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Suzuki SFV650, Service Manual

The Suzuki SFV650 Service Manual is a comprehensive guide for owners looking to maintain or repair their motorcycle. This manual is available for free download on manualshive.com, providing users with detailed instructions and diagrams to ensure their SFV650 stays running smoothly for years to come.

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Table of Contents 5- i

5

Section 5

CONTENTS

Transmission / Transaxle

Precautions .................................................5-1

Precautions............................................................. 5-1

Precautions for Transmission / Transaxle............. 5-1

Manual Transmission.............................. 5B-1

Diagnostic Information and Procedures............5B-1

Manual Transmission Symptom Diagnosis ......... 5B-1

Repair Instructions ..............................................5B-2

Transmission Components ................................. 5B-2
Transmission Removal and Installation .............. 5B-3
Transmission Construction.................................. 5B-5
Countershaft Gear / Driveshaft Gear 

Disassembly and Assembly .............................. 5B-6

Transmission Related Parts Inspection............... 5B-8
Transmission Oil Seal / Bearing Inspection ........ 5B-9
Transmission Oil Seal / Bearing Removal and 

Installation.......................................................5B-10

Gear Position Switch Inspection ....................... 5B-12
Gear Position Switch Removal and 

Installation.......................................................5B-12

Gearshift Lever Construction ............................5B-13
Gearshift Lever Removal and Installation .........5B-13
Gearshift Lever Height Inspection and 

Adjustment ......................................................5B-13

Gearshift Shaft / Gearshift Cam Plate 

Components.................................................... 5B-14

Gearshift Construction ......................................5B-14
Gearshift Shaft / Gearshift Cam Plate 

Removal and Installation................................. 5B-14

Gearshift Linkage Inspection ............................5B-17
Gearshift Shaft Oil Seal Removal and 

Installation.......................................................5B-17

Specifications.....................................................5B-18

Service Data ..................................................... 5B-18

Tightening Torque Specifications......................5B-18

Special Tools and Equipment ...........................5B-19

Recommended Service Material .......................5B-19
Special Tool ......................................................5B-19

Clutch ....................................................... 5C-1

Precautions...........................................................5C-1

Precautions for Clutch System............................5C-1

Diagnostic Information and Procedures............5C-1

Clutch System Symptom Diagnosis ....................5C-1

Repair Instructions ..............................................5C-2

Clutch Lever Position Switch Inspection .............5C-2
Clutch Cable Inspection and Adjustment ............5C-2
Clutch Cable Removal and Installation ...............5C-2
Clutch Lever Components...................................5C-3
Clutch Lever Removal and Installation................5C-4
Clutch Push Rod (Left) / Clutch Release 

Camshaft Removal and Installation ..................5C-4

Clutch Push Rod (Left) Inspection ......................5C-5
Clutch Components.............................................5C-6
Clutch Removal...................................................5C-7
Clutch Installation................................................5C-9
Clutch Parts Inspection .....................................5C-13
Primary Drive Gear Removal and Installation ...5C-14
Primary Drive Gear Inspection ..........................5C-15
Primary Drive Gear Disassembly and 

Assembly.........................................................5C-15

Specifications.....................................................5C-16

Service Data......................................................5C-16
Tightening Torque Specifications......................5C-17

Special Tools and Equipment ...........................5C-17

Recommended Service Material .......................5C-17
Special Tool ......................................................5C-17

Summary of Contents for SFV650

Page 1: ...SFV650 SERVICE MANUAL 9 9 5 0 0 3 6 1 9 0 0 1 E...

Page 2: ...cations at the time of publication If modifi cations have been made since then differences may exist between the content of this manual and the actual motorcycle Illustrations in this manual are used...

Page 3: ...System 1K 1 Suspension 2 i Precautions 2 1 Suspension General Diagnosis 2A 1 Front Suspension 2B 1 Rear Suspension 2C 1 Wheels and Tires 2D 1 Driveline Axle 3 i Precautions 3 1 Drive Chain Drive Trai...

Page 4: ......

Page 5: ...Table of Contents 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...

Page 6: ...o not touch the engine engine oil radiator and exhaust system until they have cooled After servicing the fuel oil water exhaust or brake systems check all lines and fittings related to the system for...

Page 7: ...tor 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 termi...

Page 8: ...er substitute for the band type clamp Fuse When a fuse blows always investigate the cause to correct it and then replace the fuse Do not use a fuse of a different capacity Do not use wire or any other...

Page 9: ...er 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...

Page 10: ...ndicated infinity or over limit the circuit is open between terminals A and C 2 Disconnect the coupler B and measure resistance between couplers A and B 1 If no continuity is indicated the circuit is...

Page 11: ...t to be checked branches to other parts as shown disconnect all connectors couplers of those parts Otherwise diagnosis will be misled 3 Measure resistance between terminal at one end of circuit A term...

Page 12: ...play 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 tes...

Page 13: ...ir Cleaner Element Replacement 0B 3 Air Cleaner Element Inspection and Cleaning 0B 3 Exhaust Pipe Bolts and Muffler Bolts Inspection 0B 4 Valve Clearance Inspection and Adjustment 0B 4 Spark Plug Repl...

Page 14: ...ure of engine oil and SUZUKl 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 SUZUKI SILICONE GREASE or equiva...

Page 15: ...elay Fuel Pump Relay G GEN Generator GND Ground GP Switch Gear Position Switch H HC Hydrocarbons HO2 sensor Heated Oxygen Sensor HO2S I IAP Sensor Intake Air Pressure Sensor IAPS IAT Sensor Intake Air...

Page 16: ...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 a...

Page 17: ...mmends the use of SUZUKI COOLANT anti freeze engine coolant If this is not available use an equivalent which is compatible with an aluminum radiator Liquid amount of water Engine coolant Solution capa...

Page 18: ...with Black tracer Gr Gray Gr R Gray with Red tracer Lbl Light blue Gr W Gray with White tracer Lg Light green O B Orange with Black tracer O Orange O Bl Orange with Blue tracer P Pink O G Orange with...

Page 19: ...l For E 33 4 Manual notice label For E 03 33 5 Tire information label English For E 03 33 6 Tire information label French German English For E 02 19 24 28 For E 19 24 7 General warning label English F...

Page 20: ...10 9 2 3 5 6 4 1 I944H1010006 04 1 IAP sensor 1 7 ECT sensor 13 Starter motor 2 IAP sensor 2 8 Ignition coil 2 14 Oil pressure switch 3 IAT sensor 9 Ignition coil 1 15 Cooling fan 4 TP sensor 10 Regu...

Page 21: ...uel injector 1 23 TO sensor 29 CKP sensor 18 Fuel injector 2 24 Turn signal Side stand relay 30 Speed sensor 19 Fuel pump Fuel level gauge 25 Fuse box 31 GP switch 20 Starter relay main fuse 26 Coolin...

Page 22: ...emark Type 4 stroke liquid cooled DOHC 90 V twin Number of cylinders 2 Bore 81 0 mm 3 189 in Stroke 62 6 mm 2 465 in Displacement 645 cm3 39 4 cu in Compression ratio 11 5 1 Fuel system Fuel injection...

Page 23: ...EIA 9 or DENSO IU24D Battery 12 V 36 0 kC 10 Ah 10 HR Generator Three phase A C generator Main fuse 30 A Fuse 10 10 15 15 10 10 A Headlight 12 V 60 55 W H4 Position light 12 V 5 W Brake light Tailligh...

Page 24: ...Micrometer 0 25 mm 09900 20530 Cylinder gauge set 09900 20602 Dial gauge 09900 20607 Dial gauge 09900 20701 Dial gauge chuck 09900 20803 Thickness gauge 09900 20805 Tire depth gauge 09900 21304 V bloc...

Page 25: ...alve lifter attachment 09916 33210 Valve guide reamer 4 5 mm 09916 34542 Reamer handle 09916 34580 Valve guide reamer 10 8 mm 09916 43211 Valve guide installer remover 09916 53330 Valve guide installe...

Page 26: ...g stem nut socket wrench 09940 34520 T type handle 09940 34531 Front fork assembling attachment A 09940 40211 Fuel pressure gauge adapter 09940 40220 Fuel pressure gauge attachment 09940 52861 Front f...

Page 27: ...in Section 0A Page 0A 4 Scheduled Maintenance Periodic Maintenance Schedule Chart B944H10205001 NOTE I Inspect and clean adjust replace or lubricate as necessary R Replace T Tighten Item Interval km 1...

Page 28: ...te exposed parts which are subject to rust with a rust preventative spray whenever the motorcycle has been operated under wet or rainy conditions Rear suspension I I Chassis bolts and nuts T T T T T I...

Page 29: ...the element or to use a torn element Make sure that the air cleaner is in good condition at all times Life of the engine depends largely on this component 3 After finishing the air cleaner element ins...

Page 30: ...stment B944H10206006 Inspect valve clearance Every 24 000 km 14 500 miles 48 months thereafter Inspection Tappet clearance adjustment must be checked and adjusted a at the time of periodic inspection...

Page 31: ...normal running direction All spark plugs should be removed 4 Remove the generator cover plug 4 and timing inspection plug 5 5 Turn the crankshaft to set the 1 Front cylinder at TDC of compression stro...

Page 32: ...emove the intake or exhaust camshafts Refer to Engine Top Side Disassembly in Section 1D Page 1D 25 2 Remove the tappet 1 and shim 2 by fingers or magnetic hand 3 Check the figures printed on the shim...

Page 33: ...Maintenance and Lubrication 0B 7 INTAKE SIDE SPECIFIED CLEARANCE NO ADJUSTMENT REQUIRED 12800 05820 1 65 1 75 I944H1020019 01...

Page 34: ...0B 8 Maintenance and Lubrication EXHAUST SIDE SPECIFIED CLEARANCE NO ADJUSTMENT REQUIRED 12800 05820 1 65 1 75 I944H1020020 01...

Page 35: ...it is white or glazed appearing replace the spark plug with colder type one Heat range 3 After finishing the spark plug inspection reinstall the removed parts Spark Plug Gap 1 Remove the spark plugs...

Page 36: ...Initially at 1 000 km 600 miles 2 months and every 18 000 km 11 000 miles 36 months thereafter Oil should be changed while the engine is warm Oil filter replacement at the above intervals should be do...

Page 37: ...ion CAUTION ONLY USE A GENUINE SUZUKI MOTORCYCLE OIL FILTER Other manufacturer s oil filters may differ in thread specifications thread diameter and pitch filtering performance and durability which ma...

Page 38: ...months E 33 only and every 12 000 km 7 500 miles 24 months Inspect the throttle valve synchronization periodically Refer to Throttle Valve Synchronization in Section 1D Page 1D 15 Cooling System Insp...

Page 39: ...coolant capacity excluding reservoir 1 600 ml 1 7 1 4 US Imp qt 7 Bleed air from the cooling circuit 8 After changing engine coolant reinstall the removed parts Air Bleeding From the Cooling Circuit 1...

Page 40: ...osition turn out the release screw 2 1 turn and tighten the lock nut 1 securely by holding the release screw 2 Clutch release screw 1 turn back 4 Install the clutch cover Refer to Clutch Removal in Se...

Page 41: ...2 3 Give tension to the drive chain fully by turning both chain adjuster bolts 3 4 Count out 21 pins 20 pitches on the chain and measure the distance between the two points If the distance exceeds the...

Page 42: ...s standard drive chain as a replacement Brake System Inspection B944H10206018 Inspect brake system Initially at 1 000 km 600 miles 2 months and every 6 000 km 4 000 miles 12 months thereafter Inspect...

Page 43: ...ation in Section 4A Page 4A 8 and Brake Hose Removal and Installation in Section 4A Page 4A 8 Brake Pedal Height Inspection and Adjustment 1 Inspect the brake pedal height a between the pedal top face...

Page 44: ...r 2 0 mm 0 08 in Tire Pressure If the tire pressure is too high or too low steering will be adversely affected and tire wear increased Therefore maintain the correct tire pressure for good roadability...

Page 45: ...ear suspension Every 12 000 km 7 500 miles 24 months Inspect the rear shock absorbers for oil leakage and check that there is no play in the swingarm Replace any defective parts if necessary Refer to...

Page 46: ...kgf m 16 5 lbf ft 12 Rear brake disc bolt 23 N m 2 3 kgf m 16 5 lbf ft 13 Rear brake air bleeder valve 6 N m 0 6 kgf m 4 5 lbf ft c 4 b 3 I944H1020056 01 b 8 d 5 f 9 b 3 b 7 e 6 I944H1020057 01 b 10...

Page 47: ...Lower 50 N m 5 0 kgf m 36 0 lbf ft 22 Cushion lever mounting nut 78 N m 7 8 kgf m 56 5 lbf ft 23 Cushion rod mounting nut 78 N m 7 8 kgf m 56 5 lbf ft 24 Front fork upper clamp bolt 23 N m 2 3 kgf m...

Page 48: ...material is also described in the following Lubrication Points Page 0B 2 Special Tool B944H10208002 Material SUZUKI recommended product or Specification Note Brake fluid DOT 4 Page 0B 16 09900 20803 0...

Page 49: ...N EX 0 35 0 014 Valve stem runout IN EX 0 05 0 002 Valve head thickness IN EX 0 5 0 02 Valve seat width IN EX 0 9 1 1 0 035 0 043 Valve head radial runout IN EX 0 03 0 001 Valve spring free length IN...

Page 50: ...0406 Oil 2 01 2 03 0 0791 0 0799 Piston ring thickness 1st 0 76 0 81 0 0299 0 0319 1 08 1 10 0 0425 0 0433 2nd 0 97 0 99 0 0382 0 0390 Piston pin bore I D 20 002 20 008 0 7875 0 7877 20 030 0 7886 Pi...

Page 51: ...cification Note Thermostat valve opening temperature Approx 76 5 C 170 F Thermostat valve lift 8 mm 0 31 in and over at 100 C 212 F ECT sensor resistance 20 C 68 F Approx 2 45 k 50 C 122 F Approx 0 81...

Page 52: ...16 5 22 3 k TO sensor voltage Normal 0 4 1 4 V Leaning 3 7 4 4 V When leaning 65 GP switch voltage 0 6 V and more From 1st to Top Injector voltage Battery voltage Ignition coil primary peak voltage 15...

Page 53: ...AC and more at 5 000 r min Regulated voltage 14 0 15 5 V at 5 000 r min Starter motor brush length Standard 10 0 39 Limit 6 5 0 26 Starter relay resistance 3 6 Battery Type designation YT12A BS Capaci...

Page 54: ...M C x MT 3 50 Rear 17 M C x MT 5 00 Item Standard Limit Cold inflation tire pressure Solo riding Front 225 kPa 2 25 kgf cm2 33 psi Rear 250 kPa 2 50 kgf cm2 36 psi Cold inflation tire pressure Dual ri...

Page 55: ...r connecting bolt 23 2 3 16 5 Muffler mounting nut 25 2 5 18 0 Muffler cover bolt 5 5 0 55 4 0 Exhaust cover bolt 5 5 0 55 4 0 Speed sensor rotor bolt 25 2 5 18 0 Speed sensor mounting bolt 5 0 5 3 5...

Page 56: ...lt 10 1 0 7 0 Starter motor brush holder mounting bolt 7 0 7 5 0 Starter motor housing bolt 3 5 0 35 2 5 EVAP canister bracket bolt E 33 only 7 5 0 75 5 5 Item N m kgf m lbf ft CKP sensor mounting bol...

Page 57: ...6 4 5 Rear brake caliper mounting bolt 23 2 3 16 5 Rear brake caliper sliding pin 27 2 7 19 5 Rear brake pad mounting pin 17 1 7 12 5 Pad pin plug 2 5 0 25 1 8 Rear brake master cylinder mounting bol...

Page 58: ...ked bolt N m kgf m lbf ft N m kgf m lbf ft 4 1 5 0 15 1 0 2 3 0 23 1 5 5 3 0 3 2 0 4 5 0 45 3 0 6 5 5 0 55 4 0 10 1 0 7 0 8 13 1 3 9 5 23 2 3 16 5 10 29 2 9 21 0 50 5 0 36 0 12 45 4 5 32 5 85 8 5 61 5...

Page 59: ...ottle Valve Actuator STVA Malfunction 1A 67 DTC C29 P1654 H L Secondary Throttle Position Sensor STPS Circuit Malfunction 1A 73 DTC C31 P0705 GP Switch Circuit Malfunction 1A 84 DTC C32 P0201 C33 P020...

Page 60: ...C Learned Value Reset 1D 17 Engine Assembly Removal 1D 18 Engine Assembly Installation 1D 22 Engine Top Side Disassembly 1D 25 Engine Top Side Assembly 1D 31 Valve Clearance Inspection and Adjustment...

Page 61: ...G 6 Fuel Pump Relay Inspection 1G 6 Fuel Hose Inspection 1G 7 Fuel Hose Removal and Installation 1G 7 Fuel Level Gauge Inspection 1G 7 Fuel Tank Removal and Installation 1G 7 Fuel Pump Components 1G 9...

Page 62: ...ttery Runs Down Quickly 1J 2 Repair Instructions 1J 3 Battery Current Leakage Inspection 1J 3 Regulated Voltage Inspection 1J 3 Generator Inspection 1J 4 Generator Removal and Installation 1J 4 Regula...

Page 63: ...autions 1 1 Engine Precautions Precautions Precautions for Engine B944H11000001 Refer to General Precautions in Section 00 Page 00 1 and Precautions for Electrical Circuit Service in Section 00 Page 0...

Page 64: ...e Injection Volume The 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...

Page 65: ...ed the injection time volume is increased STARTING SIGNAL When starting engine additional fuel is injected during cranking engine ACCELERATION SIGNAL DECELERATION SIGNAL During acceleration the fuel i...

Page 66: ...ECM In this case FI is indicated in the LCD panel Motorcycle does not run CHEC The LCD panel indicates CHEC when no communication signal from the ECM is received for 3 seconds and more For Example Th...

Page 67: ...es are indicated in the code form CAUTION Before checking the malfunction code do not disconnect the ECM coupler If the coupler from the ECM is disconnected the malfunction code memory may be erased a...

Page 68: ...2 3 4 5 GP switch ST SDS VA Clutch lever position switch Starter relay Starter motor M Battery Side stand switch Neutral indicator light 10 A 15 A 10 A Side stand relay 30 A IG switch 10 A Engine stop...

Page 69: ...n switch CLT 33 8 CKP sensor signal CKP 34 Fuel pump relay FP Relay 9 Power source for fuel injector VM 35 STVA signal STVA 1B 10 Power source for back up 36 Tachometer 11 Power source 37 STVA signal...

Page 70: ...10004 06 A ECM G Throttle position sensor TPS B Speedometer H Crank shaft position sensor CKPS C Intake air pressure sensor 2 IAPS I Speedometer sensor D Intake air temperature sensor IATS J Gear posi...

Page 71: ...1110005 02 A ECM R Fuel pump relay FP relay M Cooling fan S Fuel injector Front N Intake air pressure sensor 1 IAPS T Fuel injector Rear O Fuel pump U Engine coolant temperature sensor ECTS P Tip over...

Page 72: ...replace Defective fuel pump Replace Defective fuel pressure regulator Replace Defective fuel injectors Replace Defective fuel pump relay Replace Defective ECM Replace Open circuited wiring connection...

Page 73: ...ne Excessive valve chatter Too large valve clearance Adjust Weakened or broken valve springs Replace Worn tappet or cam surface Replace Worn or burnt camshaft journal Replace Noisy engine Noise seems...

Page 74: ...ive IAT sensors Replace Defective CKP sensor Replace Defective GP sensor Replace Defective IAP sensors Replace Defective ECM Replace TP sensor out of adjustment Adjust Defective STP sensor and or STVA...

Page 75: ...sor lead wire Repair or replace Sucking air from intake pipe joint Repair or replace Defective fuel injectors Replace Defective ECT sensor Replace Engine overheats Other factors Ignition timing is too...

Page 76: ...D 4 2 Connect the special tool to the mode select switch coupler at the wiring harness Special tool A 09930 82720 Mode select switch 3 Start the engine or crank the engine for more than 4 seconds 4 Tu...

Page 77: ...ed in ECM memory can be checked by SDS Be sure to read Precautions for Electrical Circuit Service in Section 00 Page 00 2 before inspection and observe what is written there 1 Remove the right frame c...

Page 78: ...Close the SDS tool and turn the ignition switch OFF 8 Disconnect the SDS tool Use of SDS Diagnosis Reset Procedures B944H11104003 NOTE The malfunction code is memorized in the ECM also when the lead...

Page 79: ...data when trouble Therefore it is possible to know engine and driving conditions e g whether the engine was warm or not where the motorcycle was running or stopped when a malfunction was detected by...

Page 80: ...Engine General Information and Diagnosis 1 Click Show data when trouble 1 to display the data 2 Click the drop down button 2 either Failure 1 or Failure 2 can be selected 1 I718H1110269 02 2 I718H1110...

Page 81: ...r vehicle which is not periodically brought in for service with no past data value having been saved if the data value of a good vehicle condition have been already saved as a master STD comparison be...

Page 82: ...at the time of racing Approx 3 000 r min Check the engine coolant temperature XX Check the manifold absolute pressure XXX kPa I944H1110108 02 Secondary throttle valve open closes in according with the...

Page 83: ...ative pressure during idling 100 C Data of manifold absolute pressure operation at the time of starting Check the engine coolant temperature XX Check the monifold absolute pressure XXX kPa I944H111011...

Page 84: ...n then you may determine how changes have occurred with the passing of time and identify what problem is currently occurring NOTE With DTC not output if the engine idling speed and secondary throttle...

Page 85: ...36 Throttle position sensor TPS 1 C15 P0115 H L Page 1A 47 Engine coolant temperature sensor ECTS C17 P0105 Page 1A 30 Intake air pressure sensor 1 IAPS For 1 cylinder C21 P0110 H L Page 1A 53 Intake...

Page 86: ...value is fixed to 101 kPa 760 mmHg YES YES TP sensor The throttle opening is fixed to full open position Ignition timing is also fixed YES YES ECT sensor Engine coolant temperature value is fixed to 7...

Page 87: ...esitation 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 I...

Page 88: ...Malfunction Code Detected Item Detected Failure Condition Check For C00 NO FAULT C12 CKP sensor The signal does not reach ECM for 2 seconds or more after receiving the starter signal CKP sensor wirin...

Page 89: ...igher than specified value STP sensor circuit shorted to VCC or ground circuit open L Sensor voltage is lower than specified value STP sensor circuit open or shorted to ground or VCC circuit open C31...

Page 90: ...onnection Battery voltage supply to the HO2 sensor P0135 C60 Cooling fan relay Cooling fan relay signal is not input to ECM Cooling fan relay lead wire coupler connection P0480 Malfunction Code Detect...

Page 91: ...Page 1A 15 Step Action Yes No 1 1 Turn the ignition switch OFF 2 Remove the right frame cover Refer to Exterior Parts Removal and Installation in Section 9D Page 9D 4 3 Disconnect the CKP sensor coup...

Page 92: ...ication Continuity Is the continuity OK Go to Step 3 Short circuit in the W wire 3 1 Measure the CKP sensor resistance Special tool A 09900 25008 Multi circuit tester set Tester knob indication Resist...

Page 93: ...use C13 C17 IAP sensor voltage is not within the following range 0 1 V Sensor voltage 4 8 V NOTE Note that atmospheric pressure varies depending on weather conditions as well as altitude Take that int...

Page 94: ...2 cylinder 2 for loose or poor contacts If OK then measure the IAP sensor input voltage 4 Disconnect the IAP sensor couplers 5 Turn the ignition switch ON 6 Measure the voltage between the R wire and...

Page 95: ...t the needle pointed probes to the lead wire coupler 4 Check there is no continuity between the R wire A and ground Also the R wire A and another wire Special tool A 09900 25008 Multi circuit tester s...

Page 96: ...al 3 1 Also the G Y wire B and ECM terminal 22 2 Special tool A 09900 25008 Multi circuit tester set B 09900 25009 Needle pointed probe set Tester knob indication Continuity 1 Cylinder 2 Cylinder Go t...

Page 97: ...re B and ground Also the G B wire A and another wire G Y wire B and another wire Special tool A 09900 25008 Multi circuit tester set B 09900 25009 Needle pointed probe set Tester knob indication Conti...

Page 98: ...is applied up to 400 mmHg by using vacuum pump gauge Special tool A 09917 47011 Vacuum pump gauge set B 09900 25008 Multi circuit tester set Tester knob indication Voltage Is the voltage OK Replace t...

Page 99: ...e 1A 15 Detected Condition Possible Cause C14 Output voltage is not within the following range 0 1 V Sensor voltage 4 8 V TP sensor maladjusted TP sensor circuit open or short TP sensor malfunction EC...

Page 100: ...e the TP sensor input voltage 4 Disconnect the TP sensor coupler 5 Turn the ignition switch ON 6 Measure the input voltage between the R wire A and ground If OK then measure the input voltage between...

Page 101: ...and Installation in Section 1C Page 1C 1 3 Check there is no continuity between the R wire A and ground Also the R wire A and another wire Special tool A 09900 25008 Multi circuit tester set Tester k...

Page 102: ...cuit tester set B 09900 25009 Needle pointed probe set Tester knob indication Continuity ECM coupler Harness side 3 If the sound is head from the tester then check there is no continuity among the P W...

Page 103: ...tle grip open and close Special tool C 09900 28630 TPS test wire harness 09900 25008 Multi circuit tester set Tester knob indication Voltage TP sensor output voltage Throttle valve is closed Approx 1...

Page 104: ...sensor lead wire continuity 4 Disconnect the TP sensor coupler 5 Turn the ignition switch ON 6 Measure the input voltage between the R wire A and B Br wire B If OK then measure the input voltage betw...

Page 105: ...cuit tester set B 09900 25009 Needle pointed probe set Tester knob indication Continuity ECM coupler Harness side 3 If the sound is head from the tester then check there is no continuity among the P W...

Page 106: ...tle grip open and close Special tool C 09900 28630 TPS test wire harness 09900 25008 Multi circuit tester set Tester knob indication Voltage TP sensor output voltage Throttle valve is closed Approx 1...

Page 107: ...poor contacts If OK then check the TP sensor lead wire continuity 4 Disconnect the TP sensor coupler and ECM coupler Refer to ECM Removal and Installation in Section 1C Page 1C 1 5 Check there is no c...

Page 108: ...cuit tester set B 09900 25009 Needle pointed probe set Tester knob indication Continuity ECM coupler Harness side 3 If the sound is head from the tester then check there is no continuity among the P W...

Page 109: ...tle grip open and close Special tool C 09900 28630 TPS test wire harness 09900 25008 Multi circuit tester set Tester knob indication Voltage TP sensor output voltage Throttle valve is closed Approx 1...

Page 110: ...SDS Diagnosis Reset Procedures Page 1A 15 Detected Condition Possible Cause C15 Output voltage is not with in the following range 0 1 V Sensor voltage 4 85 V ECT sensor circuit open or short ECT senso...

Page 111: ...If OK then measure the ECT sensor input voltage 4 Disconnect the ECT sensor coupler and turn the ignition switch ON 5 Measure the input voltage between the B Bl wire A and ground Also the B Bl wire A...

Page 112: ...Refer to ECM Removal and Installation in Section 1C Page 1C 1 9 Check there is no continuity between the B Bl wire A and ground B Br wire B and ground B Bl wire A and B Br wire B Special tool A 09900...

Page 113: ...or lead wire continuity 4 Disconnect the ECT sensor coupler and turn the ignition switch ON 5 Measure the input voltage between the B Bl wire and ground If OK then measure the input voltage between th...

Page 114: ...ck the ECT sensor lead wire continuity 4 Disconnect the ECT sensor coupler and ECM coupler Refer to ECM Removal and Installation in Section 1C Page 1C 1 5 Check there is no continuity between the B Bl...

Page 115: ...knob indication Resistance ECT sensor resistance Approx 2 45 k at 20 C 68 F Terminal Terminal NOTE Refer to ECT Sensor Inspection in Section 1C Page 1C 4 for details Is the resistance OK Replace the...

Page 116: ...of SDS Diagnosis Reset Procedures Page 1A 15 Detected Condition Possible Cause C21 Output voltage is not with in the following range 0 1 V Sensor voltage 4 6 V IAT sensor circuit open or short IAT se...

Page 117: ...the IAT sensor coupler and turn the ignition switch ON 5 Measure the input voltage between the Dg wire A and ground If OK then measure the input voltage between the Dg wire A and B Br wire B Special t...

Page 118: ...ction 1C Page 1C 1 9 Check there is no continuity between the Dg wire A and ground B Br wire B and ground Dg wire A and B Br wire B Special tool A 09900 25008 Multi circuit tester set Tester knob indi...

Page 119: ...sor lead wire continuity 4 Disconnect the IAT sensor coupler and turn the ignition switch ON 5 Measure the input voltage between the Dg wire A and ground If OK then measure the input voltage between t...

Page 120: ...check the IAT sensor lead wire continuity 4 Disconnect the IAT sensor coupler and ECM coupler Refer to ECM Removal and Installation in Section 1C Page 1C 1 5 Check there is no continuity between the D...

Page 121: ...stance Approx 2 56 k 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 4 Is th...

Page 122: ...Reset Procedures Page 1A 15 Detected Condition Possible Cause C23 The sensor voltage should be the following 0 2 V Sensor voltage 4 6 V TO sensor circuit open or short TO sensor malfunction ECM malfu...

Page 123: ...er 1 for loose or poor contacts If OK then measure the TO sensor voltage 4 Disconnect the TO sensor coupler 5 Turn the ignition switch ON 6 Measure the TO sensor input voltage between the R wire A and...

Page 124: ...Go to Step 2 Open circuit in the R wire or B Br wire 2 1 Turn the ignition switch OFF 2 Disconnect the ECM coupler Refer to ECM Removal and Installation in Section 1C Page 1C 1 3 Check there is no con...

Page 125: ...or coupler and ECM coupler Refer to ECM Removal and Installation in Section 1C Page 1C 1 5 Insert the needle pointed probes to the lead wire coupler 6 Check the continuity between the R wire A and ter...

Page 126: ...eck the continuity between the B W wire A and terminal 20 Special tool A 09900 25008 Multi circuit tester set B 09900 25009 Needle pointed probe set Tester knob indication Continuity ECM coupler Harne...

Page 127: ...contacts If OK then check the TO sensor lead wire continuity 4 Disconnect the TO sensor coupler and ECM coupler Refer to ECM Removal and Installation in Section 1C Page 1C 1 5 Check there is no contin...

Page 128: ...tinuity between the Br W wire B and ground Also the Br W wire B and another wire Special tool A 09900 25008 Multi circuit tester set Tester knob indication Continuity Is there no continuity Go to Stop...

Page 129: ...ircuit tester set B 09900 25009 Needle pointed probe set Tester knob indication Voltage TO sensor voltage Normal 0 4 1 4 V terminal Br W terminal B Br 6 Measure the voltage when it is leaned 65 and mo...

Page 130: ...strongly touch the terminal of the ECM coupler with a needle pointed tester probe to prevent terminal damage NOTE After repairing the trouble clear the DTC using SDS tool Refer to Use of SDS Diagnosi...

Page 131: ...to ECM Removal and Installation in Section 1C Page 1C 1 5 Insert the needle pointed probes to the lead wire coupler 6 Check the continuity between the W B wire A and ECM terminal 46 B Lg wire B and EC...

Page 132: ...ter then check there is no continuity among the STVA lead wire coupler each terminal and ground Special tool A 09900 25008 Multi circuit tester set Tester knob indication Continuity Are there continui...

Page 133: ...finity Terminal Ground 3 If OK then measure the STVA resistance between the B Lg wire A and P W wire B and between the G wire C and W B wire D Special tool A 09900 25008 Multi circuit tester set Teste...

Page 134: ...re coupler and ECM coupler 3 Start the engine to check the STV operation STVA operating order Open Approx 38 open Is the operation OK Replace the ECM with a new one Refer to ECM Removal and Installati...

Page 135: ...the SDS tool Refer to the SDS operation manual for further details 2 Turn the ignition switch ON 3 Click Secondary throttle operating control 1 4 Click each button 2 At this time if an operation sound...

Page 136: ...eset Procedures Page 1A 15 Detected Condition Possible Cause C29 Output voltage is not within the following range 0 1 V Sensor voltage 4 8 V STP sensor maladjusted STP sensor circuit open or short STP...

Page 137: ...easure the STP sensor input voltage 4 Disconnect the STP sensor coupler 5 Turn the ignition switch ON 6 Measure the input voltage between the R wire A and ground Also measure the voltage between the R...

Page 138: ...and Installation in Section 1C Page 1C 1 3 Check there is no continuity between the R wire A and ground Also the R wire A and another wire Special tool A 09900 25008 Multi circuit tester set Tester k...

Page 139: ...cuit tester set B 09900 25009 Needle pointed probe set Tester knob indication Continuity ECM couplers Harness side 3 If the sound is head from the tester then check there is no continuity among the Y...

Page 140: ...t the coupler between the R wire and B wire by turning the secondary throttle valve close and open with your finger Special tool B 09900 25008 Multi circuit tester set Tester knob indication Voltage S...

Page 141: ...ck the STP sensor lead wire continuity 4 Disconnect the STP sensor coupler 5 Turn the ignition switch ON 6 Measure the input voltage between the R wire A and ground Also measure the voltage between th...

Page 142: ...cuit tester set B 09900 25009 Needle pointed probe set Tester knob indication Continuity ECM couplers Harness side 3 If the sound is head from the tester then check there is no continuity among the Y...

Page 143: ...t the coupler between the R wire and B wire by turning the secondary throttle valve close and open with your finger Special tool B 09900 25008 Multi circuit tester set Tester knob indication Voltage S...

Page 144: ...poor contacts If OK then check the STP sensor lead wire continuity 4 Disconnect the STP sensor coupler and ECM coupler Refer to ECM Removal and Installation in Section 1C Page 1C 1 5 Check there is no...

Page 145: ...cuit tester set B 09900 25009 Needle pointed probe set Tester knob indication Continuity ECM couplers Harness side 3 If the sound is head from the tester then check there is no continuity among the Y...

Page 146: ...t the coupler between the R wire and B wire by turning the secondary throttle valve close and open with your finger Special tool B 09900 25008 Multi circuit tester set Tester knob indication Voltage S...

Page 147: ...nosis Reset Procedures Page 1A 15 Detected Condition Possible Cause Gear position signal voltage should be higher than the following Gear position sensor voltage 0 2 V If lower than the above value fo...

Page 148: ...on 6 Disconnect the GP switch coupler 7 Turn the ignition switch ON 8 Measure the voltage between the P wire A and B W wire B P wire A and ground Bl wire C and B W wire B Bl wire C and ground When shi...

Page 149: ...ol A 09900 25008 Multi circuit tester set B 09900 25009 Needle pointed probe set Tester knob indication Continuity 4 If the sound is head from the tester then check there is no continuity among the P...

Page 150: ...indication Voltage terminal Bl terminal Ground Is the battery voltage Go to Step 4 Short circuit in the Bl wire 4 1 Check the GP switch Refer to Side stand Ignition Interlock System Parts Inspection...

Page 151: ...ring the trouble clear the DTC using SDS tool Refer to Use of SDS Diagnosis Reset Procedures Page 1A 15 Detected Condition Possible Cause CKP signal is produced but fuel injector signal is interrupted...

Page 152: ...oose 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 Test...

Page 153: ...Assembly in Section 1D Page 1D 11 2 1 Turn the ignition switch ON 2 Measure the injector voltage between the Y R wire and ground NOTE Injector voltage can be detected only for 3 seconds after ignition...

Page 154: ...Idle speed is lower than the desired idle speed C40 P0507 Idle speed is higher than the desired idle speed Step Action Yes No 1 1 Start the engine 2 Check the engine idling speed NOTE Make sure there...

Page 155: ...hat the Desired idle speed 3 is nearly equal to the Spec 2 Also check that the number of percent 5 in the secondary throttle actuator position sensor increases Check 3 1 Click the button 6 and increas...

Page 156: ...iagnosis Reset Procedures Page 1A 15 Detected Condition Possible Cause No voltage is applied to the fuel pump although fuel pump relay is turned ON or voltage is applied to fuel pump although fuel pum...

Page 157: ...lace the FP relay with a new one 2 1 Disconnect the ECM coupler and fuel pump lead wire coupler Refer to ECM Removal and Installation in Section 1C Page 1C 1 and Fuel Tank Removal and Installation in...

Page 158: ...ck there is no continuity between the Y B wire A and ground Y R wire B and ground Y B wire A and Y R wire B Special tool A 09900 25008 Multi circuit tester set Tester knob indication Continuity Is the...

Page 159: ...side voltage between the O W wire D and ground 3 Turn the ignition switch ON engine stop switch is in ON position side stand to upright position and measure the voltage Special tool A 09900 25008 Mul...

Page 160: ...ircuit open or short ECM malfunction Detected Condition Possible Cause C44 P0130 After engine is started few minutes Sensor voltage 2 5 V Engine is cold and stopped Sensor output voltage 0 1 V In othe...

Page 161: ...oupler 1 for loose or poor contacts If OK then check the HO2 sensor lead wire continuity 4 Disconnect the HO2 sensor coupler 5 Turn the ignition switch ON 6 Check the voltage between the W G wire A an...

Page 162: ...in Section 1C Page 1C 1 2 Check there is no continuity between the W G wire A and ground Also the W G wire A and another wire Special tool A 09900 25008 Multi circuit tester set Tester knob indicatio...

Page 163: ...easure the HO2 sensor output voltage while holding the engine speed at 3 000 r min HO2 sensor output voltage at 6 000 r min 0 6 V and more terminal W G terminal B Br Is the voltage OK W G or B Br wire...

Page 164: ...r loose or poor contacts If OK then measure the HO2 sensor resistance 4 Disconnect the HO2 sensor coupler and measure the resistance between terminals CAUTION Temperature of the sensor affects resista...

Page 165: ...wire coupler 3 Check there is continuity between the W B wire A and ECM terminal 17 NOTE Battery voltage can be detected only before starting the engine Special tool A 09900 25008 Multi circuit teste...

Page 166: ...re and ground If the tester voltage indicates the battery voltage it is good condition NOTE Battery voltage can be detected only before starting the engine Special tool A 09900 25008 Multi circuit tes...

Page 167: ...age NOTE After repairing the trouble clear the DTC using SDS tool Refer to Use of SDS Diagnosis Reset Procedures Page 1A 15 Detected Condition Possible Cause Cooling fan relay signal is not input to E...

Page 168: ...o Exterior Parts Removal and Installation in Section 9D Page 9D 4 3 Check the cooling fan relay 1 coupler for loose or poor contacts If OK then inspection the cooling fan relay Refer to Cooling Fan Re...

Page 169: ...relay switch side voltage Battery voltage terminal O Bl terminal Ground 3 If OK then measure the cooling fan relay coil side voltage between the O W wire B and ground Special tool A 09900 25008 Multi...

Page 170: ...2 Disconnect the cooling fan motor coupler 1 3 Apply 12 V to the terminals and check the operation of cooling fan motor terminal Bl terminal B Is the operation OK Go to Step 4 Replace the cooling fan...

Page 171: ...een the G R wire A and ECM terminal 39 Also the B wire B and cooling fan motor B wire C Special tool A 09900 25008 Multi circuit tester set B 09900 25009 Needle pointed probe set Tester knob indicatio...

Page 172: ...ontrol 1 4 Click the Operate 2 At this time if an operation sound is heard from the cooling fan relay and cooling fan motors are operated the function is normal NOTE Cooling fan relay and cooling fan...

Page 173: ...idle speed TP sensor input voltage 4 5 5 5 V TP sensor output voltage Closed Approx 1 1 V Opened Approx 4 3 V ECT sensor input voltage 4 5 5 5 V ECT sensor resistance Approx 2 45 k at 20 C 68 F IAT se...

Page 174: ...A 101 Page 1A 102 Page 1A 103 Page 1A 106 Page 1A 106 Page 1A 108 Page 1A 29 Page 1A 31 Page 1A 32 Page 1A 33 Page 1A 34 Page 1A 35 Page 1A 37 Page 1A 38 Page 1A 39 Page 1A 39 Page 1A 40 Page 1A 41 Pa...

Page 175: ...e General Information and Diagnosis 1A 112 09917 47011 09930 82720 Vacuum pump gauge set Mode selection switch Page 1A 35 Page 1A 4 Page 1A 13 Page 1A 13 99565 01010 019 CD ROM Ver 19 Page 1A 14 Page...

Page 176: ...and adjusted to comply with the applicable emission limits With varying engine conditions all of the fuel injection volumes are precisely controlled by the programmed injection maps in the ECM to redu...

Page 177: ...event discharging crankcase emissions into the atmosphere Blow by gas in the engine is constantly drawn into the crankcase which is returned to the combustion chamber through the PCV breather hose air...

Page 178: ...y other component which conducts exhaust gases Removing or puncturing the air cleaner case air cleaner cover baffles or any other component which conducts intake air Replacing the exhaust system or mu...

Page 179: ...1A Page 1A 97 Crankcase Breather PCV Hose Inspection B944H11206006 Inspect the PCV hose 1 for wear and damage If it is worn or damaged replace the PCV hose with a new one Refer to Crankcase Breather...

Page 180: ...orque of fastener not specified in this section refer to Tightening Torque List in Section 0C Page 0C 7 Item Specification Note HO2 sensor heater resistance Approx 8 at 23 C 73 F HO2 sensor output vol...

Page 181: ...tom Diagnosis B944H11304001 Refer to Engine Symptom Diagnosis in Section 1A Page 1A 9 Repair Instructions ECM Removal and Installation B944H11306001 Removal 1 Remove the seat Refer to Exterior Parts R...

Page 182: ...reverse order of removal TP Sensor Inspection B944H11306006 Refer to DTC C14 P0120 H L TP Sensor Circuit Malfunction in Section 1A Page 1A 36 TP Sensor Removal and Installation B944H11306007 Refer to...

Page 183: ...ection B944H11306026 Refer to DTC C21 P0110 H L IAT Sensor Circuit Malfunction in Section 1A Page 1A 53 NOTE IAT sensor resistance measurement method is the same way as that of the ECT sensor Refer to...

Page 184: ...2 Connect the ECT sensor 1 to a circuit tester and place it in the oil 2 contained in a pan which is placed on a stove 3 Heat the oil to raise its temperature slowly and read the column thermometer 3...

Page 185: ...ary Throttle Position Sensor STPS Circuit Malfunction in Section 1A Page 1A 73 STP Sensor Adjustment B944H11306013 Adjust the STP sensor in the following procedures 1 Remove the air cleaner box Refer...

Page 186: ...embly mark each sensor s original position with a paint or scribe for accurate reinstallation Special tool 09930 11950 Torx wrench Installation 1 Disconnect the STVA lead wire coupler 1 2 Close the se...

Page 187: ...the STVA from the throttle body The STVA and throttle body are available only as an assembly ISC Valve Inspection B944H11306017 Refer to DTC C40 P0505 P0506 P0507 ISC Valve Circuit Malfunction in Sec...

Page 188: ...Specification Note CKP sensor resistance 160 240 CKP sensor peak voltage 4 6 V and more When cranking IAP sensor 1 2 input voltage 4 5 5 5 V IAP sensor 1 2 output voltage Approx 2 5 V at idle speed TP...

Page 189: ...Tightening torque Note N m kgf m lbf ft TP sensor mounting screw 3 5 0 35 2 5 Page 1C 3 ECT sensor 18 1 8 13 0 Page 1C 4 STP sensor mounting screw 3 5 0 35 2 5 Page 1C 6 Page 1C 6 Material SUZUKI reco...

Page 190: ...e cutaway on the secondary throttle shaft is moved causing the engine idle speed to be adjusted ISC Valve is Closed Position ISC Valve is Opened Position Schematic and Routing Diagram Camshaft and Spr...

Page 191: ...le guide and behind the headlight housing brace 3 Clutch cable D Pass the clutch cable over the wiring harness 4 Frame head pipe tape E Pass the clutch cable left side of frame head pipe Pass the thro...

Page 192: ...in the spark plug hole Make sure that the connection is tight Special tool A 09915 64512 Compression gauge B 09915 63311 Compression gauge attachment 5 Keep the throttle grip in the fully opened posi...

Page 193: ...stallation Page 1D 10 Cam chain tension adjuster Refer to Engine Top Side Disassembly Page 1D 25 Refer to Cam Chain Tension Adjuster Inspection Page 1D 45 Refer to Engine Top Side Assembly Page 1D 31...

Page 194: ...12 Gearshift shaft Refer to Gearshift Shaft Gearshift Cam Plate Removal and Installation in Section 5B Page 5B 14 Refer to Gearshift Linkage Inspection in Section 5B Page 5B 17 Refer to Gearshift Shaf...

Page 195: ...al Air Cleaner Element Inspection and Cleaning B944H11406035 Refer to Air Cleaner Element Inspection and Cleaning in Section 0B Page 0B 3 Air Cleaner Box Removal and Installation B944H11406036 Removal...

Page 196: ...rottle Body Construction Page 1D 8 Tighten the air cleaner outlet tube clamp screws 1 Throttle Body Components B944H11406040 5 I944H1140259 01 1 1 I944H1140260 01 FWD FWD 1 a 3 a 3 4 4 4 4 4 6 6 2 5 5...

Page 197: ...WD FWD 2 3 A 1 C B C D 3 I944H1140342 02 1 Clean inlet sheet B Face the tip of the front side clamp to upper b 15 25 2 Fuel hose Pass the fuel hose under the throttle body C Face the tip of the clamp...

Page 198: ...B A FWD FWD a a a 3 2 I944H1140343 03 1 Clamp The end of clamp should face forward A Yellow mark 10 N m 1 0 kgf m 7 0 lbf ft 2 HO2 sensor lead wire B The end clamp should face backward 3 Fuel feed ho...

Page 199: ...nect the fuel feed hose from the fuel pump 5 Disconnect the STVA lead wire coupler 2 STP sensor lead wire coupler 3 and TP sensor lead wire coupler 4 6 Disconnect the fuel injector couplers 5 7 Loosen...

Page 200: ...e throttle cable play Refer to Throttle Cable Play Inspection and Adjustment in Section 0B Page 0B 12 Connect the fuel injector couplers NOTE Make sure that each coupler is installed in the correct po...

Page 201: ...Remove the fuel injectors 6 from the fuel delivery pipes 7 5 Remove the TP sensor 8 and STP sensor 9 by removing each screw 10 and 11 NOTE Prior to disassembly mark sensor s original position with a...

Page 202: ...roove B of the STP sensor Apply grease to the secondary throttle shaft end A if necessary Grease 99000 25010 SUZUKI SUPER GREASE A or equivalent Special tool 09930 11950 Torx wrench Tightening torque...

Page 203: ...ace on the delivery pipe 6 where the fuel injector 5 will be seated with a clean rag Install the fuel injector 5 by pushing it straight to the delivery pipe 6 CAUTION Never turn the injector while pus...

Page 204: ...uctions 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 c...

Page 205: ...water temperature is within 80 105 C 176 221 F A 11 Check for the synchronization of vacuum from 1 and 2 cylinders 12 Equalize the vacuum of the cylinders by turning each airscrew 5 and keep it turni...

Page 206: ...ned valve using SDS tool Refer to ISC Learned Value Reset and Opening Initialization in Section 1C Page 1C 7 ISC Learned Value Reset B944H11406047 When removing or replacing the throttle body assembly...

Page 207: ...Inspection in Section 0B Page 0B 12 5 Disconnect the battery lead wire 1 6 Remove the air cleaner box 2 Refer to Air Cleaner Box Removal and Installation Page 1D 6 7 Remove the radiator assembly 3 Re...

Page 208: ...7 Disconnect the GP sensor lead wire coupler 16 18 Disconnect the starter motor lead wire 17 19 Disconnect the oil pressure switch lead wire 18 and clamps 19 20 Disconnect the water drain hose clamp 2...

Page 209: ...er cover 29 27 Remove the dowel pins 30 28 Remove the speed sensor rotor 31 by removing its bolt 32 while depressing the rear brake pedal 29 Flatten the lock washer 33 30 Remove the engine sprocket nu...

Page 210: ...allation in Section 5C Page 5C 2 37 Remove the return spring 41 and washer 42 38 Disconnect the clutch cable 43 39 Disconnect the reservoir tank over flow hose 44 40 Support the engine with a proper j...

Page 211: ...in the reverse order of engine removal Pay attention to the following points Install the engine in the reverse order of engine removal Pay attention to the following points Gradually raise the engine...

Page 212: ...nuts to the specified torque as shown in the following illustration 7 6 8 I944H1140320 02 A B C D A B C D Left Right 5 1 e a 1 a a 2 b b 3 c a a 4 d I944H1140321 02 1 Engine mounting bolt Cylinder hea...

Page 213: ...ocket nut d 145 N m 14 5 kgf m 105 0 lbf ft Bend the lock washer 11 Tighten the speed sensor rotor bolt 12 to the specified torque Tightening torque Speed sensor rotor bolt e 25 N m 2 5 kgf m 18 0 lbf...

Page 214: ...inishing the engine installation check the following items Throttle cable play Refer to Throttle Cable Play Inspection and Adjustment in Section 0B Page 0B 12 Throttle valve synchronization Refer to T...

Page 215: ...timing inspection plug 1 and generator cover plug 2 2 Turn the crankshaft to bring the I F line A on generator rotor to the index mark B of the valve inspection hole and also to bring the cams to the...

Page 216: ...Remove the front cylinder head bolt M6 L40 1 2 Remove the front cylinder head 2 by removing the cylinder head bolts M6 L70 3 and M10 4 NOTE Loosen the cylinder head bolts little by little diagonally...

Page 217: ...lean rag over the cylinder base so as not to drop the piston pin circlips into the crankcase 2 Remove the piston pin circlip 1 3 Draw out the piston pin 2 and remove the piston 3 NOTE Scribe the cylin...

Page 218: ...e parallel with the mating surface of the cylinder head 2 Remove the cam chain tension adjuster cap bolt 1 washer 2 and spring 3 3 Remove the rear cam chain tension adjuster 4 and gasket 4 Remove the...

Page 219: ...cylinder 3 NOTE Firmly grip the cylinder at both ends and lift it straight up If the cylinder does not come off lightly tap it with a plastic hammer 3 Remove the rear cylinder gasket 4 and dowel pins...

Page 220: ...hould not be aligned with the cutaway A in the piston pin bore Apply molybdenum oil solution to the position rings M O Molybdenum oil MOLYBDENUM OIL SOLUTION Position the piston ring gaps as shown in...

Page 221: ...inders keep the cam chains taut The cam chain must not be caught between cam drive sprocket and crankcase when turning the crankshaft Cylinder Head NOTE Install the front and rear cylinder heads in sa...

Page 222: ...Tighten the cylinder head bolts M10 4 to the specified two step torque with a torque wrench sequentially and diagonally Tightening torque Cylinder head bolt M10 Initial a 25 N m 2 5 kgf m 18 0 lbf ft...

Page 223: ...hafts on cylinder head apply molybdenum oil solution to their journals and cam faces Apply molybdenum oil solution to the camshaft journal holders M O Molybdenum oil MOLYBDENUM OIL SOLUTION NOTE Befor...

Page 224: ...he camshaft journal holders M O Molybdenum oil MOLYBDENUM OIL SOLUTION Install the camshaft journal holders intake and exhaust CAUTION Damage to head or camshaft journal holder thrust surfaces may res...

Page 225: ...d 1 by pushing the stopper 2 Install a new gasket 3 CAUTION Use a new gasket to prevent oil leakage Install the cam chain tension adjuster 4 with F UP mark A faced to the top of cylinder head Tighten...

Page 226: ...line A on the generator rotor with the index mark B of the valve timing inspection hole CAUTION Pull the cam chains upward or the chain will be caught between crankcase and cam drive sprocket To adju...

Page 227: ...cylinder head Engage the cam chain with the intake camshaft sprocket NOTE Before installing the camshaft check that the tappets are installed correctly The other arrow marked 2 D should now be pointin...

Page 228: ...journal holder is identified with a cast on letters IN EX Fasten the camshaft journal holders evenly by tightening the camshaft journal holder bolts sequentially and diagonally CAUTION The camshaft jo...

Page 229: ...d cam chain tension adjuster cap bolt 8 CAUTION Use a new washer to prevent oil leakage NOTE Click sound is heard when the cam chain tension adjuster cap bolt is installed Tighten the cam chain tensio...

Page 230: ...Tightening torque Generator cover plug c 11 N m 1 1 kgf m 8 0 lbf ft Valve timing inspection plug d 23 N m 2 3 kgf m 16 5 lbf ft Cylinder Head Cover Pour engine oil in each oil pocket in the cylinder...

Page 231: ...d cover bolt a 14 N m 1 4 kgf m 10 0 lbf ft Spark Plug Install the spark plugs Refer to Spark Plug Cap and Spark Plug Removal and Installation in Section 1H Page 1H 5 Exhaust Pipe Install the gasket 1...

Page 232: ...ses 2 Refer to Water Hose Routing Diagram in Section 1F Page 1F 3 Radiator Hose Breather Hose Install the radiator hose 1 oil cooler hoses 2 and breather hose 3 Refer to Water Hose Routing Diagram in...

Page 233: ...by measuring the oil clearance with the camshaft installed in place 2 Use the plastigauge to read the clearance at the widest portion which is specified as follows Special tool A 09900 22301 Plastiga...

Page 234: ...tandard 22 007 22 028 mm 0 8664 0 8672 in Special tool E 09900 20205 Micrometer 0 25 mm Camshaft journal O D IN EX Standard 21 959 21 980 mm 0 8645 0 8654 in Camshaft Runout Measure the runout using t...

Page 235: ...pection B944H11406015 Inspect the cam chain tensioner in the following procedures 1 Remove the cam chain tensioner No 1 front and rear Refer to Engine Bottom Side Disassembly Page 1D 58 2 Check the co...

Page 236: ...e a protector 4 Using the special tools compress the valve spring and remove the two cotter halves 3 from the valve stem Special tool A 09919 28620 Sleeve protector B 09916 14510 Valve spring compress...

Page 237: ...press down the spring fit the cotter halves to the stem end and release the lifter to allow the cotter 4 halves to wedge in between retainer and stem CAUTION Be sure to restore each spring and valve t...

Page 238: ...ad Distortion 1 Decarbonize the combustion chambers 2 Check the gasketed surface of the cylinder head for distortion with a straightedge and thickness gauge taking a clearance reading at several place...

Page 239: ...eflection Lift the valve about 10 mm 0 39 in from the valve seat Measure the valve stem deflection in two directions X and Y perpendicular to each other positioning the dial gauge as shown in the figu...

Page 240: ...easured exceeds the standard value or seat width is not uniform reface the seat using the seat cutter Refer to Valve Seat Repair Page 1D 53 Valve seat width a IN EX Standard 0 9 1 1 mm 0 035 0 043 in...

Page 241: ...turn it clockwise Special tool B 09916 34580 Valve guide reamer 10 8 mm C 09916 34542 Reamer handle 5 Cool down the new valve guides in a freezer for about one hour and heat the cylinder head to 100...

Page 242: ...ined to three different angles The seat contact surface is cut at 45 CAUTION The valve seat contact area must be inspected after each cut Do not use lapping compound after the final cut is made The fi...

Page 243: ...bs 33 4 mm 1 31 in Cylinder Inspection B944H11406020 Refer to Engine Top Side Disassembly Page 1D 25 Refer to Engine Top Side Assembly Page 1D 31 Cylinder Distortion Check the gasketed surface of the...

Page 244: ...ince it is apt to be broken down 1 Install the piston rings in the order of the oil ring 2nd ring and 1st ring a The first member to go into the of the oil ring groove is a spacer 1 After placing the...

Page 245: ...der and the piston Piston to cylinder clearance Service limit 0 120 mm 0 0047 in Piston Ring to groove Clearance Measure the side clearances of the 1st and 2nd piston rings using the thickness gauge I...

Page 246: ...e Piston ring end gap Service limit 1st 0 50 mm 0 020 in Service limit 2nd 0 50 mm 0 020 in Piston Pin Pin Bore Measure the piston pin bore inside diameter using the small bore gauge If measurement is...

Page 247: ...the cylinder head cylinder and piston Refer to Engine Top Side Disassembly Page 1D 25 Starter Motor Remove the starter motor 1 Generator Cover 1 Remove the generator cover 1 and clutch cable stopper...

Page 248: ...Gearshift System NOTE Do not drop the each parts into the crankcase 1 Remove the snap ring 1 and washer 2 from the gearshift shaft Special tool 09900 06107 Snap ring pliers 2 Remove the gearshift sha...

Page 249: ...tch 1 Primary Drive Gear 1 Hold the generator rotor with the special tool Special tool A 09930 44530 Rotor holder 2 Remove the primary drive gear bolt 1 CAUTION This bolt has left hand thread Turning...

Page 250: ...e the generator rotor 1 Refer to Generator Removal and Installation in Section 1J Page 1J 4 Starter Driven Gear Remove the key 1 and starter driven gear 2 Front Cam Chain 1 Remove the cam chain tensio...

Page 251: ...s M8 4 NOTE Loosen the crankcase bolts diagonally and smaller sizes first 4 Separate the crankcase into two parts right and left with the special tool NOTE Fit the crankcase separating tool so that th...

Page 252: ...Gearshift 1 Remove the transmission component Refer to Transmission Removal and Installation in Section 5B Page 5B 3 2 Remove the engine sprocket spacer 1 and O ring 2 Oil Jet Piston Cooling Oil Jet...

Page 253: ...ankshaft Journal Bearing 1 Set the special tool as shown to remove the crankshaft journal bearings 1 with the special tool NOTE Remove the crankshaft journal bearings in only one direction from inside...

Page 254: ...on in Section 5B Page 5B 17 Engine Bottom Side Assembly B944H11406025 Assembly the engine bottom side in the reverse order of disassembly Pay attention to the following points NOTE Apply engine oil to...

Page 255: ...Set the specified crankshaft journal bearings 1 to the special tool CAUTION Before setting the bearing apply molybdenum oil solution to the special tool and bearings M O Molybdenum oil MOLYBDENUM OIL...

Page 256: ...e crankcase bore Align the bearing special tool mating surface with the line D on the crankcase NOTE Install the bearing from inside to outside of each crankcase halves M O Molybdenum oil MOLYBDENUM O...

Page 257: ...Tighten the oil gallery plug M8 2 and M6 3 to the specified torque CAUTION Replace the gaskets with new ones Tightening torque Oil gallery plug M8 a 18 N m 1 8 kgf m 13 0 lbf ft Oil gallery plug M6 b...

Page 258: ...nstall the piston cooling oil jets 6 to the left and right crankcase halves Apply a small quantity of thread lock to the bolts 7 and tighten them to the specified torque Thread lock cement 99000 32110...

Page 259: ...the rear cylinder Oil Pressure Regulator Tighten the oil pressure regulator 1 to the specified torque Tightening torque Oil pressure regulator a 27 N m 2 7 kgf m 19 5 lbf ft Oil Strainer Install the...

Page 260: ...ole oil groove and bearing Apply to distorted surfaces as it forms a comparatively thick film Sealant 99000 31110 SUZUKI BOND No 1215 or equivalent Tighten the crankcase bolts a little at a time to eq...

Page 261: ...rque Tightening torque Oil plate bolt c 10 N m 1 0 kgf m 7 0 lbf ft Gear Position Switch Apply grease to the O ring CAUTION Replace the O ring with a new one NOTE Align the gear position switch pin A...

Page 262: ...ing of the starter driven gear Generator Rotor Install the generator rotor 1 Refer to Generator Removal and Installation in Section 1J Page 1J 4 Rear Cam Chain Install the cam chain drive sprocket 1 N...

Page 263: ...tch Apply bond to the thread part of the oil pressure switch 1 and tighten the oil pressure switch 1 to the specified torque NOTE Be careful not to apply bond to the hole of thread end Sealant 99000 3...

Page 264: ...per 1 bolt 2 washer 3 and return spring 4 Tighten the gearshift cam stopper bolt 2 to the specified torque NOTE Hook the return spring end A to the stopper 1 Tightening torque Gearshift cam stopper bo...

Page 265: ...d lock cement 99000 32030 THREAD LOCK CEMENT SUPER 1303 or equivalent Tightening torque Gearshift arm stopper c 19 N m 1 9 kgf m 13 5 lbf ft Install the gearshift shaft assembly 8 and washers 9 as sho...

Page 266: ...Be careful not to drop the washer 2 and pin 3 into the crankcase Install the oil pimp driven gear 4 and snap ring 5 CAUTION Replace the snap ring with a new one Special tool 09900 06107 Snap ring pli...

Page 267: ...hten the generator cover mounting bolts to the specified torque Tightening torque Generator cover mounting bolt 10 N m 1 0 kgf m 7 0 lbf ft Starter Motor Apply grease to the O ring Grease 99000 25010...

Page 268: ...ing the bearings be careful not to scratch the conrods and the bearings Installation 1 When installing the bearings into the conrod cap and conrod be sure to fix the stopper part A first and then pres...

Page 269: ...If the conrod small end inside diameter exceeds the service limit replace the conrod Special tool A 09900 20602 Dial gauge 1 1000 mm 1 mm B 09900 22403 Small bore gauge 18 35 mm Conrod small end I D...

Page 270: ...d Installation Page 1D 79 NOTE When installing the conrod cap to the crank pin make sure that I D code A on the conrod faces towards the intake side Never rotate the crankshaft or conrod when a piece...

Page 271: ...tion table CAUTION The bearings should be replaced as a set Bearing selection table Bearing thickness specification Code A I D specification 1 41 000 41 008 mm 1 6142 1 6145 in 2 41 008 41 016 mm 1 61...

Page 272: ...dard 41 985 42 000 mm 1 6529 1 6535 in Selection 1 Select the specified bearings from the crankcase journal I D codes The crankcase journal I D codes A B or C A is stamped on the inside of each crankc...

Page 273: ...0 35 0 014 Valve stem runout IN EX 0 05 0 002 Valve head thickness IN EX 0 5 0 02 Valve seat width IN EX 0 9 1 1 0 035 0 043 Valve head radial runout IN EX 0 03 0 001 Valve spring free length IN EX 3...

Page 274: ...06 0 18 0 002 0 007 0 5 0 020 Piston ring to groove clearance 1st 0 180 0 0071 2nd 0 150 0 0059 Piston ring groove width 1st 0 83 0 85 0 0327 0 0335 1 30 1 32 0 0512 0 0520 2nd 1 01 1 03 0 0398 0 040...

Page 275: ...16 5 Page 1D 41 Cylinder head cover bolt 14 1 4 10 0 Page 1D 42 Exhaust pipe bolt 23 2 3 16 5 Page 1D 42 Oil gallery plug Cylinder head M6 10 1 0 7 0 Page 1D 49 Oil gallery plug M6 10 1 0 7 0 Page 1D...

Page 276: ...ct or Specification Note Grease SUZUKI SUPER GREASE A or equivalent P No 99000 25010 Page 1D 13 Page 1D 43 Page 1D 68 Page 1D 69 Page 1D 69 Page 1D 69 Page 1D 71 Page 1D 72 Page 1D 72 Page 1D 74 Page...

Page 277: ...75 100 mm Micrometer 0 25 mm Page 1D 56 Page 1D 45 Page 1D 50 Page 1D 56 Page 1D 57 Page 1D 80 09900 20530 09900 20602 Cylinder gauge set Dial gauge Page 1D 54 Page 1D 45 Page 1D 57 Page 1D 80 09900 2...

Page 278: ...sion gauge Page 1D 3 Page 1D 3 09916 10911 09916 14510 Valve lapper set Valve lifter Page 1D 51 Page 1D 47 Page 1D 48 09916 14522 09916 33210 Valve lifter attachment Valve guide reamer 4 5 mm Page 1D...

Page 279: ...Engine Mechanical 1D 90 09920 13120 09930 11950 Crankshaft remover Torx wrench 5 mm Page 1D 62 Page 1D 12 Page 1D 13 Page 1D 14 09930 44530 Rotor holder Page 1D 60 Page 1D 74...

Page 280: ...1E 1 Engine Lubrication System Engine Engine Lubrication System Precautions Precautions for Engine Oil B944H11500001 Refer to Fuel and Oil Recommendation in Section 0A Page 0A 3...

Page 281: ...IL JET 14 OIL JET 14 REAR CYLINDER REAR CYLINDER HEAD FRONT CYLINDER FRONT CYLINDER HEAD INTAKE CAMSHAFT CAM FACES CRANK PIN FRONT AND REAR CONROD BIG END BEARINGS STARTER CLUTCH CAM FACES CAM CHAIN E...

Page 282: ...1E 3 Engine Lubrication System Engine Lubrication Circuit Diagram B944H11502002 FRONT CYLINDER I944H1150042 03...

Page 283: ...Engine Lubrication System 1E 4 REAR CYLINDER I944H1150043 02...

Page 284: ...sure 4 Warm up the engine as follows Summer 10 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...

Page 285: ...gulator Removal and Installation B944H11506003 Removal 1 Remove the engine assembly from the frame Refer to Engine Assembly Removal in Section 1D Page 1D 18 2 Disassemble the engine top side Refer to...

Page 286: ...3 Install the oil strainer Refer to Oil Strainer Oil Pressure Regulator Removal and Installation Page 1E 6 Oil Pressure Regulator Inspection B944H11506004 1 Remove the oil pressure regulator Refer to...

Page 287: ...nkcase Grease 99000 25010 SUZUKI SUPER GREASE A or equivalent Tighten the union bolt 1 to the specified torque Tightening torque Oil cooler union bolt a 70 N m 7 0 kgf m 50 5 lbf ft Oil Pressure Switc...

Page 288: ...B944H11506007 Refer to Oil Pressure Indicator Inspection in Section 9C Page 9C 6 Oil Jet Removal and Installation B944H11506008 Oil Jet For Cam Chain Tension Adjuster Removal 1 Remove the each cam cha...

Page 289: ...nd tighten them to the specified torque Thread lock cement 99000 32110 THREAD LOCK CEMENT SUPER 1322 or equivalent Tightening torque Piston cooling oil jet bolt a 10 N m 1 0 kgf m 7 0 lbf ft Oil Jet F...

Page 290: ...torque CAUTION Use new gaskets to prevent oil leakage Tightening torque Oil gallery plug M8 a 18 N m 1 8 kgf m 13 0 lbf ft Oil gallery plug M6 b 10 N m 1 0 kgf m 7 0 lbf ft Install the clutch push rod...

Page 291: ...o Clutch Removal in Section 5C Page 5C 7 3 Remove the snap ring 1 and oil pump driven gear 2 Special tool 09900 06107 Snap ring pliers 4 Remove the pin 3 and washer 4 5 Remove the oil pump 5 by removi...

Page 292: ...pump assembly CAUTION Do not attempt to disassemble the oil pump assembly The oil pump is available only as an assembly 3 Install the oil pump Refer to Oil Pump Removal and Installation Page 1E 12 Oil...

Page 293: ...htening torque of fastener not specified in this section refer to Tightening Torque List in Section 0C Page 0C 7 a 2 A B I944H1150040 01 I944H1150041 01 Item Standard Limit Oil pressure at 60 C 140 F...

Page 294: ...8 Page 1E 9 Page 1E 10 Page 1E 11 Page 1E 11 Sealant SUZUKI BOND No 1207B or equivalent P No 99000 31140 Page 1E 9 Thread lock cement THREAD LOCK CEMENT SUPER 1322 or equivalent P No 99000 32110 Page...

Page 295: ...on Engine Coolant Description B944H11601001 CAUTION Use a high quality ethylene glycol base anti freeze mixed with distilled water Do not mix an alcohol base anti freeze and different brands of anti f...

Page 296: ...ing System Schematic and Routing Diagram Cooling Circuit Diagram B944H11602001 WATER PUMP OIL COOLER RESERVE TANK RADIATOR THERMOSTAT NO 1 CYLINDER HEAD NO 1 CYLINDER NO 2 CYLINDER HEAD NO 2 CYLINDER...

Page 297: ...egulator rectifier lead wires and below the water hose 5 Reservoir tank overflow hose L Connect the thinner end of 3 way joint with the reservoir tank overflow hose 6 Reservoir tank inlet hose M Clamp...

Page 298: ...seconds CAUTION Do not exceed the radiator cap release pressure or the radiator cap and subsequently the radiator can be damaged 4 After finishing the cooling circuit inspection reinstall the removed...

Page 299: ...defects are found replace the radiator with a new one If the fins are bent or dented repair them by carefully straightening them with the blade of a small screwdriver Radiator Cleaning Blow out any f...

Page 300: ...s Tighten the cooling fan assembly mounting bolts 1 to the specified torque Tightening torque Cooling fan assembly mounting bolt a 6 5 N m 0 65 kgf m 4 5 lbf ft Connect the radiator hoses securely Ref...

Page 301: ...emoval and Installation in Section 9D Page 9D 4 3 Remove the water hose as shown in the water hose routing diagram Refer to Water Hose Routing Diagram Page 1F 3 Installation 1 Install the water hose a...

Page 302: ...diagram Refer to Water Hose Routing Diagram Page 1F 3 2 Fill the reservoir tank to the upper level A 3 Reinstall the removed parts Cooling Fan Inspection B944H11606009 Cooling fan operating temperatu...

Page 303: ...and D terminals to C and to D and check the continuity between A and B If there is no continuity replace it with a new one Special tool 09900 25008 Multi circuit tester set Tester knob indication set...

Page 304: ...even slightly under normal temperature must be replaced 4 Immerse the thermostat 1 in the water contained in a beaker and note that the immersed thermostat is in suspension 5 Heat the water by placing...

Page 305: ...I944H1160056 01 1 Snap ring 6 Bearing 11 Water pump cover screw Apply engine coolant 2 Water pump driven gear 7 O ring 12 Water drain bolt Apply engine oil 3 Pin 8 Oil seal 4 5 N m 0 45 kgf m 3 25 lbf...

Page 306: ...water pump driven gear 2 pin 3 and washer 4 Special tool 09900 06107 Snap ring pliers 4 Remove the water pump assembly 5 from the clutch cover Installation 1 Apply grease to the O rings CAUTION Replac...

Page 307: ...Remove the O ring 4 4 Remove the E ring 5 and impeller 6 5 Remove the mechanical seal ring 7 and rubber seal 8 from the impeller 6 Remove the mechanical seal with the special tool NOTE If there is no...

Page 308: ...N The removed bearings must be replaced with new ones NOTE The stamped mark on the bearings face to the crankcase side Special tool A 09913 70210 Bearing installer set 2 Install the oil seal with the...

Page 309: ...ces the impeller 7 Apply grease to the impeller shaft Grease 99000 25010 SUZUKI SUPER GREASE A or equivalent 8 Install the impeller to the water pump body 9 Fix the impeller shaft with the E ring 3 CA...

Page 310: ...y 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 Repl...

Page 311: ...00 C 212 F ECT sensor resistance 20 C 68 F Approx 2 45 k 50 C 122 F Approx 0 811 k 80 C 176 F Approx 0 318 k 110 C 230 F Approx 0 142 k Radiator cap valve opening pressure 93 123 kPa 0 93 1 23 kgf cm2...

Page 312: ...ecial Tool B944H11608002 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or equivalent P No 99000 25010 Page 1F 12 Page 1F 14 Page 1F 15 09900 06107 09900 25008...

Page 313: ...se care to minimize spillage of gasoline Spilled gasoline should be wiped off immediately Work in a well ventilated area CAUTION To prevent the fuel system fuel tank fuel hose etc from contamination w...

Page 314: ...fuel pressure regulator 6 As the fuel pressure applied to the fuel injector 8 the fuel pressure in the fuel delivery pipe is always kept at absolute fuel pressure of 300 kPa 3 0 kgf cm2 43 psi the fue...

Page 315: ...rvoir tank overflow hose above the high tension cord and below the water hose 2 Fuel tank breather hose No 1 B Align the white paint mark on the hoses with the clamp 3 Fuel tank breather hose No 2 C C...

Page 316: ...ogged fuel filter Clean or replace Defective fuel pump Replace Defective fuel pressure regulator Replace Damaged or cracked vacuum hose Replace Defective ECT sensor Replace Defective thermostat Replac...

Page 317: ...for high pressure D 09915 74521 Oil pressure gauge hose 4 Turn the ignition ON and check for fuel pressure Fuel pressure Approx 300 kPa 3 0 kgf cm2 43 psi If the fuel pressure is lower than the specif...

Page 318: ...t the fuel feed hose 1 from the fuel pump 3 Disconnect the fuel pump lead wire coupler 2 4 Connect a proper fuel hose 3 to the fuel pump 5 Place the measuring cylinder and insert the fuel hose end int...

Page 319: ...rag under the fuel feed hoses 1 3 Disconnect the fuel feed hoses 1 from the fuel delivery pipe and fuel pump 4 Remove the fuel hose 1 Installation 1 Install the fuel hose as shown in the intake system...

Page 320: ...moving the mounting bolt 7 8 Remove the fuel tank bracket 8 9 Remove the fuel tank stay and its rubber cushion 9 Installation Install the fuel tank in the reverse order of removal Pay attention to the...

Page 321: ...3 FWD FWD 3 3 4 5 6 2 1 I944H1170041 02 1 Fuel level gauge 5 Fuel pump 10 N m 1 0 kgf m 7 0 lbf ft 2 Fuel pressure regulator assembly 6 Fuel mesh filter Apply engine oil 3 O ring 7 Fuel feed hose App...

Page 322: ...talling the fuel pump assembly first tighten all the fuel pump mounting bolts lightly in the ascending order and then tighten them to the specified torque in the figure Tightening torque Fuel pump mou...

Page 323: ...nspection and Cleaning Page 1G 12 Assemble the fuel tank pump in the reverse order of the disassembly Pay attention to the following points CAUTION The removed fuel pump lead wire and fuel level gauge...

Page 324: ...ction reinstall the fuel mesh filter Refer to Fuel Pump Disassembly and Assembly Page 1G 10 Fuel Injector Fuel Delivery Pipe Removal and Installation B944H11706015 Removal 1 Remove the air cleaner box...

Page 325: ...jectors to the throttle body assembly CAUTION When installing the fuel delivery pipes to the throttle body pay attention to the difference of the fuel delivery pips Never turn the fuel injectors while...

Page 326: ...ction refer to Tightening Torque List in Section 0C Page 0C 7 I944H1170036 01 Item Specification Note Injector resistance 11 13 at 20 C 68 F Fuel pump discharge amount 166 ml 5 6 5 8 US lmp oz and mor...

Page 327: ...ecial Tool B944H11708002 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or equivalent P No 99000 25010 Page 1G 10 09900 25008 09915 74521 Multi circuit tester s...

Page 328: ...c and Routing Diagram Ignition System Diagram B944H11802001 Refer to Wire Color Symbols in Section 0A Page 0A 5 CKP sensor TP sensor ECT sensor GP switch ECM Engine stop switch Fuse Fuse Ignition swit...

Page 329: ...coils Replace Fouled spark plugs Clean or replace Defective CKP sensor Replace Defective ECM Replace Open circuited wiring connections Repair or replace Spark plug is wet or quickly becomes fouled wit...

Page 330: ...Measure the ignition coil primary peak voltage Refer to Ignition Coil and Plug Cap Inspection Page 1H 6 NOTE This inspection method is applicable only with the multi circuit tester and the peak volt...

Page 331: ...ion 4 High tension cord 1 11 Clamp With the high tension cord clamped and bent inward check that it is positioned within area a 5 High tension cord 2 A Pass the high tension cord above the horn and re...

Page 332: ...spark plugs 2 with a spark plug wrench Special tool A 09930 10121 Spark plug wrench set Installation Install the spark plug caps and spark plugs in the reverse order of removal Pay attention to the f...

Page 333: ...1806002 Refer to Spark Plug Inspection and Cleaning in Section 0B Page 0B 9 Ignition Coil and Plug Cap Inspection B944H11806003 Ignition Coil Primary Peak Voltage 1 Disconnect the all spark plug caps...

Page 334: ...he removed parts Ignition Coil Resistance 1 Disconnect the spark plug caps Refer to Spark Plug Cap and Spark Plug Removal and Installation Page 1H 5 2 Disconnect the ignition coil lead wire couplers 1...

Page 335: ...urn the ignition switch ON and grasp the clutch lever b Press the starter button and allow the engine to crank for a few seconds and then measure the CKP sensor peak voltage 5 Repeat the b procedure a...

Page 336: ...e 9D 4 2 Disconnect the right handlebar switch coupler 1 3 Inspect the engine stop switch for continuity with a tester If any abnormality is found replace the right handlebar switch assembly with a ne...

Page 337: ...CK CEMENT SUPER 1322 or equivalent Specifications Service Data B944H11807001 Electrical Unit mm in Tightening Torque Specifications B944H11807002 Reference For the tightening torque of fastener not sp...

Page 338: ...Thread lock cement THREAD LOCK CEMENT SUPER 1322 or equivalent P No 99000 32110 Page 1H 10 09900 25008 09900 25009 Multi circuit tester set Needle pointed probe set Page 1H 6 Page 1H 7 Page 1H 8 Page...

Page 339: ...motor Ignition switch Fuse 30 A Side stand switch Starter relay Engine stop switch Starter button Turn signal side stand relay Fuse 10 A Gear position switch Battery Clutch lever position switch B W B...

Page 340: ...otor 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...

Page 341: ...ring 7 Brush holder 10 N m 1 0 kgf m 7 0 lbf ft 2 Housing end Inside 8 Housing end assembly Outside Apply grease to sliding surface 3 O ring 9 O ring Apply moly past to sliding surface 4 Square ring 6...

Page 342: ...efer to Wiring Harness Routing Diagram in Section 9A Page 9A 5 NOTE Fit the clamp to the bolt A Tightening torque Starter motor mounting bolt a 10 N m 1 0 kgf m 7 0 lbf ft 4 Tighten the starter motor...

Page 343: ...e 99000 25010 SUZUKI SUPER GREASE A or equivalent Fit the washer 2 to the housing end correctly as shown in the figure Apply a small quantity of moly paste to the armature shaft Moly paste 99000 25140...

Page 344: ...e insulator 1 with a saw blade Armature coil Measure for continuity between each segment Measure for continuity between each segment and the armature shaft If there is no continuity between the segmen...

Page 345: ...ster If the starter relay clicks and continuity is found the relay is ok CAUTION Do not apply battery voltage to the starter relay for five seconds and more since the relay coil may overheat and get d...

Page 346: ...d replace the component with a new one Side stand Switch 1 Turn the ignition switch OFF position 2 Lift and support the fuel tank Refer to Fuel Tank Removal and Installation in Section 1G Page 1G 7 3...

Page 347: ...tallation Page 1I 8 2 Measure the voltage between the A B and C terminals using the multi circuit tester Special tool 09900 25008 Multi circuit tester set Tester knob indication Diode test NOTE If the...

Page 348: ...Multi circuit tester set B 09900 25009 Needle pointed probe set Tester knob indication Voltage Gear position switch voltage Except neutral position 0 6 V and more P B W 8 Turn the ignition switch OFF...

Page 349: ...y clutch 1 to the guide 2 Install the guide 3 to the generator rotor with the arrow mark B faced upward Apply THREAD LOCK to the bolts 4 and then tighten them to the specified torque with the special...

Page 350: ...otation inspect the starter clutch or the starter clutch contacting surface on the starter driven gear for wear or damage If they are found to be damaged replace them with new ones Starter Driven Gear...

Page 351: ...ightening Torque Specifications B944H11907002 NOTE The specified tightening torque is described in the following Starter Motor Components Page 1I 3 Reference For the tightening torque of fastener not...

Page 352: ...PER GREASE A or equivalent P No 99000 25010 Page 1I 4 Page 1I 5 Moly paste SUZUKI MOLY PASTE or equivalent P No 99000 25140 Page 1I 5 Thread lock cement THREAD LOCK CEMENT SUPER 1303 or equivalent P N...

Page 353: ...n generator coil 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 l...

Page 354: ...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...

Page 355: ...er to Exterior Parts Removal and Installation in Section 9D Page 9D 4 Regulated Voltage Inspection B944H11A06002 Inspect the regulated voltage in the following procedures 1 Remove the seat Refer to Ex...

Page 356: ...erator coupler No load Performance 1 Disconnect the generator coupler 1 2 Start the engine and keep it running at 5 000 r min 3 Using the multi circuit tester measure the voltage between three lead wi...

Page 357: ...and Installation in Section 9D Page 9D 4 5 Disconnect the clamp 5 CKP sensor coupler 6 and generator coupler 7 6 Remove the speed sensor 8 and generator cover 9 7 Remove the gasket 10 and dowel pins 1...

Page 358: ...met 3 to the generator cover Tightening torque Generator stator set bolt a 11 N m 1 1 kgf m 8 0 lbf ft CKP sensor mounting bolt b 6 5 N m 0 65 kgf m 4 7 lbf ft Degrease the tapered portion A of genera...

Page 359: ...ING Be careful not to pinch the finger between the generator cover and the crankcase CAUTION Fit the new gasket washer to the bolts 7 Fit the clamp to the bolt 8 Fit the clutch cable stopper 9 to the...

Page 360: ...fer to Engine Oil and Filter Replacement in Section 0B Page 0B 10 Regulator Rectifier Construction B944H11A06012 Regulator Rectifier Inspection B944H11A06006 Inspect the regulator rectifier in the fol...

Page 361: ...l and Installation in Section 9D Page 9D 4 2 Disconnect the regulator rectifier couplers 1 and clamp 2 3 Remove the regulator rectifier 3 by removing the regulator rectifier bolt 4 Installation 1 Inst...

Page 362: ...completely use the removed cap 2 as sealing caps of battery filler holes 3 Insert the nozzles of the electrolyte container 3 into the electrolyte filler holes of the battery 4 Hold the electrolyte con...

Page 363: ...tap the caps with a hammer when installing them Charging For initial charging use the charger specially designed for MF battery CAUTION For charging the battery make sure to use the charger specially...

Page 364: ...lation Page 1J 12 Battery Removal and Installation B944H11A06009 Refer to Electrical Components Location in Section 0A Page 0A 7 Removal 1 Remove the seat Refer to Exterior Parts Removal and Installat...

Page 365: ...Unit mm in CAUTION Never use anything except the specified battery Tightening Torque Specifications B944H11A07002 Reference For the tightening torque of fastener not specified in this section refer to...

Page 366: ...mmended product or Specification Note Grease SUZUKI SUPER GREASE A or equivalent P No 99000 25010 Page 1J 7 Molybdenum oil MOLYBDENUM OIL SOLUTION Page 1J 7 09900 25008 09930 30450 Multi circuit teste...

Page 367: ...tem 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...

Page 368: ...c a 4 8 b a b 7 a 5 1 a c a 6 6 I944H11B0030 05 1 Front exhaust pipe 6 Gasket 5 5 N m 0 55 kgf m 4 0 lbf ft 2 Rear exhaust pipe 7 HO2 sensor Apply muffler seal 3 Muffler 8 Chamber support bracket Do n...

Page 369: ...pport the fuel tank Refer to Fuel Tank Removal and Installation in Section 1G Page 1G 7 4 Remove the frame covers left and right Refer to Exterior Parts Removal and Installation in Section 9D Page 9D...

Page 370: ...falling 9 Remove the gasket 11 10 Remove the rear shock absorber Refer to Rear Shock Absorber Removal and Installation in Section 2C Page 2C 3 11 Remove the rear exhaust pipe 12 12 Remove the gasket...

Page 371: ...ten the muffler cover bolts 1 to the specified torque Tightening torque Muffler cover bolt a 5 5 N m 0 55 kgf m 4 0 lbf ft Tighten the HO2 sensor 2 to the specified torque Tightening torque HO2 sensor...

Page 372: ...aust pipe bolt c 23 N m 2 3 kgf m 16 5 lbf ft Install the new gasket 6 Tighten the exhaust mounting bolts 7 and front exhaust pipe bolts 8 to the specified torque Tightening torque Exhaust pipe bolt c...

Page 373: ...kgf m 18 0 lbf ft Muffler connecting bolt h 23 N m 2 3 kgf m 16 5 lbf ft Exhaust System Inspection B944H11B06005 Inspect the exhaust pipe connection and muffler connection for exhaust gas leakage and...

Page 374: ...following Exhaust System Construction Page 1K 2 Fastening part Tightening torque Note N m kgf m lbf ft Muffler cover bolt 5 5 0 55 4 0 Page 1K 5 HO2 sensor 25 2 5 18 0 Page 1K 5 Exhaust pipe bolt 23 2...

Page 375: ...ion 2C 6 Cushion Lever Bearing Removal and Installation 2C 7 Swingarm Removal and Installation 2C 8 Swingarm Related Parts Inspection 2C 9 Swingarm Bearing Removal and Installation 2C 10 Specification...

Page 376: ...suspensions bolts and nuts are an important part in that it could affect the performance of vital parts They must be tightened to the specified torque periodically and if the suspension effect is lost...

Page 377: ...ive fork oil Check level and drain Bent front axle Replace Front suspension too noisy Insufficient fork oil Check level and add Loose front suspension fastener Tighten Wobbly rear wheel Distorted whee...

Page 378: ...ring 12 Cylinder 22 Front axle pinch bolt 3 Oil seal 13 Rebound spring 23 Outer tube right 4 Oil seal retainer 14 Inner tube 20 N m 2 0 kgf m 14 5 lbf ft 5 Outer tube slide metal 15 Inner tube slide m...

Page 379: ...he reflex reflector 4 for E 24 28 6 Loose the front fork upper clamp bolt 5 NOTE Slightly loosen the front fork cap bolt 6 to facilitate later disassembly 7 Loosen the front fork lower clamp bolts 7 a...

Page 380: ...iper pump the brake lever until the pistons push the pads correctly NOTE Before tightening the front axle and front axle pinch bolt move the front fork up and down four or five times Front Fork Inspec...

Page 381: ...Remove the spacer 3 washer 4 and spring 5 4 Invert the fork and stroke it several times to drain out fork oil 5 Hold the fork inverted for a few minutes to drain oil 6 Remove the dust seal 6 7 Remove...

Page 382: ...for the front fork When reassembling replace the outer and inner tube s slide metal oil seal dust seal and cylinder bolt gasket with the new ones Use care not to cause damage to the slide metal surfa...

Page 383: ...ully Install the oil seal 3 into the outer tube using the special tool Special tool A 09940 52861 Front fork oil seal installer Install the oil seal stopper ring 5 CAUTION Make sure that the oil seal...

Page 384: ...R 1322 or equivalent Tightening torque Front fork cylinder bolt a 20 N m 2 0 kgf m 14 5 lbf ft Fork oil Place the front fork vertically without spring Compress it fully Pour specified front fork oil u...

Page 385: ...should face to the bottom side of the front fork Install the washer 1 and spacer 2 Front fork cap bolt Apply fork oil lightly to the O ring 1 CAUTION Use a new O ring 1 to prevent oil leakage Fork Oil...

Page 386: ...r 1 and cylinder ring 2 for wear or damage If any defects are found replace the cylinder or cylinder ring with a new one Specifications Service Data B944H12207001 Front Fork Unit mm in Oil I649G122003...

Page 387: ...kgf m lbf ft Front fork cap bolt 23 2 3 16 5 Page 2B 2 Front fork lower clamp bolt 23 2 3 16 5 Page 2B 3 Front fork upper clamp bolt 23 2 3 16 5 Page 2B 3 Front fork cylinder bolt 20 2 0 14 5 Page 2B...

Page 388: ...ar shock absorber 7 Cushion rod mounting nut 50 N m 5 0 kgf m 36 0 lbf ft 2 Rear shock absorber mounting nut 8 Spacer 78 N m 7 8 kgf m 56 5 lbf ft 3 Rear shock absorber mounting bolt Lower 9 Chain cas...

Page 389: ...absorber mounting nut Upper 6 Swingarm pivot nut a 1 0 mm 0 04 in 2 Rear shock absorber mounting bolt Lower 50 N m 5 0 kgf m 36 0 lbf ft b 0 25 mm 0 01 in 3 Cushion lever mounting nut 78 N m 7 8 kgf m...

Page 390: ...ear shock absorber and cushion rod Tighten the rear shock absorber upper mounting nut 1 and lower mounting bolt 2 Tightening torque Rear shock absorber upper mounting nut a 50 N m 5 0 kgf m 36 0 lbf f...

Page 391: ...ion 7 provides the stiffest STD position 3rd position Rear Shock Absorber Disposal B944H12306007 Refer to Rear Shock Absorber Removal and Installation Page 2C 3 The rear shock absorber unit contains h...

Page 392: ...rwise pressurized oil many spout out forcefully Cushion Lever Cushion Rod Removal and Installation B944H12306008 Removal 1 Support the motorcycle with a jack to be no load for the cushion lever 2 Remo...

Page 393: ...est bracket mounting bolts 4 and tighten it to the specified torque Tightening torque Front footrest bracket mounting bolts d 23 N m 2 3 kgf m 16 5 lbf ft Tighten the gearshift link arm mounting bolt...

Page 394: ...ushion lever bearings using the special tools Special tool A 09921 20240 Bearing remover set B 09913 70210 Bearing installer set Installation CAUTION The removed bearings must be replaced with new one...

Page 395: ...the rear wheel assembly Refer to Rear Wheel Assembly Removal and Installation in Section 2D Page 2D 11 3 Remove the drive chain cover mounting screws 1 and bolts 2 4 Remove the brake hose clamp screw...

Page 396: ...ft Cushion rod upper mounting nut d 78 N m 7 8 kgf m 56 5 lbf ft Swingarm Related Parts Inspection B944H12306012 Refer to Swingarm Removal and Installation Page 2C 8 Spacers 1 Remove the spacers 1 fr...

Page 397: ...t 0 3 mm 0 01 in Swingarm Bearing Removal and Installation B944H12306013 Removal 1 Remove the rear wheel assembly Refer to Rear Wheel Assembly Removal and Installation in Section 2D Page 2D 11 2 Remov...

Page 398: ...race installer 2 Install the bearing and center spacer 3 Press the bearings into the swingarm pivot with the special tool NOTE When installing the bearing stamped mark on the bearing must face outside...

Page 399: ...Limit Rear shock absorber spring adjuster 3rd position Rear wheel travel 130 5 1 Swingarm pivot shaft runout 0 3 0 01 Fastening part Tightening torque Note N m kgf m lbf ft Rear shock absorber upper m...

Page 400: ...terial SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or equivalent P No 99000 25010 Page 2C 8 Page 2C 11 09900 20607 09900 20701 Dial gauge Dial gauge chuck Page 2C 10...

Page 401: ...wheels on the same vehicle 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 vehi...

Page 402: ...1 6 4 b 2 3 8 9 10 3 b 2 5 6 7 4 I944H1240052 02 1 Front axle 6 Dust seal 65 N m 6 5 kgf m 47 0 lbf ft 2 Brake disc bolt 7 Collar 23 N m 2 3 kgf m 16 5 lbf ft 3 Brake disc 8 Tire Apply grease 4 Beari...

Page 403: ...ght Left a 1 b 2 c 3 a 4 a I944H1240042 03 1 Brake disc bolt a Clearance Apply grease 2 Brake caliper mounting bolt 23 N m 2 3 kgf m 16 5 lbf ft Apply thread lock to thread part 3 Front axle 39 N m 3...

Page 404: ...the work with the motorcycle resting on the side stand Do not support the motorcycle with the exhaust pipe Make sure that the motorcycle is supported securely 5 Draw out the front axle and remove the...

Page 405: ...0 lbf ft 4 Tighten the front axle 3 to the specified torque Special tool 09900 18710 Hexagon socket 12 mm Tightening torque Front axle b 65 N m 6 5 kgf m 47 0 lbf ft 5 Tighten axle pinch bolt 4 to th...

Page 406: ...l Inspect the wheel in the following procedures 1 Remove the brake pads Refer to Front Brake Pad Replacement in Section 4B Page 4B 2 2 Make sure that the wheel rim runout checked as shown does not exc...

Page 407: ...the special tool Special tool A 09913 50121 Oil seal remover 3 Remove the bearings 2 on both sides using the special tool Special tool B 09921 20240 Bearing remover set 4 Remove the spacer 3 Installat...

Page 408: ...the bearing must face outside 3 Install the dust seals with the special tool Special tool C 09913 70210 Bearing installer set 4 Apply grease to the lip of dust seals Grease 99000 25010 SUZUKI SUPER GR...

Page 409: ...r axle nut 2 Brake disc 10 Sprocket 18 Brake disc bolt 3 Spacer 11 Collar 23 N m 2 3 kgf m 16 5 lbf ft 4 Dust seal 12 Rear wheel 60 N m 6 0 kgf m 43 5 lbf ft 5 Bearing 13 Tire 100 N m 10 0 kgf m 72 5...

Page 410: ...ht Left c 4 c 3 a 1 b 2 a I944H1240046 03 1 Rear sprocket nut a Clearance Apply grease 2 Rear axle nut 60 N m 0 6 kgf m 16 5 lbf ft Apply thread lock to thread part 3 Brake caliper mounting bolt 100 N...

Page 411: ...rear brake pedal with the rear wheel removed 6 Remove the spacer 3 and collar 4 Installation 1 Install the collar 1 and spacer 2 2 Install the rear wheel with the rear axle and tighten the rear axle n...

Page 412: ...ck the wheel axle for runout If the runout exceeds the limit replace the axle shaft Wheel axle runout Service limit 0 25 mm 0 010 in Special tool A 09900 20607 Dial gauge 1 100 mm 10 mm B 09900 20701...

Page 413: ...er to Rear Wheel Assembly Removal and Installation Page 2D 11 2 Remove the rear sprocket mounting drum assembly 1 from the rear wheel 3 Remove the dust seal 2 Special tool A 09913 50121 Oil seal remov...

Page 414: ...Install a new dust seal with the special tool Special tool C 09913 70210 Bearing installer set 4 Apply grease to the dust seal lip Grease 99000 25010 SUZUKI SUPER GREASE A or equivalent 5 Install the...

Page 415: ...n since such a repair can cause imbalance Installation CAUTION Do not reuse the valve which has been once removed 1 Apply tire lubricant to the tire bead CAUTION Never use oil grease or gasoline on th...

Page 416: ...heck for the following points Distortion and crack Any flaws and scratches at the bead seating area Wheel rim runout Refer to Front Wheel Assembly Removal and Installation Page 2D 4 and Rear Wheel Ass...

Page 417: ...l balance in the following procedures 1 Removal the wheel assembly Refer to Front Wheel Assembly Removal and Installation Page 2D 4 and Rear Wheel Assembly Removal and Installation Page 2D 11 2 Remove...

Page 418: ...axle runout Front 0 25 0 010 Rear 0 25 0 010 Wheel rim size Front 17 M C x MT3 50 Rear 17 M C x MT5 00 Item Standard Limit Cold inflation tire pressure Solo riding Front 225 kPa 2 25 kgf cm2 33 psi Re...

Page 419: ...ended product or Specification Note Grease SUZUKI SUPER GREASE A or equivalent P No 99000 25010 Page 2D 7 Page 2D 8 Page 2D 13 Page 2D 14 09900 18710 09900 20607 Hexagon socket 12 mm Dial gauge Page 2...

Page 420: ...2D 20 Wheels and Tires...

Page 421: ...ions 3A 1 Drive Chain Related Components 3A 1 Engine Sprocket Removal and Installation 3A 2 Rear Sprocket Rear Sprocket Mounting Drum Removal and Installation 3A 4 Drive Chain Related Parts Inspection...

Page 422: ...the drive chain with a 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 chemi...

Page 423: ...rive Chain Worn sprocket Replace Worn drive chain Replace Stretched drive chain Replace Too large drive chain slack Adjust Drive chain out of adjustment Adjust FWD FWD 11 12 9 10 b 8 6 7 1 2 3 4 a 5 I...

Page 424: ...move the dowel pins 8 6 Remove the speed sensor rotor 9 by removing its bolt 10 while depressing the rear brake pedal 7 Flatten the lock washer 11 8 Remove the engine sprocket nut 12 while depressing...

Page 425: ...Lock Cement Super 1303 or equivalent Tighten the engine sprocket nut 4 to the specified torque Tightening torque Engine sprocket nut a 145 N m 14 5 kgf m 105 0 lbf ft Bend the lock washer 3 Tighten th...

Page 426: ...rear sprocket nuts 1 and separate the rear sprocket 2 from its mounting drum 3 3 Draw out the mounting drum 3 from the wheel hub 4 Remove the retainer 4 and rear sprocket bolts 5 5 Remove the wheel d...

Page 427: ...004 Refer to Rear Sprocket Rear Sprocket Mounting Drum Removal and Installation Page 3A 4 Dust Seal Inspect the sprocket mounting drum dust seal 1 for wear or damage If any damage is found replace the...

Page 428: ...ing drum assembly from the rear wheel Refer to Rear Wheel Dust Seal Bearing Removal and Installation in Section 2D Page 2D 13 3 Remove the retainer 1 4 Remove the sprocket mounting drum dust seal 2 us...

Page 429: ...7 6 Install the rear wheel assembly Refer to Rear Wheel Assembly Removal and Installation in Section 2D Page 2D 11 Drive Chain Replacement B944H13106006 Use the special tool in the following procedur...

Page 430: ...int pin has been completely pushed out of the chain NOTE After the joint pin 9 is removed loosen the pressure bolt B 4 and then pressure bolt A 3 6 Remove the joint pin 9 of the other side of joint pl...

Page 431: ...s 11 properly with the respective holes of the joint plate 10 7 Turn in the pressure bolt A 6 further using the bar 7 to press the joint plate over the joint pins 8 Continue pressing the joint plate u...

Page 432: ...Page 0B 15 Specifications Service Data B944H13107001 Drive Chain Unit mm in Tightening Torque Specifications B944H13107002 NOTE The specified tightening torque is described in the following Drive Chai...

Page 433: ...B944H13108002 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or equivalent P No 99000 25010 Page 3A 4 Page 3A 5 Page 3A 6 Page 3A 7 Page 3A 7 Thread lock cemen...

Page 434: ...3A 12 Drive Chain Drive Train Drive Shaft...

Page 435: ...ake Master Cylinder Disassembly and Assembly 4A 15 Rear Brake Master Cylinder Parts Inspection 4A 16 Specifications 4A 16 Service Data 4A 16 Tightening Torque Specifications 4A 17 Special Tools and Eq...

Page 436: ...servicing or which has been stored for long periods 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 du...

Page 437: ...f the headlight housing brace and under the throttle cables 2 Front brake hose No 2 a 14 3 Stopper After the brake hose union has contacted the stopper tighten the union bolt b 21 4 Stopper After posi...

Page 438: ...nion has contacted the stopper tighten the union bolt C Insert the reservoir hose firmly 2 Brake hose clamp Brake hose clamp ends should face backward a 84 3 Brake hose clamp Brake hose clamp ends sho...

Page 439: ...ng Replace Loose front wheel axle or rear wheel axle Tighten to specified torque Worn pads and disc Replace Foreign material in brake fluid Replace brake fluid Clogged return port of master cylinder D...

Page 440: ...d support the fuel tank Refer to Fuel Tank Removal and Installation in Section 1G Page 1G 7 2 Disconnect the rear brake light switch lead coupler 1 3 Inspect the switch for continuity with a tester If...

Page 441: ...ith paint plastic rubber materials etc Front Brake 1 Fill the master cylinder reservoir to the top of the inspection window Place the reservoir cap to prevent dirt from entering 2 Attach a hose to the...

Page 442: ...r bleeder valve Rear brake 6 N m 0 6 kgf m 4 5 lbf ft Fill the reservoir with brake fluid to the upper mark of the reservoir Install the right rear frame cover Refer to Exterior Parts Removal and Inst...

Page 443: ...r line reservoir 9 Install the reservoir cap Rear Brake Replace the brake fluid from the rear brake system as the same manner of front brake 1 Place the motorcycle on a level surface 2 Remove the righ...

Page 444: ...placement Page 4A 6 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 Routing Di...

Page 445: ...1 Reservoir cap 7 Brake lever 10 N m 1 0 kgf m 7 0 lbf ft 2 Plate 8 Brake lever pivot bolt 6 N m 0 6 kgf m 4 5 lbf ft 3 Diaphragm 9 Brake lever pivot bolt lock nut Apply brake fluid 4 Master cylinder...

Page 446: ...ont brake master cylinder in the reverse order of removal Pay attention to the following points When installing the master cylinder 1 onto the handlebars 2 align the master cylinder holder s mating su...

Page 447: ...condary cup 9 Primary cup 10 Spring 11 Assembly Assemble the master cylinder in the reverse order of disassembly Pay attention to the following points CAUTION Wash the master cylinder components with...

Page 448: ...g torque Brake lever pivot bolt a 6 N m 0 6 kgf m 4 5 lbf ft Brake lever pivot bolt lock nut b 6 N m 0 6 kgf m 4 5 lbf ft Front Brake Master Cylinder Parts Inspection B944H14106013 Refer to Front Brak...

Page 449: ...1 Reservoir tank 5 Brake hose connector 9 Rear brake master cylinder mounting bolt Apply silicone grease 2 Diaphragm 6 Piston Cup set 23 N m 2 3 kgf m 16 5 lbf ft Apply brake fluid 3 Brake hose union...

Page 450: ...voir by turning the push rod 6 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 wit...

Page 451: ...er 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...

Page 452: ...linder bore for any scratches or other damage Piston Inspect the piston surface for any scratches or other damage Rubber Parts Inspect the primary cup secondary cup and dust boot for wear or damage Sp...

Page 453: ...ponents Page 4A 13 Special Tool B944H14108002 Fastening part Tightening torque Note N m kgf m lbf ft Air bleeder valve Front brake 7 5 0 75 5 5 Page 4A 5 Page 4A 7 Air bleeder valve Rear brake 6 0 6 4...

Page 454: ...ad mounting pin 23 N m 2 3 kgf m 16 5 lbf ft 2 Front brake caliper mounting bolt 9 Air bleeder bolt Apply silicone grease to sliding surface 3 Rubber boots 10 Pad set Apply thread lock to thread part...

Page 455: ...its bolts 2 CAUTION Do not operate the brake lever while dismounting the pads 2 Remove the clip 3 3 Remove the brake pads 4 by removing the pad mounting pin 5 4 Clean up the caliper especially around...

Page 456: ...iper by removing the caliper mounting bolts 2 Installation Install the brake caliper in the reverse order of removal Pay attention to the following points Tighten each bolt to the specified torque Tig...

Page 457: ...1 Remove the brake pads Refer to Front Brake Pad Replacement Page 4B 2 2 Remove the caliper holder 1 3 Remove the rubber boots 2 and 3 4 Remove the pad spring 4 5 Remove the pad guide 5 6 Place a clea...

Page 458: ...hen washing the components use the specified brake fluid Never use different types of fluid or cleaning solvent such as gasoline kerosine or the others Apply the brake fluid to piston seals 1 and dust...

Page 459: ...r sliding pins for wear and other damage If any damage is found replace the brake caliper holder with a new one Brake Pad Spring and Pad Guide Inspect the brake pad spring and pad guide for damage and...

Page 460: ...ure 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 S...

Page 461: ...ning Torque List in Section 0C Page 0C 7 Item Standard Limit Brake disc thickness Front 4 3 4 7 0 17 0 19 4 0 0 16 Brake disc runout 0 30 0 012 Brake caliper cylinder bore Front 27 000 27 076 1 0630 1...

Page 462: ...ial Tool B944H14208002 Material SUZUKI recommended product or Specification Note Brake fluid DOT 4 Page 4B 5 Page 4B 5 Grease SUZUKI SILICONE GREASE or equivalent P No 99000 25100 Page 4B 5 Thread loc...

Page 463: ...d Replacement Page 4C 2 CAUTION Replace the brake pad as a set otherwise braking performance will be adversely affected 5 6 e e b c d a 1 2 3 4 I944H1430026 01 1 Rear caliper bracket 6 Rear brake disc...

Page 464: ...cially 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 that the detente of the pa...

Page 465: ...catch any spilt brake fluid Slightly loosen the sliding pin 2 to facilitate later disassembly if necessary 3 Remove the brake pads Refer to Rear Brake Pad Replacement Page 4C 2 4 Pivot the caliper up...

Page 466: ...rfere with safe running and discolor painted surfaces Check the brake hose and hose joints for cracks and fluid leakage Rear Brake Caliper Disassembly and Assembly B944H14306005 Refer to Rear Brake Ca...

Page 467: ...lvent such as gasoline kerosine or the others Apply the brake fluid to piston seal 1 and dust seal 2 CAUTION Replace the piston seal 1 and dust seal 2 with new ones BF Brake fluid DOT 4 Install the pi...

Page 468: ...ect the boots and spacer for damage and wear If any defects are found replace them with new ones Brake Pad Spring Inspect the brake pad springs for damage and excessive bend If any defects are found r...

Page 469: ...sure 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...

Page 470: ...ake disc thickness Rear 4 8 5 2 0 19 0 20 4 5 0 18 Brake disc runout 0 30 0 012 Brake caliper cylinder bore Rear 38 180 38 230 1 5031 1 5051 Brake caliper piston diameter Rear 38 080 38 130 1 4992 1 5...

Page 471: ...ol B944H14308002 Material SUZUKI recommended product or Specification Note Brake fluid DOT 4 Page 4C 5 Page 4C 5 Grease SUZUKI Silicone Grease or equivalent P No 99000 25100 Page 4C 5 Page 4C 5 Thread...

Page 472: ...4C 10 Rear Brakes...

Page 473: ...lation 5B 14 Gearshift Linkage Inspection 5B 17 Gearshift Shaft Oil Seal Removal and Installation 5B 17 Specifications 5B 18 Service Data 5B 18 Tightening Torque Specifications 5B 18 Special Tools and...

Page 474: ...5 1 Precautions Transmission Transaxle Precautions Precautions Precautions for Transmission Transaxle B944H15000001 Refer to General Precautions in Section 00 Page 00 1...

Page 475: ...place driveshaft Worn or rubbing primary gear Replace Worn bearing Replace Transmission will not shift Broken gearshift cam Replace Distorted gearshift fork Replace Worn gearshift pawl Replace Transmi...

Page 476: ...11 6th drive gear 20 Gearshift cam stopper plate 3 4th driven gear 12 2nd drive gear Apply oil 4 3rd driven gear 13 Gearshift fork No 1 Apply molybdenum oil solution 5 6th driven gear 14 Gearshift for...

Page 477: ...move the crankshaft 1 Gearshift cam Gearshift fork Remove the gearshift fork shafts 1 gearshift forks 2 and gearshift cam 3 Driveshaft Assembly Countershaft Assembly 1 Remove the driveshaft assembly 1...

Page 478: ...two conrods the one with the embossed letter marked should be brought to the rear cylinder Install the right crankcase Refer to Engine Bottom Side Assembly in Section 1D Page 1D 65 Install the engine...

Page 479: ...Manual Transmission 5B 5 Transmission Construction B944H15206004 3 3 3 1 3 3 2 I944H1520011 04 1 Counter shaft 2 Drive shaft 3 Snap ring Assemble snap ring with sharp edge side out...

Page 480: ...llowing points Countershaft Remove the 6th drive gear snap ring 1 from its groove and slide it towards the 3rd 4th drive gears 2 Slide the 6th 3 and 2nd 4 drive gears toward the 3rd 4th drive gears 2...

Page 481: ...be discarded and a new snap rings must be installed When installing a new snap rings do not expand the end gap larger than required to slip the snap rings over the shaft After installing a snap rings...

Page 482: ...r to Transmission Removal and Installation Page 5B 3 and Countershaft Gear Driveshaft Gear Disassembly and Assembly Page 5B 6 Gearshift Fork to Groove Clearance NOTE The clearance for each gearshift f...

Page 483: ...ft 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 Gearsh...

Page 484: ...7 Removal 1 Remove the transmission assembly Refer to Transmission Removal and Installation Page 5B 3 2 Remove the clutch push rod oil seal 1 and shift shaft oil seal 2 3 Remove the driveshaft oil sea...

Page 485: ...oil seals and bearings must be replaced with new ones 1 Install the bearings with the special tool Special tool A 09913 70210 Bearing installer set CAUTION The stamped mark side of bearing A faces ins...

Page 486: ...efer to Electrical Components Location in Section 0A Page 0A 7 Refer to Wiring Harness Routing Diagram in Section 9A Page 9A 5 Removal 1 Turn the ignition switch OFF 2 Lift and support the fuel tank R...

Page 487: ...ce the motorcycle on the center stand 2 Remove the gearshift lever as shown in the gearshift lever construction Refer to Gearshift Lever Construction Page 5B 13 Installation Refer to Gearshift Lever C...

Page 488: ...einstallation 2 Remove the engine sprocket outer cover Refer to Engine Sprocket Removal and Installation in Section 3A Page 3A 2 3 Remove the clutch components Refer to Clutch Removal in Section 5C Pa...

Page 489: ...tool 09900 06107 Snap ring pliers 7 Remove the gearshift cam plate bolt 12 and gearshift cam plate 13 8 Remove the gearshift cam stopper 14 NOTE Do not drop the each parts into the crankcase 9 Remove...

Page 490: ...the gearshift cam stopper moves smoothly Locate the gearshift cam in the neutral position Install the gearshift cam stopper plate 6 NOTE Align the gearshift cam pins B with the gearshift cam stopper...

Page 491: ...and Installation Page 5B 14 Gearshift Shaft Check the gearshift shaft for bend or wear Check the return spring for damage or fatigue If any defects are found replace the defective part s Gearshift Sh...

Page 492: ...e 5B 14 Reference For the tightening torque of fastener not specified in this section refer to Tightening Torque List in Section 0C Page 0C 7 A 1 I944H1520066 01 Item Standard Limit Primary reduction...

Page 493: ...Grease SUZUKI SUPER GREASE A or equivalent P No 99000 25010 Page 5B 12 Page 5B 13 Page 5B 18 Thread lock cement THREAD LOCK CEMENT SUPER 1303 or equivalent P No 99000 32030 Page 5B 16 THREAD LOCK CEM...

Page 494: ...orn clutch hub spline Replace clutch hub Worn clutch plate teeth Replace clutch plate Distorted clutch plate driven and drive Replace Worn clutch release bearing Replace Weakened clutch dampers Replac...

Page 495: ...3 Loosen the cable lock nut 3 and adjuster 4 NOTE Align the clutch lever cable lock nut 3 and adjuster 4 with the cutaway 4 Disconnect the clutch cable 5 clutch lever side 5 Disconnect the clutch cabl...

Page 496: ...5 6 3 4 2 1 FWD FWD FWD FWD a a I944H1530067 04 1 Adjuster 5 Oil seal 9 Clutch push rod left 2 Lock nut 6 Bearing 5 N m 0 5 kgf m 3 8 lbf ft 3 Clutch lever 7 Clutch release camshaft Apply grease 4 Clu...

Page 497: ...Pay attention to the following points Apply grease to the clutch lever pivot bolt Grease 99000 25100 SUZUKI SILICONE GREASE or equivalent Install the left handlebar components Refer to Handlebars Rem...

Page 498: ...all quantity of grease to the clutch push rod Grease 99000 25010 SUZUKI SUPER GREASE A or equivalent Install the generator cover Refer to Generator Removal and Installation in Section 1J Page 1J 4 Clu...

Page 499: ...utch push rod right 2 Thrust washer 9 Spring washer seat 16 Oil seal 3 Bearing 10 Clutch sleeve hub nut lock washer 10 N m 1 0 kgf m 7 0 lbf ft 4 Clutch push piece 11 Clutch sleeve hub 50 N m 5 0 kgf...

Page 500: ...ose 1 water bypass hose 2 oil cooler hose 3 and crankcase breather PCV hose 4 4 Remove the clutch cover 5 by removing the bolts 5 Remove the gasket 6 and dowel pins 7 6 Remove the clutch springs and c...

Page 501: ...h sleeve hub nut lock washer 12 Hold the clutch sleeve hub with the special tool and remove the clutch sleeve hub nut Special tool A 09920 53740 Clutch sleeve hub holder 13 Remove the lock washer 17 a...

Page 502: ...oved snap ring 3 must be replaced with a new one Special tool 09900 06107 Snap ring pliers 4 Install the spacer 4 and apply engine oil to it 5 Install the primary driven gear assembly 5 onto the count...

Page 503: ...sleeve hub nut 13 to the specified torque Special tool A 09920 53740 Clutch sleeve hub holder Tightening torque Clutch sleeve hub nut a 50 N m 5 0 kgf m 36 0 lbf ft 10 Bend the lock washer to lock nu...

Page 504: ...prings 17 Tighten the clutch spring set bolts to the specified torque NOTE Tighten the clutch spring set bolts diagonally Tightening torque Clutch spring set bolt 10 N m 1 0 kgf m 7 0 lbf ft 18 Loosen...

Page 505: ...l Tank Drain Hose and Breather Hose Routing Diagram in Section 1G Page 1G 3 24 Connect the crankcase breather PCV hose 32 oil cooler hose 33 water bypass hose 34 and radiator outlet hose 35 securely R...

Page 506: ...1 and No 2 12 9 mm 0 508 in Measure each driven plate for distortion with a thickness gauge and surface plate Replace driven plates which exceed the limit Special tool B 09900 20803 Thickness gauge Cl...

Page 507: ...en gear for any damages If necessary replace it with a new one Primary Drive Gear Removal and Installation B944H15306021 Removal 1 Remove the clutch cover Refer to Clutch Removal Page 5C 7 2 Hold the...

Page 508: ...primary drive gear in the following procedures 1 Remove the primary drive gear assembly Refer to Primary Drive Gear Removal and Installation Page 5C 14 2 Visually inspect the gear teeth for wear and...

Page 509: ...d snap ring 4 must be replaced with a new one After installing a snap ring always insure that it is completely seated in its groove and securely fitted Specifications Service Data B944H15307001 Clutch...

Page 510: ...2 Fastening part Tightening torque Note N m kgf m lbf ft Clutch sleeve hub nut 50 5 0 36 0 Page 5C 10 Clutch spring set bolt 10 1 0 7 0 Page 5C 11 Primary drive gear bolt 70 7 0 50 5 Page 5C 15 Materi...

Page 511: ...Components 6B 1 Handlebar Construction 6B 2 Handlebars Removal and Installation 6B 3 Handlebars Inspection 6B 4 Steering Components 6B 5 Steering Removal and Installation 6B 5 Steering Related Parts I...

Page 512: ...6 1 Precautions Steering Precautions Precautions Precautions for Steering B944H16000001 Refer to General Precautions in Section 00 Page 00 1...

Page 513: ...roken bearing in steering stem Replace Distorted steering stem Replace Not enough pressure in tires Adjust Wobbly Handlebars Loss of balance between right and left front forks Replace fork or adjust f...

Page 514: ...2 3 5 4 a 6 1 3 7 8 FWD FWD A FWD FWD I944H1620023 02 1 Throttle grip 5 Handle balancer expander A Apply handle grip bond 2 Handlebars 6 Handle balancer screw a 0 5 1 5 mm 0 02 0 06 in Throttle grip...

Page 515: ...4H16206002 3 a 2 A A b b B a a A a 1 A a a I944H1620001 03 1 Front brake master cylinder A Punch mark 10 N m 1 0 kgf m 7 0 lbf ft 2 Handlebar holder B UP mark 23 N m 2 3 kgf m 16 5 lbf ft 3 Washer The...

Page 516: ...ter cylinder Front brake lever 11 CAUTION Do not turn the front brake master cylinder upside down 3 Remove the caps and handlebar holder bolts Installation Install the handlebars in the reverse order...

Page 517: ...Handle Grip Bond commercially available Insert the projection E of the left handlebar switch box into the hole of the handlebars Rout the wiring harness and cable routing Refer to Throttle Cable Rout...

Page 518: ...to Combination Meter Removal and Installation in Section 9C Page 9C 2 5 Disconnect the turn signal light lead wire couplers 1 6 Demount the headlight bracket 2 downward by removing the bracket mounti...

Page 519: ...Page 6B 3 11 Remove the steering stem head nut 8 and washer 9 Remove the steering stem upper bracket 10 12 Remove the steering stem nut 11 with the special tool NOTE When loosening the stem nuts hold...

Page 520: ...right so that the angular ball bearings seat properly Loosen the steering stem nut 1 4 1 2 turn a NOTE This adjustment will vary from motorcycle to motorcycle Steering stem upper bracket Install the f...

Page 521: ...g Removal and Installation B944H16206010 Removal 1 Remove the dust seal and steering stem upper bearing Refer to Steering Removal and Installation Page 6B 5 2 Remove the steering stem lower bearing an...

Page 522: ...0 500 grams Special tool A 09940 92720 Spring scale 4 Do the same on the other grip end 5 If the initial force read on the scale when the handlebar starts turning is either to heavy or too light adjus...

Page 523: ...pecial Tools and Equipment Recommended Service Material B944H16208001 NOTE Required service material is also described in the following Steering Components Page 6B 5 Fastening part Tightening torque N...

Page 524: ...JT40H Page 6B 9 Page 6B 6 09930 11940 09940 14911 Torx bit holder Steering stem nut socket wrench Page 6B 6 Page 6B 6 Page 6B 7 09940 92720 09941 34513 Spring scale Bearing installer Page 6B 9 Page 6B...

Page 525: ...on 9B 13 Turn Signal Switch Inspection 9B 14 Passing Light Switch Inspection 9B 14 Dimmer Switch Inspection 9B 15 Specifications 9B 15 Service Data 9B 15 Tightening Torque Specifications 9B 15 Special...

Page 526: ...dy Structure 9E 1 Repair Instructions 9E 1 Body Frame Construction 9E 1 Front Footrest Construction 9E 2 Side stand Construction 9E 3 Specifications 9E 3 Tightening Torque Specifications 9E 3 Special...

Page 527: ...ctrical System B944H19000001 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 Locati...

Page 528: ...SWITCH HI LO DIMMER SWITCH PUSH HORN BUTTON L PUSH R TURN SIGNAL LIGHT SWITCH HORN HAZARD SWITCH OFF ON HEADLIGHT POSITION LIGHT FRONT TURN SIGNAL LIGHT R FRONT TURN SIGNAL LIGHT R PUSH OFF ON FUSE BO...

Page 529: ...PUSH W Bl Gr W B W W B G B Gr B B W G R P W Br B B Lg Y B Bl Y Gr R B G W R W Bl Y G B Br B Br G Y P W Br W B Bl O R W B Bl W Bl B Bl G B W B Br O G R W Y R O Bl B Y W G R Y G B Dg P B B B B W B B W...

Page 530: ...H HORN HAZARD SWITCH OFF ON HEADLIGHT POSITION LIGHT FRONT TURN SIGNAL LIGHT R FRONT TURN SIGNAL LIGHT R PUSH OFF ON FUSE BOX TURN SIGNAL SIDE STAND RELAY 1 2 3 4 5 6 1 HEAD HI 2 HEAD LO 3 IGNITION 4...

Page 531: ...FREE PUSH W Bl Gr W B W W B G B Gr B B W G R P W Br B B Lg Y B Bl Y Gr R B G W R W Bl Y G B Br B Br G Y P W Br W B Bl O R W B Bl W Bl B Bl G B W B Br O W R W Y R O Bl B Y W G R Y G B Dg P B B B B W B...

Page 532: ...otor lead wire with the clamp 16 Side stand switch lead wire 5 Clamp Bind the generator lead wire neutral switch lead wire and speed sensor lead wire with the clamp 17 Fuel pump lead wire coupler 6 Cl...

Page 533: ...harness and ignition switch lead wire with the clamp B Pass the TP sensor lead wire between the high tension cord and cylinder head 4 Clamp Bind the wiring harness generator lead wire and front ignit...

Page 534: ...wiring harness through the hole provided on the upper part of rear fender 4 License plate light lead wire coupler B Pass the clamp between the rear fender and the bulge and recess section of frame 5 R...

Page 535: ...kgf m 8 0 lbf ft 2 Oil pressure switch lead wire 4 5 N m 0 45 kgf m 3 0 lbf ft 3 Battery lead wire a 90 4 Side stand switch lead wire b Max 45 5 Speed sensor lead wire c Within 45 6 Generator lead wir...

Page 536: ...tightening torque is described in the following Wiring Harness Routing Diagram Page 9A 5 Reference For the tightening torque of fastener not specified in this section refer to Tightening Torque List...

Page 537: ...g Systems 9B 1 Body and Accessories Lighting Systems Repair Instructions Headlight Construction B944H19206029 4 3 3 1 2 I944H1920001 02 1 Headlight 3 Headlight side cover 2 Headlight cover 4 Headlight...

Page 538: ...9B 2 Lighting Systems Headlight Cover Construction B944H19206030 2 2 1 3 I944H1920002 02 1 Headlight cover 2 Headlight side cover 3 Headlight brace...

Page 539: ...Lighting Systems 9B 3 Headlight Components FWD FWD 3 1 2 I944H1920044 02 1 Headlight bulb 12 V 60 55 W H4 3 Bulb socket rubber cap 2 Position light bulb 12 V 5 W...

Page 540: ...B944H19206004 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...

Page 541: ...efer to Headlight Removal and Installation Page 9B 4 2 Remove the position light socket 1 3 Replace the position light bulb 2 4 Reinstall the removed parts Headlight Beam Adjustment B944H19206005 Adju...

Page 542: ...2 5 a 3 4 b I944H1920003 02 1 Rear combination light 5 Reflex refractor For E 03 28 33 2 License plate light 1 8 N m 0 18 kgf m 1 5 lbf ft 3 Rear turn signal light For E 03 28 33 1 3 N m 0 13 kgf m 1...

Page 543: ...erior Parts Removal and Installation in Section 9D Page 9D 4 2 Remove the screws 1 3 Remove the rear fender bracket 2 by removing the rear turn signal light mounting nuts 3 4 Disconnect the seat lock...

Page 544: ...ue Rear turn signal light mounting nut b 1 3 N m 0 13 kgf m 1 0 lbf ft Rear Combination Light Bulb Replacement B944H19206009 CAUTION When you touch the bulb with your bare hands clean the bulb with a...

Page 545: ...r Parts Removal and Installation in Section 9D Page 9D 4 2 Remove the rear fender bracket Refer to Rear Combination Light Removal and Installation Page 9B 7 3 Remove the license plate light assembly 1...

Page 546: ...e Do not use bulb other than those with predetermined wattage 1 Remove the license plate light assembly Refer to License Plate Light Removal and Installation Page 9B 9 2 Remove the lens 1 by removing...

Page 547: ...rn signal light 2 by removing the nut 3 Installation Install the front turn signal light in the reverse order of removal Pay attention to the following point Tighten the front turn signal light mounti...

Page 548: ...ove the rear turn signal light 7 by removing the nut 8 Installation Install the rear turn signal light in the reverse order of removal Pay attention to the following point Tighten the rear turn signal...

Page 549: ...nal switch and circuit connection If the bulb turn signal switch and circuit connection are OK the turn signal relay may be faulty therefore replace the turn signal side stand relay with a new one Ref...

Page 550: ...ty 4 After finishing the turn signal switch inspection reinstall the removed parts Passing Light Switch Inspection B944H19206022 Inspect the passing light switch in the following procedures 1 Remove t...

Page 551: ...H19207002 NOTE The specified tightening torque is described in the following Rear Lighting System Construction Page 9B 6 Rear Combination Light Components Page 9B 7 Front Turn Signal Light Constructio...

Page 552: ...9B 16 Lighting Systems Special Tools and Equipment Special Tool B944H19208001 09900 25008 Multi circuit tester set Page 9B 13 Page 9B 14 Page 9B 14 Page 9B 15...

Page 553: ...ht Emitting Diode LED is used for the illumination light and each indicator light LED is maintenance free LED is less electric power consuming and stronger to vibration resistance compared to the bulb...

Page 554: ...al 1 Remove the combination meter cover 1 by removing the screws 2 2 Remove the screws 3 and disconnect the combination meter coupler 4 3 Remove the combination meter mounting nut 5 3 1 2 4 I944H19300...

Page 555: ...is turned to ON Check that other LEDs Neutral indicator light High beam indicator light and Turn signal indicator lights light up go off by operating each switch If abnormal condition is found replac...

Page 556: ...onnect the variable resistor 2 between the terminals 4 Turn the ignition switch ON 5 Check the LED 3 and LCD 4 operations when the resistance is adjusted to the specified values If either one or all i...

Page 557: ...Install the fuel pump assembly Refer to Fuel Pump Disassembly and Assembly in Section 1G Page 1G 10 Speedometer Inspection B944H19306010 If the speedometer odometer or tripmeter does not function pro...

Page 558: ...8 Multi circuit tester set Tester knob indication Voltage 3 Move a screwdriver back and forth across the pick up surface of the speed sensor The voltage readings should cycle as follows 0 V 12 V or 12...

Page 559: ...ection 9D Page 9D 4 2 Disconnect the ignition switch coupler 1 3 Inspect the ignition switch for continuity with a tester If any abnormality is found replace the ignition switch with a new one Special...

Page 560: ...ed parts Horn Inspection 1 Remove the horn Refer to Horn Removal and Installation Page 9C 8 2 Connect a 12 V battery to terminal A and terminal B If the sound is not heard from the horn replace the ho...

Page 561: ...2 19 24 Headlight HI 60 LO 55 Position Parking light 5 Brake light Taillight 21 5 Turn signal light 21 x 4 10 x 4 License plate light 5 Speedometer light LCD Tachometer light LED Turn signal indicator...

Page 562: ...9D 1 Exterior Parts Body and Accessories Exterior Parts Schematic and Routing Diagram Seat Lock Cable Routing Diagram B944H19402001 1 Seat lock cable 2 Seat lock 1 1 2 I944H1940021 01...

Page 563: ...ts 9D 2 Repair Instructions Frame Cover Construction B944H19406001 4 3 2 2 1 3 5 I944H1940001 03 1 Frame lower cover 4 Rear frame cover 2 Frame cover 5 Cap 3 Pillion rider handle Apply thread lock to...

Page 564: ...Parts Rear Fender Construction B944H19406003 1 2 3 4 5 I944H1940003 02 1 Rear front fender 4 Rear fender cover 2 Rear fender 5 Rear fender guard For E 24 3 Rear fender bracket Apply thread lock to th...

Page 565: ...3 Push in the head of center piece until it becomes flush with the fastener outside face Exterior Parts Removal and Installation B944H19406007 Seat Removal 1 Unlock the seat with the ignition key 1 2...

Page 566: ...er handles 1 by removing the caps and bolts 2 4 Remove the rear frame cover 3 5 Disconnect the clamps 4 6 Disconnect the rear turn signal light lead wire couplers 5 rear combination lead wire coupler...

Page 567: ...D LOCK CEMENT SUPER 1322 or equivalent Rout the wiring harness Refer to Wiring Harness Routing Diagram in Section 9A Page 9A 5 Apply thread lock to the pillion rider handle mounting bolts 2 Thread loc...

Page 568: ...OTE Required service material is also described in the following Frame Cover Construction Page 9D 2 Rear Fender Construction Page 9D 3 Material SUZUKI recommended product or Specification Note Thread...

Page 569: ...Body Structure 9E 1 Body and Accessories Body Structure Repair Instructions Body Frame Construction B944H19506001 1 FWD FWD I944H1950003 01 1 Frame...

Page 570: ...9E 2 Body Structure Front Footrest Construction B944H19506004 a I944H1950001 01 18 N m 1 8 kgf m 13 0 lbf ft Apply thread lock to thread part...

Page 571: ...Reference For the tightening torque of fastener not specified in this section refer to Tightening Torque List in Section 0C Page 0C 7 Special Tools and Equipment Recommended Service Material B944H1950...

Page 572: ...Prepared by December 2008 Part No 99500 36190 01E Printed in Japan 572...

Page 573: ...Printed in Japan K9...

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