Page 1 RM-Z450 OWNER’S SERVICE MANUAL Part No. 99011-28H50-01A October, 2007...
Page 3 This manual is presented as a means whereby you • Wear a helmet and goggles can maintain your RM-Z450 in top working condi- A helmet is the most important piece of gear to tion at all times. Your riding skill and the mainte- wear.
Page 4: Serial Number Location
You need to prepare for the unex- pected by wearing a helmet and other protective gear, and practicing safe riding techniques to Engine No. minimize the damage to you and your machine. May all of your rides on your new Suzuki be winning rides!
Page 5 WARNINGS FOR SERVICING ! WARNING ! WARNING Never run the engine indoors or in a Fuel can catch on fire if you do not handle garage. Exhaust gas contains carbon mon- it properly. Gasoline vapors can catch fire oxide, a gas that is colorless and odorless easily.
Page 6: Replacement Parts
NOTE: installing a circlip. Use of replacement parts which are not equivalent • Use special tools where specified. in quality to genuine SUZUKI parts can lead to per- • Use genuine SUZUKI parts and recommended formance problems and damage. oil.
Page 7 99000-99001-SS5 Apply molybdenum oil solution. Use SUZUKI REAR SUSPENSION OIL (Mixture of engine oil and SUZUKI SS-25 or equivalent. MOLY PASTE in a ratio of 1:1) 99000-99001-S25 Apply SUZUKI SUPER GREASE “A” Use engine coolant or equivalent.
Page 8: Abbreviations Used In This Manual
ABBREVIATIONS USED IN THIS MANUAL : Maximum : Alternating Current : Minimum : American Petroleum Institute : Right Hand BTDC : Before Top Dead Center : Battery Positive Voltage : Society of Automotive Engineers CKP Sensor : Crankshaft Position Sensor (CKPS) TO Sensor : Tip-Over Sensor (TOS)
Page 9: Table Of Contents
GROUP INDEX GENERAL INFORMATION PERIODIC MAINTENANCE TROUBLESHOOTING MACHINE TUNING ENGINE REMOVAL AND INSTALLATION CYLINDER HEAD, CYLINDER AND PISTON CLUTCH KICK STARTER GEARSHIFTING TRANSMISSION AND CRANKSHAFT LUBRICATION SYSTEM FI SYSTEM DIAGNOSIS FUEL SYSTEM AND THROTTLE BODY COOLING SYSTEM ELECTRICAL SYSTEM FRONT AND REAR WHEELS FRONT AND REAR BRAKES FRONT FORK AND STEERING REAR SUSPENSION...
Page 10 GENERAL INFORMATION GENERAL INFORMATION CONTENTS LOCATION OF PARTS ................1- 2 ACCESSORY ....................1- 3 SIDE STAND ..................1- 3 FUEL AND OIL RECOMMENDATION ............1- 3 OPERATING INSTRUCTIONS ..............1- 4 STARTING THE ENGINE ..............1- 4 STOPPING THE ENGINE ..............1- 5 TRANSMISSION ...................
Page 11: Location Of Parts
GENERAL INFORMATION LOCATION OF PARTS 1 Clutch lever 2 Hot starter lever 3 Engine stop switch 4 Front brake lever 5 Throttle grip 6 Fuel tank cap 7 Starter knob/Idle screw 8 Gearshift lever 9 Front suspension compression damp- ing adjuster 0 Front suspension rebound damping adjuster A Kick starter lever...
Page 12: Accessory
Use only unleaded gasoline of at least 95 octane. (Research method)....For other countries Engine oil: SUZUKI recommends the use of SUZUKI PERFOR- MANCE 4 MOTOR OIL or equivalent engine oil. Use of SF/SG or SH/SJ in API with MA in JASO. The rec- ommended viscosity is SAE 10W-40.
Page 13: Operating Instructions
GENERAL INFORMATION OPERATING INSTRUCTIONS CAUTION Leaving the engine at idling speed after riding will cause engine overheat as this competition motorcycle does not have the radiator cooling fan and coolant reservoir. Riding the motorcycle under severe conditions such as muddy or sandy terrain with high ambient temperature can shorten time to be overheated.
Page 14: Stopping The Engine
GENERAL INFORMATION When the engine is already warm or restarts: 1) Pull the hot starter lever 1. 2) Kick the engine over, leaving the throttle closed without using the starter knob/idle screw. 3) Return the hot starter lever back immediately after the engine starts.
Page 15: Break-In (Running-In)
GENERAL INFORMATION BREAK-IN (RUNNING-IN) WHEN THE MOTORCYCLE IS NEW CLOSED CLOSED 1) Warm up the engine before starting off. 2) Ride for 60 minutes using less than 1/2 throttle opening. 3) Ride for 60 minutes using less than 3/4 throttle opening. FULL NOTE: OPEN...
Page 16: Exterior Parts
GENERAL INFORMATION EXTERIOR PARTS...
Page 17 PERIODIC MAINTENANCE 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 PERIODIC MAINTENANCE PERIODIC MAINTENANCE CONTENTS CYLINDER HEAD, CYLINDER AND PISTON ..........2-24 CYLINDER HEAD INSPECTION ............2-24 CYLINDER INSPECTION ..............2-24 PISTON INSPECTION ................2-24 MUFFLER SILENCER ................. 2-25 SILENCER INSPECTION AND REPLACEMENT ........ 2-25 DRIVE CHAIN AND SPROCKETS ............. 2-26 DRIVE CHAIN SLACK ................
Page 19: Periodic Maintenance
PERIODIC MAINTENANCE 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
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 Cleanliness Fuel tank Leakage Fuel hose • Damage •...
Page 21: Periodic Maintenance Chart
PERIODIC MAINTENANCE 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 PERIODIC MAINTENANCE Interval Every Every Every races race 3 races 6 races Remarks Service Every Every Every hours 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 SPARK PLUG • Remove the seat. (!5-2) • Remove the radiator covers and fuel tank. (!5-2, -3) • Disconnect the spark plug cap. • Remove the spark plug. " 09930-10121: Spark plug wrench set NOTE: Remove the dirt around the spark plug before removing the spark plug to prevent dirt from entering the combustion cham- ber.
Page 24: Air Cleaner
PERIODIC MAINTENANCE AIR CLEANER AIR CLEANER ELEMENT REMOVAL • Remove the seat. (!5-2) • Remove the wing nut 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 25: Engine Oil And Oil Filter
PERIODIC MAINTENANCE NOTE: Follow the instructions below to keep the air cleaner element dry when cleaning the motorcycle. • Cover the element with vinyl bag. • Install the seat. • Cover the inlet hole on the frame cover in order to prevent water from coming into the air cleaner box.
Page 26: Inspection Before Engine Oil Level Check
2-10 PERIODIC MAINTENANCE INSPECTION BEFORE ENGINE OIL LEVEL CHECK • Before starting the engine, check that there is sufficient oil for operating the engine. CAUTION If the engine is started with insufficient or no oil, the engine components will possibly be damaged. NOTE: The oil level measurement may become inaccurate unless the motorcycle is held upright as the motorcycle inclination affects...
Page 27: Engine Oil Change
PERIODIC MAINTENANCE 2-11 ENGINE OIL CHANGE • During inspection, hold the motorcycle in an upright position on a level surface. • Warm up the engine. • Remove filler cap, magneto cover guard 1, drain plug 2 and magneto cover bolt 3. Drain engine oil from the drain plug hole and magneto cover bolt hole.
Page 28: Engine Oil Filter Change
2-12 PERIODIC MAINTENANCE ENGINE OIL FILTER CHANGE • Drain the engine oil as described in the engine oil replace- ment procedure. • Remove the oil filter cap 1 and spring 2 with oil filter 3. • Apply engine oil lightly to the gasket of the new oil filter before installation.
Page 29: Oil Strainers
PERIODIC MAINTENANCE 2-13 OIL STRAINERS OIL STRAINER (No.1) REMOVAL • Drain engine oil. (!2-11) • Remove the engine oil strainer cap. CAUTION Do not lie the motorcycle to prevent dirty engine oil into the oil circuit when removing the oil strainer (No.1).
Page 30: Engine Coolant
2-14 PERIODIC MAINTENANCE ENGINE COOLANT ENGINE COOLANT LEVEL CHECK % WARNING 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 31: Engine Coolant Replenishment
PERIODIC MAINTENANCE 2-15 ENGINE COOLANT REPLENISHMENT • Use an anti-freeze and Summer engine coolant which is com- patible with aluminum radiator, mixed with distilled water at the ratio of 50:50. NOTE: The radiator, cylinder and cylinder head are made of aluminum alloy.
Page 32: Clutch Cable
2-16 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 33: Throttle Cable
THROTTLE CABLE OIL SUPPLY • Remove the throttle case 1. • Apply oil to the throttle cable. • Apply grease to the throttle cable spool. ' 99000-25010: SUZUKI SUPER GREASE “A” or equivalent...
Page 34: Hot Starter
2-18 PERIODIC MAINTENANCE HOT STARTER Adjust the hot starter cable play as follows: NOTE: Be careful not to damage the lever cover when installing. (!20-24) • Loosen the lock-nut 1. • Turn adjuster 2 so the hot starter lever clearance A mea- sured at the lever holder obtains 2 –...
Page 35: Engine Idle Speed
PERIODIC MAINTENANCE 2-19 ENGINE IDLE SPEED • Adjust the throttle cable play. (!2-17) • Warm up the engine. NOTE: Make this adjustment when the engine is hot. • Connect the multi-circuit tester or electric tachometer to the high-tension cord. " 09900-25008: Multi-circuit tester set •...
Page 36: Valve Clearance
2-20 PERIODIC MAINTENANCE VALVE CLEARANCE • Remove the seat. (!5-2) • Remove the radiator covers and fuel tank. (!5-2) • Disconnect the spark plug cap. (!2-7) • Remove the spark plug. (!2-7) • Remove the TO sensor bracket bolt and nut. •...
Page 37: Valve Clearance Adjustment
PERIODIC MAINTENANCE 2-21 VALVE CLEARANCE ADJUSTMENT The clearance is adjusted by replacing the existing tappet shim by a thicker or thinner shim. • Remove the intake or exhaust camshafts. (!6-4) • Remove the tappet 1 and shim 2 by fingers or magnetic hand.
Page 38 2-22 PERIODIC MAINTENANCE (INTAKE SIDE)
Page 39 PERIODIC MAINTENANCE 2-23 (EXHAUST SIDE)
Page 40: Cylinder Head, Cylinder And Piston
2-24 PERIODIC MAINTENANCE CYLINDER HEAD, CYLINDER AND PISTON CYLINDER HEAD INSPECTION • Remove the cylinder head. (!6-4) • 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 41: Muffler Silencer
• If necessary, replace the glass wool with a new one. • Insert the muffler silencer 3. • Apply SUZUKI BOND to the circumference of the rear muffler body 1 and inner plate 2. ( 99000-31140: SUZUKI BOND “1207B” or equivalent...
Page 42: Drive Chain And Sprockets
2-26 PERIODIC MAINTENANCE • The rear muffler body mounting bolt is of flanged type which tightens the muffler body 4, rear muffler body 1 and inner plate 2 together. When tightening, make sure to properly align the screw holes of these three parts to prevent the bolt from cross-threading or interfering with the screw holes.
Page 43: Drive Chain Adjustment
PERIODIC MAINTENANCE 2-27 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 44: Drive Chain Lubrication
2-28 PERIODIC MAINTENANCE DRIVE CHAIN LUBRICATION • Remove the chain clip and joint from the drive chain and remove the drive chain. • Clean the drive chain with kerosine. CAUTION Do not use trichloroethylene, gasoline or any similar solvent. These fluids will damage the O-ring seals. Use only kerosine to clean the drive chain.
Page 45: Drive Chain Guide, Buffer And Tensioner Roller
PERIODIC MAINTENANCE 2-29 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 46: Brakes
2-30 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. (!17-3) Inspect brake pad wear and brake fluid leakage if the brake fluid level decreases.
Page 47: Brake Pad
PERIODIC MAINTENANCE 2-31 BRAKE PAD Wear limit • Inspect the brake pads for wear. If the brake pads are worn, replace them with new ones. (!17-5) NOTE: * Pump the brake lever and pedal several times to restore the Wear limit brake pads after replacing the brake pads.
Page 48: Front Fork
2-32 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 49: Spoke Nipple And Rim Lock Inspection
PERIODIC MAINTENANCE 2-33 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 lb-ft) CAUTION Improperly tightening the spoke nipples can damage the wheel.
Page 50: 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 51: Compression Pressure Check
PERIODIC MAINTENANCE 2-35 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 kPa (4.0 kgf/cm , 57 psi) and more...
Page 52: Oil Pressure Check
2-36 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: 50 kPa (0.5 kgf/cm², 7.1 psi) at 4 000 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 53: Troubleshooting
TROUBLESHOOTING TROUBLESHOOTING CONTENTS ENGINE ......................3- 2 RADIATOR (COOLING SYSTEM) .............. 3- 8 CHASSIS ..................... 3- 9 BRAKES ...................... 3-10 ELECTRICAL ....................3-11...
Page 54: Engine
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 • Mistiming valves Adjust •...
Page 55 TROUBLESHOOTING 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 56 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 57 TROUBLESHOOTING 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 Adjust •...
Page 58 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 • Poor seating of valves Repair •...
Page 59 TROUBLESHOOTING 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 60: Radiator (Cooling System)
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 61: Chassis
TROUBLESHOOTING 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 62: 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 63: Electrical
TROUBLESHOOTING 3-11 ELECTRICAL Complaint Symptom and possible causes Remedy No sparking or poor • Defective ignition coil Replace sparking • Defective spark plug Replace • Defective CKP sensor Replace • Defective ECM Replace • Defective TO sensor Replace • Open-circuited wiring connections Repair or replace Spark plug soon •...
Page 64: Machine Tuning
MACHINE TUNING MACHINE TUNING CONTENTS FRONT FORK TUNING ................4- 2 COMPRESSION DAMPING FORCE ADJUSTMENT ......4- 2 REBOUND DAMPING FORCE ADJUSTMENT ........4- 2 OIL QUANTITY MINOR ADJUSTMENT ..........4- 3 OIL CHANGE (Only for outer tube oil chamber) ....... 4- 4 SPRING CHANGE ................
Page 65: Front Fork Tuning
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 66: Oil Quantity Minor Adjustment
Operating the motorcycle with the fork oil quantity unevenly adjusted can cause handling instability. 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...
Page 67: Oil Change (Only For Outer Tube Oil Chamber)
MACHINE TUNING OIL CHANGE (Only for outer tube oil chamber) • Remove the front forks. (!18-4) • Thoroughly clean the fork before disassembly. CAUTION 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 68 MACHINE TUNING • 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 adjustable range on the spring end) 318 –...
Page 69: Spring Change
MACHINE TUNING SPRING CHANGE • Remove the front forks. (!18-4) • Thoroughly clean the fork before disassembly. CAUTION 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 70 US/Imp oz) 321 – 415 ml 370 ml (10.85/11.30 – 51171-28H00 (12.51/13.03 14.03/14.61 US/Imp oz) US/Imp oz) 316 – 410 ml 365 ml (10.68/11.13 – Hard 51171-28H20 (12.34/12.85 13.86/14.44 US/Imp oz) US/Imp oz) # 99000-99001-SS5: SUZUKI FORK OIL SS-05 or equivalent...
Page 71: Front Fork Tuning Procedure
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 72: Rear Suspension Tuning
MACHINE TUNING 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 73: Rebound Damping Force Adjustment
MACHINE TUNING 4-10 REBOUND DAMPING FORCE ADJUSTMENT NOTE: To set the adjuster, you must gently turn the adjust screw clock- Soft Hard 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 74: Rear Suspension Tuning Procedure
4-11 MACHINE TUNING 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 52 N/mm 62211-10H10 Yellow (5.2 kgf/mm) Soft 54 N/mm 62211-10H00...
Page 75 MACHINE TUNING 4-12 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 76: Suspension Balance
4-13 MACHINE TUNING 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 77: Engine Removal And Installation
ENGINE REMOVAL AND INSTALLATION ENGINE REMOVAL AND INSTALLATION CONTENTS ENGINE REMOVAL AND INSTALLATION ..........5- 2 REMOVAL ..................... 5- 2 INSTALLATION ..................5- 6...
Page 78: Engine Removal And Installation
ENGINE REMOVAL AND INSTALLATION ENGINE REMOVAL AND INSTALLATION REMOVAL • Drain engine oil. (!2-11) • Drain engine coolant. (!14-3) • Remove the seat 1. • Remove the radiator covers 2, left and right. • Remove the right frame cover 3. •...
Page 79 ENGINE REMOVAL AND INSTALLATION • Remove the muffler 6. • Remove the exhaust pipe 7 and exhaust pipe gasket 8. • Remove the front protectors, left and right. • Remove the radiator louvers 9, left and right. • Remove the radiator mounting bolts, left and right. •...
Page 80 ENGINE REMOVAL AND INSTALLATION • Disconnect the magneto lead wire coupler D and GP switch coupler E. • Remove the clamps. • Remove the TO sensor bracket bolt and nut. • Remove the clutch cable bracket bolt F and disconnect the clutch cable.
Page 81 ENGINE REMOVAL AND INSTALLATION • Remove the gearshift lever N. NOTE: Mark the gearshift shaft head at which the gearshift lever slit set for correct reinstallation. • Remove the engine sprocket cover O. • Remove the front chain guide plate P. •...
Page 82 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 83 $ Engine sprocket cover bolt: 11 N·m (1.1 kgf-m, 8.0 lb-ft) • Install the gearshift lever in the correct position. • Apply grease to the brake pedal pivot bolt. % 99000-25010: SUZUKI SUPER GREASE “A” or equivalent • Install the brake pedal and brake pedal spring. (!20-23)
Page 84 ENGINE REMOVAL AND INSTALLATION • Install the clip 6, washer 7 and cotter pin 8. CAUTION Replace the cotter pin 8 with a new one. • Install the kick starter lever in the correct position. (!8-7) $ Kick starter lever bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft) •...
Page 85 ENGINE REMOVAL AND INSTALLATION • Install the muffler joint connector 9 and exhaust pipe gasket CAUTION Replace the connector 9 and gasket 0 with new ones to prevent exhaust gas leakage. NOTE: When installing a new connector, clean the exhaust pipe and joint of the muffler.
Page 86 CYLINDER HEAD, CYLINDER AND PISTON CYLINDER HEAD, CYLINDER AND PISTON CONTENTS CONSTRUCTION ..................6- 2 CYLINDER HEAD, CYLINDER AND PISTON ........6- 2 ENGINE TOP SIDE DISASSEMBLY ............6- 3 CYLINDER HEAD COVER REMOVAL ..........6- 3 CAMSHAFTS (AUTOMATIC DECOMP.) AND CAM CHAIN TENSION ADJUSTER REMOVAL ............
Page 87: Construction
CYLINDER HEAD, CYLINDER AND PISTON CONSTRUCTION CYLINDER HEAD, CYLINDER AND PISTON 14 N . m (1.4 kgf-m, 10.0 lb-ft) 11 N . m (1.1 kgf-m, 8.0 lb-ft) 10 N . m 51 N . m (1.0 kgf-m, (5.1 kgf-m, 37.0 lb-ft) 51 N .
Page 88: Engine Top Side Disassembly
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. (!5-2) • Disconnect the spark plug cap and remove the spark plug. (!2-7) • Remove the TO sensor bracket bolt and nut. •...
Page 89: Cylinder Head Removal
CYLINDER HEAD, CYLINDER AND PISTON • Remove the cam chain tension adjuster cap bolt 3, washer and spring. • Remove the cam chain tension adjuster 4 and its gasket. • Remove the camshaft journal holder 5. CAUTION Be sure to loosen the camshaft journal holder bolts evenly by shifting the wrench in the descending order of numbers.
Page 90 CYLINDER HEAD, CYLINDER AND PISTON • Disconnect the ECT sensor coupler 3. • Remove the cylinder head base bolts 4. • Loosen the cylinder base bolt 5. • Remove the cylinder head bolts. NOTE: When loosening the cylinder head bolts, loosen each bolt little by little diagonally.
Page 91: Cylinder Removal
CYLINDER HEAD, CYLINDER AND PISTON CYLINDER REMOVAL • Remove the cylinder head. (!6-4) • Remove the cylinder 1 by removing the cylinder base bolt. CAUTION Do not drop the cam chain into the crankcase. NOTE: If the cylinder does not come off easily, lightly tap it using a plas- tic hammer.
Page 92: Engine Top Components Inspection And Service
CYLINDER HEAD, CYLINDER AND PISTON 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 CAUTION The camshaft assembly can not be disassembled.
Page 93 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.: 35.23 mm (1.387 in) EX.: 34.03 mm (1.340 in) # 09900-20202: Micrometer (25 –...
Page 94: Cam Chain Tension Adjuster Inspection
CYLINDER HEAD, CYLINDER AND PISTON • 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 95: Cylinder Head And Valve Inspection
CYLINDER HEAD, CYLINDER AND PISTON 6-10 CYLINDER HEAD AND VALVE INSPECTION VALVE DISASSEMBLY • Remove the tappet 1 and shim 2 by fingers or magnetic hand. CAUTION Identify the position of each removed part. Organize the parts in their respective groups (i.e., intake or exhaust) so that they can be installed in their original locations.
Page 96 6-11 CYLINDER HEAD, CYLINDER AND PISTON • Remove the valve stem seal 7 and spring seat 8. CAUTION Do not reuse the removed valve stem seal. • Remove the other valves in the same manner as described previously. CYLINDER HEAD DISTORTION •...
Page 97 CYLINDER HEAD, CYLINDER AND PISTON 6-12 VALVE STEM AND VALVE FACE WEAR CONDITION • Visually inspect each valve stem and valve face for wear and pitting. • If it is worn or damaged, replace the valve with a new one. VALVE STEM DEFLECTION •...
Page 98 6-13 CYLINDER HEAD, CYLINDER AND PISTON 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 99 CYLINDER HEAD, CYLINDER AND PISTON 6-14 • 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. CAUTION Do not use a burner to heat the valve guide hole to prevent cylinder head distortion.
Page 100 6-15 CYLINDER HEAD, CYLINDER AND PISTON • 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 The valve seats 1 for both the intake valve 2 and exhaust valve 3 are machined to three different angles.
Page 101 CYLINDER HEAD, CYLINDER AND PISTON 6-16 • 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 102 6-17 CYLINDER HEAD, CYLINDER AND PISTON • 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 and sleeve protector a, press down the spring, fit the valve cotter halves to the stem end, and release the lifter to allow the valve cotter 3 to wedge in between retainer and stem.
Page 103: Intake Pipe Removal
• Remove the intake pipe clamp 1. • Remove intake pipe 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 clamp. NOTE: Make sure that the “UP”...
Page 104: Cylinder Inspection
6-19 CYLINDER HEAD, CYLINDER AND PISTON 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 105: Piston And Piston Ring Inspection
CYLINDER HEAD, CYLINDER AND PISTON 6-20 PISTON AND PISTON RING INSPECTION PISTON DIAMETER • Using a micrometer, measure the piston outside diameter at 15 mm (0.6 in) A from the piston skirt end. • If the measurement is less than the limit, replace the piston. "...
Page 106: Piston Ring Groove Width
6-21 CYLINDER HEAD, CYLINDER AND PISTON 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 107: Crankshaft And Conrod Inspection
CYLINDER HEAD, CYLINDER AND PISTON 6-22 CRANKSHAFT AND CONROD INSPECTION For inspection other than the following, refer to page 10-7. 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 108: Engine Top Side Assembly
6-23 CYLINDER HEAD, CYLINDER AND PISTON ENGINE TOP SIDE ASSEMBLY 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 109 CYLINDER HEAD, CYLINDER AND PISTON 6-24 PISTON • Install the piston with the punch mark 1 facing towards the exhaust side. • Before installing the piston pin, apply MOLYBDENUM OIL SOLUTION onto its surface. % MOLYBDENUM OIL SOLUTION • Place a clean rag over the cylinder base to prevent the piston pin circlip from dropping into crankcase.
Page 110: 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 into the crankcase and then install the cylinder gasket 1.
Page 111 CYLINDER HEAD, CYLINDER AND PISTON 6-26 CYLINDER HEAD • Install the dowel pins into the cylinder and then install the cyl- inder head gasket 1 onto the cylinder. CAUTION Use the new gasket to prevent gas leakage. • Place the cylinder head 2 on the cylinder. CAUTION Do not drop the cam chain into the crankcase.
Page 112: Camshaft (Automatic Decomp.) And Cam Chain Tension Adjuster Installation
6-27 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 113 • Install the dowel pins and C-ring 1. • Install the camshafts, intake and exhaust. • Apply grease to the new O-ring and install it to the camshaft journal holder. CAUTION Use the new O-ring to prevent oil leakage. ' 99000-25010: SUZUKI SUPER GREASE “A” or equivalent...
Page 114 6-29 CYLINDER HEAD, CYLINDER AND PISTON • Install the camshaft journal holder. • Have the camshaft journal holder evenly by tightening the camshaft journal holder bolts lightly, in the ascending order of numbers. NOTE: * When tightening the camshaft journal holder bolts, the piston position must be at TDC on the compression stroke.
Page 115 • Apply grease to the O-rings. CAUTION Use the new O-rings to prevent oil leakage. ' 99000-25010: SUZUKI SUPER GREASE “A” or equivalent • Tighten each plug to the specified torque. $ TDC plug: 14 N·m (1.4 kgf-m, 10.0 lb-ft) Crankshaft hole plug: 11 N·m (1.1 kgf-m, 8.0 lb-ft)
Page 116: Cylinder Head Cover Installation
• Apply bond to the end caps of the cylinder head cover gasket as shown. ) 99000-31140: SUZUKI BOND “1207B” or equivalent • Place the cylinder head cover on the cylinder head. • Apply engine oil to both sides of gaskets.
Page 117: Cam Chain, Cam Chain Tensioner And Cam Chain
CYLINDER HEAD, CYLINDER AND PISTON 6-32 CAM CHAIN, CAM CHAIN TENSIONER AND CAM CHAIN No.1 GUIDE REMOVAL • Remove the cylinder head. (!6-4) • Remove the magneto cover and magnet rotor. (!15-17, -18) • Remove the cam chain No.1 guide 1 and cam chain guide retainer 2.
Page 118: Installation
6-33 CYLINDER HEAD, CYLINDER AND PISTON INSTALLATION Install the cam chain and cam chain tensioner in the reverse order of removal. Pay attention to the following points: • Install the cam chain tensioner 1. $ Cam chain tensioner bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft) •...
Page 119 CLUTCH 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 120: Construction
CLUTCH CONSTRUCTION CLUTCH 10 N . m (1.0 kgf-m, 7.0 lb-ft) 90 N . m (9.0 kgf-m, 65.0 lb-ft) A Clutch drive No.1 plate (Clutch facing a : 36 pcs.) B Clutch drivn No.2 plate (Clutch facing a : 48 pcs.) C Clutch driven No.1 plate (Silver) D Clutch driven No.2 plate (Gray)
Page 121: Clutch Plate
CLUTCH CLUTCH PLATE REMOVAL • Drain engine oil. (!2-11) • Remove the brake pedal. (!17-18) • Remove the clutch cover 1 and its gasket. • Remove the clutch spring set bolts and clutch springs. NOTE: Loosen the clutch spring set bolts little by little and diagonally. •...
Page 122 CLUTCH • Remove the clutch drive plates 6 and driven plates 7. NOTE: Mark the paint mark to the clutch driven No. 2 plate. Mark the paint mark. A Clutch driven No. 2 plate B Clutch driven No. 1 plate C Direction of outside •...
Page 123: Inspection
CLUTCH INSPECTION DRIVE PLATE • Measure the drive plate thickness. " Drive plate thickness Service Limit: 2.77 mm (0.109 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 124: Installation
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 for any abnormality, partic- ularly cracks, to decide whether it can be reused or should be replaced.
Page 125 CLUTCH • Install the push rod and push piece 5. • Apply engine oil to the release bearing 6. NOTE: The covered side e of the bearing 6 should face outside. • Fit the clutch pressure plate 7. Outside • Install the clutch springs and clutch spring set bolts. •...
Page 126: Primary Driven Gear And Clutch Sleeve Hub
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 with the special tool and loosen the nut 2.
Page 127: Inspection
CLUTCH INSPECTION • Inspect the clutch sleeve hub and primary driven gear for wear and cracks. • If necessary, replace the sleeve hub or driven gear. • Inspect the needle bearing and spacer for damage and wear. • If any defects are found, replace the bearing or spacer. INSTALLATION Install the primary driven gear and clutch sleeve hub in the reverse order of removal.
Page 128 7-10 CLUTCH • Tighten the clutch sleeve hub nut 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 lb-ft) • Make sure the clutch sleeve hub for smooth movement. •...
Page 129: 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 cam chain tension adjuster cap bolt 1 and spring. (!6-4) CAUTION Do not turn the crankshaft after removing the cam chain tension adjuster cap bolt.
Page 130: Installation
Install the clutch release camshaft 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 131: Kick Starter
KICK STARTER KICK STARTER CONTENTS CONSTRUCTION ..................8- 2 KICK STARTER ..................8- 2 KICK STARTER ................... 8- 3 REMOVAL ..................... 8- 3 INSPECTION ..................8- 4 INSTALLATION ..................8- 5...
Page 132: Construction
KICK STARTER CONSTRUCTION KICK STARTER 10 N·m (1.0 kgf-m, 7.0 lb-ft) 23 N·m (2.3 kgf-m, 16.5 lb-ft) 10 N·m (1.0 kgf-m, 7.0 lb-ft)
Page 133: Removal
KICK STARTER KICK STARTER REMOVAL • Drain engine oil. (!2-11) • Drain engine coolant. (!14-3) • Remove the brake pedal. (!17-18) • Disconnect the radiator hose 1. • Remove the kick starter lever 2. • Remove the right crankcase cover 3, dowel pins, gasket and O-ring.
Page 134: Inspection
KICK STARTER • Remove the kick starter guide F. INSPECTION • Inspect the oil seal lip for wear and damage. • If any defects are found, replace the oil seal with a new one. • Inspect the kick starter drive gear teeth for damage. •...
Page 135: Installation
KICK STARTER INSTALLATION Install the kick starter in the reverse order of removal. Pay atten- tion to the following points: • Install the kick starter guide 1. # Kick starter guide bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft) • Install the kick starter drive gear 2, washer 3 and snap ring 4 onto the kick starter shaft.
Page 136 KICK STARTER • Install the washer 8 and spring 9 onto the kick starter shaft. • Install the kick starter shaft assembly onto the crankcase. NOTE: Securely engage the stopper portion C of the kick starter with the stopper guide D. •...
Page 137 KICK STARTER • Install the kick starter lever so that its punch mark F aligns with the truncated spline G. • Tighten the kick starter lever bolt to the specified torque. # Kick starter lever bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft) •...
Page 138: Gearshifting
GEARSHIFTING 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 139: Construction
GEARSHIFTING CONSTRUCTION GEARSHIFT LINKAGE 23 N . m (2.3 kgf-m, 16.5 lb-ft) 8.5 N . m (0.85 kgf-m, 6.0 lb-ft) 24 N . m (2.4 kgf-m, 17.5 lb-ft) 8.5 N . m 6.5 N . m (0.85 kgf-m, 6.0 lb-ft) (0.65 kgf-m, 4.7 lb-ft)
Page 140: Gearshift Linkage
GEARSHIFTING GEARSHIFT LINKAGE REMOVAL • Drain engine oil. (!2-11) • Drain engine coolant. (!14-3) • Remove the gearshift lever 1. NOTE: Mark the gearshift shaft head at which the gearshift lever slit set for correct reinstallation. • Remove the right crankcase cover and clutch component parts.
Page 141 GEARSHIFTING • Remove the gearshift pawls 8, pins 9, springs 0 and gear- shift roller A. • Remove the gearshift cam driven gear pin B and gearshift cam stopper plate C. • Remove the gearshift cam stopper D, spring E and washer •...
Page 142: Inspection
GEARSHIFTING 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 and gearshift roller 6 for damage.
Page 143 GEARSHIFTING • Apply a small quantity of THREAD LOCK to the gearshift cam driven pin 6 and tighten it to the specified torque. % 99000-32050: THREAD LOCK “1342” or equivalent $ Gearshift cam driven pin: 24 N·m (2.4 kgf-m, 17.5 lb-ft) •...
Page 144 GEARSHIFTING • Install the gearshift return spring D, snap ring E and washer F onto the gearshift shaft C properly. CAUTION Replace the snap ring E with a new one. NOTE: When installing the return spring, position the stopper D of gearshift arm between the return spring ends E.
Page 145: Gear Position (Gp) Switch
• Fit the new O-ring to GP switch and apply grease to it. CAUTION Replace the O-ring with a new one. & 99000-25010: SUZUKI SUPER GREASE “A” or equivalent • Install the GP switch and tighten the bolts to the specified torque.
Page 146 10-1 TRANSMISSION AND CRANKSHAFT TRANSMISSION AND CRANKSHAFT CONTENTS CONSTRUCTION ..................10- 2 TRANSMISSION AND CRANKSHAFT ..........10- 2 ENGINE BOTTOM SIDE ................10- 3 PRIMARY DRIVE GEAR REMOVAL ..........10- 3 CRANKCASE SEPARATION ............. 10- 4 TRANSMISSION REMOVAL .............. 10- 4 CRANKSHAFT REMOVAL ..............
Page 147: Construction
TRANSMISSION AND CRANKSHAFT 10-2 CONSTRUCTION TRANSMISSION AND CRANKSHAFT 8.5 N . m (0.85 kgf-m, 6.0 lb-ft) 8.5 N . m 8.5 N . m (0.85 kgf-m, 6.0 lb-ft) (0.85 kgf-m, 6.0 lb-ft) 8.5 N . m (0.85 kgf-m, 6.0 lb-ft) 8.5 N .
Page 148: Engine Bottom Side
10-3 TRANSMISSION AND CRANKSHAFT ENGINE BOTTOM SIDE • Remove the engine assembly. (!5-2 to -5) NOTE: The following parts must be removed before disassembling the engine bottom side (crankcase). • Disconnect the crankcase breather hose 1. • Remove the engine top side 2 (cylinder head, cylinder and piston).
Page 149: Crankcase Separation
TRANSMISSION AND CRANKSHAFT 10-4 CRANKCASE SEPARATION • Remove the engine sprocket spacer 1 and two O-rings 2. • Remove the oil strainer cap 3 and oil strainer (No.1). (!2-13) • Remove the crankcase bolts. • Separate the crankcase with the special tool. "...
Page 150: Crankshaft Removal
10-5 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. CAUTION Be careful not to damage the thread part of the crank- shaft.
Page 151: Transmission Inspection
TRANSMISSION AND CRANKSHAFT 10-6 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 152: Conrod Inspection
10-7 TRANSMISSION AND CRANKSHAFT • Measure the gearshift fork groove width with a vernier cali- pers. # Gearshift fork groove width Standard: 5.0 – 5.1 mm (0.197 – 0.201 in) " 09900-20101: Vernier calipers CONROD INSPECTION • For conrod inspection other than the following, refer to page 6-22.
Page 153: Oil Seal Inspection
• Remove the oil seal 4 with the suitable tool. • Apply grease to each oil seal lip. $ 99000-25010: SUZUKI SUPER GREASE “A” or equivalent • Install each new oil seal (1, 2, 3, 5) with the special tool.
Page 154: Bearing Inspection
10-9 TRANSMISSION AND CRANKSHAFT NOTE: Be sure to check the direction of the crankshaft bearing oil seal 5 before installing them. PRIMARY DRIVE GEAR SIDE BEARING INSPECTION • Inspect the bearings for play, discoloration, wear and seizure. • Move the inner race by finger and inspect for smooth move- ment.
Page 155 TRANSMISSION AND CRANKSHAFT 10-10 REMOVAL CAUTION The removed bearing should be discard. • Remove the bearings with the special tool. Bearing 1, 3, 5, 6: % 40 Attachment Bearing 7: % 32 Attachment " 09913-70210: Bearing installer set • Remove the bearings (2, 8) with the special tool. "...
Page 156 10-11 TRANSMISSION AND CRANKSHAFT INSTALLATION • Press the new bearings with the special tool. Bearing 1: % 55 Attachment Bearing 2, 8: % 40 Attachment Bearing 3: % 75 Attachment Bearing 4: % 32 Attachment Bearing 5: % 52 Attachment Bearing 6: % 72 Attachment Bearing 7: % 37 Attachment Bearing 9: % 15 Attachment...
Page 157: Crankshaft Installation
• Apply grease to the oil seal lip. CAUTION 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 158: Transmission Installation
10-13 TRANSMISSION AND CRANKSHAFT TRANSMISSION INSTALLATION CAUTION The removed snap ring should be discard. Thrust NOTE: Install the snap ring in the groove and locate its end as shown in the illustration. Sharp edge • Apply engine oil to the following parts: driveshaft, countershaft, transmission gears, bearings.
Page 159 TRANSMISSION AND CRANKSHAFT 10-14 • Install the gearshift forks (3, 4, 5) as shown. 3 For 5th driven gear (28H-1A) 4 For 4th driven gear (28H-2A) 5 For 3rd driven gear • Install the gearshift cam 6 and gearshift shafts 7. NOTE: Turn the gearshift cam to the neutral position and confirm that the driveshaft and countershaft turn without resistance.
Page 160: Crankcase Installation
• Inspect the crankshaft, countershaft and driveshaft for smooth movement. • Apply grease to the oil seal lip and O-rings 3. CAUTION Replace the O-rings with new ones. $ 99000-25010: SUZUKI SUPER GREASE “A” or equivalent • Fit the O-rings 3 and spacer 4 to the driveshaft.
Page 161: Primary Drive Gear Installation
• Install the cam chain, cam chain tensioner and cam chain guide retainer. (!6-33) • Install the magneto rotor and key. (!15-18) • Apply grease to the oil seal lip. $ 99000-25010: SUZUKI SUPER GREASE “A” or equivalent • Install the primary drive gear 1 and washer 2. NOTE: The washer is directional.
Page 162: Lubrication System
11-1 LUBRICATION SYSTEM 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 163: Engine Lubrication System
LUBRICATION SYSTEM 11-2 ENGINE LUBRICATION SYSTEM ENGINE LUBRICATION SYSTEM CHART...
Page 164: Engine Oil Level Inspection
11-3 LUBRICATION SYSTEM ENGINE OIL LEVEL INSPECTION (!2-10) ENGINE OIL CHANGE (!2-11) ENGINE OIL FILTER CHANGE (!2-12) OIL PRESSURE CHECK (!2-36) OIL STRAINER REMOVAL OIL STRAINER No.1 (!2-13) OIL STRAINER No.2 (!11-6) OIL STRAINERS INSPECTION (!2-13) OIL STRAINER INSTALLATION OIL STRAINER No.1 (!2-13) OIL STRAINER No.2 (!11-8) OIL REED VALVE REMOVAL (!10-4)
Page 165: Oil Relief Valve Inspection
LUBRICATION SYSTEM 11-4 OIL RELIEF VALVE INSPECTION • Inspect the operation of the oil relief valve by pushing on the piston with a proper bar. • If the piston does not operate, replace the oil relief valve with a new one. OIL RELIEF VALVE INSTALLATION •...
Page 166: Oil Seal Installation
" 09913-70210: Bearing installer set Oil seal: # 22 Attachment 09900-06108: Snap ring pliers • 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. (!2-11) •...
Page 167: Oil Pump No.1 And No.2 Inspection
LUBRICATION SYSTEM 11-6 OIL PUMP No.2 • Drain engine oil. (!2-11) • Remove the gearshift lever. (!9-3) • Remove the magneto cover. (!15-17) • Remove the oil pump No.2 cover 1. • Remove the snap ring 2 and oil strainer No.2 3 from the oil pump No.2 cover 1.
Page 168: Oil Pump No.1 And No.2 Installation
11-7 LUBRICATION SYSTEM OIL PUMP No.1 AND No.2 INSTALLATION OIL PUMP No.1 Install the oil pump No.1 in the reverse order of removal. Pay attention to the following points: • Install the oil pump No.1 cover 2, oil pump No.1 plate 3 and pin 4 onto the oil pump driven gear shaft 1.
Page 169 LUBRICATION SYSTEM 11-8 OIL PUMP No.2 Install the oil pump No.2 in the reverse order of removal. Pay attention to the following points: • Install the pin 2 into the oil pump No.2 shaft 1. • Install the inner rotor 3 onto the oil pump No.2 shaft 1. NOTE: Fit the slot A of the inner rotor onto the pin 2.
Page 170: Fi System Diagnosis
12-1 FI SYSTEM DIAGNOSIS FI SYSTEM DIAGNOSIS CONTENTS PRECAUTIONS IN SERVICING..............12- 3 ELECTRICAL PARTS................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 171 FI SYSTEM DIAGNOSIS 12-2 FI SYSTEM DIAGNOSIS CONTENTS SENSORS ....................12-46 CKP SENSOR/CRANKSHAFT ROTATION SIGNAL SENSOR INSPECTION ..................12-46 CKP SENSOR/CRANKSHAFT ROTATION SIGNAL SENSOR REMOVAL AND INSTALLATION ............12-46 IAP SENSOR INSPECTION ..............12-46 IAP SENSOR REMOVAL AND INSTALLATION........ 12-46 TP SENSOR INSPECTION ..............
Page 172: Precautions In Servicing
12-3 FI SYSTEM DIAGNOSIS PRECAUTIONS IN SERVICING When handling the component parts or servicing the FI system, observe the following points for the safety of the system. ELECTRICAL PARTS CONNECTOR/COUPLER • When connecting a connector, be sure to push it in until a click is felt.
Page 173: Ecm/Various Sensors
FI SYSTEM DIAGNOSIS 12-4 • 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 174 12-5 FI SYSTEM DIAGNOSIS • When disconnecting and connecting the ECM, make sure to stop the engine, or electronic parts may get damaged. INCORRECT WHEN USING THE BATTERY LEAD WIRE (Optional patrt: 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 175: Electrical Circuit Inspection Procedure
FI SYSTEM DIAGNOSIS 12-6 • 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 176 12-7 FI SYSTEM DIAGNOSIS • 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 177 FI SYSTEM DIAGNOSIS 12-8 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 178: 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 179: Fi System Technical Features
FI SYSTEM DIAGNOSIS 12-10 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 180: Compensation Of Injection Time (Volume)
12-11 FI SYSTEM DIAGNOSIS 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 181: Fi System Parts Location
FI SYSTEM DIAGNOSIS 12-12 FI SYSTEM PARTS LOCATION A ECM E ECT sensor B Ignition coil F Fuel injector C TO sensor G IAP sensor D Fuel pump...
Page 182 12-13 FI SYSTEM DIAGNOSIS A ECM J CKP sensor H IAT Sensor K Crankshaft rotation signal sensor I TP Sensor L GP switch...
Page 183: Fi System Wiring Diagram
FI SYSTEM DIAGNOSIS 12-14 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 Ignition coil...
Page 184: Ecm Terminal
12-15 FI SYSTEM DIAGNOSIS ECM TERMINAL TERMINAL TERMINAL CIRCUIT CIRCUIT Power source (+B) — TO sensor signal (TOS) Blank CKP sensor signal (CKP+) FI indicator GP switch signal (GP) ECT sensor signal (ECTS) TP sensor signal (TPS) — IAP sensor signal (IAPS) Sensors ground (E2) —...
Page 185: Self-Diagnosis Function
FI SYSTEM DIAGNOSIS 12-16 SELF-DIAGNOSIS FUNCTION The self-diagnosis function is incorporated in the ECM. The user can only be notified by 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 code of the malfunction items.
Page 186: Diagnostic Trouble Code Table
12-17 FI SYSTEM DIAGNOSIS 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 187: Tp Sensor Adjustment
FI SYSTEM DIAGNOSIS 12-18 TP SENSOR ADJUSTMENT 1. Remove the engine mounting upper bracket (LH). ("5-5) 2. Remove the front number plate. ("18-4) 3. Connect a 12 volts battery using the battery lead wire to ser- vice coupler. ("12-22) 36890-28H00: Battery lead wire (option) 4.Loosen the screw and turn the TP sensor 1.
Page 188: Fail-Safe Function
12-19 FI SYSTEM DIAGNOSIS FAIL-SAFE FUNCTION FI system is provided with fail-safe function to allow the engine to start and the motorcycle to run in a mini- mum performance necessary even under malfunction condition. STARTING RUNNING ITEM FAIL-SAFE MODE ABILITY ABILITY IAP sensor Intake air pressure is fixed to 106...
Page 189: Fi System Troubleshooting
FI SYSTEM DIAGNOSIS 12-20 FI SYSTEM TROUBLESHOOTING CUSTOMER COMPLAINT ANALYSIS Record details of the problem (failure, complaint) and how it occurred as described by the customer. For this purpose, use of such an inspection form such as below will facilitate collecting information required for proper analysis and diagnosis.
Page 190: Visual Inspection
12-21 FI SYSTEM DIAGNOSIS MOTORCYCLE/ENVIRONMENTAL CONDITION WHEN PROBLEM OCCURS Environmental condition Weather Fair Cloudy Rain Snow Always Other Temperature Warm Cool Cold ( °C / °F ) Always Frequency Always Sometimes ( times/ day, month) Only once Under certain condition Road Mountainous ( Uphill...
Page 191: Self-Diagnostic Procedures
FI SYSTEM DIAGNOSIS 12-22 SELF-DIAGNOSTIC PROCEDURES NOTE: * Do not disconnect couplers from the ECM and ECM ground wire harness from the engine before confirming the DTC (Diagnostic Trouble Code) stored in memory. Such disconnec- tion will erase the memorized information in ECM memory. * DTC stored in ECM memory can be checked by the FI indica- tor light assy.
Page 192: Dtc And Defective Condition
12-23 FI SYSTEM DIAGNOSIS 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- sec. or more, after receiving the IAP ical parts CKP sensor sensor input signal.
Page 193 FI SYSTEM DIAGNOSIS 12-24 DETECTED DTC No. DETECTED FAILURE CONDITION CHECK FOR ITEM Gear position signal voltage should be GP switch, wiring/coupler con- higher than the following for 30 sec- nection, gearshift cam, etc. Gear posi- onds and more. tion signal Gear position switch voltage 0.6 V If lower than the above value, 31 is...
Page 194: 12" Ckp Sensor Circuit Malfunction
12-25 FI SYSTEM DIAGNOSIS “12” CKP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE The signal does not reach ECM for 1 sec. or more, • Metal particles or foreign material being stuck on after receiving the IAP sensor input signal. the CKP sensor and rotor tip.
Page 195 FI SYSTEM DIAGNOSIS 12-26 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 196: 14" Tp Sensor Circuit Malfunction
12-27 FI SYSTEM DIAGNOSIS “14” TP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE Output voltage is not within the following range. • TP sensor maladjusted. Difference between actual throttle opening and • TP sensor circuit open or short. opening calculated by ECM is larger than specified •...
Page 197 FI SYSTEM DIAGNOSIS 12-28 Step 2 1) Connect the TP sensor coupler. 2) Connect a 12 volts battery using the battery lead wire to ser- vice coupler. ("12-22) 3) Insert the needle pointed probes to the lead wire coupler. 4) Measure the TP sensor output voltage at the coupler (between + Yellow and - B/Br) by turning the throttle grip.
Page 198: 15" Ect Sensor Circuit Malfunction
12-29 FI SYSTEM DIAGNOSIS “15” ECT SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE Output voltage is not within the following range. • ECT sensor circuit open or short. 0.1 V Sensor voltage < 4.8 V • ECT sensor malfunction. • ECM malfunction. ECT sensor B/BI B/Br...
Page 199 FI SYSTEM DIAGNOSIS 12-30 Step 2 1) Stop the engine. 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) ! 09900-25008: Multi-circuit tester set $ Tester knob indication: Resistance (Ω) Refer to page 12-47 for details.
Page 200: 17" Iap Sensor Circuit Malfunction
12-31 FI SYSTEM DIAGNOSIS “17” IAP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE IAP sensor voltage is not within the following range. • Clogged vacuum passage. 0.5 V Sensor voltage < 4.4 V • Air being drawn from vacuum passage between throttle body and IAP sensor.
Page 201 FI SYSTEM DIAGNOSIS 12-32 5) Connect a 12 volts battery using the battery lead wire to ser- vice coupler. ("12-22) 6) Insert the needle pointed probes to the lead wire coupler. 7) Measure the voltage at the R/Bl wire and ground. 8) If OK, then measure the voltage at the R/Bl wire and B/Br wire.
Page 202 12-33 FI SYSTEM DIAGNOSIS Step 3 1) Remove the throttle body. ("13-8) 2) Remove the IAP sensor. ("13-10) 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 203: 21" Iat Sensor Circuit Malfunction
FI SYSTEM DIAGNOSIS 12-34 “21” IAT SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE Output voltage is not within the following range. • IAT sensor circuit open or short. 0.2 V Sensor voltage < 4.8 V • IAT sensor malfunction. • ECM malfunction. IAT sensor B/Br CAUTION...
Page 204 12-35 FI SYSTEM DIAGNOSIS Step 2 1) Stop the engine. 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 $ Tester knob indication: Resistance (Ω) Is the resistance OK? ECM coupler (Harness side)
Page 205: 23" To Sensor Circuit Malfunction
FI SYSTEM DIAGNOSIS 12-36 “23” TO SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE The sensor voltage should be the following for 5 sec. • TO sensor circuit open or short. and more. • TO sensor malfunction. 0.2 V Sensor voltage < 4.6 V •...
Page 206: 24" Ignition System Malfunction
12-37 FI SYSTEM DIAGNOSIS Step 2 1) Connect the TO sensor coupler. 2) Insert the needle pointed probes to the lead wire coupler. 3) Connect a 12 volts battery using the battery lead wire to ser- vice coupler. ("12-22) 4) Measure the voltage at the wire side coupler between Br/W and B/Br wires.
Page 207: 31" Gp Switch Circuit Malfunction
FI SYSTEM DIAGNOSIS 12-38 “31” 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 0.6 V GP switch Bl/B...
Page 208 12-39 FI SYSTEM DIAGNOSIS 4) Insert the needle pointed probes to the lead wire coupler. 5) Connect a 12 volts battery using the battery lead wire to ser- vice coupler. ("12-22) 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 209: 32" Fuel Injector Circuit Malfunction
FI SYSTEM DIAGNOSIS 12-40 “32” 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 210 12-41 FI SYSTEM DIAGNOSIS 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 211: 41" Fp Relay Circuit Malfunction
FI SYSTEM DIAGNOSIS 12-42 “41” 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 Regulator...
Page 212 12-43 FI SYSTEM DIAGNOSIS 6) Connect a 12 volts battery using the battery lead wire to ser- vice coupler. ("12-22) 7) Insert the needle pointed probe to the ECM coupler. 8) Measure the voltage between terminal D and ground. # FP relay input voltage: Battery voltage ! 09900-25008: Multi-circuit tester set 09900-25009: Needle pointed probe set 36890-28H00: Battery lead wire (option)
Page 213: 63" Crankshaft Rotation Signal Circuit Malfunction
FI SYSTEM DIAGNOSIS 12-44 “63” CRANKSHAFT ROTATION SIGNAL CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE The signal does not reach ECM for 30 sec. or more. • Metal particles or foreign material being stuck on the crankshaft rotation signal sensor and rotor tip. •...
Page 214 12-45 FI SYSTEM DIAGNOSIS 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 215: Iap Sensor Inspection
FI SYSTEM DIAGNOSIS 12-46 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. ("12-25, -44) CKP SENSOR/CRANKSHAFT ROTATION SIGNAL SENSOR REMOVAL AND INSTAL- LATION •...
Page 216: Ect Sensor Removal And Installation
12-47 FI SYSTEM DIAGNOSIS ECT SENSOR INSPECTION The ECT sensor 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 217: Iat Sensor Inspection
FI SYSTEM DIAGNOSIS 12-48 • Apply engine coolant to the O-ring. CAUTION Replace the O-ring with a new one. • Tighten the ECT sensor to the specified torque. ' ECT sensor: 12 N·m (1.2 kgf-m, 8.5 lb-ft) • Connect the ECT sensor coupler. •...
Page 218: Fuel System And Throttle Body
13-1 FUEL SYSTEM AND THROTTLE BODY 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 219: Fuel System
FUEL SYSTEM AND THROTTLE BODY 13-2 FUEL SYSTEM CONSTRUCTION 10 N . m (1.0 kgf . m, 7.0 lb-ft) FUEL TANK AND FUEL PUMP REMOVAL ! WARNING Gasoline is highly flammable and explosive. Keep heat, spark and flame away. CAUTION Drain out the gasoline before remove the fuel tank.
Page 220: Fuel Tank And Fuel Pump Installation
Install the fuel pump and fuel tank in the reverse order of removal. Pay attention to the following point: • Install a new O-ring and apply grease to it. CAUTION Replace the O-ring with a new one. # 99000-25010: SUZUKI SUPER GREASE “A” or equivalent...
Page 221: Fuel Pressure Inspection
FUEL SYSTEM AND THROTTLE BODY 13-4 • When installing the fuel pump assembly, first tighten all the fuel pump mounting bolts lightly and then to the specified torque. $ Fuel pump mounting bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft) • Connect the fuel hose to the fuel pump until it locks securely (a click is heard).
Page 222: Fuel Pump Inspection
13-5 FUEL SYSTEM AND THROTTLE BODY • 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 223: Fuel Discharge Amount Inspection
FUEL SYSTEM AND THROTTLE BODY 13-6 FUEL DISCHARGE AMOUNT INSPECTION ! WARNING 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 224: Throttle Body
13-7 FUEL SYSTEM AND THROTTLE BODY THROTTLE BODY CONSTRUCTION 3.5 N . m (0.35 kgf-m, 2.5 lb-ft) 3.5 N . m (0.35 kgf-m, 2.5 lb-ft) 3.5 N . m (0.35 kgf-m, 2.5 lb-ft) 1 TP sensor 6 Cushion seal 2 O-ring 7 Fuel delivery pipe 3 Starter knob/idle screw 8 Fuel pipe...
Page 225: Removal
FUEL SYSTEM AND THROTTLE BODY 13-8 REMOVAL • Remove the seat and radiator covers. ("5-2) • Remove the fuel tank. ("13-2) • Disconnect the TP sensor coupler 1 and fuel injector coupler • Disconnect the IAP sensor coupler 3. • Remove the throttle cable cover 4. •...
Page 226: Disassembly
13-9 FUEL SYSTEM AND THROTTLE BODY • Disconnect the condenser coupler and remove the condenser • Loosen the throttle body clamp screws and remove the throt- tle body assembly. DISASSEMBLY • Remove the hot starter valve 1 and spring 2 from the hot starter cable.
Page 227 FUEL SYSTEM AND THROTTLE BODY 13-10 • Remove the fuel delivery pipe 6. • Remove the fuel injector 7 along with fuel pipe 8. • Remove the fuel injector 7 from the fuel pipe 8. • Remove the IAP sensor 9. •...
Page 228 13-11 FUEL SYSTEM AND THROTTLE BODY CAUTION Never remove the throttle valve A. CAUTION These adjusting screws (B, C) are factory adjusted at the time of delivery and therefore avoid removing or turning them unless otherwise necessary. CAUTION Never remove the throttle valve linkage.
Page 229: Cleaning
FUEL SYSTEM AND THROTTLE BODY 13-12 CLEANING ! WARNING 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 230 13-13 FUEL SYSTEM AND THROTTLE BODY • Install a new O-ring 1. CAUTION Replace the O-ring 1 with a new one. • Install the IAP sensor as shown. • Apply thin coat of engine oil to the new O-ring 2 and cushion seal 3.
Page 231 * Apply thin coat of the engine oil to the O-ring. * 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 (T25) $ TP sensor mounting screw: 3.5 N·m (0.35 kgf-m, 2.5 lb-ft)
Page 232: Installation
13-15 FUEL SYSTEM AND THROTTLE BODY • Align the groove of hot starter valve with the hot starter cable end. INSTALLATION Install the throttle body assembly in the reverse order of removal. Pay attention to the following points: • Fit the projection on the throttle body in the depression of the intake pipe.
Page 233: Fuel Injector Removal
FUEL SYSTEM AND THROTTLE BODY 13-16 FUEL INJECTOR REMOVAL • Remove the throttle body assembly. ("13-8) • 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 234 14-1 COOLING SYSTEM 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 235: Construction
COOLING SYSTEM 14-2 CONSTRUCTION 8 N . m (0.8 kgf-m, 6.0 lb-ft) 9 N . m (0.9 kgf-m, 6.5 lb-ft) 11 N . m (1.1 kgf-m, 8.0 lb-ft)
Page 236: Engine Coolant
14-3 COOLING SYSTEM ENGINE COOLANT REPLACEMENT $ WARNING Engine coolant may be harmful if swallowed or if it comes in contact with the skin or eyes. If engine cool- ant gets into the eyes or contacts the skin, flush the eyes or wash the skin thoroughly, with plenty of water.
Page 237: Cooling Circuit
COOLING SYSTEM 14-4 COOLING CIRCUIT INSPECTION • Remove the radiator cap. $ WARNING Engine coolant may be harmful if swallowed or if it comes in contact with the skin or eyes. If engine cool- ant gets into the eyes or contacts the skin, flush the eyes or wash the skin thoroughly, with plenty of water.
Page 238: Radiator
14-5 COOLING SYSTEM 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 239: Removal
COOLING SYSTEM 14-6 REMOVAL $ WARNING Engine coolant may be harmful if swallowed or if it comes in contact with the skin or eyes. If engine cool- ant gets into the eyes or contacts the skin, flush the eyes or wash the skin thoroughly, with plenty of water. If engine coolant is swallowed, induce vomiting and call a physician immediately.
Page 240: Water Pump
14-7 COOLING SYSTEM WATER PUMP REMOVAL $ WARNING Engine coolant may be harmful if swallowed or if it comes in contact with the skin or eyes. If engine cool- ant gets into the eyes or contacts the skin, flush the eyes or wash the skin thoroughly, with plenty of water.
Page 241: Inspection
COOLING SYSTEM 14-8 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 5. • Remove the oil seal. CAUTION Replace the removed oil seal with a new one.
Page 242: Installation
• Press the oil seal with the suitable size socket wrench. • Apply grease to the oil seal lips. & 99000-25010: SUZUKI SUPER GREASE “A” or equivalent IMPELLER AND WATER PUMP SHAFT • Apply engine oil to the water pump shaft.
Page 243 COOLING SYSTEM 14-10 • Fit the right crankcase cover. • Tighten the crankcase cover bolts to the specified torque. ! Right crankcase cover bolt: 11 N·m (1.1 kgf-m, 8.0 lb-ft) • Install the brake pedal. ("17-18) • Install the kick starter lever. ("8-7) WATER PUMP CASE •...
Page 244: Electrical System
15-1 ELECTRICAL SYSTEM 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 245: Cautions In Servicing
ELECTRICAL SYSTEM 15-2 CAUTIONS IN SERVICING CONNECTOR • When connecting a connector, be sure to push it in until a click is felt. Click • Inspect the connector for corrosion, contamination and break- age in its cover. COUPLER • With a lock type coupler, be sure to release the lock when dis- connecting, and push in fully to engage the lock when con- necting.
Page 246: Semi-Conductor Equipped Part
15-3 ELECTRICAL SYSTEM 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 247: Using The Multi-Circuit Tester
ELECTRICAL SYSTEM 15-4 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 248: Location Of Electrical Components
15-5 ELECTRICAL SYSTEM LOCATION OF ELECTRICAL COMPONENTS 1 Fuel injector (!12-40) 5 ECM 2 IAP sensor (!12-31) 6 Service coupler 3 Fuel pump (!13-5) 7 ECT sensor (!12-29) 4Igniton coil (!15-13) 8 TO sensor (!12-36)
Page 249 ELECTRICAL SYSTEM 15-6 9 Engine stop switch(!15-16) D Magneto (!15-9) 0 Regulator/Rectifier (!15-10) E GP switch (!12-38) A IAT sensor (!12-34) F TP sensor (!12-27) B CKP sensor (!12-25) G Condenser C Crankshaft rotation signal sensor (!12-44)
Page 250: Construction
15-7 ELECTRICAL SYSTEM CONSTRUCTION MAGNETO 5.5 N . m (0.55 kgf-m, 4.0 lb-ft) 80 N . m (8.0 kgf-m, 58.0 lb-ft) 5.5 N . m (0.55 kgf-m, 4.0 lb-ft)
Page 251: Generating System
ELECTRICAL SYSTEM 15-8 GENERATING SYSTEM Regulator/Rectifier Magneto Condenser Load INSPECTION REGULATED VOLTAGE • Insert the needle pointed probes A to the condenser coupler 1. + Prove: Red lead wire - Prove: B/W lead wire • Connect the multi-circuit tester or electric tachometer to the high-tension cord.
Page 252 15-9 ELECTRICAL SYSTEM 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 253 ELECTRICAL SYSTEM 15-10 REGULATOR/RECTIFIER • Remove the left radiator cover. (!5-2) • Remove the regulator/rectifier 1. • Measure the voltage between the lead wires using the multi- circuit tester as indicated in the table below. If the voltage is not within the specified value, replace the regulator/rectifier with a new one.
Page 254: Ignition System
15-11 ELECTRICAL SYSTEM 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 255 ELECTRICAL SYSTEM 15-12 Step 4 1) Measure the ignition coil resistance. (!15-14) Is the ignition coil resistance OK? Go to Step 5. Faulty ignition coil 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 256: Inspection
15-13 ELECTRICAL SYSTEM INSPECTION IGNITION COIL PRIMARY PEAK VOLTAGE • Remove the seat, radiator covers and fuel tank. (!5-2) • Disconnect the spark plug cap 1. • Connect a new spark plug to spark plug cap and ground it to the cylinder.
Page 257 ELECTRICAL SYSTEM 15-14 • Connect the multi-circuit tester with the peak voltage adaptor as follows. + Probe: Black/White lead wire - Probe: White/Blue lead wire NOTE: Do not disconnect the ignition coil lead wire coupler. " 09900-25008: multi-circuit tester set •...
Page 258 15-15 ELECTRICAL SYSTEM 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 as follows. CKP sensor Crankshaft rotation signal sensor + probe - probe Green "...
Page 259 ELECTRICAL SYSTEM 15-16 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. # CKP sensor resistance: 80 –...
Page 260: Magneto Rotor
15-17 ELECTRICAL SYSTEM MAGNETO ROTOR REMOVAL • Drain engine oil. (!2-11) • Disconnect the magneto lead wire coupler. • Remove the clamp. • Remove the gearshift lever. (!9-3) • Remove the magneto cover guard and magneto cover 1. • Remove the gasket 2 and dowel pins. •...
Page 261: Installation
ELECTRICAL SYSTEM 15-18 • Remove the magneto rotor 4 with the special tool. " 09930-34951: Rotor remover • Remove the magneto rotor key 5. INSTALLATION • Remove any grease from the tapered portion A of the mag- neto rotor and crankshaft B. •...
Page 262: Stator
15-19 ELECTRICAL SYSTEM • Install the dowel pins and gasket 2. CAUTION Replace the gasket 2 with a new one. • Install the magneto cover 3 and magneto cover guard 4. CAUTION Fit the new gasket washer to the bolt A. NOTE: Fit the clamp to the bolt B.
Page 263: 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 264: Construction
16-2 FRONT AND REAR WHEELS CONSTRUCTION 90 N . m (9.0 kgf-m, 65.0 lb-ft) 26 N . m (2.6 kgf-m, 19.0 lb-ft) 30 N . m (3.0 kgf-m, 21.5 lb-ft) 11 N . m (1.1 kgf-m, 8.5 lb-ft) 35 N . m (3.5 kgf-m, 25.5 lb-ft)
Page 265: 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 266: 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 267: Disc Plate Replacement
When installing the dust seal, place the manufacturer’s code indicated side of the dust seal outside. " 09913-70210: Bearing installer set Bearing: # 40 Attachment $ 99000-25010: SUZUKI SUPER GREASE “A” or equivalent DISC PLATE REPLACEMENT • Remove the disc plate.
Page 268: Installation
16-6 FRONT AND REAR WHEELS INSTALLATION • Hold the front axle shaft with the special tool and tighten the front axle nut temporarily. " 09940-34581: Attachment (F) • Remove the block from under the chassis tube and move the front forks up and down several times. •...
Page 269: 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 270: 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 together with the dust seal.
Page 271 FRONT AND REAR WHEELS 16-9 • Remove the bearings with the special tool. • Remove the spacer 2 and bearing with the special tool. CAUTION The removed bearings must be replaced with new ones. " 09921-20240: Bearing remover set (Remover 25 mm) •...
Page 272: Disc Plate Replacement
When installing the dust seal, place the manufacturer’s code indicated side of the dust seal outside. " 09913-70210: Bearing installer set Oil seal: # 42 Attachment $ 99000-25010: SUZUKI SUPER GREASE “A” or equivalent DISC PLATE REPLACEMENT • Remove the disc plate.
Page 273: Installation
FRONT AND REAR WHEELS 16-11 INSTALLATION Left Right • Install the rear wheel, chain adjuster washers and axle shaft. • Adjust the drive chain slack. ('2-26) Chain adjuster washer • Tighten the rear axle nut to the specified torque. & Rear axle nut: 90 N·m (9.0 kgf-m, 65.0 lb-ft) REAR WHEEL SPOKES REPLACEMENT ('20-28)
Page 274: Front And Rear Brakes
17-1 FRONT AND REAR BRAKES FRONT AND REAR BRAKES CONTENTS CONSTRUCTION ..................17- 2 BRAKE FLUID AIR BLEEDING ..............17- 3 BRAKE FLUID REPLACEMENT ............... 17- 4 BRAKE PADS REPLACEMENT ............... 17- 5 FRONT BRAKE PADS ................ 17- 5 REAR BRAKE PADS ................17- 5 BRAKE DISC INSPECTION ..............
Page 275: Construction
FRONT AND REAR BRAKES 17-2 CONSTRUCTION 12 N . m 10 N . m 1.0 kgf . m 1.2 kgf . m 7.0 lb-ft 8.5 lb-ft 23 N·m 23 N·m (2.3 kgf-m, (2.3 kgf-m, 16.5 lb-ft) 16.5 lb-ft) 10 N·m (1.0 kgf-m, 7.0 lb-ft) 23 N·m (2.3 kgf-m,...
Page 276: Brake Fluid Air Bleeding
17-3 FRONT AND REAR BRAKES BRAKE FLUID AIR BLEEDING " WARNING Brake fluid can be hazardous to humans and pets. Brake fluid is harmful or fatal if swallowed, and harm- ful if it comes in contact with your skin or eyes. Keep brake fluid away from children.
Page 277: Brake Fluid Replacement
FRONT AND REAR BRAKES 17-4 • 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 278: 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 279: Brake Disc Inspection
FRONT AND REAR BRAKES 17-6 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 280: Front Caliper Removal And Disassembly
17-7 FRONT AND REAR BRAKES FRONT CALIPER REMOVAL AND DISASSEMBLY • Place a rag under the brake hose union bolt to catch spilled brake fluid. • Disconnect the brake hose by removing the union bolt. • Remove the caliper mounting bolts 1. •...
Page 281: Caliper Inspection
! Specification and classification: DOT 4 • Install the springs and boots. • Apply SUZUKI SILICONE GREASE to the caliper axles. % 99000-25100: SUZUKI SILICONE GREASE or equivalent • Install the caliper bracket.
Page 282: Rear Caliper Removal And Disassembly
17-9 FRONT AND REAR BRAKES • Tighten the caliper mounting bolts 1 to the specified torque. # Brake caliper mounting bolt: 26 N·m (2.6 kgf-m, 19.0 lb-ft) • Tighten the brake pad mounting pin 2 to the specified torque. # Brake pad mounting pin: 18 N·m (1.8 kgf-m, 13.0 lb-ft) •...
Page 283: Rear Caliper Reassembly And Installation
FRONT AND REAR BRAKES 17-10 • Remove the caliper bracket 4 from the caliper. • Remove the boots 5 and 6. • Remove the spring 7. • Wrap the caliper with a rag to prevent brake fluid scatter and piston pop-out. •...
Page 284 17-11 FRONT AND REAR BRAKES • Install the springs and boots. • Apply SUZUKI SILICONE GREASE to the caliper axles. % 99000-25100: SUZUKI SILICONE GREASE or equivalent • Install the caliper bracket. • Install the brake pads. • Apply SUZUKI SILICONE GREASE to the O-ring.
Page 285: Master Cylinder
FRONT AND REAR BRAKES 17-12 MASTER CYLINDER " WARNING Brake fluid can be hazardous to humans and pets. Brake fluid is harmful or fatal if swallowed, and harm- ful if it comes in contact with your skin or eyes. Keep brake fluid away from children. Call your doctor immediately if brake fluid is swallowed, and induce vomiting.
Page 286: Master Cylinder Inspection
17-13 FRONT AND REAR BRAKES • Remove the dust boot 5 and snap ring 6. ' 09900-06108: Snap ring pliers • Remove the washer 7 and piston/cup set 8. MASTER CYLINDER INSPECTION • Inspect the cylinder bore and piston for scuffing, wear and damage.
Page 287: Front Master Cylinder Reassembly And Installation
FRONT AND REAR BRAKES 17-14 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. ($17-17) 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 288: Rear Master Cylinder Removal And Disassembly
17-15 FRONT AND REAR BRAKES REAR MASTER CYLINDER REMOVAL AND DISASSEMBLY • Drain brake fluid. ($17-4) • Remove the cotter pin and then master cylinder rod pin 1 and washer. • Remove the master cylinder 2 by removing the bolts. •...
Page 289: 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, then tighten the brake hose union bolt 1 to the specified torque.
Page 290: 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 and lock-nut to the specified torque.
Page 291: 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. ($20-23) •...
Page 292: Front Fork And Steering
18-1 FRONT FORK AND STEERING FRONT FORK AND STEERING CONTENTS CONSTRUCTION ..................18- 2 FRONT FORK, STEERING ..............18- 2 HANDLEBAR CONTROLS ..............18- 3 REMOVAL ..................18- 4 DISASSEMBLY .................. 18- 5 INSPECTION ..................18- 9 REASSEMBLY ................... 18-11 INSTALLATION ..................
Page 293: Construction
FRONT FORK AND STEERING 18-2 CONSTRUCTION FRONT FORK, STEERING 25 N . m (2.5 kgf-m, 18.0 lb-ft) 100 N . m (10.0 kgf-m, 72.5 lb-ft) 30 N . m (3.0 kgf-m, 21.5 lb-ft) 23 N . m (2.3 kgf-m, 16.5 lb-ft) 45 N .
Page 294: Handlebar Controls
18-3 FRONT FORK AND STEERING HANDLEBAR CONTROLS 25 N·m (2.5 kgf-m, 18.0 lb-ft) Apply handle grip bond. Apply handle grip bond. 6 N·m (0.6 kgf-m, 4.5 lb-ft) 6 N·m (0.6 kgf-m, 4.5 lb-ft)
Page 295: Removal
FRONT FORK AND STEERING 18-4 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 1. • Remove the protector 2. • Remove the handlebars. NOTE: Mark the paint mark A to the matching surface of handlebar holder and handlebars before removing.
Page 296: Disassembly
18-5 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. CAUTION Scratches or other damage on the inner tube or on the oil seal lip will cause oil leakage.
Page 297 FRONT FORK AND STEERING 18-6 • Clamp the axle holder 2 with a vise. Protect the axle holder with a rag when using a vise. • Loosen the center bolt 3 completely with a 21 mm socket wrench. # WARNING Clamping the axle holder too tight can damage it which will affect riding stability.
Page 298 18-7 FRONT FORK AND STEERING • With the outer tube compressed by hands, remove the special tool. CAUTION Do not remove the lock-nut 4. If removed, the inner rod may slip into the damper rod, possibly causing the threaded section to damage the oil seal. •...
Page 299 FRONT FORK AND STEERING 18-8 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 300: Inspection
18-9 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 301 FRONT FORK AND STEERING 18-10 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 302: Reassembly
18-11 FRONT FORK AND STEERING REASSEMBLY CAUTION 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 303 $ 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 • Replace the O-ring 4 with a new one. • Apply fork oil to the O-ring 4.
Page 304 18-13 FRONT FORK AND STEERING • Clamp the bottom (flat part) of the sub-tank with a vise. CAUTION 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 lb-ft) •...
Page 305 FRONT FORK AND STEERING 18-14 • 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 “COMPRESSION DAMPER UNIT” procedures (Pour the specified amount fork oil and discharge an excess of oil).
Page 306 18-15 FRONT FORK AND STEERING • Clamp the axle holder with a vise. Protect the axle holder with a rag when using a vise. # WARNING Clamping the axle holder too tight can damage it which will affect riding stability. Do not clamp the axle holder too tight.
Page 307 • Pour the specified amount of fork oil into the outer tube. $ Oil quantity (When standard fork spring is used): 370 ml (12.51/13.03 US/lmp oz) % 99000-99001-SS5: SUZUKI FORK OIL SS-05 or equivalent • Raise the outer tube and temporarily tighten the fork cap bolt (sub-tank).
Page 308: Installation
18-17 FRONT FORK AND STEERING INSTALLATION 5.0 mm • Install the front fork with the upper surface T of the outer tube (0.20 in) positioned 5.0 mm (0.20 in) from the upper surface of the upper bracket. • Check that the air valve A is positioned at the front. 5.0 mm (0.20 in) •...
Page 309: Steering
FRONT FORK AND STEERING 18-18 STEERING REMOVAL HANDLEBARS • Place the motorcycle on a block to lift front wheel off the ground. • Remove the front number plate and protector. (!18-4) • Remove the clamps. • Remove the engine stop switch 1. •...
Page 310 18-19 FRONT FORK AND STEERING • Remove the handlebars by removing the handlebar clamp bolts. NOTE: Mark the paint mark to the matching surface of handlebar holder and handlebars before removing. STEERING STEM • Remove the front wheel 1. (!16-3) •...
Page 311: Inspection
FRONT FORK AND STEERING 18-20 • Remove the handlebar holders, damper bushings and spac- ers. • Remove the steering stem nut with the special tools. NOTE: Hold the steering stem lower bracket to prevent it from falling. " 09940-14911: Steering nut socket wrench 09940-14960: Steering nut wrench socket •...
Page 312: Bearing Replacement
18-21 FRONT FORK AND STEERING BEARING REPLACEMENT • Remove the lower bearing. • Fit the lower bearing with the special tool. " 09925-18011: Steering bearing installer NOTE: Replace the outer race and bearing as a set. • Drive out the outer races using the steel rod. •...
Page 313: 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 and upper dust seal.
Page 314 18-23 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 to the specified torque. & Steering stem head nut: 100 N·m (10.0 kgf-m, 72.5 lb-ft) •...
Page 315 & Handlebar holder set nut: 45 N·m (4.5 kgf-m, 32.5 lb-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 throttle holder matching surface.
Page 316 18-25 FRONT FORK AND STEERING HANDLEBARS • Apply handle grip bond to the left handlebar end and inside of the left grip. Apply handle grip bond. Apply handle grip bond. ” mark on the left grip with the matching mark A •...
Page 317 FRONT FORK AND STEERING 18-26 • Align the matching mark B on the handlebars with the clutch lever holder matching surface. • Tighten the upper bolt first temporarily to provide clearance on the lower side and then tighten both the bolts. •...
Page 318 19-1 REAR SUSPENSION 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 319: Construction
REAR SUSPENSION 19-2 CONSTRUCTION REAR SUSPENSION 80 N . m (8.0 kgf-m, 58.0 lb-ft) 30 N . m 3.0 kgf . m 21.5 lb-ft 50 N . m 5.0 kgf . m 36.0 lb-ft 80 N . m 8.0 kgf . m 58.0 lb-ft 50 N .
Page 320: Rear Shock Absorber
19-3 REAR SUSPENSION REAR SHOCK ABSORBER REMOVAL • Place a block under chassis tube. • Remove the seat, right frame cover and right radiator cover. (!5-2) • Loosen the air cleaner clamp screw. • Remove the rubber band 1. • Disconnect the IAT sensor coupler 2 and remove the clamp. •...
Page 321: Spring Replacement
REAR SUSPENSION 19-4 • 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 322: Inspection
19-5 REAR SUSPENSION • Adjust the spring set length and tighten the lock-nut. # Standard spring set length: 6.6 mm (0.26 in) compressed from the free length Spring set length adjustable range: 247 – 263 mm (9.72 – 10.35 in) [at spring free length 265 mm (10.43 in)] a: Hardest spring setting b: Softest spring setting...
Page 323: 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 324: Oil Replacement
19-7 REAR SUSPENSION 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 325 Be sure to extend the rod after filling the oil. • Tilt the shock absorber unit as shown and pour the fresh rear suspension oil fully into the reservoir. 99000-99001-S25: SUZUKI REAR SUSPENSION OIL SS-25 or equivalent # Oil capacity: 395 ml (13.4/13.9 US/Imp oz) •...
Page 326 19-9 REAR SUSPENSION • Replace the O-rings on the compression adjuster assembly with new ones. • Apply rear suspension oil to the O-rings. • Reinstall the compression adjuster assembly 1. " 09941-53660: Rear cushion socket wrench $ Compression adjuster assembly: 30 N·m (3.0 kgf-m, 21.5 lb-ft) •...
Page 327: Disassembly And Inspection
REAR SUSPENSION 19-10 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 to the softest posi- tion. • Press the valve with a screwdriver to bleed out nitrogen gas. (!19-7) •...
Page 328: Reassembly
• Fit the stopper to the shock absorber body. • Fill the specified rear suspension oil in the rear shock absorber. (!19-8) 99000-99001-S25: SUZUKI REAR SUSPENSION OIL SS-25 or equivalent # Oil capacity: 395 ml (13.4/13.9 US/Imp oz) • Reinstall the compression adjuster assembly. (!19-9) •...
Page 329: Installation
REAR SUSPENSION 19-12 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 to the specified torque. NOTE: If necessary, move the swingarm up or down to facilitate this mounting bolt/nut tightening.
Page 330: Swingarm
19-13 REAR SUSPENSION 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. • Remove the rear master cylinder mounting bolts and brake hose guide bolt.
Page 331 REAR SUSPENSION 19-14 • Down the rear brake pedal and remove the pivot shaft. • Remove the swingarm. • Remove the chain buffer. • Remove the plates. • Remove the following parts from the swingarm. Spacer 1 Oil seal 2 Washer 3 Thrust bearing 4 Dust seal 5...
Page 332: Inspection
19-15 REAR SUSPENSION 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 333: Bearing Replacement
• Remove the bearings with the special tool. " 09921-20240: Bearing remover set (Remover 20 mm) • Press the new bearings with the special tool. (!19-23) " 09924-84521: Bearing installer • Apply grease to the bearings. % 99000-25010: SUZUKI SUPER GREASE “A” or equivalent...
Page 334: Installation
7 Spacer 4 Thrust bearing • Apply grease to the dust seals, bearings and oil seals. % 99000-25010: SUZUKI SUPER GREASE “A” or equivalent • Apply THREAD LOCK SUPER to the plate mounting screws. ' 99000-32110: THREAD LOCK SUPER “1322”...
Page 335: Rear Suspension Linkage
REAR SUSPENSION 19-18 REAR SUSPENSION LINKAGE REMOVAL • Place a block under the chassis tubes. • Remove the rear cushion rod bolt and nut. • Remove the cushion lever bolt and nut. • Remove the shock absorber lower bolt and nut. •...
Page 336: Inspection
19-19 REAR SUSPENSION INSPECTION • Inspect the cushion rod and cushion lever for damage. • Inspect the dust seals and spacers for damage. • 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 337: Bearing Replacement
(3: right side) * Position the needle roller bearing cages by referring to the illustration of page 19-22. • Apply grease to the needle roller bearings and install them. % 99000-25010: SUZUKI SUPER GREASE “A” or equivalent...
Page 338: Installation
Pay attention to the following points: • Position the dust seals 1 so that the manufacturer’s code indicated side of the seals face outside. (2: inside) • Apply grease to the dust seals. % 99000-25010: SUZUKI SUPER GREASE “A” or equivalent...
Page 339 REAR SUSPENSION 19-22 • Tighten the cushion lever, cushion rod and swingarm nuts to the specified torque. Left Right 4.1 mm (0.16 in) 4.0 mm (0.16 in) 4.1 mm (0.16 in) 4.1 mm (0.16 in) $ Tightening torque: A: 50 N·m (5.0 kgf-m, 36.0 lb-ft) D: 80 N·m (8.0 kgf-m, 58.0 lb-ft) B: 50 N·m (5.0 kgf-m, 36.0 lb-ft) E: 80 N·m (8.0 kgf-m, 58.0 lb-ft)
Page 340 19-23 REAR SUSPENSION Left Right CAUTION 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 341: Servicing Information
SERVICING INFORMATION 20-1 SERVICING INFORMATION CONTENTS SERVICE DATA ..................20- 2 TIGHTENING TORQUE ................20-11 SPECIAL TOOLS ..................20-15 WIRING DIAGRAM ..................20-18 WIRING HARNESS ROUTING ..............20-19 CABLE ROUTING ..................20-21 FUEL HOSE ROUTING ................20-22 RADIATOR HOSE ROUTING ..............20-23 REAR BRAKE PEDAL SET-UP ..............
Page 342: Service Data
20-2 SERVICING INFORMATION SERVICE DATA VALVE + GUIDE Unit: mm (in) ITEM STANDARD LIMIT Valve diam. — (1.4) — (1.2) 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 343 SERVICING INFORMATION 20-3 CAMSHAFT + CYLINDER HEAD Unit: mm (in) ITEM STANDARD LIMIT Cam height 35.53 – 35.58 35.23 (1.399 – 1.401) (1.387) 34.33 – 34.38 34.03 (1.352 – 1.354) (1.340) Camshaft journal oil clearance 0.032 – 0.066 0.150 IN. & EX. (0.001 –...
Page 344: Oil Pump
20-4 SERVICING INFORMATION CONROD + CRANKSHAFT Unit: mm (in) ITEM STANDARD LIMIT Conrod small end I.D. 19.010 – 19.018 19.040 (0.7484 – 0.7487) (0.7496) Conrod deflection — (0.12) Conrod big end side clearance 0.20 – 0.65 (0.008 – 0.026) (0.04) Conrod big end width 19.75 –...
Page 345 SERVICING INFORMATION 20-5 TRANSMISSION + DRIVE CHAIN Unit: mm (in) Except ratio ITEM STANDARD LIMIT Primary reduction ratio 2.625 (63/24) — Final reduction ratio 3.846 (50/13) — Gear ratios 1.800 (27/15) — 1.471 (25/17) — 1.235 (21/17) — 1.050 (21/20) —...
Page 346 20-6 SERVICING INFORMATION FI SENSORS ITEM STANDARD/SPECIFICATION NOTE 80 – 120 Ω CKP sensor resistance CKP sensor peak voltage 2.8 V and more Crankshaft rotation signal sensor 0.1 – 0.8 Ω resistance Crankshaft rotation signal sensor 1.7 V and more peak voltage IAP sensor input voltage 4.5 –...
Page 347 SERVICING INFORMATION 20-7 ELECTRICAL Unit: mm (in) ITEM STANDARD/SPECIFICATION NOTE Ignition timing 8° B.T.D.C. at 2 000 r/min. Spark plug Type NGK: DIMR8A10 0.9 – 1.0 (0.035 – 0.039) Spark performance Over 8 (0.3) at 1 atm. 80 – 120 Ω CKP sensor resistance G –...
Page 348 20-8 SERVICING INFORMATION 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) Brake disc thickness 3.0 ± 0.2 Front (0.118 ±...
Page 349 SERVICING INFORMATION 20-9 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 495 ± 2.5 488 (19.21) length (19.49 ± 0.10) Front fork damping Rebound MAX –...
Page 350 (1.3/1.1 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 370 ml Outer tube oil (each leg) (12.51/13.03 US/Imp oz)
Page 351: Tightening Torque
SERVICING INFORMATION 20-11 TIGHTENING TORQUE ENGINE PART N·m kgf-m lb-ft Cylinder head cover bolt 10.0 Spark plug Cylinder head bolt (Initial) 18.0 (Final) 37.0 Cylinder head base bolt Cylinder base bolt Camshaft journal holder bolt Oil gallery bolt (journal holder) Primary drive gear nut 65.0 Magneto rotor nut...
Page 352: Fi System And Intake Air System
20-12 SERVICING INFORMATION PART N·m kgf-m lb-ft Engine mounting bolt and nut 40.0 Intake pipe bolt Engine sprocket cover bolt Kick starter lever bolt 16.5 Kick starter lever screw Exhaust pipe nut 14.5 Muffler connector clamp bolt 13.5 Muffler mounting bolt (Front) 17.5 Muffler mounting bolt (Rear) 17.5...
Page 353 SERVICING INFORMATION 20-13 CHASSIS PART N·m kgf-m lb-ft Handlebar clamp bolt 18.0 Handlebar holder set nut 32.5 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 354 20-14 SERVICING INFORMATION For other bolts and nuts not listed in the table, refer to this chart. Conventional or “4” marked bolt “7” marked or crown headed bolt Bolt Diameter A (mm) N·m kgf-m lb-ft N·m kgf-m lb-ft 0.15 0.23 0.45 0.55 16.5...
Page 355: Special Tools
SERVICING INFORMATION 20-15 SPECIAL TOOLS 09900-20101 09900-20202 09900-20204 09900-06107 09900-06108 Vernier calipers Micrometer Micrometer Snap ring pliers Snap ring pliers (150 mm) (25 – 50 mm) (75 – 100 mm) 09900-20205 09900-20602 09900-20607 Micrometer 09900-20530 09900-20513 Dial gauge Dial gauge (0 –...
Page 356 20-16 SERVICING INFORMATION 09915-74521 09915-64512 09915-74511 Oil pressure gauge 09915-77331 09916-10911 Compression gauge Oil pressure gauge hose Oil pressure gauge Valve lapper set 09916-34550 09916-34580 09916-14510 09916-14522 09916-34542 Valve guide reamer Valve guide reamer Valve lifter Attachment Reamer handle (5.5 mm) (10.8 mm) 09916-44910 09916-53360...
Page 357 SERVICING INFORMATION 20-17 09930-10121 09930-30104 Spark plug wrench 09930-11950 Rotor remover slide 09930-34951 09930-35010 Torx wrench (T25) shaft Rotor remover Rotor remover 09940-14911 09940-14960 09930-44560 Steering nut socket Steering nut wrench 09940-34581 09940-40211 Rotor holder wrench socket Attachment (F) Adapter 09941-53660 09940-40220 09940-52861...
Page 358: Wiring Diagram
20-18 SERVICING INFORMATION WIRING DIAGRAM...
Page 359: Wiring Harness Routing
SERVICING INFORMATION 20-19 WIRING HARNESS ROUTING Connect the lead wire coupler over the TO sensor bracket bolt. Clamp Engine stop switch Clamp Engine stop switch Engine stop switch Clamp Clamp Engine stop switch Throttle cables Forw Forward orward Clamp 90˚ Wiring harness TP senser Engine stop switch lead wire...
Page 360 20-20 SERVICING INFORMATION Clamp GP switch lead wire Magneto lead wire Grommet CKP sensor Stator Clamp Do not slack the lead wire at this position.
Page 361: Cable Routing
SERVICING INFORMATION 20-21 CABLE ROUTING Clamp 2 – 3 mm (0.08 – 0.12 in) 14 – 16 mm Clutch cable Guide Wiring harness (0.5 – 0.6 in) Throttle cable Engine stop switch (returning cable) Pass the clutch cable and Wiring harness engine stop switch lead wire Throttle cable through the cable...
Page 362: Fuel Hose Routing
20-22 SERVICING INFORMATION FUEL HOSE ROUTING Fuel hose Fuel tank Yellow Gray Throttle body Fuel pump Air cleaner Upper Condenser Breather hose Intake pipe clamp Hose guide Upper Pass the breather hose to the Air cleaner outlet pipe clamp left side of ECT sensor. Breather hose...
Page 363: Radiator Hose Routing
SERVICING INFORMATION 20-23 RADIATOR HOSE ROUTING Radiator (R) Radiator (L) Face the white mark to the backward. Face the white Face the white mark to the mark to the backward. backward. Face the white mark to the backward. Face the white mark to the upper.
Page 364: Clutch Cable Adjuster
20-24 SERVICING INFORMATION CLUTCH CABLE ADJUSTER Quick adjuster Turn to tighten Tur urn to tighten n to tighten the clutch cable tension. the clutch cab the clutch cable tension. le tension. Turn to loosen Tur urn to loosen n to loosen the clutch cable tension.
Page 365: Front Brake Hose Routing
SERVICING INFORMATION 20-25 FRONT BRAKE HOSE ROUTING Front brake hose Front brake master cylinder Front brake hose Hose guide Stopper Set the brake hose end between the hose stopper, then tighten the brake hose union bolt to the specified torque. Front fork protector Front brake hose Clamp...
Page 366: Rear Brake Hose Routing
20-26 SERVICING INFORMATION REAR BRAKE HOSE ROUTING After the brake hose union has contacted the stopper, tighten the union bolt to the specified torque. After the brake hose union has contacted the stopper, tighten the union bolt to the specified torque. Outside...
Page 367: Handlebar Set-Up
SERVICING INFORMATION 20-27 HANDLEBAR SET-UP Align the matching surface Align the matching surface of clutch Marking of master cylinder with marking. lever holder with marking. 55˚ 66˚ Marking Align the “ ” mark on the Marking throttle grip (L) with marking. 30˚...
Page 368: Rear Wheel Spokes Installation
20-28 SERVICING INFORMATION 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 Chain roller (upper) Frame Frame Chain roller (lower)
Page 369: Specifications
SERVICING INFORMATION 20-29 SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length ............2 185 mm (86.0 in) Overall width............830 mm (32.7 in) Overall height ............. 1 260 mm (49.6 in) Wheelbase ............1 480 mm (58.3 in) Ground clearance..........350 mm (13.8 in) Seat height ............
Page 370 20-30 SERVICING INFORMATION CHASSIS Front suspension ..........Telescopic, coil spring, oil damped Rear suspension ..........Link type, coil spring, oil damped Front suspension stroke........310 mm (12.2 in) Rear wheel travel ..........310 mm (12.2 in) Caster ..............25° 30’ Trail ..............
Page 371: Spare Parts List
SERVICING INFORMATION 20-31 SPARE PARTS LIST ITEM PART NAME PART NUMBER Q’TY PARTS SET, SPARE 19900-28H00 GASKET, MAGNETO COVER 11483-28H00 GASKET, CLUTCH COVER OUTER 11484-28H00 GASKET, EXHAUST, PIPE 14181-35G00 CONNECTOR, MUF JT 14771-29F00 FILTER COMP, ENGINE OIL 16510-35G00 O-RING, WATER POMP CASE 17431-28H00 LEVER, BRAKE 57310-37F00...
Page 372: Setting Data
20-32 SERVICING INFORMATION SETTING DATA DATE RACE/COURSE TEMP./HUMIDITY WEATHER COURSE COUDITION SPARK PLUG OIL CAPACITY COMP. ADJ. POSITION RE-BOUND ADJ. POSITION SPRING SPRING SPRING SET LENGTH COMP. ADJ. POSITION LOW COMP. ADJ. POSITION HIGH RE-BOUND ADJ. POSITION FINAL REDUCTION RATIO MAKER/SIZE PRESSURE MAKER/SIZE...

Suzuki RM-z450 Owner's Service Manual

Group Index

Periodic Maintenance

Troubleshooting

Machine Tuning

Cylinder Head, Cylinder and Piston

Clutch

Kick Starter

Gearshifting

Transmission and Crankshaft

Lubrication System

Fi System Diagnosis

Fuel System and Throttle Body

Cooling System

Quick Links

Chapters

Troubleshooting

Related Manuals for Suzuki RM-z450

Summary of Contents for Suzuki RM-z450