Suzuki RM-Z250 Service Manual
  1. Manuals
  2. Brands
  3. Suzuki Manuals
  4. Motorcycle
  5. RM-Z250
  6. Service manual

Suzuki RM-Z250 Service Manual

Hide thumbs Also See for RM-Z250:
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119
120
121
122
123
124
125
126
127
128
129
130
131
132
133
134
135
136
137
138
139
140
141
142
143
144
145
146
147
148
149
150
151
152
153
154
155
156
157
158
159
160
161
162
163
164
165
166
167
168
169
170
171
172
173
174
175
176
177
178
179
180
181
182
183
184
185
186
187
188
189
190
191
192
193
194
195
196
197
198
199
200
201
202
203
204
205
206
207
208
209
210
211
212
213
214
215
216
217
218
219
220
221
222
223
224
225
226
227
228
229
230
231
232
233
234
235
236
237
238
239
240
241
242
243
244
245
246
247
248
249
250
251
252
253
254
255
256
257
258
259
260
261
262
263
264
265
266
267
268
269
270
271
272
273
274
275
276
277
278
279
280
281
282
283
284
285
286
287
288
289
290
291
292
293
294
295
296
297
298
299
300
301
302
303
304
305
306
307
308
309
310
311
312
313
314
315
316
317
318
319
320
321
322
323
324
325
326
327
328
329
330
331
332
333
334
335
336
337
338
339
340
341
342
343
344
345
346
347
348
349
350
351
352
353
354
355
356
357
358
359
360
361
362
363
364
365
366
367
368
369
370
371
372
373
374
375
376
377
378
379
380
381
382
383
384
385
386
387
388
389
390
391
392
393
394
395
396
397
398
399
400
401
402
403
404
405
406
407
408
409
410
411
Table of Contents

Advertisement

Quick Links

Download this manual See also: Owner's Service Manual, Owner's Manual

Advertisement

Table of Contents
loading

Related Manuals for Suzuki RM-Z250

Summary of Contents for Suzuki RM-Z250

  • Page 2: Table Of Contents

    FOREWORD GROUP INDEX This manual contains an introductory description on the SUZUKI RM-Z250 and procedures for its GENERAL INFORMATION inspection, service and overhaul of its main compo- nents. PERIODIC MAINTENANCE Other information considered as generally known is not included. Read the GENERAL INFORMATION section to...
  • Page 3 HOW TO USE THIS MANUAL TO LOCATE WHAT YOU ARE LOOKING FOR: 1. The text of this manual is divided into sections. 2. The section titles are listed in the GROUP INDEX. 3. Holding the manual as shown at the right will allow you to find the first page of the section easily.
  • Page 4 99000-99001-SS5 Apply molybdenum oil solution. Use REAR SUSPENSION OIL SS-25 or (Mixture of engine oil and SUZUKI equivalent. MOLY PASTE in a ratio of 1:1) Apply SUZUKI SUPER GREASE “A” Use engine coolant or equivalent.
  • Page 5 : American Petroleum Institute : Right Hand BTDC : Before Top Dead Center : Battery Positive Voltage : Society of Automotive Engineers : Suzuki Diagnosis System CKP Sensor : Crankshaft Position Sensor (CKPS) TO Sensor : Tip-Over Sensor (TOS) TP Sensor...
  • Page 6 SAE-TO-FORMER SUZUKI TERM This table lists SAE (Society of Automotive Engineers) J1930 terms and abbreviations which may be used in this manual in compliance with SAE recommendations, as well as their former SUZUKI names. SAE TERM FORMER SUZUKI TERM FULL TERM...
  • Page 7 SAE TERM FORMER SUZUKI TERM FULL TERM ABBREVIATION On-Board Diagnostic Self-Diagnosis Function Diagnostic Programmable Read Only Memory PROM –––– Random Access Memory –––– Read Only Memory Throttle Body Throttle Body (TB) Throttle Body Fuel Injection Throttle Body Fuel Injection (TBI)

  • Page 8: General Information

    GENERAL INFORMATION 1-1 GENERAL INFORMATION CONTENTS WARNING/CAUTION/NOTE .................1- 2 GENERAL PRECAUTIONS................1- 2 SUZUKI RM-Z250L0 (’10-MODEL) ...............1- 4 SERIAL NUMBER LOCATION..............1- 4 FUEL, OIL AND ENGINE COOLANT RECOMMENDATION......1- 5 FUEL (FOR USA AND CANADA)............1- 5 FUEL (FOR OTHER COUNTRIES)............1- 5 ENGINE OIL (FOR USA).................1- 5 ENGINE OIL (FOR OTHER COUNTRIES) ..........1- 5...

  • Page 9: Warning/Caution/Note

    1-2 GENERAL INFORMATION WARNING/CAUTION/NOTE Please read this manual and follow its instructions carefully. To emphasize special information, the symbol and the words WARNING, CAUTION and NOTE have special meanings. Pay special attention to the mes- sages highlighted by these signal words. ...
  • Page 10 GENERAL INFORMATION 1-3  * If parts replacement is necessary, replace the parts with Suzuki Genuine Parts or their equiva- lent. * When removing parts that are to be reused, keep them arranged in an orderly manner so that they may be reinstalled in the proper order and orientation.

  • Page 11: Suzuki Rm-Z250L0 ('10-Model)

    1-4 GENERAL INFORMATION SUZUKI RM-Z250L0 (’10-MODEL) RIGHT SIDE LEFT SIDE • Difference between photograph and actual motorcycle may exist depending on the markets. 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.

  • Page 12: Fuel, Oil And Engine Coolant Recommendation

    Suzuki recommends the use of SUZUKI PERFORMANCE 4 MOTOR OIL or equivalent engine oil. Use of SG/SH/SJ/SL in API with JASO MA/MA1/MA2. Suzuki recommends the use of SAE 10W-40 engine oil. If SAE 10W-40 engine oil is not available, select an alternative according to the following chart.

  • Page 13: Engine Coolant

    Suzuki recommends the use of SUZUKI COOLANT anti-freeze/engine coolant. If this is not available, use an equivalent which is compatible with an aluminum radiator.

  • Page 14: Information Labels

    GENERAL INFORMATION 1-7 INFORMATION LABELS APPLIED SPECIFICATION LABEL or PLATE NAME E-03 E-19 E-28 1 General warning label E 2 General warning label E 3 General warning label F 4 EC approval mark label 5 ICES Canada label E/F 6 EPA plate E 7 Manufacture label E E: English F: French...

  • Page 15: Specifications

    1-8 GENERAL INFORMATION SPECIFICATIONS DIMENSIONS AND CURB MASS Overall length ............2 170 mm (85.4 in) Overall width ............830 mm (32.7 in) Overall height ............1 270 mm (50.0 in) Wheelbase ............1 475 mm (58.1 in) Ground clearance ..........345 mm (13.6 in) Seat height............

  • Page 16: Chassis

    GENERAL INFORMATION 1-9 CHASSIS Front suspension..........Upside-down telescopic fork Rear suspension ..........Swingarm type Front suspension stroke ........310 mm (12.2 in) Rear wheel travel ..........310 mm (12.2 in) Caster..............30° 20’ Trail..............140 mm (5.5 in) Steering angle ............. 45° (right & left) Front brake ............
  • Page 17 PERIODIC MAINTENANCE 2-1 PERIODIC MAINTENANCE CONTENTS PERIODIC MAINTENANCE ................ 2- 3 INSPECTION BEFORE PRACTICE ............2- 3 INSPECTION BEFORE RACE (All items of inspection before practice on previous page plus) ..2- 4 PERIODIC MAINTENANCE CHART ............ 2- 5 SPARK PLUG ....................2- 7 AIR CLEANER .....................

  • Page 18: Contents

    PERIODIC MAINTENANCE PERIODIC MAINTENANCE CONTENTS CYLINDER HEAD, CYLINDER AND PISTON ..........2-29 CYLINDER HEAD INSPECTION ............2-29 CYLINDER INSPECTION ..............2-29 PISTON INSPECTION ................2-29 DRIVE CHAIN AND SPROCKETS .............. 2-30 DRIVE CHAIN SLACK ................2-30 CRANKCASE DRIVESHAFT OIL SEAL ..........2-30 DRIVE CHAIN ADJUSTMENT ..............

  • Page 19: Periodic Maintenance

    PERIODIC MAINTENANCE 2-3 PERIODIC MAINTENANCE INSPECTION BEFORE PRACTICE WHAT TO CHECK CHECK FOR Spark plug • Heat range, fouled electrode, tightness • Loose high-tension cord Air cleaner element • Dust • Lubrication Engine oil Oil level Coolant Coolant level Cooling system •...

  • Page 20: Inspection Before Race

    2-4 PERIODIC MAINTENANCE INSPECTION BEFORE RACE (All items of inspection before practice on previous page plus) WHAT TO CHECK CHECK FOR Clutch Clutch disc plates wear and distortion Brake pads Wear Sprockets Wear Fuel tank Leakage Fuel hose • Damage •...

  • Page 21: Periodic Maintenance Chart

    PERIODIC MAINTENANCE 2-5 PERIODIC MAINTENANCE CHART It is very important to inspect and maintain the machine regularly. Follow the guideline in the chart. The life of parts varies depending on the riding conditions. Perform more often than shown in the chart if you use the motorcycle under severe conditions.
  • Page 22 2-6 PERIODIC MAINTENANCE Interval Every Every Every races race 3 races 6 races Remarks Every Every Every hours Service Item 2 hours 6 hours 12 hours Front fork oil — — Change after 1st initial break-in. Check front fork inner tube frequently for Front fork —...

  • Page 23: Spark Plug

    PERIODIC MAINTENANCE 2-7 SPARK PLUG • Remove the seat. (5-2) • Remove the radiator covers and fuel tank. (13-2, -3) • Hold the cylinder head cover bolt immovable with the wrench. • Remove the ignition coil retainer 2 by removing its bolts 1. •...
  • Page 24 2-8 PERIODIC MAINTENANCE • Measure the spark plug gap A with a wire gauge. • If it is not within the specification, replace the spark plug.  * To prevent the damage of iridium center electrode, use a wire gauge to check the gap. * Never adjust the spark plug gap.

  • Page 25: Air Cleaner

    PERIODIC MAINTENANCE 2-9 AIR CLEANER AIR CLEANER ELEMENT REMOVAL • Remove the seat. (5-2) • Remove the wing bolt 1. • Remove the element 2 from the element holder. WASHING • Fill a washing pan large enough to hold the element with a non-flammable cleaning solvent A.

  • Page 26: Installation

    2-10 PERIODIC MAINTENANCE INSTALLATION • Apply filter oil to the element base where it contacts the air cleaner body. • Fit the element 2 onto the element holder 1. NOTE: Fit the projection A of the element holder to the hole of the ele- ment 2.

  • Page 27: Engine Oil And Oil Filter

    PERIODIC MAINTENANCE 2-11 ENGINE OIL AND OIL FILTER  * Improper engine oil treatment is hazardous. * Read engine oil container instruction before replac- ing the engine oil.  * Improper engine oil selection can cause clutch slip. * Do not use engine oil which has friction decrease additives.

  • Page 28: Engine Oil Level Inspection

    2-12 PERIODIC MAINTENANCE ENGINE OIL LEVEL INSPECTION • During inspection, hold the motorcycle in an upright position on a level surface. NOTE: The oil level measurement may become inaccurate unless the motorcycle is held upright as the motorcycle inclination affects the oil level.

  • Page 29: Engine Oil Change

    PERIODIC MAINTENANCE 2-13 ENGINE OIL CHANGE • During inspection, hold the motorcycle in an upright position on a level surface. • Warm up the engine. • Remove the filler cap, TDC plug 1, drain plug 2 and drain No.2 plug 3. Drain engine oil. •...

  • Page 30: Engine Oil Filter Change

    2-14 PERIODIC MAINTENANCE ENGINE OIL FILTER CHANGE • Drain the engine oil as described in the engine oil replace- ment procedure. • Remove the oil filter cap 2 by removing its bolts 1. • Remove the spring 3 with oil filter 4. •...

  • Page 31: Oil Strainers

    PERIODIC MAINTENANCE 2-15 OIL STRAINERS OIL STRAINER (No.1) REMOVAL • Drain engine oil. (2-13) • Remove the engine oil strainer cap 1.  Do not lie the motorcycle to prevent dirty engine oil into the oil circuit when removing the oil strainer (No.1).

  • Page 32: Inspection

    2-16 PERIODIC MAINTENANCE INSPECTION • 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 by applying compressed air.

  • Page 33: Oil Strainer (No.2) Installation

    PERIODIC MAINTENANCE 2-17 OIL STRAINER (No.2) INSTALLATION • Install the oil strainer No.2 1 and tighten the oil strainer No.2 bolts 2 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 3 and tighten the oil pump No.2 bolts 4 to the specified torque.

  • Page 34: Engine Coolant

    2-18 PERIODIC MAINTENANCE ENGINE COOLANT ENGINE COOLANT LEVEL CHECK  * You can be injured by scalding fluid or steam if you open the radiator cap when the engine is hot. * Do not open the radiator cap when the engine is hot. Wait until engine cools.

  • Page 35: Engine Coolant Replenishment

    PERIODIC MAINTENANCE 2-19 ENGINE COOLANT REPLENISHMENT • Use an antifreeze/coolant compatible with aluminum radiator, mixed with distilled water only, at the ratio of 50:50. NOTE: The radiator, cylinder and cylinder head are made of aluminum alloy. Using non-recommended engine coolant may corrode alu- minum alloy and may clog the coolant passageways.

  • Page 36: Clutch Cable

    2-20 PERIODIC MAINTENANCE CLUTCH CABLE Adjust the clutch cable play as follows: MAJOR ADJUSTMENT • Loosen the lock-nut 1. • Turn adjuster 2 so the clutch lever clearance A measured at the lever holder obtains 2 – 3 mm (0.08 – 0.12 in) when squeezing the lever until pressure is felt.

  • Page 37: Throttle Cable

    PERIODIC MAINTENANCE 2-21 THROTTLE CABLE  * Inadequate throttle cable play can cause engine speed to rise suddenly when you turn the handle- bars. This can lead to loss of rider control. * Adjust the throttle cable play so that engine speed does not rise due to handlebars movement.

  • Page 38: Throttle Cable Oil Supply

    2-22 PERIODIC 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” or equivalent...

  • Page 39: Hot Starter

    PERIODIC MAINTENANCE 2-23 HOT STARTER Adjust the hot starter cable play as follows: NOTE: Be careful not to damage the lever cover when installing. (20-28) • Loosen the lock-nut 1. • Turn adjuster 2 so the hot starter lever clearance A mea- sured at the lever holder obtains 2 –...

  • Page 40: Engine Idle Speed

    2-24 PERIODIC MAINTENANCE ENGINE IDLE SPEED • Adjust the throttle cable play. (2-21) • Warm up the engine. NOTE: Make this adjustment when the engine is hot. • Insert the needle-pointed probe to the lead wire coupler (W/Bl). • Connect the engine tachometer to the needle-pointed probe. ...

  • Page 41: Valve Clearance

    PERIODIC MAINTENANCE 2-25 VALVE CLEARANCE • Remove the seat. (5-2) • Remove the radiator covers and fuel tank. (13-2, -3) • Remove the spark plug. (2-7) • Remove the cylinder head cover 2 and gasket 3 by remov- ing their bolts 1. The valve clearance specification is different for both intake and exhaust valves.

  • Page 42: Valve Clearance Adjustment

    2-26 PERIODIC MAINTENANCE VALVE CLEARANCE ADJUSTMENT The clearance is adjusted by replacing the existing tappet shim with a thicker or thinner one. • Remove the intake or exhaust camshafts. (6-4 to -6) • Remove the tappet 1 and shim 2 by fingers or magnetic hand.
  • Page 43 PERIODIC MAINTENANCE 2-27 (INTAKE SIDE)
  • Page 44 2-28 PERIODIC MAINTENANCE (EXHAUST SIDE)

  • Page 45: Cylinder Head, Cylinder And Piston

    PERIODIC MAINTENANCE 2-29 CYLINDER HEAD, CYLINDER AND PISTON CYLINDER HEAD INSPECTION • Remove the cylinder head. (6-6, -7) • Decarbonize the combustion chambers. • Inspect for pinholes, cracks and other damage. • If any defects are found, replace the cylinder head with a new one.

  • Page 46: Drive Chain And Sprockets

    2-30 PERIODIC MAINTENANCE DRIVE CHAIN AND SPROCKETS DRIVE CHAIN SLACK • Place the motorcycle on a block to lift the rear wheel off the ground. • Inspect the drive chain slack at the middle point between the drive chain buffer and rear sprocket. ...

  • Page 47: Drive Chain Adjustment

    PERIODIC MAINTENANCE 2-31 DRIVE CHAIN ADJUSTMENT • Loosen the axle nut 1. • Loosen the lock-nuts 2 and adjust the drive chain slack to the specification by turning the adjusters 3. Make sure that the right and left adjuster washers 4 are at the same position on scales 5.

  • Page 48: Drive Chain Lubrication

    • Clean the drive chain with non-flammable cleaning solvent.  Do not use gasoline to clean the drive chain. • Dry the drive chain. • Apply 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.

  • Page 49: Drive Chain Guide, Buffer And Tensioner Roller

    PERIODIC MAINTENANCE 2-33 DRIVE CHAIN GUIDE, BUFFER AND TENSIONER ROLLER DRIVE CHAIN GUIDE INSPECTION • Inspect the drive chain guide 1 for bends and damage. NOTE: The drive chain can hit a bent guide causing noise and drive chain wear. •...

  • Page 50: Brakes

    2-34 PERIODIC MAINTENANCE BRAKES BRAKE FLUID LEVEL • Inspect the brake fluid level in both front and rear reservoirs. If the brake fluid level is lower than LOWER mark A, replenish the reservoir with the specified brake fluid to the UPPER line. Inspect brake pad wear and brake fluid leakage if the brake fluid level decreases.

  • Page 51: Brake Pad

    PERIODIC MAINTENANCE 2-35 BRAKE PAD • Inspect the brake pads for wear. If the brake pads are worn, replace them with new ones. (17-6) A Wear limit NOTE: * Pump the brake lever and pedal several times to restore the brake pads after replacing the brake pads.

  • Page 52: Front Fork

    2-36 PERIODIC MAINTENANCE FRONT FORK • Move the front fork up and down several times and inspect for smooth movement. • Inspect for damage and oil leaks. • Inspect the bolts and nuts for tightness. • If any defects are found, replace the front fork with a new one. •...

  • Page 53: Spoke Nipple And Rim Lock Inspection

    PERIODIC MAINTENANCE 2-37 SPOKE NIPPLE AND RIM LOCK INSPECTION • Inspect the spokes for tension by squeezing the spoke nip- ples. • Retighten the spoke nipples with a spoke nipple wrench so as all spokes have same tension.  Spoke nipple: 6 N·m (0.6 kgf-m, 4.5 lbf-ft) ...

  • Page 54: Lubrication

    A. Lightweight oil such as WD-40 or penetrating oil B. Aerosol type Chain Lube C. SUZUKI SUPER GREASE “A” (or equivalent grease) or Water-proof wheel bearing grease Follow the schedule closely. The disassembly necessary to lubricate many components is in itself valuable preventative maintenance.

  • Page 55: Chassis Bolts And Nuts

    PERIODIC MAINTENANCE 2-39 CHASSIS BOLTS AND NUTS Check that all chassis bolts and nuts are tightened to their specified torque. (Refer to page 2-40 for the loca- tions of the following nuts and bolts on the motorcycle.) ITEM N·m kgf-m lbf-ft 1 Steering stem head nut 10.0...
  • Page 56 2-40 PERIODIC MAINTENANCE...

  • Page 57: Compression Pressure Check

    PERIODIC MAINTENANCE 2-41 COMPRESSION PRESSURE CHECK The compression pressure reading of a cylinder is a good indicator of its internal condition. The decision to replace the cylinder is often based on the results of a compression test. COMPRESSION PRESSURE SPECIFICATION (Automatic decomp. actuated) Standard 400 –...

  • Page 58: Oil Pressure Check

    2-42 PERIODIC MAINTENANCE OIL PRESSURE CHECK Check the oil pressure periodically. This will give a good indication of the condition of the moving parts.  Oil pressure 25 kPa (0.25 kgf/cm², 3.6 psi) at 6 000 r/min, oil temp. at 50 °C (122 °F) Low or high oil pressure can indicate any of the following conditions: LOW OIL PRESSURE * Clogged oil filter...
  • Page 59 TROUBLESHOOTING 3-1 TROUBLESHOOTING CONTENTS ENGINE ......................3- 2 RADIATOR (COOLING SYSTEM) .............. 3- 8 CHASSIS ..................... 3- 9 BRAKES ...................... 3-10 ELECTRICAL ....................3-11...

  • Page 60: Engine

    3-2 TROUBLESHOOTING ENGINE Complaint Symptom and possible causes Remedy Engine will not start Compression too low or is hard to start. • Valve clearance out of adjustment Adjust • Worn valve guides or poor seating of valves Repair or replace •...
  • Page 61 TROUBLESHOOTING 3-3 Complaint Symptom and possible causes Remedy Engine idles poorly. • Valve clearance out of adjustment Adjust • Valve timing out of adjustment Adjust • Poor seating of valves Repair • Worn valve guide Replace • Worn down camshafts Replace •...
  • Page 62 3-4 TROUBLESHOOTING Complaint Symptom and possible causes Remedy Noisy engine Excessive valve chatter • Too large valve clearance Adjust • Weakened or broken valve springs Replace • Worn tappet or cam surface Replace • Worn and burnt camshaft journal Replace Noise seems to come from piston •...
  • Page 63 TROUBLESHOOTING 3-5 Complaint Symptom and possible causes Remedy Engine runs poorly Defective engine internal/electrical parts in high speed range. • Weakened valve springs Replace • Worn down camshafts Replace • Valve timing out of adjustment Adjust • Incorrect spark plug gap Replace •...
  • Page 64 3-6 TROUBLESHOOTING Complaint Symptom and possible causes Remedy Engine lacks power. Defective engine internal/electrical parts • Loss of valve clearance Adjust • Weakened valve springs Replace • Valve timing out of adjustment Adjust • Worn piston ring or cylinder Replace •...
  • Page 65 TROUBLESHOOTING 3-7 Complaint Symptom and possible causes Remedy Dirty or heavy • Too much engine oil in the engine Drain out excess oil exhaust smoke • Worn piston ring or cylinder Replace • Worn valve guides Replace • Scored or scuffed cylinder wall Replace •...

  • Page 66: Radiator (Cooling System)

    3-8 TROUBLESHOOTING RADIATOR (COOLING SYSTEM) Complaint Symptom and possible causes Remedy Engine overheats • Not enough engine coolant Add coolant • Radiator core clogged with dirt or scale Clean • Clogged water passage Clean • Air trapped in the cooling circuit Bleed air •...

  • Page 67: Chassis

    TROUBLESHOOTING 3-9 CHASSIS Complaint Symptom and possible causes Remedy Heavy steering • Overtightened steering stem nut Adjust • Broken bearing in steering stem Replace • Distorted steering stem Replace • Not enough pressure in tires Adjust Wobbly handlebars • Loss of balance between right and left front forks Adjust •...

  • Page 68: Brakes

    3-10 TROUBLESHOOTING BRAKES Complaint Symptom and possible causes Remedy Insufficient brake • Leakage of brake fluid from hydraulic system Repair or replace power • Worn pads Replace • Oil adhesion of engaging surface of pads Clean disc and pads • Worn disc Replace •...

  • Page 69: Electrical

    TROUBLESHOOTING 3-11 ELECTRICAL Complaint Symptom and possible causes Remedy No sparking or poor • Fouled spark plug Clean sparking • Wet spark plug Clean and dry • Incorrect spark plug gap Replace • Defective spark plug Replace • Defective ignition coil/plug cap Replace •...

  • Page 70: Machine Tuning

    MACHINE TUNING 4-1 MACHINE TUNING CONTENTS SELECTION OF ECM TUNING MAP ............4- 2 SHORT WIRE CONNECTING PROCEDURE ........4- 3 FRONT FORK TUNING ................4- 4 COMPRESSION DAMPING FORCE ADJUSTMENT ......4- 4 REBOUND DAMPING FORCE ADJUSTMENT ........4- 4 OIL QUANTITY MINOR ADJUSTMENT ..........

  • Page 71: Selection Of Ecm Tuning Map

    4-2 MACHINE TUNING SELECTION OF ECM TUNING MAP In the ECM of this model, there are three different maps pro- vided, a standard map and two modified maps (injection map for slightly leaner mixture and that for slightly richer mixture). Select the appropriate short wire among those that come sup- plied in the motorcycle shipping crate and connect it to the mode select coupler.

  • Page 72: Short Wire Connecting Procedure

    MACHINE TUNING 4-3 SHORT WIRE CONNECTING PROCEDURE • Disconnect 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. •...

  • Page 73: Front Fork Tuning

    4-4 MACHINE TUNING FRONT FORK TUNING The front fork compression and rebound damping force, and oil capacity are adjustable for rider’s preference, rider’s weight and course condition. NOTE: * Break-in new front forks before attempting adjustment. * Be sure to adjust both right and left front forks equally. * Inspect the following items before attempting adjustment.

  • Page 74: Oil Quantity Minor Adjustment

    * Never mix different types of fork oil. Different oils may cause chemical reaction and deteriorate.  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)

  • Page 75: Oil Change (Only For Outer Tube Oil Chamber)

    4-6 MACHINE TUNING OIL CHANGE (Only for outer tube oil chamber) • Remove the front forks. (18-5) • Thoroughly clean the fork before disassembly.  * The fork oil quantity must be adjusted equally on both fork legs to provide equal performance. * Scratches or other damage on the inner tube or on the oil seal lip will cause oil leak.
  • Page 76 MACHINE TUNING 4-7 • Slide down the outer tube. • Pour the specified amount of fork oil into the outer tube.  99000-99001-SS5: SUZUKI FORK OIL SS-05 or equivalent Identification Oil quantity Parts No. Spring rate (Slit mark Oil quantity...

  • Page 77: Spring Change

    4-8 MACHINE TUNING SPRING CHANGE • Remove the front forks. (18-5) • Thoroughly clean the fork before disassembly.  * The fork oil quantity must be adjusted equally on both fork legs to provide equal performance. * Scratches or other damage on the inner tube or on the oil seal lip will cause oil leakage.
  • Page 78 13.89/14.47 US/Imp oz) 375 ml 312 – 411 ml 51171-28H00 (12.68/13.20 (10.55/10.99 – US/Imp oz) 13.89/14.47 US/Imp oz) 375 ml 312 – 411 ml Hard 51171-28H20 (12.68/13.20 (10.55/10.99 – US/Imp oz) 13.89/14.47 US/Imp oz)  99000-99001-SS5: SUZUKI FORK OIL SS-05 or equivalent...

  • Page 79: Front Fork Tuning Procedure

    4-10 MACHINE TUNING FRONT FORK TUNING PROCEDURE Test ride the motorcycle and find out how the front suspension reacts on various types of surface. According to the symptom noticed, adjust the front fork to the best setting for rider and race track conditions. To adjust, attempt changing fork oil capacity and compression and rebound damping force following the instructions below.

  • Page 80: Rear Suspension Tuning

    MACHINE TUNING 4-11 REAR SUSPENSION TUNING The rear suspension compression and rebound damping force, and spring pre-load are adjustable for rider’s preference, rider’s weight and course condition. NOTE: * Break-in the rear suspension when riding with a new rear cushion unit. (1-6) * Inspect the following items before attempting adjustment.

  • Page 81: Rebound Damping Force Adjustment

    4-12 MACHINE TUNING REBOUND DAMPING FORCE ADJUSTMENT NOTE: To set the adjuster, you must gently turn the adjust screw clock- wise until it stops, then back it out the recommended number of turns. Do not force the adjust screw past the stopped position, or you may damage the adjuster.

  • Page 82: Rear Suspension Tuning Procedure

    MACHINE TUNING 4-13 REAR SUSPENSION TUNING PROCEDURE • Adjust the rear suspension according to the rider’s weight and preference by referring to the table below. Spring Part No. Spring rate Marking paint Set-length adjustable range 53 N/mm 62211-37FK0 Orange (5.3 kgf/mm) Soft 55 N/mm 248 –...
  • Page 83 4-14 MACHINE TUNING After the sag measurement has been set 100 mm (3.94 in), test ride the motorcycle and adjust the suspen- sion for the rider and track conditions referring to the guide below. SYMPTOM SECTION ADJUSTMENT PROCEDURE Feels too hard overall •...

  • Page 84: Suspension Balance

    MACHINE TUNING 4-15 SUSPENSION BALANCE Balancing the front to rear suspension properly is the most critical adjustment for suspension performance. If the front forks are adjusted harder than the rear suspension, such as changing to heavier front fork oil, stiffer compression and rebound setting, air pressure build up in the forks and so on, the front forks will collapse less on bumps.

  • Page 85: Engine Removal And Installation

    ENGINE REMOVAL AND INSTALLATION 5-1 ENGINE REMOVAL AND INSTALLATION CONTENTS ENGINE REMOVAL AND INSTALLATION ..........5- 2 REMOVAL ..................... 5- 2 INSTALLATION ..................5- 6...
  • Page 86 5-2 ENGINE REMOVAL AND INSTALLATION ENGINE REMOVAL AND INSTALLATION REMOVAL • Drain engine oil. (2-13) • Drain engine coolant. (14-3) • Remove the seat 1. • Remove the radiator covers 2, left and right. • Remove the right frame cover 3. •...
  • Page 87 ENGINE REMOVAL AND INSTALLATION 5-3 • Loosen the muffler connector clamp bolt 8. • Remove the muffler 0 by removing its bolts 9. • Remove the exhaust pipe B by removing their nuts A. • Remove the exhaust pipe gasket C. •...
  • Page 88 5-4 ENGINE REMOVAL AND INSTALLATION • Disconnect the GP switch coupler M. • Remove the GP switch lead wire from the clamp 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.
  • Page 89 ENGINE REMOVAL AND INSTALLATION 5-5 • Remove the master cylinder rod pin X. • Remove the brake pedal pivot bolt Y and return spring Z. • Remove the kick starter lever \ by removing its bolt [. • Remove the gearshift lever ]. (9-3) NOTE: Mark A the gearshift shaft head at which the gearshift lever slit set for correct reinstallation.
  • Page 90 5-6 ENGINE REMOVAL AND INSTALLATION INSTALLATION Install the engine in the reverse order of removal. Pay attention to the following points: • Fit the swingarm in its position and hold it with the swingarm pivot shaft. • Mount the engine on the frame. •...
  • Page 91 ENGINE REMOVAL AND INSTALLATION 5-7 • Install the engine sprocket 1 and snap ring 2. Thrust  * Replace the snap ring 2 with a new one. * Seat the snap ring 2 in the groove and locate its end Sharp as shown in the illustration.
  • Page 92 • Install the return spring 7, brake pedal 8 and master cylinder rod pin 9. • Apply grease to the brake pedal pivot bolt 0.  99000-25010: SUZUKI SUPER GREASE “A” or equivalent • Tighten the brake pedal pivot bolt 0 to the specified torque.
  • Page 93 ENGINE REMOVAL AND INSTALLATION 5-9 • Fit the projection F of the throttle body to the depression of intake pipe. • Position the clamps G correctly. (20-23) • Install the condenser H. • Align the matching mark G on the clutch cable I with the matching mark H on the clutch cable bracket.
  • Page 94 5-10 ENGINE REMOVAL AND INSTALLATION • Temporarily tighten the exhaust pipe nuts M. NOTE: Degrease the stud bolts and exhaust pipe nuts M. • Insert the muffler to the exhaust pipe. • Temporarily tighten the muffler mounting front bolt N and rear bolt O.
  • Page 95 CYLINDER HEAD, CYLINDER AND PISTON 6-1 CYLINDER HEAD, CYLINDER AND PISTON CONTENTS CONSTRUCTION ..................6- 2 CYLINDER HEAD AND CYLINDER ............. 6- 2 CAMSHAFT, CAM CHAIN AND PISTON ..........6- 3 ENGINE TOP SIDE DISASSEMBLY ............6- 4 CYLINDER HEAD COVER REMOVAL ..........6- 4 CAMSHAFTS (AUTOMATIC DECOMP.) AND CAM CHAIN TENSION ADJUSTER REMOVAL ........

  • Page 96: Construction

    6-2 CYLINDER HEAD, CYLINDER AND PISTON CONSTRUCTION CYLINDER HEAD AND CYLINDER  1 Camshaft journal holder 0 Cylinder gasket 2 O-ring A Cylinder head bolt ITEM N·m kgf-m lbf-ft 3 Cylinder head B Camshaft journal holder bolt A (Initial) 18.0 4 Cylinder head gasket C Spark plug A (Final)

  • Page 97: Camshaft, Cam Chain And Piston

    CYLINDER HEAD, CYLINDER AND PISTON 6-3 CAMSHAFT, CAM CHAIN AND PISTON  1 Exhaust camshaft 0 Cam chain 2 Intake camshaft A Cam chain No.1 guide ITEM N·m kgf-m lbf-ft 3 Tappet B Cam chain tensioner 16.5 4 Valve spring C Cam chain tension adjuster 5 Exhaust valve A Cam chain tension adjuster cap bolt...

  • Page 98: Engine Top Side Disassembly

    6-4 CYLINDER HEAD, CYLINDER AND PISTON ENGINE TOP SIDE DISASSEMBLY CYLINDER HEAD COVER REMOVAL • Remove the seat. (5-2) • Remove the radiator covers and fuel tank. (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.
  • Page 99 CYLINDER HEAD, CYLINDER AND PISTON 6-5 • Place a wrench over the crankshaft and turn it counter clock- wise to align the TDC mark A with the center of the groove B of the timing inspection hole. NOTE: * The piston must be at TDC on the compression stroke. * Make sure that the cylinder is at TDC on compression stroke and also the timing mark C on the camshafts are aligned with the mating surface of the cylinder head.

  • Page 100: Cylinder Head Removal

    6-6 CYLINDER HEAD, CYLINDER AND PISTON • Disengage the camshafts C from cam chain B. • Remove the dowel pins D and C-rings E.  Do not drop the cam chain B, dowel pins D and C- rings E into the crankcase. CYLINDER HEAD REMOVAL •...

  • Page 101: Cylinder Removal

    CYLINDER HEAD, CYLINDER AND PISTON 6-7 • Remove the cylinder head base nuts C. • Loosen the cylinder base bolt D. • Remove the cylinder head bolts E. NOTE: When loosening the cylinder head bolts E, loosen each bolt lit- tle by little diagonally.

  • Page 102: Piston And Piston Ring Removal

    6-8 CYLINDER HEAD, CYLINDER AND PISTON PISTON AND PISTON RING REMOVAL • Remove the cylinder. (6-7) • Place a clean rag over the cylinder base to prevent the piston pin circlip 1 from dropping into the crankcase. • Remove the piston pin circlip 1. •...

  • Page 103: Engine Top Components Inspection And Service

    CYLINDER HEAD, CYLINDER AND PISTON 6-9 ENGINE TOP COMPONENTS INSPECTION AND SERVICE AUTOMATIC DECOMP. INSPECTION • Check the decomp. cam moves smoothly and shaft 1 rotates together. • If any abnormal condition are found, replace the camshaft assembly. CAMSHAFT INSPECTION ...
  • Page 104 6-10 CYLINDER HEAD, CYLINDER AND PISTON CAM WEAR • Measure the cam height H using the micrometer. • Replace a camshaft if the cams are worn to the service limit.  Cam height H Service Limit IN.: 34.48 mm (1.357 in) EX.: 33.64 mm (1.324 in) ...

  • Page 105: Cam Chain Tension Adjuster Inspection

    CYLINDER HEAD, CYLINDER AND PISTON 6-11 • If the camshaft journal oil clearance measured exceeds the limit, measure the inside diameter of the camshaft journal holder and outside diameter of the camshaft journal. • Replace the camshaft or the cylinder head depending upon which one exceeds the specification.

  • Page 106: Cylinder Head And Valve Inspection

    6-12 CYLINDER HEAD, CYLINDER AND PISTON CYLINDER HEAD AND VALVE INSPECTION VALVE DISASSEMBLY • Remove the tappet 1 and shim 2 by fingers or magnetic hand.  Identify the position of each removed part. (Intake side) • Install the sleeve protector a between the valve spring and cylinder head.
  • Page 107 CYLINDER HEAD, CYLINDER AND PISTON 6-13 • Remove the valve 6 from the combustion chamber side. • Remove the valve stem seal 7 and spring seat 8. • Remove the other valves in the same manner as described previously. CYLINDER HEAD DISTORTION •...
  • Page 108 6-14 CYLINDER HEAD, CYLINDER AND PISTON VALVE HEAD RADIAL RUNOUT • Place the dial gauge at a right angle to the valve head face and measure the valve head radial runout. • If it measures more than the service limit, replace the valve. ...
  • Page 109 CYLINDER HEAD, CYLINDER AND PISTON 6-15 VALVE STEM WEAR • If the valve stem is worn down to the limit, as measured with a micrometer, replace the valve. • If the stem is within the limit, then replace the guide. •...
  • Page 110 6-16 CYLINDER HEAD, CYLINDER AND PISTON • Cool down the new valve guides in a freezer for about one hour and heat the cylinder head to 100 – 150 °C (212 – 302 °F) with a hot plate.  Do not use a burner to heat the valve guide hole to prevent cylinder head distortion.
  • Page 111 CYLINDER HEAD, CYLINDER AND PISTON 6-17 • If the seat width W measured exceeds the standard value or seat width is not uniform, refuse the seat using the seat cutter.  Valve seat width W: Standard: 0.9 – 1.1 mm (0.035 – 0.043 in) VALVE SEAT SERVICING ˚...
  • Page 112 6-18 CYLINDER HEAD, CYLINDER AND PISTON • Clean and assemble the head and valve components. Fill the intake and exhaust ports with gasoline to check for leaks. • If any leaks occur, inspect the valve seat and face for burrs or other things that could prevent the valve from sealing.
  • Page 113 CYLINDER HEAD, CYLINDER AND PISTON 6-19 • Install the valve spring with the small-pitch portion A facing cylinder head. A Small-pitch portion B Large-pitch portion C UPWARD D Paint • Put on the valve spring retainer 2, and using the valve lifter (special tool) and sleeve protector (a or b) (special tool), press down the spring, fit the valve cotter halves to the stem end, and release the lifter to allow the valve cotter 3 to...

  • Page 114: Intake Pipe Removal

    • Remove intake pipe 3 by removing 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 the specified torque.

  • Page 115: Cylinder Inspection

    CYLINDER HEAD, CYLINDER AND PISTON 6-21 CYLINDER INSPECTION CYLINDER DISTORTION • Check the gasketed surface of the cylinder for distortion with a straightedge and thickness gauge, taking a clearance read- ing at several places indicated. • If the largest reading at any position of the straightedge exceeds the limit, replace the cylinder.

  • Page 116: Piston And Piston Ring Inspection

    6-22 CYLINDER HEAD, CYLINDER AND PISTON PISTON AND PISTON RING INSPECTION PISTON DIAMETER • Using a micrometer, measure the piston outside diameter at 8.0 mm (0.31 in) A from the piston skirt end. • If the measurement is less than the limit, replace the piston. ...
  • Page 117 CYLINDER HEAD, CYLINDER AND PISTON 6-23 PISTON RING-TO-GROOVE CLEARANCE • Decarbonize the piston ring and piston ring groove. • Measure the side clearances of the 1st piston ring using the thickness gauge. • If any of the clearances exceed the limit, replace both the pis- ton and piston ring.

  • Page 118: Crankshaft And Conrod Inspection

    6-24 CYLINDER HEAD, CYLINDER AND PISTON CRANKSHAFT AND CONROD INSPECTION For inspection other than the following, refer to page 10-8. CONROD SMALL END I.D. • Using a small bore gauge, measure the inside diameter of the conrod small end. • If the inside diameter of the conrod small end exceeds the limit, replace the conrod.

  • Page 119: Engine Top Side Assembly

    CYLINDER HEAD, CYLINDER AND PISTON 6-25 ENGINE TOP SIDE ASSEMBLY CAM CHAIN, CAM CHAIN TENSIONER AND CAM CHAIN No.1 GUIDE INSTALLATION Install the cam chain and cam chain tensioner in the reverse order of removal. Pay attention to the following points: •...

  • Page 120: Piston And Piston Ring Installation

    6-26 CYLINDER HEAD, CYLINDER AND PISTON PISTON AND PISTON RING INSTALLATION Install the piston and piston ring in the reverse order of removal. Pay attention to the following points: PISTON RING • Install the piston rings in the order of oil ring and 1st ring. •...
  • Page 121 CYLINDER HEAD, CYLINDER AND PISTON 6-27 PISTON • Install the piston 1 with the punch mark A facing towards the exhaust side. • Before installing the piston pin 2, apply MOLYBDENUM OIL SOLUTION onto its surface.  MOLYBDENUM OIL SOLUTION •...

  • Page 122: Cylinder And Cylinder Head Installation

    • Thoroughly wipe off oil from the fitting surface of the crank- case. • Apply SUZUKI BOND “1215” to the crankcase as shown.  99000-31110: SUZUKI BOND “1215” or equivalent • Install the dowel pins 1 into the crankcase and then install the cylinder gasket 2.
  • Page 123 CYLINDER HEAD, CYLINDER AND PISTON 6-29 CYLINDER HEAD • Install the dowel pins 1 into the cylinder and then install the cylinder head gasket 2 onto the cylinder.  Replace the cylinder head gasket 2 with a new one. • Place the cylinder head 3 on the cylinder. ...

  • Page 124: Camshaft (Automatic Decomp.) And Cam Chain Tension Adjuster Installation

    6-30 CYLINDER HEAD, CYLINDER AND PISTON CAMSHAFT (AUTOMATIC DECOMP.) AND CAM CHAIN TENSION ADJUSTER INSTALLATION Install the camshaft and cam chain tension in the reverse order of removal. Pay attention to the following points: CAMSHAFT (AUTOMATIC DECOMP.) • Place a wrench over the crankshaft and turn it counter clock- wise to align the TDC mark A with the center of the groove B of the timing inspection hole.
  • Page 125 • Install the camshafts, intake 3 and exhaust 4. • Apply grease to the new O-ring 5 and install it to the cam- shaft journal holder 6.  Replace the O-ring 5 with a new one.  99000-25010: SUZUKI SUPER GREASE “A” or equivalent...
  • Page 126 • Retract the push rod by pushing the stopper 1. • Apply grease to the O-ring 2.  Replace the O-ring 2 with a new one.  99000-25010: SUZUKI SUPER GREASE “A” or equivalent • Install the cam chain tension adjuster 3 as shown. A Upward •...
  • Page 127 • Inspect the valve clearance. (2-25) • Apply grease to the O-rings 9.  Replace the O-rings 9 with new ones.  99000-25010: SUZUKI SUPER GREASE “A” or equivalent • Tighten the TDC plug 0 and crankshaft hole plug A to the specified torque.

  • Page 128: Cylinder Head Cover Installation

    • Apply bond to the end caps of the cylinder head cover gasket 1 as shown.  99000-31140: SUZUKI BOND “1207B” or equivalent • Install the cylinder head cover No.2 gasket 4.  Replace the cylinder head cover No.2 gasket 4 with a new one.
  • Page 129 CLUTCH 7-1 CLUTCH CONTENTS CONSTRUCTION ..................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 ..................

  • Page 130: Construction

    7-2 CLUTCH CONSTRUCTION CLUTCH  1 Clutch pressure plate 0 Lock washer 2 Bearing A Clutch sleeve hub ITEM N·m kgf-m lbf-ft 3 Push piece B Needle bearing 4 Clutch driven No.1 plate (Silver) C Primary driven gear 65.0 5 Clutch driven No.1 plate (Gray) D Spacer 6 Spring washer E Washer...

  • Page 131: Clutch Plate

    CLUTCH 7-3 CLUTCH PLATE REMOVAL • Drain engine oil. (2-13) • Remove the brake pedal. (17-20) • Remove the clutch cover 1 and its 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. •...
  • Page 132 7-4 CLUTCH • Remove the clutch 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 •...

  • Page 133: Inspection

    CLUTCH 7-5 INSPECTION DRIVE PLATE • Measure the drive plate thickness.  Drive plate thickness Service Limit: 2.42 mm (0.095 in)  09900-20101: Vernier calipers • Inspect the drive plates for wear, distortion and discoloration. • If the drive plate thickness is found to have reached the limit, replace it with a new one.

  • Page 134: Installation

    7-6 CLUTCH PUSH ROD • Inspect the push rod for wear and damage. • If any defects are found, replace the push rod with a new one. RELEASE BEARING • Inspect the clutch release bearing 1 for any abnormality, par- ticularly cracks, to decide whether it can be reused or should be replaced.
  • Page 135 CLUTCH 7-7 • Install the push rod and push piece 5. • Apply engine oil to the release bearing 6. • Install the release bearing 6 and washer 7. • Fit the clutch pressure plate 8. C Direction of outside •...

  • Page 136: Primary Driven Gear And Clutch Sleeve Hub

    7-8 CLUTCH PRIMARY DRIVEN GEAR AND CLUTCH SLEEVE HUB REMOVAL • Remove the clutch cover. (7-3) • Remove the pressure plate and clutch plates. (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.

  • Page 137: Inspection

    CLUTCH 7-9 INSPECTION • Inspect the clutch sleeve hub and primary driven gear for wear and cracks. • If any defects are found, replace the sleeve hub or driven gear with a new one. • Inspect the needle bearing and spacer for damage and wear. •...
  • Page 138 7-10 CLUTCH • Tighten the clutch sleeve hub nut 7 with the special tool to the specified torque.  09920-53740: Clutch sleeve hub holder 09920-31020: Extension handle  Clutch sleeve hub nut: 90 N·m (9.0 kgf-m, 65.0 lbf-ft) • Make sure the clutch sleeve hub for smooth movement. •...

  • Page 139: Clutch Release Camshaft

    CLUTCH 7-11 CLUTCH RELEASE CAMSHAFT REMOVAL • Remove the clutch cover and its gasket. (7-3) • Remove the pressure plate and push rod. (7-3) • Remove the retainer 2 by removing its bolt 1. • Disconnect the clutch cable 3. •...

  • Page 140: Installation

    Install the clutch release camshaft 1 in the reverse order of removal. Pay attention to the following points: • Apply SUZUKI MOLY PASTE to the clutch release camshaft.  99000-25140: SUZUKI MOLY PASTE or equivalent • Apply grease to the oil seal lip.
  • Page 141 KICK STARTER 8-1 KICK STARTER CONTENTS CONSTRUCTION ..................8- 2 KICK STARTER ..................8- 2 KICK STARTER ................... 8- 3 REMOVAL ..................... 8- 3 INSPECTION ..................8- 4 INSTALLATION ..................8- 5...

  • Page 142: Construction

    8-2 KICK STARTER CONSTRUCTION KICK STARTER  1 Kick starter lever 9 Kick starter 2 Spring guide 0 Spring ITEM N·m kgf-m lbf-ft 3 Spring A Wave washer 4 Kick starter guide B Kick starter idle gear 21.0 5 Washer A Kick starter lever screw 6 Kick starter drive gear B Kick starter lever bolt...

  • Page 143: Removal

    KICK STARTER 8-3 KICK STARTER REMOVAL • Drain engine oil. (2-13) • Drain engine coolant. (14-3) • Remove the brake 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. •...

  • Page 144: Inspection

    8-4 KICK STARTER • Remove the wave washer 9. • Unhook the end of return spring 0. • Remove the kick starter shaft assembly A. • Remove the following parts from the kick starter shaft assem- bly A. Starter shaft B Washer G Return spring C Snap ring H...

  • Page 145: Installation

    KICK STARTER 8-5 • Inspect the kick starter idle gear teeth for wear and damage. • Inspect the kick starter idle gear and its shaft contact surface for wear and damage. • Inspect the wave washer for wear and damage. •...
  • Page 146 8-6 KICK STARTER • Install the guide 9 to the kick starter shaft. NOTE: Align the concave B of guide with kick starter shaft hole A. • Install the kick starter 0 onto the kick starter shaft. NOTE: When installing the kick starter 0, align the wide spline teeth C and D.
  • Page 147 KICK STARTER 8-7 • Install the wave washer B with convex side inside onto the kick starter idle shaft. • Install the kick starter idle gear C. • Reassemble the clutch component parts. (7-9, -10) • Install the dowel pins D and gasket E. ...
  • Page 148 8-8 KICK STARTER • Tighten the kick starter lever bolt H to the specified torque.  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 •...

  • Page 149: Gearshifting

    GEARSHIFTING 9-1 GEARSHIFTING 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 ..................

  • Page 150: Construction

    9-2 GEARSHIFTING CONSTRUCTION GEARSHIFT LINKAGE  1 Gearshift shaft A Gearshift cam 2 Return spring B Gearshift cam stopper ITEM N·m kgf-m lbf-ft 3 Gearshift lever C GP switch 16.5 4 Gearshift pawl lifter A Gearshift arm stopper 0.85 5 Gearshift roller B Pawl lifter screw 17.5 6 Gearshift cam driven gear...

  • Page 151: Removal

    GEARSHIFTING 9-3 GEARSHIFT LINKAGE REMOVAL • Drain engine oil. (2-13) • Drain engine coolant. (14-3) • Remove the gearshift lever 2 by removing its bolt 1. NOTE: Mark the gearshift shaft head A at which the gearshift lever slit set for correct reinstallation. •...
  • Page 152 9-4 GEARSHIFTING • Remove the gearshift pawls A, pins B, springs C and 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 removing is bolt G.

  • Page 153: Inspection

    GEARSHIFTING 9-5 INSPECTION • Inspect the gearshift shaft 1 for bends and damage. • Inspect the return spring 2 for damage. • If necessary, replace the defective parts with a new one. • Inspect the pawls 3, pins 4, springs 5, gearshift roller 6 and gearshift cam driven gear 7 for damage.
  • Page 154 9-6 GEARSHIFTING • Align the pin groove A with the pin B when installing the stopper plate 7. • Apply a small quantity of THREAD LOCK to the gearshift cam driven gear pin 8 and tighten it to the specified torque. ...
  • Page 155 GEARSHIFTING 9-7 • Install the gearshift cam driven gear and pawl lifter. • Apply THREAD LOCK SUPER to the screws E and tighten them to the specified torque.  99000-32030: THREAD LOCK SUPER “1303” or equivalent  Pawl lifter screw: 8.5 N·m (0.85 kgf-m, 6.0 lbf-ft) •...

  • Page 156: Gear Position (Gp) Switch

    • Install the springs 1 and switch contacts 2. • Fit the new O-ring 3 to GP switch 4 and apply grease to it.  Replace the O-ring 3 with a new one.  99000-25010: SUZUKI SUPER GREASE “A” or equivalent...
  • Page 157 GEARSHIFTING 9-9 • Install the GP switch 4 and tighten the bolts 5 to the speci- fied torque.  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.

  • Page 158: Transmission And Crankshaft

    TRANSMISSION AND CRANKSHAFT 10-1 TRANSMISSION AND CRANKSHAFT CONTENTS CONSTRUCTION ..................10- 2 TRANSMISSION ................. 10- 2 CRANKSHAFT ..................10- 3 ENGINE BOTTOM SIDE ................10- 4 PRIMARY DRIVE GEAR REMOVAL ..........10- 4 CRANKCASE SEPARATION ............. 10- 5 TRANSMISSION REMOVAL .............. 10- 5 CRANKSHAFT REMOVAL ..............

  • Page 159: Construction

    10-2 TRANSMISSION AND CRANKSHAFT CONSTRUCTION TRANSMISSION  1 1st driven gear 0 Gearshift fork No.2 2 5th driven gear A Gearshift fork No.3 ITEM N·m kgf-m lbf-ft 3 4th driven gear B Gearshift cam 0.85 4 3rd driven gear C Countershaft 5 Driveshaft D 5th drive gear 6 Sliding dog...

  • Page 160: Crankshaft

    TRANSMISSION 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 0.85 4 Left crankshaft 65.0...

  • Page 161: Engine Bottom Side

    10-4 TRANSMISSION AND CRANKSHAFT ENGINE BOTTOM SIDE • Remove the engine assembly. (5-2 to -5) • Disconnect the crankcase breather hose 1. • Remove the engine top side 2 (cylinder head, cylinder and piston). (6-4 to -8) • Remove the magneto rotor and key. (15-17, -18) •...

  • Page 162: Crankcase Separation

    TRANSMISSION AND CRANKSHAFT 10-5 CRANKCASE SEPARATION • Remove the engine sprocket spacer 1 and two O-rings 2. • Remove the oil strainer cap 3 and oil strainer (No.1). (2-15) • Remove the crankcase bolts 4. • Separate the crankcase with the special tool. ...

  • Page 163: Crankshaft Removal

    10-6 TRANSMISSION AND CRANKSHAFT • Remove the gearshift fork shafts 4. • Remove the gearshift cam 5. • Remove the gearshift forks 6. • Remove the countershaft assembly 7 and driveshaft assem- bly 8. CRANKSHAFT REMOVAL • Remove the crankshaft with the special tool. ...

  • Page 164: Transmission Inspection

    TRANSMISSION AND CRANKSHAFT 10-7 TRANSMISSION INSPECTION • Inspect the gear teeth, dogs, and gearshift grooves for abnor- mal wear and damage. • Inspect the bushings and splines for abnormal wear and dis- coloration. • If necessary, replace defective parts with a new one. •...

  • Page 165: Conrod Inspection

    10-8 TRANSMISSION AND CRANKSHAFT • Measure the gearshift fork groove width with a vernier cali- pers.  Gearshift fork groove width Standard: 5.00 – 5.10 mm (0.197 – 0.201 in)  09900-20101: Vernier calipers CONROD INSPECTION • For conrod inspection other than the following, refer to page 6-24.

  • Page 166: Crankcase Reed Valve Inspection

    TRANSMISSION AND CRANKSHAFT 10-9 CRANKCASE REED VALVE INSPECTION • Inspect the crankcase reed valve 1 and reed valve guide 2 for crack and damage. • If any defects are found, replace the crankcase reed valve and reed valve guide with a new one. OIL SEAL INSPECTION •...

  • Page 167: Bearing Inspection

    Oil seal 2:  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 before installing them.

  • Page 168: Bearing Removal And Installation

    TRANSMISSION AND CRANKSHAFT 10-11 BEARING REMOVAL AND INSTALLATION REMOVAL • Remove the oil seals. (10-9) • Remove the bearing retainers 1, 2.  Replace the bearing with new a one. • Remove the bearings (3, 4, 5, 6, 7, 8) with the special tool.
  • Page 169 10-12 TRANSMISSION AND CRANKSHAFT • Remove the bearing 0 with the special tools.  09923-74511: Bearing puller 09930-30104: Rotor remover sliding shaft • Remove the bearing A with the special tools.  09921-20200: Bearing remover (10 mm) 09930-30104: Rotor remover sliding shaft •...

  • Page 170: Crankcase Reed Valve Installation

    TRANSMISSION AND CRANKSHAFT 10-13 NOTE: * Press the bearings (1, 3, 6) into the crankcase, so that the stepped side A faces inside of the crankcase. * Press the bearing 7 into the crankcase, so that the sealed side C faces outside of the crankcase. B Inside of the crankcase D Outside of the crankcase •...
  • Page 171 • Apply grease to the oil seal lip.  Replace the oil seal 4 with a new one.  99000-25010: SUZUKI SUPER GREASE “A” or equivalent • Install a new oil seal 4 with the special tool.  09930-35010: Rotor remover...

  • Page 172: Transmission Installation

    TRANSMISSION AND CRANKSHAFT 10-15 TRANSMISSION INSTALLATION  Replace the snap ring 1 with a new one. NOTE: Install the snap ring 1 in the groove and locate its end as shown in the illustration. a Thrust b Sharp edge...
  • Page 173 10-16 TRANSMISSION AND CRANKSHAFT • Apply engine oil to the following parts: driveshaft, countershaft, transmission gears, bearings. • Install the driveshaft 2 and countershaft 3 with gears installed. NOTE: * Install the washers A, B located in both ends of the driveshaft positively.

  • Page 174: Crankcase Installation

    • Inspect the crankshaft, countershaft and driveshaft for smooth movement. • Apply grease to the oil seal lip and O-rings 4.  Replace the O-rings 4 with new ones.  99000-25010: SUZUKI SUPER GREASE “A” or equivalent • Fit the O-rings 4 and spacer 5 to the driveshaft.

  • Page 175: Primary Drive Gear Installation

    • Install the kick starter idle gear and kick starter shaft assem- bly. (8-6, 7) • Apply grease to the oil seal lip.  99000-25010: SUZUKI SUPER GREASE “A” or equivalent • Install the primary drive gear 1 and washer 2.

  • Page 176: Lubrication System

    LUBRICATION SYSTEM 11-1 LUBRICATION SYSTEM CONTENTS ENGINE LUBRICATION SYSTEM ............11- 2 ENGINE LUBRICATION SYSTEM CHART ........11- 2 ENGINE OIL LEVEL INSPECTION ............. 11- 3 ENGINE OIL CHANGE ................ 11- 3 ENGINE OIL FILTER CHANGE ............11- 3 OIL PRESSURE CHECK ..............11- 3 OIL STRAINER REMOVAL ..............

  • Page 177: Engine Lubrication System

    11-2 LUBRICATION SYSTEM ENGINE LUBRICATION SYSTEM ENGINE LUBRICATION SYSTEM CHART...

  • Page 178: Engine Oil Level Inspection

    LUBRICATION SYSTEM 11-3 ENGINE OIL LEVEL INSPECTION (2-12) ENGINE OIL CHANGE (2-13) ENGINE OIL FILTER CHANGE (2-14) OIL PRESSURE CHECK (2-42) OIL STRAINER REMOVAL OIL STRAINER No.1 (2-15) OIL STRAINER No.2 (2-15) OIL STRAINERS INSPECTION (2-16) OIL STRAINER INSTALLATION OIL STRAINER No.1 (2-17) OIL STRAINER No.2 (2-17) OIL REED VALVE REMOVAL (10-5)

  • Page 179: Oil Seal Inspection

     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.1 AND No.2 REMOVAL OIL PUMP No.1 • Drain engine oil. (2-13) •...
  • Page 180 LUBRICATION SYSTEM 11-5 • Remove the clutch component parts. (7-8) • Remove the primary drive gear 3. • Remove the snap ring 4, washer 5 and oil pump idle gear  09900-06107: Snap ring remover (Open type) • Remove the oil pump No.1 8 by removing its bolts 7. •...

  • Page 181: Oil Pump No.1 And No.2 Inspection

    11-6 LUBRICATION SYSTEM • Remove the outer rotor 6, oil pump No.2 shaft 7, pin 8 and inner rotor 9. OIL PUMP No.1 AND No.2 INSPECTION • Check the oil pump with each part for 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.
  • Page 182 LUBRICATION SYSTEM 11-7 • Install the outer rotor 6.  Face the punch mark B on inner rotor 5 outer rotor 6 to the crankcase. • Apply engine oil to the oil pump driven gear shaft, outer rotor and inner rotor. •...
  • Page 183 11-8 LUBRICATION SYSTEM • Apply engine oil to the oil pump No.2 shaft 1, outer rotor 4 and inner rotor 3. • Install the oil pump No.2 shaft 1 and inner rotor 3 onto the crankcase. • Install the outer rotor 4 onto the crankcase. ...

  • Page 184: Fi System Diagnosis

    FI SYSTEM DIAGNOSIS 12-1 FI SYSTEM DIAGNOSIS CONTENTS PRECAUTIONS IN SERVICING ..............12- 3 CONNECTOR/COUPLER ..............12- 3 ECM/VARIOUS SENSORS ..............12- 4 ELECTRICAL CIRCUIT INSPECTION PROCEDURE......12- 6 USING THE MULTI CIRCUIT TESTER..........12- 9 FI SYSTEM TECHNICAL FEATURES ............12-10 INJECTION TIME (INJECTION VOLUME) ..........
  • Page 185 12-2 FI SYSTEM DIAGNOSIS FI SYSTEM DIAGNOSIS CONTENTS ECM (FI Control Unit)................12-60 REMOVAL.................... 12-60 INSTALLATION ................... 12-60 SENSORS ....................12-61 CKP SENSOR/CRANKSHAFT ROTATION SIGNAL SENSOR INSPECTION ............... 12-61 CKP SENSOR/CRANKSHAFT ROTATION SIGNAL SENSOR REMOVAL AND INSTALLATION ........12-61 IAP SENSOR INSPECTION ..............12-61 IAP SENSOR REMOVAL AND INSTALLATION ........

  • Page 186: Precautions In Servicing

    FI SYSTEM DIAGNOSIS 12-3 PRECAUTIONS IN SERVICING When handling the component parts or servicing the FI system, observe the following points for the safety of the system. CONNECTOR/COUPLER • Faulty FI system is often related to poor electrical contact of connector/coupler.

  • Page 187: Ecm/Various Sensors

    12-4 FI SYSTEM DIAGNOSIS • When taking measurements at electrical connectors using a tester probe, be sure to insert the probe from the wire harness side (backside) of the connector/coupler. 1 Coupler 2 Probe • When connecting meter probe from the terminal side of the coupler (where connection from harness side not being possi- ble), use extra care not to force and cause the male terminal to bend or the female terminal to open.
  • Page 188 FI SYSTEM DIAGNOSIS 12-5 • When disconnecting and connecting the ECM, make sure to stop the engine, or electronic parts may get damaged. WHEN USING THE BATTERY LEAD WIRE (Optional part: INCORRECT 36890-28H00) • 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.

  • Page 189: Electrical Circuit Inspection Procedure

    12-6 FI SYSTEM DIAGNOSIS • Before measuring voltage at each terminal, check to make sure that battery voltage is 11 V or higher. Terminal voltage check with a low voltage battery will lead to erroneous diagno- sis. • Never connect any tester (voltmeter, ohmmeter, or whatever) to the ECM when its coupler is disconnected.
  • Page 190 FI SYSTEM DIAGNOSIS 12-7 • Using a test male terminal, check the female terminals of the circuit being checked for contact tension. Check each terminal visually for poor contact (possibly caused by dirt, corrosion, rust, entry of foreign object, etc.). At the same time, check to make sure that each terminal is fully inserted in the coupler and locked.
  • Page 191 12-8 FI SYSTEM DIAGNOSIS VOLTAGE CHECK If voltage is supplied to the 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 ground.

  • Page 192: Using The Multi Circuit Tester

    1 ECM *1 To other parts USING THE MULTI CIRCUIT TESTER • Use the Suzuki multi circuit tester set (09900-25008). • Use well-charged batteries in the tester. • Be sure to set the tester to the correct testing range. USING THE TESTER •...

  • Page 193: Fi System Technical Features

    12-10 FI SYSTEM DIAGNOSIS FI SYSTEM TECHNICAL FEATURES INJECTION TIME (INJECTION VOLUME) The factors to determine the injection time include the basic fuel injection time, which is calculated on the basis of intake air pressure, engine speed and throttle opening angle, and various compensations. These compensations are determined according to the signals from various sensors that detect the engine and driving conditions.

  • Page 194: Compensation Of Injection Time (Volume)

    FI SYSTEM DIAGNOSIS 12-11 COMPENSATION OF INJECTION TIME (VOLUME) The following different signals are output from the respective sensors for compensation of the fuel injection time (volume). SIGNAL DESCRIPTION ENGINE COOLANT TEMPERATURE SEN- When engine coolant temperature is low, injection time (vol- SOR SIGNAL ume) is increased.

  • Page 195: Fi System Parts Location

    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...
  • Page 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...

  • Page 197: Fi System Wiring Diagram

    12-14 FI SYSTEM DIAGNOSIS FI SYSTEM WIRING DIAGRAM Magneto Crankshaft position sensor (CKPS) Regulator/rectifier Condenser Crankshaft rotation signal sensor Intake air pressure sensor R/Bl (IAPS) Fuel pump Throttle position sensor FI indicator light (option) (TPS) Fuel injector Gr/W Tip-over sensor (TOS) Br/W Intake air temperature sensor (IATS)

  • Page 198: Ecm Terminal

    FI SYSTEM DIAGNOSIS 12-15 ECM TERMINAL TERMINAL TERMINAL CIRCUIT CIRCUIT Power source (+B) — TO sensor signal (TOS) Map select input (MAP 1) CKP sensor signal (CKP+) FI indicator GP switch signal (GP) ECT sensor signal (ECTS) TP sensor signal (TPS) —...

  • Page 199: Self-Diagnosis Function

    12-16 FI SYSTEM DIAGNOSIS SELF-DIAGNOSIS FUNCTION The self-diagnosis function is incorporated in the ECM. It can be notified by using the FI indicator light assy (option). To check the function of the individual FI system devices, the dealer mode is provided. In this check, the tool is necessary to read the DTC (Diagnostic Trouble Code) that identify malfunction location.

  • Page 200: Diagnostic Trouble Code Table

    FI SYSTEM DIAGNOSIS 12-17 DIAGNOSTIC TROUBLE CODE TABLE EXAMPLE: When CKP sensor and TO sensor defective (DTC No.12 and 23) FI light Code No.12 Code No.23 Code No.12 Code No.23 0.3 0.3 0.3 0.3 0.3 0.3 Time (sec.) FI LIGHT DTC No.

  • Page 201: Tp Sensor Adjustment

    12-18 FI SYSTEM DIAGNOSIS TP SENSOR ADJUSTMENT 1. Connect a 12 volt battery using the battery lead wire to ser- vice coupler. (12-19) 36890-28H00: Battery lead wire (option) 2. Loosen the screw 1 with the special tool. 3. Turn the TP sensor 2. 4.

  • Page 202: Fi System Troubleshooting

    FI SYSTEM DIAGNOSIS 12-19 FI SYSTEM TROUBLESHOOTING VISUAL INSPECTION Prior to diagnosis using the FI indicator light assy, perform the following visual inspections. The reason for visual inspection is that mechanical failures (such as oil leakage) cannot be displayed on the FI indicator light assy.

  • Page 203: Self-Diagnosis Reset Procedure

    * How to use trigger. (Refer to the SDS operation manual for fur- ther details.)  09904-41010: SUZUKI Diagnostic system set 99565-01010-021: CD-ROM Ver.21...

  • Page 204: Use Of Sds Diagnosis Reset Procedure

    FI SYSTEM DIAGNOSIS 12-21 USE OF SDS DIAGNOSIS RESET PROCEDURE • After repairing the trouble, disconnect the battery lead wire coupler connect it again. • Click the DTC inspection button 1. • Check the DTC. • The previous malfunction history code (Past DTC) still remains stored in the ECM.

  • Page 205: Show Data When Trouble (Displaing Data At The Time Of Dtc)

    12-22 FI SYSTEM DIAGNOSIS SHOW DATA WHEN TROUBLE (DISPLAING DATA AT THE TIME OF DTC) ECM stores the engine and driving conditions (in the form of data as shown in the figure) at the moment of the detection of a malfunction in its memory. This data is called “Show data when trouble”. Therefore, it is possible to know engine and driving conditions (e.g., whether the engine was warm or not, where the vehicle was running or stopped) when a malfunction was detected by checking the show data when trouble.

  • Page 206: Sds Check

    (STD), comparison between the same models helps facilitate the troubleshooting. • Set up the SDS tools. ( 12-20)  09904-41010: SUZUKI Diagnostic system set 99565-01010-021: CD-ROM Ver.21 NOTE: * Before taking the sample of data, check and clear the Past DTC.
  • Page 207 12-24 FI SYSTEM DIAGNOSIS Data at 3 000 r/min under no load Approx. 3 000 r/min Check the engine coolant temperature. XX ˚C Check the manifold absolute pressure. XX kPa Data at the time of racing Throttle: Quick wide open Throttle: Slowly open...
  • Page 208 FI SYSTEM DIAGNOSIS 12-25 Data of intake negative pressure during idling (90 °C) Check the manifold absolute pressure. XX kPa Check the engine coolant temperature. Approx. 90 ˚C Data of manifold absolute pressure operation at the time of starting Check the manifold absolute pressure. XX kPa...
  • Page 209 12-26 FI SYSTEM DIAGNOSIS Example of trouble Three data; value 1 (past data 1), value 2 (past data 2) and value 3 (current data 3); can be made in compar- ison by showing them in the graph. Read the change of value by comparing the current data 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.

  • Page 210: Dtc And Defective Condition

    FI SYSTEM DIAGNOSIS 12-27 DTC AND DEFECTIVE CONDITION DETECTED DTC No. DETECTED FAILURE CONDITION CHECK FOR ITEM The signal does not reach ECM for 1 CKP sensor wiring and mechan- second or more, after receiving the ical parts CKP sensor IAP sensor input signal.
  • Page 211 12-28 FI SYSTEM DIAGNOSIS DETECTED DTC No. DETECTED FAILURE CONDITION CHECK FOR ITEM The sensor voltage should be the fol- TO sensor, lead wire/coupler lowing for 1 second and more. connection 0.17 V sensor voltage < 4.73 V In other than the above value, 23 (P1651) is indicated.

  • Page 212: 12" (P0335) Ckp Sensor Circuit Malfunction

    FI SYSTEM DIAGNOSIS 12-29 “12” (P0335) CKP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE The signal does not reach ECM for 1 second or • Metal particles or foreign material being stuck on more, after receiving the IAP sensor input signal. the CKP sensor and rotor tip.
  • Page 213 12-30 FI SYSTEM DIAGNOSIS 4) If OK, then check the continuity between each terminal and ground.  CKP sensor resistance: ∞ Ω (Infinity) (Green – Ground) (Red – Ground)  09900-25008: Multi circuit tester set  Tester knob indication: Resistance (Ω) Are the resistance and continuity OK? Go to step 2.

  • Page 214: 14" (P0120-H/L) Tp Sensor Circuit Malfunction

    FI SYSTEM DIAGNOSIS 12-31 “14” (P0120-H/L) TP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE Output voltage is not within the following • TP sensor maladjusted. range. • TP sensor circuit open or short. Difference between actual throttle open- • TP sensor malfunction. ing and opening calculated by ECM is •...
  • Page 215 12-32 FI SYSTEM DIAGNOSIS 5) Measure the voltage at the R/Bl wire A and ground. 6) If OK, then measure the voltage at the R/Bl wire A and B/Br wire B.  TP sensor input voltage: 4.5 – 5.5 V (+ R/Bl –...
  • Page 216 FI SYSTEM DIAGNOSIS 12-33 7) Insert the needle-pointed probes to the lead wire coupler. 8) Check the continuity between Yellow wire C and terminal 5. 9) Also, check the continuity between B/Br wire B and terminal  TP sensor lead wire continuity: Continuity () ...
  • Page 217 12-34 FI SYSTEM DIAGNOSIS 8) Insert the needle-pointed probes to the lead wire coupler. 9) Check the continuity between Yellow wire C and terminal 5. 10)Also, check the continuity between R/Bl wire A and terminal  TP sensor lead wire continuity: Continuity () ...

  • Page 218: 15" (P0115-H/L) Ect Sensor Circuit Malfunction

    FI SYSTEM DIAGNOSIS 12-35 “15” (P0115-H/L) ECT SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE Output voltage is not within the following • ECT sensor circuit open or short. range. • ECT sensor malfunction. 0.2 V Sensor voltage < 4.9 V •...
  • Page 219 12-36 FI SYSTEM DIAGNOSIS 5) Insert the needle-pointed probes to the lead wire coupler. 6) Measure the voltage between B/Bl wire terminal A and ground. 7) If OK, then measure the voltage between B/Bl wire terminal A and B/Br wire terminal B. ...
  • Page 220 FI SYSTEM DIAGNOSIS 12-37 Step 1 (When indicating P0115-L:) 1) Stop the engine. 2) Check the ECT sensor coupler 1 for loose or poor contacts. If OK, then measure the output voltage. 3) Remove the fuel tank. (13-2, -3) 4) Disconnect the ECT sensor coupler and ECM coupler. 5) Insert the needle-pointed probes to the lead wire coupler.
  • Page 221 12-38 FI SYSTEM DIAGNOSIS Step 2 1) If necessary, connect the ECM coupler. 2) Disconnect the ECT sensor coupler. 3) Measure the ECT sensor resistance.  ECT sensor resistance: Approx. 2.58 kΩ at 20 °C (68 °F) (Terminal – Terminal) ...

  • Page 222: 17" (P0105-H/L) Iap Sensor Circuit Malfunction

    FI SYSTEM DIAGNOSIS 12-39 “17” (P0105-H/L) IAP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE IAP sensor voltage is not within the fol- • Clogged vacuum passage between throttle body lowing range. and IAP sensor. 0.23 V Sensor voltage < 4.11 V •...
  • Page 223 12-40 FI SYSTEM DIAGNOSIS 4) Connect a 12 volts battery by using the battery lead wire to the service coupler. (12-19) 5) Insert the needle-pointed probes to the lead wire coupler. 6) Measure the voltage at the R/Bl wire A and ground. 7) If OK, then measure the voltage at the R/Bl wire A and B/Br wire B.
  • Page 224 FI SYSTEM DIAGNOSIS 12-41 6) Remove the fuel tank. (13-2, -3) 7) Disconnect the ECM coupler. (12-60) 8) Insert the needle-pointed probes to the lead wire coupler. 9) Check the continuity between G/B wire C and terminal 6. 10) If OK, then check the continuity between B/Br wire B and terminal N.
  • Page 225 12-42 FI SYSTEM DIAGNOSIS 7) Remove the fuel tank. (13-2, -3) 8) Disconnect the ECM coupler. (12-60) 9) Check the continuity between R/Bl wire A and terminal C. 10) Also, check the continuity between G/B wire C and terminal  IAP sensor lead wire continuity: Continuity () ...
  • Page 226 FI SYSTEM DIAGNOSIS 12-43 Step 3 1) Remove the throttle body. (13-8, -9) 2) Remove the IAP sensor. (12-61) 3) Connect the vacuum pump gauge to the vacuum port of the IAP sensor. 4) Arrange 3 new 1.5 V batteries in series 1 (check that total - voltage is 4.5 –...

  • Page 227: 21" (P0110-H/L) Iat Sensor Circuit Malfunction

    12-44 FI SYSTEM DIAGNOSIS “21” (P0110-H/L) IAT SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE Output voltage is not within the following • IAT sensor circuit open or short. range. • IAT sensor malfunction. 0.19 V Sensor voltage < 4.93 V •...
  • Page 228 FI SYSTEM DIAGNOSIS 12-45 6) Measure the voltage between Dg wire terminal A and ground. 7) If OK, then measure the voltage between Dg wire terminal A and B/Br wire terminal B.  IAT sensor input voltage: 4.5 – 5.5 V (+ Dg –...
  • Page 229 12-46 FI SYSTEM DIAGNOSIS Step 1 (When indicating P0110-L:) 1) Stop the engine. 2) Remove the seat and fuel tank rubber band. (5-2, 13-2) 3) Check the IAT sensor coupler 1 for loose or poor contacts. If OK, then check the IAT sensor lead wire continuity. 4) Remove the fuel tank.
  • Page 230 FI SYSTEM DIAGNOSIS 12-47 Step 2 1) Connect the ECM coupler. 2) Disconnect the IAT sensor coupler. 3) Measure the IAT sensor resistance.  IAT sensor resistance: Approx. 2.58 kΩ at 20 °C (68 °F) (Terminal – Terminal)  09900-25008: Multi circuit tester set ...

  • Page 231: 23" (P1651-H/L) To Sensor Circuit Malfunction

    12-48 FI SYSTEM DIAGNOSIS “23” (P1651-H/L) TO SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE The sensor voltage should be the follow- • TO sensor circuit open or short. ing for 1 second and more. • TO sensor malfunction. • ECM malfunction. 0.17 V Sensor voltage <...
  • Page 232 FI SYSTEM DIAGNOSIS 12-49 4) Remove the TO sensor. 5) Measure the resistance between terminal A and terminal B.  TO sensor resistance: 16.5 – 22.3 kΩ (Terminal A – Terminal B)  09900-25008: Multi circuit tester set  Tester knob indication: Resistance (Ω) Is the resistance OK? Go to Step 2.
  • Page 233 12-50 FI SYSTEM DIAGNOSIS Step 1 (When indicating P1651-L:) 1) Stop the engine. 2) Remove the fuel tank. (13-2, -3) 3) Check the TO sensor coupler 1 for loose or poor contacts. If OK, then check the TO sensor lead wire continuity. 4) Disconnect the TO sensor coupler and ECM coupler.
  • Page 234 FI SYSTEM DIAGNOSIS 12-51 Step 2 1) If necessary, connect the ECM coupler and TO sensor cou- pler. 2) Insert the needle-pointed probes to the lead wire coupler. 3) Connect a 12 volts battery by using the battery lead wire to the service coupler.

  • Page 235: 31" (P0705) Gp Switch Circuit Malfunction

    12-52 FI SYSTEM DIAGNOSIS “31” (P0705) GP SWITCH CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE No GP switch voltage • GP switch circuit open or short. Switch voltage is not within the following range. • GP switch malfunction. • ECM malfunction. Switch voltage 0.89 V GP switch...
  • Page 236 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.

  • Page 237: 32" (P0201) Fuel Injector Circuit Malfunction

    12-54 FI SYSTEM DIAGNOSIS “32” (P0201) FUEL INJECTOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE CKP signal is produced but fuel injector signal is • Injector circuit open or short. interrupted by 8 times or more continuously. • Injector malfunction. • ECM malfunction. Gr/W Regulator Condenser...
  • Page 238 FI SYSTEM DIAGNOSIS 12-55 5) If OK, then check the continuity between each terminal and ground.  Injector resistance: ∞ Ω (Infinity) (Terminal – Ground)  09900-25008: Multi circuit tester set  Tester knob indication: Resistance (Ω) Are the resistance and continuity OK? Go to Step 2.

  • Page 239: 41" (P0230) Fp Relay Circuit Malfunction

    12-56 FI SYSTEM DIAGNOSIS “41” (P0230) FP RELAY CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE No voltage is applied to the fuel pump although FP • FP relay circuit open or short. relay is turned ON. • FP relay (ECM) malfunction. Fuel Fuel pump pump...
  • Page 240 FI SYSTEM DIAGNOSIS 12-57 6) Connect a 12 volt battery to the service coupler using the bat- tery lead wire. (12-19) 7) Insert the needle-point probe to the ECM coupler. 8) Measure the voltage between terminal D and ground.  FP relay input voltage: Battery voltage ...

  • Page 241: 63" (P01771) Crankshaft Rotation Signal Circuit Malfunction

    12-58 FI SYSTEM DIAGNOSIS “63” (P01771) CRANKSHAFT ROTATION SIGNAL CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE CKP sensor (pick-up coil) signal is produces, but sig- • Metal particles or foreign material being stuck on nal from crankshaft rotation signal sensor is not the crankshaft rotation signal sensor and rotor tip.
  • Page 242 FI SYSTEM DIAGNOSIS 12-59 4) If OK, then check the continuity between each terminal and ground.  Crankshaft rotation signal sensor resistance: ∞ Ω (Infinity) (B/R – Ground) (R/W – Ground)  09900-25008: Multi circuit tester set  Tester knob indication: Resistance (Ω) Are the resistance and continuity OK? Go to step 2.

  • Page 243: Ecm (Fi Control Unit)

    12-60 FI SYSTEM DIAGNOSIS ECM (FI Control Unit) REMOVAL • 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. •...

  • Page 244: Sensors

    FI SYSTEM DIAGNOSIS 12-61 SENSORS CKP SENSOR/CRANKSHAFT ROTATION SIGNAL SENSOR INSPECTION The CKP sensor 1 and crankshaft rotation signal sensor 2 are installed at the inside of the magneto cover. (12-29, -58) CKP SENSOR/CRANKSHAFT ROTATION SIGNAL SENSOR REMOVAL AND INSTAL- LATION •...

  • Page 245: Ect Sensor Inspection

    12-62 FI SYSTEM DIAGNOSIS ECT SENSOR INSPECTION The ECT sensor 1 is installed on the cylinder head. • Remove the ECT sensor. (below) • Check the ECT sensor by testing it at the bench as shown in the figure. Connect the ECT sensor 1 to a circuit tester and place it in the oil 2 contained in a pan, which is placed on a stove.

  • Page 246: Iat Sensor Inspection

    FI SYSTEM DIAGNOSIS 12-63 • Apply engine coolant to the O-ring 3.  Replace the O-ring 3 with a new one. • Tighten the ECT sensor to the specified torque.  ECT sensor: 12 N·m (1.2 kgf-m, 8.5 lbf-ft) • Connect the ECT sensor coupler. •...
  • Page 247 FUEL SYSTEM AND THROTTLE BODY 13-1 FUEL SYSTEM AND THROTTLE BODY CONTENTS FUEL SYSTEM ................... 13- 2 CONSTRUCTION ................. 13- 2 FUEL TANK AND FUEL PUMP REMOVAL ........13- 2 FUEL TANK AND FUEL PUMP INSTALLATION........ 13- 3 FUEL PRESSURE INSPECTION............13- 4 FUEL PUMP INSPECTION ..............

  • Page 248: Fuel System

    13-2 FUEL SYSTEM AND THROTTLE BODY FUEL SYSTEM CONSTRUCTION  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 FUEL TANK AND FUEL PUMP REMOVAL ...

  • Page 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.  Replace the O-ring 1 with a new one.  99000-25010: SUZUKI SUPER GREASE “A” or equivalent...

  • Page 250: Fuel Pressure Inspection

    13-4 FUEL SYSTEM AND THROTTLE BODY • When installing the fuel pump assembly 2, first tighten all the fuel pump mounting bolts 3 lightly and then to the specified torque.  Fuel pump mounting bolt: 10 N·m (1.0 kgf-m, 7.0 lbf-ft) •...

  • Page 251: Fuel Pump Inspection

    FUEL SYSTEM AND THROTTLE BODY 13-5 • Connect a proper lead wire into the fuel pump coupler (fuel pump side) and apply 12 volts to the fuel pump (between ter- minal A and terminal B) and check the fuel pressure. Battery + terminal terminal A (Red wire) Battery - terminal...

  • Page 252: Fuel Discharge Amount Inspection

    13-6 FUEL SYSTEM AND THROTTLE BODY FUEL DISCHARGE AMOUNT INSPECTION  Gasoline is highly flammable and explosive. Keep heat, spark and flame away. • Remove the seat and radiator covers. (5-2) • Remove the fuel tank bolt and rubber band. (13-2) •...

  • Page 253: Throttle Body

    FUEL SYSTEM AND THROTTLE BODY 13-7 THROTTLE BODY CONSTRUCTION  1 TP 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 0.35 4 Hot starter valve A Fuel pipe mounting screw 5 Fuel injector B Fuel delivery pipe mounting screw 6 Cushion seal...

  • Page 254: Removal

    13-8 FUEL SYSTEM AND THROTTLE BODY REMOVAL • Remove the seat and radiator covers. (5-2) • Remove the fuel tank. (13-2, -3) • Disconnect the TP sensor coupler 1 and condenser coupler • Remove the condenser 3. • Disconnect the hot starter cable 4 from the throttle body. •...

  • Page 255: Disassembly

    FUEL SYSTEM AND THROTTLE BODY 13-9 • Remove the throttle cable cover 9 by removing its bolts 8. • Loosen the lock-nuts 0. • Disconnect the throttle cables from their pulley. • Remove the throttle body assembly.  After disconnecting the throttle cables, do not snap the throttle valve from full open to full close.
  • Page 256 13-10 FUEL SYSTEM AND THROTTLE BODY • Remove the fuel delivery pipe 8 by 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. •...
  • Page 257 FUEL SYSTEM AND THROTTLE BODY 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 the throttle valve linkage J.

  • Page 258: Cleaning

    13-12 FUEL SYSTEM AND THROTTLE BODY CLEANING  Some carburetor cleaning chemicals, especially dip-type soaking solutions, are very corrosive and must be handled carefully. Always follow the chemical manufacturer’s instructions on proper use, handling and storage. • Clean all passageways with a spray-type carburetor cleaner and blow dry with compressed air.
  • Page 259 FUEL SYSTEM AND THROTTLE BODY 13-13 • Install a new O-ring 3.  Replace the O-ring 3 with a new one. • Install the IAP sensor 4 as shown. • Apply thin coat of engine oil to new O-ring 5 and cushion seal ...
  • Page 260 NOTE: * Align the throttle 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 screw: 3.5 N·m (0.35 kgf-m, 2.5 lbf-ft) NOTE: * Make sure the throttle valve open or close smoothly.

  • Page 261: Installation

    FUEL SYSTEM AND THROTTLE BODY 13-15 • Align the groove F of hot starter valve with the hot starter cable end G. INSTALLATION Install the throttle body assembly in the reverse order of removal. Pay attention to the following points: •...

  • Page 262: Fuel Injector Removal

    13-16 FUEL SYSTEM AND THROTTLE BODY FUEL INJECTOR REMOVAL • Remove the throttle body assembly. (13-8, -9) • Remove the fuel injector. (13-10) FUEL INJECTOR INSPECTION Check fuel injector filter for evidence of dirt and contamination. If present, clean and check for presence of dirt in the fuel lines and fuel tank.
  • Page 263 COOLING SYSTEM 14-1 COOLING SYSTEM 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 ...................

  • Page 264: Construction

    14-2 COOLING SYSTEM CONSTRUCTION  1 Right radiator louver 0 Oil seal 2 Left radiator louver A Gasket ITEM N·m kgf-m lbf-ft 3 Right radiator cover B Water pump case 4 Left radiator cover A Radiator air bleeder bolt 5 Right radiator B Radiator cover upper bolt 6 Left radiator C Radiator cover bolt...

  • Page 265: Engine Coolant

    COOLING SYSTEM 14-3 ENGINE COOLANT REPLACEMENT  * 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, with plenty of water.

  • Page 266: Cooling Circuit

    14-4 COOLING SYSTEM COOLING CIRCUIT INSPECTION • Remove the radiator cap.  * 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, with plenty of water.

  • Page 267: Radiator

    COOLING SYSTEM 14-5 RADIATOR INSPECTION RADIATOR • Visually inspect the radiators and hose for damage. • Fins bent down or dented can be repaired by straightening them with the blade of a small screwdriver. RADIATOR CAP • Fit the cap to the radiator cap tester. •...

  • Page 268: Removal

    14-6 COOLING SYSTEM REMOVAL  * 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, with plenty of water.

  • Page 269: Water Pump

    COOLING SYSTEM 14-7 WATER PUMP REMOVAL  * 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, with plenty of water.

  • Page 270: Inspection

    14-8 COOLING SYSTEM WATER PUMP IMPELLER AND WATER PUMP SHAFT • Hold the water pump shaft 1 with a wrench and remove the impeller 2. • Remove the washers (3, 4) and water pump shaft 1. • Remove the oil seal 5. NOTE: If there is no abnormal condition, the oil seal removal is not nec- essary.

  • Page 271: Installation

    1 Oil seal 2 Right crankcase cover • Apply a small quantity 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.
  • Page 272 14-10 COOLING SYSTEM CRANKCASE COVER • Install the dowel pins 1 and gasket 2.  Replace the gasket 2 with a new one. • Fit the right crankcase cover 3. • Tighten the right crankcase cover bolts (a, b, c) to the specified torque.

  • Page 273: Electrical System

    ELECTRICAL SYSTEM 15-1 ELECTRICAL SYSTEM CONTENTS CAUTIONS IN SERVICING ............... 15- 2 CONNECTOR ..................15- 2 COUPLER ................... 15- 2 CLAMP ....................15- 2 SWITCH ....................15- 2 SEMI-CONDUCTOR EQUIPPED PART ..........15- 3 CONNECTING THE BATTERY ............15- 3 WIRING PROCEDURE ................

  • Page 274: Cautions In Servicing

    15-2 ELECTRICAL SYSTEM CAUTIONS IN SERVICING CONNECTOR • When connecting a connector, be sure to push it in until a click is felt. • Inspect the connector for corrosion, contamination and break- age in its cover. • Avoid applying grease or other similar material to connector terminals to prevent electric trouble.

  • Page 275: Semi-Conductor Equipped Part

    ELECTRICAL SYSTEM 15-3 SEMI-CONDUCTOR EQUIPPED PART • Be careful not to drop the part with a semi-conductor built in INCORRECT such as a ECM. • When inspecting this part, follow inspection instruction strictly. Neglecting proper procedure may cause damage to this part. CONNECTING THE BATTERY WHEN USING THE BATTERY LEAD WIRE (Optional part: 36890-28H00)

  • Page 276: Using The Multi Circuit Tester

    15-4 ELECTRICAL SYSTEM USING THE MULTI CIRCUIT TESTER • Properly use the multi circuit tester + and - probes. Improper use can cause damage to the motorcycle and tester. • If the voltage and current values are not known, begin mea- suring in the highest range.

  • Page 277: Location Of Electrical Components

    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)
  • Page 278 15-6 ELECTRICAL SYSTEM 8 Engine stop 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 (12-19) H Condenser C CKP sensor (12-29)

  • Page 279: Construction

    ELECTRICAL 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 0.55 58.0...

  • Page 280: Generating System

    15-8 ELECTRICAL SYSTEM GENERATING SYSTEM Regulator/Rectifier Magneto Condenser Load INSPECTION REGULATED VOLTAGE • Insert the needle-point probes A to the condenser coupler 1. + Prove: Red lead wire - Prove: B/W lead wire • Kickstart the engine. • Insert the needle-pointed probe to the lead wire coupler (W/ Bl).
  • Page 281 ELECTRICAL SYSTEM 15-9 CHARGE COIL RESISTANCE • Disconnect the magneto lead wire coupler 1. • Measure the charge coil resistance. If the resistance is out of specified value, replace the stator with a new one. Also, check that the magneto core is insu- lated properly.
  • Page 282 15-10 ELECTRICAL SYSTEM REGULATOR/RECTIFIER • Remove the seat, radiator covers and fuel tank. (5-2, 13-2, -3) • Disconnect the regulator/rectifier coupler 1. • Remove the regulator/rectifier 3 by removing its bolts 2. • Measure the voltage between the lead wires using the multi circuit tester as indicated in the table below.

  • Page 283: Ignition System

    ELECTRICAL SYSTEM 15-11 IGNITION SYSTEM Ignition coil Regulator /rectifier Condenser CKP sensor Magneto Crankshaft rotation signal sensor Engine stop switch sensor sensor switch NOTE: The fuel cut-off circuit is incorporated in this ECM in order to prevent over-running of engine. TROUBLESHOOTING No spark or poor spark Step 1...
  • Page 284 15-12 ELECTRICAL SYSTEM Step 4 1) Measure the ignition coil/plug cap resistance. (15-14) Is the ignition coil/plug cap resistance OK? Go to Step 5. Faulty ignition coil/plug cap Step 5 1) Measure the CKP sensor peak voltage and its resistance. (15-15, -16) Are the peak voltage and resistance OK? Go to Step 6.

  • Page 285: Inspection

    ELECTRICAL SYSTEM 15-13 INSPECTION IGNITION COIL PRIMARY PEAK VOLTAGE • Remove the seat, radiator covers and fuel tank. (5-2, 13-2, -3) • Hold the cylinder head cover bolt immovable with the wrench. • Remove the ignition coil retainer 2 by removing its bolts 1. •...
  • Page 286 15-14 ELECTRICAL SYSTEM • Insert the needle pointed probe A to the lead wire coupler. NOTE: Use the special tool (needle-point probe), to prevent the rubber of the water proof coupler from damage. • Measure the ignition coil primary peak voltage by depressing the kick starter lever several times forcefully.
  • Page 287 ELECTRICAL SYSTEM 15-15 CKP SENSOR AND CRANKSHAFT ROTATION SIGNAL SENSOR PEAK VOLTAGE • Disconnect the magneto lead wire coupler 1. • Connect the multi circuit tester with the peak volt adaptor A as follows. CKP sensor Crankshaft rotation signal sensor + probe - probe ...
  • Page 288 15-16 ELECTRICAL SYSTEM CKP SENSOR AND CRANKSHAFT ROTATION SIGNAL SENSOR RESISTANCE • Disconnect the magneto lead wire coupler. • Measure the resistance between the lead wires using the multi circuit tester. If the resistance is not within the specified value, replace the stator with a new one. ...

  • Page 289: Magneto Rotor

    ELECTRICAL SYSTEM 15-17 MAGNETO ROTOR REMOVAL • Drain engine oil. (2-13) • Disconnect 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. •...

  • Page 290: Installation

    15-18 ELECTRICAL SYSTEM • Remove the magneto rotor 8 with the special tool.  09930-34951: Rotor remover • Remove the magneto rotor key 9. INSTALLATION • Remove any grease from the tapered portion A of the mag- neto rotor and crankshaft B. •...

  • Page 291: Stator

    ELECTRICAL SYSTEM 15-19 • Install the dowel pins 3 and gasket 4.  Replace the gasket 4 with a new one. • Install the magneto cover 5. • Tighten the magneto cover bolts (A, B, C) to the specified torque. NOTE: * The bolts A are 5 mm longer than the others.

  • Page 292: Front And Rear Wheels

    FRONT AND REAR WHEELS 16-1 FRONT AND REAR WHEELS CONTENTS CONSTRUCTION ..................16- 2 FRONT WHEEL ..................16- 3 REMOVAL ................... 16- 3 INSPECTION ..................16- 3 DUST SEAL AND BEARING REPLACEMENT ........16- 4 DISC PLATE REPLACEMENT ............16- 5 INSTALLATION ...................

  • Page 293: Construction

    16-2 FRONT AND REAR WHEELS CONSTRUCTION  1 Rear disc plate 9 Front wheel (1.60 × 21) 2 Rear wheel (1.85 × 19) 0 Front disc plate ITEM N·m kgf-m lbf-ft 3 Spacer A Wheel bearing 65.0 4 Disc cover A Rear axle nut 19.0 5 Rim lock...

  • Page 294: Front Wheel

    FRONT AND REAR WHEELS 16-3 FRONT WHEEL REMOVAL • Remove the front axle nut 1. • Loosen the left axle holder bolts 2. • Place the motorcycle on a block to lift front wheel off the ground. • Loosen the right axle holder bolts 3. •...

  • Page 295: Dust Seal And Bearing Replacement

    16-4 FRONT AND REAR WHEELS WHEEL RIM • Measure the wheel rim runout with the dial gauge. • If the runout exceeds the limit, replace the bearings or wheel.  Service Limit: 2.0 mm (0.08 in) ... axial and radial ...

  • Page 296: Disc Plate Replacement

     09913-70210: Bearing installer set (10 – 75 ) Bearing:  40 Attachment  99000-25010: SUZUKI SUPER GREASE “A” or equivalent DISC PLATE REPLACEMENT • Remove the disc plate 2 by removing its bolts 1.

  • Page 297: Installation

    16-6 FRONT AND REAR WHEELS INSTALLATION • Hold the front axle shaft 1 with the special tool and tighten the front axle nut temporarily.  09940-34581: Front fork assembling attachment (F) • Remove the block from under the chassis tube and move the front forks up and down several times.

  • Page 298: Rear Wheel

    FRONT AND REAR WHEELS 16-7 REAR WHEEL REMOVAL • 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. •...

  • Page 299: Inspection

    16-8 FRONT AND REAR WHEELS INSPECTION WHEEL SPACER • Remove the wheel spacers from the rear wheel. • Inspect the rear 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.
  • Page 300 FRONT AND REAR WHEELS 16-9 • Remove the bearings 3 with the special tool. • Remove the spacer 4 and bearing 3 with the special tool.  The removed bearings 3 must be replaced with new ones.  09921-20240: Bearing remover set •...

  • Page 301: Disc Plate Replacement

     09913-70210: Bearing installer set (10 – 75 ) Oil seal:  42 Attachment  99000-25010: SUZUKI SUPER GREASE “A” or equivalent DISC PLATE REPLACEMENT • Remove the disc plate 2 by removing its bolts 1.

  • Page 302: Installation

    FRONT AND REAR WHEELS 16-11 INSTALLATION • Install the rear wheel, chain adjuster washers 1 and axle Left Right shaft. • Adjust the drive chain slack. (2-31) F FWD • Tighten the rear axle nut 2 to the specified torque. ...

  • Page 303: Front And Rear Brakes

    FRONT AND REAR BRAKES 17-1 FRONT AND REAR BRAKES CONTENTS CONSTRUCTION ..................17- 2 FRONT BRAKE ................... 17- 2 REAR BRAKE ..................17- 3 BRAKE FLUID AIR BLEEDING ..............17- 4 BRAKE FLUID REPLACEMENT ............... 17- 5 BRAKE PADS REPLACEMENT ............... 17- 6 FRONT BRAKE PADS ................

  • Page 304: Construction

    17-2 FRONT AND REAR BRAKES CONSTRUCTION FRONT BRAKE  1 Front caliper D Front brake hose 2 Caliper bracket E Brake hose clamp ITEM N·m kgf-m lbf-ft 3 Pad set A Front brake caliper mounting bolt 19.0 4 Piston B Front brake caliper axle bolt (caliper) 18.0 5 Dust seal C Brake air bleeder valve...

  • Page 305: Rear Brake

    FRONT AND REAR BRAKES 17-3 REAR BRAKE  1 Brake pedal C Push rod 2 Pad set D Dust boot ITEM N·m kgf-m lbf-ft 3 Rear caliper E Brake hose guide 21.0 4 Caliper bracket A Brake pedal pivot bolt 13.0 5 Piston seal B Brake pad mounting pin...

  • Page 306: Brake Fluid Air Bleeding

    17-4 FRONT AND REAR BRAKES BRAKE FLUID AIR BLEEDING  * Brake fluid can be hazardous 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.

  • Page 307: Brake Fluid Replacement

    FRONT AND REAR BRAKES 17-5 • Connect a transparent tube to the bleeder valve and set the other end into a receptacle. • Pump the brake lever/pedal until air bubbles stop coming out from the reservoir. • Hold the brake lever/pedal in the squeezed position. •...

  • Page 308: Brake Pads Replacement

    NOTE: Replace the two pads as a set. • Fit the new brake pads into the caliper. • Apply SUZUKI SILICONE GREASE to the O-ring.  99000-25100: SUZUKI SILICONE GREASE or equivalent • Tighten the brake pad mounting pin 1 to the specified torque.

  • Page 309: Brake Disc Inspection

    FRONT AND REAR BRAKES 17-7 BRAKE DISC INSPECTION • Inspect the brake discs for damage or cracks. • Measure the front and rear brake disc thickness. • Replace the disc if the thickness is less than the service limit or if damage is found. ...

  • Page 310: Front Caliper Removal And Disassembly

    17-8 FRONT AND REAR BRAKES FRONT CALIPER REMOVAL AND DISASSEMBLY • Place a rag under the brake hose union bolt 1 to catch spilled brake fluid. • Disconnect the brake hose 2 by removing the union bolt 1. • Remove the caliper mounting bolts 3. •...

  • Page 311: Caliper Inspection

    • Apply SUZKI SILICONE GREASE to the new piston seals. • Apply brake fluid to the new dust seals and pistons. • Fit the piston seals, dust seals and pistons.  99000-25100: SUZUKI SILICONE GREASE or equivalent  Specification and classification: DOT 4...
  • Page 312  Front brake caliper axle bolt (bracket): 28 N·m (2.8 kgf-m, 20.0 lbf-ft) • Install the springs and boots. • Apply SUZUKI SILICONE GREASE to the caliper axles.  99000-25100: SUZUKI SILICONE GREASE or equivalent • Install the caliper bracket 1.

  • Page 313: Rear Caliper Removal And Disassembly

    FRONT AND REAR BRAKES 17-11 REAR CALIPER REMOVAL AND DISASSEMBLY • Remove the disc cover 2 by removing its bolts 1. • Remove the caliper protector 4 by removing its bolts 3. • Place a rag under the brake hose union bolt 5 to catch spilled brake fluid.
  • Page 314 17-12 FRONT AND REAR BRAKES • Wrap the caliper with a rag to prevent brake fluid scatter and piston pop-out. • Apply low-pressure air into the caliper through the hole to remove the piston.  * Fingers can get caught between piston and caliper body when removing the piston.

  • Page 315: Rear 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 SUZUKI SILICONE GREASE to the new piston seal. • Apply brake fluid to the new dust seal and piston.

  • Page 316: Master Cylinder

    17-14 FRONT AND REAR BRAKES MASTER CYLINDER  * Brake fluid can be hazardous 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 brake fluid is swallowed, and induce vomiting.

  • Page 317: Master Cylinder Inspection

    FRONT AND REAR BRAKES 17-15 • Remove the dust boot 8 and snap ring 9.  09900-06108: Snap ring remover (Close type) • Remove the washer 0 and piston/cup set A. MASTER CYLINDER INSPECTION • Inspect the cylinder bore A and piston B for scuffing, wear and damage.

  • Page 318: Front Master Cylinder Reassembly And Installation

    17-16 FRONT AND REAR BRAKES FRONT MASTER CYLINDER REASSEMBLY AND INSTALLATION Reassemble and install the master cylinder in the reverse order of removal and disassembly. Pay attention to the following points: • Install the brake lever. (17-19) NOTE: When remounting the master cylinder onto the handlebar, align the master cylinder holder’s mating surface A with the matching mark B on the handlebar and tighten the lower bolt 1 first.

  • Page 319: Rear Master Cylinder Removal And Disassembly

    FRONT AND REAR BRAKES 17-17 REAR MASTER CYLINDER REMOVAL AND DISASSEMBLY • Drain brake fluid. (17-5) • Remove the cotter pin 1 and then master cylinder rod pin 2 and washer. (17-18) • Remove the master cylinder 4 by removing the bolts 3. •...

  • Page 320: Master Cylinder Inspection

    • Apply grease to the contact point between piston and push rod.  99000-25010: SUZUKI 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.

  • Page 321: Brake Lever

    • Apply grease to the brake lever adjuster return spring, pivot bolt and contact point between piston and brake lever.  99000-25010: SUZUKI SUPER GREASE “A” or equivalent • Tighten the brake lever pivot bolt 1 and lock-nut 2 to the specified torque.

  • Page 322: Brake Pedal

    • Remove the brake pedal pivot bolt 5 and return spring 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) •...
  • Page 323 FRONT FORK AND STEERING 18-1 FRONT FORK AND STEERING 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 ...................

  • Page 324: Construction

    18-2 FRONT FORK AND STEERING CONSTRUCTION FRONT FORK  1 O-ring A Inner tube 2 Slide bushing B Fork protector ITEM N·m kgf-m lbf-ft 3 Outer tube A Air bleeder valve 0.13 4 Push rod B Compression damper unit 21.5 5 Fork spring C Fork cap bolt 24.5...

  • Page 325: Steering

    FRONT FORK AND STEERING 18-3 STEERING  1 Handlebar upper holder 9 Damper bushing 2 Handlebar lower holder 0 Washer ITEM N·m kgf-m lbf-ft 3 Steering stem upper bracket A Handlebar clamp bolt 18.0 4 Steering stem nut B Steering stem head nut 10.0 72.5 5 Dust seal...

  • Page 326: Handlebar Controls

    18-4 FRONT FORK AND STEERING HANDLEBAR CONTROLS  1 Handlebar upper holder 0 Cooler ITEM N·m kgf-m lbf-ft 2 Handlebars A Throttle case cover 18.0 3 Left handle grip B Throttle case 4 Clutch lever C Throttle grip 5 Clutch cable adjuster bolt A Handlebar clamp bolt 6 Clutch lever cover B Brake lever pivot bolt...

  • Page 327: Removal

    FRONT FORK AND STEERING 18-5 REMOVAL • Place the motorcycle on a block to lift front wheel off the ground. • Remove the front wheel. (16-3) • Remove the front number plate 2 by removing its bolt 1. • Remove the handlebar pad 3. •...

  • Page 328: Disassembly

    18-6 FRONT FORK AND STEERING DISASSEMBLY • Set rebound and compression damper settings to the mini- mum settings (softest) before disassembling. Record the set- ting before turning the adjuster. • Thoroughly clean the fork before disassembly.  * Scratches or other damage on the inner tube or on the oil seal lip will cause oil leakage.
  • Page 329 FRONT FORK AND STEERING 18-7 • Clamp the axle holder 3 with a vise. Protect the axle holder 3 with a rag when using a vise. • Loosen the center bolt 4 completely with a 21 mm socket wrench.  * Clamping the axle holder 3 too tight can damage it which will affect riding stability.
  • Page 330 18-8 FRONT FORK AND STEERING • With the outer tube compressed by hands, remove the special tool.  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 oil seal. •...
  • Page 331 FRONT FORK AND STEERING 18-9 INNER TUBE • Separate the inner tube 1 out of the outer tube 2. • Remove the slide bushing 3 from the inner tube 1. • Remove the following parts from the inner tube 1. Guide bushing 4 Seal retainer 5 Oil seal 6...

  • Page 332: Inspection

    18-10 FRONT FORK AND STEERING • Drain the fork oil from the damper rod assembly by moving the inner rod several strokes. INSPECTION CENTER BOLT • Inspect the adjuster rod of the center bolt for damage. If it is damaged, replace it with a new one. COMPRESSION DAMPER UNIT •...
  • Page 333 FRONT FORK AND STEERING 18-11 DAMPER ROD ASSEMBLY • Inspect the damper rod assembly for scratches or bending. If it has scratches or is bent, replace it with a new one. FORK SPRING • Measure the free length of front fork spring. •...

  • Page 334: Reassembly

    18-12 FRONT FORK AND STEERING REASSEMBLY  * Clean all fork parts before reassembling. * Replace the O-rings, oil seal and dust seal with new ones. * Apply specified front fork oil when installing the O-rings, slide bushing, guide bushing, damper unit and sliding parts.
  • Page 335 • With the damper 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 oil to the O-ring 4. ...
  • Page 336 18-14 FRONT FORK AND STEERING • Clamp the bottom (flat part) of the sub-tank with a vise.  Do not clamp the sub-tank too tight. • Tighten the compression damper unit 5 to the specified torque.  Compression damper unit: 30 N·m (3.0 kgf-m, 21.5 lbf-ft) •...
  • Page 337 FRONT FORK AND STEERING 18-15 • With the damper rod in horizontal position, move the inner rod by hand to inspect it if operating smoothly. • If the inner rod is not extend, repeat the “DAMPER ROD AND COMPRESSION DAMPER UNIT” procedures (Pour the spec- ified amount fork oil and discharge an excess of oil).
  • Page 338 18-16 FRONT FORK AND STEERING • Clamp the axle holder 0 with a vise. Protect the axle holder 0 with a rag when using a vise.  * Clamping the axle holder 0 too tight can damage it which will affect riding stability. * Be careful not to clamp the axle holder 0 too tight.
  • Page 339 • Pour the specified amount of fork oil into the outer tube.  Oil quantity (When standard fork spring is used): 375 ml (12.68/13.20 US/lmp oz)  99000-99001-SS5: SUZUKI FORK OIL SS-05 or equivalent • Raise the outer tube and temporarily tighten the fork cap bolt 9 (sub-tank) with the special tool.

  • Page 340: Installation

    18-18 FRONT FORK AND STEERING INSTALLATION • Install the front fork with the upper surface T of the outer tube positioned 1.0 mm (0.04 in) B from the upper surface of the upper bracket. • Check that the air valve A is positioned at the front. •...

  • Page 341: Steering

    FRONT FORK AND STEERING 18-19 STEERING REMOVAL HANDLEBARS • Place the motorcycle on a block to lift front wheel off the ground. • Remove the front number plate and handlebar pad. (18-5) • Remove the clamps 1. • Remove the engine stop switch 3 by removing its screw 2. •...
  • Page 342 18-20 FRONT FORK AND STEERING • Remove the handlebars A by removing the handlebar clamp bolts 0. NOTE: Mark the paint mark D to the matching surface of handlebar holder and handlebars before removing. STEERING STEM • Remove the front wheel 1. (16-3) •...

  • Page 343: Inspection

    FRONT FORK AND STEERING 18-21 • Remove the handlebar holders, damper bushings and spac- ers. • Remove the steering stem nut 0 with the special tools. NOTE: Hold the steering stem lower bracket to prevent it from falling.  09940-14911: Steering stem nut socket wrench 09940-14960: Steering stem nut socket wrench •...

  • Page 344: Bearing Replacement

    18-22 FRONT FORK AND STEERING BEARING REPLACEMENT • Remove the lower bearing 1. • Fit the lower bearing with the special tool.  09925-18011: Bearing installer NOTE: Replace the outer race and bearing as a set. • Remove the upper outer race with the special tools. ...

  • Page 345: Installation

    Install the steering in the reverse order of steering removal. Pay attention to the following points: STEERING STEM • Apply grease to the bearings.  99000-25010: SUZUKI SUPER GREASE “A” or equivalent • Fit the steering stem lower bracket, upper bearing, upper dust seal and washer.
  • Page 346 18-24 FRONT FORK AND STEERING • Temporarily install the front forks to the steering stem, and tighten the lower 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) •...
  • Page 347  Handlebar holder set nut: 44 N·m (4.4 kgf-m, 32.0 lbf-ft) • Apply grease to the throttle cable and their hole.  99000-25010: SUZUKI SUPER GREASE “A” or equivalent • Align the matching mark D on the handlebars with the match- ing surface of throttle holder.
  • Page 348 18-26 FRONT FORK AND STEERING • Align the matching mark F on the handlebars with the match- ing surface master cylinder. • Tighten the master cylinder holder lower bolt G first tempo- rarily to provide clearance on the upper side and then tighten both the master cylinder holder bolts C to the specified torque.
  • Page 349 FRONT FORK AND STEERING 18-27 • Align the matching mark C on the handlebars with the match- ing surface clutch lever holder. • Tighten the upper bolt D first temporarily to provide clearance on the lower side and then tighten both the bolts 1. •...
  • Page 350 REAR SUSPENSION 19-1 REAR SUSPENSION CONTENTS CONSTRUCTION ..................19- 2 REAR SUSPENSION ................19- 2 REAR SHOCK ABSORBER ..............19- 3 REMOVAL ................... 19- 3 SPRING REPLACEMENT ..............19- 4 INSPECTION ..................19- 5 BEARING REPLACEMENT ..............19- 6 OIL REPLACEMENT ................19- 7 DISASSEMBLY AND INSPECTION ...........

  • Page 351: Construction

    19-2 REAR SUSPENSION CONSTRUCTION REAR SUSPENSION  1 Cushion lever A Cushion lever nut 2 Cushion rod B Cushion rod nut (rear) ITEM N·m kgf-m lbf-ft 3 Shock absorber body C Cushion rod nut (front) 58.0 4 Damper rod assembly D Compression adjuster assembly 21.5 5 Swingarm...

  • Page 352: Rear Shock Absorber

    REAR SUSPENSION 19-3 REAR SHOCK ABSORBER REMOVAL • Place the motorcycle on a block to lift rear wheel off the ground. • Remove the seat and right frame cover. (5-2) • Loosen the air cleaner clamp screw 1. • Remove the rubber band 2. •...

  • Page 353: Spring Replacement

    19-4 REAR SUSPENSION • Remove the rear shock absorber lower mounting bolt and nut NOTE: If necessary, move the swingarm up or down to facilitate this mounting bolt/nut removal. • Remove the rear shock absorber. SPRING REPLACEMENT • Loosen the lock-nut 1 with the special tool and turn it fully to the end of the thread.

  • Page 354: Inspection

    REAR SUSPENSION 19-5 • Adjust the spring set length and tighten the lock-nut.  Standard spring set length: 4.2 mm (0.17 in) compressed from the free length Spring set length adjustable range: 248 – 263 mm (9.76 – 10.35 in) [at spring free length 265 mm (10.43 in)] a: Hardest spring setting b: Softest spring setting...

  • Page 355: Bearing Replacement

    • Apply grease to the needle roller bearings and install them. • Apply grease to the dust seals and spacers. • Install the spacers B and C. B For right side C For left side  99000-25010: SUZUKI SUPER GREASE “A” or equivalent...

  • Page 356: Oil Replacement

    REAR SUSPENSION 19-7 OIL REPLACEMENT TOOLS AND EQUIPMENT • Following tools and equipment are required to perform oil replacement. 1 Screwdriver or small punch 7 Rags 2 Vise* 8 Nitrogen tank 3 Drain Pan 9 Filler Hose and Nozzle 4 Oil can 0 Regulator Assembly 5 Beaker A Owner’s Service Manual...
  • Page 357 19-8 REAR SUSPENSION • Remove the compression adjuster assembly 2 with the spe- cial tool from the rear shock absorber.  09941-53660: RCU socket wrench (24 mm) • Place a drain pan under the rear shock absorber unit. • Move the rod and drain the oil completely. •...
  • Page 358 REAR SUSPENSION 19-9 • Replace the O-rings 3 on the compression adjuster assem- bly with new ones. • Apply rear suspension oil to the O-rings 3. REAR SUSPENSION OIL SS-25 or equivalent • Reinstall the compression adjuster assembly 2. • Tighten the compression adjuster assembly 2 to the speci- fied torque with the special tool.

  • Page 359: Disassembly And Inspection

    19-10 REAR SUSPENSION DISASSEMBLY AND INSPECTION • Clean and dry the rear shock absorber. • Remove the spring from the rear shock absorber. (19-4) • Turn the rebound damping force adjuster 1 and compression adjuster 2 to the softest position. •...

  • Page 360: Reassembly

    REAR SUSPENSION 19-11 • Slowly draw the damper rod assembly 6 until the O-ring 7 on the seal case 4 is seen. • Draw out the seal case 4. • Cut the special tool and set it to the circlip groove A of shock absorber body.

  • Page 361: Installation

    19-12 REAR SUSPENSION INSTALLATION Install the rear shock absorber in the reverse order of removal. Pay attention to the following points: • Tighten the rear shock absorber lower mounting bolt and nut 1 to the specified torque. NOTE: If necessary, move the swingarm up or down to facilitate this mounting bolt/nut tightening.

  • Page 362: Swingarm

    REAR SUSPENSION 19-13 SWINGARM REMOVAL • Place the motorcycle on a block to lift rear wheel off the ground. • Remove the rear wheel. (16-7) • Remove the chain guide bolts and nuts 1. • Remove the chain guide plate 2 and chain guide 3. •...
  • Page 363 19-14 REAR SUSPENSION • Down the rear brake pedal A and remove 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. •...

  • Page 364: Inspection

    REAR SUSPENSION 19-15 INSPECTION PIVOT SHAFT • Measure the pivot shaft runout with the dial gauge and V blocks. • If any the runout exceeds the limit, replace the pivot shaft with a new one.  Swingarm pivot shaft runout Service Limit: 0.3 mm (0.01 in) ...

  • Page 365: Bearing Replacement

    NOTE: When installing the bearings 1 and 2, the stamped mark on the bearings must face outside.  09924-84521: Bearing installer set A Direction of outside • Apply grease to the bearings.  99000-25010: SUZUKI SUPER GREASE “A” or equivalent...

  • Page 366: Installation

    7 Spacer 4 Thrust bearing 8 Washer • Apply grease to the dust seals, bearings and oil seals.  99000-25010: SUZUKI SUPER GREASE “A” or equivalent • Apply a small quantity of THREAD LOCK SUPER to the plate mounting screws 9.

  • Page 367: Rear Suspension Linkage

    19-18 REAR SUSPENSION REAR SUSPENSION 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. •...

  • Page 368: Inspection

    REAR SUSPENSION 19-19 INSPECTION • Inspect the cushion rod and cushion lever for damage. • 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 and smooth movement.

  • Page 369: Bearing Replacement

    19-20 REAR SUSPENSION BEARING REPLACEMENT • Remove the collars, dust seals, washers and spacers. (19-18) • Remove the needle roller bearings. Cushion rod bearing (One side 32 pieces of needle roller bearing) Cushion lever bearing a (33 pieces of needle roller bearing) b (One side 32 pieces of needle roller bearing) c (One side 32 pieces of needle roller bearing) •...

  • Page 370: Installation

    REAR SUSPENSION 19-21 • Apply grease to the needle roller bearings and install them.  99000-25010: SUZUKI SUPER GREASE “A” or equivalent INSTALLATION Install the rear suspension linkage in the reverse order of removal. Pay attention to the following points: •...
  • Page 371 19-22 REAR SUSPENSION • Tighten the cushion lever, cushion rod and swingarm nuts to the specified torque. Left Right 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)
  • Page 372 REAR SUSPENSION 19-23 Left Right 4: Stamped mark d: 4.0 mm (0.16 in)  Tightening torque: F: 70 N·m (7.0 kgf-m, 50.5 lbf-ft)  * Improperly reassembled rear suspension linkage bolts can interfere 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 right side.

  • Page 373: Servicing Information

    SERVICING INFORMATION 20-1 SERVICING INFORMATION CONTENTS SERVICE DATA ..................20- 2 TIGHTENING TORQUE ................20-10 ENGINE ....................20-10 FI SYSTEM AND INTAKE AIR SYSTEM ..........20-11 COOLING SYSTEM ................20-11 CHASSIS ..................... 20-12 SPECIAL TOOLS ..................20-14 WIRING DIAGRAM ..................20-17 WIRING HARNESS ROUTING ..............

  • Page 374: Service Data

    20-2 SERVICING INFORMATION SERVICE DATA VALVE + GUIDE Unit: mm (in) ITEM STANDARD LIMIT Valve diam. — (1.22) — (0.98) Tappet clearance (when cold) 0.09 – 0.16 — (0.004 – 0.006) 0.17 – 0.24 — (0.007 – 0.009) Valve guide to valve stem 0.010 –...
  • Page 375 SERVICING INFORMATION 20-3 CAMSHAFT + CYLINDER HEAD Unit: mm (in) ITEM STANDARD LIMIT Cam height 34.78 – 34.83 34.48 (1.369 – 1.371) (1.357) 33.94 – 33.99 33.64 (1.336 – 1.338) (1.324) Camshaft journal oil clearance 0.023 – 0.066 0.150 IN. & EX. (0.0013 –...
  • Page 376 20-4 SERVICING INFORMATION CONROD + CRANKSHAFT Unit: mm (in) ITEM STANDARD LIMIT Conrod small end I.D. 16.010 – 16.018 16.040 (0.6303 – 0.6306) (0.6315) Conrod deflection — (0.12) Conrod big end side clearance 0.20 – 0.65 (0.008 – 0.026) (0.04) Conrod big end width 17.75 –...
  • Page 377 SERVICING INFORMATION 20-5 TRANSMISSION + DRIVE CHAIN Unit: mm (in) Except ratio ITEM STANDARD LIMIT Primary reduction ratio 3.316 (63/19) — Final reduction ratio 3.769 (49/13) — Gear ratios 2.153 (28/13) — 1.764 (30/17) — 1.470 (25/17) — 1.238 (26/21) —...
  • Page 378 20-6 SERVICING INFORMATION ITEM STANDARD/SPECIFICATION NOTE IAT sensor resistance Approx. 2.58 kΩ at 20 °C (68 °F) TO sensor resistance 16.5 – 22.3 kΩ TO sensor voltage Normal 0.4 – 1.4 V When Leaning 3.7 – 4.4 V leaning 65° GP switch voltage 0.89 V and more From 1st to Top...
  • Page 379 SERVICING INFORMATION 20-7 BRAKE + WHEEL Unit: mm (in) ITEM STANDARD LIMIT Brake lever adjuster length 11 – 15 — (0.4 – 0.6) Rear brake pedal height 0 – 10 (0 – 0.4) — (Below the top face of the foot rest) Brake disc thickness 2.8 –...
  • Page 380 20-8 SERVICING INFORMATION SUSPENSION Unit: mm (in) ITEM STANDARD LIMIT NOTE Front fork stroke — (12.2) Front fork inner tube — O.D. (18.5) Front fork spring free length (19.49) (19.09) Front fork damping Rebound MAX – 10 clicks — force adjuster turn back Compres- MAX –...
  • Page 381 (1.1/0.9 US/Imp qt) Air cleaner element oil type MOTUL AIR FILTER OIL or equivalent filter oil Front fork oil type SUZUKI FORK OIL SS-05 or an equivalent fork oil Front fork oil capacity 375 ml Outer tube oil (each leg) (12.68/13.20 US/Imp oz)

  • Page 382: Tightening Torque

    20-10 SERVICING INFORMATION TIGHTENING TORQUE ENGINE PART N·m kgf-m lbf-ft Cylinder head cover bolt 10.0 Spark plug Ignition coil retainer bolt Cylinder head bolt (Initial) 18.0 (Final) 37.0 Cylinder head base nut Cylinder base bolt Camshaft journal holder bolt Primary drive gear nut 65.0 Magneto rotor nut 58.0...

  • Page 383: Fi System And Intake Air System

    SERVICING INFORMATION 20-11 PART N·m kgf-m lbf-ft Engine mounting bolt (upper) 32.5 Engine mounting nut (lower) 47.5 Engine mounting nut (front) 47.5 Engine mounting bracket nut (upper) 29.0 Engine mounting bracket nut (front) 29.0 Engine sprocket cover bolt Kick starter lever bolt 21.0 Kick starter lever screw Intake pipe bolt...

  • Page 384: Chassis

    20-12 SERVICING INFORMATION CHASSIS PART N·m kgf-m lbf-ft Handlebar clamp bolt 18.0 Handlebar holder set nut 32.0 Front fork upper clamp bolt (right and left) 16.5 Front fork lower clamp bolt (right and left) 16.5 Steering stem head nut 10.0 72.5 Front fork cap bolt 24.5...
  • Page 385 SERVICING INFORMATION 20-13 PART N·m kgf-m lbf-ft Seat rail bolt and nut (upper and lower) 16.5 Footrest bolt 25.5 Cable adjuster lock-nut (throttle, clutch and hot starter) 0.22 1.60 Clutch cable bracket bolt Radiator cover upper bolt Radiator cover bolt For other bolts and nuts not listed in the table, refer to this chart.

  • Page 386: Special Tools

    20-14 SERVICING INFORMATION SPECIAL TOOLS 09900-06107 09900-06108 09900-20101 09900-20202 09900-20204 Snap ring remover Snap ring remover Vernier calipers Micrometer Micrometer (Open type) (Close type) (150 mm) (25 – 50 mm) (75 – 100 mm) 09900-20205 Micrometer 09900-20530 09900-20602 09900-20607 09900-20701 (0 –...
  • Page 387 SERVICING INFORMATION 20-15 09913-70210 09915-74511 Bearing installer set 09913-50121 09914-61010 09915-64512 Oil pressure gauge  Oil seal remover (10 – 75 Gear holder Compression gauge (600 kPa) 09916-14522 09916-14530 09916-10911 09916-14510 Valve lifter attach- Valve lifter attach- 09916-34542 Valve lapper set Valve lifter ment ment...
  • Page 388 20-16 SERVICING INFORMATION 09930-10121 09930-30104 09925-18011 Spark plug wrench 09930-11950 Rotor remover slide 09930-35020 Bearing installer Torx wrench (T25H) shaft Rotor remover 09940-14911 09940-14960 09940-34581 09940-40211 09930-44560 Steering stem nut Steering stem nut Front fork assem- Fuel pressure gauge Rotor holder socket wrench socket wrench bling attachment (F)

  • Page 389: Wiring Diagram

    SERVICING INFORMATION 20-17 WIRING DIAGRAM...

  • Page 390: Wiring Harness Routing

    20-18 SERVICING INFORMATION WIRING HARNESS ROUTING Clamp the wiring harness and fuel pump lead wire at 1 Engine stop switch lead wire the gray taping. Set the tip of the clamp inside. Bind the magneto lead wire and GP switch lead 2 Handlebars wire with the clamp.
  • Page 391 SERVICING INFORMATION 20-19 Bind the regulator/rectifier lead wire and magneto lead 1 Ignition coil/plug cap wire with the clamp. Set the tip of the clamp inside. 2 TP sensor lead wire *3 The coupler of ignition coil/plug cap faces backward. Clamp the wiring harness at the gray taping.
  • Page 392 20-20 SERVICING INFORMATION A – A Pass the GP switch lead wire under the clutch 1 GP switch lead wire 5 Magnet lead wire cable bracket. 2 Clutch cable bracket 6 Grommet *2 Do not slack the lead wire at this position. 3 Magneto rotor 7 CKP sensor 4 GP switch...

  • Page 393: Cable Routing

    SERVICING INFORMATION 20-21 CABLE ROUTING Bind the hot starter cable and wiring harness with the 1 Throttle cable (Pulling cable) clamp. 2 Throttle cable (Returning cable) *3 Pass the hot starter cable inside of frame bridge. 3 Hot starter cable *4 Pass the clutch cable between radiator bracket and frame.
  • Page 394 20-22 SERVICING INFORMATION Pass the throttle cables over the radiator and radiator overflow 1 Throttle cable (Pulling cable) hose. Pass the hot starter cable between the radiator and frame. 2 Throttle cable (Returning cable) Pass the hot starter cable under the radiator overflow hose. Bind the hot starter cable and engine stop switch lead wire 3 Hot starter cable with the clamp.

  • Page 395: Fuel Hose Routing

    SERVICING INFORMATION 20-23 FUEL HOSE ROUTING 1 Fuel hose 0 Condenser 2 Throttle 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...

  • Page 396: Radiator Hose Routing

    20-24 SERVICING INFORMATION RADIATOR HOSE ROUTING 1 Radiator LH *2 Face the white mark to the backward. 2 Radiator RH *3 Face the yellow mark to the backward. Pass the radiator overflow hose between engine mounting 3 Radiator overflow hose lower bracket.

  • Page 397: Crankcase And Cover Installation

    SERVICING INFORMATION 20-25 CRANKCASE AND COVER INSTALLATION Q Crankshaft hole plug Right crankcase cover bolt Oil check bolt R Engine oil drain No. 2 plug L: 30 mm (1.2 in) L: 10 mm (0.4 in) S Engine oil drain plug Right crankcase cover bolt Engine coolant drain bolt T TDC plug...

  • Page 398: Exhaust Pipe And Muffler Installation

    20-26 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 16.5 13.0...

  • Page 399: Clutch Cable Adjuster

    SERVICING INFORMATION 20-27 CLUTCH CABLE ADJUSTER When the movement is felt heavier, clean this and 1 Clutch cable adjuster apply grease. Do not apply grease to the rubber covers. a Turn to tighten the clutch cable tension. Fit the cover positively. b Turn to loosen the clutch cable tension.

  • Page 400: Hot Starter Lever Installation

    20-28 SERVICING INFORMATION HOT STARTER LEVER INSTALLATION Tighten the lower bolt first temporarily to provide *1 Pass the hot starter cable into the lever cover. clearance on the upper side and then tighten both the bolts to the specified torque. Install the cover of hot starter lever firmly.

  • Page 401: Brake Pedal Set-Up

    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)

  • Page 402: Front Brake Hose Routing

    20-30 SERVICING INFORMATION FRONT BRAKE HOSE ROUTING 1 Front brake hose 7 Front brake caliper Set the brake hose end between the hose stopper, then tighten the 2 Front brake master cylinder brake hose union bolt. 3 Stopper *2 Clamp the upper difference portion in brake hose diameter. After contacting the brake hose union to the stopper, tighten the 4 Hose guide union bolt.

  • Page 403: Rear Brake Hose Routing

    SERVICING INFORMATION 20-31 REAR BRAKE HOSE ROUTING A – A 1 Rear brake hose 4 Hose guide Set the brake hose end between the hose stopper, then tighten the 2 Rear brake master cylinder brake hose union bolt. 3 Rear brake caliper *2 Outside.

  • Page 404: Handlebar Set-Up

    20-32 SERVICING INFORMATION HANDLEBAR SET-UP Throttle cable Align the matching surface of d 121 mm (4.76 in) (Pulling cable) throttle case with marking. Throttle cable Align the “ ” mark on the left e 175 mm (6.89 in) (Returning cable) handlebar grip with marking.

  • Page 405: Rear Wheel Spokes Installation

    SERVICING INFORMATION 20-33 REAR WHEEL SPOKES INSTALLATION 1 Spoke (Inner) L: 206.5 mm (8.13 in) 2 Spoke (Outer) L: 204.5 mm (8.05 in) CHAIN ROLLER INSTALLATION  1 Chain roller (Upper) 3 Frame 2 Chain roller (Lower) A Chain roller bolt/nut ITEM N·m kgf-m...

  • Page 406: Fuel Tank Cushion Installation

    20-34 SERVICING INFORMATION FUEL TANK CUSHION INSTALLATION 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 adhering the cushion.

  • Page 407: Exterior Parts

    SERVICING INFORMATION 20-35 EXTERIOR PARTS  1 Front fender 5 Fuel tank 9 Rear fender Radiator cover upper 2 Front number plate 6 Right frame cover A ITEM N·m kgf-m lbf-ft bolt 3 Right radiator cover 7 Left frame cover B Radiator cover bolt 4 Left radiator cover 8 Seat...

  • Page 408: Front Fender Installation

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

  • Page 409: Frame Cover Installation

    SERVICING INFORMATION 20-37 FRAME COVER INSTALLATION 1 Seat 3 Seat rail 2 Rear fender 4 Frame cover FRAME COVER CUSHION INSTALLATION 1 Cushion 2 Frame cover...
  • Page 410 Prepared by September, 2009 Part No. 99500-42190-01E Printed in Japan...

Table of Contents