Suzuki LT-Z400 Service Manual Download Page 415

Page: 415 / 492

Manual Transmission: 5B-5

Transmission Removal and Installation

B933H25206004

Removal

1) Remove the engine assembly from the frame. Refer

to “Engine Assembly Removal in Section 1D
(Page 1D-13)”.

2) Remove the engine top side. Refer to “Engine Top

Side Disassembly in Section 1D (Page 1D-17)”.

3) Separate the left and right crankcases. Refer to

“Engine Bottom Side Disassembly in Section 1D
(Page 1D-41)”.

Reverse lock shaft / Gearshift cam / Gearshift fork

1) Remove the gearshift fork shaft (1), reverse lock

shaft (2), gearshift cam (3) and gearshift forks (4).

2) Remove the reverse lock spring (5).

Reverse idle gear assembly / Driveshaft assembly /
Countershaft assembly

1) Remove the reverse idle gear (1) with its shaft.

2) Remove the driveshaft assembly (2) and

countershaft assembly (3).

1. Countershaft

11. Reverse driven gear

21. Reverse lock shaft

2. Top drive gear

12. 1st/reverse dog

22. Gear position switch

3. 3rd drive gear

13. 1st driven gear

23. Gearshift cam stopper plate

4. 4th drive gear

14. Reverse idle gear shaft

24. Gearshift cam stopper

5. 2nd drive gear

15. Reverse idle gear

: 24 N

⋅

m (2.4 kgf-m, 17.5 lb-ft)

6. Driveshaft

16. Gearshift fork No. 1

: Apply engine oil.

7. 2nd driven gear

17. Gearshift fork No. 2

: Apply molybdenum oil solution.

8. 4th driven gear

18. Gearshift fork shaft

: Apply water resistance grease.

9. 3rd driven gear

19. Gearshift cam

: Apply thread lock to the thread part.

10. Top driven gear

20. Gearshift fork No. 3

: Do not reuse.

I933H1520015-01

I933H1520016-01

I933H1520017-02

I933H1520018-03

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877-999-5686

Summary of Contents for LT-Z400

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

Page 2: ...P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

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

Page 4: ...P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 5: ...s 00 i 00 Section 00 CONTENTS Precautions Precautions 00 1 Precautions 00 1 Warning Caution Note 00 1 General Precautions 00 1 Precautions for Electrical Circuit Service 00 2 P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 6: ...engine oil radiator and exhaust system until they have cooled After servicing the fuel oil water exhaust or brake systems check all lines and fittings related to the system for leaks CAUTION If parts replacement is necessary replace the parts with Suzuki Genuine Parts or their equivalent When removing parts that are to be reused keep them arranged in an orderly manner so that they may be reinstall...

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

Page 8: ... properly so that the wire harness is clamped securely In clamping the wire harness use care not to allow it to hang down Do not use wire or any other substitute for the band type clamp Fuse When a fuse is blows always investigate the cause to correct it and then replace the fuse Do not use a fuse of different capacity Do not use wire or any other substitute for the fuse Switch Never apply grease ...

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

Page 10: ...which could impede proper terminal contact 4 Using continuity inspect or voltage check procedure as described below inspect the wire harness terminals for open circuit and poor connection Locate abnormality if any Continuity check 1 Measure resistance across coupler B between A and C in the figure If no continuity is indicated infinity or over limit the circuit is open between terminals A and C 2 ...

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

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

Page 13: ...0B 4 Valve Clearance Inspection and Adjustment 0B 5 Spark Plug Replacement 0B 9 Spark Plug Inspection and Cleaning 0B 9 Spark Arrester Cleaning 0B 10 Engine Idle Speed Inspection and Adjustment 0B 10 Throttle Body Inspection 0B 10 Throttle Cable Play Inspection and Adjustment 0B 10 Fuel Line Replacement 0B 11 Fuel Line Inspection 0B 11 Engine Oil and Filter Replacement 0B 11 Engine Oil Hoses Inspe...

Page 14: ... MOLY PASTE in a ratio of 1 1 Apply SUZUKI SUPER GREASE A or equivalent 99000 25010 Apply SUZUKI MOLY PASTE or equivalent 99000 25140 Apply WATER RESISTANCE GREASE or equivalent 99000 25160 Apply SUZUKI SILICONE GREASE or equivalent 99000 25100 Apply SUZUKI BOND 1215 or equivalent 99000 31110 Apply SUZUKI BOND 1207B or equivalent 99000 31140 Apply THREAD LOCK SUPER 1303 or equivalent 99000 32030 A...

Page 15: ...ilation Crankcase Breather R RH Right Hand ROM Read Only Memory S SAE Society of Automotive Engineers SDS Suzuki Diagnosis System T TO Sensor Tip over Sensor TOS TP Sensor Throttle Position Sensor TPS SAE to Former SUZUKI Term B933H20101003 This list shows SAE Society of Automotive Engineers J1930 terms and abbreviations which may be used in this manual in compliance with SAE recommendations as we...

Page 16: ... serial number or V I N Vehicle Identification Number A is stamped on the left side of the front frame pipe The engine serial number B is located on the right side of the crankcase These numbers are required especially for registering the machine and ordering spare parts Fuel and Oil Recommendation B933H20101006 Fuel for USA and Canada Use only unleaded gasoline of at least 87 pump octane R 2 M 2 ...

Page 17: ... water can corrode and clog the aluminum radiator Anti freeze Engine coolant The engine coolant perform as a corrosion and rust inhibitor as well as anti freeze Therefore the engine coolant should be used at all times even though the atmospheric temperature 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 availabl...

Page 18: ...acer Dg Dark green Br W Brown with White tracer G Green G B Green with Black tracer Gr Gray G W Green with White tracer O Orange G R Green with Red tracer P Pink Gr W Gray with White tracer R Red O G Orange with Green tracer W White O W Orange with White tracer Y Yellow O Y Orange with Yellow tracer B Bl Black with Blue tracer O B Orange with Black tracer B Br Black with Brown tracer R Y Red with ...

Page 19: ...eral warning label For E 28 7 Warning no passenger label For E 19 28 33 8 AGE 16 label For E 28 9 Manual notice label For E 33 10 Gearshift label For E 19 28 33 11 Gearshift label For E 28 12 ICES Canada label For E 28 13 Compliance label For E 28 14 Chain adjustment label For E 19 28 33 15 Chain adjustment label For E 28 16 EC approval mark For E 19 17 Compliance label For E 28 18 ANSI certificat...

Page 20: ...tion B933H20103001 1 2 3 4 5 6 7 8 9 10 11 I933H1010005 02 1 Battery 5 Ignition coil 9 Cooling fan fuse 2 Ignition fuse 6 Cooling fan relay 10 Cooling fan 3 Starter relay Main fuse 7 TO sensor 11 IAT sensor 4 Fuel injector 8 ECM P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 21: ...12 I933H1010006 02 12 Mode select switch coupler 16 Regulator Rectifier 20 GP switch 13 Fuel level gauge Thermistor 17 Fuel pump 21 CKP sensor 14 IAP sensor 18 ECT sensor 22 Generator 15 TP sensor 19 Starter motor P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 22: ...d DOHC Number of cylinders 1 Bore 90 0 mm 3 543 in Stroke 62 6 mm 2 465 in Displacement 398 cm3 24 3 cu in Compression ratio 11 3 1 Fuel system Fuel injection Air cleaner Polyurethane foam element Starter system Electric Lubrication system Dry sump Idle speed 1 600 100 r min Item Specification Clutch Wet multi plate type Transmission 5 forward and 1 reverse Gearshift pattern Forward 1 down 4 up fo...

Page 23: ...ion Ignition type Electronic ignition CDI Ignition timing 5 B T D C at 1 600 r min Spark plug NGK CR7E or DENSO U22ESR N Battery 12 V 28 8 kC 8 Ah 10 HR Generator Three phase A C generator Main fuse 20 A Ignition fuse 10 A Cooling Fan fuse 10 A Headlight 12 V 40 40 W Brake light Taillight 12 V 21 5 W Neutral indicator light 12 V 1 7 W Reverse indicator light 12 V 1 7 W FI Engine coolant temperatur...

Page 24: ...000 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 Thickness gauge 09900 20805 Tire depth gauge 09900 21304 V block 100 mm 09900 22301 Plastigauge 0 025 0 076 mm 09900 22302 Plastigauge 0 051 0 152 mm 09900 22403 Small bore gauge 18 35 mm 09900 25008 Multi circuit tester set 09900 25009 Needle pointed probe set 09900...

Page 25: ...1 Meter for high pressure 09916 10911 Valve lapper set 09916 14510 Valve spring compressor 09916 14910 Valve spring compressor attachment 09916 34542 Reamer handle 09916 34570 Valve guide reamer 5 0 mm 09916 34580 Valve guide reamer 10 8 mm 09916 44310 Valve guide remover installer 09916 53360 Attachment 09916 84511 Tweezers 09917 47011 Vacuum pump gauge 09919 28610 Sleeve protector 09920 13120 Cr...

Page 26: ...emover slide shaft 09930 30721 Rotor remover 09930 31921 Rotor remover 09930 44520 Rotor holder 09930 73170 Starter torque limiter holder 09930 73180 Starter torque limiter socket 09930 82720 Mode select switch 09940 40211 Fuel pressure gauge adapter 09940 40220 Fuel pressure gauge hose attachment 09940 92460 Rear axle nut wrench set 09941 34513 Steering race installer 09942 72410 Tie rod end remo...

Page 27: ... vehicle operating at peak performance and economy Maintenance intervals are expressed in terms of kilometers miles and months for your convenience NOTE More frequent servicing may be required on vehicle that are used under severe conditions General Description Recommended Fluids and Lubricants B933H20201001 Refer to Fuel and Oil Recommendation in Section 0A Page 0A 3 and Engine Coolant Recommenda...

Page 28: ...C Idle speed I I I Throttle body I I Throttle cable play I I I Fuel line I I Replace every 4 years Engine oil and oil filter R R Engine oil hoses I I I Clutch I I Engine coolant Replace every 2 years Radiator hose I Replace every 4 years Drive chain Inspect every time before riding Brakes I I I Brake fluid I I Replace every 2 years Brake hose I Replace every 4 years Tires I I Front and rear wheel ...

Page 29: ...ing 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 especially whenever the vehicle has been operated under wet or rainy conditions 7 3 2 1 4 6 5 I933H1020001 02 1 Brake lever holder 4 Brake pedal and rod link 7 Rear suspension grease nipple 2 Throttle lever 5 Brake cam Apply water resist...

Page 30: ... in the cleaning solvent and wash it 4 Press the air cleaner element between the palms of both hands to remove the excess solvent do not twist or wring the element or it will tear 5 Immerse the element in motor oil and then squeeze out the excess oil leaving the element slightly wet 6 After cleaning the air cleaner element reinstall the removed parts 7 Remove the drain plug 1 of the air cleaner bo...

Page 31: ...verflow hose 1 and breather hose 2 4 Disconnect the spark plug cap and spark plug 3 Refer to Spark Plug Cap and Spark Plug Removal and Installation in Section 1H Page 1H 4 5 Remove the cylinder head cover 4 Refer to Engine Top Side Disassembly in Section 1D Page 1D 17 6 Remove the valve timing inspection plug 5 and generator cover cap 6 7 Turn the crankshaft counterclockwise and align the T line o...

Page 32: ...s or magnetic hand 3 Check the figures printed on the shim These figures indicate the thickness of the shim as illustrated 4 Select a replacement shim that will provide a clearance within the specified range For the purpose of this adjustment a total of 25 sizes of tappet shim are available ranging from 2 30 to 3 50 mm in steps of 0 05 mm CAUTION Both the right and left valve clearances should be ...

Page 33: ...810 I Measure tappet clearance when the engine is cold II Measure present shim size III Match clearance in vertical column with present shim size in horizontal column Example Tappet clearance is 0 23 mm Present shim size 2 70 mm Shim size to be used 2 80 mm How to use this chart I933H1020010 03 P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 34: ...arance in vertical column with present shim size in horizontal column Example Tappet clearance is 0 38 mm Present shim size 2 90 mm Shim size to be used 3 05 mm TAPPET SHIM SELECTION TABLE EXHAUST TAPPET SHIM NO 12892 41C00 XXX TAPPET SHIM SET NO 12800 41810 How to use this chart I933H1020011 02 P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 35: ...on deposits 1 Remove the spark plug Refer to Spark Plug Cap and Spark Plug Removal and Installation in Section 1H Page 1H 4 2 Check carbon deposits on the spark plug If carbon is deposited remove it using a spark plug cleaner machine or carefully use a tool with a pointed end 3 After finishing the spark plug inspection reinstall the removed parts Spark plug gap 1 Remove the spark plug Refer to Spa...

Page 36: ...meter solar cell type 3 Set the engine idle speed between 1 500 and 1 700 r min by turning the idle air screw 1 Engine idle speed 1 600 100 r min Throttle Body Inspection B933H20206008 Inspect throttle body Every 3 months Inspect the throttle body periodically for dart or mud If any dirt or mud is found clean it Refer to Throttle Body Removal and Installation in Section 1D Page 1D 9 Throttle Cable...

Page 37: ...fter finishing the fuel feed hoses and fuel hose inspection or replacement reinstall the removed parts Engine Oil and Filter Replacement B933H20206012 Replace engine oil Initially at 1 month and every 6 months thereafter Replace oil filter Initially at 1 month and every 6 months thereafter Oil should be changed while the engine is warm Oil filter replacement at the above intervals should be done t...

Page 38: ... for few minutes at idling speed 3 Turn off the engine and wait about three minutes then check the oil level on the dipstick 1 If the level is below low level line A add oil to full level line B If the level is above full level line B drain oil to full level line B Oil filter replacement CAUTION When reassembling the oil filter make sure that the oil filter is installed as properly If the filter i...

Page 39: ...val and Installation in Section 1E Page 1E 8 Clutch Inspection and Adjustment B933H20206014 Inspect clutch lever play Initially at 1 month and every 6 months thereafter Inspect and adjuster the clutch lever play a as follows Clutch lever play a 5 10 mm 0 2 0 4 in 1 Loosen the lock nut 1 2 Turn the adjuster 2 in or out until the clutch lever play a is between 5 10 mm 0 2 0 4 in 3 Tighten the lock n...

Page 40: ...ified torque CAUTION Replace the gasket with a new one Tightening torque Engine coolant drain plug a 6 N m 0 6 kgf m 4 5 lb ft 6 Pour the specified engine coolant up to the radiator inlet Engine coolant capacity Reservoir side 250 ml 0 3 0 2 US lmp qt Engine side 900 ml 1 0 0 8 US lmp qt 7 Bleed air from the cooling circuit 8 After changing engine coolant reinstall the removed parts Air bleeding f...

Page 41: ...y 4 years Refer to Water Hose Removal and Installation in Section 1F Page 1F 8 Drive Chain Inspection and Adjustment B933H20206016 Clean lubricate and inspect each time the vehicle is ridden Every time before riding Drive chain visual check 1 Support the vehicle by a jack and a wooden block turn the rear wheel slowly by hand with the transmission shifted to Neutral 2 Visually check the drive chain...

Page 42: ...n or tighten the chain adjuster nut 2 until there is 30 40 mm 1 2 1 6 in a of slack at the middle of the chain between the engine and rear sprockets as shown in the figure Drive chain slack a Standard 30 40 mm 1 2 1 6 in 4 After adjusting the drive chain tighten the rear axle housing bolts 1 to the specified torque Tightening torque Rear axle housing bolt a 100 N m 10 0 kgf m 72 5 lb ft 5 Tighten ...

Page 43: ...d and petroleum based fluids 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 a long period of time Brake fluid if it leaks will interfere with safe running and immediately discolor painted surfaces Check the brake hoses and hose joints for cracks and oil leakage before riding Brake pads check 1 Remove the...

Page 44: ...9 2 0 in 1 Loosen the parking brake adjuster lock nut 1 while holding the adjuster 2 with a wrench 2 Loosen the adjuster 2 3 Loosen the parking brake cable adjuster lock nut 3 4 Turn the cable adjuster 4 so that the cable length a is 47 51 mm 1 9 2 0 in 5 Tighten the adjuster lock nut 3 6 Turn the adjuster 2 clockwise until stops 7 Then turn the adjuster 2 1 8 1 4 back 8 Tighten the adjuster lock ...

Page 45: ...Inspection in Section 4A Page 4A 6 Front and rear brake hose inspection Inspect brake hose Every 6 months Inspect the brake hoses and hose joints for crack damage or brake oil leakage If any defects are found replace the front and rear brake hoses with new ones Refer to Brake Hose Removal and Installation in Section 4A Page 4A 9 Front and rear brake hose replacement Replace brake hose Every 4 year...

Page 46: ...t and a AT20 x 10R9 for the rear The use of tires other than those specified may cause instability It is highly recommended to use the specified tires Tire type DUNLOP Front KT331 Rear KT335 Front and Rear Wheel Set Nuts Inspection B933H20206019 Tighten front and rear wheel set nuts Each time the vehicle is ridden Tighten the front and rear wheel set nuts to the specified torque Tightening torque ...

Page 47: ... to the rear axle nut bolt 3 Thread lock cement 99000 32110 THREAD LOCK CEMENT SUPER 1322 or equivalent 6 Loosen the rear axle nut 2 7 Fit the stopper ring 4 8 Tighten the rear axle nut 2 to the specified torque with the special tool Refer to Rear Axle Nut and Lock Nut Tightening Torque in Section 3A Page 3A 7 Special tool A 09940 92460 Rear axle nut wrench set Tightening torque Rear axle nut a 24...

Page 48: ...place them with a new one Refer to Front Shock Absorber Removal and Installation in Section 2B Page 2B 3 and Rear Shock Absorber Removal and Installation in Section 2C Page 2C 3 Steering System Inspection B933H20206022 Inspect steering system Initially at 1 month and every 3 months thereafter Steering should be adjusted properly for smooth turning of handlebars and safe running 1 Place the vehicle...

Page 49: ...6 5 lb ft 3 Steering shaft nut 49 N m 4 9 kgf m 35 5 lb ft a 1 a 1 I933H1020063 01 b 2 I933H1020064 01 c 3 I933H1020065 01 4 Wishbone arm pivot nut Upper Lower 65 N m 6 5 kgf m 47 0 lb ft 5 Front hub nut 65 N m 6 5 kgf m 47 0 lb ft 6 Rear hub nut 121 N m 12 1 kgf m 87 5 lb ft 7 Wheel set nut Front Rear 66 N m 6 6 kgf m 47 5 lb ft 8 Front shock absorber mounting nut Upper Lower 60 N m 6 0 kgf m 43 ...

Page 50: ... 13 I933H1020070 02 i 15 j 17 b 16 I933H1020071 02 18 Front brake pipe nut Upper 16 N m 1 6 kgf m 11 5 lb ft 19 Footrest mounting bolt 55 N m 5 5 kgf m 40 0 lb ft 20 Front brake hose union bolt 23 N m 2 3 kgf m 16 5 lb ft 21 Front brake master cylinder mounting bolt 10 N m 1 0 kgf m 7 0 lb ft 22 Rear brake hose union bolt 23 N m 2 3 kgf m 16 5 lb ft 23 Rear brake master cylinder rod lock nut 18 N ...

Page 51: ...173 5 lb ft 31 Rear axle lock nut 240 N m 24 0 kgf m 173 5 lb ft 32 Cushion rod nut 78 N m 7 8 kgf m 56 5 lb ft 33 Cushion lever nut 78 N m 7 8 kgf m 56 5 lb ft 34 Rear shock absorber mounting nut Lower 60 N m 6 0 kgf m 43 5 lb ft s 30 g 29 s 31 g 29 r 28 I933H1020075 02 t 32 g 34 t 33 I933H1020076 02 35 Rear shock absorber mounting nut Upper 60 N m 6 0 kgf m 43 5 lb ft 36 Seat rail mounting bolt ...

Page 52: ...necting bolt 23 2 3 16 5 Page 0B 4 Muffler mounting bolt 23 2 3 16 5 Page 0B 4 Spark arrester mounting bolt 13 1 3 9 5 Page 0B 10 Oil drain plug 21 2 1 15 0 Page 0B 11 Oil drain plug 12 1 2 8 5 Page 0B 11 Engine coolant drain plug 6 0 6 4 5 Page 0B 14 Rear axle housing bolt 100 10 0 72 5 Page 0B 16 Chain adjuster nut 30 3 0 21 5 Page 0B 16 Rear brake master cylinder rod lock nut 18 1 8 13 0 Page 0...

Page 53: ...rial SUZUKI recommended product or Specification Note Brake fluid DOT 4 Page 0B 19 Thread lock cement THREAD LOCK CEMENT SUPER 1322 or equivalent P No 99000 32110 Page 0B 21 09900 20803 09900 20805 Thickness gauge Tire depth gauge Page 0B 6 Page 0B 20 09900 26006 09940 92460 Engine tachometer solar cell type Rear axle nut wrench set Page 0B 10 Page 0B 21 Page 0B 21 Page 0B 21 Page 0B 21 P a r t S ...

Page 54: ...n Item Standard Limit Cam height IN 36 190 36 240 1 4248 1 4268 35 890 1 4130 EX 34 920 34 970 1 3748 1 3768 34 620 1 3630 Camshaft journal oil clearance IN EX 0 019 0 053 0 0007 0 0021 0 150 0 0059 Camshaft journal holder I D IN EX 22 012 22 025 0 8666 0 8671 Camshaft journal O D IN EX 21 972 21 993 0 8650 0 8659 Camshaft runout 0 10 0 004 Cam chain pin at arrow 3 15th pin Cylinder head distortio...

Page 55: ...th 61 9 62 1 2 43 2 44 Crankshaft runout 0 08 0 003 Item Standard Limit Oil pressure at 60 C 140 F 20 60 kPa 0 2 0 6 kgf cm2 2 8 8 5 psi at 3 000 r min Item Standard Limit Clutch cable play 5 10 0 2 0 4 Drive plate thickness No 1 No 2 No 3 2 92 3 08 0 115 0 121 2 62 0 103 Drive plate claw width No 1 No 2 No 3 13 7 13 8 0 539 0 543 13 2 0 520 Driven plate distortion 0 10 0 004 Clutch spring free le...

Page 56: ...e amount 84 ml 2 8 3 0 US lmp qt and more 10 sec Fuel pressure regulator operating set pressure Approx 294 kPa 2 94 kgf cm2 42 psi Item Specification Note CKP sensor resistance 400 600 Ω CKP sensor peak voltage 1 0 V and more When cranking IAP sensor input voltage 4 5 5 5 V IAP sensor output voltage Approx 1 7 V at idle speed TP sensor input voltage 4 5 5 5 V TP sensor resistance Closed Approx 0 6...

Page 57: ... output 200 W at 5 000 r min Generator no load voltage When engine is cold 55 V AC and more at 5 000 r min Starter motor brush length Standard 10 0 39 Limit 6 5 0 26 Regulated voltage 13 5 15 0 V at 5 000 r min Starter relay resistance 3 6 Ω Battery Type designation YTX9 BS Capacity 12 V 28 8 kC 8 Ah 10 HR Fuse size Ignition 10 A Cooling fan 10 A Main 20 A Item Specification Headlight HI 40 LO 40 ...

Page 58: ...bsorber spring pre load length 288 5 11 36 Front suspension damping force adjuster Compression 1 and 1 4 turns out Rear shock absorber spring pre load length 234 8 9 24 Rear suspension damping force adjuster Rebound 1 and 1 4 turns out Compression 2 turns out Front wheel travel 215 8 5 Rear wheel travel 230 9 1 Swingarm pivot shaft runout 0 3 0 01 Item Specification Note Fuel type Use only unleade...

Page 59: ... Starter motor lead wire nut 6 0 6 4 5 Starter motor mounting bolt 10 1 0 7 0 Starter motor brush holder mounting nut 7 0 7 5 0 Starter motor housing bolt 3 0 3 2 0 Valve timing inspection plug 23 2 3 16 5 Engine mounting nut and bolt 66 6 6 47 5 Engine mounting bracket bolt 26 2 6 19 0 Exhaust pipe nut 23 2 3 16 5 Muffler connection bolt 23 2 3 16 5 Muffler mounting bolt 23 2 3 16 5 Starter clutc...

Page 60: ...Front brake pipe nut 16 1 6 11 5 Front brake pad mounting pin 18 1 8 13 0 Rear brake master cylinder rod lock nut 18 1 8 13 0 Rear brake pedal nut 11 1 1 8 0 Rear brake pad mounting pin 18 1 8 13 0 Rear brake caliper holder pin 18 1 8 13 0 Rear brake caliper holder slide pin 23 2 3 16 5 Brake lever pivot bolt 6 0 6 4 5 Brake lever pivot bolt lock nut 6 0 6 4 5 Parking brake bolt 23 2 3 16 5 Parkin...

Page 61: ...b 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 4 5 32 5 85 8 5 61 5 14 65 6 5 47 0 135 13 5 97 5 16 105 10 5 76 0 210 21 0 152 0 18 160 16 0 115 5 240 24 0 173 5 3 2 1 a a a I649G1030001 04 1 Conventional bolt 2 4 marked bolt 3 7 marked bolt P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 62: ...0C 9 Service Data P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 63: ...r Circuit Malfunction 1A 60 DTC C41 P0230 FP Relay Circuit Malfunction 1A 63 DTC C60 P0480 Cooling Fan Relay Circuit Malfunction 1A 65 Specifications 1A 67 Service Data 1A 67 Special Tools and Equipment 1A 68 Special Tool 1A 68 Emission Control Devices 1B 1 Precautions 1B 1 Precautions for Emission Control Devices 1B 1 Schematic and Routing Diagram 1B 1 Oil Return Tank Hose Routing Diagram 1B 1 Re...

Page 64: ...and Installation 1D 58 Crankshaft Oil Seal Inspection 1D 59 Crankshaft Oil Seal Removal and Installation 1D 59 Clutch Release Camshaft Removal and Installation 1D 59 Specifications 1D 60 Service Data 1D 60 Tightening Torque Specifications 1D 61 Special Tools and Equipment 1D 62 Recommended Service Material 1D 62 Special Tool 1D 62 Engine Lubrication System 1E 1 Precautions 1E 1 Precautions for Eng...

Page 65: ...tion System Components Location 1H 1 Diagnostic Information and Procedures 1H 2 Ignition System Symptom Diagnosis 1H 2 No Spark or Poor Spark 1H 3 Repair Instructions 1H 4 Spark Plug Cap and Spark Plug Removal and Installation 1H 4 Spark Plug Inspection and Cleaning 1H 4 Ignition Coil and Plug Cap Inspection 1H 4 CKP Sensor Inspection 1H 6 CKP Sensor Removal and Installation 1H 7 Engine Stop Switc...

Page 66: ...13 Service Data 1J 13 Tightening Torque Specifications 1J 13 Special Tools and Equipment 1J 14 Recommended Service Material 1J 14 Special Tool 1J 14 Exhaust System 1K 1 Precautions 1K 1 Precautions for Exhaust System 1K 1 Repair Instructions 1K 2 Exhaust System Construction 1K 2 Muffler Exhaust Pipe Removal and Installation 1K 3 Exhaust System Inspection 1K 4 Spark Arrester Inspection 1K 4 Specifi...

Page 67: ...ecautions Precautions Precautions for Engine B933H21000001 Refer to General Precautions in Section 00 Page 00 1 and Precautions for Electrical Circuit Service in Section 00 Page 00 2 P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 68: ...e factors to determine the injection time include the basic fuel injection time which is calculated on the basis of the intake air pressure engine speed and throttle opening angle and various compensations These compensations are determined according to the signals from various sensors that detect the engine and driving conditions I718H1110268 03 P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 69: ...he same time it monitors the voltage signal for compensation of the fuel injection time volume A longer injection time is needed to adjust injection volume in the case of low voltage ACCELERATION SIGNAL DECELERATION SIGNAL During acceleration the fuel injection time volume is increased in accordance with the throttle opening speed and engine rpm During deceleration the fuel injection time volume i...

Page 70: ...k the wiring harness between ECM and indicator panel couplers The possible cause of this indication is as follows Engine stop switch is in OFF position Ignition fuse is burnt NOTE The FI light blinks quickly two times a second when the engine coolant temperature becomes too high Dealer mode The defective function is memorized in the computer Use the special tool s coupler to connect to the mode se...

Page 71: ...ake air temperature sensor IATS Tip over sensor TOS Fuel injector FI Cooling fan relay Cooling fan 10A 10A 20A Starter switch Starter relay Starter motor Fuel indicator light FI light Ignition coil IG COIL to fuel sensor M Battery Engine stop switch Ignition switch Clutch lever position switch Fuel pump 2 5 6 1 9 25 22 24 18 21 17 30 13 14 15 33 16 3 Bl B R Y W B W B W B W Neutral indicator light ...

Page 72: ...or signal TP 23 6 IAP sensor signal IAP 24 Sensors ground E2 7 25 IAT sensor signal IAT 8 ECM ground E1 26 9 CKP sensor signal CKP 27 10 Serial data of self diagnosis 28 11 29 Reverse switch signal REV 12 Neutral switch NT 30 Starter motor STA 13 Power source for sensors VCC 31 14 Fuel pump power source FPP 32 15 Fuel pump FP 33 Cooling fan relay FAR 16 Injector 11 34 Mode select switch 17 Fuel in...

Page 73: ...ensor IATS C Engine coolant temperature sensor ECTS E Cooling fan B Ignition coil IG COIL D Cooling fan relay B E A F D G C ECM I933H1110007 02 A Intake air pressure sensor IAPS C Crankshaft position sensor CKPS E Fuel injector G Gear position switch B Throttle position sensor TPS D Tip over sensor TOS F Fuel pump FP P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 74: ...logged or defective fuel valve Clean or replace Engine will not start or is hard to start Incorrect fuel air mixture TP sensor out of adjustment Adjust Defective fuel pump Replace Defective TP sensor Replace Defective CKP sensor Replace Defective IAP sensor Replace Defective ECM Replace Defective ECT sensor Replace Defective IAT sensor Replace Engine idles poorly Valve clearance out of adjustment ...

Page 75: ...ace Worn splines Replace Worn or rubbing primary gears Replace Worn bearings Replace Engine noisy Noise seems to come from water pump Worn or damaged impeller shaft Replace Worn or damaged mechanical seal Replace Contact between pump case and impeller Replace Engine runs poorly in high speed range Defective engine internal electrical parts Weakened valve springs Replace Worn camshaft Replace Valve...

Page 76: ...ngine internal parts Heavy carbon deposit on piston crown Clean Not enough oil in the engine Add oil Defective oil pump or clogged oil circuit Replace or clean Use of incorrect engine oil Change Sucking air from intake pipe Retighten or replace Defective cooling system Refer to Engine Cooling Symptom Diagnosis in Section 1F Page 1F 4 Engine overheats Lean fuel air mixture Short circuited IAP senso...

Page 77: ...the special tool to the mode select switch coupler at the wiring harness Special tool A 09930 82720 Mode select switch 3 Start the engine or crank the engine for more than 4 seconds 4 Turn the special tool s switch ON 5 Check the DTC to determine the malfunction part Refer to DTC Table Page 1A 18 Special tool A 09930 82720 Mode select switch 6 After repairing the trouble turn OFF the ignition swit...

Page 78: ...ory can be checked by the SDS Be sure to read Precautions for Electrical Circuit Service in Section 00 Page 00 2 before inspection and observe what is written there 1 Remove the left side cover Refer to Exterior Parts Removal and Installation in Section 9D Page 9D 4 2 Set up the SDS tools Refer to the SDS operation manual for further details Special tool A 09904 41010 SDS set B 99565 01010 016 CD ...

Page 79: ...r to delete history code Past DTC Refer to Use of SDS Diagnosis Reset Procedures Page 1A 12 7 Close the SDS tool and turn the ignition switch OFF 8 Disconnect the SDS tool and install the left side cover Use of SDS Diagnosis Reset Procedures B933H21104003 NOTE The malfunction code is memorized in the ECM also when the wire coupler of any sensor is disconnected Therefore when a wire coupler has bee...

Page 80: ... Therefore it is possible to know engine and driving conditions e g whether the engine was warm or not where the vehicle was running or stopped when a malfunction was detected by checking the show data when trouble This show data when trouble function can record the maximum of two Diagnostic Trouble Codes in the ECM Also ECM has a function to store each show data when trouble for two different mal...

Page 81: ...and Diagnosis 1A 14 1 Click Show data when trouble 1 to display the data 2 Click the drop down button 2 either Failure 1 or Failure 2 can be selected 1 I718H1110269 02 2 I831G1110017 01 P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 82: ...eriodically brought in for service with no past data value having been saved if the data value of a good vehicle condition have been already saved as a master STD comparison between the same models helps to facilitate the troubleshooting 1 Remove the left side cover Refer to Exterior Parts Removal and Installation in Section 9D Page 9D 4 2 Set up the SDS tool Refer to the SDS operation manual for ...

Page 83: ...under no load Data at the time of racing Approx 3 000 r min Check the manifold absolute pressure XXX kPa Check the engine coolant temperature XX C I933H1110075 01 Throttle Quick wide open Throttle Slowly open I933H1110076 01 P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 84: ...determine how changes have occurred with the passing of time and identify what problem is currently occurring NOTE With DTC not output if the value of intake air temperature is found to be higher than the data saved previously the possible cause may probably lie in a sensor circuit opened ground circuit opened or influence of internal resistance value changes etc Check the manifold absolute pressu...

Page 85: ...7 Intake air temperature sensor IATS C23 Page 1A 52 Tip over sensor TOS C24 Page 1A 58 Ignition signal IG coil IG coil C31 Page 1A 58 Gear position signal GP switch GP switch C32 Page 1A 60 Injector signal FI Fuel injector C41 Page 1A 63 Fuel pump control system FP control system ECM C60 Page 1A 65 Cooling fan control system Cooling fan relay MCODE00C00 0 03 MCODE00C12 0 02 MCODE00C14 0 02 MCODE00...

Page 86: ...le to the workshop for complete repair EXAMPLE When CKP sensor and TO sensor defective DTC No 12 and 23 1 2 0 3 0 3 0 3 0 3 3 0 3 0 3 0 1 0 2 1 Time sec 3 2 3 2 1 0 ON OFF FI light Code No 12 Code No 23 Code No 12 Code No 23 0 3 0 3 0 3 0 3 0 3 0 3 0 3 0 3 I933H1110010 02 Item Fail Safe mode Starting ability Running ability IAP sensor Intake air pressure is fixed to 101 kPa 760 mmHg YES YES TP sen...

Page 87: ...n on acceleration No initial combustion Back fire After fire No combustion Lack of power Poor starting at Surging cold warm always Abnormal knocking Other Engine rpm jumps briefly Other Poor Idling Engine Stall when Poor fast Idle Immediately after start Abnormal idling speed Throttle valve is opened High Low r min Throttle valve is closed Unstable Load is applied Hunting r min to r min Other Othe...

Page 88: ...Malfunction code Detected item Detected failure condition Check for C00 NO FAULT C12 CKP sensor The signal does not reach ECM for 1 sec or more after receiving the IAP sensor input signal CKP sensor wiring and mechanical parts CKP sensor lead wire coupler connection P0335 C14 TP sensor The sensor should produce following voltage 0 4 V sensor voltage 4 5 V In other than the above range C14 P0120 is...

Page 89: ...oil is interrupted 5 times or more continuously In this case the code C24 P0351 is indicated Ignition coil wiring coupler connection power supply from the battery P0351 C31 Gear position signal Gear position signal voltage should be higher than the following for 3 seconds and more Gear position sensor voltage 0 9 V If lower than the above value C31 P0705 is indicated GP switch wiring coupler conne...

Page 90: ...S tool Refer to Use of SDS Diagnosis Reset Procedures Page 1A 12 Detected condition Possible cause The signal does not reach ECM for 1 sec or more after receiving the IAP sensor input signal Metal particles or foreign material being stuck on the CKP sensor and rotor tip CKP sensor circuit open or short CKP sensor malfunction ECM malfunction ECM CKP sensor G W Bl G BI CKP 3 CKP 9 I933H1110011 03 I9...

Page 91: ...sure the resistance Special tool A 09900 25008 Multi circuit tester set Tester knob indication Resistance Ω CKP sensor resistance 400 600 Ω Bl G 4 If OK then check the continuity between each terminal and ground CKP sensor continuity Ω Infinity Bl Ground G Ground Are the resistance and continuity OK Go to Step 2 Replace the CKP sensor with a new one I933H1110013 01 A I933H1110014 01 A I933H1110015...

Page 92: ...r contacts on the CKP sensor coupler or ECM coupler terminal 3 or 9 If wire and connection are OK intermittent trouble or faulty ECM Recheck each terminal and wire harness for open circuit and poor connection Replace the ECM with a known good one and inspect it again Refer to ECM Removal and Installation in Section 1C Page 1C 2 Inspect that metal particles or foreign material stuck on the CKP sens...

Page 93: ...et Procedures Page 1A 12 Detected condition Possible cause C14 Output voltage is not within the following range Difference between actual throttle opening and opening calculated by ECM is larger than specified value 0 4 V Sensor voltage 4 5 V TP sensor maladjusted TP sensor circuit open or short TP sensor malfunction ECM malfunction P0120 H Sensor voltage is higher than specified value TP sensor c...

Page 94: ... sensor coupler 5 Turn the ignition switch ON 6 Measure the input voltage at the R wire and ground If OK then measure the input voltage at the R wire and B Br wire C Special tool A 09900 25008 Multi circuit tester set B 09900 25009 Needle pointed probe set Tester knob indication Voltage TP sensor input voltage 4 5 5 5 V terminal R terminal Ground terminal R terminal B Br Is the continuity OK Go to...

Page 95: ...loose or poor contacts If OK then check the TP sensor lead wire continuity 4 Disconnect the TP sensor coupler 5 Check the continuity between Y wire and R wire If sound is not heard from the tester the circuit condition is OK Special tool A 09900 25008 Multi circuit tester set B 09900 25009 Needle pointed probe set Tester knob indication Continuity Go to Step 2 Y wire shorted to VCC or B Br wire op...

Page 96: ...ide Is the continuity OK Go to Step 2 Y wire shorted to VCC or B Br wire open Step Action Yes No B A 24 5 I933H1110021 01 Step Action Yes No 1 1 Turn the ignition switch OFF 2 Remove the fuel pump mounting bolts and move the fuel pump Refer to TP Sensor Removal and Installation in Section 1C Page 1C 3 3 Check the TP sensor coupler for loose or poor contacts If OK then check the TP sensor lead wire...

Page 97: ...09 Needle pointed probe set Tester knob indication Continuity test 6 Disconnect the ECM coupler Refer to ECM Removal and Installation in Section 1C Page 1C 2 7 Check the continuity between Y wire and terminal 5 Also check the continuity between R wire and terminal 13 Tester knob indication Continuity test ECM coupler Harness side Is the continuity OK Go to Step 2 Y or R wire open or Y wire shorted...

Page 98: ...erminal R terminal B Br In the voltage OK Go to Step 3 Open or short circuit in the R wire or B Br wire 3 1 Turn the ignition switch OFF 2 Connect the test harness the TP sensor 3 Check the continuity between terminal A Y wire and ground Special tool A 09900 25008 Multi circuit tester set C 09900 28630 TPS test wire harness Tester knob indication Resistance Ω TP sensor resistance Ω Infinity termin...

Page 99: ... Approx 3 8 kΩ 6 If OK then measure the TP sensor resistance at the test harness terminals between terminal B R wire and terminal C B Br wire TP sensor resistance Approx 5 0 kΩ Terminal B R wire Terminal C B Br wire Are the continuity and resistance OK Go to Step 4 Reset the TP sensor position correctly Replace the TP sensor with a new one Step Action Yes No ECM TPS B Br R Y C C A I933H1110073 02 ...

Page 100: ...pened Approx 3 8 V terminal Y terminal B Br Is the voltage OK Y R or B Br wire open or shorted to ground or poor 5 13 or 24 connection If wire and connection are OK intermittent trouble or faulty ECM Recheck each terminal and wire harness for open circuit and poor connection Replace the ECM with a known good one and inspect it again Refer to ECM Removal and Installation in Section 1C Page 1C 2 If ...

Page 101: ...pairing the trouble clear the DTC using SDS tool Refer to Use of SDS Diagnosis Reset Procedures Page 1A 12 Detected condition Possible cause C15 Output voltage is not with in the following range 0 2 V Sensor voltage 4 9 V ECT sensor circuit open or short ECT sensor malfunction ECM malfunction P0115 H Sensor voltage is higher than specified value ECT sensor circuit is open or ground circuit open L ...

Page 102: ...etween the B Bl wire terminal and ground If OK then measure the input voltage between B Bl wire terminal and B Br wire terminal Special tool A 09900 25008 Multi circuit tester set B 09900 25009 Needle pointed probe set Tester knob indication Voltage ECT sensor voltage 4 5 5 5 V terminal B Bl terminal Ground terminal B Bl terminal B Br Is the voltage OK Go to Step 2 Loose or poor contacts on the EC...

Page 103: ...M coupler Refer to ECM Removal and Installation in Section 1C Page 1C 2 5 Check the continuity between B Bl wire and terminal 22 Also check the continuity between B Br wire and terminal 24 Special tool A 09900 25008 Multi circuit tester set B 09900 25009 Needle pointed probe set Tester knob indication Continuity test ECM coupler Harness side Is the continuity OK Go to Step 2 B Bl or B Br wire open...

Page 104: ...ween B Bl wire and ground If sound is not heard from the tester the circuit condition is OK Special tool A 09900 25008 Multi circuit tester set B 09900 25009 Needle pointed probe set Tester knob indication Continuity test 5 Connect the ECT sensor coupler 6 Insert the needle pointed probes to the lead wire coupler 7 Turn the ignition switch ON Go to Step 2 B Bl wire shorted to ground If wire is OK ...

Page 105: ...circuit tester set B 09900 25009 Needle pointed probe set Tester knob indication Voltage ECT sensor output voltage 0 2 4 9 V terminal B Bl terminal Ground Are the continuity and voltage OK Go to Step 2 B Bl wire shorted to ground If wire is OK go to Step 2 Step Action Yes No V B A I933H1110043 01 P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 106: ...or resistance Approx 2 6 kΩ at 20 C 68 F Terminal Terminal NOTE Refer to ECT Sensor Inspection in Section 1C Page 1C 6 for details Is the resistance OK B Bl or B Br wire open or shorted to ground or poor 22 or 24 connection If wire and connection are OK intermittent trouble or faulty ECM Recheck each terminal and wire harness for open circuit and poor connection Replace the ECM with a known good o...

Page 107: ...to consideration when inspecting voltage Clogged vacuum passage between throttle body and IAP sensor Air being drawn from vacuum passage between throttle body and IAP sensor IAP sensor circuit open or shorted to the ground IAP sensor malfunction ECM malfunction P0105 H Sensor voltage is higher than specified value IAP sensor circuit is open or shorted to VCC or ground circuit open L Sensor voltage...

Page 108: ...eck the IAP sensor coupler for loose or poor contacts If OK then measure the IAP sensor input voltage 3 Disconnect the IAP sensor coupler 4 Turn the ignition switch ON 5 Measure the voltage at the R wire and ground If OK then measure the voltage at the R wire and B Br wire Special tool A 09900 25008 Multi circuit tester set B 09900 25009 Needle pointed probe set Tester knob indication Voltage IAP ...

Page 109: ...ool A 09900 25008 Multi circuit tester set B 09900 25009 Needle pointed probe set Tester knob indication Continuity 5 Disconnect the ECM coupler Refer to ECM Removal and Installation in Section 1C Page 1C 2 6 Check the continuity between the G B wire and terminal 16 If OK then check the continuity between the B Br wire and terminal 24 Tester knob indication Continuity test ECM coupler Harness side...

Page 110: ...he G B wire and ground Also check the continuity between the G B wire and B Br wire If the sound is not heard from the tester the circuit condition is OK Special tool A 09900 25008 Multi circuit tester set B 09900 25009 Needle pointed probe set Tester knob indication Continuity 5 Disconnect the ECM coupler Refer to ECM Removal and Installation in Section 1C Page 1C 2 Go to Step 2 R and G B wire op...

Page 111: ... Turn the ignition switch ON 3 Measure the input voltage at the R wire and ground If OK the measure the input voltage at the R wire and B Br wire Special tool A 09900 25008 Multi circuit tester set B 09900 25009 Needle pointed probe set Tester knob indication Voltage IAP sensor input voltage 4 5 5 5 V terminal R terminal Ground terminal R terminal B Br Is the voltage OK Go to Step 3 Open or short ...

Page 112: ...l tool A 09900 25008 Multi circuit tester set B 09900 25009 Needle pointed probe set Tester knob indication Voltage IAP sensor output voltage Approx 1 7 V at idle speed terminal G B terminal B Br Is the voltage OK Go to Step 4 Check the vacuum hose for crack or damage Open or short circuit in the G B wire If vacuum hose and wire is OK replace the IAP sensor with a new one Refer to IAP Sensor Remov...

Page 113: ...ltage Is the voltage OK G B R or B Br wire open or shorted to ground or poor 6 13 or 24 connection If wire and connection are OK intermittent trouble or faulty ECM Recheck each terminal and wire harness for open circuit and poor connection Replace the ECM with a known good one and inspect it again Refer to ECM Removal and Installation in Section 1C Page 1C 2 If check result is not satisfactory rep...

Page 114: ... repairing the trouble clear the DTC using SDS tool Refer to Use of SDS Diagnosis Reset Procedures Page 1A 12 Detected condition Possible cause C21 Output voltage is not with in the following range 0 2 V Sensor voltage 4 9 V IAT sensor circuit open or short IAT sensor malfunction ECM malfunction P0110 H Sensor voltage is higher than specified value IAT sensor circuit open or ground circuit open L ...

Page 115: ... 4 Measure the voltage between the Dg wire terminal and ground If OK then measure the input voltage between Dg wire terminal and B Br wire terminal Special tool A 09900 25008 Multi circuit tester set Tester knob indication Voltage IAT sensor input voltage 4 5 5 5 V terminal Dg terminal Ground terminal Dg terminal B Br Is the voltage OK Go to Step 2 Loose or poor contacts on the ECM coupler Open or...

Page 116: ...to ECM Removal and Installation in Section 1C Page 1C 2 5 Check the continuity between the Dg wire and terminal 25 Also check the continuity between the B Br wire and terminal 24 Special tool A 09900 25008 Multi circuit tester set B 09900 25009 Needle pointed probe set Tester knob indication Continuity test ECM coupler Harness side Is the continuity OK Connect the ECM coupler and go to step 2 Dg o...

Page 117: ...the continuity between the Dg wire and ground If the sound is not heard from the tester the circuit condition is OK Special tool A 09900 25008 Multi circuit tester set Tester knob indication Continuity test 5 Connect the IAT sensor coupler 6 Turn the ignition switch ON 7 Insert the needle pointed probes to the lead wire coupler Go to Step 2 Dg wire shorted to ground If wire is OK go to Step 2 I933...

Page 118: ...stance Ω IAT sensor resistance Approx 2 6 kΩ at 20 C 68 F Terminal Terminal NOTE IAT sensor resistance measurement method is the same way as that of the ECT sensor Refer to ECT Sensor Inspection in Section 1C Page 1C 6 Is the resistance OK B Br or Dg wire open or shorted to ground or poor 24 or 25 connection If wire and connection are OK intermittent trouble or faulty ECM Recheck each terminal and...

Page 119: ...DS tool Refer to Use of SDS Diagnosis Reset Procedures Page 1A 12 Detected condition Possible cause C23 The sensor voltage should be the following for 2 sec and more after ignition switch is turned ON 0 2 V Sensor voltage 4 7 V TO sensor circuit open or short TO sensor malfunction ECM malfunction P1651 H Sensor voltage is higher than specified value TO sensor circuit open or shorted to VCC or grou...

Page 120: ...the TO sensor resistance 4 Remove the TO sensor and disconnect the TO sensor coupler 5 Measure the resistance between terminal A and terminal B Special tool A 09900 25008 Multi circuit tester set Tester knob indication Resistance Ω TO sensor resistance 15 0 25 0 kΩ Terminal A Terminal C Is the resistance OK Go to Step 2 Replace the TO sensor with a new one Refer to TO Sensor Removal and Installati...

Page 121: ...re continuity 4 Dismount the TO sensor and disconnect the TO sensor coupler 5 Check the continuity between the R wire and B Br wire If the sound is not heard from the tester the circuit condition is OK Special tool A 09900 25008 Multi circuit tester set Tester knob indication Continuity test 6 Disconnect the ECM coupler Refer to ECM Removal and Installation in Section 1C Page 1C 2 Go to Step 2 Br ...

Page 122: ... Br W wire shorted to VCC or B Br wire open Step Action Yes No B A 2 24 I933H1110056 02 Step Action Yes No 1 1 Turn the ignition switch OFF 2 Remove the left side cover Refer to Exterior Parts Removal and Installation in Section 9D Page 9D 4 3 Check the TO sensor coupler for loose or poor contacts If OK then check the TO sensor lead wire continuity 4 Dismount the TO sensor and disconnect the TO se...

Page 123: ...nuity test 6 Disconnect the ECM coupler Refer to ECM Removal and Installation in Section 1C Page 1C 2 7 Check the continuity between R wire and terminal 13 Also then check the continuity between Br W wire and terminal 2 Special tool B 09900 25009 Needle pointed probe set Tester knob indication Continuity test Is the continuity OK Go to Step 2 R or B wire open or Br W wire shorted to the ground Ste...

Page 124: ...tal level Tester knob indication Voltage TO sensor voltage Leaning 3 7 4 4 V terminal Br W terminal B Br Is the voltage OK Br W R or B Br wire open or shorted to ground or poor 2 13 or 24 connection If wire and connection are OK intermittent trouble or faulty ECM Recheck each terminal and wire harness for open circuit and poor connection Replace the ECM with a known good one and inspect it again R...

Page 125: ...sible cause Wiring diagram ECM coupler Harness side Detected condition Possible cause No gear position switch voltage GP switch voltage is not within the following range GP switch voltage 0 9 V GP switch circuit open or short GP switch malfunction ECM malfunction Neutral indicator light N 1 5 4 2 3 ECM Ignition switch BI W B W BI B GP E1 W 8 4 R Y R R GP switch Reverse indicator light B W I933H111...

Page 126: ...al tool A 09900 25008 Multi circuit tester set B 09900 25009 Needle pointed probe set Tester knob indication Voltage GP switch voltage 0 9 V and more terminal W terminal B W Is the voltage OK W wire open or shorted to ground If wire and connection are OK intermittent trouble or faulty ECM Recheck each terminal and wire harness for open circuit and poor connection Replace the ECM with a known good ...

Page 127: ...oupler Harness side Detected condition Possible cause CKP signal is produced but fuel injector signal is interrupted by 8 times or more continuity Injector circuit open or short Injector malfunction ECM malfunction ECM Fuel injector Gr W O W O W 11 FPP Engine stop switch Ignition switch 13 16 I933H1110063 02 I933H1110012 02 P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 128: ... Installation in Section 1G Page 1G 9 3 Check the injector coupler for loose or poor contacts If OK then measure the injector resistance 4 Disconnect the injector coupler and measure the resistance between terminals Special tool A 09900 25008 Multi circuit tester set Tester knob indication Resistance Ω Injector resistance 9 17 Ω at 20 C 68 F Terminal Terminal Go to Step 2 Replace the injector with...

Page 129: ...nect the ignition switch coupler and turn the ignition switch ON 3 Measure the injector voltage between O W wire and ground Special tool A 09900 25008 Multi circuit tester set B 09900 25009 Needle pointed probe set Tester knob indication Voltage Injector voltage Battery voltage terminal O W terminal Ground Is the voltage OK Gr W wire open or shorted to ground or poor 16 connection If wire and conn...

Page 130: ...e pointed tester probe to prevent the terminal damage or terminal bend NOTE After repairing the trouble clear the DTC using SDS tool Refer to Use of SDS Diagnosis Reset Procedures Page 1A 12 Detected condition Possible cause No voltage is applied to fuel pump although FP relay is turned ON FP relay circuit open or short FP relay ECM malfunction ECM Fuel pump relay Fuel pump M FPP FP R B Engine sto...

Page 131: ...een terminal 14 and ground Special tool A 09900 25008 Multi circuit tester set B 09900 25009 Needle pointed probe set Tester knob indication Voltage FP relay input voltage Battery voltage Is the voltage OK FP relay ECM malfunction O W or R B wire open or shorted or poor terminal 14 or 15 connection If the wire and connection are OK intermittent trouble or faulty ECM Recheck each terminal and wire ...

Page 132: ... possible cause Wiring diagram ECM coupler Harness side Detected condition Possible cause Cooling fan relay signal is not input to ECM Cooling fan relay circuit open or short ECM malfunction ECM Ignition switch FAR Y B O Y Cooling fan motor Cooling fan relay 33 I933H1110071 01 I933H1110012 02 P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 133: ...ion switch OFF 2 Remove the front fender Refer to Exterior Parts Removal and Installation in Section 9D Page 9D 4 3 Check the cooling fan relay coupler for loose or poor contacts If OK then inspection the cooling fan relay Refer to Cooling Fan Relay Inspection in Section 1F Page 1F 10 Is the cooling fan relay OK O Y and Y B wire open or shorted to ground or poor 33 connection If wire and connectio...

Page 134: ...put voltage Approx 1 7 V at idle speed TP sensor input voltage 4 5 5 5 V TP sensor resistance Closed Approx 0 6 kΩ Opened Approx 3 8 kΩ TP sensor output voltage Closed Approx 0 6 V Opened Approx 3 8 V ECT sensor input voltage 4 5 5 5 V ECT sensor output voltage 0 2 4 9 V ECT sensor resistance Approx 2 6 kΩ at 20 C 68 F IAT sensor input voltage 4 5 5 5 V IAT sensor output voltage 0 2 4 9 V IAT sens...

Page 135: ...1 Page 1A 51 Page 1A 53 Page 1A 54 Page 1A 56 Page 1A 57 Page 1A 59 Page 1A 61 Page 1A 62 Page 1A 64 Page 1A 27 Page 1A 28 Page 1A 30 Page 1A 31 Page 1A 35 Page 1A 36 Page 1A 37 Page 1A 38 Page 1A 41 Page 1A 42 Page 1A 43 Page 1A 44 Page 1A 45 Page 1A 49 Page 1A 51 Page 1A 55 Page 1A 56 Page 1A 57 Page 1A 59 Page 1A 62 Page 1A 64 09900 28630 09904 41010 TPS test wire harness SDS set Page 1A 31 Pag...

Page 136: ...3H21206001 Inspect the PCV hose in the following procedures 1 Remove the fuel tank cover and front fender Refer to Exterior Parts Removal and Installation in Section 9D Page 9D 4 2 Remove the fuel tank lower cover Refer to Fuel Tank Removal and Installation in Section 1G Page 1G 9 1 1 2 Forward a A B 3 I933H1120006 08 1 Breather hose A Keep clearance between clip and ribbed of tank 2 Engine oil re...

Page 137: ...emoval the front fender and fuel tank cover Refer to Exterior Parts Removal and Installation in Section 9D Page 9D 4 2 Remove the fuel tank Refer to Fuel Tank Removal and Installation in Section 1G Page 1G 9 3 Disconnect the breather hoses 1 4 Remove the oil return tank 2 Installation 1 Install the oil return tank and connect the breather hoses Refer to Engine Oil Hose and Pipe Routing Diagram in ...

Page 138: ... and Precautions for Electrical Circuit Service in Section 00 Page 00 2 Component Location Engine Electrical Components Location B933H21303001 Refer to Electrical Components Location in Section 0A Page 0A 7 Diagnostic Information and Procedures Engine Symptom Diagnosis B933H21304001 Refer to Engine Symptom Diagnosis in Section 1A Page 1A 7 P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 139: ...he CKP sensor in the reverse order of removal Refer to Generator Removal and Installation in Section 1J Page 1J 5 IAP Sensor Inspection B933H21306004 Refer to DTC C17 P1750 H L IAP Sensor Circuit Malfunction in Section 1A Page 1A 40 IAP Sensor Removal and Installation B933H21306005 Removal 1 Remove the fuel tank cover and front fender Refer to Exterior Parts Removal and Installation in Section 9D ...

Page 140: ...NOTE Apply thin coat of engine oil to the O ring 2 Align the throttle shaft end A with the groove B of the TP sensor Apply grease to the throttle shaft end A if necessary Grease 99000 25160 Water resistance grease or equivalent Special tool 09930 11950 Torx wrench 2 Make sure the throttle lever smoothly push and release 3 For TP sensor setting procedure refer to TP Sensor Adjustment Page 1C 4 4 Ti...

Page 141: ...output voltage 0 6 3 8 V terminal Y terminal B Br 7 If the TP sensor adjustment is necessary loosen the TP sensor mounting screw with the special tool Special tool 09930 11950 Torx wrench 8 Turn the TP sensor 2 and adjust the TP sensor until the output voltage comes within to specified valve 9 Tighten the TP sensor mounting screw with the special tool Special tool 09930 11950 Torx wrench 10 Turn O...

Page 142: ...orque IAT sensor mounting screw a 2 5 N m 0 25 kgf m 2 0 lb ft ECT Sensor Removal and Installation B933H21306011 Removal 1 Drain engine coolant Refer to Cooling System Inspection in Section 0B Page 0B 13 2 Disconnect the coupler 1 and remove the ECT sensor 2 CAUTION Take special care when handling the ECT sensor It may cause damage if it gets an excessive impact Installation Install the ECT sensor...

Page 143: ...ial tool A 09900 25008 Multi circuit tester set Tester knob indication Resistance Ω Temperature sensor specification 4 Install the ECT sensor Refer to ECT Sensor Removal and Installation Page 1C 5 TO Sensor Inspection B933H21306013 Refer to DTC C23 P1651 H L TO Sensor Circuit Malfunction in Section 1A Page 1A 52 TO Sensor Removal and Installation B933H21306014 Removal 1 Remove the left side cover ...

Page 144: ... 5 5 V TP sensor resistance Closed Approx 0 6 kΩ Opened Approx 3 8 kΩ TP sensor output voltage Closed Approx 0 6 V Opened Approx 3 8 V ECT sensor input voltage 4 5 5 5 V ECT sensor output voltage 0 2 4 9 V ECT sensor resistance Approx 2 6 kΩ at 20 C 68 F IAT sensor input voltage 4 5 5 5 V IAT sensor output voltage 0 2 4 9 V IAT sensor resistance Approx 2 6 kΩ at 20 C 68 F TO sensor resistance 15 0...

Page 145: ...rial SUZUKI recommended product or Specification Note Grease Water resistance grease or equivalent P No 99000 25160 Page 1C 3 09900 25008 09900 28630 Multi circuit tester set TPS test wire harness Page 1C 4 Page 1C 6 Page 1C 4 09930 11950 Torx wrench Page 1C 3 Page 1C 3 Page 1C 4 Page 1C 4 P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 146: ...t the battery is in fully charged condition 1 Warm up the engine 2 Remove the fuel tank lower cover Refer to Fuel Tank Removal and Installation in Section 1G Page 1G 9 3 Remove the spark plug Refer to Spark Plug Cap and Spark Plug Removal and Installation in Section 1H Page 1H 4 4 Install the compression gauge and adaptor in the spark plug hole Make sure that the connection is tight Special tool A...

Page 147: ... 1D 13 Refer to Throttle Body Removal and Installation Page 1D 9 Cam chain tension adjuster Refer to Engine Top Side Disassembly Page 1D 17 Refer to Cam Chain Tension Adjuster Inspection Page 1D 28 Refer to Engine Top Side Assembly Page 1D 20 Cylinder head cover Refer to Engine Top Side Disassembly Page 1D 17 Refer to Engine Top Side Assembly Page 1D 20 Cylinder head Refer to Engine Top Side Disas...

Page 148: ...r drive driven gear Refer to Engine Bottom Side Disassembly Page 1D 41 Refer to Engine Bottom Side Assembly Page 1D 48 Water pump Refer to Water Pump Removal and Installation in Section 1F Page 1F 13 Refer to Water Pump Related Parts Inspection in Section 1F Page 1F 16 Refer to Water Pump Removal and Installation in Section 1F Page 1F 13 Item Removal Inspection Installation Generator Refer to Gene...

Page 149: ...emoval and Installation in Section 9D Page 9D 4 2 Remove the air cleaner duct 1 and disconnect the PCV breather hose 2 3 Loosen the air cleaner box clamp screw 3 CKP sensor Refer to Generator Removal and Installation in Section 1J Page 1J 5 Refer to CKP Sensor Inspection in Section 1H Page 1H 6 Refer to Generator Removal and Installation in Section 1J Page 1J 5 Starter torque limiter Refer to Star...

Page 150: ...fer to Hose and Cable Routing Diagram in Section 4A Page 4A 3 Installation Install the throttle cable in the reverse order of removal Pay attention to the following points Install the throttle cable as shown in the cable routing diagram Refer to Hose and Cable Routing Diagram in Section 4A Page 4A 3 Check the throttle cable play and proper operation Refer to Throttle Cable Play Inspection and Adju...

Page 151: ...nstallation Install the starter cable in the reverse order of removal Pay attention to the following points Install the starter cable as shown in the cable routing diagram Refer to Hose and Cable Routing Diagram in Section 4A Page 4A 3 Align the groove of starter valve with the starter cable end Connect the starter cable 1 to the starter lever Apply grease to the end of starter cable 1 Grease 9900...

Page 152: ...3 8 7 1 6 5 4 2 FWD FWD I933H1140018 07 1 TP sensor 4 L joint 7 Idle air screw Apply engine oil 2 IAP sensor 5 Fuel delivery pipe 8 Starter valve Do not reuse 3 Throttle body 6 Fuel injector Apply water resistance grease P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 153: ...tlet tube clamp RH LH RH LH Upper Upper 1 a 4 5 a 7 A 6 a 2 3 A 5 A I933H1140241 07 1 Throttle body 5 Fuel vapor return hose A White mark 2 Fuel valve 6 Air cleaner box a 10 30 3 Fuel feed hose 7 Fuel pump 4 Fuel tank 10 N m 1 0 kgf m 7 0 lb ft P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 154: ...age 1B 2 4 Disconnect the TP sensor lead wire coupler 1 5 Disconnect the fuel injector lead wire coupler 2 and IAP sensor lead wire coupler 3 6 Remove the throttle cable cover 4 7 Disconnect the throttle cable from drum CAUTION After disconnecting the throttle cable do not snap the throttle valve from full open to full close It may cause damage to the throttle valves and throttle body 8 Disconnect...

Page 155: ...nd Adjustment Page 1D 5 Throttle Body Disassembly and Assembly B933H21406013 Refer to Throttle Body Removal and Installation Page 1D 9 Disassembly 1 Remove the L joint 1 from the fuel delivery pipe 2 2 Remove the fuel delivery pipe 2 with the fuel injector 3 3 Remove the fuel injector 3 from the fuel delivery pipe 2 4 Remove the TP sensor 4 with the special tool Special tool 09930 11950 Torx wrenc...

Page 156: ...e O ring with a new one Apply thin coat of engine oil to the O ring With the throttle valve fully closed install the TP sensor 1 and tighten the TP sensor mounting screw NOTE Align the throttle shaft end A with the groove B of TP sensor Apply grease to the throttle shaft end A if necessary Grease 99000 25160 Water resistance grease or equivalent Special tool 09930 11950 Torx wrench 8 I933H1140030 ...

Page 157: ...el injector 4 by pushing it straight to the delivery pipe 5 CAUTION Never turn the injector 4 while pushing it NOTE Align the coupler C of injector with boss D of the delivery pipe Install the fuel injector 4 by pushing it straight to throttle body CAUTION Never turn the fuel injector 4 while pushing it Apply a thin coat of engine oil to the O ring CAUTION Replace the O ring with a new one I933H11...

Page 158: ...may be necessary to use a dip type cleaning solution and allow them to soak Always follow the chemical manufacturer s instructions for proper use and cleaning of the throttle body components Do not apply carburetor cleaning chemicals to the rubber and plastic materials Inspection Check following items for any defects or clogging Replace the throttle body if necessary O ring Throttle valve Idle air...

Page 159: ...Pipe Removal and Installation in Section 1K Page 1K 3 11 Disconnect the engine coolant outlet hose 8 12 Disconnect the fuel pump lead wire coupler 9 and remove the fuel pump 10 13 Disconnect the ECT sensor coupler 11 14 Remove the throttle body 12 Refer to Throttle Body Removal and Installation Page 1D 9 15 Remove the clutch cable bracket 13 16 Disconnect the clutch release arm 14 along with the c...

Page 160: ...GP switch coupler 21 20 Disconnect the clamp 21 Remove the engine sprocket 22 with drive chain 22 Remove the gear shift lever 23 and spacers NOTE Mark the gearshift shaft head at which the gearshift lever slit set for correct reinstallation 23 Support the engine with a proper jack 24 Remove the engine mounting brackets 24 15 I933H1140049 05 18 16 17 I933H1140050 01 21 19 20 I933H1140051 01 I933H11...

Page 161: ...n Tank Removal and Installation in Section 1B Page 1B 2 Install the fuel pump Refer to Fuel Pump Removal and Installation in Section 1G Page 1G 13 Install the exhaust pipe Refer to Muffler Exhaust Pipe Removal and Installation in Section 1K Page 1K 3 Install the fuel tank Refer to Fuel Tank Removal and Installation in Section 1G Page 1G 9 Install the oil tank hoses Refer to Engine Oil Pipe Removal...

Page 162: ...s e g intake exhaust so that they can be reinstalled in their original positions Cylinder head cover 1 Remove the fuel tank cover and front fender Refer to Exterior Parts Removal and Installation in Section 9D Page 9D 4 2 Remove the fuel tank and fuel tank lower cover Refer to Fuel Tank Removal and Installation in Section 1G Page 1G 9 3 Disconnect the oil tank overflow hose 1 and breather hose 2 4...

Page 163: ... drop the dowel pins and camshaft drive chain into the crankcase Cylinder head 1 Remove the exhaust pipe 1 Refer to Muffler Exhaust Pipe Removal and Installation in Section 1K Page 1K 3 2 Disconnect the ECT sensor coupler 2 and radiator inlet hose 3 3 Remove the throttle body Refer to Throttle Body Removal and Installation Page 1D 9 4 Remove the engine mounting bracket 4 5 Remove the cylinder head...

Page 164: ...emove the cam chain guide No 1 2 and cylinder 3 NOTE If the cylinder does not come off easily lightly top using a plastic hammer 3 Remove the cylinder gasket 4 and dowel pins Piston 1 Place a clean rag over the cylinder base to prevent the piston pin circlip from dropping into the crankcase 2 Remove each piston pin circlip 1 3 Draw out the piston pin 2 and remove the piston 3 I933H1140069 01 7 I93...

Page 165: ... which will occur when it is bent NOTE End gap of the circlip 1 should not be aligned with the cutaway in the piston pin bore Position the gaps of the three rings and side rails as shown in the figure Before inserting piston into the cylinder check that the gaps are so located Cylinder Thoroughly wipe off oil from the fitting surface of the crankcase Apply bond to the crankcase A as shown in the f...

Page 166: ...nd cylinder head gasket 2 CAUTION Use a new gasket to prevent gas leakage Place the cylinder head 3 on the cylinder NOTE When installing the cylinder head 3 keep the cam chain taut NOTE Apply engine oil to the threaded parts of the cylinder head bolts and both sides of the its washers Be sure to install the washer with rounded side facing up Tighten the cylinder head bolts M10 to the specified two...

Page 167: ... kgf m 19 0 lb ft Engine mounting nut d 66 N m 6 6 kgf m 47 5 lb ft Install the throttle body Refer to Throttle Body Removal and Installation Page 1D 9 Connect the radiator inlet hose 6 and ECT sensor coupler 7 Install the exhaust pipe 8 Refer to Muffler Exhaust Pipe Removal and Installation in Section 1K Page 1K 3 Camshaft Turn the crankshaft counterclockwise and align the T line on the generator...

Page 168: ...r head Engage the cam chain with the exhaust camshaft sprocket The other arrow marked 2 B should now be pointing straight up Starting from the roller pin that is directly above the arrow marked 2 B count out 15 roller pins from the exhaust camshaft side going towards the intake camshaft side Engage the 15th roller pin on the cam chain with the arrow marked 3 C on the intake sprocket NOTE The cam c...

Page 169: ...uster 4 NOTE Make sure that the UP mark A comes to the upper side Tighten the cam chain tension adjuster mounting bolts to the specified torque Tightening torque Cam chain tension adjuster mounting bolt a 10 N m 1 0 kgf m 7 0 lb ft Install the spring 5 Install the gasket 6 and cam chain tension spring holder bolt 7 NOTE Click sound is heard when the cam chain tension spring holder bolt is installe...

Page 170: ...N m 1 5 kgf m 11 0 lb ft Valve timing inspection plug d 23 N m 2 3 kgf m 16 5 lb ft Install the oil return tank Refer to Oil Return Tank Removal and Installation in Section 1B Page 1B 2 Cylinder head cover Thoroughly wipe off oil from the fitting surfaces of the cylinder head and cover Apply bond to the end caps of the cylinder head cover gasket as shown in the figure Sealant 99000 31140 SUZUKI BO...

Page 171: ...sprocket Inspect the teeth of each camshaft sprocket for wear or damage If they are worn or damaged replace the camshaft and cam chain as a set Automatic decompression Move the automatic decompression weight by hand to inspect if it is operating smoothly If the automatic decompression weight does not operate smoothly replace it with a new one Cam wear Check the camshaft for wear or damage Measure ...

Page 172: ... bolt a 10 N m 1 0 kgf m 7 0 lb ft 5 Remove the camshaft journal holders and measure the width of the compressed plastigauge using the envelope scale 6 This measurement should be taken at the widest part of the compressed plastigauge Camshaft journal oil clearance IN EX Service limit 0 150 mm 0 0059 in 7 If the camshaft journal oil clearance exceeds the limit measure the inside diameter of the cam...

Page 173: ...isassembly Page 1D 17 2 Remove the cam chain guide No 1 1 NOTE Be careful not to drop the chain into the crankcase 3 Remove the cylinder head cover Refer to Engine Top Side Disassembly Page 1D 17 4 Remove the cam chain guide No 2 2 Installation Install the cam chain guide in the reverse order of removal Cam Chain Guide Inspection B933H21406023 Inspect the cam chain No 1 and No 2 guides in the foll...

Page 174: ...utch Installation in Section 5C Page 5C 9 8 Reinstall the cylinder head Refer to Engine Top Side Assembly Page 1D 20 Cylinder Head Disassembly and Assembly B933H21406025 Refer to Engine Top Side Disassembly Page 1D 17 and Engine Top Side Assembly Page 1D 20 CAUTION Identify the position of each removed part Organize the parts in their respective groups i e intake exhaust so that they can be instal...

Page 175: ...rs 5 Remove the valve spring retainer 5 and valve spring 6 6 Pull out the valve 7 from the combustion chamber side 7 Remove the oil seal 8 and spring seat 9 8 Remove the other valves in the same manner as described previously 9 Remove the ECT sensor 10 10 Remove the thermostat case 11 and thermostat 12 11 Remove the intake pipe 13 12 Remove the oil gallery plug cylinder head 14 4 B C I933H1140118 ...

Page 176: ...s Grease 99000 25010 SUZUKI SUPER GREASE A or equivalent Tighten the intake pipe mounting bolts to the specified torque NOTE Make sure that the UP mark A faces up Tightening torque Intake pipe bolt a 9 N m 0 9 kgf m 6 5 lb ft Apply engine coolant to the rubber seal on the thermostat 2 Tighten the ECT sensor 3 to the specified torque CAUTION Use the new O ring 4 to prevent engine coolant leakage Ti...

Page 177: ...release the lifter to allow the cotter halves 7 to wedge in between retainer and stem CAUTION Be sure to restore each spring and valve to their original positions Be careful not to damage the valve and valve stem when handling them To prevent damage of the tappet sliding surface with the special tool use the sleeve protector Special tool A 09916 14510 Valve spring compressor B 09916 14910 Valve sp...

Page 178: ...cial tool 09900 20803 Thickness gauge Cylinder head distortion Service limit 0 05 mm 0 002 in Valve stem runout Support the valve using V blocks as shown in the figure and check its runout using the dial gauge If the runout exceeds the service limit replace the valve Special tool A 09900 20607 Dial gauge 1 100 mm 10 mm B 09900 20701 Magnetic stand C 09900 21304 V block 100 mm Valve stem runout IN ...

Page 179: ...aced with a new one Special tool A 09900 20607 Dial gauge 1 100 mm 10 mm B 09900 20701 Magnetic stand Valve stem deflection IN EX Service limit 0 35 mm 0 014 in Valve stem wear Measure the valve stem O D using the micrometer If it is out of specification replace the valve with a new one If the valve stem O D is within specification but the valve stem deflection is not replace the valve guide After...

Page 180: ...182 210 N 18 6 21 4 kgf 41 0 47 2 Ibs 31 5 mm 1 24 in Valve seat width 1 Visually check for valve seat width on each valve face If the valve face has worn abnormally replace the valve 2 Coat the valve seat with a red lead Prussian Blue and set the valve in place 3 Rotate the valve with light pressure Special tool A 09916 10911 Valve lapper set 4 Check that the transferred red lead blue on the valv...

Page 181: ...33H21406027 1 Remove the cylinder head Refer to Engine Top Side Disassembly Page 1D 17 2 Remove the valves Refer to Cylinder Head Disassembly and Assembly Page 1D 29 3 Using the valve guide remover drive the valve guide out toward the intake or exhaust camshaft side Special tool A 09916 44310 Valve guide remover installer NOTE Discard the removed valve guide sub assemblies Only oversized valve gui...

Page 182: ...l C 09916 34542 Reamer handle E 09916 34570 Valve guide reamer 5 0 mm NOTE Be sure to cool down the cylinder head to ambient air temperature Insert the reamer from the combustion chamber and always turn the reamer handle clockwise 9 Reassemble the cylinder head Refer to Cylinder Head Disassembly and Assembly Page 1D 29 10 Install the cylinder head assembly Refer to Engine Top Side Assembly Page 1D...

Page 183: ...sassembly Page 1D 17 and Engine Top Side Assembly Page 1D 20 Cylinder distortion Check the gasket surface of the cylinder for distortion Use a straightedge and thickness gauge Take clearance readings at several places If any reading exceeds the service limit replace the cylinder Special tool 09900 20803 Thickness gauge Cylinder distortion Service limit 0 05 mm 0 002 in Cylinder bore Inspect the cy...

Page 184: ...to be broken down 1 Install the piston rings in the order of the oil ring second ring and top ring a The first member to go into the oil ring groove is a spacer 1 After placing the spacer fit the two side rails 2 CAUTION When installing the spacer be careful not to allow its two ends to overlap in the groove b Install the 2nd ring 3 and 1st ring 4 to piston NOTE 1st ring 4 and 2nd ring 3 differ in...

Page 185: ... to groove clearance Measure the side clearances of the 1st and 2nd piston rings using the thickness gauge If any of the clearances exceed the limit replace both the piston and piston rings Special tool A 09900 20803 Thickness gauge B 09900 20205 Micrometer 0 25 mm Piston ring to groove clearance Service limit 1st 0 180 mm 0 007 in Service limit 2nd 0 150 mm 0 006 in Piston ring groove width a Sta...

Page 186: ...f the measurement is out of specification replace the piston Special tool A 09900 20602 Dial gauge 1 1000 mm 1 mm B 09900 22403 Small bore gauge 18 35 mm Piston pin bore I D Service limit 20 030 mm 0 7886 in Measure the piston pin outside diameter at three positions using the micrometer If any of the measurements are out of specification replace the piston pin Special tool C 09900 20205 Micrometer...

Page 187: ...al and Installation in Section 1J Page 1J 5 Oil filter 1 Remove the oil filter cap 1 2 Remove the oil filter 2 and O ring 3 Clutch Remove the clutch component parts 1 Refer to Clutch Removal in Section 5C Page 5C 7 Cam chain tensioner Cam chain Oil pipe 1 Remove the oil pipes 1 2 Remove the cam chain tensioner 2 and cam chain 3 1 I933H1140150 01 2 1 I933H1140151 01 1 I933H1140152 01 2 3 I933H11401...

Page 188: ...se to prevent the oil pump idle gear shaft from dropping into the crankcase 5 Remove the outer rotor 7 inner rotor 8 and pin 9 Gearshift shaft Gearshift cam plate 1 Remove the snap ring 1 and washer 2 Special tool 09900 06107 Snap ring pliers 2 Remove the gearshift shaft 3 and washer 4 3 Remove the gearshift pawl lifter 5 and gearshift cam driven gear 6 NOTE Be careful not to drop the pins and spr...

Page 189: ...520 Rotor holder 2 Remove he washer 1 balancer driven gear 2 and pin 3 Primary drive gear Balancer drive gear 1 Hold the generator rotor using the special tool and then remove the primary drive gear nut CAUTION The primary drive gear nut has left hand threads Special tool A 09930 44520 Rotor holder 2 Remove the washer 1 and primary drive gear 2 3 Remove the key 3 cam chain drive sprocket 4 and bal...

Page 190: ...or rotor key 2 and starter driven gear 3 Gear position switch 1 Remove the gear position switch 1 2 Remove the switch contacts 2 and springs 3 Crankcase 1 Remove the left crankcase securing bolts 2 Remove the right crankcase securing bolts 6 I933H1140167 01 1 I933H1140168 01 3 2 I933H1140169 02 2 3 1 I933H1140170 01 I933H1140171 01 I933H1140172 01 P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 191: ... sump filter Remove the oil sump filter 1 Transmission Gearshift Remove the transmission component Refer to Transmission Removal and Installation in Section 5B Page 5B 5 Balancer shaft Remove the balancer shaft 1 Crankshaft Remove the crankshaft from the crankcase using the special tool Special tool A 09920 13120 Crankcase separating tool A I933H1140173 01 I933H1140174 02 1 I933H1150005 01 I933H11...

Page 192: ...il seals and bearings if necessary Refer to Transmission Oil Seal Bearing Removal and Installation in Section 5B Page 5B 10 and Gearshift Shaft Oil Seal Bearing Removal and Installation in Section 5B Page 5B 18 Oil pump idle gear shaft 1 Remove the snap ring 1 Special tool 09900 06108 Snap ring pliers 2 Remove the oil pump idle gear shaft 2 1 I933H1140178 01 2 I933H1140179 01 3 4 I933H1140180 01 I...

Page 193: ...age 5B 18 Oil gallery plug Tighten each plug to the specified torque CAUTION Use each new gaskets Tightening torque Oil gallery plug M6 a 11 N m 1 1 kgf m 8 0 lb ft Oil gallery plug M8 b 13 N m 1 3 kgf m 9 5 lb ft Oil gallery plug M12 c 23 N m 2 3 kgf m 16 5 lb ft Main oil gallery plug d 18 N m 1 8 kgf m 13 0 lb ft Crankshaft When mounting the crankshaft in the crankcase it is necessary to pull it...

Page 194: ...el pins to the left crankcase Apply engine oil to the conrod big end and to the transmission gears Apply bond to the mating surface of the right crankcase as follows NOTE Spread the sealant on surfaces thinly to form an even layer and assemble the crankcases within a few minutes Take extreme care not to apply any bond to the oil hole oil groove and bearing Apply to distorted surfaces as it forms a...

Page 195: ...eplace the O ring with a new one Grease 99000 25160 Water resistance grease or equivalent Tighten the gear position switch mounting bolts to the specified torque Tightening torque Gear position switch mounting bolt a 6 5 N m 0 65 kgf m 4 7 lb ft Generator Starter driven gear Apply engine oil to the bearing of the starter driven gear Install the key 1 Install the generator rotor 2 Refer to Generato...

Page 196: ...ive gear nut 7 has left hand thread Special tool A 09930 44520 Rotor holder Tightening torque Primary drive gear nut a 140 N m 14 0 kgf m 101 5 lb ft Balancer driven gear Install the pin 1 Install the balancer driven gear 2 by aligning the matching marks A Install the washer Hold the generator rotor using the special tool and then tighten the balancer driven gear nut to the specified torque Specia...

Page 197: ...t cam stopper moves smoothly Locate the gearshift cam in the neutral position Install the gearshift cam stopper plate 5 NOTE Align the gearshift cam pin A with the gearshift cam stopper plate B Tighten the gearshift cam stopper plate bolt to the specified torque Tightening torque Gearshift cam stopper plate bolt b 24 N m 2 4 kgf m 17 5 lb ft Install each spring 6 pins 7 and pawls 8 into the gearsh...

Page 198: ...he washer 15 and new snap ring 16 CAUTION The removed snap ring 16 must be replaced with a new one Special tool 09900 06107 Snap ring pliers Oil pump Apply engine oil to the sliding surfaces of the oil pump inner rotor outer rotor and shaft When installing 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 inner rotor...

Page 199: ... rings 6 CAUTION The removed snap rings 6 must be replaced with a new one Special tool 09900 06107 Snap ring pliers Cam chain tensioner Cam chain Install the cam chain 1 Install the washer 2 and cam chain tensioner 3 Tighten the cam chain tensioner mounting bolt to the specified torque Tightening torque Cam chain tensioner mounting bolt a 10 N m 1 0 kgf m 7 0 lb ft Oil pipe Apply engine oil to the...

Page 200: ... in Section 1J Page 1J 5 Starter torque limiter Install the starter torque limiter 1 Refer to Starter Torque Limiter Starter Clutch Removal and Installation in Section 1I Page 1I 8 Starter motor Install the starter motor 1 Refer to Starter Motor Removal and Installation in Section 1I Page 1I 4 Engine top side Engine assembly Assembly the engine top side Refer to Engine Top Side Assembly Page 1D 20...

Page 201: ...0 7890 in Conrod deflection Wear On the big end of the conrod can be estimated by checking the movement of the small end of the rod This method can also check the extent of ware on the parts of the conrod s big end Special tool A 09900 20701 Magnetic stand B 09900 20607 Dial gauge 1 100 mm 10 mm C 09900 21304 V block 100 mm Conrod deflection Service Limit 3 0 mm 0 12 in Conrod big end side clearan...

Page 202: ...dures 1 Separate the crankcase left and right Refer to Engine Bottom Side Disassembly Page 1D 41 2 Remove the balancer shaft 1 3 Inspect the balancer shaft for wear or damage If any defects are found replace the balancer shaft with a new one 4 Install the balancer shaft 1 5 Reassemble the crankcase left and right Refer to Engine Bottom Side Assembly Page 1D 48 Crankshaft Bearing Balancer Shaft Bea...

Page 203: ...ver set B 09921 20210 Bearing remover C 09930 30104 Rotor remover slide shaft Installation CAUTION The removed bearings must be replace with new ones NOTE The stamped mark side of the bearing faces inside 1 Install the bearings 1 using the special tool Special tool A 09913 70210 Bearing installer set 2 Assembly the engine bottom side Refer to Engine Bottom Side Assembly Page 1D 48 3 Remount the en...

Page 204: ...e the oil seal retainer 1 3 Remove the oil seal using the special tool Special tool A 09913 50121 Oil seal remover Installation 1 Install the oil seal using the special tool CAUTION The removed oil seal must be replaced with a new one Special tool A 09913 70210 Bearing installer set 2 Apply grease to the oil seal lip Grease 99000 25010 SUZUKI SUPER GREASE A or equivalent 3 Install the oil seal ret...

Page 205: ...ournal oil clearance IN EX 0 019 0 053 0 007 0 0021 0 150 0 0059 Camshaft journal holder I D IN EX 22 012 22 025 0 8666 0 8671 Camshaft journal O D IN EX 21 972 21 993 0 8650 0 8659 Camshaft runout IN EX 0 10 0 004 Cam chain pin at arrow 3 15th pin Cylinder head distortion 0 05 0 002 Item Standard Limit Compression pressure Automatic decomp actuated Approx 1 100 kPa 11 0 kgf cm2 156 psi Piston to ...

Page 206: ... 1D 22 Cylinder base nut 10 1 0 7 0 Page 1D 22 Engine mounting bracket bolt 26 2 6 19 0 Page 1D 22 Engine mounting nut 66 6 6 47 5 Page 1D 22 Camshaft journal holder bolt 10 1 0 7 0 Page 1D 24 Page 1D 27 Cam chain tension adjuster mounting bolt 10 1 0 7 0 Page 1D 24 Cam chain tension spring holder bolt 30 3 0 21 5 Page 1D 24 Generator cover plug 15 1 5 11 0 Page 1D 25 Valve timing inspection plug ...

Page 207: ...ge 1D 20 Page 1D 49 SUZUKI BOND No 1207B or equivalent P No 99000 31140 Page 1D 25 Thread lock cement THREAD LOCK CEMENT SUPER 1303 or equivalent P No 99000 32030 Page 1D 16 THREAD LOCK CEMENT SUPER 1322 or equivalent P No 99000 32110 Page 1D 52 Page 1D 53 Page 1D 54 09900 06107 09900 06108 Snap ring pliers Snap ring pliers Page 1D 43 Page 1D 43 Page 1D 53 Page 1D 54 Page 1D 47 Page 1D 48 09900 20...

Page 208: ...21304 09900 22301 V block 100 mm Plastigauge 0 025 0 076 mm Page 1D 33 Page 1D 33 Page 1D 56 Page 1D 57 Page 1D 27 09900 22302 09900 22403 Plastigauge 0 051 0 152 mm Small bore gauge 18 35 mm Page 1D 27 Page 1D 27 Page 1D 41 09910 32812 09910 32820 Crankshaft installer Spacer Page 1D 48 Page 1D 48 09911 11310 09913 50121 Crankshaft installer attachment Oil seal remover Page 1D 48 Page 1D 59 09913 ...

Page 209: ...916 34580 09916 44310 Valve guide reamer 10 8 mm Valve guide remover installer Page 1D 36 Page 1D 36 Page 1D 37 09916 53360 09916 84511 Attachment Tweezers Page 1D 37 Page 1D 30 Page 1D 32 09919 28610 09920 13120 Sleeve protector Crankcase separating tool Page 1D 29 Page 1D 32 Page 1D 46 Page 1D 46 09921 20210 09921 20240 Bearing remover Bearing remover set Page 1D 58 Page 1D 58 Page 1D 58 09930 1...

Page 210: ...1D 65 Engine Mechanical 09930 44520 Rotor holder Page 1D 44 Page 1D 44 Page 1D 51 Page 1D 51 P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 211: ...chematic and Routing Diagram Engine Oil Hose and Pipe Routing Diagram B933H21502001 4 3 1 2 3 5 7 6 A I933H1150035 03 1 Engine oil tank 5 Cushion 2 Engine oil level gauge 6 Wiring harness 3 Engine oil pipe 7 High tension code 4 Oil tank drain bolt A Pass the engine oil tank overflow hose between the high tension cord and wiring harness P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 212: ...OVER ORIFICE CRANK PIN RIGHT CRANKSHAFT CRANKSHAFT RIGHT END CONROD BIG END BEARING CYLINDER CYLINDER HEAD REVERSE IDLE GEAR SHAFT COUNTERSHAFT LEFT END BEARING DRIVESHAFT LEFT END BEARING DRIVE SHAFT DRIVEN GEARS RIGHT CRANKCASE LEFT CRANKCASE CLUTCH PLATES CYLINDER WALL PISTON PISTON PIN STARTER CLUTCH IN EX CAM FACE IN EX CAMSHAFT JOURNAL CAM CHAIN LEFT CRANKSHAFT PISTON PISTON PIN RIGHT CRANKC...

Page 213: ... min at 2 000 r min Winter 20 min at 2 000 r min 5 After warm up increase the engine speed to 3 000 r min Observe the tachometer and read the oil pressure gauge If the oil pressure is lower or higher than the specification the following causes may be considered Oil pressure specification 20 60 kPa 0 2 0 6 kgf cm2 2 8 8 5 psi at 3 000 r min Oil temp at 60 C 140 F Condition Possible cause Correction...

Page 214: ...he engine top side Refer to Engine Top Side Disassembly in Section 1D Page 1D 17 3 Separate the left and right crankcase Refer to Engine Bottom Side Disassembly in Section 1D Page 1D 41 4 Remove the oil sump filter 1 Installation 1 Align the oil passage holes when installing the oil sump filter 1 2 Assemble the engine Refer to Engine Bottom Side Assembly in Section 1D Page 1D 48 and Engine Top Sid...

Page 215: ...ng pliers 4 Remove the oil pump idle gear 2 and oil pump driven gear 3 5 Remove the pin 4 and washer 5 6 Remove the oil pump assembly 6 CAUTION Do not remove the snap ring A before separating the crankcase to prevent the oil pump idle gear shaft from dropping into the crankcase 7 Remove the outer rotor 7 inner rotor 8 and pin 9 Installation Install the oil pump in the reverse order of removal Pay ...

Page 216: ...e Oil pump mounting screw a 8 5 N m 0 85 kgf m 6 0 lb ft When installing the oil pump driven gear align the pin 4 with the groove 5 Reinstall the clutch Refer to Clutch Installation in Section 5C Page 5C 9 Oil Pump Inspection B933H21506007 Inspect the oil pump in the following procedures 1 Remove the oil pump Refer to Oil Pump Removal and Installation Page 1E 5 2 Rotate the oil pump by hand and ch...

Page 217: ...se and Pipe Construction B933H21506008 a 2 3 2 4 1 I933H1150036 03 1 Oil tank overflow hose 12 N m 1 2 kgf m 8 5 lb ft 2 Engine oil pipe Apply engine oil 3 Oil tank Do not reuse 4 Engine oil level gauge P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 218: ...rain engine oil Refer to Engine Oil and Filter Replacement in Section 0B Page 0B 11 2 Remove the radiator cover Refer to Radiator Cover Removal and Installation in Section 1F Page 1F 8 3 Remove the oil tank lower cover 1 4 Remove the engine under cover 2 5 Remove the engine oil pipes 6 Remove the each dowel pins 3 and O rings 4 I933H1150017 01 1 I933H1150018 01 2 I933H1150019 01 I933H1150020 01 I9...

Page 219: ...nd Installation B933H21506011 Removal 1 Drain engine oil and coolant Refer to Engine Oil and Filter Replacement in Section 0B Page 0B 11 and Cooling System Inspection in Section 0B Page 0B 13 2 Remove the radiator cover Refer to Radiator Cover Removal and Installation in Section 1F Page 1F 8 3 Remove the radiator assembly Refer to Radiator Removal and Installation in Section 1F Page 1F 5 4 Remove ...

Page 220: ...ch primary driven gear assembly Refer to Clutch Removal in Section 5C Page 5C 7 4 Remove the oil pipe No 2 2 Installation CAUTION Use new O rings to prevent oil leakage 1 Apply engine oil to the O rings and install the oil pipe No 2 1 2 Install the clutch assembly Refer to Clutch Installation in Section 5C Page 5C 9 3 Apply engine oil to the O rings and install the oil pipe No 1 2 4 Install the cl...

Page 221: ...ge 1E 7 Reference For the tightening torque of fastener not specified in this section refer to Tightening Torque Specifications in Section 0C Page 0C 6 I933H1150034 01 Item Standard Limit Oil pressure at 60 C 140 F 20 60 kPa 0 2 0 6 kgf cm2 2 8 8 5 psi at 3 000 r min Item Specification Note Engine oil type SAE 10 W 40 API SF SG or SH SJ with JASO MA Engine oil capacity Change 2 000 ml 2 1 1 8 US l...

Page 222: ...truction Page 1E 7 Special Tool B933H21508002 Material SUZUKI recommended product or Specification Note Thread lock cement THREAD LOCK CEMENT SUPER 1322 or equivalent P No 99000 32110 Page 1E 6 09900 06107 09900 26006 Snap ring pliers Engine tachometer solar cell type Page 1E 5 Page 1E 3 09915 74511 09915 74533 Oil pressure gauge set Oil pressure gauge attachment Page 1E 3 Page 1E 3 P a r t S h a ...

Page 223: ...move the cap by turning it a quarter turn to allow pressure to escape and then turn the cap all the way off The engine must be cool before servicing the cooling system Coolant is harmful If it comes in contact with skin or eyes flush with water If swallowed accidentally induce vomiting and call physician immediately Keep it away from children Precautions for Engine Coolant B933H21600002 Refer to E...

Page 224: ...and excellent heat protection and will protect the cooling system from freezing at temperatures above 31 C 24 F If the vehicle is to be exposed to temperatures below 31 C 24 F this mixing ratio should be increased up to 55 or 60 according to the figure Anti freeze Proportioning Chart Fig 1 Engine coolant density freezing point curve Fig 2 Engine coolant density boiling point curve Schematic and Ro...

Page 225: ...ystem 1F 3 Water Hose Routing Diagram B933H21602002 2 4 3 1 5 6 5 6 I933H1160054 10 1 Radiator 4 Cooling fan 2 Reservoir 5 Yellow mark 3 Reservoir overflow hose 6 White mark P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 226: ...exceed the radiator cap release pressure or the radiator cap and subsequently the radiator can be damaged 4 After finishing the cooling circuit inspection reinstall the removed parts Condition Possible cause Correction Reference Item Engine overheats Not enough engine coolant Add engine coolant Radiator core clogged with dirt or scale Clean Faulty cooling fan Repair or replace Defective cooling fa...

Page 227: ... replace the radiator with a new one If the fins are bent or dented repair them by carefully straightening them with the blade of a small screwdriver 3 Reinstall the side covers left and right Radiator cleaning 1 Remove the side covers left and right Refer to Exterior Parts Removal and Installation in Section 9D Page 9D 4 2 Blow out any foreign matter that is stuck in the radiator fins using compr...

Page 228: ... the reservoir tank mounting bolts and tighten them Thread lock cement 99000 32110 THREAD LOCK CEMENT SUPER 1322 or equivalent Rout the reservoir tank hoses 1 properly Refer to Water Hose Routing Diagram Page 1F 3 Connect the radiator hoses as shown in the water hose routing diagram Refer to Water Hose Routing Diagram Page 1F 3 Pour engine coolant and bleed air from the cooling circuit Refer to Co...

Page 229: ...ox 3 and cooling fan motor assembly 4 4 Remove the boot 5 5 Remove the cooling fan 6 6 Remove the cooling fan motor 7 Installation Install the cooling fan motor in the reverse order of removal Pay attention to the following points Apply thread lock to the cooling fan motor shaft Thread lock cement 99000 32030 THREAD LOCK CEMENT SUPER 1303 or equivalent Tighten the cooling fan nut 1 I933H1160012 02...

Page 230: ...right 1 Installation Install the radiator covers 1 as shown in the figure Water Hose Removal and Installation B933H21606008 Removal 1 Drain engine coolant Refer to Cooling System Inspection in Section 0B Page 0B 13 2 Remove the side covers left and right Refer to Exterior Parts Removal and Installation in Section 9D Page 9D 4 3 Remove the water hose as shown in the water hose routing diagram Refer...

Page 231: ...tall the reservoir tank 1 2 Apply thread lock to the reservoir tank mounting bolts and tighten them Thread lock cement 99000 32110 THREAD LOCK CEMENT SUPER 1322 or equivalent 3 Connect the hoses 2 as shown in the water hose routing diagram Refer to Water Hose Routing Diagram Page 1F 3 4 Install the left side cover Cooling Fan Inspection B933H21606011 Inspect the cooling fan in the following proced...

Page 232: ...etween A and B If there is no continuity replace it with a new one Special tool 09900 25008 Multi circuit tester set Tester knob indication set Continuity test 4 Reinstall the removed parts ECT Sensor Removal and Installation B933H21606013 Refer to ECT Sensor Removal and Installation in Section 1C Page 1C 5 ECT Sensor Inspection B933H21606014 Refer to ECT Sensor Inspection in Section 1C Page 1C 6 ...

Page 233: ...ostat 1 in the water contained in a beaker and note that the immersed thermostat is in suspension 5 Heat the water by placing the beaker on a stove and observe the rising temperature on a thermometer 2 6 Read the thermometer just when opening the thermostat If this reading which is the temperature level at which the thermostat valve begins to open is out of the standard value replace the thermosta...

Page 234: ...18 6 a 2 3 2 4 5 2 1 I933H1160031 02 1 Water pump cover 4 Mechanical seal 6 N m 0 6 kgf m 4 5 lb ft Do not reuse 2 O ring 5 Oil seal Apply water resistance grease 3 Impeller 6 Water pump driven gear Apply engine coolant P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 235: ... driven gear 2 pin 3 and washer 4 Special tool 09900 06107 Snap ring pliers 4 Remove the water pump assembly 5 Installation 1 Apply grease to the O rings CAUTION Replace the O rings with new ones Grease 99000 25160 Water resistance grease or equivalent 2 Install the water pump assembly to the clutch cover 3 Install the washer 1 pin 2 water pump driven gear 3 and snap ring 4 CAUTION The removed sna...

Page 236: ...ition the mechanical seal removal is not necessary Special tool A 09921 20240 Bearing remover set 5 Remove the oil seal 6 NOTE If there is no abnormal condition the oil seal removal is not necessary Assembly 1 Install the oil seal with the special tool CAUTION Replace the oil seal with a new one NOTE The stamped mark on the oil seal should face mechanical seal side Special tool A 09913 70210 Beari...

Page 237: ...iping off the oily or greasy matter from the mechanical seal ring 2 install it into the impeller NOTE The paint marked side B of mechanical seal ring faces the impeller 6 Apply grease to the impeller shaft Grease 99000 25160 Water resistance grease or equivalent 7 Install the impeller shaft to the mechanical sealing 8 Install a new O ring 3 and apply engine coolant to it CAUTION Use a new O ring t...

Page 238: ...chanical seal that shows indications of leakage Oil seal Visually inspect the oil seal for damage with particular attention given to the lip Replace the oil seal that shows indications of leakage Impeller Visually inspect the impeller and its shaft for damage Replace the impeller if necessary Impeller shaft journal Visually inspect the journal for damage or scratch Replace the water pump body if n...

Page 239: ...ature Approx 76 5 C 170 F Thermostat valve lift 4 5 mm 0 18 in and over at 90 C 194 F ECT sensor resistance 20 C 68 F Approx 2 57 kΩ 50 C 122 F Approx 0 77 kΩ 80 C 176 F Approx 0 27 kΩ 110 C 230 F Approx 0 11 kΩ Radiator cap valve opening pressure 108 137 kPa 1 08 1 37 kgf cm2 15 4 19 5 psi Cooling fan operating temperature OFF ON Approx 98 C 208 F ON OFF Approx 93 C 199 F Engine coolant type Use ...

Page 240: ... Water resistance grease or equivalent P No 99000 25160 Page 1F 13 Page 1F 15 Page 1F 15 Thread lock cement THREAD LOCK CEMENT SUPER 1303 or equivalent P No 99000 32030 Page 1F 7 THREAD LOCK CEMENT SUPER 1322 or equivalent P No 99000 32110 Page 1F 6 Page 1F 9 09900 06107 09900 25008 Snap ring pliers Multi circuit tester set Page 1F 13 Page 1F 13 Page 1F 10 09913 70210 09921 20240 Bearing installer...

Page 241: ...pillage of gasoline Spilled gasoline should be wiped off immediately Work in a well ventilated area CAUTION To prevent the fuel system fuel tank fuel hose etc from contamination with foreign particles blind all openings After removing the throttle body tape the cylinder intake section to prevent foreign particles from entering P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 242: ...re in the fuel delivery pipe is always kept at absolute fuel pressure of approx 294 kPa 2 9 kgf cm2 41 psi the fuel is injected into the throttle body in conic dispersion when the injector opens according to the injection signal from the ECM The fuel relieved by the fuel pressure regulator flows back to the fuel tank 1 2 4 12 7 8 10 9 6 11 3 5 C A B I933H1170039 02 1 Fuel tank 5 Fuel filter For fu...

Page 243: ... D I933H1170037 03 1 Reverse gear cable 5 Fuel pump B Face the tip of clip to left 2 Fuel hose 6 Starter cable C Face the tip of clip to right 3 Fuel feed hose 7 Fuel valve D White mark 4 Parking brake cable A Set the white mark on hose to down ward a To fuel injector P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 244: ... Defective fuel pump Replace Defective fuel valve Replace Defective ECT sensor Replace Defective thermostat Replace Defective IAT sensor Replace Damaged or cracked vacuum hose Replace Engine stalls often Fuel injector improperly operating Defective fuel injector Replace No injection signal from ECM Repair or replace Open or short circuited wiring connection Repair or replace Defective battery or l...

Page 245: ...e the ignition switch Refer to Ignition Switch Removal and Installation in Section 1H Page 1H 7 5 Connect the ignition switch lead wire coupler 2 6 Turn the ignition ON and check for fuel pressure Fuel pressure Approx 294 kPa 2 94 kgf cm2 42psi If the fuel pressure is lower than the specification check for the followings Fuel hose leakage Fuel valve Fuel pump If the fuel pressure is higher than th...

Page 246: ... Fuel Tank Removal and Installation Page 1G 9 2 Lift up the fuel tank and place a rag under the fuel feed hose 1 and disconnect fuel feed hose from the fuel valve 3 Connect a proper fuel hose 2 to the fuel valve 4 Place the measuring cylinder and insert the fuel hose end into the measuring cylinder 5 Disconnect the fuel pump lead wire coupler 3 6 Connect a proper lead wire into the fuel pump lead ...

Page 247: ...ely Keep away from fire or spark Work in a well ventilated area 1 Removal the fuel tank cover Refer to Exterior Parts Removal and Installation in Section 9D Page 9D 4 2 Disconnect the fuel level gauge couplers 1 3 Remove the fuel level gauge cap 2 and fuel level gauge assembly 3 4 Remove the fuel level indicator switch thermistor cover 4 Installation Install the fuel level gauge in the reverse ord...

Page 248: ...k Construction B933H21706009 2 1 3 4 a 5 I933H1170038 01 1 Fuel tank 5 Fuel hose 2 Fuel level indicator switch Thermistor 10 N m 1 0 kgf m 7 0 lb ft 3 O ring Do not reuse 4 Fuel valve P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 249: ...lve screw clockwise 7 Disconnect the breather hose 6 8 Place a rag under the fuel feed hoses 7 and fuel hose 8 9 Disconnect the fuel feed hoses 7 and fuel hose 8 10 Remove the fuel tank 11 Remove the fuel tank lower cover 9 Installation Install the fuel tank in the reverse order of removal Pay attention to the following points Connect the fuel hose and fuel feed hoses as shown in the fuel hose rou...

Page 250: ... Spilled gasoline should be wiped off immediately Work in a well ventilated area 1 Remove the fuel tank Refer to Fuel Tank Removal and Installation Page 1G 9 2 Disconnect the fuel hose 1 and fuel feed hoses 2 3 Remove the fuel valve 3 and O ring 4 4 Remove the fuel filters 5 Installation Install the fuel valve in the reverse order of removal Pay attention to the following points Install the new O ...

Page 251: ...ogged with many sediment or rust replace the fuel filters with new ones 4 Reinstall the fuel valve Refer to Fuel Valve Removal and Installation Page 1G 10 5 Reinstall the fuel tank Refer to Fuel Tank Removal and Installation Page 1G 9 Fuel Injector Inspection and Cleaning B933H21706013 Inspect the fuel injector in the following procedures 1 Remove the fuel injector Refer to Fuel Injector Fuel Deli...

Page 252: ...he following points Apply thin coat of engine oil to the new O ring CAUTION Replace the O ring with a new one Apply thin coat of engine oil to the new cushion seal 1 and O ring 2 CAUTION Replace the cushion seal and O ring with the new ones Install the fuel injector 3 by pushing it straight to the delivery pipe 4 CAUTION Never turn the injector while pushing it NOTE Align the coupler A of injector...

Page 253: ... and disconnect the fuel feed hose 7 8 Remove the fuel pump 8 Installation 1 Connect the fuel feed hose 1 to the fuel pump until it locks securely a click is heard 2 Tighten the fuel pump mounting bolts to the specified torque Tightening torque Fuel pump mounting bolt a 10 N m 1 0 kgf m 7 0 lb ft 3 Connect the fuel vapor return hose and fuel hose as shown in the throttle body construction and fuel...

Page 254: ...m2 42 psi Item Specification Note Fuel type Use only unleaded gasoline of at least 87 pump octane R 2 M 2 or 91 octane or higher rated by the Research Method Gasoline containing MTBE Methyl Tertiary Butyl Ether less than 10 ethanol or less than 5 methanol with appropriate cosolvents and corrosion inhibitor is permissible E 28 33 Gasoline used should be graded 91 octane or higher An unleaded gasoli...

Page 255: ...e Color Symbols in Section 0A Page 0A 5 Ignition System Components Location B933H21802002 Refer to Electrical Components Location in Section 0A Page 0A 7 CKP sensor TP sensor ECT sensor GP switch Engine stop switch Fuse Fuse Ignition switch Ignition coil Battery ECM I933H1180001 02 P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 256: ...eplace Defective ECM Replace Open circuited wiring connections Repair or replace Spark plug is wet or quickly becomes fouled with carbon Excessively rich air fuel mixture Inspect FI system Excessively high idling speed Inspect FI system Incorrect gasoline Change Dirty air cleaner element Clean or replace Incorrect spark plug Cold type Change to standard spark plug Spark plug quickly becomes fouled...

Page 257: ...Coil and Plug Cap Inspection Page 1H 4 NOTE This inspection method is applicable only with the multi circuit tester and the peak volt adaptor Is the peak voltage OK Go to step 4 Go to step 5 4 Inspect the spark plug Refer to Spark Plug Inspection and Cleaning in Section 0B Page 0B 9 Is the spark plug OK Go to Step 5 Faulty spark plug 5 Inspect the ignition coil Refer to Ignition Coil and Plug Cap ...

Page 258: ...m threads of the cylinder head Special tool 09930 10121 Spark plug wrench set Tightening torque Spark plug 11 N m 1 1 kgf m 8 0 lb ft Spark Plug Inspection and Cleaning B933H21806002 Refer to Spark Plug Inspection and Cleaning in Section 0B Page 0B 9 Ignition Coil and Plug Cap Inspection B933H21806003 Ignition Coil Primary Peak Voltage 1 Remove the front fender Refer to Exterior Parts Removal and ...

Page 259: ...nspect the ignition coil and the CKP sensor Ignition coil primary peak voltage 150 V and more 10 After measuring the ignition coil primary peak voltage reinstall the removed parts Ignition Coil Resistance 1 Disconnect the spark plug cap Refer to Ignition Coil and Plug Cap Inspection Page 1H 4 2 Disconnect the ignition coil lead wire 3 Measure the ignition coil resistance in both the primary and se...

Page 260: ...oltage 5 Repeat the b procedure a few times and measure the highest CKP sensor peak voltage CKP sensor peak voltage 1 0 V and more Blue Green 6 If the peak voltage is within the specification check the continuity between the CKP sensor coupler and ECM coupler CAUTION Normally use the needle pointed probe to the backside of the lead wire coupler to prevent the terminal bend and terminal alignment 7...

Page 261: ...ter knob indication Continuity 5 After finishing the engine stop switch inspection reinstall the removed parts Ignition Switch Inspection B933H21806007 Refer to Ignition Switch Inspection in Section 9C Page 9C 4 Ignition Switch Removal and Installation B933H21806008 Removal 1 Remove the left side cover Refer to Exterior Parts Removal and Installation in Section 9D Page 9D 4 2 Remove the ignition s...

Page 262: ...E DENSO U22ESR N Gap 0 7 0 8 0 028 0 031 Spark performance Over 8 0 3 at 1 atm CKP sensor resistance 400 600 Ω CKP sensor peak voltage 1 0 V and more When cranking Ignition coil resistance Primary 0 1 1 0 Ω Terminal Ground Secondary 12 20 kΩ Plug cap Terminal Ignition coil primary peak voltage 150 V and more B W W Bl Fastening part Tightening torque Note N m kgf m lb ft Spark plug 11 1 1 8 0 Page ...

Page 263: ...Diagnosis B933H21904001 Starter relay Clutch switch Starter button Engine stop switch Ignition switch Battery Fuse 10A Starter motor Fuse 20A B R B O O Y O W Y B B B W I933H1190001 01 Condition Possible cause Correction Reference Item Starter button is not effective Run down battery Repair or replace Defective switch contacts Replace Brushes not seating properly on starter motor commutator Repair ...

Page 264: ...terminal Do not use thin wire because a large amount of current flows Does the starter motor run Faulty starter relay Loose or disconnected starter motor lead wire Loose or disconnected between starter relay and battery terminal Faulty starter motor 3 Measure the starter relay voltage at the starter relay connectors between Y B and O W when the starter button is pushed Is the voltage OK Go to Step...

Page 265: ...h holder Apply grease 2 Housing end Inside 8 Housing end Outside Apply water resistance grease 3 O ring 6 N m 0 6 kgf m 4 5 lb ft Apply moly paste to sliding surface 4 Square ring 7 N m 0 7 kgf m 5 0 lb ft Do not reuse 5 Starter motor case 10 N m 1 0 kgf m 7 0 lb ft 6 Armature 3 N m 0 3 kgf m 2 0 lb ft P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 266: ... starter motor lead wire mounting nut 3 to the specified torque Refer to Wiring Harness Routing Diagram in Section 9A Page 9A 3 Tightening torque Starter motor mounting bolt a 10 N m 1 0 kgf m 7 0 lb ft Starter motor lead wire mounting nut b 6 N m 0 6 kgf m 4 5 lb ft Starter Motor Disassembly and Assembly B933H21906003 Refer to Starter Motor Removal and Installation Page 1I 4 Disassembly Disassemb...

Page 267: ...or housing bolt b 3 N m 0 3 kgf m 2 0 lb ft Starter Motor Related Parts Inspection B933H21906004 Refer to Starter Motor Disassembly and Assembly Page 1I 4 Carbon brush Inspect the carbon brushes for abnormal wear cracks or smoothness in the brush holder If either carbon brush is defective replace the brush holder set with a new one Measure the length a of the carbon brushes using a vernier caliper...

Page 268: ...f any damage is found replace the housing end Inside Check the bearing of housing end for damage If any damage is found replace the housing end Starter Relay Removal and Installation B933H21906005 Refer to Electrical Components Location in Section 0A Page 0A 7 Removal 1 Turn the ignition switch OFF position 2 Remove the seat Refer to Exterior Parts Removal and Installation in Section 9D Page 9D 4 ...

Page 269: ...hin the specified value replace the starter relay with a new one Special tool A 09900 25008 Multi circuit tester set Starter relay resistance 3 6 Ω 4 Install the starter relay Gear Position GP Switch Inspection B933H21906007 Refer to DTC C31 P0705 GP Switch Circuit Malfunction in Section 1A Page 1A 58 Inspect the gear position switch in the following procedures 1 Disconnect the gear position switc...

Page 270: ...generator cover Starter clutch 1 Drain engine oil 2 Remove the generator cover 1 Refer to Generator Removal and Installation in Section 1J Page 1J 5 3 Remove the starter idle gear 2 and starter idle gear shaft 3 with the washers 4 4 Remove the generator rotor assembly 5 Refer to Generator Removal and Installation in Section 1J Page 1J 5 1 I933H1190020 01 2 3 I933H1190021 01 4 4 I933H1190022 01 1 I...

Page 271: ...val Pay attention to the following points Starter clutch Apply engine oil to the one way clutch 1 When inserting the one way clutch 1 into the guide 2 fit the flange A in the step of the guide 2 NOTE Be sure to seat the flange A of the one way clutch 1 to the guide 2 Install the guide to the generator rotor NOTE The arrow mark B must face the generator rotor side 6 7 I933H1190026 01 A I933H1190027...

Page 272: ...haft hole M O Molybdenum oil MOLYBDENUM OIL SOLUTION After installing the generator cover pour engine oil Refer to Engine Oil and Filter Replacement in Section 0B Page 0B 11 Starter torque limiter Apply molybdenum oil solution to the inside of bushings M O Molybdenum oil MOLYBDENUM OIL SOLUTION Fit the washers 1 onto the starter torque limiter 2 Apply engine oil to the starter torque limiter 2 Ins...

Page 273: ... Starter Clutch Related Parts Inspection B933H21906010 Refer to Starter Torque Limiter Starter Clutch Removal and Installation Page 1I 8 Starter clutch 1 Install the starter driven gear onto the starter clutch 2 Turn the starter driven gear by hand to inspect the starter clutch for smooth movement The gear turns in one direction only If a large resistance is felt for rotation inspect the starter c...

Page 274: ... bearing must face outside Starter Button Inspection B933H21906012 Inspect the starter button in the following procedures 1 Remove the left side cover Refer to Exterior Parts Removal and Installation in Section 9D Page 9D 4 2 Disconnect the handlebar switch coupler 1 and clutch lever switch coupler 2 3 Inspect the starter button for continuity with a tester If any abnormality is found replace the ...

Page 275: ...htening Torque Specifications in Section 0C Page 0C 6 Item Specification Note Starter motor brush length Standard 10 0 39 Limit 6 5 0 26 Starter relay resistance 3 6 Ω Fastening part Tightening torque Note N m kgf m lb ft Starter motor mounting bolt 10 1 0 7 0 Page 1I 4 Starter motor lead wire mounting nut 6 0 6 4 5 Page 1I 4 Starter motor brush holder mounting nut 7 0 7 5 0 Page 1I 4 Starter moto...

Page 276: ...1I 10 Moly paste SUZUKI Moly paste or equivalent P No 99000 25140 Page 1I 5 Molybdenum oil MOLYBDENUM OIL SOLUTION Page 1I 10 Page 1I 10 Thread lock cement THREAD LOCK CEMENT SUPER 1322 or equivalent P No 99000 32110 Page 1I 10 09900 20102 09900 25008 Vernier calipers 1 20 mm 200 mm Multi circuit tester set Page 1I 5 Page 1I 6 Page 1I 7 Page 1I 7 Page 1I 7 Page 1I 12 09913 70210 09930 44520 Bearin...

Page 277: ...il Replace Short circuited or punctured regulator rectifier Replace Generator does charge but charging rate is below the specification Lead wires tend to get short or open circuited or loosely connected at terminals Repair or retighten Grounded or open circuited generator coil Replace Defective regulator rectifier Replace Defective cell plates in the battery Replace the battery Generator overcharg...

Page 278: ... left unused in a cold climate for too long Replace the battery if badly sulfated Condition Possible cause Correction Reference Item Step Action Yes No 1 Check accessories which use excessive amounts of electricity Are accessories being installed Remove accessories Go to Step 2 2 Check the battery for current leakage Refer to Battery Current Leakage Inspection Page 1J 3 Is the battery for current ...

Page 279: ...egulated Voltage Inspection B933H21A06002 Inspect the regulated voltage in the following procedures 1 Remove the seat Refer to Exterior Parts Removal and Installation in Section 9D Page 9D 4 2 Connect the tachometer onto the spark plug high tension cord 3 Start the engine and keep it running at 5 000 r min with the dimmer switch turned HI position 4 Measure the DC voltage between the and battery t...

Page 280: ...ct the generator coupler 1 No load performance 1 Connect the tachometer onto the spark plug high tension cord 2 Disconnect the generator coupler 1 3 Start the engine and keep it running at 5 000 r min 4 Using the multi circuit tester measure the voltage between three lead wires If the tester reads under the specified value replace the generator with a new one Special tool 09900 25008 Multi circuit...

Page 281: ...1 and generator coupler 2 5 Remove the fuel pump mounting bolts 3 6 Release the CKP sensor and generator lead wires from the clamp 7 Remove the generator cover 4 8 Remove the gasket 5 and dowel pin 9 Remove the starter idle gear 6 and shaft 7 with the washers 10 Hold the generator rotor with the special tool Special tool A 09930 44520 Rotor holder 11 Loosen the generator rotor nut NOTE When loosen...

Page 282: ...of removal Pay attention to the following points When installing the generator stator or CKP sensor route the wire properly Tighten the generator stator set bolts lead wire bracket bolt and CKP sensor mounting bolts to the specified torque Refer to Wiring Harness Routing Diagram in Section 9A Page 9A 3 NOTE Be sure the grommet 1 is set to the generator cover Tightening torque Generator stator set ...

Page 283: ...Special tool A 09930 44520 Rotor holder Tightening torque Generator rotor nut d 120 N m 12 0 kgf m 87 0 lb ft Apply molybdenum oil solution to the idle gear shaft holes M O Molybdenum oil MOLYBDENUM OIL SOLUTION Install the dowel pins and new gasket 2 CAUTION Use a new gasket to prevent oil leakage Apply grease to the starter motor O ring Grease 99000 25160 Water resistance grease or equivalent CA...

Page 284: ...lt e 10 N m 1 0 kgf m 7 0 lb ft Adjust the reverse lock cable play Refer to Reverse Lock Cable Play Inspection and Adjustment in Section 5B Page 5B 1 After installing the removed parts pour engine oil Refer to Engine Oil and Filter Replacement in Section 0B Page 0B 11 Regulator Rectifier Inspection B933H21A06005 Inspect the regulator rectifier in the following procedures 1 Turn the ignition switch...

Page 285: ...emoved parts Battery Components B933H21A06006 Battery Charging B933H21A06007 Initial charging Filling electrolyte NOTE When filling electrolyte the battery must be removed from the vehicle and must be put on the level ground 1 Remove the aluminum tape 1 which seals the battery filler holes A B E D A C F I933H11A0023 01 A B C D E F probe of tester to A 0 4 1 1 0 1 0 8 0 1 0 8 0 1 0 8 B C D 0 1 0 8 ...

Page 286: ...all NOTE Do not allow any of the electrolyte to spill 5 Make sure that air bubbles 4 rise to the top of each electrolyte container and leave in this position for about more than 20 minutes NOTE If no air bubbles come out from a filler port tap the bottom of the electrolyte container two or three times Never remove the container from the battery 6 After confirming that the electrolyte has entered t...

Page 287: ...charging NOTE When the vehicle is not used for a long period check the battery every 1 month to prevent the battery discharge 1 Remove the battery from the vehicle Refer to Battery Removal and Installation Page 1J 12 2 Measure the battery voltage using the multi circuit tester If the voltage reading is less than the 12 V DC recharge the battery with a battery charger Recharging time 0 9 A for 5 to...

Page 288: ...thread lock to the battery plate mounting bolts and tighten them Thread lock cement 99000 32110 THREAD LOCK CEMENT SUPER 1322 or equivalent Route the battery lead wire harness properly Refer to Wiring Harness Routing Diagram in Section 9A Page 9A 3 Battery Visual Inspection B933H21A06009 Inspect the battery in the following procedures 1 Remove the seat Refer to Exterior Parts Removal and Installat...

Page 289: ...0 1 1 5 Ω Generator maximum output 200 W at 5 000 r min Generator no load voltage When engine is cold 55 V AC and more at 5 000 r min Regulated voltage 13 5 15 0 V at 5 000 r min Battery Type designation YTX9 BS Capacity 12 V 28 8 kC 8 Ah 10 HR Fastening part Tightening torque Note N m kgf m lb ft Generator stator set bolt 11 1 1 8 0 Page 1J 6 CKP sensor mounting bolt 5 5 0 55 4 0 Page 1J 6 Genera...

Page 290: ... 25160 Page 1J 7 Molybdenum oil MOLYBDENUM OIL SOLUTION Page 1J 7 Thread lock cement THREAD LOCK CEMENT SUPER 1322 or equivalent P No 99000 32110 Page 1J 12 09900 25008 09900 26006 Multi circuit tester set Engine tachometer solar cell type Page 1J 3 Page 1J 3 Page 1J 4 Page 1J 4 Page 1J 9 Page 1J 3 Page 1J 4 09930 31921 09930 44520 Rotor remover Rotor holder Page 1J 6 Page 1J 5 Page 1J 7 P a r t S...

Page 291: ...k of being burned do not touch the exhaust system when the system is hot Any service on the exhaust system should be performed when the system is cool CAUTION Make sure that the exhaust pipe and muffler have enough clearance from the rubber parts and plastic parts to avoid melting P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 292: ...2 7 b 8 I933H11B0012 03 1 Exhaust pipe 5 Muffler mounting bolt 23 N m 2 3 kgf m 16 5 lb ft 2 Muffler 6 Muffler connecting bolt 13 N m 1 3 kgf m 9 5 lb ft 3 Connector 7 Spark arrester Apply muffler seal 4 Exhaust pipe nut 8 Spark arrester mounting bolt Do not reuse P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 293: ...e 3 6 Remove the exhaust pipe 4 by removing the exhaust pipe mounting nuts NOTE Support the exhaust pipe to prevent it from falling 7 Remove the exhaust pipe gasket 5 Installation Install the muffler exhaust pipe in the reverse order of removal Pay attention to the following points CAUTION Replace the gasket and connector with new ones Install the new exhaust pipe gasket 1 Tighten the exhaust pipe...

Page 294: ...ion B933H21B06003 Inspect the exhaust pipe connection and muffler connection for exhaust gas leakage and mounting condition If any defect are found replace the exhaust pipe assembly or muffler with a new one Check the exhaust pipe nuts 1 muffler connecting bolt 2 and muffler mounting bolts 3 are tightened to their specified torque Tightening torque Exhaust pipe nut a 23 N m 2 3 kgf m 16 5 lb ft Mu...

Page 295: ...d Service Material B933H21B08001 NOTE Required service material is also described in the following Exhaust System Construction Page 1K 2 Fastening part Tightening torque Note N m kgf m lb ft Exhaust pipe mounting nut 23 2 3 16 5 Page 1K 3 Muffler mounting bolt 23 2 3 16 5 Page 1K 4 Page 1K 4 Muffler connecting bolt 23 2 3 16 5 Page 1K 4 Page 1K 4 Exhaust pipe nut 23 2 3 16 5 Page 1K 4 Material SUZ...

Page 296: ...1K 6 Exhaust System P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 297: ...nt 2B 16 Recommended Service Material 2B 16 Special Tool 2B 17 Rear Suspension 2C 1 Repair Instructions 2C 1 Rear Suspension Components 2C 1 Rear Suspension Assembly Construction 2C 2 Rear Shock Absorber Removal and Installation 2C 3 Rear Suspension Inspection 2C 4 Rear Shock Absorber Inspection 2C 4 Rear Suspension Absorber Adjustment 2C 4 Rear Shock Absorber Disposal 2C 5 Rear Wheel Hub Removal ...

Page 298: ... to the specified torque periodically and if the suspension effect is lost replace it with a new one CAUTION Never attempt to heat quench or straighten any suspension part Replace it with a new one or damage to the part may result NOTE The right and left suspension related parts shock absorbers suspension arms and knuckles are installed symmetrically and therefore the removal procedure for one sid...

Page 299: ...t Front suspension too noisy Loose front suspension system bolts Tighten Worn front wishbone arms and related bushings Replace Worn swingarm and suspension bearings Replace Wobbly rear wheel Distorted rear wheel rims Replace Damage or worn rear axel housing bearings Replace Defective or incorrect rear tires Replace Loose rear wheel hub nuts Tighten Worn rear suspension bushings Replace Loose rear ...

Page 300: ...sion Repair Instructions Front Suspension Components B933H22206001 1 3 5 5 5 6 6 7 7 8 8 9 11 14 14 15 4 4 a b b d c 10 10 c 10 5 c 16 15 18 19 20 21 18 22 23 b 10 FWD FWD 19 2 12 13 a 17 I933H1220001 14 P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 301: ...g Apply thread lock to the thread part 9 Spacer 20 Spacer Do not reuse 10 Cotter pin 21 Front wheel hub 11 Steering knuckle 22 Spacer a e a d 7 4 c f b a 6 2 g b g d 3 5 b b 1 a 4 c I933H1220066 03 1 Front shock absorber 65 N m 6 5 kgf m 47 0 lb ft 2 Front hub plate 29 N m 2 9 kgf m 21 0 lb ft 3 Steering knuckle 23 N m 2 3 kgf m 16 5 lb ft 4 Tie rod end 26 N m 2 6 kgf m 19 0 lb ft 5 Upper wishbone...

Page 302: ...ivalent Tightening torque Front shock absorber mounting nut a 60 N m 6 0 kgf m 43 5 lb ft Front Suspension Inspection B933H22206004 Refer to Suspensions Inspection in Section 0B Page 0B 22 Front Shock Absorber Parts Inspection B933H22206005 Refer to Front Shock Absorber Removal and Installation Page 2B 3 Front shock absorber Inspect the front shock absorber for damage and oil leakage and absorber ...

Page 303: ...adjustable This adjustment is performed by changing spring set length CAUTION Do not set the spring length out of the specified range 3 Loosen the lock nut 1 with the special tool Special tool A 09910 60611 Universal clamp wrench 4 Adjust the spring pre load length by turning the adjuster 2 5 Tighten the lock nut 1 to the specified torque Tightening torque Front shock absorber lock nut 34 N m 3 4 ...

Page 304: ...sure release Make sure to observe the following precautions WARNING Never apply heat or disassemble the shock absorber unit since it can explode or oil can splash hazardously When discarding the shock absorber unit be sure to release gas pressure from the unit following the procedures 1 Make the drill center at the location A using a center punch 2 Wrap front shock absorber 1 with a plastic bag 2 ...

Page 305: ...ub 6 by removing wheel hub nut 7 and washer 8 6 Remove the collar 9 and spacer 10 7 Remove the front disc brake cover 11 8 Remove the cotter pin 12 tie rod end nut 13 and spring washer 14 9 Disconnect the tie rod end with the special tool Special tool A 09942 72410 Tie rod end remover 10 Remove the cotter pins knuckle end nuts spring washers and washers 11 Remove the steering knuckle 15 with a com...

Page 306: ...9 kgf m 21 0 lb ft Tie rod end nut b 29 N m 2 9 kgf m 21 0 lb ft Install the cotter pins 5 CAUTION The removed cotter pins 5 must be replaced with new ones Apply grease to the dust seal lips collar and spacer Grease 99000 25160 Water resistance grease or equivalent Apply thread lock to the brake disc cover mounting bolts Thread lock cement 99000 32130 THREAD LOCK CEMENT SUPER 1360 or equivalent Ap...

Page 307: ...s Inspection B933H22206009 Refer to Front Wheel Hub Steering Knuckle Removal and Installation Page 2B 6 Dust seal Inspect the dust seal lips for wear or damage if any defects is found replace the dust seal with a new ones Hub bearing Inspect the inner race play of the hub bearing by hand while it is in the wheel hub Rotate the inner races by hand to inspect for abnormal noise and smooth rotation I...

Page 308: ... Hub Steering Knuckle Removal and Installation Page 2B 6 2 Remove the dust seals 1 with the special tool Special tool A 09913 50121 Oil seal remover 3 Remove the hub bearings 2 with the special tool Special tool B 09921 20240 Bearing remover set 4 Remove the spacer 3 Installation CAUTION The removed dust seals and bearings must be replaced with new ones 1 Apply grease to the hub bearings Grease 99...

Page 309: ...al and Installation Page 2B 6 Front Suspension Upper Lower Wishbone Arm Removal and Installation B933H22206012 Removal 1 Remove the front wheel assembly Refer to Front Rear Wheel Removal and Installation in Section 2D Page 2D 2 2 Remove the front brake caliper Refer to Front Brake Caliper Removal and Installation in Section 4B Page 4B 3 3 Remove the front wheel hub Refer to Front Wheel Hub Steerin...

Page 310: ...ot nuts 1 to the specified torque Tightening torque Wishbone arm pivot nut a 65 N m 6 5 kgf m 47 0 lb ft Tighten the front shock absorber lower mounting bolt and nut 2 to the specified torque Tightening torque Front shock absorber mounting nut b 60 N m 6 0 kgf m 43 5 lb ft Install the brake hose Refer to Brake Hose Removal and Installation in Section 4A Page 4A 9 Install the wishbone arms to the s...

Page 311: ... to Knuckle End Removal and Installation Page 2B 12 or Front Suspension Wishbone Arm Dust Seal Bearing Removal and Installation Page 2B 13 Knuckle End Removal and Installation B933H22206014 Removal 1 Remove the front suspension wishbone arm Refer to Front Suspension Upper Lower Wishbone Arm Removal and Installation Page 2B 10 2 Remove the snap ring 1 Special tool 09900 06107 Snap ring pliers 3 Rem...

Page 312: ...earing remover B 09930 30104 Rotor remover slide shaft Installation Install the front suspension wishbone dust seal bearing in the reverse order of removal Pay attention to the following points CAUTION The removed dust seals and bearings must be replaced with new ones NOTE Stamped marks on the dust seals and bearings must face outside Install the bearings with the special tool and a suitable size ...

Page 313: ...arts Inspection B933H22206016 Refer to Front Suspension Wishbone Arm Dust Seal Bearing Removal and Installation Page 2B 13 Upper wishbone arm 1 Remove the knuckle end boot Refer to Knuckle End Removal and Installation Page 2B 12 2 Inspect the upper wishbone arm for wear or damage If any defects are found replace the upper wishbone arm with a new one 3 Install the knuckle end boot Refer to Knuckle ...

Page 314: ...he spacers and collars for wear and damage If any defects are found replace the spacers with the new ones Dust seal Inspect the dust seal lips for wear or damage If any defects are found replace the dust seal with the new ones Bearing Insert the spacer or collar into the bearing and then check the play when moving the spacer up and down If excessive is noted replace the bearing with a new one I933...

Page 315: ...t shock absorber spring pre load length 288 5 11 36 Front suspension damping force adjuster Compression 1 and 1 4 turns out Front wheel travel 215 8 5 Fastening part Tightening torque Note N m kgf m lb ft Front shock absorber mounting nut 60 6 0 43 5 Page 2B 3 Page 2B 11 Front shock absorber lock nut 34 3 4 24 5 Page 2B 4 Steering knuckle end nut 29 2 9 21 0 Page 2B 7 Tie rod end nut 29 2 9 21 0 P...

Page 316: ...aring installer set Page 2B 9 Page 2B 10 Page 2B 10 Page 2B 12 Page 2B 12 Page 2B 14 09921 20240 09923 73210 Bearing remover set Bearing remover Page 2B 9 Page 2B 13 09924 84510 09924 84521 Bearing installer set Bearing installer set Page 2B 10 Page 2B 13 09930 30104 09942 72410 Rotor remover slide shaft Tie rod end remover Page 2B 13 Page 2B 6 P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 317: ...lb ft 2 Cushion rod 10 Chain buffer 95 N m 9 5 kgf m 68 5 lb ft 3 Cushion lever 11 Dust cover 30 N m 3 0 kgf m 21 5 lb ft 4 Collar 12 Swingarm under cover Apply water resistance grease 5 Grease nipple 13 Chain adjuster nut Apply thread lock to thread part 6 Cushion lever cover 60 N m 6 0 kgf m 43 5 lb ft Do not reuse 7 Chain adjuster plate 78 N m 7 8 kgf m 56 5 lb ft 8 Boot 5 5 N m 0 55 kgf m 4 0 ...

Page 318: ...67 05 1 Rear shock absorber mounting nut Upper 5 Cushion rod nut Upper Apply water resistance grease 2 Rear shock absorber mounting nut Lower 60 Nm 6 0 kgf m 43 5 lb ft a 45 3 Cushion rod nut Lower 78 Nm 7 8 kgf m 56 5 lb ft b 4 mm 0 6 in 4 Cushion lever nut 5 5 Nm 0 55 kgf m 4 0 lb ft c 4 5 mm 0 18 in P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 319: ...rear shock absorber Installation 1 Apply thread lock to the rear shock absorber mounting bolts and tighten the nuts to the specified torque Thread lock cement 99000 32110 THREAD LOCK CEMENT SUPER 1322 or equivalent Tightening torque Rear shock absorber mounting nut a 60 N m 6 0 kgf m 43 5 lb ft 2 Install the cushion rod and cushion lever Refer to Cushion Rod Cushion Lever Removal and Installation ...

Page 320: ...he spring pre load length if necessary NOTE The rear suspension spring pre load is adjustable This adjustment is performed by changing spring set length CAUTION Do not set the spring length out of the specified range Spring pre load length 3 Loosen the lock nut 1 with the special tool Special tool A 09910 60611 Universal clamp wrench 4 Adjust the spring pre load length by turning the adjuster 2 5 ...

Page 321: ...shock absorber unit since it can explode or oil can splash hazardously When discarding the shock absorber unit be sure to release gas pressure from the unit following the procedures 1 Make the drill center at the location A using a center punch 2 Wrap rear shock absorber 1 with a plastic bag 2 and fix it on a vise as shown in the figure 3 Drill a 2 3 mm 0 08 0 12 in hole at the marked drill center...

Page 322: ...ide Refer to Rear Suspension Assembly Construction Page 2C 2 4 Install the rear wheel assembly Refer to Front Rear Wheel Removal and Installation in Section 2D Page 2D 2 5 Tighten the hub nut 4 to the specified torque Tightening torque Rear wheel hub nut a 121 N m 12 1 kgf m 87 5 lb ft 6 Install the cotter pin 5 CAUTION The removed cotter pin 5 must be replaced with a new one Rear Wheel Hub Inspec...

Page 323: ...ead lock to the rear shock absorber mounting bolt Thread lock cement 99000 32110 THREAD LOCK CEMENT SUPER 1322 or equivalent 2 Tighten the cushion lever nut 1 and rear shock absorber mounting nut 2 to the specified torque Tightening torque Cushion lever nut a 78 N m 7 8 kgf m 56 5 lb ft Rear shock absorber mounting nut b 60 N m 6 0 kgf m 43 5 lb ft I933H1230017 01 1 I933H1230018 01 I933H1230019 01...

Page 324: ...e Tightening torque Cushion lever cover bolt d 5 5 N m 0 55 kgf m 4 0 lb ft Cushion Lever Dust Seal Bearing Removal and Installation B933H22306011 Removal 1 Remove the cushion lever Refer to Cushion Rod Cushion Lever Removal and Installation Page 2C 7 2 Remove the collars 1 and spacers 2 3 Remove the dust seals 3 c 3 I933H1230024 03 A 4 I933H1230025 01 I933H1230026 01 d 5 I933H1230028 01 2 1 1 2 I...

Page 325: ...of the bearings is shown in the figure 2 Apply grease to the bearings Grease 99000 25160 Water resistance grease or equivalent 3 Install the dust seals with the special tool Special tool B 09913 70210 Bearing installer set 4 Apply grease to the oil seal lips Grease 99000 25160 Water resistance grease or equivalent 5 Install the spacers and collars into the cushion lever 6 Install the cushion lever...

Page 326: ...stallation CAUTION The removed dust seals and bearings must be replaced with new ones NOTE Stamped marks on the dust seals and bearings must face outside 1 Install the bearings with the special tool and suitable size socket wrench Special tool A 09924 84521 Bearing installer set NOTE Position of the bearings is shown in the figure 2 Apply grease to the bearings Grease 99000 25160 Water resistance ...

Page 327: ...st Seal Bearing Removal and Installation Page 2C 8 and Cushion Rod Dust Seal Bearing Removal and Installation Page 2C 10 2 Inspect the spacers for any flaws or other damage If any defects are found replace the spacers with new ones 3 Install the spacers and collars Dust seal 1 Remove the collars and spacers Refer to Cushion Lever Dust Seal Bearing Removal and Installation Page 2C 8 and Cushion Rod...

Page 328: ...2C 8 and Cushion Rod Dust Seal Bearing Removal and Installation Page 2C 10 Cushion rod Cushion lever Inspect the cushion rod cushion lever for damage If any defect is found replace them with new ones Swingarm Removal and Installation B933H22306014 Removal 1 Remove the rear shock absorber Refer to Rear Shock Absorber Removal and Installation Page 2C 3 2 Remove the rear axle housing Refer to Rear Ax...

Page 329: ...rs lip Grease 99000 25160 Water resistance grease or equivalent Tighten the swingarm pivot nut to the specified torque Tightening torque Swingarm pivot nut a 95 N m 9 5 kgf m 68 5 lb ft Install the brake hose and parking brake cable Refer to Rear Brake Hose Routing Diagram in Section 4A Page 4A 2 and Hose and Cable Routing Diagram in Section 4A Page 4A 3 3 4 I933H1230052 01 5 I933H1230051 01 6 6 7...

Page 330: ...ls and bearings must face outside 1 Install the bushings and bearings with the special tool and suitable size socket wrench Special tool A 09924 84510 Bearing installer set NOTE Press the bushings at 6 0 mm 0 23 in depth from swingarm edge and bearings at 5 0 mm 0 20 in depth from swingarm edge Refer to Rear Axle Assembly Construction in Section 3A Page 3A 3 2 Apply grease to the bushings and bear...

Page 331: ...ge 2C 14 Chain buffer Inspect the chain buffer for wear and damage If any defect is found replace the chain buffer with a new one Swingarm bearing and bushing 1 Remove the dust seals Refer to Swingarm Dust Seal Bearing Removal and Installation Page 2C 14 2 Insert the spacers into bearing and bushing 3 Check the play by moving the spacers up and down If excessive play is noted replace the bearing w...

Page 332: ... Rear Suspension Assembly Construction Page 2C 2 Reference For the tightening torque of fastener not specified in this section refer to Tightening Torque Specifications in Section 0C Page 0C 6 I933H1230066 01 A B C I649G1230034 03 Item Standard Limit Rear shock absorber spring pre load length 234 8 9 24 Rear shock absorber damping force adjuster Rebound 1 and 1 4 turns out Compression 2 turns out ...

Page 333: ...ge 2C 14 Page 2C 15 Thread lock cement THREAD LOCK CEMENT SUPER 1322 or equivalent P No 99000 32110 Page 2C 3 Page 2C 7 09900 20607 09900 20701 Dial gauge 1 100 mm 10 mm Magnetic stand Page 2C 16 Page 2C 16 09900 21304 09910 60611 V block 100 mm Universal clamp wrench Page 2C 16 Page 2C 4 09913 70210 09923 73210 Bearing installer set Bearing remover Page 2C 9 Page 2C 11 Page 2C 14 Page 2C 9 Page 2...

Page 334: ...ehicle Do not use tires of sizes and types different from the originally installed tires Rotation of tires or use of such different tires may adversely affect handling of the vehicle and can result in loss of control Replace the wheel if it is deformed or has cracks or scratches Also replace the wheel if its runout exceeds the service limit Replacement wheels must be equivalent to the originally i...

Page 335: ...ints Tighten the wheel set nuts to the specified torque WARNING When installing the front wheel make sure that the arrow A on the tire points in the direction of rotation When installing the rear wheel make sure that the instruction SIDE FACING OUTWARDS B on the rear tire faces outwards Tighten the wheel set nuts diagonally Tightening torque Wheel set nut Front and Rear 66 N m 6 6 kgf m 47 5 lb ft...

Page 336: ...tely as shown in the figure 4 Separate the tire from the rim using a set of tire levers and rim protectors CAUTION When using the tire levers do not scratch or hit the sealing portion hump of the wheel or it may cause air leakage Installation CAUTION Do not reuse the valve which has been once removed 1 Clean up the sealing portion of the rim 2 Apply tire lubricant to the tire bead and the flange o...

Page 337: ...tire under a protective tire cage or similar protective covering device before inflating the tire To minimize the possibility of tire damage when seating the tire bead never exceed the MAXIMUM TIRE BEAD SEAT PRESSURE rating shown on the tire Maximum tire bead seat pressure Front 250 kPa 2 5 kgf cm2 36 psi Rear 250 kPa 2 5 kgf cm2 36 psi NOTE Check the rim line C cast on the tire sidewalls It must ...

Page 338: ...d replace the wheel with a new one Tire Refer to Tire Inspection in Section 0B Page 0B 19 Specifications Service Data B933H22407001 Wheel Unit mm in Tire Tightening Torque Specifications B933H22407002 NOTE The specified tightening torque is also described in the following Front and Rear Wheel Components Page 2D 1 Reference For the tightening torque of fastener not specified in this section refer t...

Page 339: ...val and Installation 3A 5 Rear Axle Nut and Lock Nut Tightening Torque 3A 7 Drive Chain Related Parts Inspection 3A 8 Drive Chain Replacement 3A 8 Drive Chain Roller Construction 3A 11 Drive Chain Roller Inspection 3A 12 Drive Chain Roller Removal and Installation 3A 12 Rear Axle Housing Removal and Installation 3A 12 Rear Axle Related Parts Inspection 3A 13 Rear Axle Dust Seal Bearing Removal and...

Page 340: ... spray type chain cleaner and blow dry with compressed air If the drive chain cannot be cleaned with a spray cleaner it may be necessary to use a kerosine Always follow the chemical manufacturer s instructions on proper use handling and storage Lubricate the drive chain with a heavy weight motor oil Wipe off any excess oil or chain lubricant Do not use any oil sold commercially as drive chain oil ...

Page 341: ...edures Drive Chain and Sprocket Symptom Diagnosis B933H23104001 Condition Possible cause Correction Reference Item Noisy Drive Chain Worn sprocket Replace Worn drive chain Replace Stretched drive chain Replace Too large drive chain slack Adjust Drive chain out of adjustment Adjust P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 342: ...0 N m 24 0 kgf m 173 5 lb ft 2 Rear axle lock nut 9 Bearing 60 N m 6 0 kgf m 43 5 lb ft 3 Rear axle nut bolt 10 Spacer Apply water resistance grease 4 Rear axle nut 11 Rear axle housing Apply thread lock to the thread part 5 Concave washer 12 Rear axle Apply thread lock to the thread part 6 Rear sprocket 13 Engine sprocket Do not reuse 7 Sprocket flange 14 Drive chain P a r t S h a r k c o m 8 7 7...

Page 343: ... 68 5 lb ft Apply water resistance grease 3 Rear sprocket mounting nut 23 N m 2 3 kgf m 16 5 lb ft Do not reuse 4 Rear axle lock nut 60 N m 6 0 kgf m 43 5 lb ft a 5 0 mm 0 20 in 5 Rear axle nut 240 N m 24 0 kgf m 173 5 lb ft b 2 0 mm 0 08 in 6 Chain adjuster nut 30 N m 3 0 kgf m 21 5 lb ft c 6 0 mm 0 23 in 7 Rear wheel hub nut 121 N m 12 1 kgf m 87 5 lb ft 8 Rear axle housing bolt 100 N m 10 0 kgf...

Page 344: ...ain adjuster nut 4 and rear axle housing bolts 5 to provide additional chain slack 5 Remove the engine sprocket 6 with drive chain Installation 1 Install the engine sprocket 1 with drive chain NOTE The letter A on the engine sprocket should face to the outside 1 I933H1310001 01 2 I933H1310002 01 3 I933H1310003 02 5 5 4 I933H1310004 01 6 I933H1310005 01 1 A I933H1310006 01 P a r t S h a r k c o m 8...

Page 345: ...val 1 Place the vehicle on the level ground and support the vehicle with a jack or wooden black 2 Remove the rear wheel hub Refer to Rear Wheel Hub Removal and Installation in Section 2C Page 2C 6 3 Loosen the rear axle lock nut 1 and axle nut 2 with the special tool by applying the rear brake Special tool A 09940 92460 Rear axle nut wrench set 4 Remove the rear axle lock nut 1 5 Loosen the rear a...

Page 346: ...y attention to the following point Tighten the rear sprocket mounting nuts to the specified torque NOTE The stamped mark A must face to right side of the vehicle Tightening torque Rear sprocket mounting nut a 60 N m 6 0 kgf m 43 5 lb ft Apply grease to the O ring and spline of sprocket flange CAUTION Replace the O ring with a new one Grease 99000 25160 Water resistance grease or equivalent 6 6 9 8...

Page 347: ...torque with the special tool Refer to Rear Axle Nut and Lock Nut Tightening Torque Page 3A 7 Special tool A 09940 92460 Rear axle nut wrench set Tightening torque Rear axle lock nut b 240 N m 24 0 kgf m 173 5 lb ft Adjust the drive chain slack Refer to Drive Chain Inspection and Adjustment in Section 0B Page 0B 15 Rear Axle Nut and Lock Nut Tightening Torque B933H23106005 Tighten the rear axle nut...

Page 348: ...6007 Use the special tool in the following procedures to cut and rejoin the drive chain NOTE When using the special tool apply a small quantity of grease to the threaded parts of the special tool Special tool 09922 22711 Drive chain cutting and joining tool Drive chain cutting 1 Set up the special tool as shown in the figure NOTE The tip of pin remover 1 should be positioned inside a approximately...

Page 349: ...pins O rings and plates Drive chain connecting WARNING Do not use joint clip type of drive chain The joint clip may have a chance to drop which may cause severe damage to vehicle and severe injury Joint plate installation 1 Set up the special tool as shown in the figure 2 Apply grease to the joint pins 8 O rings 9 and plates 10 CAUTION Replace the joint pins 8 O rings 9 and plates 10 with new ones...

Page 350: ...te makes the dimension out of specification excessively the work must be carried out again by using new joint parts Joint pin staking 1 Set up the special tool as shown in the figure NOTE Before staking the joint pin apply a small quantity of grease to the staking pin 5 2 Stake the joint pin by turning approximately 7 8 turn the pressure bolt A 3 with the bar until the pin end diameter becomes the...

Page 351: ...onnecting it Refer to Drive Chain Inspection and Adjustment in Section 0B Page 0B 15 Drive Chain Roller Construction B933H23106008 a I649G1310036 03 a 1 2 3 I933H1310048 02 1 Drive chain roller 3 Washer 2 Frame 40 N m 4 0 kgf m 29 0 lb ft P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 352: ... bolt to the specified torque Tightening torque Drive chain roller mounting bolt a 40 N m 4 0 kgf m 29 0 lb ft Rear Axle Housing Removal and Installation B933H23106011 Removal 1 Remove the rear sprocket Refer to Rear Sprocket Removal and Installation Page 3A 5 2 Draw out the rear axle Refer to Rear Brake Disc Removal and Installation in Section 4C Page 4C 8 3 Remove the rear axle housing bolts 1 a...

Page 353: ...ar Axle Housing Removal and Installation Page 3A 12 Dust seal Inspect the dust seal lips for wear or damage If any defects are found replace the dust seal with the new ones Refer to Rear Axle Dust Seal Bearing Removal and Installation Page 3A 14 Wheel bearing Inspect the play of the axle bearings by finger while they are in the axle housing Rotate the inner race by finger to inspect for abnormal n...

Page 354: ...rear axle as shown in the figure Special tool A 09900 20607 Dial gauge 1 100 mm 10 mm 09900 20701 Magnetic stand 09900 21304 V block 100 mm Rear axle runout Service limit 6 0 mm 0 24 in 3 Reinstall the removed parts Rear Axle Dust Seal Bearing Removal and Installation B933H23106013 Removal 1 Remove the rear axle housing Refer to Rear Axle Housing Removal and Installation Page 3A 12 2 Remove the du...

Page 355: ...earings must face outside Install the dust seals with the special tool NOTE The stamped mark on the dust seals must face outside Press the left dust seal at 2 0 mm 0 08 in depth from rear axle housing edge and right dust seal at 5 0 mm 0 20 in depth from rear axle housing edge Refer to Rear Suspension Assembly Construction in Section 2C Page 2C 2 Special tool D 09913 70210 Bearing installer set Ap...

Page 356: ... of fastener not specified in this section refer to Tightening Torque Specifications in Section 0C Page 0C 6 Item Standard Limit Final reduction ratio 2 857 40 14 Drive chain Type RK520SMOZ10S Links 96 20 pitch length 319 4 12 57 Drive chain slack on center stand 30 40 1 2 1 6 Item Standard Limit Wheel axle runout Rear 6 0 0 24 Fastening part Tightening torque Note N m kgf m lb ft Rear sprocket mo...

Page 357: ...LOCK CEMENT SUPER 1303 or equivalent P No 99000 32030 Page 3A 5 THREAD LOCK CEMENT SUPER 1322 or equivalent P No 99000 32110 Page 3A 7 09900 06107 09900 20607 Snap ring pliers Dial gauge 1 100 mm 10 mm Page 3A 13 Page 3A 14 09900 20701 09900 21304 Magnetic stand V block 100 mm Page 3A 14 Page 3A 14 09913 50121 09913 70210 Oil seal remover Bearing installer set Page 3A 14 Page 3A 15 Page 3A 15 0992...

Page 358: ...3A 18 Drive Chain Drive Train Drive Shaft P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 359: ...ervice Data 4A 20 Tightening Torque Specifications 4A 20 Special Tools and Equipment 4A 21 Recommended Service Material 4A 21 Special Tool 4A 21 Front Brakes 4B 1 Repair Instructions 4B 1 Front Brake Components 4B 1 Front Brake Pad Inspection 4B 2 Front Brake Pad Replacement 4B 2 Front Brake Caliper Removal and Installation 4B 3 Front Brake Caliper Disassembly and Assembly 4B 4 Front Brake Caliper...

Page 360: ...rake Removal and Installation 4D 2 Parking Brake Inspection 4D 3 Specifications 4D 4 Tightening Torque Specifications 4D 4 Special Tools and Equipment 4D 4 Recommended Service Material 4D 4 P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 361: ...has been stored for a long period of time When storing brake fluid seal the container completely and keep it away from children When replenishing brake fluid take care not to get dust into the fluid When washing brake components use new brake fluid Never use cleaning solvent A contaminated brake disc or brake pad reduces braking performance Discard contaminated pads and clean the disc with high qu...

Page 362: ...ecified torque 2 White mark B After the brake hose union has contacted the stopper tighten the bolt to the specified torque 3 Black mark C Fix the brake hose sleeve to the clamp firmly 23 N m 2 3 kgf m 16 5 lb ft D Fix the brake hose sleeve to the guide as shown in the figure 6 N m 0 6 kgf m 4 5 lb ft E Set the black mark on hose to forward 18 N m 1 8 kgf m 13 0 lb ft F After tighten the nut set t...

Page 363: ...Brake hose C Set the white mark on hose to outside 3 Brake caliper D Fix the hose to the hose guide firmly 4 Reservoir E Fix the brake hose sleeve to the guide as shown in the figure 18 N m 1 8 kgf m 13 0 lb ft F Pass the brake hose between the rear swingarm and frame 26 N m 2 6 kgf m 19 0 lb ft Apply thread lock to the thread part 23 N m 2 3 kgf m 16 5 lb ft a 47 51 mm 1 9 2 0 in 10 N m 1 0 kgf m...

Page 364: ...057 05 1 Throttle cable 5 Reverse gear cable A Pass the throttle cable inside the steering cover 2 Starter cable 6 Reverse cable adjuster B Pass the starter cable inside the steering cover 3 Clutch cable 7 Clamp C Set the clamp as shown in the figure 4 Parking brake cable 8 Rear brake hose P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 365: ...he starter cable between fuel hose and reverse gear cable 2 Reverse gear cable 6 Starter cable C Set the reverse gear cable between the oil filter case and engine sprocket cover 3 Clutch cable 7 Fuel hose 4 Rear brake hose A Pass the reverse gear cable under the throttle cable and clutch cable P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 366: ...nd pads Worn disc Replace Air in hydraulic system Bleed air Not enough brake fluid in the reservoir Replenish Defective adjustment of parking brake Adjust Brake squeaking Carbon adhesion on pad surface Repair surface with sandpaper Tilted pad Correct pad fitting or replace Worn pads and disc Replace Foreign material in brake fluid Replace brake fluid Clogged return port of master cylinder Disassem...

Page 367: ... Inspection in Section 0B Page 0B 17 Brake Hose Inspection B933H24106006 Refer to Brake System Inspection in Section 0B Page 0B 17 Air Bleeding from Brake Fluid Circuit B933H24106007 Air trapped in the brake fluid circuit acts like a cushion to absorb a large proportion of the pressure developed by the master cylinder and thus interferes with the full braking performance of the brake caliper The p...

Page 368: ...stem replenish the brake fluid in the reservoir as necessary Make sure that there is always some fluid visible in the reservoir 7 Close the air bleeder valve 1 and disconnect the hose Tightening torque Brake air bleeder valve 6 N m 0 6 kgf m 4 5 lb ft 8 Fill the reservoir with brake fluid to the upper mark of the reservoir 9 Install the master cylinder reservoir cap Rear brake Bleed air from the r...

Page 369: ... old brake fluid as much as possible 3 Fill the reservoir with new brake fluid BF Brake fluid DOT 4 4 Connect a clear hose to the air bleeder valve 1 and insert the other end of the hose into a receptacle 5 Loosen the air bleeder valve 1 and pump the brake lever until the old brake fluid flows out of the brake system 6 Close the air bleeder valve 1 and disconnect the clear hose Tightening torque B...

Page 370: ...ervoir 9 Install the fuel tank cover Refer to Exterior Parts Removal and Installation in Section 9D Page 9D 4 Brake Hose Removal and Installation B933H24106009 Removal 1 Drain brake fluid Refer to Brake Fluid Replacement Page 4A 8 2 Remove the front and rear brake hoses as shown in the front and rear brake hose routing diagram Refer to Front Brake Hose Routing Diagram Page 4A 1 and Rear Brake Hose...

Page 371: ...FWD FWD FWD I933H1410060 04 1 Reservoir cap 6 Brake lever Apply silicone grease 2 Diaphragm 7 Brake lever pivot bolt Apply brake fluid 3 Master cylinder 10 N m 1 0 kgf m 7 0 lb ft Do not reuse 4 Piston Cup set 23 N m 2 3 kgf m 16 5 lb ft 5 Brake hose union bolt 16 N m 1 6 kgf m 11 5 lb ft P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 372: ...der holder s mating surface A with the punch mark B on the handlebars 2 and tighten the upper holder bolt first Tightening torque Front brake master cylinder holder bolt Upper and Lower a 10 N m 1 0 kgf m 7 0 lb ft Set the brake hose union as shown in the front brake hose routing diagram Refer to Front Brake Hose Routing Diagram Page 4A 1 After setting the brake hose union to the stopper tighten t...

Page 373: ...sembly Assemble the master cylinder in the reverse order of disassembly Pay attention to the following points CAUTION Wash the master cylinder components with new brake fluid before reassembly Do not wipe the brake fluid off after washing the components When washing the components use the specified brake fluid Never use different types of fluid or cleaning solvents such as gasoline kerosine etc Ap...

Page 374: ...rque Brake lever pivot bolt a 6 N m 0 6 kgf m 4 5 lb ft Brake lever pivot bolt lock nut b 6 N m 0 6 kgf m 4 5 lb ft Front Brake Master Cylinder Parts Inspection B933H24106013 Refer to Front Brake Master Cylinder Brake Lever Disassembly and Assembly Page 4A 12 Master Cylinder Inspect the master cylinder bore for any scratches or other damage Piston and rubber parts Inspect the piston surface primar...

Page 375: ...24106014 4 a b 2 a 3 5 1 I933H1410061 01 1 Brake pedal 5 White mark Do not reuse 2 Brake light switch 10 N m 1 0 kgf m 7 0 lb ft a 5 mm 0 2 in 3 O ring 18 N m 1 8 kgf m 13 0 lb ft 4 Brake master cylinder Apply water resistance grease P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 376: ...edal 9 and O rings 10 Installation Install the rear brake pedal in the reverse order of removal Pay attention to the following points CAUTION The removed cotter pin and O rings must be replaced with new ones Apply grease to the O rings and rear brake pedal pivot Grease 99000 25160 Water resistance grease or equivalent Install the brake pedal spring and rear brake light switch spring properly Refer...

Page 377: ...k 6 Piston cup set 18 N m 1 8 kgf m 13 0 lb ft 2 Brake hose union bolt 7 Push rod 10 N m 1 0 kgf m 7 0 lb ft 3 Master cylinder 8 Rear brake master cylinder lock nut Apply silicone grease 4 O ring 9 Rear brake master cylinder mounting bolt Apply brake fluid 5 Connector 23 N m 2 3 kgf m 16 5 lb ft Do not reuse P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 378: ...aster cylinder mounting bolts 8 11 Remove the master cylinder along with the reservoir by turning the push rod 9 Installation Install the rear brake master cylinder in the reverse order of removal Pay attention to the following points CAUTION The seal washers should be replaced with the new ones to prevent fluid leakage Tighten the master cylinder mounting bolts 1 to the specified torque Tighten t...

Page 379: ...emove the reservoir cap 1 plate 2 and diaphragm 3 2 Disconnect the reservoir hose 4 3 Remove the lock nut 5 4 Remove the connector 6 and O ring 7 by removing the snap ring 8 Special tool 09900 06108 Snap ring pliers 5 Pull out the dust boot 9 and remove the snap ring 10 Special tool 09900 06108 Snap ring pliers 6 Remove the following parts from the master cylinder Push rod 11 Secondary cup 12 Pist...

Page 380: ...inder component to be inserted into the bore Replace the O ring and snap rings with new ones BF Brake fluid DOT 4 Apply grease to the push rod end Grease 99000 25100 SUZUKI SILICONE GREASE or equivalent Install the O ring 1 Rear Brake Master Cylinder Parts Inspection B933H24106019 Refer to Rear Brake Master Cylinder Disassembly and Assembly Page 4A 18 Master cylinder Inspect the master cylinder bo...

Page 381: ... pedal height 0 10 0 0 4 Master cylinder bore Front 12 700 12 743 0 5000 0 5017 Rear 14 000 14 043 0 5512 0 5529 Master cylinder piston diam Front 12 657 12 684 0 4983 0 4994 Rear 13 957 13 984 0 5495 0 5506 Item Specification Note Brake fluid type DOT 4 Fastening part Tightening torque Note N m kgf m lb ft Brake air bleeder valve 6 0 6 4 5 Page 4A 7 Page 4A 7 Page 4A 8 Page 4A 9 Front brake maste...

Page 382: ... 14 Rear Brake Master Cylinder Components Page 4A 16 Special Tool B933H24108002 Material SUZUKI recommended product or Specification Note Brake fluid DOT 4 Page 4A 8 Page 4A 9 Page 4A 12 Page 4A 19 Grease SUZUKI Silicone Grease or equivalent P No 99000 25100 Page 4A 13 Page 4A 19 Water resistance grease or equivalent P No 99000 25160 Page 4A 15 09900 06108 09900 25008 Snap ring pliers Multi circui...

Page 383: ... 9 Brake pad spring Apply thread lock to the thread part 3 Dust seal 10 Brake disc cover Apply thread lock to the thread part 4 Piston 6 N m 0 6 kgf m 4 5 lb ft Apply silicone grease to sliding surface 5 Brake caliper holder 18 N m 1 8 kgf m 13 0 lb ft Apply brake fluid 6 Front brake pad set 23 N m 2 3 kgf m 16 5 lb ft Do not reuse 7 Brake caliper mounting bolt 18 N m 1 8 kgf m 16 5 lb ft P a r t ...

Page 384: ...caliper 5 Clean up the caliper especially around the caliper piston 6 Install the new brake pads CAUTION Replace the brake pads as a set otherwise braking performance will be adversely affected NOTE The arrow mark A on the brake shim 4 must point in the direction of brake disc rotation The brake shim 4 must be installed to the caliper piston side pad Make sure that the detent of pad is fitted to c...

Page 385: ... receptacle NOTE Place a rag underneath the union bolt on the brake caliper to catch any spilt brake fluid Slightly loosen the brake pad mounting pins 3 to facilitate later disassembly if necessary 4 Remove the brake caliper by removing the brake caliper mounting bolts 2 Installation Install the brake caliper in the reverse order of removal Pay attention to the following points Apply a small quant...

Page 386: ...efer to Front Brake Caliper Removal and Installation Page 4B 3 Disassembly 1 Remove the brake pads Refer to Front Brake Pad Replacement Page 4B 2 2 Remove the pad spring 1 3 Place a rag over the brake caliper piston to prevent it from popping out and then force out the piston using compressed air CAUTION Do not use high pressure air to prevent brake caliper piston damage 4 Remove the dust seal 2 a...

Page 387: ...lb ft Apply silicone grease to the brake caliper holder slide pin Grease 99000 25100 SUZUKI SILICONE GREASE or equivalent Set the rubber boot onto the brake caliper holder slide pin securely Apply silicone grease to the brake caliper holder pin Grease 99000 25100 SUZUKI SILICONE GREASE or equivalent Apply thread lock to the brake caliper holder slide pin 1 Thread lock cement 99000 32030 THREAD LOC...

Page 388: ...d Never use different types of fluid or cleaning solvent such as gasoline kerosine or the others Apply the brake fluid to piston seal 4 and dust seal 5 CAUTION Replace the piston seal 4 and dust seal 5 with new ones BF Brake fluid DOT 4 Install the piston seal as shown in the figure Install the brake pads Refer to Front Brake Pad Replacement Page 4B 2 Front Brake Caliper Parts Inspection B933H2420...

Page 389: ... the mounting pin with new ones Brake caliper holder slide pin Inspect the brake caliper holder slide pin for wear or damage If any damage is found replace it with a new one Brake pad spring Inspect the brake pad springs for damage or excessive bend If any damage is found replace them with new a one Brake caliper holder Inspect the brake caliper holder and pin for damage If any damage is found rep...

Page 390: ...nt Brake Disc Inspection B933H24206008 Brake Disc Thickness 1 Dismount the front brake caliper Refer to Front Brake Pad Replacement Page 4B 2 2 Inspect the brake disc for damage or cracks and measure the thickness using the micrometer Replace the brake disc if the thickness is less than the service limit or if defect is found Special tool A 09900 20205 Micrometer 0 25 mm Brake disc thickness Servi...

Page 391: ... Front Brake Components Page 4B 1 Reference For the tightening torque of fastener not specified in this section refer to Tightening Torque Specifications in Section 0C Page 0C 6 I933H1420031 01 Item Standard Limit Brake disc thickness Front 2 8 3 2 0 11 0 13 2 5 0 10 Brake disc runout 0 30 0 012 Brake caliper cylinder bore Front 32 03 32 08 1 2610 1 2630 Brake caliper piston diam Front 31 948 31 9...

Page 392: ...te Brake fluid DOT 4 Page 4B 6 Page 4B 6 Grease SUZUKI SILICONE GREASE or equivalent P No 99000 25100 Page 4B 5 Page 4B 5 Thread lock cement THREAD LOCK CEMENT SUPER 1303 or equivalent P No 99000 32030 Page 4B 2 Page 4B 3 Page 4B 5 THREAD LOCK CEMENT SUPER 1360 or equivalent P No 99000 32130 Page 4B 8 09900 20205 09900 20607 Micrometer 0 25 mm Dial gauge 1 100 mm 10 mm Page 4B 8 Page 4B 8 09900 20...

Page 393: ...art 2 Piston seal 9 Stopper ring Apply thread lock to the thread part 3 Dust seal 10 Rear brake disc plate housing Apply silicone grease 4 Piston 6 N m 0 6 kgf m 4 5 lb ft Apply water resistance grease 5 Brake caliper holder 18 N m 1 8 kgf m 13 0 lb ft Apply brake fluid 6 Rear brake pad set 23 N m 2 3 kgf m 16 5 lb ft Do not reuse 7 Brake pad spring 26 N m 2 6 kgf m 19 0 lb ft P a r t S h a r k c ...

Page 394: ...pedal while removing the brake caliper 4 Remove the brake pads 5 by removing the pad mounting pins 1 and lock washer 6 NOTE When removing the pads push the piston all the way into the brake caliper 5 Clean up the caliper especially around the caliper piston 6 Install the new brake pads CAUTION Replace the brake pads as a set otherwise braking performance will be adversely affected NOTE Make sure t...

Page 395: ...on and then check the brake fluid level 11 Adjust the parking brake Refer to Brake System Inspection in Section 0B Page 0B 17 Rear Brake Caliper Removal and Installation B933H24306004 Removal 1 Drain brake fluid Refer to Brake Fluid Replacement in Section 4A Page 4A 8 2 Remove the parking brake Refer to Parking Brake Removal and Installation in Section 4D Page 4D 2 3 Disconnect the brake hose from...

Page 396: ... the parking brake Refer to Parking Brake Removal and Installation in Section 4D Page 4D 2 5 Bleed air from the brake system Refer to Air Bleeding from Brake Fluid Circuit in Section 4A Page 4A 6 6 Check the brake fluid leakage and brake operation WARNING Brake fluid if it leaks will interfere with safe running and discolor painted surfaces check the brake hose and hose joints for cracks and fluid...

Page 397: ...boots removal is not necessary 6 Place a rag over the brake caliper piston to prevent the piston from popping out 7 Force out the piston by pushing the piston pin 7 8 Remove the dust seal 8 piston seal 9 and O ring 10 CAUTION Do not attempt to remove the retainer 11 5 I933H1430015 01 6 6 I933H1430016 01 7 I933H1430017 01 11 10 8 9 I933H1430018 02 8 9 10 11 I933H1430019 01 P a r t S h a r k c o m 8...

Page 398: ...fluid or cleaning solvent such as gasoline kerosine or the others Apply the brake fluid to O ring 1 piston seal 2 and dust seal 3 CAUTION Replace the O ring 1 piston seal 2 and dust seal 3 with new ones BF Brake fluid DOT 4 Install the O ring 1 piston seal 2 and dust seal 3 as shown in the figure Set the rubber boots to the caliper Tighten the caliper holder pin 4 to the specified torque Tightenin...

Page 399: ... lb ft Install the brake pads Refer to Rear Brake Pad Replacement Page 4C 2 Rear Brake Caliper Parts Inspection B933H24306006 Refer to Rear Brake Caliper Disassembly and Assembly Page 4C 4 Brake caliper cylinder Inspect the brake caliper cylinder wall for nicks scratches or other damage If any damage is found replace the caliper with a new one Brake caliper piston Inspect the brake caliper piston ...

Page 400: ...ith a new one Brake caliper holder Inspect the brake caliper holder and pin for damage If any damage is found replace it with a new ones Rear Brake Disc Removal and Installation B933H24306007 Removal 1 Remove the rear sprocket assembly Refer to Rear Sprocket Removal and Installation in Section 3A Page 3A 5 2 Remove the rear brake caliper Refer to Rear Brake Pad Replacement Page 4C 2 3 Remove the r...

Page 401: ...ring with a new one Grease 99000 25160 Water resistance grease or equivalent Install the stopper ring 1 CAUTION The removed stopper ring must be replaced with a new one Apply thread lock to the brake disc bolts and tighten them to the specified torque NOTE The stamped mark A must face to left side of vehicle Thread lock cement 99000 32130 THREAD LOCK CEMENT SUPER 1360 or equivalent Tightening torq...

Page 402: ...r to Rear Brake Pad Replacement Page 4C 2 Rear Brake Disc Plate Housing Inspection B933H24306009 Inspect the rear brake disc plate housing in the following procedures 1 Remove the rear brake disc plate housing from the rear axle Refer to Rear Brake Disc Removal and Installation Page 4C 8 2 Inspect the rear brake disc plate housing flange for damage and wear of spline If any defects are found repla...

Page 403: ...rake pad mounting pin 18 1 8 13 0 Page 4C 3 Rear brake caliper holder slide pin 23 2 3 16 5 Page 4C 4 Page 4C 7 Brake hose union bolt 23 2 3 16 5 Page 4C 4 Rear brake caliper holder pin 18 1 8 13 0 Page 4C 6 Brake disc bolt 23 2 3 16 5 Page 4C 9 Material SUZUKI recommended product or Specification Note Brake fluid DOT 4 Page 4C 6 Page 4C 6 Grease SUZUKI SILICONE GREASE or equivalent P No 99000 251...

Page 404: ...ng Diagram in Section 4A Page 4A 3 Installation Install the parking brake cable in the reverse order of removal Pay attention to the following points 1 Connect the parking brake cable as shown in the cable routing diagram Refer to Hose and Cable Routing Diagram in Section 4A Page 4A 3 2 After installing the parking brake cable adjust the parking brake play Refer to Brake System Inspection in Secti...

Page 405: ...n the boot removal is not necessary Installation 1 When replacing the boot with a new one apply grease to the groove of parking brake axle Grease 99000 25100 SUZUKI SILICONE GREASE or equivalent 2 Install the gasket 1 and parking brake 2 CAUTION Replace the gasket with a new one 3 Apply small quantity of thread lock to the parking brake bolts 3 and tighten them to the specified torque Thread lock ...

Page 406: ...spring end faced the caliper as shown in the figure 8 Connect the parking cable 9 9 Install the adjuster 10 and the lock nut 11 10 Adjust the parking brake Refer to Brake System Inspection in Section 0B Page 0B 17 Parking Brake Inspection B933H24406006 Refer to Parking Brake Removal and Installation Page 4D 2 Inspect the parking brake for damage and smooth rotation by turning the axle If there is ...

Page 407: ...6 Special Tools and Equipment Recommended Service Material B933H24408001 NOTE Required service material is also described in the following Parking Brake Components Page 4D 1 Fastening part Tightening torque Note N m kgf m lb ft Parking brake bolt 23 2 3 16 5 Page 4D 2 Material SUZUKI recommended product or Specification Note Grease SUZUKI SILICONE GREASE or equivalent P No 99000 25100 Page 4D 2 Th...

Page 408: ...4D 5 Parking Brake P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 409: ...ruction 5B 14 Gearshift Shaft Gearshift Cam Plate Removal and Installation 5B 14 Gearshift Linkage Inspection 5B 17 Gearshift Shaft Oil Seal Bearing Removal and Installation 5B 18 Specifications 5B 19 Service Data 5B 19 Tightening Torque Specifications 5B 19 Special Tools and Equipment 5B 20 Recommended Service Material 5B 20 Special Tool 5B 20 Clutch 5C 1 Precautions 5C 1 Precautions for Clutch S...

Page 410: ...recautions Transmission Transaxle Precautions Precautions Precautions for Transmission Transaxle B933H25000001 Refer to General Precautions in Section 00 Page 00 1 P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 411: ...eference Item Engine is noisy Noise seems to come from the transmission Worn or rubbing gears Replace Worn countershaft splines Replace countershaft Worn driveshaft splines Replace driveshaft Worn or rubbing primary gears Replace Worn bearings Replace Transmission will not shift Broken gearshift cam Replace Distorted gearshift forks Replace Worn gearshift pawl Replace Transmission will not shift b...

Page 412: ...ck cable 7 by remove the rotor 8 7 Remove the spring 9 8 Remove the sprocket cover and bracket Refer to Engine Sprocket Removal and Installation in Section 3A Page 3A 4 9 Disconnect the reverse lock cable 7 by removing the mounting bolt 10 Remove the reverse lock cable 7 as shown in the cable routing diagram Refer to Hose and Cable Routing Diagram in Section 4A Page 4A 3 1 I933H1520003 02 2 I933H1...

Page 413: ...nect the reverse lock cable 3 to the rotor 4 through the hole of the housing Apply grease to the end of the reverse lock cable 3 and rotor 4 Grease 99000 25160 Water resistance grease or equivalent When installing the rotor hook the spring end C on the concave portion D of rotor 4 Make sure that the reverse lock cable is routed correctly Install the dust seal 5 CAUTION Replace the dust seal 5 with...

Page 414: ...5B 4 Manual Transmission Transmission Components B933H25206003 FWD FWD 23 24 a 18 19 17 16 20 22 21 5 4 2 1 6 7 13 10 11 12 15 14 9 8 3 I933H1520014 05 P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 415: ...e gear 1 with its shaft 2 Remove the driveshaft assembly 2 and countershaft assembly 3 1 Countershaft 11 Reverse driven gear 21 Reverse lock shaft 2 Top drive gear 12 1st reverse dog 22 Gear position switch 3 3rd drive gear 13 1st driven gear 23 Gearshift cam stopper plate 4 4th drive gear 14 Reverse idle gear shaft 24 Gearshift cam stopper 5 2nd drive gear 15 Reverse idle gear 24 N m 2 4 kgf m 17...

Page 416: ...e gearshift fork shaft 6 and reverse lock shaft 7 NOTE After the gearshift fork shaft and gearshift forks have been fitted make sure that the gears engage normally Set the transmission gears to the neutral position 5 Assemble the engine Refer to Engine Bottom Side Assembly in Section 1D Page 1D 48 and Engine Top Side Assembly in Section 1D Page 1D 20 6 Remount the engine assembly Refer to Engine A...

Page 417: ...n gears as shown in the transmission components and transmission construction Refer to Transmission Components Page 5B 4 and Transmission Construction Page 5B 7 Assembly Assembly the transmission in the reverse order of disassembly Pay attention to the following points NOTE When reassembling the transmission gears attention must be given to the locations and positions of washers and snap rings The...

Page 418: ...Countershaft Apply molybdenum of solution to the surface of 4th drive gear 1 M O Molybdenum oil MOLYBDENUM OIL SOLUTION Transmission Related Parts Inspection B933H25206007 Refer to Transmission Removal and Installation Page 5B 5 and Countershaft Gear Driveshaft Gear Reverse Idle Gear Disassembly and Assembly Page 5B 7 Gearshift fork to groove clearance NOTE The clearance for each gearshift fork pl...

Page 419: ...shift cam bearing Inspect the gearshift cam bearings left and right for abnormal noise and smooth rotation Replace the bearing if there is anything unusual Refer to Transmission Oil Seal Bearing Removal and Installation Page 5B 10 Gearshift cam Inspect the gearshift cam groove for abnormal wear and damage If any defects are found replace the gearshift cam with a new one Reverse lock shaft Inspect ...

Page 420: ...e in the crankcase Replace the bearing if there is anything unusual Refer to Transmission Oil Seal Bearing Removal and Installation Page 5B 10 Transmission Oil Seal Bearing Removal and Installation B933H25206009 Removal 1 Remove the transmission assembly Refer to Transmission Removal and Installation Page 5B 5 2 Remove the oil seal retainer 1 3 Remove the driveshaft oil seal 2 with the special too...

Page 421: ...d oil seals and bearings must be replaced with new ones 1 Install the bearings using the special tool Special tool A 09913 70210 Bearing installer set CAUTION The stamped mark side of bearing A faces inside The sealed side of the bearing B faces outside 5 I933H1520037 02 B I933H1520038 01 B I933H1520039 01 A A B I933H1520040 01 A A I933H1520041 01 P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 422: ...s Grease 99000 25160 Water resistance grease or equivalent 7 Install the oil seal retainer 4 8 Install the transmission assembly Refer to Transmission Removal and Installation Page 5B 5 Gear Position GP Switch Inspection B933H25206010 Refer to Gear Position GP Switch Inspection in Section 1I Page 1I 7 Gear Position GP Switch Removal and Installation B933H25206011 Removal 1 Turn the ignition switch...

Page 423: ...e to the O ring CAUTION Replace the O ring with a new one Grease 99000 25160 Water resistance grease or equivalent Tighten the gear position switch mounting bolts to the specified torque Tightening torque Gear position switch mounting bolt a 6 5 N m 0 65 kgf m 4 7 lb ft Route the gear position switch lead wire Refer to Wiring Harness Routing Diagram in Section 9A Page 9A 3 Adjust the reverse lock ...

Page 424: ... ring pliers 4 Remove the gearshift shaft 5 and washer 6 1 Gearshift lever 9 Gearshift cam stopper plate 2 Gearshift shaft 10 Gearshift cam stopper 3 Gearshift pawl lifter 19 N m 1 9 kgf m 13 5 lb ft 4 Gearshift cam roller 24 N m 2 4 kgf m 17 5 lb ft 5 Gearshift cam driven gear 9 N m 0 9 kgf m 6 5 lb ft 6 Gearshift pawl Apply thread lock to thread part 7 Pin Apply water resistance grease 8 Spring ...

Page 425: ...sher and spring 10 Remove the gearshift arm stopper 17 Installation Install the gearshift shaft gearshift cam plate in the reverse order of removal Pay attention to the following points Apply a small quantity of thread lock to the gearshift arm stopper and tighten it to the specified torque Thread lock cement 99000 32110 THREAD LOCK CEMENT SUPER 1322 or equivalent Tightening torque Gearshift arm s...

Page 426: ...cam pin A with the gearshift cam stopper plate groove B Tighten the gearshift cam stopper plate bolt to the specified torque Tightening torque Gearshift cam stopper plate bolt b 24 N m 2 4 kgf m 17 5 lb ft Install each springs 6 pins 7 and pawls 8 into the gearshift cam driven gear 9 The large shoulder C must face to the outside With the pawls 8 held in pushed position install the pawl lifter 10 1...

Page 427: ...rshift shaft return spring ends F to the gearshift arm stopper 12 and gearshift cam roller 13 to the gearshift shaft 11 Install a new snap ring 14 CAUTION The removed snap ring 14 must be replaced with a new one Special tool 09900 06107 Snap ring pliers Gearshift Linkage Inspection B933H25206015 Refer to Gearshift Shaft Gearshift Cam Plate Removal and Installation Page 5B 14 Gearshift shaft Check ...

Page 428: ...arts Removal and Installation in Section 9D Page 9D 4 3 Remove the gearshift shaft oil seal 1 4 Remove the bearing 2 with the special tools Special tool A 09921 20210 Bearing remover B 09930 30104 Rotor remover slide shaft Installation Install the oil seal and bearings in the reverse order of removal Pay attention to the following points CAUTION The removed oil seal and bearing must be replaced wi...

Page 429: ...C 6 Item Standard Limit Primary reduction ratio 2 960 74 25 Final reduction ratio 2 857 40 14 Gear ratios Low 2 538 33 13 2nd 1 666 30 18 3rd 1 238 26 21 4th 1 000 23 23 Top 0 846 22 26 Reverse 2 153 28 13 Gearshift fork to groove clearance 0 1 0 3 0 004 0 012 0 5 0 020 Gearshift fork groove width 5 0 5 1 0 197 0 201 Gearshift fork thickness 4 8 4 9 0 189 0 193 Fastening part Tightening torque Not...

Page 430: ...5B 13 Page 5B 18 Molybdenum oil MOLYBDENUM OIL SOLUTION Page 5B 8 Thread lock cement THREAD LOCK CEMENT SUPER 1303 or equivalent P No 99000 32030 Page 5B 12 THREAD LOCK CEMENT SUPER 1322 or equivalent P No 99000 32110 Page 5B 15 Page 5B 17 09900 06107 09900 20102 Snap ring pliers Vernier calipers 1 20 mm 200 mm Page 5B 14 Page 5B 17 Page 5B 9 Page 5B 9 09900 20803 09913 50121 Thickness gauge Oil s...

Page 431: ...lutch lever position switch lead wires Condition Possible cause Correction Reference Item Engine is noisy Noise seems to come from the clutch Worn countershaft spline Replace countershaft Worn clutch hub spline Replace clutch hub Worn clutch plate teeth Replace clutch plates Distorted clutch plates Replace Worn clutch release bearing Replace Weakened clutch damper Replace primary driven gear Clutc...

Page 432: ...and Installation in Section 1G Page 1G 9 7 Remove the clutch cable as shown in the cable routing diagram Refer to Hose and Cable Routing Diagram in Section 4A Page 4A 3 Installation Install the clutch cable in the reverse order of removal Pay attention to the following point Tighten the fuel pump mounting bolts to the specified torque Tightening torque Fuel pump mounting bolts a 10 N m 1 0 kgf m 7...

Page 433: ...stallation Page 5C 2 and Parking Brake Cable Removal and Installation in Section 4D Page 4D 1 2 Disconnect the clutch lever position switch coupler 3 3 Remove the clutch lever holder 4 1 3 2 4 FWD FWD I933H1530008 03 1 Clutch lever 3 Parking knob Apply grease 2 Parking lock 4 Clutch lever position switch 1 2 I933H1530009 01 3 I933H1530010 01 4 I933H1530011 01 P a r t S h a r k c o m 8 7 7 9 9 9 5 ...

Page 434: ...pring end A with the holder 3 and parking knob 4 Align the punch mark B on the handlebars with the mating surface of clutch lever holder Refer to Handlebar Construction in Section 6B Page 6B 2 Tighten the clutch lever holder clamp bolt After install the removed parts adjust the clutch cable play and parking brake cable play Refer to Clutch Cable Inspection and Adjustment Page 5C 2 and Brake System...

Page 435: ...al 3 Washer 4 Bearing 5 Installation Install the clutch release camshaft in the reverse order of removal Pay attention to the following points CAUTION The removed bearing and oil seal must be replaced with new ones Apply engine oil to the bearing NOTE The stamped mark side of the bearing face upside Apply grease to the oil seal lip Grease 99000 25160 Water resistance grease or equivalent Assemble ...

Page 436: ...ssure plate 6 Spring washer 11 Primary driven gear assembly 2 No 3 drive plate 7 Spring washer seat 12 Push rod 3 No 2 drive plate 8 Release bearing 70 N m 7 0 kgf m 50 5 lb ft 4 No 1 drive plate 7 pcs 9 Clutch push piece Apply engine oil 5 Driven plate 8 pcs 10 Clutch sleeve hub Do not reuse P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 437: ...et hose 1 4 Remove the clutch cover 2 5 Remove the gasket 3 and dowel pins 6 Remove the clutch springs and clutch pressure plate 4 NOTE Loosen the clutch spring set bolts little by little and diagonally 7 Remove the clutch release bearing with the special tool NOTE If there is no abnormal condition the clutch release bearing removal is not necessary Special tool A 09921 20240 Bearing remover set 1...

Page 438: ...special tool Special tool B 09920 53740 Clutch sleeve hub holder 13 Remove the clutch sleeve hub nut 14 Remove the washer 11 and clutch sleeve hub 12 15 Remove the thrust washer 13 and primary driven gear assembly 14 16 Remove the spacer 15 5 6 I933H1530027 01 8 7 I933H1530028 01 9 10 I933H1530029 01 11 I933H1530030 01 B I933H1530031 01 12 11 I933H1530032 01 13 14 I933H1530033 01 15 I933H1530034 0...

Page 439: ...OTE The concave side of clutch sleeve hub nut 6 faces inside 7 Hold the clutch sleeve hub with the special tool Special tool A 09920 53740 Clutch sleeve hub holder 8 Tighten the clutch sleeve hub nut 6 to the specified torque Tightening torque Clutch sleeve hub nut a 70 N m 7 0 kgf m 50 5 lb ft 9 Bend the tongue of the washer 5 securely 10 Install the clutch push rod 7 and clutch push piece 8 into...

Page 440: ...tem they can be distinguished by the inside diameter D 14 Install the clutch release bearing with the special tool NOTE The stamped mark on the clutch release bearing faces clutch push piece side Special tool B 09913 70210 Bearing installer set 15 Apply engine oil to the release bearing 16 Install the clutch pressure plate 15 11 No 2 drive plate 12 No 1 drive plate 7 pcs 13 No 3 drive plate 14 Dri...

Page 441: ...ystem Inspection in Section 0B Page 0B 13 Clutch Parts Inspection B933H25306010 Refer to Clutch Removal Page 5C 7 and Clutch Installation Page 5C 9 Clutch drive and driven plate NOTE Wipe off the engine oil from the drive and driven plates with a clean rag Measure the thickness of drive plates with a vernier calipers If the drive plate thickness is found to have reached the limit replace it with a...

Page 442: ... tool A 09900 20102 Vernier calipers 1 20 mm 200 mm Clutch spring free length Service limit 49 9 mm 1 96 in Clutch release bearing Inspect the clutch release bearing for play wear and damage Move the inner race by finger and inspect for smooth movement If any defects are found replace the clutch release bearing with a new one Push rod Inspect the push rod for wear and damage If any defects are fou...

Page 443: ...ue Specifications in Section 0C Page 0C 6 Item Standard Limit Clutch cable play 5 10 0 2 0 4 Clutch drive plate thickness No 1 No 2 No 3 2 92 3 08 0 115 0 121 2 62 0 103 Clutch drive plate claw width No 1 No 2 No 3 13 7 13 8 0 539 0 543 13 2 0 520 Clutch driven plate distortion 0 10 0 004 Clutch spring free length 52 5 2 07 49 9 1 96 Fastening part Tightening torque Note N m kgf m lb ft Fuel pump ...

Page 444: ...mmended product or Specification Note Grease Water resistance grease or equivalent P No 99000 25160 Page 5C 5 09900 20102 09900 20803 Vernier calipers 1 20 mm 200 mm Thickness gauge Page 5C 11 Page 5C 12 Page 5C 12 Page 5C 12 09900 25008 09913 70210 Multi circuit tester set Bearing installer set Page 5C 1 Page 5C 10 09920 53740 09921 20240 Clutch sleeve hub holder Bearing remover set Page 5C 8 Pag...

Page 445: ...ons 6B 1 Steering Handlebars Components 6B 1 Handlebar Construction 6B 2 Handlebars Removal and Installation 6B 3 Handlebars Inspection 6B 5 Steering Shaft Tie rod Removal and Installation 6B 5 Steering Parts Inspection 6B 10 Toe out Adjustment 6B 11 Specifications 6B 11 Service Data 6B 11 Tightening Torque Specifications 6B 12 Special Tools and Equipment 6B 12 Recommended Service Material 6B 12 S...

Page 446: ...6 1 Precautions Steering Precautions Precautions Precautions for Steering B933H26000001 Refer to General Precautions in Section 00 Page 00 1 P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 447: ...ose front wheel hub nuts Tighten Damaged or worn front wheel hub bearings Replace Worn or loose tie rod ends Replace or tighten Defective or incorrect front tiers Replace Damaged or worn wishbone arms and related bushings Replace Distorted front wheels Replace Loose chassis nuts and bolts Tighten Steering Pulls to One Side Unequally inflated tires Regulate Improper front wheel alignment Adjust Wor...

Page 448: ... bond 2 Handlebars 11 Bushing 26 N m 2 6 kgf m 19 0 lb ft 3 Handle grip 12 Dust seal 60 N m 6 0 kgf m 43 5 lb ft 4 Throttle case 13 O ring 23 N m 2 3 kgf m 16 5 lb ft 5 Starter lever 14 Dust seal 49 N m 4 9 kgf m 35 5 lb ft 6 Handlebar switch box 15 Washer 29 N m 2 9 kgf m 21 0 lb ft 7 Handlebar lower holder 16 Tie rod end Apply Water resistance grease 8 Steering shaft 17 Tie rod Do not reuse 9 St...

Page 449: ... Align the edge of throttle case upper with punch mark on handlebars 2 Handlebars B Align the edge of clutch lever holder with punch mark on handlebars 3 Handlebar clamp C Align the edge of master cylinder holder with punch mark on handlebars 26 N m 2 6 kgf m 19 0 lb ft P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 450: ... the front brake master cylinder upside down 4 Disconnect the clamp 5 Remove the clutch lever assembly 4 and handlebar switch box 5 6 Remove the left grip 6 and starter lever 7 7 Remove the steering head cover 8 8 Remove the handlebar clamp bolts and washers 9 9 Remove the handlebar holders 10 and handlebars 11 1 I933H1620002 01 2 3 I933H1620003 01 I933H1620004 02 5 4 I933H1620005 03 6 7 I933H1620...

Page 451: ...the mating surface of handlebar holder First tighten the bolts 1 to the specified torque and then tighten the bolts 2 to the specified torque NOTE The higher portion of handlebar holder must face forward so that the clearance a of holder is in back of the handlebars Tightening torque Handlebar clamp bolt a 26 N m 2 6 kgf m 19 0 lb ft Apply handle grip bond C onto the left handlebars before install...

Page 452: ...ction 9A Page 9A 3 Hose and Cable Routing Diagram in Section 4A Page 4A 3 Handlebars Inspection B933H26206004 Refer to Handlebars Removal and Installation Page 6B 3 Inspect the handlebars for distortion or damage If any defects are found replace the handlebars with a new one Steering Shaft Tie rod Removal and Installation B933H26206005 Refer to Front Suspension Steering Assembly Construction in Se...

Page 453: ... 10 Draw out the steering shaft 9 11 Disconnect each tie rod ends using the special tool Special tool A 09942 72410 Tie rod end remover 12 Loosen the lock nut 10 and 11 CAUTION The lock nut 10 have left hand threads 13 Remove the tie rod end 12 lock nut 10 and 11 from the tie rod 13 I933H1620016 01 A I933H1620017 01 5 1 3 2 4 I933H1620018 01 6 I933H1620019 01 8 7 7 I933H1620020 01 A 9 I933H1620021...

Page 454: ...nstallation Install the steering shaft tie rod in the reverse order of removal Pay attention to the following points Install the steering bushing 1 using the special tool Special tool A 09924 84521 Bearing installer set Apply grease to the steering shaft O ring 2 and dust seal 3 CAUTION Replace the O ring 2 with a new one Grease 99000 25160 Water resistance grease or equivalent Install the dust se...

Page 455: ...grease to the dust seal lip and steering shaft holders before remounting the steering shaft holders Grease 99000 25160 Water resistance grease or equivalent CAUTION To prevent the entry of dirt the dust seal end A must face forward when installing the dust seals to steering shaft Tighten the steering shaft holder bolts to the specified torque Tightening torque Steering shaft holder bolt a 23 N m 2...

Page 456: ...ed torque Tightening torque Tie rod end nut c 29 N m 2 9 kgf m 21 0 lb ft Install the new cotter pins 11 CAUTION Replace the cotter pins 11 with new ones Push the tie rod to tie rod lock nut tightening direction Tighten the lock nuts to the specification CAUTION When tightening the lock nuts hold the tie rod end with a open end wrench NOTE The lock nuts 12 have left hand threads Tightening torque ...

Page 457: ... seal Inspect the dust seal for wear or damage If any defects are found replace the dust seal with new ones Tie rod Inspect the tie rod for distortion or damage If any defects are found replace the tie rod with new ones Tie rod end Inspect the tie rod ends for smooth movement If there are any abnormalities replace the tie rod ends with new ones Inspect the tie rod end boots for wear or damage If a...

Page 458: ...tances are not equal adjust the tie rod to the right or left until the toe out is within specification Check the toe out again by measuring distances A and B 5 If the toe out is not within specification repeat the adjustment as above until the proper toe out is obtained and distances C and D become equal 6 After adjustment has been made tighten the four lock nuts 1 and 2 to the specified torque Ti...

Page 459: ...B933H26208002 Fastening part Tightening torque Note N m kgf m lb ft Handlebar holder nut 60 6 0 43 5 Page 6B 4 Handlebar clamp bolt 26 2 6 19 0 Page 6B 4 Steering shaft holder bolt 23 2 3 16 5 Page 6B 8 Steering shaft nut 49 4 9 35 5 Page 6B 9 Tie rod end nut 29 2 9 21 0 Page 6B 9 Tie rod lock nut 29 2 9 21 0 Page 6B 9 Page 6B 11 Material SUZUKI recommended product or Specification Note Grease Wat...

Page 460: ...6B 13 Steering Handlebar P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 461: ...2 Indicator Light Inspection 9C 2 Fuel Level Indicator Switch Thermistor Inspection 9C 2 Engine Coolant Temperature Indicator Light Inspection 9C 3 Engine Coolant Temperature Removal and Installation 9C 3 Neutral Indicator Switch Inspection 9C 3 Reverse Indicator Switch Inspection 9C 3 Ignition Switch Inspection 9C 4 Ignition Switch Removal and Installation 9C 4 Specifications 9C 4 Service Data 9C...

Page 462: ...9000001 Refer to General Precautions in Section 00 Page 00 1 and Precautions for Electrical Circuit Service in Section 00 Page 00 2 Component Location Electrical Components Location B933H29003001 Refer to Electrical Components Location in Section 0A Page 0A 7 P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 463: ...ng Systems 9A 1 Body and Accessories Wiring Systems Schematic and Routing Diagram Wiring Diagram B933H29102001 Refer to Wire Color Symbols in Section 0A Page 0A 5 P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 464: ...W B Bl B Bl B R R Y Y B Y B B O B O G R G R Bl B R Y Y B B O G R R Br W Br W B Br B Br O G O G B W B W B W B W Y B Y B O W O W Br W Br W Bl Bl W Y G B G B B W B W G W G W Gr Gr Bl B Bl B R O W O W O G O G Gr W Gr W Y B Y B W Bl W Bl G R G R B Bl B Bl B Br B Br Dg Dg R R Y B Y B Y B W R W R B W B W B W B W R Br W B Br O G B W B W Y B O W Br W Bl W Y G B B W G W Gr Bl B R O W O G Gr W Y B W Bl G R B...

Page 465: ...ocket cover 2 Clamp Bind the handlebar switch L and indicator light with the clamp 7 Clamp Bind the generator and gear position switch with the clamp 12 Crankcase 3 Wiring harness 8 Reverse gear cable A Pass the high tension cord of ignition coil over the overflow hose 4 Battery 9 Generator cover 5 Clamp Bind the wiring harness and starter motor with the clamp 10 Gear position switch lead wire P a...

Page 466: ...lamp 5 Starter motor 2 Clamp Bind the handlebar switch L starter cable and clutch lever position switch with the clamp 6 Wiring harness 3 Clamp 7 Clamp Bind the wiring harness with the clamp 4 Clamp Bind the Battery with the clamp 8 Brake light switch P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 467: ... 4 0 lb ft 2 Battery ground wire 10 N m 1 0 kgf m 7 0 lb ft 11 N m 1 1 kgf m 8 0 lb ft 3 Starter motor 6 N m 0 6 kgf m 4 5 lb ft a 20 4 Generator lead wire 6 5 N m 0 65 kgf m 4 7 lb ft b 20 4 mm 0 80 in 5 Gear position switch lead wire 120 N m 12 0 kgf m 87 0 lb ft c 12 8 mm 0 50 in P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 468: ...tening torque is also described in the following Wiring Harness Routing Diagram Page 9A 3 Reference For the tightening torque of fastener not specified in this section refer to Tightening Torque Specifications in Section 0C Page 0C 6 Item Specification Note Fuse size Ignition 10 A Cooling fan 10 A Main 20 A P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 469: ...ng Systems 9B 1 Body and Accessories Lighting Systems Repair Instructions Headlight Components B933H29206001 1 FWD FWD I933H1920014 02 1 Headlight bulb 12 V 35 35 W P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 470: ...e bulb failure Do not use bulb other than those with predetermined wattage Remove the bulb when it gets cool since it may be heated to an extremely high temperature when the headlight is turned ON 1 Remove the left side cover Refer to Exterior Parts Removal and Installation in Section 9D Page 9D 4 2 Remove the headlight adjusting bolt 1 3 Move the headlight assembly upward and disconnect the bulb ...

Page 471: ...the headlight adjusting bolt 1 2 Move the headlight up or downwards and adjust the headlight beam vertically 3 Tighten the headlight adjusting bolt 1 Rear Combination Light Components B933H29206005 1 I933H1920006 04 1 FWD FWD I933H1920015 02 1 Brake light Taillight bulb 12 V 21 5 W P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 472: ... Replace the rear combination light bulb in the following procedures CAUTION When you touch the bulb with your bare hands clean the bulb with a cloth moistened with alcohol or soapy water to prevent premature bulb failure Do not use bulb other than those with predetermined wattage 1 Remove the bulb socket 1 by turning it counterclockwise 2 Push in on the bulb turn it counterclockwise and pull it o...

Page 473: ...a new one Refer to Handlebars Removal and Installation in Section 6B Page 6B 3 Special tool 09900 25008 Multi circuit tester set Tester knob indication Continuity 4 After finishing the dimmer switch inspection reinstall the removed parts Specifications Service Data B933H29207001 Wattage Unit W Special Tools and Equipment Special Tool B933H29208001 2 1 I933H1920012 05 Position Color Y W Gr HI LO I9...

Page 474: ...t Removal and Installation B933H29306002 CAUTION When disconnecting and reconnecting the indicator light coupler make sure to turn OFF the ignition switch or electronic parts may get damaged Removal 1 Disconnect the indicator light coupler 1 and clamp FWD FWD 1 1 1 2 I933H1930011 02 1 12 V 1 7 W 2 12 V 3 4 W 1 I933H1930001 01 P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 475: ...up for two seconds when the ignition switch is turned to ON Check that other indicator lights Neutral indicator light and reverse indicator light light up go off by operating each switch If abnormal condition is found replace the indicator light with a new one after checking its wire harness coupler Refer to Indicator Light Replacement Page 9C 2 and Indicator Light Removal and Installation Page 9C...

Page 476: ...the indicator light 3 operations when the resistance is adjusted to the specified values If either one or all indications are abnormal replace the indicator light with a new one Refer to Indicator Light Removal and Installation Page 9C 1 5 Connect the ECT sensor coupler 1 Engine Coolant Temperature Removal and Installation B933H29306007 Refer to ECT Sensor Removal and Installation in Section 1C Pa...

Page 477: ...t Tester knob indication Continuity 4 After finishing the ignition switch inspection reinstall the removed parts Ignition Switch Removal and Installation B933H29306011 Refer to Ignition Switch Removal and Installation in Section 1H Page 1H 7 Specifications Service Data B933H29307001 Wattage Unit W Special Tools and Equipment Special Tool B933H29308001 1 I933H1930009 01 B R B O Br LIGHT ON OFF Colo...

Page 478: ...air Instructions Exterior Parts Construction B933H29406001 1 2 4 3 a FWD FWD I933H1940023 08 1 Fuel tank cover 4 Side cover LH 2 Side cover RH 12 N m 1 2 kgf m 8 5 lb ft 3 Front fender Apply thread lock to thread part P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 479: ...Exterior Parts 9D 2 1 2 3 FWD FWD I933H1940024 03 1 Rear fender 3 Mudguard LH 2 Mudguard RH Apply thread lock to thread parts P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 480: ...9D 3 Exterior Parts Fuel Tank Cover Cushion Installation B933H29406002 I933H1940025 09 P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 481: ...ad of center piece until it becomes flush with the fastener outside face Exterior Parts Removal and Installation B933H29406004 Seat Removal Pull the seat lock lever 1 upward and remove the seat 2 Installation Slide the seat hooks into the seat hook retainers and push down firmly until the seat snaps into the locked position Side cover and front fender Removal 1 Remove the side covers 1 left and ri...

Page 482: ...front fender in the reverse order of removal Pay attention to the following point Apply thread lock to the front fender mounting screws and tighten them to the specified torque Thread lock cement 99000 32110 THREAD LOCK CEMENT SUPER 1322 or equivalent Tightening torque Front fender mounting screw a 12 N m 1 2 kgf m 8 5 lb ft 4 5 I933H1940004 02 6 7 I933H1940005 01 8 8 I933H1940006 01 10 9 I933H194...

Page 483: ...ht Installation 1 Install the mud guard reinforcement 1 2 Apply thread lock to the mud guard reinforcements mounting bolt 2 rear fender mounting screw 3 and footrest mounting bolt 4 Thread lock cement 99000 32110 THREAD LOCK CEMENT SUPER 1322 or equivalent 3 Tighten the footrest mounting bolt 4 to the specified torque Tightening torque Footrest mounting bolt a 55 N m 5 5 kgf m 40 0 lb ft 4 Install...

Page 484: ...ler 6 and clamp 6 Remove the rear fender 7 Installation Install the rear fender in the reverse order of removal Pay attention to the following point Route the wiring harness Refer to Wiring Harness Routing Diagram in Section 9A Page 9A 3 Apply thread lock to the rear fender mounting screws and tighten them Thread lock cement 99000 32110 THREAD LOCK CEMENT SUPER 1322 or equivalent 1 2 I933H1940015 ...

Page 485: ...cial Tools and Equipment Recommended Service Material B933H29408001 NOTE Required service material is also described in the following Exterior Parts Construction Page 9D 1 Fastening part Tightening torque Note N m kgf m lb ft Front fender mounting screw 12 1 2 8 5 Page 9D 5 Footrest mounting bolt 55 5 5 40 0 Page 9D 6 Material SUZUKI recommended product or Specification Note Thread lock cement THR...

Page 486: ...ction B933H29506001 3 FWD FWD b 6 b 6 1 2 6 b b 6 a 5 7 4 a 5 I933H1950014 01 1 Frame 4 Rear grip 7 Battery plate 2 Seat rail 5 Seat rail mounting bolt 66 N m 6 6 kgf m 47 5 lb ft 3 Front grip 6 Engine mounting bracket bolt 26 N m 2 6 kgf m 19 0 lb ft P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 487: ...m 40 0 lb ft Front Grip Removal and Installation B933H29506003 Removal Remove the front grip 1 Installation Install the front grip in the reverse order of removal Rear Grip Removal and Installation B933H29506004 Removal Remove the rear grip 1 Installation Install the rear grip in the reverse order of removal Pay attention to the following point Apply thread lock to the rear fender mounting bolts a...

Page 488: ... cleaner box mounting bolts 1 6 Remove the footrest mud guard reinforcement mounting bolts 2 and move the rear brake hose 3 from the guide 7 Remove the seat rail 4 Installation Install the seat rail in the reverse order of removal Pay attention to the following point Apply thread lock to the footrest mud guard mounting bolts 1 and tighten them Thread lock cement 99000 32110 THREAD LOCK CEMENT SUPE...

Page 489: ...truction Page 9E 1 Reference For the tightening torque of fastener not specified in this section refer to Tightening Torque Specifications in Section 0C Page 0C 6 Special Tools and Equipment Recommended Service Material B933H29508001 b 3 b 3 I933H1950013 01 Fastening part Tightening torque Note N m kgf m lb ft Footrest mounting bolt 55 5 5 40 0 Page 9E 2 Seat rail mounting bolt 66 6 6 47 5 Page 9E...

Page 490: ...P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 491: ...P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 492: ...Prepared by March 2008 Part No 99500 43080 03E Printed in Japan 492 P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

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Summary of Contents for LT-Z400

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Suzuki LT-Z400, Service Manual, Page: 415 / 492

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