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Suzuki VLR1800, Service Manual

Find the Suzuki VLR1800 Service Manual available for free download on our website. This comprehensive manual contains all the information you need to properly maintain and repair your Suzuki VLR1800. Don't miss out on this valuable resource for keeping your bike in top condition.

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Lighting Systems:  9B-5

License Plate Light Components

B822H19206009

License Plate Light Removal and Installation

B822H19206010

Removal

1) Remove the seat. Refer to “Exterior Parts Removal 

and Installation in Section 9D (Page 9D-3)”.

2) Remove the rear fender. Refer to “Exterior Parts 

Removal and Installation in Section 9D (Page 9D-
3)”.

3) Remove the rear turn signal light cover (1) from the 

rear fender.

4) Remove the license plate light (2).

Installation

Install the license plate light in the reverse order of 
removal.

FWD

FW

D

1

2

3

I822H1920036-02

1. License plate light bulb (12 V 5 W)

2. Lens

3. Socket

1

I822H1920012-01

2

I822H1920013-05

Summary of Contents for VLR1800

Page 1: ...Japan K8 No 1377 VLR1800 S M 99500 39360 01E For PS printing 2008 1 24 Back 23 mm 1 0 DIC502 TOP BOTTOM K8 9 9 5 0 0 3 9 3 6 0 0 1 E VLR1800 THIS BOOK REMAINS THE PROPERTY OF SUZUKI NEW ZEALAND LTD F...

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: ...em 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 Train Dri...

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: ...fully to engage the lock when connecting When disconnecting the coupler be sure to hold the coupler body and do not pull the lead wires Inspect each terminal on the connector coupler for looseness or...

Page 8: ...ge 9A 7 Bend the clamp properly so that the wire harness is clamped securely In clamping the wire harness use care not to allow it to hang down Do not use wire or any other substitute for the band typ...

Page 9: ...o the electronic unit with its coupler connected If attempted damage to ECM or sensors may result Be sure to use a specified voltmeter ohmmeter Otherwise accurate measurements may not be obtained and...

Page 10: ...rocedure as described below inspect the wire harness terminals for open circuit and poor connection Locate abnormality if any Continuity check 1 Measure resistance across coupler B between A and C in...

Page 11: ...s the voltage drop in the circuit between terminals A and B Voltage between A and body ground Approx 5 V B and body ground Approx 5 V 2 V voltage drop C and body ground 3 V 2 V voltage drop Short circ...

Page 12: ...nce with the multi circuit tester 1 will be shown as 10 00 M and 1 flashes in the display Check that no voltage is applied before making the measurement If voltage is applied the tester may be damaged...

Page 13: ...Element Inspection and Cleaning 0B 3 Exhaust Pipe Bolt and Muffler Bolt Inspection 0B 4 Exhaust Control Valve Inspection 0B 4 Valve Clearance Inspection and Adjustment 0B 5 Spark Plug Replacement 0B 1...

Page 14: ...ine Control Unit ECU FI Control Unit ECT Sensor Engine Coolant Temperature Sensor ECTS Water Temp Sensor WTS EVAP Evaporative Emission EXC System Exhaust Control System EXCS EXC Valve Exhaust Control...

Page 15: ...ED Min Minimum N NOx Nitrogen Oxides O OHC Over Head Camshaft OPS Oil Pressure Switch O2 Sensor Oxygen Sensor O2S P PAIR Pulsed Secondary Air Injection PCV Positive Crankcase Ventilation Crankcase Bre...

Page 16: ...4 MOTOR OIL or equivalent engine oil Use of SF SG or SH SJ in API with MA in JASO Suzuki recommends the use of SAE 10W 40 engine oil If SAE 10W 40 engine oil is not available select and alternative a...

Page 17: ...ing beyond it would reduce its efficiency If the anti freeze engine coolant mixing ratio is below 50 rust inhabiting performance is greatly reduced Be sure to mix it above 50 even though the atmospher...

Page 18: ...ed tracer Gr Gray Gr W Gray with White tracer Lbl Light blue Gr Y Gray with Yellow tracer Lg Light green O G Orange with Green tracer O Orange O R Orange with Red tracer P Pink O W Orange with White t...

Page 19: ...label For E 28 4 Vacuum hose routing label For E 33 15 I D plate For E 02 19 24 5 Fuel caution label For E 24 16 I D label For VLR1800UF E 19 6 Fuel information label 17 Safety plate For E 03 28 33 7...

Page 20: ...TP sensor 19 Rear brake switch 2 IAP sensor 1 11 Starter motor 20 GP switch 3 Fuel injector 1 12 O2 sensor For E 02 19 24 33 21 EXCV actuator 4 Fuel injector 2 13 Horn 22 ECT sensor 5 Ignition coil 1...

Page 21: ...ery 36 Generator 27 ECM Engine Control Module 37 CKP sensor 28 Fuse box 38 Speedometer sensor 29 Ignition coil 2 39 Side stand switch 30 Mode selection switch coupler 40 Ignition coil Plug cap 2 31 Ig...

Page 22: ...cooled DOHC 54 degree V twin Number of cylinders 2 Bore 112 0 mm 4 409 in Stroke 90 5 mm 3 563 in Displacement 1 783 cm3 108 8 cu in Compression ratio 10 5 1 Fuel system Fuel injection Air cleaner Non...

Page 23: ...8 Ah 10 HR Generator Three phase A C generator Main fuse 30 A Fuse 10 10 10 10 10 15 15 A Headlight 12 V 60 55 W H4 Position light 12 V 5 W E 02 19 24 Front turn signal light 12 V 21 W E 02 19 24 Fron...

Page 24: ...00 20205 Micrometer 0 25 mm 09900 20210 Micrometer 100 125 mm 09900 20602 Dial gauge 1 1000 mm 1 mm 09900 20605 Dial calipers 1 100 mm 10 34 mm 09900 20607 Dial gauge 1 100 mm 10 mm 09900 20701 Magnet...

Page 25: ...pressure gauge hose 09915 77331 Meter for high pressure 09916 10911 Valve lapper set 09916 14510 Valve spring compressor 09916 14910 Valve spring compressor attachment 09916 34542 Reamer handle 09916...

Page 26: ...r 09924 84510 Bearing installer set 09924 84521 Bearing installer set 09925 18011 Steering bearing installer 09930 10121 Spark plug wrench set 09930 11950 Torx wrench 09930 30104 Rotor remover slide s...

Page 27: ...Steering race installer 09941 54911 Bearing outer race remover 09941 64511 Bearing remover 09941 74911 Steering bearing installer 09943 74111 Fork oil level gauge 09944 28320 Hexagon socket 19 mm 0995...

Page 28: ...ion in Section 0A Page 0A 4 Scheduled Maintenance Periodic Maintenance Schedule Chart B822H10205001 NOTE I Inspect and clean adjust replace or lubricate as necessary R Replace T Tighten Item Interval...

Page 29: ...r grime Lubricate exposed parts which are subject to rust with a rust preventative spray whenever the motorcycle has been operated under wet or rainy conditions Front fork I I Rear suspension I I Chas...

Page 30: ...leaner element more frequently 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 inspectio...

Page 31: ...trol valve Initially at 1 000 km 600 miles 2 months and every 12 000 km 7 500 miles 24 months thereafter Inspect exhaust control valve as follows 1 Remove the right frame cover Refer to Exterior Parts...

Page 32: ...moval and Installation in Section 1H Page 1H 6 6 Remove the cylinder head covers and brackets 7 Remove the PAIR reed valves Refer to PAIR Reed Valve Removal and Installation in Section 1B Page 1B 10 8...

Page 33: ...pression stroke Align the R T line on the generator rotor to the center of valve timing inspection hole and also bring the camshafts to the position B as shown 13 To inspect the 1 Rear cylinder tappet...

Page 34: ...tappet 1 and shim 2 by fingers or magnetic hand 3 Check the figures printed on the shim These figures indicate the thickness of the shim as illustrated 4 Select a replacement shim that will provide a...

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

Page 36: ...90 2 95 3 00 3 05 3 10 3 15 3 20 3 25 3 30 3 35 3 40 3 45 3 50 3 50 2 70 2 75 2 80 2 85 2 90 2 95 3 00 3 05 3 10 3 15 3 20 3 25 3 30 3 35 3 40 3 45 3 50 3 50 2 75 2 80 2 85 2 90 2 95 3 00 3 05 3 10 3...

Page 37: ...r carefully use a tool with a pointed end 3 After finishing the spark plug inspection reinstall the removed parts Spark Plug Gap 1 Remove the spark plugs Refer to Ignition Coil Plug Cap and Spark Plug...

Page 38: ...206008 Inspect evaporative emission control system Every 12 000 km 7 500 miles 24 months Inspect the evaporative emission control system periodically E 33 only Engine Oil and Filter Replacement B822H1...

Page 39: ...the low level line A and full level line B If the oil level is lower than the low level line A add oil to the full level line B NOTE Engine oil level cannot be measured correctly when the engine is n...

Page 40: ...new oil filter before installation CAUTION ONLY USE A GENUINE SUZUKI MOTORCYCLE OIL FILTER Other manufacturer s oil filters may differ in thread specifications thread diameter and pitch filtering perf...

Page 41: ...kgf m 16 5 lb ft Final gear oil capacity 200 220 ml 6 8 7 0 7 4 7 7 US lmp oz 5 Tighten the filler cap 1 CAUTION Use a new O ring to prevent oil leakage Throttle Cable Play Inspection and Adjustment...

Page 42: ...olant to the full line from the engine coolant reservoir tank filler Engine Coolant Change Refer to Engine Coolant Description in Section 1F Page 1F 1 WARNING Do not open the radiator cap when the eng...

Page 43: ...d bleed air from the radiator inlet completely 8 Add engine coolant up to the radiator inlet 9 Repeat the 6 7 procedures until no air bleeds from the radiator inlet 10 Close the radiator cap securely...

Page 44: ...the exhaust pipes and mufflers Refer to Exhaust Pipe Muffler Removal and Installation in Section 1K Page 1K 9 c Remove the clutch cover Refer to Clutch Removal in Section 5C Page 5C 4 d Loosen the loc...

Page 45: ...sed brake fluid Do not use or mix different types of fluid such as silicone based and petroleum based fluids Do not use any brake fluid taken from old used or unsealed containers Never reuse brake flu...

Page 46: ...Front and Rear Brake Hose Inspection 1 Remove the seat right frame head cover and fuel tank Refer to Exterior Parts Construction in Section 9D Page 9D 1 and Fuel Tank Removal and Installation in Secti...

Page 47: ...Rear master cylinder rod lock nut a 18 N m 1 8 kgf m 13 0 lb ft 6 Tighten the right footrest bracket bolts 1 to the specified torque Tightening torque Front footrest bracket bolt b 85 N m 8 5 kgf m 61...

Page 48: ...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 or shorter tire life will result Col...

Page 49: ...steering Refer to Steering Tension Adjustment in Section 6B Page 6B 9 Front Fork Inspection B822H10206022 Inspect front fork Every 12 000 km 7 500 miles 24 months Inspect the front forks for oil leaka...

Page 50: ...ar holder bolt 70 N m 7 0 kgf m 50 5 lb ft 5 Front fork upper clamp bolt 23 N m 2 3 kgf m 16 5 lb ft 6 Front fork cap bolt 55 N m 5 5 kgf m 40 0 lb ft b 2 a 1 I822H1020066 01 b 3 c 4 I822H1020067 01 d...

Page 51: ...valve Front brake 6 0 N m 0 6 kgf m 4 5 lb ft 8 Brake hose union bolt 23 N m 2 3 kgf m 16 5 lb ft 19 Air bleeder valve Rear brake 7 5 N m 0 75 kgf m 5 5 lb ft 20 Brake disc bolt Rear 23 N m 2 3 kgf m...

Page 52: ...ial Tool B822H10208002 Fastening part Tightening torque Note N m kgf m lb ft Exhaust pipe bolt 23 2 3 16 5 Page 0B 4 Muffler connecting bolt 23 2 3 16 5 Page 0B 4 Muffler mounting bolt 23 2 3 16 5 Pag...

Page 53: ...014 Valve stem runout IN EX 0 05 0 002 Valve head thickness IN EX 0 5 0 02 Valve seat width IN 1 1 1 3 0 043 0 051 EX 1 4 1 6 0 055 0 063 Valve head radial runout IN EX 0 03 0 001 Valve spring free l...

Page 54: ...0374 1 55 1 57 0 0610 0 0618 2nd 1 21 1 23 0 0476 0 0484 Oil 2 51 2 53 0 0988 0 0996 Piston ring thickness 1st 0 86 0 91 0 034 0 036 1 38 1 40 0 054 0 055 2nd 1 17 1 19 0 046 0 047 Piston pin bore I D...

Page 55: ...pprox 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 13 2 17 5 psi Cooling fan operating temperature OFF ON Approx 105 C...

Page 56: ...prox 1 1 V Opened Approx 4 3 V ECT sensor input voltage 4 5 5 5 V ECT sensor output voltage 0 15 4 85 V ECT sensor resistance Approx 2 45 k at 20 C 68 F IAT sensor input voltage 4 5 5 5 V IAT sensor o...

Page 57: ...y 1 1 1 9 Secondary 10 8 16 2 k CKP sensor peak voltage 1 5 V and more Ignition coil primary peak voltage 250 V and more 2 G Ground 1 Y Ground Ignition coil Plug cap primary peak voltage 80 V and more...

Page 58: ...5 Brake disc thickness Front 4 8 5 2 0 189 0 205 4 5 0 18 Rear 6 6 7 0 0 260 0 276 6 3 0 25 Brake disc runout Front Rear 0 30 0 012 Master cylinder bore Front 14 000 14 043 0 5512 0 5529 Rear 17 460...

Page 59: ...gf cm2 36 psi Rear 290 kPa 2 90 kgf cm2 42 psi Tire size Front 150 80R 16M C 71V tubeless Rear 240 55R 16M C 86V tubeless Tire type Front BRIDGESTONE G853 RADIAL E Rear BRIDGESTONE G852 RADIAL G Tire...

Page 60: ...18 0 Crank balancer drive gear bolt 24 2 4 17 5 Crank balancer driven gear bolt M6 10 1 0 7 0 M8 25 2 5 18 0 Conrod cap bolt Initial 35 3 5 25 5 Final After tightening to the above torque tighten 1 4...

Page 61: ...ear bearing housing bolt 50 5 0 36 0 Secondary bevel gear case bolt 26 2 6 19 0 Final gear case nut 40 4 0 29 0 Final drive gear coupling nut 100 10 0 72 5 Final drive bevel gear bearing stopper 110 1...

Page 62: ...e caliper mounting bolt 54 5 4 39 0 Front brake caliper air bleeder valve 6 0 6 4 5 Rear brake caliper air bleeder valve 7 5 0 75 5 5 Brake hose union bolt Front Rear 23 2 3 16 5 Brake lever pivot bol...

Page 63: ...rked bolt N m kgf m lb ft N m kgf m lb ft 4 1 5 0 15 1 0 2 3 0 23 1 5 5 3 0 3 2 0 4 5 0 45 3 0 6 5 5 0 55 4 0 10 1 0 7 0 8 13 1 3 9 5 23 2 3 16 5 10 29 2 9 21 0 50 5 0 36 0 12 45 4 5 32 5 85 8 5 61 5...

Page 64: ...0C 12 Service Data...

Page 65: ...28 P1655 Secondary Throttle Valve Actuator STVA Malfunction 1A 64 DTC C29 P1654 H L Secondary Throttle Position Sensor STPS Circuit Malfunction 1A 68 DTC C31 P0705 GP Switch Circuit Malfunction 1A 75...

Page 66: ...Specifications 1C 9 Service Data 1C 9 Tightening Torque Specifications 1C 9 Special Tools and Equipment 1C 10 Recommended Service Material 1C 10 Special Tool 1C 10 Engine Mechanical 1D 1 Schematic and...

Page 67: ...Inspection 1F 5 Radiator Inspection and Cleaning 1F 5 Radiator Cooling Fan Motor Removal and Installation 1F 5 Water Hose Inspection 1F 6 Water Hose Removal and Installation 1F 7 Radiator Reservoir T...

Page 68: ...11 Starter Torque Limiter Inspection 1I 12 Starter Clutch Inspection 1I 13 Starter Button Inspection 1I 13 Specifications 1I 14 Service Data 1I 14 Tightening Torque Specifications 1I 14 Special Tools...

Page 69: ...autions 1 1 Engine Precautions Precautions Precautions for Engine B822H11000001 Refer to General Precautions in Section 00 Page 00 1 and Precautions for Electrical Circuit Service in Section 00 Page 0...

Page 70: ...is low injection time volume is increased INTAKE AIR TEMPERATURE SENSOR SIGNAL When intake air temperature is low injection time volume is increased OXYGEN SENSOR SIGNAL For E 02 19 24 33 Air fuel ra...

Page 71: ...C when no communication signal from the ECM is received for 3 seconds and more Signal Descriptions TIP OVER SENSOR SIGNAL FUEL SHUT OFF When the motorcycle tips over the tip over sensor sends a signal...

Page 72: ...ealer Mode The defective function is memorized in the computer Use the special tool s coupler to connect to the mode select switch The memorized malfunction code is displayed on LCD DISPLAY panel Malf...

Page 73: ...Y B R Bl P B Y W G B Bl P B Bl B Br B R R B R Dg B Y Combination meter CKPS TPS IG switch signal STPS IAPS 1 IAPS 2 ECTS IATS TOS EXCVA Cooling fan relay FP Side stand relay IG switch PAIR control sol...

Page 74: ...9 24 33 46 13 47 Fuel injector 2 21 14 CKP sensor signal CKPS 48 Fuel injector 1 11 15 O2 sensor signal 2 O2S For E 02 19 24 33 49 Ignition coil 2 2 16 Power source for back up 50 Ignition coil 2 1 17...

Page 75: ...nsor 1 IAPS M Engine coolant temperature sensor ECTS B Speedometer H Fuel pump N Cooling fan C Intake air temperature sensor IATS I Ignition coil IG coil plug cap 1 O Crank shaft position sensor CKPS...

Page 76: ...ISCV Y Ignition coil IG coil plug cap 2 S Intake air pressure sensor 2 IAPS Z O2 sensor 1 O2S For E 02 19 24 33 T Ignition coil 2 a O2 sensor 2 O2S For E 02 19 24 33 U Secondary throttle position sen...

Page 77: ...filter or fuel hose Clean or replace Defective fuel pump Replace Defective fuel pressure regulator Replace Defective fuel injectors Replace Defective fuel pump relay Replace Defective ECM Replace Open...

Page 78: ...an Valve clearance out of adjustment Adjust Noisy engine Excessive valve chatter Too large valve clearance Adjust Weakened or broken valve springs Replace Worn tappet or cam surface Replace Worn or bu...

Page 79: ...replace Sucking air from throttle body joint Repair or replace Defective ECM Replace Imbalancing throttle valve synchronization Adjust Defective STP sensor or STVA Replace Engine runs poorly in high...

Page 80: ...cooling system See radiator section Defective EXCVA or EXCV Replace Engine overheats Lean fuel air mixture Short circuited IAP sensors lead wires Repair or replace Short circuited IAT sensor lead wire...

Page 81: ...D 3 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 82: ...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 sid...

Page 83: ...urn the ignition switch OFF 8 Disconnect the SDS tool and install the right frame cover Use of SDS Diagnosis Reset Procedures B822H11104003 NOTE The malfunction code is memorized in the ECM also when...

Page 84: ...ons e g whether the engine was warm or not where the motorcycle was running or stopped when a malfunction was detected by checking the show data when trouble This show data when trouble function can r...

Page 85: ...General Information and Diagnosis 1A 16 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 86: ...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 bet...

Page 87: ...emperature XX C Approx 3 000 r min Check the manifold absolute pressure XXX kPa I822H1110149 03 Throttle Quick wide open Secondary throttle valve opens closes in according with the throttle valve open...

Page 88: ...tive pressure during idling 100 C Data of manifold absolute pressure operation at the time of starting Check the engine coolant temperature XX C Check the manifold absolute pressure XXX kPa I822H11101...

Page 89: ...are side such as ISC valve air inlet hose 1 cylinder side crumple bend etc DTC Table B822H11104006 No DTC output The manifold absolute pressure 2 of the value 3 is lower than the value 1 and value 2 A...

Page 90: ...ndary throttle position sensor STPS C31 P0705 Page 1A 75 Gear position signal GP switch C32 P0201 Page 1A 77 Injector signal 1 For 1 cylinder C33 P0202 Page 1A 77 Injector signal 2 For 2 cylinder C40...

Page 91: ...also fixed YES YES ECT sensor Engine coolant temperature value is fixed to 80 C 176 F Cooling fan is fixed on position YES YES IAT sensor Intake air temperature value is fixed to 40 C 104 F YES YES Ig...

Page 92: ...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 93: ...1F Page 1F 5 Malfunction Code and Defective Condition Table B822H11104009 Malfunction Code Detected Item Detected Failure Condition Check For C00 NO FAULT C12 CKP sensor The signal does not reach ECM...

Page 94: ...A motor C28 P1655 is indicated STVA can not operate properly STVA motor STVA lead wire coupler connection P1655 C29 STP sensor The sensor should produce following voltage 0 15 V Sensor voltage 4 85 V...

Page 95: ...signal does not reach ECM or operation voltage does not reach EXCVA motor C46 P1658 is indicated EXCVA can not operate properly EXCVA EXCVA lead wire coupler P1657 H EXCVA position sensor voltage is...

Page 96: ...ter signal Metal particles or foreign material being stuck on the CKP sensor and rotor tip CKP sensor circuit open or short CKP sensor malfunction ECM malfunction Generator ECM CKP sensor CKPS To the...

Page 97: ...eft frame cover Refer to Exterior Parts Removal and Installation in Section 9D Page 9D 3 3 Remove the left frame lower cover Refer to Exterior Parts Removal and Installation in Section 9D Page 9D 3 4...

Page 98: ...ral times and measure the highest peak voltage Is the voltage OK G W or G Bl wire of the harness side open or shorted to ground Loose or poor contacts on the CKP sensor coupler or ECM coupler Terminal...

Page 99: ...being drawn from vacuum passage between throttle body and IAP sensor IAP sensor circuit open or shorted to ground IAP sensor malfunction ECM malfunction P1750 P0105 H Sensor voltage is higher than sp...

Page 100: ...nd Installation in Section 1G Page 1G 8 2 Turn the ignition switch OFF 3 Check the IAP sensor coupler 2 1 or 1 2 for loose or poor contacts If OK then measure the IAP sensor input voltage 4 Disconnect...

Page 101: ...or coupler 2 1 or 1 2 for loose or poor contacts If OK then check the IAP sensor lead wire continuity 4 Disconnect the IAP sensor coupler 5 Check the continuity between the R wire and Bl R wire or G B...

Page 102: ...een Bl R wire and terminal 26 2 or G B wire and terminal 9 1 If OK then check the continuity between B Br wire 1 and 2 and terminal 29 Special tool A 09900 25008 Multi circuit tester set B 09900 25009...

Page 103: ...or contacts If OK then check the IAP sensor lead wire continuity 4 Disconnect the IAP sensor coupler 5 Check the continuity between the Bl R wire or G B wire and ground Also check the continuity betwe...

Page 104: ...ires A 1 and 2 and terminal 11 Also check the continuity between the Bl R wire B and terminal 26 2 or G B wire B and terminal 9 1 Special tool A 09900 25008 Multi circuit tester set B 09900 25009 Need...

Page 105: ...coupler 2 Between Bl R and B Br wires 1 Between G B and B Br wires Special tool A 09900 25008 Multi circuit tester set B 09900 25009 Needle pointed probe set Tester knob indication Voltage IAP sensor...

Page 106: ...ulti circuit tester set Tester knob indication Voltage Is the voltage OK R Bl R or B Br wire open or shorted to ground or poor 11 26 or 29 connection 2 R G B or B Br wire open or shorted to ground or...

Page 107: ...lowing range Difference between actual throttle opening and opening calculated by ECM is larger than specified value 0 2 V Sensor voltage 4 8 V TP sensor maladjusted TP sensor circuit open or short TP...

Page 108: ...r input voltage 4 Disconnect the TP sensor coupler 5 Turn the ignition switch ON 6 Measure the input voltage between the R wire and ground If OK then measure the input voltage between the R wire and B...

Page 109: ...the TP sensor coupler 1 for loose or poor contacts If OK then check the TP sensor lead wire continuity 4 Disconnect the TP sensor coupler 5 Check the continuity between the P B wire and R wire If the...

Page 110: ...B wire A and terminal 8 Also check the continuity between the B Br wire B and terminal 29 Special tool A 09900 25008 Multi circuit tester set B 09900 25009 Needle pointed probe set Tester knob indica...

Page 111: ...r poor contacts If OK then check the TP sensor lead wire continuity 4 Disconnect the TP sensor coupler 5 Check the continuity between the P B wire and ground Also check the continuity between the P B...

Page 112: ...rness side Is the continuity OK Go to Step 2 R and P B wire open or P B wire shorted to ground 2 1 Connect the ECM coupler 2 Turn the ignition switch ON 3 Measure the input voltage between the R wire...

Page 113: ...wire harness TP sensor continuity Infinity Terminal C Ground 5 If OK then measure the TP sensor resistance at the test harness terminals between terminal C and terminal D 6 Turn the throttle grip and...

Page 114: ...A 09900 25008 Multi circuit tester set C 09900 28630 TPS test wire harness Tester knob indication Resistance TP sensor resistance Approx 5 0 k Terminal D Terminal E Are the continuity and resistance...

Page 115: ...Throttle valve is closed Approx 1 1 V Throttle valve is opened Approx 4 3 V terminal P B terminal B Br Is the voltage OK P B R or B Br wire open or shorted to ground or poor 8 11 or 29 connection If w...

Page 116: ...Page 1A 14 Detected Condition Possible Cause C15 Output voltage is not with in the following range 0 15 V Sensor voltage 4 85 V ECT sensor circuit open or short ECT sensor malfunction ECM malfunction...

Page 117: ...put voltage 4 Disconnect the ECT coupler and turn the ignition switch ON 5 Measure the input voltage between the B Bl wire and ground If OK then measure the input voltage between the B Bl wire and B B...

Page 118: ...or coupler 5 Disconnect the ECM coupler Refer to ECM Removal and Installation in Section 1C Page 1C 1 6 Insert the needle pointed probes to the lead wire coupler 7 Check the continuity between the B B...

Page 119: ...OK then check the ECT sensor lead wire continuity 4 Disconnect the ECT sensor coupler 5 Check the continuity between the B Bl wire and ground If the sound is not heard from the tester the circuit cond...

Page 120: ...nce Special tool A 09900 25008 Multi circuit tester set Tester knob indication Resistance ECT sensor resistance Approx 2 45 k at 20 C 68 F Terminal Terminal NOTE Refer to ECT Sensor Inspection in Sect...

Page 121: ...es Page 1A 14 Detected Condition Possible Cause C21 Output voltage is not with in the following range 0 15 V Sensor voltage 4 85 V IAT sensor circuit open or short IAT sensor malfunction ECM malfuncti...

Page 122: ...t the IAT sensor coupler and turn the ignition switch ON 5 Measure the input voltage between the Dg wire terminal and ground If OK then measure the input voltage between the Dg wire terminal and B Br...

Page 123: ...Disconnect the ECM coupler Refer to ECM Removal and Installation in Section 1C Page 1C 1 6 Insert the needle pointed probes to the lead wire coupler 7 Check the continuity between the Dg wire and term...

Page 124: ...nsor lead wire continuity 4 Disconnect the IAT sensor coupler 5 Check the continuity between the Dg wire and ground If the sound is not heard from the tester the circuit condition is OK Special tool A...

Page 125: ...ter knob indication Resistance IAT sensor resistance Approx 2 45 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 S...

Page 126: ...cuit open or short TO sensor malfunction ECM malfunction P1651 H Sensor voltage is higher than specified value TO sensor circuit is open or ground circuit open L Sensor voltage is lower than specified...

Page 127: ...ignition switch OFF 2 Remove the right frame cover Refer to Exterior Parts Removal and Installation in Section 9D Page 9D 3 3 Check the TO sensor coupler 1 for loose or poor contacts If OK then measur...

Page 128: ...sensor coupler 1 for loose or poor contacts If OK then check the TO sensor lead wire continuity 4 Disconnect the TO sensor coupler 5 Check the continuity between the R wire A and B wire B If the sound...

Page 129: ...heck the continuity between the B wire B and terminal 22 Also check the continuity between B Br wire C and terminal 29 Special tool A 09900 25008 Multi circuit tester set B 09900 25009 Needle pointed...

Page 130: ...r contacts If OK then check the TO sensor lead wire continuity 4 Disconnect the TO sensor coupler 5 Check the continuity between the B wire A and ground Also check the continuity between the B wire A...

Page 131: ...ck the continuity between the R wire C and terminal 11 Also then check the continuity between B wire A and terminal 22 Special tool A 09900 25008 Multi circuit tester set B 09900 25009 Needle pointed...

Page 132: ...sure the voltage when it is leaned 65 and more to left and right from the horizontal level TO sensor voltage Leaning 3 7 4 4 V terminal B terminal B Br Is the voltage OK R B or B Br wire open or short...

Page 133: ...d Possible Cause Wiring Diagram ECM coupler Harness side Detected Condition Possible Cause The operation voltage does not reach the STVA ECM does not receive communication signal from the STVA STVA ca...

Page 134: ...osis Reset Procedures Page 1A 14 Step Action Yes No 1 1 Remove the air cleaner chamber Refer to Air Cleaner Chamber Removal and Installation in Section 1D Page 1D 6 2 Check the STVA lead wire coupler...

Page 135: ...ndication Resistance STVA resistance Approx 7 Terminal A Terminal B Terminal C Terminal D Is the resistance OK B Lg P W G and W B wire open or shorted to ground or poor 19 2 18 and 1 connection If wir...

Page 136: ...he 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 137: ...t within the following range Difference between actual throttle opening and opening calculated by ECM is larger than specified value 0 15 V Sensor voltage 4 85 V STP sensor maladjusted STP sensor circ...

Page 138: ...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 wire A and B Br wire...

Page 139: ...P sensor coupler 1 for loose or poor contacts If OK then check the STP sensor lead wire continuity 4 Disconnect the STP sensor coupler 5 Check the continuity between the Y W wire A and R wire B If the...

Page 140: ...W wire A and terminal 20 Also check the continuity between the B Br wire C and terminal 29 Special tool A 09900 25008 Multi circuit tester set B 09900 25009 Needle pointed probe set Tester knob indica...

Page 141: ...r contacts If OK then check the STP sensor lead wire continuity 4 Disconnect the STP sensor coupler 5 Check the continuity between the Y W wire A and ground Also check the continuity between the Y W w...

Page 142: ...ness side Is the continuity OK Go to Step 2 R or Y W wire open or Y W wire shorted to ground 2 1 Connect the ECM coupler 2 Turn the ignition switch ON 3 Measure the input voltage between the R wire C...

Page 143: ...08 Multi circuit tester set Tester knob indication Voltage STP sensor output voltage Secondary throttle valve is closed Approx 0 6 V Secondary throttle valve is opened Approx 4 2 V terminal Y terminal...

Page 144: ...osis Reset Procedures Page 1A 14 Detected Condition Possible Cause No Gear Position switch voltage GP switch voltage is not within the following range GP switch voltage 0 6 V GP switch circuit open or...

Page 145: ...witch ON 9 Measure the voltage between the P and B wire when shifting the gearshift lever from 1st to Top Special tool A 09900 25008 Multi circuit tester set B 09900 25009 Needle pointed probe set Tes...

Page 146: ...signal is interrupted by 4 times or more continuity Injector circuit open or short Injector malfunction ECM malfunction ECM Fuel pump relay Fuel injector 2 cylinder 1 cylinder Y R 2 1 48 47 To the en...

Page 147: ...emove the air cleaner chamber Refer to Air Cleaner Chamber Removal and Installation in Section 1D Page 1D 6 3 Check the primary fuel injector coupler for loose or poor contacts If OK then measure the...

Page 148: ...seconds after ignition switch is turned ON Special tool A 09900 25008 Multi circuit tester set Tester knob indication Voltage Injector voltage Battery voltage terminal Y R terminal Ground Is the volta...

Page 149: ...e clear the DTC using SDS tool Refer to Use of SDS Diagnosis Reset Procedures Page 1A 14 Detected Condition Possible Cause C40 P0505 H ISC valve motor current is higher than the specified value ISC va...

Page 150: ...oupler Refer to ECM Removal and Installation in Section 1C Page 1C 1 5 Check the continuity between terminal A and terminal 53 terminal B and terminal 16 terminal C and terminal 36 terminal D and term...

Page 151: ...2 If OK then measure the resistance between the Bl R wire terminal A and Y wire terminal B and between the W Bl wire terminal C and Br wire terminal D ISC valve resistance Approx 30 at 20 C 68 F Termi...

Page 152: ...the Spec 2 slowly 4 Check that the Desired idle speed 3 is nearly equal to the Spec 2 Also check that the number of steps 5 in the ISC valve position increases Check 3 1 Click the button 6 and increas...

Page 153: ...ump relay circuit open or short Fuel pump relay malfunction P0230 H Voltage is applied to fuel pump although fuel pump relay is turned OFF Fuel pump relay switch circuit is shorted to power source Fau...

Page 154: ...ace the ECM with a known good one and inspect it again Refer to ECM Removal and Installation in Section 1C Page 1C 1 Replace the FP relay with a new one 1 I822H1110093 02 Step Action Yes No 1 1 Turn t...

Page 155: ...eck the FP relay coupler 1 for loose or poor contacts If OK then check the FP relay Refer to Fuel Pump Relay Inspection in Section 1G Page 1G 6 Is the FP relay OK Y B wire open or poor 39 connection O...

Page 156: ...ng engine operation and running condition Sensor voltage 1 0 V O2 sensor circuit open or shorted to ground Fuel system malfunction ECM malfunction P0156 P0130 ECM O2 sensor 1 Rear O2 sensor 2 Front O2...

Page 157: ...P0130 for O2 sensor 1 Use of mode select switch Step Action Yes No 1 1 Turn the ignition switch OFF 2 Remove the right frame cover All models and EVAP canister For E 33 Refer to Exterior Parts Removal...

Page 158: ...ity 6 Disconnect the ECM coupler Refer to ECM Removal and Installation in Section 1C Page 1C 1 7 Check the continuity between the W G wire or W Bl wire A and terminal 12 15 Also check the continuity b...

Page 159: ...th a proper hose clamps 6 Measure the O2 sensor output voltage while holding the engine speed at 3 000 r min O2 sensor output voltage at 3 000 r min 0 6 V and more terminal W G terminal B Br Is the vo...

Page 160: ...CC or ground circuit open EXCVA position sensor circuit open or shorted to ground or VCC circuit open EXCVA motor circuit open or short EXCVA motor malfunction P1657 H Sensor voltage is higher than sp...

Page 161: ...1 1 Turn the ignition switch OFF 2 Remove the right frame cover All models and EVAP canister For E 33 Refer to Exterior Parts Removal and Installation in Section 9D Page 9D 3 All models and Evaporativ...

Page 162: ...for E 33 in Section 1B Page 1B 13 3 Check the EXCVA position sensor coupler 1 for loose or poor contacts If OK then check the EXCVA position sensor lead wire continuity 4 Disconnect the EXCVA position...

Page 163: ...wire B and terminal 29 Special tool 09900 25008 Multi circuit tester set 09900 25009 Needle pointed probe set Tester knob indication Continuity EXCVA lead wire continuity Continuity ECM couplers Harne...

Page 164: ...age 1B 13 3 Check the EXCVA position sensor coupler 1 for loose or poor contacts If OK then check the EXCVA position sensor lead wire continuity 4 Disconnect the EXCVA position sensor coupler 5 Check...

Page 165: ...ontinuity OK Go to Step 2 and go to Step 4 R or Y wire open or Y wire shorted to ground Step Action Yes No A 5 11 B A C I822H1110109 01 Step Action Yes No 1 1 Turn the ignition switch OFF 2 Remove the...

Page 166: ...age between the R wire and B Br wire Special tool A 09900 25008 Multi circuit tester set Tester knob indication Voltage EXCVA position sensor input voltage 4 5 5 5 V terminal R terminal Ground termina...

Page 167: ...e EXCVA to adjustment position Refer to EXCVA EXCV Cable Removal and Installation in Section 1K Page 1K 4 5 Disconnect the EXCVA position sensor coupler and measure the resistance between Y and W wire...

Page 168: ...e terminal Negative wire Gr wire terminal 5 Insert the needle pointed probes to the back side of the EXCVA position sensor coupler Y W 6 Turn the ignition switch ON 7 Measure the EXCVA position sensor...

Page 169: ...he EXCVA position sensor output voltage at EXCV fully opened position Special tool A 09900 25008 Multi circuit tester set B 09900 25009 Needle pointed probe set Tester knob indication Voltage EXCVA po...

Page 170: ...sure to adjust the cable with the EXCV set in the adjustment position Refer to EXCVA EXCV Cable Removal and Installation in Section 1K Page 1K 4 Do not turn the EXCVA pulley using the wrench 3 If the...

Page 171: ...way Is the voltage OK Loose or poor contacts on the EXCVA or ECM coupler terminal 4 or 3 Open or short circuit in the B R wire or R B wire If wire and connection are OK intermittent trouble or faulty...

Page 172: ...the SDS tool Refer to the SDS operation manual for further details 2 Turn the ignition switch ON 3 Click Exhaust valve operating control 1 4 Click each button 2 At this time if an operation sound is...

Page 173: ...he trouble clear the DTC using SDS tool Refer to Use of SDS Diagnosis Reset Procedures Page 1A 14 Detected Condition Possible Cause Cooling fan relay signal is not input to ECM Cooling fan relay circu...

Page 174: ...eck the cooling fan relay 1 coupler for loose or poor contacts If OK then inspection the cooling fan relay Refer to Cooling Fan Inspection in Section 1F Page 1F 8 Is the cooling fan relay OK O B and O...

Page 175: ...properly 6 Click the off button 4 to check the cooling fan relay and cooling fan motor operation NOTE This inspection should be begun from when the engine coolant temperature is below 50 C 122 F Chec...

Page 176: ...gnals are not received by the ECM the DTC C61 P1656 is indicated PAIR control solenoid valve circuit open or short PAIR control solenoid valve malfunction ECM malfunction ECM Side stand relay Ignition...

Page 177: ...and Installation in Section 9D Page 9D 3 3 Check the PAIR control solenoid valve coupler s 1 for loose or poor contacts If OK then measure the PAIR control solenoid valve s resistance 4 Disconnect the...

Page 178: ...Tester knob indication Voltage PAIR control solenoid valve voltage Battery voltage terminal O B terminal Ground Is the voltage OK R Y wire open or shorted to ground or poor 44 connection failure If w...

Page 179: ...ected Condition Possible Cause EVAP system purge control valve voltage is not input to ECM EVAP system purge control valve circuit open or short EVAP system purge control valve malfunction ECM malfunc...

Page 180: ...ction 9D Page 9D 3 3 Check the EVAP system purge control valve coupler 1 for loose or poor contacts If OK then measure the EVAP system purge control valve resistance 4 Disconnect the EVAP system purge...

Page 181: ...ry voltage terminal O W terminal Ground Is the voltage OK W Y wire open or shorted to ground or poor 15 connection failure If wire and connection are OK intermittent trouble or faulty ECM Recheck each...

Page 182: ...ol Refer to SDS operation manual for further details 2 Turn the ignition switch ON 3 Click EVAP purge valve operating control 1 4 Click each button 2 At this time if an operating sound is heard from t...

Page 183: ...ensor 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 4 V Leaning 3 7 4 4 V When leaning 65 GP switch voltage 0 6 V and more From 1st to Top Injec...

Page 184: ...ge 1A 39 Page 1A 40 Page 1A 41 Page 1A 42 Page 1A 43 Page 1A 43 Page 1A 44 Page 1A 45 Page 1A 46 Page 1A 48 Page 1A 49 Page 1A 50 Page 1A 51 Page 1A 51 Page 1A 53 Page 1A 54 Page 1A 55 Page 1A 56 Page...

Page 185: ...904 41010 TPS test wire harness SDS set Page 1A 44 Page 1A 45 Page 1A 46 Page 1A 74 Page 1A 13 Page 1A 17 09917 47011 09930 82720 Vacuum pump gauge Mode select switch Page 1A 37 Page 1A 3 Page 1A 12 P...

Page 186: ...e applicable emission limits With varying engine conditions all of the fuel injection volumes are precisely controlled by the programmed injection maps in the ECM to reduce CO NOX and HC Adjusting int...

Page 187: ...tmosphere Blow by gas in the engine is constantly drawn into the crankcase which is returned to the combustion chamber through the PCV breather hose air cleaner and throttle body 3 1 C D E A B 2 I822H...

Page 188: ...esh air flow is controlled according to the TPS ECTS IATS IAPS and CKPS The exhaust gas flow is performed by the exhaust control valve actuator which is controlled by the ECM by changing the exhaust c...

Page 189: ...haser or while it is in use or The use of the vehicle after such device or element of design has been removed or rendered inoperative by any person Among Those Acts Presumed to Constitute Tampering ar...

Page 190: ...005 1 2 3 4 5 6 11 10 12 7 9 8 C D A B I822H1120034 01 1 Fuel vapor separator 7 EVAP canister A Fuel 2 Fuel tank 8 Purge hose B HC vapor 3 Fuel pump 9 EVAP purge control valve C Fresh air 4 Fuel feed...

Page 191: ...PAIR System Hose Routing Diagram B822H11202002 For E 02 19 24 33 a 1 D a 2 a C a a a B B A A I822H1120032 01 1 PAIR control solenoid valve C Blue mark 2 PAIR reed valve D Set the PAIR hose to the con...

Page 192: ...1B 7 Emission Control Devices For E 03 28 a a 1 A A C B B B a a A I822H1120033 01 1 PAIR reed valve C Set the PAIR hose to the concave of the air cleaner tube A White mark a 0 B Yellow mark...

Page 193: ...pper 3 Purge control valve D Align the white mark on the hose with the engine mounting plate edge 4 Surge hose E Align the white mark on the hose with the ribs on the canister 5 Purge hose F Face the...

Page 194: ...ol System Removal and Installation Only for E 33 Page 1B 13 3 Disconnect the O2 sensor 1 cylinder lead wire coupler 1 4 Remove the O2 sensor 1 cylinder 2 5 Disconnect the O2 sensor 2 cylinder read wir...

Page 195: ...ove the PAIR reed valves 3 Installation Install the PAIR reed valve in the reverse order of removal Pay attention to the following points Apply thread lock to the bolts 1 and tighten them Thread lock...

Page 196: ...ose Routing Diagram Page 1B 6 4 Reinstall the removed parts PAIR Reed Valve NOTE PAIR control solenoid valve can be checked without removing it from the motorcycle Refer to DTC C61 P1656 PAIR Control...

Page 197: ...Crankcase Breather PCV Hose Inspection B822H11206006 Inspect the crankcase breather PCV hose in the following procedures 1 Remove the fuel tank Refer to Fuel Tank Removal and Installation in Section...

Page 198: ...Emission Control System Removal and Installation Only for E 33 B822H11206009 Hose Removal 1 Remove the fuel tank refer to Fuel Tank Removal and Installation in Section 1G Page 1G 8 2 Remove the EVAP...

Page 199: ...For E 33 only B822H11206010 Refer to Evaporative Emission Control System Removal and Installation Only for E 33 Page 1B 13 Hose Inspect the hoses for wear or damage If it is worn or damage replace th...

Page 200: ...stance Approx 32 at 20 C 68 F Fuel Shut Off Valve Inspect the fuel shut off valve body for damage Inspect the fuel shut off valve operation in the following procedures 1 When air is blown into the fue...

Page 201: ...08001 Special Tool B822H11208002 Item Specification Note Heated oxygen sensor output voltage 0 4 V and less at idle speed E 02 19 24 33 0 6 V and more at 3 000 r min E 02 19 24 33 PAIR solenoid valve...

Page 202: ...o Exterior Parts Removal and Installation in Section 9D Page 9D 3 2 Remove the battery lead wire 3 Disconnect the ECM couplers 1 and remove the ECM 2 Installation Install the ECM in the reverse order...

Page 203: ...de select switch to the dealer mode coupler Refer to Self Diagnostic Procedures in Section 1A Page 1A 12 Special tool 09930 82720 Mode select switch 2 Remove the right air cleaner box Refer to Air Cle...

Page 204: ...body Refer to Throttle Body Removal and Installation in Section 1D Page 1D 10 3 Remove the intake pipes 1 4 Remove the thermostat case 2 along with the water hose 5 Remove the ECT sensor 3 CAUTION Ta...

Page 205: ...ce 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 and the ohmmeter If the ECT sensor ohmic valve does no...

Page 206: ...er to DTC C23 P1651 H L TO Sensor Circuit Malfunction in Section 1A Page 1A 57 STP Sensor Inspection B822H11306012 Refer to DTC C29 P1654 H L Secondary Throttle Position Sensor STPS Circuit Malfunctio...

Page 207: ...1950 Torx wrench Tightening torque STP sensor mounting screw 3 5 N m 0 35 kgf m 2 5 lb ft 7 Reinstall the removed parts STP Sensor Removal and Installation B822H11306014 Removal 1 Turn the ignition sw...

Page 208: ...Refer to DTC C28 P1655 Secondary Throttle Valve Actuator STVA Malfunction in Section 1A Page 1A 64 STV Actuator Removal and Installation B822H11306016 Refer to Throttle Body Disassembly and Assembly...

Page 209: ...22H11306020 Refer to DTC C44 P0156 or C64 P0130 O2 Sensor O2S Circuit Malfunction For E 02 19 24 33 in Section 1A Page 1A 87 O2 Sensor Removal and Installation B822H11306021 Refer to Oxygen Sensor O2S...

Page 210: ...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 250 V and m...

Page 211: ...erial SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or equivalent P No 99000 25010 Page 1C 7 09900 25008 09900 25009 Multi circuit tester set Needle pointed probe set P...

Page 212: ...1D 1 Engine Mechanical Engine Engine Mechanical Schematic and Routing Diagram Camshaft and Sprocket Assembly Diagram B822H11402001 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 I822H1140328 02...

Page 213: ...bles over the brake hose 2 Throttle cable No 2 returning cable B Pass the throttle cables inside the front brake switch and between the brake hose and handlebars 3 Cable guide C Pass the clutch cable...

Page 214: ...on 1H Page 1H 4 5 Install the compression gauge and adaptor in the spark plug hole Make sure that the connection is tight Special tool A 09915 64512 Compression gauge B 09913 10750 Compression gauge a...

Page 215: ...nsion No 1 and No 2 Adjuster Inspection Page 1D 45 Refer to Engine Top Side Assembly Page 1D 30 Cylinder head cover Refer to Engine Top Side Disassembly Page 1D 25 Refer to Cylinder Head Cover Inspect...

Page 216: ...Refer to Gear Position GP Switch Removal and Installation in Section 5B Page 5B 12 Item Removal Inspection Installation Generator Refer to Generator Removal and Installation in Section 1J Page 1J 5 R...

Page 217: ...pection and Cleaning B822H11406035 Refer to Air Cleaner Element Inspection and Cleaning in Section 0B Page 0B 3 Air Cleaner Chamber Removal and Installation B822H11406036 Removal 1 Remove the fuel tan...

Page 218: ...Pay attention to the following points Fit the throttle body clamps properly Refer to Throttle Body Construction Page 1D 9 Route the hoses properly Refer to Throttle Body Construction Page 1D 9 Instal...

Page 219: ...Vacuum hose 16 TP sensor mounting screw 2 STP sensor 7 Fuel injector 12 Vacuum hose E 33 only 5 N m 0 5 kgf m 3 5 Ib ft 3 STVA 8 Cushion seal 13 EVAP purge control valve E 33 only 3 5 N m 0 35 kgf m...

Page 220: ...clamp C a b c C A A 1 C 2 D B 3 4 1 C C 5 C B 3 C E I822H1140329 04 1 Canister E 33 only A Yellow mark a 15 25 2 Canister purge valve E 33 only B White mark b 25 35 3 Purge hose E 33 only C Face the...

Page 221: ...k Removal and Installation in Section 1G Page 1G 8 2 Disconnect the ISC hoses 1 and ISC lead wire coupler 2 3 Remove the ISC valve 3 Installation Install the ISC valve in the reverse order of removal...

Page 222: ...e returning cable 2 to the throttle body Tighten the throttle body clamp screws Refer to Throttle Body Construction Page 1D 9 Loosen each throttle cable lock nut Turn in each throttle cable adjuster f...

Page 223: ...hose 3 2 Remove the fuel delivery pipe assembly 4 CAUTION Be careful not to twist the fuel delivery pipe when disconnecting the fuel feed hose or removing the fuel delivery pipe 3 Remove the fuel inje...

Page 224: ...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 STP sens...

Page 225: ...h the new ones Install the fuel injector 6 by pushing it straight to the delivery pipe 7 CAUTION Never turn the injector while pushing it NOTE Align the coupler E of the injector with boss F of the de...

Page 226: ...ay cleaner it may be necessary to use a dip type cleaning solution and allow them to soak Always follow the chemical manufacturer s instructions for proper use and cleaning of the throttle body compon...

Page 227: ...Page 1D 10 4 Connect the lead wire coupler and hoses 5 Disconnect the IAP sensor and vacuum hoses 1 from the throttle body 6 Connect the respective vacuum hoses and IAP vacuum sensor hoses to each vac...

Page 228: ...a compressed air Also clean the air screw passageways NOTE Slowly turn the air screw in clockwise and count the number of turns until the screw is lightly seated Make a note of how many turns were mad...

Page 229: ...he ignition switch is turned OFF Engine Assembly Removal B822H11406059 Before taking the engine out of the frame wash the engine using a stream cleaner Engine removal is sequentially explained in the...

Page 230: ...11 Disconnect the ignition coil plug cap lead wire couplers and remove the ignition coils plug caps Refer to Ignition Coil Plug Cap and Spark Plug Cap Removal and Installation in Section 1H Page 1H 4...

Page 231: ...cooler hose 9 17 Remove the oil pressure switch lead wire 10 18 Remove the secondary gear case cover and left frame lower cover Refer to Exterior Parts Removal and Installation in Section 9D Page 9D 3...

Page 232: ...ect the clutch cable 19 25 Remove the left footrest 20 along with gear shift link arm 21 26 Support the engine with a proper jack 27 Disconnect the GP switch lead wire coupler 22 and battery lead wire...

Page 233: ...ving their bolts and nuts 32 Remove the engine bracket 28 33 Remove the engine mounting bolts and nuts 34 Remove the engine assembly NOTE Care should be taken not to drop the engine accidentally when...

Page 234: ...o mounting bolts from left side and tighten their nuts NOTE The engine mounting nuts are self locking Once the nuts have been removed they are no longer of any use Tighten the engine mounting bracket...

Page 235: ...e 5B 14 Gearshift lever height a Standard 115 125 mm 4 5 4 9 in Install the regulator rectifier 1 NOTE When installing the frame lower cover bracket 2 bring the UP mark A upward Install the right foot...

Page 236: ...nt in Section 0B Page 0B 17 Engine Top Side Disassembly B822H11406006 It is unnecessary to remove the engine assembly from the frame when servicing the cylinder head cover and camshafts NOTE Engine to...

Page 237: ...mshafts are parallel with the mating surface of the cylinder head 4 Remove the cam chain tension adjuster cap bolt 4 washer and spring 5 Remove the front cam chain tension No 2 adjuster 5 and gasket 6...

Page 238: ...r 1 Remove the generator cover 1 2 Remove the dowel pins and gasket 2 3 Remove the clutch push rod 3 Front Cylinder 1 Remove the front cylinder 1 NOTE Firmly grip the cylinder at both ends and lift it...

Page 239: ...r 1 and its gasket Rear Camshaft 1 Turn the crankshaft 2 3 234 and align the R I T line mark A on the generator rotor with the mating surfaces B of the upper crankcase Also to align the camshafts to t...

Page 240: ...ake camshaft 5 and exhaust camshaft 6 Rear Cylinder Head 1 Remove the rear cylinder head NOTE Loosen the cylinder head bolts little by little diagonally with the smaller sizes first 2 Remove the rear...

Page 241: ...move the piston pin circlip 1 3 Draw out the piston pin 2 and remove the piston 3 NOTE Scribe the cylinder number on the piston head Engine Top Side Assembly B822H11406007 Assemble the engine top side...

Page 242: ...ion rings M O Molybdenum oil MOLYBDENUM OIL SOLUTION Position the piston ring gaps as shown in the figure Before inserting each piston into the cylinder check that the gaps are properly positioned Cyl...

Page 243: ...s No 2 1 Fit the dowel pins and a new cylinder head gaskets 2 to the cylinders CAUTION There is the guide holder for the bottom end of each cam chain guides No 2 1 cast in the crankcase Be sure that t...

Page 244: ...sequentially and diagonally Tightening torque Cylinder head bolt M10 Initial 25 N m 2 5 kgf m 18 0 lb ft Cylinder head bolt M10 Final 42 N m 4 2 kgf m 30 5 lb ft Tighten the other bolts M6 and M8 to t...

Page 245: ...lling the camshaft check that the tappets are installed correctly Pull the cam chain lightly The exhaust camshaft sprocket has an arrow marked 1 C Turn the intake camshaft so that the arrow is aligned...

Page 246: ...e ascending order of numbers CAUTION The camshaft journal holder bolts are made of a special material and much superior in strength compared with other types of high strength bolts Take special care n...

Page 247: ...er bolt a 10 N m 1 0 kgf m 7 0 lb ft Install the spring 4 Install the gasket 5 and cam chain tension adjuster cap bolt 6 NOTE Click sound is heard when the cam chain tension adjuster cap bolt is insta...

Page 248: ...YBDENUM OIL SOLUTION NOTE Before installing the camshaft check that the tappets are installed correctly Pull the cam chain lightly The exhaust camshaft sprocket has an arrow marked 1 C Turn the intake...

Page 249: ...the ascending order of numbers CAUTION The camshaft journal holder bolts are made of a special material and much superior in strength compared with other types of high strength bolts Take special care...

Page 250: ...cam chain tension adjuster cap bolt 6 NOTE Click sound is heard when the cam chain tension adjuster cap bolt is installed Tighten the cam chain tension adjuster cap bolt 6 to the specified torque Tigh...

Page 251: ...cover 2 CAUTION Fit the new gasket washer to the bolts 3 Generator Cover Install the dowel pins and gasket 1 CAUTION Use a new gasket to prevent oil leakage Apply grease to the clutch push rod Grease...

Page 252: ...p edge of the washer faces A outside Cylinder Head Cover Pour engine oil in each oil pocket in the cylinder heads Install a new gaskets to the cylinder head covers CAUTION Use new gaskets to prevent o...

Page 253: ...d Installation in Section 1H Page 1H 6 Thermostat Apply engine coolant to the O ring CAUTION Use a new O ring to prevent engine coolant leakage Connect the water hoses Refer to Water Hose Routing Diag...

Page 254: ...ication The camshafts can be identified by the engraved letter Cam Wear Check the camshaft for wear or damage Measure the cam height a with a micrometer Replace a camshaft if the cams are worn to the...

Page 255: ...the compressed plastigauge Camshaft journal oil clearance IN EX Service limit 0 150 mm 0 0059 in 6 If the camshaft journal oil clearance exceeds the limit measure the inside diameter of the camshaft j...

Page 256: ...kets and automatic decomp assembly They are unserviceable 4 Install the intake and exhaust camshafts Refer to Engine Top Side Assembly Page 1D 30 Cam Chain Tension No 1 and No 2 Adjuster Inspection B8...

Page 257: ...ssembly Page 1D 30 Cam Chain Tensioner No 1 Inspection B822H11406015 Inspect the cam chain tensioner in the following procedures 1 Remove the cam chain tensioner No 1 front and rear Refer to Engine Bo...

Page 258: ...r to PAIR System Inspection in Section 1B Page 1B 11 Cylinder Head Disassembly and Assembly B822H11406016 Refer to Engine Top Side Disassembly Page 1D 25 Refer to Engine Top Side Assembly Page 1D 30 C...

Page 259: ...rotector CAUTION To prevent damage of the tappet sliding surface with the valve lifter attachment use a protector 3 Using the special tools compress the valve spring and remove the two cotter halves 3...

Page 260: ...lybdenum oil MOLYBDENUM OIL SOLUTION Install the valve spring with the small pitch portion A facing cylinder head Put on the valve spring retainer 3 and using the special tools press down the spring f...

Page 261: ...d torque Thread lock cement 99000 32110 THREAD LOCK CEMENT SUPER 1322 or equivalent Tightening torque Water jacket plug Cylinder head a 26 N m 2 6 kgf m 19 0 lb ft Water jacket pipe Apply engine coola...

Page 262: ...cial tool 09900 20803 Thickness gauge Cylinder head distortion Service limit 0 05 mm 0 002 in Valve Stem Runout Support the valve using V blocks and check its runout using the dial gauge as shown in t...

Page 263: ...he micrometer If the valve stem is worn down to the limit as measured with a micrometer replace the valve If the stem is within the limit then replace the guide After replacing valve or guide be sure...

Page 264: ...e seats be sure to check the valve clearance after the cylinder head has been reinstalled Refer to Valve Clearance Inspection and Adjustment in Section 0B Page 0B 5 Valve Guide Replacement B822H114060...

Page 265: ...r to Engine Top Side Assembly Page 1D 30 Valve Seat Repair B822H11406053 The valve seats 1 for both the intake and exhaust valves are machined to three different angles The seat contact surface is cut...

Page 266: ...in tensioner No 2 in the following procedures 1 Remove the cam chain tensioner No 2 Refer to Cylinder Head Disassembly and Assembly Page 1D 47 2 Check the contacting surface of the cam chain tensioner...

Page 267: ...ing excessively since it is apt to be broken down 3 Remove the 2nd ring and oil ring in the same procedure Installation NOTE When installing the piston ring be careful not to damage the piston Do not...

Page 268: ...ameter is less than the service limit replace the piston Special tool A 09900 20210 Micrometer 100 125 mm Piston diameter Service limit 111 880 mm 4 4047 in Piston to cylinder Clearance Subtract the p...

Page 269: ...ckness gauge If any of the measurements exceed the service limit replace the piston ring with a new one Special tool A 09900 20101 Vernier calipers 1 15 mm 150 mm Piston ring free end gap Service limi...

Page 270: ...kcase must be separated to service the crankshaft and conrod Starter Motor Remove the starter motor 1 Clutch Remove the clutch component parts 1 Refer to Clutch Removal in Section 5C Page 5C 4 Rear Ca...

Page 271: ...front cam chain tensioner No 1 mounting bolt 2 2 Remove the idler shaft 3 3 Disengage the cam chain No 1 4 from the front cam chain idler sprocket 5 4 Remove the cam chain tensioner No 1 6 5 Remove t...

Page 272: ...chain idler sprocket 3 3 Remove the cam chain No 2 4 rear cam chain idler sprocket 3 and cam chain No 1 5 Rear Cam Chain Drive Sprocket Remove the rear cam chain drive sprocket 1 Secondary Driven Gear...

Page 273: ...driven gear with the special tool and remove the secondary drive gear bolt Special tool A 09930 44541 Rotor holder Primary Driven Gear 1 Hold the primary driven gear with the special tool and remove...

Page 274: ...6 into the crankcase Gear Position Switch Remove the gear position switch 1 Oil Filter Remove the oil filter with the special tool Special tool A 09915 40610 Oil filter wrench Oil Cooler 1 Disconnect...

Page 275: ...er Cover Remove the crankcase breather cover 1 Oil Pan Remove the oil pan 1 and stay 2 Oil Pressure Regulator Oil Strainer 1 Remove the O rings 1 and oil pressure regulator 2 2 Remove the oil strainer...

Page 276: ...o separate the crankcase halves set the proper bolts and nuts to the crankcase by separating the upper and lower crankcase halves as shown in the figure 3 Remove the O rings 1 and dowel pins Transmiss...

Page 277: ...move the gearshift component parts Refer to Transmission Removal in Section 5B Page 5B 3 Engine Mount Bushing Remove the upper and lower crankcase engine mount bushings 1 if necessary Oil Jet Remove t...

Page 278: ...removing the crankshaft journal bearings be careful not to scratch the crankcase and the crankshaft journal bearings Do not touch the bearing surfaces with your hands Grasp the bearings by their edges...

Page 279: ...r equivalent Tightening torque Oil gallery plug M16 a 35 N m 3 5 kgf m 25 5 lb ft Tighten each plugs to the specified torque Tightening torque Oil gallery plug M10 b 20 N m 2 0 kgf m 14 5 lb ft Oil ga...

Page 280: ...1E 9 Balancer Shaft Crankshaft Install the oil separator 1 NOTE Align the oil separator claw with the lower crankcase hole When fitting the crankshaft journal bearings to the upper and lower crankcas...

Page 281: ...pin with the indent on the bearing Set the balancer shaft so that its punch mark A is aligned with the punch mark B on the crankshaft Turn the bearing to fit the bearing down pin C in the position Ap...

Page 282: ...urfaces thinly to form an even layer and assemble the crankcases within few minutes Take extreme care not to apply any bond to the oil hole oil groove and bearing Apply to distorted surfaces as it for...

Page 283: ...10 Initial 30 N m 3 0 kgf m 21 5 lb ft Crankcase bolt M10 Final 50 N m 5 0 kgf m 36 0 lb ft Check that the driveshaft and countershaft rotate smoothly Oil Pressure Regulator Oil Strainer Clean the oil...

Page 284: ...l dust and other foreign materials Spread on surfaces thinly to from an even layer and assemble the oil pan within few minutes Apply to distorted surfaces as it forms a comparatively thick film Sealan...

Page 285: ...ND No 1207B or equivalent Tighten the breather cover bolts NOTE Fit the clamp A to the bolts Water Pump Apply grease to the O ring CAUTION Use a new O ring to prevent oil leakage NOTE When install the...

Page 286: ...ole of thread end Sealant 99000 31110 SUZUKI BOND No 1215 or equivalent Tightening torque Oil pressure switch a 14 N m 1 4 kgf m 10 0 lb ft Oil Cooler Apply grease to the O ring CAUTION Use a new O ri...

Page 287: ...e gearshift cam hole B Grease 99000 25010 SUZUKI SUPER GREASE A or equivalent Install the gear position switch NOTE Be sure to install the grommet C to the lower crankcase Oil Pump Drive Gear Oil Pump...

Page 288: ...09930 44541 Rotor holder Tightening torque Primary driven gear bolt a 95 N m 9 5 kgf m 68 5 lb ft Secondary Drive Gear Shift the gear position to 1st or 2nd Hold the primary driven gear with the speci...

Page 289: ...the gearshift cam stopper plate 5 NOTE Align the gearshift cam pin B with the gearshift cam stopper plate hole C Apply thread lock to the gearshift cam stopper plate bolt 6 and tighten it to the spec...

Page 290: ...E and stay F to the bolts Grease 99000 25010 SUZUKI SUPER GREASE A or equivalent Secondary Driven Gear Install the shims 1 onto the secondary driven gear case Refer to Secondary Gear Shim Inspection a...

Page 291: ...rankcase hole CAUTION To adjust the camshaft timing correctly be sure to align R I T line A with the index marks B and hold this position when installing the cam chain idler sprockets front and rear E...

Page 292: ...0 N m 1 0 kgf m 7 0 lb ft Cam Chain Guide No 1 Rear Cam Chain Tensioner No 1 Apply thread lock to the bolts and tighten its to the specified torque Thread lock cement 99000 32030 THREAD LOCK CEMENT SU...

Page 293: ...ioner No 1 bolt a 18 N m 1 8 kgf m 13 0 lb ft Front Cam Chain Idler Sprocket Engage the cam chain No 1 1 and No 2 2 onto the front cam chain idler sprocket 3 and install it to the upper crankcase Pass...

Page 294: ...generator component parts 1 Refer to Generator Removal and Installation in Section 1J Page 1J 5 Starter Torque Limiter Starter Idle Gear Install the starter idle gear 1 and starter torque limiter 2 Re...

Page 295: ...l and Installation B822H11406054 Removal 1 Remove the crankshaft assembly from the crankcase Refer to Engine Bottom Side Disassembly Page 1D 59 2 Loosen the conrod cap bolts and tap the conrod cap bol...

Page 296: ...ce CAUTION Be sure to clean the conrod big end M O Molybdenum oil Molybdenum oil solution 3 When fitting the conrod cap make sure that I D code B on each conrod faces intake side 4 Apply engine oil to...

Page 297: ...remove the conrod and measure the conrod big end width and crank pin width Refer to Conrod Removal and Installation Page 1D 84 If the width exceed the limit replace the conrod or crankshaft Special to...

Page 298: ...xceeds the service limit select the specified bearings from the bearing selection table Conrod big end oil clearance Standard 0 032 0 056 mm 0 0013 0 0022 in Conrod big end oil clearance Service limit...

Page 299: ...aring 1 for any damage 2 Install the crankshaft assembly into the upper crankcase 3 Place the plastigauge axially along the crankshaft journal avoiding the oil hole as shown in the figure Special tool...

Page 300: ...en at the widest part of the compressed plastigauge If the oil clearance exceeds the service limit select the specified bearings from the bearing selection table Crankshaft journal oil clearance Stand...

Page 301: ...thickness gauge If the thrust clearance exceeds the standard range adjust the thrust clearance NOTE Pull the crankshaft to the right Primary driven gear side so that there is no clearance on the thru...

Page 302: ...Color A Part No Thrust bearing thickness Thrust clearance 2 400 2 450 mm 0 0944 0 0965 in Red 12228 48G00 0A0 2 250 2 300 mm 0 0886 0 0906 in 0 100 0 200 mm 0 0039 0 0079 in 2 450 2 500 mm 0 0965 0 09...

Page 303: ...cial tool Special tool A 09920 53740 Clutch sleeve hub holder 5 Remove the balancer driven gear bolts spacers and spring washers 6 Remove the balancer driven gear No 1 4 and No 2 5 from the special to...

Page 304: ...or equivalent Tightening torque Balancer driven gear bolt M6 a 10 N m 1 0 kgf m 7 0 lb ft Balancer driven gear bolt M8 b 25 N m 2 5 kgf m 18 0 lb ft 8 Remove the balancer driven gear assembly from th...

Page 305: ...t Parts Inspection B822H11406057 Refer to Balancer Driven Gear Disassembly and Assembly Page 1D 92 Balancer Shaft Bearing Inspect the balancer shaft bearings for abnormal noise and smooth rotation Rep...

Page 306: ...m runout IN EX 0 05 0 002 Valve head thickness IN EX 0 5 0 02 Valve seat width IN 1 1 1 3 0 043 0 051 EX 1 4 1 6 0 055 0 063 Valve head radial runout IN EX 0 03 0 001 Valve spring free length IN EX 40...

Page 307: ...d 0 150 0 0059 Piston ring groove width 1st 0 93 0 95 0 0366 0 0374 1 55 1 57 0 0610 0 0618 2nd 1 21 1 23 0 0476 0 0484 Oil 2 51 2 53 0 0988 0 0996 Piston ring thickness 1st 0 86 0 91 0 034 0 036 1 38...

Page 308: ...allery plug M16 35 3 5 25 5 Page 1D 68 Oil gallery plug M10 20 2 0 14 5 Page 1D 68 Oil gallery plug M14 25 2 5 18 0 Page 1D 68 Oil gallery plug M12 21 2 1 15 0 Page 1D 68 Oil gallery plug M6 10 1 0 7...

Page 309: ...rt Tightening torque Note N m kgf m lb ft Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or equivalent P No 99000 25010 Page 1D 13 Page 1D 40 Page 1D 42 Page 1D...

Page 310: ...110 Page 1D 47 Page 1D 50 Page 1D 68 Page 1D 69 Page 1D 78 Page 1D 78 Material SUZUKI recommended product or Specification Note 09900 06107 09900 20101 Snap ring pliers Vernier calipers 1 15 mm 150 mm...

Page 311: ...0 22301 V block 100 mm Plastigauge 0 025 0 076 mm Page 1D 45 Page 1D 51 Page 1D 51 Page 1D 43 Page 1D 86 Page 1D 88 09900 22302 09900 22403 Plastigauge 0 051 0 152 mm Small bore gauge 18 35 mm Page 1D...

Page 312: ...tensioner locking tool Page 1D 48 Page 1D 49 Page 1D 81 09918 53810 09919 28610 Chain tensioner lock tool Sleeve protector Page 1D 81 Page 1D 48 Page 1D 49 09920 53740 09930 11950 Clutch sleeve hub ho...

Page 313: ...MSHAFT JOURNAL HOLDER 1 CAMSHAFT JOURNALS CAM FACES AND TAPPETS 1 INTAKE CAMSHAFT 1 EXHAUST CAMSHAFT JOURNAL HOLDER 1 PISTON AND CYLINDER WALL OIL PIPE OIL JET OIL JET COUNTERSHAFT GEARS AND BUSHINGS...

Page 314: ...it If the circuit is OK check the oil pressure in the following manner 2 Remove the oil pressure switch lead wire and oil pressure switch 1 3 Install the oil pressure switch 1 into the special tool 4...

Page 315: ...ions Engine Oil and Filter Replacement B822H11506001 Refer to Engine Oil and Filter Replacement in Section 0B Page 0B 11 Engine Oil Level Inspection B822H11506002 Refer to Engine Oil and Filter Replac...

Page 316: ...N m 3 5 kgf m 25 5 lb ft Oil gallery plug M10 b 20 N m 2 0 kgf m 14 5 lb ft Apply grease to the O rings and install them CAUTION Use new O rings to prevent oil leakage Grease 99000 25010 SUZUKI SUPER...

Page 317: ...clamp B and stay C to the bolts CAUTION Use a new gasket washer to prevent oil leakage After installing the removed parts pour engine oil and engine coolant Refer to Engine Oil and Filter Replacement...

Page 318: ...3 and oil cooler 4 by removing the union bolt 2 Installation Install the oil cooler in the revers order of removal Pay attention to the following points Apply grease to the O ring CAUTION Use a new O...

Page 319: ...ressure switch a 14 N m 1 4 kgf m 10 0 lb ft 2 Connect the oil pressure switch lead wire securely Refer to Wiring Harness Routing Diagram in Section 9A Page 9A 7 Tightening torque Oil pressure switch...

Page 320: ...on Installation is in the reverse order of removal Refer to Engine Top Side Assembly in Section 1D Page 1D 30 Oil Jet For the Piston Cooling and Transmission Removal 1 Remove the engine assembly Refer...

Page 321: ...Installation Page 1E 7 Oil Jet Make sure that the oil jets are not clogged If they are clogged clean their oil passage using a wire of the proper size and compressed air Oil Pump Removal and Installat...

Page 322: ...Inspect the oil pump in the following procedures 1 Remove the oil pump Refer to Oil Pump Removal and Installation Page 1E 9 2 Rotate the oil pump by hand and check that it moves smoothly If it does n...

Page 323: ...2 100 psi at 3 000 r min Item Specification Note Engine oil type SAE 10W 40 API SF SG or SH SJ with JASO MA Engine oil capacity Change 3 400 ml 3 6 3 0 US lmp qt Filter change 3 600 ml 3 8 3 2 US lmp...

Page 324: ...A or equivalent P No 99000 25010 Page 1E 4 Page 1E 6 Sealant SUZUKI BOND No 1215 or equivalent P No 99000 31110 Page 1E 5 SUZUKI Bond 1207B or equivalent P No 99000 31140 Page 1E 7 Thread lock cement...

Page 325: ...on Engine Coolant Description B822H11601001 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 326: ...gine Cooling System Schematic and Routing Diagram Cooling Circuit Diagram B822H11602001 WATER PUMP RADIATOR ENGINE COOLANT TEMPERATURE SENSOR CYLINDER HEAD CYLINDER THERMOSTAT RESERVOIR TANK I822H1160...

Page 327: ...ermostat D Face the tip of the clip to lower I Face the tip of the clip to downward 2 Jiggle valve E Face the tip of the clip to upper J Face the tip of the hose to left A White mark F Face the tip of...

Page 328: ...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 329: ...tor Inspect the radiator for water leaks If any defects are found replace the radiator with a new one If the fins are bent or dented repair them by carefully straightening them with the blade of a sma...

Page 330: ...3 Pour engine coolant Refer to Cooling System Inspection in Section 0B Page 0B 15 Bleed air from the cooling circuit Refer to Cooling System Inspection in Section 0B Page 0B 15 Water Hose Inspection...

Page 331: ...Install the water hose as shown in the water hose routing diagram Refer to Water Hose Routing Diagram Page 1F 3 2 Pour engine coolant and bleed air from the cooling circuit Refer to Cooling System In...

Page 332: ...ng fan operating temperature Standard ON OFF Approx 100 C 212 F OFF ON Approx 105 C 221 F Inspect the cooling fan in the following procedures 1 Disconnect the cooling fan motor coupler 1 2 Test the co...

Page 333: ...ew one Special tool 09900 25008 Multi circuit tester set Tester knob indication set Continuity test 5 Reinstall the removed parts ECT Sensor Removal and Installation B822H11606011 Refer to ECT Sensor...

Page 334: ...ostat Refer to Thermostat Removal and Installation Page 1F 9 2 Inspect the thermostat pellet for signs of cracking 3 Test the thermostat at the bench for control action CAUTION Do not contact the ther...

Page 335: ...e the thermostat valve should have been lifted by at least 8 mm 0 31 in A thermostat failing to satisfy either of the two requirements start to open temperature and valve lift must be replaced Thermos...

Page 336: ...y gear case cover Refer to Exterior Parts Removal and Installation in Section 9D Page 9D 3 3 Disconnect the water pump inlet hose 1 and oil cooler hose 2 4 Remove the air cleaner box Refer to Air Clea...

Page 337: ...coolant Refer to Engine Oil and Filter Replacement in Section 0B Page 0B 11 and Cooling System Inspection in Section 0B Page 0B 15 Bleed air from the cooling circuit Refer to Cooling System Inspectio...

Page 338: ...necessary Special tool A 09921 20240 Bearing remover set 7 Remove the oil seal NOTE If there is no abnormal condition the oil seal removal is not necessary Assembly 1 Install the oil seal with the sp...

Page 339: ...r equivalent 5 Install the impeller shaft and washer 1 to the water pump body 6 Install the rubber seal 2 into the impeller 7 After wiping off the oily or greasy matter from the mechanical seal ring 3...

Page 340: ...s Inspection B822H11606019 Refer to Water Pump Disassembly and Assembly Page 1F 13 Mechanical Seal Visually inspect the mechanical seal for damage with particular attention given to the sealing face R...

Page 341: ...01 I822H1160055 01 Item Standard Note Thermostat valve opening temperature Approx 88 C 190 F Thermostat valve lift Over 8 mm 0 31 in at 100 C 212 F ECT sensor resistance 20 C 68 F Approx 2 45 k 50 C 1...

Page 342: ...Special Tool B822H11608002 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or equivalent P No 99000 25010 Page 1F 12 Page 1F 15 Page 1F 15 Thread lock cement THR...

Page 343: ...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 344: ...is regulated by the 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 k...

Page 345: ...efective fuel pressure regulator Replace Damaged or cracked vacuum hose Replace Defective ECT sensor Replace Defective thermostat Replace Defective IAT sensor Replace Engine stalls often Fuel injector...

Page 346: ...followings Fuel hose leakage Clogged fuel filter Pressure regulator Fuel pump If the fuel pressure is higher than the specification check for the followings Fuel pump Pressure regulator 5 Remove the s...

Page 347: ...4 Disconnect the fuel pump lead wire coupler 2 5 Connect a proper lead wire into the fuel pump lead wire coupler fuel pump side and apply 12 V to the fuel pump between R wire and B wire for 10 second...

Page 348: ...al C and negative to terminal D If continuity does not exist replace the relay with a new one Special tool 09900 25008 Multi circuit tester set Tester knob indication Continuity test Fuel Hose Inspect...

Page 349: ...1706009 1 1 2 3 2 Outside 5 a 1 4 A 7 8 6 I822H1170030 03 1 Clamp 5 Heat shield a 5 45 2 Fuel pump 6 Fuel tank bracket A Set the tip of the fuel tank cushion to the plate of the frame 3 Fuel tank cap...

Page 350: ...ting bolts 4 Lift and support the fuel tank 5 Place a rag under the fuel feed hose and disconnect the fuel feed hose 1 CAUTION When removing the fuel tank do not leave the fuel feed hose 1 on the fuel...

Page 351: ...H11706011 FWD FWD 6 7 a 5 4 3 2 1 I822H1170031 08 1 Filter cover 5 Fuel pressure regulator assembly Apply engine oil 2 Fuel mesh filter 6 Fuel level gauge Apply grease 3 Fuel pump 7 O ring Do not reus...

Page 352: ...diagonally 3 Remove the fuel pump assembly 2 and disconnect the fuel level gauge lead wire coupler 3 4 Remove the fuel level gauge 4 while pushing the pawl end A CAUTION Do not pull the lead wire whe...

Page 353: ...olt B Tightening torque Fuel pump mounting bolt 10 N m 1 0 kgf m 7 0 lb ft Fuel Pump Disassembly and Assembly B822H11706013 Refer to Fuel Pump Assembly Fuel Level Gauge Removal and Installation Page 1...

Page 354: ...e engine oil to the bushing Install the fuel pump 1 Fuel Mesh Filter Inspection and Cleaning B822H11706014 Inspect the fuel mesh filter in the following procedures 1 Remove the fuel mesh filter Refer...

Page 355: ...torque is also described in the following Fuel Pump Components Page 1G 9 Reference For the tightening torque of fastener not specified in this section refer to Tightening Torque List in Section 0C Pa...

Page 356: ...Tool B822H11708002 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or equivalent P No 99000 25010 Page 1G 11 09900 25008 09915 74521 Multi circuit tester set Oil...

Page 357: ...in Section 0A Page 0A 5 Ignition System Components Location B822H11802002 Refer to Electrical Components Location in Section 0A Page 0A 7 ECM TP sensor ECT sensor GP switch Engine stop switch Fuse Fus...

Page 358: ...place Defective CKP sensor Replace Defective ECM Replace Spark plug is wet or quickly becomes fouled with carbon Excessively rich air fuel mixture Inspect FI system Excessively high idling speed Inspe...

Page 359: ...nition Coil Plug Cap Ignition Coil Inspection Page 1H 6 NOTE This inspection method is applicable only with the multi circuit tester and the peak volt adaptor Is the peak voltage OK Go to Step 4 Go to...

Page 360: ...removing the ignition coil plug cap to avoid lead wire coupler damage 6 Remove the ignition coils plug caps 2 CAUTION Do not pry up the ignition coil plug cap with a screw driver or a bar to avoid it...

Page 361: ...the high tension cord 8 Remove the battery carrier Refer to Battery Battery Holder Removal and Installation in Section 1J Page 1J 11 9 Disconnect the ignition coil read wires 5 and disconnect the hig...

Page 362: ...6002 Refer to Spark Plug Inspection and Cleaning in Section 0B Page 0B 10 Ignition Coil Plug Cap Ignition Coil Inspection B822H11806003 Refer to Electrical Components Location in Section 0A Page 0A 7...

Page 363: ...ltage 9 Repeat the b procedure several times and measure the highest peak voltage If the voltage is lower than standard range inspect the ignition coil plug cap Ignition coil Plug cap primary peak vol...

Page 364: ...il Plug Cap Resistance 1 Disconnect the ignition coil plug caps Refer to Ignition Coil Plug Cap and Spark Plug Cap Removal and Installation Page 1H 4 2 Measure the ignition coil plug cap for resistanc...

Page 365: ...instruction manual Special tool A 09900 25008 Multi circuit tester set Tester knob indication Voltage 5 Measure the CKP sensor peak voltage in the following procedures a Shift the transmission into ne...

Page 366: ...tch coupler 1 4 Inspect the engine stop switch for continuity with a tester If any abnormality is found replace the right handlebar switch assembly with a new one Refer to Handlebars Removal and Insta...

Page 367: ...3 at 1 atm CKP sensor resistance 190 290 Ignition coil resistance Primary 1 8 3 0 Secondary 16 26 k Ignition coil Plug cap resistance Primary 1 1 1 9 Secondary 10 8 16 2 k CKP sensor peak voltage 1 5...

Page 368: ...To the ignition coil O W Y G Clutch switch B Y Starter button Engine stop switch O B Turn signal Side stand relay G Ignition switch R Fuse 30 A GP switch Neutral Fuse 15 A Battery Bl Side stand switch...

Page 369: ...starter relay Loose or disconnected starter motor lead wire Loose or disconnected between starter relay and battery terminal Faulty starter motor 3 Measure the starter relay voltage at the starter rel...

Page 370: ...lead wire mounting nut 10 N m 1 0 kgf m 7 0 lb ft 2 Housing end Inside 8 Brush holder nut 5 N m 0 5 kgf m 3 5 lb ft 3 Armature 9 Starter motor mounting bolt Apply grease 4 Starter motor case 10 Starte...

Page 371: ...l the starter motor in the reverse order of removal Pay attention to the following points Apply grease to the starter motor O ring Grease 99000 25010 SUZUKI SUPER GREASE A or equivalent CAUTION Replac...

Page 372: ...KI SUPER GREASE A or equivalent Apply a small quantity of moly paste to the armature shaft Moly paste 99000 25140 SUZUKI Moly paste or equivalent Align the projection A on the brush holder with the gr...

Page 373: ...armature If the commutator surface is discolored polish it with 400 sandpaper and wipe it using a clean dry cloth If there is no undercut scrape out the insulator 1 with a saw blade Armature Coil Mea...

Page 374: ...n the reverse order of removal Starter Relay Inspection B822H11906006 Inspect the starter relay in the following procedures 1 Remove the starter relay Refer to Starter Relay Removal and Installation P...

Page 375: ...urn signal side stand relay in the reverse order of removal Side stand Ignition Interlock System Parts Inspection B822H11906008 Check the interlock system for proper operation If the interlock system...

Page 376: ...er knob indication Continuity test 4 Install the turn signal side stand relay Refer to Turn Signal Side stand Relay Removal and Installation Page 1I 8 Diode inspection 1 Remove the turn signal side st...

Page 377: ...the gear position switch coupler to the wiring harness 5 Insert the needle pointed probes to the lead wire coupler 6 Turn the ignition switch ON and side stand to upright position 7 Measure the voltag...

Page 378: ...r Removal and Installation in Section 1J Page 1J 5 4 Remove the starter torque limiter 3 idle gear shaft 4 and starter idle gear 5 5 Remove the generator rotor assembly 6 Refer to Generator Removal an...

Page 379: ...hten them to the specified torque with the special tool Thread lock cement 99000 32030 THREAD LOCK CEMENT SUPER 1303 or equivalent Tightening torque Starter clutch bolt a 25 N m 2 5 kgf m 18 0 lb ft A...

Page 380: ...lt for rotation 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 Dri...

Page 381: ...ng Torque List in Section 0C Page 0C 8 Item Specification Note Starter motor brush length Standard 12 5 0 49 Limit 6 0 0 24 Starter torque limiter slip torque Standard 31 51 N m 3 1 5 1 kgf m 22 5 37...

Page 382: ...000 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 No 99000 32030 Page 1I 12 09900 201...

Page 383: ...or open 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 circuit...

Page 384: ...n a run down condition for a long time Replace the battery Condition Possible cause Correction Reference Item Step Action Yes No 1 Check accessories which use excessive amounts of electricity Are acce...

Page 385: ...older Removal and Installation Page 1J 11 and Exterior Parts Removal and Installation in Section 9D Page 9D 3 Regulated Voltage Inspection B822H11A06002 Inspect the regulated voltage in the following...

Page 386: ...enerator coil resistance 0 2 1 5 B B B Ground 4 Connect the generator coupler No load Performance 1 Remove the left frame lower cover and secondary gear case cover Refer to Exterior Parts Removal and...

Page 387: ...connect the CKP sensor coupler 2 and generator coupler 3 6 Remove the generator cover 4 and clutch cable guide 5 7 Remove the gasket 6 and dowel pins 8 Loosen the generator rotor bolt NOTE When loosen...

Page 388: ...gf m 8 0 lb ft CKP sensor mounting bolt c 5 5 N m 0 55 kgf m 4 0 lb ft Degrease the tapered portion A of generator rotor and also the crankshaft B Use nonflammable cleaning solvent to wipe off oily or...

Page 389: ...and the crankcase CAUTION Fit new gasket washer to the bolt 7 Install the gearshift lever Refer to Gearshift Lever Removal and Installation in Section 5B Page 5B 14 Regulator Rectifier Inspection B82...

Page 390: ...the clamp Battery Components B822H11A06007 Battery Charging B822H11A06008 Initial Charging Filling electrolyte NOTE When filling electrolyte the battery must be removed from the vehicle and must be p...

Page 391: ...ctrolyte filler holes of the battery 4 Hold the electrolyte container firmly so that it does not fall NOTE Do not allow any of the electrolyte to spill 5 Make sure that air bubbles 4 rise to the top o...

Page 392: ...Otherwise the battery may be overcharged resulting in shortened service life Do not remove the cap during charging Position the battery with the cap facing upward during charging Battery Recharging CA...

Page 393: ...Holder Removal and Installation Page 1J 11 Battery Battery Holder Removal and Installation B822H11A06009 Removal 1 Remove the seat Refer to Exterior Parts Removal and Installation in Section 9D Page...

Page 394: ...y Visual Inspection B822H11A06010 Inspect the battery in the following procedures 1 Remove the seat Refer to Exterior Parts Removal and Installation in Section 9D Page 9D 3 2 Visually inspect the surf...

Page 395: ...rator no load voltage When engine is cold 70 V AC and more at 5 000 r min Regulated voltage 14 0 15 5 V at 5 000 r min Battery Type designation FTZ16 BS Capacity 12 V 64 8 kC 18 Ah 10 HR Fastening par...

Page 396: ...nt EXCVA is mounted on the main frame The EXCV is operated by the EXCVA via the cables This system is designed to improve the engine torque at low engine rpm Exhaust Control System Operation B822H11B0...

Page 397: ...Construction B822H11B06013 a b A c c d a 3 1 2 2 1 I822H11B0002 02 1 No 1 EXCV cable A Adjustment position c 4 mm 0 16 in and more 2 No 2 EXCV cable a 44 45 mm 1 73 1 77 in d 11 12 mm 0 43 0 47 in 3...

Page 398: ...eassembling FWD FWD a a 5 a 6 A 4 A 4 3 2 a a 4 A a a 10 3 1 10 7 8 9 9 FWD FWD b I822H11B0044 03 1 Front exhaust pipe 5 Rear muffler 9 EXCV cable 5 N m 0 5 kgf m 3 5 lb ft 2 Rear exhaust pipe 6 Front...

Page 399: ...ignition switch OFF CAUTION Before removing the EXCV cables be sure to set the EXCVA pulley to the adjustment position 7 Disconnect the couplers and remove the EXCVA 1 8 Remove exhaust pipe and muffl...

Page 400: ...of No 1 cable in 44 45 mm 1 73 1 77 in by turning the adjuster 3 then tighten the lock nuts 4 4 Make the No 2 cable straight and turn in the cable adjuster 5 fully 5 Adjust the inner cable length c o...

Page 401: ...n loosening or tightening the pulley bolt be sure to fix the pulley with an adjustable wrench or EXCVA may get damaged 10 After connecting the No 2 cable 2 loosen the lock nut 12 and turn the adjuster...

Page 402: ...l and Installation Page 1K 4 2 Inspect the cables for wear or bend if it is damaged replace it with a new one NOTE The EXCV cables are identified by the plated chrome color and shape EXCVA Adjustment...

Page 403: ...probe set Tester knob indication Voltage 7 If the measured voltage is less than specification adjust the No 1 cable adjuster as follows a Set the EXCVA to the adjustment position Refer to EXCVA EXCV...

Page 404: ...the No 2 cable adjuster 1 in or out to set the output voltage within the specified value 4 After adjusting the EXCV cables perform Step 2 to confirm DTC 46 is not indicated Exhaust Pipe Muffler Remov...

Page 405: ...e the muffler support bolts 9 9 Remove the front muffler 10 along with the front and rear exhaust pipes from the motorcycle 10 Remove the rear exhaust pipe 11 11 Remove the EXCVA 12 by disconnecting E...

Page 406: ...CAUTION Take care not to expose the O2 sensor to an excessive shock Take care not to twist or damage the O2 sensor lead wire Do not apply oil or other materials to the sensor air holes Do not use an...

Page 407: ...onnecting bolts and muffler mounting bolts are tightened to their specified torque Refer to Exhaust Pipe Bolt and Muffler Bolt Inspection in Section 0B Page 0B 4 EXCV Inspection B822H11B06004 Inspect...

Page 408: ...ition sensor input voltage 4 5 5 5 V EXCVA position sensor resistance Approx 3 1 k At adjustment position EXCVA position sensor output voltage Closed 0 45 1 4 V Opened 3 5 4 5 V O2 sensor output volta...

Page 409: ...shion Rod Inspection 2C 7 Cushion Lever Cushion Rod Bearing Removal and Installation 2C 8 Swingarm Related Parts Inspection 2C 10 Swingarm Bearing Removal and Installation 2C 11 Specifications 2C 12 S...

Page 410: ...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 411: ...ve fork oil Check level and drain Bent front axle Replace Front suspension too noisy Insufficient fork oil Check level and add Loose front suspension fastener Tighten Wobbly rear wheel Distorted wheel...

Page 412: ...Damper rod 2 Dust seal 11 Damper rod bolt 33 N m 3 3 kgf m 24 0 lb ft 3 Oil seal stopper ring 12 Rebound spring 55 N m 5 5 kgf m 40 0 lb ft 4 Oil seal 13 Oil lock piece 20 N m 2 0 kgf m 14 5 lb ft 5 O...

Page 413: ...to facilitate later disassembly 3 Loosen the front fork lower clamp bolts 3 and remove the front fork NOTE Hold the front fork by the hand to prevent sliding out of the steering stem Installation 1 S...

Page 414: ...on B822H12206003 Refer to Front Fork Inspection in Section 0B Page 0B 22 Front Fork Disassembly and Assembly B822H12206005 Refer to Front Fork Removal and Installation Page 2B 2 NOTE The right and lef...

Page 415: ...mble the front fork in the reverse order of disassembly Pay attention to the following points CAUTION Thoroughly wash all the component parts being assembled Insufficient washing can result in oil lea...

Page 416: ...de metal and oil seal lip Fork Oil 99000 99044 10G SUZUKI FORK OIL G 10 or equivalent When installing the oil lock piece 4 insert the tapered end A of the oil lock piece into the inner tube 5 Install...

Page 417: ...en it to the specified torque with a 6 mm hexagon wrench and special tools CAUTION Use a new damper rod bolt gasket to prevent oil leakage NOTE Check the front fork for smoothness by stroking it after...

Page 418: ...ntil bubbles do not come out from the oil Hold the front fork vertically and adjust fork oil level with the special tool NOTE When adjusting the fork oil level remove the fork spring and compress the...

Page 419: ...o Front Fork Inspection in Section 0B Page 0B 22 Front Fork Parts Inspection B822H12206006 Refer to Front Fork Disassembly and Assembly Page 2B 3 Inner and Outer Tubes Inspect the inner tube sliding s...

Page 420: ...ront fork stroke 130 5 1 Front fork spring free length 616 9 24 3 604 23 8 Front fork inner tube O D 49 1 9 Front fork oil level Without spring inner tube fully compressed 179 7 0 Front fork oil type...

Page 421: ...UKI recommended product or Specification Note Fork Oil SUZUKI FORK OIL G 10 or equivalent P No 99000 99044 10G Page 2B 5 Page 2B 5 Page 2B 6 Page 2B 7 Page 2B 8 Thread lock cement THREAD LOCK CEMENT S...

Page 422: ...2H1230042 03 1 Rear shock absorber 7 Swingarm pivot shaft 110 N m 11 0 kgf m 79 5 lb ft 2 Rear cushion rod 8 Swingarm pivot shaft pivot bolt 100 N m 10 0 kgf m 72 5 lb ft 3 Spacer 9 Swingarm pivot bea...

Page 423: ...ut 5 Swingarm pivot shaft Tighten 5 first and then tighten 6 132 N m 13 2 kgf m 95 5 lb ft 2 Rear cushion lever upper nut 6 Swingarm pivot shaft clamp bolt Tighten 5 first and then tighten 6 110 N m 1...

Page 424: ...er rear mounting bolt and nut 5 Remove the shock absorber front mounting bolt spacer and nut 6 Remove the shock absorber Installation Install the rear shock absorber in the reverse order of removal Pa...

Page 425: ...g 1 to the desired position NOTE Position 1 provides the softest spring tension and position 7 provides the stiffest STD position 4th position Rear Shock Absorber Disposal B822H12306007 Refer to Rear...

Page 426: ...orcefully Swingarm Cushion Lever Removal and Installation B822H12306011 Removal 1 Remove the rear wheel assembly Refer to Rear Wheel Assembly Removal and Installation in Section 2D Page 2D 11 2 Remove...

Page 427: ...ttention to the following points Temporarily tighten the cushion lever upper nut 1 and cushion lever lower nut 2 Install the washer and swingarm pivot shaft Tighten the swingarm pivot shaft 3 to the s...

Page 428: ...shion Rod Inspection B822H12306009 Refer to Swingarm Cushion Lever Removal and Installation Page 2C 5 Cushion Lever Spacer 1 Remove the spacers from the cushion lever 2 Inspect the spacers for any fla...

Page 429: ...d replace the bearing with a new one Refer to Cushion Lever Cushion Rod Bearing Removal and Installation Page 2C 8 Cushion rod Inspect the cushion rods for damage and bend If any defects are found rep...

Page 430: ...2C 2 NOTE When installing the bearing stamped mark on the bearing must face outside Special tool A 09924 84521 Bearing installer set 2 Install the cushion lever seal with the special tool Special too...

Page 431: ...acers into bearings 2 Check the play by moving the spacers up and down If excessive play is noted replace the bearing with a new one Refer to Swingarm Bearing Removal and Installation Page 2C 11 Swing...

Page 432: ...t 4 Remove the center spacer 2 Installation 1 Install the center spacer 2 Press the bearings into the swingarm pivot with the special tool NOTE When installing the bearing stamped mark on the bearing...

Page 433: ...of fastener not specified in this section refer to Tightening Torque List in Section 0C Page 0C 8 Item Standard Limit Rear shock absorber spring adjuster 4 7 Rear wheel travel 118 4 6 Swingarm pivot s...

Page 434: ...SUPER GREASE A or equivalent P No 99000 25010 Page 2C 9 Page 2C 10 Page 2C 11 09900 20607 09900 20701 Dial gauge 1 100 mm 10 mm Magnetic stand Page 2C 10 Page 2C 10 09900 21304 09913 70210 V block 10...

Page 435: ...a smaller amount of tire in contact with the load which can contribute to skidding and loss of control Replace the wheel when wheel runout exceed the service limit or if find damage such as distortion...

Page 436: ...2 4 5 8 6 4 5 3 a 2 b 1 I822H1240038 02 1 Front axle 7 Front wheel 100 N m 10 0 kgf m 72 5 lb ft 2 Brake disc bolt 8 Collar Apply grease 3 Brake disc 9 Tire Apply thread lock to the thread part 4 Dus...

Page 437: ...a 1 d 3 a 1 c 2 I822H1240030 04 1 Brake disc bolt 23 N m 2 3 kgf m 16 5 lb ft Apply grease 2 Brake caliper mounting bolt 100 N m 10 0 kgf m 72 5 lb ft Apply thread lock to the thread part 3 Front axle...

Page 438: ...Remove the brake calipers Refer to Front Brake Caliper Removal and Installation in Section 4B Page 4B 3 CAUTION Do not operate the brake lever and brake pedal while removing the caliper 4 Loosen the a...

Page 439: ...lt a 26 N m 2 6 kgf m 19 0 lb ft WARNING After remounting the brake calipers pump the brake lever until the pistons push the pad correctly 5 Tighten the front axle 3 to the specified torque with the s...

Page 440: ...mit 0 25 mm 0 010 in Wheel 1 Remove the brake pads Refer to Front Brake Pad Replacement in Section 4B Page 4B 2 2 Make sure that the wheel runout checked as shown does not exceed the service limit An...

Page 441: ...set 4 Remove the spacer 3 Installation CAUTION The removed dust seals and bearings must be replaced with new ones 1 Apply grease to the wheel bearings Grease 99000 25010 SUZUKI SUPER GREASE A or equi...

Page 442: ...staller set 4 Apply grease to the lip of the dust seals Grease 99000 25010 SUZUKI SUPER GREASE A or equivalent 5 Install the front wheel assembly Refer to Front Wheel Assembly Removal and Installation...

Page 443: ...cer 17 Wheel balancer 2 Spacer 10 Rear wheel 18 Air valve 3 Bearing 11 Rear tire 23 N m 2 3 kgf m 16 5 lb ft 4 Lock washer 12 Dust seal 100 N m 10 0 kgf m 72 5 lb ft 5 Driven joint stopper 13 Collar A...

Page 444: ...embly Construction B822H12406007 LH RH b a a 1 I822H1240033 04 1 Brake disc bolt 100 N m 10 0 kgf m 72 5 lb ft Apply thread lock to the thread part a Clearance Apply grease 23 N m 2 3 kgf m 16 5 lb ft...

Page 445: ...allation in Section 4C Page 4C 3 CAUTION Do not operate the brake pedal while removing the caliper NOTE It is unnecessary to disengage the brake hose from the caliper 4 Remove the brake caliper bracke...

Page 446: ...the washer 3 and rear axle nut 4 7 Hold the rear axle with the special tool and tighten the rear axle nut 4 to the specified torque Tightening torque Rear axle nut b 100 N m 10 0 kgf m 72 5 lb ft Spe...

Page 447: ...C 2 2 Make sure that the wheel runout checked as shown does not exceed the service limit An excessive runout is usually due to worn or loosened wheel bearings and can be reduced by replacing the beari...

Page 448: ...mover set 4 Remove the spacer 3 Installation CAUTION The removed dust seals and bearings must be replaced with new ones 1 Apply grease to the wheel bearings Grease 99000 25010 SUZUKI SUPER GREASE A or...

Page 449: ...eason it is recommended to use a tire changer that can satisfy this sealing requirement and can make the operation efficient as well as functional CAUTION For operating procedures refer to the instruc...

Page 450: ...cause injury Do not stand directly over the tire while inflating In the case of preset pressure air inflator pay special care for the set pressure adjustment 5 In this condition check the grim line B...

Page 451: ...ar due to skidding Flat spot Abnormal condition of inner liner Air Valve Inspect the air valve for peeling and damage If any defect is found replace the air valve with a new one Refer to Air Valve Rem...

Page 452: ...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 Check the wheel balanc...

Page 453: ...l rim size Front 16 M C x MT 3 50 Rear 16 M C x MT 8 00 Item Standard Limit Cold inflation tire pressure Solo riding Front 250 kPa 2 50 kgf cm2 36 psi Rear 290 kPa 2 90 kgf cm2 42 psi Cold inflation t...

Page 454: ...SE A or equivalent P No 99000 25010 Page 2D 4 Page 2D 7 Page 2D 8 Page 2D 12 Page 2D 12 Page 2D 14 Page 2D 15 Thread lock cement THREAD LOCK CEMENT SUPER 1303 or equivalent P No 99000 32030 Page 2D 12...

Page 455: ...Wheels and Tires 2D 21 09941 34513 09944 28320 Steering race installer Hexagon socket 19 mm Page 2D 7 Page 2D 14 Page 2D 11 Page 2D 12...

Page 456: ...2D 22 Wheels and Tires...

Page 457: ...dary Driven Gear Related Parts Inspection 3A 9 Secondary Gear Shim Inspection and Adjustment 3A 10 Final Bevel Gear Components 3A 12 Final Gear Construction 3A 13 Final Gear Assembly Removal and Insta...

Page 458: ...Precautions Precautions Precautions for Driveline Axle B822H13000001 Refer to General Precautions in Section 00 Page 00 1 WARNING Support the motorcycle with a jack or wooden block when servicing the...

Page 459: ...evel gear and final bevel gear assemblies Oil level too low Refill Check oil jet Replace oil seal Drive and driven bevel gears damaged or worn Replace Excessive backlash Adjust Improper tooth contact...

Page 460: ...sing 14 Driven bevel gear shaft 26 N m 2 6 kgf m 19 0 lb ft 4 Bearing housing set 15 Driven bevel gear bearing Apply grease 5 O ring 16 Driven bevel gear coupling nut Apply bond 6 Shims 17 Secondary d...

Page 461: ...moval in Section 1D Page 1D 18 2 Remove the speed sensor Refer to Speed Sensor Removal and Installation in Section 9C Page 9C 6 3 Remove the secondary driven gear assembly 1 1 2 3 4 a b FWD I822H13100...

Page 462: ...ndary driven bevel gear assembly and tighten the bolts to the specified torque Tightening torque Secondary driven gear case bolt a 26 N m 2 6 kgf m 19 0 lb ft Install the speed sensor Refer to Speed S...

Page 463: ...n bearing stopper 7 8 Remove the secondary driven bearing stopper 7 with the special tool Special tool B 09924 41830 Bearing retainer wrench 9 Remove the following parts from the shaft 8 Bearing housi...

Page 464: ...ly 1 Install the bearings with the special tool CAUTION The removed bearing must be replaced with a new one NOTE When installing the bearing stamped mark on the bearing must face outside Special tool...

Page 465: ...5010 SUZUKI SUPER GREASE A or equivalent 6 Install the secondary bevel gear 1 NOTE When install the secondary driven gear fit the convex parts A of the secondary driven gear onto the concave parts B o...

Page 466: ...rease 99000 25010 SUZUKI SUPER GREASE A or equivalent 14 Install the secondary driven gear assembly to the its case 15 Apply a small quantity of the thread lock to the bearing housing bolts and tighte...

Page 467: ...ge If any defects are found replace the driven bevel gear shaft with a new one Dumper Spring Measure the free length of the damper spring If the length is shorter than the service limit replace the sp...

Page 468: ...ondary drive bevel gear securely and turn the secondary driven bevel gear coupling slightly in each direction reading the total backlash on the dial gauge Secondary bevel gear backlash Standard 0 03 0...

Page 469: ...is made the backlash must be rechecked as it may change Refer to the backlash checking sub section and readjust until both backlash and tooth contact are correct Contact Position List of shims For dri...

Page 470: ...plate 30 Final gear case pivot bolt 5 Final driven bevel gear 18 Final drive gear coupling 23 N m 2 3 kgf m 16 5 lb ft 6 Shims 19 Spring 50 N m 5 0 kgf m 36 0 lb ft 7 Final driven gear bearing 20 Snap...

Page 471: ...nut and washer 5 Remove the final gear case 2 backward Installation 1 Apply bond to the mating surface of the final gear case and swingarm Sealant 99000 31110 SUZUKI BOND No 1215 or equivalent CAUTIO...

Page 472: ...e of the washer 1 faces outside Tightening torque Final gear case nut a 40 N m 4 0 kgf m 29 0 lb ft 5 Tighten the final gear case pivot bolt 3 6 Install the rear wheel assembly Refer to Rear Wheel Ass...

Page 473: ...Final driving gear coupling holder 7 Remove the washer 6 and final drive gear coupling 7 8 Remove the bearing stopper with the special tool Special tool C 09924 62410 Final drive gear bearing holder...

Page 474: ...l gear replace the driven bevel gear also as they must be replaced together 13 Remove the final gear case bolts 14 Remove the final gear bearing case 11 from the final gear case by using two 5 mm scre...

Page 475: ...930 30104 Rotor remover slide shaft 20 Remove the final drive gear bearing 19 with the special tools Special tool H 09923 74511 Bearing remover G 09930 30104 Rotor remover slide shaft 21 Remove the oi...

Page 476: ...bevel gear side Apply grease to the oil seal lip Grease 99000 25010 SUZUKI SUPER GREASE A or equivalent Install the final driven gear bearing into the final gear case with the special tool Special too...

Page 477: ...0 31140 SUZUKI BOND No 1207B or equivalent Apply thread lock to the final gear case bolts 5 and 6 and tighten them to the specified torque Thread lock cement 99000 32110 THREAD LOCK CEMENT SUPER 1322...

Page 478: ...ue Final drive bevel gear bearing stopper c 110 N m 11 0 kgf m 79 5 lb ft Install the final drive gear coupling 13 and washer 14 Apply a small quantity of the thread lock to the final drive gear coupl...

Page 479: ...a new dust seal to prevent oil leakage Grease 99000 25010 SUZUKI SUPER GREASE A or equivalent Install the dust seal with the special tools Special tool J 09940 51410 Bearing installer K 09925 18011 St...

Page 480: ...n B822H13106018 Removal 1 Remove the swingarm Refer to Swingarm Cushion Lever Removal and Installation in Section 2C Page 2C 5 2 Remove the universal joint 1 and boot 2 Installation Install the univer...

Page 481: ...allation in Section 2D Page 2D 11 2 Flatten the lock washers 3 Remove the bolts washers and plates 4 Remove the driven hub joint 1 with the special tool and wooden block Special tool A 09913 50121 Oil...

Page 482: ...ers to lock the bolts Wheel Dumper Inspection B822H13106021 Inspect the dumpers for wear and damage Replace the dumper if there is anything unusual Final Gear Shim Inspection and Adjustment B822H13106...

Page 483: ...in each direction reading the total backlash on the dial gauge Final bevel gear backlash Standard 0 08 0 16 mm 0 003 0 006 in If the backlash is not within the specification adjust the shim thickness...

Page 484: ...ase Do not misplace the shims Remove the final driven bevel gear Clean and degrease several teeth on the final driven bevel gear Coat these teeth with machinist s dye or paste preferably of a light co...

Page 485: ...rive bevel gear bearing and final gear case If the tooth contact pattern is incorrect for either reason the appropriate shim must be installed and the tooth contact pattern rechecked by repeating the...

Page 486: ...8 33 1 757 58 33 The others 1 647 56 34 Secondary reduction ratio 1 058 18 17 Final reduction ratio 2 823 18 17 x 32 12 Fastening part Tightening torque Note N m kgf m lb ft Secondary driven gear case...

Page 487: ...3A 24 Moly paste SUZUKI MOLY PASTE or equivalent P No 99000 25140 Page 3A 14 Page 3A 21 Sealant SUZUKI BOND No 1215 or equivalent P No 99000 31110 Page 3A 13 SUZUKI BOND No 1207B or equivalent P No 9...

Page 488: ...10 Bearing retainer wrench Final drive gear bearing holder wrench Page 3A 5 Page 3A 7 Page 3A 15 Page 3A 20 09924 62430 09924 64510 Long socket 22 mm Final driving gear coupling holder Page 3A 15 Page...

Page 489: ...Drive Chain Drive Train Drive Shaft 3A 31 09951 17010 Bearing installer Page 3A 19...

Page 490: ...3A 32 Drive Chain Drive Train Drive Shaft...

Page 491: ...lation 4A 14 Rear Brake Master Cylinder Disassembly and Assembly 4A 16 Rear Brake Master Cylinder Parts Inspection 4A 17 Specifications 4A 18 Service Data 4A 18 Tightening Torque Specifications 4A 18...

Page 492: ...servicing or which has been stored for a long period of time When storing brake fluid seal the container completely and keep it away from children When replenishing brake fluid take care not to get du...

Page 493: ...e union has contacted the stopper tighten the union bolt to the specified torque 3 Rear brake hose E Pass the rear brake hose into the hose guide and pass the rear brake hose under the throttle cables...

Page 494: ...se sleeve to the hose guide firmly 3 Rear brake caliper G Set the reservoir hose as shown in the figure 4 Brake pipe flare nut H White mark A Fix the brake pipe with the clamp a 49 B After the brake h...

Page 495: ...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 Disa...

Page 496: ...nspection B822H14106003 Inspect the rear brake light switch in the following procedures 1 Disconnect the rear brake light switch lead coupler 1 2 Inspect the switch for continuity with a tester If any...

Page 497: ...aint 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 clear hose to th...

Page 498: ...iper air bleeder valve 7 5 N m 0 75 kgf m 5 5 lb ft Fill the reservoir with brake fluid to the upper mark of the reservoir Brake Fluid Replacement B822H14106008 CAUTION Handle brake fluid with care th...

Page 499: ...ce the motorcycle on a level surface 2 Move the right air cleaner box Refer to Air Cleaner Chamber Removal and Installation in Section 1D Page 1D 6 3 Remove the brake fluid reservoir cap and diaphragm...

Page 500: ...Hose Routing Diagram Page 4A 1 2 Bleed air from the front brake system Refer to Air Bleeding from Brake Fluid Circuit Page 4A 5 Rear Brake Hose Removal and Installation B822H14106010 Removal 1 Remove...

Page 501: ...D c 9 7 I822H1410055 01 1 Reservoir cap 6 Brake hose union bolt 1 N m 0 1 kgf m 0 7 lb ft 2 Plate 7 Brake lever 6 N m 0 6 kgf m 4 5 lb ft 3 Diaphragm 8 Brake lever pivot bolt Apply brake fluid 4 Maste...

Page 502: ...e following points When installing the master cylinder 1 onto the handlebars 2 align the master cylinder holder s mating surface A with the punch mark B on the handlebars 2 and tighten the upper holde...

Page 503: ...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 504: ...que Tightening torque Brake lever pivot bolt 1 N m 0 1 kgf m 0 7 lb ft Brake lever pivot bolt lock nut 6 N m 0 6 kgf m 4 5 lb ft Front Brake Master Cylinder Parts Inspection B822H14106014 Refer to Fro...

Page 505: ...15 FWD FWD 1 b 2 c 5 6 4 3 a I822H1410056 01 1 Reservoir tank 4 Master cylinder 10 N m 1 0 kgf m 7 0 lb ft Apply silicone grease 2 Brake hose union bolt 5 Piston Cup set 23 N m 2 3 kgf m 16 5 lb ft Ap...

Page 506: ...ement Page 4A 6 3 Remove the union bolt 1 4 Disconnect the rear brake light switch coupler 2 and remove the footrest bracket bolts 3 5 Loosen the lock nut 4 and remove the push rod 5 6 Remove the rese...

Page 507: ...ut 3 to the specified torque Tightening torque Rear brake master cylinder rod lock nut b 18 N m 1 8 kgf m 13 0 lb ft Tighten the footrest bracket bolts 4 to the specified torque Tightening torque Fron...

Page 508: ...and spring 8 Assembly Assemble the master cylinder in the reverse order of disassembly Pay attention to the following points CAUTION Wash the master cylinder components with new brake fluid before re...

Page 509: ...rake Master Cylinder Parts Inspection B822H14106018 Refer to Rear Brake Master Cylinder Disassembly and Assembly Page 4A 16 Master Cylinder Inspect the master cylinder bore for any scratches or other...

Page 510: ...diam Front 13 957 13 984 0 5495 0 5506 Rear 17 417 17 444 0 6857 0 6868 Brake caliper cylinder bore Front Center 22 650 22 700 0 8917 0 8937 Both side 25 400 25 450 1 0000 1 0020 Rear 30 230 30 306 1...

Page 511: ...Master Cylinder Components Page 4A 13 Special Tool B822H14108002 Material SUZUKI recommended product or Specification Note Brake fluid DOT 4 Page 4A 6 Page 4A 7 Page 4A 11 Page 4A 16 Grease SUZUKI SUP...

Page 512: ...er 7 Front brake pad set Apply silicone grease 2 Piston 8 Stopper ring Apply thread lock to the thread part 3 Oil seal Dust seal 9 Pad mounting pin Apply thread lock to the thread part 4 Caliper housi...

Page 513: ...move the brake caliper by removing the caliper mounting bolts 2 3 Remove the pads 3 by removing the pad mounting pin 1 CAUTION Do not operate the brake lever and brake pedal while dismounting the pads...

Page 514: ...Section 4A Page 4A 6 2 Remove the brake hose from the caliper by removing the union bolts 1 and catch the brake fluid in a suitable receptacle NOTE Place a rag underneath the union bolt on the brake c...

Page 515: ...ation Page 4B 3 NOTE The right and left calipers are installed symmetrically and therefore the disassembly procedure for one side is the same as that for the other side Disassembly Brake caliper 1 Rem...

Page 516: ...er slide pin a 13 N m 1 3 kgf m 9 5 lb ft Install the rubber boot 2 and pad spring 3 Brake caliper Wash the caliper bores and pistons with specified brake fluid Particularly wash the dust seal grooves...

Page 517: ...the specified torque Tightening torque Caliper housing slide pin a 23 N m 2 3 kgf m 16 5 lb ft Apply grease to the two pins Grease 99000 25100 SUZUKI SILICONE GREASE or equivalent Install the brake ca...

Page 518: ...eplace the piston with a new one Brake Pad Mounting Pin Inspect the brake Pad mounting pin for wear and other damage If any damage is found replace the mounting pin with a new one Brake Pad Spring Ins...

Page 519: ...B822H14206008 Brake Disc Thickness Check the brake disc for damage or cracks and measure the thickness using the micrometer Replace the brake disc if the thickness is less than the service limit or if...

Page 520: ...0 205 4 5 0 18 Brake disc runout Front Rear 0 30 0 012 Brake caliper cylinder bore Front Center 22 650 22 70 0 8917 0 8937 Both side 25 400 25 450 1 0000 1 0020 Brake caliper piston diam Front Center...

Page 521: ...roduct or Specification Note Brake fluid DOT 4 Page 4B 5 Page 4B 6 Grease SUZUKI SILICONE GREASE or equivalent P No 99000 25100 Page 4B 2 Page 4B 6 Thread lock cement THREAD LOCK CEMENT SUPER 1303 or...

Page 522: ...9 d I822H1430025 02 1 Rear brake caliper 7 Rear brake pad set Apply silicone grease to sliding surface 2 Piston seal Dust seal 8 Brake caliper bracket Apply brake fluid 3 Piston 9 Brake disc Do not re...

Page 523: ...ely affected Rear Brake Pad Replacement B822H14306003 1 Remove the caliper bracket mounting bolt 1 CAUTION Do not operate the brake pedal while dismounting the pads 2 Remove the pads mounting pin 2 by...

Page 524: ...4A 6 2 Remove the brake hose from the caliper by removing the union bolt 1 and catch the brake fluid in a suitable receptacle NOTE Place a rag underneath the union bolt on the brake caliper to catch a...

Page 525: ...Rear Brake Caliper Disassembly and Assembly B822H14306005 Refer to Rear Brake Caliper Removal and Installation Page 4C 3 Disassembly 1 Remove the pad spring 1 2 Remove the caliper holder 2 and rubber...

Page 526: ...luid to piston seal 1 and dust seal 2 CAUTION Replace the piston seal 1 and dust seal 2 with new ones BF Brake fluid DOT 4 Install the piston seals as shown in the figure Apply grease to the two pins...

Page 527: ...d replace the mounting clip or pin with a new one Boot Inspect the boots for damage and wear If any defects are found replace them with new ones Brake Pad Spring Inspect the brake pad springs for dama...

Page 528: ...ection B822H14306008 Brake Disc Thickness Check the brake disc for damage or cracks and measure the thickness using the micrometer Replace the brake disc if the thickness is less than the service limi...

Page 529: ...Torque List in Section 0C Page 0C 8 Item Standard Limit Rear brake pedal height 105 115 4 1 4 5 Brake disc thickness Rear 6 6 7 0 0 260 0 276 6 3 0 25 Brake disc runout Front Rear 0 30 0 012 Brake cal...

Page 530: ...mmended product or Specification Note Brake fluid DOT 4 Page 4C 5 Page 4C 5 Grease SUZUKI Silicone Grease or equivalent P No 99000 25100 Page 4C 5 Thread lock cement THREAD LOCK CEMENT SUPER 1303 or e...

Page 531: ...5B 15 Gearshift Shaft Gearshift Cam Plate Removal and Installation 5B 15 Gearshift Linkage Inspection 5B 18 Gearshift Shaft Oil Seal Bearing Removal and Installation 5B 19 Specifications 5B 20 Servic...

Page 532: ...5 1 Precautions Transmission Transaxle Precautions Precautions Precautions for Transmission Transaxle B822H15000001 Refer to General Precautions in Section 00 Page 00 1...

Page 533: ...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 534: ...rive gear 6 Driveshaft 11 1st driven gear 6 5 N m 0 65 kgf m 4 5 lb ft 2 5th drive gear 7 2nd driven gear 12 Gearshift cam Apply oil 3 4th drive gear 8 3rd driven gear 13 Gear position switch Apply gr...

Page 535: ...ottom Side Disassembly in Section 1D Page 1D 59 Driveshaft Assembly 1 Remove the driveshaft assembly 1 2 Remove the bearing pin 2 and C ring 3 NOTE Do not lose the bearing pin 2 Countershaft Assembly...

Page 536: ...n B822H15206003 Install the transmission in the reverse order of removal Pay attention to the following points Bearing CAUTION Replace the removed bearing with a new one Install the bearing 1 with the...

Page 537: ...and tighten them Thread lock cement 99000 32030 THREAD LOCK CEMENT SUPER 1303 or equivalent Countershaft Assembly Install the bearing pin 1 and C ring 2 Install the countershaft on the upper crankcas...

Page 538: ...el pin in the position A Assemble the upper and lower crankcases Refer to Engine Bottom Side Assembly in Section 1D Page 1D 68 NOTE Align the gear shift forks B with their grooves C Assemble the engin...

Page 539: ...Manual Transmission 5B 7 Transmission Construction B822H15206004 2 1 3 3 3 3 I822H1520022 02 1 Counter shaft 2 Drive shaft 3 Snap ring Assemble the snap ring with sharp edge side out...

Page 540: ...tion to the following points Countershaft Open the 3rd drive gear snap ring 1 with the special tool from its groove and slide it towards the 4th drive gear side Special tool 09900 06104 Snap ring plie...

Page 541: ...e gear 18 with the commercially available bearing remover and special tool Special tool 09913 70210 Bearing installer set NOTE Rotate the bearing by hand to inspect if there are any abnormal noises an...

Page 542: ...arded and a new snap rings must be installed When installing a new snap rings do not expand the end gap larger than required to slip the snap rings over the shaft After installing snap rings make sure...

Page 543: ...Page 5B 8 Gearshift Fork to Groove Clearance NOTE The clearance for each gearshift fork plays an important role in the smoothness and positiveness of the shifting action Using a thickness gauge check...

Page 544: ...Transmission Removal Page 5B 3 and Transmission Installation Page 5B 4 Gear Position GP Switch Inspection B822H15206007 Refer to Side stand Ignition Interlock System Parts Inspection in Section 1I Pa...

Page 545: ...rque GP switch mounting bolt a 6 5 N m 0 65 kgf m 4 5 lb ft Route the gear position switch lead wire Refer to Wiring Harness Routing Diagram in Section 9A Page 9A 7 NOTE Be sure that the grommet 2 is...

Page 546: ...Refer to Gearshift Lever Construction Page 5B 13 2 Tighten the footrest bracket bolts 1 to the specified torque Tightening torque Front footrest bracket bolt a 85 N m 8 5 kgf m 61 5 lb ft 3 After inst...

Page 547: ...ior Parts Removal and Installation in Section 9D Page 9D 3 2 Disengage the gearshift link arm by removing the bolt NOTE Mark the gearshift shaft head at which the gearshift link arm slit set for corre...

Page 548: ...on Install the gearshift shaft and gearshift cam plate in the reverse order of removal Pay attention to the following points CAUTION The removed snap rings must be replaced with the new ones Apply a s...

Page 549: ...shift cam stopper plate hole C Apply a small quantity of thread lock to the gearshift cam stopper plate bolt 7 and tighten it to the specified torque Thread lock cement 99000 32110 THREAD LOCK CEMENT...

Page 550: ...015 Refer to Gearshift Shaft Gearshift Cam Plate Removal and Installation Page 5B 15 Gearshift Shaft Check the gearshift shaft for bend or wear Check the return spring for damage or fatigue If any def...

Page 551: ...ll the oil seal and bearing in the reverse order of removal Pay attention to the following points CAUTION The removed oil seal and bearings must be replaced with new ones Install the bearings with the...

Page 552: ...1 757 58 33 The others 1 647 56 34 Secondary reduction ratio 1 058 18 17 Final reduction ratio 2 823 18 17 x 32 12 Gear ratios 1st 2 187 35 16 2nd 1 400 28 20 3rd 1 038 27 26 4th 0 827 24 29 Top 0 685...

Page 553: ...ge 5B 9 Page 5B 13 Page 5B 18 Page 5B 19 Thread lock cement THREAD LOCK CEMENT SUPER 1303 or equivalent P No 99000 32030 Page 5B 5 Page 5B 16 THREAD LOCK CEMENT SUPER 1322 or equivalent P No 99000 321...

Page 554: ...em Noise seems to come from clutch Worn splines of countershaft or hub Replace Worn teeth of clutch plates Replace Distorted clutch plates driven and drive Replace Worn clutch release bearing Replace...

Page 555: ...isconnect the clutch cable from the clutch lever Refer to Handlebars Removal and Installation in Section 6B Page 6B 2 2 Remove the left frame head cover frame lower cover and secondary gear case cover...

Page 556: ...ure plate 7 Spring washer 10 N m 1 0 kgf m 7 0 lb ft 2 Clutch push piece 8 Drive plate No 2 95 N m 9 5 kgf m 68 5 lb ft 3 Driven plate No 2 9 Clutch sleeve hub Apply engine oil 4 Drive plate No 1 10 P...

Page 557: ...e the clutch spring set bolts clutch springs and pressure plate 3 NOTE Loosen the clutch spring set bolts little by little and diagonally 6 Remove the clutch push piece 4 thrust washer 5 and bearing 6...

Page 558: ...0 Extension handle 12 Remove the clutch sleeve hub nut 13 Remove the conical spring washer 13 14 Remove the washer 14 and primary driven gear 15 NOTE If it is difficult to remove the primary driven ge...

Page 559: ...and apply engine oil to them 2 Install the primary driven gear assembly 4 and thrust washer 5 3 Install the clutch sleeve hub 6 and spring washer 7 NOTE The conical curve side of spring washer 7 face...

Page 560: ...h a center punch 7 Install the spring washer 9 and spring washer seat 10 onto the clutch sleeve hub correctly 8 Insert the clutch drive plates and driven plates one by one into the clutch sleeve hub i...

Page 561: ...he countershaft NOTE Tighten the washer 19 is located between the pressure plate and bearing 18 11 Install the pressure plate and clutch springs 12 Tighten the clutch spring set bolts to the specified...

Page 562: ...he bolts 21 CAUTION Use the gasket washers to prevent oil leakage 17 Install the clutch cover and tighten the clutch cover bolts 18 Pour engine oil Refer to Engine Oil and Filter Replacement in Sectio...

Page 563: ...the engine oil from the drive and driven plates with a clean rag Measure the thickness of the drive and driven plates with a vernier calipers If each plate thickness is found to have reached the limit...

Page 564: ...ernier calipers 1 20 mm 200 mm Clutch spring free length Service limit 52 4 mm 2 06 in Clutch Release Bearing Inspect the clutch release bearing for any abnormality especially cracks When removing the...

Page 565: ...e of fastener not specified in this section refer to Tightening Torque List in Section 0C Page 0C 8 I822H1530035 01 I822H1530041 01 Item Standard Limit Clutch cable play 10 15 0 4 0 6 Clutch release s...

Page 566: ...nt P No 99000 25010 Page 5C 10 Sealant SUZUKI Bond 1207B or equivalent P No 99000 31140 Page 5C 9 Thread lock cement THREAD LOCK CEMENT SUPER 1303 or equivalent P No 99000 32030 Page 5C 10 09900 20102...

Page 567: ...B 1 Handlebars Components 6B 1 Handlebars Removal and Installation 6B 2 Handlebars Inspection 6B 4 Steering Components 6B 4 Steering Removal and Installation 6B 5 Steering Related Parts Inspection 6B...

Page 568: ...6 1 Precautions Steering Precautions Precautions Precautions for Steering B822H16000001 Refer to General Precautions in Section 00 Page 00 1...

Page 569: ...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 570: ...Components B822H16206001 FWD FWD FWD FWD 6 4 1 5 b a 3 2 A I822H1620026 02 1 Throttle grip 4 Left handlebar grip A Apply handle grip bond 2 Handlebars 5 Right handlebar switch box 23 N m 2 3 kgf m 16...

Page 571: ...Right handlebar switch box 6 d Handlebar balancer 7 e Throttle grip 8 3 Remove the caps and handlebar clamp bolts Installation Install the handlebars in the reverse order of removal Pay attention to...

Page 572: ...concave part F of the throttle cables to the convex part G of the switch box Install the front brake master cylinder Refer to Front Brake Master Cylinder Assembly Removal and Installation in Section 4...

Page 573: ...ering Components B822H16206005 I822H1620027 01 FWD FWD a 1 2 10 b 3 a 4 c 10 5 6 7 8 9 a I822H1620028 01 1 Handlebar clamp 6 Dust seal 23 N m 2 3 kgf m 16 5 lb ft 2 Handlebar holder 7 Steering stem up...

Page 574: ...n in Section 2B Page 2B 2 5 Remove the headlight Refer to Headlight Removal and Installation in Section 9B Page 9B 2 6 Remove the cable guide 1 7 Remove the front fork upper covers 2 8 Remove the stee...

Page 575: ...er bolts Bearing Apply grease to the bearings races and dust seals before remounting the steering stem Grease 99000 25010 SUZUKI SUPER GREASE A or equivalent Steering stem nut Tighten the steering ste...

Page 576: ...mp bolts Refer to Front Fork Removal and Installation in Section 2B Page 2B 2 Handlebars Install the handlebars Refer to Handlebars Removal and Installation Page 6B 2 Apply thread lock to the handleba...

Page 577: ...m lower bearing and inner race using a chisel 4 Remove the steering stem upper and lower bearing races using the special tools Special tool A 09941 54911 Bearing outer race remover B 09941 74911 Steer...

Page 578: ...tion a First loosen the front fork upper clamp bolts and steering stem head nut and then adjust the steering stem nut by loosening or tightening it b Tighten the steering stem nut stem head nut and fr...

Page 579: ...ase SUZUKI SUPER GREASE A or equivalent P No 99000 25010 Page 6B 3 Page 6B 6 Handle grip bond Handle Grip Bond commercially available Page 6B 3 Thread lock cement THREAD LOCK CEMENT SUPER 1303 or equi...

Page 580: ...6B 11 Steering Handlebar...

Page 581: ...tions 9B 10 Service Data 9B 10 Special Tools and Equipment 9B 10 Special Tool 9B 10 Combination Meter Fuel Meter Horn 9C 1 General Description 9C 1 Combination Meter System Description 9C 1 Repair Ins...

Page 582: ...ction 9E 1 Steering Lock Bracket Construction 9E 2 Front Footrest Bracket Construction 9E 2 Side stand Construction 9E 3 Side stand Removal and Installation 9E 3 Specifications 9E 4 Tightening Torque...

Page 583: ...ctrical System B822H19000001 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 584: ...NAL 5 FUEL 6 FAN 10 A 10 A 15 A 10 A 10 A 15 A PUSH PASSING LIGHT SWITCH HI LO DIMMER SWITCH OFF ON HAZARD SWITCH PUSH HORN BUTTON L PUSH R TURN SIGNAL LIGHT SWITCH CLUTCH LEVER POSITION SWITCH FREE H...

Page 585: ...SOR TP SENSOR Y B W B W B Br W R B Y Bl B W Bl W Bl B Bl G W Lg W Bl B G Gr W Gr B R Y G R Y G Y B Bl Y Lbl Dbr B W Y R Gr G Bl B Br P B O Y Y W B Lg G O G R Bl W Bl G W W G R B Bl G B P B B G Y B R R...

Page 586: ...RUN OFF ON PUSH HANDLEBAR SWITCH R SPEEDOMETER OPTION ENGINE STOP SWITCH STARTER BUTTON FRONT BRAKE SWITCH ON OFF LOCK P IGNITION SWITCH SPEEDO METER SENSOR SIDE STAND SWITCH SIDE STAND DIODE FREE PU...

Page 587: ...G Y B R R B P W W B Dg Bl P B Br Bl W Bl B Bl G Bl Y R O G W R Gr B W Gr P B Y W Y B O W Y R R Bl R B B Br P B Lbl R Bl W Dbr R Bl Lg G W G Bl Bl G B B B B B B B R B W B Y Y G R R B W B W R B W Bl P...

Page 588: ...LEBAR SWITCH R SPEEDOMETER OPTION ENGINE STOP SWITCH STARTER BUTTON FRONT BRAKE SWITCH ON OFF LOCK P IGNITION SWITCH SPEEDO METER SENSOR EVAP SYSTEM PURGE CONTROL SOLENOID VALVE SIDE STAND SWITCH SIDE...

Page 589: ...P B B G Y B R R B P W W B Dg Bl R B Br Bl W Bl B Bl G Bl Y R O G W R Gr B W Y B O W Y R R Bl R B B Br P B Lbl R Bl W Dbr R Bl Lg G W G Bl Bl G B B B B B B B R B W B Y Y G R R B W B W R B W Bl R B R G...

Page 590: ...2 Clamp Bind the wiring harness with the clamp 7 Horn 3 Clamp Bind the brake light taillight lead wire with the clamp 8 Side stand switch 4 Clamp Bind the side stand switch lead wire and speed sensor...

Page 591: ...le with the clamp 7 Brake light taillight lead wire 3 Clamp Bind the handlebar switch L lead wire and clutch cable with the clamp A Pass the wiring harness outside of the brake hose 4 Clamp Bind the w...

Page 592: ...9 Wiring Systems Specifications Service Data B822H19107001 Electrical Unit mm in Item Specification Note Fuse size Headlight HI 10 A LO 10 A Fuel 10 A Ignition 15 A Signal 10 A Fan motor 15 A Main 30...

Page 593: ...9B 1 Body and Accessories Lighting Systems Repair Instructions Headlight Components B822H19206001 4 3 2 1 FWD FWD I822H1920034 01 1 Headlight cover 3 Headlight bulb 12 V 60 55 W H4 2 Headlight unit 4...

Page 594: ...5 Installation Install the headlight in the reverse order of removal Pay attention to the following point After installing be sure to inspect the headlight beam Refer to Headlight Beam Adjustment Page...

Page 595: ...right frame cover All models and EVAP canister For E 33 Refer to Exterior Parts Removal and Installation in Section 9D Page 9D 3 All models and Evaporative Emission Control System Diagram Only for E...

Page 596: ...ar fender Refer to Exterior Parts Removal and Installation in Section 9D Page 9D 3 2 Disconnect the rear combination light coupler 1 and remove the rear combination light 2 Installation Install the re...

Page 597: ...on 9D Page 9D 3 2 Remove the rear fender Refer to Exterior Parts Removal and Installation in Section 9D Page 9D 3 3 Remove the rear turn signal light cover 1 from the rear fender 4 Remove the license...

Page 598: ...ulb Replacement B822H19206011 1 Remove the lens 1 2 Replace the bulb 2 3 Reinstall the lens 1 Turn Signal Light Components B822H19206012 1 I822H1920014 01 2 I822H1920015 01 1 2 1 2 I822H1920038 01 1 T...

Page 599: ...ion Install the front turn signal light in the reverse order of removal Rear Turn Signal Light Removal and Installation B822H19206014 Removal 1 Remove the rear fender Refer to Exterior Parts Removal a...

Page 600: ...onnection 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 Refer to Turn Signal Side s...

Page 601: ...and Installation in Section 6B Page 6B 2 Special tool 09900 25008 Multi circuit tester set Tester knob indication Continuity 4 After finishing the turn signal switch inspection reinstall the removed...

Page 602: ...Section 6B Page 6B 2 Special tool 09900 25008 Multi circuit tester set Tester knob indication Continuity 4 After finishing the dimmer switch inspection reinstall the removed parts Specifications Servi...

Page 603: ...ED is used for the illumination light and each indicator light LED is maintenance free LED is less power consuming and more resistant to vibration resistance compared to the bulb 4 3 2 6 10 13 11 12 8...

Page 604: ...e reverse order of removal NOTE Fix the boot of the combination meter coupler properly Combination Meter Disassembly and Assembly B822H19306003 Refer to Combination Meter Removal and Installation Page...

Page 605: ...mbination meter unit with a new one after checking its wire harness coupler NOTE The pointer may not return to the proper position even turning the ignition switch on under low temperature condition I...

Page 606: ...bination Meter Removal and Installation Page 9C 2 6 Connect the ECT sensor coupler Engine Coolant Temperature Removal and Installation B822H19306006 Refer to ECT Sensor Removal and Installation in Sec...

Page 607: ...ermistor from the fuel pump Refer to Fuel Pump Disassembly and Assembly in Section 1G Page 1G 11 3 Connect 12 V battery and test bulb 12 V 3 4 W to the fuel level indicator switch as shown in the figu...

Page 608: ...edometer odometer or tripmeter does not function properly inspect the speed sensor and the coupler connections If the speed sensor and coupler connections are OK replace the combination meter unit wit...

Page 609: ...he following procedures 1 Remove the speed sensor Refer to Speed Sensor Removal and Installation Page 9C 6 2 Connect a 12 V battery between B and B W 10 k resistor between B R and B and multi circuit...

Page 610: ...d Installation B822H19306014 Refer to Oil Pressure Switch Removal and Installation in Section 1E Page 1E 7 Ignition Switch Inspection B822H19306015 Inspect the ignition switch in the following procedu...

Page 611: ...Page 6B 2 Special tool 09900 25008 Multi circuit tester set Tester knob indication Continuity Horn Inspection 1 Disconnect the horn couplers 1 2 Connect a 12 V battery to terminal A and terminal B If...

Page 612: ...em Specification Brake light Taillight LED Speedometer light LED Turn signal indicator light LED High beam indicator light LED Neutral position indicator light LED Fuel level indicator light LED Coola...

Page 613: ...s Exterior Parts Repair Instructions Exterior Parts Construction B822H19406001 9 FWD FWD 1 2 1 I822H1940015 01 1 Frame head cover 2 Frame head cover plate FWD FWD 1 1 2 3 I822H1940016 01 1 Frame side...

Page 614: ...hat the pawls A closes 2 Insert the fastener into the installation hole NOTE To prevent the pawl A from damage insert the fastener all the way into the installation hole 3 Push in the head of center p...

Page 615: ...e the band 2 3 Remove the front seat 3 Installation 1 Slide the front seat hooks into the seat hook retainer 2 Install the rear seat band and tighten the bolts 3 Slide the rear seat hooks into the sea...

Page 616: ...r frame mounting bolts left and right 5 Remove the rear fender Installation Install the rear fender in the reverse order of removal Pay attention to the following point Apply thread lock to the rear f...

Page 617: ...the fastener 1 Refer to Fastener Removal and Installation Page 9D 2 3 Remove the frame head covers 2 left and right Installation Install the frame head covers in the reverse order of removal Secondar...

Page 618: ...Tightening Torque List in Section 0C Page 0C 8 Special Tools and Equipment Recommended Service Material B822H19408001 Fastening part Tightening torque Note N m kgf m lb ft Rear frame mounting bolt 85...

Page 619: ...tructions Body Frame Construction B822H19506001 FWD FWD 1 3 b 3 b a 4 2 a 4 5 I822H1950004 01 1 Frame 5 Engine bracket 2 Frame down tube 50 N m 5 0 kgf m 36 0 lb ft 3 Rear frame 85 N m 8 5 kgf m 61 5...

Page 620: ...ootrest Bracket Construction B822H19506004 1 2 a 3 I822H1950003 01 1 Frame 2 Steering lock bracket 3 Steering lock bracket bolt 26 N m 2 6 kgf m 19 0 lb ft 1 2 a 3 I822H1950001 02 1 Footrest 3 Bolt Ap...

Page 621: ...ide stand as shown in the side stand construction Refer to Side stand Construction Page 9E 3 Installation Install the side stand as shown in the side stand construction Refer to Side stand Constructio...

Page 622: ...racket Construction Page 9E 2 Side stand Construction Page 9E 3 Reference For the tightening torque of fastener not specified in this section refer to Tightening Torque List in Section 0C Page 0C 8 Sp...

Page 623: ...Prepared by January 2008 Part No 99500 39360 01E Printed in Japan 624...

Page 624: ...VLR1800 Printed in Japan K8 No 1377 VLR1800 S M 99500 39360 01E For PS printing 2008 1 24 Back 23 mm 1 0 DIC502 TOP BOTTOM K8 9 9 5 0 0 3 9 3 6 0 0 1 E VLR1800...

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