Page 1 DL1000...
Page 2: Table Of Contents
FOREWORD GROUP INDEX This manual contains an introductory description on the SUZUKI DL1000 and procedures for its inspec- tion/service and overhaul of its main components. GENERAL INFORMATION Other information considered as generally known is not included. Read the GENERAL INFORMATION section to...
Page 3: How To Use This Manual
HOW TO USE THIS MANUAL TO LOCATE WHAT YOU ARE LOOKING FOR: 1. The text of this manual is divided into sections. 2. The section titles are listed in the GROUP INDEX. 3. Holding the manual as shown at the right will allow you to find the first page of the section easily.
Page 4 Apply molybdenum oil solution. Use fork oil. (Mixture of engine oil and SUZUKl 99000-99001-SS8 MOLY PASTE in a ratio of 1 : 1) Apply SUZUKI SUPER GREASE “A”. Apply or use brake fluid. 99000-25010 Apply SUZUKI MOLY PASTE. Measure in voltage range.
Page 5: Abbreviations Used In This Manual
ABBREVIATIONS USED IN THIS MANUAL : Engine Control Module ABDC : After Bottom Dead Center Engine Control Unit (ECU) : Alternating Current (FI Control Unit) : Air Cleaner, Air Cleaner Box ECT Sensor : Engine Coolant Temperature : American Petroleum Institute Sensor (ECTS), Water Temp.
Page 6 MAL-Code : Malfunction Code (Diagnostic Code) : Maximum : Malfunction Indicator Lamp (LED) : Minimum : Nitrogen Oxides : Over Head Camshaft : Oil Pressure Switch : Positive Crankcase Ventilation (Crankcase Breather) : Right Hand : Read Only Memory : Society of Automotive Engineers STC System : Secondary Throttle Control System (STCS) STP Sensor...
Page 7 GENERAL INFORMATION GENERAL INFORMATION CONTENTS WARNING/CAUTION/NOTE ...............1- 2 GENERAL PRECAUTIONS ..............1- 2 SUZUKI DL1000K2 (’02-MODEL) ............1- 4 SERIAL NUMBER LOCATION ............1- 4 FUEL, OIL AND ENGINE COOLANT RECOMMENDATION .....1- 4 FUEL ....................1- 4 ENGINE OIL .................1- 5 BRAKE FLUID ................1- 5 FRONT FORK OIL ...............1- 5...
Page 8: Warning/Caution/Note
GENERAL INFORMATION WARNING/CAUTION/NOTE Please read this manual and follow its instructions carefully. To emphasize special information, the symbol and the words WARNING, CAUTION and NOTE have special meanings. Pay special attention to the mes- sages highlighted by these signal words. Indicates a potential hazard that could result in death or injury.
Page 9 GENERAL INFORMATION " * If parts replacement is necessary, replace the parts with Suzuki Genuine Parts or their equiva- lent. * When removing parts that are to be reused, keep them arranged in an orderly manner so that they may be reinstalled in the proper order and orientation.
Page 10: Suzuki Dl1000K2 ('02-Model)
GENERAL INFORMATION SUZUKI DL1000K2 (’02-MODEL) LEFT SIDE RIGHT SIDE * Difference between photographs and actual motorcycles depends on the markets. SERIAL NUMBER LOCATION The frame serial number or V.I.N. (Vehicle Identification Number) 1 is stamped on the right side of the steering head pipe.
Page 11: Engine Oil
Suzuki recommends the use of SUZUKI COOLANT anti-freeze/engine coolant. If this is not available, use an equivalent which is compatible with an aluminum radiator.
Page 12: Break-Ln Procedures
GENERAL INFORMATION BREAK-lN PROCEDURES During manufacture only the best possible materials are used and all machined parts are finished to a very high standard but it is still necessary to allow the moving parts to “BREAK-IN” before subjecting the engine to maximum stresses.
Page 13: Information Labels
GENERAL INFORMATION INFORMATION LABELS Noise label (For E-03, 24, 33) Information label (For E-03, 28, 33) ICES Canada label (For E-28) " Vacuum hose routing label (For E-33) Fuel caution label (For E-02, 24) Manual notice label (For E-03, 33) Tire pressure label &...
Page 14: Specifications
GENERAL INFORMATION SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length............2 295 mm (90.4 in) Overall width ............865 mm (34.1 in) Overall height............1 335 mm (52.6 in) Wheelbase ............1 535 mm (60.4 in) Ground clearance ..........165 mm ( 6.5 in) Seat height............
Page 15 GENERAL INFORMATION CHASSIS Front suspension..........Inverted telescopic, coil spring, oil damped Rear suspension ..........Link type, coil spring, oil damped Steering angle ............. 40° (right & left) Caster..............26° 30’ Trail ..............111 mm (4.3 in) Turning radius ............. 2.7 m (8.86 ft) Front brake ............
Page 16: Country And Area Codes
1-10 GENERAL INFORMATION COUNTRY AND AREA CODES The following codes stand for the applicable country(-ies) and area(-s). CODE COUNTRY or AREA E-02 U. K. E-03 U. S. A. (Except for California) E-19 E-24 Australia E-28 Canada E-33 California (U. S. A.)
Page 17 PERIODIC MAINTENANCE PERIODIC MAINTENANCE CONTENTS PERIODIC MAINTENANCE SCHEDULE ..........2- 2 PERIODIC MAINTENANCE CHART ...........2- 2 LUBRICATION POINTS ...............2- 3 MAINTENANCE AND TUNE-UP PROCEDURES .......2- 4 AIR CLEANER ................2- 4 SPARK PLUG ................2- 5 TAPPET CLEARANCE ..............2- 7 FUEL HOSE .................2-12 ENGINE OIL AND OIL FILTER ............2-12 ENGINE IDLE SPEED ..............2-14 THROTTLE CABLE PLAY ............2-14...
Page 18: Periodic Maintenance Schedule
PERIODIC MAINTENANCE PERIODIC MAINTENANCE SCHEDULE The chart below lists the recommended intervals for all the required periodic service work necessary to keep the motorcycle operating at peak performance and economy. Mileages are expressed in terms of kilome- ters, miles and time for your convenience. NOTE: More frequent servicing may be performed on motorcycles that are used under severe conditions.
Page 19: Lubrication Points
PERIODIC MAINTENANCE LUBRICATION POINTS Proper lubrication is important for smooth operation and long life of each working part of the motorcycle. Major lubrication points are indicated below. Clutch lever holder Side-stand pivot Footrest pivot Drive chain and spring hook Brake lever holder and throttle cables Brake pedal pivot and footrest pivot...
Page 20: Maintenance And Tune-Up Procedures
PERIODIC MAINTENANCE MAINTENANCE AND TUNE-UP PRO- CEDURES This section describes the servicing procedures for each item of the Periodic Maintenance requirements. AIR CLEANER Inspect every 6 000 km (4 000 miles, 6 months) and replace every 18 000 km (11 000 miles, 18 months). •...
Page 21: Spark Plug
PERIODIC MAINTENANCE NOTE: When cleaning the air cleaner element, drain water from the air cleaner by removing the drain plug. SPARK PLUG Inspect every 6 000 km (4 000 miles, 6 months) and replace every 12 000 km (7 500 miles, 12 months). NO.1 (FRONT) SPARK PLUG REMOVAL •...
Page 22 PERIODIC MAINTENANCE NO.2 (REAR) SPARK PLUG REMOVAL • Remove the seat. (!6-4) • Lift and support the fuel tank. (!4-51) • Remove the spark plug cap. • Remove the spark plug with a spark plug wrench. HEAT RANGE • Check to see the heat range of the plug. Standard Cold type CR8EK...
Page 23: Tappet Clearance
PERIODIC MAINTENANCE SPARK PLUG AND PLUG CAP INSTALLATION " Before using a spark plug wrench, carefully turn the spark plug by finger into the threads of the cylinder head to prevent damage the aluminum threads. • Install the spark plugs to the cylinder heads by finger tight, and then tighten them to the specified torque.
Page 24 PERIODIC MAINTENANCE • Remove the generator cover plug 1 and timing inspection plug 2. • Turn the crankshaft to set the No.1 (Front) cylinder at TDC of compression stroke. (Align the “F | T” line on the generator rotor to the index mark of valve timing inspection hole and also bring the camshafts to the position as shown in page 2-7.) •...
Page 25 PERIODIC MAINTENANCE TAPPET CLEARANCE ADJUSTMENT The clearance is adjusted by replacing the existing tappet shim by a thicker or thinner shim. • Remove the intake or exhaust camshafts. (!3-20) • Remove the tappet and shim by fingers or magnetic hand. •...
Page 26 2-10 PERIODIC MAINTENANCE (INTAKE SIDE)
Page 27 PERIODIC MAINTENANCE 2-11 (EXHAUST SIDE)
Page 28: Fuel Hose
2-12 PERIODIC MAINTENANCE FUEL HOSE Inspect every 6 000 km (4 000 miles, 6 months). Replace every 4 years. Inspect the fuel feed hose A for damage and fuel leakage. If any defects are found, the fuel hoses must be replaced. ENGINE OIL AND OIL FILTER (ENGINE OIL) Replace initially at 1 000 km (600 miles, 1 month) and...
Page 29 Filter change: 2.9 L (3.1/2.6 US/Imp qt) Overhaul engine: 3.3 L (3.5/2.9 US/Imp qt) " ONLY USE A GENUINE SUZUKI MOTORCYCLE OIL FILTER. Other manufacturer’s oil filters may differ in thread specifications (thread diameter and pitch), fil- tering performance and durability which may lead to engine damage or oil leaks.
Page 30: Engine Idle Speed
2-14 PERIODIC MAINTENANCE ENGINE IDLE SPEED Inspect initially at 1 000 km (600 miles, 1 month) and every 6 000 km (4 000 miles, 6 months) thereafter. NOTE: Make this adjustment when the engine is hot. • Start up the engine and set its idle speed to the specified range by turning the throttle stop screw A.
Page 31: Throttle Valve Synchronization
PERIODIC MAINTENANCE 2-15 MAJOR ADJUSTMENT • Remove the fuel tank. (!4-52) • Remove the air cleanet box. (!4-60) • Loosen the locknut 1 of the throttle returning cable. • Turn the returning cable adjuster 2 to obtain proper cable play. •...
Page 32: Clutch
2-16 PERIODIC MAINTENANCE CLUTCH (CLUTCH HOSE AND CLUTCH FLUID) Inspect every 6 000 km (4 000 miles, 6 months). Replace hose every 4 years. Replace fluid every 2 years. CLUTCH FLUID LEVEL • Keep the motorcycle upright and place the handlebars straight.
Page 33: Cooling System
PERIODIC MAINTENANCE 2-17 COOLING SYSTEM Inspect every 6 000 km (4 000 miles, 6 months). Replace engine coolant every 2 years. ENGINE COOLANT LEVEL CHECK • Keep the motorcycle upright. • Check the engine coolant level by observing the full and lower lines on the engine coolant reserve tank.
Page 34 2-18 PERIODIC MAINTENANCE AIR BLEEDING THE ENGINE COOLANT CIRCUIT • Bleed air from the air bleeder bolt 1. • Tighten the air bleeder bolt 1 to the specified torque. & Air bleeder bolt: 13 N·m (1.3 kgf-m, 9.5 lb-ft) • Add engine coolant up to the radiator inlet. •...
Page 35: Drive Chain
PERIODIC MAINTENANCE 2-19 RADIATOR HOSES Check to see the radiator hoses for crack, damage or engine coolant leakage. If any defects are found, replace the radiator hoses with new ones. DRIVE CHAIN Inspect initially at 1 000 km (600 miles, 1 month) and every 6 000 km (4 000 miles, 6 months) thereafter.
Page 36 2-20 PERIODIC MAINTENANCE • Count out 21 pins (20 pitches) on the chain and measure the distance between the two points. If the distance exceeds the service limit, the chain must be replaced. % Drive chain 20-pitch length Service Limit: 319.4 mm (12.6 in) ADJUSTING •...
Page 37: Brake
* Do not use any oil sold commercially as “drive chain oil”. Such oil can damage the “O”-rings (or seals). * The standard drive chain is RK525SMOZ7. SUZUKI recommends that this standard drive chain should be used for the replacement.
Page 38 2-22 PERIODIC MAINTENANCE The brake system of this motorcycle is filled with a glycol-based brake fluid. Do not use or mix different types of fluid such as silicone-based or petro- leum-based. Do not use any brake fluid taken from old, used or unsealed containers. Never re-use brake fluid left over from the last servicing or stored for a long period.
Page 39 PERIODIC MAINTENANCE 2-23 BRAKE PEDAL HEIGHT • Loosen the locknut 1 and rotate the push rod 2 to locate brake pedal 20 – 30 mm (0.8 – 1.2 in) A below the top face of the footrest. • Retighten the locknut 1 to secure the push rod 2 in the proper position.
Page 40 2-24 PERIODIC MAINTENANCE AIR BLEEDING THE BRAKE FLUID CIRCUIT Air trapped in the fluid circuit acts like a cushion to absorb a large proportion of the pressure developed by the master cylin- der and thus interferes with the full braking performance of the brake caliper.
Page 41: Tire
R19M/C (59H) for front and 150/70 R17M/C (69H) for rear. The use of tires other than those specified may cause instability. It is highly recommended to use a SUZUKI Genuine Tire. TIRE TYPE BRIDGESTONE (Front : TW101F Rear : TW152F)
Page 42: Front Fork
2-26 PERIODIC MAINTENANCE FRONT FORK Inspect every 12 000 km (7 500 miles, 12 months). Inspect the front forks for oil leakage, scoring or scratches on the outer surface of the inner tubes. Replace any defective parts, if necessary. (!6-15) REAR SUSPENSION Inspect every 12 000 km (7 500 miles, 12 months).
Page 43: Chassis Bolt And Nut
PERIODIC MAINTENANCE 2-27 CHASSIS BOLT AND NUT Tighten initially at 1 000 km (600 miles, 1 month) and every 6 000 km (4 000 miles, 6 months) thereafter. Check that all chassis bolts and nuts are tightened to their specified torque. (Refer to page 2-28 for the loca- tions of the following nuts and bolts on the motorcycle.) ITEM N·m...
Page 44 2-28 PERIODIC MAINTENANCE...
Page 45: Compression Pressure Check
PERIODIC MAINTENANCE 2-29 COMPRESSION PRESSURE CHECK The compression of a cylinder is a good indicator of its internal condition. The decision to overhaul the cylinder is often based on the results of a compression test. Periodic mainte- nance records kept at your dealership should include compression readings for each maintenance service. COMPRESSION PRESSURE SPECIFICATION (Automatic de-comp.
Page 46: Oil Pressure Check
2-30 PERIODIC MAINTENANCE OIL PRESSURE CHECK Check periodically the oil pressure in the engine to judge roughly the condition of the moving parts. OIL PRESSURE SPECIFICATION Above 400 kPa (4.0 kgf/cm², 57 psi) at 3 000 r/min., Oil temp. at 60°C (140°F) Below 700 kPa (7.0 kgf/cm², 100 psi) If the oil pressure is lower or higher than the specification, the following causes may be considered.
Page 47 ENGINE ENGINE CONTENTS ENGINE COMPONENTS REMOVABLE WITH ENGINE IN PLACE ...3- 2 ENGINE REMOVAL AND INSTALLATION .........3- 3 ENGINE REMOVAL ..............3- 3 ENGINE INSTALLATION .............3-12 ENGINE DISASSEMBLY ..............3-19 ENGINE TOP SIDE ..............3-19 ENGINE BOTTOM SIDE ..............3-25 ENGINE COMPONENTS INSPECTION AND SERVICING ....3-34 CYLINDER HEAD COVER ............3-34 CAMSHAFT/CYLINDER HEAD ...........3-35 CYLINDER/PISTON INSPECTION ..........3-47...
Page 48: Engine Components Removable With Engine In Place
ENGINE ENGINE COMPONENTS REMOVABLE WITH ENGINE IN PLACE The parts listed below can be removed and reinstalled without removing the engine from the frame. Refer to the page listed in this section for removal and reinstallation instructions. ENGINE LEFT SIDE PARTS REMOVAL INSTALLATION...
Page 49: Engine Removal And Installation
ENGINE ENGINE REMOVAL AND INSTALLATION ENGINE REMOVAL Before taking the engine out of the frame, wash the engine using a steam cleaner. Engine removal is sequentially explained in the following steps. Reinstall the engine by reversing the removal procedure. • Drain engine oil. (!2-12) •...
Page 50 ENGINE • Remove the fuel tank 1. • Remove the air cleaner. • Remove the throttle body. • Remove the spark plug caps. • Remove the camshaft position sensor lead wire coupler 1. • Disconnect the gear position switch lead wire coupler 2.
Page 51 ENGINE • Disconnect the generator lead wire coupler 1 and signal gen- erator lead wire coupler 2 by removing the screw A. • Remove the gearshift lever link. • Remove the engine coolant temperature sensor lead wire coupler 3. • Bind the clutch lever with a rubber band to prevent the clutch release cylinder piston from coming out.
Page 52 ENGINE • Remove the push rod 1. • Remove the engine sprocket cover 2. • Remove the speed sensor 3. • Remove the engine sprocket nut and washer while depress- ing the brake pedal. • Remove the cotter pin. (For E-03, 28, 33) •...
Page 53 ENGINE • Disconnect the engine ground lead wire 1. sensor lead wire couplers 2, 3. • Disconnect the O ² • Remove the mufflers. (L & R) • Loosen the front exhaust pipe mounting bolts.
Page 54 ENGINE • Remove the front exhaust pipe. • Remove the mud guard 1. • Remove the rear exhaust pipe. • Remove the right footrest bracket and brake pedal. • Remove the oil cooler 2. • Disconnect the starter motor lead wire 3 and oil pressure switch lead wire 4.
Page 55 ENGINE • Support the engine with an engine jack. • Remove the engine mounting nut 1 and bolt. • Loosen the engine mounting thrust adjuster lock nut with the special tool. " 09940-14990: Engine mounting thrust adjuster socket wrench • Loosen the engine mounting thrust adjuster. "...
Page 56 3-10 ENGINE • Remove the ignition coil lead wires. • Remove the engine mounting nut 1. • Loosen the engine mounting thrust adjuster lock nut. " 09940-14990: Engine mounting thrust adjuster socket wrench • Loosen the engine mounting thrust adjuster 2. •...
Page 57 ENGINE 3-11 • Gradually lower the engine assembly by removing the bolt 1, Be careful not to damage the frame and engine when removing the engine from the frame.
Page 58: Engine Installation
3-12 ENGINE ENGINE INSTALLATION Remount the engine in the reverse order of engine removal. Pay attention to the following points: NOTE: * The engine mounting nuts are self-locking. * Once the nut has been removed, it is no longer of any use. Be sure to use new nuts, and then tighten them to the specified torque.
Page 59 ENGINE 3-13 • Before installing the engine assembly, install the spacer A, collar B and engine thrust adjuster C, D. • Install the collar B onto the crankcase properly as shown. • Apply THREAD LOCK “1342” to the engine mounting bracket bolts.
Page 60 3-14 ENGINE • Put the drive chain on the driveshaft. • Gradually raise the engine assembly and align all the bolt holes. • Install the engine mounting bolts and bracket bolts, and tighten them temporarily. • Tighten the engine mounting thrust adjuster and its lock nut to the specified torque with the special tool.
Page 61 ENGINE 3-15 • Tighten the engine mounting nut A, B to the specified torque. $ Engine mounting nut A: 75 N·m (7.5 kgf-m, 54.0 lb-ft) Engine mounting nut B: 55 N·m (5.5 kgf-m, 40.0 lb-ft) • After tightening the bolt C, tighten the pinch bolt D to the specified torque.
Page 62 3-16 ENGINE ITEM N·m kgf-m lb-ft 16.5 • Adjust the brake pedal height. & Brake pedal height A Standard: 20 – 30 mm (0.8 – 1.2 in) • Install the gearshift arm as shown. & Gearshift arm angle A: Approx. 60°...
Page 63 • Tighten the speed sensor rotor bolt to the specified torque. " Speed sensor rotor bolt: 18 N·m (1.8 kgf-m, 13.0 lb-ft) • Apply SUZUKI SUPER GREASE “A” to the push rod 1 and install it. • Install the clutch release cylinder.
Page 64 3-18 ENGINE • After installing the engine, route the wire harness, cables and hoses properly. (!8-14) • Adjust the following items. * Engine oil !2-12 * Engine coolant !2-17 * Engine idle speed !2-14 * Throttle cable play !2-14 & Engine oil capacity Oil change: 2.7 L (2.9/2.4 US/lmp qt) Oil and filter change: 2.9 L (3.1/2.6 US/lmp qt)
Page 65: Engine Disassembly
ENGINE 3-19 ENGINE DISASSEMBLY ENGINE TOP SIDE • Remove the thermostat. • Remove the valve timing inspection plug 1 and generator cover plug 2. FRONT CYLINDER HEAD COVER • Remove the front cylinder head cover 1. • Turn the crankshaft to bring the “F | T” line on generator rotor to the index mark of the valve inspection hole and also to bring the cams to the position as shown.
Page 66 3-20 ENGINE FRONT CYLINDER CAMSHAFT • Remove the camshaft journal holders. Be sure to loosen the camshaft journal holder bolts evenly by shifting the wrench diagonally. • Remove the camshafts. NOTE: Do not drop the dowel pins into the crankcase. FRONT CAM CHAIN TENSION ADJUSTER •...
Page 67 ENGINE 3-21 STARTER MOTOR • Remove the starter motor. • Remove the cylinder head nut. • Loosen the cylinder nuts. • Remove the oil cooler mounting bracket 1. • Remove the cylinder head bolts. • Remove the cylinder head. NOTE: * When loosening the cylinder head bolts, loosen each bolt little by little diagonally.
Page 68 3-22 ENGINE • Remove the cylinder base gasket and dowel pins. FRONT PISTON • Place a clean rag over the cylinder base so as not to drop the piston pin circlip into the crankcase. • Remove the piston pin circlip. •...
Page 69 ENGINE 3-23 Pull the front cam chain upward, or the chain will be caught between the crankcase and cam drive idle gear/sprocket when turning the crankshaft. REAR CYLINDER CAMSHAFT • Remove the two camshaft journal holders. Be sure to loosen the camshaft journal holder bolts evenly by shifting the wrench diagonally.
Page 70 3-24 ENGINE • Remove the cylinder head bolts and cam chain tensioner mounting bolt. • Remove the cam chain tensioner. • Remove the cylinder head nuts 1. • Remove the cylinder head nut 2. • Loosen the cylinder nuts 3. •...
Page 71: Engine Bottom Side
ENGINE 3-25 • Remove the cylinder base gasket and dowel pins. REAR PISTON • Place a clean rag over the cylinder base so as not to drop the piston pin circlip into the crankcase. • Remove the piston pin circlip. •...
Page 72 3-26 ENGINE • Remove the bushings 1 from the crankcase and generator cover. CLUTCH COVER • Remove the water pump case. WATER PUMP DISASSEMBLY !5-13 CLUTCH • Remove the clutch cover. • Hold the generator rotor with the special tool. "...
Page 73 ENGINE 3-27 • Remove the clutch push piece, bearing and thrust washer. • Remove the clutch push rod 1. • Remove the clutch drive and driven plates. • Remove the wave washer 2 and wave washer seat 3. • Unlock the clutch sleeve hub nut. •...
Page 74 3-28 ENGINE • Remove the washer 1 and 2. • Remove the clutch sleeve hub 3. • Remove the thrust washer 4. • Remove the primary driven gear assembly. • Remove the needle roller bearing, spacer and thrust washer. GEAR POSITION SWITCH •...
Page 75 ENGINE 3-29 OIL SUMP FILTER • Remove the oil sump filter. OIL PUMP • Remove the oil pump driven gear 1 by removing the snap ring. " 09900-06107: Snap ring pliers • Remove the pin 2 and washer 3. NOTE: Do not drop the snap ring, pin and washer into the crankcase.
Page 76 3-30 ENGINE • Insert a suitable bar into the holes of primary drive gears to align the teeth of scissors gears. • Remove the cam drive idle gear/sprocket and cam chain. • Remove the key 1. PRIMARY DRIVE GEAR • Hold the generator rotor with the special tool. "...
Page 77 ENGINE 3-31 • Remove the key 1 and thrust washer 2. GENENRATOR ROTOR • While holding the generator rotor with the special tool, remove its bolt. " 09930-44541: Rotor holder • Install the special tool to the boss. • Remove the generator rotor by turning the special tool while holding the generator rotor with the special tool.
Page 78 3-32 ENGINE • Draw out the gearshift shaft 1. • Remove the gearshift cam plate 2. • Remove the gearshift cam stopper 3. • Remove the engine sprocket spacer 4. • Remove the cam drive idle gear shaft 5. • Remove the crankcase bolts.
Page 79 ENGINE 3-33 • Separator the crankcase into 2 parts, right and left with the crankcase separating tool. " 09920-13120: Crankcase separating tool NOTE: * Fit the crankcase separating tool, so that the tool arms are in parallel with the side of crankcase. * The crankshaft and transmission components should remain in the left crankcase half.
Page 80: Engine Components Inspection And Servicing
• If the carbon deposit is found in the reed valve, replace it with a new one. REASSEMBLY • Apply SUZUKI SUPER GREASE “A” to the O-ring and install ' 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “B” (Others) •...
Page 81: Camshaft/Cylinder Head
ENGINE 3-35 CAMSHAFT/CYLINDER HEAD Be sure to identify each removed part as to its loca- tion, and lay the parts out in groups designated as “No.1”, “No.2”, “Exhaust”, “Intake”, so that each will be restored to the original location during assembly. CAMSHAFT “FRONT”...
Page 82 3-36 ENGINE CAMSHAFT JOURNAL WEAR Determine whether or not each journal is worn down to the limit by measuring the oil clearance with the camshaft installed in place. Use the plastigauge A to read the clearance at the widest portion, which is specified as follows: &...
Page 83: Camshaft Runout
ENGINE 3-37 CAMSHAFT RUNOUT Measure the runout with a dial gauge. Replace the camshaft if the runout exceeds the limit. & Camshaft runout Service Limit (IN & EX): 0.10 mm (0.004 in) " 09900-20607: Dial gauge (1/100 mm, 10 mm) 09900-20701: Magnetic stand 09900-21304: V-block (100 mm) CAM GEAR AND AUTOMATIC-DECOMP.
Page 84 3-38 ENGINE CYLINDER HEAD • Remove the tappets and shims 1 by fingers or magnetic hand. • Using special tools, compress the valve spring and remove the two cotter halves 2 from the valve stem. " 09916-14510: Valve lifter 09916-14910: Valve lifter attachment 09916-84511: Tweezers •...
Page 85 ENGINE 3-39 • Remove the oil seals 1 and the spring seats 2. Do not reuse the removed oil seals. CYLINDER HEAD DISTORTION Decarbonize the combustion chambers. Check the gasketed surface of the cylinder head for distortion with a straightedge and thickness gauge, taking a clearance reading at several places indicated.
Page 86 3-40 ENGINE VALVE FACE WEAR Visually inspect each valve for wear of its seating face. Replace any valve with an abnormally worn face. The thickness T decreases as the wear of the face advances. Measure the thickness and, if the thickness is found to have been reduced to the limit, replace it.
Page 87 ENGINE 3-41 • Re-finish the valve guide holes in cylinder head with the reamer and handle. " 09916-34580: Valve guide reamer 09916-34542: Reamer handle • Oil the stem hole, too, of each valve guide and drive the guide into the guide hole with the valve guide installer and attach- ment.
Page 88 3-42 ENGINE • The ring-like dye impression left on the valve face must be continuous without any break. In addition, the width of the dye ring, which is the visualized seat “width”, must be within the following specification: & Valve seat width W Standard: 0.9 –...
Page 89 ENGINE 3-43 If the contact area is too high on the valve, or if it is too wide, use Contact area too high and too the 15°/60° cutters (for exhaust side) and 30°/60° cutters (for wide on face of valve intake side) to lower and narrow the contact area.
Page 90 3-44 ENGINE VALVE SPRING The force of the coil spring keeps the valve seat tight. Weak- ened spring results in reduced engine power output, and often account for the chattering noise coming from the valve mecha- nism. Check the valve springs for proper strength by measuring their free length and also by the force required to compress them.
Page 91 ENGINE 3-45 If the thrust clearance exceeds the standard range, adjust the thrust clearance by the following procedures: • Remove the thrust washer, and measure its thickness with a micrometer. • Change the thrust washer with the other washer if the thrust clearance is incorrect.
Page 92 3-46 ENGINE • Install the valve spring with the small-pitch portion A facing cylinder head. Paint B: Large-pitch portion UPWARD • Put on the valve spring retainer, and using the valve lifter, press down the spring, fit the cotter halves to the stem end, and release the lifter to allow the cotter 1 to wedge in between retainer and stem.
Page 93: Cylinder/Piston Inspection
• When installing the intake pipe, apply grease to the O-ring. NOTE: “UP” mark faces upward. ' 99000-25030: SUZUKI SUPER GREASE ‘‘A’’ (USA) 99000-25010: SUZUKI SUPER GREASE ‘‘A’’ (Others) Use the new O-ring to prevent air from sucking through the joint.
Page 94: Piston Diameter
3-48 ENGINE CYLINDER BORE Inspect the cylinder wall for any scratches, nicks or other dam- age. Measure the cylinder bore diameter at six places. & Cylinder bore Standard: 98.000 – 98.015 mm (3.8583 – 3.8589 in) " 09900-20508: Cylinder gauge set PISTON DIAMETER Using a micrometer, measure the piston outside diameter at 10 mm (0.4 in) from the piston skirt end.
Page 95: Piston Ring Thickness
ENGINE 3-49 PISTON RING TO GROOVE CLEARANCE Using a thickness gauge, measure the side clearances of the 1st and 2nd rings. If any of the clearances exceeds the limit, replace both piston and piston rings. & Piston ring to groove clearance Service Limit (1st) : 0.18 mm (0.0071 in) (2nd) : 0.15 mm (0.0059 in) &...
Page 96: Conrod/Crankshaft
3-50 ENGINE PISTON PIN AND PIN BORE Using a small bore gauge, measure the piston pin bore inside diameter, and using a micrometer, measure the piston pin out- side diameter. If the difference between these two measure- ments is more than the limits, replace both piston and piston pin. &...
Page 97 ENGINE 3-51 & Conrod big end width Standard: 21.95 – 22.00 mm (0.864 – 0.866 in) & Crank pin width Standard: 44.17 – 44.22 mm (1.739 – 1.741 in) " 09900-20205: Micrometer (0 – 25 mm) CONROD-CRANK PIN BEARING INSPECTION •...
Page 98 3-52 ENGINE • Remove the caps and measure the width of compressed plas- tigauge with envelope scale. This measurement should be taken at the widest part. & Conrod big end oil clearance Service Limit: 0.080 mm (0.0031 in) • If oil clearance exceeds the service limit, select the specified bearings from the bearing selection table.
Page 99 ENGINE 3-53 Bearing thickness Color code Color (Part No.) Thickness Green 1.476 – 1.480 mm (12164-02F11-0A0) (0.0581 – 0.0583 in) Black 1.480 – 1.484 mm (12164-02F11-0B0) (0.0583 – 0.0584 in) Brown 1.484 – 1.488 mm (12164-02F11-0C0) (0.0584 – 0.0586 in) Yellow 1.488 –...
Page 100: Clutch
3-54 ENGINE • When fitting the conrods on the crankshaft, make sure that I.D. codes A of the conrods face each cylinder intake valve sides. Never reuse the bearing cap bolt. Apply engine oil to the bearing cap bolts. 35 N·m 3.5 kgf-m •...
Page 101 ENGINE 3-55 CLUTCH DRIVEN PLATES NOTE: Wipe off engine oil from the clutch driven plates with a clean rag. Measure each driven plate for distortion with a thickness gauge and surface plate. Replace driven plates which exceed the limit. & Driven plate distortion Service Limit: 0.10 mm (0.004 in) Measuring distortion "...
Page 102: Transmission
3-56 ENGINE TRANSMISSION CONSTRUCTION 1st driven gear 5th driven gear " 4th driven gear 3rd driven gear 6th driven gear 2nd driven gear & Drive shaft Countershaft 5th drive gear 3rd & 4th drive gear 6th drive gear 2nd drive gear...
Page 103 ENGINE 3-57 DISASSEMBLY Be sure to identify each removed part as to its loca- tion, and lay the parts out in groups designated as “Drive” and “Driven”, so that each will be restored to the original location during assembly. Countershaft •...
Page 104 3-58 ENGINE Driveshaft • Remove the low driven gear 1 and washer 2. • Remove the low driven gear bushing 3, washer 4 and 5th driven gear 5. • Remove the snap ring with the special tool. " 09900-06107: Snap ring pliers •...
Page 105 ENGINE 3-59 • Remove the washer 1. • Remove the top driven gear 2 by removing the snap ring. " 09900-06107: Snap ring pliers • Remove the snap ring with the special tool. " 09900-06107: Snap ring pliers • Remove the 2nd driven gear 3, its bushing 4 and washer 5. REASSEMBLY Assemble the transfer in the reverse order of disassembly.
Page 106 3-60 ENGINE • When installing a new snap ring, pay attention to the direction of the snap ring. Fit it to the side where the thrust is as shown Thrust in the figure. Sharp edge When installing the 3rd and 4th driven gear bushings on to the driveshaft, align the shaft oil holes A with the bushing oil hole B.
Page 107 ENGINE 3-61...
Page 108: Gearshift Fork
3-62 ENGINE GEARSHIFT FORK GEARSHIFT FORK TO GROOVE CLEARANCE Using a thickness gauge, check the gearshift fork clearance in the groove of its gear. The clearance for each gearshift fork plays an important role in the smoothness and positiveness of the shifting action. &...
Page 109: Primary Drive Gear
ENGINE 3-63 PRIMARY DRIVE GEAR PRIMARY DRIVE GEAR INSPECTION Visually inspect the gear teeth for wear and damage. If they are worn, replace the gear with a new one. PRIMARY DRIVE GEAR DISASSEMBLY • Disassemble the primary drive gear by removing the snap ring 1.
Page 110: Starter Torque Limiter
3-64 ENGINE • Install the snap ring 1 completely with the special tool. " 09900-06107: Snap ring pliers * Never reuse a snap ring. * When installing a new snap ring, care must be taken not to expand the end gap larger than required to slip a snap ring over the gear.
Page 111: Starter Clutch
ENGINE 3-65 STARTER CLUTCH DISASSEMBLY • Remove the starter clutch securing bolts by holding the rotor with the special tool. " 09930-44541: Rotor holder REASSEMBLY • Install the starter clutch in the proper direction. NOTE: * When installing the starter clutch onto the rotor, face the flange side A of the one way clutch to the rotor.
Page 112: Gearshift
3-66 ENGINE GEARSHIFT GEARSHIFT SHAFT/GEARSHIFT ARM DISASSEMBLY • Remove the following parts from the gearshift shaft/gearshift arm 1. 2 Washer 6 Plate return spring 3 Snap ring 7 Washer 4 Gearshift shaft return spring 8 Snap ring 5 Gearshift cam drive plate 9 Washer "...
Page 113 OIL PRESSURE SWITCH • Remove the oil pressure switch 1. • When installing the oil pressure switch, apply SUZUKI BOND “1215” to the thread. $ Oil pressure switch: 14 N·m (1.4 kgf-m, 10.0 lb-ft) + 99000-31110: SUZUKI BOND “1215”...
Page 114 3-68 ENGINE • Remove the oil jet with a suitable bar. • Remove the oil jet. Check the oil jets for clogging. If they are clogged, clean their oil passage with a proper wire or compressed air. • Fit the new O-ring to the oil jet. Use the new O-ring to prevent oil leakage.
Page 115 ENGINE 3-69 • Apply engine oil to the new O-ring and install it. • Apply THREAD LOCK “1342” to the screw and tighten it to the specified torque. $ Piston cooling oil nozzle screw: 8 N·m (0.8 kgf-m, 6.0 lb-ft) % 99000-32050: THREAD LOCK “1342”...
Page 116 3-70 ENGINE • Remove the oil seal. The removed oil seal must be replaced with a new one. • Remove the oil seal with the special tool. " 09913-50121: Oil seal remover The removed oil seal must be replaced with a new one. •...
Page 117: Crankcase-Crankshaft Bearing
ENGINE 3-71 • Install the bearing retainers. NOTE: When installing the bearing retainers, apply THREAD LOCK to the screws. % 09900-32050: THREAD LOCK “1342” • Install the oil seals with the special tool. " 09913-70210: Bearing installer set • Install the oil seal retainer. CRANKCASE-CRANKSHAFT BEARING CRANKCASE-CRANKSHAFT BEARING INSPECTION •...
Page 118 3-72 ENGINE CRANKCASE-CRANKSHAFT BEARING SELECTION Select the specified bearings from the crankcase bore I.D. code. The crankcase bore I.D. code A “A”, “B” or “C”, is stamped on the inside of each crankcase half. Bearing selection table I.D. code A I.D.
Page 119 ENGINE 3-73 • Gradually press out the bearing with the special tool by using the hand-press. Hand-press The removed bearings must be replaced with new Bearing Crankcase ones. NOTE: Bearing Using the hand-press is recommended to remove the crankshaft journal bearings. However, the crankshaft journal bearings can be removed by using with the following special tools.
Page 120 3-74 ENGINE • Tighten the special tool bolt to the specified torque. $ Special tool bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft) Before installing the bearings, lightly shave off the sharp edge part of the crankcase chamfer by using an oilstone and wash the crankcase bore with enough engine oil.
Page 121 1 stops the special tool 2. " 09913-60230: Journal bearing remover/installer Hand-press Bearing Bearing Use the new special tool A (09913-60230) for DL1000. The tool A and B differ in length C. For DL1000 For TL1000S/R (09913-60230) (09913-60210)
Page 122 3-76 ENGINE • After installing the bearings, check the bearing surface for any scratch or damage.
Page 123: Generator Cover
• Install the new oil seal with the special tool. " 09913-70210: Bearing installer set NOTE: Apply grease to the oil seal lip to prevent damage when install- ing the gearshift cover. ' 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others)
Page 124: Engine Reassembly
3-78 ENGINE ENGINE REASSEMBLY Reassemble the engine in the reverse order of disassembly. NOTE: Apply engine oil to each running and sliding part before reas- sembling. ENGINE BOTTOM SIDE CRANKSHAFT • Install the crankshaft into the left crankcase half. NOTE: Coat lightly molybdenum oil solution to the crankshaft journal bearings.
Page 125 99000-25010: SUZUKI SUPER GREASE “A” (Others) Use the new O-ring to prevent oil leakage. • Clean the mating surfaces of the left and right crankcase halves. • Apply SUZUKI BOND “1215” to the mating surface of the left crankcase. + 99000-31110: SUZUKI BOND ‘‘1215’’ NOTE: Use of SUZUKI BOND “1215”...
Page 126 * The grooved A side of the engine sprocket spacer faces crankcase side. * Apply grease to the oil seal lip and O-ring. ' 99000-25030: SUZUKI SUPER GREASE ‘‘A’’ (USA) 99000-25010: SUZUKI SUPER GREASE ‘‘A’’ (Others) GEARSHIFT • Install the gearshift cam stopper 2, its bolt 3, washer 4 and return spring 5.
Page 127 ENGINE 3-81 • Confirm the gearshift cam stopper movement. • Check the neutral position. • Install the gearshift cam stopper plate after aligning the gear- shift cam pin A with the gearshift cam stopper plate hole B. • Apply a small quantity of THREAD LOCK “1342” to the gear- shift cam stopper plate bolt 1 and tighten it to the specified torque.
Page 128 * Fit the clamp to the bolt A. * Apply grease to the oil seal lip before installing the gearshift cover. ' 99000-25030: SUZUKI SUPER GREASE ‘‘A’’ (USA) 99000-25010: SUZUKI SUPER GREASE ‘‘A’’ (Others) GENERATOR ROTOR • Install the cam drive idle gear shaft 1.
Page 129 ENGINE 3-83 • While holding the generator rotor with the special tool, tighten the bolt to the specified torque. $ Generator rotor bolt: 160 N·m (16.0 kgf-m, 115.5 lb-ft) " 09930-44541: Rotor holder PRIMARY DRIVE GEAR • Install the thrust washer onto the crankshaft. NOTE: The grooved side A of the thrust washer faces the crankcase side.
Page 130 3-84 ENGINE • Hold the generator rotor with the special tool. " 09930-44541: Rotor holder • While holding the generator rotor, tighten the primary drive gear nut to the specified torque. $ Primary drive gear nut: 115 N·m (11.5 kgf-m, 83.0 lb-ft) •...
Page 131 ENGINE 3-85 • Hold the generator rotor with the special tool. " 09930-44541: Rotor holder • While holding the generator rotor, tighten the cam drive idle gear/sprocket nut to the specified torque. $ Cam drive idle gear/sprocket nut: 70 N·m (7.0 kgf-m, 50.5 lb-ft) Before tightening the cam drive idle gear/sprocket nut, be sure to engage the front and rear cam chains to each sprocket.
Page 132 3-86 ENGINE • Install the gear position switch and cable guide. OIL PUMP DRIVEN GEAR • Install the washer 1 and pin 2. • Install the oil pump driven gear by installing the snap ring. " 09900-06107: Snap ring pliers NOTE: The boss A of the oil pump driven gear faces crankcase side.
Page 133 ENGINE 3-87 • Install the primary driven gear assembly 1 onto the counter- shaft. NOTE: * When installing the primary driven gear assembly, align the teeth of the primary drive gears by inserting a suitable bar to the holes of them. * Be sure to engage the oil pump drive and driven gears, pri- mary drive and driven gears.
Page 134 3-88 ENGINE • Lock the clutch sleeve hub nut with a center punch. • Install the spring washer seat 1 and spring washer 2 onto the clutch sleeve hub correctly. • Insert the clutch drive plates and driven plates one by one into the clutch sleeve hub in the prescribed order, No.3 drive plate being inserted first.
Page 135 ENGINE 3-89 Direction of outside NOTE: *The No.2 Driven plate should be installed between 4th to 7th position from the clutch sleeve hub. *Set the numbers of driven plate to the standard specifications when replacing the driven plates with the new ones. DRIVEN PLATE: No.1 Driven plate...5 –...
Page 136 * Install the bracket D. • Fit the dowel pin. • Apply the grease to the O-ring. ' 99000-25030: SUZUKI SUPER GREASE ‘‘A’’ (USA) 99000-25010: SUZUKI SUPER GREASE ‘‘A’’ (Others) • Install the water pump case. • Install the starter idle gear 1, spacer 2 and shaft 3.
Page 137 ENGINE 3-91 • Install the bushings A into the crankcase and generator cover. NOTE: Apply molybdenum oil solution to the inside of the bushings. ) MOLYBDENUM OIL • Fit the washers onto the starter torque limiter. • Install the starter torque limiter. •...
Page 138: Engine Top Side
3-92 ENGINE OIL FILTER • Apply engine oil lightly to the O-ring. • Install the oil filter turning it by hand until feeling that the O-ring contacts the mounting surface. Then tighten it 2 turns with the special tool. " 09915-40610: Oil filter wrench •...
Page 139 ENGINE 3-93 • Position the gaps of the three rings as shown. Before inserting each piston into the cylinder, check that the gaps are so located. • 2nd ring 120˚ • Lower side • Upper side rail rail 120˚ 120˚ •...
Page 140 • Apply engine oil to the new O-rings. • Install each of the oil jets. Use the new O-rings to prevent oil leakage. CYLINDER • Coat SUZUKI BOND “1215” lightly to the mating surfaces at the parting line between the right and left crankcases as shown. FRONT NOTE: When replacing the stud bolt A, apply SUZUKI BOND “1215”...
Page 141 ENGINE 3-95 • Hold the piston rings in proper position, and insert each of the pistons into the respective cylinders. NOTE: When installing the cylinders, keep the cam chains taut. The cam chain must not be caught between cam drive sprocket and crankcase when turning the crankshaft.
Page 142 3-96 ENGINE NOTE: * Install the washers to the cylinder head bolts (M10) as shown. * Apply engine oil to the washers and thread portion of the bolts before installing the cylinder head bolts. • After firmly tightening the cylinder head bolts (M10), install the cylinder head nuts and bolts.
Page 143 ENGINE 3-97 • Place the front cylinder head on the cylinder. NOTE: When installing the cylinder head, keep the cam chain taut. • Tighten the cylinder head bolts (M10) to the specified two-step torque with a torque wrench sequentially and diago- nally.
Page 144 3-98 ENGINE • Pull the cam chains upward and install the cam chain tension- ers into each cylinder head. 1 For No.1 (Front) cylinder head 2 For No.2 (Rear) cylinder head NOTE: * When installing the cam chain tensioners, insert the their holder ends A into each guide cast on the cylinder.
Page 145 ENGINE 3-99 FRONT CAM DRIVE IDLE GEAR/SPROCKET • Turn the crankshaft counterclockwise with the box wrench and align “F I T” line A on the generator rotor with the index mark B of the valve timing inspection hole while keeping the camshaft drive chain pulled upward.
Page 146 3-100 ENGINE • Check and correct the positions of the “F I T” line on the gen- erator rotor and cam drive idle gear/sprocket 1. When checking the positions, remove the cam chain slack at the cam chain guide 2 side by holding the cam drive idle gear/sprocket by hand.
Page 147 ENGINE 3-101 NOTE: When checking the cam drive idle gear/sprocket 1 position at its gear tooth, top or root, bring the eye level as shown in right illustration. 6˚ • Tighten the cam drive idle gear/sprocket shaft to the specified torque.
Page 148 3-102 ENGINE • Compress the cam chain tension adjuster rod 1 fully by releasing the ratchet 2. Push • From this position, turn out the cam chain tension adjuster bolt 3 until locking the cam chain tension adjuster rod 1. Now the cam chain tension adjuster is ready to install.
Page 149 ENGINE 3-103 • Install the cam chain tension adjuster as shown and tighten its mounting bolts to the specified torque. $ Cam chain tension adjuster mounting bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft) • Release the cam chain tension adjuster by turning in its bolt NOTE: Click sound is heard when the cam chain tension adjuster rod is released.
Page 150 NOTE: Apply grease to the O-ring before installing. ' 99000-25030: SUZUKI SUPER GREASE ‘‘A’’ (USA) 99000-25010: SUZUKI SUPER GREASE ‘‘A’’ (Others) $ Cam chain tension adjuster bolt (Rear): 7 N·m (0.7 kgf-m, 5.0 lb-ft)
Page 151 ENGINE 3-105 CAMSHAFT • Rotate the generator rotor 720 degrees (2 turns) and align the “F I T” line on the generator rotor with the index mark of the valve timing inspection hole. • Recheck the position of the engraved lines A on the front and rear cam drive idle gears/sprockets.
Page 152 3-106 ENGINE NOTE: “EXF” “INF” “EXR” “INR” The cam shafts are identified by the engraved letters. 1 No.1 (Front) exhaust camshaft 2 No.1 (Front) intake camshaft 3 No.2 (Rear) exhaust camshaft 4 No.2 (Rear) intake camshaft NOTE: Before placing the camshafts on cylinder head, apply molybde- num oil solution to their journals and cam faces.
Page 153 ENGINE 3-107 • Install the camshaft journal holders, intake and exhaust. • Fasten the camshaft journal holders evenly by tightening the camshaft journal holder bolts sequentially and diagonally. (Try to equalize the pressure by shifting the wrench in the above manner, to fasten the shafts evenly.) NOTE: * Damage to head or camshaft journal holder thrust surfaces...
Page 154 3-108 ENGINE NO.2 (REAR) CAMSHAFTS • Install the No.2 (Rear) camshafts, intake and exhaust, in the following procedure. • From the position where the No.1 (Front) camshafts have now been installed, rotate the generator rotor 360 degrees (1 turn) and align the “F I T” line on the generator rotor with the index mark of the valve timing inspection hole.
Page 155 ENGINE 3-109 • Install the camshaft journal holders, intake and exhaust. • Fasten the camshaft journal holders evenly by tightening the camshaft journal holder bolts sequentially and diagonally. (Try to equalize the pressure by shifting the wrench in the above manner, to fasten the shafts evenly.) NOTE: * Damage to head or camshaft journal holder thrust surfaces...
Page 156 3-110 ENGINE • After installing the No.2 (Rear) camshafts, rotate the genera- tor rotor 360 degrees (1 turn), and recheck the positions of the camshafts. Be sure to check the positions of the “F I T” line A on the generator rotor, engraved line B on the cam drive idle gears/sprockets and the engraved line C on the camshafts.
Page 157 Be sure to check the tappet clearance. CYLINDER HEAD COVER • Install the new gaskets ( 2, 3) to each cylinder head cover. • Apply SUZUKI BOND “1207B” to the cam end caps of the gaskets as shown. , 99000-31140: SUZUKI BOND “1207B”...
Page 158 • Install the new O-ring to the starter motor. Use the new O-ring to prevent oil leakage. • Apply grease to the O-ring. ' 99000-25030: SUZUKI SUPER GREASE ‘‘A’’ (USA) 99000-25010: SUZUKI SUPER GREASE ‘‘A’’ (Others) • Install the starter motor.
Page 159: Fi System
FI SYSTEM CONTENTS PRECAUTIONS IN SERVICING ..............4- 2 CONNECTOR/COUPLER ..............4- 2 FUSE ...................... 4- 3 ECM/VARIOUS SENSORS ..............4- 3 ELECTRICAL CIRCUIT INSPECTION PROCEDURE ......4- 5 USING TESTERS ................... 4- 8 FI SYSTEM TECHNICAL FEATURES ............4- 9 INJECTION TIME (INJECTION VOLUME) ..........
Page 160 FI SYSTEM FUEL TANK LIFT-UP ................4-51 FUEL TANK REMOVAL .................4-52 FUEL TANK INSTALLATION ..............4-52 FUEL PRESSURE INSPECTION ............4-53 FUEL PUMP INSPECTION ..............4-54 FUEL PUMP RELAY INSPECTION ............4-55 FUEL PUMP AND FUEL FILTER REMOVAL ........4-55 FUEL MESH FILTER INSPECTION AND CLEANING ......4-57 FUEL PUMP AND FUEL MESH FILTER INSTALLATION ....4-57 THROTTLE BODY AND STV ACTUATOR .............4-59 CONSTRUCTION ...................4-59...
Page 161: Precautions In Servicing
FI SYSTEM PRECAUTIONS IN SERVICING When handling the FI component parts or servicing the FI sys- tem, observe the following points for the safety of the system. CONNECTOR/COUPLER • When connecting a connector, be sure to push it in until a click is felt.
Page 162: Fuse
FI SYSTEM • When connecting meter probe from the terminal side of the coupler (connection from harness side not being possible), use extra care not to force and cause the male terminal to bend or the female terminal to open. Connect the probe as shown to avoid opening of female ter- minal.
Page 163 FI SYSTEM Ignition S/W • When disconnecting and connecting the ECM couplers, make sure to turn OFF the ignition switch, or electronic parts may get damaged. • Battery connection in reverse polarity is strictly prohibited. INCORRECT Such a wrong connection will damage the components of the FI system instantly when reverse power is applied.
Page 164: Electrical Circuit Inspection Procedure
FI SYSTEM ELECTRICAL CIRCUIT INSPECTION PROCEDURE While there are various methods for electrical circuit inspection, described here is a general method to check for open and short circuit using an ohmmeter and a voltmeter. OPEN CIRCUIT CHECK Possible causes for the open circuit are as follows. As the cause can exist in the connector/coupler or terminal, they need to be checked carefully.
Page 165 FI SYSTEM Continuity check • Measure resistance across coupler B (between A and C in the figure). If no continuity is indicated (infinity or over limit), the circuit is open between terminals A and C. • Disconnect the coupler B and measure resistance between ’...
Page 166 FI SYSTEM SHORT CIRCUIT CHECK (WIRE HARNESS TO GROUND) • Disconnect the negative cable from the battery. To other • Disconnect the connectors/couplers at both ends of the circuit parts to be checked. NOTE: If the circuit to be checked branches to other parts as shown, disconnect all connectors/couplers of those parts.
Page 167: Using Testers
FI SYSTEM USING TESTERS • Use the Suzuki multi-circuit tester (09900-25008). • Use well-charged batteries in the tester. • Be sure to set the tester to the correct testing range. Using the tester MULTI-CIRCUIT TESTER • Incorrectly connecting the + and - probes may cause the inside of the tester to burnout.
Page 168: Fi System Technical Features
FI SYSTEM FI SYSTEM TECHNICAL FEATURES INJECTION TIME (INJECTION VOLUME) The factors to determine the injection time include the basic fuel injection time which is calculated on the basis of the intake air pressure, engine speed and throttle opening angle, and various compensations. These compensations are determined according to the signals from various sensors that detect the engine and driving conditions.
Page 169: Compensation Of Injection Time (Volume)
4-10 FI SYSTEM COMPENSATION OF INJECTION TIME (VOLUME) The following different signals are output from the respective sensors for compensation of the fuel injection time (volume). SIGNAL DESCRIPTION ATMOSPHERIC PRESSURE SENSOR When atmospheric pressure is low, the sensor sends the SIGNAL signal to the ECM and reduce the injection time (volume).
Page 170: Fuel Delivery System
FI SYSTEM 4-11 FUEL DELIVERY SYSTEM The fuel delivery system consists of the fuel tank, fuel pump, fuel filters, fuel feed hose, fuel delivery pipe (including fuel injectors) and fuel pressure regulator. There is no fuel return hose. The fuel in the fuel tank is pumped up by the fuel pump and pressurized fuel flows into the injector installed in the fuel delivery pipe.
Page 171: Fuel Pump
4-12 FI SYSTEM FUEL PUMP The electric fuel pump is mounted at the bottom of the fuel tank, which consists of the armature, magnet, impeller, brush, check valve and relief valve. The ECM controls its ON/OFF operation as controlled under the FUEL PUMP CONTROL SYSTEM.
Page 172: Fuel Pressure Regulator
FI SYSTEM 4-13 FUEL PRESSURE REGULATOR The fuel pressure regulator consists of the spring and valve. It keeps absolute fuel pressure of 300 kPa (3.0 kgf/cm , 43 psi) to be applied to the injector at all times. When the fuel pressure rises more than 300 kPa (3.0 kgf/cm , 43 psi), the fuel pushes the valve in the regu- lator open and excess fuel returns to the fuel tank.
Page 173: Fuel Pump Control System
4-14 FI SYSTEM FUEL PUMP CONTROL SYSTEM When the ignition switch is turned on, current from the battery flows to the fuel pump motor through the side- stand relay and the fuel pump relay causing the motor to turn. Since the ECM has a timer function, the fuel pump motor stops turning in three seconds after the switch has been turned on.
Page 174: Ecm (Fi Control Unit)
FI SYSTEM 4-15 ECM (FI CONTROL UNIT) The ECM is located under the seat. The ECM consists of CPU (Central Processing Unit), memory (ROM) and I/O (Input/Output) sections. The signal from each sensor is sent to the input section and then sent to CPU. On the basis of signal information received, CPU calculates the volume of fuel necessary for injection using maps programmed for varying engine conditions.
Page 175: Sensors
4-16 FI SYSTEM SENSORS INTAKE AIR PRESSURE SENSOR (IAP SENSOR) The intake air pressure sensor is located at the rear side of the air cleaner box and its vacuum hose is connected to the throttle body. The sensor detects the intake air pressure, which is then con- verted into voltage signal and sent to the ECM.
Page 176 FI SYSTEM 4-17 CRANKSHAFT POSITION SENSOR (CKP SENSOR) The signal rotor is mounted on the left end of the crankshaft, and the crankshaft position sensor (Pick-up coil) is installed in the generator cover. The sensor generates the pick-up signal to be supplied to the ECM.
Page 177 4-18 FI SYSTEM ENGINE COOLANT TEMPERATURE SENSOR (ECT SENSOR) The engine coolant temperature sensor is installed at the ther- mostat case. The sensor detects the engine oil temperature in thermistor resistance value, which is then converted to voltage signal and sent to the ECM.
Page 178 FI SYSTEM 4-19 TIP OVER SENSOR (TO SENSOR) The tip over sensor is located above the AP sensor. The sensor detects the leaning of the motorcycle. When it leans more than 65°, the mechanical switch turns ON and a signal is sent to the ECM.
Page 179: Fi System Parts Location
4-20 FI SYSTEM FI SYSTEM PARTS LOCATION Atomospheric pressure sensor (APS) Speedometer Crankshaft position sensor (CKPS) Secondary throttle position sensor (STPS) Speed sensor Throttle position sensor (TPS) Fuel pump (FP) Secondary throttle valve actuator (STVA) Ignition coil (IG COIL) Tip over sensor (TOS) Fuel pump relay (FP RELAY)
Page 180 FI SYSTEM 4-21 Gear position switch Intake air temperature sensor (IATS) Heated oxygen sensor (HO Intake air pressure sensor (IAPS) PAIR solenoid valve Camshaft position sensor (CMPS) Fuel injector (FI) Engine coolant temperature sensor (ECTS)
Page 181: Fi System Wiring Diagram
4-22 FI SYSTEM FI SYSTEM WIRING DIAGRAM...
Page 182: Self-Diagnosis Function
FI SYSTEM 4-23 SELF-DIAGNOSIS FUNCTION The self-diagnosis function is incorporated in the ECM. The function has two modes, “User mode” and “Dealer mode”. The user can only be notified by the LCD (DISPLAY) panel and LED (FI light). To check the function of the individual FI system devices, the dealer mode is prepared.
Page 183: Dealer Mode
4-24 FI SYSTEM DEALER MODE The defective function is memorized in the computer. Use the special tool’s coupler to connect to the dealer mode coupler. The memorized malfunction code is displayed on LCD (DISPLAY) panel. Malfunction means that the ECM does not receive signal from the devices. These affected devices are indicated in the code form.
Page 184: Tps Adjustment
FI SYSTEM 4-25 CODE MALFUNCTION PART REMARKS None No defective part Camshaft position sensor (CMPS) Crankshaft position sensor (CKPS) Pick-up coil signal, signal generator Intake air pressure sensor (IAPS) Throttle position sensor (TPS) Engine coolant temp. sensor (ECTS) Intake air temp. sensor (IATS) Atmospheric pressure sensor (APS) Tip over sensor (TOS) Ignition signal #1 (IG coil #1)
Page 185: Fail-Safe Function
4-26 FI SYSTEM FAIL-SAFE FUNCTION FI system is provided with fail-safe function to allow the engine to start and the motorcycle to run in a mini- mum performance necessary even under malfunction condition. ITEM FAIL-SAFE MODE STARTING ABILITY RUNNING ABILITY Intake air pressure sensor Intake air pressure is “YES”...
Page 186: Fi System Troubleshooting
FI SYSTEM 4-27 FI SYSTEM TROUBLESHOOTING CUSTOMER COMPLAINT ANALYSIS Record details of the problem (failure, complaint) and how it occurred as described by the customer. For this purpose, use of such an inspection form will facilitate collecting information to the point required for proper analysis and diagnosis.
Page 187 4-28 FI SYSTEM MOTORCYCLE/ENVIRONMENTAL CONDITION WHEN PROBLEM OCCURS Environmental condition Weather Fair Cloudy Rain Snow Always Other Temperature Warm Cool Cold ( °F/ °C) Always Frequency Always Sometimes ( times/ day, month) Only once Under certain condition Road Urban Suburb Highway Mountainous ( Uphill...
Page 188: Self-Diagnostic Procedures
FI SYSTEM 4-29 SELF-DIAGNOSTIC PROCEDURES • Don’t disconnect couplers from ECM, battery cable from bat- tery, ECM ground wire harness from engine or main fuse before confirming malfunction code (self-diagnostic trouble code) stored in memory. Such disconnection will erase mem- orized information in ECM memory.
Page 189: Malfunction Code And Defective Condition
4-30 FI SYSTEM MALFUNCTION CODE AND DEFECTIVE CONDITION MALFUNCTION DETECTED FAILURE CONDITION DETECTED ITEM CODE CHECK FOR NO FAULT ––––––––––– Camshaft position sen- The signal does not reach ECM for more than 3 sec. after receiving the starter signal. The camshaft position sensor wiring and mechanical parts. (Camshaft position sensor, intake cam pin, wiring/coupler con- nection) Crankshaft position...
Page 190 FI SYSTEM 4-31 Secondary throttle When no actuator control signal is supplied from the ECM or valve actuator communication signal does not reach ECM or operation voltage does not reach STVA motor, C28 is indicated. STVA can not operate. STVA lead wire/coupler. The sensor should produce following voltage.
Page 191: C11" Cmp Sensor Circuit Malfunction
4-32 FI SYSTEM “C11” CMP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE No CMP sensor signal for 3 seconds at engine • Metal particles or foreign material being attached cranking. on the CMP sensor and rotor tip. • CMP sensor circuit open or short. •...
Page 192: C12" Ckp Sensor Circuit Malfunction
FI SYSTEM 4-33 “C12” CKP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE No CKP sensor signal for 3 seconds at engine • Metal particles or foreign material being attached cranking. on the CKP sensor and rotor tip. • CKP sensor circuit open or short. •...
Page 193: C13" Iap Sensor Circuit Malfunction
4-34 FI SYSTEM “C13” IAP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE Low pressure and low voltage. • Clogged vacuum passage between throttle body High pressure and high voltage. and IAP sensor. < • Air being drawn from vacuum passage between 0.10 V Sensor voltage 4.80 V...
Page 194 FI SYSTEM 4-35 Remove the IAP sensor. Connect the vacuum pump gauge to the vacuum port of the IAP sensor. Arrange 3 new 1.5 V batteries in series (check that total voltage is 4.5 – 5.0 V) and connect terminal to the ground terminal and terminal to the Vcc terminal.
Page 195: C14" Tp Sensor Circuit Malfunction
4-36 FI SYSTEM “C14” TP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE Signal voltage low or high. • TP sensor maladjusted. Difference between actual throttle opening and open- • TP sensor circuit open or short. ing calculated by ECM in larger than specified value. •...
Page 196 FI SYSTEM 4-37 Connect the TP sensor/injector coupler Insert the copper wires to the lead wire coupler. Turn the ignition switch ON. Measure the TP sensor output voltage at the coupler (between P/W and B/Br wires) by turning the throttle grip. B/Br B/Br TP sensor output voltage...
Page 197: C15" Ect Sensor Circuit Malfunction
4-38 FI SYSTEM “C15” ECT SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE High engine coolant temp. (Low voltage – Low • B/Bl circuit shorted to ground. resistance) • B/Br circuit open. Low engine coolant temp. (High voltage – High • ECT sensor malfunction. resistance) •...
Page 198: C21" Iat Sensor Circuit Malfunction
FI SYSTEM 4-39 “C21” IAT SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE High intake air temp. (Low voltage – Low resis- • Dg circuit shorted to ground. tance) • B/Br circuit open. Low intake air temp. (High voltage – High resis- •...
Page 199: C22" Ap Sensor Circuit Malfunction
4-40 FI SYSTEM “C22” AP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE Low pressure and low voltage. • Clogged air passage with dust. High pressure and high voltage. • Red wire circuit open or shorted to ground. < • B/Br or G/Y wire circuit shorted to ground. 0.10 V Sensor voltage 4.80 V...
Page 200 FI SYSTEM 4-41 Remove the AP sensor. Connect the vacuum pump gauge to the air passage port of the AP sensor. Arrange 3 new 1.5 V batteries in series (check that total voltage is 4.5 – 5.0 V) and connect terminal to the ground terminal and terminal to the Vcc terminal.
Page 201: C23" To Sensor Circuit Malfunction
4-42 FI SYSTEM “C23” TO SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE No TO sensor signal for more than 4 seconds, • TO sensor circuit open or short. after ignition switch turns ON. • TO sensor malfunction. Sensor voltage high. •...
Page 202: C24" Or "C25" Ignition System Malfunction
FI SYSTEM 4-43 “C24” or “C25” IGNITION SYSTEM MALFUNCTION *REFER TO THE IGNITION SYSTEM FOR DETAILS. (#7-19) “C28” STV ACTUATOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE The operation voltage does not reach the STVA. • STVA malfunction. ECM does not receive communication signal from •...
Page 203: C29" Stp Sensor Circuit Malfunction
4-44 FI SYSTEM “C29” STP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE Signal voltage low or high. • STP sensor maladjusted. Difference between actual throttle opening and • STP sensor circuit open or short. opening calculated by ECM in larger than specified •...
Page 204 FI SYSTEM 4-45 Turn the ignition switch OFF. Connect the STP sensor coupler. Insert the copper wires to the lead wire coupler. Yellow Disconnect the STVA lead wire coupler. Turn the ignition switch ON. Measure the STP sensor output voltage at the coupler B/Br (between Yellow and B/Br wires) by turning the secondary throttle valve (close and open) with a finger.
Page 205: C31" Gear Position (Gp) Switch Circuit Malfunction
4-46 FI SYSTEM “C31” GEAR POSITION (GP) SWITCH CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE No Gear Position switch voltage • Gear Position switch circuit open or short. Switch voltage low. • Gear Position switch malfunction. • ECM malfunction. Switch Voltage > 1.0 V without the above value.
Page 206: C32" Or "C33" Fuel Injection Malfunction
FI SYSTEM 4-47 “C32” or “C33” FUEL INJECTION MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE No injector current. • Injector circuit open or short. • Injector malfunction. • ECM malfunction. INSPECTION • Remove the fuel tank and air cleaner box. ( : 4-52 and -60) Turn the ignition switch OFF.
Page 207: C41" Fp Relay Circuit Malfunction
4-48 FI SYSTEM “C41” FP RELAY CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE No signal from fuel pump relay. • Fuel pump relay circuit open or short. • Fuel pump relay malfunction. • ECM malfunction. INSPECTION • Remove the seat. ( 6-4) Turn the ignition switch OFF.
Page 208: C44" Ho
FI SYSTEM 4-49 “C44” HO SENSOR (HO S) CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE Output voltage of HO Sensor higher than the spec- • HO sensor or its circuit open or short. ification or lower than the specification. • Fuel system malfunction. •...
Page 209 4-50 FI SYSTEM Turn the ignition switch OFF. Insert the copper wire to the ECM lead wire coupler terminal terminal (Heater circuit). Turn the ignition switch ON and measure the heater voltage between terminal and ground. If the tester voltage indicates the battery voltage for few seconds it is good condition.
Page 210: Fuel System
FI SYSTEM 4-51 FUEL SYSTEM FUEL TANK LIFT-UP • Remove the seat. (#6-4) • Remove the fuel tank side covers, left and right. • Remove the cowling fitting bolts, left and right. • Remove the fuel tank top cover by removing the bolts and fas- teners.
Page 211: Fuel Tank Removal
4-52 FI SYSTEM FUEL TANK REMOVAL • Lift and support the fuel tank with the fuel tank prop stay. (#4-51) • Disconnect the fuel pump lead wire coupler 1. • Place a rag under the fuel feed hose and disconnect the feed hose 2 from the fuel tank.
Page 212: Fuel Pressure Inspection
FI SYSTEM 4-53 FUEL PRESSURE INSPECTION • Lift and support the fuel tank with the fuel tank prop stay. (#4-51) • Place a rag under the fuel feed hose. (#4-52) • Remove the fuel feed hose and install the special tools between the fuel tank and fuel delivery pipe.
Page 213: Fuel Pump Inspection
4-54 FI SYSTEM FUEL PUMP INSPECTION Turn the ignition switch ON and check that the fuel pump oper- ates for few seconds. If the fuel pump motor does not make operating sound, replace the fuel pump assembly or inspect the fuel pump relay and tip over sensor.
Page 214: Fuel Pump Relay Inspection
FI SYSTEM 4-55 FUEL PUMP RELAY INSPECTION Fuel pump relay is located behind the ECM. • Remove the seat. • Remove the fuel pump relay. First, check the insulation between 1 and 2 terminals with pocket tester. Then apply 12 volts to 3 and 4 terminals, + to 3 and - to 4, and check the continuity between 1 and 2.
Page 215 4-56 FI SYSTEM • Remove the screws. • Remove the fuel pump assy from the fuel pump plate. • Remove the fuel pump holder. • Remove the fuel mesh filter. • Remove the fuel pressure regulator holder 1 and the fuel pressure regulator 2.
Page 216: Fuel Mesh Filter Inspection And Cleaning
FI SYSTEM 4-57 FUEL MESH FILTER INSPECTION AND CLEANING If the fuel mesh filter is clogged with sediment or rust, fuel will not flow smoothly and loss in engine power may result. Blow the fuel mesh filter with compressed air. NOTE: If the fuel mesh filter is clogged with many sediment or rust, replace the fuel filter cartridge with a new one.
Page 217 • Install the new O-ring and apply grease to it. The O-ring must be replaced with a new one to prevent fuel leakage. & 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) • When installing the fuel pump assembly, first tighten all the...
Page 218: Throttle Body And Stv Actuator
FI SYSTEM 4-59 THROTTLE BODY AND STV ACTUATOR CONSTRUCTION 5 N . m Intake pipe side (0.5 kgf-m, 3.7 lb-ft) Forward 3 N . m VIEW OF TOP 0.3 kgf-m, 2.0 lb-ft 15˚ – 25˚ Air cleaner side 15˚ – 25˚ 5 N .
Page 219: Throttle Body Removal
4-60 FI SYSTEM THROTTLE BODY REMOVAL • Remove the fuel tank. (#4-52) • Loosen the respective throttle body clamp screws (air cleaner side). • Disconnect the *PAIR solenoid valve lead wire coupler, IAP senor coupler and IAT sensor coupler. • Disconnect the PAIR hoses from the PAIR solenoid valve. •...
Page 220: Throttle Body Disassembly
FI SYSTEM 4-61 • Disconnect the throttle cables from their drum. • Dismount the throttle body assembly. " * Be careful not to damage the throttle cable bracket and fast idle lever when dismounting or remounting the throttle body assembly. * After disconnecting the throttle cables, do not snap the throttle valve from full open to full close.
Page 221 4-62 FI SYSTEM • Remove the fuel injectors. • Disconnect the TPS coupler. • Remove the TPS and STPS with the special tool. ! 09930-11950: Torx wrench NOTE: Prior to disassembly, mark each sensor’s original position with a paint or scribe for accurate reinstallation. •...
Page 222 FI SYSTEM 4-63 " Never remove the STVA motor yoke and motor. " Avoid removing the STV adjuster A unless absolutely necessary. " Never remove the throttle valve and secondary throttle valve.
Page 223 4-64 FI SYSTEM • Remove the throttle body link plates. • Remove the throttle lever No.2 1 and secondary throttle lever No.2 2. • Remove the throttle lever No.1 3 and secondary throttle lever No.1 4.
Page 224: Throttle Body Cleaning
Pay attention to the following points: • Be careful not to apply grease to the other parts when apply- ing the grease to the shaft. & 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) • Install the actuator cover 1.
Page 225 4-66 FI SYSTEM • Apply thread lock “1342” to the actuator cover nuts and tighten them. ( 99000-32050: THREAD LOCK “1342” ' STVA cover nut: 2.0 N·m (0.2 kgf-m, 1.5 lb-ft) • Install the fast idle cam and tighten its mounting nut. ' Fast idle cam mounting nut: 4.0 N·m (0.4 kgf-m, 3.0 lb-ft) •...
Page 226 2. • Apply a small quantity of grease to the shaft ends and seal lips. & 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) • With the STV fully closed, install the STP sensor. ! 09930-11950: Torx wrench ' STP sensor mounting screw: 3.5 N·m (0.35 kgf-m, 2.5 lb-ft)
Page 227: Stp Sensor Adjustment
4-68 FI SYSTEM • With the TV fully closed, install the TP sensor. ! 09930-11950: Torx wrench ' TP sensor mounting screw: 3.5 N·m (0.35 kgf-m, 2.5 lb-ft) • Set each STV to the same opening by turning the balance screw 1.
Page 228: Throttle Body Installation
FI SYSTEM 4-69 If the measured resistance is not within specification, adjust the STV adjuster A as follows: • Under above condition, turn in or out the STV adjuster A until the resistance becomes specified value. If the measured resistance is not obtain, replace the STP sen- sor with a new one, and adjust the STP sensor positioning again.
Page 229: Fuel Injector Removal
4-70 FI SYSTEM FUEL INJECTOR REMOVAL • Remove the fuel tank and air cleaner box. (#4-52 and -60) • Remove the fuel delivery pipe assembly. (#4-61) • Disconnect the injector couplers. • Remove the fuel injectors No.1 and No.2. (#4-62) INSPECTION Check fuel injector filter for evidence of dirt and contamination.
Page 230: Fast Idle Adjutment
FI SYSTEM 4-71 FAST IDLE ADJUTMENT • Remove the fuel tank and air cleaner box. (#4-52 and -60) • Disconnect the STVA lead wire coupler and turn the ignition switch ON. • Open the STV gradually with the finger and just when the STP sensor output voltage has become 3.0 V.
Page 231: Throttle Valve Synchronization
4-72 FI SYSTEM THROTTLE VALVE SYNCHRONIZATION Check and adjust the throttle valve synchronization between two cylinders. ! 09913-13121: Vacuum balancer gauge NOTE: Before balancing the throttle valves, calibrate each vacuum bal- ancer gauge. • Remove the fuel tank and air cleaner box. (#4-52 and -60) •...
Page 232: Throttle Cable Adjustment
FI SYSTEM 4-73 • Start up the engine and run it in idling condition for warming • Stop the warmed-up engine. • Connect a tachometer and start up the engine. • Bring the engine rpm to 1 200 rpm by the throttle stop screw. •...
Page 233: Sensor
4-74 FI SYSTEM SENSOR IAP SENSOR INSPECTION The intake air pressure sensor is located at the rear side of the air cleaner box. (#4-34) IAP SENSOR REMOVAL/INSTALLATION • Lift and support the fuel tank. (#4-51) • Remove the IAP sensor 1 by removing the screw and dis- connect the coupler 2 and vacuum hose 3.
Page 234: Ckp Sensor Inspection
FI SYSTEM 4-75 CKP SENSOR INSPECTION The signal rotor is mounted on the generator rotor and crank- shaft position sensor (Pick-up coil) is installed in the generator cover. (#4-33) CKP SENSOR REMOVAL/INSTALLATION (#3-77) CMP SENSOR INSPECTION The signal rotor is installed on the No.2 intake camshaft, and the camshaft position sensor (Pick-up coil) is installed on the No.2 cylinder head cover.
Page 235: Ect Sensor Inspection
4-76 FI SYSTEM ECT SENSOR INSPECTION The engine coolant temperature sensor is installed on the ther- mostat case. (#4-38 and 5-10) ECT SENSOR REMOVAL/INSTALLATION (#5-10) AP SENSOR INSPECTION The atmospheric pressure sensor is located under the seat. (#4-40) AP SENSOR REMOVAL/INSTALLATION •...
Page 236: Ho 2 Sensor Removal/Installation
FI SYSTEM 4-77 SENSOR REMOVAL/INSTALLATION • Remove the engine under cover. • Disconnect the HO sensor lead wire couplers. • Remove the HO sensor unit. Do not remove the HO sensor while it is hot. " Be careful not to expose it to excessive shock. Do not use an impact wrench while removing or installing the HO sensor unit.
Page 237: Cooling And Lubrication
COOLING AND LUBRICATION SYSTEM COOLING AND LUBRICATION SYSTEM CONTENTS ENGINE COOLANT ................5- 2 COOLING CIRCUIT ................5- 3 COOLING CIRCUIT INSPECTION ..........5- 3 RADIATOR ...................5- 4 REMOVAL ..................5- 4 INSPECTION AND CLEANING ...........5- 5 INSTALLATION ................5- 6 RADIATOR RESERVOIR TANK ............5- 6 REMOVAL/INSTALLATION ............5- 6 RADIATOR CAP ...................5- 6 INSPECTION ................5- 6...
Page 238: Engine Coolant
COOLING AND LUBRICATION SYSTEM ENGINE COOLANT At the time of manufacture, the cooling system is filled with a 50:50 mixture of distilled water and ethylene glycol anti-freeze. Anti-freeze Freezing point density This 50:50 mixture will provide the optimum corrosion protection and excellent heat protection, and will protect the cooling system –31˚C (–24˚F) from freezing at temperatures above –31°C (–24°F).
Page 239: Cooling Circuit
COOLING AND LUBRICATION SYSTEM COOLING CIRCUIT RESERVE TANK RADIATOR (Upper) RADIATOR (Lower) NO. 1 CYLINDER HEAD NO. 1 CYLINDER THERMOSTAT WATER PUMP NO. 2 CYLINDER NO. 2 CYLINDER HEAD COOLING CIRCUIT INSPECTION Before removing the radiator and draining the engine coolant, inspect the cooling circuit for tightness.
Page 240: Radiator
COOLING AND LUBRICATION SYSTEM RADIATOR REMOVAL • Remove the cowling. (#6-6) • Drain engine coolant. (#2-17) • Disconnect the uper and lower radiator hoses from the radia- tor. • Disconnect the siphon hose from the radiator. • Remove the reservoir tank by removing its mounting bolt. •...
Page 241: Inspection And Cleaning
COOLING AND LUBRICATION SYSTEM • With the fasteners unlocked, remove the radiator shroud 1. • Remove the cooling fan and horn. • Remove the cooling fan thermo-switch. INSPECTION AND CLEANING • Road dirt or trash stuck to the fins must be removed. •...
Page 242: Installation
COOLING AND LUBRICATION SYSTEM INSTALLATION • Install the cooling fan and horn. $ Cooling fan/horn mounting bolt: 8 N·m (0.8 kgf-m, 6.0 lb-ft) • Install a new O-ring and tigten the cooling fan thermo-switch to the specified torque. $ Cooling fan thermo-switch: 17 N·m (1.7 kgf-m, 12.5 lb-ft) •...
Page 243: Water Hose
COOLING AND LUBRICATION SYSTEM WATER HOSE INSPECTION • Remove the cowling. (#6-6) • Any water hose found in a cracked condition or flattened or water leaked must be replaced. • Any leakage from the connecting section should be corrected by proper tightening.
Page 244: Cooling Fan
COOLING AND LUBRICATION SYSTEM COOLING FAN REMOVAL • Remove the cowling. (#6-6) • Drain engine coolant. (#2-17) • Remove the radiator. (#5-4) • Remove the cooling fan. INSPECTION • Remove the cowling. (#6-6) • Disconnect the cooling fan motor lead wire coupler 1. •...
Page 245: Cooling Fan Thermo-Switch
COOLING AND LUBRICATION SYSTEM COOLING FAN THERMO-SWITCH REMOVAL • Remove the cowling. (#6-6) • Drain engine coolant. (#2-17) • Disconnect the cooling fan thermo-switch lead wire coupler • Remove the cooling fan thermo-switch 2. INSPECTION • Check the thermo-switch closing or opening temperatures by testing it at the bench as shown in the figure.
Page 246: Engine Coolant Temperature Sensor
5-10 COOLING AND LUBRICATION SYSTEM ENGINE COOLANT TEMPERATURE SENSOR REMOVAL • Drain engine coolant. (#2-17) • Remove the seat. (#6-4) • Remove the fuel tank right side cover. • Remove the IAP sensor vacuum damper. • Disconnect the engine coolant temperature sensor lead wire coupler.
Page 247: Thermostat
COOLING AND LUBRICATION SYSTEM 5-11 THERMOSTAT REMOVAL • Drain engine coolant. (!2-17) • Place a rag under the thermostat case. • Remove the thermostat case. • Remove the thermostat 1. INSPECTION Inspect the thermostat pellet for signs of cracking. Test the thermostat at the bench for control action, in the follow- ing manner.
Page 248: Installation
5-12 COOLING AND LUBRICATION SYSTEM INSTALLATION • Install the thermostat. NOTE: The jiggle valve A of the thermostat faces upside. • Install the thermostat case. • Tighten the thermostat case bolts to the specified torque. $ Thermostat case bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft) •...
Page 249: Water Pump
COOLING AND LUBRICATION SYSTEM 5-13 WATER PUMP REMOVAL AND DISASSEMBLY • Remove the engine under cover. (#3-3) • Drain engine coolant. (#2-17) • Drain engine oil. (#2-12) • Remove the right footrest. • Disconnect the water hoses and crankcase breather hose. •...
Page 250 5-14 COOLING AND LUBRICATION SYSTEM • Remove the bearing using the special tool. & 09921-20240: Bearing remover set NOTE: If there is no abnormal noise, bearing removal is not necessary. The removed bearing must be replaced with a new one. •...
Page 251: Inspection
COOLING AND LUBRICATION SYSTEM 5-15 INSPECTION BEARING • Inspect the play of the bearing by hand while it is in the water pump case. • Rotate the inner race by hand to inspect for abnormal noise and smooth rotation. • Replace the bearing if there is anything unusual. MECHANICAL SEAL •...
Page 252 5-16 COOLING AND LUBRICATION SYSTEM • Apply a small quantity of the SUZUKI SUPER GREASE “A” to the oil seal lip. ) 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) • Install the new mechanical seal using a suitable size socket wrench.
Page 253 COOLING AND LUBRICATION SYSTEM 5-17 NOTE: The paint marked side A of the mechanical seal ring faces the impeller. • Install the impeller to the water pump body. • Fix the impeller shaft with the snap ring securely. • Install a new O-ring 1. Use a new O-ring to prevent engine coolant leakage.
Page 254: Lubrication System
5-18 COOLING AND LUBRICATION SYSTEM LUBRICATION SYSTEM OIL PRESSURE #2-30 OIL FILTER #2-13 OIL PRESSURE REGULATOR #3-67 OIL STRAINER #3-29 and -85 OIL JET #3-67, -68 and -94 OIL PUMP #3-66 and -67 OIL PRESSURE SWITCH #3-67 and 7-32 OIL COOLER REMOVAL •...
Page 255: Inspection And Cleaning
COOLING AND LUBRICATION SYSTEM 5-19 • Remove the oil cooler fin guard net. • Remove the oil hoses. INSPECTION AND CLEANING • Inspect the oil cooler and hose joints for oil leakage. If any defect are found, replace the oil cooler and oil hoses with the new ones.
Page 256: Engine Lubrication Flow Chart
5-20 COOLING AND LUBRICATION SYSTEM ENGINE LUBRICATION FLOW CHART...
Page 257: Engine Lubrication Circuit
COOLING AND LUBRICATION SYSTEM 5-21 ENGINE LUBRICATION CIRCUIT...
Page 258 CHASSIS CHASSIS CONTENTS EXTERIOR PARTS ............................6- 2 CONSTRUCTION ..........................6- 2 REMOVAL ............................6- 4 FRONT WHEEL ............................6- 8 CONSTRUCTION ..........................6- 8 REMOVAL ............................6- 9 INSPECTION AND DISASSEMBLY ....................6- 9 REASSEMBLY AND REMOUNTING ..................... 6-11 FRONT FORK ..............................
Page 259: Exterior Parts
CHASSIS EXTERIOR PARTS CONSTRUCTION Screen Cowling brace " Fuel tank top cover Combination meter panel Cowling body Right cowling & Left cowling Left side cowling Right side cowling Inner cowling Engine under cover Cowling brace mounting bolt ITEM N·m kgf-m lb-ft 25.5...
Page 260 CHASSIS...
Page 261: Removal
CHASSIS REMOVAL SEAT • Remove the seat with the ignition key. FRONT TANK COVERS • Remove the seat. (!Above) • Remove the fuel tank side cover mounting secrew. • Remove thefuel tank side cover by pulling on the hooked parts. ✩: hooked part CARRIER •...
Page 262 CHASSIS FRAME COVERS • Remove the seat. (!6-4) • Remove the carrier. (!6-4) • Remove the fuel tank cover. (!6-4) • Remove the screw 1 and clip 2. • Remove the frame cover by pulling on the hooked part. ✩: hooked part REAR FENDER •...
Page 263 CHASSIS COWLING AND COWLING BRACE • Remove the screen by removing two screws. • Remove the fuel tank top cover 1 by removing the fasteners. • Remove the combination cover mounting screws. • Remove the combination meter panel 2 by removing the fas- teners.
Page 264 CHASSIS • Remove the right cowling 5. • Remove the turn signals. • Remove the cowling body 6. • Disconnect the couplers. • Remove the cowling blace 7. • Remove the combination meter. (!7-22)
Page 265: Front Wheel
CHASSIS FRONT WHEEL CONSTRUCTION Brake disc Dust seal " Bearing Center spacer Coller Front wheel Tire valve Front axle Brake disc bolt ITEM N·m kgf-m lb-ft 10.0 72.5 16.5...
Page 266: Removal
CHASSIS REMOVAL • Remove the right and left brake calipers 1. • Loosen two axle pinch bolts 2 on the right front fork leg. " Do not operate the brake lever while removing the cal- ipers. • Slightly loosen the front axle by using the special tool. # 09944-28320: Hexagon bit 19 mm •...
Page 267 6-10 CHASSIS • Remove the dust seal by using the oil seal remover. # 09913-50121: Oil seal remover " Do not reuse the removed dust seals. FRONT AXLE Using a dial gauge, check the front axle for runout and replace it if the runout exceeds the limit.
Page 268: Reassembly And Remounting
CHASSIS 6-11 REASSEMBLY AND REMOUNTING Reassemble and remount the front wheel in the reverse order of removal and disassembly. Pay attention to the following points: Left Right 39 N . m 3.9 kgf-m 39 N . m 28.0 lb-ft 3.9 kgf-m 28.0 lb-ft 23 N .
Page 269 CHASSIS WHEEL BEARING • Apply grease to the wheel bearings. % 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) • First install the left wheel bearing, then install the right wheel bearing and spacer by using the special tools.
Page 270 CHASSIS 6-13 WHEEL Install the front wheel with the front axle and tighten the front axle temporarily. The directional arrow on the wheel must point to the wheel rotation, when remounting the wheel. BRAKE CALIPER • Tighten the brake caliper mounting bolts to the specified torque.
Page 271: Front Fork
6-14 CHASSIS FRONT FORK CONSTRUCTION O-ring Washer " Spacer Spring Inner rod/damper rod (cartridge) Inner tube & Slide metal Gasket Dust seal Oil seal stopper ring Oil seal Oil seal retainer Guide metal Oil lock piece Outer tube Front fork cap bolt Inner rod lock nut Front axle pinch bolt Damper rod bolt...
Page 272: Removal And Disassembly
CHASSIS 6-15 REMOVAL AND DISASSEMBLY • Remove the front wheel. (!6-9) • Remove the front fender bolt 1 and brake hose bolt 2. • Loosen the front fork upper clamp bolts 3. NOTE: Slightly loosen the front fork cap bolts 4 before loosening the lower clamp bolts to facilitate later disassembly.
Page 273 6-16 CHASSIS • Invert the fork and drain the fork oil out of the fork by stroking. • Hold the fork inverted for a few minutes to drain oil. • Remove the front axle pinch bolts. • Remove the damper rod bolt 8. •...
Page 274 CHASSIS 6-17 • Remove the dust seal. • Remove the oil seal stopper ring. • Pull the inner tube out of the outer tube. NOTE: Be careful not to damage the inner tube. " The slide metals, oil seal and dust seal must be replaced with the new ones when reassembling the front fork.
Page 275: Inspection
6-18 CHASSIS INSPECTION INNER AND OUTER TUBES Inspect the inner tube outer surface and the outer tube inner sur- face for scratches. If any defects are found, replace them with the new ones. FORK SPRING Measure the fork spring free length. If it is shorter than the ser- vice limit, replace it with a new one.
Page 276: Reassembly And Remounting
CHASSIS 6-19 REASSEMBLY AND REMOUNTING Reassemble and remount the front fork in the reverse order of removal and disassembly. Pay attension to the following points: TUBE METALS AND SEALS • Hold the inner tube vertically and clean the metal groove and install the guide metal by hand as shown.
Page 277 FORK OIL • Place the front fork vertically without spring. • Compress the front fork fully. • Pour the specified front fork oil into the front fork up to the top of the inner rod. * 99000-99001-SS8: SUZUKI FORK OIL SS-8...
Page 278 # 09943-74111: Front fork oil level gauge $ Fork oil level: 133.0 mm (5.24 in) Capacity (each leg): 505.0 ml (17.07/17.78 US/lmp oz) * 99000-99001-SS8: SUZUKI FORK OIL SS-8 FORK SPRING • Pull the inner rod up with the inner rod holder.
Page 279 6-22 CHASSIS • Install the fork spring. NOTE: The smaller end of the fork spring should be at the bottom of the front fork. FRONT FORK CAP BOLT • Install the washer 1 and spacer 2. • Adjust the height A of the inner rod threads by turning the lock nut 3 as shown.
Page 280 CHASSIS 6-23 • Set the front fork to the front fork lower bracket temporarily by tightening the lower clamp bolts. • Tighten the front fork cap bolt 4 to the specified torque. & Front fork cap bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft) •...
Page 281: Steering And Handlebar
6-24 CHASSIS STEERING AND HANDLEBAR CONSTRUCTION Handlebars Steering stem upper bracket " Dust seal Bearing upper Bearing lower Steering stem lower bracket & Dust cover Steering stem nut Handlebar balancer Expander Spacer Washer Expander Handlebar clamp bolt Steering stem head nut Handlebar holder nut Front fork upper clamp bolt Steering stem lock nut...
Page 282: Removal
CHASSIS 6-25 REMOVAL HANDLEBARS • Remove the handlebar balancer 1. • Remove the brake/clutch lever covers 2. NOTE: Do not remove the handlebar balancer mounting screw before removing the handlebar balancer. Slightly loosen the mounting screw, and then pull the balancer assembly out of handlebars. •...
Page 283 6-26 CHASSIS • Remove the handlebars by removing the handlebar clamp bolts. STEERING STEM • Remove the front forks and front fender. (!6-15) • Remove the handlebars. (!6-25) • Remove the brake hose guide 1. • Remove the brake hose guide 2. •...
Page 284 CHASSIS 6-27 • Remove the handle holder nuts 4 and disassemble the han- dle holder. • Remove the steering stem nuts with the special tools. # 09940-14911: Steering stem nut wrench 09940-14960: Steering stem nut wrench NOTE: When loosing the stem nuts, hold the steering stem lower bracket to prevent it from falling.
Page 285: Inspection And Disassembly
6-28 CHASSIS • Remove the steering stem lower bearing 8. INSPECTION AND DISASSEMBLY Inspect the removed parts for the following abnormalities. * Handlebars distriction * Race wear and brinelling * Bearing wear or damage * Abnormal bearing noise * Distortion of the steering stem If any abnormal points are found, replace defective parts with the new ones.
Page 286: Reassembly And Remounting
• Install the lower bearing to the steering stem lower bracket. • Install the upper bearing, bearing inner race, dust seal and dust cover onto the frame. % 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) STEERING STEM •...
Page 287 6-30 CHASSIS • Install the washer. NOTE: When installing the washer, align the stopper lug to the groove of the steering stem. • Install the steering stem lock nut and tighten it to the specified torque with the special tools. # 09940-14911: Steering stem nut wrench 09940-14960: Steering stem nut wrench socket &...
Page 288 • Install the throttle cable case. • Apply grease to the throttle cables and their holes. % 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) • Align the mating surface B of the throttle case with the punch mark A on the handlebars.
Page 289: Steering Tension Adjustment
6-32 CHASSIS • Install the left handlebar switch box to the handlebars by engaging the stopper 1 with the handlebars hole 2. • Install the clutch master cylinder with the proper clutch hose routing. • Install the handlebar balancers and the rear view mirrors. (Handlbar balancer installation: !8-31) •...
Page 290: Rear Wheel
CHASSIS 6-33 REAR WHEEL CONSTRUCTION Rear axle Dust seal " Brake disc Collar Bearing Rear wheel & Tire valve Damper Spacer Bearing Retainer Sprocket mounting drum Rear sprocket Bearing Dust seal ITEM N·m kgf-m lb-ft Collar 16.5 Brake disc bolt 43.5 Rear sprocket nut Rear axle nut...
Page 291: Removal
6-34 CHASSIS REMOVAL • Remove the cotter pin. (For E-03, 28, 33) • Loosen the rear axle nut 1. • Raise the rear wheel off the ground and support the motorcy- cle with a jack or wooden block. • Remove the axle nut and draw out the rear axle. "...
Page 292: Inspection And Disassembly
CHASSIS 6-35 • Remove the brake disc. INSPECTION AND DISASSEMBLY TIRE: (!6-84) WHEEL: (!6-10 and 6-84) REAR AXLE Using a dial gauge, check the rear axle for runout. If the runout exceeds the limit, replace the rear axle. $ Axle shaft runout: Service Limit: 0.25 mm (0.010 in) # 09900-20607: Dial gauge (1/100 mm) 09900-20701: Magnetic stand 09900-21304: V-block set (100 mm)
Page 293 6-36 CHASSIS DUST SEAL • Inspect the wheel dust seal lip and sprocket mounting drum dust seal lips for wear or damage. If any damages are found, replace the dust seal with a new one. • Remove the dust seal with the special tool. # 09913-50121: Oil seal remover "...
Page 294 CHASSIS 6-37 • Remove the sprocket mounting drum bearing and wheel bear- ings by using the special tool. # 09921-20240: Bearing remover set " The removed bearings must be replaced with the new ones.
Page 295: Reassembly And Remounting
6-38 CHASSIS REASSEMBLY AND REMOUNTING Reassemble and remount the rear wheel in the reverse order of removal and disassembly. Pay attention to the following points: Left Right 60 N . m 6.0 kgf-m 43.5 lb-ft 23 N . m 2.3 kgf-m 16.5 lb-ft 100 N .
Page 296 CHASSIS 6-39 BEARING • Apply grease to the bearings before installing. % 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) • Install the new bearing to the sprocket mounting drum using the special tool. # 09924-84510: Bearing installer set...
Page 297 DUST SEAL • Install the new dust seal using the special tool. # 09913-70210: Bearing installer set • Apply SUZUKI SUPER GREASE “A” to the dust seal lips before assembling rear wheel. % 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others)
Page 298 CHASSIS 6-41 • Install the rear sprocket mounting drum to the rear wheel. • Install the collar. REAR AXLE • Remount the rear wheel and rear axle, install the washer and rear axle nut. • Tighten the rear axle nut 1 to the specified torque. •...
Page 299: Rear Shock Absorber
6-42 CHASSIS REAR SHOCK ABSORBER CONSTRUCTION Rear shock absorber Rear shock absorber upper mounting nut Rear shock absorber lower mounting nut ITEM N·m kgf-m lb-ft 36.0 36.0...
Page 300: Removal
CHASSIS 6-43 REMOVAL • Raise the rear wheel off the ground and support the motorcy- cle with a jack or wooden block. • Remove the pre-load adjuster 1. • Remove the cushion lever rod bolts/nuts and the cushion rods • Remove the rear shock absorber upper mounting bolt. •...
Page 301: Inspection
6-44 CHASSIS INSPECTION Inspect the shock absorber body and bushing for damage and oil leakage. If any defects are found, replace the shock absorber with a new one. " Do not attempt to disassemble the rear shock absorber unit. It is unserviceable. REAR SHOCK ABSORBER DISPOSAL The rear shock unit contains high-pressure nitrogen gas.
Page 302: Remounting
CHASSIS 6-45 REMOUNTING Remount the rear shock absorbers in the reverse order of removal. Pay attention to the following points: • Install the rear shock absorber and tighten the rear shock absorber upper/lower mounting nuts. & Rear shock absorber mounting lower nut: 50 N·m (5.0 kgf-m, 36.0 lb-ft) Rear shock absober mounting upper nut: 50 N·m (5.0 kgf-m, 36.0 lb-ft)
Page 303: Suspension Setting
6-46 CHASSIS SUSPENSION SETTING After installing the rear suspension, adjust the spring pre-load and damping force as follows. SPRING PRE-LOAD ADJUSTMENT The pre-load is adjusted by turning the pre-load adjuster knob without tool. Position “0” provides the softest spring pre-load. Position “5”...
Page 304: Rear Swingarm
CHASSIS 6-47 REAR SWINGARM CONSTRUCTION Rear shock absorber Rear cushion rod " Rear cushion lever Spacer Bearing Washer & Pivot spacer Chain cover Chain buffer Swingarm Center spacer Rear shock absorber upper mounting nut Rear cusion lever nut Rear cusion rod nut Swingarm pivot shaft Swingarm pivot lock nut Swingarm pivot nut...
Page 305: Removal
6-48 CHASSIS REMOVAL • Remove the exhaust pipe and exhaust muffler. (!3-7) • Raise the rear wheel off the ground and support the motorcy- cle with a jack or wooden block. • Remove the rear wheel. (!6-34) • Remove the rear brake hose guide 1. •...
Page 306: Inspection And Disassembly
CHASSIS 6-49 • Remove the mud guard 7. • Remove the brake hose guide 8. • Remove the chain buffer 9. INSPECTION AND DISASSEMBLY SPACER • Remove the spacers from swingarm and cushion lever. • Inspect the spacers for any flaws or other damage. If any defects are found, replace the spacers with the new ones.
Page 307 6-50 CHASSIS SWINGARM BEARING Insert the spacer into bearing and check the play when moving the spacer up and down. If excessive play is noted, replace the bearing with a new one. • Remove the swingarm pivot bearing and spacer with the spe- cial tools.
Page 308 CHASSIS 6-51 CUSHION LEVER BEARING Insert the spacer into bearing and check the play when moving the spacer up and down. If excessive play is noted, replace the bearing with a new one. • Draw out the cushion lever bearings with the special tool. # 09921-20240: Bearing remover set "...
Page 309: Reassembly
6-52 CHASSIS REASSEMBLY Reassemble the swingarm in the reverse order of disassembly and removal. Pay attention to the following points: Left Right Frame Rear shock 50 N . m absorber 5.0 kgf-m Washer 36.0 lb-ft Frame 78 N . m Cushion lever 7.8 kgf-m 56.5 lb-ft...
Page 310 # 09941-34513: Steering race installer NOTE: When installing the bearing, the dust seal that is embedded in the bearing must face outside. • Apply grease to the bearings and spacers. % 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others)
Page 311: Remounting
6-54 CHASSIS REMOUNTING Remount the swingarm in the reverse order of disassembly and removal, and pay attention to the following points: SWINGARM • Insert the swingarm pivot shaft and tighten it to the specified torque by using the special tool. &...
Page 312: Final Inspection And Adjustment
CHASSIS 6-55 CUSHION LEVER AND CUSHION ROD • Install the washers 1 and cushion lever. NOTE: Insert the cushion lever mounting bolt from the left side. (!6-52) • Install the cushion rod and rear shock absorber. NOTE: Insert the cushion rod mounting bolts and rear shock absorber mounting bolts from the left side.
Page 313: Front Brake
6-56 CHASSIS FRONT BRAKE CONSTRUCTION Diaphragm Dust boot " Piston/cup set Brake hose Pad mounting pin & Brake pad spring Brake pad Piston seal Dust seal Piston Caliper holder Caliper Front brake master cylinder mounting bolt Brake hose union bolt Air bleeder valve Brake caliper mounting bolt ITEM...
Page 314: Brake Pad Replacement
CHASSIS 6-57 BRAKE PAD REPLACEMENT • Remove the caliper. " Do not operate the brake lever while removing the cal- iper. • Remove the pin 1. • Remove the brake pads by removing the pad mounting pin 2. • Clean up the caliper especially around the caliper pistons. •...
Page 315: Brake Fluid Replacement
6-58 CHASSIS • Remount the caliper. • Tighten the caliper mounting bolts to the specified torque. & Front brake caliper mounting bolt: 39 N·m (3.9 kgf-m, 28.0 lb-ft) NOTE: After replacing the brake pads, pump the brake lever several times to check for proper brake operation and then check the brake fluid level.
Page 316: Caliper Removal And Disassembly
CHASSIS 6-59 CALIPER REMOVAL AND DISASSEMBLY • Drain the brake fluid. (!6-58) • Remove the brake pads. (!6-57) • Disconnect the brake hoses by removing the brake hose union bolts. NOTE: Place a rag underneath the union bolt on the brake caliper to catch any spilt brake fluid.
Page 317: Caliper Inspection
6-60 CHASSIS CALIPER INSPECTION BRAKE CALIPER Inspect the brake caliper cylinder wall for nicks, scratches and other damage. If any damage is found, replace the caliper with a new one. BRAKE CALIPER PISTON Inspect the brake caliper piston surface for any scratches and other damage.
Page 318: Caliper Reassembly And Remounting
• Install the piston seals as shown in the illustration. • Install the piston to the caliper. CALIPER HOLDER • Apply SUZUKI SILICONE GREASE to the caliper holder pin. - 99000-25100: SUZUKI SILICONE GREASE • Install the caliper holder to the caliper.
Page 319: Brake Disc Inspection
6-62 CHASSIS • Install the pad spring 1. • Install the brake pads. (!6-57) NOTE: Before remounting the caliper, push the piston all the way into the caliper. • Remount the brake caliper to the front fork. • Tighten each bolt to the specified torque. &...
Page 320: Master Cylinder Removal And Disassembly
CHASSIS 6-63 MASTER CYLINDER REMOVAL AND DISAS- SEMBLY • Remove the rear view mirror and brake lever cover. • Drain the brake fluid. (!6-58) • Disconnect the front brake light switch coupler 1. • Place a rag underneath the union bolt on the master cylinder to catch any spilt brake fluid.
Page 321: Master Cylinder Inspection
6-64 CHASSIS • Remove the piston and return spring. 6 Piston 7 Secondary cup 8 Primary cup 9 Return spring MASTER CYLINDER INSPECTION Inspect the master cylinder bore for any scratches or other dam- age. Inspect the piston surface for any scratches or other damage. Inspect the primary cup, secondary cup and dust seal for wear or damage.
Page 322 CHASSIS 6-65 • When remounting the brake master cylinder onto the handle- bars, align the master cylinder holder’s mating surface A with punch mark B on the handlebars and tighten the upper clamp bolt first as shown. & Front brake master cylinder mounting bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft) •...
Page 323: Rear Brake
6-66 CHASSIS REAR BRAKE CONSTRUCTION Brake hose union bolt Brake hose Rear brake master cylinder mounting Diaphragm Rear brake master cylinder rod lock nut " Reservoir tank hose Air bleeder valve Piston/cup set Brake caliper mounting bolt Push rod Pad mounting pin Dust boot Brake caliper sliding pin &...
Page 324: Brake Pad Replacement
CHASSIS 6-67 BRAKE PAD REPLACEMENT • Remove the plug 1. • Loosen the pad mounting pin 2. • Remove the caliper bracket bolt 3. " * Do not operate the brake pedal while dismounting the pads. * Replace the brake pads as a set, otherwise braking performance will be adversely affected.
Page 325: Brake Fluid Replacement
6-68 CHASSIS NOTE: Make sure that the detent of the pad is seated onto the retainer on the caliper bracket. • Tighten the caliper mounting bolt 7 and pad mounting pin 8 to the specified torque. & Rear brake caliper mounting bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft) Rear brake pad mounting pin: 17 N·m (17 kgf-m, 12.5 lb-ft)
Page 326: Caliper Removal And Disassembly
CHASSIS 6-69 CALIPER REMOVAL AND DISASSEMBLY • Drain the brake fluid. (!6-68) • Remove the brake pads. (!6-67) • Place a rag underneath the union bolt to catch any spilt brake fluid. • Disconnect the brake hose by removing the brake hose union bolt.
Page 327: Caliper Inspection
6-70 CHASSIS • Remove the slide pin 4. • Place a rag over the piston to prevent it from popping out and then force out the piston using compressed air. " Do not use high pressure air to prevent piston dam- age.
Page 328: Brake Disc Inspection
CHASSIS 6-71 BRAKE CALIPER SLIDING PIN Inspect the brake caliper sliding pin for wear and other damage. If any damage is found, replace the sliding pin with a new one. Inspect the boot and spacer for damage and wear. If any dam- age is found, replace boot and spacer with new ones.
Page 329: Caliper Reassembly And Remounting
• Install the piston to the caliper. SLIDING PIN • Install the boot 1. • Apply SUZUKI SILICONE GREASE to the inside of the boot. - 99000-25100: SUZUKI SILICONE GREASE • Install the spacer 2. • Tighten the sliding pin 3 to the specified torque.
Page 330: Master Cylinder Removal And Disassembly
CHASSIS 6-73 • Install the caliper to the caliper bracket 1. • Set the boot onto the sliding pin securely. • Install the brake pad. (!6-67) • Tighten the brake hose union bolt with the brake hose union pipe seated in the cutout on the caliper. (Rear brake hose routing: !8-25) &...
Page 331: Master Cylinder Inspection
6-74 CHASSIS • Place a rag underneath the union bolt on the master cylinder to catch spilled drops of brake fluid. Remove the union bolt 4 and disconnect the brake hose. • Disconnect the reservoir tank hose. " Immediately and completely wipe off any brake fluid contacting any parts of the motorcycle.
Page 332: Master Cylinder Reassembly And Remounting
2 Piston/primary cup 3 Push rod 4 Snap ring 5 Dust boot • Apply the SUZUKI MOLY PASTE to the push rod. . 99000-25140: SUZUKI MOLY PASTE • Install the O-ring 6, connector 7 and snap ring 8 to the master cylinder.
Page 333 6-76 CHASSIS • Install the reservoir tank and reservoir tank hose. (Rear brake hose routing: !8-25) • Temporarily install the master cylinder to the frame. • Connect the brake hose to the master cylinder. (Rear brake hose routing: !8-25) • Tighten the brake hose union bolt to the specified torque. &...
Page 334: Clutch Release Cylinder And Master Cylinder
CHASSIS 6-77 CLUTCH RELEASE CYLINDER AND MASTER CYLINDER CONSTRUCTION Diaphragm Push rod " Dust boot Piston/cup set Clutch hose Clutch push rod & Piston Piston cup Spring Clutch release cylinder Clutch master cylinder mounting bolt Clutch hose union bolt Air bleeder valve ITEM N·m kgf-m...
Page 335: Clutch Fluid Replacement
6-78 CHASSIS CLUTCH FLUID REPLACEMENT • Place the motorcycle on a level surface and keep the handle- bars straight. • Remove the master cylinder reservoir cap and diaphragm. • Suck up the old clutch fluid as much as possible from the res- ervoir tank.
Page 336: Clutch Release Cylinder Inspection
CHASSIS 6-79 • Place a rag over the piston to prevent it from popping out. • Force out the piston by using compressed air. " Do not use high pressure air to prevent piston dam- age. CLUTCH RELEASE CYLINDER INSPECTION Inspect the clutch release cylinder bore wall for nicks, scratches or other damage.
Page 337 4 Air bleeder valve 5 Bleeder cap 6 Clutch ralease cylinder body • Apply SUZUKI SILICONE GREASE to the concavity of piston. - 99000-25100: SUZUKI SILICONE GREASE • Install the clutch release cylinder 7 and spacer 8. • Tighten each bolt to the specified torque.
Page 338: Clutch Master Cylinder Removal And Disassembly
CHASSIS 6-81 CLUTCH MASTER CYLINDER REMOVAL AND DISASSEMBLY • Remove the rear view mirror and clutch lever cover. • Drain the clutch fluid. (!6-78) • Disconnect the clutch lever position switch lead wires. • Place a rag underneath the union bolt on the master cylinder to catch spilled drops of brake fluid.
Page 339: Clutch Master Cylinder Inspection
6-82 CHASSIS CLUTCH MASTER CYLINDER INSPECTION Inspect the piston surface for any scratches or other damage. Inspect the primary cup, secondary cup and dust seal for wear or damage. Inspect the master cylinder bore for any scratches or other dam- age.
Page 340 CHASSIS 6-83 • Apply SUZUKI MOLY PASTE to the push rod. • Install the push rod and dust boot. . 99000-25140: SUZUKI MOLY PASTE • When remounting the master cylinder on the handlebars, Upper align the master cylinder holder’s mating surface A with punched mark B on the handlebars and tighten the upper clamp bolt first.
Page 341: Tire And Wheel
6-84 CHASSIS TIRE AND WHEEL TIRE REMOVAL The most critical factor of a tubeless tire is the seal between the wheel rim and the tire bead. For this reason, it is recommended to use a tire changer that can satisfy this sealing requirement and can make the operation efficient as well as functional.
Page 342: Valve Installation
CHASSIS 6-85 VALVE • Inspect the valve after the tire is removed from the rim. Replace the valve with a new one if the seal rubber is peeling or has damage. • Inspect the valve core. If the seal has abnormal deformation, replace the valve with a new one.
Page 343 6-86 CHASSIS • When installing the tire, the arrow 1 on the side wall should point to the direction of wheel rotation. • Align the chalk mark put on the tire at the time of removal with the valve position. •...
Page 344: Electrical System
ELECTRICAL SYSTEM ELECTRICAL SYSTEM CONTENTS CAUTIONS IN SERVICING ..............7- 2 CONNECTOR ................7- 2 COUPLER ..................7- 2 CLAMP ..................7- 2 FUSE ....................7- 2 SEMI-CONDUCTOR EQUIPPED PART ........7- 2 BATTERY ..................7- 3 CONNECTING THE BATTERY ...........7- 3 WIRING PROCEDURE ..............7- 3 USING THE MULTI CIRCUIT TESTER ........7- 3 LOCATION OF ELECTRICAL COMPONENTS .........7- 4 CHARGING SYSTEM .................7- 6 TROUBLESHOOTING ..............7- 6...
Page 345: Cautions In Servicing
ELECTRICAL SYSTEM CAUTIONS IN SERVICING CONNECTOR • When connecting a connector, be sure to push it in until a click is felt. • Inspect the connector for corrosion, contamination and break- age in its cover. COUPLER • With a lock type coupler, be sure to release the lock before disconnecting it and push it in fully till the lock works when connecting it.
Page 346: Battery
ELECTRICAL SYSTEM BATTERY • The MF battery used in this motorcycle does not require main- tenance (e.g., electrolyte level inspection, distilled water replenishment). • During normal charging, no hydrogen gas is produced. How- ever, if the battery is overcharged, hydrogen gas may be pro- duced.
Page 347: Location Of Electrical Components
ELECTRICAL SYSTEM LOCATION OF ELECTRICAL COMPONENTS Battery Fuel injector ( 4-47 and 4-70) Fuse box STP sensor ( 4-44) Side-stand/turn signal relay TP sensor ( 4-36) Starter relay Secondary throttle valve actuator ( 4-43) Fuel pump relay Generator Tip over sensor ( 4-42) Speedometer sensor AP sensor (...
Page 348 ELECTRICAL SYSTEM ECT sensor ( 4-38) Oil pressure switch Gear position switch IAP sensor ( 4-34) Fuel pump ( 4-55) Ignition coil (No.1) IAT sensor ( 4-39) Cooling fan motor switch ( 5-9) Starter motor Cooling fan ( 5-8) CMP sensor ( 4-32) Horn...
Page 349: Charging System
ELECTRICAL SYSTEM CHARGING SYSTEM Regulator/rectifier Ig.switch Generator TROUBLESHOOTING Battery runs down quickly. Check accessories which use excessive Accessories • Remove accessories. are installed amounts of electricity. No accessories • Check the battery for current Current leaks Short circuit of wire harness •...
Page 350: Inspection
ELECTRICAL SYSTEM Measure the generator no-load • voltage. ( 7-9 ) Incorrect Faulty generator Correct Inspect the regulator/rectifier. Incorrect Faulty regulator/rectifier • 7-9 ) Correct Inspect wirings. Incorrect Short circuit of wire harness • Poor contact of couplers • Correct •...
Page 351 ELECTRICAL SYSTEM REGULATED VOLTAGE • Remove the seat. (!6-4). • Start the engine and keep it running at 5 000 r/min. with light- ing switch turned ON (only E02, E19) and dimmer switch turned HI position. Measure the DC voltage between the + and - battery termi- nals using the multi circuit tester.
Page 352 ELECTRICAL SYSTEM GENERATOR NO-LOAD PERFORMANCE • Remove the left frame cover. (!6-5) • Disconnect the generator coupler. • Start the engine and keep it running at 5 000 r/min. Using the multi circuit tester, measure the voltage between three lead wires. If the tester reads under the specified value, replace the genera- tor with a new one.
Page 353: Starter System And Side-Stand/Ignition Interlock System
7-10 ELECTRICAL SYSTEM STARTER SYSTEM AND SIDE-STAND/IGNITION INTERLOCK SYSTEM Engine stop Ignition switch switch Fuse (30 A) To ECM and Ignition coil Starter motor Fuse Gear position (15A) switch Starter relay Starter Turn signal/ Clutch lever button side-stand relay position switch side-stand switch TROUBLE SHOOTING...
Page 354: Starter Motor Removal And Disassembly
ELECTRICAL SYSTEM 7-11 Check the starter relay. Incorrect • Faulty starter relay 7-13) Correct • Poor contact of the starter relay The starter motor runs when the transmission is in neutral with the side-stand up or down, but does not run when the transmission is in any position other than neutral with the side-stand down.
Page 355: Starter Motor Inspection
Reassemble the starter motor in the reverse order of disassem- bly. Pay attention to the following points: • Apply SUSUKI SUPER GREASE “A” to the lip of the oil seal. - 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others)
Page 356: Starter Relay Inspection
ELECTRICAL SYSTEM 7-13 • Apply a small quantity of SUZUKI MOLY PASTE to the arma- ture shaft. . 99000-25140: SUZUKI MOLY PASTE • Apply a small quantity of THREAD LOCK “1342” to the starter motor housing bolts. / 99000-32050: THREAD LOCK “1342”...
Page 357: Side-Stand/Ignition Interlock System Parts Inspection
7-14 ELECTRICAL SYSTEM Apply 12 V to A and B terminals and check for continuity between the positive and negative terminals using the multi cir- cuit tester. If the starter relay clicks and continuity is found, the relay is ok. # 09900-25008: Multi circuit tester set + Tester knob indication: Continuity test (, "...
Page 358 ELECTRICAL SYSTEM 7-15 GEAR POSITION SWITCH • Remove the seat. (!6-4) • Remove the fuel tank front cover. • Remove the fuel tank side covers. • Lift and support the fuel tank with the fuel tank prop stay. (!4-51) • Disconnect the gear position swtich coupler and check the continuity between Blue and Black with the transmission in “NEUTRAL”.
Page 359 7-16 ELECTRICAL SYSTEM SIDE-STAND RELAY INSPECTION First check the insulation between D and E terminals with the tester. Then apply 12 V to terminals D and C ( + to D and - to C) and check the continuity between D and E. If there is no continuity, replace the turn signal/side-stand relay with a new one.
Page 360: Spark Plug
ELECTRICAL SYSTEM 7-17 IGNITION SYSTEM Engine stop switch Side- stand Power source relay circuit Ignition coil Spark plug Fuse sensor Wave form arrangement Ignition circuit switch Fuse Wave form arrangement circuit Battery Cam position sensor Throttle Gear Engine position position coolant temp.
Page 361 7-18 ELECTRICAL SYSTEM Measure the battery voltage between input lead wires (O/W and B/W) at the • ECM with the ignition switch in the Incorrect Faulty ignition switch • “ON” position. Faulty turn signal/side-stand relay • Faulty engine stop switch •...
Page 362: Inspection
ELECTRICAL SYSTEM 7-19 INSPECTION IGNITION COIL PRIMARY PEAK VOLTAGE • Lift and support the fuel tank. (!4-51) • Disconnect the two spark plug caps. • Connect new two spark plugs to each spark plug cap and ground them. NOTE: Make sure that all couplers and spark plugs are connected prop- erly and the battery used is in fully-charged condition.
Page 363 7-20 ELECTRICAL SYSTEM IGNITION COIL RESISTANCE • Remove the fuel tank. (!4-52) • Disconnect the spark plug caps and coupler. Measure the ignition coil resistance in both the primary and sec- Ω kΩ ondary windings. If the resistance is not within the standard range, replace the ignition coil with a new one.
Page 364 ELECTRICAL SYSTEM 7-21 • Shift the transmission into the neutral, and then turn the igni- tion switch to the “ON” position. CKP sensor coupler • Pull the clutch lever. coupler • Press the starter button and allow the engine to crank for a few seconds, and then measure the CKP sensor peak volt- Y/Bl CKP sensor...
Page 365: Combination Meter
7-22 ELECTRICAL SYSTEM COMBINATION METER REMOVAL AND DISASSEMBLY • Remove the combination meter panel. (!6-6). • Remove the combination meter 1. " When disconnecting and connecting the combination meter coupler, make sure to turn OFF the ignition switch, or electronic parts may get damaged. •...
Page 366: Inspection
ELECTRICAL SYSTEM 7-23 INSPECTION LED (LIGHT EMITTING DIODE) Check that the LED lights immediately after turning the ignition switch on. If the LED fails in operation, replace the combination meter unit with a new one after checking its wire har- ness/coupler.
Page 367 7-24 ELECTRICAL SYSTEM ODOMETER The odometer indicates “-----” when the odometer is faulty. Replace the combination meter unit with a new one. TRIP METER The trip meter indicates “-----” when the trip meter is faulty. In case the odometer works normaly, perform the trip meter reset.
Page 368: Engine Coolant Temperature Meter And Indicator
ELECTRICAL SYSTEM 7-25 ENGINE COOLANT TEMPERATURE METER AND INDICATOR • Disconnect the engine coolant temperature sensor coupler. " When connecting and disconnecting the engine cool- ant temp. sensor lead wire coupler, make sure to turn OFF the ignition switch, or electronic parts may get damaged.
Page 369 7-26 ELECTRICAL SYSTEM FUEL LEVEL GAUGE INSPECTION • Remove the fuel tank. (!4-52) • Remove the fuel pump. (!4-55) Measure the resistance at each fuel level gauge float position. If the resistance is incorrect, replace the fuel level gauge with a new one.
Page 370 ELECTRICAL SYSTEM 7-27 FUEL LEVEL METER • Lift and support the fuel tank with the fuel tank prop stay. (!4-51) • Connect each resistor between the Yellow/Black and Black/ White lead wires at the wire harness. • Turn the ignition switch “ON” position and wait for approx. 13 seconds.
Page 371 7-28 ELECTRICAL SYSTEM SPEEDOMETER If the speedometer, odometer or trip meter does not function properly, inspect the speedometer sensor and connection of coupler 1. If the speedometer sensor and connection are all right, replace the meter with a new one. SPEEDOMETER SENSOR •...
Page 372: Headlight
ELECTRICAL SYSTEM 7-29 LAMPS HEADLIGHT, BRAKE LIGHT/TAILLIGHT AND TURN SIGNAL LIGHT HEADLIGHT Only E02, E19 12 V 60/50 W 12 V 60/50 W + 5 W (ONLY E02, E19) BRAKE LIGHT/TAIL LIGHT 12 V 21/5 W TURN SIGNAL LIGHT 12 V 10 W HEADLIGHT BEAM ADJUSTMENT •...
Page 373: Relays
7-30 ELECTRICAL SYSTEM RELAYS TURN SIGNAL/SIDE-STAND RELAY The turn signal/side-stand relay is composed of the turn signal relay, side-stand relay and diode. INSPECTION Before removing the turn signal/side-stand relay, check the operation of the turn signal light. If the turn signal light does not illuminate, inspect the bulb, turn signal switch and circuit connection.
Page 374: Switches
ELECTRICAL SYSTEM 7-31 SWITCHES IGNITION SWITCH REMOVAL • Remove the fuel tank. (!4-52) • Remove the air cleaner box. (!4-60) • Disconnect the ignition switch coupler. • Remove the ignition switch mounting bolts using the special tools. # 09930-11920: Torx bit JT40H 09930-11940: Bit holder "...
Page 375 7-32 ELECTRICAL SYSTEM Inspect each switch for continuity with a tester. If any abnormality is found, replace the respective switch assemblies with new ones. HAZARD (Except for E03, E24, E28, E33) IGNITION SWITCH (For E24) Color Color Position Position LOCK FRONT BRAKE SWITCH (For Others) Color...
Page 376: Battery
ELECTRICAL SYSTEM 7-33 BATTERY SPECIFICATIONS Type designation FTX14-BS Capacity 12 V, 43.2 kC (12 Ah)/10 HR INITIAL CHARGING Filling electrolyte • Remove the aluminum tape 1 sealing the battery electrolyte filler holes. NOTE: When filling electrolyte, the battery must be removed from the vehicle and must be put on the level ground.
Page 377 7-34 ELECTRICAL SYSTEM NOTE: If no air bubbles are coming up from a filler port, tap the bottom of the electrolyte container two or three times. Never remove the container from the battery. • After confirming that the electrolyte has entered the battery completely, remove the electrolyte containers from the bat- tery.
Page 378: Servicing
ELECTRICAL SYSTEM 7-35 SERVICING Visually inspect the surface of the battery container. If any signs of cracking or electrolyte leakage from the sides of the battery have occurred, replace the battery with a new one. If the battery terminals are found to be coated with rust or an acidic white powdery substance, then this can be cleaned away with sandpa- per.
Page 379: Servicing Information
SERVICING INFORMATION SERVICING INFORMATION CONTENTS TROUBLESHOOTING ................8- 2 FI SYSTEM MALFUNCTION CODE AND DEFECTIVE CONDITION ..................8- 2 ENGINE ..................8- 4 RADIATOR (COOLING SYSTEM) ..........8- 9 CHASSIS ..................8-10 BRAKES ..................8-11 ELECTRICAL ................8-12 BATTERY ..................8-13 WIRE HARNESS, CABLE AND HOSE ROUTING ......8-14 WIRE HARNESS ROUTING ............8-14 ENGINE ELECTRICAL PARTS SET-UP ........8-17 HIGH-TENSION CORD ROUTING ..........8-18...
Page 380: Troubleshooting
SERVICING INFORMATION TROUBLESHOOTING FI SYSTEM MALFUNCTION CODE AND DEFECTIVE CONDITION MALFUNCTION DETECTED FAILURE CONDITION DETECTED ITEM CODE CHECK FOR NO FAULT ––––––––––– Camshaft position sen- The signal does not reach ECM for more than 3 sec. after receiving the starter signal. The camshaft position sensor wiring and mechanical parts.
Page 381 SERVICING INFORMATION Secondary throttle When no actuator control signal is supplied from the ECM or valve actuator communication signal does not reach ECM or operation voltage does not reach STVA motor, C28 is indicated. STVA can not operate. STVA lead wire/coupler. The sensor should produce following voltage.
Page 382: Engine
SERVICING INFORMATION ENGINE Complaint Symptom and possible causes Remedy Engine will not start Compression too low or is hard to start. 1. Tappet clearance out of adjustment. Adjust. 2. Worn valve guides or poor seating of valves. Repair or replace. 3.
Page 383 SERVICING INFORMATION Complaint Symptom and possible causes Remedy Engine stalls often Incorrect fuel/air mixture 1. Defective intake air pressure sensor or circuit. Repair or replace. 2. Clogged fuel filter. Clean or replace. 3. Defective fuel pump. Replace. 4. Defective fuel pressure regulator. Replace.
Page 384 SERVICING INFORMATION Complaint Symptom and possible causes Remedy Noisy engine. Excessive valve chatter 1. Too large tappet clearance. Adjust. 2. Weakened or broken valve springs. Replace. 3. Worn tappet or cam surface. Replace. 4. Worn and burnt camshaft journal. Replace. Noise seems to come from piston 1.
Page 385 SERVICING INFORMATION Complaint Symptom and possible causes Remedy Engine runs poorly in Defective air flow system high speed range. 1. Clogged air cleaner element. Clean or replace. 2. Defective throttle valve. Adjust or replace. 3. Defective secondary throttle valve. Adjust or replace. 4.
Page 386 SERVICING INFORMATION Complaint Symptom and possible causes Remedy Engine overheats. Defective engine internal parts 1. Heavy carbon deposit on piston crowns. Clean. 2. Not enough oil in the engine. Add oil. 3. Defective oil pump or clogged oil circuit. Replace or clean. 4.
Page 387: Radiator (Cooling System)
SERVICING INFORMATION RADIATOR (COOLING SYSTEM) Complaint Symptom and possible causes Remedy Engine overheats. 1. Not enough engine coolant. Add engine coolant. 2. Radiator core clogged with dirt or scale. Clean. 3. Faulty cooling fan. Repair or replace. 4. Defective cooling fan thermo-switch. Replace.
Page 388: Chassis
8-10 SERVICING INFORMATION CHASSIS Complaint Symptom and possible causes Remedy Heavy steering. 1. Overtightened steering stem nut. Adjust. 2. Broken bearing in steering stem. Replace. 3. Distorted steering stem. Replace. 4. Not enough pressure in tires. Adjust. Wobbly handlebars. 1. Loss of balance between right and left front forks. Replace.
Page 389: Brakes
SERVICING INFORMATION 8-11 BRAKES Complaint Symptom and possible causes Remedy Insufficient brake 1. Leakage of brake fluid from hydraulic system. Repair or replace. power. 2. Worn pads. Replace. 3. Oil adhesion on friction surface of pads/shoe. Clean disc and pads. 4.
Page 390: Electrical
8-12 SERVICING INFORMATION ELECTRICAL Complaint Symptom and possible causes Remedy No sparking or poor 1. Defective ignition coil or camshaft position sensor. Replace. sparking. 2. Defective spark plugs. Replace. 3. Defective crankshaft position sensor. Replace. 4. Defective ECM. Replace. 5. Defective tip over sensor. Replace.
Page 391: Battery
SERVICING INFORMATION 8-13 BATTERY Complaint Symptom and possible causes Remedy “Sulfation”, acidic 1. Cracked battery case. Replace the battery. white powdery sub- 2. Battery has been left in a run-down condition for a long Replace the battery. stance or spots on time.
Page 392: Wire Harness, Cable And Hose Routing
8-14 SERVICING INFORMATION WIRE HARNESS, CABLE AND HOSE ROUTING WIRE HARNESS ROUTING...
Page 393 SERVICING INFORMATION 8-15 Clamp IAT sensor IAP sensor CMP sensor Fixed clamp Fixed clamp Clamp sensor Clamp Fixed clamp Clamp Headlight...
Page 394 8-16 SERVICING INFORMATION...
Page 395: Engine Electrical Parts Set-Up
SERVICING INFORMATION 8-17 ENGINE ELECTRICAL PARTS SET-UP Apply bond to the groove of the grommet. #2 Cylinder 6.5 N·m (0.65 kgf-m, 4.7 lb-ft) 12 N·m (1.2 kgf-m, 8.5 lb-ft) Forward CMP sensor 10 N·m Apply bond to the groove (1.0 kgf-m, 7.3 lb-ft) of the grommet.
Page 396: High-Tension Cord Routing
8-18 SERVICING INFORMATION HIGH-TENSION CORD ROUTING...
Page 397: Throttle Cable Routing
SERVICING INFORMATION 8-19 THROTTLE CABLE ROUTING Front brake hose Throttle cable No. 2 Throttle cable No. 1 Throttle cable No. 2 Trottle cable No. 1 Fit the cable boots securely. 0 mm Throttle cable No. 2 Throttle cable No. 2 Wiring harness Throttle cable No.
Page 398: Throttle Body Installation/Hose Routing
8-20 SERVICING INFORMATION THROTTLE BODY INSTALLATION/HOSE ROUTING Crankcase breather hose (PCV hose) PAIR Valve Pass through the IAP sensor vacuum hose right side of the PAIR hose. PAIR hose Fuel pump Fuel feed hose THROTTLE BODY CLAMP POSITION Intake pipe side Forward VIEW OF TOP Air cleaner side...
Page 399: Crankcase Breather Hose Routing
SERVICING INFORMATION 8-21 CRANKCASE BREATHER HOSE ROUTING Air cleaner box rear side. : The end of the clamp should face..: The clamp screw head should face..Crankcase breather hose (PCV hose) right side. Water hose right down side.
Page 400: Clutch Hose Routing
8-22 SERVICING INFORMATION CLUTCH HOSE ROUTING...
Page 401: Cooling System Hose Routing
SERVICING INFORMATION 8-23 COOLING SYSTEM HOSE ROUTING...
Page 402: Front Brake Hose Routing
8-24 SERVICING INFORMATION FRONT BRAKE HOSE ROUTING...
Page 403: Rear Brake Hose Routing
SERVICING INFORMATION 8-25 REAR BRAKE HOSE ROUTING...
Page 404: Fuel Tank Drain Hose Routing
8-26 SERVICING INFORMATION FUEL TANK DRAIN HOSE ROUTING 50 mm Clamp should face down side.
Page 405: Fuel Tank Installation
SERVICING INFORMATION 8-27 FUEL TANK INSTALLATION Apply adhesive agent to the cushion rubber top face.
Page 406: Pair (Air Supply) System Hose Routing
8-28 SERVICING INFORMATION PAIR (AIR SUPPLY) SYSTEM HOSE ROUTING...
Page 407: Seat Lock Cable Routing
SERVICING INFORMATION 8-29 SEAT LOCK CABLE ROUTING...
Page 408: Side-Stand Set-Up
8-30 SERVICING INFORMATION SIDE-STAND SET-UP 40 N . m (4.0 kgf-m, 29.0 lb-ft) 100 N . m 10.0 kgf-m 72.5 lb-ft 50 N . m (5.0 kgf-m, 36.0 lb-ft) BRAKE PEDAL/FOOTREST SET-UP Brake light switch Footrest Bracket E-ring Outside Outside Outside Inside Inside...
Page 409: Footrest Set-Up
SERVICING INFORMATION 8-31 FOOTREST SET-UP HANDLEBAR BALANCER INSTALLATION 4 – 7 N . m 0.4 – 0.7 kgf-m 3 – 5 lb-ft Balancer weight LH clearance is 0 mm. RH clearance is 0.5 – 1.5 mm. NOTE: After installing the RH balancer weight, check that throttle grip rotate smoothly by turning it.
Page 410: Special Tools
8-32 SERVICING INFORMATION SPECIAL TOOLS 09900-20101 or 09900-20202 09900-06107 09900-06108 09900-09004 09900-20102 Micrometer Snap ring pliers Snap ring pliers Impact driver set Vernier calipers (25 – 50 mm) 09900-20204 09900-20205 09900-20602 09900-20607 Micrometer Micrometer 09900-20508 Dial gauge Dial gauge (75 – 100 mm) (0 –...
Page 411 SERVICING INFORMATION 8-33 09915-72410 09915-74521 09915-74532 09915-77331 Oil pressure gauge Oil pressure gauge Oil pressure gauge Meter (for high pres- 09916-10911 attachment hose adaptor sure) Valve lapper set 09916-14510 09916-14910 09916-24480 Valve seat cutter Valve spring com- Valve spring com- 09916-21111 Solid pilot head...
Page 412 8-34 SERVICING INFORMATION 09924-84521 09925-18011 09930-11920 09930-11940 09930-11950 Bearing installer set Steering bearing installer Torx bit JT40H Bit holder Torx wrench 09930-73110 09930-73120 09930-30102 09930-30450 09930-44541 Starter torque limiter Starter torque limiter Sliding shaft Rotor remover Rotor holder holder socket 09930-82710 09940-14911 09940-14940...
Page 413: Tightening Torque
SERVICING INFORMATION 8-35 TIGHTENING TORQUE ENGINE ITEM N·m kgf-m lb-ft Cylinder head cover bolt 10.0 Spark plug Camshaft journal holder bolt Cam chain tension adjuster bolt 16.5 Cam chain tension adjuster mounting bolt Cam drive idle gear/sprocket shaft 29.0 Cam chain tensioner mounting bolt Cylinder head nut [M: 8] 18.0...
Page 414: Fi System Parts
8-36 SERVICING INFORMATION ITEM N·m kgf-m lb-ft Exhaust pipe bolt 16.5 Muffler mounting bolt/nut 16.5 Oil cooler union bolt 16.5 Engine sprocket nut 11.5 83.0 Engine mounting pinch bolt 16.5 Engine mounting bolt/nut [M: 12] 54.0 [M: 10] 40.0 Engine mounting thrust adjuster Engine mounting thrust adjuster lock nut 32.5 Engine mounting bracket pinch bolt...
Page 415: Chassis
SERVICING INFORMATION 8-37 CHASSIS ITEM N·m kgf-m lb-ft Steering stem head nut 65.0 Steering stem lock nut 58.0 Front fork upper clamp bolt 16.5 Front fork lower clamp bolt 16.5 Front fork cap bolt 16.5 Front fork inner rod lock nut 14.5 Front fork damper rod bolt 14.5...
Page 416: Tightening Torque Chart
8-38 SERVICING INFORMATION TIGHTENING TORQUE CHART For other bolts and nuts listed previously, refer to this chart: Bolt Diameter Conventional or “4” marked bolt “7” marked bolt A A A A (mm) N·m kgf-m lb-ft N·m kgf-m lb-ft 0.15 0.23 0.45 0.55 16.5...
Page 417: Service Data
SERVICING INFORMATION 8-39 SERVICE DATA VALVE + GUIDE Unit: mm (in) ITEM STANDARD LIMIT Valve diam. — (1.42) — (1.30) Tappet clearance (when cold) 0.10 – 0.20 — (0.004 – 0.008) 0.20 – 0.30 — (0.008 – 0.012) Valve guide to valve stem clear- 0.010 –...
Page 418 8-40 SERVICING INFORMATION CAMSHAFT + CYLINDER HEAD Unit: mm (in) ITEM STANDARD LIMIT Cam height 36.28 – 36.32 35.98 (1.428 – 1.430) (1.417) 35.68 – 35.72 35.38 (1.405 – 1.406) (1.393) Camshaft journal oil clearance 0.019 – 0.053 0.150 IN. & EX. (0.0007 –...
Page 419 SERVICING INFORMATION 8-41 ITEM STANDARD LIMIT Piston ring groove width 0.93 – 0.95 — (0.0366 – 0.0374) 1.55 – 1.57 — (0.0610 – 0.0618) 1.01 – 1.03 — (0.0398 – 0.0406) 2.51 – 2.53 — (0.0988 – 0.0996) Piston ring thickness 0.86 –...
Page 420 8-42 SERVICING INFORMATION OIL PUMP ITEM STANDARD LIMIT Oil pressure (at 60°C, 140°F) Above 400 kPa (4.0 kgf/cm , 57 psi) Below 700 kPa (7.0 kgf/cm — , 100 psi) at 3 000 r/min. CLUTCH Unit: mm (in) ITEM STANDARD LIMIT Drive plate thickness 2.92 –...
Page 421: Drive Train
SERVICING INFORMATION 8-43 DRIVE TRAIN Unit: mm (in) Expect ratio ITEM STANDARD LIMIT Primary reduction ratio 1.838 (57/31) — 2.411 (41/17) — Final reduction ratio Gear ratio 3.000 (36/12) — 1.933 (29/15) — 1.500 (27/18) — 1.227 (27/22) — 1.086 (25/23) —...
Page 422: Throttle Body
8-44 SERVICING INFORMATION FI-SENSORS ITEM SPECIFICATION NOTE More than 3.7 V CMP sensor output voltage 130 – 240 Ω CKP sensor resistance CKP sensor peak voltage More than 3.7 V (When cranking) IAP sensor input voltage 4.5 – 5.5 V IAP sensor output voltage Approx.
Page 423 SERVICING INFORMATION 8-45 ELECTRICAL Unit: mm (in) ITEM SPECIFICATION NOTE Ignition timing 4° B.T.D.C. at 1 200 r/min Firing order 1·2 Spark plug NGK: CR8EK Type Denso: U24ETR 0.6 – 0.7 (0.024 – 0.028) Spark performance Over 8 (0.3) at 1 atm. Crankshaft position sensor 130 –...
Page 424: License Light
8-46 SERVICING INFORMATION WATTAGE Unit: W SPECIFICATION ITEM E-03, 24, 28, 33 The others ← 60 × 2 Headlight ← 55 × 2 Position light 5 × 2 ← 21/5 × 2 Brake light/Taillight ← 10 × 4 Turn signal light Speedometer ←...
Page 425 SERVICING INFORMATION 8-47 ITEM STANDARD LIMIT 0.25 Wheel axle runout Front — (0.010) 0.25 Rear — (0.010) Wheel rim size Front 19M/C × MT 2.50 — Rear 17M/C × MT 4.00 — Tire size Front 110/80R19M/C 59H — Rear 150/70R17M/C 69H —...
Page 426: Fuel Tank
Filter change (3.1/2.6 US/lmp qt) 3 300 ml Overhaul (3.5/2.9 US/lmp qt) Front fork oil type SUZUKI FORK OIL SS-08 or an equivalent fork oil Front fork oil capacity (each leg) 505.0 ml (17.07/17.78 US/lmp oz) Brake fluid type DOT 4...
Page 427: Emission Control Information
EMISSION CONTROL INFORMATION EMISSION CONTROL INFORMATION CONTENTS EMISSION CONTROL SYSTEMS ............9- 2 FUEL INJECTION SYSTEM ............9- 2 CRANKCASE EMISSION CONTROL SYSTEM ......9- 3 EXHAUST EMISSION CONTROL SYSTEM (PAIR SYSTEM) ..9- 4 NOISE EMISSION CONTROL SYSTEM ........9- 5 EVAPORATIVE EMISSION CONTROL SYSTEM (Only for E-33) ................9- 5 PAIR (AIR SUPPLY) SYSTEM INSPECTION ........9- 6 PAIR (AIR SUPPLY) SYSTEM HOSE ROUTING ......9- 8...
Page 428: Emission Control Systems
EMISSION CONTROL INFORMATION EMISSION CONTROL SYSTEMS FUEL INJECTION SYSTEM DL1000 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. Fuel pressure...
Page 429: Crankcase Emission Control System
EMISSION CONTROL INFORMATION CRANKCASE EMISSION CONTROL SYSTEM The engine is equipped with a PCV system. Blow-by gas in the engine is constantly drawn into the crank- case, which is returned to the combustion chamber through the breather hose, air cleaner and throttle body. Breather hose FRESH AIR FUEL/AIR MIXTURE...
Page 430: Exhaust Emission Control System (Pair System)
EMISSION CONTROL INFORMATION EXHAUST EMISSION CONTROL SYSTEM (PAIR SYSTEM) The exhaust emission control system is composed of the PAIR system and THREE-WAY CATALYST sys- tem. The fresh air is drawn into the exhaust port with the PAIR solenoid valve and PAIR reed valve. The PAIR solenoid valve is operated by the ECM, and the fresh air flow is controlled according to the TPS, ECTS, IATS, IAPS and CKPS.
Page 431: Noise Emission Control System
EMISSION CONTROL INFORMATION NOISE EMISSION CONTROL SYSTEM TAMPERING WITH THE NOISE CONTROL SYSTEM PROHIBITED: Local law prohibits the following acts or the causing thereof: 1. 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 2.
Page 432: Pair (Air Supply) System Inspection
EMISSION CONTROL INFORMATION PAIR (AIR SUPPLY) SYSTEM INSPECTION HOSES • Inspect the hoses for wear or damage. • Inspect that the hoses are securely connected. PAIR REED VAVLE • Remove the PAIR reed valve cover. • Inspect the reed valve for the carbon deposit. •...
Page 433: Pair Control Solenoid Valve
EMISSION CONTROL INFORMATION PAIR CONTROL SOLENOID VALVE (For E-02 and 19) • Disconnect the PAIR control solenoid valve lead wire coupler. • Remove the air cleaner box. • Remove the PAIR control solenoid valve. • Check that air flows through the air inlet port to the air outlet ports.
Page 434: Pair (Air Supply) System Hose Routing
EMISSION CONTROL INFORMATION PAIR (AIR SUPPLY) SYSTEM HOSE ROUTING...
Page 435: Heated Oxgen Sensor (Ho S) Inspection
EMISSION CONTROL INFORMATION HEATED OXGEN SENSOR (HO S) INSPECTION • Remove the engine under cover. • Disconnect the HO sensor lead wire coupler. • Remove the HO sensor unit. Do not remove the HO sensor while it is hot. Be careful not to expose it to excessive shock. Do not use an impact wrench while removing or installing the HO sensor unit.
Page 436: Heated Oxgen Sensor Wire Routing
9-10 EMISSION CONTROL INFORMATION HEATED OXGEN SENSOR WIRE ROUTING...
Page 437: Evaporative Emission Control System Inspection (Only For E-33)
EMISSION CONTROL INFORMATION 9-11 EVAPORATIVE EMISSION CONTROL SYSTEM INSPECTION (Only for E-33) • Remove the seat and frame cover. • Remove the fuel tank. ('4-56) HOSES Inspect the hoses for wear or damage. Make sure that the hoses are securely connected. CANISTER Inspect the canister for damage to the body.
Page 438: Canister Hose Routing (Only For E-33)
9-12 EMISSION CONTROL INFORMATION CANISTER HOSE ROUTING (Only for E-33) Fuel shut-off valve Wiring harness Chacoal canister Inside. Surge hose Down side. To throttle body Wiring harness Chacoal canister Set the hose to the hook of the rear fender. Frame Purge hose Rear fender Clamp ends should face..
Page 439: Wiring Diagram
WIRING DIAGRAM FI SYSTEM WIRING DIAGRAM MAIN SIDE-STAND 30 A 15 A ENGINE STOP IGNITION COIL RELAY SWITCH SWITCH FUEL PUMP BATTERY 15 A NEUTRAL LAMP FUEL PUMP RELAY TIP OVER SENSOR Br/W Br/W Br/W STARTER RELAY STARTER W/Bl W/Bl W/Bl BUTTON B/Bl...
Page 440 WIRING DIAGRAM E-02, 19 HANDLEBAR SWITCH (R) (OPTIONAL PARTS) IGNITION GRIP HEATER SWITCH ENGINE FRONT BRAKE STOP SWITCH SWITCH LOCK LIGHTING OIL PRESSURE REAR BRAKE SWITCH STARTER SWITCH SWITCH SWITCH : SPEEDOMETER LIGHT SENSOR : TACHOMETER LIGHT FUEL PUSH : NEUTRAL INDICATOR LIGHT PUMP SENSOR : HIGH BEAM INDICATOR LIGHT...
Page 441 E-03, 28, 33 HANDLEBAR SWITCH (R) (OPTIONAL PARTS) IGNITION GRIP HEATER SWITCH ENGINE FRONT BRAKE STOP SWITCH SWITCH LOCK OIL PRESSURE REAR BRAKE STARTER SWITCH SWITCH SWITCH SENSOR : SPEEDOMETER LIGHT : TACHOMETER LIGHT FUEL PUSH : NEUTRAL INDICATOR LIGHT PUMP : HIGH BEAM INDICATOR LIGHT FUEL PUMP...
Page 442 E-24 HANDLEBAR SWITCH (R) ENGINE STOP FRONT BRAKE SWITCH SWITCH (OPTIONAL PARTS) OIL PRESSURE IGNITION REAR BRAKE STARTER SWITCH GRIP HEATER SWITCH SWITCH SWITCH : SPEEDOMETER LIGHT SENSOR : TACHOMETER LIGHT FUEL PUSH : NEUTRAL INDICATOR LIGHT PUMP LOCK : HIGH BEAM INDICATOR LIGHT FUEL PUMP SPEEDOMETER : OIL PRESSURE INDICATOR LIGHT...
Page 443 Prepared by February, 2002 Part No. 99500-39230-01E Printed in Japan...
Page 444 Printed in Japan...

Suzuki DL1000 Service Manual

Foreword Group Index

General Information 1

Chassis

Engine

Fi System

Precautions in Servicing

Fi System Technical Features

Fi System Parts Location

Fi System Wiring Diagram

Self-Diagnosis Function

Fail-Safe Function

Fi System Troubleshooting

Fuel System

Throttle Body and Stv Actuator

Cooling and Lubrication System

Chassis

Chassis

Electrical System

Electrical

Servicing Information

Capacities

Sensor

Quick Links

Chapters

Troubleshooting

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Summary of Contents for Suzuki DL1000