Suzuki FU150CD3 Owner's Manual
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Suzuki FU150CD3 Owner's Manual

Suzuki FU150CD3 Owner's Manual

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FU150CD3
OWNER'S MANUAL
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 FU150CD3

  • Page 1 FU150CD3 OWNER’S MANUAL 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...

  • Page 2: Break-In (Running-In) Information For Your Motorcycle

    The personal safety of the rider your new motorcycle. Suzuki parts are manu- factured of high quality materials, and may be involved. Disregarding this machined parts are finished to close information could result in injury tolerances.

  • Page 3: Table Of Contents

    By following these instructions explicitly you will ensure a long trouble free operating life for FUEL AND ENGINE OIL RECOMMENDATIONS your motorcycle. Your Suzuki dealer has experienced technicians that are trained to provide your machine with the best possible service with the right tools and equipment.

  • Page 4: Consumer Information Es

    CONSUMER INFORMATION ACCESSORY INSTALLATION AND PRECAUTION SAFETY TIPS ○ ○ ○ ○ ○ ○ ○ ○ ○ MODIFICATION ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○...
  • Page 5 8 WARNING • Inspect for proper ground clearance and accessories. conditions. It is not possible for Suzuki to test bank angle. An improperly mounted load each accessory on the market or Exceeding a maximum loading could critically reduce these two safety •...
  • Page 6 Knowing these limits and staying Choose good quality motorcycle riding tested for your motorcycle. Consult within them will help you avoid accidents. apparel when riding your motorcycle. your SUZUKI dealer if you have any question.

  • Page 7: Serial Number Location

    SERIAL NUMBER LOCATION The frame and/or engine serial numbers are CONTROLS used to register the motorcycle. They are also used to assist your dealer when ordering parts or referring to special service LOCATION OF PARTS information. ○ ○ ○ ○ ○...
  • Page 8 CONTROLS LOCATION OF PARTS FU150CD3 / DX3 FU150CD3 / DX3 1 Clutch lever 7 Ignition switch F Gearshift lever 0 Spark plug 2 Left handlebar switches 8 Electric starter switch A Helmet holders G Engine oil drain plug 3 Instrument panel...
  • Page 9 Keep the spare key Please write your key number in the box in a safe place. provided for your future reference. Key number: FU150CD3 / DX3 FU150CD3 / DX3 K Rear brake fluid reservoir O Rear brake pedal L Air cleaner...

  • Page 10: Ignition Switch

    If the motorcycle falls down, turn the The ignition circuit is completed and the ignition switch off immediately. Ask engine can now be started. The key cannot your authorized Suzuki dealer to be removed from the ignition switch in this position. inspect the motorcycle for unseen 8 WARNING damage.

  • Page 11: Instrument Panel

    TACHOMETER 1 ENGINE RPM INDICATOR LIGHT 3 ” 2 INSTRUMENT PANEL FUEL METER “ The tachometer indicates the engine speed While in LOW or HIGH mode, when the The fuel meter indicates the amount of fuel in revolutions per minute (r/min). tachometer shows engine rpm within the remaining in the fuel tank.
  • Page 12 TURN SIGNAL INDICATOR LIGHT “™š” 8 OFF/LOW/HIGH Mode Selection When the previous setting is LOW or HIGH To change the display, push the MODE mode, the LOW or HIGH mark 4 comes on. When the turn signals are being operated button A.

  • Page 13: Left Handlebar

    TURN SIGNAL SWITCH “ ™š ” 3 LEFT HANDLEBAR CAUTION Moving the switch to the “™” position will flash the left turn signals. Moving the switch to the Holding the dimmer switch between “š” position will flash the right turn signals. “—”...

  • Page 14: Right Handlebar

    HORN BUTTON “‘’’” 4’’ THROTTLE GRIP 2 RIGHT HANDLEBAR FUEL TANK CAP Press the button to sound the horn. Engine speed is controlled by the position of the throttle grip. Turn it toward you to CHOKE LEVER 5’’ increase engine speed. Turn it away from The carburetor is equipped with a choke you to decrease the engine speed.

  • Page 15: Kick Starter Lever

    GEARSHIFT LEVER KICK STARTER LEVER 8 WARNING Fuel and fuel vapor are highly flammable and toxic. You can be burned or poisoned when refueling. • Stop the engine and keep flames, sparks and heat sources away. • Refuel only outdoors or in a well ventilated area.

  • Page 16: Rear Brake Pedal

    REAR BRAKE PEDAL SEAT LOCK AND HELMET HOLDERS HELMET HOLDERS NOTE: When the transmission is in neutral, the green indicator light on the instrument panel will lit. However, even when the light is SEAT LOCK illuminated, cautiously release the clutch le- ver slowly to confirm the transmission is in neutral.

  • Page 17: Side Stand

    STANDS SIDE STAND 2 8 WARNING CAUTION To place the motorcycle on the side stand, This motorcycle is equipped with a center place your right foot on the end of the side Riding with a helmet fastened to the Park the motorcycle on firm, level stand and side stand.

  • Page 18: Fuel And Engine Oil Recommendations Nl

    FUEL AND ENGINE OIL RECOMMENDATIONS FUEL ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○...

  • Page 19: Fuel, Engine Oil And Coolant Recommendations

    NOTE: SAE Engine Oil Viscosity FUEL, ENGINE OIL AND ENGINE OIL To help minimize air pollution, SUZUKI • COOLANT RECOMMENDATIONS Oil quality is a major contributor to your SUZUKI recommends the use of Suzuki recommends that you use oxygenated engine’s performance and life. Always select...
  • Page 20 Energy Conserving Suzuki Genuine Oil JASO T903 SUZUKI does not recommend the use of The JASO T903 standard is an index to API from SH to SM API SN or higher “ENERGY CONSERVING” oils. Some engine select engine oils for 4-stroke motorcycle oils which have an API classification of SH and ATV engines.

  • Page 21: Break-In (Running-In) And Inspection Before Riding S

    BREAK-IN (RUNNING-IN) AND INSPECTION BEFORE RIDING PROPER BREAK-IN PROCEDURE ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ INSPECTION BEFORE RIDING ○ ○ ○ ○ ○ ○ ○...

  • Page 22: Vary The Engine Speed

    Do not, performance from your new Suzuki. The however, use full throttle for the first 1,600 Use extra care when riding on new following guidelines...

  • Page 23: Observe Your First And Most Critical Service

    OBSERVE YOUR FIRST AND INSPECTION BEFORE RIDING 8 WARNING WHAT TO CHECK FOR: MOST CRITICAL SERVICE CHECK PRE-RIDE CHECK ITEMS Using worn, improperly inflated, or Steering • Smoothness The first 1000 km service is the most • No restriction of movement important service your motorcycle will incorrect tires will reduce stability Before riding the motorcycle, be sure to check...

  • Page 24: Riding Tips

    RIDING TIPS Throttle grip • Correct cable play • Smooth operation and positive return of the throttle grip to the closed position STARTING THE ENGINE Side stand • Smoothness ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○...
  • Page 25 RIDING TIPS When the Engine is Cold: When a Warm Engine is Hard to Start: CAUTION 1. Turn the choke lever all the way to the left. 1. Squeeze the clutch lever. 2. Squeeze the clutch lever. 2. Open the throttle grip 1/8 to 1/4 Running the engine too long without STARTING THE ENGINE 3.

  • Page 26: Starting Off

    STARTING OFF RIDING ON HILLS 8 WARNING 8 WARNING • 1. Warm up the engine in Neutral gear . When climbing steep hills, the motorcycle It will be hazardous to operate Sudden side winds, which can occur position. may begin to slow down and show lack of motorcycle If you remove even one 2.

  • Page 27: Using The Transmission

    USING THE TRANSMISSION STOPPING AND PARKING NOTE: If the motorcycle is to be parked on 8 WARNING the side stand on a slight slope, the front end 1. Turn the throttle grip away from yourself The transmission is provided to keep the of the motorcycle should face “up”...

  • Page 28: Inspection And Maintenance

    INSPECTION AND MAINTENANCE 8 WARNING 8 WARNING A hot muffler can burn you. The muffler Hard braking while turning may cause will be hot enough to burn you for some wheel skid and loss of control. MAINTENANCE SCHEDULE ○ ○ ○...

  • Page 29: Maintenance Schedule

    Your an asterisk (*). You may perform Using poor quality replacement parts Suzuki dealer can provide you with further the unmarked maintenance items can cause your motorcycle to wear guidelines. Steering...

  • Page 30: Maintenance Chart

    MAINTENANCE CHART Interval: This interval should be judged by odometer reading or months, whichever comes first. ENGINE CHASSIS Interval 1000 4000 8000 12000 16000 20000 Interval 1000 4000 8000 12000 16000 20000 Item Months Item Months Battery Drive chain *Cylinder head nuts, cylinder nuts, exhaust pipe and muffler Clean and lubricate every 1000km bolts and nut Brakes...

  • Page 31: Lubrication Points

    TOOLS LUBRICATION POINTS Proper lubrication is important for smooth and To assist you in the performance of periodic long life of each working part of your maintenance, a tool kit is supplied and is motorcycle and also for safe riding. It is a good located under the seat.
  • Page 32 BATTERY 1..Clutch lever pivot 8 WARNING 8 WARNING This battery is a sealed type battery and 2..Gearshift lever pivot requires no maintenance. Have your dealer Battery posts, terminals, and related Hydrogen gas produced by batteries 3..Side stand pivot and spring hook check the battery’s state of change 4..Center stand pivot and spring hook accessories contain lead and lead...
  • Page 33 CAUTION damage the charging system and the recycling of the used battery, consult your SUZUKI dealer. battery. Exceeding the standard charging rate for the motorcycle battery can shorten The red lead must go to the its life.

  • Page 34: Spark Plug

    Used batteries must be disposed or Use one of the spark plugs listed or recycled according to the local law the equivalent. Consult your Suzuki and must not be discarded with dealer or qualified mechanic if you are ordinary household waste. Make sure 0.7 - 0.8 mm...

  • Page 35: Air Cleaner

    Spark Plug Replacement Guide Spark Plug Installation AIR CLEANER CAUTION Carefully turn the spark plug by hand into If the air cleaner element has become DENSO REMARKS the threads until it is finger tight. If the spark clogged with dust, intake resistance will A crossthreaded or overtightened CR8E U24ESR-N...
  • Page 36 Follow the procedure below to remove the 4. Remove the air cleaner element 2. 5. Inspect the air cleaner element condition. CAUTION air cleaner element. Replace the air cleaner element periodically. If driving under dusty, wet or muddy 1. Place the motorcycle on the center stand. conditions the air cleaner element 2.

  • Page 37: Idle Speed Adjustment

    Remove the plugs and drain water and oil at described above. If you donot have one, ask the periodic maintenance interval. The air your Suzuki dealer or qualified mechanic to cleaner drain plugs are located beneath the perform this adjustment.

  • Page 38: Throttle Cable Play

    THROTTLE CABLE PLAY FRAME COVER AND SIDE COWLING To adjust the cable play: 1. Remove the boot 1. REMOVAL 2. Loosen the lock nut 2. 1. Place the motorcycle on the center stand. 3. Turn the adjuster 3 so that the throttle grip has 2.0 - 4.0 mm play.
  • Page 39 7. Disconnect the rear combination light connector 6. 6. Remove the screws 5. 4. Remove the 12 screws 3. 5. Unhook the hooks 4. 8. Remove the frame covers with rear combination light assembly 7. 6-22 6-23...
  • Page 40 9. Remove the screws 8. FUEL HOSE CLUTCH 10. Pull out the right and left clips 9 from the 1. Remove the frame cover by referring to oil cooler. Remove the side cowlings 0. the FRAME COVER AND SIDE COWLING 11.To install the frame covers and side REMOVAL section.

  • Page 41: Engine Oil Level Check

    3. Stop the engine and wait for three minutes. the adjuster 2. 5. Tighten the lock nuts, 1 and 3, after finishing the adjustment. NOTE: Any maintenance of the clutch other than the clutch cable play should be performed by your Suzuki accreditted mechanic from dealer. 6-26 6-27...

  • Page 42: Engine Oil And Filter Change

    6. Replace the oil filter 6 and the “O” ring 7 ENGINE OIL AND FILTER CHANGE 4. Remove the drain plug 2 and gasket 3 5. Remove the bolts 4 holding the filter cap Change the engine oil and oil filter at the 5 in place with a new one.
  • Page 43 Tighten the plug securely with a wrench. harmed by swallowing new or used Pour fresh oil through the filler hole. Use a genuine SUZUKI oil filter or an oil or solvent. Continuous contact with Approximately 1200 ml will be required.

  • Page 44: Drive Chain Cleaning And Oiling

    2. After thoroughly washing the chain and Riding with the chain in poor condition Attach the chain joint clip so that the allowing it to dry, oil the links with Suzuki or improperly adjusted can lead to an slit end faces opposite to the direction...

  • Page 45: Drive Chain Adjustment

    DRIVE CHAIN ADJUSTMENT To adjust the drive chain, follow these 8 WARNING directions: 1. Place the motorcycle on the center stand. A hot muffler can burn you. The muffler 2. Loosen the axle nut 1. will be hot enough to burn you for some 3.

  • Page 46: Brake Hose Inspection

    If any maintain the brakes increases your • defects are found, ask your Suzuki dealer to If there is frequent loss of brake chance of having an accident. replace the brake hose with a new one.

  • Page 47: Brake Pad

    A. animals. 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 qualified service mechanic. REAR 6-38...

  • Page 48: Rear Brake Pedal Adjustment

    NOTE: Do not squeeze the brake lever when REAR BRAKE PEDAL ADJUSTMENT Adjust the brake pedal position in the follow- 8 WARNING the pads are not in their positions. It is difficult ing manner: The rear brake pedal position must be to push the pistons back and brake fluid Riding with worn brake pads will properly adjusted at all times or the disc...

  • Page 49: Rear Brake Light Switch

    REAR BRAKE LIGHT SWITCH TIRES TIRE PRESSURE AND LOADING 8 WARNING The rear brake light switch is located under Proper tire pressure and proper tire loading the right footrest. To adjust the brake light 8 WARNING Failure to perform break-in of the tires are important factors.
  • Page 50 2.00 kgf/cm or shorten tire life. 29 psi 29 psi 225 KPa 280 KPa REAR • Ask your SUZUKI dealer or 2.25 kgf/cm 2.80 kgf/cm 33 psi 41 psi qualified mechanic to perform tire Proper tire condition and proper tire type repair, replacement, and balancing affect motorcycle performance.

  • Page 51: Light Bulb Replacement

    When you replace a tire, be sure to replace it LIGHT BULB REPLACEMENT HEADLIGHT, FRONT TURN SIGNAL Cold Tire Inflation Pressure and Tire Type Table with a tire of the size and type listed below. If LIGHT AND POSITION LIGHT The wattage rating of each bulb is shown on you use a different size or type of tire, To replace the headlight bulb, front turn...
  • Page 52 2. Pull out the bulb 3. Headlight Front Turn Signal Light 3. Fit the new bulb. 1. Remove the rubber cap 1. Push in on the To replace the front turn signal light bulb, 4. To reinstall the headlight, reverse the socket 2, twisting it to the left, and pull it follow the procedure below: sequence described above.

  • Page 53: Headlight Beam Adjustment

    2. Pull off the bulb from the socket. 2. Pull off the bulb from the socket. Position Light HEADLIGHT BEAM ADJUSTMENT 3. Fit the new bulb. 3. Fit the new bulb. 1. Turn the socket counterclockwise and re- The headlight beam can be adjusted up and move it.
  • Page 54 2. Remove the rear fender screw 3. 4. Remove the inner lens 5. REAR TURN SIGNAL LIGHT AND 3. Pull down the rear fender as shown in the illustration and remove the outer lens 4. BRAKE LIGHT/TAILLIGHT To replace the rear turn signal light and brake light/taillight bulb, follow the procedure be- low: 1.
  • Page 55 Consult your Suzuki dealer for the elec- your Suzuki dealer or qualified trical system check and repair.

  • Page 56: Catalytic Converter

    CATALYTIC CONVERTER The fuse is located under the seat The 10A CAUTION CAUTION fuse is equipped. It is designed to open when This motorcycle is equipped with catalytic a circuit overload exists in individual electri- • Improper motorcycle operation can Do not try to start the engine by converter.

  • Page 57: Troubleshooting

    TROUBLESHOOTING CAUTION If you park or operate the motorcycle in areas where there are combustible FUEL SYSTEM CHECK ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○...

  • Page 58: Fuel System Check

    If you are not sure about the proper • Dispose of drained fuel properly. f. Loosen the drain screw and check that action, consult your Suzuki dealer or the carburetor is filled back up with fuel. qualified mechanic about the problem.

  • Page 59: Ignition System Check

    ○ ○ ○ ○ ○ ○ ○ ○ there is no spark, consult your Suzuki dealer for repairs. 8 WARNING Performing the spark test improperly can cause a high voltage electrical shock explosion. Avoid performing this check if you are...
  • Page 60 NOTE: Avoid spraying or allowing water to Waxing the Motorcycle MOTORCYCLE CLEANING 3. Once the dirt have been completely flow over the following places: removed, rinse off the detergent with After washing the motorcycle, waxing and AND STORAGE PROCEDURE running water. polishing are recommended to further protect •...
  • Page 61 For this reason, Suzuki fuel. terminal. recommends that you trust this maintenance work to your Suzuki dealer. If you need to Wet brakes can cause poor braking 2. Clean the outside of the battery with a mild service the machine for storage yourself,...

  • Page 62: Procedure During Storage

    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 63 Bore ............62.0 mm amount of dust and air pollution reaching Stroke ........... 48.8 mm the surface. Your Suzuki dealer can help Displacement ........147 cm you select the right cover for your Corrected compression ratio ....10.2 : 1 motorcycle.
  • Page 64 DRIVE TRAIN ELECTRICAL gnition type .......... Electronic ignition (CDI) Clutch ........... Wet multi-plate type Transmission ........6-speed constant mesh Spark plug ..........NGK CR8E or DENSO U24ESR-N Gearshift pattern ......... 1-down, 5-up Battery ..........12V 20.5kC (5.7 Ah)/10 HR Primary reduction ratio ......3.500 (70/20) Generator ..........
  • Page 65 INDEX ACCESSORY INSTALLATION AND FRAME COVER AND SIDE PRECAUTION SAFETY TIPS COWLING REMOVAL 6-21 ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ AIR CLEANER 6-16 FUEL ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○...
  • Page 66 REAR BRAKE PEDAL ADJUSTMENT 6-41 USING THE TRANSMISSION ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ KICK STARTER LEVER 2-17 REAR BRAKE PEDAL 2-18 ○ ○...
  • Page 67 24 months or 20,000km rized by Suzuki. Owner’s Dealer • Units damaged by use of parts other whichever comes first Name Name than Suzuki Genuine Parts. EXPENDABLE PARTS NOT Address Address • Damages caused by users negligence COVERED BY WARRANTY or abuse. Model...
  • Page 68 4th Month (4,000 km) Service 16th Month (16,000 km) Service Service Date Km Reading JO No. Service Date Km Reading JO No. Servicing Servicing Dealer / Address Dealer / Address Mechanic Name / Customer Mechanic Name / Customer Signature Name / Signature Name / Signature...
  • Page 69 REPAIR AND INSPECTION RECORD (To be filled up by Suzuki dealer’s mechanic.) Repair Repair Description Servicing Dealer Mechanic Name Repair Date dd/mo/yr Order No. Reading...

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