Suzuki VS1400 Owner's Manual
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Suzuki VS1400 Owner's Manual

Suzuki VS1400 Owner's Manual

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VS1400
OWNER'S MANUAL
This owner s manual contains
important safety information.
Please read it carefully.
Part No. 99011-38B68-03A
April, 2004 Ç EN

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Summary of Contents for Suzuki VS1400

  • Page 1 VS1400 OWNER’S MANUAL This owner s manual contains important safety information. Please read it carefully. Part No. 99011-38B68-03A April, 2004 Ç EN...
  • Page 2 California Proposition 65 Warning WARNING Engine exhaust, some of its constituents, and certain product com- ponents contain or emit chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. This manual should be considered a permanent part of the mo- torcycle and should remain with the motorcycle when resold or otherwise transferred to a new owner or operator.
  • Page 3 NOTE: Indicates special information to IMPORTANT make maintenance easier or instruc- tions clearer. WARNING/CAUTION/NOTE Please read this manual and follow its WARNINGs and CAUTIONs are ar- instructions carefully. To emphasize ranged like this: special information, the symbol ! and the words WARNING, CAUTION and !WARNING-or-CAUTION NOTE have special meanings.
  • Page 4 EPA regulations. Therefore, please follow the maintenance instruc- tions closely to ensure emission compli- ance. Your authorized Suzuki dealer has experienced technicians that are trained to provide your machine with the best possible service with the right tools...
  • Page 5 Due to improvements or other changes, there may be some discrepancies in this manual. Suzuki reserves the right to make production changes at any time, without notice and without incur- ring any obligation to make the same or similar changes to vehicles previously built or sold.

  • Page 7: Table Of Contents

    TABLE OF CONTENTS THE SPORT OF MOTORCYCLING FUEL, ENGINE OIL AND COOLANT RECOMMENDATION CONTROLS, EQUIPMENT AND ADJUSTMENTS BREAK-IN AND INSPECTION BEFORE RIDING RIDING TIPS ACCESSORY USE AND MOTORCYCLE LOADING INSPECTION AND MAINTENANCE TROUBLESHOOTING STORAGE PROCEDURE AND APPEARANCE CARE CONSUMER INFORMATION SPECIFICATIONS INDEX...

  • Page 9: The Sport Of Motorcycling

    THE SPORT OF MOTORCYCLING THE SPORT OF MOTORCYCLING ..............1-2...
  • Page 10 In preparing for these challenges, you THE SPORT OF MOTORCY- will be fine-tuning your coordination, CLING concentration, and attitude. Learning the skills and strategies associated with THE SPORT OF MOTORCYCLING motorcycling is the basis for safely par- Your motorcycle and this owner’s man- ticipating in this sport.
  • Page 11 If you don’t have a helmet: buy a helmet, and Most accidents can be avoided. The most common type of motorcycle wear it EVERY TIME YOU RIDE. accident in the U.S. occurs when a car Most accidents occur within a few miles traveling toward a motorcycle turns left of home, and almost half occur at in front of the motorcycle.
  • Page 12 Emergency stopping and swerving are If a collision is imminent, DO SOMETHING! techniques that you should practice and Many riders fear locking up their brakes master before you find yourself in an or haven’t learned to swerve to avoid an emergency situation.
  • Page 13 A major cause of accidents involving Special situations require special care. only a motorcycle (and no cars) is going Of course, there are some times when too fast through a turn. Before entering full-force braking is not the correct tech- a turn, select an appropriately low cor- nique.
  • Page 14 Be extra safety-conscious on bad weather Riding a motorcycle safely requires that your mental and physical skills are fully days. part of the experience. You should not Riding on bad weather days, especially attempt to operate a motor vehicle, wet ones, requires extra caution. Brak- especially one with two wheels, if you ing distances increase on a rainy day.
  • Page 15 Inspection before riding. Practice away from traffic. Your riding skill and your mechanical Review the instructions in the INSPEC- knowledge form the foundation for safe TION BEFORE RIDING section of this riding practices. We suggest that you manual. Perform an entire pre-ride practice riding your motorcycle in a non- inspection before you head out on the traffic situation until you are thoroughly...
  • Page 16 Motorcycle Safety Foundation’s “Riding Tips Carrying a Passenger Carrying a passenger, when done cor- and Practice Guide” Handbook (for owners rectly, is a great way to share the joy of in USA). motorcycling. You will have to alter your This special handbook, supplied with riding style some- what since the extra your owner’s manual, contains a variety weight of a passenger will affect han-...
  • Page 17 Motorcycle dictable. Your motorcycle’s condition Safety Foundation. Your authorized can change. These factors can best be Suzuki dealer can help you locate the dealt with by giving every ride your full fundamental or advanced riding skills attention.
  • Page 18 1-10...
  • Page 19 FUEL, ENGINE OIL COOLANT RECOM- MENDATION FUEL ........................2-2 ENGINE OIL......................2-4 GEAR OIL ......................2-5...

  • Page 20: Fuel, Engine Oil And Coolant Recommendation

    FUEL, ENGINE Gasoline containing MTBE Unieaded gasoline containing MTBE COOLANT RECOMMENDA- (Methyl Tertiary Butyl Ether) may be TION used in your motorcycle if the MTBE content is not greater than 15%. This FUEL oxygenated fuel does not contain alco- Your motorcycle requires regular...
  • Page 21 Suzuki and may not be covered under the New Vehicle Limited War- genate and additives. If you are not...
  • Page 22 NOTE: ENGINE OIL • To help clean the air, Suzuki recom- mends that you use the oxygenated fuels. • Be sure that any oxygenated fuel you use has octane ratings of at least 87 pump octane ((R+M)/2 method). • If you are not satisfied with the drive-...
  • Page 23 GEAR OIL Use an SAE90 hyopid gear oil which is rated GL-5 under the API classification system. If you operate the motorcycle where ambient temperature is below 0°C (23°F), use SAE80 hypoid gear oil.

  • Page 25: Controls, Equipment And Adjustments

    CONTROLS, EQUIPMENT AND ADJUST- MENTS LOCATION OF PARTS..................3- 2 KEY ........................3- 5 IGNITION SWITCH ....................3- 6 STEERING LOCK ....................3- 7 INSTRUMENT PANEL..................3- 8 LEFT HANDLEBAR...................3-10 RIGHT HANDLEBAR..................3-11 FUEL TANK CAP....................3-14 FUEL VALVE .....................3-15 CHOKE LEVER....................3-17 GEARSHIFT LEVER..................3-18 REAR BRAKE PEDAL ..................3-19 HELMET HOLDER.....................3-19 SIDE STAND......................3-20 REAR SUSPENSION..................3-22...

  • Page 26: Location Of Parts

    CONTROLS, EQUIPMENT AND ADJUSTMENTS LOCATION OF PARTS 1 Clutch lever 6 Front brake fluid reservoir 2 Left handlebar switches 7 Right handlebar switches 3 Clutch fluid reservoir 8 Throttle grip 4 Speedometer 9 Front brake lever 5 Instrument panel 0 Fuel tank cap...
  • Page 27 A Choke handle F Gearshift lever B Fuel valve G Footrests C Ignition switch H Side stand D Fuses I Battery E Helmet holders J Passenger footrests...
  • Page 28 K Air cleaner P Engine oil filler cap L Tool Q Rear brake light switch M Steering lock R Engine oil filter N Rear brake fluid reservoir S Rear brake pedal O Engine oil drain plug...

  • Page 29: Key

    Please write down your key numbers in the box provided for your future refer- ence. lgnition: Key No. Steering: This motorcycle comes equipped with two pairs of keys, one for the ignition switch and the other for the steering lock. The ignition keys are stamped with an identifying number.

  • Page 30: Ignition Switch

    IGNITION SWITCH “ON” position The ignition circuit is completed and the The ignition switch has three positions. engine can be started. The headlight and taillight will automatically turn on. The key cannot be removed in this posi- tion. NOTE: Start the engine promptly after turning the key to the “ON”...

  • Page 31: Steering Lock

    STEERING LOCK !WARNING Moving the motorcycle while the steering is locked can be hazardous. You could lose your balance and fall, or you could drop the motorcycle. Never attempt to move the motorcycle when the steering is locked. Turn the handlebars all the way to the left.

  • Page 32: Instrument Panel

    Trip Meter 3 INSTRUMENT PANEL The trip meter is a resettable odometer located in the speedometer assembly. It can be used for indicating the distance traveled on short trips or between fuel stops. Turning knob 4 counterclock- wise will return the meter to zero. Oil Pressure Indicator Light 5 This indicator comes on when the engine oil pressure is below the normal...
  • Page 33 If the light still does not go out, Neutral Indicator Light 8 have your authorized SUZUKI dealer or The green indicator light will come on qualified mechanic troubleshoot your when the transmission is in neutral.

  • Page 34: Left Handlebar

    Dimmer Switch 3 LEFT HANDLEBAR “ " ” position The headlight low beam and taillight turn on. “ # ” position The headlight high beam and taillight turn on. The high beam indicator light also turns on. Turn Signal Switch 4 Clutch Lever 1 Moving the switch to the “...

  • Page 35: Right Handlebar

    RIGHT HANDLEBAR !WARNING Failure to use the turn signals, and failure to turn off the turn signals can be hazard- ous. Other drivers may misjudge your course and this may result in an accident. Always use the turn signals when you intend to change lanes or make a turn.
  • Page 36 Hazard Warning Switch 3 All four turn signal lights and indicators will flash simultaneously when the switch is turned on with the ignition switch in “ON” or “P” position. Use the hazard warning lights to warn other traf- fic during emergency parking or when your vehicle could otherwise become a traffic hazard.
  • Page 37 Throttle Grip 5 NOTE: This motorcycle has a starter interlock switches for the ignition and Engine speed is controlled by the posi- starter circuit. The engine can only be tion of the throttle grip. Turn it toward started if: you to increase engine speed. Turn it •...

  • Page 38: Fuel Tank Cap

    FUEL TANK CAP 1 Fuel level 2 Filler neck !WARNING To open the fuel tank cap, insert the Overfilling the fuel tank can cause the fuel ignition key into the lock and turn it to overflow when it expands due to heat clockwise.

  • Page 39: Fuel Valve

    FUEL VALVE !WARNING This motorcycle has a manually oper- ated fuel valve. There are three posi- Fuel and fuel vapor are highly flammable tions: “ON,” “RES” and “OFF.” and toxic. You can be burned or poisoned when refueling. • Stop the engine and keep flames, sparks and heat sources away.
  • Page 40 “RES” (RESERVE) Position “OFF” Position If the fuel level in the fuel tank becomes Turn the lever to the “OFF” position too low for the engine to operate with whenever stopping the engine for more the fuel valve lever in the “ON” position, than a few minutes.

  • Page 41: Choke Lever

    CHOKE LEVER !WARNING Leaving the fuel valve in the “ON” or “RES” position when the engine is off can be haz- ardous. The carburetor may overflow and fuel may run into the engine. This can cause a fire or cause severe damage when you start the engine.

  • Page 42: Gearshift Lever

    GEARSHIFT LEVER NOTE: When the transmission is in neutral the green indicator light on the instrument panel will be lit. However, even though the light is lit, cautiously 2 3 4 release the clutch lever slowly to con- firm whether the transmission is posi- tively in neutral.

  • Page 43: Rear Brake Pedal

    REAR BRAKE PEDAL HELMET HOLDER Pressing the rear brake pedal will apply This motorcycle has two helmet hold- the rear brake. The brake light will ers. Insert the ingnition key into the lock come on when the rear brake is oper- and turn it clockwise to open the latch.

  • Page 44: Side Stand

    SIDE STAND !WARNING Riding with a helmet fastened to either hel- met holder can interfere with rider control. Never carry a helmet fastened to a helmet holder. Fix the helmet securely atop the seat if you must carry it. The motorcycle has a side stand. place the motorcycle on the side stand, place your right foot on the end of the side stand and push down firmly until...
  • Page 45 The side stand/ignition interlock sys- CAUTION tem works as follows: • If the side stand is down and the Park the motorcycle on firm, level ground transmission is in gear, the engine to help prevent it from falling over. cannot be started. •...

  • Page 46: Rear Suspension

    REAR SUSPENSION The rear suspension spring pre-load is adjustable. The adjustment can be per- formed by changing the hidden adjuster position. Position 1 provides the softest spring pre- load and position 5 provides the stiffest. The spring pre-load is set on position 2 at the factory.

  • Page 47: Break-In And Inspection Before Riding

    BREAK-IN AND INSPECTION BEFORE RIDING BREAK-IN ......................4-2 INSPECTION BEFORE RIDING ................4-4...
  • Page 48 BREAK-IN AND INSPECTION Initial Up to Over BEFORE RIDING 500 miles 1000 miles 1000 miles (800 km) (1600 km) (1600 km) Maximum BREAK-IN recommended 4000 r/min 5000 r/min 6000 r/min engine speed The first 800 km (500 miles) is the most Corresponding vehicle speed important in the life of your motorcycle.
  • Page 49 Vary the Engine Speed !WARNING Vary the engine speed during the break-in period. This allows the parts Failure to perform break-in of the tires to “load” (aiding the mating process) could cause tire slip and loss of control. and then “unload” (allowing the parts to cool).
  • Page 50 INSPECTION BEFORE RIDING Observe Your Initial and Most Critical Ser- vice The initial service (1000 km main ten- !WARNING ance) is the most important service your motorcycle will receive. During break-in Failure to inspect and maintain your motor- operation, all of the engine components cycle properly increases the chance of an will have mated together and seated.
  • Page 51 Check the condition of the motor-cycle WHAT TO CHECK FOR: to help make sure that you do not have CHECK mechanical problems or get stranded Steering • Smoothness somewhere when you ride. Before • No restriction of movement • No play or looseness riding the motorcycle, be sure to check the following items.
  • Page 52 WHAT TO CHECK FOR: CHECK Gear oil Correct level Throttle • Proper play • Smooth response • Quick return to idle position Gearshift • No damage lever • Smooth operation Clutch • Correct fluid level • No fluid leakage • Correct function •...

  • Page 53: Riding Tips

    RIDING TIPS STARTING THE ENGINE ..................5-2 STARTING OFF AND SHIFTING ................5-3 USING THE TRANSMISSION ................5-5 RIDING ON HILLS ....................5-6 STOPPING AND PARKING.................5-7 CARRYING A PASSENGER ................5-9...

  • Page 54: Starting The Engine

    RIDING TIPS When the Engine Is Cold: 1. Turn the choke lever clockwise. Close the throttle completely. STARTING THE ENGINE 2. Squeeze the clutch lever and push Before attempting to start the engine, the electric starter button. make sure: 3. Immediately after the engine starts, •...

  • Page 55: Starting Off And Shifting

    STARTING OFF AND SHIFTING !WARNING !WARNING Running the engine indoors or in a garage can be hazardous. Exhaust gas contains carbon monoxide, a gas that is colorless Riding this motorcycle at excessive speed and odorless and can cause death or increases your chances of losing control of severe injury.
  • Page 56 Make sure that the side stand is in the !WARNING fully up position. Pull the clutch lever in and pause momentarily. Engage first Removing your hands from the handlebars gear by depressing the gearshift lever or feet from the footrests during operation downward.

  • Page 57: Using The Transmission

    USING THE TRANSMISSION Shifting down schedule The transmission is provided to keep Gear position miles/h km/h the engine operating smoothly in its Top → 4th normal operating speed range. The 4th → 3rd gear ratios have been carefully chosen to meet the characteristics of the Disengage the clutch when the motor- engine.

  • Page 58: Riding On Hills

    RIDING ON HILLS !WARNING • When climbing steep hills, the motor- cycle may begin to slow down and Downshifting while the motorcycle is show lack of power. At this point, you leaned over in a corner may cause rear should shift to a lower gear so that wheel skid and loss of control.

  • Page 59: Stopping And Parking

    STOPPING AND PARKING !WARNING 1. Turn the throttle grip away from you to close the throttle completely. Inexperienced riders tend to underutilize 2. Apply the front and rear brakes the front brake. This can cause excessive evenly and at the same time. stopping distance and lead to a collision.
  • Page 60 5. Park the motorcycle on a firm, flat !WARNING surface where it will not fall over. 6. Turn the ignition switch to the Hard braking on wet, loose, rough, or other “OFF” position. slippery surfaces can cause wheel skid 7. Turn the handlebars all the way to and loss of control.

  • Page 61: Carrying A Passenger

    CARRYING A PASSENGER Before you invite someone to be a pas- senger on your motorcycle, you need to be thoroughly familiar with motorcycle operation. Adjust tire pressures and suspension according to the Tire Pres- sure and Loading section and the Sus- pension section of this manual.
  • Page 62 5-10...

  • Page 63: Accessory Use And Motorcycle Loading

    ACCESSORY USE AND MOTORCYCLE LOADING ACCESSORY USE AND MOTORCYCLE LOADING .........6-2...
  • Page 64 It is not Never modify the motorcycle with improper possible for Suzuki to test each acces- or poorly installed accessories. Follow all sory on the market or combinations of instructions in this owner’s manual regard- all the available accessories;...
  • Page 65 • At any time that additional weight or • Never exceed the GVWR (Gross Vehicle Weight Rating) of this motor- aerodynamic affecting accessories installed, they should cycle. The GVWR is the combined weight of the machine, accessories, mounted as low as possible, as close to the motorcycle and as near the payload and riders.
  • Page 66 • Backrests, saddlebags, travel trunks, • Accessories fitted to the handle- bars or the front fork area can create seri- etc., may affect the stability of the motorcycle due to their aerodynamic ous stability problems. This extra weight will cause the motorcycle to effects.
  • Page 67 MODIFICATION • Additional electrical accessories may overload the existing electrical sys- Modification of the motorcycle, or tem. Severe overloads may damage removal of original equipment may ren- the wiring harness or create a haz- der the vehicle unsafe or illegal. Obey ardous situation due to the loss of all applicable equipment regulations in electrical power during the operation...

  • Page 69: Inspection And Maintenance

    INSPECTION AND MAINTENANCE NOTICE ......................7- 2 MAINTENANCE SCHEDULE ................7- 2 TOOLS .......................7- 7 GENERAL LUBRICATION ................7- 8 BATTERY......................7- 9 AIR CLEANER ....................7-12 SPARK PLUG ....................7-22 ENGINE OIL.......................7-24 CARBURETOR ....................7-31 CLUTCH......................7-34 FINAL GEAR OIL....................7-36 BRAKES ......................7-38 TIRES .........................7-44 SPOKE NIPPLE TIGHTNESS ................7-47 SIDE STAND/IGNITION INTER-LOCK SYSTEM ..........7-48 FRONT WHEEL REMOVAL ................7-50 REAR WHEEL REMOVAL ................7-52...

  • Page 70: Notice

    MAINTENANCE SCHEDULE INSPECTION AND MAINTE- It is very important to inspect and main- NANCE tain your motorcycle regularly. Follow the guidelines in the chart. The intervals NOTICE between periodic services in kilometers, miles and months are shown. At the MAINTENANCE, REPLACEMENT end of each interval, be sure to perform REPAIR OF THE EMISSION CONTROL...
  • Page 71 If you are not sure how to do the chart. If you have any questions any of the jobs, have your SUZUKI dealer regarding maintenance intervals, con- or qualified mechanic do them. sult your SUZUKI dealer or qualified...
  • Page 72 CAUTION Using poor quality replacement parts can cause your motorcycle to wear more quickly and may shorten its useful life. Use only genuine SUZUKI re-placement parts or their equivalent.
  • Page 73 MAINTENANCE CHART This interval should be judged by odometer reading or months, whichever comes first. Interval 1000 6000 12000 18000 24000 miles 4000 7500 11000 14500 Item months Battery – Air cleaner elements Clean every 6000 km (4000 miles) Spark plugs –...
  • Page 74 Interval 1000 6000 12000 18000 24000 miles 4000 7500 11000 14500 Item months Brake fluid *Replace every four years Brake hose *Replace every two years Tires * Steering * Front forks – – * Chassis bolts and nuts NOTE: I=Inspect and clean, adjust, replace or lubricate as necessary; R=Replace; T=Tighten...

  • Page 75: Tools

    TOOLS Remove the screw to open the tool box cover To assist you in the performance of !WARNING periodic maintenance, a tool kit is sup- plied and is stowed in the tool box. The Hot engine can burn you when removing tool box is located right side of the the screw and tool box cover.

  • Page 76: General Lubrication

    GENERAL LUBRICATION Proper lubrication is important for safe, smooth operation and a long life for your motorcycle. Be sure that all lubri- cation is performed during periodic maintenance motorcycle. Increase frequency when you use your motorcycle in severe conditions. 5..Throttle grip 6..Brake lever holder 7..Throttle cable 8..Brake pedal pivot...

  • Page 77: Battery

    BATTERY CAUTION The battery is a sealed type and requires no maintenance. The stan- Exceeding the maximum charging rate for dard charging rate is 1.4 A × 5 hours the battery can shorten its life. and the maximum rate is 7.0 A × 1 hour. Never exceed the maximum charging rate.
  • Page 78 !WARNING CAUTION A hot muffler can burn you. The muffler will Reversing the battery lead wires can dam- be hot enough to burn you for some time age the charging system and the battery. after stopping the engine. The red lead must go to the positive (+) ter- Wait until the muffler cools to avoid burns.
  • Page 79 5. Remove two bolts 4 (right and left) 4. Remove the battery positive termi- and battery case bottom plate. nal screw 3. 6. Remove the battery. 7. To reinstall the battery, reverse the procedure above. 7-11...

  • Page 80: Air Cleaner

    AIR CLEANER !WARNING The air cleaner element must be kept clean to provide good engine power Operating the engine without the air and gas mileage. If you use your motor- cleaner element in place could allow a cycle under normal low-stress condi- flame to spit back from the engine to the air tions, you should service the air cleaner cleaner, or could allow dirt to enter the...
  • Page 81 Air Cleaner Element Removal CAUTION 1. Place the motorcycle on the side stand. Clean or replace the air cleaner element frequently if the motorcycle is used in dusty, wet or muddy conditions. The air cleaner element will clog under these con- ditions, and this may cause engine dam- age, poor performance, and poor fuel economy.
  • Page 82 4. Turn the fuel tank valve 4 clock- 3. Remove two bolts 3. Pull the fuel wise to the “OFF” position with a tank backward and remove it. screwdriver. 7-14...
  • Page 83 5. Check that the fuel valve 5 is in the 6. Remove the fuel hoses 6. “OFF” position, the fuel tank cap is locked, and the ignition switch is in the “OFF” position. 7-15...
  • Page 84 !WARNING Spilling fuel when disconnecting the fuel hose can be hazardous. Fuel can catch on fire if you do not handle it properly. When disconnecting the fuel hose, always shut the engine off. Do not smoke, and never drain or refuel in an area where there are open flames or sparks.
  • Page 85 10. Remove the air cleaner case cover and air cleaner element D. 9. Remove screws A and B. Re- move frame head covers C. 7-17...
  • Page 86 12. Remove screw F and cover. 11. Remove two screws E and right frame cover. 13. Remove the air cleaner element G. 7-18...
  • Page 87 2. Squeeze the air cleaner element by Air Cleaner Element Washing pressing it between the palms of Wash the air cleaner element as fol- both hands to remove the excess lows: solvent. Do not twist or wring the air cleaner element or it will develop cracks.
  • Page 88 6. Clean any dirt or debris from inside !WARNING the air cleaner case. Be sure no dirt enters the carburetor. New and used oil and solvent can be haz- 7. Reinstall the air cleaner element in ardous. Children and pets may be harmed reverse order of removal.
  • Page 89 CAUTION Failure to position the air cleaner element properly can allow dirt to bypass the air cleaner element. This will cause engine damage. Be sure to properly install the air cleaner element. NOTE: Connect the fuel hoses cor- rectly, or the fuel valve position “ON” and “RES”...

  • Page 90: Spark Plug

    Consult your authorized dark insulator indicates that the engine SUZUKI dealer or qualified mechanic if you may need adjustment, or another plug are not sure which spark plug is correct for type may be needed. Consult your your type of usage.
  • Page 91 If not available, consult your authorized the spark plug is new, tighten it with a Suzuki dealer. wrench about 1/2 turn past finger tight. If you are reusing the old spark plug,...

  • Page 92: Engine Oil

    ENGINE OIL Engine life depends on oil amount and quality. Daily engine oil level checks and periodic changes are two of the most important maintenance items to be performed. 0.8-0.9 mm (0.031-0.035 in) To maintain a hot, strong spark, keep the plug free from carbon.
  • Page 93 1. Place the motorcycle on level Engine Oil Level Check ground on the side stand. 2. Start the engine and allow it to idle for a few minutes. 3. Stop the engine and wait for three minutes. 4. Hold the motorcycle vertically and check the engine oil level.
  • Page 94 Engine Oil and Filter Change Change the engine oil and oil filter at the scheduled times. The engine should always be warm when the engine oil is changed so the engine oil will drain easily. The procedure is as follows: 1.
  • Page 95 !WARNING New and used oil and solvent can be haz- ardous. Children and pets may be harmed by swallowing new or used oil or solvent. Continuous contact with used engine oil has been found to cause skin cancer in lab- oratory animals.
  • Page 96 5. Wipe off the mounting surface on 4. Loosen the oil filter with a Suzuki the engine where the new filter will “cap type” oil filter wrench or a be seated with a clean rag. “strap type” filter wrench of proper size and remove the oil filter.
  • Page 97 CAUTION Using an oil filter with the wrong design or thread specifications can cause oil leaks or engine damage. Use a genuine SUZUKI oil filter or an equiv- alent designed for your motorcycle. 7-29...
  • Page 98 CAUTION contacts the mounting suface. Engine damage may occur if you use oil that does not meet SUZUKI’s specifica- tions. Use the oil specified in the FUEL AND ENGINE OIL RECOMMENDATION section. Tighten the filter 2 turns.

  • Page 99: Carburetor

    To adjust the idle speed properly, you leaks. need a tachometer. If you do not have one, ask your authorized Suzuki dealer or a qualified mechanic to perform this adjustment. • Start the engine and warm it up by...
  • Page 100 Throttle Cable Adjustment 2.0 - 4.0 mm (0.08 - 0.16 in) Measure the throttle cable play by turn- 1. Turn the throttle stop screw 1 in or ing the throttle grip. The throttle grip out so that the engine idles at 900 – should have 2 –...
  • Page 101 !WARNING Inadequate throttle cable play can cause engine speed to rise suddenly when you turn the handlebars. This can lead to loss of rider control. Adjust the throttle cable play so that engine idle speed does not rise due to han- dlebar movement.

  • Page 102: Clutch

    CLUTCH !WARNING Clutch Fluid Brake fluid is harmful or fatal if swallowed, and harmful if it comes in contact with skin or eyes. If swallowed, do not induce vomiting. Immediately contact a poison control cen- ter or a physician. If brake fluid gets in eyes, flush eyes with water and seek medi- cal attention.
  • Page 103 If there is frequent damage, bring the motorcycle to your loss of fluid, take your motorcycle to a authorized Suzuki dealer or qualified SUZUKI dealer or qualified mechanic for mechanic to have the clutch hose inspection. replaced.

  • Page 104: Final Gear Oil

    FINAL GEAR OIL Clutch System Inspect your clutch system before each Change the gear oil as follows: use of the motorcycle, as follows: 1. Place the motorcycle on the side • Inspect the clutch system for signs of stand. fluid leakage. •...
  • Page 105 4. Reinstall the drain plug and tighten !WARNING it securely after all the oil has been drained out. Hold the motorcycle New and used oil and solvent can be haz- vertically and pour fresh oil through ardous. Children and pets may be harmed the filler hole until the oil level by swallowing new or used oil or solvent.

  • Page 106: Brakes

    BRAKES NOTE: Operating in mud, water, sand or other extreme conditions can cause This motorcycle has front and rear disk accelerated brake wear. If you operate brakes. your motorcycle under these conditions, the brakes must be inspected more !WARNING often than recommended in the MAIN- TENANCE SCHEDULE.
  • Page 107 If there is fre- Check the brake fluid level in both front quent loss of fluid, take your motorcycle to and rear brake fluid reservoirs and a SUZUKI dealer or qualified mechanic for inspect for brake pad wear and leaks. inspection. 7-39...
  • Page 108 Brake Pads !WARNING Brake fluid is harmful or fatal if swallowed, and harmful if it comes in contact with skin or eyes. If swallowed, do not induce vomiting. Immediately contact a poison control cen- ter or a physician. If brake fluid gets in eyes, flush eyes with water and seek medi- cal attention.
  • Page 109 Riding with worn brake pads will reduce braking performance and will increase your chance of having an accident. Inspect brake pad wear before each use. Ask your SUZUKI dealer or qualified mechanic to replace brake pads if any pad Rear is worn to the limit.
  • Page 110 NOTE: Do not squeeze/depress the brake lever/pedal when the pads are not in their positions. It is difficult to push the pistons back into position. 60 - 70 mm (2.4 - 2.8 in) Rear Brake Pedal Adjustment The rear brake pedal must be adjusted to set the clearance between the pedal and footrest.
  • Page 111 Rear Brake Light Switch CAUTION An incorrectly adjusted brake pedal may force brake pads to rub against the disk at all times, causing damage to the pads and disk. Follow the steps in this section to adjust the brake pedal properly. The rear brake light switch is located by the brake pedal pivot.

  • Page 112: Tires

    TIRES !WARNING !WARNING Failure to perform break-in of the tires could cause tire slip and loss of control. Failure to follow these warnings may result in an accident due to tire failure. Use extra care when riding on new tires. The tires on your motorcycle form the cru- Perform proper break-in of the tires refer- cial link between your motorcycle and the...
  • Page 113 Under-inflated tires make smooth cor- Check tire pressure each day be-fore you ride, according to the table below. nering difficult, and can result in rapid Tire pressure should only be checked tire wear. Over-inflated tires have a and adjusted before riding since riding smaller amount of tire in contact with will heat up the tires and lead to higher the road, which can contribute to skid-...
  • Page 114 Whenever you replace a tire, use a tire of the size and type listed be-low. If you use a tire of different size or type, motorcycle handling may be adversely affected, possibly resulting in loss of motorcycle control. FRONT REAR SIZE 110/90-19 M/C 62H 170/80-15 M/C 77H Check tire conditions each day be-fore...

  • Page 115: Spoke Nipple Tightness

    An improperly repaired, installed, or bal- anced tire can cause loss of control or shorten tire life. • Ask your SUZUKI dealer or qualified mechanic to perform tire repair, replace- ment, and balancing because proper tools and experience are required.

  • Page 116: Side Stand/Ignition Inter-Lock System

    SYSTEM torque. Loose and overtightened spoke nipples may cause unequal spoke ten- sion and may result in wheel rim distor- tion. Contact your authorized Suzuki dealer or qualified mechanic for this service. Check the side stand/ignition interlock system for proper operation as follows: 1.
  • Page 117 Have your motorcycle inspected by an Check the side stand/ignition interlock sys- authorized Suzuki dealer or some other tem for proper operation before riding. qualified service mechanic. Check that the side stand is returned to its full up position before starting off.

  • Page 118: Front Wheel Removal

    FRONT WHEEL REMOVAL 1. Place the motorcycle on the side stand. 2. Loosen the axle holder bolt 1. Loosen the axle 2 temporarily. 3. Place an accessory service stand or equivalent under the swing arm to help stabilize the rear end. Care- fully position a jack under the engine and raise until the front wheel is slightly off the ground.
  • Page 119 NOTE: Never squeeze the front brake CAUTION lever with the wheel removed. It is very difficult to force the pads back into the Improper jacking may cause damage to the caliper assembly. oil filter. 6. To reinstall the wheel assembly, Do not apply the jack head to the oil filter reverse the sequence as when jacking up the motorcycle.

  • Page 120: Rear Wheel Removal

    Torque bolts and nuts to the proper specifi- cations. If you are not sure of the proper A hot muffler can burn you. The muffler will procedure, have your authorized SUZUKI be hot enough to burn you for some time dealer or qualified mechanic do this.
  • Page 121 2. Remove the cap and loosen the 3. Remove the brake caliper mounting axle nut 1. holder bolt. 4. Place an accessory service stand or equivalent under the swing arm to help stabilize the rear end. 7-53...
  • Page 122 CAUTION Improper jacking may cause damage to the oil filter. Do not apply the jack head to the oil filter when jacking up the motorcycle. 6. Remove the wheel from the splined drive gear and set the wheel assembly on the ground. 7.

  • Page 123: Light Bulb Replacement

    Torque bolts and nuts to the proper specifi- cations. If you are not sure of the proper CAUTION procedure, have your authorized SUZUKI dealer or qualified mechanic do this. Using a light bulb with the wrong wattage rating can cause electrical system damage or shorten bulb life.
  • Page 124 Headlight 2. Disconnect socket 2 from the headlight and roll up rubber cap 3. 1. Remove two screws 1. Remove the headlight assembly. 7-56...
  • Page 125 Headlight Beam Adjustment The headlight beam can be adjusted both horizontally and vertically if neces- sary. To adjust the beam horizontally: 3. Unhook bulb holder spring 4, and pull out the bulb. CAUTION Oil from your skin may damage the head- light bulb or shorten its life.
  • Page 126 2. Turn the lens countercloskwise and remove it. Turn the adjuster 2 clockwise or coun- terclockwise. Turn Signal Light 3. Push in on the bulb, turn it to the left, and pull it out. 4. To fit the replacement bulb, push it in and turn it to the right while push- ing.
  • Page 127 Brake light/Taillight CAUTION Overtightening the screws may cause the lens to crack. Tighten the screws only until they are snug. License Plate Light 1. Loosen the two screws and re- move the lens. 1. Loosen the screws and remove the 2.

  • Page 128: Fuses/Output Terminal

    FUSES/OUTPUT TERMINAL Fuses 2. Push in on the bulb, turn it to the The fuses are located inside the left left and pull it out. frame cover. To access fuses, remove the right frame cover. The fuses are designed to open when an overload exists in individual electrical system cir- cuits.
  • Page 129 If the new fuse • 10A IGNITION fuse protects the igni- blows in a short time, consult your SUZUKI tion system, electric start system and dealer or qualified mechanic immediately. fuel pump.
  • Page 130 Output Terminal CAUTION Using electrical accessories over 120W may seriously damage the electrical sys- tem. Always use electrical accessories less than 120W. An output terminal is provided for attaching electrical accessories. To attach an electrical accessory, remove the output terminal cover and attach the wires to the terminal being certain to connect the positive wire of the acces- sory to the positive (+) output terminal...

  • Page 131: Troubleshooting

    TROUBLESHOOTING TROUBLESHOOTING ..................8-2...
  • Page 132 Loosen the drain screw located under the carburetor. If you are not sure about the properaction, Drain the fuel from the carburetor consult your authorized Suzuki dealer or into a container. qualified mechanic about the problem.
  • Page 133 c. Tighten the drain screw. !WARNING d. Turn the fuel valve lever to the “ON” position. Fuel and fuel vapor are highly flammable e. Turn the engine stop switch to and toxic. You can be burned or poisoned the “ ( ” position and the ignition when handling fuel.
  • Page 134 Keep the spark plug away from the spark tem is operating properly, a blue plug hole during this test. spark should jump across the spark plug gap. If there is no spark, take your machine to your authorized Suzuki dealer qualified mechanic.
  • Page 135 COMPLAINT: Engine stalls • Make sure there is enough fuel in the fuel tank. • Check to see that the spark plug is not fouled. Remove the plug and clean it. Replace it, if necessary. • Make sure the fuel valve is not clogged.

  • Page 137: Storage Procedure And Appearance Care

    STORAGE PROCEDURE AND APPEAR- ANCE CARE MOTORCYCLE ....................9- 2 FUEL ........................9- 3 ENGINE......................9- 4 BATTERY......................9- 4 TIRES .........................9- 5 EXTERNAL ......................9- 5 MAINTENANCE DURING STORAGE ...............9- 6 PROCEDURE FOR RETURNING TO SERVICE..........9- 6 CORROSION PREVENTION ................9- 7 MOTORCYCLE CLEANING ................9- 9 INSPECTION AFTER CLEANING..............9-11...

  • Page 138: Motorcycle

    For this reason, Suzuki recommends that you trust this maintenance work to your authorized Suzuki dealer. If you wish to service the machine for storage your- self, follow the general guidelines below:...

  • Page 139: Fuel

    FUEL !WARNING 1. Fill the fuel tank to the top with fuel mixed with the amount of gasoline Fuel and fuel vapor are highly flammable stabilizer recommended by the sta- and toxic. You can be burned or poisoned bilizer manufacturer. when handling fuel.

  • Page 140: Engine

    ENGINE BATTERY 1. Pour one tablespoon of motor oil 1. Remove the battery from the motor- into each spark plug hole. Reinstall cycle. the spark plugs and crank the 2. Clean the outside of the battery engine a few times. with mild soap and remove corro- 2.

  • Page 141: Tires

    TIRES EXTERNAL Inflate tires to the normal pressure. 1. Spray all vinyl and rubber parts with rubber protectant. 2. Spray unpainted surfaces with rust preventative. 3. Coat painted surfaces with car wax.

  • Page 142: Maintenance During Storage

    MAINTENANCE DURING STORAGE PROCEDURE FOR RETURNING TO SERVICE Once a month, recharge the battery. The standard charging rate is 1.4 A × 5 1. Clean the entire motorcycle. hours. 2. Remove the oily rags from the air cleaner intake and muffler outlet. 3.

  • Page 143: Corrosion Prevention

    CORROSION PREVENTION The above signifies the necessity of keeping your motorcycle as clean and It is important to take good care of your dry as possible. It is equally important motorcycle to protect it from corrosion. to repair any damage to the paint or protective coatings as soon as possible.
  • Page 144 Suzuki dealer or qualified mechanic Be sure that any cleaner you use is not make the repair. harmful to painted surfaces and is spe- Store your motorcycle in a dry, well- cifically intended for your purposes.

  • Page 145: Motorcycle Cleaning

    Your authorized Suzuki 2. Wash the entire motorcycle with dealer can help you select the right mild detergent or car wash soap cover for your motorcycle.
  • Page 146 3. Once the dirt has been completely CAUTION removed, rinse off the detergent with running water. Radiator and oil cooler fins can be dam- 4. After rinsing, wipe off the motorcy- aged by spraying high pressure water on cle with a wet chamois or cloth and them.

  • Page 147: Inspection After Cleaning

    INSPECTION AFTER CLEANING Waxing the Motorcycle After washing the motorcycle, waxing For extended life of your motorcycle, and polishing are recommended to fur- lubricate according GENERAL ther protect and beautify the paint. LUBRICATION section. • Only use waxes and polishes of good quality.
  • Page 148 9-12...

  • Page 149: Consumer Information

    CONSUMER INFORMATION EMISSION CONTROL WARRANTY ..............10-2 TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED......10-3 SERIAL NUMBER LOCATION................10-4 REPORTING SAFETY DEFECTS ..............10-5 LOCATION OF LABELS ...................10-6 10-1...

  • Page 150: Emission Control Warranty

    Distance EMISSION CONTROL WARRANTY 12 000 km Class I 50 to 169 cc (7 456 miles) Suzuki Motor Corporation warrants to 18 000 km the ultimate purchaser and each subse- Class II 170 to 279 cc (11 185 miles) quent purchaser that this vehicle is...

  • Page 151: Tampering With Noise Control System Prohibited

    • Removing or puncturing the air inoperative by any person. cleaner case, air cleaner cover, baf- fles, or any other component which conducts intake air. Whenever replacing parts on your motorcycle, Suzuki recommends that you use genuine Suzuki replacement parts or their equivalent. 10-3...

  • Page 152: Serial Number Location

    You also need these numbers to help your authorized Suzuki dealer when you order parts. The frame number 1 is stamped on the steering head as shown in the illustra- tion. The engine serial number 2 is stamped on the right side of the crank- case assembly.

  • Page 153: Reporting Safety Defects

    (NHTSA) in addition to notifying Ameri- vehicle safety from the Hotline. can Suzuki Motor Corp. To contact American Suzuki, owners in If NHTSA receives similar complaints, it the continental United States can call may open an investigation, and if it...

  • Page 154: Location Of Labels

    LOCATION OF LABELS Read and follow all of the warnings !WARNING labeled on your motorcycle. Make sure you understand all of the labels. Keep Failure to follow these safety precautions the labels on your motorcycle. Do not may increase your risk of injury: remove them for any reason.
  • Page 155 Read Owner’s manual for more information. If the vehicle has been resold, obtain the SOLO RIDING DUAL RIDING COLD TIRE owner’s manual from the previous owner PRESSURE kgf/cm² kgf/cm² or contact your local SUZUKI dealer for FRONT 2.00 2.00 assistance. 2.00 2.00 REAR FRONT...

  • Page 156: Specifications

    SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length............2335 mm (91.9 in) Overall width ............. 765 mm (30.1 in) Overall height............1145 mm (45.1 in) Wheelbase..............1620 mm (63.8 in) Ground clearance ............. 150 mm (5.9 in) Seat height..............740 mm (28.9 in) Dry mass..............
  • Page 157 TRANSMISSION Clutch................ Wet multi-plate type Transmission ............5-speed constant mesh Gearshift pattern ............1-down, 4-up Primary reduction ratio..........1.645 (79/48) Secondary reduction ratio......... 0.852 (29/34219/19) Final reduction ratio ..........2.666 (32/12) Gear ratios, Low............3.000 (36/12) 2nd ............1.823 (31/17) 3rd ............
  • Page 158 ELECTRICAL Ignition type .............. Electronic ignition (Transistorized) Spark plug..............NGK DPR8EA-9 or DENSO X24EPR-U9 Battery ..............12V 50.4 kC (14 Ah)/10HR Generator..............Three-phase A.C. generator Fuse................25/10/10/10/10 A Headlight..............12V 60/55W Brake light/Taillight ........... 12V 27/8W Front turn signal light ..........12V 21/5W Rear turn signal light..........

  • Page 160: Index

    INDEX ......... 7-36 ACCESSORY USE AND MOTORCYCLE LOAD- FINAL GEAR OIL .............6-2 ....7-50 FRONT WHEEL REMOVAL ........7-12 ..........2-2 AIR CLEANER FUEL ......... 3-14 FUEL TANK CAP ........3-15 FUEL VALVE ........7-9 ....7-60 BATTERY FUSES/OUTPUT TERMINAL ..........7-38 BRAKES ..........4-2 BREAK-IN ..........
  • Page 161 ............3-5 ......3-19 REAR BRAKE PEDAL ......3-22 REAR SUSPENSION ..... 7-52 REAR WHEEL REMOVAL .......3-10 ..10-5 LEFT HANDLEBAR REPORTING SAFETY DEFECTS ....7-55 ........5-6 LIGHT BULB REPLACEMENT RIDING ON HILLS ......10-6 ......3-11 LOCATION OF LABELS RIGHT HANDLEBAR ......3-2 LOCATION OF PARTS ....
  • Page 162 TAMPERING WITH NOISE CONTROL SYSTEM ........10-3 PROHIBITED ..1-2 THE SPORT OF MOTORCYCLING .........7-44 TIRES ..........7-7 TOOLS ......8-2 TROUBLESHOOTING ....5-5 USING THE TRANSMISSION Total page: 160...
  • Page 163 WARNING Failure to follow these safety precautions may increase your risk of injury: Wear a helmet, eye protection, and bright protective clothing. Don’t ride after consuming alcohol or other drugs. Slow down on slippery surfaces, unfamiliar terrain or when visibility is reduced. Read owner’s manual carefully.

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