Suzuki VLR1800 Service Manual

Table of Contents

Quick Links

VLR1800

9 9 5 0 0 - 3 9 3 6 0 - 0 1 E

Table of Contents

Summary of Contents for Suzuki VLR1800

Page 1 VLR1800 © THIS BOOK REMAINS THE PROPERTY OF SUZUKI NEW ZEALAND LTD. FOR DEALER USE ONLY. 9 9 5 0 0 - 3 9 3 6 0 - 0 1 E...
Page 2 FOREWORD This manual contains an introductory description on the SUZUKI VLR1800 and procedures for its inspection/ser- vice and overhaul of its main components. Other information considered as generally known is not included. Read the GENERAL INFORMATION section to familiarize yourself with the motorcycle and its maintenance. Use this section as well as other sections to use as a guide for proper inspection and service.
Page 3 TABLE OF CONTENTS Precautions............... 00-i Precautions ............00-1 General Information ........... 0-i General Information ..........0A-1 Maintenance and Lubrication ......... 0B-1 Service Data............0C-1 Engine ................. 1-i Precautions .............. 1-1 Engine General Information and Diagnosis ... 1A-1 Emission Control Devices ........1B-1 Engine Electrical Devices........1C-1 Engine Mechanical..........1D-1 Engine Lubrication System ........
Page 5 Table of Contents 00- i Section 00 Precautions CONTENTS Precautions ..........00-1 General Precautions ........... 00-1 Precautions for Electrical Circuit Service .... 00-2 Precautions............00-1 Warning / Caution / Note........00-1...
Page 6 CAUTION special meanings. Pay special attention to the messages highlighted by these signal words. • If parts replacement is necessary, replace the parts with Suzuki Genuine Parts or WARNING their equivalent. Indicates a potential hazard that could result • When removing parts that are to be reused, in death or injury.
Page 7 Precautions: 00-2 • Use a torque wrench to tighten fasteners • Inspect each terminal for corrosion and to the specified torque. Wipe off grease contamination. The terminals must be clean and free and oil if a thread is smeared with them. of any foreign material which could impede proper terminal contact.
Page 8 00-3 Precautions: • When connecting meter probe from the terminal side Fuse of the coupler (where connection from harness side • When a fuse is blown, always investigate the cause to not being possible), use extra care not to force and correct it and then replace the fuse.
Page 9 Precautions: 00-4 • When disconnecting and connecting the coupler, • Before measuring voltage at each terminal, check to make sure to turn OFF the ignition switch, or make sure that battery voltage is 11 V or higher. electronic parts may get damaged. Terminal voltage check with a low battery voltage will lead to erroneous diagnosis.
Page 10 00-5 Precautions: 2) Check each connector/coupler at both ends of the Continuity check circuit being checked for loose connection. Also 1) Measure resistance across coupler “B” (between “A” check for condition of the coupler lock if equipped. and “C” in the figure). If no continuity is indicated (infinity or over limit), the circuit is open between terminals “A”...
Page 11 Precautions: 00-6 Voltage check Short circuit check (Wire harness to ground) If voltage is supplied to the circuit being checked, voltage 1) Disconnect the negative (–) cable from the battery. check can be used as circuit check. 2) Disconnect the connectors/couplers at both ends of 1) With all connectors/couplers connected and voltage the circuit to be checked.
Page 12 “D”: To other parts I649G1000002-02 Using The Multi-Circuit Testers NOTE • Use the Suzuki multi-circuit tester set. • When connecting the multi-circuit tester, • Use well-charged batteries in the tester. use the needle pointed probe to the back side of the lead wire coupler and connect •...
Page 13 Table of Contents 0- i Section 0 General Information CONTENTS General Information ........ 0A-1 Valve Clearance Inspection and Adjustment ..0B-5 Spark Plug Replacement ........0B-10 General Description ..........0A-1 Spark Plug Inspection and Cleaning ....0B-10 Symbols .............. 0A-1 Fuel Line Inspection ..........0B-11 Abbreviations ............
Page 14 Use engine oil unless otherwise specified. Apply molybdenum oil solution. (Mixture of engine oil and SUZUKl MOLY PASTE in a ratio of 1 : 1). Apply SUZUKI SUPER GREASE “A” or equivalent. 99000-25010 Apply SUZUKI MOLY PASTE or equivalent. 99000-25140 Apply SUZUKI SILICONE GREASE or equivalent.
Page 15 Difference between illustration and actual FPR: Fuel Pressure Regulator motorcycles may exist depending on the FP Relay: Fuel Pump Relay markets. GEN: Generator SUZUKI VLR1800 (2008-model) GND: Ground GP Switch: Gear Position Switch Right Side HC: Hydrocarbons IAP Sensor: Intake Air Pressure Sensor (IAPS)
Page 16 Use of SF/SG or SH/SJ in API with MA in JASO. ordering spare parts. Suzuki recommends the use of SAE 10W-40 engine oil. If SAE 10W-40 engine oil is not available, select and alternative according to the chart.
Page 17 2) Upon reaching an odometer reading of 1 600 km (1 Suzuki recommends the use of SUZUKI COOLANT anti- 000 miles) you can subject the motorcycle to full freeze/engine coolant. If this is not available, use an throttle operation.
Page 18 0A-5 General Information: Country and Area Codes B822H10101010 The following codes stand for the applicable country(-ies) and area(-s). Code Country or Area Effective Frame No. VLR1800 K8 (E-02) U.K. JS1CT111200100001 – VLR1800 K8 (E-19) E.U. JS1CT111100100001 – VLR1800 K8 (E-03) U.S.A (Except for California)
Page 19 General Information: 0A-6 Warning, Caution and Information Labels Location B822H10101012 15, 17 2, 3, 16 8, 9 10, 11, 12, 13 I822H1010006-02 1. Noise label (For E-03, 33) 12. General warning label (English/French) (For E-28) 2. Noise label (For E-24) 13.
Page 20 0A-7 General Information: Component Location Electrical Components Location B822H10103001 I822H1010007-03 1. IAP sensor (#2) 10. TP sensor 19. Rear brake switch 2. IAP sensor (#1) 11. Starter motor 20. GP switch 3. Fuel injector (#1) 12. O2 sensor (For E-02, 19, 24, 33) 21.
Page 21 General Information: 0A-8 I822H1010008-05 24. Fuel level gauge 34. Regulator/Rectifier 25. Fuel pump 35. Oil pressure switch 26. Battery 36. Generator 27. ECM (Engine Control Module) 37. CKP sensor 28. Fuse box 38. Speedometer sensor 29. Ignition coil (#2) 39. Side-stand switch 30.
Page 22 0A-9 General Information: Specifications Specifications B822H10107001 NOTE These specifications are subject to change without notice. Dimensions and dry mass Item Specification Remark Overall length 2 580 mm (101.6 in) Overall width 985 mm (38.8 in) Overall height 1 150 mm (45.3 in) Wheelbase 1 755 mm (69.1 in) Ground clearance...
Page 23 General Information: 0A-10 Chassis Item Specification Remark Front suspension Telescopic, coil spring, oil damped Rear suspension Link type, coil spring, oil damped Front fork stroke 130 mm (5.1 in) Rear wheel travel 118 mm (4.6 in) Steering angle 37° (right & left) Caster 58°...
Page 24 0A-11 General Information: Special Tools and Equipment Special Tool B822H10108002 09900–06104 09900–06107 09900–06108 09900–18740 09900–20101 Snap ring pliers Snap ring pliers Snap ring pliers Hexagon socket (24 Vernier calipers (1/15 mm, 150 mm) 09900–20102 09900–20202 09900–20203 09900–20205 09900–20210 Vernier calipers (1/20 Micrometer (1/100 Micrometer (1/100 Micrometer (0 –...
Page 25 General Information: 0A-12 09913–50121 09913–60910 09913–70210 09913–75821 09913–76010 Oil seal remover Bearing remover Bearing installer set Bearing installer Bearing installer 09913–84510 09915–17410 09915–40610 09915–64512 09915–74521 Bearing installer Oil pressure gauge Oil filter wrench Compression gauge Oil pressure gauge attachment hose 09915–77331 09916–10911 09916–14510...
Page 26 0A-13 General Information: 09921–20210 09921–20240 09923–73210 09923–74511 09924–34510 Bearing remover Bearing remover set Bearing remover Bearing remover Backlash measuring tool (φ27 – 50)) 09924–41830 09924–62410 09924–62430 09924–64510 09924–84510 Bearing retainer Final drive gear Long socket (22 mm) Final driving gear Bearing installer set wrench bearing holder wrench...
Page 27 General Information: 0A-14 09940–51410 09940–51710 09940–52861 09940–92720 09941–34513 Bearing installer Bearing installer Front fork oil seal Spring scale Steering race installer installer 09941–54911 09941–64511 09941–74911 09943–74111 09944–28320 Bearing outer race Bearing remover Steering bearing Fork oil level gauge Hexagon socket (19 remover installer 09951–16080...
Page 28 0B-1 Maintenance and Lubrication: Maintenance and Lubrication General Information Precautions Precautions for Maintenance B822H10200001 The “Periodic Maintenance Schedule Chart” lists the recommended intervals for all the required periodic service work necessary to keep the motorcycle operating at peak performance and economy. Maintenance intervals are expressed in terms of kilometers, miles and months for your convenience.
Page 29 Maintenance and Lubrication: 0B-2 Interval 1 000 6 000 12 000 18 000 24 000 Item miles 4 000 7 500 11 000 14 500 months Front fork — — — Rear suspension — — — Chassis bolts and nuts Lubrication Points B822H10205002 Proper lubrication is important for smooth operation and long life of each working part of the motorcycle.
Page 30 0B-3 Maintenance and Lubrication: Repair Instructions Air Cleaner Element Replacement Cleaning B822H10206001 1) Remove the air cleaner element. Refer to “Air Replace air cleaner element Cleaner Element Removal and Installation in Section Every 18 000 km (11 000 miles, 36 months) 1D (Page 1D-6)”.
Page 31 Maintenance and Lubrication: 0B-4 Exhaust Pipe Bolt and Muffler Bolt Inspection Exhaust Control Valve Inspection B822H10206003 B822H10206028 Tighten exhaust pipe bolts, muffler bolt and nut Inspect exhaust control valve Initially at 1 000 km (600 miles, 2 months) and every Initially at 1 000 km (600 miles, 2 months) and every 12 000 km (7 500 miles, 24 months) thereafter 12 000 km (7 500 miles, 24 months) thereafter...
Page 32 0B-5 Maintenance and Lubrication: Valve Clearance Inspection and Adjustment 7) Remove the PAIR reed valves. Refer to “PAIR Reed B822H10206006 Valve Removal and Installation in Section 1B (Page 1B-10)”. Inspect valve clearance Every 24 000 km (14 500 miles, 48 months) thereafter 8) Remove the cylinder head covers (1) and (2).
Page 33 Maintenance and Lubrication: 0B-6 12) Turn the crankshaft to set the #1 (Rear) cylinder at TDC of compression stroke. (Align the “R | T” line on “B” the generator rotor to the center of valve timing inspection hole and also bring the camshafts to the position “B”...
Page 34 0B-7 Maintenance and Lubrication: 14) Turn the crankshaft 486 degrees (1-1/3 turns) to set 2) Remove the tappet (1) and shim (2) by fingers or the #2 (Front) cylinder at TDC of compression magnetic hand. stroke. (Align the “F | T” line on the generator rotor to the center of valve timing inspection hole and also bring the camshafts to the position as shown.
Page 35 Maintenance and Lubrication: 0B-8 (INTAKE SIDE) I822H1020025-03...
Page 36 0B-9 Maintenance and Lubrication: (EXHAUST SIDE) I822H1020026-03...
Page 37 Maintenance and Lubrication: 0B-10 Spark Plug Replacement Spark Plug Gap B822H10206004 1) Remove the spark plugs. Refer to “Ignition Coil / Replace spark plug Plug Cap and Spark Plug Cap Removal and Every 12 000 km (7 500 miles, 24 months) Installation in Section 1H (Page 1H-4)”.
Page 38 0B-11 Maintenance and Lubrication: Fuel Line Inspection Engine Oil and Filter Replacement B822H10206007 B822H10206009 Inspect fuel line Replace engine oil Every 6 000 km (4 000 miles, 12 months) Initially at 1 000 km (600 miles, 2 months) and every 6 000 km (4 000 miles, 12 months) thereafter Inspect the fuel line in the following procedures: Replace oil filter...
Page 39 Maintenance and Lubrication: 0B-12 3) Tighten the oil drain plugs (1) to the specified torque. Motorcycle on the side-stand position 1) Place an oil pan below the engine, and drain engine CAUTION oil by removing the oil drain plugs (1) and filler cap Replace the gasket washers with new ones.
Page 40 “B”, drain oil to full level line “B”. which may lead to engine damage or oil leaks. Also, do not use a genuine Suzuki automobile oil filter on this motorcycle. 5) Install a new oil filter. Turn it by hand until you feel that the oil filter O-ring contacts the oil filter mounting “B”...
Page 41 Maintenance and Lubrication: 0B-14 Final Gear Oil Replacement Throttle Cable Play Inspection and Adjustment B822H10206029 B822H10206010 Inspect final gear oil Inspect throttle cable play Every 12 000 km (7 500 miles, 24 months) Initially at 1 000 km (6 000 miles, 2 months) and every 6 000 km (4 000 miles, 12 months) thereafter Replace final gear oil Initially at 1 000 km (600 miles, 2 months)
Page 42 0B-15 Maintenance and Lubrication: PAIR System Inspection Engine Coolant Change B822H10206012 Refer to “Engine Coolant Description in Section 1F (Page 1F-1)”. Inspect PAIR system Every 12 000 km (7 500 miles, 24 months) WARNING Inspect the PAIR (air supply) system periodically. Refer Do not open the radiator cap when the engine to “PAIR System Inspection in Section 1B (Page 1B-11)”.
Page 43 Maintenance and Lubrication: 0B-16 Air Bleeding From the Cooling Circuit Radiator Hose Inspection Check the radiator hoses for crack, damage or engine 1) Support the motorcycle upright with a jack. coolant leakage. If any defect is found, replace the 2) Move the fuel tank. Refer to “Fuel Tank Removal and radiator hose with a new one.
Page 44 0B-17 Maintenance and Lubrication: Clutch Cable Play Inspection and Adjustment e) From that position, turn out the release screw (3) B822H10206030 1 turn and tighten the lock-nut (2) securely by holding the release screw (3). Inspect clutch cable play Every 6 000 km (4 000 miles, 12 months) Clutch release screw 1 turn back Inspect and adjustment the clutch cable play “a”...
Page 45 Maintenance and Lubrication: 0B-18 8) Loosen the lock-nut (6), and turn the cable adjuster WARNING (7) to obtain 10 – 15 mm (0.4 – 0.6 in) of free play “c” at the clutch lever end. • The brake system of this motorcycle is filled with a glycol-based brake fluid.
Page 46 0B-19 Maintenance and Lubrication: Brake Pads Check 2) Inspect the brake hoses and hose joints for crack, The extent of brake pad wear can be checked by damage or brake oil leakage. If any defects are observing the grooved limit line “A” on the pad. When the found, replace the brake hose with a new one.
Page 47 Maintenance and Lubrication: 0B-20 Brake Pedal Height Inspection and Adjustment 6) Tighten the right footrest bracket bolts (1) to the specified torque. WARNING Tightening torque Do not adjust the brake pedal height when Front footrest bracket bolt (b): 85 N·m (8.5 kgf- exhaust pipe is hot.
Page 48 0B-21 Maintenance and Lubrication: Tire Inspection Tire Pressure B822H10206020 If the tire pressure is too high or too low, steering will be adversely affected and tire wear increased. Therefore, Inspect tire maintain the correct tire pressure for good roadability or Every 6 000 km (4 000 miles, 12 months) shorter tire life will result.
Page 49 Maintenance and Lubrication: 0B-22 Steering System Inspection Rear Suspension Inspection B822H10206021 B822H10206023 Inspect steering system Inspect rear suspension Initially at 1 000 km (600 miles, 2 months) and every Every 12 000 km (7 500 miles, 24 months) 12 000 km (7 500 miles, 24 months) thereafter Inspect the rear shock absorbers for oil leakage and Steering should be adjusted properly for smooth turning check that there is no play in the swingarm.
Page 50 0B-23 Maintenance and Lubrication: Chassis Bolt and Nut Inspection B822H10206024 Tighten chassis bolt and nut Initially at 1 000 km (600 miles, 2 months) and every 6 000 km (4 000 miles, 12 months) thereafter Check that all chassis bolts and nuts are tightened to their specified torque.
Page 51 Maintenance and Lubrication: 0B-24 I822H1020072-02 I822H1020079-01 Swingarm pivot shaft 100 N⋅m (10.0 kgf-m, 72.5 lb-ft) Rear brake caliper mounting bolt 54 N⋅m (5.4 kgf-m, 39.0 lb-ft) I822H1020073-02 I822H1020075-03 Brake hose union bolt 23 N⋅m (2.3 kgf-m, 16.5 lb-ft) Front footrest bolt 85 N⋅m (8.5 kgf-m, 61.5 lb-ft) Front axle 100 N⋅m (10.0 kgf-m, 72.5 lb-ft) Brake disc bolt (Front) 23 N⋅m (2.3 kgf-m, 16.5 lb-ft) Front axle pinch bolt 33 N⋅m (3.3 kgf-m, 24.0 lb-ft)
Page 52 For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List in Section 0C (Page 0C-8)”. Special Tools and Equipment Recommended Service Material B822H10208001 Material SUZUKI recommended product or Specification Note Brake fluid DOT 4 — (Page 0B-18) NOTE Required service material is also described in the following.
Page 53 Service Data: 0C-1 Service Data General Information Specifications Service Data B822H10307001 Valve + Guide Unit: mm (in) Item Standard Limit 42 (1.65) — Valve diam. 38 (1.50) — 0.09 – 0.16 (0.004 – 0.006) — Tappet clearance (When cold) 0.20 – 0.30 (0.008 – 0.012) —...
Page 54 0C-2 Service Data: Cylinder + Piston + Piston Ring Unit: mm (in) Item Standard Limit Compression pressure 800 kPa 1 300 – 1 800 kPa (13 – 18 kgf/cm , 185 – 256 psi) (Automatic decomp. actuated) (8 kgf/cm , 114 psi) 200 kPa Compression pressure difference —...
Page 55 Service Data: 0C-3 Clutch Unit: mm (in) Item Standard Limit Clutch cable play 10 – 15 (0.4 – 0.6) — Clutch release screw 1 turn back — No. 1 2.92 – 3.08 (0.115 – 0.121) 2.62 (0.103) Clutch drive plate thickness No.
Page 56 0C-4 Service Data: Driveline / Axle Unit: mm (in) Item Standard/Specification Limit Secondary bevel gear backlash 0.03 – 0.15 (0.001 – 0.006) — Final bevel gear backlash 0.08 – 0.16 (0.003 – 0.006) — Damper spring free length — 64.6 (2.54) Final gear oil type Hypoid gear oil SAE #90, API grade GL-5 —...
Page 57 Service Data: 0C-5 Throttle Body Item Specification Bore size 52 mm (2.0 in) I.D. No. 22H1 (For E-33), 22H0 (For the others) 900 ± 100 r/min/Warmed engine Idle r/min Throttle cable play 2.0 – 4.0 mm (0.08 – 0.16 in) Electrical Unit: mm (in) Item...
Page 58 0C-6 Service Data: Wattage Unit: W Specification Item E-03, 28, 33 E-02, 19, 24 ← Headlight ← Position light — ← Brake light/Taillight Front turn signal light/Position light 21/5 — Front turn signal light — ← Rear turn signal light ←...
Page 59 Front fork oil level (Without spring, 179 (7.0) — inner tube fully compressed) Front fork oil type SUZUKI FORK OIL G-10 or an equivalent fork oil — Front fork oil capacity (Each leg) 686 ml (23.2/24.2 US/lmp oz) — Rear shock absorber spring adjuster Rear wheel travel 118 (4.6)
Page 60 0C-8 Service Data: Tightening Torque List B822H10307002 Engine Item N⋅m kgf-m lb-ft Cylinder head cover bolt Cylinder head cover bracket bolt [M6] [M8] 19.0 Cylinder head bolt Initial 18.0 [M10] Final 30.5 Cylinder nut Water jacket plug (Cylinder head plug) 19.0 Camshaft journal holder bolt Rear cam chain drive sprocket bolt...
Page 61 Service Data: 0C-9 Item N⋅m kgf-m lb-ft Starter motor lead wire mounting nut Brush holder nut Generator lead wire clamp bolt Speed sensor mounting bolt Oil filter 14.5 Engine mounting nut 40.0 Muffler connecting bolt 16.5 Muffler mounting bolt 16.5 Muffler joint bolt 16.5 Driveline / Axle...
Page 62 0C-10 Service Data: Chassis Item N⋅m kgf-m lb-ft Handlebar clamp bolt 16.5 Handlebar holder bolt 50.5 Front fork clamp bolt (upper and lower) 16.5 Front fork cap bolt 40.0 Front fork cylinder bolt 14.5 Spacer clamp bolt 0.42 Steering stem nut 45 N⋅m (4.5 kgf-m, 32.5 lb-ft) then turn back 1/2 –...
Page 63 Service Data: 0C-11 Tightening Torque Chart For other bolts and nuts not listed in the preceding page, refer to this chart: Bolt Diameter Conventional or “4” marked bolt “7” marked bolt “a” (mm) N⋅m kgf-m lb-ft N⋅m kgf-m lb-ft 0.15 0.23 0.45 0.55...
Page 64 0C-12 Service Data:...
Page 65: Table Of Contents
Table of Contents 1- i Section 1 Engine CONTENTS Precautions ..........1-1 DTC “C29” (P1654-H/L): Secondary Throttle Position Sensor (STPS) Circuit Malfunction..1A-68 Precautions............. 1-1 DTC “C31” (P0705): GP Switch Circuit Precautions for Engine.......... 1-1 Malfunction............1A-75 Engine General Information and DTC “C32” (P0201), “C33” (P0202): Fuel Injector Circuit Malfunction......1A-77 Diagnosis ..........
Page 66 1-ii Table of Contents Repair Instructions ..........1B-9 Special Tools and Equipment ......1C-10 Oxygen Sensor (O2S) Removal and Recommended Service Material .......1C-10 Installation ............1B-9 Special Tool ............1C-10 Heated Oxygen Sensor (O2S) Inspection..1B-10 Engine Mechanical ........1D-1 PAIR Reed Valve Removal and Installation..1B-10 PAIR Control Solenoid Valve Removal and Schematic and Routing Diagram ......1D-1 Installation ............
Page 67 Table of Contents 1-iii Crankshaft Thrust Clearance Inspection and Water Hose Inspection........1F-6 Selection ............1D-90 Water Hose Removal and Installation....1F-7 Balancer Driven Gear Disassembly and Radiator Reservoir Tank Inspection....1F-7 Assembly ............1D-92 Radiator Reservoir Tank Removal and Balancer Shaft Parts Inspection......1D-94 Installation ............
Page 68 1-iv Table of Contents Ignition System Components Location....1H-1 Special Tools and Equipment ......1I-15 Recommended Service Material ......1I-15 Diagnostic Information and Procedures....1H-2 Special Tool ............1I-15 Ignition System Symptom Diagnosis....1H-2 No Spark or Poor Spark ........1H-3 Charging System ........1J-1 Repair Instructions ..........1H-4 Schematic and Routing Diagram ......
Page 69: Precautions
Precautions: Precautions Engine Precautions Precautions for Engine B822H11000001 Refer to “General Precautions in Section 00 (Page 00-1)” and “Precautions for Electrical Circuit Service in Section 00 (Page 00-2)”.
Page 70: Engine General Information And Diagnosis
1A-1 Engine General Information and Diagnosis: Engine General Information and Diagnosis Engine General Description Injection Timing Description B822H11101001 Injection Time (Injection Volume) The factors to determine the injection time include the basic fuel injection time, which is calculated on the basis of the intake air pressure, engine speed and throttle opening angle, and various compensations.
Page 71: Self-Diagnosis Function
Engine General Information and Diagnosis: 1A-2 Injection Stop Control Signal Descriptions When the motorcycle tips over, the tip-over sensor sends a signal TIP-OVER SENSOR SIGNAL (FUEL SHUT-OFF) to the ECM. Then, this signal cuts OFF current supplied to the fuel pump, fuel injectors and ignition coils.
Page 72 1A-3 Engine General Information and Diagnosis: For Example: The ignition switch is turned ON, and the engine stop switch is turned OFF. In this case, the speedometer does not receive any signal from the ECM, and the panel indicates “CHEC”. If CHEC is indicated, the LCD does not indicate the trouble code.
Page 73: Schematic And Routing Diagram
Engine General Information and Diagnosis: 1A-4 Schematic and Routing Diagram FI System Wiring Diagram B822H11102001 Combination meter Cooling fan motor Cooling fan relay 15 A CKPS R/Bl Fuel injector G/Bl Gr/W Gr/B IG switch signal 10 A Engine stop switch FP relay * 65 Side-stand relay...
Page 74: Terminal Alignment Of Ecm Coupler
1A-5 Engine General Information and Diagnosis: Terminal Alignment of ECM Coupler B822H11102002 I823H1110002-01 TERMINAL NO. CIRCUIT TERMINAL NO. CIRCUIT STVA signal (STVA, 2A) ISC valve signal (ISC, 2A) STVA signal (STVA, 1A) ISC valve signal (ISC, 1A) EXCVA power (EXCVA–) —...
Page 75: Component Location
Engine General Information and Diagnosis: 1A-6 Component Location FI System Parts Location B822H11103001 I822H1110004-03 “A”: ECM “G”: Intake air pressure sensor #1 (IAPS) “M”: Engine coolant temperature sensor (ECTS) “B”: Speedometer “H”: Fuel pump “N”: Cooling fan “C”: Intake air temperature sensor (IATS) “I”: Ignition coil (IG coil)/plug cap #1 “O”: Crank shaft position sensor (CKPS) “D”: PAIR control solenoid valve (PAIR valve)
Page 76 1A-7 Engine General Information and Diagnosis: I822H1110005-01 “A”: ECM “X”: PAIR control solenoid valve [For E-02, 19, 24, 33] “R”: ISC valve (ISCV) “Y”: Ignition coil (IG coil)/plug cap #2 “S”: Intake air pressure sensor #2 (IAPS) “Z”: O2 sensor #1 (O2S) [For E-02, 19, 24, 33] “T”: Ignition coil #2 “a”: O2 sensor #2 (O2S) [For E-02, 19, 24, 33] “U”: Secondary throttle position sensor (STPS)
Page 77: Diagnostic Information And Procedures
Engine General Information and Diagnosis: 1A-8 Diagnostic Information and Procedures Engine Symptom Diagnosis B822H11104001 Condition Possible cause Correction / Reference Item Engine will not start or is Valve clearance out of adjustment. Adjust. hard to start Worn valve guide or poor seating of Repair or replace.
Page 78 1A-9 Engine General Information and Diagnosis: Condition Possible cause Correction / Reference Item Engine stalls often Defective IAP sensors or circuit. Repair or replace. (Incorrect fuel/air mixture) Clogged fuel filter. Clean or replace. Defective fuel pump. Replace. Defective fuel pressure regulator. Replace.
Page 79 Engine General Information and Diagnosis: 1A-10 Condition Possible cause Correction / Reference Item Noisy engine (Noise Too much play on pump shaft bearing. Replace. seems to come from Worn or damaged impeller shaft. Replace. water pump) Worn or damaged mechanical seal. Replace.
Page 80 1A-11 Engine General Information and Diagnosis: Condition Possible cause Correction / Reference Item Engine lacks power Low fuel pressure. Repair or replace. (Defective control circuit Defective TP sensor. Replace. or sensor) Defective IAT sensor. Replace. Defective CKP sensor. Replace. Defective GP sensor. Replace.
Page 81: Self-Diagnostic Procedures
Engine General Information and Diagnosis: 1A-12 Self-Diagnostic Procedures 3) Start the engine or crank the engine for more than 4 B822H11104002 seconds. Use of Mode Select Switch 4) Turn the special tool’s switch ON. NOTE 5) Check the DTC to determine the malfunction part. Refer to “DTC Table (Page 1A-20)”.
Page 82 1A-13 Engine General Information and Diagnosis: Use of SDS NOTE • Do not disconnect the coupler from ECM, battery cable from battery, ECM ground wire from the engine or main fuse before confirming DTC (Diagnostic Trouble Code) stored in memory. Such disconnection will erase the memorized information in ECM memory.
Page 83: Use Of Sds Diagnosis Reset Procedures
Engine General Information and Diagnosis: 1A-14 3) Check the DTC. 4) Start the engine or crank the engine for more than 4 seconds. 4) The previous malfunction history code (Past DTC) 5) Check the DTC to determine the malfunction part. still remains stored in the ECM.
Page 84: Show Data When Trouble (Displaying Data At The Time Of Dtc)
1A-15 Engine General Information and Diagnosis: Show Data When Trouble (Displaying Data at the Time of DTC) B822H11104004 Use of SDS ECM stores the engine and driving conditions (in the form of data as shown in the figure) at the moment of the detection of a malfunction in its memory.
Page 85 Engine General Information and Diagnosis: 1A-16 1) Click “Show data when trouble” (1) to display the data. I718H1110269-02 2) Click the drop down button (2), either “Failure #1” or “Failure #2” can be selected. I718H1110270-01...
Page 86: Sds Check
1A-17 Engine General Information and Diagnosis: SDS Check B822H11104005 Using SDS, sample the data at the time of new and periodic vehicle inspections. After saving the sampled data in the computer, file them by model and by user. The periodically filed data help improve the accuracy of troubleshooting since they can indicate the condition of vehicle functions that has changed with time.
Page 87 Engine General Information and Diagnosis: 1A-18 Data at 3 000 r/min under no load Approx. 3 000 r/min Check the manifold absolute pressure. XXX kPa Check the water temperature. XX °C I822H1110149-03 Data at the time of racing Throttle: Slowly open Throttle: Quick wide open Secondary throttle valve opens...
Page 88 1A-19 Engine General Information and Diagnosis: Data of intake negative pressure during idling (100 °C) Check the engine coolant temperature. XX °C Check the manifold absolute pressure. XXX kPa I822H1110151-03 Data of manifold absolute pressure operation at the time of starting Check the manifold absolute pressure.
Page 89: Dtc Table
Engine General Information and Diagnosis: 1A-20 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 comparison by showing them in the graph. Read the change of value by comparing the current data to the past data that have been saved under the same condition, then you may determine how changes have occurred with the passing of time and identify what problem is currently occurring.
Page 90 1A-21 Engine General Information and Diagnosis: Code Malfunction Part Remarks C25 (P0352) Ignition signal #2 (IG coil #2, 1) For #2 cylinder (Page 1A-64) C26 (P0353) Ignition signal #1 (IG coil #1, 2) For #1 cylinder (Page 1A-64) C27 (P0354) Ignition signal #2 (IG coil #2, 2) For #2 cylinder (Page 1A-64)
Page 91: Fail-Safe Function Table
Engine General Information and Diagnosis: 1A-22 Fail-Safe Function Table B822H11104007 FI system is provided with fail-safe function to allow the engine to start and the motorcycle to run in a minimum performance necessary even under malfunction condition. Item Fail-Safe Mode Starting Ability Running Ability Intake air pressure value is fixed to 101 kPa...
Page 92: Fi System Troubleshooting
1A-23 Engine General Information and Diagnosis: FI System Troubleshooting B822H11104008 Customer Complaint Analysis Record details of the problem (failure, complaint) and how it occurred as described by the customer. For this purpose, use of such an inspection form such as following will facilitate collecting information to the point required for proper analysis and diagnosis.
Page 93: Malfunction Code And Defective Condition Table
Engine General Information and Diagnosis: 1A-24 Visual Inspection Prior to diagnosis using the mode select switch or SDS, perform the following visual inspections. The reason for visual inspection is that mechanical failures (such as oil leakage) cannot be displayed on the screen with the use of mode select switch or SDS.
Page 94 1A-25 Engine General Information and Diagnosis: Malfunction Detected Item Detected Failure Condition Check For Code The sensor voltage should be the following. 0.15 V ≤ Sensor voltage < 4.85 V IAT sensor, lead wire/coupler In other than the above range, C21 (P0110) is connection indicated.
Page 95 Engine General Information and Diagnosis: 1A-26 Malfunction Detected Item Detected Failure Condition Check For Code No voltage is applied to the fuel pump, Fuel pump relay, lead wire/ although fuel pump relay is turned ON, or coupler connection, power voltage is applied to fuel pump although fuel source to fuel pump relay and pump relay is turned OFF.
Page 96: Dtc "C12" (P0335): Ckp Sensor Circuit Malfunction
1A-27 Engine General Information and Diagnosis: DTC “C12” (P0335): CKP Sensor Circuit Malfunction B822H11104010 Detected Condition and Possible Cause Detected Condition Possible Cause The signal does not reach ECM for 3 sec. or more, after • Metal particles or foreign material being stuck on the receiving the starter signal.
Page 97 Engine General Information and Diagnosis: 1A-28 Troubleshooting CAUTION When using the multi-circuit tester, do not strongly touch the terminal of the ECM coupler with a needle pointed tester probe to prevent terminal damage. NOTE After repairing the trouble, clear the DTC using SDS tool. Refer to “Use of SDS Diagnosis Reset Procedures (Page 1A-14)”.
Page 98 1A-29 Engine General Information and Diagnosis: Step Action 7) If OK, then check the continuity between each terminal Go to Step 2. Replace the CKP and ground. sensor with a new one. Special tool (A): 09900–25008 (Multi-circuit tester set) CKP sensor continuity ∞...
Page 99: Dtc "C13" (P1750-H/L) Or "C17" (P0105-H/L): Iap Sensor Circuit Malfunction
Engine General Information and Diagnosis: 1A-30 DTC “C13” (P1750-H/L) or “C17” (P0105-H/L): IAP Sensor Circuit Malfunction B822H11104011 Detected Condition and Possible Cause Detected Condition Possible Cause IAP sensor voltage is not within the • Clogged vacuum passage between throttle body and following range.
Page 100 1A-31 Engine General Information and Diagnosis: Troubleshooting CAUTION When using the multi-circuit tester, do not strongly touch the terminal of the ECM coupler with a needle pointed tester probe to prevent terminal damage. NOTE After repairing the trouble, clear the DTC using SDS tool. Refer to “Use of SDS Diagnosis Reset Procedures (Page 1A-14)”.
Page 101 Engine General Information and Diagnosis: 1A-32 When indicating P1750-H for IAP sensor #2 / When indicating P0105-H for IAP sensor #1 (Use of SDS) Step Action 1) Turn the ignition switch OFF. Go to Step 2. G/B or Bl/R wire shorted to VCC, or B/Br wire 2) Remove the fuel tank.
Page 102 1A-33 Engine General Information and Diagnosis: Step Action 6) Disconnect the ECM coupler. Refer to “ECM Removal Go to Step 2. G/B or Bl/R wire shorted and Installation in Section 1C (Page 1C-1)”. to VCC, or B/Br wire open. 7) Insert the needle pointed probes to the lead wire coupler. 8) Check the continuity between Bl/R wire and terminal “26”...
Page 103 Engine General Information and Diagnosis: 1A-34 When indicating P1750-L for IAP sensor #2 / When indicating P0105-L for IAP sensor #1 (Use of SDS) Step Action 1) Turn the ignition switch OFF. Go to Step 2. • R and Bl/R or G/B wire open.
Page 104 1A-35 Engine General Information and Diagnosis: Step Action 6) Disconnect the ECM coupler. Refer to “ECM Removal Go to Step 2. • R and Bl/R or G/B and Installation in Section 1C (Page 1C-1)”. wire open. 7) Insert the needle pointed probes to the lead wire coupler. •...
Page 105 Engine General Information and Diagnosis: 1A-36 Step Action 1) Connect the IAP sensor coupler and ECM coupler. Go to Step 3. • Check the vacuum hose for crack or 2) Connect the fuel feed hose and fuel pump read wire damage.
Page 106 1A-37 Engine General Information and Diagnosis: Step Action 1) Turn the ignition switch OFF. • R, Bl/R or B/Br wire If check result is not open or shorted to satisfactory, replace the 2) Remove the IAP sensor. Refer to “IAP Sensor Removal ground, or poor “11”, IAP sensor with a new and Installation in Section 1C (Page 1C-2)”.
Page 107: Dtc "C14" (P0120-H/L): Tp Sensor Circuit Malfunction
Engine General Information and Diagnosis: 1A-38 DTC “C14” (P0120-H/L): TP Sensor Circuit Malfunction B822H11104012 Detected Condition and Possible Cause Detected Condition Possible Cause Output voltage is not within the following • TP sensor maladjusted. range. • TP sensor circuit open or short. Difference between actual throttle opening •...
Page 108 1A-39 Engine General Information and Diagnosis: C14 (Use of mode select switch) Step Action 1) Turn the ignition switch OFF. Go to Step 3. • Loose or poor contacts on the ECM 2) Remove the right air cleaner box. Refer to “Air Cleaner coupler.
Page 109 Engine General Information and Diagnosis: 1A-40 P0120-H (Use of SDS) Step Action 1) Turn the ignition switch OFF. Go to Step 3. P/B wire shorted to VCC, or B/Br wire open. 2) Remove the right air cleaner box. Refer to “Air Cleaner Element Removal and Installation in Section 1D (Page 1D-6)”.
Page 110 1A-41 Engine General Information and Diagnosis: Step Action 6) Disconnect the ECM coupler. Refer to “ECM Removal Go to Step 3. P/B wire shorted to and Installation in Section 1C (Page 1C-1)”. VCC, or B/Br wire open. 7) Check the continuity between the P/B wire “A” and terminal “8”.
Page 111 Engine General Information and Diagnosis: 1A-42 P0120-L (Use of SDS) Step Action 1) Turn the ignition switch OFF. Go to Step 2. R and P/B wire open, or P/B wire shorted to 2) Remove the right air cleaner box. Refer to “Air Cleaner ground.
Page 112 1A-43 Engine General Information and Diagnosis: Step Action 6) Disconnect the ECM coupler. Refer to “ECM Removal Go to Step 2. R and P/B wire open, or and Installation in Section 1C (Page 1C-1)”. P/B wire shorted to ground. 7) Check the continuity between the P/B wire “A” and terminal “8”.
Page 113 Engine General Information and Diagnosis: 1A-44 Step Action 1) Turn the ignition switch OFF. Go to Step 3. • Reset the TP sensor position correctly. 2) Disconnect the TP sensor coupler. • Replace the TP 3) Connect the test harness to the TP sensor. sensor with a new 4) Check the continuity between terminal “C”...
Page 114 1A-45 Engine General Information and Diagnosis: Step Action 7) If OK, then measure the TP sensor resistance at the test Go to Step 3. • Reset the TP sensor harness terminals (between terminal “D” and terminal position correctly. “E”). • Replace the TP sensor with a new Special tool one.
Page 115 Engine General Information and Diagnosis: 1A-46 Step Action 1) Turn the ignition switch OFF. • P/B, R or B/Br wire If check result is not open or shorted to satisfactory, replace TP 2) Connect the special tool between the TP sensor and its ground, or poor “8”, sensor with a new one.
Page 116: Dtc "C15" (P0115-H/L): Ect Sensor Circuit Malfunction
1A-47 Engine General Information and Diagnosis: DTC “C15” (P0115-H/L): ECT Sensor Circuit Malfunction B822H11104013 Detected Condition and Possible Cause Detected Condition Possible Cause Output voltage is not with in the following • ECT sensor circuit open or short. range. • ECT sensor malfunction. 0.15 V ≤...
Page 117 Engine General Information and Diagnosis: 1A-48 C15 (Use of mode select switch) Step Action 1) Turn the ignition switch OFF. Go to Step 2. • Loose or poor contacts on the ECM 2) Remove the right air cleaner box. Refer to “Air Cleaner coupler.
Page 118 1A-49 Engine General Information and Diagnosis: P0115-H (Use of SDS) Step Action 1) Turn the ignition switch OFF. Go to Step 2. B/Bl or B/Br wire open. 2) Remove the right air cleaner box. Refer to “Air Cleaner Element Removal and Installation in Section 1D (Page 1D-6)”.
Page 119 Engine General Information and Diagnosis: 1A-50 P0115-L (Use of SDS) Step Action 1) Turn the ignition switch OFF. Go to Step 2. • B/Bl wire shorted to ground. 2) Remove the right air cleaner box. Refer to “Air Cleaner Element Removal and Installation in Section 1D •...
Page 120 1A-51 Engine General Information and Diagnosis: Step Action 8) Turn the ignition switch ON. Go to Step 2. • B/Bl wire shorted to ground. 9) Measure the output voltage between the B/Bl wire and ground. • If wire is OK, go to Step 2.
Page 121: Dtc "C21" (P0110-H/L): Iat Sensor Circuit Malfunction
Engine General Information and Diagnosis: 1A-52 DTC “C21” (P0110-H/L): IAT Sensor Circuit Malfunction B822H11104015 Detected Condition and Possible Cause Detected Condition Possible Cause Output voltage is not with in the following • IAT sensor circuit open or short. range. • IAT sensor malfunction. 0.15 V ≤...
Page 122 1A-53 Engine General Information and Diagnosis: C21 (Use of mode select switch) Step Action 1) Turn the ignition switch OFF. Go to Step 2. • Loose or poor contacts on the ECM 2) Remove the fuel tank. Refer to “Fuel Tank Removal and coupler.
Page 123 Engine General Information and Diagnosis: 1A-54 P0110-H (Use of SDS) Step Action 1) Turn the ignition switch OFF. Connect the ECM Dg or B/Br wire open. coupler and go to Step 2) Remove the fuel tank. Refer to “Fuel Tank Removal and Installation in Section 1G (Page 1G-8)”.
Page 124 1A-55 Engine General Information and Diagnosis: P0110-L (Use of SDS) Step Action 1) Turn the ignition switch OFF. Go to Step 2. • Dg wire shorted to ground. 2) Remove the fuel tank. Refer to “Fuel Tank Removal and Installation in Section 1G (Page 1G-8)”. •...
Page 125 Engine General Information and Diagnosis: 1A-56 Step Action 9) Measure the output voltage between the Dg wire and Go to Step 2. • Dg wire shorted to ground. ground. • If wire is OK, go to Special tool Step 2. (A): 09900–25008 (Multi-circuit tester set) (B): 09900–25009 (Needle pointed probe set) Tester knob indication...
Page 126: Dtc "C23" (P1651-H/L): To Sensor Circuit Malfunction
1A-57 Engine General Information and Diagnosis: DTC “C23” (P1651-H/L): TO Sensor Circuit Malfunction B822H11104016 Detected Condition and Possible Cause Detected Condition Possible Cause The sensor voltage should be the • TO sensor circuit open or short. following for 2 sec. and more, after ignition •...
Page 127 Engine General Information and Diagnosis: 1A-58 Troubleshooting CAUTION When using the multi-circuit tester, do not strongly touch the terminal of the ECM coupler with a needle pointed tester probe to prevent terminal damage. NOTE After repairing the trouble, clear the DTC using SDS tool. Refer to “Use of SDS Diagnosis Reset Procedures (Page 1A-14)”.
Page 128 1A-59 Engine General Information and Diagnosis: P1651-H (Use of SDS) Step Action 1) Turn the ignition switch OFF. Go to Step 2. B wire shorted to VCC, or B/Br wire open. 2) Remove the right frame cover. Refer to “Exterior Parts Removal and Installation in Section 9D (Page 9D-3)”.
Page 129 Engine General Information and Diagnosis: 1A-60 Step Action 6) Disconnect the ECM coupler. Refer to “ECM Removal Go to Step 2. B wire shorted to VCC, and Installation in Section 1C (Page 1C-1)”. or B/Br wire open. 7) Insert the needle pointed probes to the lead wire coupler. 8) Check the continuity between the B wire “B”...
Page 130 1A-61 Engine General Information and Diagnosis: P1651-L (Use of SDS) Step Action 1) Turn the ignition switch OFF. Go to Step 2. R or B wire open, or B wire shorted to ground. 2) Remove the right frame cover. Refer to “Exterior Parts Removal and Installation in Section 9D (Page 9D-3)”.
Page 131 Engine General Information and Diagnosis: 1A-62 Step Action 6) Disconnect the ECM coupler. Refer to “ECM Removal Go to Step 2. R or B wire open, or B and Installation in Section 1C (Page 1C-1)”. wire shorted to ground. 7) Insert the needle pointed probes to the lead wire coupler. 8) Check the continuity between the R wire “C”...
Page 132 1A-63 Engine General Information and Diagnosis: Step Action 1) Connect the ECM coupler and TO sensor coupler. • R, B or B/Br wire • Loosen or poor open or shorted to contacts on the ECM 2) Remove the TO sensor. Refer to “TO Sensor Removal ground, or poor “11”, coupler.
Page 133: Dtc "C24" (P0351), "C25" (P0352), "C26" (P0353) Or "C27" (P0354): Ignition System Malfunction
Engine General Information and Diagnosis: 1A-64 DTC “C24” (P0351), “C25” (P0352), “C26” (P0353) or “C27” (P0354): Ignition System Malfunction B822H11104017 NOTE • Refer to “No Spark or Poor Spark in Section 1H (Page 1H-3)” for details. • When indicating “C24” (P0351) and “C26” (P0353) for #1 •...
Page 134 1A-65 Engine General Information and Diagnosis: Troubleshooting CAUTION When using the multi-circuit tester, do not strongly touch the terminal of the ECM coupler with a needle pointed tester probe to prevent terminal damage. NOTE After repairing the trouble, clear the DTC using SDS tool. Refer to “Use of SDS Diagnosis Reset Procedures (Page 1A-14)”.
Page 135 Engine General Information and Diagnosis: 1A-66 Step Action 1) Turn the ignition switch OFF. • B/Lg, P/W, G and W/ • Loose or poor B wire open or contacts on the ECM 2) Disconnect the STVA lead wire coupler. shorted to ground, or coupler.
Page 136 1A-67 Engine General Information and Diagnosis: Active Control Inspection 1) Set up the SDS tool. (Refer to the SDS operation manual for further details.) 2) Turn the ignition switch ON. 3) Click “Secondary throttle operating control” (1). I822H1110060-01 4) Click each button (2). At this time, if an operation sound is heard from the STVA, the function is normal.
Page 137: Dtc "C29" (P1654-H/L): Secondary Throttle Position Sensor (Stps) Circuit Malfunction
Engine General Information and Diagnosis: 1A-68 DTC “C29” (P1654-H/L): Secondary Throttle Position Sensor (STPS) Circuit Malfunction B822H11104019 Detected Condition and Possible Cause Detected Condition Possible Cause Output voltage is not within the following • STP sensor maladjusted. range. • STP sensor circuit open or short. Difference between actual throttle opening •...
Page 138 1A-69 Engine General Information and Diagnosis: C29 (Use of mode select switch) Step Action 1) Turn the ignition switch OFF. Go to Step 2. • Loose or poor contacts on the ECM 2) Remove the right air cleaner box. Refer to “Air Cleaner coupler.
Page 139 Engine General Information and Diagnosis: 1A-70 P1654-H (Use of SDS) Step Action 1) Turn the ignition switch OFF. Go to Step 3. Y/W wire shorted to VCC, or B/Br wire open. 2) Remove the right air cleaner box. Refer to “Air Cleaner Element Removal and Installation in Section 1D (Page 1D-6)”.
Page 140 1A-71 Engine General Information and Diagnosis: Step Action 6) Disconnect the ECM coupler. Refer to “ECM Removal Go to Step 3. Y/W wire shorted to and Installation in Section 1C (Page 1C-1)”. VCC, or B/Br wire open. 7) Check the continuity between the Y/W wire “A” and terminal “20”.
Page 141 Engine General Information and Diagnosis: 1A-72 P1654-L (Use of SDS) Step Action 1) Turn the ignition switch OFF. Go to Step 2. R or Y/W wire open, or Y/W wire shorted to 2) Remove the right air cleaner box. Refer to “Air Cleaner ground.
Page 142 1A-73 Engine General Information and Diagnosis: Step Action 6) Disconnect the ECM coupler. Refer to “ECM Removal Go to Step 2. R or Y/W wire open, or and Installation in Section 1C (Page 1C-1)”. Y/W wire shorted to ground. 7) Check the continuity between the Y/W wire “A” and terminal “20”.
Page 143 Engine General Information and Diagnosis: 1A-74 Step Action 1) Turn the ignition switch OFF. • R, Y/W or B/Br wire If check result is not open or shorted to satisfactory, replace the 2) Connect the ECM coupler. ground, or poor “11”, STP sensor with a new 3) Connect the special tool between the TP sensor and its “20”...
Page 144: Dtc "C31" (P0705): Gp Switch Circuit Malfunction
1A-75 Engine General Information and Diagnosis: DTC “C31” (P0705): GP Switch Circuit Malfunction B822H11104020 Detected Condition and Possible Cause Detected Condition Possible Cause No Gear Position switch voltage • GP switch circuit open or short. GP switch voltage is not within the following range. •...
Page 145 Engine General Information and Diagnosis: 1A-76 Step Action 1) Turn the ignition switch OFF. • P wire open or • P or B wire open, or P shorted to ground. wire shorted to 2) Remove the left side cover (All models) and EVAP ground.
Page 146: Dtc "C32" (P0201), "C33" (P0202): Fuel Injector Circuit Malfunction
1A-77 Engine General Information and Diagnosis: DTC “C32” (P0201), “C33” (P0202): Fuel Injector Circuit Malfunction B822H11104021 Detected Condition and Possible Cause Detected Condition Possible Cause CKP signal is produced but fuel injector signal is • Injector circuit open or short. interrupted by 4 times or more continuity.
Page 147 Engine General Information and Diagnosis: 1A-78 Troubleshooting CAUTION When using the multi-circuit tester, do not strongly touch the terminal of the ECM coupler with a needle pointed tester probe to prevent terminal damage. NOTE After repairing the trouble, clear the DTC using SDS tool. Refer to “Use of SDS Diagnosis Reset Procedures (Page 1A-14)”.
Page 148 1A-79 Engine General Information and Diagnosis: Step Action 5) If OK, then check the continuity between each terminal Go to Step 2. Replace the injector and ground. with a new one. Refer to “Throttle Body Special tool Disassembly and (A): 09900–25008 (Multi-circuit tester set) Assembly in Section 1D Injector continuity (Page 1D-12)”.
Page 149: Dtc "C40" (P0505 / P0506 / P0507): Isc Valve Circuit Malfunction
Engine General Information and Diagnosis: 1A-80 DTC “C40” (P0505 / P0506 / P0507): ISC Valve Circuit Malfunction B822H11104022 Detected Condition and Possible Cause Detected Condition Possible Cause ISC valve motor current is higher than • ISC valve circuit shorted to BATT or ground circuit open. C40/P0505 the specified value.
Page 150 1A-81 Engine General Information and Diagnosis: Step Action 1) Turn the ignition switch OFF. Go to Step 2. Lbl, W/Y, Dgr, R/Bl or Lg wire open. 2) Remove the fuel tank. Refer to “Fuel Tank Removal and Installation in Section 1G (Page 1G-8)”. 3) Check the ISC valve coupler (1) for loose or poor contacts.
Page 151 Engine General Information and Diagnosis: 1A-82 Step Action 1) Check the continuity between each ISC valve terminal If wire is OK, Replace the ISC valve “G” and “I”, terminal “H” and “J”. intermittent trouble or with a new one. Refer to faulty ECM.
Page 152 1A-83 Engine General Information and Diagnosis: Active Control Inspection (ISC RPM Control) Check 2 Check 1 1) Click the button (4) and decrease the “Spec” (2) to 800 rpm slowly. 1) Set up the SDS tool. (Refer to the SDS operation manual for further details.) 2) Check that the “Desired idle speed”...
Page 153: Dtc "C41" (P0230-H/L): Fp Relay Circuit Malfunction
Engine General Information and Diagnosis: 1A-84 DTC “C41” (P0230-H/L): FP Relay Circuit Malfunction B822H11104023 Detected Condition and Possible Cause Detected Condition Possible Cause No voltage is applied to fuel pump. • Fuel pump relay circuit open or short. • Fuel pump relay malfunction. Voltage is applied to fuel pump although •...
Page 154 1A-85 Engine General Information and Diagnosis: C41 (Use of mode select switch) Step Action 1) Turn the ignition switch OFF. • Y/B or O/W wire open Replace the FP relay or shorted or poor with a new one. 2) Remove the battery and battery holder. Refer to “Battery “39”...
Page 155: Dtc "C42" (P1650): Ig Switch Circuit Malfunction
Engine General Information and Diagnosis: 1A-86 P0230-L (Use of SDS) Step Action 1) Turn the ignition switch OFF. • Y/B wire open or poor Replace the FP relay “39” connection. with a new one. 2) Remove the battery and battery holder. Refer to “Battery / Battery Holder Removal and Installation in Section 1J •...
Page 156: Dtc "C44" (P0156) Or "C64" (P0130): O2 Sensor (O2S) Circuit Malfunction (For
1A-87 Engine General Information and Diagnosis: DTC “C44” (P0156) or “C64” (P0130): O2 Sensor (O2S) Circuit Malfunction (For E-02, 19, 24, 33) B822H11104026 Detected Condition and Possible Cause Detected Condition Possible Cause C44/C64 O2 sensor output voltage is not input to •...
Page 157 Engine General Information and Diagnosis: 1A-88 Troubleshooting CAUTION When using the multi-circuit tester, do not strongly touch the terminal of the ECM coupler with a needle pointed tester probe to prevent terminal damage. NOTE After repairing the trouble, clear the DTC using SDS tool. Refer to “Use of SDS Diagnosis Reset Procedures (Page 1A-14)”.
Page 158 1A-89 Engine General Information and Diagnosis: Step Action 4) Disconnect the O2 sensor coupler. Go to Step 2. W/G or W/Bl wire shorted to the power 5) Check the continuity between the W/G (#1) wire or W/Bl source, or W/G and W/ (#2) wire “A”...
Page 159 Engine General Information and Diagnosis: 1A-90 Step Action 1) Connect the ECM coupler and O2 sensor coupler. • W/G, W/Bl or B/Br Replace the O2 sensor wire open or shorted with a new one. Refer to 2) Warm up the engine enough. to the power source, “Oxygen Sensor (O2S) 3) Insert the needle pointed probes to the lead wire coupler.
Page 160: Dtc "C46" (P1657-H/L Or P1658): Excv Actuator Circuit Malfunction
1A-91 Engine General Information and Diagnosis: DTC “C46” (P1657-H/L or P1658): EXCV Actuator Circuit Malfunction B822H11104033 Detected Condition Possible Cause The operation signal does not reach the • EXCVA maladjusted. EXCV actuator. • EXCVA circuit open or short. EXCVA position sensor voltage low or •...
Page 161 Engine General Information and Diagnosis: 1A-92 Troubleshooting CAUTION When using the multi-circuit taster, do not strongly touch the terminal of the ECM coupler with a needle pointed tester probe to prevent terminal damage. NOTE After repairing the trouble, clear the DTC using SDS tool. Refer to “Use of SDS Diagnosis Reset Procedures (Page 1A-14)”.
Page 162 1A-93 Engine General Information and Diagnosis: P1657-H (Use of SDS) Step Action 1) Turn the ignition switch OFF. Go to Step 4. Lbl wire shorted to VCC, or B/Br wire open. 2) Remove the right frame cover (All models) and EVAP canister (For E-33).
Page 163 Engine General Information and Diagnosis: 1A-94 Step Action 7) Check the continuity between Y wire “A” and terminal Go to Step 4. Lbl wire shorted to VCC, “5”. or B/Br wire open. Also, check the continuity between B/Br wire “B” and terminal “29”.
Page 164 1A-95 Engine General Information and Diagnosis: P1657-L (Use of SDS) Step Action 1) Turn the ignition switch OFF. Go to Step 2 and go to R or Y wire open, or Y Step 4. wire shorted to ground. 2) Remove the right frame cover (All models) and EVAP canister (For E-33).
Page 165 Engine General Information and Diagnosis: 1A-96 Step Action 6) Disconnect the ECM coupler. Go to Step 2 and go to R or Y wire open, or Y Step 4. wire shorted to ground. 7) Check the continuity between Y wire “A” and terminal “5”.
Page 166 1A-97 Engine General Information and Diagnosis: Step Action 1) Disconnect the EXCVA position sensor coupler (1). Go to Step 3. • Loose or poor contacts on the ECM coupler (terminal “11” or “29”). • Open or short circuit in the R or B/Br wire. I822H1110111-01 2) Turn the ignition switch ON.
Page 167 Engine General Information and Diagnosis: 1A-98 Step Action 1) Turn the ignition switch OFF. Go to Step 4. Replace the EXCVA with a new one. 2) Check the continuity between Y wire and ground. EXCVA position sensor continuity ∞ Ω (Infinity) I822H1110112-01 3) If OK, then measure the EXCVA position sensor resistance.
Page 168 1A-99 Engine General Information and Diagnosis: Step Action 1) Turn the ignition switch OFF. Replace the ECM with a Go to Step 5. known good one, and 2) Connect the EXCVA position sensor coupler (1). inspect it again. 3) Disconnect the EXCVA motor coupler (2). 4) Measure the EXCVA position sensor output voltage at EXCV fully closed position and fully opened position.
Page 169 Engine General Information and Diagnosis: 1A-100 Step Action 8) Then, to set the EXCV to fully opened position, apply 12 Replace the ECM with a Go to Step 5. V to the terminals oppositely. known good one, and Positive wire – Gr wire terminal inspect it again.
Page 170 1A-101 Engine General Information and Diagnosis: Step Action 1) If the EXCVA position sensor output voltage is 0.5 V and Replace the ECM with a Replace the EXCVA less at EXCV fully closed position, adjust the output known good one, and with a new one.
Page 171 Engine General Information and Diagnosis: 1A-102 Step Action 1) Turn the ignition switch OFF. • Loose or poor • Replace the EXCVA contacts on the with a new one. 2) Disconnect the EXCVA motor coupler (1). EXCVA or ECM • Inspect that the coupler (terminal “4”...
Page 172 1A-103 Engine General Information and Diagnosis: Active Control Inspection 1) Set up the SDS tool. (Refer to the SDS operation manual for further details.) 2) Turn the ignition switch ON. 3) Click “Exhaust valve operating control” (1). I822H1110120-01 4) Click each button (2). At this time, if an operation sound is heard from the EXCVA, the function is normal.
Page 173: Dtc "C60" (P0480): Cooling Fan Relay Circuit Malfunction
Engine General Information and Diagnosis: 1A-104 DTC “C60” (P0480): Cooling Fan Relay Circuit Malfunction B822H11104028 Detected Condition and Possible Cause Detected Condition Possible Cause Cooling fan relay signal is not input to ECM. • Cooling fan relay circuit open or short. •...
Page 174 1A-105 Engine General Information and Diagnosis: Step Action 1) Turn the ignition switch OFF. • O/B and O/R wire Replace the cooling fan open or shorted to relay with a new one. 2) Remove the battery holder. Refer to “Battery / Battery ground, or poor “43”...
Page 175 Engine General Information and Diagnosis: 1A-106 4) Click the “Operate” (2). At this time, if an operation sound is heard from the cooling fan relay and cooling fan motors are operated, the function is normal. NOTE Cooling fan relay and cooling fan motor operation can be checked until the engine coolant temperature is less than 100 °C (212 °F) after starting the engine.
Page 176: Dtc "C61" (P1656): Pair Control Solenoid Valve Circuit Malfunction
1A-107 Engine General Information and Diagnosis: DTC “C61” (P1656): PAIR Control Solenoid Valve Circuit Malfunction B822H11104027 Detected Condition and Possible Cause Detected Condition Possible Cause PAIR control solenoid valve voltage is not input to ECM. • PAIR control solenoid valve circuit open or short. •...
Page 177 Engine General Information and Diagnosis: 1A-108 Troubleshooting CAUTION When using the multi-circuit tester, do not strongly touch the terminal of the ECM coupler with a needle pointed tester probe to prevent terminal damage. NOTE After repairing the trouble, clear the DTC using SDS tool. Refer to “Use of SDS Diagnosis Reset Procedures (Page 1A-14)”.
Page 178 1A-109 Engine General Information and Diagnosis: Step Action 1) Turn the ignition switch ON. • R/Y wire open or Open or short circuit in shorted to ground, or the O/B wire. 2) Measure the voltage between the O/W wire and ground. poor “44”...
Page 179: Dtc "C62" (P0443): Evap System Purge Control Solenoid Valve Circuit Malfunction (For
Engine General Information and Diagnosis: 1A-110 4) Click each button (2). At this time, if an operating sound is heard from the PAIR control solenoid valve, the function is normal. I822H1110127-01 DTC “C62” (P0443): EVAP System Purge Control Solenoid Valve Circuit Malfunction (For E-33) B822H11104030 Detected Condition and Possible Cause Detected Condition...
Page 180 1A-111 Engine General Information and Diagnosis: Troubleshooting CAUTION When using the multi-circuit tester, do not strongly touch the terminal of the ECM coupler with a needle pointed tester probe to prevent terminal damage. NOTE After repairing the trouble, clear the DTC using SDS tool. Refer to “Use of SDS Diagnosis Reset Procedures (Page 1A-14)”.
Page 181 Engine General Information and Diagnosis: 1A-112 Step Action 1) Turn the ignition switch ON. • W/Y wire open or Open or short circuit in shorted to ground, or the O/W wire. 2) Measure the voltage between the O/W wire and ground. poor “15”...
Page 182 1A-113 Engine General Information and Diagnosis: Active Control Inspection 1) Set up the SDS tool. (Refer to SDS operation manual for further details.) 2) Turn the ignition switch ON. 3) Click “EVAP purge valve operating control” (1). I822H1110137-01 4) Click each button (2). At this time, if an operating sound is heard from the EVAP system purge control valve, the function is normal.
Page 183: Specifications
Engine General Information and Diagnosis: 1A-114 Specifications Service Data B822H11107001 Injector Item Specification Note 11 – 13 Ω at 23 °C (73 °F) Injector resistance FI Sensors Item Specification Note 190 – 290 Ω CKP sensor resistance CKP sensor peak voltage 1.5 V and more When cranking IAP sensor input voltage (F &...
Page 184: Special Tools And Equipment
1A-115 Engine General Information and Diagnosis: Special Tools and Equipment Special Tool B822H11108001 09900–25008 09900–25009 Multi-circuit tester set Needle pointed probe set (Page 1A-28) / (Page 1A-32) / (Page 1A-29) / (Page 1A-33) / (Page 1A-29) / (Page 1A-34) / (Page 1A-111) / (Page 1A-35) / (Page 1A-112) /...
Page 185 Engine General Information and Diagnosis: 1A-116 09900–28630 09904–41010 TPS test wire harness SDS set (Page 1A-44) / (Page 1A-13) / (Page 1A-45) / (Page 1A-17) (Page 1A-46) / (Page 1A-74) 09917–47011 09930–82720 Vacuum pump gauge Mode select switch (Page 1A-37) (Page 1A-3) / (Page 1A- 12) /...
Page 186: Emission Control Devices
Fuel Injection System Description B822H11201001 VLR1800 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 187: Crankcase Emission Control System Description
Emission Control Devices: 1B-2 Crankcase Emission Control System Description B822H11201002 The engine is equipped with a PCV system to prevent discharging crankcase emissions into the atmosphere. Blow-by gas in the engine is constantly drawn into the crankcase, which is returned to the combustion chamber through the PCV (breather) hose, air cleaner and throttle body.
Page 188: Exhaust Emission Control System Description
1B-3 Emission Control Devices: Exhaust Emission Control System Description B822H11201003 The exhaust emission control system is composed of the PAIR system, exhaust control system, O2 sensor and catalyst system. The fresh air is drawn into the exhaust port through the PAIR control solenoid valve and PAIR reed valve.
Page 189: Noise Emission Control System Description
Emission Control Devices: 1B-4 Noise Emission Control System Description B822H11201004 TAMPERING WITH THE NOISE CONTROL SYSTEM PROHIBITED: Local law or federal law prohibits the following acts or the causing thereof: • The removal or rendering inoperative by any person, other than for purposes of maintenance, repair or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use, or •...
Page 190: Evaporative Emission Control System
1B-5 Emission Control Devices: Evaporative Emission Control System Diagram (Only for E-33) B822H11201005 “A” “B” “C” “D” I822H1120034-01 1. Fuel-vapor separator 7. EVAP canister “A”: Fuel 2. Fuel tank 8. Purge hose “B”: HC vapor 3. Fuel pump 9. EVAP purge control valve “C”: Fresh air 4.
Page 191: Schematic And Routing Diagram
Emission Control Devices: 1B-6 Schematic and Routing Diagram PAIR System Hose Routing Diagram B822H11202002 For E-02, 19, 24, 33 “D” “A” “A” “ a ” “ a ” “B” “B” “ a ” “ a ” “ a ” “C” “...
Page 192 1B-7 Emission Control Devices: For E-03, 28 “C” “A” “A” “ a ” “ a ” “B” “B” “ a ” “A” “B” “ a ” I822H1120033-01 1. PAIR reed valve “C”: Set the PAIR hose to the concave of the air cleaner tube. “A”: White mark “a”: 0°...
Page 193: Evap Canister Hose Routing Diagram
Emission Control Devices: 1B-8 EVAP Canister Hose Routing Diagram (Only for E-33) B822H11202001 “B” “C” “A” “F” “E” “D” “G” “F” “H” “I” I822H1120035-02 1. EVAP canister “B”: Face the tip of the clip to backward. 2. Fuel shut-off valve “C”: Face the tip of the clip to upper.
Page 194: Repair Instructions
1B-9 Emission Control Devices: Repair Instructions Oxygen Sensor (O2S) Removal and Installation 5) Disconnect the O2 sensor (#2 cylinder) read wire B822H11206001 coupler (3). Removal WARNING Do not remove the O2 sensor while it is hot. CAUTION • Be careful not to expose the O2 sensor to excessive shock.
Page 195: Heated Oxygen Sensor (O2S) Inspection
Emission Control Devices: 1B-10 Heated Oxygen Sensor (O2S) Inspection Installation B822H11206002 Install the PAIR reed valve in the reverse order of Refer to “DTC “C44” (P0156) or “C64” (P0130): O2 removal. Pay attention to the following points: Sensor (O2S) Circuit Malfunction (For E-02, 19, 24, 33) •...
Page 196: Pair System Inspection
1B-11 Emission Control Devices: Installation PAIR Reed Valve Install the PAIR control solenoid valve in the reverse NOTE order of removal. Pay attention to the following points: PAIR control solenoid valve can be checked • Apply thin coat of the engine oil to the O-ring (-s). without removing it from the motorcycle.
Page 197: Crankcase Breather (Pcv) Hose Inspection
Emission Control Devices: 1B-12 Crankcase Breather (PCV) Hose Inspection 3) Connect the 12 V battery to the PAIR control solenoid valve terminals and check the air flow. If air B822H11206006 Inspect the crankcase breather (PCV) hose in the does not flow out, the solenoid valve is in normal following procedures: condition.
Page 198: Crankcase Breather (Pcv) Cover Inspection
1B-13 Emission Control Devices: 4) Disconnect the crankcase (PCV) cover side of PCV EVAP Canister hose (1). Removal 1) Remove the right frame side cover. Refer to “Exterior Parts Removal and Installation in Section 9D (Page 9D-3)”. 2) Disconnect the surge hose (2), purge hose (3) and drain hose (4).
Page 199: Evaporative Emission Control System Inspection (For E-33 Only)
Emission Control Devices: 1B-14 Installation Evaporative Emission Control System Inspection (For E-33 only) 1) Install the EVAP system purge control solenoid valve B822H11206010 as shown in the EVAP canister hose routing Refer to “Evaporative Emission Control System Removal diagram. Refer to “EVAP Canister Hose Routing and Installation (Only for E-33) (Page 1B-13)”.
Page 200 1B-15 Emission Control Devices: 2) Connect the 12 V battery to the terminals of the Fuel Shut-Off Valve EVAP system purge control solenoid valve and Inspect the fuel shut-off valve body for damage. Inspect check the air flow. If air flows out, the solenoid valve the fuel shut-off valve operation in the following is in normal condition.
Page 201: Specifications
For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List in Section 0C (Page 0C-8)”. Special Tools and Equipment Recommended Service Material B822H11208001 Material SUZUKI recommended product or Specification Note Thread lock cement THREAD LOCK CEMENT SUPER P/No.: 99000–32110 (Page 1B-10)
Page 202: Engine Electrical Devices
1C-1 Engine Electrical Devices: Engine Electrical Devices Engine Precautions Precautions for Engine Electrical Device B822H11300001 Refer to “General Precautions in Section 00 (Page 00-1)” and “Precautions for Electrical Circuit Service in Section 00 (Page 00-2)”. Component Location Engine Electrical Components Location B822H11303001 Refer to “Electrical Components Location in Section 0A (Page 0A-7)”.
Page 203: Iap Sensor Removal And Installation
Engine Electrical Devices: 1C-2 IAP Sensor Removal and Installation TP Sensor Adjustment B822H11306005 B822H11306025 Removal Inspect the TP sensor setting position and adjust it if necessary in the following procedures: 1) Remove the fuel tank. Refer to “Fuel Tank Removal and Installation in Section 1G (Page 1G-8)”.
Page 204: Iat Sensor Removal And Installation
1C-3 Engine Electrical Devices: IAT Sensor Removal and Installation 5) Remove the ECT sensor (3). B822H11306024 Removal CAUTION 1) Remove the fuel tank. Refer to “Fuel Tank Removal Take special care when handling the ECT and Installation in Section 1G (Page 1G-8)”. sensor.
Page 205: Ect Sensor Inspection
Engine Electrical Devices: 1C-4 ECT Sensor Inspection • Apply engine coolant to the O-ring (3) and Install the thermostat case (4). B822H11306009 Refer to “DTC “C15” (P0115-H/L): ECT Sensor Circuit Malfunction in Section 1A (Page 1A-47)”. CAUTION Inspect the ECT sensor in the following procedures: Use a new O-ring (3) to prevent engine 1) Remove the ECT sensor.
Page 206: To Sensor Removal And Installation
1C-5 Engine Electrical Devices: TO Sensor Removal and Installation TO Sensor Inspection B822H11306010 B822H11306011 Removal Refer to “DTC “C23” (P1651-H/L): TO Sensor Circuit Malfunction in Section 1A (Page 1A-57)”. 1) Remove the left frame cover and luggage box (1). Refer to “Exterior Parts Removal and Installation in STP Sensor Inspection Section 9D (Page 9D-3)”.
Page 207: Stp Sensor Removal And Installation
Engine Electrical Devices: 1C-6 STP Sensor Removal and Installation 5) Close the secondary throttle valve by finger and measure the STP sensor output voltage. B822H11306014 Removal Special tool 1) Turn the ignition switch OFF. (A): 09900–25008 (Multi-circuit tester set) 2) Disconnect the coupler (1) and remove the STP (B): 09900–25009 (Needle pointed probe sensor (2) with the special tool.
Page 208: Stv Actuator Inspection
• Apply grease to the secondary throttle Refer to “DTC “C40” (P0505 / P0506 / P0507): ISC Valve shaft end “A”, if necessary. Circuit Malfunction in Section 1A (Page 1A-80)”. : Grease 99000–25010 (SUZUKI SUPER ISC Valve Removal and Installation GREASE A or equivalent) B822H11306018 Refer to “ISC Valve Removal and Installation in Section...
Page 209: O2 Sensor Inspection
Engine Electrical Devices: 1C-8 O2 Sensor Inspection 5) Click the “Reset” button to clear the ISC leaned valve. B822H11306020 Refer to “DTC “C44” (P0156) or “C64” (P0130): O2 Sensor (O2S) Circuit Malfunction (For E-02, 19, 24, 33) in Section 1A (Page 1A-87)”. O2 Sensor Removal and Installation B822H11306021 Refer to “Oxygen Sensor (O2S) Removal and...
Page 210: Specifications
1C-9 Engine Electrical Devices: Specifications Service Data B822H11307001 FI Sensors Item Specification Note 190 – 290 Ω CKP sensor resistance CKP sensor peak voltage 1.5 V and more When cranking IAP sensor input voltage (F & R) 4.5 – 5.5 V IAP sensor output voltage (F &...
Page 211: Special Tools And Equipment
Engine Electrical Devices: 1C-10 Special Tools and Equipment Recommended Service Material B822H11308001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010 (Page 1C-7) equivalent Special Tool B822H11308002 09900–25008 09900–25009 Multi-circuit tester set Needle pointed probe set...
Page 212: Engine Mechanical
1D-1 Engine Mechanical: Engine Mechanical Engine Schematic and Routing Diagram Camshaft and Sprocket Assembly Diagram B822H11402001 I822H1140328-02...
Page 213: Throttle Cable Routing Diagram
Engine Mechanical: 1D-2 Throttle Cable Routing Diagram B822H11402002 “A” “B” “ a ” “ a ” “C” “D” “E” I822H1140362-02 1. Throttle cable No. 1 (pulling cable) “A”: Pass the throttle cables right side of the frame head pipe and it into the cable guide. Pass the throttle cables over the brake hose.
Page 214: Diagnostic Information And Procedures
1D-3 Engine Mechanical: Diagnostic Information and Procedures Engine Mechanical Symptom Diagnosis 6) Keep the throttle grip in the fully-opened position. B822H11404002 Refer to “Engine Symptom Diagnosis in Section 1A (Page 1A-8)”. Compression Pressure Check B822H11404001 The compression pressure reading of a cylinder is a good indicator of its internal condition.
Page 215: Repair Instructions
Engine Mechanical: 1D-4 Repair Instructions Engine Components Removable with the Engine in Place B822H11406001 Engine components which can be removed while the engine is installed on the frame are as follows. For the installing and removing procedures, refer to respective paragraphs describing each component. Center of Engine Item Removal...
Page 216 1D-5 Engine Mechanical: Engine Right Side Item Removal Inspection Installation Refer to “Exhaust Pipe / Refer to “Exhaust Pipe / Refer to “Exhaust System Muffler Removal and Muffler Removal and Exhaust pipe/Muffler Inspection in Section 1K Installation in Section 1K Installation in Section 1K (Page 1K-12)”.
Page 217: Air Cleaner Element Removal And Installation
Engine Mechanical: 1D-6 Air Cleaner Element Removal and Installation Installation B822H11406034 Install the air cleaner element in the reverse order of Removal removal. Pay attention following point: 1) Remove the air cleaner box mounting screws (1). • Align the oval direction of the air cleaner case and joint tube.
Page 218 1D-7 Engine Mechanical: Installation Install the air cleaner chamber in the reverse order of removal. Pay attention to the following points: • Fit the throttle body clamps properly. Refer to “Throttle Body Construction (Page 1D-9)”. • Route the hoses properly. Refer to “Throttle Body Construction (Page 1D-9)”.
Page 219: Throttle Body Components
Engine Mechanical: 1D-8 Throttle Body Components B822H11406040 I822H1140403-03 1. TP sensor 6. O-ring 11. Vacuum hose 16. TP sensor mounting screw 2. STP sensor 7. Fuel injector 12. Vacuum hose (E-33 only) : 5 N⋅m (0.5 kgf-m, 3.5 Ib-ft) 3. STVA 8.
Page 220: Throttle Body Construction
1D-9 Engine Mechanical: Throttle Body Construction B822H11406041 Intake pipe clamp Air cleaner outlet clamp Front cylinder Rear cylinder “ a ” “c ” “ b ” Rear cylinder Front cylinder “C” “C” “A” “D” “A” “C” “E” “B” “C” “C” “C”...
Page 221: Isc Valve Removal And Installation
Engine Mechanical: 1D-10 ISC Valve Removal and Installation Throttle Body Removal and Installation B822H11406060 B822H11406042 Removal Removal 1) Disconnect the battery (–) lead wire. Refer to CAUTION “Battery / Battery Holder Removal and Installation in Be careful not to disconnect the ISC valve Section 1J (Page 1J-11)”.
Page 222 1D-11 Engine Mechanical: 7) Loosen the throttle body clamp screws. • Tighten the throttle body clamp screws. Refer to “Throttle Body Construction (Page 1D-9)”. • Loosen each throttle cable lock-nut. • Turn in each throttle cable adjuster fully and locate each outer cable so that the clearance “a”...
Page 223: Throttle Body Disassembly And Assembly
Engine Mechanical: 1D-12 Throttle Body Disassembly and Assembly 3) Remove the fuel injectors (5) from the fuel delivery B822H11406043 pipe (4). Refer to “Throttle Body Removal and Installation (Page 1D-10)”. Disassembly CAUTION Identify the position of each removed part. Organize the parts in their respective groups so that they can be reinstalled in their original positions.
Page 224 1D-13 Engine Mechanical: : Grease 99000–25010 (SUZUKI SUPER CAUTION GREASE A or equivalent) Never remove the throttle valve (9) and Special tool secondary throttle valve (10). : 09930–11950 (Torx wrench) Tightening torque STP sensor mounting screw: 3.5 N·m (0.35 kgf- m, 2.5 lb-ft)
Page 225 Engine Mechanical: 1D-14 Special tool • Install the fuel injector (6) by pushing it straight to the : 09930–11950 (Torx wrench) delivery pipe (7). Tightening torque CAUTION TP sensor mounting screw: 3.5 N·m (0.35 kgf-m, Never turn the injector while pushing it. 2.5 lb-ft) NOTE Align the coupler “E”...
Page 226: Throttle Body Inspection And Cleaning
1D-15 Engine Mechanical: Throttle Body Inspection and Cleaning ISC Valve Visual Inspection B822H11406044 Visually inspect the ISC valve, if necessary. Refer to “Throttle Body Disassembly and Assembly 1) Remove the screws. (Page 1D-12)”. Cleaning WARNING Some carburetor cleaning chemicals, especially dip-type soaking solutions, are very corrosive and must be handled carefully.
Page 227: Throttle Valve Synchronization
Engine Mechanical: 1D-16 Throttle Valve Synchronization 6) Connect the respective vacuum hoses and IAP B822H11406045 vacuum sensor hoses to each vacuum nipple on the Use of SDS Tool throttle body with the special tools. Check and adjust the throttle valve synchronization Special tool between two cylinders.
Page 228 1D-17 Engine Mechanical: 13) Click “ON” button (3) to fix the ISC air volume among 2 cylinders. NOTE When making this synchronization, be sure that the water temperature is within 80 – 105 °C (176 – 221 °F). “A” “B” I822H1140332-02 “A”: Engine speed: Approx.
Page 229: Isc Valve Reset
Engine Mechanical: 1D-18 ISC Valve Reset NOTE B822H11406047 The learned value of the ISC valve is set at When removing or replacing the throttle body assembly, RESET position. reset the ISC valve learned value in the following procedures: 1) Turn the ignition switch ON position. 2) Set up the SDS tools.
Page 230 1D-19 Engine Mechanical: 7) Remove the air cleaner chamber (1). Refer to “Air 11) Disconnect the ignition coil/plug cap lead wire Cleaner Chamber Removal and Installation couplers and remove the ignition coils/plug caps. (Page 1D-6)”. Refer to “Ignition Coil / Plug Cap and Spark Plug Cap Removal and Installation in Section 1H (Page 1H- 4)”.
Page 231 Engine Mechanical: 1D-20 12) Disconnect the radiator inlet hose (4). 16) Disconnect the oil cooler hose (9). I822H1140370-01 I822H1140374-01 13) Remove the rear brake master cylinder assembly (5) 17) Remove the oil pressure switch lead wire (10). and right foot pedal (6). Refer to “Rear Brake Master Cylinder Removal and Installation in Section 4A (Page 4A-14)”.
Page 232 1D-21 Engine Mechanical: 21) Release the lead wires from the clamp (15). 25) Remove the left footrest (20) along with gear shift link arm (21). I822H1140378-01 22) Disconnect the side-stand switch lead wire coupler I822H1140382-01 (16) and speedometer sensor lead wire coupler (17). 26) Support the engine with a proper jack.
Page 233 Engine Mechanical: 1D-22 29) Remove the rear brake hose clamp bolt (25). 32) Remove the engine bracket (28). I822H1140388-01 I822H1140391-01 30) Remove the engine mounting bolt and nut (26). 33) Remove the engine mounting bolts and nuts. 31) Remove the frame down tube (27) by removing their bolts and nuts.
Page 234: Engine Assembly Installation
1D-23 Engine Mechanical: Engine Assembly Installation • Tighten the engine mounting bracket bolts. B822H11406061 Reinstall the engine in the reverse order of engine removal. Pay attention to the following points: • Install the driven bevel gear coupling to the universal joint.
Page 235 Engine Mechanical: 1D-24 • Tighten all engine mounting bolts and nuts to the specified torque, as shown in the following illustration. “ a ” 1 “ a ” 2 “ b ” I822H1140398-02 1. Engine mounting bolt (Front) “a”: 215 mm (8.5 in) 2.
Page 236: Engine Top Side Disassembly
1D-25 Engine Mechanical: • Install the air cleaner chamber. Refer to “Air Cleaner Thermostat Chamber Removal and Installation (Page 1D-6)”. Remove the thermostat assembly (1) and disconnect the water hoses (2). • Pour engine coolant and engine oil. Refer to “Cooling System Inspection in Section 0B (Page 0B-15)”...
Page 237 Engine Mechanical: 1D-26 2) Remove the valve timing inspection plug (2) and 4) Remove the cam chain tension adjuster cap bolt (4), generator cover plug (3). washer and spring. 5) Remove the front cam chain tension No. 2 adjuster (5) and gasket. I822H1140043-01 3) Turn the crankshaft to bring the “F I T”...
Page 238 1D-27 Engine Mechanical: Front Cylinder Head 2) Remove the dowel pins and gasket (2). 1) Remove the front cylinder head. 3) Remove the clutch push rod (3). NOTE Loosen the cylinder head bolts little by little diagonally with the smaller sizes first. I822H1140052-01 Front Cylinder 1) Remove the front cylinder (1).
Page 239 Engine Mechanical: 1D-28 Front Piston Rear Camshaft 1) Place a clean rag over the cylinder base so as not to 1) Turn the crankshaft 2/3 (234°) and align the “R I T” drop the piston pin circlips into the crankcase. line mark “A”...
Page 240 1D-29 Engine Mechanical: 4) Remove the cam chain guide No. 3 (3). 2) Remove the rear cylinder gasket (1) and dowel pins. 5) Remove the camshaft journal holder (4). 3) Remove the rear cam chain guide No. 2 (2). 6) Remove the dowel pins. CAUTION Be sure to loosen the camshaft journal holder bolts evenly by shifting the wrench in...
Page 241: Engine Top Side Assembly
Engine Mechanical: 1D-30 Engine Top Side Assembly Rear Cylinder B822H11406007 1) Remove the rear cylinder (1). Assemble the engine top side in the reverse order of disassembly. Pay attention to the following points: NOTE Firmly grip the cylinder at both ends, and lift Piston it straight up.
Page 242 1D-31 Engine Mechanical: • Place a clean rag over the cylinder base so as not to Cylinder drop the piston pin circlips (1) into the crankcase. • Install the dowel pins and new gaskets (1), front and • Install the piston pin circlips (1). rear.
Page 243 Engine Mechanical: 1D-32 • Hold the piston rings in proper positions, and insert CAUTION each of the pistons into the respective cylinders. • There is the guide holder for the bottom • Tighten the cylinder nuts temporarily. end of each cam chain guides No. 2 (1) NOTE cast in the crankcase.
Page 244 1D-33 Engine Mechanical: Front • Place the cylinder heads on the cylinders. NOTE • The cylinder heads can be distinguished by the embossed-letters, “F” and “R”. • When installing the cylinder head, keep the cam chain taut. I822H1140081-01 Rear I822H1140079-01 •...
Page 245 Engine Mechanical: 1D-34 Rear Camshaft • Pull the cam chain lightly. • Turn the crankshaft clockwise and align the “R I T” line • The exhaust camshaft sprocket has an arrow marked “A” on the crankshaft with the index marks “B” of the “1”...
Page 246 1D-35 Engine Mechanical: I822H1140339-01 • Install the dowel pins. • Tighten the camshaft journal holder bolts in the ascending order of numbers to the specified torque. Tightening torque Camshaft journal holder bolt: 11 N·m (1.1 kgf-m, 8.0 lb-ft) I822H1140088-01 • Install the camshaft journal holders (1) and cam chain guide No.
Page 247 Engine Mechanical: 1D-36 • Install the gasket (5) and cam chain tension adjuster Rear Cam Chain Tension No. 2 Adjuster cap bolt (6). • The rear cam chain tension No. 2 adjuster are identified by the embossed letters (R-UP). NOTE •...
Page 248 1D-37 Engine Mechanical: Front Camshaft • Pull the cam chain lightly. • Turn the crankshaft clockwise approx. 1-1/3 turns • The exhaust camshaft sprocket has an arrow marked (486°) and align “F I T” line “A” on the crankshaft with “1”...
Page 249 Engine Mechanical: 1D-38 13 14 15 17 18 I822H1140342-02 • Install the dowel pins. • Tighten the camshaft journal holder bolts in ascending order of numbers to the specified torque. Tightening torque Camshaft journal holder bolt: 11 N·m (1.1 kgf-m, 8.0 lb-ft) I822H1140097-01 •...
Page 250 1D-39 Engine Mechanical: • Install the gasket (5) and cam chain tension adjuster Front Cam Chain Tension No. 2 Adjuster cap bolt (6). • The front cam chain tension No. 2 adjuster are identified by the embossed letters (F-UP). NOTE •...
Page 251 • Be sure to check and adjust the valve clearance. • Apply grease to the clutch push rod. Refer to “Valve Clearance Inspection and Adjustment : Grease 99000–25010 (SUZUKI SUPER in Section 0B (Page 0B-5)”. GREASE A or equivalent) Clutch Cover •...
Page 252 CAUTION Use new gaskets to prevent oil leakage. • Apply bond to the cam end caps of the gaskets as shown in the figure. : Sealant 99000–31140 (SUZUKI BOND I822H1140106-01 No.1207B or equivalent) • Install the generator cover cap (6).
Page 253 • Apply grease to the O-ring. CAUTION Use a new O-ring to prevent mixture air from soaking through the joint. (A): Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) NOTE Face the “UP” mark on the intake pipe to upper.
Page 254: Valve Clearance Inspection And Adjustment
1D-43 Engine Mechanical: Valve Clearance Inspection and Adjustment Cam Wear B822H11406008 Check the camshaft for wear or damage. Refer to “Valve Clearance Inspection and Adjustment in Measure the cam height “a” with a micrometer. Section 0B (Page 0B-5)”. Replace a camshaft if the cams are worn to the service limit.
Page 255 Engine Mechanical: 1D-44 3) Install camshaft journal holder and tighten the 6) If the camshaft journal oil clearance exceeds the camshaft journal holder bolts in ascending order of limit, measure the inside diameter of the camshaft numbers to the specified torque. Refer to “Engine journal holder and the outside diameter of the Top Side Assembly (Page 1D-30)”.
Page 256: Camshaft Sprocket And Automatic-Decomp. Inspection
1D-45 Engine Mechanical: Cam Chain Tension No. 1 and No. 2 Adjuster Camshaft Runout Measure the runout using the dial gauge. Replace the Inspection camshaft if the runout exceeds the limit. B822H11406012 The cam chain tension No. 1 and No. 2 adjusters are Special tool maintained at the proper cam chain tension (A): 09900–20607 (Dial gauge (1/100 mm, 10...
Page 257: Cam Chain Guide No. 1, No. 2 And No. 3
Engine Mechanical: 1D-46 Cam Chain Guide No. 1, No. 2 and No. 3 Cam Chain Tensioner No. 1 Inspection B822H11406015 Inspection Inspect the cam chain tensioner in the following B822H11406014 procedures: Inspect the cam chain guides in the following procedures: 1) Remove the cam chain tensioner No.
Page 258: Pair Reed Valve / Pair Reed Valve Cover Inspection
1D-47 Engine Mechanical: Assembly Cylinder Head Disassembly and Assembly B822H11406016 1) Install the PAIR read valve and PAIR read valve Refer to “Engine Top Side Disassembly (Page 1D-25)”. cover. Refer to “Engine Top Side Assembly (Page 1D-30)”. 2) Apply thread lock to the bolts and tighten them. CAUTION : Thread lock cement 99000–32110 Identify the position of each removed part.
Page 259 Engine Mechanical: 1D-48 Water jacket pipe Remove the water jacket pipe (1) (for rear cylinder). I822H1140134-01 3) Using the special tools, compress the valve spring and remove the two cotter halves (3) from the valve I822H1140131-01 stem. Water jacket plug (Cylinder head) Special tool Remove the water jacket plugs (1) (for front and rear (B): 09916–14510 (Valve spring...
Page 260 1D-49 Engine Mechanical: 6) Remove the oil seal (7) and spring seat (8). M/O: Molybdenum oil (MOLYBDENUM OIL SOLUTION) I705H1140165-01 • Install the valve spring with the small-pitch portion “A” I822H1140137-01 facing cylinder head. Assembly Assembly is in the reverse order of disassembly. Pay “D”...
Page 261 Engine Mechanical: 1D-50 Water jacket pipe • Be sure that the rounded lip “E” of the cotter fits snugly into the groove “F” in the stem end. Apply engine coolant to the O-ring and install the water jacket pipe. “E” “F”...
Page 262: Cylinder Head Related Parts Inspection
1D-51 Engine Mechanical: Cam chain tensioner No. 2 Valve Stem Runout Tighten the cam chain tensioner No. 2 nuts (1) to the Support the valve using V-blocks, and check its runout specified torque. using the dial gauge as shown in the figure. If the runout exceeds the service limit, replace the valve.
Page 263 Engine Mechanical: 1D-52 Valve Stem / Valve Face Wear Condition Valve Stem Wear Visually inspect each valve stem and valve face for wear Measure the valve stem O.D. using the micrometer. and pitting. If it is worn of damaged, replace the valve If the valve stem is worn down to the limit, as measured with a new one.
Page 264: Valve Guide Replacement
1D-53 Engine Mechanical: 4) Check that the transferred red lead (Blue) on the Valve Guide Replacement valve face is uniform all around and in center of the B822H11406052 1) Remove the cylinder head. Refer to “Engine Top valve face. Side Disassembly (Page 1D-25)”. If the seat width “a”...
Page 265: Valve Seat Repair
Engine Mechanical: 1D-54 6) Drive the guide into the guide hole using the valve guide installer and attachment. NOTE Install the valve guide until the attachment contacts the cylinder head. CAUTION Failure to oil the valve guide hole before driving the new guide into place may result in a damaged guide or head.
Page 266: Cam Chain Tensioner No. 2 Inspection
1D-55 Engine Mechanical: Cam Chain Tensioner No. 2 Inspection Valve Spring The force of the coil spring keeps the valve seat tight. B822H11406051 Inspect the cam chain tensioner No. 2 in the following Weakened spring results in reduced engine power procedures: output and often accounts for the chattering noise 1) Remove the cam chain tensioner No.
Page 267: Piston Ring Removal And Installation
Engine Mechanical: 1D-56 Cylinder Bore Installation Check the cylinder wall for any scratches, nicks or other NOTE damage. • When installing the piston ring, be careful Cylinder bore not to damage the piston. Standard: 112.000 – 112.015 mm (4.4094 – 4.4100 in) •...
Page 268: Piston And Piston Ring Inspection
1D-57 Engine Mechanical: Piston and Piston Ring Inspection b) Install the 2nd ring (3) and 1st ring (4) to piston. B822H11406023 Refer to “Piston Ring Removal and Installation NOTE (Page 1D-56)”. 1st ring (4) and 2nd ring (3) differ in shape. Piston Diameter Measure the piston diameter using the micrometer at 10 mm (0.4 in) “a”...
Page 269 Engine Mechanical: 1D-58 Piston ring groove width Standard: (1st): 0.93 – 0.95 mm (0.0366 – 0.0374 in) Standard: (1st): 1.55 – 1.57 mm (0.0610 – 0.0618 in) Standard: (2nd): 1.21 – 1.23 mm (0.0476 – 0.0484 in) Standard: (Oil): 2.51 – 2.53 mm (0.0988 – 0.0996 in) Piston ring thickness Standard: (1st): 0.86 –...
Page 270: Engine Bottom Side Disassembly
1D-59 Engine Mechanical: Measure the piston pin outside diameter at three Clutch positions using the micrometer. If any of the Remove the clutch component parts (1). Refer to “Clutch measurements are out of specification, replace the Removal in Section 5C (Page 5C-4)”. piston pin.
Page 271 Engine Mechanical: 1D-60 Generator 2) Remove the idler shaft (3). Remove the generator component parts (1). Refer to 3) Disengage the cam chain No. 1 (4) from the front “Generator Removal and Installation in Section 1J cam chain idler sprocket (5). (Page 1J-5)”.
Page 272 1D-61 Engine Mechanical: Rear Cam Chain Tension No. 1 Adjuster Rear Cam Chain Drive Sprocket Remove the rear cam chain drive sprocket (1). 1) Remove the rear cam chain tensioner No. 1 (1) and cam chain guide No. 1 (2). 2) Remove the rear cam chain tension No.
Page 273 Engine Mechanical: 1D-62 2) Remove the gasket (2) and dowel pins. Primary Driven Gear 3) Draw out the gearshift shaft assembly (3). 1) Hold the primary driven gear with the special tool and remove the primary driven gear (1). Special tool (A): 09930–44541 (Rotor holder) I822H1140353-01 4) Remove the gearshift cam plate bolt (4) and...
Page 274 1D-63 Engine Mechanical: 2) Remove the snap ring (3) and oil pump driven gear Oil Filter (4). Remove the oil filter with the special tool. Special tool NOTE (A): 09915–40610 (Oil filter wrench) Do not drop the snap ring (3) into the crankcase.
Page 275 Engine Mechanical: 1D-64 Water Pump Oil Pressure Regulator / Oil Strainer 1) Disconnect the water hoses (1). 1) Remove the O-rings (1) and oil pressure regulator (2). 2) Remove the water inlet pipe/water by-pass pipe (2) and water pump assembly (3). 2) Remove the oil strainers (3).
Page 276 1D-65 Engine Mechanical: 2) Make sure that all of the bolts are removed. Then, Transmission tap the sides of the lower crankcase using a plastic Remove the drive shaft assembly (2) and countershaft hammer to separate the upper and lower crankcase assembly (3).
Page 277 Engine Mechanical: 1D-66 4) Remove the oil separator (7). Engine Mount Bushing Remove the upper and lower crankcase engine mount bushings (1), if necessary. I822H1140200-01 Oil Pump I822H1140203-01 Remove the oil pump assembly (1). Refer to “Oil Pump Removal and Installation in Section 1E (Page 1E-9)”. I822H1140204-01 Oil Jet I822H1140201-01...
Page 278 1D-67 Engine Mechanical: Oil Gallery Plug Crankshaft Journal Bearing Remove the crankshaft journal bearings (1), upper and 1) Remove the oil gallery plugs (1) from the upper lower. crankcase. CAUTION • When removing the crankshaft journal bearings, be careful not to scratch the crankcase and the crankshaft journal bearings.
Page 279: Engine Bottom Side Assembly
Engine Mechanical: 1D-68 Engine Bottom Side Assembly B822H11406025 Assembly the engine bottom side in the reverse of disassembly. Pay attention to the following points: NOTE Apply engine oil to each running and sliding part before reassembling. Oil Gallery Plug CAUTION Use each new gasket.
Page 280 1D-69 Engine Mechanical: • Apply a small quantity of thread lock to the bolts and Balancer Shaft / Crankshaft tighten them. • Install the oil separator (1). : Thread lock cement 99000–32110 NOTE (THREAD LOCK CEMENT SUPER 1322 or Align the oil separator claw with the lower equivalent) crankcase hole.
Page 281 • Turn the bearing to fit the bearing down pin “C” in the position. • Apply grease to the O-ring. I822H1140221-01 • Insert the thrust bearing with oil groove “A” facing the : Grease 99000–25010 (SUZUKI SUPER crank web. GREASE A or equivalent) • Install the oil seal (1). “C”...
Page 282 • Spread on surfaces thinly to form an even layer, and assemble the crankcases within : Grease 99000–25010 (SUZUKI SUPER few minutes. GREASE A or equivalent) • Take extreme care not to apply any bond to •...
Page 283 • Align the boss “C” with the hole “D” of the Crankcase bolt (M6): 11 N·m (1.1 kgf-m, 8.0 lb-ft) lower crankcase. Crankcase bolt (M8): 26 N·m (2.6 kgf-m, 19.0 lb-ft) : Grease 99000–25010 (SUZUKI SUPER Crankcase bolt (M10) (Initial): 30 N·m (3.0 kgf-m, GREASE A or equivalent) 21.5 lb-ft) Crankcase bolt (M10) (Final): 50 N·m (5.0 kgf-m,...
Page 284 Use the new O-rings to prevent oil leakage. • Make surfaces free from moisture, oil, dust and other foreign materials. : Grease 99000–25010 (SUZUKI SUPER • Spread on surfaces thinly to from an even GREASE A or equivalent) layer, and assemble the oil pan within few minutes.
Page 285 “A” of the oil pump shaft onto the within few minutes. concave part “B” of the water pump shaft. • Apply to distorted surfaces as it forms a : Grease 99000–25010 (SUZUKI SUPER comparatively thick film. GREASE A or equivalent) : Sealant 99000–31140 (SUZUKI BOND No.1207B or equivalent)
Page 286 Be careful not to apply bond to the hole of Oil cooler union bolt (a): 70 N·m (7.0 kgf-m, 50.5 thread end. lb-ft) : Sealant 99000–31110 (SUZUKI BOND No.1215 or equivalent) Tightening torque Oil pressure switch (a): 14 N·m (1.4 kgf-m, 10.0...
Page 287 (2) into the crankcase. Replace the O-ring with a new one. NOTE Align the gear position switch pin “A” with the gearshift cam hole “B”. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) “B” “A” I822H1140247-01 • Install the oil pump driven gear (3) and snap ring (4).
Page 288 • Shift the gear position to 1st or 2nd. • Apply grease to the seal. • Hold the primary driven gear with the special tool. : Grease 99000–25010 (SUZUKI SUPER Special tool GREASE A or equivalent) (A): 09930–44541 (Rotor holder)
Page 289 Engine Mechanical: 1D-78 Gearshift System • Install the gearshift cam stopper (1), bolt (2), washer (3) and return spring (4). “B” • Apply thread lock to the gearshift cam stopper bolt (2) and tighten it to the specified torque. “C” : Thread lock cement 99000–32110 (THREAD LOCK CEMENT SUPER 1322 or equivalent)
Page 290 • Tighten the gearshift cover bolts. NOTE I822H1140264-01 • Apply grease to the oil seal lip before installing the gearshift cover. • Fit the clamp “E” and stay “F” to the bolts. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) “E” “F” I822H1140262-02...
Page 291 Engine Mechanical: 1D-80 Rear Cam Chain Drive Sprocket • Install the rear cam chain drive sprocket (1) onto the crankshaft. CAUTION When installing the rear cam chain drive sprocket, align the wide spline teeth “A” and “B” “B”. “A” I822H1140267-01 “B”...
Page 292 1D-81 Engine Mechanical: Cam Chain Guide No. 1 / Rear Cam Chain Tensioner • Apply molybdenum oil solution to the idler shaft and install the idler shaft. No. 1 • Apply thread lock to the bolts and tighten its to the M/O: Molybdenum oil (MOLYBDENUM OIL specified torque.
Page 293 Engine Mechanical: 1D-82 • Tighten the front cam chain tension No. 1 adjuster bolts (1) to the specified torque. Tightening torque Front cam chain tension No. 1 adjuster bolt (a): “A” 10 N·m (1.0 kgf-m, 7.0 lb-ft) “B” I822H1140275-01 “B” “A”...
Page 294 1D-83 Engine Mechanical: Cam Chain Guide No. 1 Generator • Apply thread lock to the bolts and tighten it to the • Install the generator component parts (1). Refer to specified torque. “Generator Removal and Installation in Section 1J (Page 1J-5)”. : Thread lock cement 99000–32030 (THREAD LOCK CEMENT SUPER 1303 or equivalent)
Page 295: Conrod Removal And Installation
3) Remove the conrods and mark them to identify their respective cylinders. I822H1140284-01 Starter Motor • Apply grease to the O-ring. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) CAUTION I822H1140287-01 Replace the O-ring with a new one. 4) Remove the bearings (1).
Page 296 1D-85 Engine Mechanical: Installation 4) Apply engine oil to the conrod cap bolts. 1) When installing the bearings into the conrod cap and 5) Tighten the conrod cap bolts as following two steps. conrod, be sure to fix the stopper part “A” first, and Tightening torque then press in the opposite side of the bearing.
Page 297: Conrod / Crankshaft Inspection
Engine Mechanical: 1D-86 Conrod / Crankshaft Inspection Conrod big end width B822H11406055 Standard: 23.95 – 24.00 mm (0.943 – 0.945 in) Refer to “Conrod Removal and Installation (Page 1D- Crank pin width 84)”. Standard: 24.10 – 24.15 mm (0.949 – 0.951 in) Conrod Small End I.D.
Page 298 1D-87 Engine Mechanical: 3) Tighten the conrod cap bolts to the specified torque, Selection in two stages. Refer to “Conrod Removal and 1) Check the corresponding conrod I.D. code numbers Installation (Page 1D-84)”. ([1] or [2]) “A”. NOTE • When installing the conrod cap to the crank pin, make sure that I.D code “A”...
Page 299: Crankshaft Journal Bearing Inspection And Selection
Engine Mechanical: 1D-88 Crankshaft Journal Bearing Inspection and Special tool (A): 09900–20203 (Micrometer (1/100 mm, Selection 50 – 75 mm)) B822H11406029 Refer to “Engine Bottom Side Disassembly (Page 1D- 59)”. Refer to “Engine Bottom Side Assembly (Page 1D-68)”. Inspection 1) Inspect each upper and lower crankcase bearing (1) for any damage.
Page 300 1D-89 Engine Mechanical: 4) Mate the lower crankcase with the upper crankcase. Selection 5) Tighten crankcase bolts a little at a time to equalize 1) Check the corresponding crankcase journal I.D. the pressure. codes ([A], [B] or [C]) “A”, which is stamped on the rear of the upper crankcase.
Page 301: Crankshaft Thrust Clearance Inspection And Selection
Engine Mechanical: 1D-90 3) Measure the crankshaft O.D. with the special tool. If Color “C” (Part No.) Thickness any of the measurements are out of specification, Blue 2.004 – 2.007 mm replace the crankshaft. (12229-48G10-0E0) (0.0789 – 0.0790 in) Crankshaft journal O.D. specification Code “B”...
Page 302 1D-91 Engine Mechanical: Selection 1) Remove the thrust bearing and measure its thickness using the micrometer. If the thickness of the thrust bearing is below standard, replace it with a new one and once again perform the thrust clearance measurement listed above. Special tool (A): 09900–20205 (Micrometer (0 –...
Page 303: Balancer Driven Gear Disassembly And Assembly
Engine Mechanical: 1D-92 Balancer Driven Gear Disassembly and 6) Remove the balancer driven gear No. 1 (4) and No. 2 (5) from the special tool. Assembly B822H11406056 7) Remove the springs (6). Disassembly 1) Remove the balancer shaft assembly from the upper crankcase.
Page 304 1D-93 Engine Mechanical: 4) Turn the balancer driven gear No. 1 (3). 8) Remove the balancer driven gear assembly from the special tool. 5) Align the balancer driven gear No. 1 (3) with the hole of the balancer driven gear No. 2. 9) Set the balancer shaft so that its slit “A”...
Page 305: Balancer Shaft Parts Inspection
Assembly (Page 1D-92)”. Replace the oil seal with a new one. Balancer Shaft Bearing : Grease 99000–25010 (SUZUKI SUPER Inspect the balancer shaft bearings for abnormal noise GREASE A or equivalent) and smooth rotation. Replace the bearings if there is anything unusual.
Page 306: Specifications
1D-95 Engine Mechanical: Specifications Service Data B822H11407001 Valve + Guide Unit: mm (in) Item Standard Limit 42 (1.65) — Valve diam. 38 (1.50) — 0.09 – 0.16 (0.004 – 0.006) — Tappet clearance (When cold) 0.20 – 0.30 (0.008 – 0.012) —...
Page 307 Engine Mechanical: 1D-96 Cylinder + Piston + Piston Ring Unit: mm (in) Item Standard Limit Compression pressure 800 kPa 1 300 – 1 800 kPa (13 – 18 kgf/cm , 185 – 256 psi) (Automatic decomp. actuated) (8 kgf/cm , 114 psi) 200 kPa Compression pressure difference —...
Page 308: Tightening Torque Specifications
1D-97 Engine Mechanical: Tightening Torque Specifications B822H11407002 Tightening torque Fastening part Note N⋅m kgf-m lb-ft STP sensor mounting screw 0.35 (Page 1D-13) TP sensor mounting screw 0.35 (Page 1D-14) Fuel delivery pipe mounting screw (Page 1D-14) Frame down tube bolt 36.0 (Page 1D-23) Front footrest bracket bolt...
Page 309: Special Tools And Equipment
For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List in Section 0C (Page 0C-8)”. Special Tools and Equipment Recommended Service Material B822H11408001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010 (Page 1D-13) /...
Page 310: Special Tool
1D-99 Engine Mechanical: Material SUZUKI recommended product or Specification Note Thread lock cement THREAD LOCK CEMENT SUPER P/No.: 99000–32030 (Page 1D-75) / 1303 or equivalent (Page 1D-77) / (Page 1D-77) / (Page 1D-78) / (Page 1D-81) / (Page 1D-82) /...
Page 311 Engine Mechanical: 1D-100 09900–20605 09900–20607 Dial calipers (1/100 mm, 10 Dial gauge (1/100 mm, 10 – 34 mm) (Page 1D-86) (Page 1D-45) / (Page 1D-51) / (Page 1D-51) / (Page 1D-52) 09900–20701 09900–20803 Magnetic stand Thickness gauge (Page 1D-45) / (Page 1D-51) / (Page 1D-51) / (Page 1D-55) /...
Page 312 1D-101 Engine Mechanical: 09916–34542 09916–37810 Reamer handle Valve guide reamer (5.8/6.0 (Page 1D-54) (Page 1D-54) 09916–44940 09916–46020 Attachment Valve guide remover/ installer (Page 1D-54) (Page 1D-53) / (Page 1D-54) 09916–84511 09917–62420 Tweezers Chain tensioner locking tool (Page 1D-48) / (Page 1D-81) (Page 1D-49) 09918–53810 09919–28610...
Page 313: Engine Lubrication System
Engine Lubrication System: 1E-1 Engine Lubrication System Engine Precautions Precautions for Engine Oil B822H11500001 Refer to “Fuel and Oil Recommendation in Section 0A (Page 0A-3)”. Schematic and Routing Diagram Engine Lubrication System Chart Diagram B822H11502001 CLUTCH PLATES #1 EXHAUST SECONDARY CAMSHAFT BEVEL GEARS #1 PISTON PIN...
Page 314: Diagnostic Information And Procedures
1E-2 Engine Lubrication System: Diagnostic Information and Procedures Engine Lubrication Symptom Diagnosis B822H11504001 Condition Possible cause Correction / Reference Item Engine overheats Insufficient amount of engine oil. Check level and add. Defective oil pump. Replace. Clogged oil circuit. Clean. Clogged oil cooler Clean or replace.
Page 315: Repair Instructions
Engine Lubrication System: 1E-3 7) Stop the engine and remove the oil pressure gauge 5) Warm up the engine as follows: Summer: 5 min. at idle r/min and attachment. Winter: 8 min. at idle r/min 8) Reinstall the oil pressure switch (1). Refer to “Oil 6) After warm up, increase the engine speed to 3 000 r/ Pressure Switch Removal and Installation (Page 1E- 7)”.
Page 316 5) Remove the O-rings (5). • Apply grease to the O-rings and install them. CAUTION Use new O-rings to prevent oil leakage. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I822H1150007-01 Installation Installation is in the reverse order of removal.
Page 317: Oil Pressure Regulator / Oil Strainer Inspection
Refer to “Oil Pan / Oil Strainer / Oil Pressure Regulator NOTE Removal and Installation (Page 1E-3)”. Use of SUZUKI BOND is as follows: Oil pressure regulator • Make surfaces free from moisture, oil, dust Inspect the operation of the oil pressure regulator by and other foreign materials.
Page 318: Oil Cooler Removal And Installation
When installing the oil cooler, fit the concave part “A” of the oil cooler onto the convex part “B” of the crankcase. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I822H1150016-01 4) Remove the washer (3) and oil cooler (4) by removing the union bolt (2).
Page 319: Oil Pressure Switch Removal And Installation
Installation 1) Install the oil pressure switch (1), apply the bond to its thread part and tighten it to the specified torque. : Sealant 99000–31140 (SUZUKI Bond 1207B or equivalent) Tightening torque Oil pressure switch (a): 14 N·m (1.4 kgf-m, 10.0...
Page 320 1E-8 Engine Lubrication System: Installation Oil Jet (For the Piston Cooling and Transmission) Installation is in the reverse order of removal. Pay Removal attention to the following points: 1) Remove the engine assembly. Refer to “Engine • Apply engine oil to the O-ring. Bottom Side Disassembly in Section 1D (Page 1D- 59)”.
Page 321: Oil Jet / Oil Gallery Jet Inspection
Engine Lubrication System: 1E-9 Installation Installation is in the reverse order of removal. Pay attention to the following points: • Fit new O-ring (1) to each piston cooling oil jet as shown and apply engine oil to them. CAUTION Use new O-rings to prevent oil pressure leakage.
Page 322: Oil Pump Inspection
1E-10 Engine Lubrication System: • Assemble the engine. Refer to “Engine Bottom Side Assembly in Section 1D (Page 1D-68)” and “Engine Top Side Assembly in Section 1D (Page 1D-30)”. Oil Pump Inspection B822H11506012 Oil Pump Inspect the oil pump in the following procedures: 1) Remove the oil pump.
Page 323: Specifications
Engine Lubrication System: 1E-11 Specifications Service Data B822H11507001 Oil Pump Item Standard Limit Above 400 kPa (4.0 kgf/cm , 57 psi) Oil pressure (at 60 °C, 140 °F) Below 700 kPa (7.0 kgf/cm , 100 psi) — at 3 000 r/min Item Specification Note...
Page 324: Special Tools And Equipment
1E-12 Engine Lubrication System: Special Tools and Equipment Recommended Service Material B822H11508001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010 (Page 1E-4) / (Page 1E- equivalent Sealant SUZUKI BOND No.1215 or P/No.: 99000–31110...
Page 325: Engine Cooling System
Engine Cooling System: 1F-1 Engine Cooling System Engine Precautions Precautions for Engine Cooling System B822H11600001 WARNING • You can be injured by boiling fluid or steam if you open the radiator cap when the engine is hot. After the engine cools, wrap a thick cloth around cap and carefully remove the cap by turning it a quarter turn to allow pressure to escape and then turn the cap all the way off.
Page 326: Schematic And Routing Diagram
1F-2 Engine Cooling System: Schematic and Routing Diagram Cooling Circuit Diagram B822H11602001 RESERVOIR ENGINE COOLANT THERMOSTAT TANK CYLINDER HEAD TEMPERATURE SENSOR CYLINDER RADIATOR WATER PUMP I822H1160053-01...
Page 327: Water Hose Routing Diagram
Engine Cooling System: 1F-3 Water Hose Routing Diagram B822H11602002 “A” “B” “D” “E” “A” “B” “A” “B” “C” “F” “C” “B” “C” “F” “G” “D” “C” “H” “B” “G” “A” “ a ” “ b ” “ b ” “ b ” “K”...
Page 328: Diagnostic Information And Procedures
1F-4 Engine Cooling System: Diagnostic Information and Procedures Engine Cooling Symptom Diagnosis B822H11604001 Condition Possible cause Correction / Reference Item Engine overheats Not enough engine coolant. Add engine coolant. Radiator core clogged with dirt or scale. Clean. Faulty cooling fan. Repair or replace.
Page 329: Radiator Cap Inspection
Engine Cooling System: 1F-5 Radiator Cap Inspection Radiator Cleaning B822H11606002 Blow out any foreign matter that is stuck in the radiator Inspect the radiator cap in the following procedures: fins using compressed air. 1) Remove the radiator cap. Refer to “Cooling Circuit CAUTION Inspection (Page 1F-4)”.
Page 330: Water Hose Inspection
1F-6 Engine Cooling System: 4) Disconnect the radiator inlet hose (2) and cooling fan 7) Remove the radiator covers (7), left and right. motor coupler (3). I822H1160008-02 8) Disconnect the oil cooler hose (8). I822H1160005-01 5) Disconnect the water bypass hose (4) and radiator 9) Remove the cooling fan motor (9) from the radiator.
Page 331: Water Hose Removal And Installation
Engine Cooling System: 1F-7 Water Hose Removal and Installation 4) Any leakage from the connecting section should be corrected by proper tightening. Refer to “Water Hose B822H11606006 Removal Routing Diagram (Page 1F-3)”. 1) Drain engine coolant. Refer to “Cooling System Inspection in Section 0B (Page 0B-15)”.
Page 332: Radiator Reservoir Tank Removal And Installation
1F-8 Engine Cooling System: Radiator Reservoir Tank Removal and Cooling Fan Inspection B822H11606009 Installation B822H11606008 Cooling fan operating temperature Removal Standard 1) Remove the left frame lower cover and secondary (ON→OFF): Approx. 100 °C (212 °F) gear case cover. Refer to “Exterior Parts Removal (OFF→ON): Approx.
Page 333: Cooling Fan Relay Inspection
Engine Cooling System: 1F-9 Cooling Fan Relay Inspection ECT Sensor Removal and Installation B822H11606010 B822H11606011 Inspect the fan relay in the following procedures: Refer to “ECT Sensor Removal and Installation in Section 1C (Page 1C-3)”. 1) Remove the seat. Refer to “Exterior Parts Removal and Installation in Section 9D (Page 9D-3)”.
Page 334: Thermostat Inspection
1F-10 Engine Cooling System: Thermostat Inspection 5) Remove the thermostat (3). B822H11606014 Inspect the thermostat in the following procedures: 1) Remove the thermostat. Refer to “Thermostat Removal and Installation (Page 1F-9)”. 2) Inspect the thermostat pellet for signs of cracking. I822H1160021-01 Installation Install the thermostat in the reverse order of removal.
Page 335: Water Pump Components
Engine Cooling System: 1F-11 Thermostat valve lift “a” 6) Read the thermometer just when opening the Standard: 8 mm and over at 100 °C (0.31 in and thermostat. If this reading, which is the temperature over at 212 °F) level at which the thermostat valve begins to open, is out of the standard value, replace the thermostat with a new one.
Page 336: Water Pump Removal And Installation
Replace the O-ring with the a new one. 3) Disconnect the water pump inlet hose (1) and oil cooler hose (2). : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) • Install the water pump assembly with the slot on the pump shaft end “A”...
Page 337: Water Pump Disassembly And Assembly
Engine Cooling System: 1F-13 Water Pump Disassembly and Assembly • Apply engine coolant to the O-ring. B822H11606018 Refer to “Water Pump Removal and Installation CAUTION (Page 1F-12)”. Use a new O-ring to prevent engine coolant leakage. Disassembly 1) Remove the water pump case (1). I822H1160032-01 I822H1160033-01 •...
Page 338 1F-14 Engine Cooling System: 4) Remove the mechanical seal ring (3) and rubber 7) Remove the oil seal. seal (4) from the impeller (5). NOTE If there is no abnormal condition, the oil seal removal is not necessary. I822H1160036-01 5) Remove the impeller shaft (6) and washer (7). I822H1160052-01 Assembly 1) Install the oil seal with the special tool.
Page 339 Engine Cooling System: 1F-15 2) Apply a small quantity of grease to the oil seal lip. 4) Apply grease to the impeller shaft. : Grease 99000–25010 (SUZUKI SUPER : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) GREASE A or equivalent) 5) Install the impeller shaft and washer (1) to the water pump body.
Page 340: Water Pump Related Parts Inspection
1F-16 Engine Cooling System: Water Pump Related Parts Inspection 9) Install the impeller (6) and tighten the impeller securing bolt (7) to the specified torque. B822H11606019 Refer to “Water Pump Disassembly and Assembly Tightening torque (Page 1F-13)”. Impeller securing bolt (a): 8 N·m (0.8 kgf-m, 6.0 lb-ft) Mechanical Seal Visually inspect the mechanical seal for damage, with...
Page 341: Specifications
Engine Cooling System: 1F-17 Impeller / Shaft Impeller Shaft Journal Visually inspect the impeller and its shaft for damage. Visually inspect the journal for damage or scratch. Replace the impeller or shaft if necessary. Replace the water pump body if necessary. I822H1160054-01 I822H1160055-01 Specifications...
Page 342: Special Tools And Equipment
1F-18 Engine Cooling System: Special Tools and Equipment Recommended Service Material B822H11608001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010 (Page 1F-12) / equivalent (Page 1F-15) / (Page 1F-15) Thread lock cement THREAD LOCK CEMENT 1342 or P/No.: 99000–32050...
Page 343: Fuel System
Fuel System: 1G-1 Fuel System Engine Precautions Precautions for Fuel System B822H11700001 WARNING • Keep away from fire or spark. • During disassembling, use care to minimize spillage of gasoline. • Spilled gasoline should be wiped off immediately. • Work in a well-ventilated area. CAUTION •...
Page 344: General Description
1G-2 Fuel System: General Description Fuel System Description B822H11701001 Fuel System The fuel delivery system consists of the fuel tank (1), fuel pump (2), fuel filter (3), fuel feed hose (4), fuel delivery pipe (5) (including fuel injectors) and fuel pressure regulator (6). There is no fuel return hose. The fuel in the fuel tank (1) is pumped up by the fuel pump (2) and pressurized fuel flows into the injector (8) installed in the fuel delivery pipe (5).
Page 345: Diagnostic Information And Procedures
Fuel System: 1G-3 Diagnostic Information and Procedures Fuel System Diagnosis B822H11704001 Condition Possible cause Correction / Reference Item Engine will not start or is Clogged fuel filter or fuel hose. Clean or replace. hard to start (No fuel Defective fuel pump. Replace.
Page 346: Repair Instructions
1G-4 Fuel System: Repair Instructions Fuel Pressure Inspection 4) Turn the ignition ON and check for fuel pressure. B822H11706001 Fuel pressure WARNING Approx. 300 kPa (3.0 kgf/cm , 43 psi) • Keep away from fire or spark. If the fuel pressure is lower than the specification, •...
Page 347: Fuel Discharge Amount Inspection
Fuel System: 1G-5 Fuel Discharge Amount Inspection 4) Disconnect the fuel pump lead wire coupler (2). B822H11706003 WARNING • Keep away from fire or spark. • Spilled gasoline should be wiped off immediately. • Work in a well-ventilated area. Inspect the fuel discharge amount in the following procedures: 1) Lift and support the fuel tank.
Page 348: Fuel Pump Relay Inspection
1G-6 Fuel System: Fuel Pump Relay Inspection Fuel Hose Inspection B822H11706004 B822H11706005 Refer to “Electrical Components Location in Section 0A Refer to “Fuel Line Inspection in Section 0B (Page 0B- (Page 0A-7)”. 11)”. Inspect the fuel pump relay in the following procedures: Fuel Level Gauge Inspection 1) Remove the battery holder.
Page 349: Fuel Tank Construction
Fuel System: 1G-7 Fuel Tank Construction B822H11706009 Outside “ a ” “A” I822H1170030-03 1. Clamp 5. Heat shield “a”: 5 – 45° 2. Fuel pump 6. Fuel tank bracket “A”: Set the tip of the fuel tank cushion to the plate of the frame. 3.
Page 350: Fuel Tank Removal And Installation
1G-8 Fuel System: Fuel Tank Removal and Installation 6) Disconnect the fuel tank breather hose (For E-33). B822H11706010 7) Disconnect the fuel pump lead wire coupler (2). 8) Remove the fuel tank. Removal WARNING • Keep away from fire or spark. •...
Page 351: Fuel Pump Components
Fuel System: 1G-9 Fuel Pump Components B822H11706011 I822H1170031-08 1. Filter cover 5. Fuel pressure regulator assembly : Apply engine oil. 2. Fuel mesh filter 6. Fuel level gauge : Apply grease. 3. Fuel pump 7. O-ring : Do not reuse. 4.
Page 352: Fuel Pump Assembly / Fuel Level Gauge Removal And Installation
1G-10 Fuel System: Fuel Pump Assembly / Fuel Level Gauge 4) Remove the fuel level gauge (4) while pushing the pawl end “A”. Removal and Installation B822H11706012 CAUTION Removal Do not pull the lead wire when removing the fuel gauge. WARNING •...
Page 353: Fuel Pump Disassembly And Assembly
Refer to “Fuel Pump Assembly / Fuel Level Gauge CAUTION Removal and Installation (Page 1G-10)”. Replace the O-ring with a new one. Disassembly : Grease 99000–25010 (SUZUKI SUPER 1) Disconnect the fuel pump coupler (1). GREASE A or equivalent) 2) Remove the band (2) and clamp (3). I822H1170017-01 I822H1170019-02 •...
Page 354: Fuel Mesh Filter Inspection And Cleaning
1G-12 Fuel System: 7) Remove the following parts from the adapter (10). • Pressure regulator (11) • Joint (12) • Clip (13) • Insulator (14) I822H1170025-01 • Apply thin coat of the engine oil to the bushing. • Install the fuel pump (1). I822H1170022-01 Assembly Refer to “Fuel Mesh Filter Inspection and Cleaning...
Page 355: Fuel Injector / Fuel Delivery Pipe Removal And Installation
Fuel System: 1G-13 Fuel Injector / Fuel Delivery Pipe Removal and 2) Check the fuel injector filter for evidence of dirt and contamination. If present, clean and check for Installation presence of dirt in the fuel lines and fuel tank. B822H11706015 Refer to “Throttle Body Removal and Installation in Section 1D (Page 1D-10)”.
Page 356: Special Tools And Equipment
1G-14 Fuel System: Special Tools and Equipment Recommended Service Material B822H11708001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010 (Page 1G-11) equivalent NOTE Required service material is also described in the following. “Fuel Pump Components (Page 1G-9)”...
Page 357: Ignition System
Ignition System: 1H-1 Ignition System Engine Schematic and Routing Diagram Ignition System Diagram B822H11802001 Refer to “Wire Color Symbols in Section 0A (Page 0A-5)”. Engine stop switch Side-stand #1 (R) relay Power source circuit #1 (R) Fuse sensor Waveform arrangement Ignition switch circuit #2 (F)
Page 358: Diagnostic Information And Procedures
1H-2 Ignition System: Diagnostic Information and Procedures Ignition System Symptom Diagnosis B822H11804001 Condition Possible cause Correction / Reference Item Spark plug not sparking Damaged spark plugs. Replace. Fouled spark plugs. Clean or replace. Wet spark plugs. Clean and dry or replace. Defective ignition coil/plug caps.
Page 359: No Spark Or Poor Spark
Ignition System: 1H-3 No Spark or Poor Spark B822H11804002 Troubleshooting NOTE Check that the transmission is in neutral and the engine stop switch is in the “RUN” position. Grasp the clutch lever. Check that the fuse is not blown and the battery is fully-charged before diagnosing. Step Action Check the ignition system couplers for poor connections.
Page 360: Repair Instructions
1H-4 Ignition System: Repair Instructions Ignition Coil / Plug Cap and Spark Plug Cap 7) Remove the cylinder head covers (3). Removal and Installation B822H11806001 Removal WARNING The hot engine can burn you. Wait until the engine is cool enough to touch. 1) Turn the ignition switch OFF.
Page 361: Ignition Coil Removal And Installation
Ignition System: 1H-5 Ignition Coil Removal and Installation 7) Remove the ignition coil (For #2 cylinder) (4) by B822H11806009 disconnecting the high tension cord. Removal 1) Turn the ignition switch OFF. 2) Remove the fuel tank. Refer to “Fuel Tank Removal and Installation in Section 1G (Page 1G-8)”.
Page 362: Spark Plug Removal And Installation
1H-6 Ignition System: Spark Plug Removal and Installation Ignition Coil / Plug Cap / Ignition Coil Inspection B822H11806010 B822H11806003 Removal Refer to “Electrical Components Location in Section 0A (Page 0A-7)”. 1) Remove the ignition coil/plug cap and spark plug cap. Refer to “Ignition Coil / Plug Cap and Spark Ignition Coil / Plug Cap Primary Peak Voltage Plug Cap Removal and Installation (Page 1H-4)”.
Page 363 Ignition System: 1H-7 6) Insert the needle pointed probe to the lead wire 8) Measure the ignition coil/plug cap primary peak coupler. voltage in the following procedures: NOTE WARNING Use the special tool, to prevent the rubber of Do not touch the tester probes and spark the water proof coupler from damage.
Page 364 1H-8 Ignition System: 4) Repeat the b) procedure several times and measure CAUTION the highest peak voltage. Before using the multi-circuit tester and peak Ignition coil primary peak voltage volt adaptor, be sure to refer to the 250 V and more appropriate instruction manual.
Page 365: Ckp Sensor Inspection
Ignition System: 1H-9 Tester knob indication Special tool Resistance (Ω) (A): 09900–25008 (Multi-circuit tester set) Ignition coil resistance Tester knob indication: Voltage ( Primary: 1.8 – 3.0 Ω ((+) terminal – (–) terminal) (+) Probe (–) Probe CKP sensor Secondary: 16 – 26 kΩ (Plug cap – (–) terminal) I822H1180020-01 I822H1180018-03 2.
Page 366: Ckp Sensor Removal And Installation
1H-10 Ignition System: 2) Measure the resistance between the lead wires and 4) Inspect the engine stop switch for continuity with a ground. If the resistance is not within the standard tester. range, replace the CKP sensor with a new one. If any abnormality is found, replace the right Refer to “CKP Sensor Removal and Installation handlebar switch assembly with a new one.
Page 367: Specifications
Ignition System: 1H-11 Specifications Service Data B822H11807001 Electrical Unit: mm (in) Item Specification Note 1 ⋅ 2 Firing order NGK: CR7EK Type Spark plug DENSO: U22ETR 0.6 – 0.7 (0.024 – 0.028) Spark performance Over 8 (0.3) at 1 atm. 190 –...
Page 368: Starting System
1I-1 Starting System: Starting System Engine Schematic and Routing Diagram Starting System Diagram B822H11902001 Refer to “Wire Color Symbols in Section 0A (Page 0A-5)”. Ignition Engine stop switch switch Fuse To the (30 A) ignition coil Starter motor Fuse GP switch (15 A) (Neutral) Battery...
Page 369: Starter Motor Will Not Run
Starting System: 1I-2 Starter Motor will not Run B822H11904002 NOTE Make sure the fuses are not blown and the battery is fully-charged before diagnosing. Troubleshooting Step Action 1) Shift the transmission into neutral. Go to Step 2. Go to Step 3. 2) Grasp the clutch lever, turn on the ignition switch with the engine stop switch in the “RUN”...
Page 370: Repair Instructions
1I-3 Starting System: Repair Instructions Starter Motor Components B822H11906001 I822H1190040-02 1. O-ring 7. Starter motor lead wire mounting nut : 10 N⋅m (1.0 kgf-m, 7.0 lb-ft) 2. Housing end (Inside) 8. Brush holder nut : 5 N⋅m (0.5 kgf-m, 3.5 lb-ft) 3.
Page 371: Starter Motor Removal And Installation
Removal • Apply grease to the starter motor O-ring. 1) Turn the ignition switch OFF and disconnect the : Grease 99000–25010 (SUZUKI SUPER battery (–) lead wire. Refer to “Battery / Battery GREASE A or equivalent) Holder Removal and Installation in Section 1J (Page 1J-11)”.
Page 372: Starter Motor Disassembly And Assembly
• Apply a small quantity of moly paste to the armature • Align the match mark on the starter motor case with shaft. the match mark on the housing end. : Moly paste 99000–25140 (SUZUKI Moly • Tighten the starter motor housing bolts (2). paste or equivalent) Tightening torque Starter motor housing bolt (b): 5 N·m (0.5 kgf-m,...
Page 373: Starter Motor Inspection
Starting System: 1I-6 Starter Motor Inspection Armature Coil B822H11906004 Measure for continuity between each segment. Measure Refer to “Starter Motor Disassembly and Assembly for continuity between each segment and the armature (Page 1I-5)”. shaft. If there is no continuity between the segments or there is Carbon Brush continuity between the segments and shaft, replace the Inspect the carbon brushes for abnormal wear, cracks or...
Page 374: Starter Relay Removal And Installation
1I-7 Starting System: Starter Relay Inspection Oil Seal Check the seal lip for damage. B822H11906006 Inspect the starter relay in the following procedures: If any damage is found, replace the housing end 1) Remove the starter relay. Refer to “Starter Relay (Inside).
Page 375: Turn Signal / Side-Stand Relay Removal And Installation
Starting System: 1I-8 Side-stand / Ignition Interlock System Parts 3) Measure the relay coil resistance between the terminals using the multi-circuit tester. If the Inspection resistance is not within the specified value, replace B822H11906008 Check the interlock system for proper operation. If the the starter relay with a new one.
Page 376 1I-9 Starting System: 5) Connect the side-stand switch coupler. 4) Install the turn signal/side-stand relay. Refer to “Turn Signal / Side-stand Relay Removal and Installation 6) Install the left frame cover. Refer to “Exterior Parts (Page 1I-8)”. Removal and Installation in Section 9D (Page 9D- 3)”.
Page 377 Starting System: 1I-10 Gear Position Switch 4) Connect the gear position switch coupler to the wiring harness. 1) Remove the right frame cover. Refer to “Exterior Parts Removal and Installation in Section 9D 5) Insert the needle pointed probes to the lead wire (Page 9D-3)”.
Page 378: Starter Torque Limiter / Starter Clutch Removal And Installation
1I-11 Starting System: Starter Torque Limiter / Starter Clutch Removal 6) Remove the key (7) and starter driven gear (8). and Installation B822H11906009 Removal 1) Drain engine oil. 2) Remove the left foot rest (1) along with the gear shift lever.
Page 379: Starter Torque Limiter Inspection
Starting System: 1I-12 Installation • Apply thread lock to the bolts, and then tighten them Install the starter clutch in the reverse order of removal. to the specified torque with the special tool. Pay attention to the following points: : Thread lock cement 99000–32030 •...
Page 380: Starter Clutch Inspection
1I-13 Starting System: 1) Hold the starter torque limiter with the special tools Starter Driven Gear Bearing and vise. Inspect the starter driven gear bushing for wear or damage. Special tool (A): 09930–73170 (Starter torque limiter holder) (B): 09930–73140 (Starter torque limiter socket) 2) Turn the starter torque limiter with a torque wrench and check the slip torque.
Page 381: Specifications
Starting System: 1I-14 Specifications Service Data B822H11907001 Unit: mm (in) Item Specification Note Standard 12.5 (0.49) Starter motor brush length Limit 6.0 (0.24) 31 – 51 N⋅m Starter torque limiter slip torque Standard (3.1 – 5.1 kgf-m, 22.5 – 37.0 lb-ft) 3 –...
Page 382: Special Tools And Equipment
1I-15 Starting System: Special Tools and Equipment Recommended Service Material B822H11908001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010 (Page 1I-4) / (Page 1I-5) equivalent Moly paste SUZUKI Moly paste or equivalent P/No.: 99000–25140...
Page 383: Charging System
Charging System: 1J-1 Charging System Engine Schematic and Routing Diagram Charging System Diagram B822H11A02001 Regulator/Rectifier Ignition switch Generator I718H11A0001-01 Component Location Charging System Components Location B822H11A03001 Refer to “Electrical Components Location in Section 0A (Page 0A-7)”. Diagnostic Information and Procedures Charging System Symptom Diagnosis B822H11A04001 Condition...
Page 384: Battery Runs Down Quickly
1J-2 Charging System: Condition Possible cause Correction / Reference Item Battery overcharges Faulty regulator/rectifier. Replace. Faulty battery. Replace. Poor contact of generator lead wire Repair. coupler. Battery runs down quickly Trouble in charging system. Check the generator, regulator/rectifier and circuit connections and make necessary adjustments to obtain specified charging operation.
Page 385: Repair Instructions
Charging System: 1J-3 Repair Instructions Battery Current Leakage Inspection Regulated Voltage Inspection B822H11A06001 B822H11A06002 Inspect the battery current leakage in the following Inspect the regulated voltage in the following procedures: procedures: 1) Turn the ignition switch OFF. 1) Remove the seat. Refer to “Exterior Parts Removal and Installation in Section 9D (Page 9D-3)”.
Page 386: Generator Inspection
1J-4 Charging System: Generator Inspection No-load Performance B822H11A06003 1) Remove the left frame lower cover and secondary Generator Coil Resistance gear case cover. Refer to “Exterior Parts Removal 1) Remove the left frame lower cover and secondary and Installation in Section 9D (Page 9D-3)”. gear case cover.
Page 387: Generator Removal And Installation
Charging System: 1J-5 Generator Removal and Installation 7) Remove the gasket (6) and dowel pins. B822H11A06004 Removal 1) Disconnect the battery (–) lead wire. Refer to “Battery / Battery Holder Removal and Installation (Page 1J-11)”. 2) Drain engine oil. Refer to “Engine Oil and Filter Replacement in Section 0B (Page 0B-11)”.
Page 388 1J-6 Charging System: 10) Remove the key (7). • Degrease the tapered portion “A” of generator rotor and also the crankshaft “B”. Use nonflammable cleaning solvent to wipe off oily or greasy matter and make these surfaces completely dry. • Fit the key (5) in the key slot on the crankshaft. •...
Page 389: Regulator / Rectifier Inspection
Removal and Installation in Section 5B (Page 5B-14)”. shown in the figure. Regulator / Rectifier Inspection : Sealant 99000–31110 (SUZUKI BOND B822H11A06006 No.1215 or equivalent) Inspect the regulator/rectifier in the following procedures: 1) Turn the ignition switch to OFF position.
Page 390: Battery Components
1J-8 Charging System: 5) Measure the voltage between the terminals using the multi-circuit tester as indicated in the following table. If the voltage is not within the specified value, replace the regulator/rectifier with a new one. NOTE If the tester reads 1.4 V and below when the tester probes are not connected, replace its battery. Special tool : 09900–25008 (Multi-circuit tester set) Tester knob indication...
Page 391 Charging System: 1J-9 2) Remove the caps (2) from the electrolyte container. 5) Make sure that air bubbles (4) rise to the top of each electrolyte container, and leave in this position for NOTE about more than 20 minutes. • Do not remove or pierce the sealed areas “B”...
Page 392: Battery / Battery Holder Removal And Installation
1J-10 Charging System: 6) After confirming that the electrolyte has entered the Charging battery completely, remove the electrolyte containers For initial charging, use the charger specially designed from the battery. for MF battery. 7) Wait for about 20 minutes. CAUTION 8) Insert the caps (2) into the filler holes, pressing in firmly so that the top of the caps do not protrude •...
Page 393 Charging System: 1J-11 Battery / Battery Holder Removal and 3) After recharging, wait at least 30 minutes and then measure the battery voltage using the multi-circuit Installation tester. B822H11A06009 Removal If the battery voltage is less than 12.5 V, recharge 1) Remove the seat.
Page 394: Battery Visual Inspection
1J-12 Charging System: 6) Remove the TO sensor (6). • Install the battery. CAUTION Never use anything except the specified battery. • Tighten the battery lead wire mounting bolts securely. I822H11A0022-02 7) Remove the fuse box (7) and battery holder (8). I822H11A0025-01 Battery Visual Inspection B822H11A06010...
Page 395: Specifications
For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List in Section 0C (Page 0C-8)”. Special Tools and Equipment Recommended Service Material B822H11A08001 Material SUZUKI recommended product or Specification Note Molybdenum oil MOLYBDENUM OIL SOLUTION — (Page 1J-6) Sealant SUZUKI BOND No.1215 or...
Page 396: Exhaust System
1K-1 Exhaust System: Exhaust System Engine Precautions Precautions for Exhaust System B822H11B00001 WARNING To avoid the risk of being burned, do not touch the exhaust system when the system is hot. Any service on the exhaust system should be performed when the system is cool. CAUTION Make sure that the exhaust pipes, muffler joint and muffler have enough clearance from the rubber parts and plastic parts to avoid melting.
Page 397: Repair Instructions
Exhaust System: 1K-2 Repair Instructions Exhaust Control System Construction B822H11B06013 “A” “ a ” “ b ” “d” “c” “ c ” I822H11B0002-02 1. No. 1 EXCV cable “A”: Adjustment position “c”: 4 mm (0.16 in) and more 2. No. 2 EXCV cable “a”: 44 –...
Page 398: Exhaust System Components
1K-3 Exhaust System: Exhaust System Components B822H11B06001 “A” “A” “A” I822H11B0044-03 1. Front exhaust pipe 5. Rear muffler 9. EXCV cable : 5 N⋅m (0.5 kgf-m, 3.5 lb-ft) 2. Rear exhaust pipe 6. Front muffler 10. Gasket : Do not reuse. 3.
Page 399: Excva / Excv Cable Removal And Installation
Exhaust System: 1K-4 EXCVA / EXCV Cable Removal and Installation 7) Disconnect the couplers and remove the EXCVA (1). B822H11B06008 Removal 1) Turn the ignition switch OFF. 2) Remove the left frame cover. Refer to “Exterior Parts Removal and Installation in Section 9D (Page 9D- 3)”.
Page 400 1K-5 Exhaust System: 11) Remove the EXCV cables (3) by removing the lock- 3) Adjust the inner cable length “b” of No. 1 cable in 44 nuts (4). – 45 mm (1.73 – 1.77 in) by turning the adjuster (3), then tighten the lock-nuts (4).
Page 401 Exhaust System: 1K-6 8) Install the pulley (9) to the shaft (10). 10) After connecting the No. 2 cable (2), loosen the lock- nut (12) and turn the adjuster (13) in or until 11 – 12 NOTE mm (0.43 – 0.47 in) of the thread length “d” on the Make sure that the shaft’s line “A”...
Page 402: Excva Inspection
1K-7 Exhaust System: EXCVA Inspection EXCVA Adjustment B822H11B06010 B822H11B06012 Refer to “DTC “C46” (P1657-H/L or P1658): EXCV Inspect the EXCVA operation and adjust it if necessary Actuator Circuit Malfunction in Section 1A (Page 1A- in the following steps: 91)”. Step 1 EXCVA Pulley / EXCV Cable Inspection 1) Set the EXCVA to the adjustment position.
Page 403 Exhaust System: 1K-8 Step 3 7) If the measured voltage is less than specification, adjust the No. 1 cable adjuster as follows: 1) Turn the ignition switch OFF. a) Set the EXCVA to the adjustment position. Refer 2) Disconnect the EXCVA motor coupler (1). to “EXCVA / EXCV Cable Removal and 3) To set the EXCV to fully closed position, apply 12 V Installation (Page 1K-4)”.
Page 404: Exhaust Pipe / Muffler Removal And Installation
1K-9 Exhaust System: Exhaust Pipe / Muffler Removal and Installation 2) Measure the position sensor output voltage at fully opened position. B822H11B06002 Removal EXCVA position sensor out put voltage 1) Remove the right frame cover and EVAP canister. EXCV is fully opened: 3.6 ≤ Output voltage ≤ 4.55 Refer to “Exterior Parts Removal and Installation in V ((+) Y –...
Page 405 Exhaust System: 1K-10 5) Remove the muffler support bolt (5) and joint bolt (6). 9) Remove the front muffler (10) along with the front and rear exhaust pipes from the motorcycle. I822H11B0028-01 6) Remove the (rear) muffler (7). I822H11B0032-01 10) Remove the rear exhaust pipe (11). I822H11B0029-02 7) Remove the exhaust pipe bolts (8).
Page 406 1K-11 Exhaust System: 12) Disengage the front muffler (10) and front exhaust Installation pipe. Installation is in the reverse order of removal. Pay attention to the following points: • Tighten the O2 sensor (1) (front and rear) to the specified torque. Tightening torque O2 sensor (a): 48 N·m (4.8 kgf-m, 34.5 lb-ft) CAUTION...
Page 407: Exhaust System Inspection
Exhaust System: 1K-12 • Route the O2 sensor lead wire properly. Refer to “Wiring Harness Routing Diagram in Section 9A #1 cylinder (Page 9A-7)”. • Install EXCV cables and EXCV cover. Refer to “EXCVA / EXCV Cable Removal and Installation (Page 1K-4)”.
Page 408: Specifications
For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List in Section 0C (Page 0C-8)”. Special Tools and Equipment Recommended Service Material B822H11B08001 Material SUZUKI recommended product or Specification Note Muffler seal MUFFLER SEAL LOCTITE 5920 — (Page 1K-11)
Page 409 Table of Contents 2- i Section 2 Suspension CONTENTS Precautions ..........2-1 Swingarm Related Parts Inspection ....2C-10 Swingarm Bearing Removal and Installation ..2C-11 Precautions............. 2-1 Specifications .............2C-12 Precautions for Suspension ........2-1 Service Data............2C-12 Suspension General Diagnosis....2A-1 Tightening Torque Specifications......2C-12 Special Tools and Equipment ......2C-13 Diagnostic Information and Procedures....2A-1 Recommended Service Material .......2C-13...
Page 410: Precautions
2-1 Precautions: Precautions Suspension Precautions Precautions for Suspension B822H12000001 Refer to “General Precautions in Section 00 (Page 00-1)”. WARNING All suspensions, bolts and nuts are an important part in that it could affect the performance of vital parts. They must be tightened to the specified torque periodically and if the suspension effect is lost, replace it with a new one.
Page 411: Suspension General Diagnosis
Suspension General Diagnosis: 2A-1 Suspension General Diagnosis Suspension Diagnostic Information and Procedures Suspension and Wheel Symptom Diagnosis B822H12104001 Condition Possible cause Correction / Reference Item Wobbly front wheel Distorted wheel rim. Replace. Worn front wheel bearings. Replace. Defective or incorrect tire. Replace.
Page 412: Front Suspension
2B-1 Front Suspension: Front Suspension Suspension Repair Instructions Front Fork Components B822H12206001 I822H1220027-02 1. Inner tube metal 10. Gasket 19. Damper rod 2. Dust seal 11. Damper rod bolt : 33 N⋅m (3.3 kgf-m, 24.0 lb-ft) 3. Oil seal stopper ring 12.
Page 413: Front Fork Removal And Installation
Front Suspension: 2B-2 Front Fork Removal and Installation Installation B822H12206002 1) Set the front fork to the front fork lower bracket NOTE temporarily by tightening the lower clamp bolts (1). The right and left front forks are installed symmetrically and therefore the removal procedure for one side is the same as that for the other side.
Page 414: Front Fork Disassembly And Assembly
2B-3 Front Suspension: Front Fork Disassembly and Assembly 5) Tighten the front fork upper fork clamp bolt (3). B822H12206005 Tightening torque Refer to “Front Fork Removal and Installation (Page 2B- Front fork upper clamp bolt (c): 23 N·m (2.3 kgf- 2)”.
Page 415 Front Suspension: 2B-4 5) Remove the case guide (7) and dust seal (8). 9) Remove the oil seal by pulling out the inner tube. I822H1220010-05 I822H1220014-01 6) Remove the oil seal stopper ring (9). 10) Remove the following parts. • Oil lock piece (13) •...
Page 416 CAUTION Do not damage the Teflon coated surface of the inner tube’s slide metal when mounting it. • Apply fork oil to the inner tube slide metal. : Fork Oil 99000–99044–10G (SUZUKI FORK “A” OIL G-10 or equivalent) I717H1220023-01 • Install the inner tube into the outer tube with care not to drop the oil lock piece out.
Page 417 • Install the rebound spring (2) to the damper rod (3). • Apply fork oil to the damper rod ring. : Thread lock cement 99000–32110 (THREAD LOCK CEMENT SUPER 1322 or : Fork Oil 99000–99044–10G (SUZUKI FORK equivalent) OIL G-10 or equivalent) Tightening torque •...
Page 418 • Pour specified front fork oil to the inner tube. When adjusting the fork oil level, remove the fork spring and compress the inner tube fully. : Fork Oil 99000–99044–10G (SUZUKI FORK OIL G-10 or equivalent) Special tool Capacity (each leg) (A): 09943–74111 (Fork oil level gauge)
Page 419: Front Fork Parts Inspection
Use a new O-ring (1) to prevent oil leakage. Inner and Outer Tubes Inspect the inner tube sliding surface and outer tube sliding surface for scuffing. : Fork Oil 99000–99044–10G (SUZUKI FORK OIL G-10 or equivalent) • Install the front fork cap bolt to the inner tube temporarily.
Page 420: Specifications
Front fork oil level (Without spring, 179 (7.0) — inner tube fully compressed) Front fork oil type SUZUKI FORK OIL G-10 or an equivalent fork oil — Front fork oil capacity (Each leg) 686 ml (23.2/24.2 US/lmp oz) — Tightening Torque Specifications...
Page 421: Special Tools And Equipment
Front Suspension: 2B-10 Special Tools and Equipment Recommended Service Material B822H12208001 Material SUZUKI recommended product or Specification Note Fork Oil SUZUKI FORK OIL G-10 or P/No.: 99000–99044– (Page 2B-5) / (Page 2B- equivalent 5) / (Page 2B-6) / (Page 2B-7) /...
Page 422: Rear Suspension
2C-1 Rear Suspension: Rear Suspension Suspension Repair Instructions Rear Suspension Components B822H12306001 I822H1230042-03 1. Rear shock absorber 7. Swingarm pivot shaft : 110 N⋅m (11.0 kgf-m, 79.5 lb-ft) 2. Rear cushion rod 8. Swingarm pivot shaft pivot bolt : 100 N⋅m (10.0 kgf-m, 72.5 lb-ft) 3.
Page 423: Rear Suspension Assembly Construction
Rear Suspension: 2C-2 Rear Suspension Assembly Construction B822H12306002 “ a ” “ a ” “ a ” “ a ” I822H1230038-05 1. Rear shock absorber nut 5. Swingarm pivot shaft : 132 N⋅m (13.2 kgf-m, 95.5 lb-ft) : Tighten (5) first, and then tighten (6). 2.
Page 424: Rear Shock Absorber Removal And Installation
2C-3 Rear Suspension: Rear Shock Absorber Removal and Installation 6) Remove the shock absorber. B822H12306003 Removal 1) Place the motorcycle on the center stand and support the motorcycle with a jack to be no load for the rear shock absorber. 2) Remove the exhaust pipe and muffler.
Page 425: Rear Shock Absorber Inspection
Rear Suspension: 2C-4 Rear Shock Absorber Inspection Rear Shock Absorber Disposal B822H12306005 B822H12306007 Inspect the rear shock absorber in the following Refer to “Rear Shock Absorber Removal and Installation procedures: (Page 2C-3)”. The rear shock absorber unit contains high-pressure 1) Remove the rear shock absorber. Refer to “Rear nitrogen gas.
Page 426: Swingarm / Cushion Lever Removal And Installation
2C-5 Rear Suspension: 2) Wrap rear shock absorber (1) with a vinyl bag (2) 4) Remove the right frame lower cover (1). and fix it on a vise as shown in the figure. 3) Drill a 2 – 3 mm (0.08 – 0.12 in) hole at the marked drill center using a drilling machine and let out gas while taking care not to get the vinyl bag entangled with the drill bit.
Page 427 Rear Suspension: 2C-6 8) Loosen the swingarm pivot shaft clamp bolt (3) and Installation remove the swingarm pivot shaft (4) with the special Install the swingarm in the reverse order of removal. Pay tool. attention to the following points: • Temporarily tighten the cushion lever upper nut (1) Special tool and cushion lever lower nut (2).
Page 428: Cushion Lever / Cushion Rod Inspection
2C-7 Rear Suspension: Cushion Lever / Cushion Rod Inspection • Tighten the cushion lever and cushion rod nuts to the specified torque. B822H12306009 Refer to “Swingarm / Cushion Lever Removal and Tightening torque Installation (Page 2C-5)”. Rear cushion rod nut (c): 110 N·m (11.0 kgf-m, 79.5 lb-ft) Cushion Lever Rear cushion lever upper nut (d): 132 N·m (13.2...
Page 429: Cushion Lever / Cushion Rod Bearing Removal And Installation
Rear Suspension: 2C-8 Cushion lever Cushion rod Inspect the cushion lever for damage. If any defect is Inspect the cushion rods for damage and bend. If any found, replace the cushion lever with a new one. defects are found, replace the cushion rods with new ones.
Page 430 (A): 09921–20240 (Bearing remover set) I822H1230017-01 3) Apply grease to the bearings and cushion lever seals. I822H1230015-01 : Grease 99000–25010 (SUZUKI SUPER Installation GREASE A or equivalent) CAUTION The removed bearings and cushion seals must be replaced with new ones.
Page 431: Swingarm Related Parts Inspection
Rear Suspension: 2C-10 2) Apply grease to the bearings. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I822H1230032-01 Swingarm Inspect the swingarm for damage. If any defect is found, I822H1230020-01 replace the swingarm with a new one. 3) Install the cushion lever. Refer to “Swingarm / Cushion Lever Removal and Installation (Page 2C- 5)”.
Page 432: Swingarm Bearing Removal And Installation
(A): 09923–73210 (Bearing remover) (B): 09930–30104 (Rotor remover slide shaft) I822H1230036-01 3) Apply grease to the bearings. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I822H1230035-01 4) Remove the center spacer (2). I822H1230037-01 4) Install the swingarm. Refer to “Swingarm / Cushion Lever Removal and Installation (Page 2C-5)”.
Page 433: Specifications
Rear Suspension: 2C-12 Specifications Service Data B822H12307001 Suspension Unit: mm (in) Item Standard Limit Rear shock absorber spring adjuster Rear wheel travel 118 (4.6) — Swingarm pivot shaft runout — 0.3 (0.01) Tightening Torque Specifications B822H12307002 Tightening torque Fastening part Note N⋅m kgf-m...
Page 434: Special Tools And Equipment
2C-13 Rear Suspension: Special Tools and Equipment Recommended Service Material B822H12308001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010 (Page 2C-9) / (Page 2C- equivalent 10) / (Page 2C-11) NOTE Required service material is also described in the following.
Page 435: Wheels And Tires
Wheels and Tires: 2D-1 Wheels and Tires Suspension Precautions Precautions for Wheel and Tire B822H12400001 WARNING • Proper tire pressure and proper tire loading are important factors. Over loading tire can lead to tire failure and loss of motorcycle control. •...
Page 436: Repair Instructions
2D-2 Wheels and Tires: Repair Instructions Front Wheel Components B822H12406001 I822H1240038-02 1. Front axle 7. Front wheel : 100 N⋅m (10.0 kgf-m, 72.5 lb-ft) 2. Brake disc bolt 8. Collar : Apply grease. 3. Brake disc 9. Tire : Apply thread lock to the thread part. 4.
Page 437: Front Wheel Assembly Construction
Wheels and Tires: 2D-3 Front Wheel Assembly Construction B822H12406002 “ a ” I822H1240030-04 1. Brake disc bolt : 23 N⋅m (2.3 kgf-m, 16.5 lb-ft) : Apply grease. 2. Brake caliper mounting bolt : 100 N⋅m (10.0 kgf-m, 72.5 lb-ft) : Apply thread lock to the thread part. 3.
Page 438: Front Wheel Assembly Removal And Installation
Do not operate the brake lever and brake I822H1240001-01 pedal while removing the caliper. 6) Remove the collar (3). I822H1240002-01 I822H1240031-01 Installation 1) Apply grease to the collar (1) and install it. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I822H1240003-03...
Page 439 Wheels and Tires: 2D-5 2) Install the front wheel with the front axle and tighten 5) Tighten the front axle (3) to the specified torque with the front axle temporarily. the special tool. Special tool WARNING (A): 09900–18740 (Hexagon socket (24 The directional arrow on the tire should point mm)) to the wheel rotation, when remounting the...
Page 440: Front Wheel Related Parts Inspection
2D-6 Wheels and Tires: Front Wheel Related Parts Inspection Wheel B822H12406004 1) Remove the brake pads. Refer to “Front Brake Pad Refer to “Front Wheel Assembly Removal and Replacement in Section 4B (Page 4B-2)”. Installation (Page 2D-4)”. 2) Make sure that the wheel runout checked as shown does not exceed the service limit.
Page 441: Front Wheel Dust Seal / Bearing Removal And Installation
1) Remove the front wheel assembly. Refer to “Front Wheel Assembly Removal and Installation 1) Apply grease to the wheel bearings. (Page 2D-4)”. : Grease 99000–25010 (SUZUKI SUPER 2) Remove the dust seals (1). GREASE A or equivalent) Special tool (A): 09913–50121 (Oil seal remover)
Page 442 3) Install the dust seals with the special tool. Special tool (C): 09913–70210 (Bearing installer set) I822H1240013-02 4) Apply grease to the lip of the dust seals. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) “ a ” I822H1240014-01 I822H1240032-02 5) Install the front wheel assembly.
Page 443: Rear Wheel Components
Wheels and Tires: 2D-9 Rear Wheel Components B822H12406006 I822H1240039-02 1. Rear axle 9. Spacer 17. Wheel balancer 2. Spacer 10. Rear wheel 18. Air valve 3. Bearing 11. Rear tire : 23 N⋅m (2.3 kgf-m, 16.5 lb-ft) 4. Lock washer 12.
Page 444: Rear Wheel Assembly Construction
2D-10 Wheels and Tires: Rear Wheel Assembly Construction B822H12406007 “ a ” I822H1240033-04 1. Brake disc bolt : 100 N⋅m (10.0 kgf-m, 72.5 lb-ft) : Apply thread lock to the thread part. “a”: Clearance : Apply grease. : 23 N⋅m (2.3 kgf-m, 16.5 lb-ft) : Apply thread lock to the thread part.
Page 445: Rear Wheel Assembly Removal And Installation
Wheels and Tires: 2D-11 Rear Wheel Assembly Removal and Installation 5) Remove the cap (2). B822H12406008 Removal 1) Support the motorcycle with the jack or wooden block. 2) Remove the rear fender. Refer to “Exterior Parts Removal and Installation in Section 9D (Page 9D- 3)”.
Page 446: Rear Wheel Related Parts Inspection
1) Apply grease to the final gear spline. 7) Hold the rear axle with the special tool and tighten the rear axle nut (4) to the specified torque. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) Tightening torque Rear axle nut (b): 100 N·m (10.0 kgf-m, 72.5 lb-ft) Special tool (A): 09944–28320 (Hexagon socket (19...
Page 447 Wheels and Tires: 2D-13 Dust Seal Wheel Inspect the dust seal lip for wear or damage. If any 1) Remove the brake pads. Refer to “Rear Brake Pad defects is found, replace the dust seal with a new one. Replacement in Section 4C (Page 4C-2)”. Refer to “Rear Wheel Dust Seal / Bearing Removal and 2) Make sure that the wheel runout checked as shown Installation (Page 2D-14)”.
Page 448: Rear Wheel Dust Seal / Bearing Removal And Installation
1) Remove the rear wheel assembly. Refer to “Rear Wheel Assembly Removal and Installation 1) Apply grease to the wheel bearings. (Page 2D-11)”. : Grease 99000–25010 (SUZUKI SUPER 2) Remove the dust seal (1). GREASE A or equivalent) Special tool (A): 09913–50121 (Oil seal remover)
Page 449: Tire Removal And Installation
Wheels and Tires: 2D-15 4) Apply grease to the dust seal lip. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I822H1240029-01 5) Install the rear wheel assembly. Refer to “Rear Wheel Assembly Removal and Installation (Page 2D-11)”. Tire Removal and Installation...
Page 450 2D-16 Wheels and Tires: Installation 3) Bounce the tire several times while rotating. This makes the tire bead expand outward to contact the CAUTION wheel, thereby facilitating air inflation. Do not reuse the valve which has been once 4) Install the valve core and inflate the tire. removed.
Page 451: Wheel / Tire / Air Valve Inspection And Cleaning
Wheels and Tires: 2D-17 Wheel / Tire / Air Valve Inspection and Cleaning Air Valve B822H12406012 Inspect the air valve for peeling and damage. If any Refer to “Tire Removal and Installation (Page 2D-15)”. defect is found, replace the air valve with a new one. Refer to “Air Valve Removal and Installation (Page 2D- Wheel 17)”.
Page 452: Wheel Balance Check And Adjustment
2D-18 Wheels and Tires: Wheel Balance Check and Adjustment Installation Install the air valve in the reverse order of removal. Pay B822H12406014 Check and adjust the wheel balance in the following attention to the following points: procedures: • Any dust or rust around the valve hole (1) must be 1) Removal the wheel assembly.
Page 453: Specifications
Wheels and Tires: 2D-19 Specifications Service Data B822H12407001 Wheel Unit: mm (in) Item Standard Limit Axial Wheel rim runout Front & Rear — 2.0 (0.08) Radial Wheel axle runout Front & Rear — 0.25 (0.010) Front 16 M/C x MT 3.50 —...
Page 454: Special Tools And Equipment
2D-20 Wheels and Tires: Special Tools and Equipment Recommended Service Material B822H12408001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010 (Page 2D-4) / (Page 2D- equivalent 7) / (Page 2D-8) / (Page 2D-12) /...
Page 455 Wheels and Tires: 2D-21 09941–34513 09944–28320 Steering race installer Hexagon socket (19 mm) (Page 2D-7) / (Page 2D- (Page 2D-11) / (Page 2D-12)
Page 456 2D-22 Wheels and Tires:...
Page 457 Table of Contents 3- i Section 3 Driveline / Axle CONTENTS Precautions ..........3-1 Secondary Gear Shim Inspection and Adjustment ............3A-10 Precautions............. 3-1 Final Bevel Gear Components ......3A-12 Precautions for Driveline / Axle ......3-1 Final Gear Construction ........3A-13 Drive Chain / Drive Train / Drive Shaft... 3A-1 Final Gear Assembly Removal and Installation ............3A-13 Diagnostic Information and Procedures....3A-1...
Page 458: Precautions
3-1 Precautions: Precautions Driveline / Axle Precautions Precautions for Driveline / Axle B822H13000001 Refer to “General Precautions in Section 00 (Page 00-1)”. WARNING Support the motorcycle with a jack or wooden block when servicing the drive shafts and drive train.
Page 459: Drive Chain / Drive Train / Drive Shaft
Drive Chain / Drive Train / Drive Shaft: 3A-1 Drive Chain / Drive Train / Drive Shaft Driveline / Axle Diagnostic Information and Procedures Drive Chain and Sprocket Symptom Diagnosis B822H13104001 Condition Possible cause Correction / Reference Item Noisy shaft drive (Noise Oil level too low.
Page 460: Repair Instructions
3A-2 Drive Chain / Drive Train / Drive Shaft: Repair Instructions Secondary Gear Components B822H13106007 I822H1310001-05 1. Driven bevel gear coupling 12. Damper spring : 50 N⋅m (5.0 kgf-m, 36.0 lb-ft) 2. Oil seal 13. Spring cam stopper : 160 N⋅m (16.0 kgf-m, 115.5 lb-ft) 3.
Page 461: Secondary Gear Construction
Drive Chain / Drive Train / Drive Shaft: 3A-3 Secondary Gear Construction B822H13106008 I822H1310002-03 1. Shims : 95 N⋅m (9.5 kgf-m, 68.5 lb-ft) : Apply thread lock to the thread part. 2. Shims : 50 N⋅m (5.0 kgf-m, 36.0 lb-ft) : Do not reuse.
Page 462: Secondary Driven Gear Disassembly And Assembly
1) Remove the oil jet (1) and shims (2). Use a new O-ring (1) to prevent oil pressure leak. • Apply grease to the O-ring (2). : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) CAUTION Use a new O-ring (2) to prevent oil leakage.
Page 463 Drive Chain / Drive Train / Drive Shaft: 3A-5 4) Unlock the nut with a chisel. 9) Remove the following parts from the shaft (8). 5) Remove the driven bevel gear coupling nut with the • Bearing housing (9) special tool. •...
Page 464 Special tool (D): 09921–20240 (Bearing remover set) I822H1310015-01 2) Apply bond to the mating surface of the bearing housing and oil seal housing. : Sealant 99000–31140 (SUZUKI BOND No.1207B or equivalent) NOTE • Make surface free from moisture, oil, dust I822H1310022-01 13) Remove the bearing (16) with the special tools.
Page 465 CAUTION The removed oil seal must be replaced with a new one. Special tool (A): 09913–70210 (Bearing installer set) 5) Apply grease to the lip of the oil seal. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I822H1310024-01 I822H1310019-02...
Page 466 12) Install the shims (7). 13) Apply grease to the O-ring. CAUTION Replace the O-ring with a new one. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I822H1310025-01 9) Install the coupling (4) and washer (5). 10) Tighten the coupling nut (6) to the specified torque with the special tool.
Page 467: Secondary Driven Gear Related Parts Inspection
Drive Chain / Drive Train / Drive Shaft: 3A-9 Secondary Driven Gear Related Parts Dumper Spring Measure the free length of the damper spring. If the Inspection length is shorter than the service limit, replace the spring B822H13106011 Refer to “Secondary Driven Gear Disassembly and with a new one.
Page 468: Secondary Gear Shim Inspection And Adjustment
3A-10 Drive Chain / Drive Train / Drive Shaft: Secondary Gear Shim Inspection and 2) Measure the backlash as follows: Adjustment • Install the backlash measuring tool on the driven B822H13106012 bevel gear coupling, and set-up a dial gauge as Backlash shown in the figure.
Page 469 Drive Chain / Drive Train / Drive Shaft: 3A-11 Tooth Contact After bringing the backlash within specification by Contact Position changing the secondary driven bevel gear shims, it will be necessary to check tooth contact. 1) Remove the secondary gear case. 2) Clean and degrease the secondary drive bevel gear teeth, and apply a coating of machinist’s layout dye or paste to several teeth.
Page 470: Final Bevel Gear Components
3A-12 Drive Chain / Drive Train / Drive Shaft: Final Bevel Gear Components B822H13106013 I822H1310040-09 1. Oil seal 14. Final drive bevel gear bearing 27. Final gear case nut 2. Final gear bearing case 15. Oil seal 28. Final driven gear coupling nut 3.
Page 471: Final Gear Construction
1) Apply bond to the mating surface of the final gear Removal case and swingarm. 1) Drain final gear oil. Refer to “Final Gear Oil : Sealant 99000–31110 (SUZUKI BOND Replacement in Section 0B (Page 0B-14)”. No.1215 or equivalent) 2) Remove the rear wheel. Refer to “Rear Wheel...
Page 472: Final Gear Disassembly And Assembly
3A-14 Drive Chain / Drive Train / Drive Shaft: 2) Apply moly paste to the propeller shaft spline. 5) Tighten the final gear case pivot bolt (3). : Moly paste 99000–25140 (SUZUKI MOLY PASTE or equivalent) I822H1310046-05 6) Install the rear wheel assembly. Refer to “Rear...
Page 473 Drive Chain / Drive Train / Drive Shaft: 3A-15 3) Remove the snap ring (3) with the special tool. 7) Remove the washer (6) and final drive gear coupling (7). Special tool : 09900–06108 (Snap ring pliers) I822H1310052-01 8) Remove the bearing stopper with the special tool. I822H1310049-01 4) Remove the propeller shaft (4) and spring (5).
Page 474 3A-16 Drive Chain / Drive Train / Drive Shaft: 11) Remove the washer (10). 14) Remove the final gear bearing case (11) from the final gear case by using two 5 mm screws. I822H1310055-01 12) Remove the inner race with the special tool. I822H1310058-01 15) Remove the shim (12) and final driven bevel gear Special tool...
Page 475 Drive Chain / Drive Train / Drive Shaft: 3A-17 17) Remove the final driven bevel gear bearing (15) from 20) Remove the final drive gear bearing (19) with the the bevel gear with two bolts or suitable bars. special tools. Special tool NOTE (H): 09923–74511 (Bearing remover)
Page 476 • Apply grease to the lip of the oil seal. • Apply grease to the oil seal lip. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) “A”...
Page 477 I822H1310072-01 • Apply bond to the mating surface of the final gear case and final gear bearing case. CAUTION Do not block the breather passage when applying bond. : Sealant 99000–31140 (SUZUKI BOND No.1207B or equivalent) I822H1310075-03 I822H1310073-01...
Page 478 Use a new oil seal and O-ring to prevent oil I822H1310079-01 leakage. • Tighten the nut to the specified torque with the special tool. : Grease 99000–25010 (SUZUKI SUPER CAUTION GREASE A or equivalent) Use a new nut. Tightening torque Final drive gear coupling nut (d): 100 N·m (10.0...
Page 479: Final Gear Parts Inspection
(NLGI#2) to the propeller shaft splines and final drive Special tool bevel gear coupling. (J): 09940–51410 (Bearing installer) • Install the spring (15) and propeller shaft (16). (K): 09925–18011 (Steering bearing installer) : Moly paste 99000–25140 (SUZUKI MOLY PASTE or equivalent) I822H1310084-02 Final Gear Parts Inspection I822H1310081-02 B822H13106017 •...
Page 480: Universal Joint Removal And Installation
3A-22 Drive Chain / Drive Train / Drive Shaft: Universal Joint Removal and Installation Spring Inspect the spring damage or fatigue. If any defects are B822H13106018 Removal founds, replace the spring with a new one. 1) Remove the swingarm. Refer to “Swingarm / Cushion Lever Removal and Installation in Section 2C (Page 2C-5)”.
Page 481: Universal Joint Inspection
Drive Chain / Drive Train / Drive Shaft: 3A-23 Universal Joint Inspection 5) Remove the O-ring (2). B822H13106019 Inspect the play by turning the universal joint. If excessive play is noted, replace it with a new one. CAUTION Do not attempt to disassemble the universal joint.
Page 482: Wheel Dumper Inspection
Inspect the dumpers for wear and damage. Replace the dumper, if there is anything unusual. CAUTION The removed O-ring must be replaced with a new one. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I822H1310102-01 Final Gear Shim Inspection and Adjustment B822H13106022 Refer to “Final Gear Disassembly and Assembly...
Page 483 Drive Chain / Drive Train / Drive Shaft: 3A-25 2) Measure the clearance between the shims and Backlash bearing. If it is not within the specification, the must After assembling the final gear case, measure the final be changed. bevel gear backlash as follows: •...
Page 484 3A-26 Drive Chain / Drive Train / Drive Shaft: Backlash is too small EXAMPLE: Final gear to case shims (1); • Install a thicker shim pack (1) between the final driven 1.45 mm + 1.40 mm = 2.85 mm bevel gear and final gear case. Final gear bearing to bearing case shims (2), •...
Page 485 Drive Chain / Drive Train / Drive Shaft: 3A-27 • Using a socket and handle on the final drive bevel gear coupling nut, rotate the final drive bevel gear Contact Position several turns in each direction, while loading the final driven bevel gear.
Page 486: Specifications
3A-28 Drive Chain / Drive Train / Drive Shaft: Specifications Service Data B822H13107001 Drive Train Unit: mm (in) Except ratio Item Standard Limit E-03, 28, 33 1.757 (58/33) — Primary reduction ratio The others 1.647 (56/34) — Secondary reduction ratio 1.058 (18/17) —...
Page 487: Special Tools And Equipment
(Page 3A-8) / (Page 3A-18) / (Page 3A-18) / (Page 3A-20) / (Page 3A-21) / (Page 3A-24) Moly paste SUZUKI MOLY PASTE or equivalent P/No.: 99000–25140 (Page 3A-14) / (Page 3A-21) Sealant SUZUKI BOND No.1215 or P/No.: 99000–31110 (Page 3A-13) equivalent SUZUKI BOND No.1207B or...
Page 488 3A-30 Drive Chain / Drive Train / Drive Shaft: 09913–75821 09913–76010 Bearing installer Bearing installer (Page 3A-18) (Page 3A-18) 09913–84510 09921–20240 Bearing installer Bearing remover set (Page 3A-19) (Page 3A-6) / (Page 3A- 09923–74511 09924–34510 Bearing remover Backlash measuring tool (φ27 –...
Page 489 Drive Chain / Drive Train / Drive Shaft: 3A-31 09951–17010 Bearing installer (Page 3A-19)
Page 490 3A-32 Drive Chain / Drive Train / Drive Shaft:...
Page 491 Table of Contents 4- i Section 4 Brake CONTENTS Precautions ..........4-1 Special Tools and Equipment ......4A-19 Recommended Service Material .......4A-19 Precautions............. 4-1 Special Tool ............4A-19 Precautions for Brake System ......4-1 Brake Fluid Information ......... 4-1 Front Brakes ..........4B-1 Brake Control System and Diagnosis ...
Page 492: Precautions
4-1 Precautions: Precautions Brake Precautions Precautions for Brake System B822H14000001 Refer to “General Precautions in Section 00 (Page 00-1)”. Brake Fluid Information B822H14000002 WARNING • This brake system is filled with an ethylene glycol-based DOT 4 brake fluid. Do not use or mix different types of fluid, such as silicone-based or petroleum-based.
Page 493: Brake Control System And Diagnosis
Brake Control System and Diagnosis: 4A-1 Brake Control System and Diagnosis Brake Schematic and Routing Diagram Front Brake Hose Routing Diagram B822H14102001 “B” “A” “C” “D” “G” “E” “I” “F” “H” “H” “D” I822H1410048-04 1. Front brake hose “C”: Fix the hose sleeve to the steering under bracket firmly. 2.
Page 494: Rear Brake Hose Routing Diagram
4A-2 Brake Control System and Diagnosis: Rear Brake Hose Routing Diagram B822H14102002 “A” “A” “B” “C” “G” “H” “D” “ a” “b” “D” “E” “F” “B” I822H1410049-05 1. Rear brake pipe “E”: Position the brake hose guide firmly. 2. Reservoir “F”: Fix the hose sleeve to the hose guide firmly.
Page 495: Diagnostic Information And Procedures
Brake Control System and Diagnosis: 4A-3 Diagnostic Information and Procedures Brake Symptom Diagnosis B822H14104001 Condition Possible cause Correction / Reference Item Insufficient brake power Leakage of brake fluid from hydraulic Repair or replace. system. Worn pads and disc. Replace. Oil adhesion on friction surface of pads. Clean disc and pads. Air in hydraulic system.
Page 496: Repair Instructions
4A-4 Brake Control System and Diagnosis: Repair Instructions Brake Pedal Height Inspection and Adjustment Rear Brake Light Switch Inspection B822H14106001 B822H14106003 Refer to “Brake System Inspection in Section 0B Inspect the rear brake light switch in the following (Page 0B-18)”. procedures: 1) Disconnect the rear brake light switch lead coupler Front Brake Light Switch Inspection...
Page 497: Brake Fluid Level Check
Brake Control System and Diagnosis: 4A-5 Brake Fluid Level Check 2) Attach a clear hose to the air bleeder valve, and B822H14106005 insert the free end of the hose into a receptacle. Refer to “Brake System Inspection in Section 0B 3) Squeeze and release the brake lever several times (Page 0B-18)”.
Page 498: Brake Fluid Replacement
4A-6 Brake Control System and Diagnosis: 8) Fill the reservoir with brake fluid to the upper mark of • Fill the reservoir with brake fluid to the upper mark of the reservoir. the reservoir. I822H1410007-01 I822H1410010-01 9) Install the reservoir cap. Brake Fluid Replacement Rear Brake (Combination Brake) B822H14106008...
Page 499 Brake Control System and Diagnosis: 4A-7 6) Loosen the air bleeder valve and pump the brake Rear Brake (Combination Brake) lever until the old brake fluid flows out of the brake 1) Place the motorcycle on a level surface. system. 2) Move the right air cleaner box.
Page 500: Front Brake Hose Removal And Installation
4A-8 Brake Control System and Diagnosis: Front Brake Hose Removal and Installation 8) Close the air bleeder valve (1) and disconnect the clear hose. B822H14106009 Removal Tightening torque 1) Drain brake fluid. Refer to “Brake Fluid Replacement Front brake caliper air bleeder valve (a): 6 N·m ( (Page 4A-6)”.
Page 501: Front Brake Master Cylinder Components
Brake Control System and Diagnosis: 4A-9 Front Brake Master Cylinder Components B822H14106011 I822H1410055-01 1. Reservoir cap 6. Brake hose union bolt : 1 N⋅m (0.1 kgf-m, 0.7 lb-ft) 2. Plate 7. Brake lever : 6 N⋅m (0.6 kgf-m, 4.5 lb-ft) 3.
Page 502: Front Brake Master Cylinder Assembly Removal And Installation
4A-10 Brake Control System and Diagnosis: Front Brake Master Cylinder Assembly Removal and Installation B822H14106012 Removal “C” 1) Drain brake fluid. Refer to “Brake Fluid Replacement (Page 4A-6)”. 2) Disconnect the front brake light switch lead coupler (1). “B” 3) Place a rag underneath the brake hose union bolt (2) on the master cylinder to catch any spilt brake fluid.
Page 503: Front Brake Master Cylinder / Brake Lever Disassembly And Assembly
Brake Control System and Diagnosis: 4A-11 Front Brake Master Cylinder / Brake Lever 4) Remove the following parts from the master cylinder. Disassembly and Assembly • Piston (8) B822H14106013 • Secondary cup (9) Refer to “Front Brake Master Cylinder Assembly Removal and Installation (Page 4A-10)”.
Page 504: Front Brake Master Cylinder Parts Inspection
• Apply grease to the brake lever pivot bolt. • Apply grease to the contact point between piston and brake lever. I822H1410033-02 : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) Piston Inspect the piston surface for any scratches or other damage.
Page 505: Rear Brake Master Cylinder Components
Brake Control System and Diagnosis: 4A-13 Rear Brake Master Cylinder Components B822H14106015 I822H1410056-01 1. Reservoir tank 4. Master cylinder : 10 N⋅m (1.0 kgf-m, 7.0 lb-ft) : Apply silicone grease. 2. Brake hose union bolt 5. Piston/Cup set : 23 N⋅m (2.3 kgf-m, 16.5 lb-ft) : Apply brake fluid.
Page 506: Rear Brake Master Cylinder Removal And Installation
4A-14 Brake Control System and Diagnosis: Rear Brake Master Cylinder Removal and 5) Loosen the lock-nut (4) and remove the push rod (5). Installation B822H14106016 Removal 1) Remove the radiator heat shield (1). I822H1410035-04 6) Remove the reservoir hose cover (6) and master cylinder assembly (7).
Page 507 Brake Control System and Diagnosis: 4A-15 Installation • Tighten the footrest bracket bolts (4) to the specified Install the rear brake master cylinder in the reverse order torque. of removal. Pay attention to the following points: Tightening torque • Connect the reservoir hose to the master cylinder. Front footrest bracket bolt (c): 85 N·m (8.5 kgf-m, •...
Page 508: Rear Brake Master Cylinder Disassembly And Assembly
4A-16 Brake Control System and Diagnosis: Rear Brake Master Cylinder Disassembly and 3) Remove the push rod (6), piston/cup set (7) and spring (8). Assembly B822H14106017 Refer to “Rear Brake Master Cylinder Removal and Installation (Page 4A-14)”. Disassembly 1) Remove the snap ring (1), brake hose connector (2) and O-ring (3).
Page 509: Rear Brake Master Cylinder Parts Inspection
Rear Brake Master Cylinder Parts Inspection • Apply grease to the push rod end. B822H14106018 Refer to “Rear Brake Master Cylinder Disassembly and : Grease 99000–25100 (SUZUKI Silicone Assembly (Page 4A-16)”. Grease or equivalent) Master Cylinder Inspect the master cylinder bore for any scratches or other damage.
Page 510: Service Data
4A-18 Brake Control System and Diagnosis: Specifications Service Data B822H14107001 Brake Unit: mm (in) Item Standard Limit Rear brake pedal height 105 – 115 (4.1 – 4.5) — Front 4.8 – 5.2 (0.189 – 0.205) 4.5 (0.18) Brake disc thickness Rear 6.6 –...
Page 511: Special Tools And Equipment
Brake Control System and Diagnosis: 4A-19 Special Tools and Equipment Recommended Service Material B822H14108001 Material SUZUKI recommended product or Specification Note Brake fluid DOT 4 — (Page 4A-6) / (Page 4A- 7) / (Page 4A-11) / (Page 4A-16) Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010...
Page 512: Front Brakes
4B-1 Front Brakes: Front Brakes Brake Repair Instructions Front Brake Components B822H14206001 I822H1420031-01 1. Front brake caliper 7. Front brake pad set : Apply silicone grease. 2. Piston 8. Stopper ring : Apply thread lock to the thread part. 3. Oil seal/Dust seal 9.
Page 513: Front Brake Pad Inspection
1) Loosen the pad mounting pin (1). mounting pin (1). 2) Remove the brake caliper by removing the caliper mounting bolts (2). : Grease 99000–25100 (SUZUKI SILICONE GREASE or equivalent) I822H1420002-01 3) Remove the pads (3) by removing the pad mounting I822H1420005-02 pin (1).
Page 514: Front Brake Caliper Removal And Installation
4B-3 Front Brakes: 8) Tighten the brake caliper mounting bolts (2) and pad 3) Remove the caliper by removing the caliper bracket mounting pin (1) to the specified torque. mounting bolts (2). Tightening torque Front brake caliper mounting bolt (a): 26 N·m ( 2.6 kgf-m, 19.0 lb-ft) Pad mounting pin (b): 18 N·m (1.8 kgf-m, 13.0 lb- I822H1420007-02...
Page 515: Front Brake Caliper Disassembly And Assembly
Front Brakes: 4B-4 • Bleed air from the brake system after installing the 4) Remove the pin bolt (4) from the caliper. caliper. Refer to “Air Bleeding from Brake Fluid Circuit in Section 4A (Page 4A-5)”. • Check the brake fluid leakage and brake operation. WARNING Brake fluid, if it leaks, will interfere with safe running and discolor painted surfaces.
Page 516 4B-5 Front Brakes: Piston No. 2 Assembly Assemble the caliper in the reverse order of disassembly. Pay attention to the following points: Brake caliper holder • Apply thread lock to the caliper holder slide pin (1). : Thread lock cement 99000–32030 (THREAD LOCK CEMENT SUPER 1303 or equivalent) •...
Page 517 CAUTION I822H1420019-01 • Apply grease to the two pins. Replace the piston seals (1) and dust seals : Grease 99000–25100 (SUZUKI SILICONE (2) with new ones. GREASE or equivalent) BF: Brake fluid (DOT 4) • Install the brake caliper holder (4) to the brake caliper.
Page 518: Front Brake Caliper Parts Inspection
4B-7 Front Brakes: Front Brake Caliper Parts Inspection Brake Pad Spring B822H14206006 Inspect the brake pad springs for damage and excessive Refer to “Front Brake Caliper Disassembly and bend. If any defects are found, replace them with new Assembly (Page 4B-4)”. ones.
Page 519: Front Brake Disc Removal And Installation
Front Brakes: 4B-8 Front Brake Disc Inspection B822H14206008 Brake Disc Thickness Check the brake disc for damage or cracks and measure the thickness using the micrometer. Replace the brake disc if the thickness is less than the service limit or if defect is found. Special tool (A): 09900–20205 (Micrometer (0 –...
Page 520: Service Data
4B-9 Front Brakes: Specifications Service Data B822H14207001 Brake Unit: mm (in) Item Standard Limit Brake disc thickness Front 4.8 – 5.2 (0.189 – 0.205) 4.5 (0.18) Brake disc runout Front & Rear — 0.30 (0.012) 22.650 – 22.70 Center — (0.8917 –...
Page 521: Special Tools And Equipment
Front Brakes: 4B-10 Special Tools and Equipment Recommended Service Material B822H14208001 Material SUZUKI recommended product or Specification Note Brake fluid DOT 4 — (Page 4B-5) / (Page 4B- Grease SUZUKI SILICONE GREASE or P/No.: 99000–25100 (Page 4B-2) / (Page 4B-...
Page 522: Rear Brakes
4C-1 Rear Brakes: Rear Brakes Brake Repair Instructions Rear Brake Components B822H14306001 I822H1430025-02 1. Rear brake caliper 7. Rear brake pad set : Apply silicone grease to sliding surface. 2. Piston seal/Dust seal 8. Brake caliper bracket : Apply brake fluid. 3.
Page 523: Rear Brake Pad Inspection
Rear Brakes: 4C-2 Rear Brake Pad Inspection 2) Remove the pads mounting pin (2) by removing the B822H14306002 clip (3). The extent of brake pads wear can be checked by observing the grooved limit line “A” on the pads. When the wear exceeds the grooved limit line, replace the pads with new ones.
Page 524: Rear Brake Caliper Removal And Installation
4C-3 Rear Brakes: Rear Brake Caliper Removal and Installation 6) Install the new brake pads. B822H14306004 7) Insert the pad mounting pin (2) and install the clip (3) as shown in the figure. Removal 1) Drain brake fluid. Refer to “Brake Fluid Replacement in Section 4A (Page 4A-6)”.
Page 525: Rear Brake Caliper Disassembly And Assembly
Rear Brakes: 4C-4 • Bleed air from the brake system after installing the 3) Place a rag over the piston to prevent it from popping caliper. Refer to “Air Bleeding from Brake Fluid Circuit out and then force out the piston using compressed in Section 4A (Page 4A-5)”.
Page 526: Rear Brake Caliper Parts Inspection
Assembly • Apply grease to the two pins. Assemble the caliper in the reverse order of : Grease 99000–25100 (SUZUKI Silicone disassembly. Pay attention to the following points: Grease or equivalent) • Wash the caliper bore and piston with specified brake fluid.
Page 527 Rear Brakes: 4C-6 Brake Caliper Piston Brake Pad Spring Inspect the brake caliper piston surface for any Inspect the brake pad springs for damage and excessive scratches or other damage. If any damage is found, bend. If any defects are found, replace them with new replace the piston with new ones.
Page 528: Rear Brake Disc Removal And Installation
4C-7 Rear Brakes: Rear Brake Disc Removal and Installation Rear Brake Disc Inspection B822H14306007 B822H14306008 Brake Disc Thickness Removal Check the brake disc for damage or cracks and measure the thickness using the micrometer. 1) Remove the rear wheel assembly. Refer to “Rear Replace the brake disc if the thickness is less than the Wheel Assembly Removal and Installation in Section service limit or if defect is found.
Page 529: Specifications
Rear Brakes: 4C-8 Specifications Service Data B822H14307001 Brake Unit: mm (in) Item Standard Limit Rear brake pedal height 105 – 115 (4.1 – 4.5) — Brake disc thickness Rear 6.6 – 7.0 (0.260 – 0.276) 6.3 (0.25) Brake disc runout Front &...
Page 530: Special Tools And Equipment
4C-9 Rear Brakes: Special Tools and Equipment Recommended Service Material B822H14308001 Material SUZUKI recommended product or Specification Note Brake fluid DOT 4 — (Page 4C-5) / (Page 4C- Grease SUZUKI Silicone Grease or P/No.: 99000–25100 (Page 4C-5) equivalent Thread lock cement THREAD LOCK CEMENT SUPER P/No.: 99000–32030...
Page 531 Table of Contents 5- i Section 5 Transmission / Transaxle CONTENTS Precautions ..........5-1 Specifications .............5B-20 Service Data............5B-20 Precautions............. 5-1 Tightening Torque Specifications......5B-20 Precautions for Transmission / Transaxle..... 5-1 Special Tools and Equipment ......5B-21 Manual Transmission......5B-1 Recommended Service Material .......5B-21 Special Tool ............5B-21 Diagnostic Information and Procedures....5B-1 Manual Transmission Symptom Diagnosis ..
Page 532: Precautions
5-1 Precautions: Precautions Transmission / Transaxle Precautions Precautions for Transmission / Transaxle B822H15000001 Refer to “General Precautions in Section 00 (Page 00-1)”.
Page 533: Manual Transmission
Manual Transmission: 5B-1 Manual Transmission Transmission / Transaxle Diagnostic Information and Procedures Manual Transmission Symptom Diagnosis B822H15204001 Condition Possible cause Correction / Reference Item Engine is noisy (Noise Worn or rubbing gear. Replace. seems to come from the Worn countershaft spline. Replace countershaft.
Page 534: Repair Instructions
5B-2 Manual Transmission: Repair Instructions Transmission Components B822H15206001 I822H1520078-01 1. Countershaft/1st drive gear 6. Driveshaft 11. 1st driven gear : 6.5 N⋅m (0.65 kgf-m, 4.5 lb-ft) 2. 5th drive gear 7. 2nd driven gear 12. Gearshift cam : Apply oil. 3.
Page 535: Transmission Removal
Manual Transmission: 5B-3 Transmission Removal Countershaft Assembly B822H15206002 1) Remove the countershaft assembly (1). 1) Remove the engine assembly from the frame. Refer to “Engine Assembly Removal in Section 1D (Page 1D-18)”. 2) Disassemble the engine top side (1). Refer to “Engine Top Side Disassembly in Section 1D (Page 1D-25)”.
Page 536: Transmission Installation
5B-4 Manual Transmission: Transmission Installation 2) Remove the gearshift fork shafts (3) and gearshift forks (4). B822H15206003 Install the transmission in the reverse order of removal. Pay attention to the following points: Bearing CAUTION Replace the removed bearing with a new one. Install the bearing (1) with the special tool.
Page 537 Manual Transmission: 5B-5 • Install the gearshift fork shafts (3) and gearshift forks Countershaft Assembly (4). • Install the bearing pin (1) and C-ring (2). I822H1520012-01 I822H1520015-01 • Tighten the shift fork retainer plug (5) to the specified • Install the countershaft on the upper crankcase. torque.
Page 538 5B-6 Manual Transmission: Driveshaft Assembly • Turn the bearing to fit the bearing dowel pin in the position “A”. • Install the bearing pin (1) and C-ring (2). “A” I822H1520020-01 I822H1520018-01 • Assemble the upper and lower crankcases. Refer to •...
Page 539: Transmission Construction
Manual Transmission: 5B-7 Transmission Construction B822H15206004 I822H1520022-02 1. Counter shaft 2. Drive shaft 3. Snap ring : Assemble the snap ring with sharp edge side out.
Page 540: Countershaft Gear / Driveshaft Gear Disassembly And Assembly
5B-8 Manual Transmission: Countershaft Gear / Driveshaft Gear • Remove the 3rd drive gear bushing (8), washer (9), snap ring (10) and 4th drive gear (7). Disassembly and Assembly B822H15206005 Refer to “Transmission Removal (Page 5B-3)” and “Transmission Installation (Page 5B-4)”. Disassembly CAUTION Identify the position of each removed part.
Page 541 • Before installing the gears, apply engine oil to the driveshaft and countershaft. • Before installing the oil seal, apply grease to the oil seal lip. : Grease 99000–25010 (SUZUKI SUPER I822H1520029-01 • Remove the 4th driven gear bushing (10), washer GREASE A or equivalent) (11), snap ring (12) and 3rd driven gear (13).
Page 542 5B-10 Manual Transmission: • When installing a new snap ring (1), pay attention to Driveshaft its direction. Fit it to the side where the thrust is as • Install the driveshaft bearing (1), using the vice and shown in the figure. special tool.
Page 543: Transmission Related Parts Inspection
Manual Transmission: 5B-11 Transmission Related Parts Inspection Countershaft B822H15206006 Refer to “Transmission Removal (Page 5B-3)”, CAUTION “Transmission Installation (Page 5B-4)” and Never reuse countershaft bearing (1). “Countershaft Gear / Driveshaft Gear Disassembly and Assembly (Page 5B-8)”. • Install the countershaft bearing (1) to the countershaft using the hydraulic press.
Page 544: Gear Position (Gp) Switch Inspection
5B-12 Manual Transmission: Gear Position (GP) Switch Inspection Gearshift Fork Thickness Measure the gearshift fork thickness using the vernier B822H15206007 Refer to “Side-stand / Ignition Interlock System Parts calipers. Inspection in Section 1I (Page 1I-8)”. Special tool (A): 09900–20102 (Vernier calipers (1/20 mm, Gear Position (GP) Switch Removal and 200 mm)) Installation...
Page 545: Gearshift Lever Construction
Replace the O-ring with a new one. NOTE Align the gear position switch pin “A” with the gearshift cam hole “B”. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) “A” “B” I822H1520044-02 • Install the clutch cover. Refer to “Clutch Installation in Section 5C (Page 5C-6)”.
Page 546: Gearshift Lever Removal And Installation
5B-14 Manual Transmission: Gearshift Lever Removal and Installation Installation B822H15206010 1) Install the gearshift lever as shown in the gearshift Removal lever construction. Refer to “Gearshift Lever 1) Remove the frame lower cover and secondary gear Construction (Page 5B-13)”. case cover. Refer to “Exterior Parts Removal and 2) Tighten the footrest bracket bolts (1) to the specified Installation in Section 9D (Page 9D-3)”.
Page 547: Gearshift Shaft / Gearshift Cam Plate Components
Manual Transmission: 5B-15 Gearshift Shaft / Gearshift Cam Plate Removal 3) Remove the frame lower cover. Refer to “Exterior Parts Removal and Installation in Section 9D and Installation (Page 9D-3)”. B822H15206014 4) Loosen the lock-nuts (1). Removal 5) Turn the gearshift link rod (2) until the gearshift lever 1) Remove the engine sprocket outer cover.
Page 548 5B-16 Manual Transmission: 6) Remove the gearshift shaft assembly (5) and 10) Remove the gearshift arm stopper (16). washers (6). I822H1520055-01 I822H1520052-02 Installation 7) Remove the following parts from the gearshift shaft Install the gearshift shaft and gearshift cam plate in the (7).
Page 549 Manual Transmission: 5B-17 • Apply thread lock to the gearshift cam stopper bolt (3) • Apply a small quantity of thread lock to the gearshift and tighten it to the specified torque. cam stopper plate bolt (7) and tighten it to the specified torque.
Page 550: Gearshift Linkage Inspection
• Apply grease to the lip of the oil seal and install the gearshift cover (13). NOTE Fit the clamp to the bolt (14). : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I822H1520067-01 Gearshift Shaft Bearing Inspect the gearshift shaft bearing for abnormal noise and smooth rotation.
Page 551: Gearshift Shaft Oil Seal / Bearing Removal And Installation
(B): 09930–30104 (Rotor remover slide shaft) I822H1520071-01 • Install the oil seal with the special tool. Special tool (A): 09913–70210 (Bearing installer set) • Apply grease to the oil seal lip. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I822H1520069-01 I822H1520072-01 I822H1520070-01...
Page 552: Specifications
5B-20 Manual Transmission: Specifications Service Data B822H15207001 Drive Train Unit: mm (in) Except ratio Item Standard Limit E-03, 28, 33 1.757 (58/33) — Primary reduction ratio The others 1.647 (56/34) — Secondary reduction ratio 1.058 (18/17) — Final reduction ratio 2.823 (18/17 x 32/12) —...
Page 553: Special Tools And Equipment
Manual Transmission: 5B-21 Special Tools and Equipment Recommended Service Material B822H15208001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010 (Page 5B-9) / (Page 5B- equivalent 13) / (Page 5B-18) / (Page 5B-19) Thread lock cement THREAD LOCK CEMENT SUPER P/No.: 99000–32030...
Page 554: Clutch
5C-1 Clutch: Clutch Transmission / Transaxle Precautions Precautions for Clutch System B822H15300001 Refer to “General Precautions in Section 00 (Page 00-1)”. Schematic and Routing Diagram Clutch Cable Routing Diagram B822H15302001 Refer to “Throttle Cable Routing Diagram in Section 1D (Page 1D-2)”. Diagnostic Information and Procedures Clutch System Symptom Diagnosis B822H15304001...
Page 555: Repair Instructions
Clutch: 5C-2 Repair Instructions Clutch Lever Position Switch Inspection Clutch Cable Removal and Installation B822H15306001 B822H15306006 Inspect the clutch lever position switch in the following Removal procedures: 1) Disconnect the clutch cable from the clutch lever. 1) Disconnect the clutch lever position switch lead Refer to “Handlebars Removal and Installation in wires.
Page 556: Clutch Components
5C-3 Clutch: Clutch Components B822H15306015 I822H1530043-01 1. Clutch pressure plate 7. Spring washer : 10 N⋅m (1.0 kgf-m, 7.0 lb-ft) 2. Clutch push piece 8. Drive plate No. 2 : 95 N⋅m (9.5 kgf-m, 68.5 lb-ft) 3. Driven plate No. 2 9.
Page 557: Clutch Removal
Clutch: 5C-4 Clutch Removal 6) Remove the clutch push piece (4), thrust washer (5) B822H15306016 and bearing (6). 1) Drain engine oil. Refer to “Engine Oil and Filter Replacement in Section 0B (Page 0B-11)”. 2) Remove the exhaust pipes and mufflers. Refer to “Exhaust Pipe / Muffler Removal and Installation in Section 1K (Page 1K-9)”.
Page 558 5C-5 Clutch: 9) Remove the spring washer (11) and its seat (12). 13) Remove the conical spring washer (13). I822H1530009-01 I822H1530012-01 10) Unlock the clutch sleeve hub nut. 14) Remove the washer (14) and primary driven gear (15). NOTE If it is difficult to remove the primary driven gear, rotate the crankshaft.
Page 559: Clutch Installation
Clutch: 5C-6 Clutch Installation 3) Install the clutch sleeve hub (6) and spring washer B822H15306017 (7). 1) Install the washer (1), spacer (2) and bearing (3), NOTE and apply engine oil to them. The conical curve side of spring washer (7) faces outside.
Page 560 5C-7 Clutch: 4) Hold the clutch sleeve hub with the special tools. 8) Insert the clutch drive plates and driven plates one by one into the clutch sleeve hub in the prescribed Special tool order. (A): 09920–53740 (Clutch sleeve hub holder) NOTE : 09920–31020 (Extension handle)
Page 561 Clutch: 5C-8 NOTE 9) Install the clutch push rod release ball (15) and clutch push rod (16). For drive plate Two kinds of the drive plate (No. 1 & No. 2) are equipped in the clutch system, they can be distinguished by the facing. “c”...
Page 562: Primary Driven Gear Removal And Installation
Adjustment in Section 0B (Page 0B-17)”. 14) Apply a light coat of bond to the clutch cover gasket mating surface as shown in the figure. : Sealant 99000–31140 (SUZUKI Bond 1207B or equivalent) I822H1530031-03 18) Pour engine oil. Refer to “Engine Oil and Filter Replacement in Section 0B (Page 0B-11)”.
Page 563: Clutch Parts Inspection
Pay attention to the following points: Installation (Page 5C-6)”. • Apply grease to the seal. Clutch Drive and Driven Plate : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) NOTE Wipe off the engine oil from the drive and driven plates with a clean rag.
Page 564 5C-11 Clutch: Measure each plate for distortion with a thickness gauge Clutch Release Bearing and surface plate. Inspect the clutch release bearing for any abnormality, Replace driven plates which exceed the limit. especially cracks. When removing the bearing from the clutch, decide whether it can be reused or if it should be Special tool replaced.
Page 565: Specifications
Clutch: 5C-12 Clutch Sleeve Hub / Primary Driven Gear Assembly Inspect the slot of the clutch sleeve hub and primary driven gear assembly for damage or wear caused by the clutch plates. If necessary, replace it with a new one. CAUTION Do not attempt to disassemble the primary driven gear assembly.
Page 566: Special Tools And Equipment
5C-13 Clutch: Special Tools and Equipment Recommended Service Material B822H15308001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010 (Page 5C-10) equivalent Sealant SUZUKI Bond 1207B or equivalent P/No.: 99000–31140 (Page 5C-9) Thread lock cement THREAD LOCK CEMENT SUPER P/No.: 99000–32030...
Page 567 Table of Contents 6- i Section 6 Steering CONTENTS Precautions ..........6-1 Steering Components .........6B-4 Steering Removal and Installation ......6B-5 Precautions............. 6-1 Steering Related Parts Inspection.......6B-7 Precautions for Steering ........6-1 Steering System Inspection ........6B-8 Steering General Diagnosis....6A-1 Steering Stem Bearing Removal and Installation ............6B-8 Diagnostic Information and Procedures....6A-1 Steering Tension Adjustment ......6B-9...
Page 568: Precautions
6-1 Precautions: Precautions Steering Precautions Precautions for Steering B822H16000001 Refer to “General Precautions in Section 00 (Page 00-1)”.
Page 569: Steering General Diagnosis
Steering General Diagnosis: 6A-1 Steering General Diagnosis Steering Diagnostic Information and Procedures Steering Symptom Diagnosis B822H16104001 Condition Possible cause Correction / Reference Item Heavy Steering Over tightened steering stem nut. Adjust. Broken bearing in steering stem. Replace. Distorted steering stem. Replace.
Page 570: Steering / Handlebar
6B-1 Steering / Handlebar: Steering / Handlebar Steering Repair Instructions Handlebars Components B822H16206001 “A” I822H1620026-02 1. Throttle grip 4. Left handlebar grip “A”: Apply handle grip bond. 2. Handlebars 5. Right handlebar switch box : 23 N⋅m (2.3 kgf-m, 16.5 lb-ft) 3.
Page 571: Handlebars Removal And Installation
Steering / Handlebar: 6B-2 Handlebars Removal and Installation 3) Remove the caps and handlebar clamp bolts. B822H16206003 Removal 1) Remove the following parts from the left handlebar. a) Rear view mirror b) Clutch lever (1) c) Left handlebar switch box (2) d) Handlebar balancer (3) e) Handlebar grip (4) I822H1620003-01...
Page 572 I649G1620008-03 • Apply grease to the end of the throttle cables and cable pulley. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) “H” I822H1620025-01 • After installing the steering, the following adjustments are required before driving.
Page 573: Handlebars Inspection
Steering / Handlebar: 6B-4 Handlebars Inspection B822H16206004 Refer to “Handlebars Removal and Installation (Page 6B-2)”. Inspect the handlebars for distortion and damage. If any defect is found, replace the handlebars with a new one. I822H1620027-01 Steering Components B822H16206005 I822H1620028-01 1. Handlebar clamp 6.
Page 574: Steering Removal And Installation
6B-5 Steering / Handlebar: Steering Removal and Installation 8) Remove the steering stem upper bracket (3). B822H16206006 Removal 1) Support the motorcycle with a jack or a wooden block. 2) Remove the front wheel assembly. Refer to “Front Wheel Assembly Removal and Installation in Section 2D (Page 2D-4)”.
Page 575 Bearing bearing (6). • Apply grease to the bearings, races and dust seals before remounting the steering stem. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I822H1620015-02 13) Remove the handlebar holders (7), holder rubbers (8) and rubber seats (9).
Page 576: Steering Related Parts Inspection
6B-7 Steering / Handlebar: • Turn the steering stem lower bracket about five or six Handlebars times to the left and right so that the taper roller • Install the handlebars. Refer to “Handlebars Removal bearings seat properly. and Installation (Page 6B-2)”. •...
Page 577: Steering System Inspection
Steering / Handlebar: 6B-8 If any abnormal points are found, replace defective parts 3) Remove the steering stem lower bearing and inner with new ones. race using a chisel. I649G1620033-02 I822H1620022-01 4) Remove the steering stem upper and lower bearing races using the special tools.
Page 578: Steering Tension Adjustment
6B-9 Steering / Handlebar: Special tool Inner race (A): 09940–92720 (Spring scale) • Press in the lower inner race using the special tool and install the bearing. Special tool (A): 09941–74911 (Steering bearing installer) I649G1620040-02 4) Do the same on the other grip end. 5) If the initial force read on the scale when the handlebars start turning is either too heavy or too light, adjust it till it satisfies the specification.
Page 579: Special Tools And Equipment
Steering / Handlebar: 6B-10 Special Tools and Equipment Recommended Service Material B822H16208001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010 (Page 6B-3) / (Page 6B- equivalent Handle grip bond Handle Grip Bond (commercially —...
Page 580 6B-11 Steering / Handlebar:...
Page 581 Table of Contents 9- i Section 9 Body and Accessories CONTENTS Precautions ..........9-1 Combination Meter / Fuel Meter / Horn.. 9C-1 Precautions............. 9-1 General Description ..........9C-1 Precautions for Electrical System ......9-1 Combination Meter System Description....9C-1 Component Location ..........9-1 Repair Instructions ..........9C-2 Electrical Components Location ......
Page 582 9-ii Table of Contents Body Structure .........9E-1 Side-stand Removal and Installation....9E-3 Specifications ............9E-4 Repair Instructions ..........9E-1 Tightening Torque Specifications......9E-4 Body Frame Construction ........9E-1 Special Tools and Equipment ......9E-4 Steering Lock Bracket Construction....9E-2 Recommended Service Material ......9E-4 Front Footrest Bracket Construction ....9E-2 Side-stand Construction........
Page 583: Precautions
Precautions: Precautions Body and Accessories Precautions Precautions for Electrical System B822H19000001 Refer to “General Precautions in Section 00 (Page 00-1)” and “Precautions for Electrical Circuit Service in Section 00 (Page 00-2)”. Component Location Electrical Components Location B822H19003001 Refer to “Electrical Components Location in Section 0A (Page 0A-7)”.
Page 584: Wiring Systems
9A-1 Wiring Systems: Wiring Systems Body and Accessories Schematic and Routing Diagram Wiring Diagram B822H19102001 Refer to “Wire Color Symbols in Section 0A (Page 0A-5)”. For E-02, 19, 24 SIDE STAND SWITCH PUSH FREE HANDLEBAR SWITCH (R) IGNITION IGNITION IGNITION SWITCH COIL/ COIL/ IGNITION...
Page 585 Wiring Systems: 9A-2 REAR TURN SIGNAL LIGHT (R) REAR COMBNATION LIGHT LICENSE LIGHT REAR TURN SIGNAL LIGHT (L) FUEL PUMP ISC VALVE RELAY REGULATOR/ SENSOR RECTIFIER 1: MAIN FUSE (30 A) SWITCH FUEL PUMP STARTER STARTER GENERATOR MOTOR RELAY BATTERY SENSOR INJECTOR INJECTOR...
Page 586 9A-3 Wiring Systems: For E-03, 28 SIDE STAND SWITCH PUSH FREE HANDLEBAR SWITCH (R) IGNITION IGNITION IGNITION SWITCH COIL/ COIL/ IGNITION IGNITION ENGINE STOP STARTER FRONT BRAKE PLUG CAP #1 PLUG CAP #2 COIL #1 COIL #2 SWITCH SWITCH BUTTON LOCK SPEEDOMETER PUSH...
Page 587 Wiring Systems: 9A-4 REAR TURN SIGNAL LIGHT (R) REAR COMBNATION LIGHT LICENSE LIGHT REAR TURN SIGNAL LIGHT (L) FUEL PUMP ISC VALVE RELAY REGULATOR/ SENSOR RECTIFIER SWITCH 1: MAIN FUSE (30 A) FUEL PUMP STARTER STARTER GENERATOR MOTOR RELAY BATTERY SENSOR INJECTOR INJECTOR EXCV...
Page 588 9A-5 Wiring Systems: For E-33 SIDE STAND SWITCH PUSH FREE HANDLEBAR SWITCH (R) IGNITION IGNITION IGNITION SWITCH COIL/ COIL/ IGNITION IGNITION ENGINE STOP FRONT BRAKE STARTER PLUG CAP #1 PLUG CAP #2 COIL #1 COIL #2 SWITCH BUTTON SWITCH EVAP SYSTEM LOCK PURGE CONTROL SPEEDOMETER...
Page 589 Wiring Systems: 9A-6 REAR TURN SIGNAL LIGHT (R) REAR COMBNATION LIGHT LICENSE LIGHT REAR TURN SIGNAL LIGHT (L) FUEL PUMP ISC VALVE RELAY REGULATOR/ SENSOR RECTIFIER SWITCH 1: MAIN FUSE (30 A) FUEL PUMP STARTER STARTER GENERATOR BATTERY MOTOR RELAY SENSOR INJECTOR INJECTOR EXCV...
Page 590: Wiring Harness Routing Diagram
9A-7 Wiring Systems: Wiring Harness Routing Diagram B822H19102002 I822H1910905-03 1. Clamp 6. Head light housing 2. Clamp 7. Horn : Bind the wiring harness with the clamp. 3. Clamp 8. Side-stand switch : Bind the brake light/taillight lead wire with the clamp. 4.
Page 591 Wiring Systems: 9A-8 “ a ” “A” “B” I822H1910906-05 1. Clamp 6. Wiring harness 2. Clamp 7. Brake light/taillight lead wire : Bind the handlebar switch (R) lead wire and throttle cable with the clamp. 3. Clamp “A”: Pass the wiring harness outside of the brake hose. : Bind the handlebar switch (L) lead wire and clutch cable with the clamp.
Page 592: Specifications
9A-9 Wiring Systems: Specifications Service Data B822H19107001 Electrical Unit: mm (in) Item Specification Note 10 A Headlight 10 A Fuel 10 A Fuse size Ignition 15 A Signal 10 A Fan motor 15 A Main 30 A...
Page 593: Lighting Systems
Lighting Systems: 9B-1 Lighting Systems Body and Accessories Repair Instructions Headlight Components B822H19206001 I822H1920034-01 1. Headlight cover 3. Headlight bulb (12 V 60/55 W, H4) 2. Headlight unit 4. Headlight housing...
Page 594: Headlight Removal And Installation
9B-2 Lighting Systems: Headlight Removal and Installation 5) Disconnect the turn signal light lead wire couplers (3) B822H19206002 and position light lead wire couplers (4) (For E-03, Removal 28, 33). 1) Removal the headlight cover (1). I822H1920004-03 I822H1920001-02 6) Remove the headlight housing (5). 2) Remove the headlight assembly.
Page 595: Headlight Beam Adjustment
Lighting Systems: 9B-3 2) Remove the bulb socket rubber cap (1). 2) Adjust the headlight beam vertically with a screwdriver. I822H1920006-03 3) Replace the headlight bulb (2) by unhooking the bulb I822H1920009-04 holder spring (3). Headlight Relay Inspection B822H19206023 Inspect the headlight relay in the following procedures: 1) Remove the right frame cover (All models) and EVAP canister (For E-33).
Page 596: Rear Combination Light Components
9B-4 Lighting Systems: Rear Combination Light Components B822H19206005 I822H1920035-02 1. Brake light/Taillight (LED) 2. Cushion Rear Combination Light Removal and Installation B822H19206007 Removal 1) Remove the rear fender. Refer to “Exterior Parts Removal and Installation in Section 9D (Page 9D- 3)”.
Page 597: License Plate Light Components
Lighting Systems: 9B-5 License Plate Light Components B822H19206009 I822H1920036-02 1. License plate light bulb (12 V 5 W) 2. Lens 3. Socket License Plate Light Removal and Installation 4) Remove the license plate light (2). B822H19206010 Removal 1) Remove the seat. Refer to “Exterior Parts Removal and Installation in Section 9D (Page 9D-3)”.
Page 598: License Plate Light Bulb Replacement
9B-6 Lighting Systems: License Plate Light Bulb Replacement 2) Replace the bulb (2). B822H19206011 1) Remove the lens (1). I822H1920015-01 3) Reinstall the lens (1). I822H1920014-01 Turn Signal Light Components B822H19206012 I822H1920038-01 1. Turn signal light bulb (12 V 21 W x 4) 2.
Page 599: Front Turn Signal Light Removal And Installation
Lighting Systems: 9B-7 Front Turn Signal Light Removal and Rear Turn Signal Light Removal and Installation B822H19206014 Installation Removal B822H19206013 Removal 1) Remove the rear fender. Refer to “Exterior Parts Removal and Installation in Section 9D (Page 9D- 1) Remove the headlight assembly. Refer to “Headlight 3)”.
Page 600: Turn Signal Light Bulb Replacement
9B-8 Lighting Systems: Turn Signal Light Bulb Replacement Turn Signal / Side-stand Relay Removal and B822H19206015 Installation B822H19206018 CAUTION Removal When you touch the bulb with your bare 1) Remove the battery holder. Refer to “Battery / hands, clean the bulb with a cloth moistened Battery Holder Removal and Installation in Section with alcohol or soap water to prevent 1J (Page 1J-11)”.
Page 601: Turn Signal Switch Inspection
Lighting Systems: 9B-9 Passing Light Switch Inspection 3) Inspect the hazard switch for continuity with a tester. If any abnormality is found, replace the left B822H19206021 Inspect the passing light switch in the following handlebar switch assembly with a new one. Refer to procedures: “Handlebars Removal and Installation in Section 6B 1) Remove the headlight assembly.
Page 602: Dimmer Switch Inspection
9B-10 Lighting Systems: Dimmer Switch Inspection 3) Inspect the dimmer switch for continuity with a tester. B822H19206022 If any abnormality is found, replace the left Inspect the dimmer switch in the following procedures: handlebar switch assembly with a new one. 1) Remove the headlight assembly.
Page 603: Combination Meter / Fuel Meter / Horn
Combination Meter / Fuel Meter / Horn: 9C-1 Combination Meter / Fuel Meter / Horn Body and Accessories General Description Combination Meter System Description B822H19301001 This combination meter mainly consists of the stepping motor, LCD (Liquid Crystal Display) and LED (Light Emitting Diode).
Page 604: Repair Instructions
9C-2 Combination Meter / Fuel Meter / Horn: Repair Instructions Combination Meter Components B822H19306001 I822H1930033-01 1. Upper case 2. Combination meter 3. Lower case Combination Meter Removal and Installation Installation B822H19306002 Install the combination meter in the reverse order of Removal removal.
Page 605: Combination Meter Inspection
Combination Meter / Fuel Meter / Horn: 9C-3 Combination Meter Inspection 2) With the adjuster switch (1) pressed, turn the ignition B822H19306004 switch ON. LED Inspection 3) Hold the adjuster switch (1), 3 to 5 seconds after Check that the LEDs (FI indicator light, Oil pressure/ turning the ignition switch ON.
Page 606: Engine Coolant Temperature Indicator Light Inspection
9C-4 Combination Meter / Fuel Meter / Horn: Engine Coolant Temperature Indicator Light Engine Coolant Temperature Removal and Inspection Installation B822H19306005 B822H19306006 Inspect the engine coolant temperature indicator light in Refer to “ECT Sensor Removal and Installation in the following procedures: Section 1C (Page 1C-3)”.
Page 607: Fuel Level Indicator Switch (Thermistor) Inspection
Combination Meter / Fuel Meter / Horn: 9C-5 Fuel Level Indicator Switch (Thermistor) 5) Turn the ignition switch ON. Inspection 6) Check the display of fuel level indicator (LCD) as B822H19306008 shown in the figure. Inspect the fuel level indicator switch in the following If any abnormality is found, replace the combination procedures: meter with a new one.
Page 608: Fuel Level Gauge Inspection
9C-6 Combination Meter / Fuel Meter / Horn: Fuel Level Gauge Inspection Speed Sensor Removal and Installation B822H19306009 B822H19306011 Inspect the fuel level gauge in the following procedures: Removal 1) Remove the fuel level gauge. Refer to “Fuel Pump 1) Remove the secondary gear case cover. Refer to Assembly / Fuel Level Gauge Removal and “Exterior Parts Removal and Installation in Section Installation in Section 1G (Page 1G-10)”.
Page 609: Speed Sensor Inspection
Use a new O-ring to prevent oil leakage. (tester (+) probe to B and tester (–) probe to B/R) as shown in the figure. : Grease 99000–25010 (SUZUKI SUPER Special tool GREASE A or equivalent) : 09900–25008 (Multi-circuit tester set)
Page 610: Oil Pressure Indicator Inspection
9C-8 Combination Meter / Fuel Meter / Horn: Oil Pressure Indicator Inspection Ignition Switch Inspection B822H19306013 B822H19306015 Inspect the oil pressure indicator in the following Inspect the ignition switch in the following procedures: procedures: 1) Remove the left frame cover. Refer to “Exterior Parts Removal and Installation in Section 9D (Page 9D- NOTE 3)”.
Page 611: Horn Inspection
Combination Meter / Fuel Meter / Horn: 9C-9 Horn Inspection 2) Connect a 12 V battery to terminal “A” and terminal B822H19306017 “B”. If the sound is not heard from the horn, replace NOTE the horn with a new one. If the horn sound condition is normal, it is not necessary to inspect the horn button continuity.
Page 612: Specifications
For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List in Section 0C (Page 0C-8)”. Special Tools and Equipment Recommended Service Material B822H19308001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010 (Page 9C-7)
Page 613: Exterior Parts
Exterior Parts: 9D-1 Exterior Parts Body and Accessories Repair Instructions Exterior Parts Construction B822H19406001 I822H1940015-01 1. Frame head cover 2. Frame head cover plate I822H1940016-01 1. Frame side cover 2. Luggage box 3. Frame cover lock...
Page 614: Fastener Removal And Installation
9D-2 Exterior Parts: “A” I822H1940017-01 1. Frame lower cover 2. Cushion 3. Frame lower cover bracket “A”: UP mark Fastener Removal and Installation 2) Insert the fastener into the installation hole. B822H19406005 Removal NOTE 1) Depress the head of fastener center piece (1). To prevent the pawl “A”...
Page 615: Exterior Parts Removal And Installation
Exterior Parts: 9D-3 Exterior Parts Removal and Installation Installation B822H19406006 1) Slide the front seat hooks into the seat hook retainer. Seat Removal 1) Remove the rear seat (1). I822H1940004-01 2) Install the rear seat band and tighten the bolts. I822H1940001-01 2) Remove the band (2).
Page 616 9D-4 Exterior Parts: Frame Cover / Luggage Box Rear Fender Removal Removal • Remove the frame covers (1), left and right. 1) Remove the seat. 2) Disconnect the rear combination light coupler (1). 3) Remove the rear fender mounting bolt (2). “A”...
Page 617 Exterior Parts: 9D-5 Front Fender 3) Remove the frame head covers (2), left and right. Removal • Remove the front fender mounting bolts. “A” • Remove the front fender. “A” I822H1940013-01 “A”: Hooked point Installation I822H1940011-01 Install the frame head covers in the reverse order of removal.
Page 618: Specifications
For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List in Section 0C (Page 0C-8)”. Special Tools and Equipment Recommended Service Material B822H19408001 Material SUZUKI recommended product or Specification Note Thread lock cement THREAD LOCK CEMENT SUPER P/No.: 99000–32110 (Page 9D-4)
Page 619: Body Structure
Body Structure: 9E-1 Body Structure Body and Accessories Repair Instructions Body Frame Construction B822H19506001 I822H1950004-01 1. Frame 5. Engine bracket 2. Frame down tube : 50 N⋅m (5.0 kgf-m, 36.0 lb-ft) 3. Rear frame : 85 N⋅m (8.5 kgf-m, 61.5 lb-ft) 4.
Page 620: Steering Lock Bracket Construction
9E-2 Body Structure: Steering Lock Bracket Construction B822H19506007 I822H1950003-01 1. Frame 2. Steering lock bracket 3. Steering lock bracket bolt : 26 N⋅m (2.6 kgf-m, 19.0 lb-ft) Front Footrest Bracket Construction B822H19506004 I822H1950001-02 1. Footrest 3. Bolt : Apply grease to sliding surface. 2.
Page 621: Side-Stand Construction
Body Structure: 9E-3 Side-stand Construction B822H19506005 I822H1950002-02 1. Side-stand 3. Side-stand bolt : 50 N⋅m (5.0 kgf-m, 36.0 lb-ft) : Apply grease to sliding surface. 2. Spring 4. Side-stand nut : 40 N⋅m (4.0 kgf-m, 29.0 lb-ft) Side-stand Removal and Installation B822H19506006 Removal 1) Support the motorcycle with the jack or wooden block.
Page 622: Specifications
9E-4 Body Structure: Specifications Tightening Torque Specifications B822H19507001 NOTE The specified tightening torque is also described in the following. “Body Frame Construction (Page 9E-1)” “Steering Lock Bracket Construction (Page 9E-2)” “Front Footrest Bracket Construction (Page 9E-2)” “Side-stand Construction (Page 9E-3)” Reference: For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List in Section 0C (Page 0C-8)”.
Page 623 Prepared by January, 2008 Part No. 99500-39360-01E Printed in Japan...
Page 624 Printed in Japan...

Suzuki VLR1800 Service Manual

Quick Links

Related Manuals for Suzuki VLR1800

Summary of Contents for Suzuki VLR1800