Suzuki FU150MF Owner's Manual
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Suzuki FU150MF Owner's Manual

Suzuki FU150MF Owner's Manual

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FU150MF
OWNER'S MANUAL

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  • Page 1 FU150MF OWNER’S MANUAL...
  • Page 2 This manual should be considered a permanent part of the motorcycle and should remain with the motorcycle when resold or otherwise transferred to a new owner or operator. The manual contains important safety information and instructions which should be read carefully before operating the motorcycle.
  • Page 3 FOR YOUR MOTORCYCLE The first 1600 km are the most important in the life of your motorcycle. Proper break-in operation during this time will help ensure maximum life and performance from your new motorcycle. Suzuki parts are manufac- tured high quality materials, machined parts are finished to close toler- ances.
  • Page 4 Tai Nguyen; ; 06.02.2022 22:42.  WARNING/ CAUTION/NOTICE/NOTE NOTICE Please read this manual and follow its instructions carefully. To emphasize special Indicates a potential hazard that could information, the symbol  and the words result in motorcycle or equipment dam- WARNING, CAUTION, NOTICE and NOTE age.
  • Page 5 By following these instructions explicitly you will ensure a long trouble-free operating life for your motorcycle. Your Suzuki dealer has experienced technicians that are trained to provide your machine with the best possi- ble service with the right tools and equip- ment.
  • Page 6 Tai Nguyen; ; 06.02.2022 22:42.

  • Page 7: Table Of Contents

    Tai Nguyen; ; 06.02.2022 22:42. TABLE OF CONTENTS CONSUMER INFORMATION CONTROLS FUEL, ENGINE OIL AND COOLANT RECOMMENDATIONS BREAK-IN (RUNNING-IN) AND INSPECTION BEFORE RIDING RIDING TIPS INSPECTION AND MAINTENANCE TROUBLESHOOTING STORAGE PROCEDURE AND MOTORCYCLE CLEANING SPECIFICATIONS INDEX...
  • Page 8 Tai Nguyen; ; 06.02.2022 22:42.

  • Page 9: Consumer Information

    Tai Nguyen; ; 06.02.2022 22:42. CONSUMER INFORMATION ACCESSORY USE AND MOTORCYCLE LOADING ................1-2 SAFE RIDING RECOMMENDATION FOR MOTORCYCLE RIDERS ............1-5 LABELS ..............................1-7 SERIAL NUMBER LOCATION ........................1-7...

  • Page 10: Accessory Use And Motorcycle Loading

    Install and use them accord- ing the accessories on your motorcycle and ing to their instructions. If you have any consult your Suzuki dealer if you have any questions, contact your Suzuki dealer. questions.
  • Page 11 Tai Nguyen; ; 06.02.2022 22:42. ACCESSORY INSTALLATION GUIDELINES • Select an accessory which does not limit • Install aerodynamic-affecting accesso- the freedom of rider movement. ries, such as a fairing, windshield, back- • Select an electric accessory which does rests, saddlebags, and travel trunks, as not exceed motorcycle’s electrical sys- low as possible, as close the motorcycle tem capacity.
  • Page 12 Tai Nguyen; ; 06.02.2022 22:42. LOADING GUIDELINES • Do not carry any items that protrude over the tail end of the motorcycle.  WARNING • Check that both tires are properly inflated to the specified tire pressure for your loading conditions. Refer to page 6- Overloading or improper loading can cause loss of motorcycle control and an •...

  • Page 13: Safe Riding Recommendation For Motorcycle Riders

    Tai Nguyen; ; 06.02.2022 22:42. SAFE RIDING RECOMMENDATION FOR RIDING CAPACITY Capacity of this motorcycle is limited to two MOTORCYCLE RIDERS persons only. Do not admit any riders if Motorcycle riding is great fun and an excit- there’s no seat available, nor load luggages ing sport.
  • Page 14 Tai Nguyen; ; 06.02.2022 22:42. KNOW YOUR LIMITS RIDE DEFENSIVELY Ride within the boundaries of your own skill The most common type of motorcycle acci- at all times. Knowing these limits and stay- dent occurs when a car traveling towards a ing within them will help you to avoid acci- motorcycle turns round corner in front of the dents.

  • Page 15: Labels

    Tai Nguyen; ; 06.02.2022 22:42. LABELS SERIAL NUMBER LOCATION Read and follow all the labels on the motor- The frame and/or engine serial numbers are cycle. Make sure you understand all of the used to register the motorcycle. They are labels.
  • Page 16 Tai Nguyen; ; 06.02.2022 22:42. Please write down the numbers here for your reference. Frame No.: Engine No.: The frame number 1 is stamped on the steering head tube. The engine serial num- ber 2 is stamped on the crankcase assem- bly.

  • Page 17: Controls

    Tai Nguyen; ; 06.02.2022 22:42. CONTROLS LOCATION OF PARTS ..........................2-2 KEY ................................2-5 IGNITION SWITCH ............................. 2-6 INSTRUMENT PANEL ..........................2-9 LEFT HANDLEBAR ..........................2-20 RIGHT HANDLEBAR ..........................2-22 FUEL TANK CAP ............................2-24 KICK STARTER LEVER ........................... 2-25 GEARSHIFT LEVER ..........................

  • Page 18: Location Of Parts

    Tai Nguyen; ; 06.02.2022 22:42. CONTROLS LOCATION OF PARTS 1 Clutch lever 6 Ignition switch 2 Left handlebar switches 7 Engine coolant reservoir 3 Instrument panel 8 Electric starter switch 4 Front brake fluid reservoir 9 Throttle grip 5 Front brake lever...
  • Page 19 Tai Nguyen; ; 06.02.2022 22:42. 0 Front box F Seat lock A Air screw G Gearshift lever B Helmet holders H Engine oil drain plug C Fuel tank cap I Center stand D Tools J Side stand E Battery and fuses K Passenger footrests...
  • Page 20 Tai Nguyen; ; 06.02.2022 22:42. L Rear brake fluid reservoir Q Rear brake light switch M Air cleaner R Rear brake pedal N Kick starter lever S Engine oil inspection window O Engine oil filler cap T Engine oil filter P Spark plug...

  • Page 21: Key

    Tai Nguyen; ; 06.02.2022 22:42. The key number is stamped on a plate pro- vided with the keys. This number is used when making replacement keys. Please write your key number in the box provided for your future reference. Key No. This motorcycle comes equipped with a main ignition key and a spare one.

  • Page 22: Ignition Switch

    Tai Nguyen; ; 06.02.2022 22:42. IGNITION SWITCH To open the ignition key-hole shutter: To close the ignition key-hole shutter: 1. Match the ignition key head to the hole at the right of the ignition switch. Push the key-hole shutter knob 1 to close 2.
  • Page 23 Tai Nguyen; ; 06.02.2022 22:42. “ON” Position The ignition circuit is completed and the engine can now be started. The position light, license plate light and taillight will auto- matically be turned on when the key is in this position. The key cannot be removed from the ignition switch in this position.
  • Page 24 Moving the ignition switch off immediately. Ask your motorcycle while the steering is locked authorized Suzuki dealer to inspect the can be hazardous. You could lose your motorcycle for unseen damage. balance and fall, or you could drop the motorcycle.

  • Page 25: Instrument Panel

    Tai Nguyen; ; 06.02.2022 22:42. INSTRUMENT PANEL The display indicates the opening pattern shown below: 9 10 11 12 13 9 10 11 12 13 HIGH GEAR All LCD display TRIP km/h INTERVAL OIL CHANGE 9 10 11 12 13 The engine rpm indicator light 9, malfunc- FU READY.
  • Page 26 Tai Nguyen; ; 06.02.2022 22:42. SPEEDOMETER 4 The speedometer indicates the road speed in kilometers per hour. 9 10 11 12 13 TACHOMETER 5 HIGH The tachometer indicates the engine speed GEAR TRIP km/h in revolutions per minute (r/min). INTERVAL OIL CHANGE TURN SIGNAL INDICATOR LIGHT “”...
  • Page 27 Tai Nguyen; ; 06.02.2022 22:42. CLOCK 6 NOTE: When the SEL button 1 or ADJ button • 2 is pressed and held, the display will increase continuously. • The clock can be adjusted when the igni- tion switch is in the “ON” position. Time is shown when the ignition switch is in •...
  • Page 28 Tai Nguyen; ; 06.02.2022 22:42. Approximately Approximately Fuel tank Full 0.4 L 1.0 L Blink 9 10 11 12 13 Fuel segment HIGH GEAR TRIP km/h INTERVAL OIL CHANGE Blink Blink  mark FUEL METER “” 8 The fuel meter indicates the amount of fuel NOTE: The fuel meter will not indicate cor- remaining in the fuel tank.
  • Page 29 Tai Nguyen; ; 06.02.2022 22:42. OFF/LOW/HIGH/VOLUNTARINESS Mode LOW mode selection Engine rpm To change the display D, push the ADJ button Engine rpm (r/min) indicator light 9 2. The display changes in the order below. 0  engine rpm < 4000 No light 4000 ...
  • Page 30 Tai Nguyen; ; 06.02.2022 22:42. 4. After selecting the lighting mode or blink- ing mode, push the SEL button 1 to change preset engine rpm setting. 5. Push the ADJ button 2 to set preset 9 10 11 12 13 engine rpm.
  • Page 31 Suzuki dealer. If the engine A. The malfunction indicator light 0 comes stalls, try restarting the engine after turn- on and remains lit.
  • Page 32 Tai Nguyen; ; 06.02.2022 22:42. NOTICE Riding the motorcycle with the coolant 9 10 11 12 13 temperature indicator lit can cause seri- HIGH ous engine damage due to overheating. GEAR TRIP km/h INTERVAL OIL CHANGE If the engine coolant temperature indica- tor light comes on, stop the engine to let it cool.
  • Page 33 Tai Nguyen; ; 06.02.2022 22:42. OIL CHANGE INDICATOR C To preset the oil change interval: 1. Set the meter to odometer, then press and hold the ADJ button 2 for 2 sec- INTERVAL OIL CHANGE onds until the INTERVAL and OIL CHANGE indicators blink.
  • Page 34 Tai Nguyen; ; 06.02.2022 22:42. To change the display, push the SEL button 1. The display changes in the order below. 9 10 11 12 13 HIGH Odometer GEAR TRIP km/h INTERVAL OIL CHANGE TRIP ODOMETER/TRIP METER E The display has 3 functions; odometer and Trip meter A two trip meters.
  • Page 35 Tai Nguyen; ; 06.02.2022 22:42. NEUTRAL INDICATOR LIGHT “N” F ODOMETER The odometer registers the total distance The green light will come on when the trans- that the motorcycle has been ridden. The mission is in neutral. The light will go out odometer ranges from 0 to 999999.

  • Page 36: Left Handlebar

    Tai Nguyen; ; 06.02.2022 22:42. DIMMER SWITCH 2 LEFT HANDLEBAR “” position The headlight low beam and taillight turn on. “” position The headlight high beam, low beam and tail- light turn on. The high beam indicator light also turns on. NOTICE Sticking tape or placing objects in front CLUTCH LEVER 1...
  • Page 37 Tai Nguyen; ; 06.02.2022 22:42.  WARNING NOTICE Do not put objects in front of the head- Failure to use the turn signals, and fail- light or taillight when they are on, and do ure to turn off the turn signals can be not cover with clothes when the motor- hazardous.

  • Page 38: Right Handlebar

    This motorcycle is equipped with a disk Suzuki dealer for checking. brake system and excessive pressure is not required to slow the machine down properly. • When the neutral indicator light comes...
  • Page 39 Tai Nguyen; ; 06.02.2022 22:42. Suzuki Easy Start System NOTICE Suzuki Easy Start System permits engine start by simple one-push action on the elec- Engaging the starter motor for more tric starter switch. When the transmission is than five seconds at a time can damage...

  • Page 40: Fuel Tank Cap

    Tai Nguyen; ; 06.02.2022 22:42. FUEL TANK CAP 1 Fuel level 2 Filler neck Fuel tank is located under the seat. To open the fuel tank cap, turn it counterclockwise.  WARNING To close the fuel tank cap, turn it clockwise until align the cap triangle mark to tray trian- If you overfill the fuel tank, fuel may gle mark.

  • Page 41: Kick Starter Lever

    Tai Nguyen; ; 06.02.2022 22:42. KICK STARTER LEVER  WARNING Failure to follow safety precautions when refueling could result in a fire or cause you to breathe toxic fumes. Refuel in a well ventilated area. Make sure the engine is off and avoid spilling fuel on a hot engine.

  • Page 42: Gearshift Lever

    Tai Nguyen; ; 06.02.2022 22:42. 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 illuminated, cautiously release the clutch lever slowly to confirm the transmis- sion is in neutral.

  • Page 43: Rear Brake Pedal

    Tai Nguyen; ; 06.02.2022 22:42. REAR BRAKE PEDAL SEAT LOCK AND HELMET HOLDERS SEAT LOCK Depressing the rear brake pedal will apply the rear brake. The brake light will be lit when the rear brake is operated. To unlock the seat lock, insert the ignition key into the lock and turn it clockwise.

  • Page 44: Stands

    Tai Nguyen; ; 06.02.2022 22:42. HELMET HOLDERS STANDS This motorcycle is equipped with a center stand and side stand. CENTER STAND 1 To place the motorcycle on the center stand, place your right foot on the stand extension, hold the handlebars with your left hand and hold the passenger hand rail with your right hand.
  • Page 45 Tai Nguyen; ; 06.02.2022 22:42. SIDE STAND 2 NOTICE To place the motorcycle on the side stand, place your right foot on the end of the side If you do not take proper precautions stand and push down firmly until the stand when parking, the motorcycle can fall pivots fully through its arc and comes to rest over.

  • Page 46: Front Box

    Tai Nguyen; ; 06.02.2022 22:42. FRONT BOX This motorcycle is equipped with the front box. To open the front box: Insert the ignition key into the lock and turn it counterclockwise to open the lid. To close the front box: Close the lid, Insert the ignition key into the lock and turn it clockwise to lock the lid.
  • Page 47 Tai Nguyen; ; 06.02.2022 22:42. NOTE:  WARNING • temperature inside increases due to the heat from the Opening the box lid while riding can be engine and direct sunlight. Do not keep hazardous. Removing a hand from the any flammable items, low heat-resistant handlebars can reduce your ability to items, foods or drink in the box.
  • Page 48 Tai Nguyen; ; 06.02.2022 22:42.

  • Page 49: Fuel, Engine Oil And Coolant Recommendations

    Tai Nguyen; ; 06.02.2022 22:42. FUEL, ENGINE OIL AND COOLANT RECOMMENDATIONS FUEL ................................3-2 ENGINE OIL ..............................3-3 ENGINE COOLANT SOLUTION ........................ 3-5...
  • Page 50 Tai Nguyen; ; 06.02.2022 22:42. FUEL, ENGINE OIL AND improved by changing, consult your Suzuki dealer. COOLANT RECOMMENDATIONS NOTICE FUEL Spilled gasoline containing alcohol can Use unleaded gasoline with an octane rating damage the painted surfaces of your higher (Research method).
  • Page 51 Suzuki recommends the use of SAE 10W- Use Suzuki genuine engine oil or equivalent. 40 engine oil. If SAE 10W-40 engine oil is If Suzuki genuine engine oil is not available, not available, select an alternative according select a proper engine oil according to the to the following chart.
  • Page 52 Tai Nguyen; ; 06.02.2022 22:42. JASO T903 Energy Conserving The JASO T903 standard is an index to Suzuki does not recommend the use of select engine oils for 4-stroke motorcycle “ENERGY CONSERVING” or “RESOURCE and ATV engines. Motorcycle and ATV CONSERVING”...
  • Page 53 Tai Nguyen; ; 06.02.2022 22:42. API SG, SH, SJ or SL ENGINE COOLANT SOLUTION Use “SUZUKI SUPER LONG LIFE COOL- ANT” or “SUZUKI LONG LIFE COOLANT”. If “SUZUKI SUPER LONG LIFE COOLANT” 20W-50 and “SUZUKI LONG LIFE COOLANT” are not available, use a glycol-based antifreeze compatible with an aluminum radiator mixed with distilled water only at the ratio of 50:50.
  • Page 54 Tai Nguyen; ; 06.02.2022 22:42. SUZUKI SUPER LONG LIFE COOLANT NOTICE (Blue) “SUZUKI SUPER LONG LIFE COOLANT” is Spilled engine coolant can damage the pre-mixed to the proper ratio. Add only painted surfaces of your motorcycle. “SUZUKI SUPER LONG LIFE COOLANT” if coolant level drops.
  • Page 55 Tai Nguyen; ; 06.02.2022 22:42. SUZUKI LONG LIFE COOLANT (Green) Water for mixing Use distilled water only. Water other than distilled water can corrode and clog the alu- minium radiator. Required amount of water/coolant Solution capacity (total): 1260 ml Water...
  • Page 56 Tai Nguyen; ; 06.02.2022 22:42.

  • Page 57: Break-In (Running-In) And Inspection Before Riding

    Tai Nguyen; ; 06.02.2022 22:42. BREAK-IN (RUNNING-IN) AND INSPECTION BEFORE RIDING INSPECTION BEFORE RIDING ......................... 4-4...
  • Page 58 This break-in is to achieve maximum life and per- aids the mating process of the parts. It is formance from your new Suzuki. The follow- essential that some stress be placed on the ing guidelines explain proper break-in engine components during break-in to procedures.
  • Page 59 Tai Nguyen; ; 06.02.2022 22:42. BREAKING IN THE NEW TIRES AVOID CONSTANT LOW SPEED New tires need proper break-in to assure Operating the engine at constant low speed maximum performance, just as the engine (light load) can cause parts to glaze and not does.
  • Page 60 Tai Nguyen; ; 06.02.2022 22:42. OBSERVE YOUR FIRST AND INSPECTION BEFORE RIDING MOST CRITICAL SERVICE  WARNING The 1000 km service is the most important service your motorcycle will receive. During break-in all of the engine components will Failure to inspect your motorcycle have worn in and all of the other parts will before riding and to properly maintain have seated in.
  • Page 61 Tai Nguyen; ; 06.02.2022 22:42.  WARNING  WARNING If you operate this motorcycle with Checking maintenance items when the improper tires or improper or uneven tire engine is running can be hazardous. You pressure, you may lose control of the could be severely injured if your hands motorcycle.
  • Page 62 Tai Nguyen; ; 06.02.2022 22:42. Tires • Correct pressure WHAT TO CHECK FOR: ( 6-49) • Adequate tread depth CHECK • No cracks or cuts Steering • Smoothness Engine oil Correct level • No restriction of movement ( 6-30) • No play or looseness Cooling system •...

  • Page 63: Riding Tips

    Tai Nguyen; ; 06.02.2022 22:42. RIDING TIPS STARTING THE ENGINE ........................... 5-2 STARTING OFF ............................5-4 USING THE TRANSMISSION ........................5-6 RIDING ON HILLS ............................5-7 STOPPING AND PARKING ........................5-7...

  • Page 64: Starting The Engine

    If these conditions are not “ON” position. indicated on the indicator, consult your Suzuki dealer for checking.  WARNING • When the neutral indicator light comes Starting the engine improperly can be on, the gear position indicator should hazardous.
  • Page 65 When the Engine is Warm: Suzuki Easy Start System Close the throttle grip and push the electric Suzuki Easy Start System permits engine starter switch or depress the kick starter lever. start by simple one-push action on the elec- tric starter switch. When the transmission is ...

  • Page 66: Starting Off

    Tai Nguyen; ; 06.02.2022 22:42. STARTING OFF  WARNING  WARNING If you remove even one hand or foot from the motorcycle, you can reduce Riding at excessive speeds increases your ability to control the motorcycle. your chances of losing control of the This could cause you to lose your bal- motorcycle, which can result in an acci- ance and fall off the motorcycle.
  • Page 67 Tai Nguyen; ; 06.02.2022 22:42. After moving the side stand to the fully up  WARNING position, squeeze the clutch lever in and pause momentarily. Engage first gear by Sudden side winds, which can occur depressing the gearshift lever downward. when being passed by larger vehicles, at Turn the throttle grip toward you and at the tunnel exits or in hilly areas, can cause...

  • Page 68: Using The Transmission

    Tai Nguyen; ; 06.02.2022 22:42. USING THE TRANSMISSION WARNING The transmission is provided to keep the engine operating smoothly in its normal Downshifting while the motorcycle is operating speed range. The gear ratios have leaned over in a corner may cause rear been carefully chosen to meet the charac- wheel skid and loss of control.

  • Page 69: Riding On Hills

    Tai Nguyen; ; 06.02.2022 22:42. RIDING ON HILLS STOPPING AND PARKING • When climbing steep hills, the motorcy- 1. Twist the throttle grip away from yourself cle may begin to slow down and show to close the throttle completely. lack of power. At this point you should 2.
  • Page 70 Tai Nguyen; ; 06.02.2022 22:42.  WARNING  WARNING Hard braking while turning may cause Following another vehicle too closely wheel skid and loss of control. can lead to a collision. As vehicle speeds increase, stopping distance Brake before you begin to turn. increases progressively.
  • Page 71 Tai Nguyen; ; 06.02.2022 22:42. 5. Park the motorcycle on a firm, flat sur-  CAUTION face where it will not fall over. A hot muffler can cause severe burns. NOTE: If the motorcycle is to be parked on The muffler will be hot enough to cause the side stand on a slight slope, the front burns for some time after stopping the end of the motorcycle should face “up”...
  • Page 72 Tai Nguyen; ; 06.02.2022 22:42.

  • Page 73: Inspection And Maintenance

    Tai Nguyen; ; 06.02.2022 22:42. INSPECTION AND MAINTENANCE MAINTENANCE SCHEDULE ........................6-2 TOOLS ................................ 6-6 LUBRICATION POINTS ..........................6-6 BATTERY ..............................6-8 UNDER COWLINGS AND FRONT BOX REMOVAL ................6-12 SPARK PLUG ............................6-15 AIR CLEANER ............................6-18 IDLE SPEED ADJUSTMENT ........................6-23 FUEL HOSE ..............................

  • Page 74: Maintenance Schedule

    Keep your motorcycle in good condition. At the end of each interval, be sure to Ask your Suzuki dealer or a qualified inspect, check, lubricate and service as mechanic to perform the maintenance instructed. If your motorcycle is used under items marked with an asterisk (*).
  • Page 75 If you cause your motorcycle to wear more have any questions regarding maintenance quickly and may shorten its useful life. intervals, consult your Suzuki dealer or a qualified mechanic. When replacing parts on your vehicle, use only genuine Suzuki replacement...
  • Page 76 Engine oil ( 6-30) Engine oil filter ( 6-30) – Throttle cable play ( 6-24) Idle speed ( 6-23) “SUZUKI SUPER LONG Replace every 4 years or 16000 km LIFE COOLANT” (Blue) “SUZUKI LONG LIFE * Engine coolant COOLANT” (Green) or an (...
  • Page 77 Tai Nguyen; ; 06.02.2022 22:42. Interval months Item 1000 4000 8000 Drive chain ( 6-36) Clean and lubricate every 1000 km Brake ( 6-42) – Brake hose ( 6-42) * Replace every 4 years – Brake fluid ( 6-43) * Replace every 2 years Tires (...

  • Page 78: Tools

    Tai Nguyen; ; 06.02.2022 22:42. TOOLS LUBRICATION POINTS Proper lubrication is important for smooth and long life of each working part of your motorcycle and also for safe riding. It is a good practice to lubricate the motorcycle after a long rough ride and after getting it wet in the rain or after washing it.
  • Page 79 Tai Nguyen; ; 06.02.2022 22:42. 1..Clutch lever pivot 2..Side stand pivot and spring hook 3..Center stand pivot and spring hook 4..Drive chain 5..Front brake lever pivot 6..Throttle cable 7..Rear brake pedal pivot 8..Kick starter lever pivot  ..Grease ..Drive chain lubricant...

  • Page 80: Battery

    Tai Nguyen; ; 06.02.2022 22:42. BATTERY  WARNING The battery is a sealed type battery and requires no maintenance. Have your dealer Diluted sulfuric acid from the battery can check the battery’s state of charge periodi- cause blindness or severe burns. cally.
  • Page 81 Tai Nguyen; ; 06.02.2022 22:42. BATTERY REMOVAL NOTICE To remove the battery, follow the procedure below: Exceeding the maximum charging rate for the battery can shorten its life. 1. Place the motorcycle on the center stand. Never exceed the maximum charging 2.
  • Page 82 Tai Nguyen; ; 06.02.2022 22:42. To install the battery:  WARNING 1. Install the battery in the reverse order of removal. Batteries contain toxic substances 2. Connect the battery terminals securely. including sulfuric acid and lead. They could cause injury to humans or could NOTICE damage the environment.
  • Page 83 For more detailed information about disposing or recycling of the used bat- tery, consult your Suzuki dealer. The crossed-out wheeled bin symbol A located on the battery label indicates that a used battery should be collected separately from ordinary household waste.

  • Page 84: Under Cowlings And Front Box Removal

    Tai Nguyen; ; 06.02.2022 22:42. UNDER COWLINGS AND FRONT BOX REMOVAL 1. Place the motorcycle on the center stand. 2. Open the front box by referring to the FRONT BOX section. 3. Remove the right and left screws and fasteners. 6-12...
  • Page 85 Tai Nguyen; ; 06.02.2022 22:42. 4. Unhook the hooks 6. Remove the right and left bolts. 5. Remove the right and left under cowlings 6-13...
  • Page 86 Tai Nguyen; ; 06.02.2022 22:42. 7. Open the seat by referring to the SEAT 8. Remove the screw. LOCK AND HELMET HOLDERS sec- tion. Remove the right and left fasteners. 6-14...

  • Page 87: Spark Plug

    Tai Nguyen; ; 06.02.2022 22:42. SPARK PLUG SPARK PLUG REMOVAL To remove the spark plug, follow the proce- dure below: 1. Remove the right side under cowling by referring to the UNDER COWLINGS AND FRONT BOX REMOVAL section. 9. Pull off the front box assembly 2. 10.
  • Page 88 Tai Nguyen; ; 06.02.2022 22:42. SPARK PLUG INSPECTION 3. Remove the spark plug with a spark plug 0.8 – 0.9 mm wrench. Adjust the spark plug gap to 0.8 – 0.9 mm by using a spark plug gap thickness gauge. The spark plug should be replaced periodi- cally.
  • Page 89 Use one of the spark plugs listed or their Carefully turn the spark plug by hand equivalent. Consult your Suzuki dealer if into the threads. If the spark plug is new, you are not sure which spark plug is cor- tighten it with a wrench about 1/2 turn rect for your type of usage.

  • Page 90: Air Cleaner

    Tai Nguyen; ; 06.02.2022 22:42. AIR CLEANER  WARNING If the elements have become clogged with dust, intake resistance will increase with a Operating the engine without the air resultant decrease in power output and an cleaner element in place can be hazard- increase in fuel consumption.
  • Page 91 Tai Nguyen; ; 06.02.2022 22:42. Follow the procedure below to remove the NOTICE air cleaner element. Failure to inspect the air cleaner element 1. Place the motorcycle on the center frequently if the vehicle is used in dusty, stand. wet, or muddy conditions can damage your motorcycle.
  • Page 92 Tai Nguyen; ; 06.02.2022 22:42. 3. Remove the air cleaner element 2. 4. Inspect the air cleaner element condi- tion. Replace the air cleaner element periodically. NOTICE Compressed air can damage the air cleaner element. Do not blow the air cleaner element with compressed air.
  • Page 93 Tai Nguyen; ; 06.02.2022 22:42. 5. Reinstall the checked element or new air NOTICE cleaner element in reverse order of removal. Be absolutely sure that the ele- Failure to position the air cleaner ele- ment is securely in position and is seal- ment properly can allow dirt to bypass ing properly.
  • Page 94 Tai Nguyen; ; 06.02.2022 22:42. Air Cleaner Drain Plug Remove the plug and drain water and oil at the periodic maintenance interval. The air cleaner drain plug is located beneath the air cleaner box. 6-22...

  • Page 95: Idle Speed Adjustment

    Tai Nguyen; ; 06.02.2022 22:42. IDLE SPEED ADJUSTMENT 1. Remove the left under cowling by refer- ring to the UNDER COWLINGS AND FRONT BOX REMOVAL section. 2. Start up the engine and let the engine run until it warms up fully. 3.
  • Page 96 Tai Nguyen; ; 06.02.2022 22:42. THROTTLE CABLE ADJUSTMENT To adjust the cable play: 1. Remove the boot 1. 2. Loosen the lock nut 2. 3. Turn the adjuster 3 so that the throttle grip has 2.0 – 4.0 mm play. 4.

  • Page 97: Fuel Hose

    Tai Nguyen; ; 06.02.2022 22:42. THROTTLE CABLE BOOTS FUEL HOSE 1. Remove the right side under cowling by referring to the UNDER COWLINGS AND FRONT BOX REMOVAL section. The throttle cable have a boots. Check that the boots are fit securely. Do not apply water directly to the boots when washing.

  • Page 98: Clutch

    4. Minor adjustment can now be made with the adjuster 2. 5. Tighten the lock nuts, 1 and 3, after fin- ishing adjustment. NOTE: Any maintenance of the clutch other than the clutch cable play should be per- formed by your Suzuki dealer. 6-26...
  • Page 99 Tai Nguyen; ; 06.02.2022 22:42. COOLANT The coolant should be kept between the “F” (FULL) and “L” (LOW) level lines in the res- COOLANT LEVEL ervoir tank at all times. Inspect the level every time before riding with the motorcycle held vertically.
  • Page 100 Tai Nguyen; ; 06.02.2022 22:42. Unhook the hook and remove the maintenance Remove the filler cap and add specified lid. engine coolant through the filler hole until it reaches the “F” line. Refer to the FUEL, ENGINE OIL AND COOLANT RECOM- MENDATIONS section.

  • Page 101: Coolant

    Immediately contact a poison age or engine coolant leakage. If any control center or a physician. Avoid defects are found, ask your Suzuki dealer to inhaling mist or hot vapors; if inhaled, replace the radiator hose with a new one.

  • Page 102: Engine Oil

    Tai Nguyen; ; 06.02.2022 22:42. ENGINE OIL Long engine life depends much on the selection of a quality oil and the periodic changing of the oil. Daily oil level checks and periodic changes are two of the most impor- tant maintenance items to be performed. ENGINE OIL LEVEL CHECK Follow the procedure below to inspect the engine oil level.
  • Page 103 Tai Nguyen; ; 06.02.2022 22:42. NOTICE Operating the motorcycle with too little or too much oil can damage the engine. Place the motorcycle on level ground. Check the oil level with the engine oil inspection window before each use of the vehicle.
  • Page 104 Tai Nguyen; ; 06.02.2022 22:42. ENGINE OIL AND FILTER CHANGE Change the engine oil and oil filter at the scheduled time. The oil should be changed when the engine is warm so that the oil will drain thoroughly from the engine. The pro- cedure is as follows: 1.
  • Page 105 Tai Nguyen; ; 06.02.2022 22:42.  WARNING Children and pets may be harmed by swallowing new or used oil. Repeated, prolonged contact with used engine oil may cause skin cancer. Brief contact with oil may irritate skin. Keep new and used oil and used oil fil- ters away from children and pets.
  • Page 106 NOTICE Failure to use an oil filter with the correct design can damage your motorcycle’s engine. Be sure to use a genuine Suzuki oil filter or an equivalent one designed for your motorcycle. NOTICE Failure to insert the new oil filter cor- rectly can damage the engine.
  • Page 107 NOTE: Insert a new “O” ring each time the filter element is replaced. NOTICE Engine damage may occur if you use oil that does not meet Suzuki’s specifica- tions. Be sure to use the oil specified in the FUEL, ENGINE OIL AND COOLANT REC- OMMENDATIONS section.

  • Page 108: Drive Chain

    We recommend that you take your idle for three minutes. motorcycle to an authorized Suzuki dealer 12. Turn the engine off and wait approxi- or a qualified mechanic if the drive chain mately three minutes.
  • Page 109 If necessary, con- NOTE: The two sprockets should be sult your authorized Suzuki dealer or a qual- inspected for wear when a new chain is ified mechanic. installed and replace them if necessary.
  • Page 110 Ask an authorized Suzuki dealer or a qualified mechanic to per- • Do not use a volatile solvent such as form this work.
  • Page 111 Tai Nguyen; ; 06.02.2022 22:42. 3. Use a soft brush to clean the drive chain. 6. Lubricate both front and back plates of Be careful not to damage the seal ring the drive chain. even though using a soft brush. 7.
  • Page 112 Tai Nguyen; ; 06.02.2022 22:42. DRIVE CHAIN ADJUSTMENT 20 – 30 mm Check the drive chain slack at the middle between the two sprockets. The chain may require more frequent adjustment than indi- cated in the periodic maintenance schedule depending on your riding conditions. ...
  • Page 113 Tai Nguyen; ; 06.02.2022 22:42. To adjust the drive chain, follow these direc- 3. Adjust the drive chain slack by turning the right and left chain adjuster nuts 2. tions: At the same time that the chain is being  CAUTION adjusted, the rear sprocket must be kept in perfect alignment with the front sprocket.

  • Page 114: Brakes

    Inspect the brake hoses and hose joints for your motorcycle’s brake systems can cracks, damage or brake fluid leakage. If increase your chance of having an acci- any defects are found, ask your Suzuki dent. dealer to replace the brake hose with a new one.
  • Page 115 Tai Nguyen; ; 06.02.2022 22:42. BRAKE FLUID Check the brake fluid level in both the front and rear brake fluid reservoirs. If the level in either reservoir is below the lower mark, inspect for brake pad wear and leaks.  WARNING Brake fluid will gradually absorb mois- ture through the brake hoses.
  • Page 116 Tai Nguyen; ; 06.02.2022 22:42.  WARNING  WARNING The use of any fluid except DOT3 or Brake fluid is harmful or fatal if swal- DOT4 brake fluid from a sealed container lowed, and harmful if it comes in contact can damage the brake system and lead with skin or eyes.
  • Page 117 A. If a front or rear pad is worn to the grooved wear limit line, it must be replaced with a new one by your authorized Suzuki dealer or a quali- fied service mechanic. REAR...
  • Page 118 If you need to replace brake pads, have your Suzuki dealer do this work. Inspect After brake system repair or brake pad and maintain the brake pads as recom- replacement, pump the brake lever/pedal mended.
  • Page 119 Tai Nguyen; ; 06.02.2022 22:42.  WARNING Replacing only one of the two brake pads can result in uneven braking action and can increase your chance of having an accident. Always replace both pads together. 16 – 26 mm REAR BRAKE PEDAL ADJUSTMENT 1.
  • Page 120 Tai Nguyen; ; 06.02.2022 22:42. REAR BRAKE LIGHT SWITCH NOTICE An incorrectly adjusted brake pedal may force brake pads to continuously rub against the disk, causing damage to the pads and disk. Follow the steps in this section to adjust the brake pedal properly.

  • Page 121: Tires

    Tai Nguyen; ; 06.02.2022 22:42. TIRES  WARNING  WARNING Failure to perform break-in of the tires could cause tire slip and loss of control, The tires on your motorcycle form the which could result in an accident. crucial link between your motorcycle and the road.
  • Page 122 Tai Nguyen; ; 06.02.2022 22:42. TIRE PRESSURE AND LOADING Cold Tire Inflation Pressure Proper tire pressure and proper tire loading are important factors. Overloading your tires SOLO RIDING DUAL RIDING can lead to tire failure and loss of motorcycle 200 kPa 200 kPa control.
  • Page 123 Tai Nguyen; ; 06.02.2022 22:42. TIRE CONDITION AND TYPE Check the condition of your tires each day before you ride. Replace tires if tires show visual evidence of damage, such as cracks or cuts, or if tread depth is less than 1.6 mm front, 2.0 mm rear.
  • Page 124 FRONT REAR • Ask your Suzuki dealer or a qualified SIZE 70/90-17M/C 38P 80/90-17M/C 50P mechanic to perform tire repair and...
  • Page 125 Tai Nguyen; ; 06.02.2022 22:42.  WARNING • Do not use an external repair plug to repair a puncture since the plug may work loose as a result of the cornering Failure to follow the instructions below forces experienced by a motorcycle for tubeless tires may result in an acci- tire.

  • Page 126: Front Wheel Removal

    Tai Nguyen; ; 06.02.2022 22:42. FRONT WHEEL REMOVAL 1. Place the motorcycle on the center stand. 4. Draw out the axle shaft 2. 2. Remove the axle nut 1. 3. Carefully position a jack under the engine and raise until the front wheel is slightly off the ground.
  • Page 127 Tai Nguyen; ; 06.02.2022 22:42.  WARNING Failure to extend brake pads after install- ing the wheel can cause poor braking performance and may result in an acci- dent. Before riding, “pump” the brake lever repeatedly until the brake pads are pressed against the brake disks and proper lever stroke and firm feel are 5.
  • Page 128 Install the front wheel so that the tire torque wrench or do not know how to rotates in the specified direction, as indi- use one, ask your authorized Suzuki cated by the arrow on the sidewall of the dealer to check the bolts and nuts.

  • Page 129: Rear Wheel Removal

    Tai Nguyen; ; 06.02.2022 22:42. REAR WHEEL REMOVAL 1. Place the motorcycle on the center stand.  CAUTION A hot muffler can burn you. Wait until the muffler cools before removing the axle nut. NOTICE Removing the rear wheel without use of an accessory stand can result in your 2.
  • Page 130 Tai Nguyen; ; 06.02.2022 22:42. 5. Draw out the axle shaft 3. 6. With the wheel moved forward, remove the chain from the sprocket. 6-58...
  • Page 131 Tai Nguyen; ; 06.02.2022 22:42. 7. Remove the rear brake caliper assembly 8. Pull the rear wheel assembly rearward. NOTE: Never depress the rear brake pedal with the rear wheel removed. It is very diffi- cult to force the pads back into the caliper assembly.
  • Page 132 If you are not sure of stroke and firm feel are restored. Also the proper procedure, have your check that the wheel rotates freely. authorized Suzuki dealer or a qualified mechanic do this. Rear axle nut tightening torque: 54 N·m (5.4 kgf-m)

  • Page 133: Light Bulb Replacement

    Tai Nguyen; ; 06.02.2022 22:42. LIGHT BULB REPLACEMENT Headlight The wattage rating of each bulb is shown on Position light the chart below. When replacing a burned out bulb, always use the exact same wattage Front turn signal light 12V 10W × 2 rating.
  • Page 134 Tai Nguyen; ; 06.02.2022 22:42. FRONT TURN SIGNAL LIGHT To replace the front turn signal light bulb, fol- low the procedure below: 2. Remove the headlight beam adjuster bolt 2. 1. Remove the right and left bolts 1. 6-62...
  • Page 135 Tai Nguyen; ; 06.02.2022 22:42. 4. Turn the socket 5 counterclockwise and 3. Pull open headlight assembly. Remove the screw 3. Remove the remove it. meter bracket 4. 6-63...
  • Page 136 Tai Nguyen; ; 06.02.2022 22:42. HEADLIGHT BEAM ADJUSTMENT 5. Pull off the bulb from the socket. 6. Fit the new bulb. The headlight beam can be adjusted up and down if necessary. Loosen the headlight beam adjuster bolt 1. To adjust the beam, move the headlight forward or backward.
  • Page 137 Tai Nguyen; ; 06.02.2022 22:42. REAR TURN SIGNAL LIGHT AND BRAKE LIGHT/TAILLIGHT To replace the rear turn signal light and brake light/taillight bulb, follow the procedure below: 1. Open he seat by referring to the SEAT LOCK AND HELMET HOLDERS sec- tion.
  • Page 138 Tai Nguyen; ; 06.02.2022 22:42. 4. Remove the inner lens 5. Rear turn signal light bulb 4. Pull off the rear turn signal lights bulb 6 from the socket. 5. Fit the new bulb. 6-66...
  • Page 139 Tai Nguyen; ; 06.02.2022 22:42. Brake light/Taillight bulb LICENSE PLATE LIGHT 5. Push in on the brake light/taillight bulb To replace the license plate light bulb, follow 7, turn it to the left, and pull it out. the procedure steps: 6.

  • Page 140: Fuse

    If a blown fuse is found, then the electrical problem must be inspected and repaired before replacing the blown fuse with a new fuse. Consult your Suzuki dealer for the 2. Pull off the bulb from the socket. electrical system check and repair.
  • Page 141 One 20A spare fuse is located in the starter Have your motorcycle inspected immedi- relay box 1. ately by your Suzuki dealer. The fuses are located under the seat. One 10A spare fuse is located in the fuse box 2.

  • Page 142: Catalytic Converter

    Tai Nguyen; ; 06.02.2022 22:42. FUSE LIST CATALYTIC CONVERTER • 20A MAIN fuse protects all electrical cir- The purpose of the catalytic converter is to cuits. minimize the amount of harmful pollutants in • 10A SUB fuse protects the horn, cooling your motorcycle’s exhaust.
  • Page 143 Tai Nguyen; ; 06.02.2022 22:42.  WARNING NOTICE If you park or operate the motorcycle in Improper motorcycle operation can areas where there are combustible mate- cause catalyst or other motorcycle dam- rials such as dry grass or leaves, these age.

  • Page 144: Front License Plate Fitting

    Tai Nguyen; ; 06.02.2022 22:42. FRONT LICENSE PLATE FITTING • Do not try to start the engine by push- ing the motorcycle or by coasting down a hill. • Do not idle the engine with any spark plug wires disconnected or removed, such as during diagnostic testing.

  • Page 145: Troubleshooting

    Tai Nguyen; ; 06.02.2022 22:42. TROUBLESHOOTING FUEL SUPPLY CHECK ..........................7-2 IGNITION SYSTEM CHECK ........................7-3 ENGINE STALLING ............................ 7-4...
  • Page 146 If the malfunction indicator light comes on, trouble in the fuel injection system, take your This troubleshooting guide is provided to machine to an authorized Suzuki dealer. help you find the cause of some common Refer to the “INSTRUMENT PANEL” section complaints.
  • Page 147 Replace it if necessary. Retry the above procedure with the cleaned spark plug or a new one. 4. If there is still no spark, consult your Suzuki dealer for repairs.  WARNING Performing the spark test improperly can be hazardous. You could get a high volt- age electrical shock if you are not famil- iar with this procedure.
  • Page 148 2. If the malfunction indicator light comes on, trouble in the fuel injection system, take your machine to an authorized Suzuki dealer. Refer to the “INSTRU- MENT PANEL” section for an explanation of the malfunction indicator light. 3. Check the ignition system for intermittent spark.

  • Page 149: Storage Procedure And Motorcycle Cleaning

    Tai Nguyen; ; 06.02.2022 22:42. STORAGE PROCEDURE AND MOTORCYCLE CLEANING STORAGE PROCEDURE ........................... 8-2 PROCEDURE FOR RETURNING TO SERVICE ..................8-3 CORROSION PREVENTION ........................8-4 MOTORCYCLE CLEANING ........................8-5 INSPECTION AFTER CLEANING ......................8-8...

  • Page 150: Storage Procedure

    For this reason, Suzuki recommends that you trust this maintenance ENGINE work to your Suzuki dealer. If you wish to 1. Pour one tablespoon of motor oil into service the machine for storage yourself, fol- each spark plug hole. Reinstall the spark low the general guidelines below: plug and crank the engine a few times.

  • Page 151: Procedure For Returning To Service

    Tai Nguyen; ; 06.02.2022 22:42. 2. Clean the outside of the battery with a PROCEDURE FOR RETURNING TO mild soap and remove corrosion from the SERVICE terminals and wiring harness. 1. Clean the entire motorcycle. 3. Store the battery in a room above freez- 2.

  • Page 152: Corrosion Prevention

    Should you find any chips or scratches in the paint, touch them up immediately to prevent corrosion from starting. If the chips or scratches have gone through to the bare metal, have a Suzuki dealer make the repair.

  • Page 153: Motorcycle Cleaning

    NOTE: Clean the motorcycle with cool water reduce the amount of dust and air pollu- immediately after riding on road salt or tion reaching the surface. Your Suzuki riding along the coast. Be sure to use cool dealer can help you select the right water because warm water can hasten cor- cover for your motorcycle.
  • Page 154 Tai Nguyen; ; 06.02.2022 22:42. NOTE: Avoid spraying or allowing water to 3. Once the dirt has been completely flow over the following places: removed, rinse off the detergent with • Ignition switch running water. • Spark plug 4. After rinsing, wipe off the motorcycle •...
  • Page 155 Tai Nguyen; ; 06.02.2022 22:42. NOTE: The headlight lens can be fogged WAXING THE MOTORCYCLE after washing the motorcycle or riding in the After washing the motorcycle, waxing and rain. Headlight fogging will be cleared grad- polishing are recommended to further pro- ually when the headlight is turned on.

  • Page 156: Inspection After Cleaning

    Tai Nguyen; ; 06.02.2022 22:42. INSPECTION AFTER CLEANING For extended life of your motorcycle, lubri- cate it according to the “LUBRICATION POINTS” section.  WARNING Operating the motorcycle with wet brakes can be hazardous. Wet brakes may not provide as much stopping power as dry brakes.
  • Page 157 Tai Nguyen; ; 06.02.2022 22:42.

  • Page 158: Specifications

    Tai Nguyen; ; 06.02.2022 22:42. SPECIFICATIONS DIMENSIONS AND CURB MASS Overall length ............... 1945 mm Overall width................. 670 mm Overall height ............... 980 mm Wheelbase ................1280 mm Ground clearance..............140 mm Seat height ................764 mm Curb mass ................109 kg ENGINE Type..................
  • Page 159 Tai Nguyen; ; 06.02.2022 22:42. DRIVE TRAIN Clutch ................... Wet multi-plate type Transmission ................ 6-speed constant mesh Gearshift pattern ..............1-down, 5-up Primary reduction ratio ............3.285 (69/21) Gear ratios, Low..............2.923 (38/13) 2nd ..............1.933 (29/15) 3rd ..............1.476 (31/21) 4th ..............
  • Page 160 Tai Nguyen; ; 06.02.2022 22:42. ELECTRICAL Ignition type ................Electronic ignition (Transistorized) Spark plug ................NGK MR8E-9 Battery .................. 12V 18.0 kC(5.0 Ah)/10HR Generator ................Single-phase A.C.generator Fuse ..................20/10/10A Headlight ................LED Position light ................. LED Brake light/Taillight..............12V 18/5W Front turn signal light ............
  • Page 161 Tai Nguyen; ; 06.02.2022 22:42.

  • Page 162: Index

    Tai Nguyen; ; 06.02.2022 22:42. INDEX ACCESSORY USE AND ENGINE COOLANT SOLUTION ....3-5 MOTORCYCLE LOADING ......1-2 ENGINE OIL ........3-3 6-30 AIR CLEANER..........6-18 ENGINE STALLING ........7-4 BATTERY ...........6-8 FRONT BOX..........2-30 BRAKES ...........6-42 FRONT LICENSE PLATE FITTING ..6-72 FRONT WHEEL REMOVAL.....
  • Page 163 Tai Nguyen; ; 06.02.2022 22:42. IDLE SPEED ADJUSTMENT ....6-23 MAINTENANCE SCHEDULE..... 6-2 IGNITION SWITCH........2-6 MOTORCYCLE CLEANING....... 8-5 IGNITION SYSTEM CHECK ......7-3 INSPECTION AFTER CLEANING....8-8 INSPECTION BEFORE RIDING ....4-4 PROCEDURE FOR RETURNING TO INSTRUMENT PANEL .......2-9 SERVICE............ 8-3 KEY.............2-5 REAR BRAKE PEDAL......2-27 KICK STARTER LEVER......2-25 REAR WHEEL REMOVAL .......
  • Page 164 Tai Nguyen; ; 06.02.2022 22:42. SAFE RIDING RECOMMENDATION FOR UNDER COWLINGS AND FRONT BOX MOTORCYCLE RIDERS......1-5 REMOVAL ..........6-12 SEAT LOCK AND HELMET HOLDER ..2-27 USING THE TRANSMISSION....5-6 SERIAL NUMBER LOCATION ....1-7 SPARK PLUG...........6-15 STANDS ...........2-28 STARTING OFF .........5-4 STARTING THE ENGINE......5-2 STOPPING AND PARKING .......5-7 STORAGE PROCEDURE ......8-2...
  • Page 165 Tai Nguyen; ; 06.02.2022 22:42.
  • Page 166 Tai Nguyen; ; 06.02.2022 22:42.

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