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CHASSIS 9-61

• Apply SUZUKI SUPER GREASE “A” to the bolt and brake

lever end.

99000-25010: SUZUKI SUPER GREASE “A”

or equivalent

• Tighten the pivot bolt and nut.

• When installing the brake light switch, align the projection on

the switch with the hole in the master cylinder.

MASTER CYLINDER INSTALLATION

Install the master cylinder in the reverse order of removal. Pay
attention to the following points:

• When remounting the master cylinder onto the handlebars,

align the master cylinder holder’s mating surface with the
punch mark

on the handlebars and tighten the upper clamp

bolt first.

Master cylinder mount bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft)

• Tighten the brake hose union bolt to the specified torque.
• Brake hose routing. (

11-39)

Brake hose union bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft)

Upper
clamp
bolt

Master cylinder

Handlebars

Clearance

Punched
mark

* The seal washers should be replaced with the new

ones to prevent brake fluid leakage.

* Bleed air from the system after reassembling the

master cylinder. (

2-26)

Содержание Intruder VZR1800

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

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

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

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

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

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

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

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

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

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

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

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

Страница 13: ...mperature in your area does not go down to freezing point Suzuki recommends the use of SUZUKI COOLANT anti freeze engine coolant If this is not available use an equivalent which is compatible with an...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 47: ...2 30 PERIODIC MAINTENANCE...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 68: ...sket Remove the cylinder nuts Remove the cylinder 5 NOTE Firmly grip the cylinder at both ends and lift it straight up If the cylinder does not come off lightly tap on the finless portions of the cyli...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 124: ...rod cap make sure that I D code B on each conrod faces intake side Code O D specification 1 54 992 55 000 mm 2 1650 2 1654 in 2 54 984 54 992 mm 2 1647 2 1650 in 3 54 976 54 984 mm 2 1644 2 1647 in Co...

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

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

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

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

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

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

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

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

Страница 133: ...her foreign materials Spread on surfaces thinly to form an even layer and assemble the crankcases within few minutes Take extreme care not to apply any BOND to the oil hole oil groove and bearing Appl...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 197: ...coupler be sure to hold the coupler body and do not pull the lead wires Inspect each terminal on the connector coupler for looseness or bending Inspect each terminal for corrosion and contamination Th...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 221: ...or stopped when a malfunction was detected by checking the show data when trouble This show data when trouble function can record the maximum of two Diagnostic Trouble Codes in the ECM Also ECM has a...

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

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

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

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

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

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

Страница 228: ...atmospheric pressure varies depending on weather conditions as well as altitude Take that into consideration when inspecting voltage Clogged vacuum passage between throttle body and IAP sensor Air bei...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 254: ...Set up the SDS tool Refer to the SDS operation manual for further details 2 Turn the ignition switch ON 3 Click Secondary throttle operating control 1 4 Click each button 2 At this time if an operatio...

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

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

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

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

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

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

Страница 261: ...ittent trou ble or faulty ECM Recheck each terminal and wire harness for open circuit and poor connection Replace the ECM with a known good one and inspect it again NO Pink or B W wire open or Pink wi...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 287: ...manual for further details 2 Turn the ignition switch ON 3 Click PAIR Sol operating control 1 4 Click each button 2 At this time if an operation sound is heard from the PAIR control solenoid valve the...

Страница 288: ...ION POSSIBLE CAUSE Cooling fan relay signal is not input to ECM Cooling fan relay circuit open or short ECM malfunction ECM Side stand relay Ignition switch FAR O R O B Cooling fan motor Cooling fan r...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 318: ...yet correct remove each air screw and clean them with a spray type carburetor cleaner and blow dry with a compressed air Also clean the air screw passageways NOTE Slowly turn the air screw in clockwis...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 359: ...HEEL BEARINGS Inspect the play of the wheel bearings by finger while they are in the wheel Rotate the inner race by finger to inspect for abnormal noise and smooth rotation Replace the bearing in the...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 422: ...he tire with a chalk to indicate the tire position relative to the valve position Even though the tire is refitted to the original position after repairing puncture the tire may have to be balanced ag...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 443: ...ve the starter relay Apply 12 V to A and B terminals and check for continuity between the positive and negative terminals using the multi circuit tester If the starter relay clicks and continuity is f...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 488: ...0 mm 1 mm 09900 20605 Dial calipers 1 100 mm 10 34 mm 09900 20607 Dial gauge 1 100 mm 10 mm 09900 20701 Magnetic stand 09900 20803 09900 20806 Thickness gauge 09900 20805 Tire depth gauge 09900 21304...

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

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

Страница 491: ...el pressure gauge hose attachment 09940 51410 Bearing installer 09940 52841 Front fork inner rod holder 09940 52861 Front fork oil seal installer 09940 92720 Spring scale 09940 94922 Front fork spring...

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

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

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

Страница 495: ...or 4 marked bolt 7 marked bolt N m kgf m lb ft N m kgf m lb ft 4 1 5 0 15 1 0 2 3 0 23 1 5 5 3 0 3 2 0 4 5 0 45 3 0 6 5 5 0 55 4 0 10 1 0 7 0 8 13 1 3 9 5 23 2 3 16 5 10 29 2 9 21 0 50 5 0 36 0 12 45...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 528: ...s in use or 2 The use of the vehicle after such device or element of design has been removed or rendered inoperative by any person AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED...

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

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

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

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

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

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

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

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

Страница 537: ...Printed in Japan K6...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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