Suzuki TU250X Service Manual

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Page 3 FOREWORD GROUP INDEX This manual contains an introductory description on the SUZUKI TU250X 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 4 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 5 Apply oil. Use engine oil or transmis- or equivalent. sion oil unless otherwise specified. 99000-99001-SS8 Apply molybdenum oil solution. (Mixture of engine oil and SUZUKI Apply or use brake fluid. (DOT 4) MOLY PASTE in a ratio of 1:1) Apply SUZUKI SUPER GREASE “A” or equivalent.
Page 6 ABBREVIATIONS USED IN THIS MANUAL ABDC : After Bottom Dead Center : Hydrocarbons : Alternating Current HO2 Sensor : Heated Oxygen Sensor (HO2S) : Air Cleaner, Air Cleaner Box : American Petroleum Institute ATDC : After Top Dead Center IAP Sensor : Intake Air Pressure Sensor (IAPS) : Air Fuel Mixture (MAP Sensor)
Page 7 : Society of Automotive Engineers : Suzuki Diagnosis System STC System : Secondary Throttle Control System (STCS) STP Sensor : Secondary Throttle Position Sensor (STPS) ST Valve : Secondary Throttle Valve (STV) STV Actuator : Secondary Throttle Valve Actuator (STVA)
Page 8 SAE-TO-FORMER SUZUKI TERM This table lists SAE (Society of Automotive Engineers) J1930 terms and abbreviations which may be used in this manual in compliance with SAE recommendations, as well as their former SUZUKI names. SAE TERM FORMER SUZUKI TERM FULL TERM...
Page 9 SAE TERM FORMER SUZUKI TERM FULL TERM ABBREVIATION Malfunction Indicator Lamp LED Lamp Malfunction Indicator Lamp (MIL) Manifold Absolute Pressure Intake Air Pressure (IAP), Intake Vacuum Mass Air Flow Air Flow On-Board Diagnostic Self-Diagnosis Function Diagnostic Open Loop –––– Programmable Read Only Memory PROM ––––...
Page 10 WIRE COLOR : Black : Gray : Red : Blue : Light blue : Violet : Brown : Light green : White : Dark green : Orange : Yellow : Green : Pink B/Bl : Black with Blue tracer : Orange with Red tracer B/Br : Black with Brown tracer : Orange with White tracer...
Page 11: Table Of Contents
GENERAL INFORMATION 1-1 GENERAL INFORMATION CONTENTS WARNING/CAUTION/NOTE................ 1- 2 GENERAL PRECAUTIONS ................. 1- 2 SUZUKI TU250X (’09-MODEL)..............1- 4 SERIAL NUMBER LOCATION ..............1- 4 FUEL AND OIL RECOMMENDATION ............1- 5 FUEL...................... 1- 5 ENGINE OIL ..................1- 5 BRAKE FLUID..................
Page 12: Warning/Caution/Note
1-2 GENERAL INFORMATION WARNING/CAUTION/NOTE Please read this manual and follow its instructions carefully. To emphasize special information, the symbol and the words WARNING, CAUTION and NOTE have special meanings. Pay special attention to the mes- sages highlighted by these signal words. ...
Page 13 GENERAL INFORMATION 1-3  * If parts replacement is necessary, replace the parts with Suzuki Genuine Parts or their equiva- lent. * When removing parts that are to be reused, keep them arranged in an orderly manner so that they may be reinstalled in the proper order and orientation.
Page 14: Suzuki Tu250X ('09-Model)
1-4 GENERAL INFORMATION SUZUKI TU250X (’09-MODEL) RIGHT SIDE LEFT SIDE SERIAL NUMBER LOCATION The frame serial number or V.I.N. (Vehicle Identification Number) 1 is stamped on the right side of the steering head pipe. The engine serial number 2 is located on the left side of the crankcase. These numbers...
Page 15: Fuel And Oil Recommendation
Use of SF/SG or SH/SJ in API with MA in JASO. Suzuki recommends the use of SAE 10W-40 engine oil. If SAE 10W-40 engine oil is not available, select an alternative accord- ing to the following chart.
Page 16: Information Labels
1-6 GENERAL INFORMATION INFORMATION LABELS TU250X 1 Noise label 2 Information label 3 Manual notice label 4 General warning label 5 Tire information label 6 Safety plate A: Attached Right frame cover (Inside) Frame (Left side)
Page 17: Specifications
GENERAL INFORMATION 1-7 SPECIFICATIONS DIMENSIONS AND CURB MASS Overall length ................2 070 mm (81.5 in) Overall width ................750 mm (29.5 in) Overall height ................1 075 mm (42.3 in) Wheelbase ................1 375 mm (54.1 in) Ground clearance..............165 mm (6.5 in) Seat height ................
Page 18: Chassis
1-8 GENERAL INFORMATION CHASSIS Front suspension ..............Telescopic, coil spring, oil damped Rear suspension ..............Swingarm type, coil spring, oil damped Front suspension stroke............120 mm (4.7 in) Rear wheel travel ..............95 mm (3.7 in) Steering angle................. 40° (right & left) Caster ..................
Page 19 PERIODIC MAINTENANCE 2-1 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 VALVE CLEARANCE ................2- 5 SPARK PLUG ..................
Page 20: Periodic Maintenance Schedule
2-2 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. IMPORTANT: The periodic maintenance intervals and service requirements have been established in accordance with EPA regulations.
Page 21: Lubrication Points
PERIODIC MAINTENANCE 2-3 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. Brake lever holder Drive chain Side-stand pivot and spring hook Brake lever holder Throttle cables Brake pedal pivot NOTE:...
Page 22: Maintenance And Tune-Up Procedures
2-4 PERIODIC MAINTENANCE MAINTENANCE AND TUNE-UP PROCEDURES This section describes the servicing procedures for each item in the Periodic Maintenance chart. AIR CLEANER Inspect every 3 000 km (2 000 miles). If the air cleaner is clogged with dust, intake resistance will be increase, resulting in a decrease in engine output and an increase in fuel consumption.
Page 23: Valve Clearance
PERIODIC MAINTENANCE 2-5 Reinstall the cleaned air cleaner element and drain plug in the reverse order of removal. • Install the element holder with “UP” mark A faced upward.  If driving under dusty conditions, clean the air cleaner element more frequently. The surest way to accelerate engine wear is to operate the engine without the ele- ment or to use a torn element.
Page 24 2-6 PERIODIC MAINTENANCE INSPECTION The valve clearance specification is same for both valves. Valve clearance adjustment must be checked and adjusted, 1) at the time of periodic inspection, 2) when the valve mechanism is ser- viced, and 3) when the camshaft is disturbed by removing it for servicing.
Page 25: Spark Plug
PERIODIC MAINTENANCE 2-7 SPARK PLUG Inspect every 5 000 km (3 000 miles, 15 months). Replace every 10 000 km (6 000 miles, 30 months). Cold type Hot type DR8EA DR9EA DR7EA DENSO X24ESR-U X27ESR-U X22ESR-U • Disconnect the spark plug cap and remove the spark plug. ...
Page 26: Throttle Cable Play
2-8 PERIODIC MAINTENANCE THROTTLE CABLE PLAY Inspect initially at 1 000 km (600 miles, 3 months) and every 5 000 km (3 000 miles, 15 months) thereafter. Throttle cable play A should be 2.0 – 4.0 mm (0.08 – 0.16 in) as measured at throttle grip when turning the throttle grip lightly.
Page 27: Fuel Line
PERIODIC MAINTENANCE 2-9 FUEL LINE Inspect every 5 000 km (3 000 miles, 15 months) there- after. Inspect the fuel feed hose for damage and fuel leakage. If any defects are found, replace the fuel feed hose with a new one. CLUTCH CABLE PLAY Inspect every 5 000 km (3 000 miles, 15 months) there- after.
Page 28: Engine Oil And Oil Filter
2-10 PERIODIC MAINTENANCE ENGINE OIL AND OIL FILTER ENGINE OIL REPLACEMENT Replace initially at 1 000 km (600 miles, 3 months) and every 5 000 km (3 000 miles, 15 months) thereafter. • Place an oil pan below the engine. Drain oil by removing the engine oil drain plug 1.
Page 29: Drive Chain
PERIODIC MAINTENANCE 2-11 • Apply engine oil to new O-rings (4, 5). • Install a new oil filter. • Install the spring 2 correctly. • Install the oil filter cap and tighten the nuts securely. • Add new engine oil and check the oil level as described in the engine oil replacement procedure.
Page 30 2-12 PERIODIC MAINTENANCE CHECKING AND ADJUSTING • Place the motorcycle on the side-stand. • Loosen the rear axle nut 1. • Loosen the rear brake adjuster nut 2 and torque link nut (rear) 3. • Loosen the both chain adjuster lock-nuts 4. •...
Page 31  * Do not use any oil sold commercially as “drive chain oil”. Such oil can damage the O-rings. * The standard drive chain is DID520V. Suzuki recom- mends to use this standard drive chain as a replace- ment.
Page 32: Brakes
2-14 PERIODIC MAINTENANCE BRAKES (BRAKE) Inspect initially at 1 000 km (600 miles, 3 months) and every 5 000 km (3 000 miles, 15 months) thereafter. (BRAKE HOSE AND BRAKE FLUID) Inspect every 5 000 km (3 000 miles, 15 months). Replace brake hose every 4 years.
Page 33 PERIODIC MAINTENANCE 2-15 BRAKE FLUID LEVEL Inspect every 5 000 km (3 000 miles, 15 months). Replace every 2 years. • Keep the motorcycle upright and place the handlebars straight. • Check the brake fluid level by observing the lower limit line on the front brake fluid reservoir.
Page 34 2-16 PERIODIC MAINTENANCE AIR BLEEDING FROM BRAKE FLUID CIRCUIT Air trapped in the brake fluid circuit acts like a cushion to absorb a large proportion of the pressure developed by the master cyl- inder and thus interferes with the full braking performance of the brake caliper.
Page 35 PERIODIC MAINTENANCE 2-17 REAR BRAKE PEDAL HEIGHT • Loosen the lock-nut 1 and rotate the adjusting bolt 2 to locate brake pedal 25 mm (1.0 in) A below the top face of the footrest. • Retighten the lock-nut 1 to secure the adjusting bolt 2 in the proper position.
Page 36: Steering
2-18 PERIODIC MAINTENANCE REAR BRAKE SHOE WEAR This motorcycle is equipped with the brake lining wear limit indi- cator on the rear brake. To check wear of the brake lining, perform the following steps: • First, check if the brake system is properly adjusted. (2-17) •...
Page 37: Tires
PERIODIC MAINTENANCE 2-19 TIRES TIRE TREAD CONDITION Inspect every 5 000 km (3 000 miles, 15 months). Operating the motorcycle with excessively worn tires will decrease riding stability and consequently invite a dangerous situation. It is highly recommended to replace a tire when the remaining depth of tire tread reaches the following specification.
Page 38: Front Fork
2-20 PERIODIC MAINTENANCE SPOKE NIPPLES Make sure that the nipples are tight. If necessary, tighten them with a spoke nipple wrench.  Spoke nipple: 3 N·m (0.3 kgf-m, 2.0 lbf-ft)  09940-60113: Spoke nipple wrench FRONT FORK Inspect every 10 000 km (6 000 miles, 30 months). Inspect the front forks for oil leakage, scoring or scratches on the outer surface of the inner tubes.
Page 39: Exhaust Pipe Bolts And Muffler Mounting Bolts
PERIODIC MAINTENANCE 2-21 EXHAUST PIPE BOLTS AND MUFFLER MOUNTING BOLTS Tighten initially at 1 000 km (600 miles, 3 months) and every 10 000 km (6 000 miles, 30 months) thereafter. Tighten the exhaust pipe bolts, muffler connecting bolt and muf- fler mounting bolts to the specified torque.
Page 40: Chassis Bolts And Nuts
2-22 PERIODIC MAINTENANCE CHASSIS BOLTS AND NUTS Tighten initially at 1 000 km (600 miles, 3 months) and every 5 000 km (3 000 miles, 15 months) thereafter. Check that all chassis bolts and nuts are tightened to their specified torque. (Refer to page 2-23 for the loca- tions of the following bolts and nuts on the motorcycle.) Item N·m...
Page 41 PERIODIC MAINTENANCE 2-23...
Page 42: Compression Pressure Check
2-24 PERIODIC MAINTENANCE COMPRESSION PRESSURE CHECK The compression pressure reading 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 Standard Limit...
Page 43: Oil Pressure Check
PERIODIC MAINTENANCE 2-25 OIL PRESSURE CHECK Check the oil pressure periodically. This will give a good indication of the condition of the moving parts.  Oil pressure: Above 30 kPa (0.3 kgf/cm², 4.3 psi) at 3 000 r/min, oil temp. at 60 °C (140 °F) Below 70 kPa (0.7 kgf/cm², 10.0 psi) Low or high oil pressure can indicate any of the following conditions: LOW OIL PRESSURE...
Page 44: Sds Check
(STD), comparison between the same models helps facilitate the troubleshooting. • Remove the right frame cover. (8-3) • Set up the SDS tool. (4-23)  09904-41010: SUZUKI Diagnostic system set 99565-01010-020: CD-ROM Ver.20 NOTE: * Before taking the sample of data, check and clear the Past DTC.
Page 45 PERIODIC MAINTENANCE 2-27 Data at 3 000 r/min under no load Approx. 3 000 r/min Check the engine temperature. XX ˚C Check the manifold absolute pressure. XX kPa Data at the time of racing Throttle: Quick wide open Throttle: Slowly open Secondary throttle valve opens closes in according...
Page 46 2-28 PERIODIC MAINTENANCE Data of intake negative pressure during idling (90 °C) Check the manifold absolute pressure. XX kPa Check the engine temperature. Approx. 90 ˚C Data of manifold absolute pressure operation at the time of starting Check the manifold absolute pressure. XX kPa...
Page 47 PERIODIC MAINTENANCE 2-29 Example of trouble Three data; value 1 (current data 1), value 2 (past data 2) and value 3 (past data 3); can be made in compar- ison by showing them in the graph. Read the change of value by comparing the current data to the past data that have been saved under the same condition, then you may determine how changes have occurred with the passing of time and identify what problem is currently occurring.
Page 48 ENGINE 3-1 ENGINE CONTENTS ENGINE COMPONENTS REMOVABLE WITH ENGINE IN PLACE ..3- 2 ENGINE REMOVAL AND INSTALLATION..........3- 3 REMOVAL ..................... 3- 3 INSTALLATION..................3- 8 ENGINE DISASSEMBLY ................3-11 ENGINE COMPONENTS INSPECTION AND SERVICE......3-25 CYLINDER HEAD COVER..............3-25 CYLINDER HEAD..................
Page 49: Engine Components Removable With Engine In Place
3-2 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 page listed in each section for removal and reinstallation instructions. ENGINE CENTER ITEM REMOVAL INSPECTION INSTALLATION...
Page 50: Engine Removal And Installation
ENGINE 3-3 ENGINE REMOVAL AND INSTALLATION 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. • Remove the front seat. (8-3) •...
Page 51 3-4 ENGINE • Remove the PAIR control solenoid valve bracket bolts. • Loosen the clutch cable adjuster and lock-nut. • Remove the clutch cable 4 along with clutch release arm 5. • Remove the throttle body assembly 6. (5-11) • Disconnect the ET sensor coupler 7. •...
Page 52 ENGINE 3-5 • Remove the engine sprocket cover B. • Remove the PCV hose C. • Flatten the tab of lock washer D. • Remove the engine sprocket nut E and lock washer D. NOTE: When loosening the engine sprocket nut E, depress the rear brake pedal.
Page 53 3-6 ENGINE • Remove the gearshift lever J. NOTE: Mark the gearshift shaft head at which the gearshift lever slit set for correct reinstallation. • Disconnect the engine ground wire K. • Support the engine using an engine jack. • Remove the engine mounting bolts, nuts and brackets.
Page 54 ENGINE 3-7 • Remove the swingarm pivot shaft nut and washer. • Partially remove the swingarm pivot shaft so that the engine can be removed. NOTE: Be careful not to draw out the swingarm pivot shaft. • Gradually lower the engine.
Page 55: Installation
3-8 ENGINE INSTALLATION Install the engine in the reverse order of engine removal. Pay attention to the following points: • Fit the swingarm in its position and hold it with the swingarm pivot shaft. • Mount the engine on the frame. •...
Page 56 ENGINE 3-9 NOTE: * Pass the PAIR pipe 1 between the engine mounting upper plats. * Fit the clamp 2 to the bolt. * Fit the guide 3 to the bolt. • Connect the engine ground wire 4. NOTE: Fit the engine ground wire 4 and clamp 5 to the crankcase bolt.
Page 57 3-10 ENGINE • Install the throttle body assembly. (5-17) • Position the throttle body clamps correctly. (10-20) • Install the clutch release arm as shown in the illustration. NOTE: Align the release arm slit surface B with the notch mark C on the release camshaft.
Page 58: Engine Disassembly
ENGINE 3-11 ENGINE DISASSEMBLY  Identify the position of each removed part. Organize the parts in their respective groups (e.g., intake, exhaust) so that they can be reinstalled in their original positions. STARTER MOTOR • Remove the starter motor 1. SPARK PLUG •...
Page 59 3-12 ENGINE • Rotate the crankshaft and align the line A on the generator rotor with the mark B on the generator cover. NOTE: The piston must be at TDC on the compression stroke. CAM CHAIN TENSION ADJUSTER • Remove the cam chain tension adjuster cap 1. •...
Page 60 ENGINE 3-13 CAMSHAFT • Remove the cylinder head plug 1. • Remove the dowel pins. • Remove the camshaft sprocket bolts. • Remove the camshaft sprocket 2 and camshaft 3.  Do not drop the cam chain 4, locating pin 5 and dowel pin 6 into the crankcase.
Page 61 3-14 ENGINE CYLINDER HEAD/CAM CHAIN GUIDE • Remove the cylinder head nuts diagonally. • Remove the cylinder head 1. NOTE: If the cylinder head does not come off easily, lightly tap it using a plastic hammer. • Remove the dowel pins and gasket 2. •...
Page 62 ENGINE 3-15 • Remove the piston pin 2 using the special tool if necessary.  09910-34510: Piston pin puller • Remove the piston 3. NEUTRAL SWITCH • Remove the neutral switch 1 and O-ring 2. • Remove the switch contacts 3 and springs 4. GENERATOR COVER •...
Page 63 3-16 ENGINE STARTER IDLE GEAR • Remove the starter idle gear shaft 1 and starter idle gear 2. CLUTCH COVER • Remove the clutch cover 1. • Remove the dowel pins and gasket 2. CLUTCH • Remove the clutch spring set bolts, clutch springs and clutch pressure plate 1.
Page 64 ENGINE 3-17 • Remove the clutch drive No.1 plates 6 and driven plates 7. • Remove the clutch drive No.2 plate 8. • Remove the spring washer 9 and spring washer seat 0. • Flatten the lock washer A. • Hold the clutch sleeve hub with the special tools and remove the clutch sleeve hub nut B.
Page 65 3-18 ENGINE • Remove the clutch sleeve hub C. • Remove the thrust washer D. • Remove the primary driven gear assembly E. • Remove the spacer F and thrust washer G. OIL PUMP • Remove the circlip 2 and oil pump drive gear 3 from the pri- mary driven gear assembly 1.
Page 66 ENGINE 3-19 • Remove the pin 6 and washer 7. • Remove the oil pump 8.  Do not attempt to disassemble the oil pump assembly. GEARSHIFT • Remove the gearshift shaft 1. • Remove the cam guide 2 and pawl lifter 3. •...
Page 67 3-20 ENGINE • Remove the cam chain 3. • Hold the generator rotor with the special tool and remove the primary drive gear nut 4.  The primary drive nut has left-hand threads.  09930-44521: Rotor holder • Remove the washer 5, key 6, primary drive gear 7, sprocket key (L-shape) 8 and cam chain drive sprocket 9.
Page 68 ENGINE 3-21 • Remove the key 3. • Remove the starter driven gear 4 and bearing 5. • Remove the washer 6. CRANKCASE • Remove the gearshift cam stopper plug 1. • Remove the spring 2 and gearshift cam stopper No.2 3. •...
Page 69 3-22 ENGINE • Remove the crankcase bolts, left and right. • Separate the left and right crankcases with the special tool.  09920-13120: Crankcase remover NOTE: * Fit the crankcase separator, so that the tool arms are in paral- lel with the side of crankcase. * The crankshaft and transmission components should remain in the left crankcase half.
Page 70 ENGINE 3-23 • Remove the key 4 and crank balancer shaft 5. TRANSMISSION • Remove the gearshift cam stopper spring 1. • Remove the gearshift fork shafts (2, 3). • Remove the gearshift forks (4, 5, 6). • Remove the gearshift cam stopper 7. •...
Page 71 3-24 ENGINE CRANKSHAFT • Remove the crank balancer drive gear 1. • Remove the crankshaft with the special tool.  09920-13120: Crankcase remover...
Page 72: Engine Components Inspection And Service
ENGINE 3-25 ENGINE COMPONENTS INSPECTION AND SERVICE  Identify the position of each removed part. Organize the parts in their respective groups (i.e., intake or exhaust) so that they can be installed in their original locations. CYLINDER HEAD COVER DISASSEMBLY •...
Page 73: Cylinder Head
3-26 ENGINE REASSEMBLY Reassemble the cylinder head cover in the reverse order of dis- assembly. Pay attention to the following points: • Apply engine oil to the rocker arms, rocker arm shafts and O-rings.  Use the new O-rings to prevent oil leakage. •...
Page 74 ENGINE 3-27 • Remove the valve cotters 3 from the valve stem.  09916-84511: Tweezer • Remove the valve spring retainer 4 and valve spring 5. • Remove the valve 6 from the combustion chamber side. • Remove the valve stem seal 7. •...
Page 75 3-28 ENGINE VALVE FACE WEAR The thickness of the valve face decreases as the face wears. Visually inspect each valve face for wear and replace any valve with an abnormally worn face. Measure the valve face thickness T, if it is out of specification, replace the valve with a new one. ...
Page 76 ENGINE 3-29 VALVE STEM WEAR Measure the valve stem O.D. using the micrometer. If it is out of specification, replace the valve with a new one. If the valve stem O.D. is within specification but the valve stem deflection is not, replace the valve guide.
Page 77 3-30 ENGINE • Cool down the new valve guides in a freezer for about one hour and heat the cylinder head to 100 – 150 °C (212 – 302 °F) with a hot plate.  Do not use a burner to heat the valve guide hole to prevent cylinder head distortion.
Page 78 ENGINE 3-31 VALVE SEAT WIDTH INSPECTION Visually check for valve seat width on each valve face. If the valve face has worn abnormally, replace the valve. Coat the valve seat with a red lead (Prussian Blue) and set the valve in place. Rotate the valve with light pressure. Check that the transferred red lead (blue) on the valve face is uniform all around and in center of the valve face.
Page 79 3-32 ENGINE • Clean and assemble the head and valve components. Fill the intake and exhaust ports with gasoline to check for leaks. • If any leaks occur, inspect the valve seat and face for burrs or other things that could prevent the valve from sealing. ...
Page 80 ENGINE 3-33 REASSEMBLY Reassemble the cylinder head in the reverse order of disassem- bly. Pay attention to the following points: • Install each valve spring seat 1. • Apply molybdenum oil solution to the valve stem seal 2, and press-fit it into position. ...
Page 81 • Apply grease to the O-ring.  Use the new O-ring to prevent sucking air from the joint.  99000-25010: SUZUKI SUPER GREASE “A” or equivalent • Install the intake pipe with “UP” mark A faced upward. CAM CHAIN TENSIONER •...
Page 82: Camshaft
ENGINE 3-35 CAMSHAFT CAM WEAR Worn-down cams are often the cause of mistimed valve opera- tion resulting in reduced power output. Measure the cam height H using the micrometer. Replace a camshaft if the cams are worn to the service limit. ...
Page 83: Piston
3-36 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: 72.000 – 72.015 mm (2.8346 – 2.8352 in)  09900-20530: Cylinder gauge set CAM CHAIN TENSION ADJUSTER Make sure the push rod movement.
Page 84 ENGINE 3-37 PISTON TO CYLINDER CLEARANCE Subtract the piston diameter from the cylinder bore diameter. If the piston-to-cylinder clearance exceeds the service limit, replace the cylinder or the piston, or both.  Piston to cylinder clearance Service Limit: 0.120 mm (0.0047 in) PISTON PIN AND PIN BORE Measure the piston pin bore diameter using the small bore gauge.
Page 85: Conrod And Crankshaft
3-38 ENGINE PISTON RING FREE END GAP AND PISTON RING END GAP Measure the piston ring free end gap using a vernier calipers. Next, fit the piston ring squarely into the cylinder and measure the piston ring end gap using a thickness gauge. If the piston ring’s end gap is out of specification, replace the piston ring.
Page 86 ENGINE 3-39 CONROD BIG END SIDE CLEARANCE Push the big end of the conrod to one side and measure the side clearance using a thickness gauge. If the clearance exceeds the service limit, replace crankshaft assembly or bring the deflection and side clearance into specifi- cation by replacing the worn parts.
Page 87: Starter Clutch And Starter Driven Gear Bearing
3-40 ENGINE STARTER CLUTCH AND STARTER DRIVEN GEAR BEARING  1 Starter driven gear 4 Push piece 2 Bearing 5 Spring ITEM N·m kgf-m lbf-ft 3 Roller A Starter clutch bolt 19.0 STARTER CLUTCH Install the starter driven gear onto the starter clutch and turn the starter driven gear by hand (the gear turns in only one direction).
Page 88: Balancer Driven Gear
ENGINE 3-41 DISASSEMBLY • Remove the starter driven gear. • Remove the rollers 1, push pieces 2 and springs 3. • Hold the generator rotor with the special tool and remove the starter clutch bolts.  09930-44521: Rotor holder • Remove the starter clutch body 4. REASSEMBLY •...
Page 89: Generator
3-42 ENGINE • Align the punch mark A on inner race with the punch mark B on balancer driven gear. GENERATOR REMOVAL • Remove the stator coil 1 and CKP sensor 2. INSTALLATION Install the stator coil and CKP sensor in the reverse order of removal.
Page 90: Oil Filter
ENGINE 3-43 OIL FILTER REMOVAL • Remove the oil filter cap 1. • Remove the oil filter 2. INSTALLATION • Apply engine oil to the O-rings (1, 2) and install them. • Install a new oil filter 3. • Install the spring 4 and oil filter cap 5. NOTE: Before installing the new oil filter and oil filter cap, make sure that the spring 4 and new O-rings (1, 2) are installed cor-...
Page 91: Oil Pump
Crankcase • Apply grease to the O-ring 2 and install it.  Replace the O-ring with a new one.  99000-25010: SUZUKI SUPER GREASE “A” or equivalent • Install the oil strainer cap and tighten the oil strainer bolts securely.
Page 92: Transmission
ENGINE 3-45 TRANSMISSION DISASSEMBLY • Disassemble the transmission gears as shown in the illustration.  1 1st driven gear 7 Countershaft 2 5th driven gear 8 5th drive gear ITEM N·m kgf-m lbf-ft 3 3rd driven gear 9 3rd drive gear 65.0 4 4th driven gear 0 4th drive gear...
Page 93 3-46 ENGINE REASSEMBLY Assemble the countershaft and driveshaft in the reverse order of disassembly. Pay attention to the following points: NOTE: * Rotate the bearings by hand to inspect for smooth rotation. Replace the bearings if there is anything unusual. * Before installing the gears, apply engine oil to the driveshaft and countershaft.
Page 94 ENGINE 3-47 TRANSMISSION PARTS LOCATION A 2 mm (0.08 in) B 1 mm (0.03 in) 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 95: Clutch
3-48 ENGINE GEARSHIFT FORK GROOVE WIDTH Measure the gearshift fork groove width using the vernier cali- pers.  Shift fork groove width Standard (No.1, 2, 3): 4.25 – 4.35 mm (0.167 – 0.171 in)  09900-20101: Vernier calipers (150 mm) GEARSHIFT FORK THICKNESS Measure the gearshift fork thickness using the vernier calipers.
Page 96: Crankcase Bearing And Oil Seal
ENGINE 3-49 CLUTCH SPRING FREE LENGTH Measure the free length of each clutch spring using vernier cali- pers. If any spring is not within the service limit, replace all of the spring.  Clutch spring free length Service Limit: 40.9 mm (1.61 in) ...
Page 97 3-50 ENGINE BEARING AND OIL SEAL REMOVAL  The removed bearings and oil seals must be replaced with new ones. Right crankcase • Remove the bearing retainer 1. • Remove the bearings (2, 3, 4, 5) with the special tool. Bearing 2: 47 Attachment Bearing 3: 40 Attachment Bearing 4: 35 Attachment...
Page 98 ENGINE 3-51 • Remove the oil seal 8 with the special tool. Oil seal 8: 62 Attachment  09913-70210: Bearing installer set (10 – 75 ) • Remove the bearing 9 with the special tool. Bearing 9: 35 Attachment  09913-70210: Bearing installer set (10 – 75 ) •...
Page 99 3-52 ENGINE • Install a new oil seal 3 with the special tool. Oil seal 3: 68 Attachment  Align the oil hole of crankcase with the concave part of oil seal 3.  09913-70210: Bearing installer set (10 – 75 ) •...
Page 100 • Install a new oil seal 0 with the special tool. Oil seal 0: 22 Attachment  09913-70210: Bearing installer set (10 – 75 ) • Apply a small quantity of grease to each oil seal lip.  99000-25010: SUZUKI SUPER GREASE “A” or equivalent...
Page 101: Clutch Release Camshaft
• Remove the clutch release camshaft 3, oil seal 4 and washer 5. INSTALLATION • Apply a small quantity of grease to the oil seal lip.  99000-25010: SUZUKI SUPER GREASE “A” or equivalent • Install the clutch release camshaft 1, washer 2 and new oil seal 3.
Page 102: Clutch Cover
• Install a new oil seal 1 with the special tool.  09913-70210: Bearing installer set (10 – 75 ) • Install the oil seal retainer. • Apply a small quantity of grease to the oil seal lip.  99000-25010: SUZUKI SUPER GREASE “A” or equivalent...
Page 103: Engine Reassembly
3-56 ENGINE ENGINE REASSEMBLY Reassemble the engine in the reverse order of disassembly. The following steps require special attention or precautionary measures should be taken. NOTE: Apply engine oil to each running and sliding part before reas- sembling. CRANKSHAFT • When installing the crankshaft into the crankcase, it is neces- sary to pull its left end into the left crankcase with the special tools.
Page 104 ENGINE 3-57 • Align the pin groove A of gearshift cam stopper plate 1 with the pin B on gearshift cam. • Install the gearshift cam stopper 2. • Install the gearshift forks and gearshift cam 6. 3: Gearshift fork No.1 4: Gearshift fork No.2 5: Gearshift fork No.3 •...
Page 105 • Install the dowel pins into the left crankcase. • Apply bond to the both crankcases. Right crankcase  99000-31110: SUZUKI BOND “1215” or equivalent  * Coat the sealant evenly without break. * Application of sealant must be performed within a short period of time.
Page 106 2.  Replace the O-ring with a new one. • Apply grease to each oil seal lip.  99000-25010: SUZUKI SUPER GREASE “A” or equivalent • Install the engine sprocket spacer 2. NOTE: The oil hole side B of engine sprocket spacer faces inside.
Page 107 3-60 ENGINE • Install the gearshift cam stopper No.2 3, spring 4 and gear- shift cam stopper plug 5.  Gearshift cam stopper plug: 23 N·m (2.3 kgf-m, 16.5 lbf-ft) GENERATOR • Install the washer 1. NOTE: The chamber side A of washer faces inside. •...
Page 108 ENGINE 3-61 • Apply thread lock to the generator rotor nut 6.  99000-32030: THREAD LOCK SUPER “1303” or equivalent • Hold the generator rotor with the special tool. • Tighten the generator rotor nut 6 to the specified torque. ...
Page 109 3-62 ENGINE • Install the cam chain 7. • Install the washer 8. • Apply thread lock to the crank balancer bolt 9.  99000-32110: THREAD LOCK SUPER “1322” or equivalent • Hold the generator rotor with special tool. • Tighten the crank balancer bolt to the specified torque. ...
Page 110 ENGINE 3-63 • Install the gearshift shaft 9. NOTE: Align the center teeth on the gearshift shaft with the center teeth on the gearshift cam driven gear. OIL PUMP • Install the oil pump 1 with the oil pump mounting bolts and then tighten them to the specified torque.
Page 111 3-64 ENGINE CLUTCH • Install the thrust washer 1 and spacer 2. • Apply engine oil to the inside and outside surfaces of the spacer 2. • Install the primary driven gear assembly 3 and thrust washer NOTE: Be sure to engage the oil pump driven gear with the drive gear and the primary driven gear with the drive gear.
Page 112 ENGINE 3-65 • Apply engine oil to the clutch drive plates and driven plates. • Insert the clutch drive plates and driven plates one by one into the clutch sleeve hub in the prescribed order. 0 Clutch drive No.2 plate ..1 pc. A Clutch driven plate ....
Page 113 3-66 ENGINE CLUTCH RELEASE SCREW ADJUSTMENT • Loosen the lock-nut 1, and turn in the release screw 2 to feel resistance. • From that position, turn out the release screw 2 1/4 turn, and tighten the lock-nut 1 by holding the release screw 2. CLUTCH COVER •...
Page 114 • Install the springs 1 and switch contacts 2. • Apply grease to the O-ring 3 and install it.  Replace the O-ring with a new one.  99000-25010: SUZUKI SUPER GREASE “A” or equivalent • Install the neutral switch 4. PISTON RING •...
Page 115 3-68 ENGINE • Install the 2nd ring 4 and 1st ring 5. NOTE: 1st ring and 2nd ring differ in shape. • Face the stamped mark A upward when assembling. 1st ring 2nd ring • Position the gaps of the three ring as shown. Before inserting each piston into the cylinder, check that the gaps are so located.
Page 116 • Apply bond to the mating surfaces at the parting line between the left and right crankcases as shown.  99000-31110: SUZUKI BOND “1215” or equivalent • Apply engine oil to the big end of conrod. • Install the dowel pins (1, 2) and cylinder gasket 3.
Page 117 3-70 ENGINE CYLINDER HEAD/CAM CHAIN GUIDE • Install the cam chain guide 1.  When installing the cam chain guide, check that the chain is properly engaged with the crankshaft sprocket. • Install the dowel pin and cylinder head gasket 2. ...
Page 118 ENGINE 3-71 • Install the C-ring 3.  Do not drop the C-ring into the crankcase. • Apply engine oil to the camshaft bearings. • Apply molybdenum oil solution to the cam faces.  MOLYBDENUM OIL SOLUTION • Set the notch C on camshaft toward the intake side of cylin- der head.
Page 119 • Install the dowel pins and cylinder head plug 1. • Apply bond to the cylinder head cover and part A of the cylin- der head.  99000-31110: SUZUKI BOND “1215” or equivalent  * Coat the sealant evenly without break.
Page 120 • Apply grease to the O-ring 1.  Replace the O-ring 1 and gasket 2 with new ones.  99000-25010: SUZUKI SUPER GREASE “A” or equivalent • Tighten the TDC plug and the generator cover plug to the specified torque.
Page 121 • Apply grease to the O-rings and install the valve inspection caps.  Replace the O-rings with new ones.  99000-25010: SUZUKI SUPER GREASE “A” or equivalent SPARK PLUG • Tighten the spark plug 1 to the specified torque.  Spark plug: 18 N·m (1.8 kgf-m, 13.0 lbf-ft) ...
Page 122 FI SYSTEM DIAGNOSIS 4-1 FI SYSTEM DIAGNOSIS CONTENTS PRECAUTIONS IN SERVICING ..............4- 3 ELECTRICAL PARTS ................4- 3 FUSE...................... 4- 4 SWITCH ....................4- 4 ECM/VARIOUS SENSORS ..............4- 4 ELECTRICAL CIRCUIT INSPECTION PROCEDURE......4- 6 USING THE MULTI CIRCUIT TESTER..........4- 9 FI SYSTEM TECHNICAL FEATURES............
Page 123 4-2 FI SYSTEM DIAGNOSIS FI SYSTEM DIAGNOSIS CONTENTS SENSORS ....................4-68 CKP SENSOR INSPECTION ..............4-68 CKP SENSOR REMOVAL AND INSTALLATION ........ 4-68 IAP SENSOR INSPECTION ..............4-68 IAP SENSOR REMOVAL AND INSTALLATION........4-68 TP SENSOR INSPECTION ..............4-68 TP SENSOR REMOVAL AND INSTALLATION ........4-68 TPS ADJUSTMENT................
Page 124: Precautions In Servicing
FI SYSTEM DIAGNOSIS 4-3 PRECAUTIONS IN SERVICING When handling the component parts or servicing the FI system, observe the following points for the safety of the system. ELECTRICAL PARTS CONNECTOR/COUPLER • Faulty FI system is often related to poor electrical contact of connector/coupler.
Page 125: Fuse
4-4 FI SYSTEM DIAGNOSIS • When taking measurements at electrical connectors using a tester probe, be sure to insert the probe from the wire harness side (backside) of the connector/coupler. 1 Coupler 2 Probe • When connecting meter probe from the terminal side of the coupler (where connection from harness side not being possi- ble), use extra care not to force and cause the male terminal to bend or the female terminal to open.
Page 126 FI SYSTEM DIAGNOSIS 4-5 • Be careful not to touch the electrical terminals of the ECM. The static electricity from your body may damage this part. • When disconnecting and connecting the ECM, make sure to turn OFF the ignition switch 1, or electronic parts may get damaged.
Page 127: Electrical Circuit Inspection Procedure
4-6 FI SYSTEM DIAGNOSIS • Never connect any tester (voltmeter, ohmmeter, or whatever) to the ECM when its coupler is disconnected. Otherwise, damage to ECM may result. • Never connect an ohmmeter to the ECM with its coupler con- nected. If attempted, damage to ECM or sensors may result. •...
Page 128 FI SYSTEM DIAGNOSIS 4-7 • Using continuity inspect or voltage check procedure as described below, inspect the wire harness terminals for open circuit and poor connection. Locate abnormality, if any. A Looseness of crimping B Open C Thin wire (a few strands left) Continuity check •...
Page 129 4-8 FI SYSTEM DIAGNOSIS VOLTAGE CHECK If voltage is supplied to the circuit being checked, voltage check can be used as circuit check. • With all connectors/couplers connected and voltage applied to the circuit being checked, measure voltage between each terminal and body ground.
Page 130: Using The Multi Circuit Tester
1 ECM *1 To other parts USING THE MULTI CIRCUIT TESTER • Use the Suzuki multi circuit tester set (09900-25008). • Use well-charged batteries in the tester. • Be sure to set the tester to the correct testing range. USING THE TESTER •...
Page 131: Fi System Technical Features
4-10 FI SYSTEM DIAGNOSIS FI SYSTEM TECHNICAL FEATURES INJECTION TIME (INJECTION VOLUME) The factors to determine the injection time include the basic fuel injection time, which is calculated on the basis of intake air pressure, engine speed and throttle opening angle, and various compensations. These compensations are determined according to the signals from various sensors that detect the engine and driving conditions.
Page 132: Compensation Of Injection Time (Volume)
FI SYSTEM DIAGNOSIS 4-11 COMPENSATION OF INJECTION TIME (VOLUME) The following different signals are output from the respective sensors for compensation of the fuel injection time (volume). SIGNAL DESCRIPTION ENGINE TEMPERATURE SENSOR SIG- When engine temperature is low, injection time (volume) is increased.
Page 133: Fi System Parts Location
4-12 FI SYSTEM DIAGNOSIS FI SYSTEM PARTS LOCATION A ECM E Engine temperature sensor (ET) B Tip-over sensor (TOS) F Fuel pump (FP) C Heated oxygen sensor (HO2S) G Ignition coil (IG coil) D PAIR control solenoid valve H Intake air temperature sensor (IATS) A ECM L Secondary throttle position sensor (STPS) I Speedometer...
Page 134: Fi System Wiring Diagram
FI SYSTEM DIAGNOSIS 4-13 FI SYSTEM WIRING DIAGRAM Speedometer Bl/R Crankshaft positon sensor (CKPS) Lg/W Fuel Throttle position injector sensor (TPS) Main relay Bl/Y Secondary throttle Ignition position sensor (STPS) coil W/Bl Fuel pump Intake air pressure sensor (IAPS) Intake air temperatue PAIR control Engine sensor (IATS)
Page 135: Ecm Terminal
4-14 FI SYSTEM DIAGNOSIS ECM TERMINAL TERMINAL TERMINAL CIRCUIT CIRCUIT STVA signal (STVA. 2A) STVA signal (STVA. 2B) STVA signal (STVA. 1A) STVA signal (STVA. 1B) TP sensor signal (TPS) STP sensor (STPS) TO sensor signal (TOS) HO2 sensor (HO2S) IAT sensor signal (IAT) ET sensor (ET) —...
Page 136: Self-Diagnosis Function
FI SYSTEM DIAGNOSIS 4-15 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 FI indicator light. To check the function of the individual FI system devices, the dealer mode is provided.
Page 137: Dealer Mode
4-16 FI SYSTEM DIAGNOSIS DEALER MODE The defective function is memorized in the ECM. Use the special tool’s coupler to connect to the dealer mode coupler. The memorized malfunction code is displayed by the flashing pattern of FI indicator light. Malfunction means that the ECM does not receive normal signal from the devices.
Page 138: Fail-Safe Function
FI SYSTEM DIAGNOSIS 4-17 FAIL-SAFE FUNCTION FI system is provided with fail-safe function to allow the engine to start and the motorcycle to run in a mini- mum performance necessary even under malfunction condition. STARTING RUNNING ITEM FAIL-SAFE MODE ABILITY ABILITY IAP sensor Intake air pressure is fixed to 101.3...
Page 139: Fi System Troubleshooting
4-18 FI SYSTEM DIAGNOSIS FI SYSTEM TROUBLESHOOTING CUSTOMER COMPLAINT ANALYSIS Record details of the problem (failure, complaint) and how it occurred as described by the customer. For this purpose, use of such an inspection form such as below will facilitate collecting information required for proper analysis and diagnosis.
Page 140 FI SYSTEM DIAGNOSIS 4-19 MOTORCYCLE/ENVIRONMENTAL CONDITION WHEN PROBLEM OCCURS Environmental condition Weather Fair Cloudy Rain Snow Always Other Temperature Warm Cool Cold ( °C) Always Frequency Always Sometimes ( times/ day, month) Only once Under certain condition Road Urban Suburb Highway Mountainous ( Uphill...
Page 141: Self-Diagnostic Procedures
4-20 FI SYSTEM DIAGNOSIS SELF-DIAGNOSTIC PROCEDURES NOTE: * Do not disconnect the couplers from ECM, battery cable from battery, ECM ground wire from engine or main fuse before confirming the DTC (Diagnostic Trouble Code) stored in mem- ory. Such disconnection may erase the memorized information in ECM memory.
Page 142 FI SYSTEM DIAGNOSIS 4-21 DTC INDICATION CHART FLASHING PATTERN DTC No. MALFUNCTION PART REMARKS None CKP sensor (4-29) Pick up coil signal IAP sensor (4-31) TP sensor (4-36) ET sensor (4-41) IAT sensor (4-45) TO sensor (4-49) Ignition coil (4-52) STV actuator (4-53) STP sensor (4-56) Fuel injector (4-60)
Page 143 4-22 FI SYSTEM DIAGNOSIS FLASHING PATTERN DTC No. MALFUNCTION PART REMARKS HO2 sensor (4-64) PAIR control solenoid valve (4-66) SELF-DIAGNOSIS RESET PROCEDURE • After repairing the trouble, turn OFF the ignition switch and turn ON again. • If the FI indicator light turns OFF, the malfunction is cleared. •...
Page 144: Use Of Sds Diagnostic Procedures
• SDS is not only used for detecting DTC but also for reproduc- ing and checking on screen the failure condition as described by customers using the trigger. • How to use trigger, refer to the SDS operation manual for fur- ther details.  09904-41010: SUZUKI Diagnostic system set 99565-01010-020: CD-ROM Ver.20...
Page 145: Use Of Sds Diagnosis Reset Procedure
4-24 FI SYSTEM DIAGNOSIS USE OF SDS DIAGNOSIS RESET PROCE- DURE • After repairing the trouble, turn OFF the ignition switch and turn ON again. • Click the DTC inspection button 1. • Check the DTC. • The previous malfunction history code (Past DTC) still remains stored in the ECM.
Page 146: Show Data When Trouble (Displaing Data At The Time Of Dtc)
FI SYSTEM DIAGNOSIS 4-25 SHOW DATA WHEN TROUBLE (DISPLAING DATA AT THE TIME OF DTC) ECM stores the engine and driving conditions (in the form of data as shown in the figure) at the moment of the detection of a malfunction in its memory. This data is called “Show data when trouble”. Therefore, it is possible to know engine and driving conditions (e.g., whether the engine was warm or not, where the motorcycle was running or stopped) when a malfunction was detected by checking the show data when trouble.
Page 147: Malfunction Code And Defective Condition
4-26 FI SYSTEM DIAGNOSIS MALFUNCTION CODE AND DEFECTIVE CONDITION DETECTED DTC No. DETECTED FAILURE CONDITION CHECK FOR ITEM NO FAULT ––––––––––– ––––––––––– CKP sensor The CKP sensor signal does not reach CKP sensor wiring and mechan- ECM for 3 seconds or more, after ical parts receiving the starter signal.
Page 148 FI SYSTEM DIAGNOSIS 4-27 DETECTED DTC No. DETECTED FAILURE CONDITION CHECK FOR ITEM TO sensor The sensor voltage should be the fol- TO sensor, lead wire/coupler lowing. connection 0.2 V sensor voltage < 4.6 V In other than the above value, 23 (P1651) is indicated.
Page 149 4-28 FI SYSTEM DIAGNOSIS DETECTED DTC No. DETECTED FAILURE CONDITION CHECK FOR ITEM HO2 sensor HO2 sensor output voltage is not input HO2 sensor circuit open or to ECM during engine operation and shorted to ground running condition. (Sensor voltage < 0.60 V) In other than the above value, 44 P0130 (P0130) is indicated.
Page 150: 12" (P0335) Ckp Sensor Circuit Malfunction
FI SYSTEM DIAGNOSIS 4-29 “12” (P0335) CKP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE The signal does not reach ECM for 3 seconds or • Metal particles or foreign material being stuck on more, after receiving the starter signal. the CKP sensor and rotor tip •...
Page 151 4-30 FI SYSTEM DIAGNOSIS 5) If OK, then check the continuity between each terminal and ground.  CKP sensor continuity: ∞ Ω (Infinity) (Bl – Ground) (G – Ground)  09900-25008: Multi circuit tester set  Tester knob indication: Resistance (Ω) Are the resistance and continuity OK? Go to Step 2.
Page 152: 13" (P0105-H/L) Iap Sensor Circuit Malfunction
FI SYSTEM DIAGNOSIS 4-31 “13” (P0105-H/L) IAP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE IAP sensor voltage is not within the fol- • Clogged vacuum passage between throttle body lowing range. and IAP sensor. 0.24 V Sensor voltage < 4.1 V •...
Page 153 4-32 FI SYSTEM DIAGNOSIS 3) Disconnect the IAP sensor coupler. 4) Turn the ignition switch ON. 5) Insert the needle-point probes to the lead wire coupler. 6) Measure the voltage at the R wire and ground. 7) If OK, then measure the voltage at the R wire and B/Br wire. ...
Page 154 FI SYSTEM DIAGNOSIS 4-33 5) Disconnect the ECM coupler. 6) Check the continuity between W/Bl wire A and terminal 7. 7) If OK, then check the continuity between B/Br wire B and ter- minal T.  IAPS lead wire continuity: Continuity () ...
Page 155 4-34 FI SYSTEM DIAGNOSIS 6) Disconnect the ECM coupler. 7) Check the continuity between R wire C and terminal A. 8) Also, check the continuity between W/Bl wire A and terminal  IAPS lead wire continuity: Continuity ()  09900-25008: Multi circuit tester set 09900-25009: Needle-point probe set ...
Page 156 FI SYSTEM DIAGNOSIS 4-35 Step 3 1) Turn the ignition switch OFF. 2) Remove the IAP sensor. (4-68) 3) Connect the vacuum pump gauge to the vacuum port of the IAP sensor. Arrange 3 new 1.5 V batteries in series 1 (check that total - voltage is 4.5 –...
Page 157: 14" (P0120-H/L) Tp Sensor Circuit Malfunction
4-36 FI SYSTEM DIAGNOSIS “14” (P0120-H/L) TP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE Output voltage is not within the following • TP sensor maladjusted range. • TP sensor circuit open or short 0.35 V Sensor voltage < 4.9 V •...
Page 158 FI SYSTEM DIAGNOSIS 4-37 3) Disconnect the TP sensor coupler. 4) Turn the ignition switch ON. 5) Measure the voltage at the R wire and ground. 6) If OK, then measure the voltage at the R wire and B/Br wire. ...
Page 159 4-38 FI SYSTEM DIAGNOSIS 5) Disconnect the ECM coupler. 6) Check the continuity between V wire A and terminal 3. 7) Also, check the continuity between B/Br wire C and terminal  TP sensor lead wire continuity: Continuity ()  09900-25008: Multi circuit tester set 09900-25009: Needle-point probe set ...
Page 160 FI SYSTEM DIAGNOSIS 4-39 6) Disconnect the ECM coupler. 7) Check the continuity between V wire A and terminal 3. 8) Also, check the continuity between R wire B and terminal A.  TP sensor lead wire continuity: Continuity () ...
Page 161 4-40 FI SYSTEM DIAGNOSIS TP LEARNED VALUE RESET When replacing the throttle body assembly or TP sensor with a new one or reinstalling the TP sensor, reset the TP learned value in the following procedures: 1) Turn the ignition switch ON. 2) Set up the SDS tool.
Page 162: 15" (P0115-H/L) Et Sensor Circuit Malfunction
FI SYSTEM DIAGNOSIS 4-41 “15” (P0115-H/L) ET SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE Output voltage is not within the following • ET sensor circuit open or short range. • ET sensor malfunction 0.1 V Sensor voltage < 4.7 V •...
Page 163 4-42 FI SYSTEM DIAGNOSIS 3) Disconnect the coupler and turn the ignition switch ON. 4) Measure the voltage between B/Bl wire terminal and ground. 5) If OK, then measure the voltage between B/Bl wire terminal and B/Br wire terminal.  ET sensor voltage: 4.5 – 5.5 V (+ B/Bl –...
Page 164 FI SYSTEM DIAGNOSIS 4-43 Step 1 (When indicating P0115-L:) 1) Turn the ignition switch OFF. 2) Check the ET sensor coupler for loose or poor contacts. If OK, then check the ET sensor lead wire continuity. 3) Disconnect the ET sensor coupler. 4) Check the continuity between B/Bl wire and ground.
Page 165 4-44 FI SYSTEM DIAGNOSIS Step 2 1) Turn the ignition switch OFF. 2) Disconnect the ET sensor coupler. 3) Measure the ET sensor resistance.  ET sensor resistance: 1.95 – 4.18 kΩ at 20 – 40 °C (68 – 104 °F) (Terminal –...
Page 166: 21" (P0110-H/L) Iat Sensor Circuit Malfunction
FI SYSTEM DIAGNOSIS 4-45 “21” (P0110-H/L) IAT SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE Output voltage is not within the following • IAT sensor circuit open or short range. • IAT sensor malfunction 0.15 V Sensor voltage < 4.85 V •...
Page 167 4-46 FI SYSTEM DIAGNOSIS 4) Disconnect the coupler and turn the ignition switch ON. 5) Measure the voltage between Y/R wire terminal and ground. 6) If OK, then measure the voltage between Y/R wire terminal and B/Br wire terminal.  IAT sensor input voltage: 4.5 – 5.5 V (+ Y/R –...
Page 168 FI SYSTEM DIAGNOSIS 4-47 Step 1 (When indicating P0110-L:) 1) Turn the ignition switch OFF. 2) Remove the fuel tank. (5-3) 3) Check the IAT sensor coupler for loose or poor contacts. If OK, then check the IAT sensor lead wire continuity. 4) Disconnect the IAT sensor coupler.
Page 169 4-48 FI SYSTEM DIAGNOSIS Step 2 1) Turn the ignition switch OFF. 2) Disconnect the IAT sensor coupler. 3) Measure the IAT sensor resistance.  IAT sensor resistance: Approx. 2.45 kΩ at 20 °C (68 °F) (Terminal – Terminal)  09900-25008: Multi circuit tester set ...
Page 170: 23" (P1651-H/L) To Sensor Circuit Malfunction
FI SYSTEM DIAGNOSIS 4-49 “23” (P1651-H/L) TO SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE The sensor voltage is not within the fol- • TO sensor circuit open or short lowing range. • TO sensor malfunction 0.2 V Sensor voltage < 4.8 V •...
Page 171 4-50 FI SYSTEM DIAGNOSIS 4) Measure the resistance between terminal A and terminal C.  TO sensor resistance: 16.5 – 22.3 kΩ (Terminal A – Terminal C)  09900-25008: Multi circuit tester set  Tester knob indication: Resistance (Ω) Is the resistance OK? Go to Step 2.
Page 172 FI SYSTEM DIAGNOSIS 4-51 Step 1 (When indicating P1651-L:) 1) Turn the ignition switch OFF. 2) Check the TO sensor coupler for loose or poor contacts. If OK, then check the TO sensor lead wire continuity. 3) Disconnect the TO sensor coupler. 4) Check the continuity between Br wire B and ground.
Page 173: 24" (P0351) Ignition System Malfunction
4-52 FI SYSTEM DIAGNOSIS Step 2 1) Remove the TO sensor. (4-71) 2) Connect the TO sensor coupler and ECM coupler. 3) Insert the needle-point probes to the lead wire coupler. 4) Turn the ignition switch ON. 5) Measure the voltage at the wire side coupler between Br and B/Br wires.
Page 174: 28" (P1655) Stv Actuator Circuit Malfunction
FI SYSTEM DIAGNOSIS 4-53 “28” (P1655) 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 • STVA circuit open or short the STVA. •...
Page 175 4-54 FI SYSTEM DIAGNOSIS Step 2 1) Turn the ignition switch OFF. 2) Disconnect the STVA lead wire coupler. 3) Check the continuity between each terminal and ground.  STVA continuity: ∞ Ω (Infinity) (Terminal – Ground) 4) If OK, then measure the STVA resistance (between B wire A and P wire B) and (between G wire C and W/BI wire D).
Page 176 FI SYSTEM DIAGNOSIS 4-55 ACTIVE CONTROL INSPECTION 1) Set up the SDS tool. (Refer to the SDS operation manual for further details.) 2) Turn the ignition switch ON. 3) Click “Secondary throttle operating control” 1. 4) Click each button 2. At this time, if an operation sound is heard from the STVA, the function is normal.
Page 177: 29" (P1654-H/L) Stp Sensor Circuit Malfunction
4-56 FI SYSTEM DIAGNOSIS “29” (P1654-H/L) STP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE Signal voltage is not within the following • STP sensor maladjusted range. • STP sensor circuit open or short Difference between actual throttle open- • STP sensor malfunction ing and opening calculated by ECM is •...
Page 178 FI SYSTEM DIAGNOSIS 4-57 4) Disconnect the STP sensor coupler. 5) Turn the ignition switch ON. 6) Measure the voltage at the R wire A and ground. 7) Also, measure the voltage at the R wire A and B/Br wire C. ...
Page 179 4-58 FI SYSTEM DIAGNOSIS 6) Disconnect the ECM coupler. 7) Check the continuity between Bl/Y wire B and terminal J. 8) Also, check the continuity between B/Br wire C and terminal  STPS lead wire continuity: Continuity ()  09900-25008: Multi circuit tester set 09900-25009: Needle-point probe set ...
Page 180 FI SYSTEM DIAGNOSIS 4-59 Step 2 1) Turn the ignition switch OFF. 2) Connect the STP sensor coupler. 3) Insert the needle-point probes to the STP sensor coupler. 4) Disconnect the STVA lead wire coupler 1. 5) Turn the ignition switch ON. 6) Measure the STP sensor output voltage at the coupler (between + Y wire and - B wire) by turning the fast idle cam 2 (secondary throttle valve close and open) with a finger.
Page 181: 32" (P0201) Fuel Injector Circuit Malfunction
4-60 FI SYSTEM DIAGNOSIS “32” (P0201) FUEL INJECTOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE Fuel injector signal is interrupted by 4 times or more • Injector circuit open or short continuously although ignition signal is supplied from • Injector malfunction the ECM.
Page 182 FI SYSTEM DIAGNOSIS 4-61 5) If OK, then check the continuity between each terminal and ground.  Fuel injector continuity: ∞ Ω (Infinity)  09900-25008: Multi circuit tester set  Tester knob indication: Resistance (Ω) Are the resistance and continuity OK? Go to Step 2.
Page 183: 41" (P0230-H/L) Fp Circuit Malfunction
4-62 FI SYSTEM DIAGNOSIS “41” (P0230-H/L) FP CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE No voltage is applied to fuel pump. • FP circuit open or short • FP malfunction • ECM malfunction P0230 Voltage is applied to fuel pump although •...
Page 184: 42" (P01650) Ig Switch Circuit Malfunction
FI SYSTEM DIAGNOSIS 4-63 Is the fuel pump OK? ECM coupler (Harness side) • O/W or Y/W wire open or shorted to ground or poor V connection • If wire and connection are OK, intermittent trou- ble or faulty ECM. •...
Page 185: 44" (P0130) Ho2 Sensor (Ho2S) Circuit Malfunction
4-64 FI SYSTEM DIAGNOSIS “44” (P0130) HO2 SENSOR (HO2S) CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE HO2 sensor output voltage is not input to ECM dur- • HO2 sensor circuit open or short ing engine operation and running condition. • ECM malfunction •...
Page 186 FI SYSTEM DIAGNOSIS 4-65 7) Disconnect the ECM coupler. 8) Check the continuity between Bl/W wire A and terminal K. 9) Also, check the continuity between B/Br wire B and terminal  HO2S lead wire continuity: Continuity ()  09900-25008: Multi circuit tester set 09900-25009: Needle-point probe set ...
Page 187: 49" (P1656) Pair Control Solenoid Valve Circuit Malfunction
4-66 FI SYSTEM DIAGNOSIS “49” (P1656) PAIR CONTROL SOLENOID VALVE CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE PAIR control solenoid valve voltage is not input to • PAIR control solenoid valve circuit open or short ECM. • PAIR control solenoid valve malfunction Ignition switch PAIR To side-stand...
Page 188 FI SYSTEM DIAGNOSIS 4-67 Step 2 1) Turn the ignition switch ON. 2) Measure the voltage between O/W wire and ground.  PAIR valve voltage: Battery voltage (+ O/W – - Ground)  09900-25008: Multi circuit tester set  Tester knob indication: Voltage () Is the voltage OK? ECM coupler (Harness side) •...
Page 189: Sensors
4-68 FI SYSTEM DIAGNOSIS SENSORS CKP SENSOR INSPECTION The crankshaft position sensor is installed in the generator cover. (9-25) CKP SENSOR REMOVAL AND INSTALLATION • Remove the generator cover. (3-15) • Remove the CKP sensor from the generator cover. (3-42) •...
Page 190: Tps Adjustment
FI SYSTEM DIAGNOSIS 4-69 TPS ADJUSTMENT Inspect the TP sensor setting position and adjust it if necessary in the following procedures: 1) Connect the special tool between TP sensor and its coupler.  09900-28630: TP Sensor test lead 2) Warm up the engine and keep it running at idling speed. 3) Measure the TP sensor output voltage at the terminals.
Page 191: Et Sensor Inspection
4-70 FI SYSTEM DIAGNOSIS ET SENSOR INSPECTION The engine temperature sensor is installed at the cylinder. (4-41) • Check the ET sensor by testing it at the bench as shown in the figure. Connect the ET sensor 1 to a circuit tester and place it in the oil 2 contained in a pan, which is placed on a stove.
Page 192: To Sensor Inspection
FI SYSTEM DIAGNOSIS 4-71 TO SENSOR INSPECTION The tip-over sensor is located in front of the battery holder. (4-49) TO SENSOR REMOVAL AND INSTALLATION • Remove the PAIR solenoid valve bracket bolt. • Remove the TO sensor from the battery holder. •...
Page 193: Ho2 Sensor Removal And Installation
4-72 FI SYSTEM DIAGNOSIS 4) Disconnect the HO2 sensor coupler and measure the resis- tance between terminals. If the resistance is not specified value, replace the HO2 sensor with a new one.  HO2 heater resistance: Approx. 8 Ω at 23 °C (73 °F) (W –...
Page 194 FUEL SYSTEM AND THROTTLE BODY 5-1 FUEL SYSTEM AND THROTTLE BODY CONTENTS FUEL DELIVERY SYSTEM................5- 2 FUEL SYSTEM..................... 5- 3 FUEL TANK REMOVAL................ 5- 3 FUEL TANK INSTALLATION ............... 5- 3 FUEL PRESSURE INSPECTION ............5- 4 FUEL PUMP INSPECTION ..............5- 5 FUEL DISCHARGE AMOUNT INSPECTION ........
Page 195: Fuel Delivery System
5-2 FUEL SYSTEM AND THROTTLE BODY FUEL DELIVERY SYSTEM The fuel delivery system consists of the fuel tank, fuel pump, fuel mesh filter, fuel feed hose, fuel delivery pipe (including fuel injector) and fuel pressure regulator. 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 196: Fuel System
FUEL SYSTEM AND THROTTLE BODY 5-3 FUEL SYSTEM FUEL TANK REMOVAL  Gasoline is highly flammable and explosive. Keep heat, spark and flame away. • Remove the front seat. (8-3) • Remove the fuel tank mounting bolt. • Lift up the fuel tank. •...
Page 197: Fuel Pressure Inspection
5-4 FUEL SYSTEM AND THROTTLE BODY FUEL PRESSURE INSPECTION • Lift up the fuel tank by removing the fuel tank mounting bolt. (5-3) • Place a clean rag under the fuel feed hose 1. • Remove the fuel feed hose 1. •...
Page 198: Fuel Pump Inspection
FUEL SYSTEM AND THROTTLE BODY 5-5 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, inspect the fuel pump circuit connections and TO sensor. If the TO sensor and fuel pump circuit connections are OK, the fuel pump may be faulty, replace the fuel pump with a new one.
Page 199: Fuel Pump Construction
5-6 FUEL SYSTEM AND THROTTLE BODY FUEL PUMP CONSTRUCTION  1 Fuel pressure regulator 5 Fuel mesh filter 2 O-ring 6 O-ring ITEM N·m kgf-m lbf-ft 3 Fuel pump A Fuel pump mounting bolt 4 O-ring...
Page 200: Fuel Pump Removal And Disassembly
FUEL SYSTEM AND THROTTLE BODY 5-7 FUEL PUMP REMOVAL AND DISASSEMBLY  Gasoline is highly flammable and explosive. Keep heat, spark and flame away. • Remove the fuel tank. (5-3) • Remove the fuel pump assembly 1 by removing its mounting bolts diagonally.
Page 201: Fuel Mesh Filter Inspection
5-8 FUEL SYSTEM AND THROTTLE BODY • Remove the wire clamp 0, fuel hose A and fuel return hose • Remove the adapter C along with the fuel pressure regulator • Remove the fuel pressure regulator E and joint F. ...
Page 202: Fuel Pump Reassembly And Installation
 The O-ring must be replaced with a new one to prevent fuel leakage.  99000-25010: SUZUKI SUPER GREASE “A” or equivalent • When installing the fuel pump assembly, first tighten all the fuel pump mounting bolts lightly and then to the specified torque, in the ascending order of numbers.
Page 203: Throttle Body
5-10 FUEL SYSTEM AND THROTTLE BODY THROTTLE BODY CONSTRUCTION  1 Fuel delivery pipe 7 TP sensor 2 O-ring 8 O-ring ITEM N·m kgf-m lbf-ft 3 Fuel injector 9 IAP sensor 0.35 4 Cushion seal 0 O-ring 0.35 5 STVA A TP sensor mounting screw 6 STP sensor B STP sensor mounting screw...
Page 204: Throttle Body Removal
FUEL SYSTEM AND THROTTLE BODY 5-11 THROTTLE BODY REMOVAL  Once the throttle body has been removed, disassem- bled or replaced, the TP learned value reset must be performed using SDS tool with the throttle body assembled. (4-40) • Turn the ignition switch OFF. •...
Page 205: Throttle Body Disassembly
5-12 FUEL SYSTEM AND THROTTLE BODY • Loosen the throttle body clamp screws and remove the throt- tle body assembly 7. THROTTLE BODY DISASSEMBLY • Remove the fuel feed hose 1. • Remove the fuel delivery pipe 2 along with the fuel injector •...
Page 206 FUEL SYSTEM AND THROTTLE BODY 5-13 • Remove the IAP sensor 4. • Remove the TP sensor 5 and STP sensor 6 with the special tool. NOTE: Prior to disassembly, mark the each sensor’s original position with a paint or scribe for accurate reinstallation. ...
Page 207: Throttle Body Cleaning
5-14 FUEL SYSTEM AND THROTTLE BODY  Never remove the throttle valve 9.  * The air screw 0 should not be turned or removed unless necessary. * The adjusting screw A is factory-adjusted at the time of delivery and do not turn or remove it. THROTTLE BODY CLEANING ...
Page 208: Throttle Body Reassembly
* Align the secondary throttle shaft end A with the groove B of STP sensor. * Apply grease to the secondary throttle shaft end A if neces- sary.  99000-25010: SUZUKI SUPER GREASE “A” or equivalent  STP sensor mounting screw: 3.5 N·m (0.35 kgf-m, 2.5 lbf-ft) ...
Page 209 5-16 FUEL SYSTEM AND THROTTLE BODY • Install a new O-ring 3 and IAP sensor 4.  Replace the O-ring with a new one. • Apply thin coat of engine oil to the cushion seal 5 and O-ring  Replace the cushion seal and O-ring with new ones. •...
Page 210: Throttle Body Installation
FUEL SYSTEM AND THROTTLE BODY 5-17 THROTTLE BODY INSTALLATION Install the throttle body in the reverse order of removal. Pay attention to the following points: • Fit the projection on the throttle body in the depression of the intake pipe. •...
Page 211: Stp Sensor Adjustment
5-18 FUEL SYSTEM AND THROTTLE BODY STP SENSOR ADJUSTMENT If the STP sensor adjustment is necessary, measure the sensor output voltage and adjust the STP sensor position as follows: • Lift up the fuel tank by removing the fuel tank mounting bolt. (5-3) •...
Page 212: Fast Idle
FUEL SYSTEM AND THROTTLE BODY 5-19 FAST IDLE The fast idle system is automatic type. On the secondary throttle valve shaft 1, the fast idle cam 2 is installed. When this fast idle cam 2 is operated, the throttle valve is opened to control the fast idle speed. With the secondary throttle valve 1 turned, the fast idle cam 2 pushes the throttle lever 3, causing the throttle valve to open slightly and increase the engine speed to the fast idle.
Page 213 EXHAUST SYSTEM 6-1 EXHAUST SYSTEM CONTENTS EXHAUST SYSTEM ..................6- 2 REMOVAL ..................... 6- 2 INSPECTION ..................6- 4 INSTALLATION..................6- 4...
Page 214: Exhaust System
6-2 EXHAUST SYSTEM EXHAUST SYSTEM REMOVAL  To avoid the danger of being burned, do not touch the exhaust system when the system is hot. Any service on the exhaust system should be performed when the system is cool.  Make sure that the exhaust pipe and muffler have enough clearance from the rubber parts and plastic parts to avoid melting.
Page 215 EXHAUST SYSTEM 6-3 • Remove the exhaust pipe/muffler 5 by removing the mount- ing bolt and nut. NOTE: Support the muffler to prevent it from falling. • Remove the exhaust pipe gasket 6. • Remove the exhaust pipe cover 7. •...
Page 216: Inspection
6-4 EXHAUST SYSTEM INSPECTION Inspect the exhaust pipe connection and muffler connection for exhaust gas leakage and mounting condi- tion. If any defect is found, replace the exhaust pipe or muffler with a new one. Check the exhaust pipe bolts, muffler connecting bolt and muffler mounting bolts are tightened to their spec- ified torque.
Page 217 EXHAUST SYSTEM 6-5 • Install the muffler connector 2.  Replace the muffler connector with a new one. NOTE: The chamfer side A faces backward. • Tighten the muffler connecting bolt 3 to the specified torque.  Muffler connecting bolt: 23 N·m (2.3 kgf-m, 16.5 lbf-ft) •...
Page 218 6-6 EXHAUST SYSTEM • Tighten the exhaust pipe bolts 7 to the specified torque.  Exhaust pipe bolt: 23 N·m (2.3 kgf-m, 16.5 lbf-ft) • Apply thread lock to the muffler mounting bolt (Front) 8.  99000-32110: THREAD LOCK SUPER “1322” or equivalent •...
Page 219 LUBRICATION SYSTEM 7-1 LUBRICATION SYSTEM CONTENTS LUBRICATION SYSTEM ................7- 2 OIL PRESSURE ..................7- 2 OIL FILTER.................... 7- 2 OIL STRAINER..................7- 2 OIL PUMP....................7- 2 ENGINE LUBRICATION SYSTEM CHART .......... 7- 2...
Page 220 7-2 LUBRICATION SYSTEM LUBRICATION SYSTEM OIL PRESSURE 2-25 OIL FILTER 2-10, 3-43 OIL STRAINER 3-43 OIL PUMP 3-19, -44, -63 ENGINE LUBRICATION SYSTEM CHART CAMSHAFT JOURNAL BEARING PISTON CYLINDER WALL CONROD SMALL END CAM FACES CONROD BIG END BEARING CAM CHAIN CLUTCH RELEASE CAM OIL FILTER CRANKSHAFT...
Page 221 CHASSIS 8-1 CHASSIS CONTENTS EXTERIOR PARTS ..................8- 3 REMOVAL ..................... 8- 3 INSTALLATION..................8- 3 FRONT WHEEL ................... 8- 4 CONSTRUCTION .................. 8- 4 REMOVAL ..................... 8- 4 INSPECTION AND DISASSEMBLY ............. 8- 6 REASSEMBLY AND INSTALLATION ..........8- 7 FRONT BRAKE....................
Page 222 8-2 CHASSIS CHASSIS CONTENTS REAR BRAKE....................8-39 CONSTRUCTION .................. 8-39 REMOVAL AND DISASSEMBLY ............8-39 INSPECTION ..................8-40 REASSEMBLY AND INSTALLATION ..........8-41 REAR BRAKE PEDAL REMOVAL ............8-42 REAR BRAKE PEDAL INSTALLATION..........8-42 REAR SHOCK ABSORBER ................ 8-43 CONSTRUCTION .................. 8-43 REMOVAL .....................
Page 223: Exterior Parts
CHASSIS 8-3 EXTERIOR PARTS REMOVAL FRONT SEAT • Remove the front seat by removing the bolts (left & right). REAR SEAT • Remove the front seat. (Above) • Remove the rear seat by removing the bolts. LEFT FRAME COVER • Remove the screw. •...
Page 224: Front Wheel
8-4 CHASSIS FRONT WHEEL CONSTRUCTION  1 Collar 6 Speedometer gearbox 2 Bearing 7 Balancer weight ITEM N·m kgf-m lbf-ft 3 Front wheel A Front axle 47.0 4 Spacer B Spoke nipple 5 Brake disc C Brake disc bolt 16.5 REMOVAL •...
Page 225 CHASSIS 8-5 • Loosen the front axle pinch bolt 2. • Loosen the front axle 3 with the special tool.  09900-18710: Hexagon socket (12 mm) • Raise the front wheel off the ground and support the motorcy- cle with a jack or a wooden block. ...
Page 226: Inspection And Disassembly
8-6 CHASSIS INSPECTION AND DISASSEMBLY TIRE (8-59) BRAKE DISC (8-17) SPEEDOMETER GEARBOX Turn the speedometer gear and check that the gear turns smoothly together with the speedometer pinion. WHEEL (2-19) SPOKE NIPPLE (2-20) WHEEL BEARING Inspect the play of the wheel bearings by finger while they are in the wheel.
Page 227: Reassembly And Installation
REASSEMBLY AND INSTALLATION Reassembly and install the front wheel in the reverse order of removal and disassembly. Pay attention to the following points: WHEEL BEARING • Apply grease to the wheel bearings.  99000-25010: SUZUKI SUPER GREASE “A” or equivalent...
Page 228 8-8 CHASSIS • Install new wheel bearings with removed wheel bearings and the special tool.  * First install the left wheel bearing, then install the spacer and right wheel bearing. * The sealed cover of bearing must face outside. ...
Page 229  Front brake disc bolt: 23 N·m (2.3 kgf-m, 16.5 lbf-ft) SPEEDOMETER GEARBOX • Apply grease to the speedometer gearbox.  99000-25010: SUZUKI SUPER GREASE “A” or equivalent • Align the lugs A of speedometer gearbox with the recesses B on front wheel.
Page 230 8-10 CHASSIS • Connect the speedometer cable 3.  Tighten the speedometer cable nut firmly. 90 ± 5˚ • Set the speedometer gearbox 4 as shown. 90 ± 5˚ • Tighten the front axle 2 to the specified torque.  09900-18710: Hexagon socket (12 mm) ...
Page 231: Front Brake
CHASSIS 8-11 FRONT BRAKE CONSTRUCTION  1 Reservoir cap A Brake pad 2 Diaphragm B Brake lever ITEM N·m kgf-m lbf-ft 3 Piston/cup set C Brake light switch 4 Master cylinder A Master cylinder holder bolt 16.5 5 Brake hose B Brake hose union bolt 0.75 6 Caliper holder...
Page 232: Brake Pad Replacement
8-12 CHASSIS  * This brake system is filled with an ethylene glycol-based DOT 4 brake fluid. Do not use mix different types of fluid such as silicone-based or petroleum-based. * Do not use any brake fluid taken from old, used or unsealed containers. Never reuse brake fluid left over from the last servicing or stored for long periods.
Page 233: Brake Fluid Replacement
CHASSIS 8-13 BRAKE FLUID REPLACEMENT • Place the motorcycle on a level surface and keep the handle- bars straight. • Remove the brake fluid reservoir cap 1 and diaphragm 2. • Suck up the old brake fluid as much as possible. •...
Page 234: Brake Caliper Inspection
8-14 CHASSIS • Remove the brake pads. (8-12) • Remove the brake caliper holder 3. • Remove the pad spring 4 and pad guide 5. • Remove the rubber boots (6, 7). • Place a clean rag over the piston to prevent it from popping out and then force out the piston using compressed air.
Page 235: Caliper Reassembly And Installation
CHASSIS 8-15 PAD SPRING Inspect the brake pad spring for damage excessive bend. If any damage is found, replace it with a new one. RUBBER PARTS Inspect the boots for damage and cracks. If any defects are found, replace it with a new one. CALIPER REASSEMBLY AND INSTALLATION Reassemble and install the caliper in the reverse order of...
Page 236 • Install new piston seals 1 and dust seals 2 as shown in the illustration. CALIPER HOLDER • Apply grease to the caliper holder pins.  99000-25100: SUZUKI SILICONE GREASE or equivalent • Tighten the brake caliper mounting bolts to the specified torque.
Page 237: Brake Disc Inspection
CHASSIS 8-17 BRAKE DISC INSPECTION Check the brake disc for cracks or damage and measure the thickness using the micrometer. Replace the disc if the thickness is less than the service limit, or if damage is found. (8-5, -9)  Brake disc thickness Service Limit: 4.5 mm (0.18 in) ...
Page 238: Master Cylinder Inspection
8-18 CHASSIS • Remove the brake light switch 5 and brake lever 6. • Pull out the dust boot 7. • Remove the snap ring 8. • Remove the piston/cup set 9. MASTER CYLINDER INSPECTION MASTER CYLINDER Inspect the master cylinder bore for any scratches or damage. If any damage is found, replace the master cylinder with a new one.
Page 239: Master Cylinder Reassembly And Installation
• When installing the brake light switch, align the projection A on switch with the hole B of master cylinder. • Apply grease to the brake lever pivot bolt. • Apply grease to the contacting surfaces between piston and brake lever.  99000-25010: SUZUKI SUPER GREASE “A” or equivalent...
Page 240 8-20 CHASSIS • Tighten the brake lever pivot bolt 7 and lock-nut 8 to the specified torque.  Front brake lever pivot bolt: 6 N·m (0.6 kgf-m, 4.5 lbf-ft) Front brake lever pivot bolt lock-nut: 6 N·m (0.6 kgf-m, 4.5 lbf-ft) •...
Page 241: Handlebars
CHASSIS 8-21 HANDLEBARS CONSTRUCTION 1 Handlebars 4 Right handlebar switch box 2 Handlebar balancer 5 Left handlebar grip 3 Throttle grip 6 Left handlebar switch box REMOVAL HANDLEBAR LEFT SIDE PARTS • Remove the rear view mirror (LH) 1. • Remove the left handlebar switch box 2. •...
Page 242: Inspection
8-22 CHASSIS • Remove the handlebar clamps 7 by removing the handlebar clamp bolts. • Remove the right handlebar switch box 9, throttle grip 0 and clutch lever holder A from the handlebars 8. INSPECTION Inspect the handlebars for distortion or damage. If any defects are found, replace the handlebars with a new one.
Page 243: Installation
• Insert the right handlebar switch box 2, throttle grip 3 and clutch lever holder 4 onto the handlebars. • Apply grease to the throttle cables.  99000-25010: SUZUKI SUPER GREASE “A” or equivalent • Engage the projection C of right handlebar switch box with the hole of handlebars.
Page 244 8-24 CHASSIS • Align the mating surface of clutch lever holder with the punch mark D on handlebars. • Tighten the clutch lever holder bolt to the specified torque.  Clutch lever holder bolt: 10 N·m (1.0 kgf-m, 7.0 lbf-ft) •...
Page 245: Front Fork
CHASSIS 8-25 FRONT FORK CONSTRUCTION  1 O-ring A Oil seal stopper ring 2 Spring collar B Oil seal ITEM N·m kgf-m lbf-ft 3 Spring joint C Spacer 16.5 4 Front fork spring D Guide bushing 16.5 5 Damper rod ring E Oil lock piece 14.5 6 Damper rod...
Page 246: Removal And Disassembly
8-26 CHASSIS REMOVAL AND DISASSEMBLY NOTE: * The left and right front forks are installed symmetrically and therefore the disassembly procedure for one side is the same as that for the other side. * When the brake caliper is removed, care must be used so as not to cause stress to the brake hose.
Page 247 CHASSIS 8-27 • Remove the spring collar 9, spring joint 0 and front fork spring A. • Invert the front fork and stroke it several times to drain out fork oil. • Hold the front fork inverted for a few minutes to drain oil. •...
Page 248: Inspection
8-28 CHASSIS • Pull the inner tube out of the outer tube. • Remove the oil lock piece G. • Remove the oil seal H, spacer I, guide bushing J and slide bushing K. INSPECTION INNER AND OUTER TUBE Inspect the inner tube sliding surface and outer tube sliding sur- face for any scuffing or damage.
Page 249: Reassembly And Installation
The stamped mark on the oil seal outside. • Apply fork oil to the slide bushing 1, guide bushing 2 and oil seal lip 4.  99000-99001-SS8: SUZUKI FORK OIL SS-08 or equivalent • Insert the oil lock piece 5 into the inner tube.
Page 250 8-30 CHASSIS • Insert the inner tube into the outer tube and install the oil seal using the special tool.  09940-52861: Front fork oil seal installer • Install the oil seal stopper ring 6 and dust seal 7.  Make sure that the oil seal stopper ring is fitted securely.
Page 251 • Pour specified front fork oil into the inner tube.  Front fork oil capacity (each leg): 411 ml (13.9 US oz)  99000-99001-SS8: SUZUKI FORK OIL SS-08 or equivalent • Move the inner tube up and down several strokes until no more bubbles come out from the fork oil.
Page 252 8-32 CHASSIS • Install the front fork to the motorcycle. • Align the upper surface of the inner tube with the upper sur- face of the steering stem upper bracket. • Tighten the front fork lower clamp bolt 1 and front fork cap bolt 2 to the specified torque.
Page 253: Steering
CHASSIS 8-33 STEERING CONSTRUCTION  1 Steering stem upper bracket A Steering stem head bolt 2 Dust seal B Handlebar clamp bolt ITEM N·m kgf-m lbf-ft 3 Steering stem upper bearing C Front fork upper clamp bolt 47.0 4 Steering stem lower bearing D Front fork lower clamp bolt 11.5 5 Lower seal...
Page 254 8-34 CHASSIS • Remove the headlight. (9-30) • Disconnect the ignition switch coupler, speedometer coupler and turn signal couplers. • Remove the headlight housing bolts, nuts and clamps. • Remove the headlight housing 2 by removing the clamp and housing plate bolt. •...
Page 255 CHASSIS 8-35 • Remove the steering stem upper bracket 6 by removing the steering stem head bolt and washer. NOTE: Place a clean rag on the fuel tank to prevent the fuel tank scratched. • Remove the steering stem nut with the special tool. ...
Page 256: Inspection
8-36 CHASSIS INSPECTION Inspect the removed parts for the following abnormalities. If any abnormal points are found, replace the respective parts with new ones. * Bearing race wear or damage * Bearing wear or damage * Abnormal bearing noise * Distortion of steering stem •...
Page 257: Reassembly And Installation
• Press in the steering stem lower inner race using the special tool.  09941-74911: Steering race installer • Apply grease to the steering stem upper and lower bearings.  99000-25010: SUZUKI SUPER GREASE “A” or equivalent STEERING STEM • Tighten the steering stem nut 1 to the specified torque (45 N·m (4.5 kgf-m, 32.5 lbf-ft)) using the special tool.
Page 258 8-38 CHASSIS • Before tightening the steering stem head bolt 2, temporarily install the front forks 3. • Tighten the steering stem head bolt 2 to the specified torque.  Steering stem head bolt: 65 N·m (6.5 kgf-m, 47.0 lbf-ft) NOTE: Tightening the steering stem head bolt can affect the steering stem nut adjustment.
Page 259 CHASSIS 8-39 REAR BRAKE CONSTRUCTION  1 Brake pedal 6 Spring 2 Brake pedal return spring 7 Brake cam ITEM N·m kgf-m lbf-ft 3 Brake rod 8 Brake shoe 4 Brake panel A Brake cam lever nut 5 Brake cam lever REMOVAL AND DISASSEMBLY BRAKE SHOE •...
Page 260 8-40 CHASSIS • Remove the brake cam lever nut 3. • Remove the brake cam lever 4. • Remove the brake cam 5. • Remove the washer 6 and O-ring 7. INSPECTION BRAKE DRUM Inspect the brake drum and measure the brake drum I.D. to determine the extent of wear.
Page 261 Reassemble and install the rear brake in the reverse order of removal and disassembly. Pay attention to the following points: • Apply grease to the camshaft, cam face and pin.  99000-25010: SUZUKI SUPER GREASE “A” or equivalent • Install the brake shoes with spring hooks 1 faced inside.
Page 262: Rear Brake Pedal Removal
Install the rear brake pedal in the reverse order of removal. Pay attention to the following points: • Apply grease to the brake pedal shaft.  99000-25160: SUZUKI WATER RESISTANCE GREASE or equivalent • After assembling, check the brake for operating condition, play and braking effect.
Page 263: Rear Shock Absorber
CHASSIS 8-43 REAR SHOCK ABSORBER CONSTRUCTION  1 Rear shock absorber 3 Washer 2 Washer A Rear shock absorber nut ITEM N·m kgf-m lbf-ft 21.0 REMOVAL NOTE: The left and right rear shock absorbers are installed symmetri- cally and therefore the removal procedure for one side is the same as that for the other side.
Page 264: Inspection
8-44 CHASSIS INSPECTION Inspect the shock absorber body and bushings 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. It is unserviceable. INSTALLATION •...
Page 265: Rear Wheel
CHASSIS 8-45 REAR WHEEL CONSTRUCTION  1 Rear axle B Wheel damper 2 Spacer C Sprocket mounting drum ITEM N·m kgf-m lbf-ft 3 Brake cam lever D Collar 47.0 4 Brake panel E Bearing 5 Brake cam F Spacer 43.5 6 Brake shoe G Rear sprocket 7 Spring...
Page 266: Removal
8-46 CHASSIS REMOVAL • Remove the drive chain case 1. • Remove the torque link nut (rear) 2, brake adjuster nut 3, pin 4, spring 5 and washer 6. NOTE: When removing the brake rod, depressing the brake pedal. • Remove the rear axle nut 7. •...
Page 267 CHASSIS 8-47 • Remove the brake panel E. • Remove the rear sprocket F along with sprocket mounting drum G. • Remove the wheel damper H.
Page 268: Inspection And Disassembly
8-48 CHASSIS INSPECTION AND DISASSEMBLY WHEEL (2-19) TIRE (8-59) SPOKE NIPPLE (2-20) REAR AXLE Measure the rear axle runout using the dial gauge. If the runout exceeds the service limit, replace the rear axle with a new one.  Axle shaft runout Service Limit: 0.25 mm (0.010 in) ...
Page 269 CHASSIS 8-49 BEARING Inspect the play of the wheel and sprocket mounting drum bear- ings by finger while they are in the wheel and drum. Rotate the inner race by finger to inspect for abnormal noise and smooth rotation. Replace the bearing if there is anything unusual. •...
Page 270 NOTE: The stamped mark A on the sprocket should face outside. BEARING • Apply grease to the bearings before installing them.  99000-25010: SUZUKI SUPER GREASE “A” or equivalent • Install the collar 1 into the sprocket mounting drum. NOTE:...
Page 271 CHASSIS 8-51 • Install a new sprocket mounting drum bearing with the special tool. NOTE: The stamped mark on bearing should face outside.  09913-70210: Bearing installer set (10 – 75) WHEEL BEARING • Install new wheel bearings with removed wheel bearing and special tool.
Page 272 • Install a new dust seal with the special tool.  09913-70210: Bearing installer set (10 – 75) • Apply grease to the dust seal lip.  99000-25010: SUZUKI SUPER GREASE “A” or equivalent REAR SPROCKET MOUNTING DRUM • Apply grease to the contacting surface between the sprocket mounting drum and rear wheel hub.
Page 273: Swingarm
CHASSIS 8-53 SWINGARM CONSTRUCTION  1 Torque link 6 Collar 2 Dust cover 7 Chain buffer ITEM N·m kgf-m lbf-ft 3 Washer 8 Swingarm pivot shaft 47.0 4 Dust seal A Swingarm pivot nut 11.5 5 Swingarm pivot bushing B Torque link nut...
Page 274: Removal
8-54 CHASSIS REMOVAL • Remove the rear wheel. (8-46) • Remove the rear shock absorber nuts (lower) 1 and wash- ers. • Remove the rear brake light switch spring 2. • Remove the swingarm pivot nut 3 and washer. • Draw out the swingarm pivot shaft and remove the swingarm assembly 4.
Page 275 CHASSIS 8-55 • Remove the dust covers 8, washers 9 and collars 0. • Remove the dust seals A. • Remove the chain buffer B. INSPECTION AND DISASSEMBLY SWINGARM Inspect the swingarm for damage. If any damage is found, replace the swingarm with a new one. CHAIN BUFFER Inspect the chain buffer for wear or damage.
Page 276: Reassembly
8-56 CHASSIS SWINGARM PIVOT SHAFT Measure the pivot shaft runout using the dial gauge. If the runout exceeds the service limit, replace the pivot shaft with a new one.  Swingarm pivot shaft runout Service limit: 0.6 mm (0.02 in) ...
Page 277 CHASSIS 8-57 • Apply grease to the dust seals, swingarm pivot bushings and dust covers.  99000-25010: SUZUKI SUPER GREASE “A” or equivalent 1 Swingarm pivot bushing A 8 mm (0.31 in) 2 Swingarm B 3 mm (0.12 in) 3 Dust seal (Inner)
Page 278: Installation
8-58 CHASSIS INSTALLATION Install the swingarm in the reverse order of removal. Pay atten- tion to the following points: • Tighten the swingarm pivot nut to the specified torque.  Swingarm pivot nut: 65 N·m (6.5 kgf-m, 47.0 lbf-ft) • Tighten the rear shock absorber nuts (lower) to the specified torque.
Page 279: Tire And Wheel
CHASSIS 8-59 TIRE AND WHEEL TIRE REMOVAL Tube tires are used for this motorcycle. When removing or installing the tire, be careful not to damage the tube. For operating procedures, refer to the instructions supplied by the tire changer manufacturer. NOTE: When removing the tire in the case of repair or inspection, mark the tire with a chalk to indicate the tire position relative to the...
Page 280: Tire Installation
8-60 CHASSIS TIRE INSTALLATION • Apply tire lubricant to the tire bead.  Do not use oil, grease or gasoline on the tire bead in place of tire lubricant. • Install the tube. When installing the tire onto the wheel, observe the following points.
Page 281 CHASSIS 8-61 • In this condition, check the “rim line” cast on the tire side walls. The line must be equidistant from the wheel rim all around. If the distance between the rim line and wheel rim Rim line varies, this indicates that the bead is not properly seated. If this is the case, deflate the tire completely and unseat the bead for both sides.
Page 282 ELECTRICAL SYSTEM 9-1 ELECTRICAL SYSTEM CONTENTS CAUTIONS IN SERVICING ................. 9- 3 CONNECTOR ..................9- 3 COUPLER....................9- 3 CLAMP ....................9- 3 FUSE...................... 9- 3 SWITCH ....................9- 4 SEMI-CONDUCTOR EQUIPPED PART ..........9- 4 BATTERY ....................9- 4 CONNECTING THE BATTERY.............
Page 283 9-2 ELECTRICAL SYSTEM ELECTRICAL SYSTEM CONTENTS LAMPS ......................9-30 HEADLIGHT ..................9-30 BRAKE LIGHT/TAILLIGHT..............9-32 TURN SIGNAL LIGHT................9-33 RELAYS ...................... 9-34 TURN SIGNAL/SIDE-STAND RELAY ..........9-34 MAIN RELAY..................9-34 CHECK RELAY ..................9-34 SWITCH ....................... 9-35 IGNITION SWITCH REMOVAL ............. 9-35 IGNITION SWITCH INSTALLATION.............
Page 284: Cautions In Servicing
ELECTRICAL SYSTEM 9-3 CAUTIONS IN SERVICING CONNECTOR • When connecting a connector, be sure to push it in until a click is felt. • Inspect the connector for corrosion, contamination and break- age in its cover. • Avoid applying grease or other similar material to connec- tor/coupler terminals to prevent electric trouble.
Page 285: Switch
9-4 ELECTRICAL SYSTEM SWITCH • Never apply grease material to switch contact points to pre- vent damage. SEMI-CONDUCTOR EQUIPPED PART • Be careful not to drop the part with a semi-conductor built in INCORRECT such as a ECM. • When inspecting these parts, follow the instructions carefully. Failure to follow the proper procedure can cause damage to these parts.
Page 286: Wiring Procedure
ELECTRICAL SYSTEM 9-5 WIRING PROCEDURE • Properly route the wire harness according to the “WIRING HARNESS ROUTING” section. (10-12 to -14) USING THE MULTI CIRCUIT TESTER • Properly use the multi circuit tester + and - probes. Improper use can cause damage to the motorcycle and tester.
Page 287: Location Of Electrical Components
9-6 ELECTRICAL SYSTEM LOCATION OF ELECTRICAL COMPONENTS 1 ECM 9 Mode select coupler 2 Check relay or Main relay 0 TO sensor 3 Main relay or Check relay A PAIR control solenoid valve 4 IAT sensor B ET sensor 5 Ignition coil C HO2 sensor 6 Starter relay/Main fuse D Starter motor...
Page 288 ELECTRICAL SYSTEM 9-7 1 Fuel pump 7 Turn signal/Side-stand relay 2 TP sensor 8 Generator 3 STP sensor 9 CKP sensor 4 STV actuator 0 Neutral switch 5 IAP sensor A Side-stand switch 6 Fuel injector B Regulator/Rectifier...
Page 289: Charging System
9-8 ELECTRICAL SYSTEM CHARGING SYSTEM Regulator/Rectifier Ignition switch Generator TROUBLESHOOTING Battery runs down quickly Step 1 1) Check accessories which use excessive amounts of electricity. Are accessories being installed? Remove accessories. Go to Step 2. Step 2 1) Check the battery for current leaks. (9-9) Is the battery for current leaks OK? Go to Step 3.
Page 290: Inspection
ELECTRICAL SYSTEM 9-9 Step 5 1) Measure the generator no-load performance. (9-11) Is the generator no-load performance OK? Go to Step 6. Faulty generator Step 6 1) Inspect the regulator/rectifier. (9-11) Is the regulator/rectifier OK? Go to Step 7. Faulty regulator/rectifier Step 7 1) Inspect wirings.
Page 291 9-10 ELECTRICAL SYSTEM REGULATED VOLTAGE • Remove the right frame cover. (8-3) • Start the engine and keep it running at 5 000 r/min with the dimmer switch turned HI position. • Measure the DC voltage between the + and - battery termi- nals using the multi circuit tester.
Page 292 ELECTRICAL SYSTEM 9-11 GENERATOR NO-LOAD PERFORMANCE • Remove the front seat. (8-3) • 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 gen- erator with a new one.
Page 293: Starter System And Side-Stand/Ignition Interlock System
9-12 ELECTRICAL SYSTEM STARTER SYSTEM AND SIDE-STAND/IGNITION INTERLOCK SYSTEM Engine stop Ignition switch switch Fuse (30 A) To Ignition coil Starter Bl/B motor B/Bl Fuse Neutral switch (10 A) Battery Starter relay Starter Turn signal/ button side-stand relay Clutch switch side-stand switch TROUBLESHOOTING...
Page 294: Starter Motor Removal
ELECTRICAL SYSTEM 9-13 Step 3 1) Measure the starter relay voltage at the starter relay connectors (between Bl/B + and B/Y -) when the starter button is pushed. Is a voltage OK? Go to Step 4. • Faulty engine stop switch •...
Page 295: Starter Motor Disassembly
9-14 ELECTRICAL SYSTEM STARTER MOTOR DISASSEMBLY • Disassemble the starter motor as shown in the illustration. 1 O-ring 6 Bearing A Spring 2 O-ring 7 Snap ring B Brush holder 3 Housing end (inside) 8 Armature C Brush 4 O-ring 9 Shim D Housing end (outside) 5 Oil seal...
Page 296: Starter Motor Inspection
ELECTRICAL SYSTEM 9-15 STARTER MOTOR INSPECTION CARBON BRUSH Inspect the carbon brushes for abnormal wear, cracks or smoothness in the brush holder. If either carbon brush is defective, replace the brushes with new ones. Measure the length A of the carbon brushes using a vernier cal- ipers.
Page 297: Starter Motor Reassembly
NOTE: The sealed side of bearing should face inside. • Apply a small quantity of moly paste to the armature shaft.  99000-25140: SUZUKI MOLY PASTE or equivalent • Apply grease to the bearing.  99000-25010: SUZUKI SUPER GREASE “A”...
Page 298: Starter Motor Installation
• Align the match mark E on starter motor case with the bolt hole. STARTER MOTOR INSTALLATION • Apply grease to the O-ring.  99000-25010: SUZUKI SUPER GREASE “A” or equivalent • Tighten the starter motor mounting bolt 1 and starter motor lead wire nut 2.
Page 299: Starter Relay Inspection
9-18 ELECTRICAL SYSTEM STARTER RELAY INSPECTION • Remove the right frame cover. (8-3) • Disconnect the battery - lead wire from the battery. • Disconnect the starter relay coupler 1 and remove the starter relay cover 2. • Disconnect the starter motor lead wire 3 and battery lead wire 4.
Page 300: Side Stand/Ignition Interlock System Parts Inspection
ELECTRICAL SYSTEM 9-19 SIDE STAND/IGNITION INTERLOCK SYSTEM PARTS INSPECTION Check the interlock system for proper operation. If the interlock system does not operate properly, check each component for damage or abnormalities. If any abnormality is found, replace the component with a new one. SIDE-STAND SWITCH •...
Page 301 9-20 ELECTRICAL SYSTEM TURN SIGNAL/SIDE-STAND RELAY The turn signal/side-stand relay is composed of the turn signal relay, side-stand relay and diode. • Disconnect the PCV hose 1. • Remove the turn signal/side-stand relay 2. SIDE-STAND RELAY INSPECTION First check the insulation between D and E terminals with the tester.
Page 302: Ignition System
ELECTRICAL SYSTEM 9-21 IGNITION SYSTEM Main relay Engine stop switch Side-stand relay lgnition fuse lgnition coil sensor lgnition switch Main fuse Battery Neutral sensor sensor switch NOTE: The fuel cut-off circuit is incorporated in this ECM in order to prevent over-running of engine. When engine speed reaches 9 700 r/min, this circuit cuts off fuel at the fuel injector.
Page 303: Troubleshooting
9-22 ELECTRICAL SYSTEM TROUBLESHOOTING No spark or poor spark NOTE: * Check that the transmission is in neutral and the engine stop switch is in the RUN position. Grasp the clutch lever. * Check that the fuse is not blown and the battery is fully-charged before diagnosing. Step 1 1) Check the ignition system couplers for poor connections.
Page 304: Inspection
ELECTRICAL SYSTEM 9-23 Step 5 1) Inspect the ignition coil. (9-24) Is the ignition coil OK? Go to Step 6. • Poor connection of the ignition coil • Faulty ignition coil Step 6 1) Measure the CKP sensor peak voltage and its resistance. (9-25) NOTE: The CKP sensor peak voltage inspection is applicable only with the multi circuit tester and peak volt adaptor.
Page 305 9-24 ELECTRICAL SYSTEM • Shift the transmission into neutral and turn the ignition switch • Squeeze the clutch lever. • Press the starter button and allow the engine to crank for a few seconds, and then measure the ignition coil primary peak voltage.
Page 306 ELECTRICAL SYSTEM 9-25 CKP SENSOR PEAK VOLTAGE NOTE: * Check that all the couplers are connected properly. * Check that the battery is fully charged. • Remove the front seat. (8-3) • Disconnect the CKP sensor lead wire coupler 1 and connect the multi circuit tester with the peak volt adaptor as follows.
Page 307: Speedometer
9-26 ELECTRICAL SYSTEM SPEEDOMETER REMOVAL AND DISASSEMBLY • Remove the speedometer. (8-34) • Disassemble the speedometer as shown. 1 Speedometer 3 Bulb 2 Bracket 4 Cover...
Page 308: Inspection
ELECTRICAL SYSTEM 9-27 INSPECTION Check the continuity between the lead wires using the multi circuit tester. If there is no continuity replace the respective parts.  09900-25008: Multi circuit tester set  Tester knob indication: Continuity test () Speedometer FI indicator light High beam indicator light Fuel indicator light Neutral indicator light...
Page 309 9-28 ELECTRICAL SYSTEM DIODE (For speedometer) • Remove the headlight. (9-30) • Remove the diode 1. Measure the voltage between the terminals using the multi cir- cuit tester. Refer to the following table. + Probe of tester to: C, B 1.4 V and more C, B (Tester’s battery voltage)
Page 310 ELECTRICAL SYSTEM 9-29 FUEL LEVEL INDICATOR LIGHT Check that the fuel level indicator light immediately after turning the ignition switch to “ ” position. If the fuel level indicator light does not light up, check the lead wires, couplers, check relay and ignition switch. CHECK RELAY (For fuel level indicator light) •...
Page 311: Lamps
9-30 ELECTRICAL SYSTEM LAMPS HEADLIGHT Headlight: 12 V 60/55 W 1  If you touch the bulb with your bare hands, clean the bulb with a cloth moistened with alcohol or soapy water to prevent premature bulb failure. * Do not use bulb other than those with predetermined wattage. * Remove the bulb when it gets cool, since it may be heated to an extremely high temperature when the headlight is turned ON.
Page 312 ELECTRICAL SYSTEM 9-31 • Remove the rubber cap 2. • Unhook the holder spring 3 and replace the headlight bulb • When installing the headlight, hang the hook A of the head- light to the projection B of the housing. HEADLIGHT BEAM ADJUSTMENT •...
Page 313: Brake Light/Taillight
9-32 ELECTRICAL SYSTEM BRAKE LIGHT/TAILLIGHT Brake light/taillight: 12 V 21/5 W 1  If you touch the bulb with your bare hands, clean the bulb with a cloth moistened with alcohol or soapy water to prevent premature bulb failure. * Do not use bulb other than those with predetermined wattage. BRAKE LIGHT/TAILLIGHT BULB REPLACEMENT •...
Page 314: Turn Signal Light
ELECTRICAL SYSTEM 9-33 TURN SIGNAL LIGHT Turn signal light: 12 V 21 W 1  If you touch the bulb with your bare hands, clean the bulb with a cloth moistened with alcohol or soapy water to prevent premature bulb failure. * Do not use bulb other than those with predetermined wattage.
Page 315: Relays
9-34 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 316: Switch
ELECTRICAL SYSTEM 9-35 SWITCH IGNITION SWITCH REMOVAL • Remove the headlight. (9-30) • Disconnect the ignition switch lead wire couplers 1. • Remove the ignition switch mounting bolts using the special tools.  09930-11920: Torx bit (JT40H) 09930-11940: Torx bit holder •...
Page 317: Switch Inspection
9-36 ELECTRICAL SYSTEM SWITCH INSPECTION Inspect each switch for continuity with a tester. If any abnormality is found, replace the respective switch assemblies withe new one.  09900-25008: Multi circuit tester set  Tester knob indication: Continuity test () IGNITION SWITCH STARTER BUTTON Color Color...
Page 318: Battery
ELECTRICAL SYSTEM 9-37 BATTERY SPECIFICATIONS Type designation YTX7L-BS Capacity 12 V, 21.6 kC (6 Ah)/10 HR 1 Upper cover breather 5 Terminal 2 Cathode plates 6 Safety valve 3 Stopper 7 Anode plates 4 Filter 8 Separator (Fiberglass plate) INITIAL CHARGING Filling electrolyte •...
Page 319 9-38 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 320: Servicing
ELECTRICAL SYSTEM 9-39 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, clean the battery terminals with sandpaper.
Page 321 SERVICING INFORMATION 10-1 SERVICING INFORMATION CONTENTS TROUBLESHOOTING ................10- 2 FI SYSTEM MALFUNCTION CODE AND DEFECTIVE CONDITION..............10- 2 ENGINE ....................10- 2 CHASSIS ..................... 10- 8 BRAKES ....................10- 9 ELECTRICAL ..................10-10 BATTERY .................... 10-11 WIRING HARNESS, CABLE AND HOSE ROUTING........ 10-12 WIRING HARNESS ROUTING............
Page 322: Troubleshooting
10-2 SERVICING INFORMATION TROUBLESHOOTING FI SYSTEM MALFUNCTION CODE AND DEFECTIVE CONDITION (4-26 to -28) ENGINE Complaint Symptom and possible causes Remedy Engine will not start Compression too low or is hard to start. 1. Valve clearance out of adjustment Adjust. 2.
Page 323 SERVICING INFORMATION 10-3 Complaint Symptom and possible causes Remedy Engine idles poorly. 1. Valve clearance out of adjustment Adjust. 2. Poor seating of valves Replace or repair. 3. Defective valve guides Replace. 4. Worn rocker arms or cam surfaces Replace. 5.
Page 324 10-4 SERVICING INFORMATION Complaint Symptom and possible causes Remedy Noisy engine Excessive valve chatter 1. Too large valve clearance Adjust. 2. Weakened or broken valve springs Replace. 3. Worn rocker arms or cam surfaces Replace. 4. Worn and burnt camshaft journal bearings Replace.
Page 325 SERVICING INFORMATION 10-5 Complaint Symptom and possible causes Remedy Engine runs poorly Defective engine internal/electrical parts in high speed range. 1. Weakened valve springs Replace. 2. Worn camshaft Replace. 3. Valve timing out of adjustment Adjust. 4. Too narrow spark plug gap Adjust.
Page 326 10-6 SERVICING INFORMATION Complaint Symptom and possible causes Remedy Engine lacks power. Defective engine internal/electrical parts 1. Loss of valve clearance Adjust. 2. Weakened valve springs Replace. 3. Valve timing out of adjustment Adjust. 4. Worn piston rings or cylinder Replace.
Page 327 SERVICING INFORMATION 10-7 Complaint Symptom and possible causes Remedy Engine overheats Defective engine internal parts 1. Heavy carbon deposit on piston crown Clean. 2. Not enough oil in the engine Add oil. 3. Defective oil pump or clogged oil circuit Replace or clean.
Page 328: Chassis
10-8 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 Adjust.
Page 329: Brakes
SERVICING INFORMATION 10-9 BRAKES Complaint Symptom and possible causes Remedy Insufficient brake 1. Leakage of brake fluid from hydraulic system Repair or replace. power (Front) 2. Worn disc or pads Replace. 3. Friction surfaces of pad are dirty with oil or dust Clean disc/pads or replace.
Page 330: Electrical
10-10 SERVICING INFORMATION ELECTRICAL Complaint Symptom and possible causes Remedy No sparking or poor 1. Defective ignition coil Replace. sparking 2. Defective spark plug Replace. 3. Defective CKP sensor Replace. 4. Defective ECM Replace. 5. Defective TO sensor Replace. 6. Open-circuited wiring connections Check and repair.
Page 331: Battery
SERVICING INFORMATION 10-11 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 Replace the battery. stance or spots on a long time. surface of cell plates Battery runs down...
Page 332: Wiring Harness, Cable And Hose Routing
10-12 SERVICING INFORMATION WIRING HARNESS, CABLE AND HOSE ROUTING WIRING HARNESS ROUTING Clamp Clamp Clamp Rear turn signal (RH) Wiring harness Handlebar switch (RH) *1, *6 Handlebar switch (LH) Clamp Rear turn signal (LH) Wiring harness Rear combination Clamp Clamp Clamp Wiring harness Clutch cable...
Page 333 SERVICING INFORMATION 10-13 White tape Clamp Ignition switch Clamp Handlebar switch (LH & RH) Wiring harness Turn signal (LH & RH) Speedometer Clamp Starter motor Throttle cables Clamp Brake light switch Battery + Starter motor Clamp Clamp Fender brace Rear combination light Rear fender Weld clamp 15 –...
Page 334 10-14 SERVICING INFORMATION 160 N . m (16.0 kgf-m, 115.5 lbf-ft) 0 ± 10˚ 1 Generator lead wire 9 Generator cover 2 Battery - terminal *1 Pass the generator lead wire inside of the breather hose. 3 Clamp *2 Contact the battery - terminal onto the crankcase. 4 Neutral switch *3 Bent the oil seal retainer.
Page 335: Throttle Cable Routing
SERVICING INFORMATION 10-15 THROTTLE CABLE ROUTING 0 mm (0 in) 0 mm (0 in) 90˚ 1 Throttle cable No.1 8 Wiring harness 2 Throttle cable No.2 *1 Pass the throttle cable No.2 over the throttle cable No.1. 3 Starter motor lead wire *2 Pass the throttle cables outside of the brake hose.
Page 336: Speedometer Cable Routing
10-16 SERVICING INFORMATION SPEEDOMETER CABLE ROUTING 45 ± 15˚ 90 ± 5˚ 90 ± 5˚ 1 Front fork 6 Cable guide 2 Brake hose 7 Speedometer gearbox 3 Speedometer cable Bind the speedometer cable and hose guide with the clamp. 4 Cable guide Cut off the excess end of clamp.
Page 337: Front Brake Hose Routing
SERVICING INFORMATION 10-17 FRONT BRAKE HOSE ROUTING 20 – 30˚ 1 Throttle cable No.1 7 Front fender 2 Throttle cable No.2 *1 Do not contact the brake hose and upper bracket. 3 Speedometer cable *2 Attach the brake hose to the hose guide firmly. 4 Clamp After the brake hose union has contacted the stopper, tighten 5 Brake hose...
Page 338: Pair (Air Supply) System Hose Routing
10-18 SERVICING INFORMATION PAIR (AIR SUPPLY) SYSTEM HOSE ROUTING 0 – 2 mm (0 – 0.08 in) 10 N . m (1.0 kgf-m, 7.0 lbf-ft) 1 Match mark (White) *1 Do not clamp the clip at the nipple of PAIR pipe. 2 Match mark (Yellow) *2 To air cleaner 3 PAIR control solenoid valve...
Page 339: Cylinder Head Rubber Pad Installation
SERVICING INFORMATION 10-19 CYLINDER HEAD RUBBER PAD INSTALLATION DIRECTION OF RUBBER PAD INSERT DIRECTION OF RUBBER PAD INSERT NOTE: Insert the rubber pads at 0 – 4 mm (0 – 0.16 in) depth from the fin ends. A 40 mm (1.6 in) C 118 –...
Page 340: Throttle Body And Fuel Pump Installation
10-20 SERVICING INFORMATION THROTTLE BODY AND FUEL PUMP INSTALLATION 10 N . m (1.0 kgf-m, 7.0 lbf-ft) 1, 6 6 N . m (0.6 kgf-m, 4.5 lbf-ft) 10 N . m (1.0 kgf-m, 7.0 lbf-ft) 10 – 20˚ 45˚ 1 Fuel feed hose 6 Outlet tube clamp 2 Match mark (White) When installing the fuel pump assembly, first tighten all the...
Page 341: Rear Brake Pedal Installation
SERVICING INFORMATION 10-21 REAR BRAKE PEDAL INSTALLATION 1 Rear brake pedal 5 Cotter pin D 90 mm (3.5 in) 2 Rear brake rod A 20 mm (0.8 in) a Free travel adjustable range 3 Rear brake cam lever B 30 mm (1.2 in) 4 Rear brake adjuster nut C 65.5 mm (2.58 in) TORQUE LINK INSTALLATION...
Page 342: Side-Stand Installation
10-22 SERVICING INFORMATION SIDE-STAND INSTALLATION 50 N . m (5.0 kgf-m, 36.0 lbf-ft) 55 N . m (5.5 kgf-m, 40.0 lbf-ft)
Page 343: Front Turn Signal Light Installation
SERVICING INFORMATION 10-23 FRONT TURN SIGNAL LIGHT INSTALLATION 13 N . m (1.3 kgf-m, 9.5 lbf-ft) 1 Front turn signal light 2 Headlight bracket REAR TURN SIGNAL LIGHT INSTALLATION 15 N . m (1.5 kgf-m, 11.0 lbf-ft) 13 N . m (1.3 kgf-m, 9.5 lbf-ft) 1 Rear fender 4 Rear turn signal light...
Page 344: Special Tools
Thickness gauge Tire depth gauge V blocks (18 – 35 mm) 09900-25008 09900-25009 09900-26006 09904-41010 Multi circuit tester Needle-point Engine 09900-28630 SUZUKI Diagnos- probe set tachometer TP Sensor lead tic system set 09910-20116 09910-32812 09910-32840 Connecting rod Crankshaft Crankshaft 09910-34510...
Page 345 SERVICING INFORMATION 10-25 09913-70210 09915-63210 09915-64512 09915-74511 Bearing installer Compression Compression Oil pressure 09916-10911 set (10 – 75) gauge adaptor gauge gauge (600 kPa) Valve lapper set 09916-14910 09916-34550 09916-34561 09916-34542 09916-14510 Valve lifter attach- Valve guide Valve guide Reamer handle Valve lifter ment reamer (5.5 mm)
Page 346 10-26 SERVICING INFORMATION 09930-30104 09930-82720 09940-14911 Rotor remover 09930-34960 09930-44521 Mode selection Steering stem nut sliding shaft Rotor remover Rotor holder switch socket wrench 09940-30230 09940-34561 09940-40211 09940-40220 Hexagon socket 09940-34520 Front fork assem- Fuel pressure Fuel pressure (17 mm) T type handle bling attachment (D) gauge adaptor...
Page 347: Tightening Torque
SERVICING INFORMATION 10-27 TIGHTENING TORQUE ENGINE ITEM N·m kgf-m lbf-ft Engine mounting bolt 29.5 Engine mounting upper plate nut 29.0 Engine mounting lower plate nut 20.0 Exhaust pipe bolt 16.5 Muffler mounting bolt Front 16.5 Rear 36.0 Muffler connecting bolt 16.5 Exhaust pipe cover screw Cylinder head cover bolt/nut...
Page 348: Fi System And Intake Air System
10-28 SERVICING INFORMATION FI SYSTEM AND INTAKE AIR SYSTEM ITEM N·m kgf-m lbf-ft Air cleaner box mounting bolt Air cleaner box lower mounting bolt Fuel pump mounting bolt TP sensor mounting screw 0.35 STP sensor mounting screw 0.35 ET sensor 13.0 HO2 sensor 18.0...
Page 349: Tightening Torque Chart
SERVICING INFORMATION 10-29 TIGHTENING TORQUE CHART For other nuts and bolts not listed in the preceding page, refer to this chart: Bolt Diameter Conventional or “4” marked bolt “7” marked bolt A (mm) N·m kgf-m lbf-ft N·m kgf-m lbf-ft 0.15 0.23 0.45 0.55...
Page 350: Service Data
10-30 SERVICING INFORMATION SERVICE DATA VALVE + VALVE GUIDE Unit: mm (in) ITEM STANDARD LIMIT Valve diam. — (1.3) — (1.1) Valve clearance (when cold) 0.03 – 0.08 — (0.001 – 0.003) 0.08 – 0.13 — (0.003 – 0.005) Valve guide to valve stem 0.025 –...
Page 351 SERVICING INFORMATION 10-31 CAMSHAFT + CYLINDER HEAD Unit: mm (in) ITEM STANDARD LIMIT Cam height 33.84 – 33.89 33.54 (1.332 – 1.334) (1.320) 33.30 – 33.35 33.00 (1.311 – 1.313) (1.299) Camshaft runout 0.10 — (0.004) Rocker arm I.D. 12.000 – 12.018 IN.
Page 352 10-32 SERVICING INFORMATION ITEM STANDARD LIMIT Piston ring thickness 0.975 – 0.990 — (0.0384 – 0.0390) 1.170 – 1.190 — (0.0461 – 0.0469) Piston pin bore I.D. 18.002 – 18.008 18.030 (0.7087 – 0.7090) (0.7098) Piston pin O.D. 17.992 – 18.000 17.980 (0.7083 –...
Page 353 SERVICING INFORMATION 10-33 TRANSMISSION + DRIVE CHAIN Unit: mm (in) Except ratio ITEM STANDARD LIMIT Primary reduction ratio 3.238 (68/21) — Final reduction ratio 2.866 (43/15) — Gear ratios 2.636 (29/11) — 1.687 (27/16) — 1.200 (24/20) — 0.952 (20/21) —...
Page 354 10-34 SERVICING INFORMATION FI SENSORS ITEM SPECIFICATION NOTE 420 – 620 Ω CKP sensor resistance Bl – G +: G – -: Bl CKP sensor peak voltage 2.0 V and more (When cranking) IAP sensor input voltage 4.5 – 5.5 V +: W/Bl –...
Page 355 SERVICING INFORMATION 10-35 THROTTLE BODY ITEM SPECIFICATION Bore size 32 mm I.D. No. 26GA Fast idle r/min 1 800 – 2 300 r/min Idle r/min 1 300 ± 100 r/min Throttle cable play 2.0 – 4.0 mm (0.08 – 0.16 in) ELECTRICAL Unit: mm (in) ITEM...
Page 356 10-36 SERVICING INFORMATION WATTAGE Unit: W ITEM STANDARD/SPECIFICATION Headlight Brake light/Taillight 21/5 Turn signal light Speedometer light High beam indicator light Neutral indicator light Turn signal indicator light Fuel injection indicator light Fuel level indicator light BRAKE + WHEEL Unit: mm (in) ITEM STANDARD LIMIT...
Page 357 Front fork oil level (without spring, — outer tube fully compressed) (2.8) Front fork oil type SUZUKI FORK OIL SS-08 or an equivalent fork oil — Front fork oil capacity (each leg) 411 ml (13.9 US oz) — Front fork inner tube O.D.
Page 358 10-38 SERVICING INFORMATION FUEL + OIL ITEM SPECIFICATION NOTE Fuel type Use only unleaded gasoline of at least 87 pump octane (R/2 + M/2). Gasoline containing MTBE (Methyl Tertiary Butyl Ether), less than 10% ethanol, or less than 5% methanol with appropriate cosolvents and corro- sion inhibitor is permissible.
Page 359 EMISSION CONTROL INFORMATION 11-1 EMISSION CONTROL INFORMATION CONTENTS EMISSION CONTROL SYSTEMS .............. 11- 2 FUEL INJECTION SYSTEM..............11- 2 CRANKCASE EMISSION CONTROL SYSTEM........11- 3 EXHAUST EMISSION CONTROL SYSTEM........11- 4 HO2 SENSOR INSPECTION ............... 11- 5 HO2 SENSOR REMOVAL AND INSTALLATION ....... 11- 5 NOISE EMISSION CONTROL SYSTEM..........
Page 360: Emission Control Systems
EMISSION CONTROL SYSTEMS FUEL INJECTION SYSTEM TU250X 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. With varying engine conditions, all of the fuel injection volumes are precisely controlled by the programmed injection maps in the ECM to reduce CO, NOX and HC.
Page 361: Crankcase Emission Control System
EMISSION CONTROL INFORMATION 11-3 CRANKCASE EMISSION CONTROL SYSTEM The engine is equipped with a PCV system to prevent discharging crankcase emissions into the atomo- sphere. Blow-by gas in the engine is constantly drawn into the crankcase, which is returned to the combus- tion chamber through the PCV (breather) hose, air cleaner and throttle body.
Page 362: Exhaust Emission Control System
11-4 EMISSION CONTROL INFORMATION EXHAUST EMISSION CONTROL SYSTEM The exhaust emission control system is composed of the PAIR system, HO2 sensor and three-way catalyst system. The fresh air is drawn into the exhaust port through the PAIR control solenoid valve and PAIR reed valve.
Page 363: Ho2 Sensor Inspection
EMISSION CONTROL INFORMATION 11-5 HO2 SENSOR INSPECTION (4-64) HO2 SENSOR REMOVAL AND INSTALLATION (4-72) NOISE EMISSION CONTROL SYSTEM TAMPERING WITH THE NOISE CONTROL SYSTEM PROHIBITED: Local law or federal 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 364: Pair (Air Supply) System And Emission Control System Inspection
11-6 EMISSION CONTROL INFORMATION PAIR (AIR SUPPLY) SYSTEM AND EMISSION CONTROL SYSTEM INSPECTION PAIR HOSES • Inspect the PAIR hoses and PAIR pipe for wear or damage. • Inspect the PAIR hoses and PAIR pipe for secure connection. PAIR REED VALVE REMOVAL •...
Page 365: Pcv Hose
EMISSION CONTROL INFORMATION 11-7 PCV HOSE • Inspect the PCV hose for wear and damage. • If it is worn or damaged, replace the PCV hose with a new one. PAIR CONTROL SOLENOID VALVE REMOVAL • Disconnect the PAIR control solenoid valve coupler 1 and PAIR hose 2.
Page 366 11-8 EMISSION CONTROL INFORMATION INSPECTION • Check that air flows through the air inlet port to the air outlet port. • If air does not flow out, replace the PAIR control solenoid valve with a new one. A Air flow •...
Page 367: Pair (Air Supply) System Diagram
EMISSION CONTROL INFORMATION 11-9 PAIR (AIR SUPPLY) SYSTEM DIAGRAM 1 PAIR control solenoid valve A FRESH AIR 2 PAIR reed valve B EXHAUST GAS 3 Air cleaner PAIR (AIR SUPPLY) SYSTEM HOSE ROUTING (10-18)
Page 368 WIRING DIAGRAM Wiring diagrams wire color, refer to section “WIRE COLOR”. HANDLEBAR SWITCH (RH) ENGINE REAR BRAKE STOP STARTER FRONT BRAKE LIGHT SWITCH SWITCH BUTTON LIGHT SWITCH PUSH PAIR IGNITION SWITCH CONTROL SOLENOID FUEL PUMP VALVE STVA SPEEDOMETER LOCK CHECK RELAY IGNITION COIL DIODE...

Suzuki TU250X Service Manual

General Information 1

Periodic Maintenance

Engine

Fi System Diagnosis

Fuel System and Throttle Body

Exhaust System

Chassis

Electrical System

Servicing Information

Emission Control Information

Quick Links

Chapters

Troubleshooting

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Summary of Contents for Suzuki TU250X