Page 1 * This manual is written for persons who have enough knowledge, skills and tools, including special tools, for servicing SUZUKI motorcycles. If you do not have the proper knowledge and tools, ask your authorized SUZUKI motorcycle dealer to help you.
Page 3 TABLE OF CONTENTS Precautions............... 00-i Precautions ............00-1 General Information ........... 0-i General Information ..........0A-1 Maintenance and Lubrication ......... 0B-1 Service Data............0C-1 Engine ................. 1-i Precautions .............. 1-1 Engine General Information and Diagnosis ... 1A-1 Emission Control Devices ........1B-1 Engine Electrical Devices........1C-1 Engine Mechanical..........1D-1 Engine Lubrication System ........
Page 5: Table Of Contents
Table of Contents 00- i Section 00 Precautions CONTENTS Precautions ..........00-1 Precautions for Electrical Circuit Service .... 00-2 Special Tools and Equipment ......00-8 Precautions............00-1 Special Tool ............00-8 Warning / Caution / Note........00-1 General Precautions ........... 00-1...
Page 6: Precautions
CAUTION special meanings. Pay special attention to the messages highlighted by these signal words. • If parts replacement is necessary, replace the parts with Suzuki Genuine Parts or WARNING their equivalent. Indicates a potential hazard that could result • When removing parts that are to be reused, in death or injury.
Page 7: Precautions For Electrical Circuit Service
Precautions: 00-2 • Use a torque wrench to tighten fasteners • Before refitting the sealed coupler, make sure its seal to the specified torque. Wipe off grease rubber is positioned properly. The seal rubber may and oil if a thread is smeared with them. possibly come off the position during disconnecting work and if the coupler is refitted with the seal rubber •...
Page 8 00-3 Precautions: • When connecting meter probe from the terminal side Fuse of the coupler (where connection from harness side • When a fuse is blown, always investigate the cause to not being possible), use extra care not to force and correct it and then replace the fuse.
Page 9 Precautions: 00-4 • When disconnecting and connecting the coupler, • Before measuring voltage at each terminal, check to make sure to turn OFF the ignition switch, or make sure that battery voltage is 11 V or higher. electronic parts may get damaged. Terminal voltage check with a low battery voltage will lead to erroneous diagnosis.
Page 10 00-5 Precautions: When checking system circuits including an electronic 4) Using continuity inspect or voltage check procedure control unit such as ECM, etc., it is important to perform as described below, inspect the wire harness careful check, starting with items which are easier to terminals for open circuit and poor connection.
Page 11 Precautions: 00-6 Voltage check Short circuit check (Wire harness to ground) If voltage is supplied to the circuit being checked, voltage 1) Disconnect the negative (–) cable from the battery. check can be used as circuit check. 2) Disconnect the connectors/couplers at both ends of 1) With all connectors/couplers connected and voltage the circuit to be checked.
Page 12 “D”: To other parts I649G1000002-02 Using The Multi-Circuit Testers NOTE • Use the Suzuki multi-circuit tester set. • When connecting the multi-circuit tester, • Use well-charged batteries in the tester. use the needle pointed probe to the back side of the lead wire coupler and connect •...
Page 13: Special Tools And Equipment
Precautions: 00-8 Special Tools and Equipment Special Tool B940H20008001 09900–25008 09900–25009 Multi-circuit tester set Needle pointed probe set (Page 00-7) / (Page 00- (Page 00-7)
Page 14 00-9 Precautions:...
Page 15: General Information
Spark Plug Inspection and Cleaning ....0B-7 Symbols .............. 0A-1 Fuel Line Inspection ..........0B-7 Abbreviations ............0A-1 Evaporative Emission Control System SAE-to-Former SUZUKI Term ......0A-2 Inspection (E-33 Only) ........0B-8 Vehicle Side View ..........0A-3 Engine Oil and Filter Replacement .....0B-8 Vehicle Identification Number ......0A-3 Final Gear Oil Replacement......0B-10...
Page 16 Use engine oil unless otherwise specified. Apply molybdenum oil solution. (Mixture of engine oil and SUZUKl MOLY PASTE in a ratio of 1 : 1). Apply SUZUKI SUPER GREASE “A” or equivalent. 99000-25010 Apply SUZUKI MOLY PASTE or equivalent. 99000-25140 Apply SUZUKI SILICONE GREASE or equivalent.
Page 17 J1930 terms and abbreviations which may be used in Open Loop (OL): — this manual in compliance with SAE recommendations, as well as their former SUZUKI names. Programmable Read Only Memory (PROM): — Ex. SAE term (Abbreviation): Former SUZUKI term...
Page 18 PERFORMANCE 4 MOTOR OIL or equivalent engine oil. Use of SF/SG or SH/SJ in API with MA in JASO. Suzuki recommends the use of SAE 10W-40 engine oil. If SAE 10W-40 engine oil is not available, select and alternative according to the chart.
Page 19: Cylinder Identification
2 650 ml (2.8/2.3 US/Imp qt) oil. Use of SF/SG or SH/SJ in API with MA in JASO. Suzuki recommends the use of SAE 10W-40 engine oil. For engine coolant mixture information, refer to “Engine If SAE 10W-40 engine oil is not available, select an Coolant Description in Section 1F (Page 1F-1)”.
Page 20 0A-5 General Information: Country and Area Codes B940H20101009 The following codes stand for the applicable country(-ies) and area(-s). Code Country or Area Effective Frame No. VZ1500 K9 (E-02) U.K. JS1CU111200100001 – VZ1500 K9 (E-19) E.U. JS1CU111100100001 – VZ1500 K9 (E-03) U.S.A (Except for California) JS1VY55A 92100001 –...
Page 21 General Information: 0A-6 Warning, Caution and Information Labels Location B940H20101011 2, 3 8, 9, 10 12, 13 1, 11 6, 7 I940H1010008-05 1. Noise label (For E-03, 33) 10. General warning label (French/German/Italian/Swedish) (For E-19) 2. Noise label (For E-24) 11.
Page 22 0A-7 General Information: Component Location Electrical Components Location B940H20103001 I940H1010006-03 1. IAP sensor (#2) 9. HO2 sensor (For E-02, 19, 24, 33) 17. ISC valve 2. IAP sensor (#1) 10. Horn 18. ECM (Engine Control Module) 3. Ignition coil (#1) 11.
Page 23 General Information: 0A-8 I940H1010007-02 24. Fuel injector #1 32. Generator 25. Fuel injector #2 33. CKP sensor 26. Fuel level gauge 34. Speedometer sensor 27. Fuel pump 35. Side-stand switch 28. Ignition coil (#2) 36. TO sensor 29. Ignition switch 37.
Page 24: Front Suspension
0A-9 General Information: Specifications Specifications B940H20107001 NOTE These specifications are subject to change without notice. Dimensions and curb mass Item Specification Remark 2 390 mm (94.1 in) E-03, 28, 33 Overall length 2 410 mm (94.9 in) E-02, 19, 24 Overall width 870 mm (34.3 in) Overall height...
Page 25 General Information: 0A-10 Electrical Item Specification Remark Ignition type Electronic ignition (Transistorized) Ignition timing 4° B.T.D.C. at 1 000 r/min Spark plug NGK CR6E or DENSO U20ESR-N Battery 12 V 64.8 kC (18 Ah)/10 HR Generator Three-phase A.C. generator Main fuse 30 A Fuse 10/10/10/10/15/15 A...
Page 26 0A-11 General Information: Special Tools and Equipment Special Tool B940H20108001 09900–06104 09900–06107 09900–06108 09900–18720 09900–18740 Snap ring pliers Snap ring pliers Snap ring pliers Hexagon socket (14 Hexagon socket (24 09900–20101 09900–20102 09900–20202 09900–20203 09900–20204 Vernier calipers (1/15 Vernier calipers (1/20 Micrometer (1/100 Micrometer (1/100 Micrometer (75 –...
Page 27 General Information: 0A-12 09900–26006 09900–28630 09904–41010 09910–60611 09913–10130 Engine tachometer TPS test wire harness SDS set Universal clamp Carburetor adjust (solar cell type) wrench driver 09913–10750 09913–50121 09913–60250 09913–60910 09913–70210 Compression gauge Oil seal remover Journal bearing Bearing remover Bearing installer set adapter remover/installer 09913–75821...
Page 28 0A-13 General Information: 09916–44920 09916–84511 09917–10410 09917–47011 09920–13120 Valve guide installer Tweezers Valve adjuster driver Vacuum pump gauge Crankcase separating attachment tool 09920–31020 09920–53740 09921–20210 09921–20240 09923–73210 Extension handle Clutch sleeve hub Bearing remover Bearing remover set Bearing remover holder 09923–74511 09924–34510 09924–41830...
Page 29 General Information: 0A-14 09930–73140 09930–73170 09930–82720 09940–14911 09940–30221 Starter torque limiter Starter torque limiter Mode select switch Steering stem nut Front fork assembling socket holder wrench tool 09940–34520 09940–34531 09940–40211 09940–40220 09940–51410 T handle Attachment A Fuel pressure gauge Fuel pressure gauge Bearing installer adapter hose attachment...
Page 30 0B-1 Maintenance and Lubrication: Maintenance and Lubrication General Information Precautions Precautions for Maintenance B940H20200001 The “Periodic Maintenance Schedule Chart” lists the recommended intervals for all the required periodic service work necessary to keep the motorcycle operating at peak performance and economy. Maintenance intervals are expressed in terms of kilometers, miles and months for your convenience.
Page 31: Lubrication Points
Maintenance and Lubrication: 0B-2 Interval 1 000 6 000 12 000 18 000 24 000 Item miles 4 000 7 500 11 000 14 500 months Tires — Steering — — Front fork — — — Rear suspension — — —...
Page 32: Exterior Parts
0B-3 Maintenance and Lubrication: Exhaust Pipe Bolt and Muffler Bolt Inspection 2) Inspect the air cleaner element for clogging. If it is clogged with dirt, replace it with a new one. B940H20206003 Tighten exhaust pipe bolts, muffler bolt and nut CAUTION Initially at 1 000 km (600 miles, 2 months) and every 12 000 km (7 500 miles, 24 months) thereafter...
Page 33 Maintenance and Lubrication: 0B-4 #2 Cylinder 3) Remove the cylinder head cover caps. I940H1020009-01 I940H1020006-01 NOTE The valve clearance specification is different for both intake and exhaust valves. Valve clearance (When cold) IN.: 0.08 – 0.13 mm (0.003 – 0.005 in) EX.: 0.17 –...
Page 34 0B-5 Maintenance and Lubrication: 8) Turn the crankshaft to set the #1 (Rear) cylinder at 10) If the clearance is out of the specification, bring it into TDC of compression stroke. (Align the “R | T” line of the specified range by using the special tool. “A”...
Page 35 O-rings and install Valve timing inspection plug (c): 23 N·m (2.3 the inspection caps (6). kgf-m, 16.5 lbf-ft) : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) CAUTION Use a new O-rings to prevent oil leakage.
Page 36 0B-7 Maintenance and Lubrication: Spark Plug Inspection and Cleaning 2) Measure the spark plug gap using a thickness B940H20206006 gauge. Adjust the spark plug gap if necessary. Inspect spark plug Every 6 000 km (4 000 miles, 12 months) Spark plug gap 0.7 –...
Page 37 Maintenance and Lubrication: 0B-8 4) Inspect the fuel feed hose for damage and fuel leakage. If any defects are found, the fuel feed hose must be replaced. I940H1020021-01 3) Tighten the oil drain plug (1) to the specified torque. CAUTION I940H1020074-01 5) After finishing the fuel feed hose inspection, reinstall Replace the gasket washers with new one.
Page 38 “B”, drain oil to full level line “B”. which may lead to engine damage or oil leaks. Also, do not use a genuine Suzuki automobile oil filter on this motorcycle. 4) Install a new oil filter. Turn it by hand until you feel that the oil filter O-ring contacts the oil filter mounting “B”...
Page 39 Maintenance and Lubrication: 0B-10 Final Gear Oil Replacement Throttle Cable Play Inspection and Adjustment B940H20206010 B940H20206011 Inspect final gear oil Inspect throttle cable play Every 12 000 km (7 500 miles, 24 months) Initially at 1 000 km (600 miles, 2 months) and every 6 000 km (4 000 miles, 12 months) thereafter Replace final gear oil Initially at 1 000 km (600 miles, 2 months)
Page 40 0B-11 Maintenance and Lubrication: Throttle Valve Synchronization 1) Move the fuel tank. Refer to “Fuel Tank Removal and B940H20206013 Installation in Section 1G (Page 1G-9)”. Inspect throttle valve synchronization 2) Remove the radiator cap (1). Initially 1 000 km (600 miles, 2 months) (E-33 only) and every 12 000 km (7 500 miles, 24 months) Inspect the throttle valve synchronization periodically.
Page 41 Maintenance and Lubrication: 0B-12 4) Pour engine coolant up to the radiator inlet. I940H1020031-01 I940H1020029-01 Clutch Cable Play Inspection and Adjustment 5) Slowly swing the motorcycle, right and left, to bleed B940H20206015 the air trapped in the cooling circuit. Inspect clutch cable play 6) Add engine coolant up to the radiator inlet.
Page 42 0B-13 Maintenance and Lubrication: 4) If the clutch release arm play “a” less than the 6) Loosen the lock-nut (4). service limit, adjust the clutch release screw as 7) Turn in the adjuster (5) until 3 - 5 mm (0.1 - 0.2 in) “b” follows.
Page 43 Maintenance and Lubrication: 0B-14 11) Install the secondary gear case cover and frame side lower cover. Refer to “Exterior Parts Removal and Installation in Section 9D (Page 9D-5)”. Brake System Inspection B940H20206016 Inspect brake system Initially at 1 000 km (600 miles, 2 months) and every 6 000 km (4 000 miles, 12 months) thereafter Inspect brake hose and brake fluid Every 6 000 km (4 000 miles, 12 months)
Page 44 0B-15 Maintenance and Lubrication: Front and Rear Brake Hose Inspection 1) Remove the seat, right frame head cover and fuel tank. Refer to “Exterior Parts Construction in Section 9D (Page 9D-2)” and “Fuel Tank Removal and Installation in Section 1G (Page 1G-9)”. 2) Inspect the brake hoses and hose joints for crack, damage or brake oil leakage.
Page 45 Maintenance and Lubrication: 0B-16 5) Tighten the lock-nut (2) to the specified torque. Brake Fluid Replacement Tightening torque Replace brake fluid Rear master cylinder rod lock-nut (a): 18 N·m ( Every 2 years 1.8 kgf-m, 13.0 lbf-ft) Refer to “Brake Fluid Replacement in Section 4A (Page 4A-6)”.
Page 46 0B-17 Maintenance and Lubrication: Tire Pressure 1) Check that there is no play in the front fork. If the tire pressure is too high or too low, steering will be 2) Support the motorcycle so that the front wheel is off adversely affected and tire wear increased.
Page 47 Maintenance and Lubrication: 0B-18 Rear Suspension Inspection B940H20206020 Inspect rear suspension Every 12 000 km (7 500 miles, 24 months) Inspect the rear shock absorbers for oil leakage and check that there is no play in the swingarm. Replace any defective parts, if necessary. Refer to “Rear Shock Absorber Removal and Installation in Section 2C (Page 2C-6)”...
Page 48 0B-19 Maintenance and Lubrication: I940H1020059-04 I940H1020056-02 Brake hose union bolt 23 N⋅m (2.3 kgf-m, 16.5 lbf-ft) Rear shock absorber mounting nut 65 N⋅m (6.5 kgf-m, 47.0 lbf-ft) Air bleeder valve 7.5 N⋅m (0.75 kgf-m, 5.5 lbf-ft) Cushion lever nut 132 N⋅m (13.2 kgf-m, 95.5 lbf-ft) Rear brake caliper mounting bolt 54 N⋅m (5.4 kgf-m, 39.0 lbf-ft) Cushion rod nut 132 N⋅m (13.2 kgf-m, 95.5 lbf-ft) Rear brake caliper bracket mounting bolt 94 N⋅m (9.4 kgf-m, 68.0...
Page 49 Maintenance and Lubrication: 0B-20 I940H1020062-04 I940H1020069-02 Brake hose union bolt 23 N⋅m (2.3 kgf-m, 16.5 lbf-ft) Rear brake pedal boss bolt 16 N⋅m (1.6 kgf-m, 11.5 lbf-ft) Rear brake master cylinder mounting bolt 10 N⋅m (1.0 kgf-m, 7.0 lbf-ft) Compression Pressure Check Rear brake master cylinder rod lock-nut 18 N⋅m (1.8 kgf-m, 13.0 B940H20206022 lbf-ft)
Page 50 0B-21 Maintenance and Lubrication: Special Tools and Equipment Recommended Service Material B940H20208001 Material SUZUKI recommended product or Specification Note Brake fluid DOT 4 — (Page 0B-14) Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010 (Page 0B-6) equivalent Thread lock cement THREAD LOCK CEMENT SUPER P/No.: 99000–32110...
Page 51: Service Data
Service Data: 0C-1 Service Data General Information Specifications Service Data B940H20307001 Valve + Guide Unit: mm (in) Item Standard Limit 33 (1.30) — Valve diam. 30 (1.18) — 0.08 – 0.13 (0.003 – 0.005) — Tappet clearance (When cold) 0.17 – 0.22 (0.007 – 0.009) —...
Page 52 0C-2 Service Data: Cylinder + Piston + Piston Ring Unit: mm (in) Item Standard Limit 750 kPa 850 – 1 450 kPa (8.5 – 14.5 kgf/cm , 121 – #1 Cylinder (7.5 kgf/cm , 106.7 Compression pressure 206 psi) psi) (Automatic decomp.
Page 53 Service Data: 0C-3 Clutch Unit: mm (in) Item Standard Limit Clutch cable play 10 – 15 (0.4 – 0.6) — Clutch release arm play 6.0 (0.24) 2.0 (0.08) Clutch release screw 1/2 turn back — No. 1 3.72 – 3.88 (0.146 – 0.153) 3.42 (0.135) Clutch drive plate thickness No.
Page 54 0C-4 Service Data: Driveline / Axle Unit: mm (in) Item Standard/Specification Limit Secondary bevel gear backlash 0.03 – 0.15 (0.001 – 0.006) — Final bevel gear backlash 0.08 – 0.16 (0.003 – 0.006) — Damper spring free length — 20.5 (0.81) Final gear oil type Hypoid gear oil SAE #90, API grade GL-5 —...
Page 55 Service Data: 0C-5 Throttle Body Item Specification Bore size 42 mm (2.0 in) I.D. No. 40H1 (For E-33), 40H0 (For the others) 1 000 ± 100 r/min/Warmed engine Idle r/min Throttle cable play 2.0 – 4.0 mm (0.08 – 0.16 in) Electrical Unit: mm (in) Item...
Page 56 0C-6 Service Data: Wattage Unit: W Specification Item E-03, 28, 33 E-02, 19, 24 ← Headlight ← Position light — ← Brake light/Taillight Front turn signal light/Position light 21/5 — Front turn signal light — ← Rear turn signal light ←...
Page 57 Front fork oil level (Without spring, 121 (4.8) — inner tube fully compressed) Front fork oil type SUZUKI FORK OIL L01 or an equivalent fork oil — Front fork oil capacity (Each leg) 636 ml (21.5/22.4 US/lmp oz) — Rear shock absorber spring pre-set 192 (7.56)
Page 58 0C-8 Service Data: Tightening Torque List B940H20307002 Engine Item N⋅m kgf-m lbf-ft Cylinder head cover bolt 10.0 Cylinder head cover bracket bolt [L160] 19.0 [L180] 19.0 Cylinder head bolt Initial 18.0 [L190] Final 30.5 Cylinder head inspection cap bolts Water jacket plug (Cylinder head) 19.0 Camshaft journal holder bolt Cam chain sprocket bolt...
Page 59 Service Data: 0C-9 Item N⋅m kgf-m lbf-ft Muffler support bolt 19.0 Muffler joint bolt 19.0 Muffler mounting nut 19.0 Rear muffler upper cover mounting bolt Air cleaner box mounting bolt 0.55 Driveline / Axle Item N⋅m kgf-m lbf-ft Secondary drive gear bolt 16.0 115.5 Secondary driven bevel gear bearing stopper...
Page 60 0C-10 Service Data: Chassis Item N⋅m kgf-m lbf-ft Handlebar clamp bolt 16.5 Handlebar holder bolt 32.5 Front fork clamp bolt (Upper & Lower) 16.5 Front fork cap bolt 16.5 Front fork cylinder bolt 21.5 Steering stem nut 45 N⋅m (4.5 kgf-m, 32.5 lbf-ft) then turn back 1/2 – 1/4 Steering stem head nut 65.0 Front axle...
Page 61 Service Data: 0C-11 Tightening Torque Chart For other bolts and nuts not listed in the preceding page, refer to this chart: Bolt Diameter Conventional or “4” marked bolt “7” marked bolt “a” (mm) N⋅m kgf-m lbf-ft N⋅m kgf-m lbf-ft 0.15 0.23 0.45 0.55...
Page 62 0C-12 Service Data:...
Page 63 Table of Contents 1- i Section 1 Engine CONTENTS Precautions ..........1-1 DTC “C31” (P0705): GP Switch Circuit Malfunction............1A-69 Precautions............. 1-1 DTC “C32” (P0201), “C33” (P0202): Fuel Precautions for Engine.......... 1-1 Injector Circuit Malfunction......1A-71 Engine General Information and DTC “C40” (P0505 / P0506 / P0507): ISC Valve Circuit Malfunction.........1A-74 Diagnosis ..........
Page 64 1-ii Table of Contents PAIR Reed Valve Removal and Installation..1B-8 Engine Mechanical ........1D-1 PAIR Control Solenoid Valve Removal and Schematic and Routing Diagram ......1D-1 Installation ............1B-9 Throttle Cable Routing Diagram......1D-2 PAIR System Inspection ........1B-9 Diagnostic Information and Procedures ....1D-3 Crankcase Breather (PCV) Hose Inspection..1B-10 Engine Mechanical Symptom Diagnosis .....1D-3 Crankcase Breather (PCV) Hose Removal...
Page 65 Table of Contents 1-iii Special Tool ............1D-86 Water pump Components ......... 1F-11 Water Pump Removal and Installation....1F-11 Engine Lubrication System ....1E-1 Water Pump Disassembly and Assembly ..1F-13 Water Pump Related Parts Inspection ....1F-15 Precautions............1E-1 Precautions for Engine Oil ........1E-1 Specifications .............
Page 66 1-iv Table of Contents Spark Plug Cap and Spark Plug Removal and Tightening Torque Specifications....... 1I-14 Installation ............1H-4 Special Tools and Equipment ......1I-14 Ignition Coil Construction ........1H-5 Recommended Service Material ......1I-14 Ignition Coil Removal and Installation ....1H-6 Special Tool ............1I-15 Spark Plug Inspection and Cleaning ....1H-6 Charging System ........
Page 67: Precautions
Precautions: Precautions Engine Precautions Precautions for Engine B940H21000001 Refer to “General Precautions in Section 00 (Page 00-1)” and “Precautions for Electrical Circuit Service in Section 00 (Page 00-2)”.
Page 68: Engine General Information And Diagnosis
1A-1 Engine General Information and Diagnosis: Engine General Information and Diagnosis Engine General Description Injection Timing Description B940H21101001 Injection Time (Injection Volume) The factors to determine the injection time include the basic fuel injection time, which is calculated on the basis of the intake air pressure, engine speed and throttle opening angle, and various compensations.
Page 69: Self-Diagnosis Function
Engine General Information and Diagnosis: 1A-2 Injection Stop Control Signal Descriptions When the motorcycle tips over, the tip-over sensor sends a signal TIP-OVER SENSOR SIGNAL (FUEL SHUT-OFF) to the ECM. Then, this signal cuts OFF current supplied to the fuel pump, fuel injectors and ignition coils.
Page 70 1A-3 Engine General Information and Diagnosis: For Example: The ignition switch is turned ON, and the engine stop switch is turned OFF. In this case, the speedometer does not receive any signal from the ECM, and the panel indicates “CHEC”. If CHEC is indicated, the LCD does not indicate the trouble code.
Page 71: Schematic And Routing Diagram
Engine General Information and Diagnosis: 1A-4 Schematic and Routing Diagram FI System Wiring Diagram B940H21102001 Combination meter Pilot lamp Cooling fan motor Cooling fan relay 15 A CKPS R/Bl Fuel injector Gr/W Gr/B IG switch signal FP relay 10 A Engine stop switch Side-stand relay...
Page 72: Terminal Alignment Of Ecm Coupler
1A-5 Engine General Information and Diagnosis: Terminal Alignment of ECM Coupler B940H21102002 I940H1110005-03 TERMINAL NO. CIRCUIT TERMINAL NO. CIRCUIT GP switch signal (GP) — IAT sensor signal (IATS) — IAP sensor signal #2 (IAPS.2) — STP sensor (STPS) Serial data for speedometer Power source for sensors (VCC) Serial data for self-diagnosis HO2 sensor signal (HO2S)(For E-02,...
Page 73: Component Location
Engine General Information and Diagnosis: 1A-6 Component Location FI System Parts Location B940H21103001 I940H1110007-04 “A”: ECM “F”: Fuel injector #1 “K”: Engine coolant temperature sensor (ECTS) “B”: Speedometer “G”: Fuel injector #2 “L”: Crank shaft position sensor (CKPS) “C”: Pilot lamp “H”: Intake air pressure sensor #1 (IAPS) “M”: Speedometer sensor “D”: Intake air temperature sensor (IATS)
Page 74: Diagnostic Information And Procedures
1A-7 Engine General Information and Diagnosis: Diagnostic Information and Procedures Engine Symptom Diagnosis B940H21104001 Condition Possible cause Correction / Reference Item Engine will not start or is Valve clearance out of adjustment. Adjust. hard to start Worn valve guide or poor seating of Repair or replace.
Page 75 Engine General Information and Diagnosis: 1A-8 Condition Possible cause Correction / Reference Item Engine stalls often Defective IAP sensors or circuit. Repair or replace. (Incorrect fuel/air mixture) Clogged fuel filter. Clean or replace. Defective fuel pump. Replace. Defective fuel pressure regulator. Replace.
Page 76 1A-9 Engine General Information and Diagnosis: Condition Possible cause Correction / Reference Item Noisy engine (Noise Too much play on pump shaft bearing. Replace. seems to come from Worn or damaged impeller shaft. Replace. water pump) Worn or damaged mechanical seal. Replace.
Page 77 Engine General Information and Diagnosis: 1A-10 Condition Possible cause Correction / Reference Item Engine lacks power Low fuel pressure. Repair or replace. (Defective control circuit Defective TP sensor. Replace. or sensor) Defective IAT sensor. Replace. Defective CKP sensor. Replace. Defective GP sensor. Replace.
Page 78: Self-Diagnostic Procedures
1A-11 Engine General Information and Diagnosis: Self-Diagnostic Procedures 3) Start the engine or crank the engine for more than 4 B940H21104002 seconds. Use of Mode Select Switch 4) Turn the special tool’s switch ON. NOTE 5) Check the DTC to determine the malfunction part. Refer to “DTC Table (Page 1A-20)”.
Page 79 Engine General Information and Diagnosis: 1A-12 Use of SDS NOTE • Do not disconnect the coupler from ECM, battery cable from battery, ECM ground wire from the engine or main fuse before confirming DTC (Diagnostic Trouble Code) stored in memory. Such disconnection will erase the memorized information in ECM memory.
Page 80: Use Of Sds Diagnosis Reset Procedures
1A-13 Engine General Information and Diagnosis: 3) Check the DTC. 4) Start the engine or crank the engine for more than 4 seconds. 4) The previous malfunction history code (Past DTC) 5) Check the DTC to determine the malfunction part. still remains stored in the ECM.
Page 81: Show Data When Trouble (Displaying Data At The Time Of Dtc)
Engine General Information and Diagnosis: 1A-14 Show Data When Trouble (Displaying Data at the Time of DTC) B940H21104004 Use of SDS ECM stores the engine and driving conditions (in the form of data as shown in the figure) at the moment of the detection of a malfunction in its memory.
Page 82 1A-15 Engine General Information and Diagnosis: 1) Click “Show data when trouble” (1) to display the data. I718H1110269-02 2) Click the drop down button (2), either “Failure #1” or “Failure #2” can be selected. I718H1110270-01...
Page 83: Sds Check
Engine General Information and Diagnosis: 1A-16 SDS Check B940H21104005 Using SDS, sample the data at the time of new and periodic vehicle inspections. After saving the sampled data in the computer, file them by model and by user. The periodically filed data help improve the accuracy of troubleshooting since they can indicate the condition of vehicle functions that has changed with time.
Page 84 1A-17 Engine General Information and Diagnosis: Data at 3 000 r/min under no load Approx. 3 000 r/min Check the manifold absolute pressure. XXX kPa Check the water temperature. XX °C I940H1110096-01 Data at the time of racing Throttle: Slowly open Throttle: Quick wide open Secondary throttle valve opens...
Page 85 Engine General Information and Diagnosis: 1A-18 Data of intake negative pressure during idling (100 °C) Check the engine coolant temperature. XX °C Check the manifold absolute pressure. XXX kPa Check the manifold absolute pressure. XXX kPa I940H1110098-02 Data of manifold absolute pressure operation at the time of starting Check the manifold absolute pressure.
Page 86 1A-19 Engine General Information and Diagnosis: Example of Trouble Three data; value 1 (past data 1), value 2 (past data 2) and value 3 (current data 3); can be made in comparison by showing them in the graph. Read the change of value by comparing the current data to the past data that have been saved under the same condition, then you may determine how changes have occurred with the passing of time and identify what problem is currently occurring.
Page 87: Dtc Table
Engine General Information and Diagnosis: 1A-20 DTC Table B940H21104006 Code Malfunction Part Remarks None No defective part C12 (P0335) Crankshaft position sensor (CKPS) Pick-up coil signal, signal generator (Page 1A-26) C13 (P1750) Intake air pressure sensor #2 (IAPS) For #2 cylinder (Page 1A-29) C14 (P0120-H/L) Throttle position sensor (TPS)
Page 88: Fail-Safe Function Table
1A-21 Engine General Information and Diagnosis: Fail-Safe Function Table B940H21104007 FI system is provided with fail-safe function to allow the engine to start and the motorcycle to run in a minimum performance necessary even under malfunction condition. Item Fail-Safe Mode Starting Ability Running Ability Intake air pressure value is fixed to 101 kPa...
Page 89: Fi System Troubleshooting
Engine General Information and Diagnosis: 1A-22 FI System Troubleshooting B940H21104008 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 following will facilitate collecting information to the point required for proper analysis and diagnosis.
Page 90: Malfunction Code And Defective Condition Table
1A-23 Engine General Information and Diagnosis: Visual Inspection Prior to diagnosis using the mode select switch or SDS, perform the following visual inspections. The reason for visual inspection is that mechanical failures (such as oil leakage) cannot be displayed on the screen with the use of mode select switch or SDS.
Page 91 Engine General Information and Diagnosis: 1A-24 Malfunction Detected Item Detected Failure Condition Check For Code The sensor voltage should be the following for 2 sec. and more, after ignition switch is turned TO sensor, lead wire/coupler 0.2 V < Sensor voltage < 4.6 V connection In other than the above value, C23 (P1651) is TO sensor...
Page 92 1A-25 Engine General Information and Diagnosis: Malfunction Detected Item Detected Failure Condition Check For Code Ignition switch, lead wire/ Ignition switch Ignition switch signal is not input to the ECM. P1650 coupler HO2 sensor output voltage is not input to ECM during engine operation and running HO2S lead sensor circuit open condition.
Page 93: Dtc "C12" (P0335): Ckp Sensor Circuit Malfunction
Engine General Information and Diagnosis: 1A-26 DTC “C12” (P0335): CKP Sensor Circuit Malfunction B940H21104010 Detected Condition and Possible Cause Detected Condition Possible Cause The signal does not reach ECM for 3 sec. or more, after • Metal particles or foreign material being stuck on the receiving the starter signal.
Page 94 1A-27 Engine General Information and Diagnosis: Step Action 1) Turn the ignition switch OFF. Go to Step 2. Replace the CKP sensor with a new one. 2) Remove the left frame side cover. Refer to “Exterior Parts Removal and Installation in Section 9D (Page 9D- 5)”.
Page 95 Engine General Information and Diagnosis: 1A-28 Step Action 6) If OK, then check the continuity between each terminal Go to Step 2. Replace the CKP and ground. sensor with a new one. Special tool (A): 09900–25008 (Multi-circuit tester set) CKP sensor continuity ∞...
Page 96: Dtc "C13" (P1750) Or "C17" (P0105): Iap Sensor Circuit Malfunction
1A-29 Engine General Information and Diagnosis: DTC “C13” (P1750) or “C17” (P0105): IAP Sensor Circuit Malfunction B940H21104011 Detected Condition and Possible Cause Detected Condition Possible Cause IAP sensor voltage is not within the following range. • Clogged vacuum passage between throttle body and 0.1 V ≤...
Page 97 Engine General Information and Diagnosis: 1A-30 Step Action 1) Remove the fuel tank. Refer to “Fuel Tank Removal and Go to Step 2. • Loose or poor Installation in Section 1G (Page 1G-9)”. contacts on the ECM coupler. (terminal “11” 2) Turn the ignition switch OFF.
Page 98 1A-31 Engine General Information and Diagnosis: Step Action 1) Connect the IAP sensor coupler and ECM coupler. Go to Step 3. • Check the vacuum hose for crack or 2) Connect the fuel feed hose and fuel pump read wire damage.
Page 99 Engine General Information and Diagnosis: 1A-32 Step Action 1) Turn the ignition switch OFF. • R, P/B or B/Br wire If check result is not open or shorted to satisfactory, replace the 2) Remove the IAP sensor. Refer to “IAP Sensor Removal ground, or poor “5”, IAP sensor with a new and Installation in Section 1C (Page 1C-2)”.
Page 100: Dtc "C14" (P0120-H/L): Tp Sensor Circuit Malfunction
1A-33 Engine General Information and Diagnosis: DTC “C14” (P0120-H/L): TP Sensor Circuit Malfunction B940H21104012 Detected Condition and Possible Cause Detected Condition Possible Cause Output voltage is not within the following • TP sensor maladjusted. range. • TP sensor circuit open or short. Difference between actual throttle opening •...
Page 101 Engine General Information and Diagnosis: 1A-34 C14 (Use of mode select switch) Step Action 1) Turn the ignition switch OFF. Go to Step 3. • Loose or poor contacts on the ECM 2) Lift and support the fuel tank. Refer to “Fuel Tank coupler.
Page 102 1A-35 Engine General Information and Diagnosis: P0120-H (Use of SDS) Step Action 1) Turn the ignition switch OFF. Go to Step 3. P/B wire shorted to VCC, or B/Br wire open. 2) Lift and support the fuel tank. Refer to “Fuel Tank Removal and Installation in Section 1G (Page 1G-9)”.
Page 103 Engine General Information and Diagnosis: 1A-36 Step Action 7) Check the continuity between the P/B wire “A” and Go to Step 3. P/B wire shorted to terminal “21”. VCC, or B/Br wire open. Also, check the continuity between the B/Br wire “B” and terminal “12”.
Page 104 1A-37 Engine General Information and Diagnosis: P0120-L (Use of SDS) Step Action 1) Turn the ignition switch OFF. Go to Step 2. R and P/B wire open, or P/B wire shorted to 2) Lift and support the fuel tank. Refer to “Fuel Tank ground.
Page 105 Engine General Information and Diagnosis: 1A-38 Step Action 7) Check the continuity between the P/B wire “A” and Go to Step 2. R and P/B wire open, or terminal “21”. P/B wire shorted to Also, check the continuity between the R wire “B” and ground.
Page 106 1A-39 Engine General Information and Diagnosis: Step Action 1) Turn the ignition switch OFF. Go to Step 3. • Reset the TP sensor position correctly. 2) Disconnect the TP sensor coupler. • Replace the TP 3) Connect the test harness to the TP sensor. sensor with a new 4) Check the continuity between terminal “A”...
Page 107 Engine General Information and Diagnosis: 1A-40 Step Action 7) If OK, then measure the TP sensor resistance at the test Go to Step 3. • Reset the TP sensor harness terminals (between terminal “A” and terminal position correctly. “B”). • Replace the TP sensor with a new Special tool one.
Page 108: Dtc "C15" (P0115-H/L): Ect Sensor Circuit Malfunction
1A-41 Engine General Information and Diagnosis: DTC “C15” (P0115-H/L): ECT Sensor Circuit Malfunction B940H21104013 Detected Condition and Possible Cause Detected Condition Possible Cause Output voltage is not with in the following • ECT sensor circuit open or short. range. • ECT sensor malfunction. 0.1 V ≤...
Page 109 Engine General Information and Diagnosis: 1A-42 C15 (Use of mode select switch) Step Action 1) Turn the ignition switch OFF. Go to Step 2. • Loose or poor contacts on the ECM 2) Remove the right air cleaner box. Refer to “Air Cleaner coupler.
Page 110 1A-43 Engine General Information and Diagnosis: P0115-H (Use of SDS) Step Action 1) Turn the ignition switch OFF. Go to Step 2. B/Bl or B/Br wire open. 2) Remove the right air cleaner box. Refer to “Air Cleaner Element Removal and Installation in Section 1D (Page 1D-6)”.
Page 111 Engine General Information and Diagnosis: 1A-44 P0115-L (Use of SDS) Step Action 1) Turn the ignition switch OFF. Go to Step 2. • B/Bl wire shorted to ground. 2) Remove the right air cleaner box. Refer to “Air Cleaner Element Removal and Installation in Section 1D •...
Page 112 1A-45 Engine General Information and Diagnosis: Step Action 9) Measure the output voltage between the B/Bl wire and Go to Step 2. • B/Bl wire shorted to ground. ground. • If wire is OK, go to Special tool Step 2. (A): 09900–25008 (Multi-circuit tester set) (B): 09900–25009 (Needle pointed probe set) Tester knob indication...
Page 113: Dtc "C21" (P0110-H/L): Iat Sensor Circuit Malfunction
Engine General Information and Diagnosis: 1A-46 DTC “C21” (P0110-H/L): IAT Sensor Circuit Malfunction B940H21104014 Detected Condition and Possible Cause Detected Condition Possible Cause Output voltage is not with in the following • IAT sensor circuit open or short. range. • IAT sensor malfunction. 0.1 V ≤...
Page 114 1A-47 Engine General Information and Diagnosis: C21 (Use of mode select switch) Step Action 1) Turn the ignition switch OFF. Go to Step 2. • Loose or poor contacts on the ECM 2) Remove the fuel tank. Refer to “Fuel Tank Removal and coupler.
Page 115 Engine General Information and Diagnosis: 1A-48 P0110-H (Use of SDS) Step Action 1) Turn the ignition switch OFF. Connect the ECM Dg or B/Br wire open. coupler and go to Step 2) Remove the fuel tank. Refer to “Fuel Tank Removal and Installation in Section 1G (Page 1G-9)”.
Page 116 1A-49 Engine General Information and Diagnosis: P0110-L (Use of SDS) Step Action 1) Turn the ignition switch OFF. Go to Step 2. • Dg wire shorted to ground. 2) Remove the fuel tank. Refer to “Fuel Tank Removal and Installation in Section 1G (Page 1G-9)”. •...
Page 117 Engine General Information and Diagnosis: 1A-50 Step Action 9) Measure the output voltage between the Dg wire and Go to Step 2. • Dg wire shorted to ground. ground. • If wire is OK, go to Special tool Step 2. (A): 09900–25008 (Multi-circuit tester set) (B): 09900–25009 (Needle pointed probe set) Tester knob indication...
Page 118: Dtc "C23" (P1651-H/L): To Sensor Circuit Malfunction
1A-51 Engine General Information and Diagnosis: DTC “C23” (P1651-H/L): TO Sensor Circuit Malfunction B940H21104015 Detected Condition and Possible Cause Detected Condition Possible Cause The sensor voltage should be the • TO sensor circuit open or short. following for 2 sec. and more, after ignition •...
Page 119 Engine General Information and Diagnosis: 1A-52 C23 (Use of mode select switch) Step Action 1) Turn the ignition switch OFF. Go to Step 2. Replace the TO sensor with a new one. Refer to 2) Remove the TO sensor. Refer to “TO Sensor Removal “TO Sensor Removal and Installation in Section 1C (Page 1C-5)”.
Page 120 1A-53 Engine General Information and Diagnosis: P1651-H (Use of SDS) Step Action 1) Turn the ignition switch OFF. Go to Step 2. Br wire shorted to VCC, or B/Br wire open. 2) Remove the TO sensor. Refer to “TO Sensor Removal and Installation in Section 1C (Page 1C-5)”.
Page 121 Engine General Information and Diagnosis: 1A-54 Step Action 8) Check the continuity between the Br wire “B” and Go to Step 2. Br wire shorted to VCC, terminal “20”. or B/Br wire open. Also, check the continuity between B/Br wire “C” and terminal “12”.
Page 122 1A-55 Engine General Information and Diagnosis: P1651-L (Use of SDS) Step Action 1) Turn the ignition switch OFF. Go to Step 2. R or Br wire open, or Br wire shorted to ground. 2) Remove the TO sensor. Refer to “TO Sensor Removal and Installation in Section 1C (Page 1C-5)”.
Page 123 Engine General Information and Diagnosis: 1A-56 Step Action 8) Check the continuity between the R wire “C” and Go to Step 2. R or Br wire open, or Br terminal “5”. wire shorted to ground. Also, then check the continuity between Br wire “A” and terminal “20”.
Page 124 1A-57 Engine General Information and Diagnosis: Step Action 1) Connect the ECM coupler and TO sensor coupler. • R, Br or B/Br wire • Loosen or poor open or shorted to contacts on the ECM 2) Remove the TO sensor. Refer to “TO Sensor Removal ground, or poor “5”, coupler.
Page 125: Dtc "C24" (P0351), "C25" (P0352): Ignition System Malfunction
Engine General Information and Diagnosis: 1A-58 DTC “C24” (P0351), “C25” (P0352): Ignition System Malfunction B940H21104016 NOTE • Refer to “No Spark or Poor Spark in Section 1H (Page 1H-3)” for details. • When indicating “C24” (P0351) for #1 • When indicating “C25” (P0352) for #2 DTC “C28”...
Page 126 1A-59 Engine General Information and Diagnosis: Step Action 1) Remove the air cleaner chamber. Refer to “Air Cleaner Go to Step 2. • Loose or poor Chamber Removal and Installation in Section 1D contacts on the (Page 1D-7)”. coupler. 2) Check the STVA lead wire coupler (1) for loose or poor •...
Page 127 Engine General Information and Diagnosis: 1A-60 Step Action 1) Turn the ignition switch OFF. • B/Lg, P/W, G and W/ • Loose or poor B wire open or contacts on the ECM 2) Disconnect the STVA lead wire coupler. shorted to ground, or coupler.
Page 128 1A-61 Engine General Information and Diagnosis: Active Control Inspection 1) Set up the SDS tool. (Refer to the SDS operation manual for further details.) 2) Turn the ignition switch ON. 3) Click “Secondary throttle operating control” (1). I940H1110094-02 4) Click each button (2). At this time, if an operation sound is heard from the STVA, the function is normal.
Page 129: Dtc "C29" (P1654-H/L): Secondary Throttle Position Sensor (Stps) Circuit Malfunction
Engine General Information and Diagnosis: 1A-62 DTC “C29” (P1654-H/L): Secondary Throttle Position Sensor (STPS) Circuit Malfunction B940H21104018 Detected Condition and Possible Cause Detected Condition Possible Cause Output voltage is not within the following • STP sensor maladjusted. range. • STP sensor circuit open or short. Difference between actual throttle opening •...
Page 130 1A-63 Engine General Information and Diagnosis: C29 (Use of mode select switch) Step Action 1) Turn the ignition switch OFF. Go to Step 2. • Loose or poor contacts on the ECM 2) Remove the fuel tank. Refer to “Fuel Tank Removal and coupler.
Page 131 Engine General Information and Diagnosis: 1A-64 P1654-H (Use of SDS) Step Action 1) Turn the ignition switch OFF. Go to Step 3. Y/W wire shorted to VCC, or B/Br wire open. 2) Lift and support the fuel tank. Refer to “Fuel Tank Removal and Installation in Section 1G (Page 1G-9)”.
Page 132 1A-65 Engine General Information and Diagnosis: Step Action 7) Check the continuity between the Y/W wire “A” and Go to Step 3. Y/W wire shorted to terminal “4”. VCC, or B/Br wire open. Also, check the continuity between the B/Br wire “C” and terminal “12”.
Page 133 Engine General Information and Diagnosis: 1A-66 P1654-L (Use of SDS) Step Action 1) Turn the ignition switch OFF. Go to Step 2. R or Y/W wire open, or Y/W wire shorted to 2) Lift and support the fuel tank. Refer to “Fuel Tank ground.
Page 134 1A-67 Engine General Information and Diagnosis: Step Action 7) Check the continuity between the Y/W wire “A” and Go to Step 2. R or Y/W wire open, or terminal “4”. Y/W wire shorted to Also, check the continuity between the R wire “C” and ground.
Page 135 Engine General Information and Diagnosis: 1A-68 Step Action 1) Turn the ignition switch OFF. • R, Y/W or B/Br wire If check result is not open or shorted to satisfactory, replace the 2) Connect the ECM coupler. ground, or poor “5”, STP sensor with a new 3) Remove the right air cleaner box.
Page 136: Dtc "C31" (P0705): Gp Switch Circuit Malfunction
1A-69 Engine General Information and Diagnosis: DTC “C31” (P0705): GP Switch Circuit Malfunction B940H21104019 Detected Condition and Possible Cause Detected Condition Possible Cause No Gear Position switch voltage • GP switch circuit open or short. GP switch voltage is not within the following range. •...
Page 137 Engine General Information and Diagnosis: 1A-70 Step Action 1) Turn the ignition switch OFF. • P wire open or • P or B/W wire open, shorted to ground. or P wire shorted to 2) Remove the left frame side cover. Refer to “Exterior ground.
Page 138: Dtc "C32" (P0201), "C33" (P0202): Fuel Injector Circuit Malfunction
1A-71 Engine General Information and Diagnosis: DTC “C32” (P0201), “C33” (P0202): Fuel Injector Circuit Malfunction B940H21104020 Detected Condition and Possible Cause Detected Condition Possible Cause CKP signal is produced but fuel injector signal is • Injector circuit open or short. interrupted by 8 times or more continuity.
Page 139 Engine General Information and Diagnosis: 1A-72 Step Action 1) Turn the ignition switch OFF. Go to Step 2. Replace the injector with a new one. Refer to 2) Remove the air cleaner chamber. Refer to “Air Cleaner “Throttle Body Chamber Removal and Installation in Section 1D Disassembly and (Page 1D-7)”.
Page 140 1A-73 Engine General Information and Diagnosis: Step Action 5) If OK, then check the continuity between each terminal Go to Step 2. Replace the injector and ground. with a new one. Refer to “Throttle Body Special tool Disassembly and (A): 09900–25008 (Multi-circuit tester set) Assembly in Section 1D Injector continuity (Page 1D-14)”.
Page 141: Dtc "C40" (P0505 / P0506 / P0507): Isc Valve Circuit Malfunction
Engine General Information and Diagnosis: 1A-74 DTC “C40” (P0505 / P0506 / P0507): ISC Valve Circuit Malfunction B940H21104021 Detected Condition and Possible Cause Detected Condition Possible Cause The circuit voltage of motor drive is • ISC valve circuit open or shorted to the ground. C40/P0505 unusual.
Page 142 1A-75 Engine General Information and Diagnosis: Step Action 1) Turn the ignition switch OFF. Go to Step 2. B/R, B/Bl, B/G, or Dg wire open. 2) Check the ISC valve coupler (1) for loose or poor contacts. If OK, then check the ISC valve lead wire continuity. I940H1110066-01 3) Disconnect the ISC valve coupler and ECM coupler.
Page 143 Engine General Information and Diagnosis: 1A-76 Step Action 1) Disconnect the ISC valve coupler. If wire is OK, Replace the ISC valve intermittent trouble or with a new one. Refer to 2) Check the continuity between each terminal and ground. faulty ECM.
Page 144 1A-77 Engine General Information and Diagnosis: Active Control Inspection (ISC RPM Control) Check 2 Check 1 1) Click the button (4) and decrease the “Spec” (2) to 900 rpm slowly. 1) Set up the SDS tool. (Refer to the SDS operation manual for further details.) 2) Check that the “Desired idle speed”...
Page 145: Dtc "C41" (P0230): Fp Relay Circuit Malfunction
Engine General Information and Diagnosis: 1A-78 DTC “C41” (P0230): FP Relay Circuit Malfunction B940H21104022 Detected Condition and Possible Cause Detected Condition Possible Cause No voltage is applied to fuel pump. • Fuel pump relay circuit open or short. • Fuel pump relay malfunction. •...
Page 146: Dtc "C42" (P1650): Ig Switch Circuit Malfunction
1A-79 Engine General Information and Diagnosis: Step Action 1) Turn the ignition switch OFF. • Y/B or O/W wire open Replace the FP relay or shorted or poor with a new one. 2) Remove the front seat. Refer to “Exterior Parts Removal “34”...
Page 147: Dtc "C44" (P0130/P0135): Ho2 Sensor (Ho2S) Circuit Malfunction (For
Engine General Information and Diagnosis: 1A-80 DTC “C44” (P0130/P0135): HO2 Sensor (HO2S) Circuit Malfunction (For E-02, 19, 24, 33) B940H21104024 Detected Condition and Possible Cause Detected Condition Possible Cause HO2 sensor output voltage is not input to • HO2 sensor circuit is open or shorted to the power ECM during engine operation and running source.
Page 148 1A-81 Engine General Information and Diagnosis: Step Action 1) Turn the ignition switch OFF. Go to Step 2. W/G wire shorted to ground, or Br or B/Br 2) Remove the right frame side cover. Refer to “Exterior wire open. Parts Removal and Installation in Section 9D (Page 9D- 5)”.
Page 149 Engine General Information and Diagnosis: 1A-82 Step Action 7) Check the continuity between the Br wire “B” and Go to Step 2. W/G wire shorted to terminal “6”. Also check the continuity between the B/Br ground, or Br or B/Br wire “A”...
Page 150 1A-83 Engine General Information and Diagnosis: Step Action 1) Connect the ECM coupler and HO2 sensor coupler. • Br or B/Br wire open Replace the HO2 or shorted to the sensor with a new one. 2) Warm up the engine enough. power source, or Refer to “Heated 3) Insert the needle pointed probes to the lead wire coupler.
Page 151 Engine General Information and Diagnosis: 1A-84 Troubleshooting (When Indicating C44/P0135:) NOTE After repairing the trouble, clear the DTC using SDS tool. Refer to “Use of SDS Diagnosis Reset Procedures (Page 1A-13)”. Step Action 1) Turn the ignition switch OFF. Go to Step 2. Replace the HO2 sensor with a new one.
Page 152 1A-85 Engine General Information and Diagnosis: Step Action 1) Connect the HO2 sensor coupler. • B/G or B/R wire open • Open or short circuit or shorted to the in the B/R wire or B/G 2) Insert the needle pointed probes to the lead wire coupler. ground, or poor “17”...
Page 153: Dtc "C49" (P1656): Pair Solenoid Valve Circuit Malfunction
Engine General Information and Diagnosis: 1A-86 DTC “C49” (P1656): PAIR Solenoid Valve Circuit Malfunction B940H21104025 Detected Condition and Possible Cause Detected Condition Possible Cause PAIR control solenoid valve ampere is not input to ECM. • PAIR control solenoid valve circuit open or short. •...
Page 154 1A-87 Engine General Information and Diagnosis: Step Action 1) Turn the ignition switch OFF. Go to Step 2. Replace the PAIR control solenoid with a 2) Remove the right frame head cover. Refer to “Exterior new one. Refer to “PAIR Parts Removal and Installation in Section 9D (Page 9D- Control Solenoid Valve 5)”.
Page 155 Engine General Information and Diagnosis: 1A-88 Step Action 6) Measure the resistance between terminals. Go to Step 2. Replace the PAIR control solenoid with a Special tool new one. Refer to “PAIR (A): 09900–25008 (Multi-circuit tester set) Control Solenoid Valve Tester knob indication Removal and Resistance (Ω)
Page 156 1A-89 Engine General Information and Diagnosis: Active Control Inspection 1) Set up the SDS tool. (Refer to the SDS operation manual for further details.) 2) Turn the ignition switch ON. 3) Click “PAIR Sol operating control” (1). I940H1110110-02 4) Click each button (2). At this time, if an operating sound is heard from the PAIR control solenoid valve, the function is normal.
Page 157: Dtc "C60" (P0480): Cooling Fan Relay Circuit Malfunction
Engine General Information and Diagnosis: 1A-90 DTC “C60” (P0480): Cooling Fan Relay Circuit Malfunction B940H21104026 Detected Condition and Possible Cause Detected Condition Possible Cause Cooling fan relay signal is not input to ECM. • Cooling fan relay circuit open or short. •...
Page 158 1A-91 Engine General Information and Diagnosis: Step Action 1) Turn the ignition switch OFF. • O/B and G/R wire Replace the cooling fan open or shorted to relay with a new one. 2) Remove the right frame side cover. Refer to “Exterior ground, or poor “24”...
Page 159 Engine General Information and Diagnosis: 1A-92 4) Click the “Operate” (2). At this time, if an operation sound is heard from the cooling fan relay and cooling fan motors are operated, the function is normal. NOTE Cooling fan relay and cooling fan motor operation can be checked until the engine coolant temperature is less than 100 °C (212 °F) after starting the engine.
Page 160: Dtc "C62" (P0443): Evap System Purge Control Solenoid Valve Circuit Malfunction (For
1A-93 Engine General Information and Diagnosis: DTC “C62” (P0443): EVAP System Purge Control Solenoid Valve Circuit Malfunction (For E-33) B940H21104027 Detected Condition and Possible Cause Detected Condition Possible Cause EVAP system purge control valve voltage is not input to • EVAP system purge control valve circuit open or short. ECM.
Page 161 Engine General Information and Diagnosis: 1A-94 Step Action 1) Turn the ignition switch OFF. Go to Step 2. Replace the EVAP system purge control 2) Remove the seat. Refer to “Exterior Parts Removal and with a new one. Refer to Installation in Section 9D (Page 9D-5)”.
Page 162 1A-95 Engine General Information and Diagnosis: Step Action 1) Turn the ignition switch ON. • W/Y wire open or Open or short circuit in shorted to ground, or the O/W wire. 2) Measure the voltage between the O/W wire and ground. poor “36”...
Page 163: Specifications
Engine General Information and Diagnosis: 1A-96 4) Click each button (2). At this time, if an operating sound is heard from the EVAP system purge control valve, the function is normal. I940H1110116-01 Specifications Service Data B940H21107001 Injector Item Specification Note 11 –...
Page 164: Special Tools And Equipment
1A-97 Engine General Information and Diagnosis: Special Tools and Equipment Special Tool B940H21108001 09900–25008 09900–25009 Multi-circuit tester set Needle pointed probe set (Page 1A-27) / (Page 1A-31) / (Page 1A-28) / (Page 1A-36) / (Page 1A-38) / (Page 1A-28) / (Page 1A-30) / (Page 1A-43) / (Page 1A-31) /...
Page 165: Emission Control Devices
Emission Control Devices: 1B-1 Emission Control Devices Engine Precautions Precautions for Emission Control Devices B940H21200001 Refer to “General Precautions in Section 00 (Page 00-1)”. General Description Fuel Injection System Description B940H21201001 VZ1500 motorcycles are equipped with a fuel injection system for emission level control. This fuel injection system is precision designed, manufactured and adjusted to comply with the applicable emission limits.
Page 166: Crankcase Emission Control System Description
1B-2 Emission Control Devices: Crankcase Emission Control System Description B940H21201002 The engine is equipped with a PCV system to prevent discharging crankcase emissions into the atmosphere. Blow-by gas in the engine is constantly drawn into the crankcase, which is returned to the combustion chamber through the PCV (breather) hose, air cleaner chamber and throttle body.
Page 167: Exhaust Emission Control System Description
Emission Control Devices: 1B-3 Exhaust Emission Control System Description B940H21201003 The exhaust emission control system is composed of the PAIR system, three way catalyst system and ISC system. The fresh air is drawn into the exhaust port through the PAIR control solenoid valve and PAIR reed valve. The PAIR control solenoid valve is operated by the ECM, which is controlled according to the signals from TPS, ECTS, IATS, IAPS and CKPS.
Page 168: Noise Emission Control System Description
1B-4 Emission Control Devices: Noise Emission Control System Description B940H21201004 TAMPERING WITH THE NOISE CONTROL SYSTEM PROHIBITED: Local law or federal law prohibits the following acts or the causing thereof: • The removal or rendering inoperative by any person, other than for purposes of maintenance, repair or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use, or •...
Page 169: Evaporative Emission Control System
Emission Control Devices: 1B-5 Evaporative Emission Control System Diagram (Only for E-33) B940H21201005 “A” “B” “C” “D” I940H1120018-01 1. Fuel-vapor separator 7. EVAP canister “A”: Fuel 2. Fuel tank 8. Purge hose “B”: HC vapor 3. Fuel pump 9. EVAP purge control valve “C”: Fresh air 4.
Page 170: Schematic And Routing Diagram
1B-6 Emission Control Devices: Schematic and Routing Diagram PAIR System Hose Routing Diagram B940H21202001 “A” “ a ” “B” “A” “ a ” “ a ” “A” “ a ” “ a ” I940H1120001-03 1. PAIR control solenoid valve 5. PAIR reed valve 2.
Page 171: Evap Canister Hose Routing Diagram
Emission Control Devices: 1B-7 EVAP Canister Hose Routing Diagram (Only for E-33) B940H21202002 “F” “B” “A” “C” “B” “E” “D” I940H1120021-01 1. EVAP canister “A”: Face the white mark on the hose to backward. 2. Fuel shut-off valve “B”: Face the tip of the clip to backward. 3.
Page 172: Repair Instructions
1B-8 Emission Control Devices: Repair Instructions Heated Oxygen Sensor (HO2S) Removal and 3) Disconnect the PAIR hoses (1) and remove the PAIR reed valve covers (2). Installation B940H21206001 Removal Refer to “Exhaust Pipe / Muffler Removal and Installation in Section 1K (Page 1K-2)”. WARNING Do not remove the HO2 sensor while it is hot.
Page 173: Pair Control Solenoid Valve Removal And Installation
Emission Control Devices: 1B-9 PAIR Control Solenoid Valve Removal and PAIR System Inspection B940H21206005 Installation PAIR Hose B940H21206004 1) Remove the fuel tank. Refer to “Fuel Tank Removal Removal and Installation in Section 1G (Page 1G-9)”. 1) Remove the fuel tank. Refer to “Fuel Tank Removal 2) Remove the air cleaner chamber.
Page 174: Crankcase Breather (Pcv) Hose Inspection
1B-10 Emission Control Devices: 3) Reinstall the PAIR reed valves. Refer to “PAIR Reed 4) Check the resistance between the terminals of the Valve Removal and Installation (Page 1B-8)”. PAIR control solenoid valve. Special tool PAIR Control Solenoid Valve : 09900–25008 (Multi-circuit tester set) 1) Remove the PAIR control solenoid valve.
Page 175: Crankcase Breather (Pcv) Hose Removal And Installation
Emission Control Devices: 1B-11 Crankcase Breather (PCV) Hose Removal and Installation Installation 1) Install the EVAP hose as shown in the EVAP canister B940H21206007 hose routing diagram. Refer to “EVAP Canister Hose Removal Routing Diagram (Only for E-33) (Page 1B-7)”. 1) Remove the fuel tank.
Page 176: Evaporative Emission Control System Inspection (For E-33 Only)
1B-12 Emission Control Devices: Installation 3) Disconnect the surge hoses (2). 1) Install the EVAP system purge control solenoid valve 4) Remove the fuel shut-off valve (3). as shown in the EVAP canister hose routing diagram. Refer to “EVAP Canister Hose Routing Diagram (Only for E-33) (Page 1B-7)”.
Page 177 Emission Control Devices: 1B-13 EVAP System Purge Control Solenoid Valve 3) Check the resistance between the terminals of the EVAP system purge control solenoid valve. If the NOTE resistance is not within the standard range, replace EVAP system purge control solenoid valve the EVAP system purge control solenoid valve with a can be checked without removing it from the new one.
Page 178: Specifications
For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List in Section 0C (Page 0C-8)”. Special Tools and Equipment Recommended Service Material B940H21208001 Material SUZUKI recommended product or Specification Note Thread lock cement THREAD LOCK CEMENT SUPER P/No.: 99000–32110 (Page 1B-8)
Page 179: Engine Electrical Devices
Engine Electrical Devices: 1C-1 Engine Electrical Devices Engine Precautions Precautions for Engine Electrical Device B940H21300001 Refer to “General Precautions in Section 00 (Page 00-1)” and “Precautions for Electrical Circuit Service in Section 00 (Page 00-2)”. Component Location Engine Electrical Components Location B940H21303001 Refer to “Electrical Components Location in Section 0A (Page 0A-7)”.
Page 180: Iap Sensor Removal And Installation
• Align the throttle shaft end “A” with the groove “B” of the TP sensor. • Apply grease to the throttle shaft end “A”, if necessary. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) Special tool I940H1130027-01 : 09930–11950 (Torx wrench)
Page 181: Tp Sensor Adjustment
Engine Electrical Devices: 1C-3 TP Sensor Adjustment IAT Sensor Removal and Installation B940H21306008 B940H21306009 Inspect the TP sensor setting position and adjust it if Removal necessary in the following procedures: 1) Remove the fuel tank. Refer to “Fuel Tank Removal 1) Connect the special tool (Mode select switch) to the and Installation in Section 1G (Page 1G-9)”.
Page 182: Ect Sensor Removal And Installation
1C-4 Engine Electrical Devices: ECT Sensor Removal and Installation 6) Remove the ECT sensor (4). B940H21306010 Removal CAUTION 1) Drain engine coolant. Refer to “Cooling System Take special care when handling the ECT Inspection in Section 0B (Page 0B-11)”. sensor. It may cause damage if it gets an 2) Remove the throttle body.
Page 183: Ect Sensor Inspection
Engine Electrical Devices: 1C-5 • Apply engine coolant to the O-ring (3) and Install the 3) Heat the oil to raise its temperature slowly and read thermostat case (4). the column thermometer (3) and the ohmmeter. If the ECT sensor ohmic valve does not change in CAUTION the proportion indicated, replace it with a new one.
Page 184: To Sensor Inspection
1C-6 Engine Electrical Devices: STP Sensor Inspection 3) Remove the battery holder mounting bolts and move the battery holder as shown. B940H21306014 Refer to “DTC “C29” (P1654-H/L): Secondary Throttle Position Sensor (STPS) Circuit Malfunction in Section 1A (Page 1A-62)”. STP Sensor Adjustment B940H21306015 Adjust the STP sensor in the following procedures: 1) Move the each air cleaner box and lift and support...
Page 185: Stp Sensor Removal And Installation
Engine Electrical Devices: 1C-7 6) Close the secondary throttle valve by finger and 8) Disconnect the special tool and reinstall the removed measure the STP sensor output voltage. parts. Special tool STP Sensor Removal and Installation (A): 09900–28630 (TPS test wire harness) B940H21306016 (B): 09900–25008 (Multi-circuit tester set) Removal...
Page 186: Stv Actuator Inspection
“A”, if necessary. valve to the following procedures: 1) Turn the ignition switch ON. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) 2) Set up the SDS tool. (Refer to the SDS operation manual for further details.) Special tool 3) Click the “Active control”.
Page 187: Ho2 Sensor Inspection
Engine Electrical Devices: 1C-9 5) Click the “Reset” button (2) to clear the ISC leaned 6) Close the SDS tool and turn the ignition switch OFF. valve. NOTE The ISC valve opening initialization is automatically started after the ignition switch is turned OFF position.
Page 188: Specifications
1C-10 Engine Electrical Devices: Specifications Service Data B940H21307001 FI Sensors Item Specification Note 170 – 260 Ω CKP sensor resistance CKP sensor peak voltage 3.0 V and more When cranking IAP sensor input voltage (F & R) 4.5 – 5.5 V IAP sensor output voltage (F &...
Page 189: Special Tools And Equipment
Engine Electrical Devices: 1C-11 Special Tools and Equipment Recommended Service Material B940H21308001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010 (Page 1C-2) / (Page 1C- equivalent Special Tool B940H21308002 09900–25008 09900–28630 Multi-circuit tester set...
Page 190: Engine Mechanical
1D-1 Engine Mechanical: Engine Mechanical Engine Schematic and Routing Diagram...
Page 191: Throttle Cable Routing Diagram
Engine Mechanical: 1D-2 Throttle Cable Routing Diagram B940H21402001 “ a ” “ a ” “A” “B” “C” “D” “E” “ b ” “F” I940H1140323-06 1. Throttle cable No. 1 “A”: Pass the throttle cables behind the cable guide. Pass the brake hose in front of the cable guide.
Page 192: Diagnostic Information And Procedures
1D-3 Engine Mechanical: Diagnostic Information and Procedures Engine Mechanical Symptom Diagnosis 5) Install the compression gauge and adaptor in the B940H21404001 spark plug hole. Make sure that the connection is Refer to “Engine Symptom Diagnosis in Section 1A tight. (Page 1A-7)”. Special tool (A): 09915–64512 (Compression gauge) Compression Pressure Check...
Page 193: Repair Instructions
Engine Mechanical: 1D-4 8) Repeat this procedure from 4) to 7) with the other • Poor valve seating cylinder. • Ruptured or otherwise defective cylinder head gasket Compression pressure specification Overhaul the engine in the following cases: Standard Limit • Compression pressure in one of the cylinders is 850 –...
Page 194 1D-5 Engine Mechanical: Item Removal Inspection Installation Refer to “PAIR Reed Valve Refer to “PAIR System Refer to “PAIR Reed Valve PAIR reed valve Removal and Installation in Inspection in Section 1B Removal and Installation in Section 1B (Page 1B-8)”. (Page 1B-9)”.
Page 195: Air Cleaner Element Removal And Installation
Engine Mechanical: 1D-6 Item Removal Inspection Installation Refer to “Gear Position (GP) Refer to “Gear Position (GP) Refer to “Gear Position (GP) Switch Removal and Switch Removal and Gear position switch Switch Inspection in Section Installation in Section 5B Installation in Section 5B 5B (Page 5B-10)”.
Page 196: Air Cleaner Element Inspection And Cleaning
1D-7 Engine Mechanical: • Connect the ISC hoses (1) and ISC coupler (2). 4) Remove the following parts from the air cleaner chamber. a) IAP sensor (3) b) IAT sensor coupler (4) c) PCV hose (5) I940H1140013-03 • Tighten the air cleaner box mounting bolts to the specified torque.
Page 197 Engine Mechanical: 1D-8 Installation • Connect the ISC hoses (1) and ISC connector (2). Install the air cleaner chamber in the reverse order of removal. Pay attention to the following points: • Fit the throttle body clamps properly. Refer to “Throttle Body Construction (Page 1D-10)”.
Page 198: Throttle Body Components
1D-9 Engine Mechanical: Throttle Body Components B940H21406005 I940H1140378-01 1. TP sensor 7. Fuel injector 13. Fuel delivery pipe mounting screw : 3.5 N⋅m (0.35 kgf-m, 2.5 lbf-ft) 2. STP sensor 8. Cushion seal 14. STP sensor mounting screw : 4.5 N⋅m (0.45 kgf-m, 3.0 lbf-ft) 3.
Page 199: Throttle Body Construction
Engine Mechanical: 1D-10 Throttle Body Construction B940H21406006 #2 Cylinder #1 Cylinder “C” “ a ” “B” “C” “A” “E” “B” “D” “ b ” “A” “A” I940H1140337-04 1. PCV hose “A”: White mark “E”: Face the lip right side of motorcycle. 2.
Page 200 1D-11 Engine Mechanical: “C” “B” “A” I940H1140338-04 1. Canister (E-33 only) 4. PCV hose “C”: Face the tip of the clip to outside. 2. Canister purge valve (E-33 only) “A”: White mark 3. Purge hose (E-33 only) “B”: Match mark...
Page 201: Isc Valve Removal And Installation
Engine Mechanical: 1D-12 ISC Valve Removal and Installation • Tighten the ISC valve mounting bolts to the specified B940H21406007 torque. Removal Tightening torque CAUTION ISC valve mounting bolt (a): 4.5 N·m (0.45 kgf-m, 3.0 lbf-ft) Be careful not to disconnect the ISC valve coupler at least 5 seconds after ignition switch is turned to OFF.
Page 202 1D-13 Engine Mechanical: 5) Remove the clamp and disconnect the fuel injector 8) Disconnect the EVAP hoses (5). (For E-33) couplers (4). I940H1140028-03 I940H1140025-02 Installation 6) Loosen the throttle body clamp screws. Install the throttle body in the reverse order of removal. Pay attention to the following points: •...
Page 203: Throttle Body Disassembly And Assembly
Engine Mechanical: 1D-14 Throttle Body Disassembly and Assembly • Turn in each throttle cable adjuster fully and locate each outer cable so that the clearance “a” is 0 – 1.0 B940H21406009 Refer to “Throttle Body Removal and Installation mm (0 – 0.04 in). (Page 1D-12)”.
Page 204 • Align the secondary throttle shaft end “A” with the groove “B” of the STP sensor. • Apply grease to the secondary throttle shaft end “A”, if necessary. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I940H1140036-02 Special tool CAUTION : 09930–11950 (Torx wrench)
Page 205 Engine Mechanical: 1D-16 NOTE NOTE Make sure the STP valve open or close Make sure the throttle valve open or close smoothly. If the STP sensor adjustment is smoothly. If the TP sensor adjustment is necessary, refer to “STP Sensor Adjustment necessary, refer to “TP Sensor Adjustment in in Section 1C (Page 1C-6)”.
Page 206: Throttle Body Inspection And Cleaning
1D-17 Engine Mechanical: Throttle Body Inspection and Cleaning • Install the fuel injector (6) by pushing it straight to the delivery pipe (7). B940H21406010 Refer to “Throttle Body Disassembly and Assembly (Page 1D-14)”. CAUTION Never turn the injector while pushing it. Cleaning NOTE WARNING...
Page 207: Throttle Valve Synchronization
Engine Mechanical: 1D-18 2) Inspect the ISC valve for any carbon deposition 4) Connect the respective vacuum hoses to each defects. Clean or replace the ISC valve, if necessary. vacuum nipple on the throttle body. CAUTION Normally, the removed O-ring must be replaced with a new one.
Page 208 1D-19 Engine Mechanical: 13) Click “ON” button (3) to fix the ISC air volume among 2 cylinders. NOTE When making this synchronization, be sure that the water temperature is within 70 – 100 °C (158 – 212 °F). I940H1140374-02 14) Check for the synchronization of vacuum from #1 16) If the adjustment is not yet correct, remove each air and #2 cylinder.
Page 209: Isc Valve Reset
Engine Mechanical: 1D-20 ISC Valve Reset NOTE B940H21406012 The learned value of the ISC valve is set at When removing or replacing the throttle body assembly, RESET position. reset the ISC valve learned value in the following procedures: 1) Turn the ignition switch ON position. 2) Set up the SDS tools.
Page 210 1D-21 Engine Mechanical: 6) Remove the air cleaner chamber (1). Refer to “Air 10) Disconnect the PAIR hoses (5). Cleaner Chamber Removal and Installation (Page 1D-7)”. I940H1140345-01 11) Remove the ignition coils/plug caps. Refer to “Spark Plug Cap and Spark Plug Removal and Installation in I940H1140341-01 7) Disconnect the thermostat outlet hose (2).
Page 211 Engine Mechanical: 1D-22 13) Remove the heat shield (6). 17) Remove the secondary gear case cover and left frame lower cover. Refer to “Exterior Parts Removal and Installation in Section 9D (Page 9D-5)”. 18) Remove the regulator/rectifier (10). I940H1140346-01 14) Disconnect the starter motor lead wire (7). I940H1140349-01 19) Disconnect the generator lead wire coupler (11), regulator/rectifier lead wire coupler (12) and CKP...
Page 212 1D-23 Engine Mechanical: 22) Disconnect the clutch cable (17). 26) Remove the right frame lower cover (22). I940H1140351-01 I940H1140312-02 23) Remove the left footrest (18) along with gearshift link 27) Remove the rear brake pipe (23) from the down arm (19). tube.
Page 213: Engine Assembly Installation
Engine Mechanical: 1D-24 30) Release the lead wires. 34) Remove the engine mounting bolts, nuts and engine mounting plates (28). I940H1140358-01 31) Remove the engine mounting bolt and nut (25). I940H1140362-01 35) Remove the engine assembly. 32) Remove the frame down tube (26) by removing their bolts and nuts.
Page 214 1D-25 Engine Mechanical: • Install the engine mounting plates (1). • Install the frame down tube (2). • Insert the two mounting bolts from left side, and • Tighten the bolts and nuts to the specified torque. tighten their nuts. NOTE NOTE The frame down tube nuts are self-locking.
Page 215 Engine Mechanical: 1D-26 • After remounting the engine, route the wiring harness • Install the right footrest and rear brake master cylinder properly. Refer to “Wiring Harness Routing Diagram in assembly. Refer to “Rear Brake Master Cylinder Section 9A (Page 9A-5)”. Removal and Installation in Section 4A (Page 4A-13)”.
Page 216: Engine Top Side Disassembly
1D-27 Engine Mechanical: Engine Top Side Disassembly Cylinder Head Cover (#1 Cylinder) B940H21406015 1) Remove the spark plugs. Refer to “Spark Plug Cap It is unnecessary to remove the engine assembly from and Spark Plug Removal and Installation in Section the frame when servicing the cylinder head cover and 1H (Page 1H-4)”.
Page 217 Engine Mechanical: 1D-28 3) Remove the cam chain sprocket bolts (3) and lock 8) Remove the dowel pins (9) and O-ring (10). washer (4). 9) Remove the camshaft (11). I940H1140333-02 I940H1140076-04 4) Remove the cam chain tension adjuster cap bolt (5) 10) Remove the camshaft C-ring (12).
Page 218 1D-29 Engine Mechanical: Cylinder Head (#1 Cylinder) 2) Remove the rear cylinder gasket (3) and dowel pins. 1) Remove the rear cylinder head. NOTE Loosen the cylinder head bolts little by little diagonally with the smaller sizes first. I940H1140081-02 Rear Piston (#1 Cylinder) 1) Place a clean rag over the cylinder base so as not to drop the piston pin circlips into the crankcase.
Page 219 Engine Mechanical: 1D-30 Camshaft (#2 Cylinder) 5) Remove the cam chain sprocket (5). 1) Turn the crankshaft 486 degrees (1 – 1/3 turns) to bring the “F I T” line mark on generator rotor to the index mark of the valve inspection hole. I940H1140332-01 6) Remove the camshaft journal holder (6).
Page 220 1D-31 Engine Mechanical: Rocker Arm (#2 Cylinder) 2) Remove the front cylinder head gasket (1) and dowel pins. CAUTION Be sure to identify each removed part as to its location, and lay the parts out in groups designated as “Exhaust”, “Intake”, so that each will be restored to the original location during assembly.
Page 221: Engine Top Side Assembly
Engine Mechanical: 1D-32 Front Piston (#2 Cylinder) Rear 1) Place a clean rag over the cylinder base so as not to drop the piston pin circlips into the crankcase. 2) Remove the piston pin circlip (1). 3) Draw out the piston pin (2) and remove the piston (3).
Page 222 • Hold the piston rings in proper positions, and insert • Apply bond lightly to the mating surface of crankcase. each of the pistons into the respective cylinders. : Sealant 99000–31110 (SUZUKI BOND NOTE No.1215 or equivalent) The cylinders can be distinguished by the •...
Page 223 Engine Mechanical: 1D-34 Cylinder Head • Place the cylinder heads on the cylinders. • Pull the cam chains out of the cylinders and install the NOTE cam chain guides (1). • The cylinder heads can be distinguished • Fit the dowel pins and a new cylinder head gaskets by the embossed-letters, “F”...
Page 224 1D-35 Engine Mechanical: • Install the C-rings. Front I940H1140096-01 I940H1140093-02 • The camshafts are identified by the embossed letters. I.D. mark Rear Front (#2) Rear (#1) • Before replacing the camshafts on cylinder head, apply molybdenum oil solution to their journals and cam faces.
Page 225 Engine Mechanical: 1D-36 • Temporally install the cam chain sprockets and align • Bend up the washer tongue positively to lock the the arrow marks on the front and rear camshafts so it bolts. is parallel with the surface of the cylinder heads. NOTE Each arrow mark points to forward, when the rear piston is at TDC.
Page 226 Align the groove “A” of the rocker arm shafts and holes “B” of the camshaft journal. I940H1140110-01 • Apply grease to the new O-rings. CAUTION I940H1140115-01 Replace the O-rings with new ones. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) “C” “A” “D” “B” I940H1140111-01 “A”...
Page 227 Engine Mechanical: 1D-38 • The rear cam chain tension adjuster are identified by • Tighten the cam chain tension adjuster cap bolt (7) to the embossed letters (R-UP). the specified torque. • Retract the push rod by pushing the stopper (2). Tightening torque Cam chain tension adjuster cap bolt (b): 23 N·m ( 2.3 kgf-m, 16.5 lbf-ft)
Page 228 1D-39 Engine Mechanical: • The front cam chain tension adjuster are identified by • Tighten the cam chain tension adjuster cap bolt (13) the embossed letters (F-UP). to the specified torque. • Retract the push rod by pushing the stopper (8). Tightening torque Cam chain tension adjuster cap bolt (d): 23 N·m ( 2.3 kgf-m, 16.5 lbf-ft)
Page 229 Spark Plug shown in the figure. Install the spark plugs. Refer to “Spark Plug Cap and Spark Plug Removal and Installation in Section 1H : Sealant 99000–31140 (SUZUKI BOND (Page 1H-4)”. No.1207B or equivalent) Thermostat • Apply engine coolant to the O-ring.
Page 230: Valve Clearance Inspection And Adjustment
Use a new O-ring to prevent mixture air from soaking through the joint. Camshaft Identification The camshafts can be identified by the engraved letter. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) NOTE Face the “UP” mark on the intake pipe to upper.
Page 231 Engine Mechanical: 1D-42 Camshaft Journal Wear 5) This measurement should be taken at the widest Inspect the camshaft journal wear in the following part of the compressed plastigauge. procedures: Camshaft journal oil clearance (IN. & EX.) 1) Determine whether or not each journal is worn down Service limit: 0.150 mm (0.0059 in) to the limit by measuring the oil clearance with the camshaft installed in place.
Page 232: Automatic-Decomp. Inspection
1D-43 Engine Mechanical: Automatic Decompression Move the automatic decompression weight by hand to inspect if it is operating smoothly. If it does not operate smoothly, replace the camshaft/automatic “ a ” decompression assembly with a new one. “ b ” CAUTION Do not attempt to disassemble the cam sprockets and automatic-decomp.
Page 233: Cylinder Head Cover Disassembly And Assembly
CAUTION 1) Remove the head cover brackets (1) and (2), left and Replace the O-rings (1) with new ones. right. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I940H1140134-01 2) Remove the PAIR read valve cover (3) and PAIR read valve (4).
Page 234: Pair Reed Valve / Pair Reed Valve Cover Inspection
1D-45 Engine Mechanical: 5) Install the cylinder head cover brackets, left and Water jacket plug (Cylinder head) right. Remove the water jacket plug (1) (for front and rear cylinder). 6) Tighten the cylinder head cover bracket bolts (3). Tightening torque Cylinder head cover bracket bolt (b): 10 N·m (1.0 kgf-m, 7.0 lbf-ft) I940H1140142-01...
Page 235 Engine Mechanical: 1D-46 4) Remove the oil seal (6) and spring seat (7). I705H1140165-01 • Install the valve springs with the small-pitch portion “A” facing cylinder head. I940H1140145-01 “D” “D” Assembly Assembly is in the reverse order of disassembly. Pay attention to the following points: “B”...
Page 236: Cylinder Head Related Parts Inspection
1D-47 Engine Mechanical: Cylinder Head Related Parts Inspection • Be sure that the rounded lip “E” of the cotter fits snugly into the groove “F” in the stem end. B940H21406025 Refer to “Cylinder Head Disassembly and Assembly (Page 1D-45)”. “F” “E”...
Page 237 Engine Mechanical: 1D-48 3) Install each rocker arm inside diameter using the dial Valve Stem Runout caliper. Support the valve using V-blocks, and check its runout using the dial gauge as shown in the figure. If the runout Special tool exceeds the service limit, replace the valve.
Page 238 1D-49 Engine Mechanical: Valve Stem / Valve Face Wear Condition Special tool Visually inspect each valve stem and valve face for wear (A): 09900–20205 (Micrometer (0 – 25 mm)) and pitting. If it is worn of damaged, replace the valve Valve stem O.D.
Page 239: Valve Guide Replacement
Engine Mechanical: 1D-50 3) Rotate the valve with light pressure. Special tool (A): 09916–10911 (Valve lapper set) I940H1140159-02 NOTE After servicing the valve seats, be sure to I940H1140158-01 check the valve clearance after the cylinder 4) Check that the transferred red lead (Blue) on the head has been reinstalled.
Page 240 1D-51 Engine Mechanical: 4) Refinish the valve guide holes in the cylinder head using the reamer and handle. CAUTION When refinishing or removing the reamer from the valve guide hole, always turn it clockwise. “a” Special tool (B): 09916–34580 (Valve guide reamer (10.8 mm)) I940H1140161-02 (C): 09916–34542 (Reamer handle)
Page 241: Valve Seat Repair
Engine Mechanical: 1D-52 9) Install the valves and springs. Refer to “Cylinder Valve Spring Head Disassembly and Assembly (Page 1D-45)”. The force of the coil spring keeps the valve seat tight. Weakened spring results in reduced engine power 10) Install the cylinder head. Refer to “Engine Top Side output and often accounts for the chattering noise Assembly (Page 1D-32)”.
Page 242: Cam Chain Guide Inspection
1D-53 Engine Mechanical: Cam Chain Guide Inspection Cylinder Bore B940H21406028 Check the cylinder wall for any scratches, nicks or other Inspect the cam chain guide in the following procedures: damage. 1) Remove the cam chain guides. Refer to “Engine Top Cylinder bore Side Disassembly (Page 1D-27)”.
Page 243 Engine Mechanical: 1D-54 Installation b) Install the 2nd ring (3) and 1st ring (4) to piston. NOTE NOTE • When installing the piston ring, be careful • 1st ring has letters “IT” marked on the not to damage the piston. side.
Page 244: Piston And Piston Ring Inspection
1D-55 Engine Mechanical: Piston and Piston Ring Inspection Piston Ring-to-groove Clearance B940H21406031 Measure the side clearances of the 1st and 2nd piston Refer to “Piston Ring Removal and Installation rings using the thickness gauge. If any of the clearances (Page 1D-53)”. exceed the limit, replace both the piston and piston rings.
Page 245: Engine Bottom Side Disassembly
Engine Mechanical: 1D-56 Piston Ring Free End Gap and Piston Ring End Gap Measure the piston ring free end gap using vernier calipers. Next, fit the piston ring squarely into the cylinder and measure the piston ring end gap using the thickness gauge.
Page 246 1D-57 Engine Mechanical: Clutch Release Assembly / Push Rod Starter Driven Gear / Starter Torque Limiter / Starter Remove the clutch release assembly and push rod. Idle Gear Refer to “Clutch Release Assembly / Push Rod Removal • Remove the key (1) and starter driven gear (2). and Installation in Section 5C (Page 5C-2)”.
Page 247 Engine Mechanical: 1D-58 Clutch / Secondary Drive Gear 5) Loosen the secondary drive gear bolt (5) and remove the secondary drive gear (6) and shim (7). 1) Remove the clutch drive plates (1) and driven plates (2). Refer to “Clutch Removal in Section 5C (Page 5C- 6)”.
Page 248 1D-59 Engine Mechanical: 9) Remove the needle roller bearing (12), spacer (13) Oil Pump Drive Gear / Oil Pressure Regulator and washer (14). 1) Remove the oil pressure regulator (1). 2) Remove the snap ring (2) and oil pump driven gear (3).
Page 249 Engine Mechanical: 1D-60 2) Draw out the gearshift shaft assembly (3) and Oil Filter washer (4). Remove the oil filter with the special tool. Special tool (A): 09915–40620 (Oil filter wrench) I940H1140189-01 3) Remove the gearshift cam plate bolt (5) and gearshift cam plate (6).
Page 250 1D-61 Engine Mechanical: Crankcase 3) Remove the O-rings (1) and dowel pins (2). 1) Remove the crankcase bolts. NOTE Loosen the crankcase bolts diagonally with the smaller sizes first. I940H1140200-01 I940H1140197-01 2) Make sure that all of the bolts are removed. Then, tap the sides of the right crankcase using a plastic hammer to separate the left and right crankcase halves and then lift the right crankcase off of the left...
Page 251 Engine Mechanical: 1D-62 Oil Pump / Oil Sump Filter Oil Jet Remove the oil pump assembly (1) and oil sump filter 1) Remove the piston cooling jets (1) and oil jet (2). Refer to “Oil Pump Removal and Installation in (secondary gear) (2) from the each crankcase.
Page 252 1D-63 Engine Mechanical: Oil Gallery Plug NOTE 1) Remove the oil gallery plugs (1) from the right • Do not remove the crankshaft journal crankcase. bearings unless absolutely necessary. • Make a note of where the crankshaft journal bearings are removed from so that they can be reinstalled in their original positions.
Page 253: Engine Bottom Side Assembly
Engine Mechanical: 1D-64 Engine Bottom Side Assembly B940H21406033 Assembly the engine bottom side in the reverse of disassembly. Pay attention to the following points: NOTE Apply engine oil to each running and sliding part before reassembling. Oil Gallery Plug CAUTION Use each new gasket.
Page 254 1D-65 Engine Mechanical: • Fit the new O-ring (3) to each piston cooling oil jets • Apply molybdenum oil solution to the thrust bearing. and apply engine oil to them. M/O: Molybdenum oil (MOLYBDENUM OIL SOLUTION) • Insert the thrust bearing with oil groove “A” facing the crank web.
Page 255 • Apply grease to the O-ring. CAUTION Use the new O-ring to prevent oil pressure leak. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) • Install the dowel pins and O-ring in the left crankcase. I940H1140223-01 • Apply bond to the mating surface of the lower crankcase.
Page 256 Be careful not to apply bond to the hole of thread end. NOTE Fit the new copper washers “A” and lead wire : Sealant 99000–31140 (SUZUKI BOND “B” to the crankcase bolts. No.1207B or equivalent) Tightening torque Tightening torque Oil pressure switch (a): 14 N·m (1.4 kgf-m, 10 lbf-ft)
Page 257 Special tool : 09900–06107 (Snap ring pliers) NOTE Align the gear position switch pin “A” with the gearshift cam hole “B”. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) “A” “B” I940H1140233-01 • Apply grease to the O-rings and pass in the oil pressure regulator (5) to the lower crankcase.
Page 258 1D-69 Engine Mechanical: Gearshift System • Apply thread lock to the gearshift arm stopper (1) and tighten it to the specified torque. : Thread lock cement 99000–32030 (THREAD LOCK CEMENT SUPER 1303 or equivalent) “A” Tightening torque Gearshift arm stopper (a): 19 N·m (1.9 kgf-m, 13.5 lbf-ft) I940H1140320-01 •...
Page 259 Engine Mechanical: 1D-70 • Install the gearshift cam shaft assembly (8). • Apply thread lock to the bolts and tighten its to the specified torque. NOTE : Thread lock cement 99000–32030 Pinch the gearshift arm stopper (1) with (THREAD LOCK CEMENT SUPER 1303 or return spring ends “D”.
Page 260 1D-71 Engine Mechanical: Clutch / Secondary Drive Gear • Install the clutch sleeve hub. Refer to “Clutch Installation in Section 5C (Page 5C-8)”. NOTE It is difficult to install the primary driven gear, rotate the crankshaft. • Shift the transmission into 1st gear. •...
Page 261 When install the water pump, fit the convex part “A” of the oil pump shaft onto the concave part “B” of the water pump shaft. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I940H1140250-01 • Install the key (1).
Page 262: Cam Chain Tensioner Inspection
• Apply grease to the O-ring. 1) Remove the cam chain tensioner. Refer to “Engine Bottom Side Disassembly (Page 1D-56)” and : Grease 99000–25010 (SUZUKI SUPER “Engine Bottom Side Assembly (Page 1D-64)”. GREASE A or equivalent) 2) Check the contacting surface of the cam chain CAUTION tensioner.
Page 263: Conrod Removal And Installation
Engine Mechanical: 1D-74 Conrod Removal and Installation Installation B940H21406035 1) When installing the bearings into the conrod cap and Removal conrod, be sure to fix the stopper part “A” first, and 1) Remove the crankshaft assembly from the then press in the opposite side of the bearing. crankcase.
Page 264: Conrod / Crankshaft Inspection
1D-75 Engine Mechanical: 4) Apply engine oil to the conrod cap bolts. 5) Tighten the conrod cap bolts as following two steps. Tightening torque Conrod cap bolt: 35 N⋅m (3.5 kgf-m, 25.5 Ib-ft) then turn in 1/4 (90°) turn I940H1140261-01 Conrod Big End Side Clearance 1) Check the conrod big end side clearance using the thickness gauge.
Page 265: Conrod Crank Pin Bearing Inspection And Selection
Engine Mechanical: 1D-76 Conrod Crank Pin Bearing Inspection and Selection B940H21406037 Refer to “Conrod Removal and Installation (Page 1D- 74)”. Inspection “A” 1) Inspect the bearing surfaces for any signs of fusion, pitting, burn or flaws. If any, replace them with a specified set of bearings.
Page 266: Crankshaft Bearing Inspection And Adjustment
1D-77 Engine Mechanical: 2) Check the corresponding crank pin O.D. code Bearing thickness specification numbers ([1], [2] or [3]) “B”. Color “C” (Part No.) Thickness Green 1.480 – 1.484 mm (12164-40H00-0A0) (0.0583 – 0.0584 in) Black 1.484 – 1.488 mm “B”...
Page 267: Crankshaft Bearing Replacement
Engine Mechanical: 1D-78 2) Measure the crankshaft journal O.D. with the special 5) If each crankshaft journal oil clearance is not within tool. the standard range, replace crankshaft journal bearings with new ones. Special tool (A): 09900–20203 (Micrometer (1/100 mm, CAUTION 50 –...
Page 268 1D-79 Engine Mechanical: • Gradually press out the bearing (1) with the special • Tighten the special tool bolt to the specified torque. tool by using the hydraulic press. Tightening torque Special tool bolt (a): 23 N·m (2.3 kgf-m, 16.5 lbf-ft) CAUTION The removed bearings must be replaced with new ones.
Page 269: Crankshaft Thrust Clearance Inspection And Adjustment
Engine Mechanical: 1D-80 • Apply enough engine oil to the special tool and the • After installing the bearings, check the bearing bearings and then set the special tool carefully. surface for any scratch or damage. • Gradually press in the bearing (1) into the main journal bore by using the hydraulic press until the special tool (2) stops the special tool (3).
Page 270 1D-81 Engine Mechanical: NOTE 2) Place the thrust washer, camshaft drive sprocket and primary drive gear on the right end of the crankshaft Pull the crankshaft to the right (Primary and tighten primary drive gear bolt (2) to the driven gear side) so that there is no specified torque.
Page 271: Specifications
Engine Mechanical: 1D-82 2) Select a thrust bearing from the selection table. Thrust bearing selection table Part No. Thrust bearing thickness Thrust clearance 1.925 – 1.950 mm 0.100 – 0.150 mm (12228-40H00-0A0) (0.0758 – 0.0768 in) (0.0040 – 0.0059 in) 1.950 –...
Page 272 1D-83 Engine Mechanical: Camshaft + Cylinder Head Unit: mm (in) Item Standard Limit 33.060 – 33.110 (1.3016 – 1.3035) 32.760 (1.2898) Cam height 33.110 – 33.160 (1.304 – 1.306) 32.810 (1.2917) Camshaft journal oil clearance IN. & EX. 0.032 – 0.066 (0.0013 – 0.0026) 0.150 (0.0059) Sprocket 22.012 –...
Page 273: Tightening Torque Specifications
Engine Mechanical: 1D-84 Tightening Torque Specifications B940H21407002 Tightening torque Fastening part Note N⋅m kgf-m lbf-ft Air cleaner box mounting bolt 0.55 (Page 1D-7) ISC valve mounting bolt 0.45 (Page 1D-12) STP sensor mounting screw 0.35 (Page 1D-15) TP sensor mounting screw 0.35 (Page 1D-16) Fuel delivery pipe mounting screw...
Page 274: Special Tools And Equipment
1D-85 Engine Mechanical: Special Tools and Equipment Recommended Service Material B940H21408001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010 (Page 1D-15) / equivalent (Page 1D-37) / (Page 1D-41) / (Page 1D-44) / (Page 1D-66) /...
Page 275 Engine Mechanical: 1D-86 Special Tool B940H21408002 09900–06107 09900–20101 Snap ring pliers Vernier calipers (1/15 mm, 150 mm) (Page 1D-59) / (Page 1D-56) (Page 1D-68) 09900–20102 09900–20202 Vernier calipers (1/20 mm, Micrometer (1/100 mm, 25 – 200 mm) 50 mm) (Page 1D-52) (Page 1D-41) 09900–20203 09900–20204...
Page 276 1D-87 Engine Mechanical: 09900–21304 09900–22301 V-block (100 mm) Plastigauge (0.025 – 0.076 (Page 1D-43) / (Page 1D-42) / (Page 1D-48) / (Page 1D-76) (Page 1D-48) 09900–22302 09900–22403 Plastigauge (0.051 – 0.152 Small bore gauge (18 – 35 (Page 1D-42) (Page 1D-42) / (Page 1D-56) / (Page 1D-75) 09913–10130...
Page 277 Engine Mechanical: 1D-88 09916–44920 09916–84511 Valve guide installer Tweezers attachment (Page 1D-51) (Page 1D-45) / (Page 1D-46) 09920–31020 09920–53740 Extension handle Clutch sleeve hub holder (Page 1D-58) / (Page 1D-58) / (Page 1D-71) (Page 1D-71) 09930–11950 Torx wrench (Page 1D-15) / (Page 1D-15) / (Page 1D-16)
Page 278: Engine Lubrication System
1E-1 Engine Lubrication System: Engine Lubrication System Engine Precautions Precautions for Engine Oil B940H21500001 Refer to “Fuel and Oil Recommendation in Section 0A (Page 0A-3)”. Schematic and Routing Diagram Engine Lubrication System Chart Diagram B940H21502001 SECONDARY CLUTCH PLATES BEVEL GEARS AND BEARING ROCKER ARM (IN) CLUTCH...
Page 279: Diagnostic Information And Procedures
Engine Lubrication System: 1E-2 Diagnostic Information and Procedures Engine Lubrication Symptom Diagnosis B940H21504001 Condition Possible cause Correction / Reference Item Engine overheats Insufficient amount of engine oil. Check level and add. Defective oil pump. Replace. Clogged oil circuit. Clean. Clogged oil cooler Clean or replace.
Page 280: Repair Instructions
Engine Oil Level Inspection CAUTION B940H21506002 Refer to “Engine Oil and Filter Replacement in Section Use new O-rings to prevent oil leakage. 0B (Page 0B-8)”. : Grease 99000–25010 (SUZUKI SUPER Oil Pressure Regulator Removal and GREASE A or equivalent) Installation B940H21506003 Removal 1) Drain engine oil.
Page 281: Oil Sump Filter Removal And Installation
Engine Lubrication System: 1E-4 Oil Sump Filter Removal and Installation B940H21506004 “B” Removal 1) Remove the engine assembly from the frame. Refer to “Engine Assembly Removal in Section 1D Downside “A” (Page 1D-20)”. 2) Disassemble the engine top side. Refer to “Engine Top Side Disassembly in Section 1D (Page 1D-27)”.
Page 282: Oil Pressure Switch Removal And Installation
Installation 1) Install the oil pressure switch (1), apply the bond to its thread part and tighten it to the specified torque. : Sealant 99000–31140 (SUZUKI BOND No.1207B or equivalent) Tightening torque Oil pressure switch (a): 14 N·m (1.4 kgf-m, 10.0...
Page 283 Engine Lubrication System: 1E-6 Installation Oil Jet (For Piston Cooling) Installation is in the reverse order of removal. Pay Removal attention to the following point: 1) Remove the engine assembly. Refer to “Engine • Apply engine oil to the O-ring. Bottom Side Disassembly in Section 1D (Page 1D- 56)”.
Page 284 1E-7 Engine Lubrication System: • Tighten the oil jet plate bolts securely. Installation Installation is in the reverse order of removal. Pay attention to the following points: • Apply engine oil to the O-ring. CAUTION Use a new O-ring to prevent oil leakage. I940H1150024-01 Oil Jet (For Transmission) Removal...
Page 285: Oil Jet Inspection
Engine Lubrication System: 1E-8 • Tighten the oil gallery plug (2) to the specified torque. Installation Installation is in the reverse order of removal. Pay CAUTION attention to the following points: Use a new gasket to prevent oil leakage. • Apply engine oil to the O-ring. CAUTION Tightening torque Oil gallery plug (M8) (b): 18 N·m (1.8 kgf-m, 13.0...
Page 286: Oil Pump Removal And Installation
1E-9 Engine Lubrication System: Oil Pump Removal and Installation • Apply engine oil to the oil pump sliding surface of the B940H21506010 oil pump outer rotor (2). Removal • Check the punch marks “C” of the rotors faces 1) Separate the crankcase. Refer to “Engine Bottom outside.
Page 287: Oil Pump Inspection
Engine Lubrication System: 1E-10 • Tighten the oil pump mounting bolts. I940H1150040-01 3) Install the oil pump. Refer to “Oil Pump Removal and I940H1150039-01 • Assemble the engine. Refer to “Engine Bottom Side Installation (Page 1E-9)”. Assembly in Section 1D (Page 1D-64)” and “Engine Top Side Assembly in Section 1D (Page 1D-32)”.
Page 288: Tightening Torque Specifications
For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List in Section 0C (Page 0C-8)”. Special Tools and Equipment Recommended Service Material B940H21508001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010 (Page 1E-3)
Page 289: Engine Cooling System
Engine Cooling System: 1F-1 Engine Cooling System Engine Precautions Precautions for Engine Cooling System B940H21600001 WARNING • You can be injured by boiling fluid or steam if you open the radiator cap when the engine is hot. After the engine cools, wrap a thick cloth around cap and carefully remove the cap by turning it a quarter turn to allow pressure to escape and then turn the cap all the way off.
Page 290: Engine Coolant Description
1F-2 Engine Cooling System: Schematic and Routing Diagram Cooling Circuit Diagram B940H21602001 RESERVOIR ENGINE COOLANT THERMOSTAT TANK CYLINDER HEAD TEMPERATURE SENSOR CYLINDER RADIATOR WATER PUMP I822H1160053-01...
Page 291: Water Hose Routing Diagram
Engine Cooling System: 1F-3 Water Hose Routing Diagram B940H21602002 “ a ” “K” “B” “D” “A” “C” “E” “N” “D” “D” “C” “F” “M” “H” “H” “I” “D” “G” “L” “F” “D” “H” “F” “H” INSIDE “C” Except for E-33 INSIDE “J”...
Page 292: Diagnostic Information And Procedures
1F-4 Engine Cooling System: Diagnostic Information and Procedures Engine Cooling Symptom Diagnosis B940H21604001 Condition Possible cause Correction / Reference Item Engine overheats Not enough engine coolant. Add engine coolant. Radiator core clogged with dirt or scale. Clean. Faulty cooling fan. Repair or replace.
Page 293: Radiator Cap Inspection
Engine Cooling System: 1F-5 Radiator Cap Inspection Radiator Cleaning B940H21606002 Blow out any foreign matter that is stuck in the radiator Inspect the radiator cap in the following procedures: fins using compressed air. 1) Remove the radiator cap. Refer to “Cooling Circuit CAUTION Inspection (Page 1F-4)”.
Page 294: Water Hose Inspection
1F-6 Engine Cooling System: 4) Remove the radiator cover (1). Installation Install the radiator in the reverse order of removal. Pay attention to the following points: • Apply thread lock to the cooling fan mounting bolts (1) and tighten them to the specified torque. : Thread lock cement 99000–32110 (THREAD LOCK CEMENT SUPER 1322 or equivalent)
Page 295: Water Hose Removal And Installation
Engine Cooling System: 1F-7 Radiator Reservoir Tank Inspection 4) Any leakage from the connecting section should be corrected by proper tightening. Refer to “Water Hose B940H21606007 Inspect the radiator reservoir tank in the following Routing Diagram (Page 1F-3)”. procedures: 1) Remove the left frame lower cover and secondary gear case cover.
Page 296: Cooling Fan Inspection
1F-8 Engine Cooling System: Installation NOTE Install radiator reservoir tank in the reverse order of • When making this test, it is not necessary removal. Pay attention to the following point: to remove the cooling fan. • Fill the reservoir tank to the upper level “A”. Refer to •...
Page 297: Ect Sensor Removal And Installation
Engine Cooling System: 1F-9 4) First check the insulation between “A” and “B” 5) Remove the thermostat (3). terminals with tester. Then apply 12 V to “C” and “D” terminals, (+) to “C” and (–) to “D”, and check the continuity between “A”...
Page 298: Thermostat Inspection
1F-10 Engine Cooling System: Thermostat Inspection 6) Read the thermometer just when opening the B940H21606014 thermostat. If this reading, which is the temperature Inspect the thermostat in the following procedures: level at which the thermostat valve begins to open, is 1) Remove the thermostat.
Page 299: Water Pump Components
Engine Cooling System: 1F-11 Water pump Components B940H21606015 I940H1160050-02 1. Connector 6. Mechanical seal : Apply engine coolant. 2. O-ring 7. Oil seal : Apply molybdenum oil solution. 3. Water pump case 8. O-ring : Do not reuse. 4. O-ring : 5.5 N⋅m (0.55 kgf-m, 4.0 Ibf-ft) 5.
Page 300 Replace the O-ring with the a new one. 11)”. • Bleed air from the cooling circuit. Refer to “Cooling : Grease 99000–25010 (SUZUKI SUPER System Inspection in Section 0B (Page 0B-11)”. GREASE A or equivalent) • Install the water pump assembly with the slot on the pump shaft end “A”...
Page 301: Water Pump Disassembly And Assembly
Engine Cooling System: 1F-13 Water Pump Disassembly and Assembly 6) Remove the mechanical seal ring (8) and rubber B940H21606017 seal (9) from the impeller assembly. Refer to “Water Pump Removal and Installation (Page 1F-11)”. Disassembly 1) Disconnect the water hoses. 2) Remove the connector (1) and water pump case (2).
Page 302 “A” I940H1160037-01 I940H1160035-01 2) Apply a small quantity of grease to the oil seal lip. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I940H1160038-01 4) Install the rubber seal (1) into the impeller. 5) After wiping off the oily or greasy matter from the mechanical seal ring (2), install it into the impeller.
Page 303: Water Pump Related Parts Inspection
Engine Cooling System: 1F-15 6) Apply molybdenum solution to the impeller shaft (3). 9) Fit the water pump case and tighten the water pump case screws to the specified torque. M/O: Molybdenum oil (MOLYBDENUM OIL SOLUTION) Tightening torque Water pump case screw (a): 5.5 N·m (0.55 kgf- m, 4.0 lbf-ft) I940H1160040-01 7) Install the impeller (4).
Page 304: Specifications
1F-16 Engine Cooling System: Impeller / Shaft Impeller Shaft Journal Visually inspect the impeller and its shaft for damage. Visually inspect the journal for damage or scratch. Replace the impeller or shaft if necessary. Replace the water pump body if necessary. I940H1160046-01 I940H1160047-01 Specifications...
Page 305: Tightening Torque Specifications
For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List in Section 0C (Page 0C-8)”. Special Tools and Equipment Recommended Service Material B940H21608001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010 (Page 1F-12) /...
Page 306: Fuel System
1G-1 Fuel System: Fuel System Engine Precautions Precautions for Fuel System B940H21700001 WARNING • Keep away from fire or spark. • During disassembling, use care to minimize spillage of gasoline. • Spilled gasoline should be wiped off immediately. • Work in a well-ventilated area. CAUTION •...
Page 307: General Description
Fuel System: 1G-2 General Description Fuel System Description B940H21701001 Fuel System The fuel delivery system consists of the fuel tank (1), fuel pump (2), fuel feed hose (3), fuel delivery pipe (4) (including fuel injectors), fuel pressure regulator (5) and fuel filter (6). There is no fuel return hose. The fuel in the fuel tank (1) is pumped up by the fuel pump (2) and pressurized fuel flows into the injector (7) installed in the fuel delivery pipe (4).
Page 308: Schematic And Routing Diagram
1G-3 Fuel System: Schematic and Routing Diagram Fuel Tank Breather Hose Routing Diagram B940H21702001 “B” “D” “B” “A” “C” Inside Outside I940H1170036-01 1. Fuel tank breather hose “A”: White mark 2. Fuel tank breather valve “B”: Face the tip of the clip lower. 3.
Page 309: Diagnostic Information And Procedures
Fuel System: 1G-4 Diagnostic Information and Procedures Fuel System Diagnosis B940H21704001 Condition Possible cause Correction / Reference Item Engine will not start or is Clogged fuel filter or fuel hose. Clean or replace. hard to start (No fuel Defective fuel pump. Replace.
Page 310: Repair Instructions
1G-5 Fuel System: Repair Instructions Fuel Pressure Inspection 4) Turn the ignition ON and check for fuel pressure. B940H21706001 Fuel pressure WARNING Approx. 300 kPa (3.0 kgf/cm , 43 psi) • Keep away from fire or spark. If the fuel pressure is lower than the specification, •...
Page 311: Fuel Discharge Amount Inspection
Fuel System: 1G-6 Fuel Discharge Amount Inspection 6) Connect a proper lead wire into the fuel pump lead B940H21706003 wire coupler (fuel pump side) and apply 12 V to the WARNING fuel pump (between (+) R wire and (–) B wire) for 10 seconds and measure the amount of fuel •...
Page 312: Fuel Hose Inspection
1G-7 Fuel System: Fuel Hose Inspection 3) First, check for insulation with the tester between terminals “A” and “B”. Next, check for continuity B940H21706005 Refer to “Fuel Line Inspection in Section 0B (Page 0B- between “A” and “B” with 12 V voltage applied, 7)”.
Page 313: Fuel Tank Construction
Fuel System: 1G-8 Fuel Tank Construction B940H21706009 OUTSIDE “ a ” I940H1170032-06 1. Clamp 4. Wiring harness 7. Cushion “a”: 45° ± 5° 2. Fuel tank 5. Fuel tank bracket 3. Fuel tank cap 6. Fuel tank cushion...
Page 314: Fuel Tank Removal And Installation
1G-9 Fuel System: Fuel Tank Removal and Installation 4) Place a rag under the fuel feed hose and disconnect B940H21706010 the fuel feed hose (1). Removal CAUTION When removing the fuel tank, do not leave WARNING the fuel feed hose (1) on the fuel pump side. •...
Page 315 Fuel System: 1G-10 8) Remove the fuel tank. • Connect the fuel feed hose (1) until it locks securely (a click is heard). CAUTION Be careful not to scratch the radiator cap. Installation Install the fuel tank in the reverse order of removal. Pay attention to the following points: CAUTION •...
Page 316: Fuel Pump Components
1G-11 Fuel System: Fuel Pump Components B940H21706011 I940H1170035-02 1. Filter cover 5. Fuel pressure regulator assembly : Apply engine oil. 2. Fuel mesh filter 6. Fuel level gauge : Apply grease. 3. Fuel pump 7. O-ring : Do not reuse. 4.
Page 317: Fuel Pump Assembly / Fuel Level Gauge Removal And Installation
Fuel System: 1G-12 Fuel Pump Assembly / Fuel Level Gauge 5) Remove the fuel level gauge (4) while pushing the pawl end “A”. Removal and Installation B940H21706012 CAUTION Removal Do not pull the lead wire when removing the fuel gauge. WARNING •...
Page 318: Fuel Pump Disassembly And Assembly
• Apply grease to the O-ring (2). 2) Remove the hose (2), clamp (3) and filter cover (4). CAUTION Replace the O-ring with a new one. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I940H1170022-03 3) Remove the fuel mesh filter (5).
Page 319: Fuel Mesh Filter Inspection
Fuel System: 1G-14 Assembly • Apply thin coat of the engine oil to the bushing. Refer to “Fuel Mesh Filter Inspection (Page 1G-14)”. • Install the fuel pump (1). Assemble the fuel tank pump in the reverse order of the disassembly.
Page 320: Fuel Injector Inspection And Cleaning
1G-15 Fuel System: Fuel Injector Inspection and Cleaning Installation B940H21706016 1) Install the fuel shut-off valve as shown in the Fuel Inspect the fuel injector in the following procedures: tank breather hose routing diagram. Refer to “Fuel 1) Remove the fuel injector. Refer to “Throttle Body Tank Breather Hose Routing Diagram (Page 1G-3)”.
Page 321: Specifications
Fuel System: 1G-16 Specifications Service Data B940H21707001 Injector + Fuel Pump + Fuel Pressure Regulator Item Specification Note 11 – 13 Ω at 23 °C (73 °F) Injector resistance 168 ml and more (5.7/5.9 US/lmp oz) Fuel discharge amount for 10 seconds at 300 kPa (3.0 kgf/cm , 43 psi) Fuel pressure regulator operating Approx.
Page 322: Special Tools And Equipment
1G-17 Fuel System: Special Tools and Equipment Recommended Service Material B940H21708001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010 (Page 1G-13) equivalent NOTE Required service material is also described in the following. “Fuel Pump Components (Page 1G-11)”...
Page 323: Ignition System
Ignition System: 1H-1 Ignition System Engine Schematic and Routing Diagram Ignition System Diagram B940H21802001 Refer to “Wire Color Symbols in Section 0A (Page 0A-5)”. Engine stop switch Side-stand #1 (R) relay Power source circuit Fuse sensor Waveform arrangement Ignition switch circuit #2 (F) Fuse...
Page 324: Diagnostic Information And Procedures
1H-2 Ignition System: Diagnostic Information and Procedures Ignition System Symptom Diagnosis B940H21804001 Condition Possible cause Correction / Reference Item Spark plug not sparking Damaged spark plugs. Replace. Fouled spark plugs. Clean or replace. Wet spark plugs. Clean and dry or replace. Defective ignition coil/plug caps.
Page 325: No Spark Or Poor Spark
Ignition System: 1H-3 No Spark or Poor Spark B940H21804002 Troubleshooting NOTE Check that the transmission is in neutral and the engine stop switch is in the “RUN” position. Grasp the clutch lever. Check that the fuse is not blown and the battery is fully-charged before diagnosing. Step Action Check the ignition system couplers for poor connections.
Page 326: Repair Instructions
1H-4 Ignition System: Repair Instructions Spark Plug Cap and Spark Plug Removal and Installation Install the spark plugs and spark plug caps in the reverse Installation order of removal. Pay attention to the following points: B940H21806001 Removal • Screw the spark plugs into the cylinder head with fingers, and then tighten them to the specified torque.
Page 327: Ignition Coil Construction
Ignition System: 1H-5 Ignition Coil Construction B940H21806002 “ a ” I940H1180017-01 1. Clamp 4. Cushion : Clamp the high tension code so it does not contact to the cylinder head cover cap. : Align both edges of cushion when adhering it. 2.
Page 328: Ignition Coil Removal And Installation
1H-6 Ignition System: Ignition Coil Removal and Installation 3) Move the rear brake reservoir tank (1) by removing B940H21806003 the mounting bolt. Removal 4) Disconnect the #2 ignition coil lead wire coupler (2). #1 cylinder 1) Turn the ignition switch OFF. 2) Remove the fuel tank.
Page 329: Ignition Coil And Plug Cap Inspection
Ignition System: 1H-7 Ignition Coil and Plug Cap Inspection B940H21806005 Refer to “Electrical Components Location in Section 0A (Page 0A-7)”. (–) Ignition Coil Primary Peak Voltage Inspect the multi-circuit tester with peak voltage adaptor “B” as procedures: 1) Connect new spark plug to each spark plug cap and ground them to the cylinder head.
Page 330: Ckp Sensor Inspection
1H-8 Ignition System: Ignition Coil Resistance • Disconnect the spark plug caps. Refer to “Spark Plug Cap and Spark Plug Removal and Installation (Page 1H-4)”. • Measure the ignition coil resistance in both the primary and secondary windings. If the resistance is not within the standard range, replace the ignition coil with a new one.
Page 331: Ckp Sensor Removal And Installation
Ignition System: 1H-9 CKP Sensor Removal and Installation 7) If the peak voltage is within the specification, check the continuity between the CKP sensor coupler and B940H21806007 Refer to “Generator Removal and Installation in Section ECM coupler. 1J (Page 1J-5)”. CAUTION Engine Stop Switch Inspection Normally, use the needle pointed probe to the...
Page 332: Ignition Switch Removal And Installation
1H-10 Ignition System: Ignition Switch Removal and Installation B940H21806010 Removal 1) Remove the left frame side cover. Refer to “Exterior Parts Removal and Installation in Section 9D (Page 9D-5)”. 2) Remove the ignition switch (1). 3) Disconnect the ignition switch lead wire coupler (2). I940H1180015-02 Installation Install the ignition switch in the reverse order of removal.
Page 333: Special Tools And Equipment
Ignition System: 1H-11 Special Tools and Equipment Special Tool B940H21808001 09900–25008 09900–25009 Multi-circuit tester set Needle pointed probe set (Page 1H-7) / (Page 1H- (Page 1H-7) 8) / (Page 1H-8) / (Page 1H-9) 09930–10121 Spark plug wrench set (Page 1H-4) / (Page 1H-...
Page 334: Starting System
1I-1 Starting System: Starting System Engine Schematic and Routing Diagram Starting System Diagram B940H21902001 Refer to “Wire Color Symbols in Section 0A (Page 0A-5)”. Ignition Engine stop switch switch Fuse To the (30 A) ignition coil Starter motor Fuse GP switch (15 A) (Neutral) Battery...
Page 335: Starter Motor Will Not Run
Starting System: 1I-2 Starter Motor will not Run B940H21904002 NOTE Make sure the fuses are not blown and the battery is fully-charged before diagnosing. Troubleshooting Step Action 1) Shift the transmission into neutral. Go to Step 2. Go to Step 3. 2) Grasp the clutch lever, turn on the ignition switch with the engine stop switch in the “RUN”...
Page 336: Repair Instructions
1I-3 Starting System: Repair Instructions Starter Motor Components B940H21906001 I940H1190038-01 1. O-ring 7. Starter motor lead wire mounting nut : 10 N⋅m (1.0 kgf-m, 7.0 lbf-ft) 2. Housing end (Inside) 8. Brush holder nut : 5 N⋅m (0.5 kgf-m, 3.5 lbf-ft) 3.
Page 337 Installation Install the starter motor in the reverse order of removal. Pay attention to the following points: • Apply grease to the starter motor O-ring. : Grease 99000–25010 (SUZUKI SUPER I940H1190006-01 GREASE A or equivalent) CAUTION Replace the O-ring with a new one.
Page 338: Starter Motor Disassembly And Assembly
• Apply a small quantity of moly paste to the armature the specified torque. shaft. Tightening torque : Moly paste 99000–25140 (SUZUKI Moly Radiator heat shield mounting bolt (Left side) paste or equivalent) (c): 5.5 N·m (0.55 kgf-m, 4.0 lbf-ft) Radiator heat shield mounting bolt (Right side) (d): 10 N·m (1.0 kgf-m, 7.0 lbf-ft)
Page 339: Starter Motor Inspection
Starting System: 1I-6 • Align the match mark on the starter motor case with Commutator the match mark on the housing end. Inspect the commutator for discoloration, abnormal wear or undercut “A”. • Tighten the starter motor housing bolts (2). If the commutator is abnormally worn, replace the Tightening torque armature.
Page 340: Starter Relay Removal And Installation
1I-7 Starting System: Starter Relay Inspection Oil Seal Check the seal lip for damage. B940H21906006 Inspect the starter relay in the following procedures: If any damage is found, replace the housing end 1) Remove the starter relay. Refer to “Starter Relay (Inside).
Page 341: Turn Signal / Side-Stand Relay Removal And Installation
Starting System: 1I-8 3) Measure the relay coil resistance between the Side-stand Switch terminals using the multi-circuit tester. If the 1) Turn the ignition switch OFF. resistance is not within the specified value, replace 2) Remove the left frame side cover. Refer to “Exterior the starter relay with a new one.
Page 342 1I-9 Starting System: Turn Signal / Side-stand Relay Diode inspection The turn signal/side-stand relay is composed of the turn 1) Remove the turn signal/side-stand relay. Refer to signal relay, side-stand relay and diode. “Turn Signal / Side-stand Relay Removal and Installation (Page 1I-8)”.
Page 343: Starter Torque Limiter / Starter Clutch Removal And Installation
Starting System: 1I-10 Gear Position Switch 1) Remove the right frame side cover. Refer to “Exterior Parts Removal and Installation in Section 9D (Page 9D-5)”. 2) Disconnect the gear position switch coupler. CAUTION When disconnecting and connecting the gear position switch coupler, make sure to turn off the ignition switch, or electronic parts may get damaged.
Page 344 1I-11 Starting System: 5) Hold the generator rotor and remove the starter clutch bolts. I718H1190031-01 • Install the guide (2) to the generator rotor. NOTE The arrow mark “B” must face to the I940H1190024-01 generator rotor side. 6) Remove the one way clutch (6) from the guide (7). “B”...
Page 345: Starter Torque Limiter Inspection
Starting System: 1I-12 • Apply molybdenum oil solution to the idle gear shaft 2) Turn the starter torque limiter with a torque wrench holes. and check the slip torque. If the slip torque is not within the specification, replace the starter torque M/O: Molybdenum oil (MOLYBDENUM OIL limiter with a new one.
Page 346: Starter Button Inspection
1I-13 Starting System: Starter Driven Gear Bearing 3) Inspect the starter button for continuity with a tester. Inspect the starter driven gear bushing for wear or If any abnormality is found, replace the right handle damage. switch assembly with a new one. Refer to “Handlebars Removal and Installation in Section 6B (Page 6B-1)”.
Page 347: Specifications
For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List in Section 0C (Page 0C-8)”. Special Tools and Equipment Recommended Service Material B940H21908001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010 (Page 1I-4) /...
Page 348: Special Tool
1I-15 Starting System: Special Tool B940H21908002 09900–20102 09900–25008 Vernier calipers (1/20 mm, Multi-circuit tester set 200 mm) (Page 1I-6) (Page 1I-6) / (Page 1I-7) (Page 1I-8) / (Page 1I- 8) / (Page 1I-9) / (Page 1I-9) / (Page 1I- 10) / (Page 1I-10) / (Page 1I-13) 09900–25009...
Page 349: Charging System
Charging System: 1J-1 Charging System Engine Schematic and Routing Diagram Charging System Diagram B940H21A02001 Regulator/Rectifier Ignition switch Generator I940H11A0026-03 Component Location Charging System Components Location B940H21A03001 Refer to “Electrical Components Location in Section 0A (Page 0A-7)”.
Page 350: Diagnostic Information And Procedures
1J-2 Charging System: Diagnostic Information and Procedures Charging System Symptom Diagnosis B940H21A04001 Condition Possible cause Correction / Reference Item Generator does not Open- or short-circuited lead wires, or Repair, replace or connect properly. charge loose lead connections. Short-circuited, grounded or open Replace.
Page 351: Battery Runs Down Quickly
Charging System: 1J-3 Battery Runs Down Quickly B940H21A04002 Troubleshooting Step Action Check accessories which use excessive amounts of Remove accessories. Go to Step 2. electricity. Are accessories being installed? Check the battery for current leakage. Refer to “Battery Go to Step 3. •...
Page 352: Regulated Voltage Inspection
1J-4 Charging System: Generator Inspection 5) Connect the battery (–) terminal and install the seat. Refer to “Battery / Battery Holder Removal and B940H21A06003 Generator Coil Resistance Installation (Page 1J-11)” and “Exterior Parts 1) Remove the left frame lower cover. Refer to “Exterior Removal and Installation in Section 9D (Page 9D- Parts Removal and Installation in Section 9D 5)”.
Page 353: Generator Removal And Installation
Charging System: 1J-5 4) Connect the special tool to the high-tension cord. 4) Remove the left foot rest (1) along with the gearshift lever. Special tool : 09900–26006 (Engine tachometer (solar cell type)) I940H11A0004-01 5) Remove the clutch release assembly. Refer to “Clutch Release Assembly / Push Rod Removal and I940H11A0001-03 Installation in Section 5C (Page 5C-2)”.
Page 354 1J-6 Charging System: 9) Loosen the generator rotor bolt. 12) Remove the generator stator (7) along with the CKP sensor (8). NOTE When loosen the rotor bolt, do not remove it. The rotor bolt is used in conjunction with the rotor remover when removing the rotor.
Page 355 Charging System: 1J-7 • Degrease the tapered portion “A” of generator rotor • Install the dowel pins and new gasket (5). and also the crankshaft “B”. Use nonflammable CAUTION cleaning solvent to wipe off oily or greasy matter and make these surfaces completely dry. Use a new gasket to prevent oil leakage.
Page 356: Regulator / Rectifier Inspection
1J-8 Charging System: Regulator / Rectifier Inspection 4) Disconnect the regulator/rectifier couplers (2). B940H21A06005 Inspect the regulator/rectifier in the following procedures: 1) Turn the ignition switch to OFF position. 2) Remove the left frame lower cover. Refer to “Exterior Parts Removal and Installation in Section 9D (Page 9D-5)”.
Page 357: Battery Components
Charging System: 1J-9 Battery Components 2) Remove the caps (2) from the electrolyte container. B940H21A06006 NOTE • Do not remove or pierce the sealed areas “B” of the electrolyte container. • After filling the electrolyte completely, use the removed cap (2) as sealing caps of battery-filler holes.
Page 358: Battery / Battery Holder Removal And Installation
1J-10 Charging System: NOTE Correct If no air bubbles come out from a filler port, tap the bottom of the electrolyte container two or three times. Never remove the container from the battery. Incorrect I310G11A0024-01 6) After confirming that the electrolyte has entered the battery completely, remove the electrolyte containers from the battery.
Page 359 Charging System: 1J-11 Battery / Battery Holder Removal and 2) Measure the battery voltage using the multi-circuit tester. Installation If the voltage reading is less than the 12 V (DC), B940H21A06008 Removal recharge the battery with a battery charger. 1) Remove the seat. Refer to “Exterior Parts Removal Recharging time and Installation in Section 9D (Page 9D-5)”.
Page 360: Battery Visual Inspection
1J-12 Charging System: 8) Remove the side stand relay. Refer to “Turn Signal / Installation Side-stand Relay Removal and Installation in Install the battery holder and battery in the reverse order Section 1I (Page 1I-8)”. of removal. Pay attention to the following points: 9) Lift the battery holder (9) by removing the bolts.
Page 361: Specifications
For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List in Section 0C (Page 0C-8)”. Special Tools and Equipment Recommended Service Material B940H21A08001 Material SUZUKI recommended product or Specification Note Molybdenum oil MOLYBDENUM OIL SOLUTION — (Page 1J-7)
Page 362: Exhaust System
1K-1 Exhaust System: Exhaust System Engine Precautions Precautions for Exhaust System B940H21B00001 WARNING To avoid the risk of being burned, do not touch the exhaust system when the system is hot. Any service on the exhaust system should be performed when the system is cool. CAUTION Make sure that the exhaust pipes and muffler have enough clearance from the rubber parts and plastic parts to avoid melting.
Page 363: Exhaust Pipe / Muffler Removal And Installation
Exhaust System: 1K-2 Exhaust Pipe / Muffler Removal and Installation 5) Remove the muffler joint bolts (5). B940H21B06002 Removal 1) Remove the right frame side cover. Refer to “Exterior Parts Removal and Installation in Section 9D (Page 9D-5)”. 2) Disconnect the HO2 sensor lead wire coupler (1) and remove the clamp (2).
Page 364 1K-3 Exhaust System: 9) Remove the front muffler (9) along with the exhaust Installation pipe. Installation is in the reverse order of removal. Pay attention to the following points: • Tighten the HO2 sensor to the specified torque. Tightening torque HO2 sensor (a): 48 N·m (4.8 kgf-m, 34.5 lbf-ft) CAUTION •...
Page 365: Exhaust System Inspection
Exhaust System: 1K-4 • Tighten the front muffler connecting bolt to the • Tighten the muffler support nuts and muffler specified torque. connecting bolts to the specified torque. Tightening torque Tightening torque Muffler connecting bolt (Front) (b): 26 N·m (2.6 Muffler support nut (d): 26 N·m (2.6 kgf-m, 19.0 kgf-m, 19.0 lbf-ft) lbf-ft)
Page 366: Specifications
For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List in Section 0C (Page 0C-8)”. Special Tools and Equipment Recommended Service Material B940H21B08001 Material SUZUKI recommended product or Specification Note Thread lock cement THREAD LOCK CEMENT SUPER P/No.: 99000–32130 (Page 1K-4)
Page 367 Table of Contents 2- i Section 2 Suspension CONTENTS Precautions ..........2-1 Swingarm Related Parts Inspection ....2C-9 Swingarm Bearing Removal and Installation ..2C-11 Precautions............. 2-1 Specifications.............2C-12 Precautions for Suspension ........2-1 Service Data............2C-12 Suspension General Diagnosis....2A-1 Tightening Torque Specifications......2C-12 Special Tools and Equipment ......2C-12 Diagnostic Information and Procedures....2A-1 Recommended Service Material .......2C-12 Suspension and Wheel Symptom Diagnosis ..
Page 368: Precautions
2-1 Precautions: Precautions Suspension Precautions Precautions for Suspension B940H22000001 Refer to “General Precautions in Section 00 (Page 00-1)”. WARNING All suspensions, bolts and nuts are an important part in that it could affect the performance of vital parts. They must be tightened to the specified torque periodically and if the suspension effect is lost, replace it with a new one.
Page 369: Suspension General Diagnosis
Suspension General Diagnosis: 2A-1 Suspension General Diagnosis Suspension Diagnostic Information and Procedures Suspension and Wheel Symptom Diagnosis B940H22104001 Condition Possible cause Correction / Reference Item Wobbly front wheel Distorted wheel rim. Replace. Worn front wheel bearings. Replace. Defective or incorrect tire. Replace.
Page 370: Front Suspension
2B-1 Front Suspension: Front Suspension Suspension Repair Instructions Front Fork Components B940H22206001 I940H1220031-01 1. O-ring 8. Spring 15. Front fork cap bolt 2. Spacer 9. Inner rod lock-nut : 15 N⋅m (1.5 kgf-m, 11.0 lbf-ft) 3. Outer tube 10. Inner rod/Damper rod (cartridge) : 23 N⋅m (2.3 kgf-m, 16.5 lbf-ft) 4.
Page 371: Front Fork Removal And Installation
Front Suspension: 2B-2 Front Fork Removal and Installation Installation B940H22206002 1) Set the front fork to the front fork lower bracket CAUTION temporarily by tightening the lower clamp bolts (1). Do not operate the front brake lever and brake pedal with the front wheel removed. NOTE The right and left front forks are installed symmetrically and therefore the removal...
Page 372: Front Fork Disassembly And Assembly
2B-3 Front Suspension: Front Fork Disassembly and Assembly 6) Tighten the front fork upper clamp bolt (3). B940H22206004 Tightening torque Refer to “Front Fork Removal and Installation (Page 2B- Front fork upper clamp bolt (c): 23 N·m (2.3 kgf- 2)”. m, 16.5 lbf-ft) NOTE The right and left front forks are installed...
Page 373 Front Suspension: 2B-4 4) Remove the spacer (3) and spring (4). 9) Remove the inner rod/damper rod (cartridge) (6). CAUTION Do not disassemble the inner rod/damper rod (cartridge). I940H1220010-01 5) Invent the fork and stroke it several times to drain out fork oil.
Page 374 • When installing the oil seal to inner tube, be careful not to damage the oil seal lip. • Apply fork oil to the oil seal lip. : Fork Oil 99000–99044–L01 (SUZUKI FORK OIL L01 or equivalent) I940H1220018-02...
Page 375 • Compress it fully. special tools. • Pour specified front fork oil to the inner tube. CAUTION : Fork Oil 99000–99044–L01 (SUZUKI FORK Use a new cylinder bolt gasket to prevent oil OIL L01 or equivalent) leakage. Capacity (each leg) 636 ml (21.5/22.4 US/lmp oz)
Page 376 2B-7 Front Suspension: • Refill specified front fork oil up to the top level of the Front fork inner rod lock-nut outer tube again. Move the outer tube up and down Loosen the lock-nut (1) to the bottom of inner rod several strokes until bubbles do not come out from the threads.
Page 377: Front Fork Parts Inspection
Front Suspension: 2B-8 • If any defects are found, replace them with the new ones. CAUTION Do not remove the “ANTI-FRICTION” metals “A” and “B”. “A” “B” I940H1220025-01 • Slowly turn the cap bolt completely by hand until the end of the cap bolt seats on the lock-nut. •...
Page 378: Specifications
Front fork oil level (Without spring, 121 (4.8) — inner tube fully compressed) Front fork oil type SUZUKI FORK OIL L01 or an equivalent fork oil — Front fork oil capacity (Each leg) 636 ml (21.5/22.4 US/lmp oz) — Tightening Torque Specifications...
Page 379: Special Tool
Front Suspension: 2B-10 Special Tool B940H22208002 09913–50121 09940–30221 Oil seal remover Front fork assembling tool (Page 2B-5) (Page 2B-4) 09940–34520 09940–34531 T handle Attachment A (Page 2B-6) (Page 2B-6) 09940–52841 09940–52861 Front fork inner rod holder Front fork oil seal installer (Page 2B-6) / (Page 2B- (Page 2B-5)
Page 380: Rear Suspension
2C-1 Rear Suspension: Rear Suspension Suspension Repair Instructions Rear Suspension Components B940H22306001 I940H1230044-05 1. Rear shock absorber 8. Swingarm pivot shaft nut : 65 N⋅m (6.5 kgf-m, 47.0 lbf-ft) 2. Rear cushion rod 9. Swingarm pivot bearing : 132 N⋅m (13.2 kgf-m, 95.5 lbf-ft) 3.
Page 381: Rear Suspension Assembly Construction
Rear Suspension: 2C-2 Rear Suspension Assembly Construction B940H22306002 “b” “ b ” “ a ” “ c ” “c ” “d” “ d ” I940H1230042-04 1. Rear shock absorber mounting nut (Upper) “a”: 0.25 mm (0.01 in) 2. Rear shock absorber mounting nut (Lower) “b”: 5.0 mm (0.20 in) 3.
Page 382: Swingarm Assembly Removal And Installation
2C-3 Rear Suspension: Swingarm Assembly Removal and Installation 6) Remove the final gear assembly (4). Refer to “Final B940H22306003 Gear Assembly Removal and Installation in Section 3A (Page 3A-12)”. Removal CAUTION Make sure that the motorcycle is supported securely. 1) Remove the exhaust pipe and muffler. Refer to “Exhaust Pipe / Muffler Removal and Installation in Section 1K (Page 1K-2)”.
Page 383 Rear Suspension: 2C-4 10) Hold the swingarm pivot shaft (6) with the special 14) Remove the spacer (11), cushion rod seal (12), and tool and remove the swingarm pivot shaft nut (7). cushion rod bearing (13) with the special tools. Special tool Special tool (A): 09900–18720 (Hexagon socket (14...
Page 384 2C-5 Rear Suspension: • Install the oil seal with the special tool. • Install the rear shock absorber (4) and tighten the rear shock absorber mounting nut to the specified torque. CAUTION Tightening torque Replace the oil seal with a new one. Rear shock absorber mounting nut (Lower) (b): 65 N·m (6.5 kgf-m, 47.0 lbf-ft) Special tool...
Page 385: Rear Suspension Inspection
Rear Suspension: 2C-6 • Tighten the cushion lever mounting nut to the specified torque. Tightening torque Cushion lever mounting nut (e): 132 N·m (13.2 kgf-m, 95.5 lbf-ft) I940H1230016-01 3) Install the rear shock absorber. Refer to “Swingarm Assembly Removal and Installation (Page 2C-3)”. Rear Suspension Adjustment B940H22306007 I940H1230015-02...
Page 386: Rear Shock Absorber Disposal
2C-7 Rear Suspension: Rear Shock Absorber Disposal WARNING B940H22306008 Refer to “Swingarm Assembly Removal and Installation • Be sure to wear protective glasses since (Page 2C-3)”. drilling chips and oil may fly off with The rear shock absorber unit contains high-pressure blowing gas when the drill bit has nitrogen gas.
Page 387: Cushion Lever Bearing Removal And Installation
Rear Suspension: 2C-8 Cushion lever bearing 2) Remove the cushion lever bearings using the special tools. 1) Insert the spacers into bearings. 2) Check the play by moving the spacers up and down. Special tool If excessive play is noted, replace the bearing with a (A): 09921–20240 (Bearing remover set) new one.
Page 388: Swingarm Related Parts Inspection
4) Apply grease to the bearings and cushion lever seal. (A): 09924–84510 (Bearing installer set) (B): 09941–34513 (Steering race installer) : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I940H1230026-01 2) Install the cushion lever seal with the special tool.
Page 389 Rear Suspension: 2C-10 Swingarm Bearing Cushion Rod Inspect the cushion rods for damage and bend. If any 1) Insert the spacers into bearings. defects are found, replace the cushion rods with new 2) Check the play by moving the spacers up and down. ones.
Page 390: Swingarm Bearing Removal And Installation
(A): 09941–34513 (Steering race installer) Special tool (A): 09921–20240 (Bearing remover set) I940H1230037-01 3) Apply grease to the bearings. : Grease 99000–25010 (SUZUKI SUPER I940H1230035-01 4) Remove the center spacer (2). GREASE A or equivalent) I940H1230036-01 I940H1230040-01 4) Install the swingarm. Refer to “Cushion Lever Removal and Installation (Page 2C-7)”.
Page 391: Specifications
For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List in Section 0C (Page 0C-8)”. Special Tools and Equipment Recommended Service Material B940H22308001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010 (Page 2C-9) /...
Page 392: Special Tool
2C-13 Rear Suspension: Special Tool B940H22308002 09900–18720 09900–20607 Hexagon socket (14 mm) Dial gauge (1/100 mm, 10 (Page 2C-4) (Page 2C-10) 09900–20701 09900–21304 Magnetic stand V-block (100 mm) (Page 2C-10) (Page 2C-10) 09910–60611 09913–70210 Universal clamp wrench Bearing installer set (Page 2C-6) (Page 2C-5) / (Page 2C-...
Page 393: Wheels And Tires
Wheels and Tires: 2D-1 Wheels and Tires Suspension Precautions Precautions for Wheel and Tire B940H22400001 WARNING • Proper tire inflation pressure and loading are important factors to ensure riding safety. Overloading can lead not only to tire damage but also to loss of control. •...
Page 394: Repair Instructions
2D-2 Wheels and Tires: Repair Instructions Front Wheel Components B940H22406001 I940H1240047-02 1. Front axle 7. Front wheel : 100 N⋅m (10.0 kgf-m, 72.5 lbf-ft) 2. Dust seal 8. Front tire : Apply grease. 3. Bearing 9. Collar : Apply thread lock to the thread part. 4.
Page 395: Front Wheel Assembly Construction
Wheels and Tires: 2D-3 Front Wheel Assembly Construction B940H22406002 “ a ” I940H1240042-05 1. Brake disc bolt “a”: Clearance : 39 N⋅m (3.9 kgf-m, 28.0 lbf-ft) 2. Brake caliper mounting bolt : 23 N⋅m (2.3 kgf-m, 16.5 lbf-ft) : Apply grease. 3.
Page 396 WARNING After remounting the brake calipers, pump the brake lever until the pistons push the pad correctly. I940H1240005-02 Installation 1) Apply grease to the collar (1) and install it. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I940H1240010-02 I940H1240007-01...
Page 397: Front Wheel Related Parts Inspection
Wheels and Tires: 2D-5 Front Wheel Related Parts Inspection 4) Tighten the front axle (3) to the specified torque with the special tool. B940H22406004 Refer to “Front Wheel Assembly Removal and Special tool Installation (Page 2D-3)”. (A): 09900–18740 (Hexagon socket (24 mm)) Tire Refer to “Tire Inspection in Section 0B (Page 0B-16)”.
Page 398: Front Wheel Dust Seal / Bearing Removal And Installation
2D-6 Wheels and Tires: Front Wheel Dust Seal / Bearing Removal and Wheel Installation 1) Remove the brake pads. Refer to “Front Brake Pad B940H22406005 Replacement in Section 4B (Page 4B-2)”. 2) Make sure that the wheel runout checked as shown Removal does not exceed the service limit.
Page 399 CAUTION The removed dust seals and bearings must be replaced with new ones. 1) Apply grease to the wheel bearings. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I649G1240019-02 2) First install the right wheel bearing, then install the spacer (1) and left wheel bearing with the special tool.
Page 400 2D-8 Wheels and Tires: 4) Apply grease to the lip of the dust seals. 5) Install the front wheel assembly. Refer to “Front Wheel Assembly Removal and Installation : Grease 99000–25010 (SUZUKI SUPER (Page 2D-3)”. GREASE A or equivalent) I940H1240021-01...
Page 401: Rear Wheel Components
Wheels and Tires: 2D-9 Rear Wheel Components B940H22406006 I940H1240046-02 1. Rear axle 9. Spacer 17. Wheel balancer 2. Spacer 10. Rear wheel 18. Air valve 3. Bearing 11. Rear tire : 23 N⋅m (2.3 kgf-m, 16.5 lbf-ft) 4. Lock washer 12.
Page 402: Rear Wheel Assembly Construction
2D-10 Wheels and Tires: Rear Wheel Assembly Construction B940H22406007 “ a ” I940H1240044-04 1. Brake disc bolt : 100 N⋅m (10.0 kgf-m, 72.5 lbf-ft) : Apply grease. “a”: Clearance : Apply thread lock to the thread part. : 23 N⋅m (2.3 kgf-m, 16.5 lbf-ft) : Apply thread lock to the thread part.
Page 403 Installation the axle nut (3) and washer (4). 1) Apply grease to the final gear spline. Special tool (A): 09944–28320 (Hexagon socket (19 : Grease 99000–25010 (SUZUKI SUPER mm)) GREASE A or equivalent) I940H1240024-01 I940H1240028-01 6) Draw out the rear axle (5).
Page 404: Rear Wheel Related Parts Inspection
2D-12 Wheels and Tires: 3) Apply grease to the dust seal lip. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) 4) Install the collar (1). I940H1240032-01 9) Install the cap (5). I940H1240030-01 5) Install the rear wheel, rear axle and brake caliper bracket.
Page 405: Rear Wheel Dust Seal / Bearing Removal And Installation
Wheels and Tires: 2D-13 Dust Seal Inspect the dust seal lip for wear or damage. If any defects are found, replace the dust seal with a new one. Refer to “Rear Wheel Dust Seal / Bearing Removal and Installation (Page 2D-13)”. I649G1240014-02 Bearing Inspect the play of the wheel bearings by hand while...
Page 406 I940H1240037-01 Installation CAUTION The removed dust seals and bearings must be replaced with new ones. 1) Apply grease to the wheel bearings. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) “ a ” I649G1240019-02 I940H1240045-02 1. Spacer “a”: Clearance...
Page 407: Tire Removal And Installation
I940H1240039-01 4) Apply grease to the dust seal lip. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I649G1240037-02 Installation CAUTION Do not reuse the valve which has been once removed.
Page 408: Wheel / Tire / Air Valve Inspection And Cleaning
2D-16 Wheels and Tires: 2) Install the tire onto the wheel. 7) When the bead has been fitted properly, adjust the pressure to specification. CAUTION 8) As necessary, adjust the tire balance. Refer to For installation procedure of tire onto the “Wheel Balance Check and Adjustment (Page 2D- wheel, follow the instructions given by the 18)”.
Page 409: Air Valve Removal And Installation
Wheels and Tires: 2D-17 Tire Inspect the valve core seal (1) for wear and damage. If Tire must be checked for the following points: any defect is found, replace the valve core with a new one. Refer to “Air Valve Removal and Installation •...
Page 410: Wheel Balance Check And Adjustment
2D-18 Wheels and Tires: Wheel Balance Check and Adjustment • Install the air valve (2) in the wheel (3). B940H22406014 Check and adjust the wheel balance in the following CAUTION procedures: • Be careful not to damage the lip (4) of the 1) Removal the wheel assembly.
Page 411: Tightening Torque Specifications
For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List in Section 0C (Page 0C-8)”. Special Tools and Equipment Recommended Service Material B940H22408001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010 (Page 2D-4) /...
Page 412: Special Tool
2D-20 Wheels and Tires: Special Tool B940H22408002 09900–18740 09900–20607 Hexagon socket (24 mm) Dial gauge (1/100 mm, 10 (Page 2D-4) / (Page 2D- (Page 2D-5) / (Page 2D- 09900–20701 09900–21304 Magnetic stand V-block (100 mm) (Page 2D-5) / (Page 2D- (Page 2D-5) / (Page 2D- 09913–50121...
Page 413 Table of Contents 3- i Section 3 Driveline / Axle CONTENTS Precautions ..........3-1 Secondary Gear Shim Inspection and Adjustment ............3A-9 Precautions............. 3-1 Final Bevel Gear Components ......3A-11 Precautions for Driveline / Axle ......3-1 Final Gear Construction ........3A-12 Drive Chain / Drive Train / Drive Shaft... 3A-1 Final Gear Assembly Removal and Installation ............3A-12 Diagnostic Information and Procedures....3A-1...
Page 414: Precautions
3-1 Precautions: Precautions Driveline / Axle Precautions Precautions for Driveline / Axle B940H23000001 Refer to “General Precautions in Section 00 (Page 00-1)”. WARNING Support the motorcycle with a jack or wooden block when servicing the driveshafts and drive train.
Page 415: Drive Chain / Drive Train / Drive Shaft
Drive Chain / Drive Train / Drive Shaft: 3A-1 Drive Chain / Drive Train / Drive Shaft Driveline / Axle Diagnostic Information and Procedures Drive Chain and Sprocket Symptom Diagnosis B940H23104001 Condition Possible cause Correction / Reference Item Noisy shaft drive (Noise Oil level too low.
Page 416: Repair Instructions
3A-2 Drive Chain / Drive Train / Drive Shaft: Repair Instructions Secondary Gear Components B940H23106001 I940H1310057-02 1. Driven bevel gear coupling nut 9. Oil seal 17. Shim(-s) 2. Washer 10. Bearing : 95 N⋅m (9.5 kgf-m, 68.5 lbf-ft) 3. Driven bevel gear coupling 11.
Page 417: Secondary Gear Construction
Drive Chain / Drive Train / Drive Shaft: 3A-3 Secondary Gear Construction B940H23106002 I940H1310019-02 1. Shims 4. Secondary driven gear : Apply grease. 2. Shims : 95 N⋅m (9.5 kgf-m, 68.5 lbf-ft) : Apply thread lock to the thread part. 3.
Page 418 55 N·m (5.5 kgf-m, 40.0 lbf-ft) case few minutes. • Take extreme care not to apply any bond to the oil hole, oil groove and bearing. : Sealant 99000–31110 (SUZUKI BOND No.1215 or equivalent) “C” I940H1310027-03 • Tighten the secondary gear bolts to the specified torque.
Page 419: Secondary Driven Gear Disassembly And Assembly
Drive Chain / Drive Train / Drive Shaft: 3A-5 Secondary Driven Gear Disassembly and 5) Remove the following parts from the shaft (4). Assembly • Secondary shaft spacer (5) B940H23106004 • Bearing housing (6) Refer to “Secondary Driven Gear Assembly Removal and Installation (Page 3A-3)”.
Page 420 3A-6 Drive Chain / Drive Train / Drive Shaft: 9) Remove the oil seal with the special tool. Special tool (C): 09913–50121 (Oil seal remover) I940H1310037-01 2) Install the oil seal with the special tool. CAUTION I940H1310035-01 The removed oil seal must be replaced with a 10) Remove the bearing (11).
Page 421 (7). (C): 09924–41830 (Bearing retainer wrench) Tightening torque CAUTION Secondary driven bevel gear bearing stopper Replace the O-ring with a new one. (a): 105 N·m (10.5 kgf-m, 76.0 lbf-ft) : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I940H1310041-02 I940H1310044-01...
Page 422: Secondary Driven Gear Related Parts Inspection
3A-8 Drive Chain / Drive Train / Drive Shaft: 8) Install the coupling (8) and washer (9). 9) Tighten the coupling nut (10) to the specified torque with the special tool. CAUTION Replace the coupling nut (10) with a new one. Special tool (D): 09924–64510 (Final driving gear coupling holder)
Page 423: Secondary Gear Shim Inspection And Adjustment
Drive Chain / Drive Train / Drive Shaft: 3A-9 Oil Seal 2) Measure the backlash as follows: Inspect the oil seal for wear or damage. If any defects • Install the backlash measuring tool on the driven are found, replace the oil seal with a new one. bevel gear coupling, and set-up a dial gauge as shown in the figure.
Page 424 3A-10 Drive Chain / Drive Train / Drive Shaft: Contact Position Tooth Contact After bringing the backlash within specification by changing the secondary driven bevel gear shims, it will be necessary to check tooth contact. 1) Remove the secondary gear case. 2) Clean and degrease the secondary drive bevel gear teeth, and apply a coating of machinist’s layout dye or paste to several teeth.
Page 425: Final Bevel Gear Components
Drive Chain / Drive Train / Drive Shaft: 3A-11 Final Bevel Gear Components B940H23106007 I940H1310058-02 1. Oil seal 15. Oil seal 29. Drive bearing stopper 2. Final gear bearing case 16. O-ring 30. Final gear case pivot bolt 3. Shims 17.
Page 426: Final Gear Construction
3A-12 Drive Chain / Drive Train / Drive Shaft: Final Gear Construction B940H23106008 I822H1310041-05 1. Shims 5. Final driven bevel gear : Apply bond to matching surface. 2. Shims : 40 N⋅m (4.0 kgf-m, 29.0 lbf-ft) : Apply bond to matching surface. 3.
Page 427 The conical side of the washer (3) faces I940H1310003-02 outside. 2) Apply moly paste to the propeller shaft spline. Tightening torque : Moly paste 99000–25140 (SUZUKI MOLY Final gear case nut (a): 40 N·m (4.0 kgf-m, 29.0 PASTE or equivalent) lbf-ft) I940H1310018-01...
Page 428: Final Gear Disassembly And Assembly
3A-14 Drive Chain / Drive Train / Drive Shaft: 6) Install the rear wheel assembly. Refer to “Rear 4) Remove the propeller shaft (4) and spring (5). Wheel Assembly Removal and Installation in Section 2D (Page 2D-10)”. 7) Pour final gear oil. Refer to “Final Gear Oil Replacement in Section 0B (Page 0B-10)”.
Page 429 Drive Chain / Drive Train / Drive Shaft: 3A-15 8) Remove the bearing stopper with the special tool. 12) Remove the inner race with the special tool. Special tool Special tool (C): 09924–62410 (Final drive gear bearing (D): 09913–60910 (Bearing remover) holder wrench) CAUTION When replacing the drive bevel gear, replace...
Page 430 3A-16 Drive Chain / Drive Train / Drive Shaft: 15) Remove the shim (12) and final driven bevel gear 18) Remove the oil seal (16) with the special tool. (13). Special tool (E): 09913–50121 (Oil seal remover) I822H1310059-01 16) Remove the shims (14). I822H1310062-01 19) Remove the final driven gear bearing (16) and oil seal (17) with the special tools.
Page 431 • Use a new oil seal to prevent oil leakage. • The lip and spring of the oil seal “A” should face to the driven bevel gear side. • Apply grease to the oil seal lip. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I940H1310051-01 Assembly Reassemble the final gear case in the reverse order of disassembly.
Page 432 (D): 09951–16310 (Bearing installer) Do not block the breather passage when • Apply grease to the lip of the oil seal. applying bond. : Grease 99000–25010 (SUZUKI SUPER : Sealant 99000–31140 (SUZUKI BOND GREASE A or equivalent) No.1207B or equivalent) I822H1310070-02 •...
Page 433 • Apply grease to the O-ring and the lip of the oil seal. • Install the bearing stopper (12). CAUTION Use a new oil seal and O-ring to prevent oil I822H1310079-01 leakage. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I822H1310077-01...
Page 434 (NLGI#2) to the propeller shaft splines and final drive bevel gear coupling. • Install the spring (15) and propeller shaft (16). : Moly paste 99000–25140 (SUZUKI MOLY PASTE or equivalent) I822H1310083-02 • Install the dust seal with the special tools.
Page 435: Final Gear Parts Inspection
Drive Chain / Drive Train / Drive Shaft: 3A-21 Final Gear Parts Inspection Oil Seal B940H23106011 Inspect the oil seal for wear and damage. If any defects are found, replace the oil seal with a new one. Drive / Driven Bevel Gear Inspect the drive and/or driven bevel gear wear or damage.
Page 436: Universal Joint Inspection
3A-22 Drive Chain / Drive Train / Drive Shaft: Rear Wheel Dumper Removal and Installation Installation Install the universal joint in the reverse order of removal. B940H23106014 Removal Pay attention to the following point: 1) Remove the rear wheel assembly. Refer to “Rear •...
Page 437: Wheel Dumper Inspection
Wheel Dumper Inspection spline. B940H23106015 Inspect the dumpers for wear and damage. Replace the CAUTION dumper, if there is anything unusual. The removed O-ring must be replaced with a new one. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I822H1310102-01 I940H1310015-01...
Page 438: Final Gear Shim Inspection And Adjustment
3A-24 Drive Chain / Drive Train / Drive Shaft: Final Gear Shim Inspection and Adjustment 2) Measure the clearance between the shims (1) and B940H23106016 bearing. If it is not within the specification, the must Refer to “Final Gear Disassembly and Assembly be changed.
Page 439 Drive Chain / Drive Train / Drive Shaft: 3A-25 • Adjust the dial gauge so that it touches the backlash Backlash is too small measuring tool arm at the mark; hold the final driven • Install a thicker shim pack (1) between the final driven bevel gear securely, and turn the final drive bevel gear bevel gear and final gear case.
Page 440 3A-26 Drive Chain / Drive Train / Drive Shaft: EXAMPLE: • Using a socket and handle on the final drive bevel Final gear to case shims (1); gear coupling nut, rotate the final drive bevel gear 1.45 mm + 1.40 mm = 2.85 mm several turns in each direction, while loading the final Final gear bearing to bearing case shims (2), driven bevel gear.
Page 441 Drive Chain / Drive Train / Drive Shaft: 3A-27 • If the tooth contact pattern is incorrect for either List of shims (4) reason, the appropriate shim must be installed, and Part number Shim thickness the tooth contact pattern rechecked by repeating the 27445-24A01-030 0.30 mm (0.012 in) tooth coating procedure above.
Page 442: Specifications
3A-28 Drive Chain / Drive Train / Drive Shaft: Specifications Service Data B940H23107001 Drive Train Unit: mm (in) Except ratio Item Standard Limit Primary reduction ratio 1.407 (76/54) — Final reduction ratio 3.137 (20/17 x 32/12) — Tightening Torque Specifications B940H23107002 Tightening torque Fastening part...
Page 443: Special Tools And Equipment
17) / (Page 3A-18) / (Page 3A-19) / (Page 3A-20) / (Page 3A-23) Moly paste SUZUKI MOLY PASTE or equivalent P/No.: 99000–25140 (Page 3A-13) / (Page 3A-20) Sealant SUZUKI BOND No.1215 or P/No.: 99000–31110 (Page 3A-4) / (Page 3A- equivalent SUZUKI BOND No.1207B or...
Page 444 3A-30 Drive Chain / Drive Train / Drive Shaft: 09913–84510 09923–74511 Bearing installer Bearing remover (Page 3A-19) (Page 3A-16) 09924–34510 09924–41830 Backlash measuring tool Bearing retainer wrench (φ27 – 50) (Page 3A-9) / (Page 3A- (Page 3A-5) / (Page 3A- 09924–62410 09924–62430 Final drive gear bearing...
Page 445 Table of Contents 4- i Section 4 Brake CONTENTS Precautions ..........4-1 Special Tools and Equipment ......4A-19 Recommended Service Material .......4A-19 Precautions............. 4-1 Special Tool ............4A-19 Precautions for Brake System ......4-1 Brake Fluid Information ......... 4-1 Front Brakes ..........4B-1 Brake Control System and Diagnosis ...
Page 446: Precautions
4-1 Precautions: Precautions Brake Precautions Precautions for Brake System B940H24000001 Refer to “General Precautions in Section 00 (Page 00-1)”. Brake Fluid Information B940H24000002 WARNING • This brake system is filled with an ethylene glycol-based DOT 4 brake fluid. Do not use or mix different types of fluid, such as silicone-based or petroleum-based.
Page 447: Brake Control System And Diagnosis
Brake Control System and Diagnosis: 4A-1 Brake Control System and Diagnosis Brake Schematic and Routing Diagram Front Brake Hose Routing Diagram B940H24102001 “A” “B” “ a ” “B” “C” “B” “B” “ b ” “D” “C” “C” “ b ” “D”...
Page 448: Rear Brake Hose Routing Diagram
4A-2 Brake Control System and Diagnosis: Rear Brake Hose Routing Diagram B940H24102002 “H” “C” “B” “D” “A” “E” “F” “ b ” “ a ” “G” “G” “A” I940H1410082-10 “A”: White marking “G”: Position the brake hose union with the stopper before tightening the bolt.
Page 449: Diagnostic Information And Procedures
Brake Control System and Diagnosis: 4A-3 Diagnostic Information and Procedures Brake Symptom Diagnosis B940H24104001 Condition Possible cause Correction / Reference Item Insufficient brake power Leakage of brake fluid from hydraulic Repair or replace. system. Worn pads and disc. Replace. Oil adhesion on friction surface of pads. Clean disc and pads. Air in hydraulic system.
Page 450: Rear Brake Light Switch Inspection
4A-4 Brake Control System and Diagnosis: Rear Brake Light Switch Inspection Brake Fluid Level Check B940H24106003 B940H24106005 Inspect the rear brake light switch in the following Refer to “Brake System Inspection in Section 0B procedures: (Page 0B-14)”. 1) Disconnect the rear brake light switch lead coupler Brake Hose Inspection (1).
Page 451 Brake Control System and Diagnosis: 4A-5 2) Attach a clear hose to the air bleeder valve, and 8) Fill the reservoir with brake fluid to the upper mark of insert the free end of the hose into a receptacle. the reservoir. 3) Squeeze and release the brake lever several times in rapid succession and squeeze the lever fully without releasing it.
Page 452: Brake Fluid Replacement
4A-6 Brake Control System and Diagnosis: 5) Connect a clear hose to the air bleeder valve and • Fill the reservoir with brake fluid to the upper mark of insert the other end of the hose into a receptacle. the reservoir. I940H1410029-01 I940H1410026-02 6) Loosen the air bleeder valve and pump the brake...
Page 453 Brake Control System and Diagnosis: 4A-7 8) Fill the reservoir with brake fluid to the upper mark of 7) Loosen the air bleeder valve and pump the brake the reservoir. pedal until the old brake fluid flows out of the brake system.
Page 454: Front Brake Hose Removal And Installation
4A-8 Brake Control System and Diagnosis: Rear Brake Hose Removal and Installation 9) Fill the reservoir with brake fluid to the upper mark of the reservoir. B940H24106010 Removal 1) Remove the fuel tank. Refer to “Fuel Tank Removal and Installation in Section 1G (Page 1G-9)”. 2) Remove the frame head cover.
Page 455: Front Brake Master Cylinder Components
Brake Control System and Diagnosis: 4A-9 Front Brake Master Cylinder Components B940H24106011 I940H1410088-02 1. Reservoir cap 7. Brake lever : 10 N⋅m (1.0 kgf-m, 7.0 lbf-ft) 2. Plate 8. Brake lever pivot bolt : Apply brake fluid. 3. Diaphragm 9. Brake lever pivot bolt lock-nut : Apply silicone grease.
Page 456: Front Brake Master Cylinder Assembly Removal And Installation
4A-10 Brake Control System and Diagnosis: Front Brake Master Cylinder Assembly Removal and Installation B940H24106012 Removal “C” 1) Drain brake fluid. Refer to “Brake Fluid Replacement (Page 4A-6)”. 2) Disconnect the front brake light switch lead coupler (1). “B” 3) Place a rag underneath the brake hose union bolt (2) “A”...
Page 457: Front Brake Master Cylinder / Brake Lever Disassembly And Assembly
Brake Control System and Diagnosis: 4A-11 Front Brake Master Cylinder / Brake Lever 4) Remove the following parts from the master cylinder. Disassembly and Assembly • Piston (8) B940H24106013 • Secondary cup (9) Refer to “Front Brake Master Cylinder Assembly Removal and Installation (Page 4A-10)”.
Page 458: Front Brake Master Cylinder Parts Inspection
• Apply grease to the contact point between piston and Refer to “Front Brake Master Cylinder / Brake Lever brake lever. Disassembly and Assembly (Page 4A-11)”. : Grease 99000–25100 (SUZUKI SILICONE Master Cylinder GREASE or equivalent) Inspect the master cylinder bore for any scratches or other damage.
Page 459: Rear Brake Master Cylinder Components
Brake Control System and Diagnosis: 4A-13 Rear Brake Master Cylinder Components B940H24106015 I940H1410089-02 1. Reservoir tank 4. Master cylinder : 10 N⋅m (1.0 kgf-m, 7.0 lbf-ft) : Apply silicone grease. 2. Brake hose union bolt 5. Piston/Cup set : 23 N⋅m (2.3 kgf-m, 16.5 lbf-ft) : Apply brake fluid.
Page 460 4A-14 Brake Control System and Diagnosis: 3) Remove the union bolt (2). 8) Remove the reservoir (9) along with reservoir hose (10). 4) Disconnect the rear reservoir tank hose (3). I940H1410062-03 I940H1410058-02 5) Remove the footrest bracket bolts (4). Installation Install the rear brake master cylinder in the reverse order of removal.
Page 461 Brake Control System and Diagnosis: 4A-15 • Turn the push rod (5) until the brake pedal becomes • Apply thread lock to the footrest bracket bolts (7) and 60 – 70 mm (2.4 – 2.8 in.) “a” above the top of the tighten them to the specified torque.
Page 462: Rear Brake Master Cylinder Disassembly And Assembly
2) Pull out the dust boot (4) and remove the snap ring (5). Special tool : 09900–06108 (Snap ring pliers) I649G1410036-02 • Apply grease to the push rod end. : Grease 99000–25100 (SUZUKI Silicone Grease or equivalent) I940H1410074-01 3) Remove the push rod (6), piston/cup set (7) and spring (8). I940H1410076-01...
Page 463: Rear Brake Master Cylinder Parts Inspection
Brake Control System and Diagnosis: 4A-17 • Install the O-ring (1) and brake hose connector (2). Piston Inspect the piston surface for any scratches or other CAUTION damage. Replace the O-ring (1) with a new one. Rubber Parts Inspect the primary cup, secondary cup and dust boot •...
Page 464: Specifications
4A-18 Brake Control System and Diagnosis: • Apply thread lock to the right foot bracket bolts (2) and Installation Install the rear brake pedal in the reverse order of tighten them to the specified torque. removal. Pay attention to the following points: : Thread lock cement 99000–32110 •...
Page 465: Special Tools And Equipment
For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List in Section 0C (Page 0C-8)”. Special Tools and Equipment Recommended Service Material B940H24108001 Material SUZUKI recommended product or Specification Note Brake fluid DOT 4 — (Page 4A-6) /...
Page 466: Front Brakes
4B-1 Front Brakes: Front Brakes Brake Repair Instructions Front Brake Components B940H24206001 I940H1420024-02 1. Front brake caliper 6. Brake disc : Apply silicone grease. 2. Piston 7. Front brake pad set : Apply thread lock to the thread part. 3. Oil seal/Dust seal : 7.5 N⋅m (0.75 kgf-m, 5.5 lbf-ft) : Apply brake fluid.
Page 467: Front Brake Pad Replacement
Front Brakes: 4B-2 Front Brake Pad Replacement 4) Install the new brake pads. B940H24206003 5) Insert the pad set pin (4) and pad set pin clip (3) as 1) Remove the brake caliper by removing the caliper shown in the figure. mounting bolts (1).
Page 468: Front Brake Caliper Removal And Installation
4B-3 Front Brakes: Front Brake Caliper Removal and Installation B940H24206004 NOTE The right and left calipers are installed symmetrically and therefore the removal procedure for one side is the same as that for the other side. Removal 1) Drain brake fluid. Refer to “Brake Fluid Replacement in Section 4A (Page 4A-6)”.
Page 469 Front Brakes: 4B-4 3) Remove the caliper holder (2) and boots (3). 5) Remove the dust seals (5) and piston seals (6). I940H1420010-01 I940H1420013-01 4) Place a rag over the pistons to prevent it from Brake caliper carrier popping out and then force out the pistons (4) using compressed air.
Page 470: Front Brake Caliper Parts Inspection
4B-5 Front Brakes: Brake caliper • Apply grease to the two pins. • Wash the caliper bores and pistons with specified : Grease 99000–25100 (SUZUKI SILICONE brake fluid. Particularly wash the dust seal grooves GREASE or equivalent) and piston seal grooves.
Page 471 Front Brakes: 4B-6 Brake Caliper Piston Brake Pad Guide Inspect the brake caliper piston surface for any Inspect the brake pad guide for damage and excessive scratches or other damage. If any damage is found, bend. If any defects are found, replace the brake pad replace the piston with a new one.
Page 472: Front Brake Disc Removal And Installation
4B-7 Front Brakes: Front Brake Disc Removal and Installation Front Brake Disc Inspection B940H24206007 B940H24206008 Removal Brake Disc Thickness Check the brake disc for damage or cracks and measure 1) Remove the front wheel assembly. Refer to “Front the thickness using the micrometer. Wheel Assembly Removal and Installation in Section Replace the brake disc if the thickness is less than the 2D (Page 2D-3)”.
Page 473: Specifications
For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List in Section 0C (Page 0C-8)”. Special Tools and Equipment Recommended Service Material B940H24208001 Material SUZUKI recommended product or Specification Note Brake fluid DOT 4 — (Page 4B-5) /...
Page 474: Special Tool
4B-9 Front Brakes: Special Tool B940H24208002 09900–20205 09900–20607 Micrometer (0 – 25 mm) Dial gauge (1/100 mm, 10 (Page 4B-7) (Page 4B-7) 09900–20701 Magnetic stand (Page 4B-7)
Page 475: Rear Brakes
Rear Brakes: 4C-1 Rear Brakes Brake Repair Instructions Rear Brake Components B940H24306001 I940H1430023-02 1. Rear brake caliper 7. Brake caliper bracket : Apply thread lock to the thread part. 2. Piston seal/Dust seal 8. Brake disc : Apply thread lock to the thread part. 3.
Page 476: Rear Brake Pad Inspection
4C-2 Rear Brakes: Rear Brake Pad Inspection 2) Remove the pads mounting pin (2) by removing the B940H24306002 clip (3). The extent of brake pads wear can be checked by observing the grooved limit line “A” on the pads. When the wear exceeds the grooved limit line, replace the pads with new ones.
Page 477: Rear Brake Caliper Removal And Installation
Rear Brakes: 4C-3 Rear Brake Caliper Removal and Installation 6) Insert the pad mounting pin (2) and install the clip (3) as shown in the figure. B940H24306004 Removal 1) Drain brake fluid. Refer to “Brake Fluid Replacement in Section 4A (Page 4A-6)”. 2) Remove the brake hose from the caliper by removing the union bolt (1) and catch the brake fluid in a suitable receptacle.
Page 478: Rear Brake Caliper Disassembly And Assembly
4C-4 Rear Brakes: • Bleed air from the brake system after installing the 3) Place a rag over the piston to prevent it from popping caliper. Refer to “Air Bleeding from Brake Fluid Circuit out and then force out the pistons (4) using in Section 4A (Page 4A-4)”.
Page 479 Particularly wash the dust seal grooves and piston seal grooves. I822H1420030-01 • Apply grease to the two pins. BF: Brake fluid (DOT 4) : Grease 99000–25100 (SUZUKI Silicone CAUTION Grease or equivalent) • Wash the caliper components with fresh brake fluid before reassembly. Never use cleaning solvent or gasoline to wash them.
Page 480: Rear Brake Caliper Parts Inspection
4C-6 Rear Brakes: Rear Brake Caliper Parts Inspection Boot B940H24306006 Inspect the boots for damage and wear. If any defects Refer to “Rear Brake Caliper Disassembly and are found, replace them with new ones. Assembly (Page 4C-4)”. Brake Caliper Cylinder Inspect the brake caliper cylinder wall for nicks, scratches or other damage.
Page 481: Rear Brake Disc Removal And Installation
Rear Brakes: 4C-7 Brake Caliper Carrier Installation Inspect the brake caliper carrier for damage. If any Install the rear brake disc in the reverse order of damages are found, replace the brake caliper carrier removal. Pay attention to the following points: with new one.
Page 482: Specifications
4C-8 Rear Brakes: Brake Disc Runout 1) Dismount the rear brake caliper. Refer to “Rear Brake Caliper Removal and Installation (Page 4C- 3)”. 2) Measure the runout using the dial gauge. Replace the disc if the runout exceeds the service limit.
Page 483: Special Tools And Equipment
Rear Brakes: 4C-9 Special Tools and Equipment Recommended Service Material B940H24308001 Material SUZUKI recommended product or Specification Note Brake fluid DOT 4 — (Page 4C-5) / (Page 4C- Grease SUZUKI Silicone Grease or P/No.: 99000–25100 (Page 4C-5) equivalent Thread lock cement THREAD LOCK CEMENT SUPER P/No.: 99000–32030...
Page 484 4C-10 Rear Brakes:...
Page 485 Table of Contents 5- i Section 5 Transmission / Transaxle CONTENTS Precautions ..........5-1 Special Tools and Equipment ......5B-18 Recommended Service Material .......5B-18 Precautions............. 5-1 Special Tool ............5B-19 Precautions for Transmission / Transaxle..... 5-1 Clutch ............5C-1 Manual Transmission......5B-1 Precautions............5C-1 Diagnostic Information and Procedures....5B-1 Precautions for Clutch System......5C-1 Manual Transmission Symptom Diagnosis ..
Page 486: Precautions
5-1 Precautions: Precautions Transmission / Transaxle Precautions Precautions for Transmission / Transaxle B940H25000001 Refer to “General Precautions in Section 00 (Page 00-1)”.
Page 487: Manual Transmission
Manual Transmission: 5B-1 Manual Transmission Transmission / Transaxle Diagnostic Information and Procedures Manual Transmission Symptom Diagnosis B940H25204001 Condition Possible cause Correction / Reference Item Engine is noisy (Noise Worn or rubbing gear. Replace. seems to come from the Worn countershaft spline. Replace countershaft.
Page 488: Repair Instructions
5B-2 Manual Transmission: Repair Instructions Transmission Components B940H25206001 I940H1520072-03 1. Countershaft/1st drive gear 6. Driveshaft 11. 1st driven gear : 6.5 N⋅m (0.65 kgf-m, 4.5 lbf-ft) 2. 5th drive gear 7. 2nd driven gear 12. Gearshift cam : Apply oil. 3.
Page 489: Transmission Removal And Installation
Manual Transmission: 5B-3 Transmission Removal and Installation 6) Remove the countershaft assembly (5) as shown. B940H25206002 Removal 1) Remove the engine assembly from the frame. Refer to “Engine Assembly Removal in Section 1D (Page 1D-20)”. 2) Disassemble the engine top side. Refer to “Engine Top Side Disassembly in Section 1D (Page 1D-27)”.
Page 490: Transmission Construction
5B-4 Manual Transmission: • Install the gearshift forks (3). • Install the gearshift cam (4). • With engaging each fork (3) and to the cam groove, insert the fork shaft (5) and gear shift fork (6). I940H1520007-02 I940H1520009-03 • Assemble the engine. Refer to “Engine Bottom Side Assembly in Section 1D (Page 1D-64)”.
Page 491: Countershaft Gear / Driveshaft Gear Disassembly And Assembly
Manual Transmission: 5B-5 Countershaft Gear / Driveshaft Gear • Remove the 3rd drive gear bushing (5), washer (6), snap ring (7) and 4th drive gear (8). Disassembly and Assembly B940H25206004 Refer to “Transmission Removal and Installation (Page 5B-3)”. Disassembly CAUTION Identify the position of each removed part.
Page 492 Replace the bearing if there is anything unusual. • Before installing the gears, apply engine oil to the driveshaft and countershaft. • Before installing the oil seal, apply grease to the oil seal lip. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I940H1520018-01...
Page 493: Bearing Removal And Installation
Manual Transmission: 5B-7 Bearing Removal and Installation When installing a new snap ring (1), pay attention to its direction. Fit it to the side where the thrust is as shown in B940H25206005 Removal the figure. 1) Remove the countershaft assembly and driveshaft assembly.
Page 494 5B-8 Manual Transmission: 5) Remove the left driveshaft bearing (4) with the • Install the right driveshaft bearings (1) and special tool. countershaft bearing (2) with the special tool and install the right gearshift cam bearing (3) by hand. Special tool (D): 09913–70210 (Bearing installer set) CAUTION Use the special tool suitable size for each...
Page 495: Transmission Related Parts Inspection
Manual Transmission: 5B-9 • Install the left driveshaft bearing (5) using the hydraulic press and special tool. Special tool (A): 09913–70210 (Bearing installer set) “B” NOTE The stamped mark side of bearing faces secondary drive gear side. I940H1520040-01 I940H1520036-01 • Apply thread lock to the screws, and install the retainers (6) by tightening them.
Page 496: Gear Position (Gp) Switch Inspection
5B-10 Manual Transmission: Gearshift Fork Groove Width Measure the gearshift fork groove width using the vernier calipers. Special tool (A): 09900–20102 (Vernier calipers (1/20 mm, 200 mm)) Gearshift fork groove width Standard: 5.0 – 5.1 mm (0.197 – 0.201 in) I940H1520049-01 Gear Position (GP) Switch Inspection B940H25206007...
Page 497: Gearshift Lever Construction
Replace the O-ring with a new one. NOTE Align the gear position switch pin “A” with the gearshift cam hole “B”. I940H1520042-03 : Grease 99000–25010 (SUZUKI SUPER 1. Gearshift lever “A”: Footrest top surface GREASE A or equivalent) 2. Gearshift link arm “a”: 95 –...
Page 498: Gearshift Lever Height Inspection And Adjustment
5B-12 Manual Transmission: Gearshift Lever Height Inspection and 3) Remove the left footrest along with the gearshift lever. Adjustment B940H25206011 Inspect and adjust the gearshift lever height in the following procedures: 1) Inspect the gearshift lever height “a” between the pedal top face and footrest.
Page 499: Gearshift Shaft / Gearshift Cam Plate Components
Manual Transmission: 5B-13 Gearshift Shaft / Gearshift Cam Plate 3) Remove the snap ring (2) and washer (3). Components B940H25206012 I940H1520050-01 4) Remove the gearshift shaft assembly (4). I940H1520073-02 1. Gearshift shaft I940H1520051-01 5) Remove the following parts from the gearshift shaft 2.
Page 500 5B-14 Manual Transmission: 6) Remove the gearshift cam plate bolt (12) and gearshift cam plate (13). 7) Remove the gearshift cam stopper (14). I940H1520055-01 • Install the gearshift cam stopper (2), bolt (3), washer (4) and return spring (5). • Apply thread lock to the gearshift cam stopper bolt (3) I940H1520053-02 8) Remove the gearshift arm stopper (15).
Page 501 • Apply grease to the lip of the oil seal and install the gearshift shaft (8). • Locate the gearshift cam in the neutral position. • Install the gearshift cam stopper plate (6). : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) NOTE Align the gearshift cam pin “B” with the gearshift cam stopper plate hole “C”.
Page 502: Gearshift Linkage Inspection
5B-16 Manual Transmission: • Install the clutch component parts (10). Refer to Gearshift Shaft Bearing “Clutch Installation in Section 5C (Page 5C-8)”. Inspect the gearshift shaft bearing for abnormal noise and smooth rotation. Replace the bearing if there is anything unusual. I940H1520064-01 •...
Page 503: Specifications
(A): 09913–70210 (Bearing installer set) CAUTION • Apply grease to the oil seal lip. The removed oil seal and bearings must be : Grease 99000–25010 (SUZUKI SUPER replaced with new ones. GREASE A or equivalent) • Install the bearing with the special tool.
Page 504: Tightening Torque Specifications
For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List in Section 0C (Page 0C-8)”. Special Tools and Equipment Recommended Service Material B940H25208001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010 (Page 5B-6) /...
Page 505: Special Tool
Manual Transmission: 5B-19 Special Tool B940H25208002 09900–06104 09900–06107 Snap ring pliers Snap ring pliers (Page 5B-5) (Page 5B-5) / (Page 5B- 09900–20102 09900–20803 Vernier calipers (1/20 mm, Thickness gauge 200 mm) (Page 5B-10) / (Page 5B-9) (Page 5B-10) 09913–70210 09920–13120 Bearing installer set Crankcase separating tool (Page 5B-8) /...
Page 506: Clutch
5C-1 Clutch: Clutch Transmission / Transaxle Precautions Precautions for Clutch System B940H25300001 Refer to “General Precautions in Section 00 (Page 00-1)”. Schematic and Routing Diagram Clutch Cable Routing Diagram B940H25302001 Refer to “Throttle Cable Routing Diagram in Section 1D (Page 1D-2)”. Diagnostic Information and Procedures Clutch System Symptom Diagnosis B940H25304001...
Page 507: Repair Instructions
Clutch: 5C-2 Repair Instructions Clutch Lever Position Switch Inspection Installation B940H25306001 1) Install the clutch cable as shown in the throttle cable Inspect the clutch lever position switch in the following diagram. Refer to “Throttle Cable Routing Diagram procedures: in Section 1D (Page 1D-2)”. 1) Disconnect the clutch lever position switch lead 2) Adjust the clutch cable play.
Page 508 • Apply grease to the each oil seal lip. CAUTION The removed oil seal must be replaced with a new one. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I940H1530005-01 7) Remove the clutch release arm (5), return spring (6) and washer (7) if necessary.
Page 509: Removal And Installation
• Apply a small quantity of grease to the O-ring (1) and push rod. CAUTION The O-ring (1) should be replaced with a new one to prevent engine oil leakage. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I940H1530074-01 Clutch Push Rod (Left) Inspection B940H25306005 Inspect the push rod in the following procedures: 1) Remove the clutch push rod.
Page 510: Clutch Components
5C-5 Clutch: Clutch Components B940H25306006 I940H1530075-01 1. Clutch pressure plate 8. Driven plate No. 2 : 95 N⋅m (9.5 kgf-m, 68.5 lbf-ft) 2. Clutch push piece 9. Clutch sleeve hub : 150 N⋅m (15.0 kgf-m, 108.5 lbf-ft) 3. Drive plate No. 3 10.
Page 511: Clutch Removal
Clutch: 5C-6 Clutch Removal 6) Remove the clutch push piece (4), thrust washer (5) B940H25306007 and bearing (6). 1) Drain engine oil. Refer to “Engine Oil and Filter Replacement in Section 0B (Page 0B-8)”. 2) Remove the exhaust pipes and mufflers. Refer to “Exhaust Pipe / Muffler Removal and Installation in Section 1K (Page 1K-2)”.
Page 512 5C-7 Clutch: 10) Unlock the clutch sleeve hub nut. 14) Remove the clutch sleeve hub (14). I940H1530014-01 I940H1530017-01 11) Hold the clutch sleeve hub with the special tools. 15) Remove the washer (15) and primary driven gear (16). Special tool (A): 09920–53740 (Clutch sleeve hub NOTE holder)
Page 513: Clutch Installation
Clutch: 5C-8 17) Remove the oil pump driven gear (18). 2) Install the washer (2) onto the countershaft. NOTE The chamfer side “A” of washer should face the crankcase side. I940H1530020-01 Clutch Installation B940H25306008 “A” 1) Install the oil pump driven gear (1). I940H1530023-01 NOTE 3) Install the spacer (3) and bearing (4) and apply...
Page 514 5C-9 Clutch: 5) Install the clutch lifter drive cam (7), driven cam (8) to 6) Install the clutch sleeve hub (9) and spring washer the clutch sleeve hub (9). (11). NOTE NOTE The conical curve side of spring washer (11) •...
Page 515: Tightening Torque
Clutch: 5C-10 8) Tighten the new clutch sleeve hub nut (12) to the 11) Insert the clutch drive plates and driven plates one specified torque. by one into the clutch sleeve hub in the prescribed order. CAUTION NOTE Do not use the removed clutch sleeve hub Insert the outermost No.
Page 516 5C-11 Clutch: NOTE 13) Install the clutch push piece (21), bearing (22) and thrust washer (23) to the countershaft. Three kinds of the drive plate (No. 1, No. 2 and No. 3) are equipped in the clutch system, NOTE they can be distinguished by the inside Tighten the washer (23) is located between diameter and clutch facing “G”.
Page 517: Clutch Parts Inspection
Clutch: 5C-12 16) After installed pressure plate, adjust the clutch push Measure the thickness of the drive and driven plates with piece. Refer to “Clutch Cable Play Inspection and a vernier calipers. If each plate thickness is found to Adjustment in Section 0B (Page 0B-12)”. have reached the limit, replace it with a new one.
Page 518: Primary Drive Gear Removal And Installation
5C-13 Clutch: Clutch Spring Clutch Sleeve Hub / Primary Driven Gear Assembly Measure the free length of each coil spring with a vernier Inspect the slot of the clutch sleeve hub and primary calipers, and compare the length with the specified limit. driven gear assembly for damage or wear caused by the Replace all the springs if any spring is not within the clutch plates.
Page 519: Specifications
Clutch: 5C-14 2) Hold the primary drive gear (2) with the special tool and remove the primary drive gear bolt. “A” CAUTION The primary drive gear bolt has left-hand “B” threads. Special tool (A): 09930–40113 (Rotor holder) I940H1530042-01 • Hold the primary drive gear (1) with the special tool and tighten the primary drive gear bolt (2) to the specified torque.
Page 520: Tightening Torque Specifications
For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List in Section 0C (Page 0C-8)”. Special Tools and Equipment Recommended Service Material B940H25308001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010 (Page 5C-3) /...
Page 521 Clutch: 5C-16 09920–53740 09930–40113 Clutch sleeve hub holder Rotor holder (Page 5C-7) / (Page 5C- (Page 5C-14) / (Page 5C-14)
Page 522 5C-17 Clutch:...
Page 523 Table of Contents 6- i Section 6 Steering CONTENTS Precautions ..........6-1 Steering Components .........6B-4 Steering Removal and Installation ......6B-4 Precautions............. 6-1 Steering Related Parts Inspection.......6B-7 Precautions for Steering ........6-1 Steering System Inspection ........6B-7 Steering General Diagnosis....6A-1 Steering Stem Bearing Removal and Installation ............6B-7 Diagnostic Information and Procedures....6A-1 Steering Tension Adjustment ......6B-8...
Page 524: Precautions
6-1 Precautions: Precautions Steering Precautions Precautions for Steering B940H26000001 Refer to “General Precautions in Section 00 (Page 00-1)”.
Page 525: Steering General Diagnosis
Steering General Diagnosis: 6A-1 Steering General Diagnosis Steering Diagnostic Information and Procedures Steering Symptom Diagnosis B940H26104001 Condition Possible cause Correction / Reference Item Heavy Steering Over tightened steering stem nut. Adjust. Broken bearing in steering stem. Replace. Distorted steering stem. Replace.
Page 526: Steering / Handlebar
6B-1 Steering / Handlebar: Steering / Handlebar Steering Repair Instructions Handlebars Components B940H26206001 “A” I940H1620023-01 1. Throttle grip 5. Right handlebar switch box : 23 N⋅m (2.3 kgf-m, 16.5 lbf-ft) 2. Handlebars 6. Left handlebar switch box : 10 N⋅m (1.0 kgf-m, 7.0 lbf-ft) 3.
Page 527 Steering / Handlebar: 6B-2 2) Remove the following parts from the right handlebar. • Tighten the handlebar clamp bolts (1) to the specified torque. a) Front brake master cylinder/Front brake lever (5) NOTE CAUTION First tighten the handlebar clamp bolts (front Do not turn the front brake master cylinder ones).
Page 528: Handlebars Inspection
Brake Master Cylinder Assembly Removal and Installation in Section 4A (Page 4A-10)”. : Grease 99000–25010 (SUZUKI SUPER • Insert the projection “H” of the left handlebar switch GREASE A or equivalent) box into the hole of the handlebars.
Page 529: Steering Components
Steering / Handlebar: 6B-4 Steering Components B940H26206004 I940H1620024-02 1. Handlebar clamp bolt 7. Dust seal : 90 N⋅m (9.0 kgf-m, 65.0 lbf-ft) 2. Handlebar clamp 8. Steering stem upper bearing : 45 N⋅m (4.5 kgf-m, 32.5 lbf-ft) 3. Handlebar holder 9.
Page 530 6B-5 Steering / Handlebar: 6) Remove the wire harness, brake hose and each 12) Remove the steering stem lower bracket. cables. Refer to “Wiring Harness Routing Diagram in Section 9A (Page 9A-5)”, “Front Brake Hose Routing Diagram in Section 4A (Page 4A-1)” and “Throttle Cable Routing Diagram in Section 1D (Page 1D-2)”.
Page 531 Bearing • Apply grease to the bearings, races and dust seals before remounting the steering stem. “ a ” : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I649G1620026-02 Steering stem upper bracket Install the front forks and steering stem upper bracket in...
Page 532: Steering Related Parts Inspection
6B-7 Steering / Handlebar: 4) Temporary install the handlebars and tighten the handlebar bolts (2) to the specified torque. Tightening torque Handlebar holder bolt (b): 45 N·m (4.5 kgf-m, 32.5 lbf-ft) I940H1620021-01 Steering System Inspection B940H26206007 Refer to “Steering System Inspection in Section 0B (Page 0B-17)”.
Page 533: Steering Tension Adjustment
Steering / Handlebar: 6B-8 4) Remove the steering stem upper and lower bearing Inner race races using the special tools. • Press in the lower inner race using the special tool and install the bearing. Special tool (A): 09941–54911 (Bearing outer race Special tool remover) (A): 09941–74911 (Steering bearing installer)
Page 534: Specifications
For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List in Section 0C (Page 0C-8)”. Special Tools and Equipment Recommended Service Material B940H26208001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010 (Page 6B-3) /...
Page 535: Special Tool
Steering / Handlebar: 6B-10 Special Tool B940H26208002 09940–14911 09940–92720 Steering stem nut wrench Spring scale (Page 6B-5) / (Page 6B- (Page 6B-8) 09941–34513 09941–54911 Steering race installer Bearing outer race remover (Page 6B-8) (Page 6B-8) 09941–74911 Steering bearing installer (Page 6B-8) / (Page 6B-...
Page 536 6B-11 Steering / Handlebar:...
Page 537 Table of Contents 9- i Section 9 Body and Accessories CONTENTS Precautions ..........9-1 Special Tools and Equipment ......9B-12 Special Tool ............9B-12 Precautions............. 9-1 Precautions for Electrical System ......9-1 Combination Meter / Fuel Meter / Horn.. 9C-1 Component Location ..........9-1 General Description ..........9C-1 Electrical Components Location ......
Page 538 9-ii Table of Contents Specifications............9D-7 Steering Lock Bracket Construction ....9E-2 Tightening Torque Specifications......9D-7 Side-stand Construction........9E-2 Side-stand Removal and Installation....9E-3 Special Tools and Equipment ......9D-7 Recommended Service Material ......9D-7 Specifications ............9E-3 Tightening Torque Specifications......9E-3 Body Structure .........9E-1 Special Tools and Equipment ......9E-3 Repair Instructions ..........
Page 539: Precautions
Precautions: Precautions Body and Accessories Precautions Precautions for Electrical System B940H29000001 Refer to “General Precautions in Section 00 (Page 00-1)” and “Precautions for Electrical Circuit Service in Section 00 (Page 00-2)”. Component Location Electrical Components Location B940H29003001 Refer to “Electrical Components Location in Section 0A (Page 0A-7)”.
Page 540: Wiring Systems
9A-1 Wiring Systems: Wiring Systems Body and Accessories Schematic and Routing Diagram Wiring Diagram B940H29102001 Refer to “Wire Color Symbols in Section 0A (Page 0A-5)”.
Page 541 Wiring Systems: 9A-2 For E-02, 19, 24 I940H2910901-01...
Page 542 9A-3 Wiring Systems: For E-03, 28 I940H2910902-01...
Page 543 Wiring Systems: 9A-4 For E-33 I940H2910903-01...
Page 544: Wiring Harness Routing Diagram
9A-5 Wiring Systems: Wiring Harness Routing Diagram B940H29102002 “ b ” “ d ” “ b ” “ c” “A” “B” “ e ” “ a ” “D” “C” I940H1910907-08 1. Clamp 11. Clamp : Bind the handlebar switch (L) lead wire and clutch cable with the clamp. Cut the : Bind the HO2 sensor lead wire with the clamp.
Page 545 Wiring Systems: 9A-6 “ b ” “ a ” “ a ” “ a ” “a” “A” “E” “B” “F” “C” “D” I940H1910909-04 1. Clamp “B”: Pass the wiring harness under the high tension cord. 2. Clamp “C”: Pass the wiring harness backward of the clutch cable. : Cut the tip of clamp after clamping.
Page 546: Specifications
9A-7 Wiring Systems: Specifications Service Data B940H2910S001 Electrical Unit: mm (in) Item Specification Note 10 A Headlight 10 A Fuel 10 A Fuse size Ignition 15 A Signal 10 A Fan motor 15 A Main 30 A...
Page 547: Lighting Systems
Lighting Systems: 9B-1 Lighting Systems Body and Accessories Repair Instructions Front Lighting System Construction B940H29206001 I940H1920033-04 1. Headlight housing brace 3. Headlight cover plate : 8.5 N⋅m (0.85 kgf-m, 6.0 lbf-ft) 2. Front turn signal cover 4. Headlight front cover...
Page 548: Headlight Components
9B-2 Lighting Systems: Headlight Components B940H29206002 I940H1920045-02 1. Headlight unit 2. Headlight bulb (12 V 60/55 W, H4) Headlight Removal and Installation 4) Remove the headlight assembly (3). B940H29206003 Removal “A” 1) Disconnect the headlight coupler (1). 2) Disconnect the position light coupler (2) (For E-02, 19, 24).
Page 549: Headlight Bulb Replacement
Lighting Systems: 9B-3 5) Remove the headlight unit (4). • Tighten the bolts (1) to the specified torque. Tightening torque Headlight cover mounting bolt (a): 8.5 N·m (0.85 kgf-m, 6.0 lbf-ft) I940H1920003-03 Installation Install the headlight in the reverse order of removal. Pay I940H1920041-02 attention to the following points: •...
Page 550: Headlight Beam Adjustment
9B-4 Lighting Systems: Headlight Relay Inspection 3) Replace the headlight bulb (3) by unhooking the bulb holder spring (4). B940H29206006 Inspect the headlight relay in the following procedures: 1) Remove the front seat. Refer to “Exterior Parts Removal and Installation in Section 9D (Page 9D- 5)”.
Page 551: Rear Lighting System Construction
Lighting Systems: 9B-5 Rear Lighting System Construction B940H29206007 I940H1920034-01 1. Rear fender extension 3. License plate bracket (E-02, 19, 24 only) 5. Brake light/Tail light 2. License plate light 4. Rear fender : 5 N⋅m (0.5 kgf-m, 3.5 lbf-ft) Rear Combination Light Removal and Installation B940H29206008 Removal...
Page 552: License Plate Light Components
9B-6 Lighting Systems: 3) Remove the rear fender from the rear fender brace. Refer to “Rear Fender Construction in Section 9D (Page 9D-4)”. 4) Remove the rear combination light (2). I940H1920012-02 Installation Install the rear combination light in the reverse order of removal.
Page 553: License Plate Light Bulb Replacement
Lighting Systems: 9B-7 3) Remove the license plate light by removing the nuts. 2) Remove the lens by removing the screws. I940H1920014-01 I940H1920016-01 3) Replace the bulb (1). Installation Install the license plate light in the reverse order of removal. License Plate Light Bulb Replacement B940H29206011 1) Remove the license plate light by removing the nuts.
Page 554: Turn Signal Light Components
9B-8 Lighting Systems: Turn Signal Light Components B940H29206012 I940H1920048-02 1. Front turn signal light bulb (12 V 21/5 W x 2 for E-03, 28, 33) 3. Lens Front turn signal light bulb (12 V 21 W x 2 for E-02, 19, 24) 2.
Page 555: Rear Turn Signal Light Removal And Installation
Lighting Systems: 9B-9 Rear Turn Signal Light Removal and Installation Turn Signal Light Bulb Replacement B940H29206014 B940H29206015 CAUTION Removal 1) Remove the rear fender. Refer to “Exterior Parts When you touch the bulb with your bare Removal and Installation in Section 9D (Page 9D- hands, clean the bulb with a cloth moistened 5)”.
Page 556: Turn Signal / Side-Stand Relay Inspection
9B-10 Lighting Systems: Turn Signal / Side-stand Relay Inspection 2) Inspect the hazard switch for continuity with a tester. B940H29206016 If any abnormality is found, replace the left Refer to “Electrical Components Location in Section 0A handlebar switch assembly with a new one. Refer to (Page 0A-7)”.
Page 557: Passing Light Switch Inspection
Lighting Systems: 9B-11 Passing Light Switch Inspection Dimmer Switch Inspection B940H29206020 B940H29206021 Inspect the passing light switch in the following Inspect the dimmer switch in the following procedures: procedures: 1) Disconnect the left handlebar switch coupler (1). 1) Disconnect the left handlebar switch coupler (1). I940H1920035-01 2) Inspect the dimmer switch for continuity with a tester.
Page 558: Tightening Torque Specifications
9B-12 Lighting Systems: Tightening Torque Specifications B940H29207002 Tightening torque Fastening part Note N⋅m kgf-m lbf-ft Headlight cover mounting bolt 0.85 (Page 9B-3) NOTE The specified tightening torque is described in the following. “Front Lighting System Construction (Page 9B-1)” “Rear Lighting System Construction (Page 9B-5)” Reference: For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List in Section 0C (Page 0C-8)”.
Page 559: Combination Meter / Fuel Meter / Horn
Combination Meter / Fuel Meter / Horn: 9C-1 Combination Meter / Fuel Meter / Horn Body and Accessories General Description Combination Meter System Description B940H29301001 This combination meter mainly consists of the stepping motor, LCD (Liquid Crystal Display) and LED (Light Emitting Diode).
Page 560: Repair Instructions
9C-2 Combination Meter / Fuel Meter / Horn: Repair Instructions Combination Meter Components B940H29306001 I940H1930032-01 1. Upper cover 3. Combination meter 5. Pilot lamp assembly 2. Upper case assembly 4. Lower case Combination Meter Removal and Installation B940H29306002 Removal 1) Remove the headlight assembly. Refer to “Headlight Removal and Installation in Section 9B (Page 9B-2)”.
Page 561: Combination Meter Disassembly And Assembly
Combination Meter / Fuel Meter / Horn: 9C-3 4) Remove the front brake hose joint (3). • Install the combination meter and tighten the bolts (4) to the specified torque. Tightening torque Combination meter mounting bolt (a): 10 N·m (1.0 kgf-m, 7.0 lbf-ft) I940H1930003-01 5) Remove the combination meter by removing the...
Page 562: Combination Meter Inspection
9C-4 Combination Meter / Fuel Meter / Horn: Combination Meter Inspection 2) With the adjuster switch (1) pressed, turn the ignition B940H29306004 switch ON. LED Inspection 3) Hold the adjuster switch (1), 3 to 5 seconds after Check that the LEDs (FI indicator light, Oil pressure/ turning the ignition switch ON.
Page 563: Engine Coolant Temperature Indicator Light Inspection
Combination Meter / Fuel Meter / Horn: 9C-5 3) Disconnect the pilot lamp lead wire coupler (2). 3) Connect the variable resistor (2) between the terminals. I940H1930012-01 I718H1930009-05 4) Remove the pilot lamp (3) from the fuel tank cover 4) Turn the ignition switch ON. (1).
Page 564: Fuel Level Indicator Inspection
9C-6 Combination Meter / Fuel Meter / Horn: Fuel Level Indicator Inspection B940H29306008 Inspect the fuel level indicator in the following Resistance Thermistor Fuel level meter procedures: 1) Support the motorcycle with a jack or wooden block. Flicker — 2) Lift and support the fuel tank. Refer to “Fuel Tank Removal and Installation in Section 1G (Page 1G- 9)”.
Page 565: Fuel Level Gauge Inspection
Combination Meter / Fuel Meter / Horn: 9C-7 4) When the switch is immersed in kerosene, the bulb should go out. If the bulb remains lit, replace the unit with a new one. NOTE “ a ” “A” • When the bulb turns off, immediately pick up the switch from kerosene.
Page 566: Speed Sensor Inspection
• Apply grease to the O-ring. 12 V 10 kΩ CAUTION Use a new O-ring to prevent oil leakage. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I831G1930018-05 1. Speed sensor 3) Move a screwdriver back and forth across the pick- up surface of the speed sensor.
Page 567: Oil Pressure Switch Removal And Installation
Combination Meter / Fuel Meter / Horn: 9C-9 1) Disconnect the oil pressure switch lead wire (1) from 3) Inspect the ignition switch for continuity with a tester. the oil pressure switch. If any abnormality is found, replace the ignition switch with a new one.
Page 568: Horn Removal And Installation
9C-10 Combination Meter / Fuel Meter / Horn: Horn Removal and Installation 3) Inspect the horn button for continuity with a tester. If any abnormality is found, replace the left B940H29306019 Removal handlebar switch assembly with a new one. 1) Disconnect the horn couplers (1). Refer to “Handlebars Removal and Installation in Section 6B (Page 6B-1)”.
Page 569: Specifications
For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List in Section 0C (Page 0C-8)”. Special Tools and Equipment Recommended Service Material B940H29308001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010 (Page 9C-8)
Page 570: Exterior Parts
9D-1 Exterior Parts: Exterior Parts Body and Accessories Schematic and Routing Diagram Seat Lock Cable Routing Diagram B940H29402001 “A” I940H1940018-03 1. Frame 3. Seat lock 5. Clamp “A”: White tape : Clamp the seat lock cable only. 2. Seat lock cable 4.
Page 571: Repair Instructions
Exterior Parts: 9D-2 Repair Instructions Exterior Parts Construction B940H29406001 I940H1940014-03 1. Frame head cover 5. Frame head cover 2. Frame lower cover (RH) 6. Regulator/Rectifier 3. Frame side cover (RH) 7. Frame lower cover (LH) 4. Frame side lower cover (RH) 8.
Page 572: Frame Head Cover Cushion Construction
9D-3 Exterior Parts: Frame Head Cover Cushion Construction B940H29406002 I940H1940015-02 1. Cushion 3. Frame head cover (RH) : When sticking the cushion on the frame head cover, align the cushion edge with the extension of stopping line. 2. Frame head cover (LH)
Page 573: Rear Fender Construction
Exterior Parts: 9D-4 Rear Fender Construction B940H29406003 “B” “A” “C” I940H1940016-07 1. Rear frame 6. Rear fender “ABC”: After temporary tightening, tighten the bolts to the specified torque in order of “A” → “B” → “C”. 2. Rear fender brace 3.
Page 574: Exterior Parts Removal And Installation
9D-5 Exterior Parts: Exterior Parts Removal and Installation Installation B940H29406004 1) Slide the hook into the seat hook retainer. Front Seat Removal 1) Remove the right frame side cover. Refer to “Exterior Parts Removal and Installation (Page 9D-5)”. 2) Remove the seat with the ignition key. I940H1940004-01 2) Tighten the bolts (1) securely.
Page 575 Exterior Parts: 9D-6 Installation 5) Remove the rear fender brace, rear fender extension Install the frame covers in the reverse order of removal. and rear fender as shown rear fender construction. Pay attention following point: Refer to “Rear Fender Construction (Page 9D-4)”. •...
Page 576: Specifications
For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List in Section 0C (Page 0C-8)”. Special Tools and Equipment Recommended Service Material B940H29408001 Material SUZUKI recommended product or Specification Note Thread lock cement THREAD LOCK CEMENT SUPER P/No.: 99000–32110 (Page 9D-7)
Page 577: Body Structure
Body Structure: 9E-1 Body Structure Body and Accessories Repair Instructions Body Frame Construction B940H29506001 “B” “A” “C” I940H1950003-02 “ABC”: After temporary tightening, tighten the bolts to the specified torque in order of “A” → “B” → “C”. 1. Frame 2. Frame down tube : 50 N⋅m (5.0 kgf-m, 36.0 lbf-ft) 3.
Page 578: Steering Lock Bracket Construction
9E-2 Body Structure: Steering Lock Bracket Construction B940H29506002 I940H1950001-02 1. Frame 3. Steering lock bracket bolt : Do not reuse. 2. Steering lock bracket : 26 N⋅m (2.6 kgf-m, 19.0 lbf-ft) Side-stand Construction B940H29506003 I940H1950002-01 1. Side-stand 3. Side-stand bolt : 50 N⋅m (5.0 kgf-m, 36.0 lbf-ft) : Apply grease to sliding surface.
Page 579: Side-Stand Removal And Installation
Body Structure: 9E-3 Side-stand Removal and Installation Installation B940H29506004 Install the side-stand as shown in the side-stand Removal construction. Refer to “Side-stand Construction 1) Support the motorcycle with the jack or wooden (Page 9E-2)”. block. 2) Remove the side-stand as shown in the side-stand construction.
Page 580 Prepared by September, 2008 Part No. 99500-39370-03E Printed in U.S.A.

Suzuki Intruder VZ1500 Service Manual

Precautions

Precautions

Special Tools and Equipment

Section 1 Engine

Precautions

General Description

Engine General Information and Diagnosis

Schematic and Routing Diagram

Component Location

Diagnostic Information and Procedures

Specifications

Special Tools and Equipment

Emission Control Devices

Precautions

General Description

Schematic and Routing Diagram

Repair Instructions

Special Tools and Equipment

Specifications

Engine Electrical Devices

Precautions

Component Location

Diagnostic Information and Procedures

Repair Instructions

Specifications

Special Tools and Equipment

Schematic and Routing Diagram

Engine Mechanical

Diagnostic Information and Procedures

Repair Instructions

Specifications

Special Tools and Equipment

Engine Lubrication System

Precautions

Schematic and Routing Diagram

Diagnostic Information and Procedures

Repair Instructions

Specifications

Special Tools and Equipment

Engine Cooling System

Precautions

General Description

Schematic and Routing Diagram

Repair Instructions

Diagnostic Information and Procedures

Specifications

Special Tools and Equipment

Fuel System

Precautions

General Description

Schematic and Routing Diagram

Diagnostic Information and Procedures

Repair Instructions

Specifications

Special Tools and Equipment

Ignition System

Schematic and Routing Diagram

Diagnostic Information and Procedures

Repair Instructions

Specifications

Special Tools and Equipment

Diagnostic Information and Procedures

Schematic and Routing Diagram

Starting System

Component Location

Repair Instructions

Specifications

Special Tools and Equipment

Charging System

Schematic and Routing Diagram

Component Location

Diagnostic Information and Procedures

Repair Instructions

Specifications

Special Tools and Equipment

Exhaust System

Precautions

Repair Instructions

Specifications