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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 DR-Z400S
- 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.
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Page 2: Break-In (Running-In) Information For Your Motorcycle
WARNING new motorcycle. Suzuki parts are manufactured of high quality materi- Indicates a potential hazard that als, and machined parts are finished could result in death or serious to close tolerances. - Page 3 Suzuki reserves the right to make changes at any time. Please note that this manual applies to all specifications for all respective destinations and explains all equip- ment.
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Page 4: Table Of Contents
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 6: Consumer Information
CONSUMER INFORMATION ACCESSORY USE AND MOTORCYCLE LOADING ......... 1-2 SAFE RIDING RECOMMENDATION FOR MOTORCYCLE RIDERS ....1-4 LABELS ....................... 1-5 SERIAL NUMBER LOCATION ................1-6... -
Page 7: Accessory Use And Motorcycle Loading
It is not possible for Suzuki to mounted. test each accessory on the market or • Inspect for proper ground clear- combinations of all the available ance and bank angle. -
Page 8: Loading Limit
LOADING LIMIT LOADING GUIDELINES This motorcycle is primarily intended WARNING to carry small items when you are not riding with a passenger. Follow the loading guidelines below: Overloading or improper loading • Balance the load between the left can cause loss of motorcycle con- and right side of the motorcycle trol and an accident. -
Page 9: Safe Riding Recommendation For Motorcycle Riders
SAFE RIDING RECOMMENDATION FAMILIARIZE YOURSELF WITH THE MOTORCYCLE FOR MOTORCYCLE RIDERS Your riding skill and your mechanical Motorcycle riding is great fun and an knowledge form the foundation for exciting sport. Motorcycle riding also safe riding practices. We suggest that requires that some extra precautions you practice riding your motorcycle in be taken to ensure the safety of the... -
Page 10: Ride Defensively
LABELS RIDE DEFENSIVELY The most common type of motorcycle Read and follow all the labels on the accident occurs when a car traveling motorcycle. Make sure you under- towards a motorcycle turns round cor- stand all of the labels. Do not remove ner in front of the motorcyclist. -
Page 11: Serial Number Location
SERIAL NUMBER LOCATION The frame and/or engine serial num- bers are used to register the motorcy- cle. They are also used to assist your dealer when ordering parts or refer- ring to special service information. The frame number 1 is stamped on the steering head tube. -
Page 12: Controls
CONTROLS LOCATION OF PARTS ..................2-2 KEY ........................2-5 IGNITION SWITCH ....................2-5 STEERING LOCK ....................2-6 INSTRUMENT PANEL ..................2-7 LEFT HANDLEBAR ................... 2-18 RIGHT HANDLEBAR ..................2-19 FUEL TANK CAP ....................2-21 FUEL VALVE ..................... 2-22 GEARSHIFT LEVER ..................2-24 REAR BRAKE PEDAL .................. -
Page 13: Location Of Parts
CONTROLS LOCATION OF PARTS DR-Z400S 1 Clutch lever 2 Left handlebar switches 3 Ignition switch 4 Indicator light 5 Instrument panel 6 Front brake fluid reservoir 7 Right handlebar switches 8 Front brake lever 9 Throttle grip 0 Fuel tank cap... - Page 14 DR-Z400S A Spark plug B Fuel valve C Choke knob D Throttle stop screw E Air cleaner F Passenger footrests G Battery and fuse H Tools I Helmet holder J Gearshift lever K Footrests L Engine coolant reservoir M Side stand...
- Page 15 DR-Z400S N Spark arrester O Steering lock P Radiator cap Q Rear brake fluid reservoir R Rear brake pedal S Crankcase drain plug T Oil loss check bolt U Engine oil filter V Frame tube drain plug...
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Page 16: Key
IGNITION SWITCH This motorcycle comes equipped with “OFF” POSITION two pairs of keys, one for the ignition All electrical circuits are cut off. The switch and the other for the steering engine will not start. The key can be lock. Keep the spare key in a safe removed. -
Page 17: Steering Lock
If the motorcycle falls down, turn the ignition switch off immedi- To lock the steering, turn the handle- ately. Ask your authorized Suzuki bars all the way to the left, insert the dealer to inspect the motorcycle key into the lock, turn it counterclock- for unseen damage. -
Page 18: Instrument Panel
INSTRUMENT PANEL COOLANT TEMPERATURE INDICATOR LIGHT “” 4 If this light comes on while riding it means that the coolant temperature is too high. When the coolant tempera- TIME ture indicator light comes on, stop the CLOCK km/h engine and check the coolant level TRIP TRIP TOTAL... - Page 19 WARNING Changing the display while riding TIME can be hazardous. Removing a CLOCK km/h hand from the handlebars can TRIP TRIP TOTAL reduce your ability to control the TIME/ TRIP TIME TRIP TRIP motorcycle. MODE ADJUST Never change the display while riding.
- Page 20 NOTE: When the trip meter exceeds Resetting 999.9, the trip meter will return to 0.0 and start counting again. TIME/ TRIP TRIP NOTE: The trip meter will be reset to zero when the battery is removed or battery is discharged. Display Selection TRIP TRIP...
- Page 21 The symbol “” beside A or B shows the trip meter is in the subtraction mode. TIME NOTE: The indication range of the trip CLOCK km/h meter is from – 999.9 km to 999.9 km. TRIP TRIP TOTAL If the kilometer is beyond the range, TIME/ TRIP TIME...
- Page 22 Compensation Usually, it is not necessary to change this setting. But, for off road use, the compensating function is provided to ADJUST the trip meters. The input kilometer from front wheel 2. Set the compensation percentage can be multiplied by compensation by pushing the “ADJUST- +”...
- Page 23 The underline “–” under the “TIME” or “ TIME” shows that its figure is adjustable. TIME Clock CLOCK km/h The clock is 24 hour type. TRIP TRIP TOTAL TIME/ TRIP TIME TRIP TRIP To adjust the clock, follow the proce- dure below: MODE ADJUST...
- Page 24 TIME/ TRIP TIME TRIP TRIP CLOCK MODE 4. After adjustment, push After that, adjustable digit can be “MODE-TIME” button 0. changed by pushing the “SET-TIME/ TRIP” button B in the order below. underline “–” disappears and the set time is registered. NOTE: This clock is powered by the Second Minute...
- Page 25 TIME/ TRIP TRIP TIME TIME CLOCK km/h TRIP TRIP TOTAL To start/stop the stop watch, push the TIME/ TRIP TIME TRIP TRIP “SET-TIME/TRIP” button B while MODE ADJUST the underline “–” indicates the stop watch. The display of “TIME” is flash- ing while the stop watch is counting Stop Watch (TIME) time.
- Page 26 The starting time is adjustable. To adjust the starting time, follow the pro- Second Minute Hour cedure below: digit digit digit TIME/ TRIP TRIP TIME 1. Push the “SET-TRIP” button A ADJUST while the underline “–” is indicated under the stop watch. The display of second digit is flashing and sec- 2.
- Page 27 To set the starting time, follow the pro- cedure below: TIME CLOCK TIME/ TRIP TRIP km/h TIME TRIP TRIP TOTAL TIME/ TRIP TIME TRIP TRIP MODE ADJUST 1. Push the “SET-TRIP” button A while the underline “–” is indicated under the timer. The display of Timer (...
- Page 28 TIME/ TRIP TRIP Second Minute Hour digit digit digit 3. After adjustment is done, push the “SET-TRIP” button A. TIME/ TRIP TRIP ADJUST TIME 2. Set the time of adjustable digit by To start/stop the timer, push the pushing the “ADJUST- +” button “SET-TIME/TRIP”...
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Page 29: Left Handlebar
LEFT HANDLEBAR Holding dimmer switch between the “” and “” posi- tion will light both the high and low headlight beam. This improper operation can damage the motor- cycle’s headlight. Use the dimmer switch to select only the “” or “” position. CLUTCH LEVER 1 The clutch lever is used for disengag- ing the drive to the rear wheel when... -
Page 30: Turn Signal Light Switch
RIGHT HANDLEBAR TURN SIGNAL LIGHT SWITCH “” 3 Moving the switch to the “” position will flash the left turn signals. Moving the switch to the “” position will flash the right turn signals. The indi- cator light will also flash intermittently. To cancel turn signal operation, push the switch on. -
Page 31: Throttle Grip
Engaging the starter motor for more than five seconds at a time can damage the starter motor and wiring harness from overheating. Do not engage the starter motor for more than five seconds at a time. If the engine does not start after several attempts, check the ELECTRIC STARTER SWITCH “”... -
Page 32: Fuel Tank Cap
FUEL TANK CAP 1 Bottom of the filler neck 2 Fuel WARNING If you overfill the fuel tank, fuel may overflow when it expands due to engine heat or heating by the sun. Fuel that overflows can catch fire. Stop adding fuel when the fuel To open the fuel tank cap, insert the level reaches the bottom of the... -
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 dif- FUEL ficult to start. Do not refuel above the bottom of the filler neck. - Page 34 CHOKE KNOB “” FUEL “PRI” (PRIMING) POSITION When there is no fuel in the carbure- tor, turn the lever to the “PRI” position. The carburetor is equipped with a Upon starting the engine, be sure to choke system to provide easy starting return the lever to the “ON”...
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Page 35: Gearshift Lever
GEARSHIFT LEVER REAR BRAKE PEDAL This motorcycle has a 5-speed trans- Depressing the rear brake pedal will mission which operates as shown. To apply the rear brake. The brake light shift properly, squeeze the clutch will be illuminated when the rear lever and close the throttle at the brake is operated. -
Page 36: Helmet Holder
HELMET HOLDER SIDE STAND To open the latch of the helmet This motorcycle is equipped with a holder, insert the ignition key into the side stand to support the motorcycle lock and turn it clockwise. To close when parking. An interlock system is the latch, turn the key counterclock- provided to cut off the ignition circuit wise. -
Page 37: Suspension Adjustment
SUSPENSION ADJUSTMENT WARNING Riding with the side stand incom- pletely retracted can result in an Turning adjusters by force can accident when you turn left. damage the suspensions. Check operation of the side stand/ Do not turn adjusters beyond their ignition interlock system before natural limits. - Page 38 To adjust the damping force turn in Air Pressure Adjustment the adjuster fully and turn it out. As 1. Place a block under the chassis you turn the adjuster, you will notice tube to lift the front wheel off the the clicks.
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Page 39: Rear Suspension
This unit contains high-pressure nitrogen gas. Mishandling can cause explosion. • Keep away from fire and heat. • Read owner’s manual for more information. NOTE: Ask your Suzuki dealer to dis- pose of the rear suspension unit. 2-28... - Page 40 The rear shock contains high pressure nitrogen gas and can explode if improperly disas- sembled or disposed of. Service or disposal should only be done by your authorized Suzuki dealer or a qualified mechanic. 2-29...
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Page 42: Fuel, Engine Oil And Coolant Recommendations
FUEL, ENGINE OIL AND COOLANT RECOMMENDATIONS FUEL OCTANE RATING ..................3-2 OXYGENATED FUEL RECOMMENDATION ............3-2 ENGINE OIL ......................3-3 ENGINE COOLANT SOLUTION ................. 3-5... -
Page 43: Fuel Octane Rating
If the sit- uation is not improved by chang- Use the recommended gasoline. ing, consult your Suzuki dealer. • If pinking or knocking is experi- enced, substitute higher octane grade gasoline or another brand, because there are differences between brand. -
Page 44: Engine Oil
NOTE: ENGINE OIL • To help minimize air pollution, Suzuki recommends that you use DESCRIPTION oxygenated fuels. Engine life depends on oil amount • Be sure that any oxygenated fuel and quality. Daily oil level checks and recommended periodic changes are two of the most octane ratings. - Page 45 SAE Engine Oil Viscosity JASO T903 If SAE 10W-40 engine oil is not avail- The JASO T903 standard is an index able, select an alternative according to select engine oils for 4-stroke to the following chart. motorcycle and ATV engines. Motor- cycle and ATV engines lubricate clutch and transmission gears with engine oil.
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Page 46: Engine Coolant Solution
ENGINE COOLANT SOLUTION Energy Conserving Suzuki does not recommend the use Use “SUZUKI SUPER LONG LIFE “ENERGY CONSERVING” COOLANT” or “SUZUKI LONG LIFE “RESOURCE CONSERVING” oils. COOLANT”. If “SUZUKI SUPER Some engine oils which have an API LONG LIFE COOLANT”... - Page 47 Required amount of water/coolant Solution capacity (total): SUZUKI SUPER LONG LIFE 1250 ml (1.3/1.1 US/Imp. qt) COOLANT (Blue) “SUZUKI SUPER LONG LIFE COOL- ANT” is pre-mixed to the proper ratio. 625 ml Water (0.7/0.5 US/Imp. qt) Add only “SUZUKI SUPER LONG LIFE COOLANT”...
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Page 48: Break-In (Running-In) And Inspection Before Riding
BREAK-IN (RUNNING-IN) AND INSPECTION BEFORE RIDING MAXIMUM ENGINE SPEED RECOMMENDATION ..........4-2 VARY THE ENGINE SPEED ................4-2 AVOID CONSTANT LOW SPEED ..............4-2 ALLOW THE ENGINE OIL TO CIRCULATE BEFORE RIDING ......4-2 OBSERVE YOUR FIRST AND MOST CRITICAL SERVICE ......4-2 INSPECTION BEFORE RIDING ................ -
Page 49: Maximum Engine Speed Recommendation
Do not, mum life and performance from your however, use full throttle for the first new Suzuki. The following guidelines 1600 km (1000 miles). explain proper break-in procedures. ALLOW THE ENGINE OIL TO... -
Page 50: Inspection Before Riding
INSPECTION BEFORE RIDING WARNING WARNING Checking maintenance items when the engine is running can be Failure to inspect your motorcy- hazardous. You could be severely cle before riding and to properly injured if your hands or clothing maintain your motorcycle get caught in moving engine... - Page 51 Side stand/ Proper operation WHAT TO CHECK FOR: Ignition CHECK interlock Steering • Smoothness system • No restriction of movement ( 6-32) • No play or looseness Throttle • Correct play in the throttle ( 6-19) cable • Smooth operation and positive return of the throttle grip to the closed position...
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Page 52: Riding Tips
RIDING TIPS ENGINE STARTING .................... 5-2 STARTING OFF ....................5-3 USING THE TRANSMISSION ................5-4 RIDING ON HILLS ....................5-5 STOPPING AND PARKING ................5-6 CARRYING A PASSENGER ................5-7... -
Page 53: Engine Starting
RIDING TIPS When a cold Engine is Hard to Start: 1. Pull the choke knob all the way up (full choke position). ENGINE STARTING 2. With the throttle grip opened 1/8 1. Check that the fuel valve is in the to 1/4, push the electric starter “ON”... -
Page 54: Starting Off
STARTING OFF When a Warm Engine is Hard to Start: WARNING 1. Confirm that the choke knob is in the “OFF” position. 2. With the throttle grip opened 1/8 Riding excessive speeds to 1/4, push the electric starter increases your chances of losing switch. -
Page 55: Using The Transmission
USING THE TRANSMISSION WARNING The transmission is provided to keep the engine operating smoothly in its Sudden side winds, which can normal operating speed range. The occur when being passed by gear ratios have been carefully cho- larger vehicles, at tunnel exits or sen to meet the characteristics of the in hilly areas, can cause you to engine. -
Page 56: Riding On Hills
RIDING ON HILLS WARNING • When climbing steep hills, the motorcycle may begin to slow Downshifting when engine speed down and show lack of power. At is too high can: this point you should shift to a • cause the rear wheel to skid and lower gear so that the engine will lose traction due to increased again be operating in its normal... -
Page 57: Stopping And Parking
STOPPING AND PARKING WARNING 1. Turn the throttle grip away from you to close the throttle com- Continuous brake application for a pletely. long time can overheat the brakes 2. Apply the front and rear brakes and reduce their effectiveness, evenly and at the same time. -
Page 58: Carrying A Passenger
5. Park the motorcycle on a firm, flat CARRYING A PASSENGER surface where it will not fall over. Before you invite someone to be a passenger on your motorcycle, you CAUTION need to be thoroughly familiar with motorcycle operation. Adjust tire pressures and suspension according A hot muffler can cause severe... - Page 59 WARNING Carrying a passenger or attach- ing cargo to the seat can greatly reduce your ability to balance and steer this motorcycle on rough ter- rain. You may need the full length of the seat to change position to maneuver the motorcycle and deal with quickly changing off-road conditions, and a passenger or...
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Page 60: Inspection And Maintenance
INSPECTION AND MAINTENANCE MAINTENANCE SCHEDULE ................6-2 TOOLS ......................... 6-5 LUBRICATION POINTS ..................6-5 BATTERY ......................6-6 AIR CLEANER ..................... 6-8 SPARK PLUG ....................6-11 FUEL HOSE ....................... 6-14 ENGINE OIL ....................... 6-15 CARBURETOR ....................6-19 CLUTCH ......................6-21 DRIVE CHAIN ....................6-21 ENGINE COOLANT ................... -
Page 61: Maintenance Schedule
Suzuki dealer to do the nance section. Your Suzuki dealer maintenance. can provide you with further guide- lines. - Page 62 Suzuki dealer or a qualified mechanic. Turn off the ignition switch before servicing the electric parts to avoid short-circuit damage. Poorly-made replacement parts can cause your motorcycle to wear more quickly and may shorten its useful life.
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Page 63: Maintenance Chart
– – – Engine oil hoses “SUZUKI SUPER LONG LIFE Replace every 4 years or 48000 km (29000 miles) COOLANT” (Blue) “SUZUKI LONG LIFE * Engine coolant COOLANT” (Green) ( 6-24) or an engine coolant – – – other than “SUZUKI SUPER LONG LIFE COOLANT”... -
Page 64: Tools
TOOLS A tool kit is supplied. 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 motorcycle after a long rough ride and after get- ting it wet in the rain or after washing it. -
Page 65: Battery
• If you cannot charge the battery, WARNING consult your authorized Suzuki dealer. Wiping the battery with a dry cloth WARNING can cause a static electricity spark, which can start a fire. -
Page 66: Battery Removal
BATTERY REMOVAL To remove the battery, follow the pro- cedure below: Reversing the battery lead wires 1. Place the motorcycle on the side can damage the charging system stand. and the battery. Always attach the red lead to the (+) positive terminal and the black (or black with white tracer) lead to the (–) negative terminal. -
Page 67: Air Cleaner
The recycling element. of materials will help to conserve nat- ural resources. For more detailed Never run the engine without the information about disposing or recy- air cleaner element in place. cling of the used battery, consult your Suzuki dealer. - Page 68 To remove the air cleaner: Failure to inspect the air cleaner element frequently if the vehicle is used in dusty, wet, or muddy con- ditions can damage your motorcy- cle. The air cleaner element can become clogged under these con- ditions, and engine damage may result.
- Page 69 WASHING THE ELEMENT WARNING New and used oil and solvent can be hazardous. Children and pets may be harmed by swallowing new or used oil or solvent. Repeated, prolonged contact with used engine oil may cause skin cancer. Brief contact with used oil or solvent may irritate skin.
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Page 70: Spark Plug
SPARK PLUG To remove the spark plug, follow the procedure below. A torn air cleaner element will allow dirt to enter the engine and can damage the engine. Replace the air cleaner element with a new one if it is torn. Care- fully examine the air cleaner ele- ment for tears during cleaning. - Page 71 4. Loosen the screws 6 (right and 7. Remove the fuel tank by pulling it left.) backward. 5. Turn the fuel valve to the “ON” or 8. Pull off the spark plug cap. “RES” position. 9. Remove the spark plug with a 6.
- Page 72 Use one of the spark plugs listed or their equivalent. Consult your Suzuki dealer if you are not sure which spark plug is correct for your type of usage. 6-13...
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Page 73: Installation
FUEL HOSE INSTALLATION Improper installation of the spark plug can damage your motorcycle. An overly-tight or cross-threaded spark plug will damage the alumi- num threads of the cylinder head. Carefully turn the spark plug by hand into the threads. If the spark plug is new, tighten it with a Inspect the fuel hose for damage and wrench about 1/2 turn past finger... -
Page 74: Engine Oil
ENGINE OIL The oil is pumped up to the oil tank while the engine is running. The Long engine life depends much on engine oil tank of this motorcycle is the selection of a quality oil and the located at the upper part of the frame. periodic changing of the oil. -
Page 75: Engine Oil And Filter Change
6. Holding the motorcycle vertically, ENGINE OIL AND FILTER CHANGE reinsert the dipstick until the Change the engine oil and oil filter at threads touch the filler neck, but the scheduled times. The engine do not screw the cap in. should always be warm when the oil 7. - Page 76 Turning the engine while draining the engine oil will cause oil film shortage and adversely affect the engine. Do not use the electric starter switch during engine oil replace- ment work. 4. Remove the drain plug 3 and gasket 4 from the bottom of the NOTE: engine and drain the engine oil •...
- Page 77 8. Replace the oil filter cap and tighten the nuts securely but do Be sure to use a genuine Suzuki not overtighten them. oil filter or an equivalent one 9. Replace the drain plug gaskets 2, designed for your motorcycle.
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Page 78: Carburetor
To adjust the engine idle speed prop- section. erly, you need a tachometer. If you do not have one, ask your Suzuki dealer 10. Start the engine (while the motor- or a qualified mechanic to perform cycle is outside on level ground) this adjustment. -
Page 79: Throttle Cable Adjustment
THROTTLE CABLE ADJUSTMENT THROTTLE CABLE BOOTS 2.0 – 4.0 mm (0.08 – 0.16 in) Measure the throttle cable play by The throttle cable has a boots. Check that the boots are fit securely. Do not turning the throttle grip. The throttle apply water directly to the boots when grip should have 2.0 –... -
Page 80: Clutch
It is an endless type that does not use a master link. We recommend that you take your motorcycle to your authorized Suzuki dealer to have the drive chain replaced when it becomes worn. The drive chain is also constructed of spe-... -
Page 81: Drive Chain Cleaning And Oiling
If the drive chain has any of these DRIVE CHAIN CLEANING AND condition, then there is a strong pos- OILING sibility that the sprockets will have 1. Remove dirt and dust from the some damage to them also. Inspect drive chain. Be careful not to dam- the sprockets for the following: age the seal ring. -
Page 82: Drive Chain Adjustment
DRIVE CHAIN ADJUSTMENT Some drive chain lubricant con- tains solvents and additives which could damage the seal rings in the drive chain. Use sealed drive chain lubricant 40 – 50 mm which is specifically intended for (1.6 – 2.0 in) use with sealed drive chains. -
Page 83: Engine Coolant
The slack of the drive chain should be ENGINE COOLANT 40 – 50 mm (1.6 – 2.0 in) as mea- sured at the mid-point between the chain buffer and rear sprocket. 1. Place the motorcycle on the side stand. 2. Loosen the axle nut 1. 3. -
Page 84: Radiator Hose Inspection
Inspect the radiator hoses for cracks, cover. damage or engine coolant leakage. If any defects are found, ask your Suzuki dealer to replace the radiator hose with a new one. 2. Loosen the screw and turn the radiator cap counterclockwise and remove it. -
Page 85: Brakes
Properly operating brake fluid leakage. If any defects are found, systems are vital to safe riding. Be ask your Suzuki dealer to replace the sure to perform the brake inspection brake hose with a new one. as scheduled. -
Page 86: Brake Fluid
BRAKE FLUID WARNING Spilled brake fluid can damage painted surfaces and plastic parts. Brake fluid will gradually absorb moisture through the brake hoses. Be careful not to spill any fluid Brake fluid with high water con- when filling the brake fluid reser- tent lowers the boiling point and voir. -
Page 87: Brake Pad
NOTE: Do not squeeze/depress the authorized Suzuki dealer or a quali- brake lever/pedal when the pads are fied service mechanic. not in their positions. It is difficult to ... -
Page 88: Rear Brake Pedal Adjustment
REAR BRAKE PEDAL ADJUSTMENT An incorrectly adjusted brake pedal may force brake pads to continuously rub against the disc, causing damage to the pads and disc. Follow the steps in this section to adjust the brake pedal properly. The rear brake pedal position must be properly adjusted at all times or the disc brake pads will rub against the disc causing damage to the pads and... -
Page 89: Tires
TIRES TIRE PRESSURE AND LOADING Proper tire pressure and proper tire WARNING loading are important factors. Over- loading your tires can lead to tire fail- ure and loss of vehicle control. The tires on your motorcycle form the crucial link between your Check tire pressure each day before motorcycle and the road. - Page 90 NOTE: These wear limits will be • Ask your Suzuki dealer or a reached before the wear bars molded qualified mechanic to perform into the tire make contact with the tire repair, replacement, and bal- road.
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Page 91: Spoke Nipple Tightness
Contact lock system is working properly. If the your Suzuki dealer for this service to engine continues to run with the side be performed. stand down and the transmission in... -
Page 92: Spark Arrester
SPARK ARRESTER WARNING The muffler has a spark arrester which must be periodically cleaned to If the side stand/ignition interlock maintain good efficiency. At the inter- system is not working properly, it vals shown in the maintenance chart, is possible to ride the motorcycle clean the spark arrester as follows. -
Page 93: Front Wheel Removal
FRONT WHEEL REMOVAL 1. Place the motorcycle on the side stand. 2. Use a brush to remove carbon deposits from the spark arrester screen. Be careful not to damage the spark arrester screen. Check 2. Loosen the axle nut. that the screen has no holes or tears. - Page 94 If you do not have a torque wrench or do not know how to use one, ask your authorized Suzuki dealer to 6. Slide the front wheel forward. check the bolts and nuts. NOTE: Never squeeze the front brake lever with the front wheel removed.
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Page 95: Rear Wheel Removal
REAR WHEEL REMOVAL 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. 5. Draw out the axle shaft. 6. -
Page 96: Light Bulb Replacement
Suzuki dealer or a qualified mechanic do this. Use only the light bulbs shown in the chart as replacement bulbs. WARNING... - Page 97 HEADLIGHT To replace the headlight bulb, follow the procedure below: 5. Unhook the bulb holder spring 6 and remove the bulb 7. 6. To reinstall the headlight, reverse the sequence described above. 1. Remove the right and left screws 1, 2 and take off the headlight cover.
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Page 98: Headlight Beam Adjustment
HEADLIGHT BEAM ADJUSTMENT TURN SIGNAL LIGHT To replace the turn signal light bulb, follow these directions: The headlight beam can be adjusted 1. Remove the screw and take off both up and down or right and left if the lens. necessary. -
Page 99: Brake Light/Taillight
If a blown fuse is found, then the elec- trical problem must be inspected and repaired before replacing the blown fuse with a new fuse. Consult your Suzuki dealer for the electrical system check and repair. 1. Remove the two screws and WARNING remove the lens. - Page 100 The fuse is located under the left side frame cover. To access the fuse, remove the left side frame cover by referring to the BATTERY REMOVAL section. One 20A spare fuse is located in the fuse box. 6-41...
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Page 102: Troubleshooting
TROUBLESHOOTING FUEL SYSTEM CHECK ..................7-2 IGNITION SYSTEM CHECK ................7-3 ENGINE STALLING ..................... 7-3... -
Page 103: Fuel System Check
• Do not smoke. If you are not sure about the • Wipe up spills immediately. proper action, consult your Suzuki • Avoid breathing fuel vapor. dealer about the problem. • Keep children and pets away. • Dispose of drained fuel prop- erly. -
Page 104: Ignition System Check
If there is still no spark, take your motorcycle to an authorized Suzuki dealer. WARNING Performing the spark test improp- erly can be hazardous. You could... -
Page 106: Storage Procedure And Motorcycle Cleaning
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 ............... 8-7... -
Page 107: Storage Procedure
For this reason, well-ventilated area. Suzuki recommends that you trust • Do not smoke. this maintenance work to your Suzuki • Wipe up spills immediately. dealer. If you need to service the • Avoid breathing fuel vapor. -
Page 108: Procedure For Returning To Service
8. Start the motorcycle as outlined in • Coat the painted surfaces with car this manual. wax. PROCEDURE DURING STORAGE Once a month, recharge the battery by referring to the BATTERY section. If you cannot charge the battery, con- sult your authorized Suzuki dealer. -
Page 109: Corrosion Prevention
Important Information About If the chips or scratches have Corrosion gone through to the bare metal, Common causes of corrosion have a Suzuki dealer make the • Accumulation of road salt, dirt, repair. moisture, or chemicals in hard-to- •... -
Page 110: Motorcycle Cleaning
MOTORCYCLE CLEANING WASHING THE MOTORCYCLE High pressure washers such as When washing the motorcycle, follow those found at coin-operated car the instruction below: washes have enough pressure to 1. Remove dirt and mud from the damage the parts of your motorcy- motorcycle with cool... -
Page 111: Plastic Parts
NOTE: The headlight lens can be PLASTIC PARTS fogged after washing the motorcycle Plastic parts such as headlight lens or riding in the rain. Headlight fogging and speedometer display, are easy to will be cleared gradually when the be damaged. When such part is headlight is turned on. -
Page 112: Inspection After Cleaning
INSPECTION AFTER CLEANING WAXING THE MOTORCYCLE After washing the motorcycle, waxing For extended life of your motorcycle, and polishing are recommended to lubricate it according to the “LUBRI- further protect and beautify the paint. CATION POINTS” section. • Only use waxes and polishes of good quality. -
Page 113: Specifications
SPECIFICATIONS DIMENSIONS AND CURB MASS Overall length ..........2310 mm (90.9 in) Overall width............ 875 mm (34.4 in) Overall height ..........1230 mm (48.4 in) Wheelbase ............1485 mm (58.5 in) Ground clearance..........300 mm (11.8 in) Seat height ............935 mm (36.8 in) Curb mass (weight) ......... - Page 114 ELECTRICAL Ignition type .............Electronic ignition (CDI) Spark plug ............NGK CR8E or DENSO U24ESR-N Battery .............12V 21.6 kC(6 Ah)/10 HR Generator ............Three-phase A.C. generator Fuse ..............20A Headlight ............12V 60/55W (H4) Turn signal light ..........12V 21W × 4 Brake light/Taillight...........12V 21/5W Speedometer light ...........LED Neutral indicator light........LED High beam indicator light.........LED Turn signal indicator light.........LED...
- Page 115 INDEX ACCESSORY USE AND GEARSHIFT LEVER ..... 2-24 MOTORCYCLE LOADING ....1-2 AIR CLEANER......... 6-8 ALLOW THE ENGINE OIL TO HELMET HOLDER ......2-25 CIRCULATE BEFORE RIDING ..4-2 AVOID CONSTANT LOW SPEED ........4-2 IGNITION SWITCH......2-5 IGNITION SYSTEM CHECK ... 7-3 INSPECTION AFTER BATTERY ........
- Page 116 OBSERVE YOUR FIRST AND TIRES ..........6-30 MOST CRITICAL SERVICE .... 4-2 TOOLS..........6-5 OXYGENATED FUEL RECOMMENDATION...... 3-2 USING THE TRANSMISSION..5-4 PROCEDURE FOR RETURNING TO SERVICE ......... 8-3 VARY THE ENGINE SPEED... 4-2 REAR BRAKE PEDAL....2-24 REAR WHEEL REMOVAL .... 6-36 RIDING ON HILLS......
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