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Suzuki RM-Z250, Руководство по обслуживанию


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FI SYSTEM DIAGNOSIS     12-53

4) Insert the needle-point probes to the lead wire coupler.
5) Connect a 12 volt battery to the service coupler using the bat-

tery lead wire. (

12-19)

6) 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: 0.89 V and more

(

+

 Pink – 

-

 B/W)

09900-25008: Multi circuit tester set
09900-25009: Needle-point probe set
36890-28H00: Battery lead wire (option)

Tester knob indication: Voltage (

)

Is the voltage OK?

YES

• Pink wire open or 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 poor connection.

• Replace the ECM with a known good one, and 

inspect it again.

NO

• Pink or B/W wire open, or Pink wire shorted to 

ground.

• Loose or poor contacts on the ECM coupler 

(terminal 

4

 or 

8

).

• If wire and connection are OK, replace the GP 

switch with a new one.

1

V

ECM coupler (Harness side)

1

Содержание RM-Z250

Страница 1: ......

Страница 2: ...er sec tions as a guide for proper inspection and service This manual will help you know the motorcycle bet ter so that you can assure your customers of fast and reliable service This manual has been...

Страница 3: ...E DONE Under the name of each system or unit is its exploded view Work instructions and other service information such as the tightening torque lubricating points and locking agent points are provided...

Страница 4: ...Y PASTE in a ratio of 1 1 Use REAR SUSPENSION OIL SS 25 or equivalent Apply SUZUKI SUPER GREASE A or equivalent 99000 25010 Use engine coolant or equivalent Apply SUZUKI SILICONE GREASE or equivalent...

Страница 5: ...ax Maximum Min Minimum R RH Right Hand S SAE Society of Automotive Engineers SDS Suzuki Diagnosis System T TO Sensor Tip Over Sensor TOS TP Sensor Throttle Position Sensor TPS WIRE COLOR B Black Lg Li...

Страница 6: ...ostic Code Malfunction Code E Electronic Ignition El Engine Control Module ECM Engine Control Module ECM Fl Control Unit Engine Control Unit ECU Engine Coolant Level ECL Coolant Level Engine Coolant T...

Страница 7: ...tion Diagnostic P Programmable Read Only Memory PROM R Random Access Memory RAM Read Only Memory ROM ROM T Throttle Body TB Throttle Body TB Throttle Body Fuel Injection TBI Throttle Body Fuel Injecti...

Страница 8: ...RONT FORK OIL 1 5 REAR SUSPENSION OIL 1 5 ENGINE COOLANT 1 6 BREAK IN RUNNING IN 1 6 WHEN THE MOTORCYCLE IS NEW 1 6 WHEN ENGINE PARTS ARE REPLACED 1 6 INFORMATION LABELS 1 7 SPECIFICATIONS 1 8 DIMENSI...

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 rear si...

Страница 12: ...re longer service life of your motorcy cle Use of SG SH SJ SL in API with JASO MA MA1 MA2 The recommended viscosity is SAE 10W 40 If an SAE 10W 40 motor oil is not available select an alternative acco...

Страница 13: ...60 minutes using less than 1 2 throttle opening 3 Ride for 60 minutes using less than 3 4 throttle opening NOTE The break in running in period is the period of greatest wear The bolts and nuts of the...

Страница 14: ...hed No LABEL or PLATE NAME APPLIED SPECIFICATION E 03 E 19 E 28 1 General warning label E A 2 General warning label E A A 3 General warning label F A A 4 EC approval mark label A 5 ICES Canada label E...

Страница 15: ...0 mm 3 03 in Stroke 53 6 mm 2 11 in Displacement 249 cm3 15 2 cu in Compression ratio 13 5 1 Fuel system Fuel injection Air cleaner Polyurethane foam element Starter system Primary kick Lubrication sy...

Страница 16: ...rake Front tire size 80 100 21 51M tube type Rear tire size 100 90 19 57M tube type ELECTRICAL Ignition type Electronic Ignition CDI Ignition timing 8 B T D C at 2 100 r min Spark plug NGK CR8EIA 10 C...

Страница 17: ...NGINE OIL CHANGE 2 13 ENGINE OIL FILTER CHANGE 2 14 OIL STRAINERS 2 15 OIL STRAINER No 1 REMOVAL 2 15 OIL STRAINER No 2 REMOVAL 2 15 INSPECTION 2 16 OIL STRAINER No 2 INSTALLATION 2 17 OIL STRAINER No...

Страница 18: ...N GUIDE BUFFER AND TENSIONER ROLLER 2 33 DRIVE CHAIN GUIDE INSPECTION 2 33 DRIVE CHAIN BUFFER AND ROLLER INSPECTION 2 33 BRAKES 2 34 BRAKE FLUID LEVEL 2 34 BRAKE PAD 2 35 FRONT BRAKE LEVER ADJUSTMENT...

Страница 19: ...operation Throttle Play Smooth operation Crankcase breather hose Breather hose clogging and bend Engine idle speed Revolution speed Brake fluid Fluid level Brakes Brake lever position Brake pedal hei...

Страница 20: ...tch disc plates wear and distortion Brake pads Wear Sprockets Wear Fuel tank Leakage Fuel hose Damage Hoses are connected Exhaust pipe and muffler Damage Cylinder head Combustion chamber carbon deposi...

Страница 21: ...initial break in Cooling system I Replace radiator hose and engine coolant every year Flushing for overhaul or storage Clutch I Replace clutch plates as necessary Throttle cable and clutch cable I L...

Страница 22: ...Every 12 hours Front fork oil R Change after 1st initial break in Front fork I Check front fork inner tube frequently for abnormality Check the air pressure Rear suspension I Check rear suspension sys...

Страница 23: ...the spark plug condition electrode color carbon deposits spark plug gap and insulator damage If it is extremely worn or burnt replace the spark plug Also replace the spark plug if it has a broken ins...

Страница 24: ...h fingers 09930 10121 Spark plug wrench set Spark plug 11 N m 1 1 kgf m 8 0 lbf ft Install the ignition coil plug cap securely Connect the lead wire coupler 4 NOTE The coupler 4 of ignition coil plug...

Страница 25: ...e cleaning solvent A Immerse the element in the solvent and wash it A MOTUL AIR FILTER CLEAN or equivalent cleaning solvent Squeeze the element by grasping it to remove excess sol vent Do not twist or...

Страница 26: ...ner body NOTE Follow the instructions below to prevent water from entering the engine through the air cleaner element when cleaning the motorcycle Cover the element with a plastic bag Install the seat...

Страница 27: ...comes out from oil level check hole Tighten the oil check bolt 1 Engine oil check bolt 11 N m 1 1 kgf m 8 0 lbf ft Improper engine oil treatment is hazardous Read engine oil container instruction bef...

Страница 28: ...be inspected may be affected Stop and leave the engine standstill for two minutes Thereaf ter if oil flows out when the engine oil check bolt 1 is removed the oil level is appropriate If oil is exces...

Страница 29: ...Swing the motorcycle to the right and left two times and more Drain engine oil thoroughly Replace the gasket washers with new ones and tighten the drain plugs Engine oil drain plug 21 N m 2 1 kgf m 1...

Страница 30: ...ilter 5 Apply engine oil lightly to the new O ring 6 Install the oil filter cap and tighten the bolts Oil filter cap bolt 11 N m 1 1 kgf m 8 0 lbf ft Add new engine oil and check the oil level as desc...

Страница 31: ...rainer No 1 every engine oil change OIL STRAINER No 2 REMOVAL Drain engine oil 2 13 Remove the gearshift lever 9 3 Remove the magneto cover 15 17 Remove the oil pump No 2 cover 2 by removing its bolts...

Страница 32: ...NSPECTION Check each oil strainer for any damage or clogging If the oil strainer is clogging clean the oil strainer with a com pressed air A OIl strainer No 1 B OIl strainer No 2 Clean the oil nozzle...

Страница 33: ...s 4 to the specified torque Oil pump No 2 bolt 11 N m 1 1 kgf m 8 0 lbf ft Install the magneto cover 15 19 Install the gearshift lever 9 7 INSPECTION AFTER INSTALLATION Engine oil level and oil leakag...

Страница 34: ...l dilute engine coolant and it may decrease cooling performance If the motorcycle is to be exposed to temperatures below 31 C 24 F the percentage of antifreeze should be increased to 55 or 60 accordin...

Страница 35: ...ways COOLING SYSTEM INSPECTION Inspect the following items before practice and races Engine coolant leakage Radiator hose cracks and deterioration Radiator mounting condition Radiator over flow hose c...

Страница 36: ...12 in when squeezing the lever until pressure is felt Tighten the lock nut 1 to the specified torque Clutch lever clearance A 2 3 mm 0 08 0 12 in Cable adjuster lock nut 2 2 N m 0 22 kgf m 1 60 lbf f...

Страница 37: ...0 08 0 16 in Cable adjuster lock nut 2 2 N m 0 22 kgf m 1 60 lbf ft Inadequate throttle cable play can cause engine speed to rise suddenly when you turn the handle bars This can lead to loss of rider...

Страница 38: ...C MAINTENANCE THROTTLE CABLE OIL SUPPLY Remove the throttle case 2 by removing its screws 1 Apply oil to the throttle cable Apply grease to the throttle cable spool 99000 25010 SUZUKI SUPER GREASE A o...

Страница 39: ...er obtains 2 3 mm 0 08 0 12 in when squeezing the lever until pressure is felt Tighten the lock nut 1 Hot starter lever clearance A 2 3 mm 0 08 0 12 in Cable adjuster lock nut 2 2 N m 0 22 kgf m 1 60...

Страница 40: ...edle pointed probe set 09900 26006 Engine tachometer Start the engine turn the starter knob idle screw 1 and set the engine idle speed as follows Engine idle speed 2 100 50 r min CRANKCASE BREATHER HO...

Страница 41: ...ng NOTE The piston must be at top dead center TDC on the compres sion stroke in order to check or adjust the valve clearance The valve clearance should only be checked when the engine is cold Drain en...

Страница 42: ...ze with micrometer to ensure its size Refer to the tappet shim selection table 2 27 28 for details NOTE Be sure to apply engine oil to tappet shim top and bottom faces When seating the tappet shim be...

Страница 43: ...725 1 750 1 775 1 800 1 825 1 850 1 875 1 900 1 925 1 950 1 975 1 650 2 000 2 025 2 050 2 075 2 100 2 125 2 150 2 175 2 200 2 200 1 625 1 600 1 575 1 550 1 525 1 500 1 475 1 450 1 425 1 400 1 375 1 35...

Страница 44: ...5 1 600 1 575 1 550 1 525 1 500 1 475 1 450 1 425 1 675 1 700 1 725 1 750 1 775 1 800 1 825 1 850 1 875 1 900 1 925 1 950 1 975 1 650 2 000 2 025 2 050 2 075 2 100 2 125 2 150 2 175 2 200 2 200 1 625...

Страница 45: ...er head with a new one CYLINDER INSPECTION Remove the cylinder 6 7 Inspect the cylinder wall for any scratches nicks or other damage If any defects are found replace the cylinder with a new one PISTON...

Страница 46: ...off the ground Inspect the drive chain slack at the middle point between the drive chain buffer and rear sprocket Drive chain slack A 35 45 mm 1 4 1 8 in CRANKCASE DRIVESHAFT OIL SEAL Remove the engin...

Страница 47: ...t adjuster washers 4 are at the same position on scales 5 With the adjusters 3 held in position tighten the lock nuts 2 Push the adjuster washers 4 to the adjusters 3 and tighten the axle nut 1 Axle n...

Страница 48: ...Suzuki Chain Lube or equivalent to the link plates and rollers Reassemble the drive chain NOTE Reassemble the drive chain clip so the slit end faces opposite the direction of rotation Inspect the dri...

Страница 49: ...ace the defective parts with a new one DRIVE CHAIN BUFFER AND ROLLER INSPECTION Inspect the drive chain buffer 1 for wear and cracks Inspect the drive chain rollers 2 for wear If necessary replace the...

Страница 50: ...l if it comes in contact with your skin or eyes Keep brake fluid away from children Call your doc tor immediately if brake fluid is swallowed and induce vomiting Flush eyes or skin with water if brake...

Страница 51: ...n as follows Loosen the lock nut 1 Turn in or out adjuster 2 to obtain the proper brake lever position The standard adjuster length A is from 11 15 mm 0 4 0 6 in Tighten the lock nut 1 Adjuster length...

Страница 52: ...l the air bleeder valve 1 Front fork air bleeder valve 1 3 N m 0 13 kgf m 1 0 lbf ft REAR SUSPENSION Move the rear suspension up and down several times and inspect for smooth movement Inspect for dama...

Страница 53: ...bf ft Rear wheel rim lock 17 N m 1 7 kgf m 12 5 lbf ft TIRE PRESSURE Inspect front and rear tire pressure Tire pressure cold 70 110 kPa 0 7 1 1 kgf cm2 10 16 psi STEERING Inspect the steering by movin...

Страница 54: ...the cable ends where they pivot 2 Throttle grip throttle housing cable A Pre race Lightly grease the inside of throttle spool Keep free from dirt 3 Rear brake pedal C Pre race Grease the brake pedal...

Страница 55: ...wer 12 1 2 8 5 A Front brake caliper mounting bolt 26 2 6 19 0 B Front brake pad mounting pin 18 1 8 13 0 C Brake hose union bolt Front Rear 23 2 3 16 5 D Air bleeder valve Front Rear brake caliper 6...

Страница 56: ...2 40 PERIODIC MAINTENANCE...

Страница 57: ...NOTE Before testing the engine for compression pressure make sure that the cylinder head nuts are tightened to the specified torque values and the valves are properly adjusted Warm up the engine befor...

Страница 58: ...ct the engine tachometer to the needle pointed probe 09900 25009 Needle pointed probe set 09900 26006 Engine tachometer Remove the exhaust pipe cover 2 by removing its bolts 1 Remove the oil gallery p...

Страница 59: ...TROUBLESHOOTING TROUBLESHOOTING 3 1 3 CONTENTS ENGINE 3 2 RADIATOR COOLING SYSTEM 3 8 CHASSIS 3 9 BRAKES 3 10 ELECTRICAL 3 11...

Страница 60: ...g connections Defective magneto No fuel reaching the intake manifold Clogged fuel filter or fuel hose Defective fuel pump Defective fuel pressure regulator Defective fuel injector Defective ECM Defect...

Страница 61: ...fuel filter Defective fuel pump Defective fuel pressure regulator Defective ECT sensor Defective IAT sensor Fuel injector improperly operating Defective fuel injector Defective ECM Open or short circu...

Страница 62: ...e from clutch Worn splines of countershaft or clutch sleeve hub Worn teeth of clutch plates Distorted clutch plates driven and drive Worn clutch release bearing Noise seems to come from crankshaft Rat...

Страница 63: ...fuel hose resulting in inadequate fuel sup ply to injector Defective fuel pump Defective TP sensor Defective air flow system Clogged air cleaner element Defective throttle valve Sucking air from throt...

Страница 64: ...t or replace Replace Clean or replace Retighten or replace Drain out excess oil Replace Replace Replace Replace Replace Replace Replace Replace Replace Engine overheats Defective engine internal parts...

Страница 65: ...le play Replace Replace Replace Adjust Dragging clutch Some clutch spring weakened while others are not Distorted pressure plates or clutch plates Replace Replace Transmission will not shift Broken ge...

Страница 66: ...ine coolant Radiator core clogged with dirt or scale Clogged water passage Air trapped in the cooling circuit Defective water pump Use incorrect coolant Defective ECM Defective ECT sensor Add coolant...

Страница 67: ...place Adjust Front suspension too stiff Too viscous fork oil Too much fork oil Bent front fork Improperly set front fork damping force adjuster Replace Drain excess oil Replace Adjust Noisy front susp...

Страница 68: ...logged return port of master cylinder Repair surface with sandpaper Correct pad fitting or replace Replace Replace Tighten to specified torque Replace brake fluid Disassemble and clean master cylinder...

Страница 69: ...lace Spark plug elec trodes overheat or burn Too hot spark plug Overheated the engine Loose spark plug Too lean mixture Replace with cold type plug Tune up Retighten Inspect FI system Magneto does not...

Страница 70: ...FORCE ADJUSTMENT 4 4 OIL QUANTITY MINOR ADJUSTMENT 4 5 OIL CHANGE Only for outer tube oil chamber 4 6 SPRING CHANGE 4 8 FRONT FORK TUNING PROCEDURE 4 10 REAR SUSPENSION TUNING 4 11 COMPRESSION DAMPING...

Страница 71: ...d map either injection map for slightly leaner mixture or that for slightly richer mixture depending on the selected shunt wire NOTE The changeover is executed immediately after the engine has been st...

Страница 72: ...isconnect the mode select coupler 2 from the bracket 1 Disconnect the mode select coupler cap 3 Connect the short wire 4 to the mode select coupler 2 Reinstall the mode select coupler Start the engine...

Страница 73: ...o set the adjuster you must gently turn the adjuster screw clockwise until it stops then back it out the recommended num ber of turns Do not force the adjuster screw past the stopped position or you m...

Страница 74: ...fork oil from the air bleed hole Front fork tuning procedure 4 10 99000 99001 SS5 SUZUKI FORK OIL SS 05 or equivalent Front fork air bleeder valve 1 3 N m 0 13 kgf m 1 0 lbf ft The fork oil quantity...

Страница 75: ...e 18 6 09941 53630 Front fork top cap wrench Hold the front fork inverted position for more than 20 minutes to allow the fork oil to fully drain Force out the remaining oil using compressed air comple...

Страница 76: ...dentification Slit mark on the spring end STD Oil quantity Oil quantity adjustable range Soft 51171 28H10 4 5 N mm 0 45 kgf mm 45 I 120 II See Fig 1 below 375 ml 12 68 13 20 US Imp oz 312 411 ml 10 55...

Страница 77: ...nt fork inverted position for more than 20 minutes the allow the fork oil to fully drain 4 6 Force out the remaining oil using compressed air completely 4 6 Replace the spring The fork oil quantity mu...

Страница 78: ...cified torque Lock nut center bolt 22 N m 2 2 kgf m 16 0 lbf ft Tighten the center bolt to the specified torque Center bolt 69 N m 6 9 kgf m 50 0 lbf ft b 1 mm 0 04 in and more Pour the specified amou...

Страница 79: ...nd rebound damping force to a softer setting 2 Decrease fork oil capacity 3 Change the spring with an optional softer one Feels too soft overall and bottoms Jump Large bump When braking 1 Adjust the c...

Страница 80: ...im lock tightness 2 37 COMPRESSION DAMPING FORCE ADJUSTMENT NOTE To set the adjuster you must gently turn the adjust screw or bolt clockwise until it stops then back it out the recommended num ber of...

Страница 81: ...setting 14 clicks turn back SPRING PRE LOAD ADJUSTMENT Place a block under the chassis tube Remove the muffler and seat rail assembly 19 3 Loosen the lock nut 1 with the special tool 09910 60611 Unive...

Страница 82: ...le normally in full riding gear Find the sag by subtracting L2 from L1 Standard sag range is 100 mm 3 94 in Spring Part No Spring rate Marking paint Set length adjustable range Soft 62211 37FK0 53 N m...

Страница 83: ...the low speed compression damping force to a harder setting See note below 2 Adjust the rebound damping force to a harder setting See note below 3 Change the spring with an optional stiffer one 4 13...

Страница 84: ...to bottom where as it felt fine before the front fork adjustment was made BALANCE TEST Stand next to the motorcycle on level ground Place one foot on the foot rest closest to you Sharply push down Th...

Страница 85: ...ENGINE REMOVAL AND INSTALLATION 5 1 ENGINE REMOVAL AND INSTALLATION 5 CONTENTS ENGINE REMOVAL AND INSTALLATION 5 2 REMOVAL 5 2 INSTALLATION 5 6...

Страница 86: ...move the fuel tank bolt 4 and rubber band 5 Lift and hold the fuel tank Disconnect the fuel pump coupler 6 Place a rag under the fuel hose 7 and disconnect the fuel hose 7 from the fuel pump Remove th...

Страница 87: ...B by removing their nuts A Remove the exhaust pipe gasket C Remove the front protectors E by removing their bolts D Remove the radiator louvers F left and right Remove the radiator mounting bolts G le...

Страница 88: ...p N Disconnect the magneto lead wire coupler O Remove the clamps P Remove the clutch cable bracket bolt Q and disconnect the clutch cable R NOTE Loosen the clutch cable adjuster when disconnecting Rem...

Страница 89: ...n c Remove the snap ring d and engine sprocket e 09900 06107 Snap ring remover Open type Remove the engine mounting upper brackets g by removing their bolts and nut f Remove the engine mounting front...

Страница 90: ...Tighten the engine mounting bolts nuts and swingarm pivot shaft nut to the specified torque NOTE After the engine has been installed and run make sure to retighten the fasteners as they are subject to...

Страница 91: ...nd engine sprocket cover 4 Tighten the engine sprocket cover bolts 5 to the specified torque Engine sprocket cover bolt 11 N m 1 1 kgf m 8 0 lbf ft Install the gearshift lever 6 in the correct positio...

Страница 92: ...e pedal pivot bolt 29 N m 2 9 kgf m 21 0 lbf ft Install the clip A washer B and cotter pin C Install the kick starter lever D in the correct position 8 7 8 Tighten the kick starter lever bolt E to the...

Страница 93: ...cable I with the matching mark H on the clutch cable bracket Tighten the clutch cable bracket bolt J to the specified torque Clutch cable bracket bolt 6 N m 0 6 kgf m 4 5 lbf ft Install the muffler j...

Страница 94: ...ween exhausted pipe and radiator hose Be sure to tighten the bolts and nuts in the following order 1 Muffler mounting front bolt N and rear bolt O 2 Exhaust pipe nuts 3 Connector clamp bolt P Exhaust...

Страница 95: ...CAMSHAFT INSPECTION 6 9 CAM CHAIN TENSION ADJUSTER INSPECTION 6 11 CAM CHAIN No 1 GUIDE CAM CHAIN No 2 GUIDE AND CAM CHAIN TENSIONER INSPECTION 6 11 CYLINDER HEAD AND VALVE INSPECTION 6 12 INTAKE PIP...

Страница 96: ...head B Camshaft journal holder bolt A Initial 25 2 5 18 0 4 Cylinder head gasket C Spark plug A Final 51 5 1 37 0 5 C ring D Oil gallery plug BDE 10 1 0 7 0 6 Cylinder head cover E Cylinder head base...

Страница 97: ...TEM N m kgf m lbf ft 3 Tappet B Cam chain tensioner A 23 2 3 16 5 4 Valve spring C Cam chain tension adjuster BCD 10 1 0 7 0 5 Exhaust valve A Cam chain tension adjuster cap bolt 6 Intake valve B Cam...

Страница 98: ...k 13 2 3 Remove the ignition coil plug cap and spark plug 2 7 Remove the cylinder head cover 2 and gasket 3 by remov ing their bolts 1 Remove the cylinder head cover No 2 gasket 4 CAMSHAFTS AUTOMATIC...

Страница 99: ...fts are aligned with the mating surface of the cylinder head C Timing mark Disconnect the condenser coupler 3 and remove the con denser 4 Remove the cam chain tension adjuster cap bolt 5 gasket 6 bar...

Страница 100: ...uffler connector clamp bolt 1 Remove the exhaust pipe 3 by removing their nuts 2 Remove the exhaust pipe gasket 4 Disconnect the radiator hoses 6 by loosing their clamp screws 5 Disconnect the ECT sen...

Страница 101: ...does not come off easily lightly tap it using a plastic hammer Remove the cylinder head gasket G dowel pins H and cam chain No 1 guide I CYLINDER REMOVAL Remove the cylinder head 6 6 Remove the cylin...

Страница 102: ...y spread the ring opening with your thumbs and then push up the opposite side of the ring 4 to remove it Remove the oil ring in the same procedure CAM CHAIN CAM CHAIN TENSIONER AND CAM CHAIN No 1 GUID...

Страница 103: ...lace the camshaft assembly CAMSHAFT INSPECTION CAM SPROCKET Inspect the sprocket teeth for wear If they are worn replace the camshafts crankshaft and cam chain as a set CAMSHAFT BEARING Inspect the be...

Страница 104: ...e the plastigauge to read the clearance at the widest por tion which is specified as follows 09900 22301 Plastigauge 0 025 0 076 mm 09900 22302 Plastigauge 0 051 0 152 mm Tighten the camshaft journal...

Страница 105: ...Small bore gauge 18 35 mm Camshaft journal O D Standard IN EX 21 959 21 980 mm 0 8645 0 8654 in 09900 20205 Micrometer 0 25 mm CAM CHAIN TENSION ADJUSTER INSPECTION Remove the cam chain tension adjus...

Страница 106: ...09919 28620 Sleeve protector Exhaust side Install the sleeve protector b between the valve spring and cylinder head Using the special tools compress the valve spring and remove the two cotter halves...

Страница 107: ...reading at several places indicated If the largest reading at any position of the straightedge exceeds the limit replace the cylinder head Cylinder head distortion Service Limit 0 05 mm 0 002 in 0990...

Страница 108: ...h valve stem and valve face for wear and pitting If it is worn or damaged replace the valve with a new one VALVE STEM DEFLECTION Lift the valve about 10 mm 0 39 in from the valve seat Measure the valv...

Страница 109: ...emoved for replacement after inspecting related parts carry out the steps shown in valve guide servicing VALVE GUIDE SERVICING Drive the valve guide out toward the intake or exhaust cam shaft side wit...

Страница 110: ...6 33210 Valve guide reamer 4 5 mm 09916 34542 Reamer handle NOTE Be sure to cool down the cylinder head to ambient air temper ature Insert the reamer from the combustion chamber and always turn the re...

Страница 111: ...ed 2 25 INTAKE EXHAUST Seat angle 15 45 60 Seat width 0 9 1 1 mm 0 035 0 043 in Valve diameter 31 mm 1 22 in 25 mm 0 98 in Valve guide I D 4 500 4 512 mm 0 1772 0 1776 in 60 45 15 The valve seat conta...

Страница 112: ...replace the spring Valve spring free length Service limit IN 37 1 mm 1 46 in EX 37 5 mm 1 48 in 09900 20101 Vernier calipers 150 mm Valve spring tension Standard IN 142 157 N 14 5 16 0 kgf 33 55 mm 31...

Страница 113: ...otector For IN side 09916 14530 Valve lifter attachment For EX side 09919 28610 Sleeve protector For EX side 09916 84511 Tweezer Be sure that the rounded lip E of the cotter fits snugly into the groov...

Страница 114: ...emoving its bolts 2 INTAKE PIPE INSTALLATION Apply grease to O ring of the intake pipe 99000 25010 SUZUKI SUPER GREASE A or equivalent Install the intake pipe 1 and tighten the intake pipe bolts 2 to...

Страница 115: ...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 a...

Страница 116: ...the piston to cylinder clearance 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...

Страница 117: ...andard 1st 1 01 1 03 mm 0 0398 0 0406 in Oil 1 51 1 53 mm 0 0594 0 0602 in Piston ring thickness Standard 1st 0 97 0 99 mm 0 0382 0 0390 in PISTON RING FREE END GAP AND PISTON RING END GAP Measure the...

Страница 118: ...conrod Conrod small end I D Service Limit 16 040 mm 0 6315 in 09900 20602 Dial gauge 09900 22403 Small bore gauge 18 35 mm CONROD BIG END SIDE CLEARANCE Inspect the conrod side clearance by using a t...

Страница 119: ...bolt 10 N m 1 0 kgf m 7 0 lbf ft Install the cam chain 4 to the crankshaft sprocket Install the cam chain guide retainer 5 and tighten the cam chain guide retainer bolt 6 to the specified torque Cam c...

Страница 120: ...After placing the spacer fit the two side rails 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...

Страница 121: ...ly MOLYBDENUM OIL SOLUTION onto its surface MOLYBDENUM OIL SOLUTION Place a clean rag over the cylinder base to prevent the piston pin circlip 3 from dropping into crankcase Install the piston pin cir...

Страница 122: ...LUTION to the sliding surface of the piston and cylinder bore MOLYBDENUM OIL SOLUTION Hold each piston ring with the piston ring sections positioned correctly and put it into the cylinder Make sure th...

Страница 123: ...lts 5 to the specified torque Cylinder head bolt Initial 25 N m 2 5 kgf m 18 0 lbf ft Final 51 N m 5 1 kgf m 37 0 lbf ft After tightening the cylinder head bolts to specification tighten the cylinder...

Страница 124: ...rk A with the center of the groove B of the timing inspection hole Just before installing the camshaft into the cylinder head apply MOLYBDENUM OIL SOLUTION to the camshaft jour nals camshaft journal h...

Страница 125: ...e exhaust camshaft side going towards the intake camshaft side Engage the 13th roller pin on the cam chain with the timing marked E on the camshaft sprocket intake side Refer to the following illustra...

Страница 126: ...en the camshaft journal holder bolts in ascending order of numbers to the specified torque Camshaft journal holder bolt 10 N m 1 0 kgf m 7 0 lbf ft CAM CHAIN TENSION ADJUSTER Retract the push rod by p...

Страница 127: ...hafts 6 31 Inspect the valve clearance 2 25 Apply grease to the O rings 9 99000 25010 SUZUKI SUPER GREASE A or equivalent Tighten the TDC plug 0 and crankshaft hole plug A to the specified torque TDC...

Страница 128: ...oil to both sides of gaskets 5 Tighten the cylinder head cover bolts 6 to the specified torque Cylinder head cover bolt 14 N m 1 4 kgf m 10 0 lbf ft Install the spark plug and ignition coil plug cap...

Страница 129: ...7 2 CLUTCH 7 2 CLUTCH PLATE 7 3 REMOVAL 7 3 INSPECTION 7 5 INSTALLATION 7 6 PRIMARY DRIVEN GEAR AND CLUTCH SLEEVE HUB 7 8 REMOVAL 7 8 INSPECTION 7 9 INSTALLATION 7 9 CLUTCH RELEASE CAMSHAFT 7 11 REMOV...

Страница 130: ...EM N m kgf m lbf ft 3 Push piece B Needle bearing A 10 1 0 7 0 4 Clutch driven No 1 plate Silver C Primary driven gear B 90 9 0 65 0 5 Clutch driven No 1 plate Gray D Spacer 6 Spring washer E Washer 7...

Страница 131: ...s gasket 2 Remove the clutch spring set bolts 3 and clutch springs NOTE Loosen the clutch spring set bolts 3 little by little and diagonally Remove the clutch pressure plate 4 washer 5 bearing 6 and p...

Страница 132: ...ch drive plates 9 and driven plates 0 NOTE Mark the paint mark a to the clutch driven No 2 plate A Clutch driven No 2 plate B Clutch driven No 1 plate C Direction of outside Remove the spring washer A...

Страница 133: ...ve plate claw width Service Limit 13 05 mm 0 514 in 09900 20101 Vernier calipers DRIVEN PLATE Measure the driven plate distortion Driven plate distortion Service Limit 0 10 mm 0 004 in 09900 20803 Thi...

Страница 134: ...earing If any defects are found replace the clutch release bearing with a new one INSTALLATION Install the clutch plates in the reverse order of removal Pay attention to the following points Install t...

Страница 135: ...orque NOTE Tighten the clutch spring set bolts 9 diagonally Clutch spring set bolt 10 N m 1 0 kgf m 7 0 lbf ft Install the gasket 0 and clutch cover A Tighten the clutch cover bolts A B diagonally to...

Страница 136: ...s 7 3 4 Flatten the lock washer 1 Hold the clutch sleeve hub 3 with the special tool and loosen the clutch sleeve hub nut 2 09920 53740 Clutch sleeve hub holder 09920 31020 Extension handle Remove the...

Страница 137: ...ound replace the bearing or spacer with a new one INSTALLATION Install the primary driven gear and clutch sleeve hub in the reverse order of removal Pay attention to the following points Apply engine...

Страница 138: ...ock washer to secure the nut Reassemble the clutch plates and pressure plate 7 6 7 Install the gasket 8 and clutch cover 9 Tighten the clutch cover bolts A B diagonally to the speci fied torque Clutch...

Страница 139: ...tch release camshaft 4 out of crankcase INSPECTION CLUTCH RELEASE CAMSHAFT Inspect the clutch release camshaft for abnormal deflection and damage If any defects are found replace the release camshaft...

Страница 140: ...valent Apply grease to the oil seal lip 99000 25010 SUZUKI SUPER GREASE A or equivalent Install the clutch release camshaft 1 and connect the clutch cable 2 Install the push rod and pressure plate 7 7...

Страница 141: ...KICK STARTER KICK STARTER 8 1 8 CONTENTS CONSTRUCTION 8 2 KICK STARTER 8 2 KICK STARTER 8 3 REMOVAL 8 3 INSPECTION 8 4 INSTALLATION 8 5...

Страница 142: ...ring guide 0 Spring ITEM N m kgf m lbf ft 3 Spring A Wave washer AC 10 1 0 7 0 4 Kick starter guide B Kick starter idle gear B 29 2 9 21 0 5 Washer A Kick starter lever screw 6 Kick starter drive gear...

Страница 143: ...ake pedal 17 20 Disconnect the radiator hose 2 by loosing its clamp screw 1 Remove the kick starter lever 4 by removing its bolt 3 Remove the right crankcase cover 5 by removing its bolts Remove the d...

Страница 144: ...ar F 09900 06107 Snap ring remover Open type Remove the kick starter guide L by removing its bolt K INSPECTION Inspect the oil seal lip A for wear and damage If any defects are found replace the oil s...

Страница 145: ...on to the following points Install the kick starter guide 1 and tighten the kick starter guide bolt 2 to the specified torque Kick starter guide bolt 10 N m 1 0 kgf m 7 0 lbf ft Install the washer 3 o...

Страница 146: ...rter 0 align the wide spline teeth C and D Install the spring A to the kick starter shaft Apply MOLYBDENUM OIL SOLUTION to the stopper portion E of the kick starter and F of the stopper guide MOLYBDEN...

Страница 147: ...all the right crankcase cover F Tighten the right crankcase cover bolts a b c d to the specified torque Right crankcase cover bolt 11 N m 1 1kgf m 8 0 lbf ft a Length 30 mm 1 2 in b Length 60 mm 2 4 i...

Страница 148: ...que Kick starter lever bolt 29 N m 2 9 kgf m 21 0 lbf ft Install the brake pedal 17 20 Connect the radiator hose 20 24 INSPECTION AFTER INSTALLATION Engine oil level and oil leakage 2 12 Engine coolan...

Страница 149: ...ING GEARSHIFTING 9 1 9 CONTENTS CONSTRUCTION 9 2 GEARSHIFT LINKAGE 9 2 GEARSHIFT LINKAGE 9 3 REMOVAL 9 3 INSPECTION 9 5 INSTALLATION 9 5 GEAR POSITION GP SWITCH 9 8 REMOVAL 9 8 INSPECTION 9 8 INSTALLA...

Страница 150: ...tch A 23 2 3 16 5 4 Gearshift pawl lifter A Gearshift arm stopper B 8 5 0 85 6 0 5 Gearshift roller B Pawl lifter screw C 24 2 4 17 5 6 Gearshift cam driven gear C Gearshift cam driven gear pin D 10 1...

Страница 151: ...llation Remove the right crankcase cover and clutch component parts 7 9 8 3 Remove the gearshift shaft assembly 3 and washer 4 Remove the washer 4 snap ring 6 and return spring 7 from the gearshift sh...

Страница 152: ...nd gear shift roller D from the gearshift cam driven gear 0 Remove the gearshift cam driven gear pin E and gearshift cam stopper plate F Remove the gearshift cam stopper H spring I and washer J by rem...

Страница 153: ...LLATION Install the gearshift in the reverse order of removal Pay atten tion to the following points Install the washer 1 and gearshift arm stopper 2 Apply a small quantity of THREAD LOCK SUPER to the...

Страница 154: ...r pin 8 and tighten it to the specified torque 99000 32050 THREAD LOCK 1342 or equivalent Gearshift cam driven gear pin 24 N m 2 4 kgf m 17 5 lbf ft Fit the springs 9 pins 0 pawls A and gearshift roll...

Страница 155: ...e stopper D of gearshift arm between the return spring ends E 09900 06107 Snap ring remover Open type Install the gearshift shaft assembly J NOTE Pinch the gearshift arm stopper F with return spring e...

Страница 156: ...plate 4 Remove the clamps 5 Remove the GP switch 7 by removing its bolts 6 Remove the O ring 8 switch contacts 9 and springs 0 INSPECTION Refer to page 12 52 53 for details INSTALLATION Install the g...

Страница 157: ...que GP switch mounting bolt 6 5 N m 0 65 kgf m 4 7 lbf ft Install the front chain guide plate 6 and engine sprocket cover 7 Tighten the engine sprocket cover bolts 8 to specified torque Engine sprocke...

Страница 158: ...EED VALVE REMOVAL 10 6 TRANSMISSION INSPECTION 10 7 CONROD INSPECTION 10 8 CRANKSHAFT INSPCECTION 10 8 OIL REED VALVE INSPECTION 10 8 CRANKCASE REED VALVE INSPECTION 10 9 OIL SEAL INSPECTION 10 9 OIL...

Страница 159: ...riven gear A Gearshift fork No 3 ITEM N m kgf m lbf ft 3 4th driven gear B Gearshift cam A 8 5 0 85 6 0 4 3rd driven gear C Countershaft 5 Driveshaft D 5th drive gear 6 Sliding dog E 3rd 4th drive gea...

Страница 160: ...AND CRANKSHAFT 10 3 CRANKSHAFT 1 Right crankshaft 5 Primary drive gear 2 Conrod A Bearing retainer screw ITEM N m kgf m lbf ft 3 Crank pin B Primary drive gear nut A 8 5 0 85 6 0 4 Left crankshaft B...

Страница 161: ...ensioner 6 8 Remove the right crankcase cover 8 3 PRIMARY DRIVE GEAR REMOVAL Hold the crankshaft immovable with the special tool 09914 61010 Gear holder Remove the primary drive gear nut 1 and washer...

Страница 162: ...crankcase bolts 4 Separate the crankcase with the special tool 09920 13120 Crankshaft remover NOTE Set the crankcase separating tool to the clutch side of the crankcase Separate the crankcase graduall...

Страница 163: ...move the countershaft assembly 7 and driveshaft assem bly 8 CRANKSHAFT REMOVAL Remove the crankshaft with the special tool 09920 13120 Crankshaft remover CRANKCASE REED VALVE REMOVAL Remove the reed v...

Страница 164: ...ace the gearshift cam with a new one Inspect the gearshift forks and shaft for wear and damage If any defects are found replace the gearshift fork or shaft Measure the gearshift fork to groove clearan...

Страница 165: ...3 0 mm 0 12 in 09900 20607 Dial gauge 09900 20701 Dial gauge chuck 09900 21304 V blocks CRANKSHAFT INSPCECTION Measure the crankshaft runout with V blocks and dial gauge NOTE Place the crankshaft ont...

Страница 166: ...rankcase reed valve and reed valve guide with a new one OIL SEAL INSPECTION Inspect each oil seal lip A for wear and damage If any defects are found replace the oil seal with a new one OIL SEAL REMOVA...

Страница 167: ...22 Attachment Oil seal 3 17 Attachment Apply grease to each oil seal lip 99000 25010 SUZUKI SUPER GREASE A or equivalent NOTE Be sure to check the direction of the crankshaft bearing oil seal 5 befor...

Страница 168: ...2 Remove the bearings 3 4 5 6 7 8 with the special tool Bearing 3 7 37 Attachment Bearing 4 8 40 Attachment Bearing 5 42 Attachment Bearing 6 32 Attachment 09913 70210 Bearing installer set 10 75 Rem...

Страница 169: ...new bearings with the special tool 09913 70210 Bearing installer set Bearing 1 52 Attachment Bearing 2 8 40 Attachment Bearing 3 6 62 Attachment Bearing 4 32 Attachment Bearing 5 47 Attachment Bearin...

Страница 170: ...ecified torque Bearing retainer screw 8 5 N m 0 85 kgf m 6 0 lbf ft CRANKCASE REED VALVE INSTALLATION Install the crankcase reed valve 1 and reed valve guide 2 direction as shown Tighten the reed valv...

Страница 171: ...9000 25010 SUZUKI SUPER GREASE A or equivalent Install a new oil seal 4 with the special tool 09930 35010 Rotor remover NOTE Be sure to check the direction of the crankshaft bearing oil seal 4 before...

Страница 172: ...ISSION AND CRANKSHAFT 10 15 TRANSMISSION INSTALLATION NOTE Install the snap ring 1 in the groove and locate its end as shown in the illustration a Thrust b Sharp edge Replace the snap ring 1 with a ne...

Страница 173: ...n both ends of the driveshaft positively Install the washer C located in end of the countershaft 3 pos itively Install the gearshift forks 4 5 6 as shown 4 For 5th driven gear 5 For sliding dog 6 For...

Страница 174: ...bolts separate the crankcase and con firm that the transmission parts are assembled correctly Install the oil strainer No 1 and oil strainer cap 3 2 17 a Length 40 mm 1 6 in b Length 50 mm 2 0 in c Le...

Страница 175: ...the clutch component parts 7 9 10 Apply THREAD LOCK SUPER to the primary drive gear nut 3 99000 32110 THREAD LOCK SUPER 1322 or equivalent Hold the magneto rotor with the special tool and tighten the...

Страница 176: ...GE 11 3 OIL PRESSURE CHECK 11 3 OIL STRAINER REMOVAL 11 3 OIL STRAINERS INSPECTION 11 3 OIL STRAINER INSTALLATION 11 3 OIL REED VALVE REMOVAL 11 3 OIL REED VALVE INSPECTION 11 3 OIL REED VALVE INSTALL...

Страница 177: ...11 2 LUBRICATION SYSTEM ENGINE LUBRICATION SYSTEM ENGINE LUBRICATION SYSTEM CHART CAM CHAIN...

Страница 178: ...ION 2 16 OIL STRAINER INSTALLATION OIL STRAINER No 1 2 17 OIL STRAINER No 2 2 17 OIL REED VALVE REMOVAL 10 5 OIL REED VALVE INSPECTION Inspect the oil reed valve for wear and damage If any defects are...

Страница 179: ...ng 09913 70210 Bearing installer set 10 75 Oil seal 22 Attachment 09900 06108 Snap ring remover Close type Apply grease to the oil seal lip 99000 25010 SUZUKI SUPER GREASE A or equivalent OIL PUMP No...

Страница 180: ...oving its bolts 7 Remove the following parts from the oil pump No 1 Outer rotor 9 Inner rotor 0 Pin A Washer B Oil pump No 1 cover C Oil pump driven gear shaft D OIL PUMP No 2 Drain engine oil 2 13 Re...

Страница 181: ...r any defects or wear If necessary replace the defective parts with a new one OIL PUMP No 1 AND No 2 INSTALLATION OIL PUMP No 1 Install the oil pump No 1 in the reverse order of removal Pay attention...

Страница 182: ...00 32110 THREAD LOCK SUPER 1322 or equivalent Hold the crankshaft immovable with the special tool and tighten the primary drive gear nut B to the specified torque 09914 61010 Gear holder Primary drive...

Страница 183: ...bolts 6 to the specified torque Oil strainer No 2 bolt 5 5 N m 0 55 kgf m 4 0 lbf ft Install the oil pump No 2 cover 7 and tighten the oil pump No 2 bolts 8 to the specified torque Oil pump No 2 bolt...

Страница 184: ...CTION 12 19 SELF DIAGNOSTIC PROCEDURES 12 19 SELF DIAGNOSIS RESET PROCEDURE 12 20 USE OF SDS DIAGNOSTIC PROCEDURES 12 20 USE OF SDS DIAGNOSIS RESET PROCEDURE 12 21 SHOW DATA WHEN TROUBLE DISPLAING DAT...

Страница 185: ...SHAFT ROTATION SIGNAL SENSOR REMOVAL AND INSTALLATION 12 61 IAP SENSOR INSPECTION 12 61 IAP SENSOR REMOVAL AND INSTALLATION 12 61 TP SENSOR INSPECTION 12 61 TP SENSOR REMOVAL AND INSTALLATION 12 61 EC...

Страница 186: ...y and do not pull the lead wires Inspect each terminal on the connector coupler for looseness or bending Push in the coupler straightly An angled or skewed insertion may cause the terminal to be defor...

Страница 187: ...l to open Connect the probe as shown to avoid opening of female ter minal Never push in the probe where male terminal is supposed to fit Check the male connector for bend and female connector for exce...

Страница 188: ...00 Battery connection in reverse polarity is strictly prohibited Such a wrong connection will damage the components of the FI system instantly when reverse power is applied Removing the condenser coup...

Страница 189: ...result ELECTRICAL CIRCUIT INSPECTION PROCEDURE While there are various methods for electrical circuit inspection described here is a general method to check for open and short circuit using an ohmmete...

Страница 190: ...and removing 2 Check each terminal for bend and proper alignment Using continuity inspect or voltage check procedure as described below inspect the wire harness terminals for open circuit and poor co...

Страница 191: ...ues are as listed below a resistance abnormality exists which causes the voltage drop in the circuit between terminals A and B Voltage Between C and body ground Approx 5 V B and body ground Approx 5 V...

Страница 192: ...e ments using the highest range When measuring the resistance with the multi circuit tester 1 will be shown as 10 00 M and 1 flashes in the display Check that no voltage is applied before making the m...

Страница 193: ...d 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 194: ...me it monitors the voltage signal for compensation of the fuel injection time volume A longer injection time is needed to adjust injection volume in the case of low voltage ACCELERATION SIGNAL DECELER...

Страница 195: ...12 12 FI SYSTEM DIAGNOSIS FI SYSTEM PARTS LOCATION A ECM D Fuel pump B Ignition coil plug cap E ECT sensor C TO sensor F Fuel injector...

Страница 196: ...FI SYSTEM DIAGNOSIS 12 13 A ECM J CKP sensor G IAP Sensor K Crankshaft rotation signal sensor H IAT Sensor L GP switch I TP Sensor...

Страница 197: ...ke air temperature sensor IATS Engine coolant temperature sensor ECTS Engine stop switch Gear position switch Ignition coil plug cap Fuel injector FI indicator light option Fuel pump Regulator rectifi...

Страница 198: ...or signal TPS M 6 IAP sensor signal IAPS N Sensor ground E2 7 O IAT sensor signal IATS 8 Ground E1 P 9 CKP sensor signal CKPS Q 0 Serial data for self diagnosis R A Blank S Map select input MAP 2 B Ne...

Страница 199: ...g the battery lead wire 2 The DTC is displayed by flashing pattern of FI indicator light This means that the ECM has not received signals indicating a correct condition from the sensors or device con...

Страница 200: ...ator 14 TP sensor 12 31 15 ECT sensor 12 35 17 IAP sensor 12 39 21 IAT sensor 12 44 23 TO sensor 12 48 24 Ignition signal 12 51 Ignition coil plug cap 31 Gear position signal 12 52 GP switch 32 Fuel...

Страница 201: ...rovided with fail safe function to allow the engine to start and the motorcycle to run in a mini mum performance necessary even under malfunction condition The engine can start and can run even if the...

Страница 202: ...king the DTC Diagnostic Trouble Code Such discon nection will erase the DTC DTC can be checked by the FI indicator light assy Before checking DTC read SELF DIAGNOSIS FUNCTION 12 16 carefully to have g...

Страница 203: ...e coupler 12 19 36890 28H00 Battery lead wire option NOTE The DTC Diagnostic Trouble Code check does not require the battery to be connected during running of the engine but it needs the battery power...

Страница 204: ...red in 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...

Страница 205: ...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 206: ...to be determined Also in the case of a customer vehicle which is not periodically brought in for service with no past data value having been saved if the data value of a good vehicle condition have be...

Страница 207: ...GNOSIS Data at 3 000 r min under no load Data at the time of racing Approx 3 000 r min Check the manifold absolute pressure XX kPa Check the engine coolant temperature XX C Throttle Quick wide open Th...

Страница 208: ...egative pressure during idling 90 C Data of manifold absolute pressure operation at the time of starting Check the manifold absolute pressure XX kPa Check the engine coolant temperature Approx 90 C Ch...

Страница 209: ...a to the past data that have been saved under the same condition then you may determine how changes have occurred with the pass of time and identify what problem is currently occurring With DTC not ou...

Страница 210: ...nge 15 P0115 is indicated ECT sensor lead wire coupler connection P0115 H Sensor voltage is higher than specified value ECT sensor circuit open or ground circuit open L Sensor voltage is lower than sp...

Страница 211: ...om the battery P0351 31 Gear posi tion signal Gear position signal voltage should be higher than the following Gear position switch voltage 0 89 V If lower than the above value for 3 sec onds or more...

Страница 212: ...nce CKP sensor resistance 80 120 Green Red DETECTED CONDITION POSSIBLE CAUSE The signal does not reach ECM for 1 second or more after receiving the IAP sensor input signal Metal particles or foreign m...

Страница 213: ...olt adaptor 09900 25008 Multi circuit tester set Tester knob indication Voltage Is the voltage OK YES Go to step 2 NO Replace the CKP sensor with a new one YES G W or BI wire open or shorted to ground...

Страница 214: ...in the following range Difference between actual throttle open ing and opening calculated by ECM is larger than specified value 0 39 V Sensor voltage 4 51 V TP sensor maladjusted TP sensor circuit ope...

Страница 215: ...ep 1 When indicating P0120 H 1 Stop the engine 2 Check the TP sensor coupler 1 for loose or poor contacts If OK then check the TP sensor lead wire continuity 3 Disconnect the TP sensor coupler 4 Remov...

Страница 216: ...the continuity OK Step 1 When indicating P0120 L 1 Stop the engine 2 Check the TP sensor coupler 1 for loose or poor contacts If OK then check the TP sensor lead wire continuity 3 Disconnect the TP s...

Страница 217: ...ween Yellow and B Br by turning the throttle grip TP sensor output voltage Throttle valve is closed Approx 0 6 V Throttle valve is opened Approx 3 8 V 09900 25008 Multi circuit tester set 09900 25009...

Страница 218: ...wire to the service coupler 12 19 DETECTED CONDITION POSSIBLE CAUSE 15 Output voltage is not within the following range 0 2 V Sensor voltage 4 9 V ECT sensor circuit open or short ECT sensor malfunct...

Страница 219: ...1 for loose or poor contacts If OK then check the ECT sensor lead wire continuity 3 Remove the fuel tank 13 2 3 4 Disconnect the ECT sensor coupler and ECM coupler 5 Insert the needle pointed probes t...

Страница 220: ...uit condition is OK Tester knob indication Continuity test 7 Connect the ECT sensor coupler 1 and ECM coupler 8 Insert the needle pointed probe to the lead wire coupler 9 Connect a 12 volts battery by...

Страница 221: ...ECT sensor specification YES B Bl or B Br wire open or shorted to ground or poor L or N connection If wire and connection are OK intermittent trou ble or faulty ECM Recheck each terminal and wire har...

Страница 222: ...ns as well as altitude Take that into consideration when inspecting voltage Clogged vacuum passage between throttle body and IAP sensor Air being drawn from vacuum passage between throttle body and IA...

Страница 223: ...obe set 36890 28H00 Battery lead wire option Tester knob indication Voltage Is the voltage OK Step 1 When indicating P0105 H 1 Stop the engine 2 Check the IAP sensor coupler 1 for loose or poor contac...

Страница 224: ...ester knob indication Continuity test Is the continuity OK Step 1 When indicating P0105 L 1 Stop the engine 2 Check the IAP sensor coupler 1 for loose or poor contacts If OK then check the IAP sensor...

Страница 225: ...he IAP sensor out put voltage 2 Connect the ECM coupler and IAP sensor coupler 3 Insert the needle pointed probes to the lead wire coupler 4 Kickstart the engine at idle speed 5 Measure the IAP sensor...

Страница 226: ...uge 09900 25008 Multi circuit tester set Tester knob indication Voltage Is the voltage OK Output voltage VCC voltage 4 5 5 0 V ambient temp 25 C 77 F YES G B R Bl or B Br wire open or shorted to groun...

Страница 227: ...y by using the battery lead wire to the service coupler 12 19 DETECTED CONDITION POSSIBLE CAUSE 21 Output voltage is not within the following range 0 19 V Sensor voltage 4 93 V IAT sensor circuit open...

Страница 228: ...ts If OK then check the IAT sensor lead wire continuity 4 Remove the fuel tank 13 2 3 5 Disconnect the IAT sensor coupler and ECM coupler 12 60 6 Insert the needle pointed probes to the lead wire coup...

Страница 229: ...e tester the circuit condition is OK Tester knob indication Continuity test 7 Connect the IAT sensor coupler 8 Insert the needle pointed probe to the lead wire coupler 9 Connect a 12 volts battery by...

Страница 230: ...ce measurement method is the same way as that of the ECT sensor 12 62 2 YES Dg or B Br wire open or shorted to ground or poor O or N connection If wire and connection are OK intermittent trou ble or f...

Страница 231: ...should be the follow ing for 1 second and more 0 17 V Sensor voltage 4 73 V TO sensor circuit open or short TO sensor malfunction ECM malfunction P1651 H Sensor voltage is higher than specified value...

Страница 232: ...nsor coupler and ECM coupler 5 Check the continuity between R Bl wire A and Br W wire C If the sound is not heard from the tester the circuit condition is OK 6 Insert the needle pointed probes to the...

Страница 233: ...wire C and B Br wire B If the sound is not heard from the tester the circuit condition is OK 7 Insert the needle pointed probes to the lead wire coupler 8 Check the continuity between R Bl wire A and...

Страница 234: ...circuit tester set 09900 25009 Needle pointed probe set 36890 28H00 Battery lead wire option Tester knob indication Voltage Is the voltage OK 24 P0351 IGNITION SYSTEM CIRCUIT MALFUNCTION Refer to the...

Страница 235: ...K then measure the GP switch voltage DETECTED CONDITION POSSIBLE CAUSE No GP switch voltage Switch voltage is not within the following range Switch voltage 0 89 V GP switch circuit open or short GP sw...

Страница 236: ...t 09900 25009 Needle point probe set 36890 28H00 Battery lead wire option Tester knob indication Voltage Is the voltage OK YES Pink wire open or shorted to ground If wire and connection are OK intermi...

Страница 237: ...he injector coupler and measure the resistance between terminals Injector resistance 10 0 11 0 at 24 C 75 F Terminal Terminal DETECTED CONDITION POSSIBLE CAUSE CKP signal is produced but fuel injector...

Страница 238: ...age between B R wire and ground Injector voltage Battery voltage B R Ground 09900 25008 Multi circuit tester set 09900 25009 Needle point probe set 36890 28H00 Battery lead wire option Tester knob ind...

Страница 239: ...e 4 Remove the ECM bracket mounting bolts 2 5 Disconnect the ECM coupler 1 DETECTED CONDITION POSSIBLE CAUSE No voltage is applied to the fuel pump although FP relay is turned ON FP relay circuit open...

Страница 240: ...9900 25009 Needle point probe set 36890 28H00 Battery lead wire option Tester knob indication Voltage Is the voltage OK YES FP relay ECM malfunction B R or R B wire open or shorted or poor termi nal D...

Страница 241: ...sensor resistance 0 1 0 8 B R R W DETECTED CONDITION POSSIBLE CAUSE CKP sensor pick up coil signal is produces but sig nal from crankshaft rotation signal sensor is not input for 3 seconds or more Met...

Страница 242: ...or 09900 25008 Multi circuit tester set Tester knob indication Voltage Is the voltage OK YES Go to step 2 NO Replace the crankshaft rotation signal sensor with a new one YES B R or R W wire open or sh...

Страница 243: ...AL Remove the fuel tank 13 2 3 Remove the ECM bracket mounting bolts 1 Disconnect the ECM coupler 2 Remove the ECM assembly 3 Disconnect the rubber band 4 Remove the ECM 5 from ECM bracket 6 INSTALLAT...

Страница 244: ...stall the CKP sensor and crankshaft rotation signal sensor in the reverse order of removal IAP SENSOR INSPECTION The IAP sensor 1 is installed on the throttle body 12 39 IAP SENSOR REMOVAL AND INSTALL...

Страница 245: ...If the ECT sensor ohmic value does not change in the propor tion indicated replace it with a new one ECT sensor specification 09900 25008 Multi circuit tester set Tester knob indication Resistance ECT...

Страница 246: ...1 Disconnect the IAT sensor screw 2 Remove the IAT sensor 3 from the air cleaner outlet tube Install the IAT sensor in the reverse order of removal IAT sensor mounting screw 1 3 N m 0 13 kgf m 0 95 lb...

Страница 247: ...URE INSPECTION 13 4 FUEL PUMP INSPECTION 13 5 FUEL DISCHARGE AMOUNT INSPECTION 13 6 THROTTLE BODY 13 7 CONSTRUCTION 13 7 REMOVAL 13 8 DISASSEMBLY 13 9 CLEANING 13 12 INSPECTION 13 12 REASSEMBLY 13 12...

Страница 248: ...covers left and right 5 2 Remove the fuel tank bolt 1 and rubber band 2 FWD 1 Fuel tank filler cap 4 Fuel pump 2 Fuel tank 5 Fuel hose ITEM N m kgf m lbf ft 3 O ring A Fuel pump mounting bolt A 10 1 0...

Страница 249: ...FUEL TANK AND FUEL PUMP INSTALLATION Install the fuel pump and fuel tank in the reverse order of removal Pay attention to the following points Install a new O ring 1 and apply grease to it 99000 25010...

Страница 250: ...ber band 13 2 Lift and hold the fuel tank Place a rag under the fuel hose and remove the fuel hose 1 Disconnect the fuel pump coupler 2 Install the special tools between the fuel pump and fuel deliv e...

Страница 251: ...essure regulator Fuel pump If the fuel pressure is higher than the specification inspect the following items Fuel pump Pressure regulator FUEL PUMP INSPECTION Connect a proper lead wire into the fuel...

Страница 252: ...coupler fuel pump side and apply 12 volts to the fuel pump between ter minal A and terminal B for 10 seconds and measure the amount of fuel discharged Battery terminal terminal A Red wire Battery term...

Страница 253: ...sensor 7 Fuel delivery pipe 2 O ring 8 Fuel pipe ITEM N m kgf m lbf ft 3 Starter knob idle screw 9 IAP sensor ABC 3 5 0 35 2 5 4 Hot starter valve A Fuel pipe mounting screw 5 Fuel injector B Fuel del...

Страница 254: ...connect the TP sensor coupler 1 and condenser coupler 2 Remove the condenser 3 Disconnect the hot starter cable 4 from the throttle body Loosen the throttle body clamp screws 5 Move the air cleaner ba...

Страница 255: ...emove the TP sensor 6 by removing its bolt 5 with the special tool NOTE Prior to disassembly mark the sensor original position with a paint or scribe for accurate reinstallation 09930 11950 Torx wrenc...

Страница 256: ...removing its screw 7 Remove the fuel pipe 0 along with fuel injector A by remov ing their screws 9 Remove the fuel injector A from the fuel pipe 0 Remove the IAP sensor C by removing its screw B Remo...

Страница 257: ...Y 13 11 Never remove the throttle valve G These adjusting screws H I are factory adjusted at the time of delivery and therefore avoid removing or turning them unless otherwise necessary Never remove t...

Страница 258: ...10 N m 1 0 kgf m 7 0 lbf ft Some carburetor cleaning chemicals especially dip type soaking solutions are very corrosive and must be handled carefully Always follow the chemical manufacturer s instruct...

Страница 259: ...n the coupler A of the injector 7 with groove B of the fuel pipe 8 Install the fuel injector 7 by pushing it straight to the throttle body Tighten the fuel pipe mounting screws 9 to the specified torq...

Страница 260: ...tle shaft end C with the groove D of TP sensor Apply grease to the throttle shaft end C if necessary 99000 25010 SUZUKI SUPER GREASE A or equivalent 09930 11950 Torx wrench T25H TP sensor mounting scr...

Страница 261: ...uster fully and locate each outer cable so that the clearance a is 0 1 5 mm 0 0 06 in Tighten each lock nut 3 to the specified torque Cable adjuster lock nut 2 2 N m 0 22 kgf m 1 60 lbf ft a 0 1 5 mm...

Страница 262: ...amination If present clean and check for presence of dirt in the fuel lines and fuel tank NOTE The fuel injector can be checked without removing it from the throttle body 12 54 FUEL INJECTOR INSTALLAT...

Страница 263: ...TEM 14 CONTENTS CONSTRUCTION 14 2 ENGINE COOLANT 14 3 REPLACEMENT 14 3 COOLING CIRCUIT 14 4 INSPECTION 14 4 RADIATOR 14 5 INSPECTION 14 5 REMOVAL 14 6 INSTALLATION 14 6 WATER PUMP 14 7 REMOVAL 14 7 IN...

Страница 264: ...iator cover B Water pump case AC 6 0 6 4 5 4 Left radiator cover A Radiator air bleeder bolt B 10 1 0 7 0 5 Right radiator B Radiator cover upper bolt DE 11 1 1 8 0 6 Left radiator C Radiator cover bo...

Страница 265: ...the specified torque Radiator air bleeder bolt 6 N m 0 6 kgf m 4 5 lbf ft Add engine coolant up to the radiator inlet Tighten the radiator cap securely After warming up and cooling down the engine add...

Страница 266: ...part Engine coolant may be harmful if swallowed or if it comes in contact with the skin or eyes If engine coolant gets into the eyes or contacts the skin flush the eyes or wash the skin thoroughly wi...

Страница 267: ...he radiator cap tester Build up pressure slowly by operating the tester Make sure that the pressure build up stops at 95 125 kPa 0 95 1 25 kgf cm2 14 18 psi and that with the tester held standstill th...

Страница 268: ...the radiator in the reverse order of removal Connect the radiator hoses securely 20 24 Inspect the engine coolant level and leakage 2 18 19 Engine coolant may be harmful if swallowed or if it comes in...

Страница 269: ...SE COVER Remove the brake pedal 17 20 Remove the kick starter lever 8 3 Remove the right crankcase cover 2 dowel pins and gasket by removing crankcase bolts 1 Engine coolant may be harmful if swallowe...

Страница 270: ...ve the oil seal 5 NOTE If there is no abnormal condition the oil seal removal is not nec essary INSPECTION WATER PUMP IMPELLER AND WATER PUMP SHAFT Inspect the water pump impeller and water pump shaft...

Страница 271: ...of grease to the oil seal lips 99000 25010 SUZUKI SUPER GREASE A or equivalent WATER PUMP IMPELLER AND WATER PUMP SHAFT Apply engine oil to the water pump shaft 1 Hold the water pump shaft with a wre...

Страница 272: ...tall the spring 3 and gasket 4 Apply engine coolant to the gasket 4 Fit the water pump case 5 Tighten the water pump case bolts d e f and drain bolt 6 to the specified torque Water pump case bolt 11 N...

Страница 273: ...15 3 CONNECTING THE BATTERY 15 3 WIRING PROCEDURE 15 3 USING THE MULTI CIRCUIT TESTER 15 4 LOCATION OF ELECTRICAL COMPONENTS 15 5 CONSTRUCTION 15 7 MAGNETO 15 7 GENERATING SYSTEM 15 8 INSPECTION 15 8...

Страница 274: ...be deformed possibly resulting in poor electrical contact Inspect each terminal for corrosion and contamination Before refitting the sealed coupler make sure its seal rubber is positioned properly The...

Страница 275: ...cause damage to this part CONNECTING THE BATTERY WHEN USING THE BATTERY LEAD WIRE Optional part 36890 28H00 When disconnecting terminals from the battery for servicing be sure to disconnect the batte...

Страница 276: ...is applied If voltage is applied the tester will be damaged After using the tester be sure to turn the switch to the OFF 09900 25008 Multi circuit tester set NOTE When connecting the multi circuit tes...

Страница 277: ...ELECTRICAL SYSTEM 15 5 LOCATION OF ELECTRICAL COMPONENTS 1 IAT sensor 12 44 5 TO sensor 12 48 2 ECM 6 Ignition coil Plug cap 15 13 3 Fuel pump 13 5 7 Service coupler 12 19 4 ECT sensor 12 35...

Страница 278: ...p switch 15 16 D Crankshaft rotation signal sensor 12 58 9 Regulator Rectifier 15 10 E Magneto 15 9 0 Fuel injector 12 54 F GP switch 12 52 A IAP sensor 12 39 G TP sensor 12 31 B Mode select coupler 1...

Страница 279: ...ECTRICAL SYSTEM 15 7 CONSTRUCTION MAGNETO 1 CKP sensor A CKP sensor bolt 2 Stator coil B Magneto rotor nut ITEM N m kgf m lbf ft 3 Magneto rotor C Stator coil mounting bolt AC 5 5 0 55 4 0 B 80 8 0 58...

Страница 280: ...ted probe Kickstart the engine and keep the engine running at 5 000 r min Measure the DC voltage using the multi circuit tester If the voltage is not within the specified value inspect the magneto and...

Страница 281: ...l tank 13 4 Disconnect the regulator rectifier coupler 1 Connect a 12 volt battery to the service coupler using the bat tery lead wire optional part 12 19 Insert the needle pointed probe to the lead w...

Страница 282: ...ter as indicated in the table below If the voltage is not within the specified value replace the regulator rectifier with a new one 09900 25008 Multi circuit tester set Tester knob indication Diode te...

Страница 283: ...ignition system couplers Step 2 1 Measure the ignition coil primary peak voltage 15 13 Is the peak voltage OK Step 3 1 Inspect the spark plug 2 7 8 Is the spark plug OK YES Go to Step 2 NO Poor connec...

Страница 284: ...Step 7 1 Check the stator 15 9 Is the stator OK Step 8 1 Measure the engine stop switch resistance 15 16 Is the resistance OK YES Go to Step 5 NO Faulty ignition coil plug cap YES Go to Step 6 NO Fau...

Страница 285: ...ignition coil plug cap lead wire coupler to the igni tion coil plug cap and ground it to the cylinder head NOTE Be sure that the coupler and spark plug are connected properly Do not remove the ignitio...

Страница 286: ...B Peak volt adaptor E To engine stop switch C ECM F New spark plug D Ignition coil IGNITION COIL PLUG CAP INSPECTION Remove the seat radiator covers and fuel tank 5 2 13 2 3 Disconnect the ignition co...

Страница 287: ...tage CKP sensor peak voltage 2 8 V and more Crankshaft rotation signal sensor peak voltage 3 5 V and more Tester knob indication Voltage If the peak voltage is within the specification check the conti...

Страница 288: ...k 5 2 13 2 3 Disconnect the engine stop switch lead wire coupler 1 Measure the engine stop switch resistance between B Y lead wire and B W lead wire Engine stop switch resistance ON Under 1 B Y B W OF...

Страница 289: ...nnect the magneto lead wire coupler 1 Remove the clamp 2 Remove the gearshift lever 9 3 Remove the magneto cover 4 by removing its bolts 3 Remove the gasket 5 and dowel pins 6 Hold the magneto rotor w...

Страница 290: ...key 9 INSTALLATION Remove any grease from the tapered portion A of the mag neto rotor and crankshaft B Fit the magneto rotor key 1 to the crankshaft Install the magneto rotor Tighten the magneto rotor...

Страница 291: ...engine oil 2 13 STATOR REMOVAL Remove the magneto cover 15 19 Remove the clamp 2 by removing its bolts 1 Remove the CKP sensor 4 along with stator 5 by removing stator bolts 3 INSTALLATION Install the...

Страница 292: ...6 3 INSPECTION 16 3 DUST SEAL AND BEARING REPLACEMENT 16 4 DISC PLATE REPLACEMENT 16 5 INSTALLATION 16 6 REAR WHEEL 16 7 REMOVAL 16 7 INSPECTION 16 8 DUST SEAL AND BEARING REPLACEMENT 16 8 DISC PLATE...

Страница 293: ...ront disc plate ITEM N m kgf m lbf ft 3 Spacer A Wheel bearing A 90 9 0 65 0 4 Disc cover A Rear axle nut B 26 2 6 19 0 5 Rim lock B Disc plate bolt Rear C 30 3 0 21 5 6 Rear sprocket C Rear sprocket...

Страница 294: ...m the front wheel Inspect the right and left wheel spacers 1 and dust seals 2 for wear and cracks If any defects are found replace the spacer 1 together with the dust seal 2 NOTE Apply grease to the s...

Страница 295: ...y finger and inspect it for smooth move ment Inspect for bearing damage If any defects are found replace the bearing with a new one DUST SEAL AND BEARING REPLACEMENT Remove the dust seals 1 with the s...

Страница 296: ...all new dust seals 1 and apply grease to their lips NOTE When installing the dust seal 1 place the manufacturer s code indicated side of the dust seal outside 09913 70210 Bearing installer set 10 75 B...

Страница 297: ...Front fork assembling attachment F Remove the block from under the chassis tube and move the front forks up and down several times Tighten the front axle nut 2 to the specified torque Front axle nut 3...

Страница 298: ...L Loosen the rear axle nut 1 Place the motorcycle on a block to lift the rear wheel off the ground Remove rear axle nut 1 and washer 2 Remove the rear axle shaft 3 and chain adjuster washers 4 Disenga...

Страница 299: ...e reas sembling SPROCKET Inspect the sprocket teeth for wear If they are worn as shown replace the two sprockets and drive chain as a set AXLE SHAFT 16 3 WHEEL RIM 16 4 WHEEL BEARING 16 4 DUST SEAL AN...

Страница 300: ...on of bearings 09941 34513 Bearing installer NOTE Install the left side sprocket side bearings first and then the right side bearing After installing the bearings inspect the bearings for smooth movem...

Страница 301: ...ove the disc plate 2 by removing its bolts 1 Apply THREAD LOCK SUPER to the disc plate bolts 1 99000 32110 THREAD LOCK SUPER 1322 or equivalent Tighten the disc plate bolts 1 to the specified torque D...

Страница 302: ...stall the rear wheel chain adjuster washers 1 and axle shaft Adjust the drive chain slack 2 31 F FWD Tighten the rear axle nut 2 to the specified torque Rear axle nut 90 N m 9 0 kgf m 65 0 lbf ft REAR...

Страница 303: ...FRONT CALIPER REASSEMBLY AND INSTALLATION 17 9 REAR CALIPER REMOVAL AND DISASSEMBLY 17 11 REAR CALIPER REASSEMBLY AND INSTALLATION 17 13 MASTER CYLINDER 17 14 FRONT MASTER CYLINDER REMOVAL AND DISASSE...

Страница 304: ...2 5 18 0 5 Dust seal C Brake air bleeder valve C 6 0 6 4 5 6 Piston seal D Front brake caliper axle bolt bracket D 28 2 8 20 0 7 Reservoir cap E Brake pad mounting pin E 18 1 8 13 0 8 Diaphragm F Fron...

Страница 305: ...13 0 5 Piston seal B Brake pad mounting pin C 27 2 7 19 5 6 Dust seal C Rear brake caliper axle bolt caliper DH 6 0 6 4 5 7 Piston D Brake air bleeder valve E 13 1 3 9 5 8 Reservoir cap E Rear brake c...

Страница 306: ...children Call your doc tor immediately if brake fluid is swallowed and induce vomiting Flush eyes or skin with water if brake fluid gets in eyes or comes in contact with skin The use of any fluid exce...

Страница 307: ...lve is opened Replenish brake fluid to the UPPER line when the brake fluid level drops below LOWER line Tighten the air bleeder valve Air bleeder valve 6 N m 0 6 kgf m 4 5 lbf ft Pour brake fluid up t...

Страница 308: ...ft NOTE Pump the brake lever several times to seat the brake pads after reassembling REAR BRAKE PADS Remove the pad mounting pin 1 Remove the brake pads 2 NOTE Replace the two pads as a set Fit the ne...

Страница 309: ...10 CALIPER The use of any brake fluid except DOT 4 brake fluid from a sealed container can damage the brake sys tem and lead to an accident Use only DOT 4 brake fluid from a sealed container Never us...

Страница 310: ...racket 5 from the caliper Remove the boots 6 and 7 Remove the spring 8 Remove the front brake caliper axle bolt bracket 9 Wrap the caliper with a rag to prevent brake fluid scatter and piston pop out...

Страница 311: ...per parts FRONT CALIPER REASSEMBLY AND INSTALLATION Reassemble and install the brake caliper in the reverse order of removal and disassembly Pay attention to the following points Apply THREAD LOCK SU...

Страница 312: ...ket 1 Install the brake pads Temporarily tighten the brake pad mounting pin Tighten the caliper mounting bolts 2 to the specified torque Front brake caliper mounting bolt 26 N m 2 6 kgf m 19 0 lbf ft...

Страница 313: ...Place a rag under the brake hose union bolt 5 to catch spilled brake fluid Disconnect the brake hose 6 by removing the union bolt 5 Remove the rear wheel 16 7 Remove the caliper Remove the brake pad...

Страница 314: ...low pressure air into the caliper through the hole to remove the piston Remove the dust seal D and piston seal E BRAKE CALIPER INSPECTION 17 9 CALIPER CLEANING 17 9 Fingers can get caught between pis...

Страница 315: ...ke caliper axle bolt bracket 13 N m 1 3 kgf m 9 5 lbf ft Install the springs and boots Apply SUZUKI SILICONE GREASE to the caliper axles 99000 25100 SUZUKI SILICONE GREASE or equivalent Install the ca...

Страница 316: ...azardous to humans and pets Brake fluid is harmful or fatal if swallowed and harmful if it comes in contact with your skin or eyes Keep brake fluid away from children Call your doc tor immediately if...

Страница 317: ...piston B for scuffing wear and damage Inspect the piston B and spring C for damage If necessary replace the defective parts with a new one MASTER CYLINDER CLEANING Flush the master cylinder ports wit...

Страница 318: ...r bolt 1 first Tighten the master cylinder holder bolts 1 2 to the speci fied torque Master cylinder holder bolt Lower 1 12 N m 1 2 kgf m 8 5 lbf ft Upper 2 10 N m 1 0 kgf m 7 0 lbf ft NOTE Fast tight...

Страница 319: ...d washer 17 18 Remove the master cylinder 4 by removing the bolts 3 Place a rag under the brake hose union bolt 5 to catch spilled brake fluid Disconnect the brake hose 6 by removing the union bolt 5...

Страница 320: ...SUPER GREASE A or equivalent Set the brake hose end between the hose stoppers A then tighten the brake hose union bolt 1 to the specified torque Brake hose union bolt 23 N m 2 3 kgf m 16 5 lbf ft Tig...

Страница 321: ...LATION Install the brake lever in the reverse order of removal Pay atten tion to the following points Apply grease to the brake lever adjuster return spring pivot bolt and contact point between piston...

Страница 322: ...6 INSTALLATION Apply grease to the oil seals and brake pedal pivot bolt 99000 25010 SUZUKI SUPER GREASE A or equivalent Install the return spring 1 properly 20 29 Tighten the brake pedal pivot bolt 2...

Страница 323: ...CONTENTS CONSTRUCTION 18 2 FRONT FORK 18 2 STEERING 18 3 HANDLEBAR CONTROLS 18 4 REMOVAL 18 5 DISASSEMBLY 18 6 INSPECTION 18 10 REASSEMBLY 18 12 INSTALLATION 18 18 STEERING 18 19 REMOVAL 18 19 INSPEC...

Страница 324: ...ube A Air bleeder valve A 1 3 0 13 1 0 4 Push rod B Compression damper unit B 30 3 0 21 5 5 Fork spring C Fork cap bolt C 34 3 4 24 5 6 Guide busing D Lock nut Center bolt D 22 2 2 16 0 7 Seal retaine...

Страница 325: ...ing stem upper bracket A Handlebar clamp bolt A 25 2 5 18 0 4 Steering stem nut B Steering stem head nut B 100 10 0 72 5 5 Dust seal C Front fork upper clamp bolt C 23 2 3 16 5 6 Bearing D Front fork...

Страница 326: ...e case cover A 25 2 5 18 0 3 Left handle grip B Throttle case B 6 0 6 4 5 4 Clutch lever C Throttle grip C 6 0 6 4 5 5 Clutch cable adjuster bolt A Handlebar clamp bolt 6 Clutch lever cover B Brake le...

Страница 327: ...ts 4 NOTE Mark the paint mark A to the matching surface of handlebar holder and handlebars before removing Remove the fork protector 7 by removing the mounting bolts 6 Remove the brake caliper 8 17 8...

Страница 328: ...own the outer tube 09941 53630 Front fork cap socket wrench 50 mm Place a drain pan under the front fork and drain fork oil NOTE Face the oil hole A on the sub tank downward Raise the outer tube and t...

Страница 329: ...ench Compress the outer tube by hands and install the piston holder special tool between the axle holder 3 bottom and lock nut 5 09910 20115 Piston holder Hold the lock nut 5 with a wrench and remove...

Страница 330: ...fork spring 9 Remove the dust seal 0 Remove the stopper ring A Do not remove the lock nut 5 If removed the inner rod may slip into the damper rod possibly causing the threaded section to damage the oi...

Страница 331: ...shing 4 Seal retainer 5 Oil seal 6 Stopper ring 7 Dust seal 8 DANPER ROD AND COMPRESSION DAMPER UNIT Clamp the bottom flat part of the sub tank with a vise Loosen the compression damper unit 1 Remove...

Страница 332: ...it with a new one INNER TUBE AND OUTER TUBE Inspect the inner tube for scratches If it has scratches replace it with a new one Inspect the outer tube for dent If it is dented all the way to the inner...

Страница 333: ...h of front fork spring If it is shorter than service limit replace it with a new one Service Limit 485 mm 19 09 in SLIDE BUSHING AND GUIDE BUSHING Inspect the teflon coating metals slide bushing 1 and...

Страница 334: ...the bush ings have a large crack or excessive play after installing them replace them with new ones Insert the inner tube into the outer tube Install a new oil seal 3 with the special tool until the s...

Страница 335: ...rod in fully extended position pour the spec ified amount of fork oil Fork oil quantity Inside the damper rod 193 ml 6 5 6 8 US lmp oz 99000 99001 SS5 SUZUKI FORK OIL SS 05 or equivalent Apply fork oi...

Страница 336: ...n slowly move the inner rod several strokes a 100 mm 3 9 in Tighten the lock nut 7 by hand completely With the damper rod held in vertical position compress the damper rod fully to discharge an excess...

Страница 337: ...rocedures Pour the spec ified amount fork oil and discharge an excess of oil 18 13 14 a 100 mm 3 9 in Make sure approx 10 mm 0 39 in of inner rod thread is exposed on the end b Approx 10 mm 0 39 in 7...

Страница 338: ...e push rod B Slowly tighten the center bolt B until resistance is felt and check the clearance between the lock nut 7 and center bolt B to provide 1 mm 0 04 in and more C 1 mm 0 04 in and more Turn th...

Страница 339: ...nd slowly slide down the outer tube 09941 53630 Front fork cap socket wrench 50 mm Pour the specified amount of fork oil into the outer tube Oil quantity When standard fork spring is used 375 ml 12 68...

Страница 340: ...rque with the special tool 09941 53630 Front fork cap socket wrench 50 mm Fork cap bolt 34 N m 3 4 kgf m 24 5 lbf ft Tighten the fork upper clamp bolts 3 to the specified torque Fork upper clamp bolt...

Страница 341: ...4 NOTE Mark the paint marks A to the matching surfaces of clutch lever holder and handlebars left handlebar grip and handlebars Remove the left handlebar grip 6 Remove the front brake master cylinder...

Страница 342: ...rface of handlebar holder and handlebars before removing STEERING STEM Remove the front wheel 1 16 3 Remove the brake hose guide 2 Remove the front forks 3 18 5 Remove the front fender 5 by removing i...

Страница 343: ...ocket wrench 09940 14960 Steering stem nut socket wrench Remove the steering stem lower bracket A and lower bear ing Remove the washer B upper dust seal C and upper bearing D INSPECTION Inspect the re...

Страница 344: ...place the outer race and bearing as a set Remove the upper outer race with the special tools 09941 54911 Bearing outer race remover 09941 74911 Steering race installer Drive out the lower outer race u...

Страница 345: ...1 Steering stem nut socket wrench 09940 14960 Steering stem nut socket wrench Move the steering stem right and left several times to seat the bearings Turn back the steering stem nut by 1 4 1 2 turn S...

Страница 346: ...r clamp bolts Tighten the steering stem head nut 4 to the specified torque Steering stem head nut 100 N m 10 0 kgf m 72 5 lbf ft Install the front fender 5 as shown Reinstall the front forks 18 18 Ins...

Страница 347: ...ts 9 first tighten the bolts C Handlebar clamp bolt 25 N m 2 5 kgf m 18 0 lbf ft Tighten the handlebar holder set nuts 0 to the specified torque Handlebar holder set nut 44 N m 4 4 kgf m 32 0 lbf ft A...

Страница 348: ...ovide clearance on the upper side and then tighten both the master cylinder holder bolts C to the specified torque 20 28 Master cylinder holder bolt Lower 12 N m 1 2 kgf m 8 5 lbf ft Upper 10 N m 1 0...

Страница 349: ...r bolt D first temporarily to provide clearance on the lower side and then tighten both the bolts 1 Install the engine stop switch 2 and clamps 3 Install the front number plate and handlebar pad INSPE...

Страница 350: ...9 4 INSPECTION 19 5 BEARING REPLACEMENT 19 6 OIL REPLACEMENT 19 7 DISASSEMBLY AND INSPECTION 19 10 REASSEMBLY 19 11 INSTALLATION 19 12 DISPOSAL 19 12 SWINGARM 19 13 REMOVAL 19 13 INSPECTION 19 15 BEAR...

Страница 351: ...body C Cushion rod nut front ABC 80 8 0 58 0 4 Damper rod assembly D Compression adjuster assembly D 30 3 0 21 5 5 Swingarm E Rear shock absorber mounting nut upper EF 50 5 0 36 0 6 Chain guide G 44 4...

Страница 352: ...ight frame cover 5 2 Loosen the air cleaner clamp screw 1 Remove the rubber band 2 Disconnect the IAT sensor coupler 3 and remove the clamp 4 Loosen the muffler connector clamp bolt 5 Remove the muffl...

Страница 353: ...it fully to the end of the thread Turn the adjuster 2 as well as the lock nut 1 09910 60611 Universal clamp wrench Depress the spring seat 3 and remove the stopper ring 4 Remove the spring seat 3 and...

Страница 354: ...adjuster lock nut 44 N m 4 4 kgf m 32 0 lbf ft INSPECTION Inspect the rear shock absorber for oil leakage Inspect the damper rod for bends and smooth movement Inspect the bump rubber for deterioration...

Страница 355: ...d mark on the bearing must face left side Position the needle roller bearing cage by referring to the illus tration of page 19 22 09924 84521 Bearing installer set Press the new dust seals 4 with the...

Страница 356: ...unit 19 4 NOTE Inspect the rear shock absorber unit for oil leakage Turn the rebound damping force adjuster screw 1 counterclock wise until it stops so that the rear suspension oil can be poured easil...

Страница 357: ...specified rear suspension oil as shown while moving the rod NOTE Be sure to extend the rod after filling the oil Tilt the shock absorber unit as shown and pour the fresh rear suspension oil fully int...

Страница 358: ...nstall the spring 19 4 Use of flammable gas for pressuring the rear shock absorber unit can be hazardous Flammable gas such as gas welding oxygen can cause a fire hazard Use nitrogen gas If nitrogen g...

Страница 359: ...ogen gas 19 7 Remove the compression adjuster assembly and drain the oil 19 8 Vise the rear shock absorber unit in inverted position Depress the bump rubber fully to protect the damper rod Evenly hamm...

Страница 360: ...ner surface of the body Inspect the piston ring 8 back up rings 9 and packing 0 on the piston Replace the O rings with new ones Replace the piston ring 8 back up rings 9 and packing 0 by cutting off t...

Страница 361: ...n the upper mounting bolt and nut 2 to the specified torque Rear shock absorber upper mounting nut 50 N m 5 0 kgf m 36 0 lbf ft DISPOSAL High pressure nitrogen gas is sealed in the rear shock absorber...

Страница 362: ...e chain guide bolts and nuts 1 Remove the chain guide plate 2 and chain guide 3 Remove the rear master cylinder mounting bolts 4 and brake hose guide screw 5 Remove the rear brake caliper assembly 6 f...

Страница 363: ...ve the pivot shaft B Remove the swingarm Remove the chain buffer D by removing its screws C Remove the plates F by removing its screws E Remove the following parts from the swingarm Spacer G Oil seal...

Страница 364: ...gauge 09900 20701 Dial gauge chuck 09900 21304 V blocks CHAIN BUFFER AND CHAIN GUIDE Inspect the chain buffer 1 and chain guide 2 for damage and excessive wear If any defects are found replace the cha...

Страница 365: ...y is noted replace the bearing with a new one BEARING REPLACEMENT Remove the bearings 1 and 2 with the special tool 09921 20240 Bearing remover set Remover 20 mm Press the new bearings 1 and 2 with th...

Страница 366: ...UPER 1322 or equivalent Tighten the plate mounting screws 9 securely Install the chain buffer Install the swingarm Tighten the swingarm pivot nut 0 to the specified torque Swingarm pivot nut 70 N m 7...

Страница 367: ...LINKAGE REMOVAL Place a block under the chassis tubes Remove the rear cushion rod bolts and nuts 1 Remove the cushion lever bolt and nut 2 Remove the shock absorber lower bolt and nut 3 Remove the co...

Страница 368: ...amage Inspect the collars dust seals washers and spacers for dam age If necessary replace the defective parts with a new one Insert the spacers into the bearings and inspect them for excessive play an...

Страница 369: ...side 32 pieces of needle roller bearing Remove the needle roller bearing cages 1 and 2 with the special tool 09921 20240 Bearing remover set Remover 20 mm Press fit the new needle roller bearing cage...

Страница 370: ...lent INSTALLATION Install the rear suspension linkage in the reverse order of removal Pay attention to the following points Install the washers 1 Position the dust seals 2 so that the manufacturer s c...

Страница 371: ...e 3 Rear suspension linkage bolt Tightening torque A 50 N m 5 0 kgf m 36 0 lbf ft D 80 N m 8 0 kgf m 58 0 lbf ft a 6 25 mm 0 25 in B 50 N m 5 0 kgf m 36 0 lbf ft E 80 N m 8 0 kgf m 58 0 lbf ft b 4 5 m...

Страница 372: ...ere with suspension move ment and damage the rear suspension linkage Make sure that the rear shock absorber rebound damping adjuster on the bottom bracket of the rear shock absorber is located to the...

Страница 373: ...20 24 CRANKCASE AND COVER INSTALLATION 20 25 EXHAUST PIPE AND MUFFLER INSTALLATION 20 26 CLUTCH CABLE ADJUSTER 20 27 HOT STARTER LEVER INSTALLATION 20 28 BRAKE PEDAL SET UP 20 29 FRONT BRAKE HOSE ROU...

Страница 374: ...alve stem deflection IN EX 0 25 0 010 Valve guide I D IN EX 4 500 4 512 0 1772 0 1176 Valve stem O D IN 4 475 4 490 0 1762 0 1768 EX 4 455 4 470 0 1754 0 1760 Valve stem runout IN EX 0 05 0 002 Valve...

Страница 375: ...tomatic decomp actuated 400 800 kPa 4 0 8 0 kgf cm2 57 114 psi Piston to cylinder clearance 0 030 0 040 0 0012 0 0016 0 120 0 0047 Cylinder bore 77 000 77 015 3 0315 3 0321 Nicks or scratches Piston d...

Страница 376: ...Oil pressure at 50 C 122 F 25 kPa 0 25 kgf cm2 3 6 psi at 6 000 r min ITEM STANDARD LIMIT Clutch cable play 2 3 0 08 0 16 Drive plate thickness 2 72 2 88 0 107 0 113 2 42 0 095 Drive plate claw width...

Страница 377: ...hift lever height 10 15 0 4 0 6 Above the top face of the foot rest ITEM SPECIFICATION NOTE Injector resistance 10 11 at 24 C 75 F Fuel pump discharge amount 89 ml 3 0 3 1 US Imp oz and more 10 sec Fu...

Страница 378: ...E Ignition timing 8 B T D C at 2 100 r min Spark plug Type NGK CR8EIA10 Gap 0 9 1 0 0 035 0 039 Spark performance Over 8 0 3 at 1 atm CKP sensor resistance 80 120 R G Crankshaft rotation signal sensor...

Страница 379: ...57 10 984 0 4314 0 4324 Rear 10 957 10 984 0 4314 0 4324 Brake caliper cylinder bore Front 27 000 27 050 1 0630 1 0650 Rear 25 400 25 450 1 0000 1 0020 Brake caliper piston diam Front 26 900 26 950 1...

Страница 380: ...ure 0 kPa 0 kgf cm2 0 psi Front fork spring rate 4 7 N mm 0 47 kgf mm Rear shock absorber gas pressure 784 kPa 8 0 kgf cm2 113 8psi Rear shock absorber spring set length 4 2 0 17 4 2 mm 0 17 in com pr...

Страница 381: ...H SJ SL with JASO MA MA1 MA2 The others Engine oil capacity Change 850 ml 0 9 0 7 US Imp qt Filter change 900 ml 1 0 0 8 US Imp qt Overhaul 1 000 ml 1 1 0 9 US Imp qt Air cleaner element oil type MOTU...

Страница 382: ...7 0 Cam chain tension adjuster mounting bolt 10 1 0 7 0 Cam chain tension adjuster cap bolt 23 2 3 16 5 Cam chain tensioner bolt 10 1 0 7 0 Cam chain guide retainer mounting bolt 10 1 0 7 0 Right cran...

Страница 383: ...8 13 0 Muffler connector clamp bolt 18 1 8 13 0 Muffler mounting bolt front rear 23 2 3 16 5 Exhaust pipe cover bolt 11 1 1 8 0 ITEM N m kgf m lbf ft CKP sensor bolt 5 5 0 55 4 0 IAT sensor mounting s...

Страница 384: ...29 2 9 21 0 Brake hose union bolt front and rear 23 2 3 16 5 Front brake hose guide bolt 3 0 3 2 0 Front brake caliper mounting bolt 26 2 6 19 0 Brake pad mounting pin front and rear 18 1 8 13 0 Fron...

Страница 385: ...t 6 0 6 4 5 Radiator cover upper bolt 6 0 6 4 5 Radiator cover bolt 10 1 0 7 0 Bolt Diameter mm Conventional or 4 marked bolt 7 marked or crown headed bolt N m kgf m lbf ft N m kgf m lbf ft 4 1 5 0 15...

Страница 386: ...09900 20701 Dial gauge chuck 09900 20803 Thickness gauge 09900 20805 Tire depth gauge 09900 21304 V blocks 09900 22301 Plastigauge 0 025 0 076 mm 09900 22302 Plastigauge 0 051 0 152 mm 09900 22401 Sma...

Страница 387: ...6 34542 Reamer handle 09916 33210 Valve guide reamer 4 5 mm 09916 33320 Valve guide reamer 9 8 mm 09916 43211 Valve guide installer remover 09916 44920 Valve guide installer attachment 09916 84511 Twe...

Страница 388: ...ket wrench 09940 14960 Steering stem nut socket wrench 09940 34581 Front fork assem bling attachment F 09940 40211 Fuel pressure gauge adapter 09940 52861 Front fork oil seal installer set 09941 34513...

Страница 389: ...OR B W B Y B W B Y W Bl B W W Bl B Br Br W R B B W R B B R Br W G W P Y G B Bl W B W Bl Gr Bl B R Bl B R R B Gr W W Bl Lg G W R B Bl Bl R B Br Dg Bl Y W G Bl G Y B B B Y B W B W B W Bl W W G Bl G Bl R...

Страница 390: ...AT sensor 5 Bind the magneto lead wire GP switch lead wire and overflow hose with the clamp Pass the over flow hose inside of left engine mounting lower bracket Set the tip of the clamp inside 1 Bind...

Страница 391: ...nd TP sensor lead wire with the clamp Set the tip of clamp downward 5 Engine stop switch lead wire 6 Pass the service coupler lead wire inside of the bracket 6 GP switch lead wire 7 Tighten coupler br...

Страница 392: ...A A 1 GP switch lead wire 5 Magnet lead wire 1 Pass the GP switch lead wire under the clutch cable bracket 2 Clutch cable bracket 6 Grommet 2 Do not slack the lead wire at this position 3 Magneto roto...

Страница 393: ...arness between radia tor hose and frame 5 Radiator overflow hose 6 Pass the overflow hose between engine mounting lower bracket 6 Cable guide 7 Align the matching marks on the clutch cable bracket and...

Страница 394: ...starter cable 3 Bind the hot starter cable and engine stop switch lead wire with the clamp 4 Radiator overflow hose 4 Pass the hot starter cable over the radiator hose 5 Engine stop switch lead wire...

Страница 395: ...rottle body A ECT sensor 3 Air cleaner B Breather hose 4 IAT sensor C Air cleaner box 5 Intake pipe clamp A Upward 6 Air cleaner outlet pipe clamp 1 Gray button 7 Fuel pump 2 Yellow button 8 Fuel tank...

Страница 396: ...e mark to the backward 2 Radiator RH 3 Face the yellow mark to the backward 3 Radiator overflow hose 4 Pass the radiator overflow hose between engine mounting lower bracket a 15 10 5 Face the blue mar...

Страница 397: ...lt L 60 mm 2 4 in K Engine sprocket cover bolt L 30 mm 1 2 in U Engine oil strainer cap a 70 10 D Clutch cover bolt L 25 mm 1 0 in L Magneto cover bolt L 35 mm 1 4 in E Water pump case bolt L 60 mm 2...

Страница 398: ...SERVICING INFORMATION EXHAUST PIPE AND MUFFLER INSTALLATION A Muffler mounting bolt B Muffler connector clamp bolt ITEM N m kgf m lbf ft C Exhaust pipe cover bolt A 23 2 3 16 5 B 18 1 8 13 0 C 11 1 1...

Страница 399: ...Clutch cable adjuster 1 When the movement is felt heavier clean this and apply grease a Turn to tighten the clutch cable tension 2 Do not apply grease to the rubber covers Fit the cover positively b T...

Страница 400: ...clearance on the upper side and then tighten both the bolts to the specified torque 2 Connect the hot starter cable to the master cylin der holder and hot starter lever 5 Install the cover of hot sta...

Страница 401: ...SERVICING INFORMATION 20 29 BRAKE PEDAL SET UP 1 Rear master cylinder 3 Brake pedal 2 Return spring a 0 10 0 0 4 in...

Страница 402: ...e brake hose end between the hose stopper then tighten the brake hose union bolt 3 Stopper 2 Clamp the upper difference portion in brake hose diameter 4 Hose guide 3 After contacting the brake hose un...

Страница 403: ...0 31 REAR BRAKE HOSE ROUTING 1 1 2 A A A A 1 Rear brake hose 4 Hose guide 2 Rear brake master cylinder 1 Set the brake hose end between the hose stopper then tighten the brake hose union bolt 3 Rear b...

Страница 404: ...he left handlebar grip with marking A Marking f 14 16 mm 0 55 0 63 in 6 Apply adhesive to the handlebars and inner of left handlebar grip a 145 mm 5 71 in 1 Align the matching surface of master cylind...

Страница 405: ...AR WHEEL SPOKES INSTALLATION CHAIN ROLLER INSTALLATION 1 Spoke Inner L 206 5 mm 8 13 in 2 Spoke Outer L 204 5 mm 8 05 in 1 Chain roller Upper 3 Frame 2 Chain roller Lower A Chain roller bolt nut ITEM...

Страница 406: ...ORMATION FUEL TANK CUSHION INSTALLATION 1 1 Fuel tank rear cushion 5 Frame 2 Spacer 6 Fuel tank side cushion 3 Fuel tank front cushion a 213 mm 8 39 in 4 Fuel tank 1 Clean an adhesive surface before a...

Страница 407: ...nt fender 5 Fuel tank 9 Rear fender 2 Front number plate 6 Right frame cover A Radiator cover upper bolt ITEM N m kgf m lbf ft 3 Right radiator cover 7 Left frame cover B Radiator cover bolt A 6 0 6 4...

Страница 408: ...20 36 SERVICING INFORMATION FRONT FENDER INSTALLATION REAR FENDER INSTALLATION 1 Front fender 1 Seat rail 2 Rear fender...

Страница 409: ...SERVICING INFORMATION 20 37 FRAME COVER INSTALLATION FRAME COVER CUSHION INSTALLATION 1 Seat 3 Seat rail 2 Rear fender 4 Frame cover 1 Cushion 2 Frame cover...

Страница 410: ...Prepared by September 2009 Part No 99500 42190 01E Printed in Japan 420...

Страница 411: ......

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