Suzuki LT-A700X 2004 Service Manual

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Page 2 FOREWORD GROUP INDEX This manual contains an introductory description on the SUZUKI LT-A700X and procedures for its inspection/service and overhaul of its main compo- GENERAL INFORMATION nents. Other information considered as generally known is not included. PERIODIC MAINTENANCE Read the GENERAL INFORMATION section to familiarize yourself with the motorcycle and its main- tenance.
Page 3 HOW TO USE THIS MANUAL TO LOCATE WHAT YOU ARE LOOKING FOR: 1. The text of this manual is divided into sections. 2. The section titles are listed in the GROUP INDEX. 3. Holding the manual as shown at the right will allow you to find the first page of the section easily.
Page 4 Apply molybdenum oil solution. Apply or use brake fluid. (mixture of engine oil and SUZUKl MOLY PASTE in a ratio of 1 : 1) Apply SUZUKI SUPER GREASE “A”. Measure in voltage range. 99000-25030 (USA) 99000-25010 (Others) Apply SUZUKI SILICONE GREASE.
Page 5 ABBREVIATIONS USED IN THIS MANUAL ABDC : After Bottom Dead Center : Engine Control Module : Alternating Current Engine Control Unit (ECU) : Air Cleaner, Air Cleaner Box (FI Control Unit) : American Petroleum Institute ECT Sensor : Engine Coolant Temperature ATDC : After Top Dead Center Sensor (ECTS), Water Temp.
Page 6 : Oil Pressure Switch : Positive Crankcase Ventilation (Crankcase Breather) : Rectifier : Regulator : Right Hand : Read Only Memory : Society of Automotive Engineers : Suzuki Diagnosis System TO Sensor : Tip-Over Sensor (TOS) TP Sensor : Throttle Position Sensor (TPS)
Page 7 WIRE COLOR : Black : Gray : Red : Blue : White : Brown : Light green : Yellow : Dark green : Orange : Green : Pink B/Bl : Black with Blue tracer B/Br : Black with Brown tracer : Black with Green tracer B/Lg : Black with Light green tracer...
Page 8: Table Of Contents
GENERAL INFORMATION GENERAL INFORMATION CONTENTS WARNING/CAUTION/NOTE .................1- 2 GENERAL PRECAUTIONS................1- 2 SUZUKI LT-A700XK5 (’05-MODEL) .............1- 4 SERIAL NUMBER LOCATION..............1- 4 FUEL, OIL AND ENGINE COOLANT RECOMMENDATION......1- 5 FUEL (FOR USA AND CANADA)............1- 5 FUEL (FOR OTHER COUNTRIES)............1- 5 ENGINE OIL (FOR USA).................1- 5 ENGINE OIL (FOR OTHER COUNTRIES) ..........1- 5...
Page 9: Warning/Caution/Note
GENERAL INFORMATION WARNING/CAUTION/NOTE Please read this manual and follow its instructions carefully. To emphasize special information, the symbol and the words WARNING, CAUTION and NOTE have special meanings. Pay special attention to the mes- sages highlighted by these signal words. Indicates a potential hazard that could result in death or injury.
Page 10 GENERAL INFORMATION * If parts replacement is necessary, replace the parts with Suzuki Genuine Parts or their equiva- lents. * When removing parts that are to be reused, keep them arranged in an orderly manner so that they may be reinstalled in the proper order and orientation.
Page 11: Suzuki Lt-A700Xk5 ('05-Model)
GENERAL INFORMATION SUZUKI LT-A700XK5 (’05-MODEL) RIGHT SIDE LEFT SIDE • Difference between photograph and actual vehicle may exist depending on the markets. SERIAL NUMBER LOCATION The frame serial number or V.I.N. (Vehicle Identification Number) 1 is stamped, on the left side of the front frame pipe.
Page 12: Fuel, Oil And Engine Coolant Recommendation
ENGINE OIL (FOR USA) SUZUKI recommends the use of SUZUKI PERFORMANCE 4 MOTOR OIL or an oil which is rated SF or SG under the API (American Petroleum Institute) service classification. The recommended viscosity is SAE 10W-40. If SAE 10W-40 oil is not available, select an alternative according to the following chart.
Page 13: Engine Coolant
Suzuki recommends the use of SUZUKI COOLANT anti-freeze/engine coolant. If this is not available, use an equivalent which is compatible with an aluminum radiator.
Page 14: Break-In Procedures
GENERAL INFORMATION BREAK-IN PROCEDURES During manufacture only the best possible materials are used and all machined parts are finished to a very high standard but it is still necessary to allow the moving parts to “BREAK-IN” before subjecting the engine to maximum stresses.
Page 15: Information Labels
GENERAL INFORMATION INFORMATION LABELS 1 Certification plate A (For E-24, 33) 2 Information label A (For E-33) 3 Gearshift label 4 Gearshift label A (For E-28) 5 Tire air pressure label 6 Tire air pressure label and warning no-passenger label A (For E-28) 7 General warning &...
Page 16: Specifications
GENERAL INFORMATION SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length ................2 115 mm (83.3 in) ..E-28, 33 2 135 mm (84.1 in) ..E-17, 24 Overall width ................1 210 mm (47.6 in) ..E-28, 33 1 250 mm (49.2 in) ..E-17, 24 Overall height ................
Page 17: Chassis
1-10 GENERAL INFORMATION CHASSIS Front suspension ..............Independent, double wishbone, coil spring, oil damped Rear suspension ..............Independent, double wishbone, coil spring, oil damped Front wheel travel ..............180 mm (7.1 in) Rear wheel travel ..............200 mm (7.9 in) Caster ..................
Page 18 PERIODIC MAINTENANCE PERIODIC MAINTENANCE CONTENTS PERIODIC MAINTENANCE SCHEDULE .............2- 2 PERIODIC MAINTENANCE CHART .............2- 2 MAINTENANCE AND TUNE-UP PROCEDURES ........2- 3 AIR CLEANER ..................2- 3 EXHAUST PIPE NUTS AND MUFFLER MOUNTING BOLTS ....2- 5 VALVE CLEARANCE ................2- 5 SPARK PLUG ..................2-10 SPARK ARRESTER ................2-11 FUEL LINE .....................2-11 THROTTLE CABLE PLAY ..............2-12...
Page 19: Periodic Maintenance Schedule
PERIODIC MAINTENANCE PERIODIC MAINTENANCE SCHEDULE The chart below lists the recommended intervals for all the required periodic service work necessary to keep the vehicle operating at peak performance and economy. Maintenance intervals are expressed in terms of kilometers, miles and months, and are dependent on whichever comes first. NOTE: More frequent servicing may be performed on vehicles that are used under severe conditions.
Page 20: Maintenance And Tune-Up Procedures
PERIODIC MAINTENANCE MAINTENANCE AND TUNE-UP PROCEDURES This section describes the servicing procedures for each item mentioned in the periodic maintenance chart. Before performing the servicing procedures mentioned in the periodic maintenance chart, remove following parts to ease ser- vicing work; •...
Page 21 PERIODIC MAINTENANCE • Using compressed air, blow the dust from the cleaner ele- ment. Always use air pressure from the inside of the air cleaner element. If air pressure is used on the other side, dirt will be forced into the pores of the air cleaner element thus restricting air flow through the air cleaner element.
Page 22: Exhaust Pipe Nuts And Muffler Mounting Bolts
PERIODIC MAINTENANCE EXHAUST PIPE NUTS AND MUFFLER MOUNTING BOLTS Tighten initially at 200 km (100 miles, 1 month) and every 1 000 km (600 miles, 3 months) thereafter. • Remove the right inner fender. ( $ 8-6) • Remove the right side cover. ( $ 8-8) •...
Page 23 PERIODIC MAINTENANCE • Remove the valve timing inspection plug 1 . • Turn the crankshaft to bring the “TDC” line A on the starter clutch to the lug mark B. • Read the valve clearance at all the valves with the special tool.
Page 24 • Install the new gasket 1 to the cylinder head cover. • Apply SUZUKI BOND to the cam end caps of the gasket as shown. ' 99104-31140: SUZUKI BOND “1207B” (USA) 99000-31110: SUZUKI BOND “1215”...
Page 25 PERIODIC MAINTENANCE (INTAKE SIDE)
Page 26 PERIODIC MAINTENANCE (EXHAUST SIDE)
Page 27: Spark Plug
2-10 PERIODIC MAINTENANCE SPARK PLUG Inspect every 2 000 km (1 200 miles, 6 months). Replace every 6 000 km (4 000 miles). • Remove the right inner fender. ($8-6) • Disconnect the spark plug cap 1 and remove the spark plug. Standard Cold type CR6E...
Page 28: Spark Arrester
PERIODIC MAINTENANCE 2-11 SPARK PLUG INSTALLATION To avoid damaging the cylinder head threads; first, tighten the spark plug by hand, and then tighten it to the specified torque using the spark plug wrench. • Insert the spark plug and tighten it to the cylinder head by hand then tighten it to the specified torque.
Page 29: Throttle Cable Play
2-12 PERIODIC MAINTENANCE THROTTLE CABLE PLAY Inspect initially at 200 km (100 miles, 1 month) and every 1 000 km (600 miles, 3 months) thereafter. Adjust the throttle cable play A as follows. • Loosen the locknut 1 of the throttle cable. •...
Page 30 Oil and filter change: 2.5 L (2.6 US qt, 2.2 lmp qt) Engine overhaul: 3.0 L (3.2 US qt, 2.6 lmp qt) ONLY USE A GENUINE SUZUKI MOTORCYCLE OIL FILTER. Other manufacture’s oil filters may differ in thread specifications (thread diameter and pitch), filtering performance and durability which may lead to engine damage or oil leaks.
Page 31: Differential Gear Oil Inspection
2-14 PERIODIC MAINTENANCE DIFFERENTIAL GEAR OIL INSPECTION Inspect every 2 000 km (1 200 miles, 6 months). Replace every two years. • Place the vehicle on level ground. • Remove the oil level plug 1 and oil filler plug 2, and inspect the oil level.
Page 32: Final Gear Oil
PERIODIC MAINTENANCE 2-15 FINAL GEAR OIL Inspect every 2 000 km (1 200 miles, 6 months). Replace every year. FINAL GEAR OIL INSPECTION • Keep the vehicle on a level position. • Remove the filler plug 1, and inspect the oil level. If the oil level is below, add fresh oil until the oil level reaches the bot- tom tip of the thread.
Page 33: Engine Coolant
2-16 PERIODIC MAINTENANCE ENGINE COOLANT Repalce the engine coolant every two years. ENGINE COOLANT LEVEL CHECK • Check the engine coolant level by observing the upper 1 and lower 2 lines on the engine coolant reservoir tank. • If the level is below the lower line, add engine coolant until the level reaches the upper line.
Page 34: Radiator
PERIODIC MAINTENANCE 2-17 • Install the radiator cap 1 securely. • After warming up and cooling down the engine, add the spec- ified engine coolant until the level is between the upper and lower lines on the engine coolant reservoir tank. Repeat the above procedure several times and make sure the radiator is filled with engine coolant to the upper line of the engine coolant reservoir tank.
Page 35: Drive Belt
2-18 PERIODIC MAINTENANCE DRIVE BELT Inspect every 1 000 km (600 miles, 3 months). Replace every 2 000 km (1 200 miles, 6 months). REMOVAL • Remove the right inner fender. ($8-6) • Remove the right mud guard. ($8-8) • Remove the right footrest bar 1. •...
Page 36 PERIODIC MAINTENANCE 2-19 • Hold the movable driven face with the special tool and loose the movable driven face bolt 2. % 09930-40113: Rotor holder • Remove the movable drive face bolt 1 and housing bolts. • Remove the dowel pins 3. •...
Page 37 2-20 PERIODIC MAINTENANCE REMOUNTING Remount the drive belt in reverse older of removal. Pay attention to the following points: • Insert the drive belt, as low as possible, between the movable driven face to provide the maximum drive belt clearance before installing.
Page 38 PERIODIC MAINTENANCE 2-21 • Hold the movable drive face with the special tool, and tighten the bolts to the specified torque. % 09930-40113: Rotor holder " Movable drive face bolt: 110 N·m (11.0 kgf-m, 79.5 lb-ft) • Install the movable drive face cover. •...
Page 39: Brakes
2-22 PERIODIC MAINTENANCE BRAKES Inspect initially at 200 km (100 miles, 1 month) and every 1 000 km (600 miles, 3 months) thereafter. FRONT BRAKE PAD • Remove the front wheels. ($8-13) The extent of front brake pad wear can be checked by observing the limit line 1 on the side of brake pads.
Page 40: Brake Fluid
PERIODIC MAINTENANCE 2-23 REAR BRAKE LEVER • After adjusting the brake pedal, check the rear brake lever play 1. The brake lever play 1 as measured at the lever holder should be between 6 – 8 mm (0.2 – 0.3 in) when the lever is lightly pulled in towards the grip.
Page 41 2-24 PERIODIC MAINTENANCE AIR BLEEDING THE BRAKE FLUID CIRCUIT Air trapped in the brake fluid circuit acts like a cushion absorb a large proportion of the pressure developed by the master cylin- der and thus interferes with the full braking performance of the brake caliper.
Page 42: Brake Hoses
PERIODIC MAINTENANCE 2-25 BRAKE HOSES Inspect every 2 000 km (1 200 miles, 6 months). Replace every four years. • Check the brake hoses for leakage, cracks, wear and dam- age. If any damages are found, replace the brake hoses with new ones.
Page 43: Steering
2-26 PERIODIC MAINTENANCE To minimize the possiblility of tire damage from over-inflation, we strongly recommended that a man- ual type air pump be used rather than a high pressure air compressor as found in service stations. When fill- ing air into the tires, never exceed 70 kPa (0.7 kgf/cm², 10 psi).
Page 44: Suspensions
PERIODIC MAINTENANCE 2-27 SUSPENSIONS Inspect every 2 000 km (1 200 miles, 6 months). • Support the vehicle with a jack and wooden blocks. • Remove the front and rear wheels. ($8-13) • Inspect the wishbone arm and bushing for scratches, wear, or damage.
Page 45: Chassis Nuts And Bolts
2-28 PERIODIC MAINTENANCE CHASSIS NUTS AND BOLTS Tighten initially at 200 km (100 miles, 1 month) and every 1 000 km (600 miles, 3 months) thereafter. Check that all chassis nuts and bolts are tightened to their specified torque. (Refer to page 2-29 for the loca- tions of the following nuts and bolts.) Item N·m...
Page 46 PERIODIC MAINTENANCE 2-29...
Page 47: General Lubrication
2-30 PERIODIC MAINTENANCE GENERAL LUBRICATION Lubricate every 1000 km (600 miles, 3 months). Proper lubrication is important for smooth operation and long life of each working part of the vehicle. Major lubrication points are indicated below. + Grease 1 Steering shaft holder 5 Drive shaft joint spline 2 Brake lever holder and throttle lever 6 Drive belt cover bearing (inner race)
Page 48: Compression Pressure Check
PERIODIC MAINTENANCE 2-31 COMPRESSION PRESSURE CHECK The compression pressure reading of a cylinder is a good indicator of its internal condition. The decision to overhaul the cylinder is often based on the results of a compression test. Periodic mainte- nance records kept at your dealership shoud include compression readings for each maintenance service. &...
Page 49: Oil Pressure Check
2-32 PERIODIC MAINTENANCE OIL PRESSURE CHECK Check the engine oil pressure periodically. This will give a good indication of the condition of the moving parts. & Oil pressure: Above 140 kPa (1.4 kgf/cm², 20.0 psi) Below 180 kPa (1.8 kgf/cm², 26.0 psi) Low or high oil pressure can indicate any of the following conditions: LOW OIL PRESSURE * Clogged oil filter...
Page 50: Initial Engagement And Clutch Lock-Up Inspection
PERIODIC MAINTENANCE 2-33 INITIAL ENGAGEMENT AND CLUTCH LOCK-UP INSPECTION The LT-A700X is equipped with a centrifugal type automatic clutch. To insure proper performance and longevity of the clutch assemblies it is essential that the clutches engage smoothly and gradually. Before checking the initial engagement and clutch lock-up two inspection checks must be performed to thoroughly check the operation of the drive train.
Page 51: Clutch Lock-Up Inspection
2-34 PERIODIC MAINTENANCE CLUTCH LOCK-UP INSPECTION Perform this inspection to determine if the clutch is engaging fully and not slipping. • Connect a tachometer onto the spark plug high-tension code. • Start the engine. • Shift the range lever to the “High” position. •...
Page 52 ENGINE ENGINE CONTENTS ENGINE COMPONENTS REMOVABLE WITH ENGINE IN PLACE ...3- 2 ENGINE LEFT SIDE ................3- 2 ENGINE RIGHT SIDE ................3- 2 ENGINE CENTER ..................3- 2 ENGINE REMOVAL AND INSTALLATION ..........3- 3 ENGINE REMOVAL ................3- 3 ENGINE INSTALLATION ...............3- 9 ENGINE DISASSEMBLY ................3-12 ENGINE TOP SIDE ................3-12 ENGINE BOTTOM SIDE ................3-16...
Page 53: Engine Components Removable With Engine In Place
ENGINE ENGINE COMPONENTS REMOVABLE WITH ENGINE IN PLACE The parts listed below can be removed and installed without removing the engine from the frame. Refer to the page listed in each section for removal and installation instructions. ENGINE LEFT SIDE PARTS REMOVAL INSTALLATION...
Page 54: Engine Removal And Installation
ENGINE ENGINE REMOVAL AND INSTALLATION ENGINE REMOVAL Before taking the engine out of the frame, wash the engine using a steam cleaner. Engine removal is sequentially explained in the following steps. • Drain engine oil. ($2-12) • Drain engine coolant. ($2-16) •...
Page 55 ENGINE • Disconnect the IAP sensor coupler 1 and hose 2. • Disconnect the IAT sensor coupler 3. • Remover the air cleaner box. • Disconnect the injector coupler 4 and TPS coupler 5. • Disconnect the ISC valve coupler 6 and fuel feed hose 7. •...
Page 56 ENGINE • Disconnect the speed sensor coupler and clamp. • Disconnect the couplers and wiring harness clamp. • Remove the differential relay stay 1. • Remove the regulator/rectifier 2. • Remove the cooling ducts. (Intake and outlet) • Disconnect the spark plug cap.
Page 57 ENGINE • Remove the exhaust pipe bolts. • Remove the muffler. • Remove the right footrest bar mounting bolts 1. • Remove the rear brake wire clamp bolt 2. • Remove the right footrest bar 3.
Page 58 ENGINE • Remove the rear brake pedal. • Remove the front differential mounting bolts/nuts. • Slide the front differential assy forward. • Remove the front propeller shaft spring. • Remove the engine mounting bolts/nuts.
Page 59 ENGINE • Remove the engine from the right side.
Page 60: Engine Installation
ENGINE ENGINE INSTALLATION Remount the engine in the reverse order of engine removal. Pay attention to the following points: " ITEM N·m kgf-m lb-ft 43.5 43.5...
Page 61 3-10 ENGINE • Tighten the engine mounting nuts to the specified torque. " Engine mounting nut: 60 N·m (6.0 kgf-m, 43.5 lb-ft) • Tighten the front differential gear mounting nuts to the speci- fied torque. • Apply thread lock to the nuts. , 99000-32030: THREAD LOCK SUPER “1303”...
Page 62 ENGINE 3-11 • When installing the transfer shift cam lever, align the both ser- rations. • Apply THREAD LOCK SUPER “1303” to the footrest bolts, and tighten them to the specified torque. , 99000-32030: THREAD LOCK SUPER “1303” " Footrest bolt (M8): 26 N·m (2.6 kgf-m, 19.0 lb-ft) (M10): 55 N·m (5.5 kgf-m, 40.0 lb-ft) •...
Page 63: Engine Disassembly
3-12 ENGINE ENGINE DISASSEMBLY ENGINE TOP SIDE FRONT PROPELLER SHAFT • Remove the front propeller shaft. ($4-19) SPARK PLUG • Remove the spark plug. STARTER MOTOR AND PCV HOSE • Remove the starter motor 1. • Remove the PCV (Positive Crankcase Ventilation) hose 2. WATER HOSE AND WATER UNION •...
Page 64 ENGINE 3-13 RECOIL STARTER AND VALVE TIMING INSPECTION PLUG • Remove the recoil starter 1. • Remove the valve timing inspection plug 2. CYLINDER HEAD COVER • Remove the cylinder head cover 1. CAMSHAFT • Turn the crankshaft to bring the “TDC” line A on the starter clutch to the index mark B of the crankcase.
Page 65 3-14 ENGINE • Remove the camshaft journal holders 1. Be sure to loosen the camshaft journal holder bolts evenly by shifting the wrench diagonally. • Remove the dowel pins 2 and camshafts 3. NOTE: Be careful not to drop the dowel pins into the crankcase. CAM CHAIN TENSIONER •...
Page 66 ENGINE 3-15 • Remove the cylinder head bolts (M10) and washers. NOTE: When loosening the cylinder head bolts, loosen each bolt little by little diagonally. • Remove the cylinder head 6. CYLINDER • Remove the dowel pins 1 and gasket 2. •...
Page 67: Engine Bottom Side
3-16 ENGINE ENGINE BOTTOM SIDE OIL FILTER • Remove the oil filter with the special tool. % 09915-40610: Oil filter wrench WATER PUMP • Remove the water pump 1. GENERATOR COVER • Remove the starter cup nut with a suitable bar 1. •...
Page 68 ENGINE 3-17 STARTER TORQUE LIMITER • Remove the washers 1 and starter torque limiter 2. STARTER IDLE GEAR • Remove the washer 1 and starter idle gear 2. GEARSHIFT • Remove the washers 1 and gearshift shaft 2. • Remove the cam driven gear 3 by removing its bolt 4. •...
Page 69 3-18 ENGINE • Remove the spacer 3. GENERATOR • Remove the generator rotor bolt 1. • Install the special tool to the crankshaft end. % 09930-31921: Rotor remover attachment • Remove the generator rotor 2 with the special tool. % 09930-30721: Rotor remover •...
Page 70 ENGINE 3-19 CAM CHAIN AND CAM CHAIN TENSIONER • Remove the cam chain tensioner bolt 1, cam chain tensioner 2 and washer. • Remove the cam chain 3. OIL PUMP • Remove the snap ring 1. NOTE: Be careful not to drop the snap ring 1 into the crankcase. •...
Page 71 3-20 ENGINE • Remove the keys 4. • Remove the crank balancer drive gear nut with the special tools. % 09920-53740: Clutch sleeve hub holder 09924-52460: Socket wrench 52 mm • Remove the washer 5 and crank balancer drive gear 6. •...
Page 72 ENGINE 3-21 • Remove the cap 2. MOVABLE DRIVE FACE • Remove the movable drive face bolt with the special tool. % 09930-40113: Rotor holder • Remove the movable drive face cover 1 and collar 2. • Remove the dowel pins 3. •...
Page 73 3-22 ENGINE FIXED DRIVE FACE • Remove the fixed drive face 1. • Remove the clutch inner cover 2 and gasket. GEAR POSITION SWITCH • Remove the gear position switch 1. • Remove the pins 2 and springs 3. CLUTCH HOUSING CASE •...
Page 74 ENGINE 3-23 • Remove the oil jet 5. CLUTCH SHOE • Remove the one way clutch 1. • Remove the clutch shoe nut with the special tool. The clutch shoe nut has left-hand threads. % 09930-40113: Rotor holder 09930-40131: Attachment •...
Page 75 3-24 ENGINE • Separate the crankcase with the special tool. NOTE: * The crankcase separator plate is parallel with the end face of the crankcase. * The crankshaft must remain in the left crankcase half. % 09920-13120: Crankcase separator • Remove the collar 2. •...
Page 76 ENGINE 3-25 TRANSFER • Remove the gearshift fork shaft 1 and gearshift cam 2. • Remove the gearshift forks 3. • Remove the transfer output shaft assembly 4, reverse idle gear 5 with shaft and transfer input shaft 6. DRIVE BEVEL GEAR •...
Page 77 3-26 ENGINE • Hold the transfer output driven gear with the special tool. • Remove the drive bevel gear nut. % 09920-53740: Clutch sleeve hub holder • Remove the washer 1 and drive bevel gear 2. • Remove the shim 3. •...
Page 78 ENGINE 3-27 CRANKSHAFT • Install the removed generator cover 1 and tighten the bolts. • Remove the crankshaft with the special tool. % 09920-13120: Crankcase separator • Remove the generator cover.
Page 79: Engine Components Inspection And Servicing
3-28 ENGINE ENGINE COMPONENTS INSPECTION AND SERVICING Be sure to identify each removed part as to its loca- tion, and lay the parts out in groups designated as “Exhaust”, “Intake”, so that each will be restored to the original location during assembly. CAMSHAFT AND CYLINDER HEAD CAMSHAFT “I”...
Page 80 ENGINE 3-29 Do not attempt to disassemble the camshaft/auto- matic decompression assembly. It is not serviceable. CAM WEAR Worn-down cams are often the cause of mistimed valve opera- tion resulting in reduced output power. The limit of cam wear is specified for both intake and exhaust cams in terms of cam height H, which is to be measured with a micrometer.
Page 81 3-30 ENGINE NOTE: Do not rotate the camshaft with the plastigauge in place. Remove the camshaft holders, and read the width of the com- pressed plastigauge with envelope scale. This measurement should be taken at the widest part. If the camshaft journal oil clearance measured exceeds the limit, measure the inside diameter of the camshaft journal holder and outside diameter of the camshaft journal.
Page 82 ENGINE 3-31 CYLINDER HEAD • Remove the tappets 1 and shims 2 by fingers or magnetic hand. • Using special tools, compress the valve spring and remove the two cotter halves 3 from the valve stem. % 09916-14510: Valve lifter 09916-14910: Valve lifter attachment 09916-84511: Tweezers •...
Page 83 3-32 ENGINE • Remove the oil seals 7 and the spring seats 8. Do not reuse the removed oil seals. CYLINDER HEAD DISTORTION Decarbonize the combustion chambers. Check the gasketed surface of the cylinder head for distortion with a straightedge and thickness gauge, taking a clearance reading at several places indicated.
Page 84 ENGINE 3-33 VALVE FACE WEAR Visually inspect each valve for wear of its seating face. Replace any valve with an abnormally worn face. The thickness T decreases as the wear of the face advances. Measure the thickness and, if the thickness is found to have been reduced to the limit, replace it.
Page 85 3-34 ENGINE • Re-finish the valve guide holes in cylinder head with the reamer and handle. % 09916-34580: Valve guide reamer 09916-34542: Reamer handle When refinishing or removing the reamer from the valve guide hole, always turn it clockwise. • Cool down the new valve guides in a freezer for about one hour and heat the cylinder head to 100 –...
Page 86 ENGINE 3-35 VALVE SEAT WIDTH INSPECTION Coat the valve seat uniformly with Prussian blue. Fit the valve and tap the coated seat with the valve face in a rotating manner, in order to obtain a clear impression of the seating contact. In this operation, use the valve lapper to hold the valve head.
Page 87 3-36 ENGINE • Insert the solid pilot with a slight rotation. Seat the pilot snugly. Install the 45° cutter, attachment and T-handle. INITIAL SEAT CUT • Using the 45° cutter, descale and clean up the seat with one or two turns. •...
Page 88 ENGINE 3-37 • If the contact area is too low or too narrow, use the 45° cutter to raise and widen the contact area. NOTE: After cutting the 15°, 30° and 60° angles, it is possible that the valve seat (45°) is too valve seat to the correct width. 45˚...
Page 89 3-38 ENGINE VALVE SPRING The force of the coil spring keeps the valve seat tight. Weak- ened spring results in reduced engine power output, and often account for the chattering noise coming from the valve mecha- nism. Check the valve springs for proper strength by measuring their free length and also by the force required to compress them.
Page 90 ENGINE 3-39 • Install the valve spring with the small-pitch portion A facing cylinder head. B Large-pitch portion C UPWARD D Paint • Put on the valve spring retainer, and using the valve lifter, press down the spring, fit the cotter halves to the stem end, and release the lifter to allow the cotter 3 to wedge in between retainer and stem.
Page 91 3-40 ENGINE " Cam drive idle gear/sprocket shaft: 41 N·m (4.1 kgf-m, 30.0 lb-ft) % 09900-20803: Thickness gauge If the thrust clearance is not within specification, adjust the thrust clearance by the following procedures: • Remove the shim, and measure its thickness with a microme- ter.
Page 92 ENGINE 3-41 • Apply SUZUKI SUPER GREASE “A” to the O-ring. . 99000-25030: SUZUKI SUPER GREASE ‘‘A’’ (USA) 99000-25010: SUZUKI SUPER GREASE ‘‘A’’ (Others) Use the new O-ring to prevent air from sucking through the joint. • Apply THREAD LOCK to the intake pipe bolts.
Page 93 3-42 ENGINE THERMOSTAT • Remove the thermostat bracket 1 and thermostat cover 2. • Remove the thermostat. THERMOSTAT INSPECTION ($7-10) THERMOSTAT INSTALLATION ($7-10) ECT SENSOR • Remove the ECT sensor 1. ECT SENSOR INSPECTION ($7-9) ECT SENSOR INSTALLATION ($7-9)
Page 94: Cam Chain Tensioner
ENGINE 3-43 CAM CHAIN TENSIONER INSPECTION Check that the push rod slides smoothly when releasing stopper If it dose not slide smoothly, replace the cam chain tensioner with a new one. CAM CHAIN GUIDE INSPECTION Check the contacting surface of the cam chain guide for wear and damage.
Page 95 3-44 ENGINE CYLINDER BORE Inspect the cylinder wall for any scratches, nicks or other dam- age. Measure the cylinder bore diameter at six places. & Cylinder bore: Standard: 102.000 – 102.015 mm (4.0157 – 4.0163 in) % 09900-20508: Cylinder gauge set 09900-20520: Red cylinder gauge 100 mm...
Page 96: Piston
ENGINE 3-45 PISTON PISTON DIAMETER Using a micrometer, measure the piston outside diameter at the place shown in Fig. If the measurement is less than the limit, replace the piston. & Piston diameter: Service Limit: 101.880 mm (4.0110 in) 15 mm (0.6 in) % 09900-20210: Micrometer (100 –...
Page 97 3-46 ENGINE PISTON RING FREE END GAP AND PISTON RING END GAP Before installing piston rings, measure the free end gap of each ring with vernier calipers. Next, fit the ring in the cylinder and measure each ring end gap with a thickness gauge.
Page 98: Conrod/Crankshaft
ENGINE 3-47 CONROD/CRANKSHAFT CONROD SMALL END I.D. Measure the conrod small end inside diameter using the caliper gauge. If the conrod small end inside diameter exceeds the limit, replace the conrod. & Conrod small end I.D.: Service Limit: 23.040 mm (0.9071 in) % 09900-20605: Dial calipers (10 –...
Page 99: Starter Torque Limiter
3-48 ENGINE STARTER TORQUE LIMITER INSPECTION Do not attempt to disassemble the starter torque lim- iter. The starter torque limiter is available only as an assembly. Check the slip torque with the special tools. % 09930-73170: Starter torque limiter holder 1 09930-73140: Starter torque limiter socket 2 &...
Page 100: Clutch
ENGINE 3-49 CLUTCH CLUTCH SHOE Inspect the clutch shoe for chips, cracks, uneven wear, and heat discoloration. Also, check the depth of the grooves on the clutch shoe. If there is no groove at any part of the shoe, replace the shoe as a set.
Page 101 3-50 ENGINE • Install the starter driven gear to the starter clutch. • Check that the starter driven gear turns in the opposite direc- tion of the arrow mark B on the rotor while holding the gener- ator rotor. The gear never turns in the direction of the arrow. •...
Page 102: Movable Drive Face And Driven Face
ENGINE 3-51 MOVABLE DRIVE FACE AND DRIVEN FACE 1 Movable drive plate A Movable driven face 2 Damper (4 pcs) B Pin (4 pcs) 3 Spacer C Specer (4 pcs) 4 Roller (8 pcs) D O-ring (2 pcs) 5 Oil seal (2 pcs) E Spring seat "...
Page 103 3-52 ENGINE MOVABLE DRIVE FACE DISASSEMBLY • Remove the spacer 1. • Remove the movable drive face plate 2 and rollers 3. ROLLER AND SLIDING SURFACE Inspect each roller and their sliding surface for wear or damage. If any damages are found, replace the rollers as a set. NOTE: The rollers must always be changed as a set.
Page 104 Reassemble the movable and fixed drive face in the reverse order of disassembly. Pay attention to the following points: • Apply a small amount of SUZUKI SUPER GREASE “A” to the bore and oil seal lip. . 99000-25030:SUZUKI SUPER GREASE “A” (USA) 99000-25010:SUZUKI SUPER GREASE “A”...
Page 105 3-54 ENGINE • Install the spacer 4. NOTE: When inserting the spacer, press down the movable drive face plate so as not to cause the rollers to come out of position. MOVABLE DRIVEN FACE DISASSEMBLY • Hold the movable driven face assembly with the special tools and vise, loosen the movable driven face ring nut with the special tools.
Page 106 ENGINE 3-55 • Remove the spring plate 2 and spring 3. • Remove the spring seat 4. • Remove the pins and rollers. • Remove the movable driven face 5. O-RING AND OIL SEAL Inspect the O-rings and oil seals for wear or damage. If any damages are found, replace the O-rings and oil seals with new ones.
Page 107 REASSEMBLY • Install the new O-rings 1. • Apply SUZUKI SUPER GREASE “A” to the oil seal lips and movable driven face inside grease groove. . 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) •...
Page 108 ENGINE 3-57 • Install the rollers and pins. To prevent damaging the oil seal lip from during installation, slide the lip using a 0.1-mm steel sheet as a guide. • Install the spring seat by aligning the hole A with the hole B. •...
Page 109: Drive Belt
3-58 ENGINE • Tighten the movable driven face ring nut to the specified torque with the special tool. " Movable driven face ring nut: 110 N·m (11.0 kgf-m, 79.5 lb-ft) % 09917-23711: Ring nut socket wrench 09924-52450: Fixed driven face holder DRIVE BELT INSPECTION Check that the drive belt is free from any greasy substance.
Page 110: Transfer
ENGINE 3-59 TRANSFER DISASSEMBLY • Disassemble the transfer as shown. 1 Washer 8 Low driven gear 2 Reverse idle gear 9 Dog 3 Reverse idle gear shaft 0 Reverse driven gear 4 Spacer A High driven gear 5 Bearing B Counter shaft 6 Oil seal C Snap ring 7 Transfer input shaft...
Page 111 3-60 ENGINE * Never reuse a snap ring. After a snap ring has been removed from a shaft, it should be discarded and a new snap ring must be installed. * When installing a new snap ring, do not expand the end gap larger than required to slip the snap ring over the shaft.
Page 112 ENGINE 3-61 • Install the reverse drive gear bushing 3 and low driven gear bushing 4. When installing the bushing onto the transfer output shaft, aline the shaft oil hole B with the bushing oil hole C.
Page 113: Gearshift Fork
3-62 ENGINE GEARSHIFT FORK GEARSHIFT FORK-TO-GROOVE CLEARANCE Using a thickness gauge, check the shifting fork clearance in the groove of its gear. The clearance for each of the two shifting forks plays an impor- tant role in the smoothness and positiveness of shifting action. If the clearance exceeds the limit, replace the fork or its gear, or both.
Page 114: Gearshift Cam
ENGINE 3-63 GEARSHIFT CAM DISASSEMBLY • Disassemble the gearshift cam as shown. 1 Gear position switch 7 Washer C Gearshift fork (for Reverse) 2 O-ring 8 Spring D Gearshift fork (for High/Low) 3 Gearshift shaft 9 Dog (for High/Low) E Gearshift fork shaft 4 Snap ring 0 Snap ring F Gearshift shaft...
Page 115: Crankshaft
3-64 ENGINE CRANKSHAFT DISASSEMBLY 1 Crankshaft (R) 5 Washer 2 Washer 6 Crank pin 3 Conrod 7 Crankshaft (L) 4 Bearing...
Page 116 ENGINE 3-65 REASSEMBLY • Determine the width between the webs referring to the figure when rebuilding the crankshaft. & Crank web to web width: Standard: 72.9 – 73.1 mm (2.87 – 2.88 in)
Page 117: Drive Train (Front And Rear Output Shaft)
3-66 ENGINE DRIVE TRAIN (FRONT AND REAR OUTPUT SHAFT) CONSTRUCTION 1 Shim (s) 4 Shim (s) 2 Front output shaft 5 Driven bevel gear 3 Drive bevel gear 6 Rear output shaft...
Page 118 ENGINE 3-67 FRONT OUTPUT SHAFT REMOVAL • Remove the front output shaft 1. INSPECTION Inspect the front output shaft for distortion and gear for wear or damage. If distortion and any wear or damage are found, replace the front output shaft with a new one. FRONT OUTPUT SHAFT INSTALLATION •...
Page 119 3-68 ENGINE INSPECTION Inspect the rear output shaft for distortion. If distortion is found, replace the rear output shaft with a new one. Inspect the drive and driven bevel gears for wear or damage. If any wear or damage is found, replace the drive and driven bevel gears as a set.
Page 120 ENGINE 3-69 • With the rear output shaft held immovable with a vise, tighten the new nut to the specified torque. " Rear output shaft nut C: 100 N·m (10.0 kgf-m, 72.5 lb-ft) NOTE: Do not stake a lock portion on the nut at this stage. After the backlash and tooth contact have been checked or adjusted, stake the nut with a center punch.
Page 121: Shim Adjustment
3-70 ENGINE SHIM ADJUSTMENT BACKLASH • Install the output driven gear and drive bevel gear. ($3-74) • Place the rear output shaft on the right crankcase half and hold bearings with the special tool. % 09921-21910: Bearing holder • Set a dial gauge as shown on the drive bevel gear. Measure the backlash by turning the drive bevel gear shaft in For driven bevel gear ( 3-68)
Page 122 ENGINE 3-71 TOOTH CONTACT After backlash adjustment is carried out, the tooth contact must be checked. Pay attention to the following procedures: • Remove the rear output shaft from the crankcase. • Clean and degrease several teeth of the drive and driven bevel gears.
Page 123 3-72 ENGINE Shim thickness Part No. 0.550 mm (0.0217 in) 24935-03G50-055 0.575 mm (0.0226 in) 24935-03G50-058 0.600 mm (0.0236 in) 24935-03G50-060 0.625 mm (0.0246 in) 24935-03G50-063 0.650 mm (0.0256 in) 24935-03G50-065 0.675 mm (0.0266 in) 24935-03G50-068 0.700 mm (0.0276 in) 24935-03G50-070 0.725 mm (0.0285 in) 24935-03G50-073...
Page 124: Crankcase
ENGINE 3-73 CRANKCASE DRIVE BEVEL GEAR REMOVAL • Using a chisel, unlock the nut. • Hold the transfer output driven gear with the special tool, and remove the drive bevel gear nut. % 09920-53740: Clutch sleeve hub holder • Remove the washer 1 and drive bevel gear 2. •...
Page 125 3-74 ENGINE DRIVE BEVEL GEAR INSTALLATION • Install the transfer output shaft with a plastic mallet. • Install the shim 1. • Install the drive bevel gear 2 and washer 3. • Tighten the drive bevel gear nut to the specified torque with the special tool.
Page 126 ENGINE 3-75 CRANKCASE BEARING INSPECTION Play Play Rotate the bearing inner race by finger to inspect for abnormal play, noise and smooth rotation while the bearings are in the crankcase. Replace the bearing in the following procedure if there is any- thing unusual.
Page 127 3-76 ENGINE • Install the bearing retainers. NOTE: When installing the bearing retainers, apply a small quantity of THREAD LOCK to the screws. / 09900-32050: THREAD LOCK “1342” RIGHT CRANKCASE BEARING REMOVAL NOTE: If there is no abnormal noise, the bearing removal is not neces- sary.
Page 128 ENGINE 3-77 RIGHT CRANKCASE BEARING INSTALLATION • Install the bearings with the special tool. % 09913-70210: Bearing installer set NOTE: The stamped mark side of the bearing face outside. • Install the bearing retainers. NOTE: When installing the bearing retainers, apply THREAD LOCK to the screws.
Page 129: Generator Cover
3-78 ENGINE GENERATOR COVER DISASSEMBLY • Remove the generator stator. • Remove the snap rings 1 and 2. • Remove the bearings with the special tool. % 09921-20240: Bearing remover set (3, 4: 25 mm) (5: 12 mm) NOTE: If there is no abnormal noise, the bearing removal is not neces- sary.
Page 130 ENGINE 3-79 REASSEMBLY • Apply SUZUKI SUPER GREASE “A” to the O-ring. . 99000-25010: SUZUKI SUPER GREASE “A” (USA) 99000-25030: SUZUKI SUPER GREASE “A” (Others) • Install the speed sensor. • Install the oil seals with the special tool. % 09913-70210: Bearing installer set •...
Page 131: Recoil Starter
3-80 ENGINE RECOIL STARTER 1 O-ring 5 Reel 2 Starter cup 6 Spiral spring 3 Starter cup nut 7 Rope assembly 4 Ratchet set DISASSEMBLY • After removing the nut 1, take out the recoil starter related parts from the housing. 1 Nut 6 Spring 2 Friction plate...
Page 132 • Install the pin, spacer, spring cover, ratchet and ratchet guide. NOTE: • Apply SUZUKI SUPER GREASE “A” to the shaft and ratchet guide. . 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others)
Page 133 3-82 ENGINE • Pull the rope and check that the ratchet is pushed out.
Page 134: Engine Reassembly
ENGINE 3-83 ENGINE REASSEMBLY Reassemble the engine in the reverse order of disassembly. Pay special attention to the following points: NOTE: Apply engine oil to each running and sliding part before reas- sembling. Always keep the drive belt, drive face and driven face away from any greasy matter.
Page 135 3-84 ENGINE • Install the shim 1. • Install the drive bevel gear and washer 2. • Hold the transfer out driven gear with the special tool. • Tighten the drive bevel gear nut to the specified torque. " Drive bevel gear nut: 100 N·m (10.0 kgf-m, 72.5 lb-ft) % 09920-53740: Clutch sleeve hub holder •...
Page 136 ENGINE 3-85 REAR OUTPUT SHAFT • Install the C-ring 1. • Install the rear output shaft. NOTE: Be sure to fit the pin A on the bearing into the groove of the crankcase. OIL SUMP FILTER • Install the oil sump filter 1. NOTE: Fit the projection A of the oil sump filter in the concave portion of the crankcase.
Page 137 • Fit the dowel pins 1 onto the left half on the crankcase. • Apply engine oil to the conrod big end and the gears. • Apply SUZUKI BOND “1207B”/“1215” to the mating surface of the right crankcase. ' 99104-31140: SUZUKI BOND “1207B” (USA) 1 99000-31110: SUZUKI BOND “1215”...
Page 138 • Install the one way clutch with facing the “OUTSIDE” mark A outside. CLUTCH HOUSING CASE • Apply SUZUKI SUPER GREASE “A” to the O-ring. • Install the oil jet as shown in photograph. . 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A”...
Page 139 3-88 ENGINE • Tighten the clutch housing case bolts. GEAR POSITION SWITCH • Install the springs 1 and switch contacts 2. • Install the gear position switch 3. CLUTCH INNER COVER • Install the clutch inner cover and gasket. FIXED DRIVE FACE •...
Page 140 ENGINE 3-89 MOVABLE DRIVE/DRIVEN FACE AND DRIVE BELT • Install the drive belt, as low as possible, between the movable driven face and fixed driven face by tapping with a plastic mal- let. * The drive belt should be installed so that the arrows on the drive belt periphery point in the normal turn- ing direction.
Page 141 3-90 ENGINE Install the callar 3 and movable drive face bolt 4. NOTE: Be careful direction of the collar 3 . • Tighten the movable drive face bolt to the specified torque with the special tool. " Movable drive face bolt: 110 N·m (11.0 kgf-m, 79.5 lb-ft) % 09930-40113: Rotor holder NOTE: Turn the fixed drive face until the belt is seated in and both the...
Page 142 ENGINE 3-91 CLUTCH COVER • Install the new gasket and clutch cover. • Tighten the clutch cover bolts to the spesified torque. " Clutch cover bolt: 9 N·m (0.9 kgf-m, 6.5 lb-ft) BALANCER SHAFT DRIVE/DRIVEN GEAR • Install the pin 1. •...
Page 143 3-92 ENGINE • Install the keys 2. • Install the crank balancer driven gears 3, water pump drive gear 4 and oil pump drive gear 5. NOTE: Align the punched marks A as shown. NOTE: Pay attention to the direction of the water pump drive gear and oil pump drive gear.
Page 144 ENGINE 3-93 • Hold the crank balancer drive gear nut with the special tool and tighten the crank balancer shaft driven gear bolts to the specified torque. % 09924-52460: Socket wrench 52 mm " Crank balancer driven gear bolt: 50 N·m (5.0 kgf-m, 36.0 lb-ft) OIL PUMP •...
Page 145 3-94 ENGINE • Install the generator rotor assembly. Make sure that the one way clutch on the crankshaft rotor is fitted into the generator rotor properly. • Tighten the generator rotor nut to the specified torque. " Generator rotor nut: 160 N·m (16.0 kgf-m, 115.5 lb-ft) •...
Page 146 • Install the generator cover 3. NOTE: Fit the clamp to the bolt A . STARTER CUP • Apply SUZUKI SUPER GREASE “A” to the O-ring and lip of the oil seal. • Install the starter cup 1. . 99000-25030: SUZUKI SUPER GREASE “A” (USA)
Page 147: Engine Top Side
• Tighten the starter cup nut to the specified torque. " Starter cup nut: 26 N·m (2.6 kgf-m, 19.0 lb-ft) WATER PUMP • Apply SUZUKI SUPER GREASE “A” to the O-ring. . 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) Use the new O-ring to prevent oil leakage.
Page 148 ENGINE 3-97 • Install the 2nd ring A and 1st ring B. • 2nd ring has letter “RN” marked on the side. Be sure to bring the marked side to the top when fitting it to the piston. 1st ring 2nd ring •...
Page 149 3-98 ENGINE • Coat SUZUKI BOND lightly to the mating surfaces among the crankcase mating surfaces. ' 99104-31140: SUZUKI BOND “1207B” (USA) 1 99000-31110: SUZUKI BOND “1215” (Others) • Fit the dowel pins 1 and the new gasket 2. Use a new gasket to prevent gas leakage.
Page 150 ENGINE 3-99 NOTE: Apply engine oil to the both side of washer and thread portion of the bolts before installimg the cylinder head bolts. CAM DRIVE IDLE GEAR/SPROCKET • Align the line A on the generator rotor with the index mark B on the crankcase.
Page 151 3-100 ENGINE NOTE: Root of tooth Due to special valve train mechanism, aligning of the three ele- White White ments; the punched mark C , embossed line D and the gear paint paint tooth root on the cam drive idle gear/sprocket; can occur once every other rotation of crankshaft.
Page 152 ENGINE 3-101 • Install the new O-ring 2 and spring 3. Use the new O-ring to prevent oil leakage. • Install the cam chain tensioner cap bolt 4. NOTE: Click sound is heard when the cam chain tensioner cap bolt is installed.
Page 153 • Pour engine oil in each oil pocket in the cylinder head. CYLINDER HEAD COVER • Install the new gasket 1 to the cylinder head cover. • Apply SUZUKI BOND to the cam end caps of the gasket as shown. ' 99104-31140: SUZUKI BOND “1207B” (USA) 99000-31110: SUZUKI BOND “1215”...
Page 154 STARTER MOTOR • Install the new O-ring to the starter motor. Use the new O-ring to prevent oil leakage. • Apply SUZUKI SUPER GREASE “A” to the O-ring. . 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others)
Page 156 DRIVE TRAIN DRIVE TRAIN CONTENTS FRONT DRIVE TRAIN (DIFFERENTIAL) .............4- 2 CONSTRUCTION ...................4- 2 REMOVAL ....................4- 3 DISASSEMBLY ..................4- 4 INSPECTION ..................4- 7 REASSEMBLY ..................4- 9 REMOUNTING ..................4-14 SHIM ADJUSTMENT ................4-15 REASSEMBLY INFORMATION .............4-18 FRONT PROPELLER SHAFT ..............4-19 REMOVAL ....................4-19 INSPECTION ..................4-19 REASSEMBLY ..................4-20 REAR DRIVE TRAIN ..................4-22...
Page 157: Front Drive Train (Differential)
DRIVE TRAIN FRONT DRIVE TRAIN (DIFFERENTIAL) CONSTRUCTION Front drive train (differential) Snap ring gear case Front drive train (differential) 2WD/4WD shifting sleeve gear case cover 3 Shim (right side) I Snap ring 4 Bearing J Bearing 5 Front drive train (differential) gear K Snap ring 6 Bearing L Oil seal 7 Shim (left side)
Page 158: Removal
DRIVE TRAIN REMOVAL • Remove the front wheels. ($8-13) • Drain the front differential gear oil. ($2-14) • Remove the front suspension. ($8-36) • Hold the inboard joint 1 of the front drive shaft and tug the drive shaft horizontally. NOTE: If it is difficult to remove the front drive shaft from the front differ- ential gear case, use the suitable tool.
Page 159: Disassembly
DRIVE TRAIN • Remove the front drive train (differential) gear case mounting bolts/nuts. • Remove the front drive train (differential) gear case assembly out of the frame. DISASSEMBLY ACTUATOR • Remove the actuator assembly. MOTOR INSPECTION ($9-22) FRONT DRIVE TRAIN (DIFFERENTIAL) GEAR •...
Page 160 DRIVE TRAIN • Remove the front drive train (differential) gear assembly 2. • Remove the shims from the case and case cover. 2WD/4WD SHIFTING DEVICE • Remove the gear shifting fork shaft 1. • Remove the gear shifting fork 2. •...
Page 161 DRIVE TRAIN • Remove the input shaft 6. • Remove the gear shifting sleeve 7. • Remove the snap ring 8. DRIVE BEVEL GEAR • Remove the snap ring 1. • Remove the drive bevel gear 2 together with the bearing.
Page 162: Inspection
DRIVE TRAIN INSPECTION FRONT DRIVE TRAIN (DIFFERENTIAL) GEAR CASE OIL SEAL Inspect the oil seal for wear or damage. If any wear or damage is found, replace the oil seal a new one. • Remove the oil seal with the special tool. % 09913-50121: Oil seal remover DRIVE BEVEL GEAR BEARING Inspect the outer race play and smooth rotation of the bearing by...
Page 163 DRIVE TRAIN FRONT DRIVE TRAIN (DIFFERENTIAL) GEAR BEARING Inspect the outer race play and smooth rotation of the bearing while it is in place. If any abnormality is found, replace the bearing with a new one. • Remove the bearing with the special tool. % 09913-60910: Bearing &...
Page 164: Reassembly
• Install the new oil seals into the front differential gear case and case cover with the special tool. • Apply grease to the oil seal lips. % 09913-70210: Bearing installer set . 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others)
Page 165 4-10 DRIVE TRAIN • Install the new bearing onto the drive bevel gear shaft with the special tool. % 09913-70210: Bearing installer set • Install the new bearing into the front drive train (differential) gear case with the special tool. % 09913-70210: Bearing installer set •...
Page 166 DRIVE TRAIN 4-11 • Install the input shaft with the special tool. % 09913-70210: Bearing installer set • Install the new snap ring 1, new oil seal 2 and cap 3. • Install the input shaft into the gear case with the special tool. % 09913-70210: Bearing installer set 09924-74550: Final gear case oil seal installer 09922-21410: Long socket 46 mm...
Page 167 • After the backlash and tooth contact have been checked or adjusted, apply bond to the mating surface of the case. ' 99104-31140: SUZUKI BOND “1207B” (USA) 1 99000-31110: SUZUKI BOND “1215” (Others) • Turn the shifting cam 5 clockwise, and install the shifting fork pin to the bottom.
Page 168 • Apply grease to the new O-ring. • Apply thread lock to the case cover bolts and tighten them to the specified torque diagonally. . 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) , 99000-32030: THREAD LOCK SUPER “1303”...
Page 169: Remounting
• Apply grease to the spline of the front drive shafts and install the front drive shafts to the front differential gear case. . 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) Be careful not to damage the front differential gear case oil seals.
Page 170: Shim Adjustment
DRIVE TRAIN 4-15 SHIM ADJUSTMENT BACKLASH • Install the removed left and right side shims and differential assembly. • Assemble the gear case cover. ($4-9) NOTE: At this time, it is not necessary to apply a sealant to the mating surface of the gear case.
Page 171 4-16 DRIVE TRAIN LEFT SIDE SHIM SELECTION • Install the removed right side shim(s) and differential assem- bly. • Put a few pieces of solder (O.D.: 1.2 – 1.5 mm × L: 6 mm) on the bearing outer race, as shown. NOTE: * Do not install the left side shim(s) at this time.
Page 172 DRIVE TRAIN 4-17 TOOTH CONTACT After backlash adjustment and left side shim selection are car- ried out, the tooth contact must be checked. Pay attention to the following points: • Remove the differential ring gear. • Clean and degreas several teeth on the ring gear and pinion gear, and then apply a coating of machinist’s layout dye or paste to several teeth of the pinion gear.
Page 173: Reassembly Information
4-18 DRIVE TRAIN REASSEMBLY INFORMATION 22 N·m Mating surfaces (2.2 kgf-m, 16.0 lb-ft) shim shim 4-5 gram 4-5 gram 4-5 gram...
Page 174: Front Propeller Shaft
DRIVE TRAIN 4-19 FRONT PROPELLER SHAFT REMOVAL • Remove the front drive train (differential) gear case assembly. ($4-3) • Remove the front propeller shaft spring 1. • Loosen the clamp screw and remove the boots (2 and 3). NOTE: Apply oil to the removing direction of the boots before removing. •...
Page 175: Reassembly
4-20 DRIVE TRAIN BOOTS Inspect the boots for wear or damage. If any crack or damage is found, replace it with a new one. Check the circlip attached to the universal joint portion. NOTE: If any wear or damage is found, replace it with a new one. REASSEMBLY •...
Page 176 DRIVE TRAIN 4-21 • Attach the spring. • Apply 4-5 gram of grease to the spline of the input shaft and spring. 2 99000-25160: WATER RESISTANCE GREASE • Install the front drive train (differential) gear case assembly. • Tighten the mounting nuts to the specified torque. •...
Page 177: Rear Drive Train
4-22 DRIVE TRAIN REAR DRIVE TRAIN CONSTRUCTION 1 Final gear case E Rear propeller shaft coupling 2 Final gear case cover F Washer 3 Ring gear G Locknut 4 Shim (right side) H Snap ring 5 Shim (left side) I Propeller shaft joint 6 Bearing J Spring plate 7 Oil seal...
Page 178: Disassembly
DRIVE TRAIN 4-23 DISASSEMBLY • Remove the rear brake. ($8-59) • Remove the cover bolts diagonally and evenly. • Pry the case cover with 5 mm screw as shown. • Remove the ring gear 1 and shims 2 from the final gear case cover 3.
Page 179 4-24 DRIVE TRAIN • Remove the final gear case cover bearing with the special tool. % 09913-70210: Bearing installer set NOTE: If there is no abnormal condition, the bearing removal is not nec- essary. The removed bearing must be replaced with a new one.
Page 180 DRIVE TRAIN 4-25 • Unlock the bearing with a small chisel or drill. • Remove the bearing locknut with the special tool. % 09924-41830: Bearing locknut wrench The removed locknut must be replaced with a new one. • Remove the pinion gear assembly. •...
Page 181 4-26 DRIVE TRAIN • Remove the pinion gear bearing with the special tool and suit- able tool. % 09917-50410: Bearing remover NOTE: If there is no abnormal condition, the bearing removal is not nec- essary. The removed bearing must be replaced with a new one.
Page 182: Inspection
DRIVE TRAIN 4-27 INSPECTION GEAR CASE COVER/FINAL GEAR CASE COVER OIL SEAL Inspect the oil seal for wear or damage. If any wear or damage is found, replace it with a new one. GEAR CASE COVER/FINAL GEAR CASE COVER BEARING Inspect the bearing for wear or damage.
Page 183: Reassembly
4-28 DRIVE TRAIN REASSEMBLY • Reassemble the rear drive train in the reverse order of disas- sembly. Pay attention to the following points: NOTE: Before reassembly, thoroughly clean all parts in cleaning sol- vent. GEAR CASE BEARING • Install the gear case bearing to the gear case with the special tool.
Page 184 • Apply grease to the oil seal lips. % 09913-70210: Bearing installer set 09913-84510: Bearing installer . 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) PINION GEAR SHAFT BEARING AND LOCKNUT • Drive the bearing onto the shaft with the special tool and suit- able tool.
Page 185 3. • Install the gear case cover 4 and shims 5. • Apply grease to the O-ring 6. . 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) NOTE: After the backlash and tooth contact have been checked or adjusted, install a new O-ring and apply grease.
Page 186: Shim Adjustment
DRIVE TRAIN 4-31 SHIM ADJUSTMENT BACKLASH • Install the pinion gear assembly, removed shim(s) and new bearing locknut. ($4-28) • Tighten the bearing locknut to the specified torque. ($4-29) NOTE: At this time, it is not necessary to bend the bearing locknut col- lar.
Page 187 4-32 DRIVE TRAIN LEFT SIDE SHIM SELECTION • After the backlash has been checked or adjusted, put a few pieces of solder (O.D.: 1.2 – 1.5 mm × L: 6 mm) on the ring gear back side, as shown. NOTE: * Do not install the left side shim(s) at this time.
Page 188 DRIVE TRAIN 4-33 TOOTH CONTACT After backlash adjustment and left shim selection are carried out, the tooth contact must be checked. Pay attention to the fol- lowing procedures: • Remove the ring gear. • Clean and degreas several teeth on the ring gear and pinion gear, and then apply a coating of machinist’s layout dye or paste to several teeth of the pinion gear.
Page 189: Reassembly Information
4-34 DRIVE TRAIN REASSEMBLY INFORMATION 100 N·m (10.0 kgf-m, 72.5 lb-ft) 4 – 5 gram 4 – 5 gram 100 N·m (10 kgf-m, 22.5 lb-ft) 100 N·m (10 kgf-m, 22.5 lb-ft) Mating surfaces 100 N·m (10 kgf-m, 72.5 lb-ft) Pinion gear shim (S) shim (right side) shim (left side) 26 N·m...
Page 190: Rear Propeller Shaft
DRIVE TRAIN 4-35 REAR PROPELLER SHAFT REMOVAL AND DISASSEMBLY • Remove the rear drive shaft. ($8-54) • Remove the rear final gear assy. ($8-59) • Remove the rear propeller shaft joint 2 and spring 3 from the rear propeller shaft 1. •...
Page 191 4-36 DRIVE TRAIN • Remove the rear propeller shaft 9. • Remove the C-rings from the universal joint. Replace the removed C-ring with a new one. • Remove the bearings by tapping with the special tool. % 09913-70210: Bearing installer set •...
Page 192: Inspection
DRIVE TRAIN 4-37 INSPECTION REAR PROPELLER SHAFT Inspect the rear propeller shaft for wear or damage. If any wear or damage is found, replace it with a new one. UNIVERSAL JOINT Inspect the universal joint and outer surface of the bearing for scuffing, wear and damage.
Page 193: Reassembly And Remounting
4-38 DRIVE TRAIN REASSEMBLY AND REMOUNTING • Reassemble and remount the rear propeller shaft assembly in the reverse order of removal and disassembly. • Tighten the new locknut. • Bend the locknut callar to the notch of the shaft. • Install the new C-ring to the universal joint. •...
Page 194 DRIVE TRAIN 4-39 • Install the rear propeller shaft spring plate 3. • Install the rear propeller shaft spring 4. • Install the rear propeller shaft joint 5. • Apply 4-5 gram of grease to the inner spline of the rear pro- peller shaft joint 5.
Page 195 FI SYSTEM DIAGNOSIS CONTENTS PRECAUTIONS IN SERVICING..............5- 2 ELECTRICAL PARTS................5- 2 FUSE .......................5- 3 ECM/VARIOUS SENSORS..............5- 3 ELECTRICAL CIRCUIT INSPECTION PROCEDURE ......5- 5 USING THE MULTI-CIRCUIT TESTER ..........5- 8 FI SYSTEM TECHNICAL FEATURES ............5- 9 INJECTION TIME (INJECTION VOLUME)..........5- 9 COMPENSATION OF INJECTION TIME (VOLUME)......5-10 INJECTION STOP CONTROL ..............5-10 FI SYSTEM PARTS LOCATION.............5-11...
Page 196 FI SYSTEM DIAGNOSIS SENSORS ..................... 5-66 CKP SENSOR INSPECTION..............5-66 CKP SENSOR REMOVAL AND INSTALLATION ......... 5-66 IAP SENSOR INSPECTION ..............5-66 IAP SENSOR REMOVAL AND INSTALLATION ........5-66 TP SENSOR INSPECTION..............5-66 TP SENSOR REMOVAL AND INSTALLATION ........5-66 TPS ADJUSTMENT................
Page 197: Precautions In Servicing
FI SYSTEM DIAGNOSIS PRECAUTIONS IN SERVICING When handling the component parts or servicing the FI system, observe the following points for the safety of the system. ELECTRICAL PARTS CONNECTOR/COUPLER • When connecting a connector, be sure to push it in until a Click click is felt.
Page 198: Fuse
FI SYSTEM DIAGNOSIS • When connecting meter probe from the terminal side of the coupler (connection from harness side not being possible), use extra care not to force and cause the male terminal to bend or the female terminal to open. Connect the probe as shown to avoid opening of female ter- minal.
Page 199 FI SYSTEM DIAGNOSIS • When disconnecting and connecting the ECM, make sure to turn OFF the ignition switch 1, or electronic parts may get damaged. • Do not disconnect the ECM coupler within 3 seconds from turning OFF the ignition switch. INCORRECT •...
Page 200: Electrical Circuit Inspection Procedure
FI SYSTEM DIAGNOSIS ELECTRICAL CIRCUIT INSPECTION PROCEDURE While there are various methods for electrical circuit inspection, described here is a general method to check for open and short circuit using an ohmmeter and a voltmeter. OPEN CIRCUIT CHECK Possible causes for the open circuits are as follows. As the cause can exist in the connector/coupler or terminal, they need to be checked carefully.
Page 201 FI SYSTEM DIAGNOSIS Continuity check • Measure resistance across coupler B (between A and C in the figure). If no continuity is indicated (infinity or over limit), the circuit is open between terminals A and C. 1 ECM • Disconnect the coupler B and measure resistance between couplers A and B.
Page 202 FI SYSTEM DIAGNOSIS SHORT CIRCUIT CHECK (WIRE HARNESS TO GROUND) • Disconnect the negative cable from the battery. • Disconnect the connectors/couplers at both ends of the circuit to be checked. NOTE: If the circuit to be checked branches to other parts as shown, disconnect all connectors/couplers of those parts.
Page 203: Using The Multi-Circuit Tester
FI SYSTEM DIAGNOSIS USING THE MULTI-CIRCUIT TESTER • Use the Suzuki multi-circuit tester set (09900-25008). • Use well-charged batteries in the tester. • Be sure to set the tester to the correct testing range. USING THE TESTER • Incorrectly connecting the + and - probes may cause the inside of the tester to burnout.
Page 204: Fi System Technical Features
FI SYSTEM DIAGNOSIS FI SYSTEM TECHNICAL FEATURES INJECTION TIME (INJECTION VOLUME) The factors to determine the injection time include the basic fuel injection time, which is calculated on the basis of intake air pressure, engine speed and throttle opening angle, and various compensations. These compensations are determined according to the signals from various sensors that detect the engine and driving conditions.
Page 205: Compensation Of Injection Time (Volume)
5-10 FI SYSTEM DIAGNOSIS COMPENSATION OF INJECTION TIME (VOLUME) The following different signals are output from the respective sensors for compensation of the fuel injection time (volume). SIGNAL DESCRIPTION ENGINE COOLANT TEMPERATURE SEN- When engine coolant temperature is low, injection time (vol- SOR SIGNAL ume) is increased.
Page 206: Fi System Parts Location
FI SYSTEM DIAGNOSIS 5-11 FI SYSTEM PARTS LOCATION A Speed sensor E IAT sensor B ISC valve F CKP sensor C TP sensor G Combination meter D IAP sensor H Diff-lock relay...
Page 207 5-12 FI SYSTEM DIAGNOSIS I ECT sensor L Ignition coil J TO sensor M FP relay K Fuel injector N Fuel pump...
Page 208: Fi System Wiring Diagram
FI SYSTEM DIAGNOSIS 5-13 FI SYSTEM WIRING DIAGRAM...
Page 209: Self-Diagnosis Function
5-14 FI SYSTEM DIAGNOSIS SELF-DIAGNOSIS FUNCTION The self-diagnosis function is incorporated in the ECM. The function has two modes, “User mode” and “Dealer mode”. The user can only be notified by the LCD (DISPLAY) panel and LED (FI light). To check the function of the individual FI system devices, the dealer mode is prepared.
Page 210: Dealer Mode
FI SYSTEM DIAGNOSIS 5-15 DEALER MODE The defective function is memorized in the computer. Use the special tool’s coupler to connect to the dealer mode coupler. The memorized malfunction code is displayed on LCD (DISPLAY) panel. Malfunction means that the ECM does not receive signal from the devices. These affected devices are indicated in the code form.
Page 211 5-16 FI SYSTEM DIAGNOSIS CODE MALFUNCTION PART REMARKS None No defective part Crankshaft position sensor (CKP sensor) Pick-up coil signal, signal generator Intake air pressure sensor (IAP sensor) Throttle position sensor (TP sensor) Engine coolant temperature sensor (ECT sensor) Differential lock relay (Diff-lock relay) Intake air temperature sensor (IAT sensor) Tip-over sensor (TO sensor) Ignition signal (Ignition coil)
Page 212: Tps Adjustment
FI SYSTEM DIAGNOSIS 5-17 TPS ADJUSTMENT 1. Remove the left side cover. ($8-8) 2. Connect the special tool (Mode select switch) to the dealer mode coupler at the wiring harness. NOTE: Check the engine has warmed up before adjusting the TPS. 3.
Page 213: Fail-Safe Function
5-18 FI SYSTEM DIAGNOSIS FAIL-SAFE FUNCTION FI system is provided with fail-safe function to allow the engine to start and the vehicle to run in a minimum performance necessary even under malfunction condition. STARTING RUNNING ITEM FAIL-SAFE MODE ABILITY ABILITY IAP sensor Intake air pressure is fixed to 760 “YES”...
Page 214: Fi System Troubleshooting
FI SYSTEM DIAGNOSIS 5-19 FI SYSTEM TROUBLESHOOTING CUSTOMER COMPLAINT ANALYSIS Record details of the problem (failure, complaint) and how it occurred as described by the customer. For this purpose, use of an inspection form such as below will facilitate collecting information required for proper analysis and diagnosis.
Page 215: Visual Inspection
5-20 FI SYSTEM DIAGNOSIS VEHICLE/ENVIRONMENTAL CONDITION WHEN PROBLEM OCCURS Environmental condition Weather Fair Cloudy Rain Snow Always Other Temperature Warm Cool Cold ( °F/ °C) Always Frequency Always Sometimes ( times/ day, month) Only once Under certain condition Road Mountainous ( Uphill Downhill) Gravel...
Page 216: Self-Diagnostic Procedures
FI SYSTEM DIAGNOSIS 5-21 SELF-DIAGNOSTIC PROCEDURES NOTE: * Don’t disconnect the coupler from ECM, the battery cable from the battery, before confirming the malfunction code (self-diag- nostic trouble code) stored in the memory. Such disconnection will erase the memorized information in ECM memory. * Malfunction code stored in ECM memory can be checked by the special tool.
Page 217: Self-Diagnosis Reset Procedure
5-22 FI SYSTEM DIAGNOSIS SELF-DIAGNOSIS RESET PROCEDURE • After repairing the trouble, turn the ignition switch to OFF and turn to ON again. • If the malfunction code indicates (C00), the malfunction is cleared. • Disconnect the special tool from the dealer mode coupler. NOTE: * Even though the malfunction code (C00) is indicated, the previ- ous malfunction history code still remains stored in the ECM.
Page 218: Use Of Sds Diagnosis Reset Procedure
FI SYSTEM DIAGNOSIS 5-23 USE OF SDS DIAGNOSIS RESET PROCE- DURE • After repairing the trouble, turn the ignition switch to OFF and turn to ON again. • Click the “DTC inspection” button 1. • Check the DTC. • The previous malfunction history code (Past DTC) still remains stored in the ECM.
Page 219: Show Data When Trouble (Displaying Data At The Time Of Dtc)
5-24 FI SYSTEM DIAGNOSIS SHOW DATA WHEN TROUBLE (DISPLAYING DATA AT THE TIME OF DTC) ECM stores the engine and driving conditions (in the form of data as shown in the figure) at the moment of the detection of a malfunction in its memory. This data is called “Show data when trouble”. Therefore, it is possible to know engine and driving conditions (e.g., whether the engine was warm or not, where the vehicle was running or stopped) when a malfunction was detected by checking the “Show data when trouble”.
Page 220 FI SYSTEM DIAGNOSIS 5-25 • Click “Show data when trouble” 1 to display the data. By clicking the drop down button 2, either “Failure #1” or “Failure #2” can be selected.
Page 221: Ecm Terminal
5-26 FI SYSTEM DIAGNOSIS ECM TERMINAL Wire harness side TERMINAL TERMINAL CIRCUIT CIRCUIT Ignition coil (IG1) CKP sensor signal (CKP-) Fuel injector (#1) Fuel pump relay (FP Relay) Power source (+B) Injector power voltage (VM) Back up power (BATT) Diff-lock relay (DL Relay) Brake switch (BRK) Serial data for self-diagnosis (SDL) Power source for sensors (VCC)
Page 222: Malfunction Code And Defective Condition
FI SYSTEM DIAGNOSIS 5-27 MALFUNCTION CODE AND DEFECTIVE CONDITION DETECTED DTC No. DETECTED FAILURE CONDITION CHECK FOR ITEM NO FAULT ––––––––––– ––––––––––– CKP sensor The signal does not reach ECM for 3 CKP sensor wiring and mechan- sec. or more, after receiving the starter ical parts.
Page 223 5-28 FI SYSTEM DIAGNOSIS DETECTED DTC No. DETECTED FAILURE CONDITION CHECK FOR ITEM IAT sensor The sensor voltage should be the fol- IAT sensor, lead wire/coupler lowing. connection. 0.15 V < sensor voltage 4.85 V In other than the above range, C21 (P0110) is indicated.
Page 224: C12" (P0335) Ckp Sensor Circuit Malfunction
FI SYSTEM DIAGNOSIS 5-29 “C12” (P0335) CKP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE The signal does not reach ECM for 3 sec. or more, • Metal particles or foreign material being stuck on after receiving the starter signal. the CKP sensor and rotor tip. •...
Page 225 5-30 FI SYSTEM DIAGNOSIS 3) Disconnect the CKP sensor coupler and measure the resis- tance. & CKP sensor resistance: 150 – 250 Ω (Blue – White) 4) Also, check the continuity between each terminal and ground. & CKP sensor continuity: ∞ Ω (Infinity) (Blue –...
Page 226 FI SYSTEM DIAGNOSIS 5-31 Step 2 1) Disconnect the CKP sensor coupler. 2) Crank the engine a few seconds with the starter motor, and measure the CKP sensor peak voltage at the coupler. & CKP sensor peak voltage: 5.0 V and more (+ Blue –...
Page 227: C13" (P0105) Iap Sensor Circuit Malfunction
5-32 FI SYSTEM DIAGNOSIS “C13” (P0105) IAP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE IAP sensor voltage is not within the fol- • Clogged vacuum passage between throttle body lowing range. and IAP sensor. 0.5 V < Sensor voltage 4.85 V •...
Page 228 FI SYSTEM DIAGNOSIS 5-33 4) Remove the IAP sensor from the air cleaner box. 5) Disconnect the IAP sensor coupler. 6) Turn the ignition switch ON. 7) Measure the voltage at the Red wire and ground. 8) Also, measure the voltage at the Red wire and B/Br wire. &...
Page 229 5-34 FI SYSTEM DIAGNOSIS Step 2 1) Connect the IAP sensor coupler. 2) Insert the needle pointed probes to the lead wire coupler. Start the engine at idle speed and measure the IAP sensor output voltage at the wire side coupler between G/B and B/Br wires.
Page 230 FI SYSTEM DIAGNOSIS 5-35 Is the voltage OK? • G/B, R or B/Br wire open or shorted to ground, or poor 6, C or N connection. • If wire and connection are OK, intermittent trou- ble or faulty ECM. • Recheck each terminal and wire harness for open circuit and poor connection.
Page 231: C14" (P0120) Tp Sensor Circuit Malfunction
5-36 FI SYSTEM DIAGNOSIS “C14” (P0120) TP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE Output voltage is not within the following • TP sensor maladjusted. range. • TP sensor circuit open or short. Difference between actual throttle open- • TP sensor malfunction. ing and opening calculated by ECM is •...
Page 232 FI SYSTEM DIAGNOSIS 5-37 Step 1 (When indicating P0120-H:) 1) Remove the left side cover. ($8-8) 2) Turn the ignition switch OFF. 3) Check the TP sensor coupler for loose or poor contacts. If OK, then check the TP sensor lead wire continuity. 4) Disconnect the TP sensor coupler.
Page 233 5-38 FI SYSTEM DIAGNOSIS Step 1 (When indicating P0120-L:) 1) Remove the left side cover. ($8-8) 2) Turn the ignition switch OFF. 3) Check the TP sensor coupler for loose or poor contacts. If OK, then check the TP sensor lead wire continuity. 4) Disconnect the TP sensor coupler.
Page 234 FI SYSTEM DIAGNOSIS 5-39 Step 2 1) Turn the ignition switch OFF. 2) Disconnect the TP sensor coupler. 3) Check the continuity between terminal B and ground. & TP sensor continuity: ∞ Ω (Infinity) (Terminal B – Ground) Terminal side 4) If OK, then measure the TP sensor resistance between termi- nal B and terminal C.
Page 235 5-40 FI SYSTEM DIAGNOSIS Step 3 1) Connect the TP sensor coupler. 2) Insert the needle pointed probes to the lead wire coupler. 3) Turn the ignition switch ON. 4) Measure the TP sensor output voltage at the coupler (between + Red wire and - B/Br wire) by turning the throttle grip.
Page 236: C15" (P0115) Ect Sensor Circuit Malfunction
FI SYSTEM DIAGNOSIS 5-41 “C15” (P0115) ECT SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE Output voltage is not within the following • ECT sensor circuit open or short. range. • ECT sensor malfunction. 0.15 < Sensor voltage 4.85 V • ECM malfunction. P0115 Sensor voltage is higher than specified •...
Page 237 5-42 FI SYSTEM DIAGNOSIS Step 1 (When indicating P0115-H:) 1) Remove the left side cover. ($8-8) 2) Turn the ignition switch OFF. 3) Check the ECT sensor coupler for loose or poor contacts. If OK, then check the ECT sensor lead wire continuity. 4) Disconnect the ECT sensor coupler and ECM coupler.
Page 238 FI SYSTEM DIAGNOSIS 5-43 Step 1 (When indicating P0115-L:) 1) Remove the left side cover. ($8-8) 2) Turn the ignition switch OFF. 3) Check the ECT sensor coupler for loose or poor contacts. If OK, then check the ECT sensor lead wire continuity. 4) Disconnect the ECT sensor coupler.
Page 239 5-44 FI SYSTEM DIAGNOSIS Step 2 1) Turn the ignition switch OFF. 2) Measure the ECT sensor resistance. & ECT sensor resistance: 2.3 – 2.6 kΩ at 20 °C (68 °F) (Terminal – Terminal) % 09900-25008: Multi-circuit tester set 3 Tester knob indication: Resistance (Ω) 3) Remove the ECT sensor.
Page 240: C20" (P1752) Diff-Lock Relay Circuit Malfunction
FI SYSTEM DIAGNOSIS 5-45 “C20” (P1752) DIFF-LOCK RELAY CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE No voltage is applied to diff-lock motor, although • Diff-lock relay circuit open or short. ignition switch is turned ON, or voltage is applied to • Diff-lock relay malfunction. diff-lock motor, although ignition switch is turned •...
Page 241 5-46 FI SYSTEM DIAGNOSIS SDS operation check (Transfer selecting switch) 1) Check that the transfer selecting switch (diff-lock position switch 1 and diff-lock switch 2) is turned OFF. 2) Set up the SDS tool. (Refer to the SDS operation manual for further details.) 3) Open the “Data monitor”.
Page 242 FI SYSTEM DIAGNOSIS 5-47 5) Turn the transfer selecting switch (diff-lock position switch and diff-lock switch) ON position. 6) Check that both “Differential lock position switch signal” 5 and “Differential lock switch signal” 6 are “GND”. If the transfer selecting switch dose not function properly, inspect the transfer selecting switch for details.
Page 243: C21" (P0110) Iat Sensor Circuit Malfunction
5-48 FI SYSTEM DIAGNOSIS “C21” (P0110) IAT SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE Output voltage is not within the following • IAT sensor circuit open or short. range. • IAT sensor malfunction. 0.15 < Sensor voltage 4.85 V • ECM malfunction. P0110 Sensor voltage is higher than specified •...
Page 244 FI SYSTEM DIAGNOSIS 5-49 Step 1 (When indicating P0110-H:) 1) Remove the left side cover. ($8-8) 2) Turn the ignition switch OFF. 3) Check the IAT sensor coupler for loose or poor contacts. If OK, then check the IAT sensor lead wire continuity. 4) Disconnect the IAT sensor coupler and ECM coupler.
Page 245 5-50 FI SYSTEM DIAGNOSIS Step 1 (When indicating P0110-L:) 1) Remove the left side cover. ($8-8) 2) Turn the ignition switch OFF. 3) Check the IAT sensor coupler for loose or poor contacts. If OK, then check the IAT sensor lead wire continuity. 4) Disconnect the IAT sensor coupler.
Page 246 FI SYSTEM DIAGNOSIS 5-51 Step 2 1) Turn the ignition switch OFF. 2) Measure the IAT sensor resistance. & IAT sensor resistance: Approx. 1.6 kΩ at 20 °C (68 °F) (Terminal – Terminal) % 09900-25008: Multi-circuit tester set 3 Tester knob indication: Resistance (Ω) Is the resistance OK? •...
Page 247: C23" (P1651) To Sensor Circuit Malfunction
5-52 FI SYSTEM DIAGNOSIS “C23” (P1651) TO SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE The sensor voltage should be the fol- • TO sensor circuit open or short. lowing for 2 sec. and more, after ignition • TO sensor malfunction. switch is turned ON.
Page 248 FI SYSTEM DIAGNOSIS 5-53 Step 1 (When indicating P1651-H:) 1) Remove the side covers. ($8-8) 2) Turn the ignition switch OFF. 3) Check the TO sensor coupler for loose or poor contacts. If OK, then check the TO sensor lead wire continuity. 4) Remove the TO sensor.
Page 249 5-54 FI SYSTEM DIAGNOSIS Step 1 (When indicating P1651-L:) 1) Remove the side covers. ($8-8) 2) Turn the ignition switch OFF. 3) Check the TO sensor coupler for loose or poor contacts. If OK, then check the TO sensor lead wire continuity. 4) Remove the TO sensor.
Page 250 FI SYSTEM DIAGNOSIS 5-55 Step 2 1) Connect the TO sensor coupler. 2) Insert the needle pointed probes to the lead wire coupler. 3) Turn the ignition switch ON. 4) Measure the voltage at the wire side coupler between Br/W and B/Br wires.
Page 251: C24" (P0351) Ignition Coil Circuit Malfunction
5-56 FI SYSTEM DIAGNOSIS “C24” (P0351) IGNITION COIL CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE CKP signal is produced but signal from ignition coil • Ignition coil circuit open or short. is interrupted 8 times or more continuously. • Ignition coil malfunction. •...
Page 252 FI SYSTEM DIAGNOSIS 5-57 Step 3 1) Disconnect the ECM coupler. 2) Check the continuity between B/W wire A and terminal 7. 3) Also, check the continuity between W/B wire B and terminal % 09900-25008: Multi-circuit tester set 09900-25009: Needle pointed probe set 7 Tester knob indication: Continuity tester (6) Is the continuity OK? •...
Page 253: C32" (P0201) Fuel Injector Circuit Malfunction
5-58 FI SYSTEM DIAGNOSIS “C32” (P0201) FUEL INJECTOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE CKP signal is produced but fuel injector signal is • Injector circuit open or short. interrupted 4 times or more continuously. • Injector malfunction. • ECM malfunction. Fuel Main Fuel pump relay...
Page 254 FI SYSTEM DIAGNOSIS 5-59 Step 2 1) Turn the ignition switch ON. 2) Measure the injector voltage between Y/R wire and ground. & Injector voltage: Battery voltage (+ Y/R – - Ground) NOTE: Injector voltage can be detected only for 3 seconds after ignition switch is turned ON.
Page 255: C40" (P0505) Isc Valve Circuit Malfunction
5-60 FI SYSTEM DIAGNOSIS “C40” (P0505) ISC VALVE CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE No voltage is applied to ISC valve motor, although ISC valve circuit open or short. ignition switch is turned ON, or voltage is applied to ISC valve malfunction. ISC valve motor, although ignition switch is turned ECM malfunction.
Page 256 FI SYSTEM DIAGNOSIS 5-61 Tester knob indication: Continuity test (6) Is the continuity OK? Go to Step2 B/Lg, R/B, P/W, G or W/Bl wire open. Terminal side Step 2 Measure the resistance between terminals 1 and 2, termi- nals 3 and 4. &...
Page 257 5-62 FI SYSTEM DIAGNOSIS ACTIVE CONTROL INSPECTION (ISC RPM CONTROL) Check 1 1) Set up the SDS tool. (Refer to the SDS operation manual for further details.) 2) Check that the engine is running. 3) Check that the “Engine coolant/oil temperature” is more than 70°C (158°F).
Page 258 FI SYSTEM DIAGNOSIS 5-63 Check 2 1) Click the button 4 and decrease the “Spec” 2 to 1 000 rpm slowly. 2) Check that the “Desired idle speed” 3 is equal to the “Spec” 3) Check that the “Engine speed” 5 is close to the “Spec” 2. 4) Click the button 1 and increase the “Spec”...
Page 259 5-64 FI SYSTEM DIAGNOSIS Check 3 1) Click the button 1 and increase the “Spec” 2 to 1 600 rpm slowly. 2) Check that the “Desired idle speed” 3 is equal to the “Spec” 3) Check that the “Engine speed” 4 is close to the “Spec” 2. 4) Check that the “ISC valve position”...
Page 260: C41" (P0230) Fp Relay Circuit Malfunction
FI SYSTEM DIAGNOSIS 5-65 “C41” (P0230) FP RELAY CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE No voltage is applied to fuel pump, although fuel • Fuel pump relay circuit open or short. pump relay is turned ON, or voltage is applied to fuel •...
Page 261 5-66 FI SYSTEM DIAGNOSIS SENSORS CKP SENSOR INSPECTION The crankshaft position sensor is installed in the generator cover. ($3-16) CKP SENSOR REMOVAL AND INSTALLATION • Remove the generator cover. ($3-16) • Install the generator cover in the reverse order of removal. IAP SENSOR INSPECTION The intake air pressure sensor is installed in front of the air cleaner box.
Page 262 FI SYSTEM DIAGNOSIS 5-67 TO SENSOR INSPECTION The tip-over sensor is located in front of the throttle body. ($5-52) TO SENSOR REMOVAL AND INSTALLATION • Remove the TO sensor. ($5-52) • Install the TO sensor in the reverse order of removal. NOTE: When installing the TO sensor, the arrow mark A must be pointed upward.
Page 264 FUEL SYSTEM AND THROTTLE BODY FUEL SYSTEM AND THROTTLE BODY CONTENTS FUEL TANK AND FUEL PUMP ..............6- 2 FUEL LINE INSPECTION ...............6- 2 FUEL TANK REMOVAL................6- 2 FUEL TANK INSPECTION..............6- 3 FUEL TANK INSTALLATION ..............6- 3 FUEL PRESSURE INSPECTION............6- 4 FUEL PUMP INSPECTION ..............6- 5 FUEL PUMP RELAY INSPECTION ............6- 6 FUEL PUMP REMOVAL .................6- 6...
Page 265: Fuel Tank And Fuel Pump
FUEL SYSTEM AND THROTTLE BODY FUEL TANK AND FUEL PUMP FUEL LINE INSPECTION Inspect the fuel hose, fuel tank cap for damage or fuel leakage. If any damage or fuel leakage is found, replace them with new ones. FUEL TANK REMOVAL •...
Page 266: Fuel Tank Inspection
FUEL SYSTEM AND THROTTLE BODY • Remove the fuel tank mounting bolt. • Remove the fuel tank side cover. • Remove the fuel hose. • Disconnect the fuel pump coupler. • Remove the fuel tank mounting bolts. • Remove the fuel tank assy. FUEL TANK INSPECTION Inspect the fuel tank for damage or fuel leakage.
Page 267: Fuel Pressure Inspection
FUEL SYSTEM AND THROTTLE BODY FUEL PRESSURE INSPECTION • Remove the seat. ($8-4) • Remove the left side cover. ($8-8) • Place a rag under the fuel feed hose. • Remove the fuel feed hose 1. • Install the special tools between the fuel tank and fuel delivery pipe.
Page 268: Fuel Pump Inspection
FUEL SYSTEM AND THROTTLE BODY FUEL PUMP INSPECTION Turn the ignition switch ON and check that the fuel pump oper- ates for a few seconds. If the fuel pump motor does not make operating sound, replace the fuel pump assembly or inspect the fuel pump relay and tip-over sensor.
Page 269: Fuel Pump Relay Inspection
FUEL SYSTEM AND THROTTLE BODY • Connect a proper lead wire into the fuel pump lead wire cou- pler (fuel pump side) and apply 12 volts to the fuel pump (between Y/R wire and B/W wire) for 10 seconds and mea- sure the amount of fuel discharged.
Page 270: Fuel Filter Cleaning And Fuel Pump Inspection
FUEL SYSTEM AND THROTTLE BODY FUEL FILTER CLEANING AND FUEL PUMP INSPECTION • If the fuel filter is clogged with sediment or rust, fuel will not flow smoothly and loss in engine power may result. Clean the fuel filter. Inspect whether the float moves smoothly or not. If the float dose not move smoothly, replace the fuel pump assembly.
Page 271: Throttle Body
FUEL SYSTEM AND THROTTLE BODY THROTTLE BODY CONSTRUCTION 1 TP sensor 8 Vacuum hose 2 ISC valve 9 Throttle linkage cover " 3 IAP sensor 0 IAP sensor cover 4 Fuel delivery pipe A TP sensor mounting screw ITEM N·m kgf-m lb-ft 5 O-ring B ISC valve mounting screw 6 Fuel injector...
Page 272: Air Cleaner Box Removal
FUEL SYSTEM AND THROTTLE BODY AIR CLEANER BOX REMOVAL • Remove the front fender. ($8-5) • Disconnect the IAP sensor lead wire coupler 1 and vacuum hose 2. • Remove the air cleaner box mounting bolts 3. • Remove the IAT sensor lead wire coupler 4. •...
Page 273: Throttle Body Removal
6-10 FUEL SYSTEM AND THROTTLE BODY THROTTLE BODY REMOVAL • Remove the air cleaner box. ($3-4) • Disconnect the fuel injector coupler 1. • Place a rag under the fuel feed hose 2 and disconnect its hose. • Disconnect the TP sensor lead wire coupler 3. •...
Page 274: Throttle Body Disassembly
FUEL SYSTEM AND THROTTLE BODY 6-11 THROTTLE BODY DISASSEMBLY • Disconnect the vacuum hose 1. • Remove the fuel delivery pipe assembly 2 by removing its mounting screws. • Remove the fuel injector 3. • Remove the ISC valve 4. •...
Page 275 6-12 FUEL SYSTEM AND THROTTLE BODY Never remove the throttle valve 6. * Do not loosen the locknut 7. * The fast idle screw 8 is factory-adjusted at the time of delivery and therefore avoid removing or turning it unless otherwise necessary.
Page 276: Throttle Body Cleaning
FUEL SYSTEM AND THROTTLE BODY 6-13 THROTTLE BODY CLEANING Some carburetor cleaning chemicals, especially dip-type soaking solutions, are very corrosive and must be handled carefully. Always follow the chemical manufacturer’s instructions for proper use, handling and storage. • Clean all passageways with a spray-type carburetor cleaner and blow dry with compressed air.
Page 277: Fuel Injector Inspection
TP sensor mounting screw to the specified torque. NOTE: * Align the throttle shaft end A with the groove B of TP sensor. * Apply SUZUKI SUPER GREASE “A” to the secondary throttle shaft end A if necessary. . 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A”...
Page 278: Throttle Body Installation
FUEL SYSTEM AND THROTTLE BODY 6-15 • Install the fuel injector 4 by pushing it straight to the throttle body. Replace the dust seal and O-ring with the new ones. Never turn the injector while pushing it. • Install the fuel delivery pipe assembly 5 to the throttle body. Never turn the fuel injector while installing the delivery pipe.
Page 279: Air Cleaner Box Installation
6-16 FUEL SYSTEM AND THROTTLE BODY AIR CLEANER BOX INSTALLATION Install the air cleaner box in the reverse order of removal. Pay LEFT attention to the following points: SIDE • Install the air cleaner box and tighten the throttle body clamp screws as shown in the illustration.
Page 280: Fast Idle
FUEL SYSTEM AND THROTTLE BODY 6-17 FAST IDLE The fast idle system is automatic type. When the fast idle cam is turned by the actuator, the cam pushes the lever on the throttle valve shaft causing the throttle valve to open and raise the engine speed. When the engine has warmed up, depending on the water temperature, ambient tem- perature and lapsed time, the fast idle is cancelled allowing the engine to resume idle speed.
Page 281: Throttle Position Sensor (Tps) Setting
6-18 FUEL SYSTEM AND THROTTLE BODY THROTTLE POSITION SENSOR (TPS) SETTING After all adjustments are completed, check or adjust the TPS 1 setting condition. (Refer to page 5-17 for TPS setting procedure.)
Page 282 COOLING AND LUBRICATION SYSTEM COOLING AND LUBRICATION SYSTEM CONTENTS ENGINE COOLANT ..................7- 2 COOLING CIRCUIT ..................7- 3 COOLING CIRCUIT INSPECTION ............7- 3 RADIATOR AND HOSES ................7- 4 RADIATOR REMOVAL ................7- 4 RADIATOR INSPECTION AND CLEANING .........7- 4 RADIATOR REMOUNTING ..............7- 5 RADIATOR RESERVOIR TANK ............7- 5 RADIATOR CAP INSPECTION .............7- 5 RADIATOR HOSE INSPECTION ............7- 6...
Page 283: Engine Coolant
COOLING AND LUBRICATION SYSTEM ENGINE COOLANT At the time of manufacture, the cooling system is filled with a 50:50 mixture of distilled water and ethylene glycol anti-freeze. This 50:50 mixture will provide the optimum corrosion protection and excellent heat pro- tection, and will protect the cooling system from freezing at temperatures above –31°C (–24°F).
Page 284: Cooling Circuit
COOLING AND LUBRICATION SYSTEM COOLING CIRCUIT RESERVOIR ENGINE COOLANT THERMOSTAT TEMPERATURE CYLINDER HEAD TANK SWITCH CYLINDER BYPASS COOLING FAN THERMO RADIATOR SWITCH WATER PUMP COOLING CIRCUIT INSPECTION Before removing the radiator and draining the engine coolant, inspect the cooling circuit for tightness. •...
Page 285: Radiator And Hoses
COOLING AND LUBRICATION SYSTEM RADIATOR AND HOSES RADIATOR REMOVAL • Remove the left inner fender. ($8-6) • Remove the front under cover. ($2-16) • Drain engine coolant by removing the drain plug. • Remove the radiator cap lid. • Remove the right headlight. •...
Page 286: Radiator Remounting
COOLING AND LUBRICATION SYSTEM • Fins bent down or dented can be repaired by straightening them with the blade of a small screwdriver. RADIATOR REMOUNTING • Install the radiator in the reverse order of removal. • Pay attention to the following points: •...
Page 287: Radiator Hose Inspection
COOLING AND LUBRICATION SYSTEM RADIATOR HOSE INSPECTION • Remove the front grill upper cover. ($8-4) • Remove the left headlight. ($8-5) • Remove the left inner fender. ($8-6) • Remove the left side cover. ($8-8) Any radiator hose found in a cracked condition or flattened must be replaced.
Page 288: Cooling Fan
COOLING AND LUBRICATION SYSTEM COOLING FAN INSPECTION • Remove the radiator cap lid. • Disconnect the cooling fan motor lead wire coupler 1. Test the cooling fan motor for load current with an ammeter con- nected as shown in the illustration. The voltmeter is for making sure that the battery 2 applies 12 volts to the motor 3.
Page 289: Cooling Fan Thermo-Switch
COOLING AND LUBRICATION SYSTEM COOLING FAN THERMO-SWITCH REMOVAL • Remove the left headlight. ($8-5) • Drain engine coolant. ($2-16) • Disconnect the cooling fan thermo-switch lead wire coupler • Remove the cooling fan thermo-switch 2. INSPECTION Check the thermo-switch closing or opening temperatures by testing it at the bench as shown in the figure.
Page 290: Ect Sensor
COOLING AND LUBRICATION SYSTEM ECT SENSOR REMOVAL • Remove the left side cover. ($8-8) • Disconnect the ECT sensor coupler 1. • Place a rag under the ECT sensor and remove the ECT sen- sor. INSPECTION Check the ECT sensor by testing it at the bench as shown in the figure.
Page 291: Thermostat
7-10 COOLING AND LUBRICATION SYSTEM THERMOSTAT REMOVAL • Remove the left side cover. ($8-8) • Drain engine coolant. ($2-16) • Place a rag under the thermostat cover 1. • Remove the thermostat cover 1. • Remove the thermostat 2. INSPECTION Inspect the thermostat pellet for signs of cracking.
Page 292: Installation
COOLING AND LUBRICATION SYSTEM 7-11 INSTALLATION • Install the thermostat in the reverse order of removal. • Apply engine coolant to the rubber seal on the thermostat. NOTE: The jiggle valve A of the thermostat faces upside. • After installing the thermostat, be sure to add engine coolant. ($2-16) •...
Page 293: Water Pump
7-12 COOLING AND LUBRICATION SYSTEM WATER PUMP REMOVAL AND DISASSEMBLY • Remove the left mud guard. ($8-8) • Drain engine coolant. ($2-16) • Drain engine oil. ($2-12) • Remove the water pump. ($3-16) NOTE: Before draining engine coolant, inspect engine coolant leakage between the water pump and crankcase.
Page 294 COOLING AND LUBRICATION SYSTEM 7-13 • Remove the impeller shaft. MECHANICAL SEAL Visually inspect the mechanical seal for damage, with particular attention given to the sealing face. Replace the mechanical seal that shows indications of leakage. Also replace the seal ring if necessary. •...
Page 295: Reassembly And Installation
% 09913-70210: Bearing installer set NOTE: The stamped mark on the oil seal faces outside. • Apply a small quantity of the SUZUKI SUPER GREASE “A” to the oil seal lip. . 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others)
Page 296 On the new mechanical seal, the sealer A has been applied. • Apply grease to the impeller shaft. . 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) • Install the impeller shaft to the water pump body.
Page 297 * Apply engine coolant to the O-ring 1 . * Apply grease to the O-ring 2 . . 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) • Tighten the water pump cover screws to the specified torque.
Page 298: Lubrication System
COOLING AND LUBRICATION SYSTEM 7-17 LUBRICATION SYSTEM OIL PRESSURE $2-32 OIL FILTER $2-13 OIL SUMP FILTER $3-24 OIL PUMP $3-58...
Page 299: Engine Lubrication System Chart
7-18 COOLING AND LUBRICATION SYSTEM ENGINE LUBRICATION SYSTEM CHART CAM FACE CAM FACE CYLINDER WALL CLUCH SHOE & TAPPET & TAPPET & PISTON CAMSHAFT CONROD ONE-WAY CAMSHAFT JOURNAL (R) BIG END BEARING CLUCH JOURNAL (R) CAM FACE IN. CAMSHAFT EX. CAMSHAFT OIL JET &...
Page 300: Engine Lubrication System
COOLING AND LUBRICATION SYSTEM 7-19 ENGINE LUBRICATION SYSTEM To cylinder head and clutch housing OIL PUMP...
Page 301 7-20 COOLING AND LUBRICATION SYSTEM EXHAUST SIDE INTAKE SIDE...
Page 303 CHASSIS CONTENTS EXTERIOR PARTS ..................8- 2 CONSTRUCTION ...................8- 2 REMOVAL ....................8- 4 EXHAUST PIPE ....................8-12 REMOVAL ....................8-12 REMOUNTING ..................8-12 FRONT AND REAR WHEELS ..............8-13 CONSTRUCTION ...................8-13 REMOVAL ....................8-13 REMOUNTING ..................8-13 TIRES ......................8-14 TIRE REPLACEMENT ................8-14 FRONT DRIVE SHAFT .................8-16 CONSTRUCTION ...................8-16 REMOVAL AND DISASSEMBLY ............
Page 304 CHASSIS INSPECTION ..................8-48 REASSEMBLY AND REMOUNTING ............ 8-50 TOE-OUT ADJUSTMENT ..............8-52 FRONT WHEEL, FRONT BRAKE, FRONT SUSPENSION AND STEERING REASSEMBLING INFORMATION ........8-53 REAR DRIVE SHAFT ................... 8-54 CONSTRUCTION .................. 8-54 REMOVAL ..................... 8-54 INSPECTION AND REASSEMBLY ............8-55 REMOUNTING ..................
Page 305: Exterior Parts
CHASSIS EXTERIOR PARTS CONSTRUCTION 1 Front fender 5 Right inner fender 2 Radiator cap lid 6 Left inner fender 3 Right side cover 7 Front box 4 Left side cover 8 Front grill upper cover...
Page 306 CHASSIS 1 Rear fender 4 Left upper mud guard 2 Right mud guard 5 Rear box 3 Left lower mud guard...
Page 307: Removal
CHASSIS REMOVAL SEAT • Move the seat lock 1 upward, and remove the seat. FRONT CARRIER • Remove the front grill lower cover 1 by removing the right and left clips 2 and bolts 3. • Remove the front grill upper cover 4 by removing the right and left clips 5.
Page 308 CHASSIS FRONT GRIP BAR • Remove the front carrier. (!8-4) • Remove the headlight housing screws 1. • Remove the headlight housing clips 2. • Remove the headlight housing bolts 3. • Disconnect the headlight couplers. • Remove the right and left headlight assemblies. •...
Page 309 CHASSIS • Remove the left mud guard clips 1 and screw 2. • Remove the left inner fender 3. • Remove the right side cover 4. • Remove the right mud guard clips 5 and screw 6. • Remove the right inner fender 7.
Page 310 CHASSIS • Disconnect the power source socket coupler. • Remove the front fender. FRONT BOX • Remove the front box cap 1. • Disconnect the front box cap wire. • Remove the front box mounting screw. • Turn the front box counterclockwise and remove it. •...
Page 311 CHASSIS SIDE COVER • Remove the left side cover 1. • Remove the right side cover 2. MUD GUARD • Remove the left side cover 1. • Remove the left upper and lower mud guard 2. • Remove the right side cover 3. •...
Page 312 CHASSIS REAR CARRIER • Remove the rear carrier 1.
Page 313 8-10 CHASSIS FUEL TANK COVER • Remove the fuel tank cover 1. REAR FENDER • Remove the seat. (!8-4) • Remove the rear carrier. (!8-9) • Remove the right and left mud guard. (!8-8) • Remove the rear box. (!8-8) •...
Page 314 CHASSIS 8-11 REMOUNTING • Remount the exterior parts in the reverse order of removal. Pay attention to the to following points. • Apply thread lock to the front carrier mounting bolts/nuts. " 99000-32050: THREAD LOCK “1342” • Apply thread lock to the front grip bar mounting bolts. "...
Page 315: Exhaust Pipe
8-12 CHASSIS EXHAUST PIPE REMOVAL • Remove the right inner fender. (!8-6) • Remove the rear fender. (!8-10) • Remove the exhaust pipe nuts 1 and muffler mounting bolts • Remove the exhaust pipe out of the frame. REMOUNTING • Remount the exhaust pipe in the reverse order of removal. Pay attention to the following points.
Page 316: Front And Rear Wheels
CHASSIS 8-13 FRONT AND REAR WHEELS CONSTRUCTION 1 Front tire 6 Rear wheel 2 Front wheel 7 Rear wheel set nut ITEM N·m kgf-m lb-ft 3 Front wheel set nut 8 Rear wheel air valve 43.5 4 Front wheel air valve 9 Brake disc bolt 43.5 5 Rear tire...
Page 317: Tires
8-14 CHASSIS TIRES TIRE REPLACEMENT • Remove the front and rear wheels. (!8-13) • After removing the air valve caps, release the tire pressure by depressing the valves. • Dismount the bead from the rim completely as shown. • Separate the tire from the rim using a set of tire levers and rim protectors.
Page 318 CHASSIS 8-15 • When installing each tire, make sure the arrow A on the tire points in the direction of rotation. Also, make sure the outer side of the wheel rim is facing outward. NOTE: For inspecting the tires, refer to page 2-25. Inspect the valve cores, before installing.
Page 319: Front Drive Shaft
8-16 CHASSIS FRONT DRIVE SHAFT CONSTRUCTION 1 Circlip 6 Inner boot band (small) 2 Snap ring 7 Drive shaft 3 Stopper ring 8 Outer boot band (small) 4 Inner boot band (large) 9 Outer boot 5 Inner boot 0 Outer boot band (large) REMOVAL AND DISASSEMBLY •...
Page 320 CHASSIS 8-17 • Remove the boot bands of the differential side joint (double offset joint). Replace the removed boot bands with new ones. • Slide the boot toward the center of the front drive shaft and remove the stopper ring from the outer race. Replace the removed stopper ring with a new one.
Page 321: Inspection And Reassembly
8-18 CHASSIS INSPECTION AND REASSEMBLY Inspect the boots for wear or damage. If any damages are found, replace them with new ones. Inspect the axle play by using a push-and-pull motion given to the axle shaft and wheel spindle, as shown. NOTE: * Wash the disassembled parts (except for the boots).
Page 322 CHASSIS 8-19 • Install the new snap ring. • Apply grease to the entire surface of the cage and the inside of the outer race. Position Wheel side Differential side Grease Quantity 45 g 85 g NOTE: The tube of joint grease is included in the wheel side boot set or wheel side joint assembly of spare parts.
Page 323: Remounting
8-20 CHASSIS • After installing the boot on the outer race, insert a screw driver into the boot on the outer race side and allow air to enter the boot so that the air pressure in the boot becomes the same as the atmospheric pressure at the positions indicated in the illustration.
Page 324: Front Brake
CHASSIS 8-21 FRONT BRAKE CONSTRUCTION 1 Master cylinder reservior cap D Dust seal 2 Diaphragm E Brake caliper 3 Master cylinder clamp F Brake caliper holder 4 Boot G Brake pad 5 Piston/cup set H Pad spring ITEM N·m kgf-m lb-ft 6 Cup A Master cylinder clamp bolt...
Page 325 8-22 CHASSIS * 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 brake fluids. * Do not use any brake fluid taken from old, used or unsealed containers. Never reuse brake fluid left over from the last servicing or which has been stored for a long periods of time.
Page 326: Brake Pad Replacement
CHASSIS 8-23 BRAKE PAD REPLACEMENT • Remove the front wheel. (!8-13) • Remove the brake caliper mounting bolts 1 and brake pad mounting pins 2. • Remove the brake pads. * Do not operate the brake lever during or after brake pads removal.
Page 327: Brake Fluid Replacement
8-24 CHASSIS BRAKE FLUID REPLACEMENT • Place the vehicle on level ground and keep the handlebar straight. • Remove the master cylinder reservoir cap and diaphragm. • Suck up the old brake fluid as much as possible. • Fill the reservoir with new brake fluid. ) Specification and classification: DOT 4 •...
Page 328 CHASSIS 8-25 • Remove the pad spring 1. • Place a rag over the brake caliper piston to prevent it from popping out and then force out the piston using compressed air. Do not use high pressure air to prevent brake caliper piston damage.
Page 329: Brake Caliper Inspection
8-26 CHASSIS BRAKE CALIPER INSPECTION BRAKE CALIPER Inspect the brake caliper cylinder wall for nicks, scratches or other damage. If any damages are found, replace the brake cal- iper with a new one. BRAKE CALIPER PISTON Inspect the brake caliper piston for any scratches or other dam- age.
Page 330: Brake Caliper Reassembly And Remounting
CHASSIS 8-27 BRAKE CALIPER REASSEMBLY AND REMOUNTING Reassemble the caliper in the reverse order of disassembly. Pay attention to the following points: • Clean the caliper bore and piston with specified brake fluid, especially the dust seal groove and piston seal groove. ) Specification and Classification: DOT 4 * Clean the caliper components with fresh brake fluid before reassembly.
Page 331 # Caliper holder pin: 18 N·m (1.8 kgf-m, 13.0 lb-ft) Caliper holder slide pin: 23 N·m (2.3 kgf-m, 16.5 lb-ft) • Apply SUZUKI SILICON GREASE to the brake caliper holder pin. * 99000-25100: SUZUKI SILICONE GREASE • Install the caliper holder 1 to the caliper 4.
Page 332: Brake Disc Removal And Disassembly
CHASSIS 8-29 BRAKE DISC REMOVAL AND DISASSEMBLY • Remove the front wheel. (!8-13) • Remove the cotter pin. Replace the removed cotter pin with a new one. • Loosen the hub nut 1. • Remove the brake caliper. (!8-24) • Remove the hub nut 1. •...
Page 333: Brake Disc Inspection
Reassemble and remount the brake disc in the reverse order of removal and disassembly. Pay attention to the following points: • Apply SUZUKI SUPER GREASE “A” to the wheel hub spline. + 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) •...
Page 334: Master Cylinder Removal And Disassembly
CHASSIS 8-31 • Install the wheel hub. • Install the front caliper. (!8-27) • Tighten the front wheel set nuts 2, and hub nut 3 to the specified torque. # Front wheel set nut: 60 N·m (6.0 kgf-m, 43.5 lb-ft) Front hub nut: 110 N·m (11.0 kgf-m, 79.5 lb-ft) NOTE: * First, remount the front wheels, and then tighten the front hub...
Page 335 8-32 CHASSIS • Remove the brake lever 1 and front brake switch 2. • Remove the reservoir cap 3 and diaphragm 4. • Drain the brake fluid. • Pull the dust boot 5 out and remove the circlip 6. • Remove the piston/secondary cup, primary cup and spring. 7 Secondary cup 8 Piston 9 Primary cup...
Page 336: Master Cylinder Inspection
CHASSIS 8-33 MASTER CYLINDER INSPECTION MASTER CYLINDER Inspect the master cylinder bore for any scratches or damage. If any damages are found, replace the master cylinder with a new one. PISTON AND RUBBER PARTS Inspect the piston surface, primary cup, secondary cup and dust boot for any scratches, wear or damage.
Page 337 8-34 CHASSIS • When remounting the master cylinder on the handlebars, align the master cylinder holder’s mating surface 1 with the punch mark 2 on the handlebars and tighten the upper clamp bolt first and lower clamp bolt. # Master cylinder clamp bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft) A Master cylinder upper clamp bolt B Handlebars C Clearance...
Page 338: Front Suspension
CHASSIS 8-35 FRONT SUSPENSION CONSTRUCTION 1 Shock absorber A Snap ring 2 Upper wishbone arm B Cotter pin 3 Lower wishbone arm A Shock absorber mounting upper bolt ITEM N·m kgf-m lb-ft 4 Steering knuckle B Shock absorber mounting lower nut 40.0 5 Tie rod C Wishbone arm pivot nut (upper)
Page 339: Removal And Disassembly
8-36 CHASSIS REMOVAL AND DISASSEMBLY • Remove the front wheel hubs with brake discs. (!8-29) • Remove the front brake hose clamps. • Remove the front grill lower cover. • Remove the drive shaft cover. • Remove the cotter pins and tie rod end nuts. Replace the removed cotter pins with new ones.
Page 340 CHASSIS 8-37 • Remove the cotter pins and knuckle end nuts. Replace the removed cotter pins with new ones. • Remove the upper wishbone arm pivot bolts/nuts and the shock absorber mounting lower bolts/nuts. • Remove the upper wishbone arms 1. •...
Page 341: Inspection
8-38 CHASSIS INSPECTION FRONT SHOCK ABSORBER Inspect the shock absorbers for oil leakage or damage. If any damages are found, replace it with a new one. KNUCKLE END • Remove the snap ring. Inspect the knuckle end boots for wear or damage. If any dam- ages are found, replace it with a new one.
Page 342 CHASSIS 8-39 DRIVE SHAFT COVER Inspect the drive shaft cover for wear or damage. If any dam- ages are found, replace it with a new one. BRAKE DISC COVER Inspect the brake disc covers for wear or damage. If any dam- ages are found, replace it with a new one.
Page 343 8-40 CHASSIS DUST SEAL Inspect the dust seal lips for wear or damage. If any damages are found, replace them with new ones. • Remove the steering knuckle dust seals with the special tool. & 09913-50121: Oil seal remover Replace the removed dust seals with new ones. HUB BEARING Inspect the inner race play of the hub bearings by hand while they are in the steering knuckles.
Page 344: Reassembly And Remounting
CHASSIS 8-41 REASSEMBLY AND REMOUNTING Reassemble and remount the front suspension in the reverse order of removal and disassembly. Pay attention to the following points: • Install the hub bearings with the special tool. & 09924-84510: Bearing installer set • Install the steering knuckle dust seals with the special tool. &...
Page 345 8-42 CHASSIS • Tighten the shock absorber mounting lower nut 1 to the specified torque. # Shock absorber mounting lower nut: 60 N·m (6.0 kgf-m, 43.5 lb-ft) • Tighten the shock absorber mounting upper bolt 2 to the specified torque. # Shock absorber mounting upper bolt: 55 N·m (5.5 kgf-m, 40.0 lb-ft) •...
Page 346 CHASSIS 8-43 SPRING PRE-LOAD ADJUSTMENT After installing the front shock absorbers, adjust the spring pre- load. Position “1” provides the minimum spring pre-load. Position “5” provides the maximum spring pre-load. STD POSITION: 2/5 POSITION “1” POSITION “5” Be sure to adjust the spring pre-load on the both shock absorbers equally.
Page 347: Steering
8-44 CHASSIS STEERING CONSTRUCTION 1 Handlebar 0 O-ring 2 Handlebar upper clamp A Washer 3 Handlebar upper clamp bolt B Steering shaft lower nut 4 Steering shaft C Cotter pin 5 Steering shaft holder D Throttle cable 6 Dust seal E Rear brake cable ITEM N·m...
Page 348: Removal And Disassembly
CHASSIS 8-45 REMOVAL AND DISASSEMBLY • Remove the front fender. (!8-5) • Remove the front wheels. (!8-13) • Remove the front brake master cylinder assembly. (!8-31) • Remove the throttle lever case. • Remove the throttle cable band. • Disconnect the parking brake cable 1 and remove the handle switch (L) 2.
Page 349 8-46 CHASSIS • Remove the speedometer cover 3 and auxiliary headlight cover 4. • Remove the speedometer assembly. • Remove the handlebar clamp bolts. • Remove the handlebar upper clamps 5 and handlebars.
Page 350 CHASSIS 8-47 • Disconnect the auxiliary headlight coupler. • Disconnect the brake hose clamp. • Remove the cooling duct 6. • Remove the cotter pins and tie rod end nuts. Replace the removed cotter pins with new ones. • Separate the tie rod ends 1, nuts 2 and 3, and tie rods 4. The locknuts 2 have left-hand threads.
Page 351 8-48 CHASSIS • Remove the cotter pin and steering shaft lower nut and washer. Replace the removed cotter pin with a new one. • Remove the steering shaft holder bolts and harness holder bands. • Remove the steering shaft holder 1. •...
Page 352 CHASSIS 8-49 TIE ROD Inspect the tie rod for distortion or damage. If any damages are found, replace it with a new one. TIE ROD END Inspect the tie rod ends and boots for smooth movement. If there are any abnormalities, replace them with new ones. STEERING SHAFT AND HOLDER Inspect the steering shaft for distortion or bends.
Page 353: Reassembly And Remounting
Reassemble and remount the steering in the reverse order of removal and disassembly. Pay attention to the following points: STEERING SHAFT • Apply SUZUKI SUPER GREASE “A” to the O-ring 1 and dust seal 2 before remounting the steering shaft. . 99000-25160: WATER RESISTANCE GREASE •...
Page 354 CHASSIS 8-51 • Install the steering shaft lower nut and washer. • Tighten the steering shaft lower nut to the specified torque. # Steering shaft lower nut: 120 N·m (12.0 kgf-m, 87.0 lb-ft) NOTE: After installing the steering shaft lower nut, install a new cotter pin into the steering shaft.
Page 355: Toe-Out Adjustment
8-52 CHASSIS HANDLEBAR SWITCH • Align the handlebar switch lug 1 with the handlebar hole 2. TOE-OUT ADJUSTMENT Adjust the toe-out as follows: • Place the vehicle on level ground and set the handlebars straight. • Make sure all the tires are inflated to the standard pressure. (!2-25) •...
Page 356: Front Wheel, Front Brake, Front Suspension And Steering Reassembling Information
CHASSIS 8-53 FRONT WHEEL, FRONT BRAKE, FRONT SUSPENSION AND STEERING REASSEMBLING INFORMATION ITEM N·m kgf-m lb-ft ITEM N·m kgf-m lb-ft ITEM N·m kgf-m lb-ft 19.0 32.5 21.0 43.5 40.0 43.5 16.5 43.5 11.0 49.5 21.0 47.0 21.0 12.0 87.0 43.5...
Page 357: Rear Drive Shaft
8-54 CHASSIS REAR DRIVE SHAFT CONSTRUCTION 1 Circlip 6 Inner boot band (small) 2 Snap ring 7 Drive shaft 3 Stopper ring 8 Outer boot band (small) 4 Inner boot band (large) 9 Outer boot 5 Inner boot 0 Outer boot band (large) REMOVAL •...
Page 358: Inspection And Reassembly
CHASSIS 8-55 INSPECTION AND REASSEMBLY Inspect the boots for wear or damage. If any damages are found, replace the boots with new ones. Inspect the stopper ring, snap ring and boot bands for wear or damage. If any damages are found, replace them with new ones.
Page 359 8-56 CHASSIS • Install the new snap ring. • Apply grease to the entire surface of the cage and the inside of the outer race. Position Outer Inner Grease Quantity 45 g 85 g NOTE: The tube of joint grease is included in the wheel side boot set or wheel side joint assembly of spare parts.
Page 360: Remounting
CHASSIS 8-57 • After fitting the boot on the outer race, insert a screw driver into the boot on the outer race side and allow air to enter the boot so that the air pressure in the boot becomes the same as the atmospheric pressure at the positions indicated in the illustration.
Page 361: Rear Brake
8-58 CHASSIS REAR BRAKE CONSTRUCTION 1 Steel plates 8 Rear brkae cam lever 2 Friction plates 9 Rear brake case cover 3 Rear brake return spring 0 Bearing 4 Rear brake pressure plate A Snap ring 5 Ball B Oil seal ITEM N·m kgf-m...
Page 362: Removal And Disassembly
CHASSIS 8-59 REMOVAL AND DISASSEMBLY • Remove the rear wheels. (!8-13) • Remove the exhaust pipe. (!8-12) • Drain the final gear oil. (!2-15) • Remove the rear drive shaft. (!8-54) • Remove the rear brake adjust nut 2 and brake cables 3. •...
Page 363: Disassmbly
8-60 CHASSIS • Remove the trailer towing (option) 8. • Remove the rear final gear case assembly mounting bolts 0. • Remove the rear final gear case bolts A. • Rear final gear case assembly is pulled for a while back. •...
Page 364 CHASSIS 8-61 • Remove the rear brake case cover. • Remove the gasket. Replace the removed gasket with a new one. • Remove the rear brake friction plate and steel plate 4. • Remove the rear brake cam 5. • Remove the rear brake cam shaft 6. •...
Page 365: Inspection
8-62 CHASSIS • Remove the oil seal with the special tool. & 09913-50121: Oil seal remover Replace the removed oil seal with a new one. • Remove the rear final drive gear shaft 4 with the special tool. & 09940-52861: Frontfork seal installer set •...
Page 366 CHASSIS 8-63 BEARING Inspect the inner race play of the bearing by band while it is in the rear brake case cover. Turn the inner race by band to inspect for abnormal noise or smooth rotation. • If there is anything unusual, replace it with a new one. REAR BRAKE CAM SHAFT Inspect the rear brake cam shaft for wear or damage.
Page 367 8-64 CHASSIS BRAKE PLATE RETURN SPRING • Measure the free length A. • If the free length A is shorter than the limit, replace the spring with a new one. % Brake plate return spring: Service Limit: 20.2 mm (0.80 in) Replace the removed plate stopper 1 with a new one.
Page 368: Reassembly And Remount
CHASSIS 8-65 REASSEMBLY AND REMOUNT • Reassemble and remount the rear brake in the reverse order of removal and disassembly. Pay attention to the following points. • Install the bearing with the spesial tool. & 09913-70210: Bearing installer set • Apply oil to the bearing before installing it. / Specification and classification: MOBIL FLUID 424 •...
Page 369 • When installing the rear brake pressure plate 7, align its groove to the rear brake cam shaft 6. • Apply grease to the rear brake camshaft 6. + 99000-25010: SUZUKI SUPER GREASE “A” Measure the outer distance A between the steel plates as shown.
Page 370 CHASSIS 8-67 • Install the rear brake cam lever B to the shaft. NOTE: When installing the brake cam lever, align the punched mark. • Tighten the cam lever nut C to the specified torque. # Rear brake cam lever nut: 11 N·m (1.1 kgf-m, 8.0 lb-ft) •...
Page 371: Rear Suspension
8-68 CHASSIS REAR SUSPENSION CONSTRUCTION 1 Rear shock absorber 9 Rear knuckle 2 Rear stabilizer bar 0 Hub bearing 3 Rear stabilizer bushing A Snap ring 4 Rear stabilizer bracket B Dust seal ITEM N·m kgf-m lb-ft 5 Rear stabilizer link A Rear shock absorber mounting nut 43.5 6 Upper wishbone arm...
Page 372: Removal
CHASSIS 8-69 REMOVAL • Remove the rear wheel. (!8-13) • Remove the rear box. (!8-8) • Remove the exhaust pipe. (!8-12) • Drain the final gear oil. (!2-15) • Remove the rear drive shaft cover 1. • Remove the cotter pin and rear hub nut. •...
Page 373: Inspection And Disassembly
8-70 CHASSIS • Remove the upper wishbone arm by removing the pivot bolt/ nut. • Remove the rear shock absorber 2. • Remove the lower wishbone arm 3 by removing the pivot bolt/nuts. INSPECTION AND DISASSEMBLY REAR SHOCK ABSORBER Inspect the shock absorber for oil leakage or damage. If any damages are found, replace the rear shock absorber with a new one.
Page 374 CHASSIS 8-71 • Remove the rear knuckle dust seal with the special tool. & 09913-50121: Oil seal remover Replace the removed dust seal with a new one. HUB BEARINGS Inspect the inner race play of the hub bearing by hand while it is in the rear knuckle.
Page 375: Reassembly And Remounting
8-72 CHASSIS REASSEMBLY AND REMOUNTING Reassemble and remount the rear suspension in the reverse order of removal and disassembly. Pay attention to the following points: • Apply grease to the hub bearings and the lips of the dust seals before installing them. .
Page 376 CHASSIS 8-73 • Apply THREAD LOCK SUPER “1303 ” or “1322” to the rear shock absorber mounting bolts, and then tighten the nut to the specified torque. ( 99000-32030: THREAD LOCK SUPER “1303” (USA) - 99000-32110: THREAD LOCK SUPER “1322” (Others) # Shock absorber mounting nut (upper and lower): 60 N·m (6.0 kgf-m, 43.5 lb-ft) •...
Page 377 8-74 CHASSIS SPRING PRE-LOAD ADJUSTMENT After installing the rear shock absorber, adjust the spring pre- load. Position “1” provides the minimum spring pre-load. Position “5” provides the maximum spring pre-load. STD POSITION: 2/5 POSITION “1” POSITION “5” Be sure to adjust the spring pre-load on the both sus- pensions equally.
Page 378: Rear Stabilizer Removal
CHASSIS 8-75 REAR STABILIZER REMOVAL • Remove the rear wheel. (!8-13) • Remove the rear stabilizer link lower bolt/nut. • Remove the rear stabilizer bracket bolts. • Remove the rear stabilizer bar. INSPECTION REAR STABILIZER BAR Inspect the stabilizer for damage. If any damages are found, replace the rear stabilizer bar with a new one.
Page 379: Rear Stabilizer Installation
8-76 CHASSIS REAR STABILIZER INSTALLATION • Install the rear stabilizer bar. • Tighten the rear stabilizer bracket bolts. • Tighten the rear stabilizer link lower bolt/nut.
Page 380: Rear Wheel, Rear Brake, Rear Suspension And Rear Axle Shaft Reassembling Information
CHASSIS 8-77 REAR WHEEL, REAR BRAKE, REAR SUSPENSION AND REAR AXLE SHAFT REASSEMBLING INFORMATION ITEM N·m kgf-m lb-ft ITEM N·m kgf-m lb-ft 43.5 24.5 43.5 43.5 11.0 79.5 43.5 43.5 43.5 43.5 43.5...
Page 381: Transfer Gear Shift Lever
8-78 CHASSIS TRANSFER GEAR SHIFT LEVER CONSTRUCTION 1 Transfer gear shift lever assembly 3 Knob 2 Rod 4 Mounting bolt ITEM N·m kgf-m lb-ft...
Page 382: Removal
CHASSIS 8-79 REMOVAL • Remove the left inner fender. (!8-6) • Remove the left side cover. (!8-8) • Remove the left upper mud guard. (!8-8) • Remove the transfer gear shift lever mounting bolts. • Loosen the bolt 1 and remove the gear shift arm 2. •...
Page 383: Remounting
Remount the gearshift lever in the reverse order of removal. Pay attention to the following points: • Apply grease to pivot. + 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) • Install the shift lever assembly to the frame bracket.
Page 384: Shift Rod
CHASSIS 8-81 SHIFT ROD INSTALLATION GEAR SELECTION ROD Before removing the shift lever assembly, keep the gear shift arm 1 in the “N” position. • Install the gear shift arm 1 on its shaft. 30 ˚ 33 ˚ NOTE: 33 ˚ When remounting the gear shift arm, align the arm’s grooves with the spline of the shaft.
Page 385: Shift Rod Adjustment
8-82 CHASSIS SHIFT ROD ADJUSTMENT • Holding the rod 2, loosen the locknuts 1. • Turning the rod 2, adjust the length of the rod. NOTE: Be careful not to separate the rod from the joint by turning the rod too much.
Page 387 ELECTRICAL SYSTEM CONTENTS CAUTIONS IN SERVICING ................9- 2 CONNECTOR ..................9- 2 COUPLER ....................9- 2 CLAMP....................9- 2 FUSE .......................9- 2 SEMI-CONDUCTOR EQUIPPED PART ..........9- 3 BATTERY....................9- 3 CONNECTING THE BATTERY ..............9- 3 WIRING PROCEDURE ................9- 3 USING THE MULTI-CIRCUIT TESTER ..........9- 4 LOCATION OF ELECTRICAL COMPONENTS ...........
Page 388 ELECTRICAL SYSTEM LAMPS ......................9-31 HEADLIGHT AND AUXILIARY HEADLIGHT.........9-31 HEADLIGHT INSTALLATION..............9-33 BRAKE LIGHT/TAILLIGHT..............9-34 DIODE ......................9-36 BACKUP LIGHT RELAY (FOR E-17) ............9-36 SWITCHES ....................9-37 BATTERY .....................9-38 SPECIFICATIONS...................9-38 INITIAL CHARGING................9-38 SERVICING .....................9-40 RECHARGING OPERATION ..............9-40...
Page 389: Cautions In Servicing
ELECTRICAL SYSTEM CAUTIONS IN SERVICING CONNECTOR • When connecting a connector, be sure to push it in until a click is felt. Click • Inspect the connector for corrosion, contamination and break- age in its cover. COUPLER Click • With a lock type coupler, be sure to release the lock before disconnecting and push it in fully till the lock works when con- necting.
Page 390: Battery
ELECTRICAL SYSTEM SEMI-CONDUCTOR EQUIPPED PART • Be careful not to drop the part with a semi-conductor built in INCORRECT such as a ECM. • When inspecting this part, follow inspection instruction strictly. Neglecting proper procedure may cause damage to this part. BATTERY •...
Page 391: Using The Multi-Circuit Tester
ELECTRICAL SYSTEM USING THE MULTI-CIRCUIT TESTER • Properly use the multi-circuit tester + and - probes. Improper use can cause damage to the vehicle and tester. • If the voltage and current values are not known, begin mea- suring in the highest range. •...
Page 392: Main Fuse
ELECTRICAL SYSTEM LOCATION OF ELECTRICAL COMPONENTS 1 Battery 9 Starter motor 2 Main fuse 0 Transfer selecting switch 3 Starter relay A Brake lever switch (R) 4 Fuse box B Ignition switch 5 Neutral relay C Power source 6 Fuel pump relay D Ignition coil 7 ECM E Foot brake switch...
Page 393 ELECTRICAL SYSTEM 1 Cooling fan thermo-switch 7 Diff-lock relay 2 Handle switch (L) 8 Cooling fan 3 Parking brake switch 9 Actuator 4 Brake lever switch (L) 0 High position diode 5 Regulator/rectifier A Low position diode 6 Ignition/starter control relay B Speed sensor...
Page 394: Fuse
ELECTRICAL SYSTEM CHARGING SYSTEM Ignition switch Main fuse Battery Generator Regulator/rectifier TROUBLESHOOTING Battery runs down quickly Step 1 1) Check accessories which use excessive amounts of electricity. Are accessories being installed? Remove accessories. Go to Step 2. Step 2 1) Check the battery for current leaks. (!9-8) Is the battery current leakage OK? Go to Step 3.
Page 395: Inspection
ELECTRICAL SYSTEM Step 5 1) Measure the generator no-load performance. (!9-10) Is the generator no-load performance OK? Go to Step 6. Faulty generator. Step 6 1) Inspect the regulator/rectifier. (!9-10) Is the regulator/rectifier OK? Go to Step 7. Faulty regulator/rectifier. Step 7 1) Inspect wirings.
Page 396 ELECTRICAL SYSTEM REGULATED VOLTAGE • Remove the seat. (!8-4) • Remove the battery stay 1. • Start the engine and keep it running at 5 000 r/min. with the ignition switch turned to AUX. Measure the DC voltage between the + and - battery termi- nals with the multi-circuit tester.
Page 397 9-10 ELECTRICAL SYSTEM GENERATOR NO-LOAD PERFORMANCE • Remove the rear fender. (!8-10) • Disconnect the generator coupler 1. • Start the engine and keep it running at 5 000 r/min. Measure the voltage between three lead wires with the multi-cir- cuit tester.
Page 398: Starter System
ELECTRICAL SYSTEM 9-11 STARTER SYSTEM Starter Engine Ignition stop switch Ignition button switch fuse Main Neutral relay fuse Starter motor Neutral indicator light Ignition/ starter B/Bl Starter relay Bl/B control relay Bl/B Neutral Gear diode position switch Parking brake switch TROUBLESHOOTING Make sure that the fuses are not blown and the battery is fully-charged before diagnosing.
Page 399: Starter Motor Removal
9-12 ELECTRICAL SYSTEM Step 3 1) Measure the starter relay voltage at the starter relay connectors (between Y/B + and B/W -) when the starter button is pushed. Is a voltage OK? Go to Step 4. • Faulty engine stop switch. •...
Page 400: Starter Motor Disassembly
ELECTRICAL SYSTEM 9-13 STARTER MOTOR DISASSEMBLY • Disassemble the starter motor as shown in the illustration. 1 O-ring 4 Armature 2 Housing end (inside) 5 Housing end (outside) ITEM N·m kgf-m lb-ft 3 Starter motor case A Lead wire connecting nut...
Page 401: Starter Motor Inspection
Reassemble the starter motor in the reverse order of disassem- bly. Pay attention to the following points: • Apply SUZUKI SUPER GREASE “A” to the lip of the oil seal. . 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others)
Page 402: Starter Motor Installation
ELECTRICAL SYSTEM 9-15 • Apply a small quantity of SUZUKI MOLY PASTE to the arma- ture shaft. / 99000-25140: SUZUKI MOLY PASTE • Align the marks on the housing ends with the marks on the starter motor case. • Apply SUZUKI SUPER GREASE “A” to the O-ring.
Page 403: Neutral Relay Inspection
9-16 ELECTRICAL SYSTEM Measure the relay coil resistance between the terminals with the multi-circuit tester. If the resistance is not within the specified value, replace the starter relay with a new one. " 09900-25008: Multi-circuit tester set ( Tester knob indication: Resistance (Ω) &...
Page 404: Ignition System
ELECTRICAL SYSTEM 9-17 IGNITION SYSTEM Engine stop switch Ignition fuse Power source circuit Ignition sensor switch Waveform arrangement Main circuit fuse Battery Intake air Throttle Engine Gear pressure position coolant position sensor sensor temp. switch sensor TROUBLESHOOTING No spark or poor spark NOTE: Check that the transfer is in neutral and the engine stop switch is in the “RUN”...
Page 405 9-18 ELECTRICAL SYSTEM Step 2 1) Measure the battery voltage between input lead wires (O/W and B/W) at the ECM with the ignition switch in the “ON” position. Is the voltage OK? Go to Step 3. • Faulty ignition switch. •...
Page 406: Inspection
ELECTRICAL SYSTEM 9-19 INSPECTION IGNITION COIL PRIMARY PEAK VOLTAGE • Remove the right side cover. (!8-8) • Remove the right inner fender. (!8-6) • Remove the spark plug cap. • Connect a new spark plug 1 to spark plug cap and ground it to the cylinder head cover bolt.
Page 407 9-20 ELECTRICAL SYSTEM IGNITION COIL RESISTANCE • Remove the right side cover. (!8-8) • Disconnect the ignition coil lead wire and spark plug cap, and remove the ignition coil. Measure the ignition coil resistance in both the primary and sec- ondary windings with the multi-circuit tester.
Page 408 ELECTRICAL SYSTEM 9-21 If the peak voltage is lower than the standard range, check the peak voltage at the CKP sensor lead wire coupler. • Remove the seat. (!8-4) • Disconnect the CKP sensor lead wire coupler 1 and connect the multi-circuit tester with the peak volt adaptor.
Page 409: Transfer Selecting System
9-22 ELECTRICAL SYSTEM TRANSFER SELECTING SYSTEM INSPECTION ACTUATOR • Remove the left inner fender. (!8-6) • Disconnect the actuator coupler 1. • Remove the front drive train (differential) gear case assembly out of the frame. (!4-3) • Remove the actuator assembly. Connect the 12 V battery to the actuator lead wires (B/R and R/B wire).
Page 410 ELECTRICAL SYSTEM 9-23 First check the continuity between B and C and between A and C terminals with the tester. Check the insulation between 5 and B and between 5 and A. Apply 12 V to the terminals as shown in Fig-1, and check the insulation between B and C.
Page 411: Combination Meter
9-24 ELECTRICAL SYSTEM COMBINATION METER DESCRIPTION This combination meter mainly consists of LCD (Liquid Crystal Display) and LED (Light Emitting Diode). This combination meter is light, thin and of high response compared to those currently in use because of this composition.
Page 412: Operating Procedure
ELECTRICAL SYSTEM 9-25 OPERATING PROCEDURE INITIAL DISPLAY When the ignition switch is set to ON, all LCD, ECT/FI, neutral indicator, reverse indicator and diff-lock indicator light. light up for two seconds. NOTE: If the power supply is cut (e.g., when the battery is replaced); * The odometer, tripmeter and clock are displayed after the ini- tial display appears.
Page 413 9-26 ELECTRICAL SYSTEM CLOCK Displays the time (hour and minutes) on a 12-hour clock. Setting the time Hold down the button over two seconds and then flashing the minute display. 1 Select the correct minutes by min. pressing the button. Decide the minutes by pressing the ODO/TRIP button, and then flashing the hour display.
Page 414: Removal And Disassembly
ELECTRICAL SYSTEM 9-27 REMOVAL AND DISASSEMBLY • Remove the screws 1 and clips 2. • Remove the auxiliary headlight cover 3. • Remove the combination meter cover 4. • Remove the combination meter 5. * When disconnecting and reconnecting the combina- tion meter coupler, make sure to turn OFF the igni- tion switch, or electronic parts may get damaged.
Page 415: Inspection
9-28 ELECTRICAL SYSTEM INSPECTION LED (LIGHT EMITTING DIODE) Check that the LED lights (diff-lock, reverse, neutral and ECT/FI) immediately after turning the ignition switch ON. Also, check them for lighting in accordance with their switch positions. If the LED fails in operation, replace the combination meter unit with a new one after checking its wire har- ness/coupler.
Page 416 ELECTRICAL SYSTEM 9-29 FUEL METER • Remove the rear fender. (!8-10) • Connect each resistor between the terminals as shown. • Turn the ignition switch “ON” position and wait for approx. 13 seconds. Check the display of fuel meter as shown below, If any abnor- mality is found, replace the combination meter with a new one.
Page 417 9-30 ELECTRICAL SYSTEM SPEEDOMETER If the speedometer, odometer or trip meter does not function properly, inspect the speed sensor and connection of coupler. If the speed sensor and connection are functioning properly, replace the speedometer with a new one. SPEED SENSOR •...
Page 418: Headlight And Auxiliary Headlight
ELECTRICAL SYSTEM 9-31 LAMPS HEADLIGHT AND AUXILIARY HEADLIGHT HEADLIGHT BULB 12 V 30/30 W × 2 AUXILIARY HEADLIGHT 12 V 40 W If you touch the bulb with your bare hands, clean the bulb with a cloth moistened with alcohol or soapy water to prevent premature bulb failure.
Page 419 9-32 ELECTRICAL SYSTEM • Remove the rubber cap 2. • Remove the bulb. • Install the new bulb in the reverse order of removal. Install the rubber cap correctly. HEADLIGHT BEAM ADJUSTMENT • Adjust the headlight vertical beam.
Page 420: Headlight Installation
ELECTRICAL SYSTEM 9-33 HEADLIGHT INSTALLATION Head light coupler Head light (R) Adjusting point...
Page 421: Brake Light/Taillight
9-34 ELECTRICAL SYSTEM AUXILIARY HEADLIGHT BULB REPLACEMENT • Remove the auxiliary headlight cover. (!8-45) • Remove the speedometer. (!8-45) • Disconnect the lead wire coupler 1. • Remove the socket 2. • Install the new bulb assembly in the reverse order of removal. If you touch the bulb with your bare hands, clean the bulb with a cloth moistened with alcohol or soapy water to prevent premature bulb failure.
Page 422 ELECTRICAL SYSTEM 9-35 BULB REPLACEMENT • Remove the brake light/taillight. • Remove the socket. • Remove the bulb. • Install the new bulb in the reverse order of removal.
Page 423: Diode
9-36 ELECTRICAL SYSTEM DIODE • The differential transfer actuator diode is located near the radiator. • The neutral relay diodes are located near the radiator. Measure the voltage between the terminals using the multi-cir- cuit tester as indicated in the table below. "...
Page 424: Switches
ELECTRICAL SYSTEM 9-37 SWITCHES Measure each switch for continuity using a multi-circuit tester. If any abnormality is found, replace the respective switch assemblies with new ones. " 09900-25008: Multi-circuit tester set REAR BRAKE SWITCH IGNITION SWITCH Color Color Position Position OVER RIDE SWITCH Color Position...
Page 425: Battery
9-38 ELECTRICAL SYSTEM BATTERY SPECIFICATIONS Type designation FTZ16-BS Capacity 12 V, 64.8 kC (18 Ah)/10 HR 1 Upper cover breather 5 Terminal 2 Cathode plates 6 Safety valve 3 Stopper 7 Anode plates 4 Filter 8 Separator (Fiberglass plate) INITIAL CHARGING Filling electrolyte •...
Page 426 ELECTRICAL SYSTEM 9-39 NOTE: If no air bubbles are coming up from a filler port, tap the bottom of the electrolyte container two or three times. Never remove the container from the battery. • After confirming that the electrolyte has entered the battery completely, remove the electrolyte containers from the bat- tery.
Page 427: Servicing
9-40 ELECTRICAL SYSTEM SERVICING Visually inspect the surface of the battery container. If any signs of cracking or electrolyte leakage from the sides of the battery have occurred, replace the battery with a new one. If the battery terminals are found to be coated with rust or an acidic white powdery substance, clean the battery terminals with sandpaper.
Page 428 SERVICING INFORMATION 10-1 SERVICING INFORMATION CONTENTS TROUBLESHOOTING.................10- 2 FI SYSTEM MALFUNCTION CODE AND DEFECTIVE CONDITION...................10- 2 ENGINE ....................10- 4 RADIATOR (COOLING SYSTEM) ............10-10 CHASSIS ....................10-11 BRAKES....................10-13 ELECTRICAL ..................10-14 BATTERY ....................10-16 WIRING HARNESS, CABLE AND HOSE ROUTING........10-17 WIRING HARNESS ROUTING .............10-17 CABLE ROUTING .................10-19 FUEL HOSE ROUTING.................10-21 COOLING SYSTEM HOSE ROUTING..........10-22...
Page 429: Troubleshooting
10-2 SERVICING INFORMATION TROUBLESHOOTING FI SYSTEM MALFUNCTION CODE AND DEFECTIVE CONDITION MALFUNCTION DETECTED FAILURE CONDITION DETECTED ITEM CODE CHECK FOR NO FAULT ––––––––––– CKP sensor The signal does not reach ECM for 3 sec. and more, after receiving the starter signal. The CKP sensor wiring and mechanical parts.
Page 430 SERVICING INFORMATION 10-3 MALFUNCTION DETECTED FAILURE CONDITION DETECTED ITEM CODE CHECK FOR Fuel pump relay No voltage is applied to the fuel pump, although fuel pump relay is turned ON, or voltage is applied to fuel pump although fuel pump relay is turned OFF. Fuel pump relay, connecting lead wire, power source to fuel pump relay, fuel injector.
Page 431: Engine
10-4 SERVICING INFORMATION ENGINE ENGINE WILL NOT START OR IS HARD TO START Symptom, possible causes and remedy 1) Compression too low • Valve clearance out of adjustment. Adjust. • Worn valve guides or poor seating of valves. Repair or replace. •...
Page 432 SERVICING INFORMATION 10-5 ENGINE IDLES POORLY Symptom, possible causes and remedy • Valve clearance out of adjustment. Adjust. • Poor seating of valves. Replace or repair. • Defective valve guides. Replace. • Worn down camshafts. Replace. • Too wide spark plug gap. Adjust or replace.
Page 433 10-6 SERVICING INFORMATION NOISY ENGINE Symptom, possible causes and remedy 1) Excessive valve chatter • Too large valve clearance. Adjust. • Weakened or broken valve springs. Replace. • Worn tappet or cam surface. Replace. • Worn and burnt camshaft journal. Replace.
Page 434 SERVICING INFORMATION 10-7 ENGINE RUNS POORLY IN HIGH SPEED RANGE Symptom, possible causes and remedy 1) Defective engine internal/electrical parts • Weakened valve springs. Replace. • Worn camshafts. Replace. • Valve timing out of adjustment. Adjust. • Too narrow spark plug gap. Adjust.
Page 435 10-8 SERVICING INFORMATION ENGINE LACKS POWER Symptom, possible causes and remedy 1) Defective engine internal/electrical parts • Loss of valve clearance. Adjust. • Weakened valve springs. Replace. • Valve timing out of adjustment. Adjust. • Worn piston rings or cylinder. Replace.
Page 436 SERVICING INFORMATION 10-9 DIRTY OR HEAVY EXHAUST SMOKE Symptom, possible causes and remedy • Too much engine oil in the engine. Check with inspection window. Drain excess oil. • Worn piston rings or cylinder. Replace. • Worn valve guides. Replace. •...
Page 437: Radiator (Cooling System)
10-10 SERVICING INFORMATION RADIATOR (COOLING SYSTEM) ENGINE OVERHEATS Symptom, possible causes and remedy • Not enough engine coolant. Add coolant. • Radiator core clogged with dirt. Clean. • Faulty cooling fan. Repair or replace. • Defective cooling fan thermo-switch. Replace. •...
Page 438: Chassis
SERVICING INFORMATION 10-11 CHASSIS HEAVY STEERING Symptom, possible causes and remedy • Distorted steering shaft. Replace. • Not enough pressure in tires. Adjust. • Improper front wheel alignment. Adjust. • Insufficiently lubricated. Lubricate. • Linkage connections tending seize. Repair or replace. •...
Page 439 10-12 SERVICING INFORMATION FRONT SUSPENSION TOO SOFT Symptom, possible causes and remedy • Weakened spring of shock absorber. Replace. • Shock absorber leaks oil. Replace. • Improperly set front shock absorber. Adjust. FRONT SUSPENSION TOO STIFF Symptom, possible causes and remedy •...
Page 440: Brakes
SERVICING INFORMATION 10-13 BRAKES INSUFFICIENT BRAKE POWER Symptom, possible causes and remedy Front • Leakage of brake fluid from hydraulic system. Repair or replace. • Worn pads. Replace. • Oil adhesion on friction surface of pads. Clean disc and pads. •...
Page 441: Electrical
10-14 SERVICING INFORMATION ELECTRICAL NO SPARKING OR POOR SPARKING Symptom, possible causes and remedy • Defective ignition coil. Replace. • Defective spark plug. Replace. • Defective CKP sensor. Replace. • Defective ECM. Replace. • Defective TO sensor. Replace. • Open-circuited wiring connections. Check and repair.
Page 442 SERVICING INFORMATION 10-15 UNSTABLE CHARGING Symptom, possible causes and remedy • Lead wire insulation frayed due to vibration, Repair or replace. resulting in intermittent short-circuiting. • Internally short-circuited generator. Replace. • Defective regulator/rectifier. Replace. START BUTTON IS NOT EFFECTIVE Symptom, possible causes and remedy •...
Page 443: Battery
10-16 SERVICING INFORMATION BATTERY “SULFATION”, ACIDIC WHITE POWDERY SUBSTANCE OR SPOTS ON SURFACE OF CELL PLATES Symptom, possible causes and remedy • Cracked battery case. Replace the battery. • Battery has been left in a run-down condition for a Replace the battery. long time.
Page 444: Wiring Harness, Cable And Hose Routing
SERVICING INFORMATION 10-17 WIRING HARNESS, CABLE AND HOSE ROUTING WIRING HARNESS ROUTING Clamp 60~80 Wiring harness Ignition coil Wiring harness Clamp To power source Clamp Wiring harness Clamp Clamp Hose Wiring harness Brake light/taillight Clamp Wiring harness Cooling fan thermo switch Back up relay (E-17) Wiring harness ISC valve...
Page 445 10-18 SERVICING INFORMATION Clamp Horn switch (E-17, E-24) Set sag under combination meter Emergency switch (E-17) Handle switch (L) To combination meter Handle switch (L) Parking brake switch Parking brake switch Brake lever switch (L) Brake lever switch (L) Brake lever switch (R) Horn switch (E-17, E-24) Transfer selecting switch Pass combination meter wire...
Page 446: Cable Routing
SERVICING INFORMATION 10-19 CABLE ROUTING Frame Parking brake cable Wiring harness Parking brake cable Throttle cable Frame Parking brake cable Location of cable and harness: as shown Wiring harness Parking brake cable Parking brake cable guide Fix foot brake cable to the footrest bar Handlebar Locate throttle cable as shown.
Page 447 10-20 SERVICING INFORMATION Wiring harness Parking brake cable Rear fender Parking brake cable Tie protector with clamp as shown. Screw Frame Protector Frame Parking brake cable Rear fender Foot brake pedal Parking brake cable Washer Adjust nut Front side Cotter pin Rear brake assy Foot brake cable Fix foot brake cable...
Page 448: Fuel Hose Routing
SERVICING INFORMATION 10-21 FUEL HOSE ROUTING...
Page 449: Cooling System Hose Routing
10-22 SERVICING INFORMATION COOLING SYSTEM HOSE ROUTING Thermostat Reservoir tank Radiator Radiator upper hose Bypass hose Bypass hose Radiator lower hose Water pump...
Page 450: Rear Drive Breather Hose Routing
SERVICING INFORMATION 10-23 REAR DRIVE BREATHER HOSE ROUTING Breather hose Breather hose Fuel tank lower cover Fuel tank Belt cooling outlet duct Rear drive assy Rear drive assy...
Page 451: Front Brake Hose And Pipe Routing
10-24 SERVICING INFORMATION FRONT BRAKE HOSE AND PIPE ROUTING Master cylinder reservoir tank Master cylinder reservoir tank Tighten bolt with the Union bolt end-fitting contacted with the tank. Assemble front brake hose firmly into the guide. Front brake hose 23 N·m Through front brake hose (2.3 kgf-m, 16.5 lb-ft) rear of the throttle cable...
Page 452: Fender Installation
SERVICING INFORMATION 10-25 FENDER INSTALLATION Front fender Right inner fender Left mud guard Left inner fender...
Page 453 10-26 SERVICING INFORMATION Rear box Rear fender Right mud guard Left mud guard...
Page 454: Rear Fender Heat Shield Installation
SERVICING INFORMATION 10-27 REAR FENDER HEAT SHIELD INSTALLATION 1 – 3 mm (0.04 – 0.12 in) Rear fender 1 – 3 mm (0.04 – 0.12 in) 1 – 3 mm Heat shield (0.04 – 0.12 in) 5 mm (0.20 in) Heat shield 8 mm (0.32 in) 67 mm (2.64 in)
Page 455: Belt Cooling Duct Installation
10-28 SERVICING INFORMATION BELT COOLING DUCT INSTALLATION...
Page 456: Rear Brake Pedal
SERVICING INFORMATION 10-29 REAR BRAKE PEDAL...
Page 457: Trailer Towing Installation (Option)
10-30 SERVICING INFORMATION TRAILER TOWING INSTALLATION (OPTION) Trailer to warning label (E-17 (CH), 28) Trailer to warning label Trailer towing mounting bolt 60 N·m (6.0 kgf-m, 43.5 lb-ft) Trailer towing...
Page 458: Engine Mounting
SERVICING INFORMATION 10-31 ENGINE MOUNTING Engine mounting Thermostat cover Thermostat cover bolt 10 N·m (1.0 kgf-m, 7.0 lb-ft) Water hose clamp screw 1.5 N·m Recoil starter (0.15 kgf-m, 1.0 lb-ft) Speed sensor Engine mounting bolt 10 N·m 10 N·m (1.0 kgf-m, 7.0 lb-ft) (1.0 kgf-m, 7.0 lb-ft) Engine mounting bolt Engine mounting nut...
Page 459: Special Tools
10-32 SERVICING INFORMATION SPECIAL TOOLS 09900-18740 09900-20101 09900-20202 09900-20203 09900-20205 Hexagon socket 09900-20102 Micrometer Micrometer Micrometer (24 mm) Vernier calipers (25 – 50 mm) (50 – 75 mm) (0 – 25 mm) 09900-20210 09900-20520 09900-20602 09900-20605 Micrometer 09900-20508 Rod cylinder Dial gauge Dial calipers (100 –...
Page 460 SERVICING INFORMATION 10-33 09913-13121 09910-20115 09913-10750 Vacuum balancer 09913-50121 09913-70210 Conrod stopper Adaptor gauge Oil seal remover Bearing installer set 09915-64512 09915-74521 09915-74540 09915-77331 09915-40610 Compression Oil pressure gauge Oil pressure gauge Meter Oil filter wrench gauge set hose attachment (for high pressure) 09916-14521 09916-21111...
Page 461 10-34 SERVICING INFORMATION 09916-57360 09917-47011 09920-33540 09916-53330 Valve guide installer attachment 09916-84511 Vacuum pump Clutch shone Attachment (12.5 mm: EX. 14.5 mm: IN.) Tweezers gauge remover 09920-34830 09920-53740 09922-22711 Starter clutch Clutch sleeve hub 09921-20210 09921-20240 Drive chain cutting holder holder Bearing remover Bearing remover set...
Page 462 SERVICING INFORMATION 10-35 09940-14911 09940-14960 09930-34980 09930-44520 09930-82720 Steering stem nut Steering stem nut Rotor remover Rotor holder Mode select switch wrench wrench socket 09940-14940 09940-14990 09940-30221 09940-40211 09940-40220 Swingarm pivot thrust Engine mounting thrust Front fork assem- Fuel pressure Fuel pressure gauge adjuster socket wrench adjuster socket wrench...
Page 463: Tightening Torque
10-36 SERVICING INFORMATION TIGHTENING TORQUE ENGINE ITEM N·m kgf-m lb-ft Intial Cylinder head cover bolt Final 10.0 Cam drive idle gear/sprocket shaft 29.5 Cylinder head bolt (6 mm) Intial 18.0 Cylinder head bolt (10 mm) Final 27.0 Cam chain tensioner bolt 16.5 Cam chain tension adjuster bolt Cam chain tension adjuster cap bolt...
Page 464: Drive Train
SERVICING INFORMATION 10-37 DRIVE TRAIN ITEM N·m kgf-m lb-ft 2WD/4WD shifting motor mounting bolt 16.0 Front differential gear case bolt 16.0 Front drive train gear case mounting nut 36.0 Front differential gear oil filler plug 25.5 Front propeller shaft boot clamp screw 0.18 Front differential gear oil drain plug 23.0...
Page 465: Chassis
10-38 SERVICING INFORMATION CHASSIS ITEM N·m kgf-m lb-ft Handlebar clamp bolt 19.0 Handlebar holder nut 43.5 Steering shaft holder bolt 16.5 Steering shaft lower nut 12.0 87.0 (upper) 43.5 Front wishbone arm pivot nut (lower) 47.0 Steering knuckle end nut (upper and lower) 21.0 Tie rod end nut 21.0...
Page 466: Tightening Torque Chart
SERVICING INFORMATION 10-39 TIGHTENING TORQUE CHART For other nuts and bolts not listed in the preceding page, refer to this chart: Bolt Diameter Conventional or “4” marked bolt “7” marked bolt A (mm) N·m kgf-m lb-ft N·m kgf-m lb-ft 0.15 0.23 0.45 0.55...
Page 467: Service Data
10-40 SERVICING INFORMATION SERVICE DATA VALVE + VALVE GUIDE Unit: mm (in) ITEM STANDARD LIMIT Valve diam. 36.0 ---- (1.42) 33.0 ---- (1.30) Tappet clearance (when cold) 0.10 – 0.20 ---- (0.004 – 0.008) 0.20 – 0.30 ---- (0.008 – 0.012) Valve guide to valve stem 0.010 –...
Page 468 SERVICING INFORMATION 10-41 CAMSHAFT + CYLINDER HEAD Unit: mm (in) ITEM STANDARD LIMIT Cam height 36.330 – 36.380 36.030 (1.4303 – 1.4323) (1.4185) 35.300 – 35.350 35.000 (1.3898 – 1.3917) (1.3780) Camshaft journal oil clearance 0.019 – 0.053 0.150 IN. & EX. (0.0007 –...
Page 469 10-42 SERVICING INFORMATION ITEM STANDARD LIMIT Piston ring groove width 0.83 – 0.85 (0.0327 – 0.0335) ---- 1.30 – 1.32 (0.0512 – 0.0520) 1.01 – 1.03 ---- (0.0398 – 0.0406) 2.01 – 2.03 ---- (0.0791 – 0.0799) Piston ring thickness 1.08 –...
Page 470 SERVICING INFORMATION 10-43 CLUTCH Unit: mm (in) ITEM STANDARD LIMIT Clutch wheel I.D. 140.0 – 140.2 140.5 (5.512 – 5.520) (5.53) Clutch shoe No groove at — any part Clutch engagement r/min. 1 600 – 2 000 r/min. — Clutch lock-up r/min. 3 500 –...
Page 471 10-44 SERVICING INFORMATION THERMOSTAT + RADIATOR + FAN + COOLANT ITEM STANDARD/SPECIFICATION NOTE Thermostat valve opening Approx. 82 °C (180 °F) temperature Thermostat valve lift 8 mm (0.315 in) and over at 95 °C (203 °F) ECT sensor resistance 20 °C Approx.
Page 472 SERVICING INFORMATION 10-45 FI SENSORS+ SECONDARY THROTTLE VALVE ACTUATOR ITEM SPECIFICATION NOTE 150 – 250 Ω CKP sensor resistance CKP sensor peak voltage 5.0 V and more When cranking IAP sensor input voltage 4.5 – 5.5 V IAP sensor output voltage Approx.
Page 473 10-46 SERVICING INFORMATION THROTTLE BODY ITEM STANDARD/SPECIFICATION Bore size 42 mm I.D. No. 31G0 Idle r/min. 1 300 ± 100 r/min. Fast idle r/min. 1 500 – 2 000 r/min. (When cold engine) Throttle cable play 3 – 5 mm (0.12 –...
Page 474: Backup Light
SERVICING INFORMATION 10-47 WATTAGE Unit: W STANDARD/SPECIFICATION ITEM E-24, -28, -33 E-17 ← Headlight 30 × 2 ← 30 × 2 ← Auxiliary headlight ← Brake light/Taillight 21/5 Backup light ← Speedometer light High beam indicator light ← Neutral indicator light FI indicator light/Engine coolant ←...
Page 475 10-48 SERVICING INFORMATION ITEM STANDARD LIMIT Steering angle 46 ° (right & left) ---- Turning radius 3.1 m (10.2 ft) ---- Toe-out (with 75 kg, 165 lbs) 10 ± 4 mm (0.39 ± 0.16 in) ---- Camber 0.64 ° ---- Caster 1.6 °...
Page 476 SERVICING INFORMATION 10-49 FUEL + OIL ITEM SPECIFICATION NOTE Fuel type Use only unleaded gasoline of at least 87 pump octane (R/2 + M/2) or 91 octane or higher rated by the Research Method. Gasoline containing MTBE (Methyl Tertiary E-28, 33 Butyl Ether), less than 10 % ethanol, or less than 5 % methanol with appropriate cosolvents and corrosion inhibitor is permissible.
Page 478 WIRING DIAGRAM For E-24, 28, 33 ENGINE ENGINE : DIFF-LOCK INDICATOR LIGHT START STOP SWITCH REAR : REVERSE INDICATOR LIGHT SWITCH OVER RIDE BRAKE : NEUTRAL INDICATOR LIGHT BRAKE SWITCH SWITCH BRAKE : HI-BEAM INDICATOR LIGHT (E-17) LEVER LEVER : ECT/FI INDICATOR DIMMER SWITCH PUSH...
Page 479 For E-17 ENGINE ENGINE : DIFF-LOCK INDICATOR LIGHT START STOP REAR : REVERSE INDICATOR LIGHT SWITCH SWITCH OVER RIDE BRAKE : NEUTRAL INDICATOR LIGHT BRAKE SWITCH SWITCH BRAKE : HI-BEAM INDICATOR LIGHT(E-17) LEVER LEVER : ECT/FI INDICATOR SWITCH DIMMER PUSH SWITCH SWITCH SPEEDOMETER...
Page 480 Prepared by September, 2004 Part No.99500-46060-01E Printed in U.S.A...
Page 481 Printed in U.S.A...

This manual is also suitable for:

Lt-a700x k5 2004

Suzuki LT-A700X 2004 Service Manual

General Information 1

Chassis

Engine

Drive Train

Fi System Diagnosis

Fuel System and Throttle Body

Cooling and Lubrication System

Chassis

Electrical System

Quick Links

Chapters

Troubleshooting

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Summary of Contents for Suzuki LT-A700X 2004