Suzuki AN650 2002 Service Manual

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Page 2 FOREWORD GROUP INDEX This manual contains an introductory description on the SUZUKI AN650 and procedures for its inspec- tion/service and overhaul of its main components. GENERAL INFORMATION Other information considered as generally known is not included. Read the GENERAL INFORMATION section to...
Page 3 HOW TO USE THIS MANUAL 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. 99000-25010 Apply SUZUKI MOLY PASTE. Measure in current range.
Page 5 ABBREVIATIONS USED IN THIS MANUAL : Engine Control Module ABDC : After Bottom Dead Center Engine Control Unit (ECU) : Alternating Current (FI Control Unit) : Air Cleaner, Air Cleaner Box ECT Sensor : Engine Coolant Temperature : American Petroleum Institute Sensor (ECTS), Water Temp.
Page 6 MAL-Code : Malfunction Code (Diagnostic Code) : Maximum : Malfunction Indicator Lamp (LED) : Minimum : Nitrogen Oxides : Over Head Camshaft : Oil Level Switch : Oil Pressure Switch : Positive Crankcase Ventilation (Crankcase Breather) : Right Hand : Read Only Memory : Society of Automotive Engineers TO Sensor : Tip Over Sensor (TOS)
Page 7 WIRE COLOR : Black : Green : Pink : Blue : Gray : Red : Brown : Light blue : Violet : Dark green : Light green : White : Dark gray : Orange : Yellow B/Bl : Black with Blue tracer B/Br : Black with Brown tracer B/G : Black with Green tracer B/O : Black with Orange tracer...
Page 8: Table Of Contents
GENERAL INFORMATION CONTENTS WARNING/ CAUTION/ NOTE .............1- 2 GENERAL PRECAUTIONS ..............1- 2 SUZUKI AN650K3 (’03-MODEL) ............1- 4 SERIAL NUMBER LOCATION ............1- 4 FUEL, OIL AND ENGINE COOLANT RECOMMENDATION .....1- 4 FUEL (FOR USA AND CANADA) ..........1- 4 FUEL (FOR OTHER COUNTRIES) ..........1- 4 ENGINE OIL AND TRANSMISSION OIL (FOR USA) ....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- lent. * When removing parts that are to be reused, keep them arranged in an orderly manner so that they may be reinstalled in the proper order and orientation.
Page 11: Suzuki An650K3 ('03-Model)
GENERAL INFORMATION SUZUKI AN650K3 (’03-MODEL) RIGHT SIDE LEFT SIDE * Difference between photographs and actual motorcycles depends on the markets. SERIAL NUMBER LOCATION The frame serial number or V.I.N. (Vehicle Identification Number) 1 is stamped on the right side of the frame down tube.
Page 12: Engine Oil And Transmission Oil (For Usa)
GENERAL INFORMATION ENGINE OIL AND TRANSMISSION 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 Pertoleum Institute) service classification. The recommended viscosity is SAE 10W-40.
Page 13: Liquid Amount Of Water/Engine Coolant
GENERAL INFORMATION LIQUID AMOUNT OF WATER/ENGINE COOLANT Solution capacity (total): 1 300 ml (1.4/1.1 US/Imp qt) For engine coolant mixture information, refer to cooling system section, page 8-3. Mixing of anti-freeze/engine coolant should be limited to 60%. Mixing beyond it would reduce its efficiency.
Page 14: Break-Ln Procedures
GENERAL INFORMATION BREAK-lN PROCEDURES During manufacture only the best possible materials are used and all machined parts are finished to a very high standard but it is still necessary to allow the moving parts to “BREAK-IN” before subjecting the engine to maximum stresses.
Page 15: Information Labels
GENERAL INFORMATION INFORMATION LABELS Warning safety label Engine starting label Screen warning label " Tire pressure label Fuel caution label (For E-02, 24) Fuel information label Front box loading capacity label & Trunk box loading capacity label ID label (For E-02, 19, 24) Noise label (For E-24) ICES CANADA label (For E-28) Information label (For E-28)
Page 16: Specifications
GENERAL INFORMATION SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length ............2 260 mm (89.0 in) Overall width ............810 mm (31.9 in) Overall height ............1 430 mm (56.3 in) Wheelbase ............1 595 mm (62.8 in) Ground clearance..........125 mm ( 4.9 in) Seat height ............
Page 17 1-10 GENERAL INFORMATION ELECTRICAL lgnition type............Electronic ignition (ECM, Transistorized) lgnition timing ............10° B. T. D. C at 1 200 r/min Spark plug............NGK: CR8E or DENSO: U24ESR-N Battery..............12 V 43.2 kC (12 Ah)/10 HR Generator.............Three-phase A.C. Generator Main fuse .............40 A CVT fuse ..............40 A Fuse ..............15/15/15/15/10/10/10 A Headlight..............12 V 60/55 W + 55 W (H4 + H7) ..
Page 18: Country And Area Codes
GENERAL INFORMATION 1-11 COUNTRY AND AREA CODES The following codes stand for the applicable country(-ies) and area(-s). CODE COUNTRY or AREA E-02 U. K. E-03 U. S. A. (Except for California) E-19 E-24 Australia E-28 Canada E-33 California (U. S. A.)
Page 19 PERIODIC MAINTENANCE PERIODIC MAINTENANCE CONTENTS PERIODIC MAINTENANCE SCHEDULE ..........2- 2 PERIODIC MAINTENANCE CHART ...........2- 2 LUBRICATION POINTS ...............2- 3 MAINTENANCE AND TUNE-UP PROCEDURES .......2- 4 AIR CLEANER ................2- 4 SPARK PLUG ................2- 6 TAPPET CLEARANCE ..............2- 7 FUEL HOSE .................2-13 ENGINE OIL AND OIL FILTER ............2-13 TRANSMISSION OIL ..............2-15 FINAL GEAR OIL .................2-15...
Page 20: Periodic Maintenance Schedule
PERIODIC MAINTENANCE PERIODIC MAINTENANCE SCHEDULE The chart below lists the recommended intervals for all the required periodic service work necessary to keep the motorcycle operating at peak performance and economy. Mileages are expressed in terms of kilome- ters, miles and time for your convenience. NOTE: More frequent servicing may be performed on motorcycles that are used under severe conditions.
Page 21: Lubrication Points
PERIODIC MAINTENANCE LUBRICATION POINTS Proper lubrication is important for smooth operation and long life of each working part of the motorcycle. Major lubrication points are indicated below. Rear brake lever holder Center stand pivot and spring hook Side stand pivot and spring hook Front brake lever holder Throttle cable NOTE:...
Page 22: Maintenance And Tune-Up Procedures
PERIODIC MAINTENANCE MAINTENANCE AND TUNE-UP PROCEDURES This section describes the servicing procedures for each item of the Periodic Maintenance requirements. AIR CLEANER Inspect every 6 000 km (4 000 miles, 6 months) and replace every 18 000 km (11 000 miles, 18 months). •...
Page 23 PERIODIC MAINTENANCE • Carefully use air hose to blow the dust from the cleaner ele- ment. Always use air pressure on the throttle body side 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 24: Spark Plug
PERIODIC MAINTENANCE SPARK PLUG Inspect every 6 000 km (4 000 miles, 6 months) and replace every 12 000 km (7 500 miles, 12 months). SPARK PLUG REMOVAL • Remove the lower leg shield. ( 9-10) • Remove the bolt. •...
Page 25: Tappet Clearance
PERIODIC MAINTENANCE CARBON DEPOSIT • Check to see if there are carbons deposit on the plugs. If car- bon is deposited, remove it with a spark plug cleaner machine or carefully using a tool with a pointed end. SPARK PLUG GAP •...
Page 26 PERIODIC MAINTENANCE The tappet clearance specification is different for intake and exhaust valves. Tappet clearance must be checked and adjusted, 1) at the time of periodic inspection, 2) when the valve mechanism is serviced, and 3) when the camshafts are removed for servicing.
Page 27 PERIODIC MAINTENANCE • In this condition, read the tappet clearance at the valves (In and Ex of No.2). • If the clearance is out of specification, adjust the clearance as shown below. 09900-20803: Thickness gauge • Turn the crankshaft 360 degrees (one rotation) to bring the “TOP”...
Page 28 2-10 PERIODIC MAINTENANCE NOTE: * Be sure to apply engine oil to tappet shim top and bottom faces. * When seating the tappet shim, be sure to face figure printed surface to the tappet. 1.70 mm Reinstall the camshafts as the specified manner. 3-72) •...
Page 29 PERIODIC MAINTENANCE 2-11 (INTAKE SIDE)
Page 30 2-12 PERIODIC MAINTENANCE (EXHAUST SIDE)
Page 31: Fuel Hose
PERIODIC MAINTENANCE 2-13 FUEL HOSE Inspect every 6 000 km (4 000 miles, 6 months). Replace every 4 years. Inspect the fuel feed hose A for damage and fuel leakage. If any defects are found, the fuel hoses must be replaced. ENGINE OIL AND OIL FILTER (ENGINE OIL) Replace initially at 1 000 km (600 miles, 1 month) and...
Page 32 Filter change: 2.9 L (3.1/2.6 US/Imp qt) Overhaul engine: 3.4 L (3.6/3.0 US/Imp qt) ONLY USE A GENUINE SUZUKI MOTORCYCLE OIL FILTER. Other manufacturer’s oil filters may differ in thread specifications (thread diameter and pitch), fil- tering performance and durability which may lead to engine damage or oil leaks.
Page 33: Transmission Oil
PERIODIC MAINTENANCE 2-15 TRANSMISSION OIL Replace initially at 1 000 km (600 miles, 1 month) and every 12 000 km (7 500 miles, 12 months) thereafter. Inspect every 6 000 km (4 000 miles, 6 months) there- after. TRANSMISSION OIL REPLACEMENT •...
Page 34: Cvt Filter
2-16 PERIODIC MAINTENANCE • Remove the oil drain plug 2 and oil level plug 3. • Tighten the oil drain plug 2 to the specified torque, and pour fresh oil through the oil level hole until the oil over flows from the oil level hole.
Page 35 PERIODIC MAINTENANCE 2-17 • Inspect the CVT filter for damage and dirt. If any defects are found, the CVT filter must be replaced.
Page 36: Engine Idle Speed
2-18 PERIODIC MAINTENANCE ENGINE IDLE SPEED Inspect initially at 1 000 km (600 miles, 1 month) and every 6 000 km (4 000 miles, 6 months) thereafter. NOTE: Make this adjustment when the engine is hot. • Remove the maintenance lid. ( 9-13) •...
Page 37: Throttle Valve Synchronization
PERIODIC MAINTENANCE 2-19 MAJOR ADJUSTMENT • Remove the front box. ( 9-18) • Loosen the locknut 1 of the throttle returning cable 2. • Turn the returning cable adjuster 3 to obtain proper cable play. • Loosen the locknut 4 of the throttle pulling cable 5. •...
Page 38: Cooling System
2-20 PERIODIC MAINTENANCE COOLING SYSTEM Inspect every 6 000 km (4 000 miles, 6 months). Replace engine coolant every 2 years. ENGINE COOLANT LEVEL CHECK • Keep the motorcycle upright with the center stand. • Check the engine coolant level by observing the full and lower lines on the engine coolant reserve tank.
Page 39 PERIODIC MAINTENANCE 2-21 • Remove the front box. ( 9-18) • Remove the foot board. ( 9-18) • Drain engine coolant by disconnecting the radiator hose 2. • Flush the radiator with fresh water if necessary. • Tighten the water drain bolt A to the specified torque. Water drain bolt A: 6 N·m (0.6 kgf-m, 4.3 lb-ft) •...
Page 40: Brake
2-22 PERIODIC MAINTENANCE RADIATOR HOSES Check to see the radiator hoses for crack, damage or engine coolant leakage. If any defects are found, replace the radiator hoses with new ones. BRAKE (BRAKE) Inspect initially at 1 000 km (600 miles, 1 month) and every 6 000 km (4 000 miles, 6 months) thereafter.
Page 41 PERIODIC MAINTENANCE 2-23 The brake system of this motorcycle is filled with a glycol-based brake fluid. Do not use or mix different types of fluid such as silicone-based or petro- leum-based. Do not use any brake fluid taken from old, used or unsealed containers. Never re-use brake fluid left over from the last servicing or stored for a long period.
Page 42 2-24 PERIODIC MAINTENANCE AIR BLEEDING THE BRAKE FLUID CIRCUIT Air trapped in the fluid circuit acts like a cushion to absorb a large proportion of the pressure developed by the master cylin- der and thus interferes with the full braking performance of the brake caliper.
Page 43: Tire
PERIODIC MAINTENANCE 2-25 • The procedure to bleed the rear brake is indentical to that of the front. TIRE Inspect every 6 000 km (4 000 miles, 6 months). TIRE TREAD CONDITION Operating the motorcycle with excessively worn tires will decrease riding stability and consequently invite a dangerous situation.
Page 44: Steering
The standard tire fitted on this motorcycle is 120/70 R15M/C 56H for front and 160/60 R14M/C 65H for rear. The use of tires other than those specified may cause instability. It is highly recommended to use a SUZUKI Genuine Tire. TIRE TYPE...
Page 45: Rear Suspension
PERIODIC MAINTENANCE 2-27 REAR SUSPENSION Inspect every 12 000 km (7 500 miles, 12 months). Inspect the rear shock absorbers for oil leakage and mounting rubbers for wear and damage. Replace any defective parts, if necessary. ( 9-57) EXHAUST PIPE BOLT AND MUFFLER MOUNTING BOLT Tighten initially at 1 000 km (600 miles, 1 month) and every 12 000 km (7 500 miles, 12 months) thereafter.
Page 46: Chassis Bolt And Nut
2-28 PERIODIC MAINTENANCE CHASSIS BOLT AND NUT Tighten initially at 1 000 km (600 miles, 1 month) and every 6 000 km (4 000 miles, 6 months) thereafter. Check that all chassis bolts and nuts are tightened to their specified torque. (Refer to page 2-28 for the loca- tions of the following nuts and bolts on the motorcycle.) ITEM N·m...
Page 47 PERIODIC MAINTENANCE 2-29...
Page 48: Compression Pressure Check
2-30 PERIODIC MAINTENANCE COMPRESSION PRESSURE CHECK The compression of a cylinder is a good indicator of its internal condition. The decision to overhaul the cylinder is often based on the results of a compression test. Periodic mainte- nance records kept at your dealership should include compression readings for each maintenance service. COMPRESSION PRESSURE SPECIFICATION Standard Limit...
Page 49: Oil Pressure Check
PERIODIC MAINTENANCE 2-31 OIL PRESSURE CHECK Check periodically the oil pressure in the engine to judge roughly the condition of the moving parts. OIL PRESSURE SPECIFICATION Above 350 kPa (3.5 kgf/cm², 50 psi) at 3 000 r/min., Oil temp. at 60°C (140°F) Below 550 kPa (5.5 kgf/cm², 78 psi) If the oil pressure is lower or higher than the specification, the following causes may be considered.
Page 50: Automatic Clutch Inspection
2-32 PERIODIC MAINTENANCE AUTOMATIC CLUTCH INSPECTION This motorcycle is equipped with an automatic clutch and vari- able ratio belt drive transmission. The engagement of the clutch is governed by engine RPMs and centrifugal mechanism located in the clutch. To insure proper performance and longer lifetime of the clutch assembly it is essential that the clutch engages smoothly and gradually.
Page 51: Brake-Lock Inspection
PERIODIC MAINTENANCE 2-33 BRAKE-LOCK INSPECTION Inspect that the rear wheel is locked up when pulling the brake-lock lever 4 to 6 notches and moving the motorcycle for- ward to make sure that the brake-lock acts enough. Adjust the brake-lock, if necessary. ( 9-85)
Page 52 ENGINE ENGINE CONTENTS ENGINE COMPONENTS REMOVABLE WITH THE ENGINE IN PLACE .....................3- 2 ENGINE REMOVAL AND REMOUNTING ...........3- 3 ENGINE REMOVAL ..............3- 3 ENGINE REMOUNTING ..............3-10 ENGINE DISASSEMBLY ..............3-12 ENGINE COMPONENT INSPECTION AND SERVICE .......3-22 CYLINDER HEAD COVER ............3-22 CAMSHAFT ..................3-23 CAM CHAIN TENSION ADJUSTER ..........3-25 CAM CHAIN TENSIONER ............3-25 CAM CHAIN GUIDE ..............3-25...
Page 53: Engine Components Removable With The Engine In Place
ENGINE ENGINE COMPONENTS REMOVABLE WITH THE ENGINE IN PLACE Engine components which can be removed while the engine is installed on the chassis are listed below. For the installing and removing procedures, refer to respective paragraphs describing each component. ITEM REMOVAL INSPECTION INSTALLATION...
Page 54: Engine Removal And Remounting
ENGINE ENGINE REMOVAL AND REMOUNTING ENGINE REMOVAL • Drain the engine oil and transmission oil. ( 2-10, 2-13) • Drain the engine coolant. ( 2-20) NOTE: If the engine is stained, clean with steam cleaner before removal. • Cover the parts, A and B, to prevent water from entering the CVT unit.
Page 55 ENGINE • Remove the IAP sensor lead wire coupler 1, IAT sensor 2, and PAIR solenoid valve lead wire coupler 3. • Disconnect the vacuum hose 4. • Loosen the throttle body clamp screws. • Remove the PAIR solenoid valve 5. •...
Page 56 ENGINE • Disconnect the PAIR hose 1 and crankcase breather hose • Disconnect the engine coolant breather hose 3 and radiator hose 4. • Disconnect the radiator inlet hose. • Disconnect the cooling fan switch coupler 5. • Remove the radiator.
Page 57 ENGINE • Disconnect the engine ground lead wire. • Disconnect the center stand switch lead wire coupler 1, CVT pulley position sensor lead wire coupler 2, CVT motor lead wire coupler 3, CVT scondary pulley revolution sensor lead wire coupler 4 and HO2 sensor lead wire coupler 5. •...
Page 58 ENGINE • Disconnect the generator coupler 1. • Disconnect the HO2 sensor coupler 2. • Remove the muffler. • Remove the brake-lock cable clamp. • Remove the rear brake hose clamp. • Remove the rear brake caliper bolts and remove the rear brake caliper 3.
Page 59 ENGINE • Remove the clamps. • Move the fuel feed hose not to interfere with the work. • Support the engine using an engine jack. • Remove the engine mounting bolts and nuts. • Remove the foot board bracket. • Remove the engine from the frame.
Page 60 ENGINE • Remove the CVT assembly. ( 5-2) • Remove the swingarm. ( 9-59) • Remove the final gear case assembly. ( 4-3) Be careful not to allow the engine main body to fall down. • Remove the center stand.
Page 61: Engine Remounting
3-10 ENGINE ENGINE REMOUNTING • Reinstall the engine assembly following the procedure below: Assembling of center stand ( 11-26) Installation of final gear case ( 4-7) Installation of rear wheel ( 9-56) Installation of CVT unit ( 5-4) Installation of rear brake caliper ( 9-81) •...
Page 62 ENGINE 3-11 MUFFLER ITEM N·m kgf-m lb-ft 16.5 After mounting the engine, connect the wiring, cables and hoses securely. ( 11-14, 11-18) • Supply a specified amount of engine oil and transmission oil. 2-13) • Supply a specified amount of cooling water. ( 2-29) Adjust or inspect the following items: •...
Page 63: Engine Disassembly
3-12 ENGINE ENGINE DISASSEMBLY STARTER MOTOR • Remove the starter motor 1. • Disconnect the water bypass hose 2. OIL PRESSURE SWITCH • Remove the oil pressure switch. OIL LEVEL SWITCH • Remove the oil level switch 3. CYLINDER HEAD COVER •...
Page 64 ENGINE 3-13 • Push the cam chain tension adjuster rod and insert the spe- cial tool. 09918-53810: Chain tensioner lock tool • Remove the two camshaft journal holders 1 by removing the bolts. Be sure to loosen the camshaft journal holder bolts evenly by shifting the wrench diagonally.
Page 65 3-14 ENGINE • Remove the cylinder head gasket 1, dowel pins 2 and cam chain guide 3. • Remove the cylinder 4. • Remove the cylinder base gasket 5 and dowel pins 6. PISTON • Place a clean rag over the cylinder base so as not to drop the piston pin circlip into the crankcase.
Page 66 ENGINE 3-15 • Remove the oil sump filter 1. GENERATOR • Remove the generator rotor nut with the special tool. 09930-40113: Rotor holder • Remove the generator rotor 2 with the special tools. 09930-40113: Rotor holder 09930-30450: Rotor remover • Remove the generator stator 3, CKP sensor 4 and lead wire grommet 5.
Page 67 3-16 ENGINE CLUTCH • Remove the clutch cover 1. • Remove the clutch housing nut and washer. • Remove the clutch assembly. 09930-40113: Rotor holder • Remove the clutch shaft 3. • Remove the driveshaft oil seal retainer 4. STARTER CLUTCH •...
Page 68 ENGINE 3-17 • Remove the starter clutch bolt with the special tool. 09920-34830: Starter clutch rotor holder CAM CHAIN • Remove the cam chain tensioner 1 and cam chain 2. • Remove the cam chain sprocket 3. WATER PUMP • Remove the water pump assembly. OIL FILTER •...
Page 69 3-18 ENGINE OIL COOLER • Untighten the union bolt and remove the oil cooler. SEPARATION OF CRANKCASE • Untighten the crankcase tightening bolts diagonally. • Separate the crankcase into 2 parts, right and left, with the crankcase separating tool. 09920-13120: Crankcase/crankshft separator NOTE: * Pay attention when separating the crankcase so that it is kept horizontal with the mating surface.
Page 70 ENGINE 3-19 DRIVESHAFT • Remove the driveshaft assembly 1 and idle shaft 2. • Remove the idle gear 3. • Remove the circlip 4 and counter drive gear 5. • Remove the counter drive gear shaft 6. BALANCER SHAFT • Remove the upper balancer shaft 7. •...
Page 71 3-20 ENGINE OIL PUMP • Remove the pin 1, washer 2 and oil pump assembly 3. • Remove the oil sump filter 4. OIL PRESSURE REGULATOR • Remove the oil pressure regulator 5. PISTON COOLING NOZZLE • Remove the piston cooling nozzle. •...
Page 72 ENGINE 3-21 • Remove the oil separator. CRANKSHAFT • Remove the crankshaft assembly 1. PRIMARY DRIVEN GEAR • Remove the primary drive gear 2. RETURN OIL PUMP • Remove the circlip 3 and return oil pump gear 4. • Remove the pin 5 and return oil pump assembly 6.
Page 73: Engine Component Inspection And Service
3-22 ENGINE ENGINE COMPONENT INSPECTION AND SERVICE Identify the position of each removed part. Organize the parts in their respective groups (i.e., intake, exhaust, No.1 or No.2) so that they can be installed in their original locations. CYLINDER HEAD COVER •...
Page 74: Camshaft
ENGINE 3-23 CAM POSITION SENSOR • Apply SUZUKI SUPER GREASE “A” to the O-ring and install • Install the CMP sensor. Cam position sensor bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft) 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) CAMSHAFT •...
Page 75 3-24 ENGINE CAMSHAFT JOURNAL WEAR • Determine whether or not each journal is worn down to the limit by measuring the oil clearance with the camshaft installed in place. • Use the plastigauge to read the clearance at the widest por- tion, which is specified as follows: Camshaft journal oil clearance: Standard: (IN &...
Page 76: Cam Chain Tension Adjuster
ENGINE 3-25 CAM CHAIN TENSION ADJUSTER INSPECTION • Remove the cam chain tension adjuster cap bolt. • Check that the push rod slides smoothly when releasing stop- per. • If it does not slide smoothly, replace the cam chain tension adjuster with a new one.
Page 77: Cylinder Head
3-26 ENGINE CYLINDER HEAD VALVE AND VALVE SPRING DIASSEMBLY • Remove the tappets and shims by fingers or magnetic hand. Identify the position of each removed part. • Using special tools, compress the valve spring and remove the two cotter halves 1 from valve stem. 09916-14510: Valve lifter 09916-14521: Valve lifter attachment (24 mm) 09916-84511: Tweezers...
Page 78 ENGINE 3-27 VALVE STEM DEFLECTION • Lift the valve about 10 mm (0.39 in) from the valve seat. • Measure the valve stem deflection in two directions, perpen- dicular to each other, by positioning the dial gauge as shown. • If the deflection measured exceeds the limit, then determine whether the valve or the guide should be replaced with a new one.
Page 79 3-28 ENGINE VALVE FACE WEAR • Visually inspect each valve face for wear. Replace any valve with an abnormally worn face. The thickness of the valve face decreases as the face wears. Measure the valve face T. If it is out of specification, replace the valve with a new one. Valve head thickness T: Service Limit: 0.5 mm (0.02 in) VALVE SPRING...
Page 80 ENGINE 3-29 VALVE GUIDE SERVICING • Using the valve guide remover, drive the valve guide out toward the intake or exhaust camshaft side. 09916-53310: Valve guide remover/installer NOTE: * Discard the removed valve guide subassemblies. * Only oversized valve guides are available as replacement parts.
Page 81 3-30 ENGINE VALVE SEAT WIDTH INSPECTION • Visually check for valve seat width on each valve face. • If the valve face has worn abnormally, replace the valve. • Coat the valve seat with Prussian Blue and set the valve in place.
Page 82 ENGINE 3-31 INITIAL SEAT CUT • Install the 45° cutter 1, attachment 2 and T-handle 3. • Using the 45° cutter, descale and clean up the seat. Rotate the cutter one or two turns. • Measure the valve seat width W after every cut. 45˚...
Page 83 3-32 ENGINE BOTTOM NARROWING CUT • If the contact area W is too wide or too low, use the 60° cutter to narrow and raise the contact area. 60˚ Too low or too narrow FINAL SEAT CUT contact surface on valve •...
Page 84 ENGINE 3-33 VALVE AND VALVE SPRING REASSEMBLY • Apply molybdenum oil solution to each oil seal, and press-fit them into position with the valve guide installer. 09916-43210: Valve guide remover/installer MOLYBDENUM OIL SOLUTION Do not reuse the removed oil seals. •...
Page 85: Cylinder
INTAKE PIPE • Coat the O-ring with grease and install the intake pipe together with the O-ring. 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) CYLINDER • Disconnect the water pipe 1 and remove the O-ring.
Page 86 ENGINE 3-35 CYLINDER BORE • Check the cylinder bore for stepped wear or scars. • Measure the 6 positions as shown in the right figure with a cyl- inder gauge. 09900-20508: Cylinder gauge set Cylinder bore: Standard: 75.500 – 75.515 mm (2.9724 – 2.9730 in) Service Limit: 75.585 mm (2.9758 in) •...
Page 87: Piston And Piston Ring
3-36 ENGINE PISTON AND PISTON RING PISTON DIAMETER • Using a micrometer, measure the piston outside diameter at 15 mm (0.6 in) from the piston skirt end. • If the measurement is less than the limit, replace the piston. Piston diameter: Standard: 75.450 –...
Page 88 ENGINE 3-37 PISTON RING TO GROOVE CLEARANCE • Measure the side clearances of the 1st and 2nd piston rings using the thickness gauge. • If any of the clearances exceed the limit, replace both the pis- ton and piston rings. 09900-20803: Thickness gauge 09900-20205: Micrometer (0 –...
Page 89: Clutch
3-38 ENGINE CLUTCH Circlip Spring seat " Concaved washer Outer plate Driven plate No.2 Clutch plate concaved washer & Drive plate 5.5 N·m Driven plate No.1 0.55 kgf-m Clutch hub 4.0 lb-ft Spring Inner plate Roller Clutch housing DISASSEMBLY • Remove the circlip 1 with the special tools. 09920-33530: Clutch spring compressor 09924-84510: Bearing installer set •...
Page 90 ENGINE 3-39 • Remove the spring seat and concaved washer. • Remove the outer plate, driven plate No.1, clutch plate con- caved washer, drive plate and driven plate No.2. • Remove the clutch spring bolts 2, springs 3 and clutch inner plate 4.
Page 91 3-40 ENGINE • Measure the claw width of drive plates with a vernier calipers. • Replace the drive plates found to have worn down to the limit. Drive plate claw width: Service Limit: 13.05 mm (0.5138 in) 09900-20102: Vernier calipers CLUTCH DRIVEN PLATE NO.2 INSPECTION •...
Page 92 ENGINE 3-41 REASSEMBLY NOTE: Reassemble the clutch in the reverse order of removal and dis- assembly. Pay attention to the following points: • Install the rollers. • Tighten the clutch spring bolts to the specified torque. Clutch spring bolt: 5.5 N·m (0.55 kgf-m, 4.0 lb-ft) •...
Page 93 3-42 ENGINE Driven plate No.2 Driven plate No.1 Drive plate Expanded view Clutch plate concaved washer Concaved washer Engine side Outside • Install the driven plate No.1, driven plate No.2, drive plate, clutch plate concaved washer outer plate, concaved washer and spring seat.
Page 94: Starter Clutch
ENGINE 3-43 STARTER CLUTCH Washer Starter torque limiter " Idle gear Wahser Starter clutch 55 N . m 5.5 kgf-m 40.0 lb-ft INSPECTION • Install the starter driven gear onto the starter clutch. • Turn the starter driven gear by hand. •...
Page 95: Starter Torque Limiter
3-44 ENGINE STARTER TORQUE LIMITER INSPECTION • Measure the torque when slipping by means of the special tool and torque wrench. • If the measurement result is out of standard value, replace the starter torque limiter with a new one. Slip torque standard: 22 –...
Page 96: Crank Balancer
ENGINE 3-45 CRANK BALANCER DISASSEMBLY • Remove the circlip 1, washer 2, spring 3 and scissors gear REASSEMBLY • Carry out the assembly procedure in the reverse order of dis- assembly while observing the following instructions. • Assemble the scissors gear with its punch mark side the out- side.
Page 97 • Coat the spline area of the cam dog 2 with grease. 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) • Install the bushing 1, final drive gear 2, cam dog 3, dumper spring 4, spring stopper 5, washer 6 and nut 7 to the drive- shaft.
Page 98: Conrod/Crankshaft
ENGINE 3-47 CONROD/CRANKSHAFT CONROD SMALL END I.D. • Using a small bore gauge, measure the inside diameter of the conrod small end. 09900-20602: Dial gauge (1/1000 mm, 1 mm) 09900-22401: Small bore gauge (10 – 18 mm) Conrod small end I.D.: Service Limit: 16.040 mm (0.6315 in) •...
Page 99 3-48 ENGINE CONROD-CRANK PIN BEARING SELECTION • Place the plastigauge axially along the crank pin, avoiding the oil hole, as shown. 09900-22301: Plastigauge • Tighten the conrod cap bolts to the specified torque, in two stages. ( 3-50) * Apply engine oil to the bearing cap bolt. * Never rotate the crankshaft or conrod when a piece of plastigauge is installed.
Page 100 ENGINE 3-49 Conrod I.D. Code A I.D. specification 48.000 – 48.008 mm – (1.8898 1.8901 in) 48.008 – 48.016 mm (1.8901 – 1.8904 in) Crank pin O.D. Code B O.D. specification 44.992 – 45.000 mm (1.7713 – 1.7717 in) 44.984 – 44.992 mm (1.7710 –...
Page 101 3-50 ENGINE • When fitting the conrods on the crankshaft, make sure that 21 N·m I.D. A of the conrods face each cylinder intake valve sides. 2.1 kgf-m 90˚ 15 lb-ft • Apply engine oil to the bearing cap bolts. •...
Page 102 ENGINE 3-51 CRANKSHAFT JOURNAL BEARING REPLACEMENT Hand press • Use the special tool to replace the crankshaft journal bear- ings. The replacement procedure is as follows. 09913-60230: Journal bearing remover/installer Bearing Crankcase • Set the special tool as shown to remove the crankshaft journal bearings.
Page 103 3-52 ENGINE • Set the specified crankshaft journal bearings to the special tool. 09913-60241: Jornal bearing installer holder * Before setting the bearing, apply enough engine oil to the special tool and bearings. * When setting the bearing, align the bearing side with the engraved line A and also the bearing edge with the mating surface of the special tool.
Page 104 ENGINE 3-53 • Set the bearings installed in the special tool to the crankcase half as shown. * Be sure the bearing protruded side A faces the crankcase bore. * Align the special tool mating surface with the line mark B on the crankcase. •...
Page 105 3-54 ENGINE NOTE: Using the hand-press is recommended to install the crankshaft journal bearings. However, the crankshaft journal bearings can be installed by using the following special tools. Match the hole center of the special tool correctly. 09924-84510: Bearing installer CRANKSHAFT THRUST CLEARANCE •...
Page 106: Oil Jet
ENGINE 3-55 OIL JET • Check the oil jets for clogging. NOTE: Before fitting, coat the O-ring with engine oil. Use a new O-ring. Note the carved mark not to mistake the size. NOTE: The crankcase side of the oil jet is identified by letter 8. NOTE: The cylinder head side of the oil jet is identified by letter 14.
Page 107: Crankcase
ENGINE CRANKCASE OIL PRESSURE SWITCH • Remove the oil pressure switch. • When installing the switch, apply SUZUKI BOND “1207B”. Oil pressure switch: 13 N·m (1.3 kgf-m, 10.0 lb-ft) 99104-31140: SUZUKI BOND “1207B” (USA) 99000-31140: SUZUKI BOND “1207B” (Others) • Remove the right crankcase cover 1.
Page 108 ENGINE 3-57 BEARING INSPECTION Play Rotate the bearing inner race by finger to inspect for abnormal play, noise and smooth rotation while the bearings are in the crankcase. Play Replace the bearing in the following procedure if there is any- thing unusual.
Page 109 3-58 ENGINE OIL SEAL REASSEMBLY • Apply grease to the oil seal lip. 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) • Install the oil seal with the special tool. 09913-70210: Bearing installer set Use a new Oil seal.
Page 110: Engine Reassembly
ENGINE 3-59 ENGINE REASSEMBLY • Reassemble the engine in the reverse order of disassembly. • The following steps require special attention or precautionary measures should be taken. NOTE: Apply engine oil to each running and sliding part before reas- sembling. RETURN OIL PUMP •...
Page 111 3-60 ENGINE • Install the crankcase oil separator. OIL SUMP FILTER • Install the oil sump filter by aligning the projection of the oil sump filter to the concave of the crankcase. PISTON COOLING NOZZLE • Coat the O-ring with a small amount of grease and install the piston cooling nozzle 1.
Page 112 ENGINE 3-61 CRANK BALANCER SHAFT • Install the upper crank balancer shaft 1. • Install the lower crank balancer 2, oil pump drive gear 3 and oil pump drive chain 4. • Engage the drive chain to the oil pump gear and install the oil pump gear by aligning the groove and pin.
Page 113 • Install the spacer 2. Use a new O-ring. • Clean the mating surfaces of the left and right crankcase halves. • Apply SUZUKI BOND to the mating surface of the right crank- case. 99104-31140: SUZUKI BOND “1207B” (USA) 99000-31110: SUZUKI BOND “1215” (Others) * Coat the sealing agent quickly in uniform thickness without interruption.
Page 114 ENGINE 3-63 OIL COOLER • Coat the O-ring with engine oil and install the oil cooler. • Install the washer 1 and tighten the union bolt 2 to the spec- ified torque. Oil cooler union bolt: 70 N·m (7.0 kgf-m, 50.5 lb-ft) NOTE: Use a new O-ring.
Page 115 3-64 ENGINE STARTER CLUTCH • Install the washer 1. • Coat the internal surface of the starter clutch gear and crank- shaft with engine oil. • Install the starter clutch assembly to the crankshaft. NOTE: Align the engraved line A of the starter clutch and punched mark B of the crankshaft.
Page 116 ENGINE 3-65 • Install the new gasket 1 and dowel pin. • Coat the starter clutch cover bearings with molybdenum oil. MOLYBDENUM OIL SOLUTION • Install the starter clutch cover. NOTE: Tighten the starter clutch cover bolt A together with the clamp.
Page 117 Use a new O-ring. CLUTCH • Install the clutch shaft to the clutch assembly. • Coat the part A of the clutch shaft with SUZUKI MOLY PASTE. 99000-25140: SUZUKI MOLY PASTE • Install the clutch assembly, washer 1 and clutch housing nut 2 to the left crankcase.
Page 118 ENGINE 3-67 GENERATOR • Wipe off the oily from the tapered part of the crankshaft. • Install the key. • Install the stator coil 1 and CKP sensor 2. • Fit the grommet firmly. • Using the special tool, tighten the generator rotor nut to the specified torque.
Page 119 3-68 ENGINE • Install the generator cover. NOTE: Tighten the generator cover bolt A together with the clamp. • Fit the gasket washers 3 and union bolts to the oil hose 1 and oil return hose 2. NOTE: Use a new gasket washer. •...
Page 120 ENGINE 3-69 PISTON RING • Install the piston rings in the order of the oil ring, second ring and top ring. • Install the spacer 1 of the oil ring first and then the side rail * When installing the spacer, be careful so that the both edges are not overlapped.
Page 121 3-70 ENGINE PISTON • Coat the piston pin and conrod small end with molybdenum oil. MOLYBDENUM OIL SOLUTION • Face the indent mark on the piston head to the exhaust side of the cylinder, install the pistons 1. • Place a clean cloth under the piston and fit the circlip 2. Use a new circlip.
Page 122 ENGINE 3-71 CYLINDER HEAD • Install the dowel pins 1, cylinder head gasket 2 and cam chain guide 3 to the cylinder. Use a new gasket. • Coat the thread of the cylinder head bolts with engine oil. • Tighten the cylinder head bolts 1 and 2 in ascending order of the numbers as illustrated.
Page 123 3-72 ENGINE CAMSHAFT • Turn the crankshaft counterclockwise and bring the piston to the top dead center. ( 2-8) • Before installing the camshafts to the cylinder head, coat the journals, cam surfaces and camshaft journal holders with molybdenum oil. MOLYBDENUM OIL NOTE: Before installing the camshafts, check that the tappet is properly...
Page 124 ENGINE 3-73 POSITION OF CAMSHAFTS AND SPROCKETS...
Page 125 • Assemble the new gasket to the cylinder head cover. • Coat the semicircular part of the gasket with sealing agent. 1216 99000-31230: SUZUKI BOND “1216B” 1216 NOTE: Do not remove the dowel pin at the backside of the cylinder head cover since it is embedded.
Page 126 ENGINE 3-75 OIL LEVEL SWITCH • Install the oil level switch. Oil level switch bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft) STARTER MOTOR • Install the starter motor 1. • Install the water bypass hose 2. Starter motor bolt: 6 N·m (0.6 kgf-m, 4.5 lb-ft)
Page 127 DRIVE TRAIN DRIVE TRAIN CONTENTS DRIVE TRAIN ..................4- 2 CONSTRUCTION .................4- 2 REMOVAL AND DISASSEMBLY ..........4- 3 INSPECTION AND REPLACEMENT ...........4- 4 REASSEMBLY AND REMOUNTING ..........4- 7...
Page 128: Drive Train
DRIVE TRAIN DRIVE TRAIN CONSTRUCTION 10 N . m Final drive gear (1.0 kgf-m, 7.0 lb-ft) No.1 gear " No.2 gear No.3 gear Final driven gear Final gear case cover & Final gear case Plate Final driven gear hub Right oil seal Left oil seal Oil seal Circlip...
Page 129: Removal And Disassembly
DRIVE TRAIN REMOVAL AND DISASSEMBLY • Remove the right/left side leg shield cover. ( 9-12) • Drain the final gear oil. ( 2-15) • Remove the rear wheel. ( 9-48) • Remove the swingarm. ( 9-59) • Remove the speedometer sensor 1 and harness guide 2. •...
Page 130: Inspection And Replacement
DRIVE TRAIN • Remove the gascket 3 and dowel pins. • Remove the following gears. A Final drive gear B No.1 gear C No.2 gear D No.3 gear E Final driven gear • Remove the final drive gear hub 4. INSPECTION AND REPLACEMENT GEARS Inspect the gears for wear and damage.
Page 131 09913-50121: Oil seal remover Replace the removed oil seal with a new one. • Install the new oil seal to the final gear case. • Apply SUZUKI SUPER GREASE “A” to the oil seals. 99000-25010: SUZUKI SUPER GREASE “A” NOTE: Direction of the oil seal is shown in the illustration at page 4-2.
Page 132 DRIVE TRAIN • Remove the final driven gear bearing by using the appropriate bar. • Remove the final drive gear bearing with the special tools. 09941-64511: Bearing remover 09930-30104: Sliding shaft • Install the bearings to the final gear case with the special tool. 09913-70210: Bearing installer set Replace the removed bearing with a new one.
Page 133: Reassembly And Remounting
• Install the gears and final driven gear hub onto the final gear case cover. • Install the dowel pins 1 and the new gasket. • Apply SUZUKI SUPER GREASE “A” to spline of the final drive gear. 99000-25010: SUZUKI SUPER GREASE “A”...
Page 134 DRIVE TRAIN • Clamp the breather hose 4 and speedometer sensor harness • Install the swingarm. ( 9-61) • Install the exhaust muffler. ( 3-11) • Install the rear wheel. ( 9-56) • Install the right/left side leg shield covers. •...
Page 135 C V T CONTENTS CVT ASSEMBLY REMOVAL AND INSTALLATION ......5- 2 CVT ASSEMBLY REMOVAL ............5- 2 CVT ASSEMBLY INSTALLATION ..........5- 4 CVT DISASSEMBLY AND REASSEMBLY .........5- 5 CVT DISASSEMBLY ..............5- 6 CVT INSPECTION ................5-11 CVT PRIMARY PULLEY SHIMS ADJUSTMENT ......5-16 CVT REASSEMBLY ..............5-19...
Page 136: Cvt Assembly Removal And Installation
CVT ASSEMBLY REMOVAL AND INSTALLATION CVT ASSEMBLY REMOVAL • Remove the engine assembly. ENGINE REMOVAL • Remove the bracket 1. • Remove the bolts, 2 and 3. • Install the special tool as shown. 09920-31050: CVT guide...
Page 137 • Remove the CVT mounting bolts. • Remove the CVT assembly.
Page 138: Cvt Assembly Installation
CVT ASSEMBLY INSTALLATION • Remove the valve timing inspection cap 1. • Install the special tool to the engine assembly as shown. • Apply SUZUKI MOLY PASTE to the primary driven gear shaft and clutch shaft. 09920-31050: CVT guide 99000-25140: SUZUKI MOLY PASTE •...
Page 139: Cvt Disassembly And Reassembly
CVT DISASSEMBLY AND REASSEMBLY Oil seal Secondary pulley shaft nut Washer Secondary pulley shaft adaptor Secondary pulley assembly O-ring Secondary pulley fan Primary pulley shaft bolt Bearing Primary pulley shaft adaptor Snap ring CVT casing Primary slide pulley idle gear Bearing Secondary pulley revolution O-ring...
Page 140: Cvt Disassembly
CVT DISASSEMBLY CVT CASING/COVER • Remove the pulley position sensor 1. • Remove the secondary pulley revolution sensor 2. • Remove the CVT motor. • Remove the CVT filter cover. • Remove the CVT filter...
Page 141 • Remove the secondary pulley shaft nut by holding the shaft with the special tools. 09920-31020: Extension handle 09920-31030: CVT secondary pulley shaft holder • Remove the secondary shaft adaptor with a bearing puller. • Remove the primary pulley shaft bolt by holding the primary pulley shaft with the special tools.
Page 142 • Separate the CVT assembly by using 6 mm screws. NOTE: When separating the CVT assembly, position the right side fac- ing downward. • After separating the CVT assembly, remove the CVT casing with the special tool. 09920-13120: Crankcase separater The crankcase separator plate is parallel with the end face of the CVT crankcase.
Page 143 SECONDARY PULLEY ASSEMBLY • Remove the washer 1 on the secondary pulley shaft. • Turn the primary slide pulley idle gear clockwise and open the primary pulley fully. • Remove the primary slide pulley idle gear 2 and 3. • Place a piece of clean rag on the primary pulley faces to pre- vent them from scratches.
Page 144 5-10 CVT BELT • Place a piece of clean rag on the CVT cover mating face to prevent the CVT belt from scratches. • Remove the CVT belt. • Mark the direction mark on the CVT belt. PRIMARY PULLEY • Remove the primary pulley stopper bolt A. NOTE: In the case of replacing the CVT belt only, removing of the primary pulley is not necessary.
Page 145: Cvt Inspection
5-11 • Remove the shim 1 and O-ring 2. CVT INSPECTION PRIMARY PULLEY INSPECTION • Check that the primary pulley faces are free from any greasy substance. • Inspect the primary pulley faces for any abnormal conditions such as scratches or stepped wear. If the surface is found greasy, make sure to degrease it thoroughly.
Page 146 5-12 • Rotate the bearing outer race by finger to inspect for abnor- mal play, noise and smooth rotation. • Inspect the secondary pulley fan for cracks or damage. • Replace the bearing or secondary pulley fan if there is any- thing unusual.
Page 147 5-13 SECONDARY PULLEY REASSEMBLY • Fit the special tool and install a new bearing by a hydraulic press. Bearing 09913-75810: Bearing installer Replace the removed bearing with a new one. • Install the snap ring. 09900-06107: Snap ring pliers • Apply THREAD LOCK “1342” to the secondary pulley fan bolts and tighten them.
Page 148 • Replace the bearing if there is anything unusual. • Replace the O-ring with a new one. • Apply SUZUKI SUPER GREASE “A” to the new O-ring and install it. 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A”...
Page 149 5-15 • Remove the bearing with the special tool. 09921-20240: Bearing remover set • Remove the bearing together with the oil seal by using the special tool. 09913-70210: Bearing installer set CVT CASING/COVER REASSEMBLY • Install the bearing with the special tool. 09913-70210: Bearing installer set •...
Page 150: Cvt Primary Pulley Shims Adjustment
5-16 PRIMARY SLIDE PULLEY IDLE GEAR INSPECTION • Inspect the pulley gears for wear or damage. • Rotate the bearing by finger to inspect for abnormal play, noise and smooth rotation. • If any wear or damage is found, replace the idle gear assem- bly with a new one.
Page 151 5-17 • Tighten the primary pulley shaft bolt to the specified torque with the special tools. Primary pulley shaft bolt: 64 N·m (6.4 kgf-m, 46.5 lb-ft) 09920-31010: CVT primary pulley shaft holder 09920-31020: Extension handle • Fix the CVT casing securely with its mating face positioned horizontally.
Page 152 5-18 SHIM SELECTION • Get the average depth Da by averaging D and D • Get the average height Ha by averaging H and H • Obtain the valve X by subtracting Da from Ha. • Using the chart below, select the appropriate shim with reference to the value X. SHIM SELECTION TABLE SHIM THICKNESS VALUE X...
Page 153: Cvt Reassembly
5-19 CVT REASSEMBLY PRIMARY PULLEY ASSEMBLY Wear clean protective gloves. • Degrease the inside of the CVT cover and CVT casing com- pletely with a cleaning solvent by using a clean rag. • Install the O-ring 1 and shim 2. If any of the primary pulley, CVT casing or CVT cover has been replaced, install the shim whose thickness has been adjusted in the shim adjustment procedure.
Page 154 5-20 NOTE: Primary pulley cover has the protrusion A and C. • Turn the primary pulley cover 180 degrees along the groove on the screw shaft and align the cutaway B with D or E posi- tion of the primary pulley cover. •...
Page 155 5-21 • Place a piece of clean rag on the CVT casing mating face to prevent the CVT belt from scratches. • Install the CVT belt so that the direction mark on the CVT belt points in the normal turning direction. Never touch the side walls of the CVT belt.
Page 156 5-22 • Check that the CVT belt is in parallel with the CVT cover mat- ing face. • Install the primary slide pulley idle gear 1 and 2. • Turn the idle gear until the primary pulley faces just touch the CVT belt.
Page 157 • Apply a small quantity of engine oil to the main lip B of the oil seal. ENGINE OIL • Apply SUZUKI BOND “1215” to the mating surface of the CVT casing. 99000-31110: SUZUKI BOND “1215” NOTE: * Make surfaces free from moisture, oil, dust and other foreign materials.
Page 158 CVT cover bolt: 22 N·m (2.2 kgf-m, 16.0 lb-ft) NOTE: Fit the clamp to the bolt A. • Apply SUZUKI SUPER GREASE “A” to the primary pulley shaft adaptor. 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) •...
Page 159 • Apply a small quantity of engine oil to the secondary pulley bearing. • Apply grease to the secondary pulley shaft adaptor. ENGINE OIL 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) • Install the special tool onto the secondary pulley shaft. 09910-32850: Crankshaft installer attachment •...
Page 160 5-26 • Clean the CVT filter by using compressed air. • Install the CVT filter. • Install the CVT filter cover. • Fit the clamp to the bolts A. • Install the CVT motor. NOTE: Pay attention to the direction of the CVT motor. •...
Page 161 5-27 • Install the pulley position sensor 1 with the sensor pushed toward the primary pulley shaft side. CVT BELT BRAKE-IN PROCEDURES • It is necessary to allow the CVT belt to “BRAKE-IN” before subjecting the CVT to maximum stresses. Brake -in engine speed Initial 800 km (500 miles): Below 4 000 rpm.
Page 162 FI SYSTEM/ CVT SYSTEM FI SYSTEM/ CVT SYSTEM CONTENTS PRECAUTIONS IN SERVICING ............. 6- 2 ELECTRICAL PARTS ..............6- 2 ELECTRICAL CIRCUIT INSPECTION PROCEDURE ..... 6- 5 USING TESTERS ................6- 8 FI SYSTEM TECHNICAL FEATURES ............ 6- 9 INJECTION TIME (INJECTION VOLUME) ........6- 9 COMPENSATION OF INJECTION TIME (VOLUME) ......
Page 163: Precautions In Servicing
FI SYSTEM/ CVT SYSTEM PRECAUTIONS IN SERVICING When handling the FI/CVT component parts or servicing the FI system/CVT 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 164 FI SYSTEM/ CVT SYSTEM 6-3 • 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 165 FI SYSTEM/ CVT SYSTEM Ignition S/W • When disconnecting and connecting the ECM/CVT control unit couplers, make sure to turn OFF the ignition switch, or electronic parts may get damaged. • Battery connection in reverse polarity is strictly prohibited. INCORRECT Such a wrong connection will damage the components of the FI system/CVT control unit instantly when reverse power is applied.
Page 166: Electrical Circuit Inspection Procedure
FI SYSTEM/ CVT SYSTEM 6-5 ELECTRICAL CIRCUIT INSPECTION PROCEDURE While there are various methods for electrical circuit inspection, described here is a general method to check for open and short circuit using an ohmmeter and a voltmeter. OPEN CIRCUIT CHECK Possible causes for the open circuit are as follows.
Page 167 FI SYSTEM/ CVT SYSTEM Continuity check • Measure resistance across coupler B (between A and C in the figure). If no continuity is indicated (infinity or over limit), the circuit is open between terminals A and C. • Disconnect the coupler B and measure resistance between ’...
Page 168 FI SYSTEM/ CVT SYSTEM 6-7 SHORT CIRCUIT CHECK (WIRE HARNESS TO GROUND) • Disconnect the negative cable from the battery. To other • Disconnect the connectors/couplers at both ends of the circuit parts to be checked. NOTE: If the circuit to be checked branches to other parts as shown, disconnect all connectors/couplers of those parts.
Page 169: Using Testers
FI SYSTEM/ CVT SYSTEM USING TESTERS • Use the Suzuki multi-circuit tester (09900-25008). • Use well-charged batteries in the tester. • Be sure to set the tester to the correct testing range. USING THE TESTER MULTI-CIRCUIT TESTER • Incorrectly connecting the + and - probes may cause the inside of the tester to burnout.
Page 170: Fi System Technical Features
FI SYSTEM/ CVT SYSTEM FI SYSTEM TECHNICAL FEATURES INJECTION TIME (INJECTION VOLUME) The factors to determine the injection time include the basic fuel injection time which is calculated on the basis of the intake air pressure, engine speed and throttle opening angle, and various compensations. These compensations are determined according to the signals from various sensors that detect the engine and driving conditions.
Page 171: Compensation Of Injection Time (Volume)
6-10 FI SYSTEM/ CVT SYSTEM COMPENSATION OF INJECTION TIME (VOLUME) The following different signals are output from the respective sensors for compensation of the fuel injection time (volume). SIGNAL DESCRIPTION ATMOSPHERIC PRESSURE SENSOR When atmospheric pressure is low, the sensor sends the SIGNAL signal to the ECM and reduce the injection time (volume).
Page 172: Fi System Parts Location
FI SYSTEM/ CVT SYSTEM 6-11 FI SYSTEM PARTS LOCATION...
Page 173 6-12 FI SYSTEM/ CVT SYSTEM...
Page 174: Fi System Wiring Diagram
FI SYSTEM/ CVT SYSTEM 6-13 FI SYSTEM WIRING DIAGRAM...
Page 175: Cvt System Technical Features
6-14 FI SYSTEM/ CVT SYSTEM CVT SYSTEM TECHNICAL FEATURES The CVT reduction ratio is controlled in relation to Actual CVT ratio and Target CVT ratio. The reduction ratio as detected by the CVT pulley position sensor is compensated for more accurate valve as Actual CVT ratio by comparing with the signals from the crankshaft position sensor and CVT secondary pully revolution sensor.
Page 176: Cvt System Parts Location
FI SYSTEM/ CVT SYSTEM 6-15 CVT SYSTEM PARTS LOCATION...
Page 177 6-16 FI SYSTEM/ CVT SYSTEM...
Page 178 FI SYSTEM/ CVT SYSTEM 6-17 The CVT control unit adjusts the CVT reduction ratio by making the pulley wider or narrower. The slide pul- ley movement is controlled by the CVT motor revolution. The secondary pulley squeezes the CVT belt with the spring force and the width of pulley adjusts itself in accordance with that of the primary pulley.
Page 179: Self-Diagnosis Function
6-18 FI SYSTEM/ CVT SYSTEM 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 FI light. To check the func- tion of the individual FI system devices, the dealer mode is prepared.
Page 180: Dealer Mode
FI SYSTEM/ CVT SYSTEM 6-19 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 181: Tps Adjustment
6-20 FI SYSTEM/ CVT SYSTEM CODE MALFUNCTION PART REMARKS None No defective part Camshaft position sensor (CMPS) Crankshaft position sensor (CKPS) Pick-up coil signal, signal generator Intake air pressure sensor (IAPS) Throttle position sensor (TPS) Engine coolant temp. sensor (ECTS) Speed sensor Speed sensor signal for FI system Intake air temperature sensor (IATS)
Page 182: Fail-Safe Function
FI SYSTEM/ CVT SYSTEM 6-21 FAIL-SAFE FUNCTION FI system/CVT system is provided with fail-safe function to allow the engine to start and the motorcycle to run in a minimum performance necessary even under malfunction condition. STARTING RUNNING ITEM FAIL-SAFE MODE ABILITY ABILITY Camshaft position sensor...
Page 183: Fi System/ Cvt System Troubleshooting
6-22 FI SYSTEM/ CVT SYSTEM FI SYSTEM/ CVT SYSTEM TROUBLESHOOTING CUSTOMER COMPLAINT ANALYSIS Record details of the problem (failure, complaint) and how it occurred as described by the customer. For this purpose, use of such an inspection form will facilitate collecting information to the point required for proper analysis and diagnosis.
Page 184 FI SYSTEM/ CVT SYSTEM 6-23 MOTORCYCLE/ENVIRONMENTAL CONDITION WHEN PROBLEM OCCURS Environmental condition Weather Fair Cloudy Rain Snow Always Other Temperature Warm Cool Cold ( °F/ °C) Always Frequency Always Sometimes ( times/ day, month) Only once Under certain condition Road Urban Suburb Highway...
Page 185: Self-Diagnostic Procedures
6-24 FI SYSTEM/ CVT SYSTEM SELF-DIAGNOSTIC PROCEDURES • Don’t disconnect couplers from ECM/CVT control unit, battery cable from battery, ECM ground wire harness from engine or main fuse before confirming malfunction code (self-diagnostic trouble code) stored in memory. Such disconnection will erase memorized information in ECM memory.
Page 186: Battery
FI SYSTEM/ CVT SYSTEM 6-25 MALFUNCTION CODE AND DEFECTIVE CONDITION MALFUNCTION DETECTED FAILURE CONDITION DETECTED ITEM CODE CHECK FOR NO FAULT ––––––––––– Camshaft position The signal does not reach ECM for more than 2 sec. after sensor receiving the starter signal. The camshaft position sensor wiring and mechanical parts.
Page 187 6-26 FI SYSTEM/ CVT SYSTEM Fuel injector Crankshaft position sensor (pick-up coil) signal is produced but fuel injector signal is interrupted continuous by 4 times or more. C32 or C33 In this case, the code C32 or C33 is indicated. Injector, wiring/coupler connection, power supply to the injector.
Page 188: C11" Cmp Sensor Circuit Malfunction
FI SYSTEM/ CVT SYSTEM 6-27 “C11” CMP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE No CMP sensor signal for more than 2 seconds • Metal particles or foreign material being attached after receiving the starter signal. on the CMP sensor and rotor tip. •...
Page 189: C12" Ckp Sensor Circuit Malfunction
6-28 FI SYSTEM/ CVT SYSTEM “C12” CKP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE No CKP sensor signal for more than 2 seconds after • Metal particles or foreign material being attached receiving the starter signal. on the CKP sensor and rotor tip. •...
Page 190: C13" Iap Sensor Circuit Malfunction
FI SYSTEM/ CVT SYSTEM 6-29 “C13” IAP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE IAP sensor voltage low or high. • Clogged vacuum passage between throttle body and IAP sensor. < 0.50 V Sensor voltage 4.85 V • Air being drawn from vacuum passage between without the above range.
Page 191 6-30 FI SYSTEM/ CVT SYSTEM Ground Remove the IAP sensor. Vout Connect the vacuum pump gauge to the vacuum port of the IAP sensor. Arrange 3 new 1.5 V batteries in series (check that total voltage is 4.5 – 5.0 V) and connect terminal to the ground terminal and terminal to the Vcc terminal.
Page 192: C14" Tp Sensor Circuit Malfunction
FI SYSTEM/ CVT SYSTEM 6-31 “C14” TP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE Output voltage low or high. • TP sensor maladjusted. < • TP sensor circuit open or short. 0.20 V Sensor voltage 4.80 V • TP sensor malfunction. without the above range.
Page 193 6-32 FI SYSTEM/ CVT SYSTEM Connect the TP sensor coupler. Insert the copper wires to the lead wire coupler. Turn the ignition switch ON. Measure the TP sensor output voltage at the coupler (be- tween Yellow and Gr or R wires) by turning the throttle grip. TP sensor output voltage Yellow Throttle valve is closed...
Page 194: C15" Ect Sensor Circuit Malfunction
FI SYSTEM/ CVT SYSTEM 6-33 “C15” ECT SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE Output voltage low or high. • ECT sensor circuit open or short. < • ECT sensor malfunction. 0.15 V Sensor voltage 4.85 V • ECM malfunction. without the above range.
Page 195: C16" Speed Sensor Circuit Malfunction
6-34 FI SYSTEM/ CVT SYSTEM “C16” SPEED SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE The speed sensor signal is not input to ECM for • Speed sensor circuit open or short. more than 3 sec. during vehicle deceleration. • Metal particles or foreign material being attached on the speed sensor.
Page 196 FI SYSTEM/ CVT SYSTEM 6-35 Check the speed sensor output voltage. Insert the copper wires to the lead wire caupler. (White – Black/White) Turn the ignition switch ON. Check that the voltage varies when a screwdriver is brought close to the pick-up face of the speed sensor. 09900-25008: Multi circuit tester Tester knob indication: Voltage ( Short circuit in the lead...
Page 197: C21" Iat Sensor Circuit Malfunction
6-36 FI SYSTEM/ CVT SYSTEM “C21” IAT SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE Output voltage low or high. • IAT sensor circuit open or short. < • IAT sensor malfunction. 0.15 V Sensor voltage 4.85 V • ECM malfunction. without the above range.
Page 198: C22" Ap Sensor Circuit Malfunction
FI SYSTEM/ CVT SYSTEM 6-37 “C22” AP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE Output voltage low or high. • Clogged air passage with dust. < • AP sensor circuit open or short. 0.50 V Sensor voltage 4.85 V • AP sensor malfunction. without the above range.
Page 199 6-38 FI SYSTEM/ CVT SYSTEM Remove the AP sensor. Connect the vacuum pump gauge to the air passage port Ground of the AP sensor. Arrange 3 new 1.5 V batteries in series (check that total voltage is 4.5 – 5.0 V) and connect terminal to the ground terminal and terminal to the Vcc terminal.
Page 200: C23" To Sensor Circuit Malfunction
FI SYSTEM/ CVT SYSTEM 6-39 “C23” TO SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE Output voltage low or high. • TO sensor circuit open or short. < • TO sensor malfunction. 0.20 V Sensor voltage 4.80 V • ECM malfunction. without the above range.
Page 201: C24" Or "C25" Ignition System Malfunction
6-40 FI SYSTEM/ CVT SYSTEM “C24” or “C25” IGNITION SYSTEM MALFUNCTION *Refer to the IGNITION SYSTEM for details. ( 10-18) “C32” or “C33” FUEL INJECTOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE CKP signal is produced but fuel injector signal is •...
Page 202: C40" Iac Valve Circuit Malfunction
FI SYSTEM/ CVT SYSTEM 6-41 “C40” IAC VALVE CIRCUIT MALFUNCTION *Refer to the IAC VALVE INSPECTION for details. ( 7-20) “C41” 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 •...
Page 203: C44" Ho2 Sensor (Ho2S) Circuit Malfunction (E-02, 19)
6-42 FI SYSTEM/ CVT SYSTEM “C44” HO2 SENSOR (HO2S) CIRCUIT MALFUNCTION (E-02, 19) DETECTED CONDITION POSSIBLE CAUSE During O2 feedback control, O2 sensor voltage is • HO2 sensor or its circuit open or short. higher or lower than the specification. •...
Page 204 FI SYSTEM/ CVT SYSTEM 6-43 Turn the ignition switch OFF. Turn the ignition switch ON and measure the heater voltage between Orange/White wire (ECM side) and ground. If the tester voltage indicates the battery voltage for few seconds, it is good condition. Heater voltage: Battery voltage (O/W –...
Page 205: C50" Cvt Serial Communication Circuit Malfunction
6-44 FI SYSTEM/ CVT SYSTEM “C50” CVT SERIAL COMMUNICATION CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE No signal is supplied from CVT control unit to ECM • “C58” circuit open or short. for more than 5 sec. after starting the engine. •...
Page 206: C51" Cvt Motor Circuit Malfunction
FI SYSTEM/ CVT SYSTEM 6-45 “C51” CVT MOTOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE CVT motor operating voltage is not supplied from • CVT motor circuit open or short. CVT control unit. • CVT motor malfunction. • CVT control unit malfunction. INSPECTION •...
Page 207 6-46 FI SYSTEM/ CVT SYSTEM Remove the CVT motor. Apply 12 volts to the terminals of the CVT motor lead wire coupler. Check the CVT motor movement. Then, swap the wires supplied 12 volts and check the movement. Check the CVT motor both way movements. Replace the CVT motor.
Page 208: C52" Cvt Pulley Position Sensor (Pps) Circuit Malfunction
FI SYSTEM/ CVT SYSTEM 6-47 “C52” CVT PULLEY POSITION SENSOR (PPS) CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE PPS voltage low or high. • PPS circuit open or short. • PPS malfunction. 0.06 V Sensor voltage 5.04 V • CVT control unit malfunction. without the above range.
Page 209 6-48 FI SYSTEM/ CVT SYSTEM Turn the ignition switch OFF. Remove the PPS. Measure the resistance each when the sensor is compressed and extended to the maximum between Ω Lbl/Y or Bl wire and B wire terminals. PPS resistance : (Lbl/Y or Bl – B) Compressed : 1.9 –...
Page 210: C53" Cvt Speed Sensor Circuit Malfunction
FI SYSTEM/ CVT SYSTEM 6-49 “C53” CVT SPEED SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE The speed sensor signal is not input to CVT control • Speed sensor circuit open or short. unit for more than 3 sec. during vehicle running. •...
Page 211 6-50 FI SYSTEM/ CVT SYSTEM Check the speed sensor output voltage. Insert the copper wires to the lead wire caupler. (White – Black/White) Turn the ignition switch ON. Check that the voltage varies when a screwdriver is brought close to the pick-up face of the speed sensor. 09900-25008: Multi circuit tester Tester knob indication: Voltage ( Short circuit in the lead...
Page 212: C54" Cvt Secondary Pulley Revolution Sensor Circuit Malfunction
FI SYSTEM/ CVT SYSTEM 6-51 “C54” CVT SECONDARY PULLEY REVOLUTION SENSOR CIRCUIT MAL- FUNCTION DETECTED CONDITION POSSIBLE CAUSE The CVT secondary pulley revolution signal is not • Sensor circuit open or short. input to CVT control unit at speed of 20 km or •...
Page 213 6-52 FI SYSTEM/ CVT SYSTEM Remove the CVT assembly. ( 5-2) Remove the CVT secondary pulley revolution sensor Clean away metal particles or foreign material. It “C54” code is indicated, replace the CVT control unit.
Page 214: C55" Cvt Engine Revolution Signal Circuit Malfunction
FI SYSTEM/ CVT SYSTEM 6-53 “C55” CVT ENGINE REVOLUTION SIGNAL CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE The CVT engine revolution signal is not input to • Lead wire open or short. CVT control unit from ECM at speed of 20 km or •...
Page 215: C56" Cvt Throttle Position Signal Circuit Malfunction
6-54 FI SYSTEM/ CVT SYSTEM “C56” CVT THROTTLE POSITION SIGNAL CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE The CVT throttle position signal is not input to CVT • Lead wire open or short. control unit from ECM for more than 5 sec. after •...
Page 216: C58" Cvt Reduction Ratio Disagreement
FI SYSTEM/ CVT SYSTEM 6-55 “C58” CVT REDUCTION RATIO DISAGREEMENT DETECTED CONDITION POSSIBLE CAUSE The revolution ratio detected by CVT pulley position PPS is stuck immovable. sensor (PPS) disagrees with actual revolution ratio Foreign substance such as water, oil or metal parti- for more than 4 sec.
Page 217: Sensors
6-56 FI SYSTEM/ CVT SYSTEM SENSORS THROTTLE POSITION SENSOR (TPS) SETTING • After all adjustments are completed, check or adjust the TPS setting condition. TPS SETTING PROCEDURE ( 6-20) CMP SENSOR The signal rotor is installed on the exhaust camshaft, and the camshaft position sensor (Pick-up coil) is installed on the cylin- der head cover.
Page 218 FI SYSTEM/ CVT SYSTEM 6-57 TP SENSOR • The throttle position sensor is installed on the No.2 throttle body. ( 6-31) ECT SENSOR • The engine coolant temperature sensor is installed on the cyl- inder head. ( 6-33) ECT sensor: 18 N·m (1.8 kgf-m, 13.0 lb-ft) SPEED SENSOR •...
Page 219 6-58 FI SYSTEM/ CVT SYSTEM TO SENSOR • The tip over sensor is located under the combination meter. 6-39) NOTE: When installing the TO sensor, bring the “UPPER” letter to the top. HO2 SENSOR (E-02, 19) • The heated oxygen sensor is installed on the exhaust pipe. 6-42) Do not remove the HO2 sensor while it is hot.
Page 220 FUEL SYSTEM AND THROTTLE BODY FUEL SYSTEM AND THROTTLE BODY CONTENTS FUEL SYSTEM ..................7- 2 FUEL TANK COMPONENTS ............7- 2 FUEL TANK REMOVAL ..............7- 3 FUEL TANK INSTALLATION ............7- 4 FUEL TANK PRESSURE CONTROL (FTPC) VALVE INSPECTION ................7- 4 FUEL PRESSURE INSPECTION ..........7- 5 FUEL PUMP INSPECTION ............7- 6 FUEL PUMP RELAY INSPECTION ..........7- 6 FUEL PUMP COMPONENTS ............7- 7...
Page 221: Fuel System
FUEL SYSTEM AND THROTTLE BODY FUEL SYSTEM FUEL TANK COMPONENTS 33 N·m (3.3 kgf-m, 24 lb-ft) Fuel tank Seal ring " Ring locknut Fuel tank pressure control valve (Orange/Black) Fuel tank pressure control valve (Gray/Black) Fuel tank inlet pipe & Fuel tank inlet hose Fuel filler Fuel filler cap...
Page 222: Fuel Tank Removal
FUEL SYSTEM AND THROTTLE BODY FUEL TANK REMOVAL The fuel tank is located under the seat. • Remove the following parts. ( 9-6) * Seat * Pillion rider handles * Battery cover * Lower frame cover * Center frame cover * Helmet box cover * Frame covers * Helmet box...
Page 223: Fuel Tank Installation
FUEL SYSTEM AND THROTTLE BODY • Remove the fuel tank sideward. Gasoline is highly flammable and explosive. Keep heat, spark and flame away. FUEL TANK INSTALLATION Installation is in the reverse order of removal. FUEL TANK PRESSURE CONTROL (FTPC) VALVE INSPECTION Two kinds of the FTPC valve are equipped in the fuel tank, they can be distinguished by the color.
Page 224: Fuel Pressure Inspection
FUEL SYSTEM AND THROTTLE BODY FUEL PRESSURE INSPECTION • Remove the front box. ( 9-18) • Place a rag under the fuel feed hose. • Disconnect the fuel feed hose at the fuel delivery pipe, and install the special tools between the fuel feed hose and fuel delivery pipe.
Page 225: 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 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 226: Fuel Pump Components
FUEL SYSTEM AND THROTTLE BODY FUEL PUMP COMPONENTS 33 N·m 3.3 kgf-m 24 lb-ft Align the marks in line. Fuel pump assembly O-ring " Fuel filter cartridge assembly Fuel pressure regulator O-ring Fuel level gauge & Fuel pump upper cover Fuel pump lower cover Fuel feed hose FUEL PUMP/FUEL LEVEL GAUGE...
Page 227 FUEL SYSTEM AND THROTTLE BODY • Remove the fuel pump ring locknut by using the special tool. 09941-51010: Ring locknut wrench Gasoline is highly flammable and explosive. Keep heat, spark and flame away. • Remove the fuel pump assembly. • Disconnect the fuel level gauge lead wire coupler. •...
Page 228 FUEL SYSTEM AND THROTTLE BODY • Disconnect the fuel pump lead wire coupler and ground wire. • Remove the fuel pump lower case 1. • Disconnect the fuel feed hose 2. • Disconnect the fuel pump lead wire coupler. • Remove the fuel pump from its holder.
Page 229: Fuel Mesh Filter Inspection And Cleaning
7-10 FUEL SYSTEM AND THROTTLE BODY FUEL MESH FILTER INSPECTION AND CLEANING If the fuel mesh filter is clogged with sediment or rust, fuel will not flow smoothly and loss in engine power may result. Blow the fuel mesh filter with compressed air. NOTE: If the fuel mesh filter is clogged with many sediment or rust, replace the fuel filter cartridge with a new one.
Page 230: Fuel Pump/Fuel Level Gauge Reassembly And Installation
FUEL SYSTEM AND THROTTLE BODY 7-11 FUEL PUMP/FUEL LEVEL GAUGE REASSEMBLY AND INSTALLATION Install the fuel pump/fuel level gauge in the reverse order of removal and disassembly, and pay attention to the following points: • Install the new O-rings to the fuel pump, fuel pressure regula- tor and fuel feed hose.
Page 231 7-12 FUEL SYSTEM AND THROTTLE BODY • Install the fuel pressure regulator and ground wire. • Install the fuel level gauge. • Connect the fuel pump lead wire coupler, ground wire and fuel level gauge lead wire coupler. • Install the new seal ring 1 to the fuel tank. •...
Page 232 FUEL SYSTEM AND THROTTLE BODY 7-13 • Align the alignment marks A and B in line. • Using the special tool, tighten the fuel pump ring locknut to the specified torque. 09941-51010: Ring locknut wrench Ring locknut: 33 N·m (3.3 kgf-m, 24 lb-ft)
Page 233: Throttle Body
7-14 FUEL SYSTEM AND THROTTLE BODY THROTTLE BODY THROTTLE BODY COMPONENTS TP sensor O-ring " Fuel injector Fuel injector seal O-ring Fuel delivery pipe & Fuel delivery pipe joint O-ring IAC hose connector O-ring 3.5 N·m IAC valve 0.35 kgf-m O-ring 2.5 lb-ft Throttle stop screw...
Page 234: Throttle Body Removal
FUEL SYSTEM AND THROTTLE BODY 7-15 THROTTLE BODY REMOVAL • Remove the front box. ( 9-18) • Disconnect the PCV hose from the bottom side of the air cleaner box. • Remove the air cleaner box 1. • Remove the IAP sensor 2. •...
Page 235 7-16 FUEL SYSTEM AND THROTTLE BODY • Disconnect the IAC hose 5. • Remove the air chamber 6. • Disconnect the various lead wire couplers. 7 TPS 8 IAC valve 9 FI • Disconnect the fuel feed hose 0. • Disconnect the throttle cables. After disconnecting the throttle cables, do not snap the throttle valve from full open to full close.
Page 236: Throttle Body Disassembly
FUEL SYSTEM AND THROTTLE BODY 7-17 THROTTLE BODY DISASSEMBLY • Remove the IAC hose. • Remove the vacuum hoses. • Remove the fuel delivery pipe. • Remove the fuel injectors. • Remove the IAC valve. • Remove the TPS. NOTE: Prior to disassembly, mark sensor’s original position with a paint or scribe for accurate reinstallation.
Page 237 7-18 FUEL SYSTEM AND THROTTLE BODY Never remove the throttle valve. Avoid removing the throttle lever stopper screw A. • Remove the IAC hose connector. • Remove the throttle cable bracket. • Remove the synchronizing screws. NOTE: Before removing the synchronizing screw, determine the setting by slowly turning it clockwise and count the number of turns required to lightly seat the screw.
Page 238: Throttle Body Cleaning And Inspection
FUEL SYSTEM AND THROTTLE BODY 7-19 THROTTLE BODY CLEANING AND INSPECTION Some carburetor cleaning chemicals, especially dip-type soaking solutions, are very corrosive and must be handled carefully. Always follow the chemical manufacturer’s instructions on proper use, handling and storage. • Clean all passageways with a spray-type carburetor cleaner and blow dry with compressed air.
Page 239: Iac Valve Inspection
7-20 FUEL SYSTEM AND THROTTLE BODY IAC VALVE INSPECTION Ω The IAC valve can be checked without removing it from the throttle body. • Remove the front box. ( 9-18) • Disconnect the IAC valve lead wire coupler. • Check the resistance between the terminals of the IAC valve. Resistance: Approx.
Page 240 7-21 • Apply a small quantity of grease to the shaft end and seal lip. 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) • With the TV fully closed, install the TP sensor to the original setting position.
Page 241: Throttle Body Installation
7-22 FUEL SYSTEM AND THROTTLE BODY • Install the IAC hose connector. Replace the O-ring with a new one. • Apply thin coat of the engine oil to the new O-ring. • Install the synchronizing screw to the original setting by turn- ing the screw in until it lightly seats, and then backing it out the same number of turns counted during disassembly.
Page 242: Throttle Cable Adjustment
FUEL SYSTEM AND THROTTLE BODY 7-23 THROTTLE CABLE ADJUSTMENT NOTE: Minor adjustment can be made by the throttle grip side adjuster. 2-18) TP SENSOR ADJUSTMENT • After checking or adjusting the throttle valve synchronization, adjust the TP sensor positioning as follows: •...
Page 243: Throttle Valve Synchronization
7-24 FUEL SYSTEM AND THROTTLE BODY THROTTLE VALVE SYNCHRONIZATION Check and adjust the throttle valve synchronization between two cylinders. To synchronize throttle valves, disconnect the IAP sensor’s vacuum hoses from the vacuum nipples on the respec- tive throttle bodies and connect the vacuum balancer gauge hoses to each vacuum nipple.
Page 244 COOLING AND LUBRICATION SYSTEM COOLING AND LUBRICATION SYSTEM CONTENTS COOLING SYSTEM ................8- 2 DESCRIPTION ................8- 2 COOLING CIRCUIT ..............8- 2 OIL COOLER ................8- 2 ENGINE COOLANT ................8- 3 RADIATOR AND HOSES ..............8- 4 COOLING CIRCUIT INSPECTION ..........8- 4 RADIATOR CAP INSPECTION ...........8- 4 RADIATOR INSPECTION ............8- 4 RADIATOR HOSE INSPECTION ..........8- 5 RADIATOR REMOVAL ..............8- 6...
Page 245: Cooling System
COOLING AND LUBRICATION SYSTEM COOLING SYSTEM DESCRIPTION The engine is cooled by the forced circulation of engine coolant, using a high-capacity, centrifugal water pump, through water jackets formed in the cylinder and cylinder head, and through the radiator. The tube- and-fin type radiator is made of aluminum, which is characterized by lightness in weight and good heat dissi- pation.
Page 246: Engine Coolant
COOLING AND LUBRICATION SYSTEM ENGINE COOLANT At the time of manufacture, the cooling system is filled with a 50:50 mixture of distilled water and ethylene glycol anti-freeze. Anti-freeze Freezing point This 50:50 mixture will provide the optimum corrosion protection density and excellent heat protection, and will protect the cooling system –31˚C (–24˚F) from freezing at temperatures above –31°C (–24°F).
Page 247: Radiator And Hoses
COOLING AND LUBRICATION SYSTEM RADIATOR AND HOSES COOLING CIRCUIT INSPECTION Before removing the radiator and draining the engine coolant, check the following. Check the cooling system for leaks with a radiator tester 1. Remove the radiator cap and connect the radiator tester to the filler.
Page 248: Radiator Hose Inspection
COOLING AND LUBRICATION SYSTEM RADIATOR HOSE INSPECTION • Remove the leg shield and footboard. ( 9-10, 9-18) Any radiator hose found in a cracked condition or flattened must be replaced. Any leakage from the connecting section should be corrected by proper tightening.
Page 249: Radiator Removal
COOLING AND LUBRICATION SYSTEM RADIATOR REMOVAL • Remove the leg shield and footboard. ( 9-10, 9-18) • Drain engine coolant by removing the drain plug. • Disconnect the fan motor lead wire coupler 1. • Disconnect the upper and lower radiator hoses. •...
Page 250: Radiator Remounting
COOLING AND LUBRICATION SYSTEM • Remove the four fixing places and the heat shield. RADIATOR REMOUNTING Install the radiator and the radiator hoses in the reverse order of removal. Pay attention to the following points: • Connect the fan motor lead wire coupler. •...
Page 251: Cooling Fan
COOLING AND LUBRICATION SYSTEM COOLING FAN INSPECTION • Remove the leg side cover and footboard. ( 9-12, 9-18) • Disconnect the cooling fan motor lead wire coupler 1 and fan switch coupler 2. Test the cooling fan motor for load current with an ammeter con- nected as shown in the illustration.
Page 252: Remounting
COOLING AND LUBRICATION SYSTEM • Remove the cooling fan. REMOUNTING Remount the cooling fan in the reverse order of removal. Pay attention to the following point: • Tighten the cooling fan mounting bolts to the specified torque. Cooling fan mounting bolt: 6.5 N·m (0.65 kgf-m, 4.7 lb-ft)
Page 253: Main Fuse
8-10 COOLING AND LUBRICATION SYSTEM COOLING FAN THERMO-SWITCH The cooling fan is secured behind the radiator by three bolts and is automatically controlled by the thermo- switch. The thermo-switch remains open when the temperature of the engine coolant is low, but closes when the temperature reaches approximately 98°C (208°F) setting the cooling fan in motion.
Page 254: Inspection
COOLING AND LUBRICATION SYSTEM 8-11 INSPECTION • Check the thermo-switch closing or opening temperatures by testing it at the bench as shown in the figure. Connect the thermo-switch 1 to a circuit tester and place it in the oil con- tained in a pan, which is placed on a stove.
Page 255: Engine Coolant Temperature Sensor
8-12 COOLING AND LUBRICATION SYSTEM ENGINE COOLANT TEMPERATURE SENSOR The following circuit diagram shows the electrical wiring for the thermometer. The major components are temperature sensor in contact with coolant; and temperature indicator (engine coolant temperature meter). Water temp warning Speedometer Ignition B/Br...
Page 256: Inspection
COOLING AND LUBRICATION SYSTEM 8-13 INSPECTION • Check the engine coolant temperature by testing it at the bench as shown in the figure. Connect the temperature sen- Ω sor 1 to a circuit tester and place it in the oil contained in a pan, which is placed on a stove.
Page 257: Thermostat
8-14 COOLING AND LUBRICATION SYSTEM THERMOSTAT REMOVAL • Remove the leg shield and footboard. ( 9-10, 9-18) • Drain a small amount of engine coolant. ( 2-20) • Place a rag under the thermostat case. • Remove the thermostat case. •...
Page 258: Installation
COOLING AND LUBRICATION SYSTEM 8-15 • Keep on heating the water to raise its temperature. • Just when the water temperature reaches specified value, the Valve lift thermostat valve should have lifted by at least 8.0 mm (0.31 in). Thermostat valve lift Standard: Over 8.0 mm at 100°C (Over 0.31 in at 212°F) •...
Page 259: Water Pump
8-16 COOLING AND LUBRICATION SYSTEM WATER PUMP CONSTRUCTION Water pump cover O-ring " Impeller Mechanical seal Oil seal O-ring & Inner bearing Outer bearing E-ring Circlip O-ring Oil pump drive chain Inner bearing Outer bearing Oil pump Impeller Impeller shaft Shaft Oil pump driven sprocket Mechanical seal...
Page 260: Removal And Disassembly
COOLING AND LUBRICATION SYSTEM 8-17 REMOVAL AND DISASSEMBLY • Remove the leg shield and footboard. ( 9-10, 9-18) • Drain engine coolant. ( 2-20) • Hold the chassis by side stand. * Do not open the radiator cap when the engine is hot, as you may be injured by escaping hot liquid or vapor.
Page 261 8-18 COOLING AND LUBRICATION SYSTEM • Remove the E-ring 1 and impeller 2. • Remove the mechanical seal using the special tool. 09921-20240: Bearing remover set NOTE: If there is no abnormal condition, the mechanical seal removal is not necessary. The removed mechanical seal must be replaced with a new one.
Page 262: Inspection
COOLING AND LUBRICATION SYSTEM 8-19 • Place a rag over the water pump body. • Remove the oil seal using a suitable bar. NOTE: If there is no abnormal condition, the oil seal removal is not nec- essary. The removed oil seal must be replaced with a new one. •...
Page 263 8-20 COOLING AND LUBRICATION SYSTEM OIL SEAL • Visually inspect the oil seal for damage, with particular atten- tion given to the lip. • Replace the oil seal that shows indications of leakage. BEARING CASE/MECHANICAL CASE • Visually inspect the bearing case and mechanical case for damage.
Page 264: 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 265 Make sure the mechanical seal ring is fit into the impeller. • 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 266 8-23 • Install the new O-rings 1 and 2. • Apply grease to the O-rings. 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) • Install the water pump body 1 with impeller 2 to the crank- case.
Page 267 8-24 COOLING AND LUBRICATION SYSTEM • Connect the radiator hose. • Pour engine coolant. ( 2-21) • Bleed air from the cooling circuit. ( 2-21) • Install the leg shield and footboard.
Page 268: Lubrication System
COOLING AND LUBRICATION SYSTEM 8-25 LUBRICATION SYSTEM OIL PRESSURE 2-31 OIL FILTER 2-14 OIL COOLER 3-17, 3-63 OIL PRESSURE REGULATOR 3-44 OIL SUMP FILTER 3-44 OIL LEVEL SWITCH 10-29 OIL PRESSURE SWITCH 10-36 OIL PUMP 3-20, 3-60 OIL RETURN PUMP 3-21, 3-59...
Page 269: Engine Lubrication System Chart
8-26 COOLING AND LUBRICATION SYSTEM ENGINE LUBRICATION SYSTEM CHART...
Page 270: Engine Lubrication System
COOLING AND LUBRICATION SYSTEM 8-27 ENGINE LUBRICATION SYSTEM EXHAUST SIDE INTAKE SIDE To oil pump OIL SUMP FILTER LUBRICATION OIL RETURNED OIL MAIN GALLERY...
Page 271 8-28 COOLING AND LUBRICATION SYSTEM OIL FILTER OIL COOLER To A From A OIL PRESSURE REGULATOR OIL SUMP FILTER OIL PUMP OIL RETURN PUMP ORIFICE JET OIL SUMP FILTER DRIVESHAFT BEARING LUBRICATION OIL RETURNED OIL...
Page 272 CHASSIS CONTENTS EXTERIOR PARTS ................9- 2 CONSTRUCTION ................ 9- 2 REMOVAL ................... 9- 6 REMOUNTING ................9-23 FRONT WHEEL ................... 9-25 CONSTRUCTION ................ 9-25 REMOVAL ................... 9-26 INSPECTION AND DISASSEMBLY ........... 9-27 REASSEMBLY AND REMOUNTING .......... 9-29 FRONT FORK ..................9-32 CONSTRUCTION ................
Page 273 CHASSIS REAR SWINGARM ................9-59 CONSTRUCTION ................ 9-59 REMOVAL ................... 9-59 INSPECTION ................9-60 REMOUNTING ................9-61 FRONT BRAKE ................... 9-63 CONSTRUCTION ................ 9-63 BRAKE PAD REPLACEMENT ........... 9-64 BRAKE FLUID REPLACEMENT ..........9-65 CALIPER REMOVAL AND DISASSEMBLY ......9-66 CALIPER INSPECTION ..............
Page 274: Exterior Parts
CHASSIS EXTERIOR PARTS CONSTRUCTION Front meter panel Leg shield brace " Meter cover Front panel Leg shield Lower leg shield & Floor mat Front box...
Page 275 CHASSIS For E-28 Maintenance lid Foot board " Frame cover Leg side cover Center frame cover Lower frame cover & Rear fender Floor mat Tray Packing...
Page 276 CHASSIS Outside Weather strip Frame Upper trunk box : Max 1mm (0.04 in) Both ends of weather strip should be butted at the front of the trunk box. Lower trunk box Battery cover Trunk box cover Fuel tank Frame cover Foot board Frame...
Page 277 CHASSIS FRONT BOX Front box " Cushion Cushion Front inner box Cushion FOOT BOARD ASSEMBLY Foot board Louver Duct...
Page 278: Removal
CHASSIS REMOVAL LOCATION OF EXTERIOR COMPONENTS Wind screen ( 9-7) Seat ( 9-13) Trunk box ( 9-20) Handlebar cover ( 9-8) Seat damper ( 9-14) Lower frame cover ( 9-15) Front panel ( 9-8) Pillion rider handle (right and left) Center frame cover ( 9-15) Rear view mirror (right and left)
Page 279 CHASSIS WIND SCREEN • Remove the screws. • Remove the wind screen cover 1. ✩: hooked part • Remove the wind screen. • Remove the wind screen brace 2.
Page 280 CHASSIS HANDLEBAR COVER • Remove the handlebar rear cover 1. • Remove the handlebar front cover 2. FRONT PANEL • Remove the handlebar cover. ( above) • Remove the screws. • Remove the front panel.
Page 281 CHASSIS REAR VIEW MIRROR • Remove the handlebar covers. ( 9-8) • Remove the front panel. ( 9-8) • Remove the bolts. • Disconnect the turn signal coupler which is located under the combination meter. • Remove the screws. • Insert the screw driver into the hole A. •...
Page 282 9-10 CHASSIS LOWER LEG SHIELD • Disconnect the fasteners 1 by pulling the tab of fastener. • Remove the screws. • Remove the lower leg shield 2. LEG SHIELD • Remove the handlebar covers. ( 9-8) • Remove the front panel. ( 9-8) •...
Page 283 CHASSIS 9-11 • Remove the front leg shield cover 1. ✩: hooked part • Remove the screws. • Disconnect the headlight couplers, ECM couplers and posi- tion light couplers (only E02, E19). • Remove the leg shield.
Page 284 9-12 CHASSIS RIGHT LEG SIDE COVER • Remove the floor mats. • Remove the screws and fasteners. • Remove the right leg side cover by detaching the insertings. Foot board Leg side cover LEFT LEG SIDE COVER • Remove the floor mats. •...
Page 285 CHASSIS 9-13 MAINTENANCE LID • Remove the screw. • Detach the inserting A of maintenance lid. • Remove the maintenance lid. NOTE: Cover the hatched areas in order to prevent the front box from getting damage. Foot board Maintenance lid SEAT •...
Page 286 9-14 CHASSIS SEAT DAMPER • Remove the right frame cover. ( 9-16) • Remove the clip 1, washer 2 and mounting bolt 3. • Remove the seat damper 4. Upward Seat Right Frame...
Page 287 CHASSIS 9-15 PILLION RIDER HANDLE • Lift the seat up. • Remove the lower frame cover 1 by removing the fasteners. • Remove the center frame cover 2. • Remove the pillion rider handles 3.
Page 288 9-16 CHASSIS TRUNK BOX COVER • Remove the battery cover 1. • Remove the starter relay 2 and coupler 3 from the battery cover. • Remove the battery. ( 10-3) • Remove the trunk box cover 4. FRAME COVER • Remove the lower frame cover, center frame cover and pillion rider handles 1.
Page 289 CHASSIS 9-17 • Remove the fuel tank cap. • Remove the fuel inlet mounting screws. NOTE: When removing the screws, close the fuel cap in order to pre- vent the screws and washers from falling in the fuel inlet. For E-28 •...
Page 290 9-18 CHASSIS FOOT BOARD • Remove the following parts. Pillion rider handles ( 9-15) Trunk box cover ( 9-16) Frame covers ( 9-16) Right/left leg side covers ( 9-12) Front box ( 9-18) • Remove the screws on the cooling duct. •...
Page 291 CHASSIS 9-19 • Pull the brake-lock knob. • Remove the brake-lock knob 1. • Remove the inner box 2. • Remove the ignition switch 3 by using the special tools. 09930-11930: Torx bit JT30H 09930-11940: Bit holder • Remove the screws. •...
Page 292 9-20 CHASSIS REAR FENDER • Remove the lower frame cover 1. • Remove the fasteners and bolts. • Remove the rear fender 2. • Disconnect the license light coupler. TRUNK BOX • Remove the following parts. Seat ( 9-13) Pillion rider handles ( 9-15) Right/left frame covers ( 9-16)
Page 293 CHASSIS 9-21 • Remove the seat lock 3. • Remove the trunk box screws. • Remove the muffler bracket 4. • Remove the seat rail 5. • Remove the trunk box 6.
Page 294 9-22 CHASSIS LEG SHIELD BRACE • Remove the wind screen and wind screen brace. ( 9-7) • Remove the leg shield. ( 9-10) • Remove the front meter panel 1 and the combination meter assembly. • Remove the electrical parts from the leg shield brace. •...
Page 295: Remounting
CHASSIS 9-23 REMOUNTING Remounting the exterior parts in the reverse order of removal. Pay attention to the following points: SEAT RAIL • Apply THREAD LOCK SUPER “1360” to the seat rail mount- ing bolts (only M10). 99000-32130: THREAD LOCK SUPER “1360” •...
Page 296 9-24 CHASSIS HANDLEBAR COVER After installing the handlebar covers, inspect clearance between the handlebar cover 1 and the front panel 2/meter panel 3. If Handlebars the clearance is less than 5 mm (0.2 in), adjust the handlebar position by rotating the handlebar so that the clearance would Clearance Clearance be more than 5 mm (0.2 in) all around the handlebar cover.
Page 297: Front Wheel
CHASSIS 9-25 FRONT WHEEL CONSTRUCTION Brake disc Coller " Dust seal Bearing Front tire Front wheel & Spacer Tire valve Disc bolt Front axle ITEM N·m kgf-m lb-ft 16.5 47.0...
Page 298: Removal
9-26 CHASSIS REMOVAL • Remove the right and left brake hose clamp bolts. • Remove the right and left brake calipers. NOTE: * Cover the front fender, especially hatched area A, from dam- age. * Do not operate the brake lever while removing the caliper. •...
Page 299: Inspection And Disassembly
CHASSIS 9-27 INSPECTION AND DISASSEMBLY • Remove the discs. DUST SEAL Inspect the dust seal’s lip for wear or damage. If any damages are found, replace the dust seals with new ones. • Remove the dust seals by using the special tool. 09913-50121: Oil seal remover Do not reuse the removed dust seals.
Page 300 9-28 CHASSIS WHEEL BEARING Inspect the play of the wheel bearings by finger while they are in the wheel. Rotate the inner race by finger to inspect for abnor- mal noise and smooth rotation. Replace the bearing in the following procedure if there is any- thing unusual.
Page 301: Reassembly And Remounting
CHASSIS 9-29 REASSEMBLY AND REMOUNTING Reassemble and remount the front wheel in the reverse order of removal and disassembly. Pay attention to the following points: Left Right 65 N . m 6.5 kgf-m 47.0 lb-ft 23 N . m 23 N . m 2.3 kgf-m 2.3 kgf-m 16.5 lb-ft...
Page 302 CHASSIS WHEEL BEARING • Apply grease to the wheel bearings. 99000-25010: SUZUKI SUPER GREASE “A” • First install the right wheel bearing, then install the left wheel bearing and spacer by using the special tools. 09941-34513: Bearing/Steering race installer set 09913-70210: Bearing installer set The sealed cover of the bearing must face outside.
Page 303 CHASSIS 9-31 DUST SEAL • Apply SUZUKI SUPER GREASE “A” to the dust seals. 99000-25010: SUZUKI SUPER GREASE “A” • Install the dust seals to the wheel. NOTE: Inside The spring A of dust seal must face to the bearing.
Page 304: Front Fork
9-32 CHASSIS FRONT FORK CONSTRUCTION O-ring Spacer " Washer Spring Piston ring Fork cap bolt Cylinder Axle pinch bolt & Rebound spring Cylinder bolt Inner tube Dust seal Stopper ring Oil seal Retainer Guide metal Slide metal Oil lock piece Fork cover Outer tube Gasket...
Page 305: Removal And Disassembly
CHASSIS 9-33 REMOVAL AND DISASSEMBLY • Remove the handlebar cover. ( 9-8) • Remove the front panel. ( 9-8) • Remove the front wheel. ( 9-26) • Remove the front fender. • Loosen the front fork upper clamp bolt 1. NOTE: Slightly loosen the front fork cap bolt 2 before loosening the lower clamp bolts to facilitate later disassembly.
Page 306 9-34 CHASSIS • Remove the spacer 4, washer 5 and spring 6. • Invert the fork and drain the fork oil out of the fork by stroking. • Hold the fork inverted for a few minutes to drain oil. • Remove the cylinder bolt 7. NOTE: If the cylinder turns together with the cylinder bolt, temporarily install the fork spring, spacer, washer and cap bolt to prevent the...
Page 307: Inspection
CHASSIS 9-35 • Pull the inner tube out of the outer tube. NOTE: Be careful not to damage the inner tube. The slide metal, guide metal, oil seal and dust seal must be replaced with the new ones when reassem- bling the front fork.
Page 308: Reassembly And Remounting
9-36 CHASSIS CYLINDER Inspect the cylinder and piston ring 1 for damage. If any defects are found, replace them with new ones. REASSEMBLY AND REMOUNTING Reassemble and remount the front fork in the reverse order of removal and disassembly. Pay attention to the following points: METALS AND SEALS •...
Page 309 CHASSIS 9-37 • Install the oil lock piece into the inner tube. • Install the inner tube into the outer tube with care not to drop the oil lock piece out. NOTE: After installing the inner tube into the outer tube, keep the oil lock piece into the inner tube by compressing the front fork fully.
Page 310 • Place the front fork vertically without spring. • Compress the front fork fully. • Pour the specified front fork oil into the front fork. 99000-99044-10G: SUZUKI FORK OIL #10 Front fork oil capacity (each leg): 482 ml (16.29/16.97 US/Imp oz) •...
Page 311 CHASSIS 9-39 FORK SPRING • Install the fork spring into the front fork. • Install the washer 1 and the spacer 2. NOTE: The smaller spring pitch end must face upward. FRONT FORK CAP BOLT • Apply fork oil lightly to the O-ring. Use a new O-ring to prevent oil leakage.
Page 312: Steering And Handlebars
9-40 CHASSIS STEERING AND HANDLEBARS CONSTRUCTION Handlebar clamp Steering stem upper bracket " Dust seal Upper bearing Lower bearing Steering stem lower bracket Dust seal Handlebar clamp bolt Upper clamp bolt Lower clamp bolt Steering stem head nut ITEM N·m kgf-m lb-ft 16.5...
Page 313: Removal
CHASSIS 9-41 REMOVAL HANDLEBARS • Remove the handlebar covers. ( 9-8) • Remove the right switch box 1. • Disconnect the brake switch coupler. • Remove the front brake master cylinder 2. • Remove the left switch box 3. • Disconnect the brake switch coupler. •...
Page 314 9-42 CHASSIS • Remove the brake hose clamp 3. • Remove the front brake assembly. Take care not to make air come in the front brake sys- tem. • Remove the steering stem upper bracket. • Remove the steering stem nut with the special tool. 09940-14911: Steering socket wrench •...
Page 315: Inspection And Disassembly
CHASSIS 9-43 INSPECTION AND DISASSEMBLY Inspect the removed parts for the following abnormalities. * Handlebars distriction * Race wear and brinelling * Bearing wear or damage * Abnormal bearing noise * Distortion of the steering stem If any abnormal points are found, replace defective parts with the new ones.
Page 316 • Apply grease to the bearings, dust cover and dust seal. • Install the upper bearing and the dust cover onto the frame. 99000-25010: SUZUKI SUPER GREASE “A” STEERING STEM • Tighten the steering stem nut to the specified torque with the special tools.
Page 317 CHASSIS 9-45 • Tighten the handlebar clamp bolt to the specified torque. Handlebar clamp bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft) NOTE: When tightening the handlebar clamp bolts, first tighten the bolts 1 and then tighten the bolts 2. • Install the left switch box 3 to the handlebars by engaging the stopper D with the hole E on the handlebars.
Page 318: Steering Tension Adjustment
9-46 CHASSIS STEERING TENSION ADJUSTMENT Check the steering movement in the following procedure. • By supporting the motorcycle with a jack, lift the front wheel until it is off the floor by 20 – 30 mm (0.8 – 1.2 in). •...
Page 319: Rear Wheel
CHASSIS 9-47 REAR WHEEL CONSTRUCTION Washer Spacer " Collar Dust seal Bearing Brake disc & Rear tire Spacer Hub damper Washer Lock washer O-ring Rear hub driven joint Spacer Rear axle Rear wheel Disc bolt Rear axle nut ITEM N·m kgf-m lb-ft 16.5...
Page 320: Removal
9-48 CHASSIS REMOVAL • Place the motorcycle on the center stand. • Remove the final gear case cover 1. • Disconnect the brake-lock cable 2. ( 9-85) • Remove the cotter pin. (For E-03, 28, 33) • Loosen the rear axle nut. •...
Page 321 CHASSIS 9-49 • Flatten the lock washers 5. • Remove the bolts and washers 6. • Remove the rear hub driven joint 7. • Remove the O-ring 8. Replace the removed O-ring with a new one. • Remove the brake disc.
Page 322: Inspection And Disassembly
9-50 CHASSIS INSPECTION AND DISASSEMBLY TIRE: ( 9-91) WHEEL: ( 9-27 and 9-91) REAR AXLE Using a dial gauge, check the rear axle for runout. If the runout exceeds the limit, replace the rear axle. Axle shaft runout: Service Limit: 0.25 mm (0.010 in) 09900-20607: Dial gauge (1/100 mm) 09900-20701: Magnetic stand 09900-21304: V-block set (100 mm)
Page 323 CHASSIS 9-51 DUST SEAL Inspect the wheel dust seal lip for wear or damage. If any dam- ages are found, replace the dust seal with a new one. • Remove the dust seal with the special tool. 09913-50121: Oil seal remover Do not reuse the removed dust seal.
Page 324: Reassembly And Remounting
9-52 CHASSIS REASSEMBLY AND REMOUNTING Reassemble and remount the rear wheel in the reverse order of removal and disassembly. Pay attention to the following points: Left Right 100 N . m 10.0 kgf-m 72.5 lb-ft For E-03, 28, 33 23 N . m 2.3 kgf-m 16.5 lb-ft...
Page 325 CHASSIS 9-53 BEARING • Apply grease to the bearings before installing. 99000-25010: SUZUKI SUPER GREASE “A” • First install the right wheel bearing, then install the left wheel bearing and spacer using the special tool. 09941-34513: Bearing/Steering race installer set The sealed cover of the bearing must face outside.
Page 326 CHASSIS DUST SEAL • Install the new dust seal using the special tool. 09913-70210: Bearing installer set • Apply SUZUKI SUPER GREASE “A” to the dust seal lips before assembling rear wheel. 99000-25010: SUZUKI SUPER GREASE “A” NOTE: When installing the dust seals, the stamped mark of dust seal must face the special tool.
Page 327 CHASSIS 9-55 • Install the rear hub driven gear joint. • Install the washers 1, lock washers 2. • Apply THREAD LOCK SUPER “1303” to the bolts and tighten them. 99000-32030: THREAD LOCK SUPER “1303” • Bend the lock washers securely. •...
Page 328 9-56 CHASSIS REAR AXLE • Install the left spacer 1 into the final gear case 2. • Remount the rear wheel, coller, spacer and rear axle. • Install the washer and rear axle nut. • Tighten the rear axle nut 3 to the specified torque. Rear axle nut: 100 N·m (10.0 kgf-m, 72.5 lb-ft) •...
Page 329: Rear Shock Absorber
CHASSIS 9-57 REAR SHOCK ABSORBER CONSTRUCTION Left Right Rear shock absorber Frame " Swingarm Final gear case Washer Rear shock absorber nut Rear shock absorber bolt kgf - m ITEM N·m lb-ft 21.0 21.0 REMOVAL • Place the motorcycle on the center stand. •...
Page 330: Inspection
9-58 CHASSIS INSPECTION Inspect the shock absorber body and bushing for damage and oil leakage. If any defects are found, replace the shock absorber with a new one. Do not attempt to disassemble the rear shock absorber unit. It is unserviceable. REMOUNTING •...
Page 331: Rear Swingarm
CHASSIS 9-59 REAR SWINGARM CONSTRUCTION Rear shock absorber Swingarm " Bushing Bearing Dowel pin Rear shock absorber mounting nut Rear shock absorber mounting bolt Pivot bolt Locknut ITEM N·m kgf-m lb-ft 21.0 21.0 0.95 10.0 72.5 REMOVAL • Place the motorcycle on the center stand. •...
Page 332: Inspection
9-60 CHASSIS • Remove the swingarm bolts. • Remove the swingarm 4. • Remove the swingarm pivot bearing. • Remove the swingarm pivot locknut 5, washer and the swin- garm pivot bolt 6. INSPECTION SWINGARM BEARING Insert the bearing and check smoothness of rotation. If there is anything unusual, replace the bearing with a new one.
Page 333: Remounting
REMOUNTING Remount the swingarm in the reverse order of disassembly and removal, and pay attention to the following points: • Apply SUZUKI SUPER GREASE “A” to the bearing, and then install the bearing. 99000-25010: SUZUKI SUPER GREASE “A” • Install the dowel pins 1.
Page 334 9-62 CHASSIS • Tighten the swingarm pivot bolt to the specified torque. Swingarm pivot bolt: 9.5 N·m (0.95 kgf-m, 7.0 lb-ft) • Tighten the swingarm pivot locknut 2 to the specified torque. Swingarm pivot locknut: 100 N·m (10.0 kgf-m, 72.5 lb-ft) •...
Page 335: Front Brake
CHASSIS 9-63 FRONT BRAKE CONSTRUCTION Diaphragm Dust boot " Piston/cup set Brake hose Boot Caliper & Brake pad spring Brake pad Piston seal Dust seal Piston Caliper holder Insulator Shim Front brake master cylinder mounting bolt Brake hose union bolt Air bleeder valve Brake caliper mounting bolt Pad mounting pin...
Page 336: Brake Pad Replacement
9-64 CHASSIS BRAKE PAD REPLACEMENT • Remove the plug 1. • Remove the pad mounting pin 2. • Remove the pads 3. • Inspect the pad mounting pin for wear. If excessive wear is found, replace the mounting pin with a new one. •...
Page 337: Brake Fluid Replacement
CHASSIS 9-65 • Tighten the pad mounting pin 7 to the specified torque. Front brake pad mounting pin: 18 N·m (1.8 kgf-m, 13.0 lb-ft) • Install the brake hose clamp bolt. • Install the plug 8 and tighten it to the specified torque. Pad pin plug: 2.5 N·m (0.25 kgf-m, 1.8 lb-ft) NOTE: After replacing the brake pads, pump the brake lever several...
Page 338: Caliper Removal And Disassembly
9-66 CHASSIS • Connect a clear hose to the caliper air bleeder valve and insert the other end of hose into a receptacle. • Loosen the air bleeder valve and pump the brake lever until old brake fluid flows out of the bleeder system. •...
Page 339: Caliper Inspection
CHASSIS 9-67 • Place a rag over the pistons to prevent them from popping out and then force out the pistons using compressed air. Do not use high pressure air to prevent piston dam- age. • Remove the dust seals and piston seals. Do not reuse the removed dust seals and piston seals to prevent fluid leakage.
Page 340: Caliper Reassembly And Remounting
9-68 CHASSIS RUBBER PARTS Inspect the rubber parts for damage. If any damage is found, replace them with the new ones. CALIPER REASSEMBLY AND REMOUNTING Reassemble the caliper in the reverse order of removal and dis- assembly. Pay attention to the following points: •...
Page 341 • Tighten the pin 2 to the caliper holder 1 to the specified torque. Caliper holder pin: 13 N·m (1.3 kgf-m, 9.5 lb-ft) • Apply SUZUKI SILICONE GREASE to the brake caliper holder pin 2. 99000-25100: SUZUKI SILICONE GREASE • Be sure to check that the boot is fitted on the slide pin.
Page 342: Brake Disc Inspection
9-70 CHASSIS BRAKE DISC INSPECTION Visually check the brake disc for damage or cracks. Measure the thickness with a micrometer. Replace the disc if the thickness is less than the service limit or if damage is found. Front disc thickness Service Limit: 4.0 mm (0.16 in) 09900-20205: Micrometer (0 –...
Page 343: Master Cylinder Inspection
CHASSIS 9-71 • Pull out the dust boot 4 and remove the snap ring 5. • Remove the piston and return spring. 6 Piston 7 Secondary cup 8 Primary cup 9 Return spring MASTER CYLINDER INSPECTION Inspect the master cylinder bore for any scratches or other dam- age.
Page 344 9-72 CHASSIS • Apply brake fluid to the piston and cups. • Install the following parts to the master cylinder. 1 Dust boot 2 Snap ring 3 Secondary cup 4 Piston 5 Primary cup 6 Return spring • When remounting the brake master cylinder onto the handle- bars, align the master cylinder holder’s mating surface A with punch mark B on the handlebars and tighten the upper bolt 7 first.
Page 345: Rear Brake
CHASSIS 9-73 REAR BRAKE CONSTRUCTION Diaphragm Master cylinder bolt Piston/cup set Brake hose union bolt " Master cylinder Brake pipe nut Brake hose No. 1 Caliper holder sliding pin Brake pipe Caliper holder sliding pin Brake hose No. 2 Air bleeder valve &...
Page 346: Brake Pad Replacement
9-74 CHASSIS BRAKE PAD REPLACEMENT • Remove the brake-lock arm 1 and spring 2. • Disconnect the brake-lock cable 3. ( 9-85) • Remove the caliper. Do not operate the brake lever while dismounting the pads. • Remove the pad mounting pins 4, and then remove the brake pads.
Page 347 CHASSIS 9-75 • Turn the piston 8 clockwise until it stops. • Align the groove with line A by turning the piston out. • Install the pad with the projection B fitted in the groove on the piston. • Install the pad to the caliper with the pad seated at the hatched area C of pad spring.
Page 348: Brake Fluid Replacement
9-76 CHASSIS BRAKE FLUID REPLACEMENT • Place the motorcycle on a level surface and keep the handle- bars straight. • Remove the brake fluid reservoir cap and diaphragm. • Suck up the old brake fluid as much as possible. • Fill the reservoir with the new brake fluid. Specification and Classification: DOT 4 •...
Page 349 CHASSIS 9-77 • Remove the pad spring 1 and caliper holder 2. • Remove the parking brake housing 3. • Disassemble the parking brake. Replace the removed O-ring with a new one. • Turn the piston counterclockwise fully. • Place a rag over the piston to prevent it from popping out and then force out the piston using compressed air.
Page 350: Caliper Inspection
9-78 CHASSIS • Remove the dust seals 4 and piston seals 5. Do not reuse the dust seal and piston seal to prevent fluid leakage. CALIPER INSPECTION BRAKE CALIPER Inspect the brake caliper cylinder walls for nicks, scratches and other damage. If any damage is found, replace the caliper with a new one.
Page 351: Caliper Reassembly And Remounting
CHASSIS 9-79 CALIPER HOLDER Inspect the brake holder sliding pins for wear and other damage. If any damage is found, replace the sliding pin with a new one. BOOT Inspect the boots for damage and wear. If any damage is found, replace boots with new ones.
Page 352 Caliper sliding pin 1: 23 N·m (2.3 kgf-m, 16.5 lb-ft) Caliper sliding pin 2: 13 N·m (1.3 kgf-m, 9.5 lb-ft) • Apply SUZUKI SILICONE GREASE to the sliding pin. 99000-25100: SUZUKI SILICONE GREASE • Install the caliper holder to the caliper.
Page 353 Check the brake hose and hose joints for cracks and fluid leakage. BRAKE-LOCK • Apply SUZUKI SILICONE GREASE to the brake-lock bolt end 99000-25100: SUZUKI SILICONE GREASE • Install the new gasket and the brake-lock housing to the cali- per.
Page 354 9-82 CHASSIS • Apply SUZUKI SILICONE GREASE to the brake-lock shaft. 99000-25100: SUZUKI SILICONE GREASE • Install the brake-lock shaft so that the punch mark B can be positioned in C when the brake-lock shaft is turned clockwise until it stops.
Page 355: Brake Disc Inspection
CHASSIS 9-83 BRAKE DISC INSPECTION Inspect the rear brake disc in the same manner as the front brake disc. ( 9-70) Service Limit Rear disc thickness: 5.0 mm (0.20 in) Rear disc runout: 0.30 mm (0.012 in) * Brake disc removal ( 9-49) * Brake disc installation ( 9-54)
Page 356: Brake-Lock Adjustment
9-84 CHASSIS When remounting the brake master cylinder onto the handle- bars, align the master cylinder holder’s mating surface A with the punch mark B on the handlebars and tighten the upper bolt 7 first. Master cylinder mounting bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft) •...
Page 357: Brake-Lock Cable Replacement
CHASSIS 9-85 • Turn the adjuster bolt 2 clockwise until it stops. • Tighten the locknut 1 to the specified torque with the adjust bolt 2 held in that position. Brake-lock adjust locknut: 9.5 N·m (0.95 kgf-m, 7.0 lb-ft) NOTE: Do not turn the adjust bolt more than the given position, or the adjust bolt may be damaged.
Page 358 9-86 CHASSIS • Install the brake-lock cable. (CABLE ROUTING: 11-18) • Turn the nut 7 until the clearance is 0 mm (0 in). Clearance • Connect the brake-lock cable to the brake-lock lever assem- bly. • Fit the nut 8 into the concavity on the brake-lock lever assembly.
Page 359: Brake-Lock System
CHASSIS 9-87 BRAKE-LOCK SYSTEM BRAKE-LOCK OPERATION The brake-lock arm turns through the brake-lock cable as soon as pulling the brake-lock lever. The turning movement is converted to axial movement by the brake-lock adjuster connected to the body with the thread A. The axial movement transmits automatically from sleeve piston to adjust-bolt.
Page 360 9-88 CHASSIS AUTOMATIC BRAKE-LOCK ADJUSTER SYSTEM The automatic brake-lock adjuster system is equipped on the brake-lock. If the brake pad worn, the adjust- bolt/nut adjust the position of caliper piston so as to keep the certain clearance between brake pad and brake disk.
Page 361 CHASSIS 9-89 OPERATION (Brake pads are worn➔ ➔ ➔ ➔ Braking➔ ➔ ➔ ➔ Automatic adjuster operate) If braking when the brake pad being worn, the caliper piston/adjust-nut move [ 1] untill the clearance depended on abrasion is done away. The axial movement [ 2] is converted to rotary movement and acts on the adjust-bolt and adjust-nut.
Page 362 9-90 CHASSIS OVER-ADJUST PREVENTION MECHANISM When rapid braking [ 1], the automatic brake-lock adjuster operation works too fast [ 2]. The caliper piston/adjust-nut is forced to stop [ 3] as soon as the brake pad contacts with brake disk, but the adjust-bolt turns by inertia force [ 4] after that.
Page 363: Tire And Wheel
CHASSIS 9-91 TIRE AND WHEEL TIRE REMOVAL The most critical factor of a tubeless tire is the seal between the wheel rim and the tire bead. For this reason, it is recommended to use a tire changer that can satisfy this sealing requirement and can make the operation efficient as well as functional.
Page 364: Valve Installation
9-92 CHASSIS VALVE • Inspect the valve after the tire is removed from the rim. Replace the valve with a new one if the seal rubber is peeling or has damage. • Inspect the valve core. If the seal has abnormal deformation, replace the valve with a new one.
Page 365: Balancer Weight Installation
CHASSIS 9-93 • When installing the tire, the arrow 1 on the side wall should point to the direction of wheel rotation. • Align the chalk mark put on the tire at the time of removal with the valve position. •...
Page 366 ELECTRICAL SYSTEM 10-1 ELECTRICAL SYSTEM CONTENTS CAUTIONS IN SERVICING ................. 10- 2 CONNECTORS ..................10- 2 COUPLERS ..................10- 2 CLAMPS ....................10- 2 FUSES ....................10- 2 SEMI-CONDUCTOR EQUIPPED PARTS ........... 10- 2 BATTERY .................... 10- 3 CONNECTING THE BATTERY ............10- 3 WIRING PROCEDURE ................
Page 367: Cautions In Servicing
10-2 ELECTRICAL SYSTEM CAUTIONS IN SERVICING CONNECTORS • When disconnecting a connector, be sure to hold the termi- nals; do not pull the lead wires. • When connecting a connector, push it in so it is firmly attached. • Inspect the connector for corrosion, contamination and any breakage in the cover.
Page 368: Battery
ELECTRICAL SYSTEM 10-3 BATTERY • The MF battery used in this motorcycle does not require main- tenance (e.g., electrolyte level inspection, distilled water replenishment). • During normal charging, no hydrogen gas is produced. How- ever, if the battery is overcharged, hydrogen gas may be pro- duced.
Page 369: Location Of Electrical Components
10-4 ELECTRICAL SYSTEM LOCATION OF ELECTRICAL COMPONENTS Starter motor Atmospheric pressure sensor ( 6-37) Engine coolant temp. sensor ( 8-13) TO sensor ( 6-39) CVT control unit IAC valve ( 7-20) ECM (Engine Control Module) Injector ( 6-40) Solenoid ( 12-6) Throttle position sensor ( 6-31)
Page 370 ELECTRICAL SYSTEM 10-5 Fuel pump/fuel gauge Speedometer sensor Starter relay diode Ignition coil/plug cap (#1) Main fuse Ignition coil/plug cap (#2) Generator CTV fuse Oil pressure switch Battery Side-stand switch Trunk light seat switch Cam position sensor ( 6-27) Starter relay Fan motor ( 8-8) Trunk light...
Page 371: Charging System
10-6 ELECTRICAL SYSTEM CHARGING SYSTEM Ignition switch Main fuse Battery Generator Regulator/rectifier TROUBLESHOOTING Battery runs down quickly. Accessories Check accessories which use excessive • Remove accessories are installed amounts of electricity. No accessories Check the battery for current leaks. Current leaks •...
Page 372 ELECTRICAL SYSTEM 10-7 Measure the continuity of the generator coil. No continuity • Faulty generator coil or 10-9) disconnected lead wires Continuity Measure the generator no-load voltage. Incorrect • Faulty generator 10-10) Correct Inspect the regulator/rectifier. Incorrect • Faulty regulator/rectifier 10-10) Correct Incorrect...
Page 373: Inspection
10-8 ELECTRICAL SYSTEM INSPECTION BATTERY CURRENT LEAKAGE • Open the seat. • Remove the tool bag. • Remove the battery cover 1 with starter relay. • Turn the ignition switch to the “OFF” position. • Disconnect the - battery lead wire 2. Measure the current between - battery terminal and the - bat- tery lead wire using the multi circuit tester.
Page 374 ELECTRICAL SYSTEM 10-9 REGULATED VOLTAGE • Open the seat. • Remove the battery cover. ( 10-8) • Start the engine, turn the ignition switch to LIGHT ( ) (for Italy) and the dimmer switch to HI and run the engine at 5 000 r/min.
Page 375 10-10 ELECTRICAL SYSTEM GENERATOR NO-LOAD PERFORMANCE • Remove the left frame cover. ( 9-16) • Disconnect the generator lead wire coupler. • Start the engine and run it at 5 000 r/min. Measure the AC voltage between the lead wires of the generator using the multi circuit tester.
Page 376: Starter System
ELECTRICAL SYSTEM 10-11 STARTER SYSTEM Starter button Front brake switch Stater relay Rear brake switch To ignition coil/plug cap Engine Fuse Fuse Ignition stop switch switch Side-stand relay Starter motor Battery Side-stand switch TROUBLESHOOTING Make sure the fuses are not blown and the battery is fully-charged Starter motor will not run.
Page 377: Starter Motor Removal And Disassembly
10-12 ELECTRICAL SYSTEM Check the starter relay. Incorrect • Faulty starter relay 10-15) Correct • Improper starter relay contact Others Engine does not turn though the starter motor runs. • Faulty starter clutch STARTER MOTOR REMOVAL AND DISASSEMBLY • Remove the foot board. ( 9-18) •...
Page 378: Starter Motor Inspection
ELECTRICAL SYSTEM 10-13 • Disassembly the starter motor, as shown. Housing end (outside) Brush holder " Brush spring O-ring Brush terminal set Starter motor case & Armature Housing end (inside) O-ring ITEM N·m kgf-m lb-ft Starter motor bolt Lead wire nut STARTER MOTOR INSPECTION CARBON BRUSHES Inspect the carbon brushes for abnormal wear, cracks, or...
Page 379: Starter Motor Reassembly
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 380: Starter Relay Inspection
ELECTRICAL SYSTEM 10-15 STARTER RELAY INSPECTION • Open the seat. • Remove the battery cover. ( 10-8) • Disconnect the battery - lead wire from the battery. • Disconnect the battery lead wire 1 and starter motor lead wire 2. •...
Page 381: Side-Stand/Ignition Interlock System Parts Inspection
10-16 ELECTRICAL SYSTEM Measure the relay coil resistance between the terminals using 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 Starter relay resistance: 3 – 6 Ω Ω Ω Ω SIDE-STAND/IGNITION INTERLOCK SYSTEM PARTS INSPECTION Check the interlock system for proper operation.
Page 382 ELECTRICAL SYSTEM 10-17 First check the insulation between A and B terminals with the tester. Then apply 12 V to terminals as shown and check the continuity between A and B. If there is no continuity, replace the side-stand relay with a new one. STARTER RELAY DIODE INSPECTION •...
Page 383: Ignition System
10-18 ELECTRICAL SYSTEM IGNITION SYSTEM Engine stop switch Ignition fuse Power source circuit Ignition sensor Wave form switch arrangement circuit Main fuse Battery Wave form arrangement circuit Cam position sensor Throttle Engine CVT control position coolant unit sensor temp. sensor NOTE: The ignition cut-off circuit is incorporated in this ECM to prevent over-running of engine.
Page 384 ELECTRICAL SYSTEM 10-19 Measure the battery voltage between input lead wires (O/W and B/W) at the Incorrect • Faulty ignition switch ECM with the ignition switch in the • Faulty engine stop switch “ON” position. • Broken wire harness or poor connection of related circuit couplers Correct...
Page 385: Inspection
10-20 ELECTRICAL SYSTEM INSPECTION IGNITION COIL PRIMARY PEAK VOLTAGE • Remove the lower leg shield. ( 9-10) • Remove the radiator mounting bolt. • Disconnect the two ignition coil/plug caps. • Connect the new spark plugs to the each ignition coil/plug cap and ground them on the cylinder head.
Page 386 ELECTRICAL SYSTEM 10-21 IGNITION COIL/PLUG CAP RESISTANCE • Remove the radiator mounting bolt. ( 10-20) • Remove the ignition coil/plug cap and disconnect its coupler. Measure the ignition coil/plug cap resistance in both the primary and secondary windings. If the resistance is not within the stan- dard range, replace the ignition coil/plug cap with a new one.
Page 387 10-22 ELECTRICAL SYSTEM • Turn the ignition switch to the “ON” position. • Pull the front or rear brake. CKP sensor coupler • Press the starter button and allow the engine to crank for a coupler few seconds, and then measure the CKP sensor peak volt- age.
Page 388: Combination Meter
ELECTRICAL SYSTEM 10-23 COMBINATION METER PARTS NAMES Engine coolant temp. indicator light FI indicator light Engine coolant temp. meter Engine oil pressure indicator light Fuel meter High beam indicator light Turn signal indicator light (L) Clock hour adjust button Engine oil change indicator Clock minute adjust button Engine oil level indicator Clock...
Page 389: Operating Procedure
10-24 ELECTRICAL SYSTEM OPERATING PROCEDURE INITIAL DISPLAY When the ignition switch is set to ON, all LCD (Liquid Crystal Display) and engine coolant temp. Indicator, FI indicator and shift indicator lights light up for two seconds. The tachometer light up for 0.5 second and then it operates 0 ↔ 10 000 r/min two times.
Page 390 ELECTRICAL SYSTEM 10-25 OIL CHANGE INDICATOR The oil change indicator warns the driver of engine oil replacement timing. The indicator comes on at initial 1 000 km (600 miles) and the preset intervals thereafter. The preset interval can be varied in the range between 500 km (300 miles) to 6 000 km (3 600 miles) with a step of 500 km (300 miles).
Page 391: Inspection
10-26 ELECTRICAL SYSTEM INSPECTION ENGINE COOLANT TEMPERATURE METER AND INDICA- TOR LIGHT • Disconnect the engine coolant temperature sensor coupler. When connecting and disconnecting the engine cool- ant temp. sensor lead wire coupler, make sure to turn OFF the ignition switch, or electronic parts may get damaged.
Page 392 ELECTRICAL SYSTEM 10-27 FUEL METER • Remove the trunk box. ( 9-16) • Connect each resistor between the Red/Black and Black/ White lead wires at the wire harness. • Turn the ignition switch “ON” position and wait for approx. 13 seconds.
Page 393 10-28 ELECTRICAL SYSTEM • Remove the fuel gauge 1 from the fuel pump. • Install the fuel gauge. • Install the fuel pump. ( 7-11) FUEL PUMP RELAY • Remove the fuel pump relay. ( 10-4) Same as side-stand relay. ( 10-17) OIL PRESSURE INDICATOR NOTE:...
Page 394 ELECTRICAL SYSTEM 10-29 ENGINE OIL LEVEL INDICATOR • Remove the maintenance lid. ( 9-13) • Disconnect the oil level switch lead wire 1. • Turn the ignition switch to the ON position. Check if the oil level indicator comes on. If the oil level indicator does not come on, check the combination meter coupler or replace the combination meter.
Page 395 The highest voltage reading in this test will be the same as that of battery voltage (12 V). (Battery voltage) • Apply SUZUKI SUPER GREASE “A” to the speed sensor O- ring before installing it. 99000-25030: SUZUKI SUPER GREASE “A” (USA)
Page 396: Headlight
ELECTRICAL SYSTEM 10-31 LAMP HEADLIGHT E-02 E-19 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. HEADLIGHT BULB REPLACEMENT • Disconnect the lead wire couplers. •...
Page 397: Brake Light/ Taillight, Turn Signal Light And License Light
10-32 ELECTRICAL SYSTEM BRAKE LIGHT/ TAILLIGHT, TURN SIGNAL LIGHT AND LICENSE LIGHT 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. BULB REPLACEMENT Front turn signal light •...
Page 398 ELECTRICAL SYSTEM 10-33 Rear turn signal light • Remove the center frame cover. ( 9-15) • Remove the socket 1. • Remove the bulb 2. • Install the turn signal light in the reverse order of removal. Brake light/taillight • Remove the center frame cover. ( 9-15) •...
Page 399: Turn Signal Light
10-34 ELECTRICAL SYSTEM RELAYS TURN SIGNAL RELAY INSPECTION Before removing the turn signal relay, check the operation of the turn signal light. If the turn signal light does not illuminate, inspect the bulb, turn signal switch and circuit connection. If the bulb, turn signal switch and circuit connection are OK, the turn signal relay may be faulty;...
Page 400 ELECTRICAL SYSTEM 10-35 HAZARD SWITCH INSPECTION Except for E-24 and AN650L Inspect each switch for continuity with a tester. Color If any abnormality is found, replace the respective Position switch assemblies with new ones. IGNITION SWITCH For E-24 ENGINE STOP SWITCH Color Color Position...
Page 401 10-36 ELECTRICAL SYSTEM CVT POWER SWITCH WIRE COLOR Color Br/W Position : Black : Light blue : Yellow FREE : Brown : Light green : White : Green : Orange PUSH : Gray : Red B/Bl : Black with Blue tracer CVT “D”...
Page 402: Battery
ELECTRICAL SYSTEM 10-37 BATTERY SPECIFICATIONS Type designation FTX14-BS Capacity 12V, 43.2 kC (12 Ah)/10HR a Anode plates e Stopper b Separator (fiberglass plate) f Filter c Cathode plates g Terminal d Upper cover breather h Safty valve INITIAL CHARGING FILLING ELECTROLYTE •...
Page 403 10-38 ELECTRICAL SYSTEM NOTE: If air bubbles do not rise from any one of the filler ports, tap the bottom of the electrolyte container two or three times. Never remove the electrolyte container from the battery while there is still electrolyte in the container. •...
Page 404: Servicing
ELECTRICAL SYSTEM 10-39 SERVICING Visually inspect the surface of the battery container. If any signs of cracking or electrolyte leakage from the sides of the battery have occurred, replace the battery with a new one. If the battery terminals are found to be coated with rust or an acidic white powdery substance, clean the battery terminals with sandpaper.
Page 405 SERVICING INFORMATION 11-1 SERVICING INFORMATION CONTENTS TROUBLESHOOTING ................11- 2 FI SYSTEM/ CVT SYSTEM MALFUNCTION CODE AND DEFECTIVE CONDITION ............11- 2 ENGINE ..................11- 4 CVT ....................11- 9 RADIATOR (COOLING SYSTEM) ..........11- 9 CHASSIS ..................11-10 BRAKES ..................11-11 ELECTRICAL ................11-12 BATTERY ...................11-13 WIRING HARNESS, CABLE AND HOSE ROUTING ......11-14 WIRING HARNESS ROUTING ..........11-14 CABLE ROUTING ..............11-18 THROTTLE BODY INSTALLATION/HOSE ROUTING .....11-20...
Page 406: Troubleshooting
11-2 SERVICING INFORMATION TROUBLESHOOTING FI SYSTEM/ CVT SYSTEM MALFUNCTION CODE AND DEFECTIVE CONDITION MALFUNCTION DETECTED FAILURE CONDITION DETECTED ITEM CODE CHECK FOR NO FAULT ––––––––––– Camshaft position The signal does not reach ECM for more than 2 sec. after sensor receiving the starter signal.
Page 407 SERVICING INFORMATION 11-3 Fuel injector Crankshaft position sensor (pick-up coil) signal is produced but fuel injector signal is interrupted continuous by 4 times or more. In this case, the code C32 or C33 is indicated. C32 or C33 Injector, wiring/coupler connection, power supply to the injec- tor.
Page 408: Engine
11-4 SERVICING INFORMATION ENGINE Complaint Symptom and possible causes Remedy Engine will not start Compression too low or is hard to start. 1. Tappet clearance out of adjustment. Adjust. 2. Worn valve guides or poor seating of valves. Repair or replace. 3.
Page 409 SERVICING INFORMATION 11-5 Complaint Symptom and possible causes Remedy Engine stalls often Incorrect fuel/air mixture 1. Defective intake air pressure sensor or circuit. Repair or replace. 2. Clogged fuel filter. Clean or replace. 3. Defective fuel pump. Replace. 4. Defective fuel pressure regulator. Replace.
Page 410 11-6 SERVICING INFORMATION Complaint Symptom and possible causes Remedy Noisy engine. Excessive valve chatter 1. Too large tappet clearance. Adjust. 2. Weakened or broken valve springs. Replace. 3. Worn tappet or cam surface. Replace. 4. Worn and burnt camshaft journal. Replace.
Page 411 SERVICING INFORMATION 11-7 Complaint Symptom and possible causes Remedy Engine runs poorly in Defective air flow system high speed range. 1. Clogged air cleaner element. Clean or replace. 2. Defective throttle valve. Adjust or replace. 3. Defective IAC valve. Replace. 4.
Page 412 11-8 SERVICING INFORMATION Complaint Symptom and possible causes Remedy Engine overheats. Defective engine internal parts 1. Heavy carbon deposit on piston crowns. Clean. 2. Not enough oil in the engine. Add oil. 3. Defective oil pump or clogged oil circuit. Replace or clean.
Page 413: Cvt
SERVICING INFORMATION 11-9 Complaint Symptom and possible causes Remedy CVT is noisy. 1. Worn or burnt bearing. Replace. 2. Primary pulley shim maladjusted. Adjust. 3. Broken CVT motor gear. Replace. 4. Broken or damaged secondary pulley fan. Replace. Slipping CVT belt. 1.
Page 414: Chassis
11-10 SERVICING INFORMATION CHASSIS Complaint Symptom and possible causes Remedy Heavy steering. 1. Overtightened steering stem nut. Adjust. 2. Broken bearing in steering stem. Replace. 3. Distorted steering stem. Replace. 4. Not enough pressure in tires. Adjust. Wobbly handlebars. 1. Loss of balance between right and left front forks. Replace.
Page 415: Brakes
SERVICING INFORMATION 11-11 BRAKES Complaint Symptom and possible causes Remedy Insufficient brake 1. Leakage of brake fluid from hydraulic system. Repair or replace. power. 2. Worn pads. Replace. 3. Oil adhesion on friction surface of pads/shoe. Clean disc and pads. 4.
Page 416: Electrical
11-12 SERVICING INFORMATION ELECTRICAL Complaint Symptom and possible causes Remedy No sparking or poor 1. Defective ignition coil/plug cap or camshaft position Replace. sparking. sensor. 2. Defective spark plugs. Replace. 3. Defective generator. Replace. 4. Defective ECM. Replace. 5. Defective tip over sensor. Replace.
Page 417: Battery
SERVICING INFORMATION 11-13 BATTERY Complaint Symptom and possible causes Remedy “Sulfation”, acidic 1. Cracked battery case. Replace the battery. white powdery sub- 2. Battery has been left in a run-down condition for a long Replace the battery. stance or spots on time.
Page 418: Wiring Harness, Cable And Hose Routing
11-14 SERVICING INFORMATION WIRING HARNESS, CABLE AND HOSE ROUTING WIRING HARNESS ROUTING Throttle cable Clamp Wiring harness CVT control unit Position light (R) Position light (L) Headlight (L) Headlight (R) Wiring harness Front turn signal light (L) Front turn signal light (R) Clamp Clamp Wiring harness...
Page 419 SERVICING INFORMATION 11-15 Battery Battery lead wire coupler Set the lead wires under the fuel hose. Wiring harness Battery terminal Battery terminal Fuel hose Set the battery lead wire coupler under the wiring harness. Starter relay Fix the starter relay lead wire coupler to hole of the battery cover.
Page 420 11-16 SERVICING INFORMATION Engine coolant temp. sensor Clamp Wiring harness Injector #2 Starter motor Center stand switch Clamp CVT revolution sensor Wiring harness PP sensor Solenoide CVT motor sensor IAC valve Injector #1 TPS sensor Wiring harness Clamp Clamp Set the regulator/ Clamp rectifier lead wire coupler Clamp...
Page 421 SERVICING INFORMATION 11-17...
Page 422: Cable Routing
11-18 SERVICING INFORMATION CABLE ROUTING...
Page 423 SERVICING INFORMATION 11-19...
Page 424: Throttle Body Installation/Hose Routing
11-20 SERVICING INFORMATION THROTTLE BODY INSTALLATION/HOSE ROUTING...
Page 425: Fuel Tank Mounting
SERVICING INFORMATION 11-21 FUEL TANK MOUNTING...
Page 426 11-22 SERVICING INFORMATION FUEL TANK MOUNTING (Only for E-28)
Page 427: Fuel Tank Hose Routing
SERVICING INFORMATION 11-23 FUEL TANK HOSE ROUTING TPC valve Orange Black Clamp TPC valve 5 – 8 mm 5 – 8 mm Gray Black 5 mm...
Page 428 11-24 SERVICING INFORMATION FUEL TANK HOSE ROUTING (Only for E-28) TPC valve Orange Black Clamp TPC valve 5 – 8 mm 5 – 8 mm Gray Black 5 mm...
Page 429: Radiator Hose Routing
SERVICING INFORMATION 11-25 RADIATOR HOSE ROUTING...
Page 430: Front Brake Hose Routing
11-26 SERVICING INFORMATION FRONT BRAKE HOSE ROUTING...
Page 431: Rear Brake Hose Routing
SERVICING INFORMATION 11-27 REAR BRAKE HOSE ROUTING...
Page 432: Side-Stand Set-Up
11-28 SERVICING INFORMATION SIDE-STAND SET-UP 50 N·m 40 N·m 5.0 kgf-m 4.0 kgf-m 36.0 lb-ft 29.0 lb-ft Out side CENTER STAND SET-UP 23 N·m (2.3 kgf-m, 16.5 lb-ft) 29 N·m 2.9 kgf-m Spring position 21.0 lb-ft VIEW A...
Page 433: Special Tools
SERVICING INFORMATION 11-29 SPECIAL TOOLS 09900-18710 09900-06107 09900-06108 09900-09004 Hexagon socket 09900-20102 Snap ring pliers Snap ring pliers Impact driver set 12 mm Vernier calipers 09900-20202 09900-20204 09900-20205 09900-20602 Micrometer Micrometer Micrometer 09900-20508 Dial gauge (25 – 50 mm) (75 – 100 mm) (0 –...
Page 434 11-30 SERVICING INFORMATION 09915-63311 09913-70210 09913-75810 09915-40610 Compression gauge 09915-74511 Bearing installer set Bearing installer Oil filter wrench attachment Compression gauge 09915-74521 09915-74532 09915-77331 09916-14510 Oil pressure gauge Oil pressure gauge Meter (for high pres- 09916-10911 Valve spring hose adaptor sure) Valve lapper set compressor...
Page 435 SERVICING INFORMATION 11-31 09920-31040 09920-31030 CVT primary pulley 09920-33530 CVT secondary shaft adaptor 09920-31050 Clutch spring 09920-34830 pulley shaft holder remover CVT guide compressor Starter clutch holder 09924-74570 09920-53740 Final drive gear 09925-18011 Clutch sleeve hub 09921-20240 bearing installer/ 09924-84510 Steering bearing holder Bearing remover set...
Page 436 11-32 SERVICING INFORMATION 09940-40220 09940-52861 09941-34513 Fuel pressure gauge Front fork oil seal 09940-92720 Steering race 09941-51010 hose attachment installer Spring scale installer Ring locknut wrench 09941-54911 09941-74911 Bearing outer race 09943-74111 Steering bearing remover Fork oil level gauge installer NOTE: When ordering a special tool, please confirm whether it is available or not.
Page 437: Tightening Torque
SERVICING INFORMATION 11-33 TIGHTENING TORQUE ENGINE ITEM N·m kgf-m lb-ft Cylinder head cover bolt Tighten lightly. Tighten firmly. 10.0 Cylinder head bolt (M8) (M10) Tighten lightly. Tighten firmly. 38.5 Cam chain tension adjuster bolt Clutch spring set bolt 0.55 Clutch housing nut 50.5 Generator rotor bolt 16.0...
Page 438: Cvt
11-34 SERVICING INFORMATION ITEM N·m kgf-m lb-ft CVT mounting bolt 36.0 Primary pulley stopper bolt 26.0 CVT cover bolt 16.0 Primary pulley shaft bolt 46.5 Secondary pulley shaft nut 22.6 163.5 CHASSIS ITEM N·m kgf-m lb-ft Handlebar clamp bolt 16.5 Steering stem head nut 47.0 Steering stem nut...
Page 439: Tightening Torque Chart
SERVICING INFORMATION 11-35 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 A A A (mm) N·m kgf-m lb-ft N·m kgf-m lb-ft 0.15...
Page 440: Service Data
11-36 SERVICING INFORMATION SERVICE DATA VALVE + GUIDE Unit: mm (in) ITEM STANDARD LIMIT Valve diam. 29.5 — (1.16) 25.0 — (0.98) Tappet clearance (when cold) 0.10 – 0.20 — (0.0039 – 0.0079) 0.20 – 0.30 — (0.0079 – 0.0118) Valve guide to valve stem 0.010 –...
Page 441 SERVICING INFORMATION 11-37 CAMSHAFT + CYLINDER HEAD Unit: mm (in) ITEM STANDARD LIMIT Cam height 35.38 – 35.43 35.10 (1.393 – 1.395) (1.382) 33.98 – 34.03 33.70 (1.338 – 1.340) (1.327) Camshaft journal oil clearance 0.032– 0.066 0.150 IN. & EX. (0.0013 –...
Page 442 11-38 SERVICING INFORMATION ITEM STANDARD LIMIT Piston ring thickness 0.97 – 0.99 — (0.038 – 0.039) 0.97 – 0.99 — (0.038 – 0.039) Piston pin bore 16.002 – 16.008 16.030 (0.6300 – 0.6302) (0.6311) Piston pin O.D. 15.995 – 16.000 15.980 (0.6297 –...
Page 443 SERVICING INFORMATION 11-39 CLUTCH Unit: mm (in) ITEM STANDARD LIMIT Drive plate thickness 2.92 – 3.08 2.62 (0.115 – 0.121) (0.103) Drive plate claw width 13.85 – 13.96 13.05 (0.545 – 0.550) (0.514) Driven plate No.2 thickness 2.42 – 2.58 2.27 (0.095 –...
Page 444 11-40 SERVICING INFORMATION FI/CVT-SENSORS ITEM SPECIFICATION NOTE CMP sensor resistance 0.9 – 1.7 kΩ +: B/Y, -: Br CMP sensor peak voltage More than 0.5 V (When cranking) 150 – 300 Ω CKP sensor resistance +: Bl, -: G CKP sensor peak voltage More than 2.0 V (When cranking) IAP sensor input voltage 4.5 –...
Page 445 SERVICING INFORMATION 11-41 THROTTLE BODY ITEM SPECIFICATION ID No. 10GO Bore size 32 mm Fast idle r/min. 1 300 – 1600 r/min. Idle r/min. 1 200 ± 100 r/min. Synchronizing screw opening turns out Approx. 4 Ω at 20 – 24 °C (68 – 75 °F) IAC valve resistance Throttle cable play 2.0 –...
Page 446: License Light
11-42 SERVICING INFORMATION ITEM STD/SPEC. NOTE Generator no-load voltage More than 50 V at 5 000 r/min. (When cold) Generator Max. output Approx. 500 W at 5 000 r/min. Regulated voltage 14.0 – 15.5 V at 5 000 r/min. 3 – 6 Ω Starter relay resistance Battery Type...
Page 447 — (4.1) Front fork spring free length — (13.4) Front fork oil type SUZUKI FORK OIL G-10 (#10) — or an equivalent fork oil Front fork oil capacity (each leg) 482 ml (16.29/16.97 US/Imp oz) — Front fork oil level —...
Page 448 11-44 SERVICING INFORMATION TIRE ITEM STANDARD LIMIT Cold inflation tire pressure 225 kPa Front — (2.25 kgf/cm , 33 psi) Solo riding 250 kPa Rear — (2.50 kgf/cm , 36 psi) 225 kPa Front — (2.25 kgf/cm , 33 psi) Dual riding 280 kPa...
Page 449 EMISSION CONTROL INFORMATION 12-1 EMISSION CONTROL INFORMATION CONTENTS EMISSION CONTROL SYSTEMS ............12- 2 FUEL INJECTION SYSTEM ............12- 2 CRANKCASE EMISSION CONTROL SYSTEM ......12- 3 EXHAUST EMISSION CONTROL SYSTEM (PAIR SYSTEM) ..12- 4 NOISE EMISSION CONTROL SYSTEM ........12- 5 PAIR (AIR SUPPLY) SYSTEM INSPECTION ........12- 6 HOSE ..................12- 6 PAIR REED VALVE ..............12- 6 PAIR CONTROL SOLENOID VALVE ........12- 6...
Page 450: Emission Control Systems
12-2 EMISSION CONTROL INFORMATION EMISSION CONTROL SYSTEMS FUEL INJECTION SYSTEM AN650 motorcycles are equipped with a fuel injection system for emission level control. This fuel injection system is precision designed, manufactured and adjusted to comply with the applicable emission limits.
Page 451: Crankcase Emission Control System
EMISSION CONTROL INFORMATION 12-3 CRANKCASE EMISSION CONTROL SYSTEM The engine is equipped with a PCV system. Blow-by gas in the engine is constantly drawn into the crank- case, which is returned to the combustion chamber through the PCV (breather) hose, air cleaner and throttle body.
Page 452: Exhaust Emission Control System (Pair System)
12-4 EMISSION CONTROL INFORMATION EXHAUST EMISSION CONTROL SYSTEM (PAIR SYSTEM) The exhaust emission control system is composed of the PAIR system and THREE-WAY CATALYST sys- tem. The fresh air is drawn into the exhaust port with the PAIR solenoid valve and PAIR reed valve. The PAIR solenoid valve is operated by the ECM, and the fresh air flow is controlled according to the TPS, ECTS, IATS, IAPS and CKPS.
Page 453: Noise Emission Control System
EMISSION CONTROL INFORMATION 12-5 NOISE EMISSION CONTROL SYSTEM TAMPERING WITH THE NOISE CONTROL SYSTEM PROHIBITED: Local law prohibits the following acts or the causing thereof: 1. The removal or rendering inoperative by any person, other than for purposes of maintenance, repair or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use, or 2.
Page 454: Pair (Air Supply) System Inspection
12-6 EMISSION CONTROL INFORMATION PAIR (AIR SUPPLY) SYSTEM INSPECTION HOSE • Remove the front box. ( 9-18) • Inspect the hose for wear or damage. • Inspect that the hose is securely connected. PAIR REED VALVE • Remove the air chamber. ( 7-16) •...
Page 455 EMISSION CONTROL INFORMATION 12-7 • Connect the 12 V battery to the PAIR control solenoid valve terminals and check the air flow. • If air does not flow out, the solenoid valve is in normal condi- Battery tion. • Check the resistance between the terminals of the PAIR con- trol solenoid valve.
Page 456: Pair (Air Supply) System Hose Routing
12-8 EMISSION CONTROL INFORMATION PAIR (AIR SUPPLY) SYSTEM HOSE ROUTING 10 N . m (1.0 kgf-m, 7.3 lb-ft) PAIR control solenoid valve 3 – 5 mm (0.1 – 0.2 in) PAIR reed valve PAIR control solenoid valve...
Page 457: Heated Oxgen Sensor (Ho2S) Inspection
EMISSION CONTROL INFORMATION 12-9 HEATED OXGEN SENSOR (HO2S) INSPECTION • Remove the foot board. ( 9-18) • Disconnect the HO2 sensor lead wire coupler. • Remove the HO2 sensor unit. Do not remove the HO2 sensor while it is hot. Be careful not to expose it to excessive shock.
Page 458 WIRING DIAGRAM E-02, 19 : HIGH BEAM INDICATOR LIGHT : OIL PRESSURE INDICATOR LIGHT : FI PILOT : BRAKE LOCK INDICATOR LIGHT : TURN SIGNAL INDICATOR LIGHT (R) : ILLUMINATION : TURN SIGNAL INDICATOR LIGHT (L) : ENGINE COOLANT TEMP. INDICATOR LIGHT : GEAR POSITION INDICATOR –...
Page 459 AN650L : HIGH BEAM INDICATOR LIGHT : OIL PRESSURE INDICATOR LIGHT : FI PILOT : BRAKE LOCK INDICATOR LIGHT : TURN SIGNAL INDICATOR LIGHT (R) : ILLUMINATION : TURN SIGNAL INDICATOR LIGHT (L) : ENGINE COOLANT TEMP. INDICATOR LIGHT – : GEAR POSITION INDICATOR : DRIVE MODE INDICATOR : POWER MODE INDICATOR...
Page 460 E-24 : HIGH BEAM INDICATOR LIGHT : OIL PRESSURE INDICATOR LIGHT : FI PILOT : BRAKE LOCK INDICATOR LIGHT : TURN SIGNAL INDICATOR LIGHT (R) : ILLUMINATION : TURN SIGNAL INDICATOR LIGHT (L) : ENGINE COOLANT TEMP. INDICATOR LIGHT – : GEAR POSITION INDICATOR : DRIVE MODE INDICATOR : POWER MODE INDICATOR...
Page 461 E-03, 28, 33 : HIGH BEAM INDICATOR LIGHT : OIL PRESSURE INDICATOR LIGHT : FI PILOT : BRAKE LOCK INDICATOR LIGHT : TURN SIGNAL INDICATOR LIGHT (R) : ILLUMINATION : TURN SIGNAL INDICATOR LIGHT (L) : ENGINE COOLANT TEMP. INDICATOR LIGHT : GEAR POSITION INDICATOR : DRIVE MODE INDICATOR : POWER MODE INDICATOR...
Page 462 Prepared by July, 2002 Part No. 99500-36110-01E Printed in Japan...

This manual is also suitable for:

An650l 2002 E-24 2002 An650k3 2002

Suzuki AN650 2002 Service Manual

General Information 1

Electrical

Engine

Drive Train

Cvt Assembly Removal and Installation/Cvt Disassembly and Reassembly

Fi System/ Cvt System

Fuel System and Throttle Body

Cooling and Lubrication System

Chassis

Electrical System

Quick Links

Chapters

Troubleshooting

Related Manuals for Suzuki AN650 2002

Summary of Contents for Suzuki AN650 2002