Suzuki Djebel 200 Owner's Manual
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Suzuki Djebel 200 Owner's Manual

Suzuki Djebel 200 Owner's Manual

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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.

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Summary of Contents for Suzuki Djebel 200

  • Page 1 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 2 Proper break-in operation during this time will help ensure maximum life and perfor- mance from your new motorcycle. Suzuki parts are manufactured of high quality mate- rials, and machined parts are finished to close tolerances.
  • Page 3  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 vehicle or equipment damage. WARNING, CAUTION, NOTICE and NOTE have special meanings.
  • Page 4 Owner’s in this manual and your motorcycle. Suzuki Manual before riding the motorcycle. reserves the right to make changes at any time.

  • Page 6: Table Of Contents

    TABLE OF CONTENTS CONSUMER INFORMATION CONTROLS FUEL AND ENGINE OIL RECOMMENDATIONS BREAK-IN (RUNNING-IN) AND INSPECTION BEFORE RIDING RIDING TIPS INSPECTION AND MAINTENANCE TROUBLESHOOTING STORAGE PROCEDURE AND MOTORCYCLE CLEANING SPECIFICATIONS INDEX...

  • Page 8: Consumer Information

    CONSUMER INFORMATION ACCESSORY USE AND MOTORCYCLE LOADING ................1-2 SAFE RIDING RECOMMENDATION FOR MOTORCYCLE RIDERS ............1-5 LABELS ..............................1-8 SERIAL NUMBER LOCATION ........................1-8 NOISE CONTROL SYSTEM (AUSTRALIA ONLY) ..................1-9...

  • Page 9: Accessory Use And Motorcycle Loading

    Install and use them accord- extreme caution when selecting and install- ing to their instructions. If you have any ing the accessories on your motorcycle and questions, contact your Suzuki dealer. consult your Suzuki dealer if you have any questions.
  • Page 10 ACCESSORY INSTALLATION • Certain accessories displace the rider GUIDELINES from his or her normal riding position. • Install aerodynamic-affecting accesso- This limits the freedom of movement of ries, such as a fairing, windshield, back- the rider and may limit his or her control rests, saddlebags, and travel trunks, as ability.
  • Page 11 LOADING LIMIT G.V.W.: 300 kg (660 lbs) at the tire pressure (cold)  WARNING Front: 150 kPa (1.50 kgf/cm , 22 psi) Rear: 200 kPa (2.00 kgf/cm , 29 psi) Overloading or improper loading can LOADING GUIDELINES cause loss of motorcycle control and an This motorcycle is primarily intended to accident.

  • Page 12: Safe Riding Recommendation For Motorcycle Riders

    • Do not carry any items that protrude over SAFE RIDING RECOMMENDATION FOR the tail end of the motorcycle. MOTORCYCLE RIDERS • Check that both tires are properly Motorcycle riding is great fun and an excit- inflated to the specified tire pressure for ing sport.
  • Page 13 RIDING APPAREL FAMILIARIZE YOURSELF WITH THE Loose, fancy clothing can be uncomfortable MOTORCYCLE and unsafe when riding your motorcycle. Your riding skill and your mechanical knowl- Choose good quality motorcycle riding edge form the foundation for safe riding apparel when riding your motorcycle. practices.
  • Page 14 BE EXTRA SAFETY CONSCIOUS ON RIDE DEFENSIVELY BAD WEATHER DAYS The most common type of motorcycle acci- Riding on bad weather days, especially wet dent occurs when a car traveling towards a ones, requires extra caution. Braking dis- motorcycle turns round corner in front of the tances double on a rainy day.

  • Page 15: Labels

    LABELS SERIAL NUMBER LOCATION Read and follow all the labels on the motor- cycle. Make sure you understand all of the labels. Do not remove any labels from the motorcycle.

  • Page 16: Noise Control System (Australia Only)

    The frame and/or engine serial numbers are NOISE CONTROL SYSTEM used to register the motorcycle. They are (AUSTRALIA ONLY) also used to assist your dealer when order- ing parts or referring to special service infor- TAMPERING WITH NOISE CONTROL mation. The frame number 1 is stamped on SYSTEM PROHIBITED the steering head tube.

  • Page 18: Controls

    CONTROLS LOCATION OF PARTS ..........................2-2 KEY ................................2-5 IGNITION SWITCH ............................. 2-5 INSTRUMENT PANEL ..........................2-7 LEFT HANDLEBAR ............................ 2-9 RIGHT HANDLEBAR ..........................2-12 FUEL TANK CAP ............................2-14 FUEL VALVE ............................2-16 GEARSHIFT LEVER ..........................2-19 REAR BRAKE PEDAL ..........................2-20 HELMET HOLDER ............................

  • Page 19: Location Of Parts

    CONTROLS LOCATION OF PARTS DR200S 1 Clutch lever 6 Front brake fluid reservoir 2 Left handlebar switches 7 Right handlebar switches 3 Speedometer 8 Front brake lever 4 Ignition switch 9 Throttle grip 5 Indicator light 0 Fuel tank cap...
  • Page 20 DR200S A Fuel valve G Helmet holder B Choke knob H Gearshift lever C Throttle stop screw I Engine oil drain plug D Air cleaner J Footrests E Battery K Side stand F Tools L Passenger footrests...
  • Page 21 DR200S M Fuse Q Engine oil inspection window N Carburetor R Rear brake pedal O Spark plug S Engine oil filler cap P Rear brake light switch T Engine oil filter...

  • Page 22: Key

    IGNITION SWITCH This motorcycle comes equipped with a pair The ignition switch has 3 positions: of identical ignition keys. Keep the spare key “OFF” POSITION in a safe place. All electrical circuits are cut off. The engine will not start. The key can be removed.
  • Page 23 “ON” POSITION  WARNING The ignition circuit is completed and the engine can now be started. The headlight Turning the ignition switch to the and taillight will automatically be turned on “LOCK” position while the motorcycle is when the key is in this position. The key can- moving can be hazardous.

  • Page 24: Instrument Panel

    If the motorcycle falls down, turn the ignition switch off immediately. Ask your authorized Suzuki dealer to inspect the SPEEDOMETER 1 motorcycle for unseen damage. The speedometer indicates the road speed in kilometers per hour.
  • Page 25 NEUTRAL INDICATOR LIGHT “N” 5 The green indicator light will come on when the transmission is in neutral. The light will go out when you shift into any gear other than neutral. TURN SIGNAL INDICATOR LIGHT “” When the turn signals are being operated either to the right or to the left, the indicator light will blink intermittently.

  • Page 26: Left Handlebar

    HIGH BEAM INDICATOR LIGHT “” 7 LEFT HANDLEBAR This blue indicator light will be lit when the headlight high beam is turned on. CLUTCH LEVER 1 The clutch lever is used for disengaging the drive to the rear wheel when starting the engine or shifting transmission gears.
  • Page 27 NOTICE Holding the dimmer switch between the “” and “” position will light both the high and low headlight beam. This improper operation can damage the motorcycle’s headlight. Use the dimmer switch to select only the “” or “” position. DIMMER SWITCH 2 “”...
  • Page 28  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 29: Right Handlebar

    RIGHT HANDLEBAR NOTICE  Changing the engine stop switch from     or from while rid- ing may damage to the engine or the cat- alytic converter (if equipped). Do not use the engine stop switch except for an emergency. FRONT BRAKE LEVER 2 The front brake is applied by squeezing the ENGINE STOP SWITCH 1...
  • Page 30 ELECTRIC STARTER SWITCH “” 3 NOTICE Use this switch to operate the starter motor. With the ignition switch in the “ON” position, Engaging the starter motor for more the engine stop switch in the “” position, than five seconds at a time can damage and the transmission in neutral, squeeze the the starter motor and wiring harness clutch lever and push the electric starter...

  • Page 31: Fuel Tank Cap

    FRONT BRAKE LEVER PLAY FUEL TANK CAP ADJUSTMENT 0.1 – 0.3 mm (0.004 – 0.01 in) To open the fuel tank cap, insert the ignition key and turn it counterclockwise. Turn the Adjust the front brake lever play as follows: cap counterclockwise and remove it.
  • Page 32 Use fresh gasoline when filling up the fuel  WARNING tank. Do not use bad gasoline which is con- taminated with dirt, dust, water or other liq- If you overfill the fuel tank, fuel may uid. Be careful that dirt, dust or water does overflow when it expands due to engine not enter the fuel tank when refueling.

  • Page 33: Fuel Valve

    FUEL VALVE There are three positions: “ON,” “RES” and “PRI.” Filling the fuel tank with more than the specified amount of fuel may cause engine failure or make it difficult to start. FUEL Do not refuel above the bottom of the filler neck.
  • Page 34 FUEL FUEL “RES” (RESERVE) POSITION “PRI” (PRIMING) POSITION If the fuel level in the tank is too low, turn the When there is no fuel in the carburetor, turn fuel valve lever to the “RES” position to use the fuel valve lever to the “PRI” position. the 2.5 L (0.7/0.5 US/Imp.
  • Page 35 CHOKE KNOB “” carburetor this motorcycle equipped with a choke system to provide easy starting. When starting a cold engine, pull the choke knob all the way out. Immedi- ately after the engine starts, return the choke knob halfway and let the engine run until the engine sufficiently warms up, there- after push the choke knob down to its nor- mal disengaged position.

  • Page 36: Gearshift Lever

    GEARSHIFT LEVER This motorcycle has a 5-speed transmission which operates as shown. To shift properly, squeeze the clutch lever and close the throt- tle at the same time you operate the gear- shift lever. Lift the gearshift lever to upshift and depress the lever to downshift.

  • Page 37: Rear Brake Pedal

    REAR BRAKE PEDAL HELMET HOLDER Depressing the rear brake pedal will apply To open the latch of the helmet holder, insert the rear brake. The brake light will be illumi- the ignition key into the lock and turn it nated when the rear brake is operated. clockwise.

  • Page 38: Side Stand

    SIDE STAND  WARNING Riding with a helmet fastened to the hel- met holder can interfere with rider con- trol. Never carry a helmet fastened to a hel- met holder. Fix the helmet securely atop the seat if you must carry it. This motorcycle is equipped with a side stand to support the motorcycle when park- ing.
  • Page 39 The side stand/ignition interlock system NOTICE works as follows: 1. If the side stand is down and the trans- If you do not take proper precautions mission is in gear, the engine can not be when parking, the motorcycle can fall started.

  • Page 40: Suspension Adjustment

    • Read owner’s manual for more information. The adjustment can be performed by chang- ing the adjuster ring position. However, NOTE: Ask your Suzuki dealer to dispose of Suzuki recommends that this adjustment be the rear suspension unit. done by your authorized Suzuki dealer, since a special tool is needed for this job.

  • Page 42: Fuel And Engine Oil Recommendations

    FUEL AND ENGINE OIL RECOMMENDATIONS FUEL OCTANE RATING ..........................3-2 OXYGENATED FUEL RECOMMENDATION ..................... 3-3 ENGINE OIL ..............................3-4...
  • Page 43 Use unleaded gasoline with an octane rating situation is not improved by changing, higher (Research method). consult your Suzuki dealer. Unleaded gasoline can extend spark plug • If pinking or knocking is experienced, life and exhaust components life. substitute higher octane grade gasoline...
  • Page 44 OXYGENATED FUEL RECOMMENDATION Gasoline/Ethanol Blends Blends of unleaded gasoline and ethanol (Canada, UK, EU) (grain alcohol), also known as “GASOHOL”, Oxygenated fuels which meet the minimum are commercially available in some areas. octane requirement and the requirements Blends of this type may be used in your described below may be used in your motor- motorcycle if they are no more than 10% cycle without jeopardizing the New Vehicle...
  • Page 45 NOTE: ENGINE OIL • To help minimize air pollution, Suzuki recommends that you use oxygenated DESCRIPTION fuels. Engine life depends on oil amount and qual- • Be sure that any oxygenated fuel you ity. Daily oil level checks and periodic use has recommended octane ratings.
  • Page 46 SELECTING THE ENGINE OIL SAE Engine Oil Viscosity Suzuki recommends the use of SUZUKI If SAE 10W-40 engine oil is not available, Genuine Oil or Equivalent Engine Oil. select an alternative according to the follow- ing chart. < SUZUKI Genuine Oil >...
  • Page 47 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” oils. Some engine oils...
  • Page 48 API SG, SH, SJ, SL, SM or SN 10W-40 Recommended API SH, SJ, SL or SM API SN 10W-40 10W-40 Not recommended...

  • Page 50: Break-In (Running-In) And Inspection Before Riding

    BREAK-IN (RUNNING-IN) AND INSPECTION BEFORE RIDING MAXIMUM THROTTLE OPERATION RECOMMENDATION ..............4-2 VARY THE ENGINE SPEED ........................4-2 AVOID CONSTANT LOW SPEED ......................4-3 ALLOW THE ENGINE OIL TO CIRCULATE BEFORE RIDING ..............4-3 OBSERVE YOUR FIRST AND MOST CRITICAL SERVICE ..............4-3 INSPECTION BEFORE RIDING .........................
  • Page 51 This break-in is to achieving maximum life and aids the mating process of the parts. It is performance from your new Suzuki. The fol- essential that some stress be placed on the lowing guidelines explain proper break-in engine components during break-in to procedures.
  • Page 52 AVOID CONSTANT LOW SPEED OBSERVE YOUR FIRST AND MOST Operating the engine at constant low speed CRITICAL SERVICE (light load) can cause parts to glaze and not The 1000 km (600 miles) service is the most seat in. Allow the engine to accelerate freely important service your motorcycle will through the gears, without exceeding the receive.
  • Page 53 INSPECTION BEFORE RIDING  WARNING  WARNING If you operate this motorcycle with improper tires or improper or uneven tire Failure to inspect your motorcycle pressure, you may lose control of the before riding and to properly maintain motorcycle. This will increase your risk your motorcycle increases the chances of an accident.
  • Page 54 Before riding the motorcycle, be sure to WHAT TO check the following items. Never underesti- CHECK FOR: CHECK mate the importance of these checks. Per- Steering • Smoothness form them before riding • No restriction of movement motorcycle. • No play or looseness Throttle •...
  • Page 55 Tires • Correct pressure ( 6-55) • Adequate tread depth • No cracks or cuts Engine oil Correct level ( 6-25) Lighting Operation of all lights and ( 2-7, 2-9) indicators Horn Correct function ( 2-11) Engine stop Correct function switch (...

  • Page 56: Riding Tips

    RIDING TIPS STARTING THE ENGINE ........................... 5-2 STARTING OFF ............................5-4 USING THE TRANSMISSION ........................5-6 RIDING ON HILLS ............................5-8 STOPPING AND PARKING ........................5-8 CARRYING A PASSENGER ........................5-11...

  • Page 57: Starting The Engine

    RIDING TIPS When the Engine is Cold: 1. Pull out the choke knob fully. 2. Squeeze the clutch lever. 3. With the throttle grip in the fully closed STARTING THE ENGINE position, push the electric starter switch. Before attempting to start the engine, make 4.
  • Page 58 When the Engine is Warm: NOTICE 1. Confirm that the choke knob is in the “OFF” position. Leaving the engine running for an 2. Squeeze the clutch lever. extended period or keeping the throttle 3. With the throttle grip opened 1/8 to 1/4, opened, without traveling, in order to push the electric starter switch.

  • Page 59: Starting Off

    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 60 1. Warm up the engine.  WARNING 2. Squeeze the clutch lever and depress the gearshift lever downward. Sudden side winds, which can occur 3. Turn the throttle grip toward you. At the when being passed by larger vehicles, at same time release the clutch lever gently tunnel exits or in hilly areas, can cause and the motorcycle will move forward.

  • Page 61: Using The Transmission

    USING THE TRANSMISSION The table below shows the approximate speed range for each gear. The transmission is provided to keep the engine operating smoothly in its normal (Canada) operating speed range. The gear ratios have Shifting up schedule been carefully chosen to meet the charac- teristics of the engine.
  • Page 62  WARNING  WARNING Downshifting when engine speed is too Downshifting while the motorcycle is high can; leaned over in a corner may cause rear • cause the rear wheel to skid and lose wheel skid and loss of control. traction due to increased engine brak- ing, resulting in an accident;...

  • Page 63: Riding On Hills

    RIDING ON HILLS STOPPING AND PARKING • When climbing steep hills, the motorcy- 1. Turn 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 64  WARNING  WARNING Inexperienced riders tend to underuti- Continuous brake application for a long lize the front brake. This can cause time can overheat the brakes and reduce excessive stopping distance and lead to their effectiveness, which can result in a collision.
  • Page 65 5. Park the motorcycle on a firm, flat sur-  WARNING face where it will not fall over. Following another vehicle too closely  CAUTION can lead to a collision. As vehicle speeds increase, stopping distance A hot muffler can cause severe burns. increases progressively.

  • Page 66: Carrying A Passenger

    6. Turn the key to the “OFF” position. CARRYING A PASSENGER 7. Turn the handlebars all the way to the Before you invite someone to be a passen- left and lock the steering for security. ger on your motorcycle, you need to be thor- 8.
  • Page 67 To help prevent burn injuries, warn your pas-  WARNING senger not to contact the muffler when mounting or dismounting your motorcycle. Carrying a passenger or attaching cargo to the seat can greatly reduce your abil- Although your Dual Sport motorcycle is ity to balance and steer this motorcycle equipped to carry a passenger, carrying a on rough terrain.

  • Page 68: Inspection And Maintenance

    INSPECTION AND MAINTENANCE MAINTENANCE SCHEDULE ........................6-2 TOOLS ................................ 6-7 LUBRICATION POINTS ..........................6-7 FRAME COVER AND SEAT REMOVAL ....................6-9 BATTERY ..............................6-11 AIR CLEANER ............................6-16 SPARK PLUG ............................6-22 FUEL HOSE .............................. 6-25 ENGINE OIL .............................. 6-25 CARBURETOR ............................

  • Page 69: Maintenance Schedule

    Keep your motorcycle in good condition. months. At the end of each interval, be sure Ask your Suzuki dealer or a qualified to inspect, check, lubricate and service as mechanic to perform the maintenance instructed.
  • Page 70  WARNING NOTICE Exhaust gas contains carbon monoxide, Servicing electric parts with the ignition a dangerous gas that is difficult to detect switch in the “ON” position can damage because it is colorless and odorless. the electric parts when the electric cir- Breathing carbon monoxide can cause cuit is shorted.
  • Page 71 If you quickly and may shorten its useful life. have any questions regarding maintenance intervals, consult your Suzuki dealer or a When replacing parts on your vehicle, qualified mechanic. use only genuine Suzuki replacement...
  • Page 72 MAINTENANCE CHART Interval: This interval should be judged by number of months or odometer reading, whichever comes first. Interval months 1000 5000 10000 15000 Item miles 3000 6000 9500 * Exhaust pipe bolts – Air cleaner ( 6-16) – * Valve clearance Spark plug (...
  • Page 73 Interval months 1000 5000 10000 15000 Item miles 3000 6000 9500 * Brakes ( 6-46) – Brake hose ( 6-46) * Replace every 4 years – Brake fluid ( 6-47) * Replace every 2 years Tire ( 6-55) – * Steering –...

  • Page 74: Tools

    TOOLS LUBRICATION POINTS Proper lubrication is important for smooth operation and long life of each working part of your motorcycle and also for safe riding. It is a good practice to lubricate the motorcy- cle after a long rough ride and after getting it wet it in the rain or after washing it.
  • Page 75 1..Clutch lever pivot and clutch cable 2..Side stand pivot and spring hook 3..Drive chain 4..Brake lever pivot 5..Brake pedal pivot  ..Motor oil  ..Grease ..Drive chain lubricant...

  • Page 76: Frame Cover And Seat Removal

    FRAME COVER AND SEAT REMOVAL The frame covers and the seat can be removed when servicing some parts of your motorcycle. When removing them, follow the procedure below: 1. Place the motorcycle on the side stand. 2. Remove the bolt. Unhook the hooks and remove the right and left side frame cover 1.
  • Page 77 4. Remove the seat by sliding rearward. 3. Remove the bolt. Unhook the hooks and remove the right and left side frame cover 2. 6-10...

  • Page 78: Battery

    • If you cannot charge the battery, consult Latch the seat securely in its proper your authorized Suzuki dealer. position.  WARNING Battery posts, terminals, and related accessories contain lead and lead com- pounds. Lead is harmful to your health if it gets into your blood stream.
  • Page 79  WARNING  WARNING Diluted sulfuric acid from the battery can Batteries produce flammable hydrogen cause blindness or severe burns. gas which can explode if exposed to flames or sparks. When working near the battery, use proper eye protection and gloves. Flush Keep flames and sparks away from the eyes or body with ample water and get battery.
  • Page 80 BATTERY REMOVAL NOTICE To remove the battery, follow the procedure below: Exceeding the maximum charging rate 1. Place the motorcycle on the side stand. for the battery can shorten its life. 2. Remove the left side frame covers by referring to the FRAME COVER AND Never exceed the maximum charging SEAT REMOVAL section.
  • Page 81 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 82 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 83: Air Cleaner

    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. If you use your ous.
  • Page 84 REMOVING THE ELEMENT NOTICE 1. Remove the right and left frame covers and seat by referring to the FRAME Failure to inspect the air cleaner element COVER AND SEAT REMOVAL section. frequently if the vehicle is used in dusty, wet, or muddy conditions can damage your motorcycle.
  • Page 85 3. Remove the wing nut 2 and remove the 4. Separate the polyurethane foam element polyurethane foam element assembly from the frame. 6-18...
  • Page 86 WASHING THE ELEMENT 4. Put the element in a wash pan. Pour in some air filter oil B and work the oil into Wash the element as follows: the element. 5. Squeeze the element to remove the excess oil. NOTICE A torn air cleaner element will allow dirt to enter the engine and can damage the engine.
  • Page 87  WARNING NOTICE New and used oil and solvent can be Failure to position the air cleaner ele- hazardous. Children and pets may be ment properly can allow dirt to bypass harmed by swallowing new or used oil or the air cleaner element. This will cause solvent.
  • Page 88 AIR CLEANER DRAIN PLUGS Remove the plugs and drain water and oil at the periodic maintenance interval. 6-21...

  • Page 89: Spark Plug

    Use one of the spark plugs listed or their equivalent. Consult your Suzuki dealer if you are not sure which spark plug is cor- rect for your type of usage.
  • Page 90 Plug Replacement Guide DENSO REMARKS If the standard plug is wet in appearance or DR7EA X22ESR-U very dark in color, replace with this plug. DR8EA X24ESR-U Standard If the standard plug is glazed appearing or DR9EA X27ESR-U very white, replace with 0.6 –...
  • Page 91 NOTICE NOTICE Improper installation of the spark plug Dirt can damage the moving engine can damage your motorcycle. An overly- parts of your motorcycle if it enters an tight or cross-threaded spark plug will open spark plug hole. damage the aluminum threads of the cyl- inder head.

  • Page 92: Fuel Hose

    FUEL HOSE 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 93 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. Be sure the engine oil level is always above the “L”...
  • Page 94 ENGINE OIL AND FILTER CHANGE The oil should be changed when the engine is hot so that the oil will drain thoroughly from the engine. The procedure is as fol- lows: 1. Place the motorcycle on the side stand. 4. Remove the drain plug 2 and gasket 3 with a wrench and drain out the engine oil while holding the motorcycle verti- cally.
  • Page 95  WARNING NOTICE Children and pets may be harmed by Turning the engine while draining the swallowing new or used oil. Repeated, engine oil will cause oil film shortage prolonged contact with used engine oil and adversely affect the engine. may cause skin cancer.
  • Page 96 5. Remove the three nuts 4 holding the fil- ter cap 5 in place. 6. Replace the oil filter 6 and the “O” ring 7 with a new one. 6-29...
  • Page 97 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. 7. Before fitting the oil filter cap, be sure to NOTICE check that the filter spring 8 and the “O”...
  • Page 98 OIL STRAINER CLEANING 10. Remove the screws and oil strainer A. 9. Remove the bolts and oil strainer cap 0. 6-31...
  • Page 99 12. Reinstall the strainer A and tighten the 11. Clean the strainer using compressed air. screws securely. 6-32...
  • Page 100 14. Replace the drain plug gasket 3 with a new one. Reinstall the drain plug 2 and gasket 3. Tighten the plug securely with a torque wrench. Pour 950 ml (1.0/0.84 US/Imp. qt) of new engine oil through the filler hole and install the filler cap. Be sure to always use the specified engine oil described in the FUEL AND ENGINE OIL RECOMMENDATIONS section.
  • Page 101 Engine damage may occur if you use oil 16. Turn the engine off and wait approxi- that does not meet Suzuki’s specifica- mately three minutes. Recheck the oil tions. level on the engine oil inspection window while holding the motorcycle vertically.

  • Page 102: Carburetor

    To adjust the idle speed properly, you need a tachometer. If you do not have one, ask Adjusting the engine idle speed below your Suzuki dealer or a qualified mechanic the specified value can cause engine to perform this adjustment.
  • Page 103 THROTTLE CABLE ADJUSTMENT Measure the throttle cable play by turning the throttle grip. The throttle grip should have 2.0 – 4.0 mm (0.08 – 0.16 in) play. 1. Remove the boot 1. 2.0 – 4.0 mm 2. Loosen the lock nut 2. (0.08 –...
  • Page 104 THROTTLE CABLE BOOTS  WARNING Inadequate throttle cable play can cause engine speed to rise suddenly when you turn the handlebars. This can lead to loss of control and an accident. Adjust the throttle cable play so that engine idle speed does not rise due to handlebar movement.

  • Page 105: Clutch

    CLUTCH Major Adjustment Minor Adjustment 10 – 15 mm (0.4 – 0.6 in) 6-38...
  • Page 106 The cable play should be 10 – 15 formed by your Suzuki dealer. mm (0.4 – 0.6 in) as measured at the clutch lever end before the clutch begins to disen- gage.
  • Page 107 CLUTCH CABLE BOOTS The clutch cable has a boots. Check that the boots are fit securely. Do not apply water directly to the boots when washing. Wipe off dirt from the boots with a wet cloth when the boots are dirty. 6-40...

  • Page 108: Drive Chain

    We recommend that 2. Damaged rollers you take your motorcycle to your authorized 3. Dry or rusted links Suzuki dealer to have the drive chain 4. Kinked or binding links replaced when it becomes worn. The drive 5. Excessive wear chain is also constructed of special materi- 6.
  • Page 109 If the drive chain has any of these items DRIVE CHAIN CLEANING AND OILING wrong with it, then there is a strong possibil- 1. Remove dirt and dust from the drive ity that the sprockets will have some dam- chain. Be careful not to damage the seal age to them also.
  • Page 110 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. Wipe off excess lubricant after lubricat- 4.
  • Page 111 DRIVE CHAIN ADJUSTMENT To adjust the drive chain, follow the proce- dure below: 1. Place the motorcycle on the side stand. 25 – 40 mm (1.0 – 1.6 in) Inspect the drive chain slack before each use of the motorcycle. The drive chain should be adjusted for 25 –...
  • Page 112 7. Tighten the axle nut 4 securely. 8. Tighten the torque link nut 2. Replace the cotter pin 3 with a new one. 9. Readjust the rear brake pedal. Refer to the rear brake pedal adjustment section. 10. Recheck the chain slack after tightening and readjust if necessary.

  • Page 113: Brakes

    Inspect the brake hoses and hose joints for increase your chance of having an acci- cracks, damage or brake fluid leakage. If dent. any defects are found, ask your Suzuki dealer to replace the brake hose with a new Be sure to inspect the brakes before one.
  • Page 114 FRONT BRAKE  WARNING Brake Fluid Brake fluid will gradually absorb mois- ture through the brake hoses. Brake fluid with high water content lowers the boil- ing point and can cause brake system malfunction due to corrosion of brake LOWER components.
  • Page 115  WARNING  WARNING The use of any fluid except DOT4 brake Brake fluid is harmful or fatal if swal- fluid from a sealed container can dam- lowed, and harmful if it comes in contact age the brake system and lead to an with skin or eyes.
  • Page 116 Brake Pad NOTICE Spilled brake fluid can damage painted surfaces and plastic parts. Be careful not to spill any fluid when fill- ing the brake fluid reservoir. Wipe spilled fluid up immediately. Check the brake fluid level in front brake fluid reservoir.
  • Page 117 If you need to replace brake pads, have NOTE: Do not squeeze the brake lever your Suzuki dealer do this work. Inspect when the pads are not in their positions. It is and maintain the brake pads as recom- difficult to push the pistons back and brake mended.
  • Page 118 REAR BRAKE  WARNING Rear Brake Pedal Adjustment Replacing only one of the two brake pads can result in uneven braking action NOTICE and can increase your chance of having an accident. An incorrectly adjusted brake pedal may force brake shoes to rub against the Always replace both pads together.
  • Page 119 15 – 20 mm (0.6 – 0.8 in) 0 – 5 mm (0 – 0.2 in) 1. Loosen the lock nut 1. 2. Adjust the brake pedal height by turning the adjuster 2 to locate the pedal 0 – 5 mm (0 –...
  • Page 120 3. Tighten the lock nut 1. Brake Lining Wear Limit 4. Adjust the free travel to 15 – 20 mm (0.6 This motorcycle is equipped with brake lin- – 0.8 in) by screwing in or out the brake ing wear limit indicator for the rear brake. adjusting nut 3.
  • Page 121 Inspect brake shoe wear before each use. Ask your Suzuki dealer or a quali- fied mechanic to replace brake shoes if the shoes are worn to the limit. 3. If the extension line is outside this range as shown in Fig.

  • Page 122: Tires

    Rear Brake Light Switch TIRES  WARNING The tires on your motorcycle form the crucial link between your motorcycle and the road. Failure to take the precau- tions below may result in an accident due to tire failure. • Check tire condition and pressure before each ride, and adjust pressure if necessary.
  • Page 123 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 vehicle 150 kPa 150 kPa control. FRONT 1.50 kgf/cm 1.50 kgf/cm 22 psi...
  • Page 124 TIRE TREAD CONDITION When you replace a tire, be sure to replace it with a tire of the size and type listed below. If you use a different size or type of tire, motorcycle handling may be adversely affected, possibly resulting in loss of motor- cycle control.

  • Page 125: Spoke Nipple Tightness

    An improperly repaired or installed tire can cause loss of control and an acci- dent, or can wear out sooner. • Ask your Suzuki dealer or a qualified mechanic to perform tire repair and replacement because proper tools and experience are required.

  • Page 126: Side Stand/Ignition Interlock System

    Loosened and overtightened spoke nipples may cause unequal tension of spokes and may result in distortion of the wheel rim. Contact your Suzuki dealer for this service to be performed. Check the side stand/ignition interlock sys- tem for proper operation as follows: 1.
  • Page 127 Have your motorcycle inspected by an turn and could cause an accident. authorized Suzuki dealer or a qualified ser- vice mechanic. Check the side stand/ignition interlock system for proper operation before riding.

  • Page 128: Spark Arrester

    SPARK ARRESTER 1. Shift into neutral. The muffler has a spark arrester which must be periodically cleaned to maintain good efficiency. At the intervals shown in the maintenance chart, clean the spark arrester as follows.  CAUTION A hot muffler can burn you. The muffler will be hot enough to burn you for some time after stopping the engine.
  • Page 129 4. Stop the engine. Wait until the muffler  WARNING cools, then replace the drain bolt and tighten it securely. Running the engine indoors or in a garage can be hazardous. Exhaust gas  WARNING contains carbon monoxide, a gas that is colorless and odorless and can cause Running the engine with a loose drain death or severe injury.

  • Page 130: Front Wheel Removal

    FRONT WHEEL REMOVAL 1. Place the motorcycle on the side stand. 4. Draw out the axle shaft 2. 2. Remove the axle nut 1. 3. Lift the front end of the motorcycle up and place a jack or a block under the engine or chassis tubes.
  • Page 131 6. Slide the front wheel forward. 7. To reinstall the wheel assembly, reverse the sequence described above. Align the NOTE: Never squeeze the front brake lever speedometer gear projections with the with the front wheel removed. It is very diffi- wheel hub before fitting the wheel into cult to force the pads back into the caliper the front fork.
  • Page 132 Suzuki stroke and firm feel are restored. Also dealer to check the bolts and nuts.

  • Page 133: Rear Wheel Removal

    REAR WHEEL REMOVAL 1. Place the motorcycle on the side stand.  CAUTION A hot muffler can burn you. The muffler will be hot enough to burn you for some time after stopping the engine. Wait until the muffler cools to avoid burns.
  • Page 134 3. Remove the brake adjusting nut 2. 4. Remove the axle nut 5. Remove the torque link nut 4 after pull- 5. Lift the rear wheel up and place a jack or ing off the cotter pin 3. a block under the engine or under the chassis tubes.
  • Page 135 6. Draw out the axle shaft 6. 7. With the wheel moved forward, remove the chain from the sprocket. 6-68...
  • Page 136 • Torque bolts and nuts to the proper specifications. If you are not sure of 8. Pull the wheel assembly rearward. the proper procedure, have your 9. To replace the wheel, reverse the com- authorized Suzuki dealer or a qualified plete sequence described above.

  • Page 137: Light Bulb Replacement

    LIGHT BULB REPLACEMENT HEADLIGHT To replace the headlight bulb, follow the pro- The wattage rating of each bulb is shown on cedure below: the chart below. When replacing a burned out bulb, always use the exact same wattage rating. Using other than the specified rating can result in overloading the electrical sys- tem or premature failure of a bulb.
  • Page 138 3. Disconnect the socket 3 from the head- 2. Remove the four bolts and remove the headlight assembly 2 forward. light and remove the rubber cap 4. 6-71...
  • Page 139 4. Unhook the bulb holder spring 5 and 5. Fit the new bulb. pull out the bulb 6. 6. To replace the headlight bulb, reverse the above sequence. 6-72...
  • Page 140 HEADLIGHT BEAM ADJUSTMENT NOTICE The headlight beam can be adjusted both up and down or right and left if necessary. The headlight bulb’s life may be short- ened by oil from your fingers if you touch it. When replacing the headlight bulb, be careful not to touch the glass.
  • Page 141 TURN SIGNAL LIGHT To replace the turn signal light bulb, follow the procedure below: 2. Push in on the bulb, turn it to the left, and pull it out. 3. To fit the replacement bulb, push it in and turn it to the right while pushing. 1.
  • Page 142 BRAKE LIGHT/TAILLIGHT NOTICE To replace the brake light/taillight bulb, follow the procedure below: Overtightening the screws when rein- stalling the lens may cause the lens to crack. Tighten the screws only until they are snug. 1. Remove the two screws and remove the lens.
  • Page 143 NOTICE Overtightening the screws when rein- stalling the lens may cause the lens to crack. Tighten the screws only until they are snug. 2. Push in on the bulb, turn it to the left, and pull it out. 3. To fit the replacement bulb, push it in and turn it to the right while pushing.

  • Page 144: Fuse

    Consult your Suzuki dealer for the If the new fuse blows in a short time, the electrical system check and repair. electrical problem may not be fixed.
  • Page 145 The fuse is located under the right side frame cover. To access the fuse, remove the right side frame cover by referring to the FRAME COVER AND SEAT REMOVAL sec- tion. One 20A spare fuse is located in the fuse case. 6-78...

  • Page 146: Troubleshooting

    TROUBLESHOOTING FUEL SYSTEM CHECK ..........................7-2 IGNITION SYSTEM CHECK ........................7-4 ENGINE STALLING ............................ 7-5...
  • Page 147 Such damage may not be covered under warranty. If you are not sure about the proper action, consult your Suzuki dealer about the problem. If the engine refuses to start, perform the fol- lowing inspections to determine the cause.
  • Page 148 b. Place the empty container under the  WARNING carburetor. Turn the fuel valve lever to the “PRI” position and see if the fuel Fuel and fuel vapor are highly flammable flows from the drain hole. and toxic. You can be burned or poi- c.
  • Page 149 If the ignition system is operating properly, a blue spark should jump across the spark plug gap. If there is still no spark, take your motor- cycle to an authorized Suzuki dealer.
  • Page 150 ENGINE STALLING 1. Check the fuel supply in the fuel tank. 2. Check the ignition system for intermittent spark. 3. Check the idle speed.

  • Page 152: Storage Procedure And Motorcycle Cleaning

    STORAGE PROCEDURE AND MOTORCYCLE CLEANING STORAGE PROCEDURE ........................... 8-2 PROCEDURE FOR RETURNING TO SERVICE ..................8-4 CORROSION PREVENTION ........................8-5 MOTORCYCLE CLEANING ........................8-7 INSPECTION AFTER CLEANING ......................8-10...

  • Page 153: Storage Procedure

    Suzuki recommends that you trust this manufacturer. maintenance work to your Suzuki dealer. If 2. Drain the carburetor or run the engine for you need to service the machine for storage a few minutes until the stabilized gaso- yourself, follow the general guidelines below.
  • Page 154 ENGINE  WARNING 1. Pour one tablespoon of motor oil into each spark plug hole. Reinstall the spark Fuel and fuel vapor are highly flammable plug and crank the engine a few times. and toxic. You can be burned or poi- 2.

  • Page 155: Procedure For Returning To Service

    BATTERY section. If you 6. Make sure that the motorcycle is prop- cannot charge the battery, consult your erly lubricated. authorized Suzuki dealer. 7. Perform the INSPECTION BEFORE RIDING as listed in this manual. 8. Start the motorcycle as outlined in this...

  • Page 156: Corrosion Prevention

    CORROSION PREVENTION How to Help Prevent Corrosion • Wash your motorcycle frequently, at It is important to take good care of your least once a month. Keep your motorcy- motorcycle to protect it from corrosion and cle as clean and dry as possible. keep it looking new for years to come.
  • Page 157 UV rays in sunlight, and can the bare metal, have a Suzuki dealer reduce the amount of dust and air pollu- tion reaching the surface. Your Suzuki make the repair.

  • Page 158: Motorcycle Cleaning

    MOTORCYCLE CLEANING NOTE: Avoid spraying or allowing water to flow over the following places: • Ignition switch WASHING THE MOTORCYCLE • Spark plug When washing the motorcycle, follow the • Fuel tank cap instruction below: • Carburetor 1. Remove dirt and mud from the motorcy- •...
  • Page 159 3. Once the dirt has been completely NOTE: The headlight lens can be fogged removed, rinse off the detergent with after washing the motorcycle or riding in the plenty of water. rain. Headlight fogging will be cleared grad- ually when the headlight is turned on. When NOTE: The detergent used to wash the clearing the headlight lens fogging, run the motorcycle can negatively affect plastic...
  • Page 160 PLASTIC PARTS WAXING THE MOTORCYCLE Plastic parts such as headlight lens and After washing the motorcycle, waxing and speedometer display, are easy to be dam- polishing are recommended to further pro- aged. When such part is cleaned, wash it tect and beautify the paint. using water after cleaning it using neutral •...

  • Page 161: Inspection After Cleaning

    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. This could lead to an accident.

  • Page 163: Specifications

    SPECIFICATIONS DIMENSIONS AND CURB MASS Overall length ............... 2155 mm (84.8 in) Overall width................. 805 mm (31.7 in) Overall height ............... 1140 mm (44.9 in) Wheelbase ................1405 mm (55.3 in) Ground clearance..............255 mm (10.0 in) Seat height ................845 mm (33.3 in) Curb mass (weight) ..............
  • Page 164 DRIVE TRAIN Clutch ................... Wet multi-plate type Transmission ................ 5-speed constant mesh Gearshift pattern..............1-down, 4-up Primary reduction ratio ............3.157 (60/19) Final reduction ratio.............. 3.000 (45/15) Gear ratios, Low..............3.000 (33/11) 2nd ..............1.933 (29/15) 3rd ..............1.437 (23/16) 4th ..............
  • Page 165 ELECTRICAL Ignition type ................Electronic ignition (CDI) Spark plug ................NGK DR8EA or DENSO X24ESR-U Battery .................. 12V 21.6 kC(6 Ah)/10 HR Generator ................Three-phase A.C. generator Fuse ..................20A Headlight ................12V 60/55W (H4) Brake light/Taillight ............... 12V 21/5W Turn signal light ..............

  • Page 167: Index

    INDEX ACCESSORY USE AND MOTORCYCLE ENGINE OIL ........3-4 6-25 LOADING............1-2 ENGINE STALLING ........7-5 AIR CLEANER..........6-16 ALLOW THE ENGINE OIL TO CIRCULATE BEFORE RIDING ........4-3 FRAME COVER AND AVOID CONSTANT LOW SPEED .....4-3 SEAT REMOVAL........6-9 FRONT WHEEL REMOVAL..... 6-63 FUEL HOSE ..........
  • Page 168 IGNITION SWITCH........2-5 MAINTENANCE SCHEDULE..... 6-2 IGNITION SYSTEM CHECK ......7-4 MAXIMUM THROTTLE OPERATION INSPECTION AFTER CLEANING....8-10 RECOMMENDATION......... 4-2 INSPECTION BEFORE RIDING ....4-4 MOTORCYCLE CLEANING....... 8-7 INSTRUMENT PANEL .......2-7 NOISE CONTROL SYSTEM KEY.............2-5 (AUSTRALIA ONLY) ........1-9 LABELS ............1-8 OBSERVE YOUR FIRST AND LEFT HANDLEBAR ........2-9 MOST CRITICAL SERVICE .......
  • Page 169 REAR BRAKE PEDAL......2-20 TIRES ............6-55 REAR WHEEL REMOVAL .......6-66 TOOLS ............6-7 RIDING ON HILLS........5-8 RIGHT HANDLEBAR........2-12 USING THE TRANSMISSION....5-6 SAFE RIDING RECOMMENDATION FOR MOTORCYCLE RIDERS......1-5 VARY THE ENGINE SPEED...... 4-2 SERIAL NUMBER LOCATION ....1-8 SIDE STAND ..........2-21 SIDE STAND/IGNITION INTERLOCK SYSTEM ...........6-59 SPARK ARRESTER .........6-61...

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