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Suzuki TU250X, Service Manual

The Suzuki TU250X is a reliable and classic motorcycle known for its retro styling and smooth performance. Ensure your bike is always in top condition by downloading the free Service Manual from manualshive.com. This manual offers detailed instructions and maintenance tips to keep your Suzuki running smoothly for years to come.

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SERVICING INFORMATION     10-25

09913-70210
Bearing installer 
set (10 – 75

)

09915-63210
Compression 
gauge adaptor

09915-64512
Compression 
gauge

09915-74511
Oil pressure 
gauge (600 kPa)

09916-10911
Valve lapper set

09916-14510
Valve lifter

09916-14910
Valve lifter attach-
ment

09916-34542
Reamer handle

09916-34550
Valve guide 
reamer (5.5 mm)

09916-34561
Valve guide 
reamer (11.3 mm)

09916-44910
Valve guide 
installer & remover

09916-84511
Tweezer

09917-14910
Tappet adjust 
driver

09917-47011
Vacuum pump 
gauge set

09920-13120
Crankshaft 
remover

09920-31020
Extension handle

09920-53740
Clutch sleeve hub 
holder

09921-20240
Bearing remover 
set

09923-74511
Bearing remover

09924-84510
Bearing installer 
set

09924-84521
Bearing installer 
set

09930-10121
Spark plug wrench 
set

09930-11920
Torx bit (JT40H)

09930-11940
Torx bit holder

09930-11950
Torx wrench 
(5 mm)

Summary of Contents for TU250X

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Page 3: ...stomers of fast and reliable service COPYRIGHT SUZUKI MOTOR CORPORATION 2009 This manual has been prepared on the basis of the latest specifications at the time of publi cation If modifications have b...

Page 4: ...section to help you find the item and page you need COMPONENT PARTS AND WORK TO BE DONE Under the name of each system or unit is its exploded view Work instructions and other service information such...

Page 5: ...f engine oil and SUZUKI MOLY PASTE in a ratio of 1 1 Apply or use brake fluid DOT 4 Apply SUZUKI SUPER GREASE A or equivalent 99000 25010 Measure in voltage range Apply SUZUKI SILICONE GREASE or equiv...

Page 6: ...ouble Code E ECM Engine Control Module Engine Control Unit ECU FI Control Unit ET Sensor Engine Temperature Sensor ETS F FI Fuel Injection Fuel Injector FP Fuel Pump FPR Fuel Pressure Regulator G GEN...

Page 7: ...m STC System Secondary Throttle Control System STCS STP Sensor Secondary Throttle Position Sensor STPS ST Valve Secondary Throttle Valve STV STV Actuator Secondary Throttle Valve Actuator STVA T TO Se...

Page 8: ...nsor CKP Sensor Crankshaft Position Sensor CKPS Crank Angle D Data Link Connector DLC Dealer Mode Coupler Diagnostic Test Mode DTM Diagnostic Trouble Code DTC Diagnostic Code Malfunction Code E Electr...

Page 9: ...r Injection PAIR Pulse Air Control PAIR R Random Access Memory RAM Read Only Memory ROM ROM S Secondary Air Injection AIR Secondary Throttle Control System STCS STC System STCS Secondary Throttle Valv...

Page 10: ...White tracer B W Black with White tracer R Y Red with Yellow tracer B Y Black with Yellow tracer W B White with Black tracer Bl B Blue with Black tracer W Bl White with Blue tracer Bl R Blue with Red...

Page 11: ...L 1 5 ENGINE OIL 1 5 BRAKE FLUID 1 5 FRONT FORK OIL 1 5 BREAK IN PROCEDURES 1 5 INFORMATION LABELS 1 6 SPECIFICATIONS 1 7 DIMENSIONS AND CURB MASS 1 7 ENGINE 1 7 DRIVE TRAIN 1 7 CHASSIS 1 8 ELECTRICAL...

Page 12: ...must use good judgement and basic mechanical safety principles If you are unsure about how to perform a particular service operation ask a more experienced mechanic for advice GENERAL PRECAUTIONS Prop...

Page 13: ...bolts and nuts tighten the larger sizes first Always tighten the bolts and nuts diagonally from the inside toward outside and to the speci fied tightening torque Whenever you remove oil seals gaskets...

Page 14: ...number or V I N Vehicle Identification Number 1 is stamped on the right side of the steering head pipe The engine serial number 2 is located on the left side of the crankcase These numbers are require...

Page 15: ...e materials are used and all machined parts are finished to a very high standard but it is still necessary to allow the moving parts to BREAK IN before subjecting the engine to maximum stresses The fu...

Page 16: ...MATION INFORMATION LABELS A Attached TU250X 1 Noise label A 2 Information label A 3 Manual notice label A 4 General warning label A 5 Tire information label A 6 Safety plate A Right frame cover Inside...

Page 17: ...0 mm 2 835 in Stroke 61 2 mm 2 409 in Displacement 249 cm 15 2 cu in Compression ratio 9 2 1 Fuel system Fuel injection Air cleaner Polyurethane foam element Starter system Electric Lubrication system...

Page 18: ...T D C at 1 300 r min Spark plug NGK DR8EA or DENSO X24ESR U Battery 12 V 21 6 kC 6 Ah 10 HR Generator Three phase A C generator Main fuse 30 A Fuse 10 10 10 10 10 A Headlight 12 V 60 55 W H4 Brake lig...

Page 19: ...TTLE CABLE PLAY 2 8 ENGINE IDLE SPEED 2 8 FUEL LINE 2 9 CLUTCH CABLE PLAY 2 9 PAIR AIR SUPPLY SYSTEM 2 9 ENGINE OIL AND OIL FILTER 2 10 DRIVE CHAIN 2 11 BRAKES 2 14 STEERING 2 18 TIRES 2 19 FRONT FORK...

Page 20: ...on motorcycles that are used under severe conditions PERIODIC MAINTENANCE CHART NOTE I Inspect and clean adjust replace or lubricate as necessary R Replace T Tighten Interval km 1 000 5 000 10 000 15...

Page 21: ...cated below NOTE Before lubricating each part clean off any rusty spots and wipe off any grease oil dirt or grime Lubricate exposed parts which are subject to rust with a rust preventative spray whene...

Page 22: ...oam element 2 from the air cleaner element holder 1 Fill a container with a non flammable cleaning solvent Immerse the air cleaner element in the cleaning solvent and wash it Squeeze the cleaning solv...

Page 23: ...r drum 5 11 Remove the valve inspection caps 1 Remove the TDC plug 2 and generator cover plug 3 If driving under dusty conditions clean the air cleaner element more frequently The surest way to accele...

Page 24: ...be removed Rotate the crankshaft and align the line A on the generator rotor with the mark B on the generator cover Insert a thickness gauge between the valve stem end and the adjusting screw on the...

Page 25: ...the spark plug for burns If any abnormalities are found replace the spark plug Tighten the spark plug to the specified torque using the spe cial tool Spark plug 18 N m 1 8 kgf m 13 0 lbf ft 09930 101...

Page 26: ...n the engine is hot Connect the multi circuit tester or engine tachometer 1 to the high tension cord Start the engine and set the engine idle speed between 1 200 and 1 400 r min by turning the air scr...

Page 27: ...he lock nut 3 and turn the cable adjuster 4 to obtain 10 15 mm 0 4 0 6 in of free play A at the clutch lever end Tighten the lock nut 3 Clutch lever play A 10 15 mm 0 4 0 6 in PAIR AIR SUPPLY SYSTEM I...

Page 28: ...ne is cooled Place the motorcycle on level ground and hold it vertically Install the oil filler cap 2 Start the engine and allow it to run for a few minutes at idling speed Turn off the engine and wai...

Page 29: ...sually inspect the drive chain for the possible defects listed below Loose pins Improper chain adjustment Damaged rollers Excessive wear Dry or rusted links Kinked or binding links Missing O ring seal...

Page 30: ...n adjuster lock nuts 4 Tense the drive chain fully by turning both chain adjuster bolts 5 Count out 21 pins 20 pitch on the chain measure the dis tance between the two points If the distance exceeds t...

Page 31: ...sary Tighten both chain adjuster lock nut securely Tighten the torque link nut rear to the specified torque Torque link nut rear 16 N m 1 6 kgf m 11 5 lbf ft Readjust the rear brake pedal free travel...

Page 32: ...the brake hose for leakage cracks wear and damage If any defects are found replace the brake hose with new a one BRAKE Inspect initially at 1 000 km 600 miles 3 months and every 5 000 km 3 000 miles 1...

Page 33: ...8 13 Inspect every 5 000 km 3 000 miles 15 months Replace every 2 years The brake system of this motorcycle is filled with a glycol based brake fluid Do not use or mix different types of fluid such a...

Page 34: ...e free end of the hose into a receptacle Bleed air from the brake system Squeeze and release the brake lever several times in rapid succession and squeeze the lever fully without releasing it Loosen t...

Page 35: ...the top face of the footrest Retighten the lock nut 1 to secure the adjusting bolt 2 in the proper position Brake pedal height A 20 30 mm 0 8 1 2 in REAR BRAKE ADJUSTING By repositioning the adjusting...

Page 36: ...H Adjust the rear brake light switch so that the brake light will come on just before pressure is fell when the brake pedal is depressed STEERING The steering should be adjusted properly for smooth tu...

Page 37: ...lation tire pressure Solo riding Front 175 kPa 1 75 kgf cm2 25 psi Rear 200 kPa 2 00 kgf cm2 29 psi Dual riding Front 175 kPa 1 75 kgf cm2 25 psi Rear 225 kPa 2 25 kgf cm2 33 psi TIRE TYPE CHENG SHIN...

Page 38: ...h FRONT FORK Inspect the front forks for oil leakage scoring or scratches on the outer surface of the inner tubes Replace any defective parts if necessary 8 26 REAR SUSPENSION Inspect the rear shock a...

Page 39: ...lts to the specified torque Exhaust pipe bolt 1 23 N m 2 3 kgf m 16 5 lbf ft Muffler connecting bolt 2 23 N m 2 3 kgf m 16 5 lbf ft Muffler mounting bolt Front 3 23 N m 2 3 kgf m 16 5 lbf ft Muffler m...

Page 40: ...3 2 3 16 5 4 Front fork lower clamp bolt 33 3 3 24 0 5 Front axle 65 6 5 47 0 6 Front axle pinch bolt 23 2 3 16 5 7 Front brake caliper mounting bolt 39 3 9 28 0 8 Front brake hose union bolt 23 2 3 1...

Page 41: ...PERIODIC MAINTENANCE 2 23...

Page 42: ...bove COMPRESSION TEST PROCEDURE NOTE Before testing the engine for compression pressure make sure that the cylinder head nuts are tightened to the specified torque values and the valves are properly a...

Page 43: ...SURE TEST PROCEDURE Connect the multi circuit tester or engine tachometer to the high tension cord 2 8 Remove the oil gallery plug 1 Install the oil pressure gauge and adaptor into the main oil galler...

Page 44: ...ined Also in the case of a customer motorcycle which is not periodically brought in for service with no past data value having been saved if the data value of a good motorcycle condition have been alr...

Page 45: ...r min Check the manifold absolute pressure XX kPa Check the engine temperature XX C PAIR control solenoid valve ON OFF in according with the throttle valve opens closes Secondary throttle valve opens...

Page 46: ...ke negative pressure during idling 90 C Data of manifold absolute pressure operation at the time of starting Check the manifold absolute pressure XX kPa Check the engine temperature Approx 90 C Check...

Page 47: ...hen 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 value of engine temperature is found to be low...

Page 48: ...25 CYLINDER HEAD COVER 3 25 CYLINDER HEAD 3 26 CAMSHAFT 3 35 CYLINDER 3 35 PISTON 3 36 CONROD AND CRANKSHAFT 3 38 STARTER CLUTCH AND STARTER DRIVEN GEAR BEARING 3 40 BALANCER DRIVEN GEAR 3 41 GENERAT...

Page 49: ...3 26 3 32 3 34 Cam chain guide 3 14 3 36 3 70 Spark plug 2 7 2 7 2 7 Cylinder 3 14 3 35 3 69 Piston 3 14 3 36 3 68 Cam chain 3 20 3 62 Oil strainer 3 43 3 43 3 44 Clutch release camshaft 3 54 3 54 IT...

Page 50: ...uentially explained in the following steps Reinstall the engine by reversing the removal procedure Remove the front seat 8 3 Remove the fuel tank 5 3 Drain engine oil 2 10 Remove the frame covers 8 3...

Page 51: ...e adjuster and lock nut Remove the clutch cable 4 along with clutch release arm 5 Remove the throttle body assembly 6 5 11 Disconnect the ET sensor coupler 7 Disconnect the starter motor lead wire 8 R...

Page 52: ...ocket nut E and lock washer D NOTE When loosening the engine sprocket nut E depress the rear brake pedal Loosen the rear axle nut F Loosen the both chain adjuster lock nuts G Loosen the both chain adj...

Page 53: ...ever J NOTE Mark the gearshift shaft head at which the gearshift lever slit set for correct reinstallation Disconnect the engine ground wire K Support the engine using an engine jack Remove the engine...

Page 54: ...7 Remove the swingarm pivot shaft nut and washer Partially remove the swingarm pivot shaft so that the engine can be removed NOTE Be careful not to draw out the swingarm pivot shaft Gradually lower th...

Page 55: ...ot nut to the specified torque NOTE The engine mounting nuts and swingarm pivot nut are self locking Once the nuts have been removed they are no longer of any use The engine mounting nuts and swingarm...

Page 56: ...ound wire 4 and clamp 5 to the crankcase bolt Crankcase bolt 11 N m 1 1 kgf m 8 0 lbf ft Install the engine sprocket NOTE The convex part side A of engine sprocket faces outside Tighten the engine spr...

Page 57: ...the PAIR pipe bolt and nut to the specified torque PAIR pipe bolt nut 10 N m 1 0 kgf m 7 0 lbf ft Install the exhaust pipe muffler 6 6 5 After remounting the engine route the wiring harness cables and...

Page 58: ...lug 1 09930 10121 Spark plug wrench set CAP PLUG Remove the valve inspection caps 1 Remove the generator cover plug 2 and TDC plug 3 Identify the position of each removed part Organize the parts in th...

Page 59: ...ator cover NOTE The piston must be at TDC on the compression stroke CAM CHAIN TENSION ADJUSTER Remove the cam chain tension adjuster cap 1 Turn the adjusting screw clockwise until the push rod locked...

Page 60: ...e the camshaft sprocket bolts Remove the camshaft sprocket 2 and camshaft 3 Remove the locating pin 5 and dowel pin 6 from the cam shaft 3 Remove the C ring 7 Do not drop the cam chain 4 locating pin...

Page 61: ...plastic hammer Remove the dowel pins and gasket 2 Remove the cam chain guide 3 CYLINDER Remove the cylinder 1 NOTE If the cylinder does not come off easily lightly tap it using a plas tic hammer Remov...

Page 62: ...ial tool if necessary 09910 34510 Piston pin puller Remove the piston 3 NEUTRAL SWITCH Remove the neutral switch 1 and O ring 2 Remove the switch contacts 3 and springs 4 GENERATOR COVER Remove the ge...

Page 63: ...he dowel pins and gasket 2 CLUTCH Remove the clutch spring set bolts clutch springs and clutch pressure plate 1 NOTE Loosen the clutch spring set bolts little by little and diagonally Remove the washe...

Page 64: ...lutch drive No 2 plate 8 Remove the spring washer 9 and spring washer seat 0 Flatten the lock washer A Hold the clutch sleeve hub with the special tools and remove the clutch sleeve hub nut B 09920 31...

Page 65: ...Remove the primary driven gear assembly E Remove the spacer F and thrust washer G OIL PUMP Remove the circlip 2 and oil pump drive gear 3 from the pri mary driven gear assembly 1 Remove the snap ring...

Page 66: ...arshift cam driven gear 4 NOTE When removing the gearshift cam driven gear 4 do not lose the pawls 5 pins 6 and springs 7 Remove the gearshift arm stopper 8 PRIMARY DRIVE GEAR Hold the generator rotor...

Page 67: ...er Remove the washer 5 key 6 primary drive gear 7 sprocket key L shape 8 and cam chain drive sprocket 9 GENERATOR Hold the generator rotor with the special tool and remove the generator rotor nut 1 09...

Page 68: ...driven gear 4 and bearing 5 Remove the washer 6 CRANKCASE Remove the gearshift cam stopper plug 1 Remove the spring 2 and gearshift cam stopper No 2 3 Remove the oil seal retainer 4 and engine sprocke...

Page 69: ...case separator so that the tool arms are in paral lel with the side of crankcase The crankshaft and transmission components should remain in the left crankcase half When separating the crankcase tap t...

Page 70: ...cam stopper spring 1 Remove the gearshift fork shafts 2 3 Remove the gearshift forks 4 5 6 Remove the gearshift cam stopper 7 Remove the gearshift cam 8 Remove the gearshift cam stopper plate 9 and pi...

Page 71: ...3 24 ENGINE CRANKSHAFT Remove the crank balancer drive gear 1 Remove the crankshaft with the special tool 09920 13120 Crankcase remover...

Page 72: ...nder head cover distortion Service Limit 0 05 mm 0 002 in 09900 20803 Thickness gauge ROCKER ARM SHAFT O D Measure the diameter of the rocker arm shafts Rocker arm shaft O D Standard IN EX 11 983 11 9...

Page 73: ...the rocker arm shaft align the shaft hole A with the bolt hole B CYLINDER HEAD DISASSEMBLY Remove the cam chain tensioner 1 Remove the intake pipe 2 Compress the valve spring with the special tools 09...

Page 74: ...he valve spring seat 8 NOTE Remove the intake valve in the same manner CYLINDER HEAD DISTORTION Decarbonize the combustion chamber Check the gasket surface of the cylinder head for distortion using a...

Page 75: ...00 20701 Dial gauge chuck 09900 21304 V blocks VALVE HEAD RADIAL RUNOUT Place the dial gauge at a right angle to the valve head face and measure the valve head radial runout If it measures more than t...

Page 76: ...00 20205 Micrometer 0 25 mm NOTE If valve guides have to be replaced refer to the valve guide ser vicing steps below VALVE GUIDE SERVICING Using the valve guide remover drive the valve guide out towar...

Page 77: ...6 44910 Valve guide installer remover After installing the valve guides re finish their guiding bores using the valve guide reamer Clean and oil the valve guides after reaming 09916 34542 Reamer handl...

Page 78: ...The valve seats 1 for both the intake valve and exhaust valve are machined to two different angles The seat contact sur face is cut at 45 NOTE After servicing the valve seats be sure to check the valv...

Page 79: ...ngth A Service Limit IN EX 2 1 mm 0 08 in 09900 20101 Venier calipers 150 mm VALVE SPRING Check the valve spring for proper strength by measuring its free length and also the force required to compres...

Page 80: ...s fit it into position MOLYBDENUM OIL SOLUTION Insert the valve with its stem coated with molybdenum oil solution all around and along the full stem length without any break MOLYBDENUM OIL SOLUTION In...

Page 81: ...SUZUKI SUPER GREASE A or equivalent Install the intake pipe with UP mark A faced upward CAM CHAIN TENSIONER Install the cam chain tensioner 1 and gasket Tighten the cam chain tensioner bolt 2 to the s...

Page 82: ...ter races by finger to inspect for abnormal play noise and smooth rotation Replace the camshaft assembly if there is anything unusual CAMSHAFT SPROCKET Check the camshaft sprocket teeth for wear or da...

Page 83: ...nt If the push rod is stuck or spring mechanism failed replace the cam chain tension adjuster with a new one CAM CHAIN GUIDE Inspect the cam chain guide for damage If any damage is found replace the c...

Page 84: ...ny of the measurements is out of specification replace the piston pin Piston pin O D Service Limit 17 980 mm 0 7079 in 09900 20205 Micrometer 0 25 mm PISTON RING GROOVE CLEARANCE Measure the side clea...

Page 85: ...3 Thickness gauge CONROD AND CRANKSHAFT CONROD SMALL END I D Measure the conrod small end inside diameter using the dial cal ipers If the conrod small end inside diameter exceeds the ser vice limit re...

Page 86: ...auge CRANKSHAFT RUNOUT With the right and left crank journals supported with V blocks turn the crankshaft slowly At this time measure the crankshaft end runout using a dial gauge If the runout exceeds...

Page 87: ...surface of the starter driven gear which contacts the starter clutch for wear or damage If any defects are found replace the defective part s STARTER DRIVEN GEAR BEARING Install the starter driven gea...

Page 88: ...tity of thread lock to the starter clutch bolts and tighten them to the specified torque while holding the spe cial tool 99000 32030 THREAD LOCK SUPER 1303 or equivalent Starter clutch bolt 26 N m 2 6...

Page 89: ...the lead wire properly 10 14 GEARSHIFT SHAFT DISASSEMBLY Remove the return spring 2 and spacer 3 from the gearshift shaft 1 INSPECTION Inspect the gearshift shaft for wear or bend Inspect the return s...

Page 90: ...r 3 Install the spring 4 and oil filter cap 5 NOTE Before installing the new oil filter and oil filter cap make sure that the spring 4 and new O rings 1 2 are installed cor rectly OIL STRAINER REMOVAL...

Page 91: ...nstall the oil strainer cap and tighten the oil strainer bolts securely OIL PUMP INSPECTION Rotate the oil pump by hand and check that it moves smoothly If it does not move smoothly replace the oil pu...

Page 92: ...as shown in the illustration 1 1st driven gear 7 Countershaft 2 5th driven gear 8 5th drive gear ITEM N m kgf m lbf ft 3 3rd driven gear 9 3rd drive gear A 90 9 0 65 0 4 4th driven gear 0 4th drive ge...

Page 93: ...s of washers and snap rings The cross sectional view shows the correct position of the gears washers and snap rings 3 47 When installing a new snap ring pay attention to its direction Fit it to the si...

Page 94: ...gear The clearance for each gearshift fork plays an important role in the smoothness and positiveness of the shifting action Shift fork to groove clearance Service Limit No 1 2 3 0 60 mm 0 024 in 0990...

Page 95: ...the thickness and claw width of the clutch drive plates using vernier calipers If a clutch drive plate is not within the ser vice limit replace the clutch plates as a set Clutch drive plate thickness...

Page 96: ...from the clutch decide whether it can be reused or if it should be replaced Smooth engagement and disengagement of the clutch depends on the condition of this bearing CRANKCASE BEARING AND OIL SEAL BE...

Page 97: ...chment Bearing 5 30 Attachment 09913 70210 Bearing installer set 10 75 Left crankcase Remove the oil seals 1 2 3 with the special tool 09913 50121 Oil seal remover Remove the bearings 4 5 6 with the s...

Page 98: ...Install new bearings 1 2 3 4 with the special tool Bearing 1 72 Attachment Bearing 2 62 Attachment Bearing 3 55 Attachment Bearing 4 40 Attachment 09913 70210 Bearing installer set 10 75 Install the b...

Page 99: ...er 4 faces outside Install a new bearing 5 with the special tool Bearing 5 75 Attachment 09913 70210 Bearing installer set 10 75 Install new bearings 6 7 with the special tool Bearing 6 40 Attachment...

Page 100: ...al 0 with the special tool Oil seal 0 22 Attachment 09913 70210 Bearing installer set 10 75 Apply a small quantity of grease to each oil seal lip 99000 25010 SUZUKI SUPER GREASE A or equivalent The st...

Page 101: ...Remove the clutch release camshaft 3 oil seal 4 and washer 5 INSTALLATION Apply a small quantity of grease to the oil seal lip 99000 25010 SUZUKI SUPER GREASE A or equivalent Install the clutch relea...

Page 102: ...EAL REMOVAL Remove the oil seal retainer 1 Remove the oil seal 2 with the special tool 09913 50121 Oil seal remover OIL SEAL INSTALLATION Install a new oil seal 1 with the special tool 09913 70210 Bea...

Page 103: ...ith the special tools 09910 20116 Connecting rod stopper 09910 32812 Crankshaft installer 09910 32840 Crankshaft installer adapter Apply engine oil to the crankshaft bearings Install the crank balance...

Page 104: ...4 Gearshift fork No 2 5 Gearshift fork No 3 Install the gearshift fork shafts 7 8 NOTE Three kinds of gearshift forks 3 4 5 are used They resem ble each other very closely in external appearance and c...

Page 105: ...he O rings 1 and install them Apply engine oil to the gears and bearings Install the dowel pins into the left crankcase Apply bond to the both crankcases 99000 31110 SUZUKI BOND 1215 or equivalent Ass...

Page 106: ...been tightened check if the crankshaft countershaft and driveshaft rotates smoothly Apply grease to the O ring and install it to the engine sprocket spacer 2 Apply grease to each oil seal lip 99000 25...

Page 107: ...the washer 1 NOTE The chamber side A of washer faces inside Apply engine oil to the bearing 2 and install it Install the starter driven gear 4 onto the starter clutch 3 Degrease the tapered portion B...

Page 108: ...the cam chain drive sprocket 1 and sprocket key L shape 2 Install the primary drive gear 3 and key 4 Install the washer 5 and primary drive gear nut 6 NOTE The conical curve side of washer faces outs...

Page 109: ...SHIFT Apply a small quantity of thread lock to the gearshift arm stop per 1 and tighten it to the specified torque 99000 32030 THREAD LOCK SUPER 1303 or equivalent Gearshift arm stopper 19 N m 1 9 kgf...

Page 110: ...nd then tighten them to the specified torque Oil pump mounting bolt 10 N m 1 0 kgf m 7 0 lbf ft Install the washer 2 and pin 3 Install the oil pump driven gear 4 and snap ring 5 NOTE Align the groove...

Page 111: ...with the drive gear Install the clutch sleeve hub 5 and lock washer 6 Hold the clutch sleeve hub with the special tools and tighten the clutch sleeve hub nut 7 to the specified torque Clutch sleeve hu...

Page 112: ...stall the push rod C push piece D release bearing E and washer F Apply engine oil to the release bearing E Install the clutch pressure plate G clutch spring and clutch spring set bolt Tighten the clut...

Page 113: ...crew 2 CLUTCH COVER Install the dowel pins and gasket 1 Dowel pin length 18 mm 0 71 in 2 pcs Install the clutch cover 2 and tighten the clutch cover bolts to the specified torque Clutch cover bolt 11...

Page 114: ...he O ring 3 and install it 99000 25010 SUZUKI SUPER GREASE A or equivalent Install the neutral switch 4 PISTON RING Install the piston rings in the order of oil ring 2nd ring and 1st ring To install t...

Page 115: ...as shown Before inserting each piston into the cylinder check that the gaps are so located B 2nd ring and lower side rail C Upper side rail D 1st ring and spacer PISTON Apply molybdenum oil solution t...

Page 116: ...o the big end of conrod Install the dowel pins 1 2 and cylinder gasket 3 1 Dowel pin length 18 mm 0 71 in 2 Dowel pin length 14 mm 0 55 in Apply molybdenum oil solution to the cylinder wall MOLYBDENUM...

Page 117: ...inder head nut 37 N m 3 7 kgf m 27 0 lbf ft CAMSHAFT Turn the crankshaft counterclockwise and align the line A on the generator rotor with the mark B on the generator cover while keeping the cam chain...

Page 118: ...Engage the cam chain on the camshaft sprocket Make sure that the locating pin E on the camshaft aligns with the locat ing pin hole on the camshaft sprocket Apply a small quantity of thread lock to th...

Page 119: ...0 SUZUKI BOND 1215 or equivalent Install the cylinder head cover Lightly tighten the cylinder head cover bolts and nuts diago nally and then tighten them to the specified torque Cylinder head cover bo...

Page 120: ...ck the push rod by turning the adjusting screw counter clockwise Install the cam chain tension adjuster cap 2 NOTE Be sure to check the valve clearance 2 5 CAP PLUG Apply grease to the O ring 1 99000...

Page 121: ...nt SPARK PLUG Tighten the spark plug 1 to the specified torque Spark plug 18 N m 1 8 kgf m 13 0 lbf ft 09930 10121 Spark plug wrench set STARTER MOTOR Apply grease to the O ring and install the starte...

Page 122: ...S 4 23 USE OF SDS DIAGNOSIS RESET PROCEDURE 4 24 SHOW DATA WHEN TROUBLE DISPLAING DATA AT THE TIME OF DTC 4 25 MALFUNCTION CODE AND DEFECTIVE CONDITION 4 26 12 P0335 CKP SENSOR CIRCUIT MALFUNCTION 4 2...

Page 123: ...68 TP SENSOR REMOVAL AND INSTALLATION 4 68 TPS ADJUSTMENT 4 69 ET SENSOR INSPECTION 4 70 ET SENSOR REMOVAL AND INSTALLATION 4 70 IAT SENSOR INSPECTION 4 70 IAT SENSOR REMOVAL AND INSTALLATION 4 70 TO...

Page 124: ...pler body and do not pull the lead wires Inspect each terminal on the connector coupler for looseness or bending Push in the coupler straightly An angled or skewed insertion may cause the terminal to...

Page 125: ...Never push in the probe where male terminal is supposed to fit Check the male connector for bend and female connector for excessive opening Also check the coupler for locking loose ness corrosion dust...

Page 126: ...rohibited Such a wrong connection will damage the components of the FI system instantly when reverse power is applied Removing any battery terminal of a running engine is strictly prohibited The momen...

Page 127: ...Poor contact of terminal due to dirt corrosion or rust poor contact tension entry of foreign object etc Wire harness being open Poor terminal to wire connection Disconnect the negative cable from the...

Page 128: ...nuity check Measure resistance across coupler B between A and C in the figure If no continuity is indicated infinity or over limit the circuit is open between terminals A and C 1 ECM Disconnect the co...

Page 129: ...a resistance abnormality exists which causes the voltage drop in the circuit between terminals A and B Voltage Between C and body ground Approx 5 V B and body ground Approx 5 V 2 V voltage drop A and...

Page 130: ...sure ments using the highest range When measuring the resistance with the multi circuit tester 1 will be shown as 10 00 M and 1 flashes in the display Check that no voltage is applied before making th...

Page 131: ...nd various compensations These compensations are determined according to the signals from various sensors that detect the engine and driving conditions Intake Air Pressure Sensor IAP Sensor Intake air...

Page 132: ...compensation of the fuel injection time volume A longer injection time is needed to adjust injection volume in the case of low voltage ENGINE RPM SIGNAL At high speed the injection time volume is incr...

Page 133: ...ated oxygen sensor HO2S G Ignition coil IG coil D PAIR control solenoid valve H Intake air temperature sensor IATS A ECM L Secondary throttle position sensor STPS I Speedometer M Secondary throttle va...

Page 134: ...Br Br B W R B R W B O R Lg W B G Y W O Y R Y B Bl P B Y B W B W B Crankshaft positon sensor CKPS Speedometer Throttle position sensor TPS Secondary throttle position sensor STPS Intake air pressure s...

Page 135: ...nal IAT L ET sensor ET 6 M 7 IAP sensor signal IAP N 8 Gear position switch signal GP O 9 Starter relay P Mode selection switch 0 Neutral signal Q A Power source for sensors VCC R Clutch lever switch...

Page 136: ...uit works and injection is not stopped In this case FI indica tor light is lighted and the motorcycle can run 2 The injection signal is stopped when the crankshaft position sensor signal tip over sens...

Page 137: ...eans that the ECM does not receive normal signal from the devices These affected devices are indicated in the code form 09930 82720 Mode selection switch The DTC is indicated from small code to large...

Page 138: ...TEM FAIL SAFE MODE STARTING ABILITY RUNNING ABILITY IAP sensor Intake air pressure is fixed to 101 3 kPa 760 mmHg YES YES TP sensor The throttle opening is fixed to full open position Ignition timing...

Page 139: ...Date Reg Date of problem Mileage FI indicator light condition Always ON Sometimes ON Always OFF Good condition PROBLEM SYMPTOMS Difficult Starting Poor Driveability No cranking Hesitation on accelerat...

Page 140: ...n fuse FI indicator light operation 4 15 9 27 Speedometer operation Exhaust gas leakage and noise 6 4 Each coupler disconnection MOTORCYCLE ENVIRONMENTAL CONDITION WHEN PROBLEM OCCURS Environmental co...

Page 141: ...coupler at the wir ing harness and start the engine or crank the engine for more than 4 seconds Turn the special tool s switch ON and check the malfunction code to determine the malfunction part 4 21...

Page 142: ...None 12 CKP sensor 4 29 Pick up coil signal 13 IAP sensor 4 31 14 TP sensor 4 36 15 ET sensor 4 41 21 IAT sensor 4 45 23 TO sensor 4 49 24 Ignition coil 4 52 28 STV actuator 4 53 29 STP sensor 4 56 32...

Page 143: ...e Current DTC is cleared Past DTC previous malfunction history code still remains stored in the ECM Therefore erase the Past DTC memorized in the ECM using SDS DTC is memorized in the ECM also when th...

Page 144: ...ore inspection and observe what is written there Remove the front right frame cover 8 3 Set up the SDS tool Refer to the SDS operation manual for further details Read the DTC Diagnostic Trouble Code a...

Page 145: ...n the ECM Therefore erase the history code memorized in the ECM using SDS tool NOTE The malfunction code is memorized in the ECM also when the wire coupler of any sensor is disconnected Therefore when...

Page 146: ...or stopped when a malfunction was detected by checking the show data when trouble This show data when trouble function can record the maximum of two Diagnostic Trouble Codes in the ECM Also ECM has a...

Page 147: ...r than the above range 14 P0120 is indicated TP sensor lead wire coupler connection P0120 H Sensor voltage is higher than specified value TP sensor circuit shorted to VCC or ground circuit open L Sens...

Page 148: ...indicated STVA can not operate STVA motor STVA lead wire coupler connection P1655 29 STP sensor The sensor should produce following voltage 0 35 V sensor voltage 4 9 V In other than the above range C...

Page 149: ...not input to ECM during engine operation and running condition Sensor voltage 0 60 V In other than the above value 44 P0130 is indicated HO2 sensor circuit open or shorted to ground P0130 49 PAIR cont...

Page 150: ...easure the CKP sensor resistance 4 Disconnect the CKP sensor coupler and measure the resis tance CKP sensor resistance 420 620 Bl G DETECTED CONDITION POSSIBLE CAUSE The signal does not reach ECM for...

Page 151: ...eak volt adaptor 09900 25008 Multi circuit tester set Tester knob indication Voltage Is the voltage OK YES Go to Step 2 NO Replace the CKP sensor with a new one YES Bl R or B Br wire open or shorted t...

Page 152: ...well as altitude Take that into consideration when inspecting voltage Clogged vacuum passage between throttle body and IAP sensor Air being drawn from vacuum passage between throttle body and IAP sens...

Page 153: ...900 25009 Needle point probe set Tester knob indication Voltage Is the voltage OK Step 1 When indicating P0105 H 1 Turn the ignition switch OFF 2 Check the IAP sensor coupler for loose or poor contact...

Page 154: ...ity test Is the continuity OK Step 1 When indicating P0105 L 1 Turn the ignition switch OFF 2 Check the IAP sensor coupler for loose or poor contacts If OK then check the IAP sensor lead wire continui...

Page 155: ...sert the needle point probes to the lead wire coupler 3 Start the engine at idle speed and measure the IAP sensor output voltage at the wire side coupler between W Bl and B Br wires IAP sensor output...

Page 156: ...et 09900 25008 Multi circuit tester set Tester knob indication Voltage Is the voltage OK Output voltage VCC voltage 4 5 5 0 V ambient temp 20 30 C 68 86 F YES W Bl R or B Br wire open or shorted to gr...

Page 157: ...sor maladjusted TP sensor circuit open or short TP sensor malfunction ECM malfunction P0120 H Sensor voltage is higher than specified value TP sensor circuit shorted to VCC or ground circuit open TP s...

Page 158: ...indication Voltage Is the voltage OK Step 1 When indicating P0120 H 1 Turn the ignition switch OFF 2 Check the TP sensor coupler for loose or poor contacts If OK then check the TP sensor lead wire con...

Page 159: ...tinuity test Is the continuity OK Step 1 When indicating P0120 L 1 Turn the ignition switch OFF 2 Check the TP sensor coupler for loose or poor contacts If OK then check the TP sensor lead wire contin...

Page 160: ...switch and ON again 5 Measure the TP sensor output voltage at the terminals between V and B Br by turning the throttle grip TP sensor output voltage Throttle valve is closed Approx 0 6 V Throttle valv...

Page 161: ...in the following procedures 1 Turn the ignition switch ON 2 Set up the SDS tool Refer to the SDS operation manual for further details 3 Click the Active control 4 Click the TP learned value reset 1 5...

Page 162: ...POSSIBLE CAUSE 15 Output voltage is not within the following range 0 1 V Sensor voltage 4 7 V ET sensor circuit open or short ET sensor malfunction ECM malfunction P0115 H Sensor voltage is higher th...

Page 163: ...sensor coupler for loose or poor contacts If OK then check the ET sensor lead wire continuity 3 Disconnect the ET sensor coupler and ECM coupler 4 Check the continuity between B Bl wire A and terminal...

Page 164: ...the sound is not heard from the tester the circuit condition is OK Tester knob indication Continuity test 5 Connect the ET sensor coupler and turn the ignition switch ON 6 Measure the voltage between...

Page 165: ...r set Tester knob indication Resistance Refer to page 4 70 for details Is the resistance OK YES B Bl or B Br wire open or shorted to ground or poor L or T connection If wire and connection are OK inte...

Page 166: ...ED CONDITION POSSIBLE CAUSE 21 Output voltage is not within the following range 0 15 V Sensor voltage 4 85 V IAT sensor circuit open or short IAT sensor malfunction ECM malfunction P0110 H Sensor volt...

Page 167: ...eck the IAT sensor coupler for loose or poor contacts If OK then check the IAT sensor lead wire continuity 4 Disconnect the IAT sensor coupler and ECM coupler 5 Check the continuity between Y R wire A...

Page 168: ...nd ground If the sound is not heard from the tester the circuit condition is OK Tester knob indication Continuity test 6 Connect the IAT sensor coupler and turn the ignition switch ON 7 Measure the vo...

Page 169: ...sensor resistance measurement method is the same way as that of the ET sensor Refer to page 4 70 for details 2 YES Y R or B Br wire open or shorted to ground or poor 5 or T connection If wire and conn...

Page 170: ...he sensor voltage is not within the fol lowing range 0 2 V Sensor voltage 4 8 V TO sensor circuit open or short TO sensor malfunction ECM malfunction P1651 H Sensor voltage is higher than specified va...

Page 171: ...the TO sensor coupler 4 Check the continuity between R wire A and Br wire B If the sound is not heard from the tester the circuit condition is OK 5 Disconnect the ECM coupler 6 Check the continuity b...

Page 172: ...en Br wire B and B Br wire C If the sound is not heard from the tester the circuit condi tion is OK 6 Disconnect the ECM coupler 7 Check the continuity between R wire A and terminal A 8 Also then chec...

Page 173: ...Br B Br 09900 25008 Multi circuit tester set 09900 25009 Needle point probe set Tester knob indication Voltage Is the voltage OK 24 P0351 IGNITION SYSTEM MALFUNCTION Refer to the IGNITION SYSTEM for...

Page 174: ...pen Close Is the operation OK DETECTED CONDITION POSSIBLE CAUSE The operation voltage does not reach the STVA ECM does not receive communication signal from the STVA STVA malfunction STVA circuit open...

Page 175: ...STVA resistance Approx 6 5 B A P B G C W BI D 09900 25008 Multi circuit tester set Tester knob indication Resistance Is the resistance OK 2 2 YES W B W R B R and B wire open or shorted to ground or p...

Page 176: ...Set up the SDS tool Refer to the SDS operation manual for further details 2 Turn the ignition switch ON 3 Click Secondary throttle operating control 1 4 Click each button 2 At this time if an operatio...

Page 177: ...Difference between actual throttle open ing and opening calculated by ECM is larger than specified value 0 35 V Sensor voltage 4 9 V STP sensor maladjusted STP sensor circuit open or short STP sensor...

Page 178: ...tep 1 When indicating P1654 H 1 Turn the ignition switch OFF 2 Lift up the fuel tank by removing the fuel tank mounting bolt 5 3 3 Check the STP sensor coupler for loose or poor contacts If OK then ch...

Page 179: ...ire continuity 4 Disconnect the STP sensor coupler 5 Check the continuity between Bl Y wire B and ground 6 Also check the continuity between Bl Y wire B and B Br wire C If the sound is not heard from...

Page 180: ...hrottle valve is closed Approx 0 5 V Secondary throttle valve is opened Approx 3 9 V 09900 25008 Multi circuit tester set 09900 25009 Needle point probe set Tester knob indication Voltage Is the volta...

Page 181: ...coupler and measure the resis tance between terminals Fuel injector resistance Approx 10 5 at 20 C 68 F Terminal Terminal DETECTED CONDITION POSSIBLE CAUSE Fuel injector signal is interrupted by 4 ti...

Page 182: ...Ground NOTE Injector voltage can be detected only for 3 seconds after ignition switch is turned ON 09900 25008 Multi circuit tester set Tester knob indication Voltage Is the voltage OK YES Go to Step...

Page 183: ...CONDITION POSSIBLE CAUSE 41 No voltage is applied to fuel pump FP circuit open or short FP malfunction ECM malfunction P0230 H Voltage is applied to fuel pump although FP circuit is shut FP circuit s...

Page 184: ...ils 9 36 NOTE After repairing the trouble clear the DTC using SDS tool 4 24 YES O W or Y W wire open or shorted to ground or poor V connection If wire and connection are OK intermittent trou ble or fa...

Page 185: ...wire A and B Br wire B If the sound is not heard from the tester the circuit condition is OK 09900 25008 Multi circuit tester set Tester knob indication Continuity test DETECTED CONDITION POSSIBLE CA...

Page 186: ...4 If OK then pinch the PAIR hose with proper hose clamps 5 Measure the HO2 sensor output voltage while holding the engine speed at 5 000 r min HO2 sensor output voltage at 5 000 r min 0 6 V and more B...

Page 187: ...ance Approx 22 at 20 C 68 F Terminal Terminal 09900 25008 Multi circuit tester set Tester knob indication Resistance Is the resistance OK DETECTED CONDITION POSSIBLE CAUSE PAIR control solenoid valve...

Page 188: ...ails 2 Turn the ignition switch to ON 3 Click PAIR Sol operating control 1 4 Click each button 2 At this time if an operation sound is heard from the PAIR control solenoid valve the function is normal...

Page 189: ...val IAP SENSOR INSPECTION The intake air pressure sensor is installed on the top side of the throttle body 4 31 IAP SENSOR REMOVAL AND INSTALLATION Remove the throttle body 5 11 Remove the IAP sensor...

Page 190: ...ut voltage make sure that the fast idle cam is not contacted to the throttle lever 09900 25008 Malti circuit tester set Tester knob indication Voltage 4 Loosen the TP sensor mounting screw 1 using the...

Page 191: ...ue does not change in the propor tion indicated replace it with a new one ET sensor specification ET SENSOR REMOVAL AND INSTALLATION Disconnect the ET sensor coupler 1 Remove the ET sensor 2 Install t...

Page 192: ...STP SENSOR INSPECTION The secondary throttle position sensor is installed at the left side of the throttle body 4 56 STP SENSOR REMOVAL AND INSTALLATION Remove the STP sensor 5 13 Install the STP sens...

Page 193: ...HO2 SENSOR REMOVAL AND INSTALLATION Remove the left frame cover 8 3 Remove the bracket bolt 1 Disconnect the HO2 sensor coupler 2 Pass the HO2 sensor lead wire 3 between the engine and frame tube Remo...

Page 194: ...5 7 FUEL MESH FILTER INSPECTION 5 8 FUEL PUMP REASSEMBLY AND INSTALLATION 5 9 THROTTLE BODY 5 10 CONSTRUCTION 5 10 THROTTLE BODY REMOVAL 5 11 THROTTLE BODY DISASSEMBLY 5 12 THROTTLE BODY CLEANING 5 1...

Page 195: ...fuel pressure regulator As the fuel pressure applied to the fuel injector the fuel pressure in the fuel delivery pipe is always kept at absolute fuel pressure of 294 kPa 2 94 kgf cm2 41 8 psi the fue...

Page 196: ...g under the fuel feed hose 2 and disconnect the fuel feed hose 2 from the fuel pump Remove the fuel tank assembly FUEL TANK INSTALLATION Install the fuel tank in the reverse order of removal Pay atten...

Page 197: ...achment Turn the ignition switch ON and check the fuel pressure Fuel pressure Approx 294 kPa 2 94 kgf cm2 41 8 psi If the fuel pressure is lower than the specification inspect the following items Clog...

Page 198: ...m the fuel delivery pipe Disconnect the fuel pump lead wire coupler 2 Place the measuring cylinder and insert the fuel feed hose end into it Connect proper lead wires to the fuel pump lead wire couple...

Page 199: ...UEL SYSTEM AND THROTTLE BODY FUEL PUMP CONSTRUCTION FWD FWD 1 Fuel pressure regulator 5 Fuel mesh filter 2 O ring 6 O ring ITEM N m kgf m lbf ft 3 Fuel pump A Fuel pump mounting bolt A 10 1 0 7 0 4 O...

Page 200: ...by removing its mounting bolts diagonally Remove the O ring 2 Remove the clip and then fuel mesh filter 3 Remove the band 4 Disconnect the fuel hose 5 and fuel pump terminals 6 Remove the fuel pump as...

Page 201: ...joint F FUEL MESH FILTER INSPECTION If the fuel mesh filter is clogged with sediment or rust fuel will not flow smoothly and loss in engine power may result NOTE If the fuel mesh filter is clogged wit...

Page 202: ...ER GREASE A or equivalent When installing the fuel pump assembly first tighten all the fuel pump mounting bolts lightly and then to the specified torque in the ascending order of numbers Fuel pump mou...

Page 203: ...ONSTRUCTION FWD FWD 1 Fuel delivery pipe 7 TP sensor 2 O ring 8 O ring ITEM N m kgf m lbf ft 3 Fuel injector 9 IAP sensor A 3 5 0 35 2 5 4 Cushion seal 0 O ring B 3 5 0 35 2 5 5 STVA A TP sensor mount...

Page 204: ...ire coupler 3 fuel injector lead wire coupler 4 and IAP sensor lead wire coupler 5 Disconnect the throttle cables 6 from their drum Once the throttle body has been removed disassem bled or replaced th...

Page 205: ...e throttle body clamp screws and remove the throt tle body assembly 7 THROTTLE BODY DISASSEMBLY Remove the fuel feed hose 1 Remove the fuel delivery pipe 2 along with the fuel injector 3 Remove the fu...

Page 206: ...5 and STP sensor 6 with the special tool NOTE Prior to disassembly mark the each sensor s original position with a paint or scribe for accurate reinstallation 09930 11950 Torx wrench 5 mm Never remov...

Page 207: ...e of delivery and do not turn or remove it Some carburetor cleaning chemicals especially dip type soaking solutions are very corrosive and must be handled carefully Always follow the chemical manufact...

Page 208: ...lbf ft 09930 11950 Torx wrench 5 mm NOTE Make sure the secondary throttle valve smoothly open and close If the STP sensor adjustment is necessary refer to page 5 18 for STP sensor setting procedure Wi...

Page 209: ...he fuel delivery pipe 8 NOTE Align the coupler E of injector with the groove F of delivery pipe Fit the projection G on the fuel delivery pipe in the hole H of the throttle body Install the fuel deliv...

Page 210: ...pipe Position the throttle body clamps correctly 10 20 Loosen each throttle cable lock nut 1 Turn in each throttle cable adjuster 2 fully and locate each outer cable 3 so that the clearance is 0 mm 0...

Page 211: ...m 2 Insert the needle point probes to the STP sensor coupler Turn the ignition switch ON and measure the STP sensor out put voltage STP sensor output voltage ST valve is fully closed Approx 0 5 V Y B...

Page 212: ...perature ambient temperature and lapsed time the fast idle is cancelled allowing the engine to resume idle speed FUEL INJECTOR REMOVAL Remove the throttle body assembly 5 11 Remove the fuel delivery p...

Page 213: ...EXHAUST SYSTEM 6 1 6 EXHAUST SYSTEM CONTENTS EXHAUST SYSTEM 6 2 REMOVAL 6 2 INSPECTION 6 4 INSTALLATION 6 4...

Page 214: ...muffler cover 3 Hooked part Remove the exhaust pipe bolts 4 To avoid the danger of being burned do not touch the exhaust system when the system is hot Any service on the exhaust system should be perfo...

Page 215: ...e exhaust pipe gasket 6 Remove the exhaust pipe cover 7 Loosen the muffler connecting bolt 8 Remove the exhaust pipe 0 from the muffler 9 Remove the HO2 sensor A Be careful not to expose the HO2 senso...

Page 216: ...ed to their spec ified torque Exhaust pipe bolt 1 23 N m 2 3 kgf m 16 5 lbf ft Muffler connecting bolt 2 23 N m 2 3 kgf m 16 5 lbf ft Muffler mounting bolt Front 3 23 N m 2 3 kgf m 16 5 lbf ft Muffler...

Page 217: ...pipe cover 4 Tighten the exhaust pipe cover screw 5 to the specified torque NOTE The tip B of clamp should face inside of the exhaust pipe cover Exhaust pipe cover screw 4 N m 0 4 kgf m 3 0 lbf ft Ins...

Page 218: ...99000 32110 THREAD LOCK SUPER 1322 or equivalent Tighten the muffler mounting bolts 8 9 to the specified torque Muffler mounting bolt Front 23 N m 2 3 kgf m 16 5 lbf ft Muffler mounting bolt Rear 50...

Page 219: ...LUBRICATION SYSTEM 7 1 7 LUBRICATION SYSTEM CONTENTS LUBRICATION SYSTEM 7 2 OIL PRESSURE 7 2 OIL FILTER 7 2 OIL STRAINER 7 2 OIL PUMP 7 2 ENGINE LUBRICATION SYSTEM CHART 7 2...

Page 220: ...ION SYSTEM CHART CAM FACES CAM CHAIN CAMSHAFT JOURNAL BEARING ENGINE SPROCKET SPACER DRIVESHAFT GEARS AND BEARING OIL PAN OIL STRAINER OIL PUMP OIL FILTER PISTON CYLINDER WALL CONROD SMALL END CONROD...

Page 221: ...KE CALIPER INSPECTION 8 14 CALIPER REASSEMBLY AND INSTALLATION 8 15 BRAKE DISC INSPECTION 8 17 MASTER CYLINDER REMOVAL AND DISASSEMBLY 8 17 MASTER CYLINDER INSPECTION 8 18 MASTER CYLINDER REASSEMBLY A...

Page 222: ...HOCK ABSORBER 8 43 CONSTRUCTION 8 43 REMOVAL 8 43 INSPECTION 8 44 INSTALLATION 8 44 REAR SUSPENSION SETTING 8 44 REAR WHEEL 8 45 CONSTRUCTION 8 45 REMOVAL 8 46 INSPECTION AND DISASSEMBLY 8 48 REASSEMB...

Page 223: ...SEAT Remove the front seat Above Remove the rear seat by removing the bolts LEFT FRAME COVER Remove the screw Remove the left frame cover Hooked part RIGHT FRAME COVER Remove the screw Remove the righ...

Page 224: ...e speedometer cable 1 1 Collar 6 Speedometer gearbox 2 Bearing 7 Balancer weight ITEM N m kgf m lbf ft 3 Front wheel A Front axle A 65 6 5 47 0 4 Spacer B Spoke nipple B 3 0 3 2 0 5 Brake disc C Brake...

Page 225: ...support the motorcy cle with a jack or a wooden block Remove the front wheel 4 by removing the front axle 3 Remove the collar 5 and speedometer gearbox 6 Remove the brake disc 7 by removing its bolts...

Page 226: ...k that the gear turns smoothly together with the speedometer pinion WHEEL 2 19 SPOKE NIPPLE 2 20 WHEEL BEARING Inspect the play of the wheel bearings by finger while they are in the wheel Rotate the i...

Page 227: ...le with a new one Axle shaft runout Service Limit 0 25 mm 0 010 in 09900 20607 Dial gauge 09900 20701 Dial gauge chuck 09900 21304 V blocks REASSEMBLY AND INSTALLATION Reassembly and install the front...

Page 228: ...ring installer set NOTE The flange side A of spacer should face front brake disc side First install the left wheel bearing then install the spacer and right wheel bearing The sealed cover of bearing m...

Page 229: ...X Apply grease to the speedometer gearbox 99000 25010 SUZUKI SUPER GREASE A or equivalent Align the lugs A of speedometer gearbox with the recesses B on front wheel FRONT WHEEL Install the collar 1 an...

Page 230: ...5 kgf m 47 0 lbf ft Tighten the front axle pinch bolt 5 to the specified torque Front axle pinch bolt 23 N m 2 3 kgf m 16 5 lbf ft NOTE Before tightening the front axle pinch bolt move the front fork...

Page 231: ...itch A 10 1 0 7 0 4 Master cylinder A Master cylinder holder bolt B 23 2 3 16 5 5 Brake hose B Brake hose union bolt C 7 5 0 75 5 5 6 Caliper holder C Air bleeder valve D 39 3 9 28 0 7 Piston D Brake...

Page 232: ...brake fluid taken from old used or unsealed containers Never reuse brake fluid left over from the last servicing or stored for long periods When storing the brake fluid seal the container completely a...

Page 233: ...out of the brake system Close the air bleeder valve and disconnect a clear hose Fill the reservoir with new brake fluid to the upper line of the res ervoir Front brake caliper air bleeder valve 7 5 N...

Page 234: ...sing compressed air Remove the dust seals 8 and piston seals 9 BRAKE CALIPER INSPECTION CALIPER AND PISTON Inspect the caliper cylinder wall and piston surface for scratch corrosion or other damages I...

Page 235: ...bores and pistons with specified brake fluid especially the dust seal grooves and piston seal grooves Specification and classification DOT 4 Clean the caliper components with fresh brake fluid before...

Page 236: ...r mounting bolts to the specified torque Front brake caliper mounting bolt 39 N m 3 9 kgf m 28 0 lbf ft With the brake hose union contacted to the stopper A tighten the brake hose union bolt 1 to the...

Page 237: ...e 8 5 9 Brake disc runout Service Limit 0 30 mm 0 012 in 09900 20607 Dial gauge 09900 20701 Dial gauge chuck MASTER CYLINDER REMOVAL AND DISASSEMBLY Drain brake fluid 8 13 Remove the brake hose union...

Page 238: ...R INSPECTION MASTER CYLINDER Inspect the master cylinder bore for any scratches or damage If any damage is found replace the master cylinder with a new one PISTON CUP SET Inspect the piston surface fo...

Page 239: ...Dust boot When installing the brake light switch align the projection A on switch with the hole B of master cylinder Apply grease to the brake lever pivot bolt Apply grease to the contacting surfaces...

Page 240: ...r s mating surface with punch mark C on the handlebar and tighten the upper holder bolt A first as shown Front brake master cylinder holder bolt 10 N m 1 0 kgf m 7 0 lbf ft Install the brake hose unio...

Page 241: ...handlebar grip 5 Loosen the clutch lever holder bolt 6 Remove the clamp 7 HANDLEBAR RIGHT SIDE PARTS Remove the rear view mirror RH 1 Remove the right handlebar switch box screws 2 Disconnect the bra...

Page 242: ...g the handlebar clamp bolts Remove the right handlebar switch box 9 throttle grip 0 and clutch lever holder A from the handlebars 8 INSPECTION Inspect the handlebars for distortion or damage If any de...

Page 243: ...dlebar clamp bolt 16 N m 1 6 kgf m 11 5 lbf ft NOTE The clearances B between the handlebar clamp and holder should be even Insert the right handlebar switch box 2 throttle grip 3 and clutch lever hold...

Page 244: ...bars Tighten the clutch lever holder bolt to the specified torque Clutch lever holder bolt 10 N m 1 0 kgf m 7 0 lbf ft Apply handle grip bond to the left handlebar end E before installing the left han...

Page 245: ...lbf ft 3 Spring joint C Spacer A 23 2 3 16 5 4 Front fork spring D Guide bushing B 23 2 3 16 5 5 Damper rod ring E Oil lock piece C 20 2 0 14 5 6 Damper rod F Outer tube 7 Rebound spring G Reflex ref...

Page 246: ...8 4 Disconnect the speedometer cable guide 1 Remove the front fender 2 Remove the front fork cap 3 Loosen the front fork upper clamp bolt 4 NOTE Slightly loosen the front fork cap bolt 5 to facilitate...

Page 247: ...fork oil Hold the front fork inverted for a few minutes to drain oil Remove the damper rod bolt B using the wrench and special tools 09940 34520 T type handle 09940 34561 Front fork assembling attachm...

Page 248: ...sliding surface and outer tube sliding sur face for any scuffing or damage FRONT FORK SPRING Measure the fork spring free length If the fork spring free length is shorter than the service limit replac...

Page 249: ...o the slide bushing 1 guide bushing 2 and oil seal lip 4 99000 99001 SS8 SUZUKI FORK OIL SS 08 or equivalent Insert the oil lock piece 5 into the inner tube NOTE When installing the oil lock piece ins...

Page 250: ...rod 1 and install them to the inner tube Apply thread lock to the damper rod bolt 3 and tighten it to the specified torque using the hexagon wrench and special tools Damper rod bolt 20 N m 2 0 kgf m 1...

Page 251: ...he fork oil level A by using the special tool NOTE When adjusting the fork oil level compress the inner tube fully without the fork spring Front fork oil level without spring 72 mm 2 8 in 09943 74111...

Page 252: ...ue Front fork lower clamp bolt 33 N m 3 3 kgf m 24 0 lbf ft Front fork cap bolt 23 N m 2 3 kgf m 16 5 lbf ft Front fork upper clamp bolt 23 N m 2 3 kgf m 16 5 lbf ft Install the front fender and tight...

Page 253: ...A Steering stem head bolt 2 Dust seal B Handlebar clamp bolt ITEM N m kgf m lbf ft 3 Steering stem upper bearing C Front fork upper clamp bolt A 65 6 5 47 0 4 Steering stem lower bearing D Front fork...

Page 254: ...itch coupler speedometer coupler and turn signal couplers Remove the headlight housing bolts nuts and clamps Remove the headlight housing 2 by removing the clamp and housing plate bolt Remove the head...

Page 255: ...ool 09940 14911 Steering stem nut socket wrench Remove the steering stem lower bracket 7 Remove the dust seal 8 and upper bearing inner race 9 Remove the steering stem upper bearing 0 and lower bear i...

Page 256: ...se Distortion of steering stem Remove the steering stem lower inner race 1 and lower seal 2 using a chisel Remove the steering stem upper and lower bearing races using the special tools 09941 54911 Be...

Page 257: ...ZUKI SUPER GREASE A or equivalent STEERING STEM Tighten the steering stem nut 1 to the specified torque 45 N m 4 5 kgf m 32 5 lbf ft using the special tool 09940 14911 Steering stem nut socket wrench...

Page 258: ...c ified torque 8 32 Front fork upper clamp bolt 23 N m 2 3 kgf m 16 5 lbf ft Front fork lower clamp bolt 33 N m 3 3 kgf m 24 0 lbf ft Install the headlight Install the front wheel 8 9 Check that the c...

Page 259: ...emove the rear wheel 8 46 Remove the brake panel 1 Remove the brake shoes 2 from the brake panel 1 Brake pedal 6 Spring 2 Brake pedal return spring 7 Brake cam ITEM N m kgf m lbf ft 3 Brake rod 8 Brak...

Page 260: ...f wear If the measurement exceeds the service limit replace the brake drum with a new one The value of this limit is indicated inside the brake drum Brake drum I D Service Limit 130 7 mm 5 15 in 09900...

Page 261: ...n the reverse order of removal and disassembly Pay attention to the following points Apply grease to the camshaft cam face and pin 99000 25010 SUZUKI SUPER GREASE A or equivalent Install the brake sho...

Page 262: ...the brake pedal return spring 8 Remove the brake pedal 9 along with brake rod REAR BRAKE PEDAL INSTALLATION Install the rear brake pedal in the reverse order of removal Pay attention to the following...

Page 263: ...ht rear shock absorbers are installed symmetri cally and therefore the removal procedure for one side is the same as that for the other side Remove the rear shock absorber 1 1 Rear shock absorber 3 Wa...

Page 264: ...Tighten the rear shock absorber nuts to the specified torque Rear shock absorber nut 29 N m 2 9 kgf m 21 0 lbf ft Check the rear suspension for proper operation REAR SUSPENSION SETTING The rear shock...

Page 265: ...TEM N m kgf m lbf ft 3 Brake cam lever D Collar A 65 6 5 47 0 4 Brake panel E Bearing B 10 1 0 7 0 5 Brake cam F Spacer C 60 6 0 43 5 6 Brake shoe G Rear sprocket D 3 0 3 2 0 7 Spring A Rear axle nut...

Page 266: ...Remove the rear axle nut 7 Raise the rear wheel off the ground and support the motorcy cle with a jack or a wooden block Loosen the both chain adjuster lock nuts 8 Loosen the both chain adjuster bolts...

Page 267: ...CHASSIS 8 47 Remove the brake panel E Remove the rear sprocket F along with sprocket mounting drum G Remove the wheel damper H...

Page 268: ...Service Limit 0 25 mm 0 010 in 09900 20607 Dial gauge 09900 20701 Dial gauge chuck 09900 21304 V blocks WHEEL DAMPER Inspect the dampers for wear or damage Replace the damper if there is anything unus...

Page 269: ...th the special tool 09913 70210 Bearing installer set 10 75 Remove the wheel bearings 3 with the special tool 09941 50111 Wheel bearing remover set Remove the spacer 4 REAR SPROCKET Inspect the rear s...

Page 270: ...ghten the rear sprocket nut to the specified torque Rear sprocket nut 60 N m 6 0 kgf m 43 5 lbf ft NOTE The stamped mark A on the sprocket should face outside BEARING Apply grease to the bearings befo...

Page 271: ...installer set 10 75 WHEEL BEARING Install new wheel bearings with removed wheel bearing and special tool 09924 84510 Bearing installer set First install the right wheel bearing then install the space...

Page 272: ...he sprocket mounting drum and rear wheel hub 99000 25010 SUZUKI SUPER GREASE A or equivalent REAR WHEEL Adjust the drive chain slack after installing the rear wheel 2 13 Temporary tighten the rear axe...

Page 273: ...CONSTRUCTION 1 Torque link 6 Collar 2 Dust cover 7 Chain buffer ITEM N m kgf m lbf ft 3 Washer 8 Swingarm pivot shaft A 65 6 5 47 0 4 Dust seal A Swingarm pivot nut B 16 1 6 11 5 5 Swingarm pivot bush...

Page 274: ...er nuts lower 1 and wash ers Remove the rear brake light switch spring 2 Remove the swingarm pivot nut 3 and washer Draw out the swingarm pivot shaft and remove the swingarm assembly 4 Remove the engi...

Page 275: ...als A Remove the chain buffer B INSPECTION AND DISASSEMBLY SWINGARM Inspect the swingarm for damage If any damage is found replace the swingarm with a new one CHAIN BUFFER Inspect the chain buffer for...

Page 276: ...es Remove the swingarm pivot bushings with the special tools 09923 74511 Bearing remover 09930 30104 Rotor remover sliding shaft REASSEMBLY Reassemble the swingarm in the reverse order of disassembly...

Page 277: ...ot bushings and dust covers 99000 25010 SUZUKI SUPER GREASE A or equivalent LH RH 1 Swingarm pivot bushing A 8 mm 0 31 in 2 Swingarm B 3 mm 0 12 in 3 Dust seal Inner C 0 mm 0 in 4 Dust seal Outer D 64...

Page 278: ...65 N m 6 5 kgf m 47 0 lbf ft Tighten the rear shock absorber nuts lower to the specified torque Rear shock absorber nut 29 N m 2 9 kgf m 21 0 lbf ft Install the rear wheel 8 52 FINAL INSPECTION AND AD...

Page 279: ...position after repairing puncture the tire may have to be balanced again since such a repair can cause imbalance INSPECTION WHEEL Wipe the wheel clean and check for the following Distortion and crack...

Page 280: ...alve position For installation procedure of tire onto the wheel follow the instructions given by the tire changer manufacturer Bounce the tire several times while rotating This makes the tire bead exp...

Page 281: ...s Coat the bead with lubricant and fit the tire again When the bead has been fitted properly adjust the pressure to specification As necessary adjust the tire balance Tire pressure After mending a pun...

Page 282: ...6 CHARGING SYSTEM 9 8 TROUBLESHOOTING 9 8 INSPECTION 9 9 STARTER SYSTEM AND SIDE STAND IGNITION INTERLOCK SYSTEM 9 12 TROUBLESHOOTING 9 12 STARTER MOTOR REMOVAL 9 13 STARTER MOTOR DISASSEMBLY 9 14 STA...

Page 283: ...32 TURN SIGNAL LIGHT 9 33 RELAYS 9 34 TURN SIGNAL SIDE STAND RELAY 9 34 MAIN RELAY 9 34 CHECK RELAY 9 34 SWITCH 9 35 IGNITION SWITCH REMOVAL 9 35 IGNITION SWITCH INSTALLATION 9 35 SWITCH INSPECTION 9...

Page 284: ...angled or skewed insertion may cause the terminal to be deformed possibly resulting in poor electrical contact Before refitting the sealed coupler make sure its seal rubber is positioned properly The...

Page 285: ...Therefore be sure there are no fire or spark sources e g short circuit nearby when charging the battery Be sure to recharge the battery in a well ventilated and open area Note that the charging system...

Page 286: ...applied the tester will be damaged After using the tester be sure to turn the switch OFF 09900 25008 Multi circuit tester set NOTE When connecting the multi circuit tester use the needle point probe t...

Page 287: ...TS 1 ECM 2 Check relay or Main relay 3 Main relay or Check relay 4 IAT sensor 5 Ignition coil 6 Starter relay Main fuse 7 Battery 8 Fuse box 9 Mode select coupler 0 TO sensor A PAIR control solenoid v...

Page 288: ...L SYSTEM 9 7 1 Fuel pump 2 TP sensor 3 STP sensor 4 STV actuator 5 IAP sensor 6 Fuel injector 7 Turn signal Side stand relay 8 Generator 9 CKP sensor 0 Neutral switch A Side stand switch B Regulator R...

Page 289: ...voltage between the battery terminals 9 10 Is the regulated voltage OK Step 4 1 Measure the resistance of the generator coil 9 10 Is the resistance of generator coil OK YES Remove accessories NO Go to...

Page 290: ...n switch OFF Disconnect the battery lead wire Measure the current between battery terminal and the battery lead wire using the multi circuit tester If the reading exceeds the specified value leakage i...

Page 291: ...rged condition Regulated voltage Charging output 13 5 15 5 V at 5 000 r min 09900 25008 Multi circuit tester set Tester knob indication Voltage GENERATOR COIL RESISTANCE Remove the front seat 8 3 Disc...

Page 292: ...REGULATOR RECTIFIER Disconnect the regulator rectifier coupler 1 and remove the regulator rectifier 2 Measure the voltage between the lead wires using the multi circuit tester as indicated in the tab...

Page 293: ...d Is a click sound heard Step 2 1 Check if the starter motor runs when its terminal is connected to the battery terminal Do not use thin wire because a large amount of current flows Does the starter m...

Page 294: ...and switch 9 19 Is the side stand switch OK Step 2 1 Check the starter clutch Is the starter clutch OK STARTER MOTOR REMOVAL Disconnect the battery lead wire Disconnect the starter motor lead wire 1 R...

Page 295: ...BLY Disassemble the starter motor as shown in the illustration 1 O ring 6 Bearing A Spring 2 O ring 7 Snap ring B Brush holder 3 Housing end inside 8 Armature C Brush 4 O ring 9 Shim D Housing end out...

Page 296: ...ormal wear is found replace the armature with a new one If the commutator surface is discolored polish it with 400 sand paper and wipe it using a clean dry cloth If there is no undercut scrape out the...

Page 297: ...10 75 Apply grease to the of the oil seal lip 99000 25010 SUZUKI SUPER GREASE A or equivalent Install the bushing 1 and positive terminal brush 2 NOTE The convex part A of bush holder should face hou...

Page 298: ...oove B of housing end with the match mark D on starter motor case Align the match mark E on starter motor case with the bolt hole STARTER MOTOR INSTALLATION Apply grease to the O ring 99000 25010 SUZU...

Page 299: ...ive and negative terminals using the multi circuit tester If the starter relay clicks and continuity is found the relay is OK 09900 25008 Multi circuit tester set Tester knob indication Continuity tes...

Page 300: ...nob indication Diode test NOTE If the tester reads 1 4 V and below when the tester probes are not connected replace its battery NEUTRAL SWITCH Remove the front seat 8 3 Disconnect the neutral switch c...

Page 301: ...If there is no continuity replace the turn signal side stand relay with a new one 09900 25008 Multi circuit tester set Tester knob indication Continuity test DIODE INSPECTION Measure the voltage betwe...

Page 302: ...in order to prevent over running of engine When engine speed reaches 9 700 r min this circuit cuts off fuel at the fuel injector ECM CKP sensor TP sensor ET sensor Neutral switch lgnition coil Engine...

Page 303: ...wires at the ECM with the ignition switch in ON position R Y and B W Is the voltage OK Step 3 1 Measure the ignition coil primary peak voltage 9 23 NOTE This inspection method is applicable only with...

Page 304: ...attery is fully charged Measure ignition coil primary peak voltage using the multi circuit tester in the following procedure Connect the multi circuit tester with the peak voltage adaptor as follows P...

Page 305: ...ower than the specified value inspect the ignition coil Below IGNITION COIL RESISTANCE Remove the fuel tank 5 3 Disconnect the ignition coil lead wires and spark plug cap Measure the ignition coil res...

Page 306: ...point probe set Tester knob indication Voltage If the peak voltage is lower than the specified value inspect for coupler connection and metal particles or foreign material being stuck on the CKP senso...

Page 307: ...9 26 ELECTRICAL SYSTEM SPEEDOMETER REMOVAL AND DISASSEMBLY Remove the speedometer 8 34 Disassemble the speedometer as shown 1 Speedometer 3 Bulb 2 Bracket 4 Cover...

Page 308: ...e respective parts 09900 25008 Multi circuit tester set Tester knob indication Continuity test Neutral indicator light Turn signal indicator light High beam indicator light Fuel indicator light Speedo...

Page 309: ...assembly 5 7 Connect 12 V battery and test bulb 12 V 3 4 W to the fuel level indicator switch as shown in the right illustration The bulb should come on after one minutes if the switch is in good con...

Page 310: ...ignition switch CHECK RELAY For fuel level indicator light Remove the front seat and right frame cover 8 3 Remove the check relay 1 First check the insulation between A and B terminals with the multi...

Page 311: ...headlight socket 1 If you touch the bulb with your bare hands clean the bulb with a cloth moistened with alcohol or soapy water to prevent premature bulb failure Do not use bulb other than those with...

Page 312: ...spring 3 and replace the headlight bulb 4 When installing the headlight hang the hook A of the head light to the projection B of the housing HEADLIGHT BEAM ADJUSTMENT Adjust the headlight beam both v...

Page 313: ...LACEMENT Remove the lens by removing the screws Push in on the bulb turn it counterclockwise and pull it out If you touch the bulb with your bare hands clean the bulb with a cloth moistened with alcoh...

Page 314: ...emoving the screws Push in on the bulb turn it counter clockwise and pull it out If you touch the bulb with your bare hands clean the bulb with a cloth moistened with alcohol or soapy water to prevent...

Page 315: ...ot illuminate inspect the bulb turn signal switch and circuit connection If the bulb turn signal switch and circuit connection are OK the turn signal relay may be faulty In this case replace the turn...

Page 316: ...ion switch 2 IGNITION SWITCH INSTALLATION Install the ignition switch in the reverse order of removal Pay attention to the following points Apply thread lock to the ignition switch mounting bolts 9900...

Page 317: ...H REAR BRAKE LIGHT SWITCH CLUTCH LEVER POSITION SWITCH Color Position B Y B Y OFF ON Color Position O W B OFF ON Color Position B R B Bl OFF ON Color Position B Bl B W PUSH Color Position IGNITION SWI...

Page 318: ...ground Remove the caps 2 NOTE After filling the electrolyte completely use the removed cap 2 as sealing caps of battery filler holes Do not remove or pierce the sealed areas 3 of the electrolyte conta...

Page 319: ...caps do not protrude above the upper surface of the battery s top cover For initial charging use the charger specially designed for MF battery Never use anything except the specified battery Once the...

Page 320: ...period B Stop charging Recharging time 3 A for 1 hour or 0 7 A for 5 to 10 hours After recharging wait for 30 minutes and more and check the battery voltage with a multi circuit tester If the battery...

Page 321: ...FRONT BRAKE HOSE ROUTING 10 17 PAIR AIR SUPPLY SYSTEM HOSE ROUTING 10 18 CYLINDER HEAD RUBBER PAD INSTALLATION 10 19 EXHAUST SYSTEM CONSTRUCTION 10 19 THROTTLE BODY AND FUEL PUMP INSTALLATION 10 20 R...

Page 322: ...circuited wiring connections No fuel reaching the intake manifold 1 Clogged fuel mesh filter or fuel hose 2 Defective fuel pump 3 Defective fuel pressure regulator 4 Defective fuel injector 5 Defecti...

Page 323: ...ive fuel pressure regulator 5 Defective ET sensor 6 Defective IAT sensor Fuel injector improperly operating 1 Defective fuel injector 2 No injection signal from ECM 3 Open or short circuited wiring co...

Page 324: ...Noise seems to come from clutch 1 Worn splines of countershaft or hub 2 Worn teeth of clutch plates 3 Distorted clutch plates driven and drive 4 Worn clutch release bearing Noise seems to come from c...

Page 325: ...sensor 13 Defective STP sensor or STVA Defective air flow system 1 Clogged air cleaner element 2 Defective throttle valve 3 Defective secondary throttle valve 4 Sucking air from throttle body joint 5...

Page 326: ...ir from throttle body joint 12 Too much engine oil 13 Defective fuel pump or ECM 14 Defective CKP sensor or ignition coil 15 Defective STP sensor or STVA Defective control circuit or sensor 1 Low fuel...

Page 327: ...red or scuffed cylinder wall 5 Worn valve stems 6 Defective valve stem seals 7 Worn oil ring side rails Check with inspection window drain out excess oil Replace Replace Replace Replace Replace Replac...

Page 328: ...k oil 3 Wrong weight fork oil Replace Replenish Replace Front suspension too stiff 1 Too viscous fork oil 2 Too much fork oil 3 Bent front axle Replace Drain excess oil Replace Noisy front suspen sion...

Page 329: ...r Brake squeaking Rear 1 Carbon adhesion on shoe surface 2 Tilted shoe 3 Damaged wheel bearings 4 Loosen rear axle nut 5 Brake shoe surface glazed 6 Worn shoes Repair surface with sandpaper Correct sh...

Page 330: ...res or loose lead connections 2 Short circuited grounded or open generator coil 3 Short circuited or punctured regulator rectifier Repair or replace or retighten Replace Replace Generator does charge...

Page 331: ...lt of overcharging 3 Internal short circuit in the battery 4 Too low battery voltage 5 Too old battery Check the generator regu lator rectifier and circuit connections and make nec essary adjustments...

Page 332: ...r cleaner bracket 6 Clutch cable 1 Cut off the excess end of clamp 6 Before clamping the lead wire draw the protector tube to the rear turn signal lead wire coupler 2 The tip of clamp must face upward...

Page 333: ...motor lead wire most up 6 Do not contact the ground lead wire and bracket 7 Cut off the excess end of clamp The end of clamp must face upward 2 Pass the wiring harness outside of the battery lead wire...

Page 334: ...onto the crankcase 4 Neutral switch 3 Bent the oil seal retainer 5 CKP sensor 4 Pass the stator coil lead wire between the boss and rib Do not pinch the stator coil lead wire with the clamp boss and r...

Page 335: ...e No 1 3 Starter motor lead wire 2 Pass the throttle cables outside of the brake hose 4 Cable guide 3 Pass the throttle cable No 1 under the throttle cable No 2 5 Clutch cable 4 Set the protector of c...

Page 336: ...ETER CABLE ROUTING 1 Front fork 6 Cable guide 2 Brake hose 7 Speedometer gearbox 3 Speedometer cable 1 Bind the speedometer cable and hose guide with the clamp Cut off the excess end of clamp 4 Cable...

Page 337: ...No 2 1 Do not contact the brake hose and upper bracket 3 Speedometer cable 2 Attach the brake hose to the hose guide firmly 4 Clamp 3 After the brake hose union has contacted the stopper tighten the...

Page 338: ...AIR SUPPLY SYSTEM HOSE ROUTING 1 Match mark White 1 Do not clamp the clip at the nipple of PAIR pipe 2 Match mark Yellow 2 To air cleaner 3 PAIR control solenoid valve 3 To PAIR pipe 1 2 3 10 N m 1 0...

Page 339: ...46 mm 1 8 in D 32 34 mm 1 26 1 34 in 1 Exhaust pipe gasket 4 Muffler connector 2 Exhaust pipe cover 5 Muffler cover 3 HO2 sensor 1 The tip of clamp must face inside of the exhaust pipe cover DIRECTIO...

Page 340: ...ite 1 When installing the fuel pump assembly first tighten all the fuel pump mounting bolts lightly and then to the specified torque in the ascending order of numbers 3 Fuel pump 4 Throttle body 5 Int...

Page 341: ...ear brake pedal 5 Cotter pin D 90 mm 3 5 in 2 Rear brake rod A 20 mm 0 8 in a Free travel adjustable range 3 Rear brake cam lever B 30 mm 1 2 in 4 Rear brake adjuster nut C 65 5 mm 2 58 in 1 Torque li...

Page 342: ...10 22 SERVICING INFORMATION SIDE STAND INSTALLATION 50 N m 5 0 kgf m 36 0 lbf ft 55 N m 5 5 kgf m 40 0 lbf ft...

Page 343: ...N 1 Front turn signal light 2 Headlight bracket 1 Rear fender 4 Rear turn signal light 2 Rear turn signal bracket 1 After the edge of bracket has contacted the frame tighten the bracket mounting bolt...

Page 344: ...pers 10 34 mm 09900 20607 Dial gauge 09900 20701 Dial gauge chuck 09900 20803 Thickness gauge 09900 20805 Tire depth gauge 09900 21304 V blocks 09900 22403 Small bore gauge 18 35 mm 09900 25008 Multi...

Page 345: ...er 5 5 mm 09916 34561 Valve guide reamer 11 3 mm 09916 44910 Valve guide installer remover 09916 84511 Tweezer 09917 14910 Tappet adjust driver 09917 47011 Vacuum pump gauge set 09920 13120 Crankshaft...

Page 346: ...940 30230 Hexagon socket 17 mm 09940 34520 T type handle 09940 34561 Front fork assem bling attachment D 09940 40211 Fuel pressure gauge adaptor 09940 40220 Fuel pressure gauge attachment 09940 52861...

Page 347: ...0 29 0 Cam chain tension adjuster bolt 10 1 0 7 0 Cam chain tensioner bolt 10 1 0 7 0 Generator rotor nut 160 16 0 115 5 Starter clutch bolt 26 2 6 19 0 TDC plug 21 2 1 15 0 Generator cover plug 15 1...

Page 348: ...16 5 Front brake caliper air bleeder valve 7 5 0 75 5 5 Front brake caliper mounting bolt 39 3 9 28 0 Front brake disc bolt 23 2 3 16 5 Front brake master cylinder holder bolt 10 1 0 7 0 Front brake l...

Page 349: ...or 4 marked bolt 7 marked 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 4...

Page 350: ...26 Valve guide I D IN EX 5 500 5 512 0 2165 0 2170 Valve stem O D IN 5 460 5 475 0 2150 0 2156 EX 5 445 5 460 0 2144 0 2150 Valve stem deflection IN EX 0 35 0 014 Valve stem runout IN EX 0 05 0 002 Va...

Page 351: ...a 12 14 kgf cm 171 199 psi 850 kPa 8 5 kgf cm2 121 psi Piston to cylinder clearance 0 020 0 030 0 0008 0 0012 0 120 0 0047 Cylinder bore 72 000 72 015 2 8346 2 8352 Nicks or Scratches Piston diam 71 9...

Page 352: ...2 Conrod big end side clearance 0 10 0 65 0 004 0 026 1 0 0 04 Conrod big end width 20 95 21 00 0 825 0 827 Crank web to web width 59 9 60 1 2 36 2 37 Crankshaft runout 0 080 0 0031 ITEM STANDARD LIMI...

Page 353: ...groove clearance No 1 2 and 3 0 20 0 40 0 008 0 016 0 60 0 024 Shift fork groove width No 1 2 and 3 4 25 4 35 0 167 0 171 Shift fork thickness No 1 2 and 3 3 95 4 05 0 156 0 159 Drive chain Type DID5...

Page 354: ...4 F IAT sensor input voltage 4 5 5 5 V IAT sensor output voltage 0 15 4 84 V Y R Ground IAT sensor resistance Approx 2 45 k at 20 C 68 F TO sensor resistance 16 5 22 3 k TO sensor voltage Normal 0 4 1...

Page 355: ...oltage 2 0 V and more When cranking G Bl Ignition coil resistance Primary 2 9 4 1 Terminal Terminal Secondary 24 0 36 2 k Terminal Plug cap Ignition coil primary peak voltage 200 V and more B Ground G...

Page 356: ...e travel 20 30 0 8 1 2 Rear brake pedal height 20 30 0 8 1 2 Brake disc thickness Front 4 8 5 2 0 19 0 20 4 5 0 18 Brake disc runout Front 0 30 0 012 Brake drum I D Rear 130 7 5 15 Brake master cylind...

Page 357: ...S Tire type Front CHENG SHIN C 6009 Rear CHENG SHIN C 822 Tire tread depth Recommended depth Front 1 6 0 06 Rear 2 0 0 08 ITEM STANDARD LIMIT Front fork stroke 120 4 7 Front fork spring free length 34...

Page 358: ...than 10 ethanol or less than 5 methanol with appropriate cosolvents and corro sion inhibitor is permissible Fuel tank capacity Including reserve 12 0 L 3 2 US gal Fuel level indicator light lighting...

Page 359: ...3 EXHAUST EMISSION CONTROL SYSTEM 11 4 HO2 SENSOR INSPECTION 11 5 HO2 SENSOR REMOVAL AND INSTALLATION 11 5 NOISE EMISSION CONTROL SYSTEM 11 5 PAIR AIR SUPPLY SYSTEM AND EMISSION CONTROL SYSTEM INSPECT...

Page 360: ...ll of the fuel injection volumes are precisely controlled by the programmed injection maps in the ECM to reduce CO NOX and HC Adjusting interfering with improper replacement or resetting of any of the...

Page 361: ...rankcase emissions into the atomo sphere Blow by gas in the engine is constantly drawn into the crankcase which is returned to the combus tion chamber through the PCV breather hose air cleaner and thr...

Page 362: ...resh air is drawn into the exhaust port through the PAIR control solenoid valve and PAIR reed valve The PAIR control solenoid valve is operated by the ECM which is controlled according to the signals...

Page 363: ...ry to the ultimate purchaser or while it is in use or 2 The use of the vehicle after such device or element of design has been removed or rendered inoperative by any person AMONG THOSE ACTS PRESUMED T...

Page 364: ...PAIR control solenoid valve 11 7 Remove the PAIR reed valve cover 1 and PAIR reed valve 2 INSPECTION Inspect the reed valve for the carbon deposit If the carbon deposit is found in the reed valve repl...

Page 365: ...or damaged replace the PCV hose with a new one PAIR CONTROL SOLENOID VALVE REMOVAL Disconnect the PAIR control solenoid valve coupler 1 and PAIR hose 2 Disconnect the PAIR hose 3 and remove the PAIR...

Page 366: ...flow out the solenoid valve is in normal condi tion Check the resistance between the terminals of the PAIR con trol solenoid valve PAIR control solenoid valve resistance Approx 22 at 20 C 68 F 09900 2...

Page 367: ...EMISSION CONTROL INFORMATION 11 9 PAIR AIR SUPPLY SYSTEM DIAGRAM PAIR AIR SUPPLY SYSTEM HOSE ROUTING 10 18 1 PAIR control solenoid valve A FRESH AIR 2 PAIR reed valve B EXHAUST GAS 3 Air cleaner...

Page 368: ...Br Bl W Bl B Lbl B W W R R W R O W B O W B R O O Y B W Gr Br O W O W B O B O W Y G O R Y W B R B Bl O Dg W B B B W B B W B B W B B W Br B W W B Br B W W B Lg B W R W O Bl O W O G B W B Br W Bl R Y R B...

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