ...et bolt Rear 23 2 3 16 5 Engine mounting nut 55 5 5 40 0 ITEM N m kgf m lb ft Secondary drive gear bolt 160 16 0 115 5 Secondary driven bearing stopper 105 10 5 76 0 Secondary driven gear coupling nut...

Page 494: ...acket mounting bolt 80 8 0 58 0 Brake caliper mounting bolt Front Rear 39 3 9 28 0 Brake caliper air bleeder valve Front Rear 7 5 0 75 5 5 Brake hose union bolt Front Rear 23 2 3 16 5 Brake master cyl...

Page 495: ...or 4 marked bolt 7 marked bolt N m kgf m lb ft N m kgf m lb 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...

Page 496: ...m deflection IN EX 0 35 0 014 Valve stem runout IN EX 0 05 0 002 Valve head thickness IN EX 0 5 0 02 Valve seat width IN 1 1 1 3 0 043 0 051 EX 1 4 1 6 0 055 0 063 Valve head radial runout IN EX 0 03...

Page 497: ...ston diam 111 967 111 983 4 4081 4 4088 Measure at 10 mm 0 4 in from the skirt end 111 880 4 4047 Cylinder distortion 0 05 0 002 Piston ring free end gap 1st Approx 15 7 0 62 12 6 0 50 2nd Approx 14 5...

Page 498: ...al O D 54 982 55 000 2 1646 2 1654 Crankshaft thrust bearing thickness 2 250 2 550 0 0886 0 1004 Crankshaft thrust clearance 0 100 0 200 0 0039 0 0079 Crankshaft runout 0 05 0 002 ITEM STANDARD LIMIT...

Page 499: ...Approx 105 C 221 F ON OFF Approx 100 C 212 F Engine coolant type Use an anti freeze coolant compatible with alumi num radiator mixed with distilled water only at the ratio of 50 50 Engine coolant Rese...

Page 500: ...more When cranking IAP sensor input voltage F R 4 5 5 5 V IAP sensor output voltage F R Approx 2 6 V at idle speed TP sensor input voltage 4 5 5 5 V TP sensor resistance Closed Approx 1 1 k Opened App...

Page 501: ...86 F ITEM SPECIFICATION I D No 48G1 For E 33 48G0 Others Bore size 56 mm Idle r min 900 100 r min Warmed engine Throttle cable play 2 0 4 0 mm 0 08 0 16 in ITEM SPECIFICATION NOTE Firing order 1 2 Sp...

Page 502: ...urn signal 15 A Fan motor 15 A Main 30 A Starter motor brush length Standard 12 5 0 49 Limit 6 0 0 24 ITEM SPECIFICATION E 03 28 33 E 02 19 24 Headlight HI 60 LO 55 Position light 5 Brake light Tailli...

Page 503: ...g Front 30 280 30 356 1 1921 1 1951 Trailing 34 010 34 086 1 3390 1 3420 Leading Trailing Rear 30 230 30 306 1 1902 1 1931 Brake caliper piston diam Leading Front 30 150 30 200 1 1870 1 1890 Trailing...

Page 504: ...RIDING kPa kgf cm2 psi kPa kgf cm2 psi FRONT 250 2 50 36 250 2 50 36 REAR 290 2 90 42 290 2 90 42 ITEM SPECIFICATION NOTE Fuel type Use only unleaded gasoline of at least 90 pump octane R 2 M 2 Gasol...

Page 505: ...iring harness and fuel tank and frame Clamp Wiring harness Clamp To the HO2 sensor Clamp Clamp Upper Regulator rectifier Clamp Do not touch the regulator rectifier lead wire to the other part Clamp Si...

Page 506: ...r the breather hose Pass the lead wire outside of the terminal Pass the ignition coil plug cap cord upper the breather hose Horn Clamp Pass the starter motor lead wire inside of the rear brake hose Do...

Page 507: ...ECTRICAL PARTS LEAD WIRE ROUTING Clamp Battery ground wire Grommet Gear position switch Starter motor Starter motor lead wire Generator lead wire Speedometer sensor CKP sensor Clamp Oil pressure switc...

Page 508: ...e Throttle cable No 1 pulling cable Throttle cable No 2 returning cable 0 mm 0 mm Pass the clutch cable inside of heat shield plate Pass the clutch cable between nuts Clutch cable 0 mm Clutch cable st...

Page 509: ...nder 9 Brake caliper R 3 Throttle cable 0 Brake caliper L 4 Cable guide 1 Tighten the brake hose union bolt to the specified torque after touching the brake hose union to the stopper 5 Hose guide 2 Pa...

Page 510: ...ose D Fix the brake hose to the clamp 5 Brake caliper E Master cylinder cover 6 Clamp F Reservoir hose 7 Face the tip of clamp to backward G Pass the reservoir hose inside of the master cylinder cover...

Page 511: ...e hose R 0 Bolt 2 ISC valve hose L 1 Yellow mark 3 Throttle body 2 Face the tip of clip to upper 4 Boost hose 3 Do not touch the end of screw to the stopper when tightening it 5 Purge hose For E 33 4...

Page 512: ...flow hose Red mark Face the tip of clamp to the forward White mark Face the tip of clamp to the upper White mark Red mark Face the tip of clamp to the backward Face the tip of clip to the backward Yel...

Page 513: ...ATION 11 43 PAIR AIR SUPPLY SYSTEM HOSE ROUTING FOR E 03 28 33 Set the PAIR hose to the concave of air cleaner tube VIEW A Blue mark Yellow mark A White mark White mark 1 PAIR control solenoid valve 2...

Page 514: ...ERVICING INFORMATION PAIR AIR SUPPLY SYSTEM HOSE ROUTING FOR THE OTHERS Set the PAIR hose to the concave of air cleaner tube Yellow mark White mark White mark 1 PAIR control solenoid valve 2 PAIR reed...

Page 515: ...r fender cover cushion 3 Clamp 8 Apply instant adhesive to the shaded portion 4 Face the tip of clamp to the backward 9 Fuel tank rear bracket 5 Face the arrow mark to the forward when install ing the...

Page 516: ...VER INSTALLATION 1 Frame head cover R 6 Radiator lower cover L 2 Radiator cover R 7 Radiator bottom cover 3 Radiator lower cover R 8 Throttle cable No 1 pulling cable 4 Frame head cover L 9 Throttle c...

Page 517: ...7 FRAME HEAD COVER CUSHION INSTALLATION RADIATOR UPPER COVER CUSHION INSTALLATION 1 Cushion 3 Frame head cover L 2 Frame head cover R 3 mm 0 1 in 18 mm 0 7 in 16 mm 0 6 in 2 mm 0 08 in 1 Radiator uppe...

Page 518: ...11 48 SERVICING INFORMATION LEFT FRAME COVERS INSTALLATION 1 Rear fender 4 Side cover 2 Rear fender cover 5 Lower side cover 3 Rear side cover...

Page 519: ...SERVICING INFORMATION 11 49 RIGHT FRAME COVERS INSTALLATION 1 Rear fender 4 Side cover 2 Rear fender cover 5 Lower cover 3 Rear side cover...

Page 520: ...50 SERVICING INFORMATION HEADLIGHT COVER INSTALLATION 1 Headlight lower cover 4 Headlight cover brace 2 Headlight cover 5 Steering stem upper bracket 3 Headlight back cover 6 Steering stem lower brack...

Page 521: ...SERVICING INFORMATION 11 51 IGNITION COIL INSTALLATION SIDE STAND INSTALLATION Forward 1 Ignition coil 1 3 Ignition coil bracket 2 Ignition coil 2 4 Spacer...

Page 522: ...right and left rear turn signal light lead wires and license light lead wire with clamp Fit the lead wires with iron clamp 2 Connect the right rear turn signal light lead wire to the wiring harness 5...

Page 523: ...CENSE LIGHT AND LICENSE PLATE INSTALLATION BRAKE LIGHT TAILLIGHT INSTALLATION 1 License light 4 Washer 2 License plate 5 Spacer ITEM N m kgf m lb ft 3 Nut A License light nut A 5 0 5 3 5 1 Rear frame...

Page 524: ...MISSION CONTROL SYSTEM PAIR SYSTEM 12 4 NOISE EMISSION CONTROL SYSTEM 12 5 PAIR AIR SUPPLY SYSTEM AND EMISSION CONTROL SYSTEM INSPECTION 12 6 PAIR HOSES 12 6 PAIR REED VALVE 12 6 PAIR CONTROL SOLENOID...

Page 525: ...ction maps in the ECM by varying engine conditions Adjusting interfering with improper replacement or resetting of any of the fuel injection components may adversely affect injection performance and c...

Page 526: ...ing crankcase emissions into the atomo sphere Blow by gas in the engine is constantly drawn into the crankcase which is returned to the combus tion chamber through the PCV breather hose air cleaner an...

Page 527: ...IR control solenoid valve is operated by the ECM and the fresh air flow is controlled according to the TPS ECTS IATS IAPS and CKPS The exhaust gas flow is performed by the exhaust control valve actuat...

Page 528: ...s in use or 2 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...

Page 529: ...osit If the carbon deposit is found in the reed valve replace the PAIR reed valve with a new one PAIR CONTROL SOLENOID VALVE REMOVAL Remove the air cleaner chamber 6 13 Remove the PAIR control solenoi...

Page 530: ...is not within the standard range replace the PAIR control solenoid valve with a new one Installation is in the reverse order of removal Pay attention to the following points Install the PAIR control...

Page 531: ...OL INFORMATION PAIR AIR SUPPLY SYSTEM HOSE ROUTING FOR E 03 28 33 Set the PAIR hose to the concave of air cleaner tube VIEW A Blue mark Yellow mark A White mark White mark 1 PAIR control solenoid valv...

Page 532: ...ONTROL INFORMATION 12 9 PAIR AIR SUPPLY SYSTEM HOSE ROUTING FOR THE OTHERS 1 PAIR control solenoid valve 2 PAIR reed valve Set the PAIR hose to the concave of air cleaner tube Yellow mark White mark W...

Page 533: ...e If the resistance is not within the standard range replace the HO2 sensor with a new one NOTE Temperature of the sensor affects resistance value largely Make sure that the sensor heater is at correc...

Page 534: ...O Y O G Br O R W B W O B R Y O R P B W R O O Y Gr Br Gr P B Y W Y R B W B Lg R B HEADLIGHT POSITION LIGHT FRONT TURN SIGNAL LIGHT R FRONT TURN SIGNAL LIGHT L OFF RUN OFF ON PUSH HANDLEBAR SWITCH R SPE...

Page 535: ...Gr P B Y W HEADLIGHT FRONT TURN SIGNAL LIGHT R POSITION LIGHT FRONT TURN SIGNAL LIGHT L POSITION LIGHT OFF RUN OFF ON PUSH HANDLEBAR SWITCH R ENGINE STOP SWITCH STARTER BUTTON FRONT BRAKE SWITCH ON O...

Page 536: ...Prepared by January 2006 Part No 99500 39290 01E Printed in Japan 540...

Page 537: ...Printed in Japan K6...

Page 538: ...lletin contains service manual correction information for the VZR1800K7 Insert a copy of each of the attached pages of this bulletin into the service manual at the appropriate page AFFECTED DEPARTMENT...

Page 539: ...TTLE BODY 6 7 FUEL PUMP AND FUEL LEVEL GAUGE REMOVAL CONSTRUCTION 1 Regulator 5 O ring 2 Fuel pump 6 Fuel level gauge ITEM N m kgf m lb ft 3 Fuel mesh filter Thermistor A 10 1 0 7 0 4 Filter cover Fue...

Page 540: ...above condition the bulb should go out If the bulb remains lit replace the unit with a new one FUEL LEVEL INDICATOR LIGHT INSPECTION If the fuel level indicator light does not function properly check...

Page 541: ...R1800 SERVICE MANUAL P N 99500 39292 03E prior to 08 07 revision Pages 3 21 and 3 95 NOTICE This bulletin contains service manual correction information for the VZR1800 Please change the valve spring...

Page 542: ...al tool 09917 62430 Chain tensioner lock tool Remove the rear cam chain tensioner No 1 assy 2 Remove the cam chain guide No 1 3 and rear cam chain tension adjuster No 1 4 REAR CAM CHAIN IDLER SPROCKET...

Page 543: ...l the spring washer 6 NOTE The conical curve side of spring washer 6 faces outside Hold the generator rotor and tighten the clutch sleeve hub nut to the specified torque Clutch sleeve hub nut 95 N m 9...

Page 544: ...the VZR1800 correct clutch cable play adjustment is important to prevent clutch slippage particularly under heavy load Inspect and adjust the clutch cable play during pre delivery inspection and perio...

Page 545: ...or hoses with new ones CLUTCH CABLE PLAY Remove the secondary gear case cover 1 Remove the clutch cable holder 2 with the clutch cable Inspect the clutch release arm play A Clutch release arm play A S...

Page 546: ...lock nut 5 Turn in the adjuster 6 all the way into the clutch lever assem bly Loosen the lock nut 7 and turn the cable adjuster 8 to obtain 10 15 mm 0 4 0 6 in of free play B at the clutch lever end...

Page 547: ...n the wear exceeds the grooved limit line replace the pads with the new ones 9 52 The brake system of this motorcycle is filled with a glycol based brake fluid Do not use or mix different types of flu...

Page 548: ...il the brake pedal height becomes 25 35 mm 1 0 1 4 in A below the top of the footrest Tighten the lock nut 1 securely Rear brake master cylinder rod lock nut 18 N m 1 8 kgf m 13 0 Ib ft Brake pedal he...

Page 549: ...This bulletin contains additional technical information for the VZR1800K8 Please place a copy of this bulletin with your dealership s VZR1800 Service Manual AFFECTED DEPARTMENTS The following departme...

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Page 580: ...d that on some affected motorcycles the fuel hose that connects the two metal fuel delivery pipes mounted on the throttle body may have been clamped at a location on the pipes that is not completely r...

Page 581: ...crates WHAT SUZUKI WILL DO On Friday April 6 2007 Suzuki will mail notification letters to the owners of affected motorcycles for whom we have information The letter asks the customer to contact the d...

Page 582: ...r MILEAGE Enter mileage on unit CAMPAIGN NUMBER 2096 LABOR HOURS 1 0 hrs SUZUKI AUTH NUMBER As approved by TECH LINE PARTS REPLACEMENT PART NUMBER NO PARTS REQUIRED FAILURE DESCRIPTION DESCRIPTION OF...

Page 583: ...nto the fuel delivery pipe and throttle body respectively Install the new fuel delivery pipe assembly in the reverse order of removal 5 Connect the fuel injector couplers A and clamp the injector harn...

Page 584: ...al costs your customers may incur are not normally covered However if you have a customer with special needs contact your Technical Service Manager 800 756 3251 to discuss possible solutions CUSTOMER...

Page 585: ...service scheduled and performed as quickly as possible Schedule an appointment for the recall service to be performed Parts are currently available but it will be necessary for your dealer to order th...

Page 586: ...1 800 828 7433 Customer Reimbursement If your motorcycle is included in the recall and you have paid for the repair or replacement of the fuel delivery pipe assembly you may be eligible for full or pa...

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