Suzuki kq500 Service Manual

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This manual contains an introductory description on the SUZUKI LT-A500XP/Z and procedures for its inspection/

service and overhaul of its main components.

Other information considered as generally known is not included.

Read the GENERAL INFORMATION section to familiarize yourself with the vehicle and its maintenance. Use this

section as well as other sections to use as a guide for proper inspection and service.

This manual will help you know the vehicle better so that you can assure your customers of fast and reliable ser-

vice.

* This manual has been prepared on the basis of the latest specifications at the time of publication. If modifi-

cations have been made since then, differences may exist between the content of this manual and the

actual vehicle.

* Illustrations in this manual are used to show the basic principles of operation and work procedures. They

may not represent the actual vehicle exactly in detail.

* This manual is written for persons who have enough knowledge, skills and tools, including special tools, for

servicing SUZUKI vehicles. If you do not have the proper knowledge and tools, ask your authorized

SUZUKI motorcycle dealer to help you.

WARNING

Inexperienced mechanics or mechanics without the proper tools and equipment may not be able to

properly perform the services described in this manual.

Improper repair may result in injury to the mechanic and may render the vehicle unsafe for the rider.

FOREWORD

Table of Contents

Chapters

Table of Contents

Troubleshooting

Need help?

Do you have a question about the kq500 and is the answer not in the manual?

Questions and answers

Normand Sylvain

April 13, 2025

en dessou pompe a eau a i a til un tube a collecter

Summary of Contents for Suzuki kq500

Page 1 * This manual is written for persons who have enough knowledge, skills and tools, including special tools, for servicing SUZUKI vehicles. If you do not have the proper knowledge and tools, ask your authorized SUZUKI motorcycle dealer to help you.
Page 3: Table Of Contents
TABLE OF CONTENTS Precautions............... 00-i Body and Accessories..........9-i Precautions .............. 9-1 Precautions ............00-1 Wiring Systems ............9A-1 General Information ........... 0-i Lighting Systems ............9B-1 General Information ..........0A-1 Combination Meter / Fuel Meter / Horn ....9C-1 Maintenance and Lubrication ......... 0B-1 Exterior Parts ............9D-1 Service Data............0C-1 Body Structure ............9E-1...
Page 5: Precautions
Table of Contents 00- i Section 00 Precautions CONTENTS Precautions ..........00-1 General Precautions ........... 00-1 Precautions for Electrical Circuit Service .... 00-2 Precautions............00-1 Warning / Caution / Note........00-1...
Page 6: Exhaust System
CAUTION Indicates a potential hazard that could result • If parts replacement is necessary, replace in death or injury. the parts with Suzuki Genuine Parts or their equivalent. CAUTION • When removing parts that are to be reused, keep them arranged in an orderly manner...
Page 7 Precautions: 00-2 • Never reuse a circlip. When installing a • Inspect each terminal for corrosion and new circlip, take care not to expand the contamination. The terminals must be clean and free end gap larger than required to slip the of any foreign material which could impede proper circlip over the shaft.
Page 8 00-3 Precautions: • When connecting meter probe from the terminal side Fuse of the coupler (where connection from harness side • When a fuse blows, always investigate the cause to not being possible), use extra care not to force and correct it and then replace the fuse.
Page 9 Precautions: 00-4 • Be careful not to touch the electrical terminals of the • The EPS control unit and EPS body assembly cannot electronic parts (ECM, etc.). The static electricity from be disassembled. Replace the whole unit with a new your body may damage these.
Page 10 00-5 Precautions: • Before measuring voltage at each terminal, check to When checking system circuits including an electronic make sure that battery voltage is 11 V or higher. control unit such as ECM, etc., it is important to perform Terminal voltage check with a low battery voltage will careful check, starting with items which are easier to lead to erroneous diagnosis.
Page 11 Precautions: 00-6 4) Using continuity inspect or voltage check procedure Voltage check as described below, inspect the wire harness If voltage is supplied to the circuit being checked, voltage terminals for open circuit and poor connection. check can be used as circuit check. Locate abnormality, if any.
Page 12 “A” “D”: To other parts “D” “B” Using The Multi-Circuit Testers • Use the Suzuki multi-circuit tester set. • Use well-charged batteries in the tester. “C” • Be sure to set the tester to the correct testing range. Special tool (A): 09900–25008 (Multi-circuit tester set)
Page 13 Precautions: 00-8 Using the testers NOTE • Incorrectly connecting the (+) and (–) probes may • When connecting the multi-circuit tester, cause the inside of the tester to be burnout. use the needle pointed probe to the back • If the voltage and current are not known, make side of the lead wire coupler and connect measurements using the highest range.
Page 14 00-9 Precautions:...
Page 15: Maintenance And Lubrication
Symbols .............. 0A-1 Front Differential Gear Oil Replacement ...0B-11 Abbreviations ............0A-1 Final Gear Oil Inspection........0B-12 SAE-to-Former SUZUKI Term ......0A-2 Final Gear Oil Replacement......0B-12 Vehicle Side View ..........0A-3 Throttle Cable Play Inspection and Vehicle Identification Number ......0A-3 Adjustment ............0B-13...
Page 16: General Information
Apply oil. Use engine oil unless otherwise specified. Apply molybdenum oil solution. (Mixture of engine oil and SUZUKl MOLY PASTE in a ratio of 1:1). Apply SUZUKI SUPER GREASE “A” or equivalent. 99000-25010 Apply SUZUKI MOLY PASTE or equivalent. 99000-25140 Apply WATER RESISTANCE GREASE.
Page 17 J1930 terms and abbreviations which may be used in (TPS) this manual in compliance with SAE recommendations, as well as their former SUZUKI names. Voltage Regulator (VR): Voltage Regulator Ex. SAE term (Abbreviation): Former SUZUKI term Air Cleaner (ACL): Air Cleaner, Air Cleaner Box...
Page 18 PERFORMANCE 4 MOTOR OIL or an equivalent engine oil. Use of SF/SG or SH/SJ in API with MA in JASO. Suzuki recommends the use of SAE 10W-40 engine oil. If SAE 10W-40 engine oil is not available, select and alternative according to the chart.
Page 19 Use of SF/SG or SH/SJ in API with MA in JASO. aluminum radiator, mixed with distilled water only. Suzuki recommends the use of SAE 10W-40 engine oil. If SAE 10W-40 engine oil is not available, select an Water for mixing alternative according to the chart.
Page 20 0A-5 General Information: Country and Area Codes B931H20101009 The following codes stand for the applicable country(-ies) and area(-s). Code Country or Area Effective Frame No. LT-A500XPK9 (P-17) Sweden LT-A500XPK9 (P-24) Australia LT-A500XPK9 (P-28) Canada LT-A500XPK9 (P-33) U.S.A. 5SAAM45P97100001 – LT-A500XPZK9 (P-17) Sweden LT-A500XPZK9 (P-24) Australia...
Page 21 General Information: 0A-6 Warning, Caution and Information Labels Location B931H20101011 12, 13 1, 20, 21 22, 23 15, 16 17, 18 2, 26, 27 I931H1010010-03 1. Certification plate (English) For P-24, 33 15. Front carrier warning label (English) For P-24, 33 2.
Page 22 0A-7 General Information: Component Location Electrical Components Location B931H20103001 I931H1010005-03 1. Battery 7. Drive relay 13. Ignition switch 2. Starter relay/Main fuse 8. Mode select switch coupler 14. Power source 3. Fuse box 9. Starter motor 15. Ignition coil 4. Neutral relay 10.
Page 23 General Information: 0A-8 I931H1010006-05 19. Cooling fan thermo-switch 26. Parking/rear brake switch 33. Speed sensor 20. Resister 27. Regulator/Rectifier 34. CKP sensor 21. 4WD/Diff-lock actuator diode 28. Parking brake relay 35. Generator 22. Neutral relay diode 29. Diff-lock relay 36. EPS control unit 23.
Page 24: Fuel System
0A-9 General Information: Specifications Specifications B931H20107001 NOTE These specifications are subject to change without notice. Dimensions and dry mass Item Specification Remark 2 115 mm (83.3 in) P-28, 33 Overall length 2 165 mm (85.2 in) P-17, 24 1 210 mm (47.6 in) P-28, 33 Overall width 1 250 mm (49.2 in)
Page 25: Front Suspension
General Information: 0A-10 Chassis Item Specification Remark Front suspension Independent, double wishbone, coil spring, oil damped Rear suspension Independent, double wishbone, coil spring, oil damped Front wheel travel 170 mm (6.7 in) Rear wheel travel 195 mm (7.7 in) Caster 3.7°...
Page 26 09900–22302 09900–22403 09900–25008 09900–25009 Plastigauge Plastigauge Small bore gauge (18 Multi circuit tester set Needle pointed probe – 35 mm) 09900–26006 09904–41010 09910–32812 09910–32820 09912–34510 Engine tachometer SUZUKI Diagnostic Crankshaft installer Crankshaft installer Cylinder disassembly system set attachment ring tool...
Page 27 General Information: 0A-12 09913–10750 09913–50121 09913–60910 09913–61510 09913–70210 Compression gauge Oil seal remover Bearing and gear Bearing puller Bearing installer set adapter puller (10 – 75) 09913–75520 09915–40620 09915–64512 09915–74511 09915–74521 Bearing installing tool Oil filter wrench Compression gauge Oil pressure gauge Adapter hose (600 kPa) 09915–74533...
Page 28 0A-13 General Information: 09920–33540 09920–53740 09921–20240 09921–21910 09922–31430 Clutch shoe remover Clutch sleeve hub Bearing remover set Bearing holder set Clutch spring holder compressor 09923–73210 09923–74511 09924–41830 09924–52420 09924–52450 Bearing remover Bearing remover Bearing retainer Secondary bevel gear Fixed driven face wrench (50 mm) holder holder...
Page 29 General Information: 0A-14 09930–82720 09940–40211 09940–40220 09940–92430 09941–34513 Mode selection switch Fuel pressure gauge Fuel pressure gauge Rear axle nut wrench Bearing installer adapter attachment (36×36 mm) 09941–51012 09941–53610 09942–72410 09942–83110 09943–88211 Ring locknut wrench Front fork oil seal Tie-rod end remover Clip remover Pinion bearing installer hammer...
Page 30: Maintenance And Lubrication
0B-1 Maintenance and Lubrication: Maintenance and Lubrication General Information Precautions Precautions for Maintenance B931H20200001 The “Periodic Maintenance Schedule Chart” lists the recommended intervals for all the required periodic service work necessary to keep the vehicle operating at peak performance and economy. Maintenance intervals are expressed in terms of kilometers, miles and months for your convenience.
Page 31 Maintenance and Lubrication: 0B-2 Interval Initial 200 Every 1 000 Every 2 000 Item miles Initial 100 Every 600 Every 1 200 months Initial 1 Every 3 Every 6 — Brake fluid Replace every 2 years. — — Brake hose Replace every 4 years.
Page 32 0B-3 Maintenance and Lubrication: Repair Instructions Air Cleaner Element Inspection and Cleaning 3) Carefully use compressed air to clean the air cleaner B931H20206001 element. Inspect and clean element CAUTION Every 1 000 km (600 miles, 3 months) Always apply compressed air to the inside of Inspection the air cleaner element.
Page 33 Maintenance and Lubrication: 0B-4 Exhaust Pipe Bolt and Muffler Bolt Inspection Valve Clearance Inspection and Adjustment B931H20206002 B931H20206003 Tighten exhaust pipe bolts, muffler bolt and nut Inspect valve clearance Initially at 200 km (100 miles, 1 month) and every 1 Initially at 200 km (100 miles, 1 month) and every 2 000 km (600 miles, 3 months) thereafter 000 km (1 200 miles, 6 months) thereafter...
Page 34 0B-5 Maintenance and Lubrication: 5) Remove the spark plug cap and spark plug. Refer to 9) Insert the thickness gauge to check the clearance “Spark Plug Cap and Spark Plug Removal and between the valve stem end and the adjusting screw Installation: in Section 1H”.
Page 35 O-rings and install the inspection caps (1). Replace spark plug Every 6 000 km (4 000 miles) : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) Refer to “Spark Plug Cap and Spark Plug Removal and Installation: in Section 1H”.
Page 36 0B-7 Maintenance and Lubrication: Spark Plug Gap Spark Arrester Cleaning B931H20206006 1) Remove the spark plug. Refer to “Spark Plug Cap Spark arrester cleaning and Spark Plug Removal and Installation: in Every 2 000 km (1 200 miles, 6 months) Section 1H”.
Page 37 Maintenance and Lubrication: 0B-8 4) Tighten the muffler end cover nut (3) to the specified 4) Inspect the fuel feed hose for damage and fuel torque. leakage. If any defects are found, the fuel feed hose must be replaced. Tightening torque Muffler end cover nut (a): 11 N·m (1.1 kgf-m, 8.0 lbf-ft) I931H1020015-01...
Page 38 0B-9 Maintenance and Lubrication: Engine Oil Replacement 5) Pour new oil through the oil filler. When performing an oil change (without oil filter replacement), the 1) Place the vehicle on a level ground and set the brake engine will hold about 2.3 L (2.4/2.0 US/lmp qt) of oil. lock.
Page 39 Also, do not use a genuine Suzuki automobile oil filter on this vehicle. 5) Install a new oil filter. Turn it by hand until you feel that the oil filter O-ring contacts the oil filter mounting surface.
Page 40 0B-11 Maintenance and Lubrication: 3) Tighten the oil level plug (1) and oil filler plug (2) to 4) Tighten the oil drain plug (1) to the specified torque. the specified torque. CAUTION CAUTION Replace the gasket washers with a new one. Replace the gasket washers with new ones.
Page 41 Maintenance and Lubrication: 0B-12 Final Gear Oil Inspection 4) Drain oil by removing the oil drain plug (1) and oil B931H20206011 filler plug (2). Inspect final gear oil Every 2 000 km (1 200 miles, 6 months) 1) Place the vehicle on a level ground. 2) Remove the filler plug (1), and inspect the oil level.
Page 42 0B-13 Maintenance and Lubrication: Throttle Cable Play Inspection and Adjustment Cooling System Inspection B931H20206013 B931H20206015 Inspect throttle cable play Replace engine coolant Initially at 200 km (100 miles, 1 month) and every 1 Every 2 years 000 km (600 miles, 3 months) thereafter Engine Coolant Level Inspection Inspect and adjust the throttle cable play “a”...
Page 43 Maintenance and Lubrication: 0B-14 3) Remove the left inner fender. Refer to “Front Side 8) Pour the specified engine coolant up to the radiator Exterior Parts Removal and Installation: in inlet. Section 9D”. Engine coolant capacity (including reservoir) 4) Remove the front under cover. Refer to “Under 2 450 ml (2.6/2.2 US/lmp qt) Cover Removal and Installation: in Section 9D”.
Page 44 0B-15 Maintenance and Lubrication: Radiator Hoses Inspection Drive V-belt Inspection and Replacement B931H20206016 Inspect radiator hoses Inspect drive V-belt Every 2 000 km (1 200 miles, 6 months) Every 1 000 km (600 miles, 3 months) Inspect the radiator hoses for damage and engine Replace drive V-belt coolant leakage.
Page 45 Maintenance and Lubrication: 0B-16 Drive Shaft Boots Inspection Brake Fluid Level Check B931H20206017 Inspect brake fluid level Inspect drive shaft Every 1 000 km (600 miles, 3 months) Initially at 200 km (100 miles, 1 month) and every 1 1) Place the vehicle on a level ground. 000 km (600 miles, 3 months) thereafter 2) Check the brake fluid level by observing the lower •...
Page 46 0B-17 Maintenance and Lubrication: Front Brake Pads Check Front Brake Hose Replacement The extent of front brake pad wear can be checked by Replace brake hose observing the grooved limit line “A” on the pad. When the Every 4 years wear exceeds the grooved limit line, replace the pads with new ones.
Page 47 Maintenance and Lubrication: 0B-18 Brake Pedal Free Travel Rear Brake (Parking Brake) Lever Play Adjustment Inspection 1) After adjusting the brake pedal, check the rear brake Inspect and adjust the rear brake pedal free travel “a” as lever play “a”. The brake lever play “a” as measured follows.
Page 48 0B-19 Maintenance and Lubrication: 5) After adjusting the play, check that the rear wheels roll freely without applying the brake, the “a” transmission in neutral and the rear wheels off the ground. Readjust the rear brake lever if the rear wheels could not roll freely.
Page 49 Maintenance and Lubrication: 0B-20 Steering System Inspection Toe Adjustment B931H20206022 B931H20206023 Adjust the toe-out as follows: Inspect steering system 1) Loosen the lock-nuts (1), (2) on each tie-rod. Initially at 200 km (100 miles, 1 month) and every 1 000 km (600 miles, 3 months) thereafter CAUTION Steering should be adjusted properly for smooth turning •...
Page 50 0B-21 Maintenance and Lubrication: 5) After adjustment has been made, tighten the four lock-nuts to the specified torque. Tightening torque Tie-rod lock-nut (a): 29 N·m (2.9 kgf-m, 21.0 lbf- I931H1020059-01 Handlebar holder nut 60 N⋅m (6.0 kgf-m, 43.5 lbf-ft) I831G1020089-01 Suspensions Inspection B931H20206024 Inspect suspension...
Page 51 Maintenance and Lubrication: 0B-22 I931H1020060-02 I931H1020062-04 Steering shaft lower nut 162 N⋅m (16.2 kgf-m, 117.0 lbf-ft) Front suspension arm pivot nut (Upper) 60 N⋅m (6.0 kgf-m, 43.5 lbf-ft) Tie-rod end nut 29 N⋅m (2.9 kgf-m, 21.0 lbf-ft) Front suspension arm pivot nut (Lower) 65 N⋅m (6.5 kgf-m, 47.0 lbf-ft) I931H1020082-01 Steering shaft upper nut 120 N⋅m (12.0 kgf-m, 87.0 lbf-ft)
Page 52 0B-23 Maintenance and Lubrication: I931H1020065-04 I931H1020068-04 Tie-rod end nut 29 N⋅m (2.9 kgf-m, 21.0 lbf-ft) Footrest mounting bolt (M8) 26 N⋅m (2.6 kgf-m, 19.0 lbf-ft) Steering knuckle end nut (Upper and Lower) 29 N⋅m (2.9 kgf-m, Footrest mounting bolt (M10) 55 N⋅m (5.5 kgf-m, 40.0 lbf-ft) 21.0 lbf-ft) I931H1020069-03 I931H1020066-04...
Page 53 Maintenance and Lubrication: 0B-24 I931H1020072-03 I931H1020075-02 Rear brake case bolt 26 N⋅m (2.6 kgf-m, 19.0 lbf-ft) Rear stabilizer joint nut 60 N⋅m (6.0 kgf-m, 43.5 lbf-ft) Rear brake cam lever nut 11 N⋅m (1.1 kgf-m, 8.0 lbf-ft) I931H1020076-02 I931H1020073-02 Trailer towing mounting bolt 60 N⋅m (6.0 kgf-m, 43.5 lbf-ft) Rear shock absorber mounting nut (Upper and Lower) 60 N⋅m (6.0 kgf-m, 43.5 lbf-ft) Rear suspension arm pivot nut (Upper and Lower) 60 N⋅m (6.0...
Page 54: Rear Brakes
0B-25 Maintenance and Lubrication: Compression Pressure Check 4) Start the engine. B931H20206026 5) Shift the range lever to the “High” position. Refer to “Compression Pressure Check: in Section 6) Slowly open the throttle and note the engine speed 1D”. (r/min) when the vehicle begins to move forward. Oil Pressure Check Engagement speed B931H20206027...
Page 55 For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List: in Section 0C”. Special Tools and Equipment Recommended Service Material B931H20208001 Material SUZUKI recommended product or Specification Note Brake fluid DOT 4 — (Page 0B-16)
Page 56 0B-27 Maintenance and Lubrication: Special Tool B931H20208002 09900–20803 09900–20805 Thickness gauge Tire depth gauge (Page 0B-5) / (Page 0B- (Page 0B-19) 09900–25008 09900–26006 Multi circuit tester set Engine tachometer (Page 0B-25) (Page 0B-25) / (Page 0B-25) 09915–40620 09917–14910 Oil filter wrench Tappet adjust driver (Page 0B-10) / (Page 0B-5)
Page 57: Service Data
Service Data: 0C-1 Service Data General Information Specifications Service Data B931H20307001 Valve + Valve Guide Unit: mm (in) Item Standard Limit 30.6 (1.20) — Valve diam. 27.0 (1.06) — 0.05 – 0.10 (0.002 – 0.004) — Valve clearance (When cold) 0.17 –...
Page 58 0C-2 Service Data: Cylinder + Piston + Piston Ring Unit: mm (in) Item Standard Limit Compression pressure Approx. 1 000 kPa (10.0 kgf/cm , 142 psi) — (Automatic-decomp. actuated) Piston-to-cylinder clearance 0.030 – 0.040 (0.0012 – 0.0016) 0.120 (0.0047) Nicks or Cylinder bore 87.500 –...
Page 59 Service Data: 0C-3 Drive Train Unit: mm (in) Except ratio Item Standard Limit Automatic transmission ratio Variable change (2.902 – 0.779) — Secondary reduction ratio 2.733 (41/19 x 19/15) — Front 3.600 (36/10) — Final reduction ratio Rear 3.600 (36/10) —...
Page 60 0C-4 Service Data: Injector + Fuel Pump + Fuel Pressure Regulator Item Specification Note 11 – 13 Ω at 20 °C (68 °F) Injector resistance Fuel pump discharge amount 55.5 ml (1.88/1.95 US/lmp qt) and more/10 sec. Fuel pressure regulator operating Approx.
Page 61 Service Data: 0C-5 Electrical Unit: mm (in) Item Standard/Specification Note NGK: CR6E Type Spark plug DENSO: U20ESR-N 0.7 – 0.8 (0.028 – 0.031) Spark performance Over 8 (0.3) at 1 atm. Terminal – 0.1 – 0.6 Ω Primary Ground Ignition coil resistance Plug cap –...
Page 62 0C-6 Service Data: Brake + Wheel Unit: mm (in) Item Standard/Specification Limit Rear brake pedal height 12.5 – 22.5 (0.5 – 0.9) — Rear brake pedal free travel 20 – 30 (0.8 – 1.2) — Front brake disc thickness 3.3 – 3.7 (0.13 – 0.15) 3.0 (0.20) Front brake disc runout —...
Page 63 Service Data: 0C-7 Tightening Torque List B931H20307002 Engine Item N⋅m kgf-m lbf-ft Spark plug Air cleaner box mounting bolt 0.45 Cylinder head cover bolt Rocket arm shaft bolt 20.0 Intake pipe bolt Cylinder head bolt (M8) 18.0 Initial 18.0 Cylinder head bolt (M10) Final 27.0 Cylinder head base nut...
Page 64 0C-8 Service Data: Drive Train Item N⋅m kgf-m lbf-ft 4WD/Diff-lock actuator mounting bolt Front drive (differential) gear case cover bolt Front drive (differential) gear case mounting nut 36.0 Front differential gear oil level plug 0.81 Front differential gear oil filler plug 25.5 Front differential gear oil drain plug 23.0...
Page 65 Service Data: 0C-9 Chassis Item N⋅m kgf-m lbf-ft Handlebar upper clamp bolt 19.0 Handlebar holder nut 43.5 Rear brake lever holder clamp bolt Throttle lever case clamp bolt Throttle lever case screw EPS body assembly mounting bolt 19.0 EPS body assembly mounting nut 20.0 Steering shaft upper nut 87.0...
Page 66 0C-10 Service Data: Tightening Torque Chart For other bolts and nuts not listed in the preceding page, refer to this chart: Bolt Diameter Conventional or “4” marked bolt “7” marked bolt “a” (mm) N⋅m kgf-m lbf-ft N⋅m kgf-m lbf-ft 0.15 0.23 0.45 0.55...
Page 67: Engine General Information And Diagnosis
Table of Contents 1- i Section 1 Engine CONTENTS Precautions ..........1-1 DTC “C40” (P0505-H/L): ISC Valve Circuit Malfunction............1A-62 Precautions............. 1-1 DTC “C41” (P230-H/L): FP Relay Circuit Precautions for Engine.......... 1-1 Malfunction............1A-68 Engine General Information and Specifications .............1A-70 Service Data............1A-70 Diagnosis ..........1A-1 Special Tools and Equipment ......1A-71 General Description ..........1A-1 Special Tool ............1A-71...
Page 68: Engine Mechanical
1-ii Table of Contents Engine Mechanical ........1D-1 Special Tools and Equipment ......1D-70 Recommended Service Material .......1D-70 Schematic and Routing Diagram......1D-1 Special Tool ............1D-70 Throttle Cable Routing Diagram......1D-1 Diagnostic Information and Procedures....1D-2 Engine Lubrication System ....1E-1 Engine Mechanical Symptom Diagnosis.....1D-2 Precautions............1E-1 Compression Pressure Check ......1D-2 Precautions for Engine Oil ........1E-1...
Page 69: Ignition System
Table of Contents 1-iii Thermostat Inspection ........1F-11 Repair Instructions ..........1H-3 Water Pump Components......... 1F-12 Spark Plug Cap and Spark Plug Removal and Water Pump Removal and Installation....1F-12 Installation ............1H-3 Water Pump Disassembly and Assembly ..1F-13 Spark Plug Inspection and Cleaning ....1H-3 Water Pump Related Parts Inspection ....
Page 70: Charging System
1-iv Table of Contents Charging System ........1J-1 Specifications ............. 1J-12 Service Data............1J-12 Schematic and Routing Diagram......1J-1 Tightening Torque Specifications...... 1J-13 Charging System Diagram ........1J-1 Special Tools and Equipment ......1J-13 Component Location ........... 1J-1 Recommended Service Material ....... 1J-13 Charging System Components Location.....
Page 71: Precautions
Precautions: Precautions Engine Precautions Precautions for Engine B931H21000001 Refer to “General Precautions: in Section 00” and “Precautions for Electrical Circuit Service: in Section 00”.
Page 72: Engine General Information And Diagnosis
1A-1 Engine General Information and Diagnosis: Engine General Information and Diagnosis Engine General Description Injection Timing Description B931H21101001 Injection Time (Injection Volume) The factors to determine the injection time include the basic fuel injection time, which is calculated on the basis of the intake air pressure, engine speed and throttle opening angle, and various compensations.
Page 73 Engine General Information and Diagnosis: 1A-2 Injection Stop Control Signal Descriptions When the vehicle tips over, the tip-over sensor sends a signal to TIP-OVER SENSOR SIGNAL (FUEL SHUT-OFF) the ECM. Then, this signal cuts OFF current supplied to the fuel pump, fuel injectors and ignition coils.
Page 74 1A-3 Engine General Information and Diagnosis: Dealer Mode The defective function is memorized in the computer. Use the special tool’s coupler to connect to the mode select switch. The memorized malfunction code is displayed on LCD (DISPLAY) panel. Malfunction means that the ECM does not receive signal from the devices.
Page 75: Schematic And Routing Diagram
Engine General Information and Diagnosis: 1A-4 Schematic and Routing Diagram FI System Wiring Diagram B931H21102001 I931H1110005-03...
Page 76: Terminal Alignment Of Ecm Coupler
1A-5 Engine General Information and Diagnosis: Terminal Alignment of ECM Coupler B931H21102002 I931H1110006-01 TERMINAL NO. CIRCUIT TERMINAL NO. CIRCUIT Ignition coil (IG1) CKP sensor signal (CKP-) Fuel injector (#1) Fuel pump relay (FP relay) Power source (+B) Power source for fuel injector Power source for back-up (BATT) Diff-lock relay (DL relay) Brake switch (BRK)
Page 77: Component Location
Engine General Information and Diagnosis: 1A-6 Component Location FI System Parts Location B931H21103001 “F” “C” “B” “G” “D” “E” I931H1110007-05 “A”: ECM “C”: IAP/TP/IAT sensor “E”: Speed sensor “G”: Diff-lock relay “B”: ISC valve “D”: CKP sensor “F”: Combination meter “I”...
Page 78: Diagnostic Information And Procedures
1A-7 Engine General Information and Diagnosis: Diagnostic Information and Procedures Engine Symptom Diagnosis B931H21104001 Condition Possible cause Correction / Reference Item Engine will not start or is Valve clearance out of adjustment. Adjust. hard to start Worn valve guides or poor seating of Repair or replace.
Page 79 Engine General Information and Diagnosis: 1A-8 Condition Possible cause Correction / Reference Item Engine stalls often Defective ECM. Replace. (Control circuit or sensor Defective fuel pressure regulator. Replace. improperly operating) Defective TP sensor. Replace. Defective IAT sensor. Replace. Defective CKP sensor. Replace.
Page 80 1A-9 Engine General Information and Diagnosis: Condition Possible cause Correction / Reference Item Engine runs poorly in Low fuel pressure. Repair or replace. high speed range Defective TP sensor. Replace. (Defective control circuit Defective IAT sensors. Replace. or sensor) Defective IAP sensor. Replace.
Page 81: Self-Diagnostic Procedures
Engine General Information and Diagnosis: 1A-10 Self-Diagnostic Procedures 5) Check the DTC to determine the malfunction part. B931H21104002 Refer to “DTC Table (Page 1A-18)”. Use of Mode Select Switch Special tool NOTE (A): 09930–82720 (Mode selection switch) • Do not disconnect coupler from ECM, the battery cable from the battery, ECM ground wire harness from the engine or main fuse before confirming DTC (Diagnostic Trouble...
Page 82 1) Remove the seat. Refer to “Seat Removal and Installation: in Section 9D”. 2) Set up the SDS tools. (Refer to the SDS operation manual for further details.) Special tool (A): 09904–41010 (SUZUKI Diagnostic system set) (B): 99565–01010–019 (CD-ROM Ver.19) I705H1110116-03 3) Click the DTC inspection button (1).
Page 83: Use Of Sds Diagnosis Reset Procedures
Engine General Information and Diagnosis: 1A-12 4) Start the engine or crank the engine for more than 4 3) Check the DTC. seconds. 4) The previous malfunction history code (Past DTC) 5) Check the DTC to determine the malfunction part. still remains stored in the ECM.
Page 84: Show Data When Trouble (Displaying Data At The Time Of Dtc)
1A-13 Engine General Information and Diagnosis: Show Data When Trouble (Displaying Data at the Time of DTC) B931H21104004 Use of SDS ECM stores the engine and driving conditions (in the form of data as shown in the figure) at the moment of the detection of a malfunction in its memory.
Page 85 Engine General Information and Diagnosis: 1A-14 1) Click “Show data when trouble” (1) to display the data. I718H1110269-02 2) Click the drop down button (2), either “Failure #1” or “Failure #2” can be selected. I831G1110017-01...
Page 86: Sds Check
1) Remove the seat. Refer to “Seat Removal and Installation: in Section 9D”. 2) Set up the SDS tool. (Refer to the SDS operation manual for further details.) Special tool : 09904–41010 (SUZUKI Diagnostic system set) : 99565–01010–019 (CD-ROM Ver.19) NOTE •...
Page 87 Engine General Information and Diagnosis: 1A-16 Data at 3 000 r/min under no load Approx. 3 000 r/min. Check the manifold absolute pressure XXX kPa. I931H1110068-01 Data at the time of racing Throttle: Quick wide open Throttle: Slowly open I931H1110069-01...
Page 88 1A-17 Engine General Information and Diagnosis: Example of Trouble Three data; value 3 (current data 3), value 2 (past data 2) and value 1 (past data 1); can be made in comparison by showing them in the graph. Read the change of value by comparing the current data to the past data that have been saved under the same condition, then you may determine how changes have occurred with the passing of time and identify what problem is currently occurring.
Page 89: Dtc Table
Engine General Information and Diagnosis: 1A-18 DTC Table B931H21104006 Code Malfunction Part Remarks None No defective part C12 (P0335) Crankshaft position sensor (CKP sensor) Pick-up coil signal, signal generator (Page 1A-23) C13 (P0105-H/L) Intake air pressure sensor (IAP sensor) (Page 1A-26) C14 (P0120-H/L) Throttle position sensor (TP sensor) (Page 1A-33)
Page 90: Fi System Troubleshooting
1A-19 Engine General Information and Diagnosis: FI System Troubleshooting B931H21104008 Customer Complaint Analysis Record details of the problem (failure, complaint) and how it occurred as described by the customer. For this purpose, use of an inspection form such as below will facilitate collecting information required for proper analysis and diagnosis. EXAMPLE: CUSTOMER PROBLEM INSPECTION FORM User name: Model:...
Page 91 Engine General Information and Diagnosis: 1A-20 NOTE The above form is a standard sample. The form should be modified according to condition and characteristics of each market. Visual Inspection Prior to diagnosis using the mode select switch or SDS, perform the following visual inspections. The reason for visual inspection is that mechanical failures (such as oil leakage) cannot be displayed on the screen with the use of mode select switch or SDS.
Page 92: Malfunction Code And Defective Condition Table
1A-21 Engine General Information and Diagnosis: Malfunction Code and Defective Condition Table B931H21104009 Malfunction Detected Item Detected Failure Condition Check For Code NO FAULT — — CKP sensor wiring and The signal does not reach ECM for 3 sec. or mechanical parts.
Page 93 Engine General Information and Diagnosis: 1A-22 Malfunction Detected Item Detected Failure Condition Check For Code CKP sensor (pick-up coil) signal is produced, Ignition coil, wiring/coupler but signal from ignition coil is interrupted 8 Ignition signal connection, power supply from P0351 times or more continuously.
Page 94: Dtc "C12" (P0335): Ckp Sensor Circuit Malfunction
1A-23 Engine General Information and Diagnosis: DTC “C12” (P0335): CKP Sensor Circuit Malfunction B931H21104010 Detected Condition and Possible Cause Detected Condition Possible Cause The signal does not reach ECM for 3 sec. or more, after • Metal particles or foreign material being stuck on the receiving the starter signal.
Page 95 Engine General Information and Diagnosis: 1A-24 Step Action 1) Remove the left side cover. Refer to “Front Side Go to Step 2. Replace the CKP Exterior Parts Removal and Installation: in Section sensor with a new one. 9D”. 2) Turn the ignition switch OFF. 3) Check the CKP sensor coupler for loose or poor contacts.
Page 96 1A-25 Engine General Information and Diagnosis: Step Action 5) If OK, then check the continuity between each terminal Go to Step 2. Replace the CKP and ground. sensor with a new one. Special tool (A): 09900–25008 (Multi-circuit tester set) CKP sensor continuity ∞...
Page 97: Dtc "C13" (P0105-H/L): Iap Sensor Circuit Malfunction
Engine General Information and Diagnosis: 1A-26 DTC “C13” (P0105-H/L): IAP Sensor Circuit Malfunction B931H21104011 Detected Condition and Possible Cause Detected Condition Possible Cause IAP sensor voltage is not within the • Clogged vacuum passage between throttle body and following range. IAP sensor.
Page 98 1A-27 Engine General Information and Diagnosis: C13 (Use of mode select switch) Step Action 1) Remove the left side cover. Refer to “Front Side Go to Step 2. • Loose or poor Exterior Parts Removal and Installation: in Section contacts on the ECM 9D”.
Page 99 Engine General Information and Diagnosis: 1A-28 P0105-H for IAP sensor (Use of SDS) Step Action 1) Turn the ignition switch OFF. Go to Step 3. G/B wire shorted to VCC, or B/Br wire open. 2) Remove the left side cover. Refer to “Front Side Exterior Parts Removal and Installation: in Section 9D”.
Page 100 1A-29 Engine General Information and Diagnosis: Step Action 6) Disconnect the ECM coupler. Refer to “ECM Removal Go to Step 3. G/B wire shorted to and Installation: in Section 1C”. VCC, or B/Br wire open. 7) Insert the needle pointed probes to the lead wire coupler. 8) Check the continuity between the G/B wire “B”...
Page 101 Engine General Information and Diagnosis: 1A-30 P0105-L for IAP sensor (Use of SDS) Step Action 1) Turn the ignition switch OFF. Go to Step 3. R and G/B wire open, G/ B wire shorted to the 2) Remove the left side cover. Refer to “Front Side ground.
Page 102 1A-31 Engine General Information and Diagnosis: Step Action 8) Check the continuity between the R wire “A” and Go to Step 3. R and G/B wire open, G/ terminal “6”. Also, check the continuity between the G/B B wire shorted to the wire “B”...
Page 103 Engine General Information and Diagnosis: 1A-32 Step Action 1) Turn the ignition switch OFF. • G/B, R or B/Br wire If check result is not open or shorted to satisfactory, replace IAP 2) Connect the IAP sensor coupler. ground, or poor “6”, sensor (throttle body) 3) Insert the needle pointed probes to the lead wire coupler.
Page 104: Dtc "C14" (P0120-H/L): Tp Sensor Circuit Malfunction
1A-33 Engine General Information and Diagnosis: DTC “C14” (P0120-H/L): TP Sensor Circuit Malfunction B931H21104012 Detected Condition and Possible Cause Detected Condition Possible Cause Output voltage is not within the following • TP sensor maladjusted. range. • TP sensor circuit open or short. 0.2 V ≤...
Page 105 Engine General Information and Diagnosis: 1A-34 C14 (Use of mode select switch) Step Action 1) Remove the left side cover. Refer to “Front Side Go to Step 2. • Loose or poor Exterior Parts Removal and Installation: in Section contacts on the ECM 9D”.
Page 106 1A-35 Engine General Information and Diagnosis: P0120-H (Use of SDS) Step Action 1) Remove the left side cover. Refer to “Front Side Go to Step 2. R wire shorted to VCC Exterior Parts Removal and Installation: in Section or B/Br wire open. 9D”.
Page 107 Engine General Information and Diagnosis: 1A-36 Step Action 8) Check the continuity between Y wire “B” and terminal Go to Step 2. R wire shorted to VCC “14”. or B/Br wire open. Also, check the continuity between B/Br wire “C” and terminal “24”.
Page 108 1A-37 Engine General Information and Diagnosis: P0120-L (Use of SDS) Step Action 1) Remove the left side cover. Refer to “Front Side Go to Step 2. Y or R wire open, or Y Exterior Parts Removal and Installation: in Section wire shorted to ground.
Page 109 Engine General Information and Diagnosis: 1A-38 Step Action 8) Check the continuity between Y wire “B” and terminal Go to Step 2. Y or R wire open, or Y “14”. wire shorted to ground. Also, check the continuity between R wire “A” and terminal “6”.
Page 110 1A-39 Engine General Information and Diagnosis: Step Action 1) Connect the TP sensor coupler. • Y, B/Br or R wire If check result is not open or shorted to satisfactory, replace TP 2) Insert the needle pointed probes to the lead wire coupler. ground, or poor “14”, sensor with a new one.
Page 111: Dtc "C15" (P0115-H/L): Ect Sensor Circuit Malfunction
Engine General Information and Diagnosis: 1A-40 DTC “C15” (P0115-H/L): ECT Sensor Circuit Malfunction B931H21104013 Detected Condition and Possible Cause Detected Condition Possible Cause Output voltage is not within the following • ECT sensor circuit open or short. range. • ECT sensor malfunction. 0.15 V ≤...
Page 112 1A-41 Engine General Information and Diagnosis: C15 (Use of mode select switch) Step Action 1) Remove the right side cover. Refer to “Front Side Go to Step 2. • Loose or poor Exterior Parts Removal and Installation: in Section contacts on the ECM 9D”.
Page 113 Engine General Information and Diagnosis: 1A-42 P0115-H (Use of SDS) Step Action 1) Remove the right side cover. Refer to “Front Side Go to Step 2. B/Bl or B/Br wire open. Exterior Parts Removal and Installation: in Section 9D”. 2) Turn the ignition switch OFF. 3) Check the ECT sensor coupler for loose or poor contacts.
Page 114 1A-43 Engine General Information and Diagnosis: P0115-L (Use of SDS) Step Action 1) Remove the left side cover. Refer to “Front Side Go to Step 2. • B/Bl wire shorted to Exterior Parts Removal and Installation: in Section ground. 9D”. •...
Page 115 Engine General Information and Diagnosis: 1A-44 Step Action 9) Measure the output voltage between B/Bl wire and Go to Step 2. • B/Bl wire shorted to ground. ground. • If wire is OK, go to Special tool Step 2. (A): 09900–25008 (Multi-circuit tester set) (B): 09900–25009 (Needle pointed probe set) Tester knob indication Voltage (...
Page 116: Dtc "C20" (P1752): Diff-Lock Relay Circuit Malfunction
1A-45 Engine General Information and Diagnosis: DTC “C20” (P1752): Diff-lock Relay Circuit Malfunction B931H21104014 Detected Condition and Possible Cause Detected Condition Possible Cause No voltage is applied to diff-lock motor, although ignition • Diff-lock relay circuit open or short. switch is turned ON, or voltage is applied to diff-lock •...
Page 117 Engine General Information and Diagnosis: 1A-46 Step Action 1) Remove the left side cover and engine side cover. Refer • Inspect the 4WD/diff- Replace the diff-lock to “Front Side Exterior Parts Removal and lock switch. relay with a new one. Installation: in Section 9D”.
Page 118: Dtc "C21" (P0110-H/L): Iat Sensor Circuit Malfunction
1A-47 Engine General Information and Diagnosis: DTC “C21” (P0110-H/L): IAT Sensor Circuit Malfunction B931H21104015 Detected Condition and Possible Cause Detected Condition Possible Cause Output voltage is not within the following • IAT sensor circuit open or short. range. • IAT sensor malfunction. 0.15 V ≤...
Page 119 Engine General Information and Diagnosis: 1A-48 C21 (Use of mode select switch) Step Action 1) Remove the left side cover. Refer to “Front Side Go to Step 2. • Loose or poor Exterior Parts Removal and Installation: in Section contacts on the ECM 9D”.
Page 120 1A-49 Engine General Information and Diagnosis: P0110-H (Use of SDS) Step Action 1) Remove the left side cover. Refer to “Front Side Connect the ECM Dg or B/Br wire open. Exterior Parts Removal and Installation: in Section coupler and go to step 9D”.
Page 121 Engine General Information and Diagnosis: 1A-50 P0110-L (Use of SDS) Step Action 1) Turn the ignition switch OFF. Go to Step 2. • Dg wire shorted to the ground. 2) Check the IAT sensor coupler for loose or poor contacts. If OK, then check the IAT sensor lead wire continuity.
Page 122 1A-51 Engine General Information and Diagnosis: Step Action 9) Measure the output voltage between the Dg wire and Go to Step 2. • Dg wire shorted to ground. the ground. • If wire is OK, go to Special tool Step 2. (A): 09900–25008 (Multi-circuit tester set) (B): 09900–25009 (Needle pointed probe set) Tester knob indication...
Page 123: Dtc "C23" (P1651-H/L): To Sensor Circuit Malfunction
Engine General Information and Diagnosis: 1A-52 DTC “C23” (P1651-H/L): TO Sensor Circuit Malfunction B931H21104016 Detected Condition and Possible Cause Detected Condition Possible Cause The sensor voltage is not within the • TO sensor circuit open or short. following range. • TO sensor malfunction. 0.2 V ≤...
Page 124 1A-53 Engine General Information and Diagnosis: C23 (Use of mode select switch) Step Action 1) Remove the air cleaner box. Refer to “Air Cleaner Box Go to Step 2. Replace the TO sensor Removal and Installation: in Section 1D”. with a new one. Refer to “TO Sensor Removal 2) Turn the ignition switch OFF.
Page 125 Engine General Information and Diagnosis: 1A-54 P1651-H (Use of SDS) Step Action 1) Remove the air cleaner box. Refer to “Air Cleaner Box Go to Step 2. Br/W wire shorted to Removal and Installation: in Section 1D”. VCC, or B/Br wire open. 2) Turn the ignition switch OFF.
Page 126 1A-55 Engine General Information and Diagnosis: Step Action 8) Check the continuity between Br/W wire “B” and terminal Go to Step 2. Br/W wire shorted to “10”. Also, check the continuity between B/Br wire “C” VCC, or B/Br wire open. and terminal “24”.
Page 127 Engine General Information and Diagnosis: 1A-56 P1651-L (Use of SDS) Step Action 1) Remove the air cleaner box. Refer to “Air Cleaner Box Go to Step 2. R or B wire open, or Br/ Removal and Installation: in Section 1D”. W wire shorted to the ground.
Page 128 1A-57 Engine General Information and Diagnosis: Step Action 9) Check the continuity between R wire “A” and terminal Go to Step 2. R or B wire open, or Br/ “6”. W wire shorted to the Also, then check the continuity between Br/W wire “B” ground.
Page 129 Engine General Information and Diagnosis: 1A-58 Step Action 1) Connect the TO sensor coupler. • R, B/Br or Br/W wire • Loose or poor open or shorted to contacts on the ECM 2) Insert the needle pointed probes to the lead wire coupler. ground, or poor “6”, coupler.
Page 130: Dtc "C24" (P0351): Ignition Coil Circuit Malfunction
1A-59 Engine General Information and Diagnosis: DTC “C24” (P0351): Ignition Coil Circuit Malfunction B931H21104017 NOTE Refer to “No Spark or Poor Spark: in Section 1H” for details. DTC “C32” (P0201): Fuel Injector Circuit Malfunction B931H21104018 Detected Condition and Possible Cause Detected Condition Possible Cause CKP signal is produced but fuel injector signal is...
Page 131 Engine General Information and Diagnosis: 1A-60 Step Action 1) Remove the air cleaner box. Refer to “Air Cleaner Box Go to Step 2. Replace the injector Removal and Installation: in Section 1D”. with a new one. Refer to “Throttle Body 2) Turn the ignition switch OFF.
Page 132 1A-61 Engine General Information and Diagnosis: Step Action 5) If OK, then check the continuity between each terminal Go to Step 2. Replace the injector and ground. with a new one. Refer to “Throttle Body Special tool Disassembly and (A): 09900–25008 (Multi-circuit tester set) Assembly: in Section Injector continuity 1D”.
Page 133: Dtc "C40" (P0505-H/L): Isc Valve Circuit Malfunction
Engine General Information and Diagnosis: 1A-62 DTC “C40” (P0505-H/L): ISC Valve Circuit Malfunction B931H21104019 Detected Condition and Possible Cause Detected Condition Possible Cause ISC value motor current is higher than the • ISC valve circuit shorted to BATT or ground circuit open. C40/ specified value.
Page 134 1A-63 Engine General Information and Diagnosis: Step Action 1) Remove the air cleaner box. Refer to “Air Cleaner Box Go to Step 2. B/Lg, R/B, P/W, G or W/ Removal and Installation: in Section 1D”. Bl wire open. 2) Turn the ignition switch OFF. 3) Check the ISC valve coupler for loose or poor contacts.
Page 135 Engine General Information and Diagnosis: 1A-64 Step Action 1) Move the throttle body as shown. Refer to “Throttle If wire is OK, Replace the ISC valve Body Removal and Installation: in Section 1D”. intermittent trouble or with a new one. Refer to faulty ECM.
Page 136 1A-65 Engine General Information and Diagnosis: Step Action 3) If OK, then measure the resistance between terminals If wire is OK, Replace the ISC valve “A” and “B”, terminals “C” and “D”. intermittent trouble or with a new one. Refer to faulty ECM.
Page 137 Engine General Information and Diagnosis: 1A-66 ACTIVE CONTROL INSPECTION (ISC RPM CONTROL) Check 1 1) Set up the SDS tool. (Refer to the SDS operation manual for further details.) 2) Check that the engine is running. 3) Click the “Active control”. 4) Click the “ISC rpm control”...
Page 138 1A-67 Engine General Information and Diagnosis: Check 3 1) Click the button (6) and increase the “Spec” (2) to 1 600 rpm slowly. 2) Check that the “Desired idle speed” (3) is nearly equal to the “Spec” (2). Also, check that the number of steps (5) in the ISC valve position increases.
Page 139: Dtc "C41" (P230-H/L): Fp Relay Circuit Malfunction
Engine General Information and Diagnosis: 1A-68 DTC “C41” (P230-H/L): FP Relay Circuit Malfunction B931H21104020 Detected Condition and Possible Cause Detected Condition Possible Cause No voltage is applied to fuel pump • Fuel pump relay circuit open or short. although fuel pump relay is turned ON, or •...
Page 140 1A-69 Engine General Information and Diagnosis: C41 (Use of mode select switch) Step Action 1) Remove the seat. Refer to “Seat Removal and • Y/Bl or O/W wire Replace the FP relay Installation: in Section 9D”. open or shorted to with a new one.
Page 141: Specifications
Engine General Information and Diagnosis: 1A-70 P0230-L (Use of SDS) Step Action 1) Turn the ignition switch to OFF. • Y/Bl wire open or Replace the FP relay poor “19” connection. with a new one. 2) Remove the seat. Refer to “Front Side Exterior Parts Removal and Installation: in Section 9D”.
Page 142: Special Tools And Equipment
(Page 1A-57) / (Page 1A-48) / (Page 1A-58) / (Page 1A-49) / (Page 1A-58) / (Page 1A-50) (Page 1A-63) 09904–41010 09930–82720 SUZUKI Diagnostic system Mode selection switch (Page 1A-11) / (Page 1A-3) / (Page 1A- (Page 1A-15) 10) / (Page 1A-10) 99565–01010–019 CD-ROM Ver.19...
Page 143: Emission Control Devices
Emission Control Devices: 1B-1 Emission Control Devices Engine Precautions Precautions for Emission Control Devices B931H21200001 Refer to “General Precautions: in Section 00”. Repair Instructions Crankcase Breather (PCV) Hose Inspection Crankcase Breather (PCV) Hose Removal and B931H21206001 Installation Inspect the PCV hose in the following procedures: B931H21206002 Removal 1) Remove the seat.
Page 144: Precautions
1C-1 Engine Electrical Devices: Engine Electrical Devices Engine Precautions Precautions for Engine Electrical Device B931H21300001 Refer to “General Precautions: in Section 00” and “Precautions for Electrical Circuit Service: in Section 00”. Component Location Engine Electrical Components Location B931H21303001 Refer to “Electrical Components Location: in Section 0A”. Diagnostic Information and Procedures Engine Symptom Diagnosis B931H21304001...
Page 145: Iap / Tp / Iat Sensor Removal And
Engine Electrical Devices: 1C-2 CKP Sensor Removal and Installation ECT Sensor Removal and Installation B931H21306003 B931H21306006 Removal Removal 1) Remove the generator cover. Refer to “Generator 1) Drain engine coolant. Refer to “Cooling System Removal and Installation: in Section 1J”. Inspection: in Section 0B”.
Page 146: Ect Sensor Inspection
1C-3 Engine Electrical Devices: ECT Sensor Inspection TO Sensor Inspection B931H21306007 B931H21306008 Refer to “DTC “C15” (P0115-H/L): ECT Sensor Circuit Refer to “DTC “C23” (P1651-H/L): TO Sensor Circuit Malfunction: in Section 1A”. Malfunction: in Section 1A”. Inspect the ECT sensor in the following procedures: TO Sensor Removal and Installation 1) Remove the ECT sensor.
Page 147: Isc Valve Removal And Installation
Engine Electrical Devices: 1C-4 ISC Valve Removal and Installation Installation B931H21306011 Removal NOTE After replacing the ISC valve, turn ON the CAUTION ignition switch and OFF again. Be careful not to disconnect the ISC valve coupler at least 3 seconds after ignition Install the ISC valve in the reverse order of removal.
Page 148: Specifications
1C-5 Engine Electrical Devices: Specifications Service Data B931H21307001 FI Sensors Item Specification Note 170 – 250 Ω CKP sensor resistance CKP sensor peak voltage 5.0 V and more When cranking IAP sensor input voltage 4.5 – 5.5 V IAP sensor output voltage 1.78 –...
Page 149: Engine Mechanical
Engine Mechanical: 1D-1 Engine Mechanical Engine Schematic and Routing Diagram Throttle Cable Routing Diagram B931H21402001 “A” “B” I931H1140114-01 1. Throttle cable 5. Throttle cable guide 2. Brake hose 6. Clamp 3. Handlebar “A”: Pass through the throttle cable inside of pin. 4.
Page 150: Diagnostic Information And Procedures
1D-2 Engine Mechanical: Diagnostic Information and Procedures Engine Mechanical Symptom Diagnosis B931H21404001 Refer to “Engine Symptom Diagnosis: in Section 1A”. Compression Pressure Check B931H21404002 The compression pressure reading of a cylinder is a good indicator of its internal condition. Periodic maintenance records kept at your dealership should include compression readings for each maintenance service.
Page 151: Repair Instructions
Engine Mechanical: 1D-3 Repair Instructions Engine Components Removable with the Engine in Place B931H21406001 Engine components which can be removed while the engine is installed on the frame are as follows. For the installing and removing procedures, refer to respective paragraphs describing each component. Center of Engine Item Removal...
Page 152 1D-4 Engine Mechanical: Engine Right Side Item Removal Inspection Installation Refer to “Spark Plug Cap Refer to “Spark Plug Cap Refer to “Spark Plug and Spark Plug Removal and Spark Plug Removal Spark plug Inspection and Cleaning: and Installation: in Section and Installation: in Section in Section 1H”.
Page 153: Air Cleaner Element Removal And Installation
Engine Mechanical: 1D-5 Engine Left Side Item Removal Inspection Installation Refer to “Generator Refer to “Generator Refer to “Generator Generator Removal and Installation: Removal and Installation: Inspection: in Section 1J”. in Section 1J”. in Section 1J”. Refer to “Starter Idle Gear / Refer to “Starter Idle Gear / Refer to “Starter Related Starter Clutch Removal...
Page 154: Air Cleaner Inlet Sheet Construction
1D-6 Engine Mechanical: Air Cleaner Inlet Sheet Construction B931H21406004 “B” “B” “A” “A” “C” I931H1140288-01 1. Air cleaner inlet sheet “A”: Insert the air cleaner inlet sheet between the rear fender and frame. 2. Air cleaner box “B”: Align the hole of the air cleaner inlet sheet and cushion. 3.
Page 155: Throttle Cable Removal And Installation
Engine Mechanical: 1D-7 2) Remove the air cleaner box mounting bolts (1). Installation Install the air cleaner box in the reverse order of removal. Pay attention to the following points: • Install the air cleaner box (1) and tighten the throttle body clamp screw.
Page 156: Throttle Cable Inspection
1D-8 Engine Mechanical: 3) Remove the throttle cable as shown in the cable Throttle Cable Inspection B931H21406008 routing diagram. Refer to “Throttle Cable Routing Check that the throttle lever moves smoothly from full Diagram (Page 1D-1)”. open to full close. If it does not move smoothly, lubricate the throttle cable.
Page 157: Throttle Body Construction
Engine Mechanical: 1D-9 Throttle Body Construction B931H21406011 “A” “A” I931H1140291-02 1. Air cleaner box 4. Clamp 2. Fuel hose “A”: Pass through the fuel hose between air cleaner guide ribs. 3. PCV hose Throttle Body Removal and Installation B931H21406012 Removal 1) Remove the air cleaner box.
Page 158 1D-10 Engine Mechanical: 3) Disconnect the fuel injector coupler (2) and TP/IAP/ 7) Loosen the throttle body clamp screw and remove IAT sensor coupler (3). the throttle body assembly. 4) Disconnect the ISC valve coupler (4). I931H1140017-01 I931H1140014-02 Installation 5) Remove the throttle cable cover (5). NOTE When replacing the throttle body, turn ON the ignition switch and turn OFF again.
Page 159: Throttle Body Disassembly And Assembly
Engine Mechanical: 1D-11 • Connect the throttle cable (1). 3) Remove the ISC valve (3). CAUTION Because the O-ring is not available as spare part, the ISC valve should not be removed unless necessary. I931H1140020-01 • After installed throttle cable, adjust the throttle cable play.
Page 160 1D-12 Engine Mechanical: • Tighten the ISC valve mounting screws to the CAUTION specified torque. • Do not loosen the lock-nut (6). Special tool • The fast idle screw (7) is factory-adjusted : 09930–11950 (Torx wrench (5 mm)) at the time of delivery and therefore avoid Tightening torque removing or turning it unless otherwise ISC valve mounting screw (a): 2 N·m (0.2 kgf-m,...
Page 161: Throttle Body Inspection And Cleaning
Engine Mechanical: 1D-13 • Install the fuel delivery pipe assembly (4) to the fuel Inspection injector. Move the throttle valve by hand to inspect it if operating smoothly. CAUTION Never turn the fuel injector while installing them. • Tighten the fuel delivery pipe mounting screws to the specified torque.
Page 162 1D-14 Engine Mechanical: 5) Remove the battery. 8) Disconnect the starter motor lead wire (2) and ground lead wire (3). CAUTION When disconnecting the battery lead wires, be sure to disconnect the battery (–) lead wire first. I931H1140036-02 9) Disconnect the radiator inlet hose (4) and outlet hose (5).
Page 163 Engine Mechanical: 1D-15 11) Remove the throttle body assembly (6). Refer to 15) Disconnect the generator coupler (11), CKP sensor “Throttle Body Removal and Installation (Page 1D- coupler (12) and GP switch coupler (13). 9)”. 12) Disconnect the ECT sensor coupler (7). I931H1140042-01 16) Remove the inlet cooling duct assembly (14).
Page 164 1D-16 Engine Mechanical: 25) Remove the final gear assembly (24) and rear 20) Remove the right footrest (19). propeller shaft (25). Refer to “Final Gear Assembly Removal and Installation: in Section 3B” and “Rear Propeller Shaft Removal and Installation: in Section 3D”. I931H1140046-01 21) Remove the rear brake pedal (20).
Page 165: Engine Assembly Installation
Engine Mechanical: 1D-17 Engine Assembly Installation • Tighten the engine mounting damper stopper bolts (4) B931H21406016 to the specified torque. Reinstall the engine in the reverse order of engine Tightening torque removal. Pay attention to the following points: Engine mounting damper stopper bolt (b): 23 N·m •...
Page 166: Engine Top Side Disassembly
1D-18 Engine Mechanical: • After finishing the engine installation, check the 5) Remove the shift lever assembly (1). Refer to “Shift following items: Lever Assembly Removal and Installation: in Section 5A”. – Throttle cable play Refer to “Throttle Cable Play Inspection and 6) Remove the air cleaner box (2).
Page 167 Engine Mechanical: 1D-19 Exhaust Pipe Cam Chain Tension Adjuster Remove the exhaust pipe (1). Refer to “Exhaust Pipe / 1) Remove the TDC plug (1). Muffler Removal and Installation: in Section 1K”. I931H1140063-01 I931H1140060-01 2) Turn the crankshaft and align the match mark “A” on the crankshaft with the mark “B”...
Page 168 1D-20 Engine Mechanical: 5) Remove the cam chain tension adjuster (3) and Camshaft / Crankshaft Sprocket gasket (4). 1) Flatten the tongues of the lock washer (1). 2) Remove the camshaft sprocket bolts and lock washer (1). I931H1140067-01 Cylinder Head Cover I931H1140071-01 1) Remove the valve clearance inspection caps (1) and 3) Turn the crankshaft and position the camshaft...
Page 169 Engine Mechanical: 1D-21 5) Remove the C-ring (2) and draw out the camshaft (3) Cylinder Head from the camshaft sprocket. 1) Remove the cylinder head base nuts (1). NOTE Be careful not to drop the C-ring (2) and locating pin (4) into the crankcase. I931H1140077-01 2) Remove the cylinder head bolts (M8) (2).
Page 170: Engine Top Side Assembly
1D-22 Engine Mechanical: 5) Remove the dowel pins (4) and gasket (5). Piston 1) Place a clean rag over the cylinder base so as not to drop the piston pin circlips into the crankcase. 2) Remove the piston pin circlips (1). I931H1140080-02 Cylinder 1) Remove the cam chain guide (1).
Page 171 • Apply a bond lightly to the mating surfaces at the parting line between the left and right crankcases. • Install the piston pin circlips (1). : Sealant 99000–31140 (SUZUKI BOND CAUTION No.1207B or equivalent) Use new piston pin circlips (1) to prevent circlip failure which will occur when it is bent.
Page 172 1D-24 Engine Mechanical: • Apply molybdenum oil solution to the sliding surface Cylinder Head of the piston and piston rings. • Fit the dowel pins (1) and cylinder head gasket (2). M/O: Molybdenum oil (MOLYBDENUM OIL CAUTION SOLUTION) Use the new gasket to prevent gas leakage. •...
Page 173 Engine Mechanical: 1D-25 • Tighten the cylinder head bolts (M10) to the specified Camshaft / Camshaft Sprocket two-step torque with a torque wrench sequentially and • Turn the crankshaft and align the match mark “A” on diagonally. the crankshaft with the mark “B” on the crankcase. Tightening torque CAUTION Cylinder head bolt (M10) (Initial): 25 N·m (2.5 kgf-...
Page 174 1D-26 Engine Mechanical: • Align the marks “C” on the camshaft so that they are • Bend up the washer tongue positively to lock the parallel with the surface of the cylinder head. bolts. • Engage the hole of the camshaft sprocket with the locating pin (4) on the camshaft.
Page 175 When installing the cylinder head cover, the Use the new O-rings to prevent oil leakage. piston must be at the top dead center on the compression stroke. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) : Sealant 99000–31230 (SUZUKI BOND No.1216B or equivalent) •...
Page 176 1D-28 Engine Mechanical: • Fit a new gasket (1) and install the cam chain tension adjuster. CAUTION Use the new gasket to prevent oil leakage. • Tighten the cam chain tension adjuster mounting bolts to the specified torque. Tightening torque Cam chain tension adjuster mounting bolt (a): 10 N·m (1.0 kgf-m, 7.0 lbf-ft) I931H1140110-01...
Page 177: Valve Clearance Inspection And Adjustment
Engine Mechanical: 1D-29 • Tighten the engine mounting damper stopper bolts (3) Cam Wear to the specified torque. Check the camshaft for wear or damage. Measure the cam height “a” with a micrometer. Tightening torque Replace a camshaft if the cams are worn to the service Engine mounting damper stopper bolt (a): 23 N·m limit.
Page 178 1D-30 Engine Mechanical: Camshaft Journal Wear 5) Remove the cylinder head cover and measure the Inspect the camshaft journal wear in the following width of the compressed plastigauge using the procedures: envelope scale. 1) Determine whether or not each journal is worn down 6) This measurement should be taken at the widest to the limit by measuring the oil clearance with the part of the compressed plastigauge.
Page 179: Camshaft Sprocket Inspection
Engine Mechanical: 1D-31 Special tool Cam Chain Tension Adjuster Inspection B931H21406022 (E): 09900–20205 (Micrometer (0 – 25 mm)) The cam chain tension adjuster is maintained at the Camshaft journal O.D. proper tension by an automatically adjusted. Standard (point “c”): 17.466 – 17.484 mm (0.6876 1) Remove the cam chain tension adjuster.
Page 180: Cam Chain Tensioner Inspection
1D-32 Engine Mechanical: Cam Chain Tensioner Inspection Cylinder Bore B931H21406024 Inspect the cylinder wall for any scratches, nicks or other Inspect the cam chain tensioner in the following damage. Measure the cylinder bore diameter at six procedures: places. If any defects are found, replace the cylinder with 1) Remove the cam chain tensioner.
Page 181: Piston Ring Removal And Installation
Engine Mechanical: 1D-33 Piston Ring Removal and Installation CAUTION B931H21406026 Removal When installing the spacer, be careful so that the both edges are not overlapped. 1) Draw out the piston pin and remove the piston. Refer to “Engine Top Side Disassembly (Page 1D-18)”. 2) Carefully spread the ring opening with your thumbs and then push up the opposite side of the 1st ring to “A”...
Page 182: Piston And Piston Ring Inspection
1D-34 Engine Mechanical: 2) Position the gaps of the three rings and side rails as Piston-to-cylinder Clearance shown. Before inserting piston into the cylinder, Subtract the piston diameter from the cylinder bore check that the gaps are so located. diameter. If the piston-to-cylinder clearance exceeds the service limit, replace both the cylinder and the piston.
Page 183 Engine Mechanical: 1D-35 Special tool (B): 09900–20205 (Micrometer (0 – 25 mm)) Piston ring thickness Standard: (1st: “c”): 0.71 – 0.76 mm (0.028 – 0.030 in) Standard: (1st: “d”): 1.08 – 1.10 mm (0.0425 – 0.0433 Standard: (2nd): 0.97 – 0.99 mm (0.038 – 0.039 in) I931H1140135-01 Piston Pin and Pin Bore Measure the piston pin bore inside diameter using the...
Page 184: Cylinder Head Cover Disassembly And Assembly
1D-36 Engine Mechanical: Cylinder Head Cover Disassembly and Assembly Assembly 1) Apply engine oil to the rocker arm shafts (1). B931H21406028 Refer to “Engine Top Side Disassembly (Page 1D-18)”. Refer to “Engine Top Side Assembly (Page 1D-22)”. CAUTION Identify the position of each removed part. Organize the parts in their respective groups (i.e., intake, exhaust) so that they can be installed in their original positions.
Page 185: Cylinder Head Cover Related Parts Inspection
Engine Mechanical: 1D-37 3) Tighten the rocker arm shaft bolts (4) to the specified Rocker Arm Shaft Outside Diameter torque. Measure each rocker arm shaft out side diameter using the micrometer. If the diameter exceeds the limit, replace CAUTION the rocker arm shaft with a new one. Replace the gaskets with new ones.
Page 186: Cylinder Head Disassembly And Assembly
1D-38 Engine Mechanical: Cylinder Head Disassembly and Assembly 4) Using the special tools, compress the valve spring B931H21406030 and remove the two cotter halves (8) from the valve Refer to “Engine Top Side Disassembly (Page 1D-18)”. stem. Refer to “Engine Top Side Assembly (Page 1D-22)”. Special tool CAUTION (A): 09916–14510 (Valve lifter)
Page 187 Engine Mechanical: 1D-39 7) Remove the oil seal (12) and valve spring seat (13). I705H1140165-01 • Install the valve spring with the small-pitch portion “A” facing cylinder head. I931H1140154-01 8) Remove the other valves in the same manner as “D” described previously.
Page 188 “F” in the stem end. CAUTION “E” Replace the O-ring with a new one. “F” : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I931H1140158-01 3. Valve spring retainer 4. Cotter • Install the other valves and springs in the same manner as described previously.
Page 189: Cylinder Head Related Parts Inspection
Engine Mechanical: 1D-41 • Install the thermostat, thermostat cover and engine Valve Stem Runout mounting dumper plate. Refer to “Thermostat Support the valve using V-blocks, as shown, and check Removal and Installation: in Section 1F”. its runout using the dial gauge. If the runout exceeds the service limit, replace the valve.
Page 190 1D-42 Engine Mechanical: Valve Face Wear Valve Stem Wear Visually inspect each valve face for wear. Replace any Measure the valve stem O.D. using the micrometer. If it valve with an abnormally worn face. The thickness of the is out of specification, replace the valve with a new one. valve face decreases as the face wears.
Page 191 Engine Mechanical: 1D-43 Valve Spring Valve Seat Width The force of the coil spring keeps the valve seat tight. A 1) Visually check for valve seat width on each valve weakened spring results in reduced engine power output face. If the valve face has worn abnormally, replace and often accounts for the chattering noise coming from the valve.
Page 192: Valve Guide Replacement
1D-44 Engine Mechanical: Valve Seat Sealing Condition NOTE 1) Clean and assemble the cylinder head and valve • Discard the removed valve guide sub- components. assemblies. 2) Fill the intake and exhaust ports with gasoline to • Only oversized valve guides are available check for leaks.
Page 193 Engine Mechanical: 1D-45 5) Cool down the new valve guides in a freezer for 8) After installing the valve guides, refinish their guiding about one hour and heat the cylinder head to 100 – bores using the reamer. Be sure to clean and oil the 150 °C (212 –...
Page 194: Valve Seat Repair
1D-46 Engine Mechanical: Valve Seat Repair Engine Bottom Side Disassembly B931H21406033 B931H21406034 The valve seats (1) for both the intake and exhaust 1) Remove the engine assembly. Refer to “Engine valves are machined to two different angles. The seat Assembly Removal (Page 1D-13)”. contact surface is cut at 45°.
Page 195 Engine Mechanical: 1D-47 Oil Filter Generator Remove the oil filter (1) with the special tool. Remove the generator component parts (1). Refer to “Generator Removal and Installation: in Section 1J”. Special tool (A): 09915–40620 (Oil filter wrench) I931H1140178-01 I931H1140174-01 Starter Idle Gear 1) Remove the starter idle gear No.
Page 196 1D-48 Engine Mechanical: Starter Driven Gear Transfer Output Drive Gear Remove the key (1) and starter driven gear (2). 1) Remove the snap ring (1) and transfer output drive gear (2). Special tool : 09900–06107 (Snap ring remover (Open type)) 2) Remove the drive gear spacer (3).
Page 197 Engine Mechanical: 1D-49 Crank Balancer Driven Gear 4) Remove the pin (5) and washer (6). 1) Hold the crank balancer drive gear (1) with the 5) Remove the oil pump (7). special tools. 2) Remove the bolt (2) and crank balancer driven gear (3).
Page 198 1D-50 Engine Mechanical: 3) Remove the washer (2) and crank balancer drive Oil Jet gear (3). Remove the oil jet (1) from the right crankcase. I931H1140194-01 I931H1140197-01 4) Remove the pin (4). Gear Position Switch 1) Remove the gear position switch (1). I931H1140195-02 Automatic Transmission I931H1140198-01...
Page 199 Engine Mechanical: 1D-51 Crankcase Oil Sump Filter Remove the oil sump filter (1). 1) Remove the crankcase bolts (M6 and M8) and clamp (1). NOTE Loosen the crankcase bolts diagonally with the smaller sizes first. I931H1140203-01 Transfer / Rear Output Shaft / Rear Output Shaft Bevel Gear Remove the transfer component parts (1), rear output shaft (2) and rear output shaft bevel gear component...
Page 200: Engine Bottom Side Assembly
1D-52 Engine Mechanical: Crankshaft Engine Bottom Side Assembly B931H21406035 1) Install the removed generator cover (1) and tighten Assemble the engine bottom side in the reverse order of the bolts. disassembly. Pay attention to the following points: NOTE Apply engine oil to each running and sliding part before reassembling.
Page 201 • Apply sealant to distorted surfaces as it Install the oil sump filter (1). forms a comparatively thick film. NOTE : Sealant 99000–31110 (SUZUKI BOND Fit the projection “A” of the oil sump filter in No.1215 or equivalent) the concave portion of the crankcase.
Page 202 1D-54 Engine Mechanical: • Apply grease to the oil seals and match the left and right crankcases. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I931H1140219-01 • Apply grease to the O-ring and install the spacer. CAUTION Use the new O-ring to prevent oil leakage.
Page 203 Engine Mechanical: 1D-55 • Tighten the gear position switch mounting bolts. Crank Balancer Drive Gear • Clamp the lead wire firmly. • Install the pin (1). I931H1140223-01 I931H1140226-01 • Install the crank balancer drive gear (2) and washer Oil Jet (3).
Page 204 1D-56 Engine Mechanical: • Lock the crank balancer drive gear nut with a center • Install the key (5) and oil pump drive gear (6). punch. I931H1140233-01 I931H1140229-01 Crank Balancer Driven Gear Oil Pump • Install the crank balancer driven gear (1). •...
Page 205 Engine Mechanical: 1D-57 • Hold the crank balancer drive gear with the special tools and tighten the crank balancer driven gear bolt to the specified torque. Special tool (A): 09920–53740 (Clutch sleeve hub holder) : 09920–31020 (Extension handle) Tightening torque Crank balancer driven gear bolt (a): 50 N·m (5.0 kgf-m, 36.0 lbf-ft) I931H1140236-02...
Page 206 1D-58 Engine Mechanical: • Install the washers (6). Starter Idle Gear • Install the shaft (1) and starter idle gear No. 2 (2). I931H1140239-02 • Install the gearshift shaft (7). I931H1140242-01 • Install the shaft (3) and starter idle gear No. 1 (4). NOTE Align the punch mark “D”...
Page 207 • Apply grease to the O-rings. CAUTION CAUTION Replace the O-ring with a new one. Replace the O-rings with new ones. : Grease 99000–25010 (SUZUKI SUPER : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) GREASE A or equivalent) • Install the left crankshaft spacer.
Page 208: Conrod And Crankshaft Inspection
1D-60 Engine Mechanical: Oil Filter / Starter Motor Conrod and Crankshaft Inspection B931H21406036 Install a new oil filter (1) and starter motor (2). Refer to Refer to “Engine Bottom Side Disassembly (Page 1D- “Engine Oil and Filter Replacement: in Section 0B” 46)”.
Page 209: Width Between Crankshaft Webs
Engine Mechanical: 1D-61 Conrod Big End Side Clearance Width Between Crankshaft Webs B931H21406037 Check the conrod big end side clearance with the Measure the width between crankshaft webs “a”. thickness gauge. If the clearance exceeds the limit, replace the crankshaft assembly and conrod with a new one.
Page 210: Bearing (Crankcase And Generator Cover) Inspection
1D-62 Engine Mechanical: Bearing (Crankcase and Generator Cover) Generator cover Inspection B931H21406039 Refer to “Engine Bottom Side Disassembly (Page 1D- 46)”. Refer to “Engine Bottom Side Assembly (Page 1D-52)”. Rotate the bearing inner race by finger to inspect for abnormal play, noise and smooth rotation while the bearings are in the crankcase.
Page 211 Engine Mechanical: 1D-63 3) Remove the other bearings (2) with the special tool. 3) Remove the crankshaft oil seals (3) and (4) with the special tool. Special tool (B): 09913–70210 (Bearing installer set (10 Special tool – 75)) (A): 09913–50121 (Oil seal remover) I931H1140259-01 I931H1140262-01 4) Remove the bearing retainers.
Page 212 1D-64 Engine Mechanical: 6) Remove the each bearing (6) with the special tool. 2) Remove the generator stator. Refer to “Generator Removal and Installation: in Section 1J”. Special tool 3) Remove the snap ring (2) with the special tool. (C): 09913–70210 (Bearing installer set (10 –...
Page 213 7) Apply grease to the lip of oil seal (4). 1) Install the oil seal (1) with suitable socket. 2) Apply grease to the lip of oil seal (1). : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) : Grease 99000–25010 (SUZUKI SUPER...
Page 214 2) Apply thread lock to the bearing retainer screws and 6) Apply grease to the lip of oil seal (3). tighten them. : Grease 99000–25010 (SUZUKI SUPER : Thread lock cement 99000–32030 GREASE A or equivalent) (THREAD LOCK CEMENT SUPER 1303 or...
Page 215: Specifications
Engine Mechanical: 1D-67 Left crankcase 2) Apply thread lock to the bearing retainer screws and tighten them. 1) Install the each bearing (1) with the special tool. : Thread lock cement 99000–32030 NOTE (THREAD LOCK CEMENT SUPER 1303 or The stamped mark side of the bearing faces equivalent) inside of crankcase.
Page 216 1D-68 Engine Mechanical: Camshaft + Cylinder Head Unit: mm (in) Item Standard Limit 33.45 – 33.50 (1.317 – 1.319) 33.15 (1.305) Cam height 33.47 – 33.52 (1.318 – 1.320) 33.17 (1.306) Camshaft 0.028 – 0.059 (0.0011 – 0.0023) Camshaft journal oil clearance end side 0.150 (0.0059) Other side...
Page 217: Tightening Torque Specifications
Engine Mechanical: 1D-69 Tightening Torque Specifications B931H21407002 Tightening torque Fastening part Note N⋅m kgf-m lbf-ft Air cleaner box mounting bolt 0.45 (Page 1D-7) ISC valve mounting screw (Page 1D-12) Fuel delivery pipe mounting screw (Page 1D-13) Engine mounting nut 43.5 (Page 1D-17) Engine mounting damper stopper bolt (Page 1D-17) /...
Page 218: Recommended Service Material
1D-70 Engine Mechanical: Special Tools and Equipment Recommended Service Material B931H21408001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010 (Page 1D-27) / equivalent (Page 1D-40) / (Page 1D-54) / (Page 1D-54) / (Page 1D-54) /...
Page 219 Engine Mechanical: 1D-71 09900–20204 09900–20205 Micrometer (75 – 100 mm) Micrometer (0 – 25 mm) (Page 1D-34) (Page 1D-31) / (Page 1D-35) / (Page 1D-35) / (Page 1D-37) / (Page 1D-42) 09900–20530 09900–20602 Cylinder gauge set Dial gauge (Page 1D-32) (Page 1D-30) / (Page 1D-35) 09900–20605...
Page 220 1D-72 Engine Mechanical: 09913–10750 09913–50121 Compression gauge adapter Oil seal remover (Page 1D-2) (Page 1D-63) / (Page 1D-63) / (Page 1D-64) / (Page 1D-64) 09913–70210 09915–40620 Bearing installer set (10 – Oil filter wrench (Page 1D-66) / (Page 1D-47) (Page 1D-66) / (Page 1D-67) / (Page 1D-63) / (Page 1D-64) /...
Page 221 Engine Mechanical: 1D-73 09920–13120 09920–31020 Crankshaft remover Extension handle (Page 1D-51) / (Page 1D-49) / (Page 1D-52) (Page 1D-49) / (Page 1D-55) / (Page 1D-57) 09920–53740 09921–20240 Clutch sleeve hub holder Bearing remover set (Page 1D-49) / (Page 1D-62) / (Page 1D-49) / (Page 1D-63) / (Page 1D-55) /...
Page 222: Engine Lubrication System
1E-1 Engine Lubrication System: Engine Lubrication System Engine Precautions Precautions for Engine Oil B931H21500001 Refer to “Fuel and Oil Recommendation: in Section 0A”. Schematic and Routing Diagram Engine Lubrication System Chart Diagram B931H21502001 CHAIN ONE-WAY CLUTCH CAM FACE STARTER DRIVEN CYLINDER WALL CLUTCH GEAR BEARING...
Page 223: Engine Lubrication Circuit Diagram
Engine Lubrication System: 1E-2 Engine Lubrication Circuit Diagram B931H21502002 To cylinder head OIL PUMP I931H1150002-03...
Page 224 1E-3 Engine Lubrication System: EXHAUST SIDE INTAKE SIDE I931H1150003-02...
Page 225: Diagnostic Information And Procedures
Engine Lubrication System: 1E-4 Diagnostic Information and Procedures Engine Lubrication Symptom Diagnosis B931H21504001 Condition Possible cause Correction / Reference Item Engine overheats Insufficient amount of engine oil. Check level and add. Defective oil pump. Replace. Clogged oil circuit. Clean. Incorrect engine oil. Change.
Page 226: Repair Instructions
1E-5 Engine Lubrication System: 8) Stop the engine and remove the oil pressure gauge and attachment. 9) Reinstall the main oil gallery plug (1) and tighten it to the specified torque. CAUTION Use a new gasket to prevent oil leakage. Tightening torque Main oil gallery plug (a): 18 N·m (1.8 kgf-m, 13.0 lbf-ft)
Page 227: Oil Sump Filter Inspection And Cleaning
Engine Lubrication System: 1E-6 Oil Sump Filter Inspection and Cleaning 2) Remove the oil jet (1). B931H21506004 Inspect the oil sump filter in the following procedures: 1) Remove the oil sump filter. Refer to “Oil Sump Filter Removal and Installation (Page 1E-5)”. 2) If the oil sump filter is clogged with sediment or rust, clean the oil sump filter using compressed air.
Page 228: Oil Pump Construction
1E-7 Engine Lubrication System: Oil Pump Construction B931H21506006 I931H1150025-01 1. Oil pump 5. Water pump shaft 2. Oil pump driven gear : 50 N⋅m (5.0 kgf-m, 36.0 lbf-ft) 3. Oil pump drive gear : Apply thread lock to the thread part. 4.
Page 229 Engine Lubrication System: 1E-8 4) Install the left crankshaft spacer (5). 7) Remove the pin (8), washer (9) and oil pump (10). I931H1150014-01 I931H1150018-01 5) Hold the crankshaft spacer (5) and remove the crank Installation balancer driven gear bolt and washer. Install the oil pump in the reverse order of removal.
Page 230: Oil Pump Inspection
1E-9 Engine Lubrication System: • Install the crank balancer driven gear (3). • Hold the crank shaft spacer (5) and tighten the crank balancer driven gear bolt (4) to the specified torque. NOTE Tightening torque Align the punch mark “A” of crank balancer Crank balancer driven gear bolt (a): 50 N·m (5.0 drive gear with the punch marks “B”...
Page 231: Specifications
For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List: in Section 0C”. Special Tools and Equipment Recommended Service Material B931H21508001 Material SUZUKI recommended product or Specification Note Thread lock cement THREAD LOCK CEMENT SUPER P/No.: 99000–32030...
Page 232: Special Tool
1E-11 Engine Lubrication System: Special Tool B931H21508002 09900–06107 09900–26006 Snap ring remover (Open Engine tachometer type) (Page 1E-8) / (Page 1E- (Page 1E-4) 09915–74511 09915–74533 Oil pressure gauge (600 Oil pressure gauge adapter kPa) (Page 1E-4) (Page 1E-4)
Page 233: Engine Cooling System
Engine Cooling System: 1F-1 Engine Cooling System Engine Precautions Precautions for Engine Cooling System B931H21600001 WARNING • You can be injured by boiling fluid or steam if you open the radiator cap when the engine is hot. After the engine cools, wrap a thick cloth around cap and carefully remove the cap by turning it a quarter turn to allow pressure to escape and then turn the cap all the way off.
Page 234: General Description
1F-2 Engine Cooling System: General Description Engine Coolant Description Fig.1: Engine coolant density-freezing point curve B931H21601001 CAUTION • Use a high quality ethylene glycol base anti-freeze, mixed with distilled water. Do not mix an alcohol base anti-freeze and different brands of anti-freeze. •...
Page 235: Water Hose Routing Diagram
Engine Cooling System: 1F-3 Water Hose Routing Diagram B931H21602002 “ D ” “A” “B” “A” “B” “C” I931H1160057-01 1. Thermostat 6. Radiator outlet hose “D”: Face the tip of the clip to upper. 2. Radiator 7. Water pump : 17 N⋅m (1.7 kgf-m, 12.5 lbf-ft) 3.
Page 236: Diagnostic Information And Procedures
1F-4 Engine Cooling System: Diagnostic Information and Procedures Engine Cooling Symptom Diagnosis B931H21604001 Condition Possible cause Correction / Reference Item Engine overheats Not enough engine coolant. Add engine coolant. Radiator core clogged with dirt or scale. Clean. Faulty cooling fan. Repair or replace.
Page 237: Radiator Cap Inspection
Engine Cooling System: 1F-5 Radiator Cap Inspection CAUTION B931H21606002 Inspect the radiator cap in the following procedures: • Make sure not to bend the fins when using 1) Remove the radiator cap. Refer to “Cooling Circuit compressed air. Inspection (Page 1F-4)”. •...
Page 238: Water Hose Removal And Installation
1F-6 Engine Cooling System: Installation 6) Disconnect the cooling fan thermo-switch coupler (6) and cooling fan motor coupler (7). Install the cooling fan assembly and radiator in the reverse order of removal. Pay attention to the following points: • Install the cooling fan thermo switch. Refer to “Cooling “A”...
Page 239: Cooling Fan Inspection
Engine Cooling System: 1F-7 Cooling Fan Inspection Radiator Reservoir Tank Removal and B931H21606006 Installation Inspect the cooling fan in the following procedures: B931H21606007 Removal 1) Disconnect the cooling fan motor coupler (1). 1) Remove the radiator cap lid (1). I931H1160012-01 2) Test the cooling fan motor for load current with an I931H1160059-01 ammeter connected as shown in the figure.
Page 240: Radiator Reservoir Tank Inspection
1F-8 Engine Cooling System: Radiator Reservoir Tank Inspection B931H21606008 Inspect the radiator reservoir tank coolant leaks. If any defects are found, replace the radiator reservoir tank with a new one. I931H1160018-01 4) After finishing the water hose inspection, reinstall the removed parts.
Page 241: Cooling Fan Thermo-Switch Inspection
Engine Cooling System: 1F-9 Installation Cooling Fan Thermo-switch Inspection B931H21606013 Install the cooling fan thermo-switch in the reverse order Inspect the cooling fan thermo-switch in the following of removal. Pay attention to the following points: procedures: • Apply engine coolant to the O-ring. 1) Remove the cooling fan thermo-switch.
Page 242: Thermostat Removal And Installation
1F-10 Engine Cooling System: Thermostat Removal and Installation Installation B931H21606014 Install the thermostat in the reverse order of removal. Removal Pay attention to the following points: 1) Drain a small amount of engine coolant. Refer to • Apply engine coolant to the rubber seal on the “Cooling System Inspection: in Section 0B”.
Page 243: Thermostat Inspection
Engine Cooling System: 1F-11 Thermostat Inspection 6) Read the thermometer just when opening the B931H21606015 thermostat. If this reading, which is the temperature Inspect the thermostat in the following procedures: level at which the thermostat valve begins to open, is 1) Remove the thermostat.
Page 244: Water Pump Components
1F-12 Engine Cooling System: Water Pump Components B931H21606016 I931H1160056-03 1. Water pump cover 4. Mechanical seal : 13 N⋅m (1.3 kgf-m, 9.5 lbf-ft) : Apply molybdenum oil. 2. O-ring 5. Oil seal : 10 N⋅m (1.0 kgf-m, 7.0 lbf-ft) : Apply engine coolant. 3.
Page 245: Water Pump Disassembly And Assembly
B931H21606018 Refer to “Water Pump Removal and Installation Replace the O-rings with the new ones. (Page 1F-12)”. : Grease 99000–25010 (SUZUKI SUPER Disassembly GREASE A or equivalent) 1) Remove the O-rings (1). • Install the water pump assembly with the slot on the pump shaft end “A”...
Page 246 1F-14 Engine Cooling System: 3) Remove the O-ring (3). 7) Remove the mechanical seal ring (9) and rubber seal (10) from the impeller. I931H1160035-01 4) Remove the E-ring (4) and cap (5). I931H1160039-01 8) Remove the mechanical seal with the special tool. NOTE If there is no abnormal condition, the mechanical seal removal is not necessary.
Page 247 I931H1160044-01 I931H1160042-01 2) Apply a small quantity of the grease to the oil seal lip. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I931H1160045-01 4) Install the rubber seal (1) into the impeller. 5) After wiping off the oily or greasy matter from the mechanical seal ring (2), install it into the impeller.
Page 248 1F-16 Engine Cooling System: 6) Apply silicone grease to the mechanical seal ring (2). 11) Install a new O-ring (7) and apply engine coolant to : Grease 99000–25100 (SUZUKI SILICONE GREASE or equivalent) CAUTION 7) Apply molybdenum solution to the impeller shaft.
Page 249: Water Pump Related Parts Inspection
Engine Cooling System: 1F-17 Water Pump Related Parts Inspection Impeller B931H21606019 Visually inspect the impeller and its shaft for damage. Refer to “Water Pump Disassembly and Assembly Replace the impeller if necessary. (Page 1F-13)”. Mechanical Seal Visually inspect the mechanical seal for damage, with particular attention given to the sealing face.
Page 250: Specifications
1F-18 Engine Cooling System: Specifications Service Data B931H21607001 Thermostat + Radiator + Fan + Coolant Item Standard Note Thermostat valve opening 80.5 – 83.5 °C (177 – 182 °F) — temperature 8 mm (0.31 in) and over at 95 °C (203 °F) Thermostat valve lift —...
Page 251: Special Tools And Equipment
Engine Cooling System: 1F-19 Special Tools and Equipment Recommended Service Material B931H21608001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010 (Page 1F-13) / equivalent (Page 1F-15) SUZUKI SILICONE GREASE or P/No.: 99000–25100 (Page 1F-16)
Page 252: Fuel System
1G-1 Fuel System: Fuel System Engine Precautions Precautions for Fuel System B931H21700001 WARNING • Keep away from fire or spark. • During disassembling, use care to minimize spillage of gasoline. • Spilled gasoline should be wiped off immediately. • Work in a well-ventilated area. CAUTION •...
Page 253: General Description
Fuel System: 1G-2 General Description Fuel System Description B931H21701001 Fuel System The fuel delivery system consists of the fuel tank (1), fuel pump (2), fuel mesh filter (3), fuel feed hose (4), fuel delivery pipe (5) (including fuel injector) and fuel pressure regulator (6). There is no fuel return hose. The fuel in the fuel tank (1) is pumped up by the fuel pump (2) and pressurized fuel flows into the injector (7) installed in the fuel delivery pipe (5).
Page 254: Schematic And Routing Diagram
1G-3 Fuel System: Schematic and Routing Diagram Fuel Hose Routing Diagram B931H21702001 I931H1170028-01 1. Fuel hose 3. PCV hose 2. Air cleaner box 4. Pass the fuel hose between the air cleaner guide.
Page 255: Fuel Tank Breather Hose Routing Diagram
Fuel System: 1G-4 Fuel Tank Breather Hose Routing Diagram B931H21702002 “A” I831G1170003-04 1. Frame 5. Valve (Black) “A”: Align the fuel pump nipple with the mark. 2. Fuel tank breather hose 6. Valve (Orange) : 35 N⋅m (3.5 kgf-m, 25.5 lbf-ft) 3.
Page 256: Diagnostic Information And Procedures
1G-5 Fuel System: Diagnostic Information and Procedures Fuel System Diagnosis B931H21704001 Condition Possible cause Correction / Reference Item Engine will not start or is Clogged fuel filter or fuel hose. Clean or replace. hard to start (No fuel Defective fuel pump. Replace.
Page 257: Repair Instructions
Fuel System: 1G-6 Repair Instructions Fuel Pressure Inspection 5) Turn the ignition ON and check for fuel pressure. B931H21706001 Fuel pressure WARNING Approx. 294 kPa (2.9 kgf/cm , 41 psi) • Keep away from fire or spark. If the fuel pressure is lower than the specification, •...
Page 258: Fuel Pump Relay Inspection
1G-7 Fuel System: 2) Place a rag under the fuel feed hose (1) and disconnect fuel feed hose from the fuel pump. I931H1170007-02 6) After finishing the fuel discharge inspection, reinstall the rear fender. Refer to “Rear Side Exterior Parts I931H1170004-01 3) Place the measuring cylinder and insert the fuel feed Removal and Installation: in Section 9D”.
Page 259: Fuel Hose Inspection
Fuel System: 1G-8 Fuel Hose Inspection 1) Remove the rear fender. Refer to “Rear Side B931H21706005 Exterior Parts Removal and Installation: in Refer to “Fuel Line Inspection: in Section 0B”. Section 9D”. 2) Remove the fuel tank outer cover. Refer to “Rear Fuel Feed Hose Removal and Installation Side Exterior Parts Removal and Installation: in B931H21706006...
Page 260: Fuel Pump Components
1G-9 Fuel System: Fuel Pump Components B931H21706010 I931H1170013-01 Installation Install the fuel pump assembly in the reverse order of removal. Pay attention to the following points: • Install the fuel pump gasket (1). CAUTION If there are wear or damage, replace the gasket (1) with a new one.
Page 261: Fuel Pump Assembly Removal And Installation
Fuel System: 1G-10 Fuel Pump Disassembly and Assembly Fuel Injector Inspection and Cleaning B931H21706012 B931H21706014 Refer to “Fuel Pump Assembly Removal and Installation Inspect the fuel injector in the following procedures: (Page 1G-9)”. 1) Remove the fuel injector. Refer to “Fuel Injector / Fuel Delivery Pipe Removal and Installation Disassembly (Page 1G-10)”.
Page 262 1G-11 Fuel System: 3) Place a rug under the fuel feed hose (1) and disconnect the fuel feed hose (1) from the fuel delivery pipe. 4) Disconnect the injector coupler (2). I931H1170021-01 • Install the fuel injector (3) by pushing it straight to the delivery pipe (4).
Page 263: Fuel Tank Pressure Control (Ftpc) Valve Removal And Installation
Fuel System: 1G-12 Fuel Tank Pressure Control (FTPC) Valve 6) Remove the fuel tank cap (3). Removal and Installation CAUTION B931H21706016 Removal To prevent the fuel tank from contamination 1) Remove the rear carrier. Refer to “Rear Carrier with foreign particles, blind opening. Removal and Installation: in Section 9E”.
Page 264: Fuel Tank Pressure Control (Ftpc) Valve Inspection
1G-13 Fuel System: Fuel Tank Pressure Control (FTPC) Valve Inspection B931H21706017 Inspect the FTPC valve in the following procedures: 1) Remove the FTPC valve. Refer to “Fuel Tank Pressure Control (FTPC) Valve Removal and Installation (Page 1G-12)”. 2) Check the FTPC valve if air can pass through smoothly when blown from the orange color side and not from the other side.
Page 265: Special Tools And Equipment
Fuel System: 1G-14 Special Tools and Equipment Special Tool B931H21708001 09900–25008 09915–74521 Multi circuit tester set Adapter hose (Page 1G-7) (Page 1G-6) 09915–77331 09940–40211 Oil pressure gauge (1000 Fuel pressure gauge kPa) adapter (Page 1G-6) (Page 1G-6) 09940–40220 09941–51012 Fuel pressure gauge Ring locknut wrench attachment (Page 1G-6)
Page 266: Ignition System
1H-1 Ignition System: Ignition System Engine General Description Override Switch Description B931H21801001 The override switch allows the rider to increase the power available by overriding the normal speed limiter in forward Differential Lock or Reverse. For example, the rider may need to use extra power when stuck in the mud.
Page 267: Diagnostic Information And Procedures
Ignition System: 1H-2 Diagnostic Information and Procedures Ignition System Symptom Diagnosis B931H21804001 Condition Possible cause Correction / Reference Item Spark plug not sparking Damaged spark plug. Replace. Fouled spark plug. Clean or replace. Wet spark plug. Clean and dry or replace. Defective ignition coil.
Page 268: Repair Instructions
1H-3 Ignition System: Step Action Inspect the spark plug. Refer to “Spark Plug Inspection Go to Step 5. Faulty spark plug. and Cleaning: in Section 0B”. Is the spark plug OK? Inspect the ignition coil. Refer to “Ignition Coil and Plug Cap Go to step 6.
Page 269: Ignition Coil And Plug Cap Inspection
Ignition System: 1H-4 Ignition Coil and Plug Cap Inspection B931H21806003 Refer to “Electrical Components Location: in Section 0A”. Ignition Coil Primary Peak Voltage 1) Remove the right side cover and right inner fender. Refer to “Front Side Exterior Parts Removal and Installation: in Section 9D”.
Page 270: Ignition Coil Removal And Installation
1H-5 Ignition System: CKP Sensor Inspection Ignition Coil Resistance B931H21806005 1) Disconnect the spark plug cap. Refer to “Ignition Coil Refer to “Electrical Components Location: in Section and Plug Cap Inspection (Page 1H-4)”. 0A”. 2) Disconnect the ignition coil lead wire. CKP Sensor Peak Voltage 3) Measure the ignition coil resistance in both the primary and secondary coils.
Page 271: Ckp Sensor Removal And Installation
Ignition System: 1H-6 4) Measure the CKP sensor peak voltage in the following procedures: a) Shift the transfer to the neutral, turn the ignition switch ON. b) Press the starter button and allow the engine to crank for a few seconds, and then measure the CKP sensor peak voltage.
Page 272: Ignition Switch Inspection
1H-7 Ignition System: 5) After finishing the engine stop switch inspection, Override Switch Inspection B931H21806010 reinstall the removed parts. 1) Remove the left inner fender. Refer to “Front Side Exterior Parts Removal and Installation: in Ignition Switch Inspection Section 9D”. B931H21806008 Refer to “Ignition Switch Inspection: in Section 9C”.
Page 273: Emergency Switch Inspection (For
Ignition System: 1H-8 Emergency Switch Inspection (For P-17) Emergency Switch Removal and Installation B931H21806011 (For P-17) Inspect the emergency switch for continuity with a tester. B931H21806012 If any abnormality is found, replace the emergency Removal switch assembly with a new one. Refer to “Wiring Disconnect the coupler and remove the emergency Harness Routing Diagram: in Section 9A”.
Page 274: Starting System
1I-1 Starting System: Starting System Engine Schematic and Routing Diagram Starting System Diagram B931H21902001 Refer to “Wire Color Symbols: in Section 0A”. Starter Engine Ignition button stop switch Ignition switch fuse Main Neutral relay fuse Starter motor Neutral indicator light Parking B/Bl Starter relay...
Page 275: Starter Motor Will Not Run
Starting System: 1I-2 Starter Motor will not Run B931H21904002 NOTE Make sure the fuses are not blown and the battery is fully-charged before diagnosing. Troubleshooting Step Action 1) Shift the transfer to neutral. Go to step 2. Go to step 3. 2) Turn on the ignition switch with the engine stop switch in the “RUN”...
Page 276: Repair Instructions
1I-3 Starting System: Repair Instructions Starter Motor Components B931H21906001 I931H1190037-02 1. O-ring 6. Starter motor case : 10 N⋅m (1.0 kgf-m, 7.0 lbf-ft) 2. Housing end (Inside) 7. Brush holder : 3.5 N⋅m (0.35 kgf-m, 2.5 lbf-ft) 3. O-ring 8. Housing end (Outside) : Apply grease.
Page 277: Starter Motor Disassembly And Assembly
• Apply grease to the starter motor O-ring. Replace the O-rings with new ones to prevent oil leakage and moisture. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) • Tighten the brush holder mounting nut (1) to the specified torque.
Page 278: Starter Motor Related Parts Inspection
• Apply a small quantity of moly paste to the armature Starter Motor Related Parts Inspection B931H21906004 shaft. Refer to “Starter Motor Disassembly and Assembly : Moly paste 99000–25140 (SUZUKI Moly (Page 1I-4)”. paste or equivalent) Carbon Brush Inspect the carbon brushes for abnormal wear, cracks or smoothness in the brush holder.
Page 279: Starter Relay Removal And Installation
Starting System: 1I-6 Armature Coil Starter Relay Removal and Installation B931H21906005 Measure for continuity between each segment. Measure Refer to “Electrical Components Location: in Section for continuity between each segment and the armature 0A”. shaft. If there is no continuity between the segments or there is Removal continuity between the segments and shaft, replace the 1) Turn the ignition switch OFF position.
Page 280: Starter Relay Inspection
1I-7 Starting System: Starter Relay Inspection 3) Measure the relay coil resistance between the B931H21906006 terminals using the multi-circuit tester. If the Inspect the starter relay in the following procedures: resistance is not within the specified value, replace 1) Remove the starter relay. Refer to “Starter Relay the starter relay with a new one.
Page 281: Neutral Relay Inspection
Starting System: 1I-8 Neutral Relay Inspection B931H21906008 Inspect the neutral relay in the following procedures: 1) Remove the neutral relay. Refer to “Neutral Relay “A” “B” Removal and Installation (Page 1I-7)”. 2) Check the insulation between “A” and “B” terminals using the multi-circuit tester.
Page 282: Parking Brake Relay Inspection
1I-9 Starting System: Parking Brake Relay Inspection 3) Inspect the parking/rear brake switch for continuity B931H21906011 with a tester. If any abnormality is found, replace the Inspect the parking brake relay in the following parking/rear brake switch with a new one. Refer to procedures: “Handlebars Removal and Installation: in Section 1) Remove the parking brake relay.
Page 283: Starter Idle Gear / Starter Clutch Removal And Installation
Starting System: 1I-10 4) After finishing the gear position switch inspection, 4) Remove the generator rotor assembly. Refer to reinstall the removed parts. “Generator Removal and Installation: in Section 1J”. Starter Idle Gear / Starter Clutch Removal and 5) Remove the key (4) and starter driven gear (5). Installation B931H21906014 Removal...
Page 284 1I-11 Starting System: Installation • Apply thread lock to the bolts, and tighten them to the Install the starter clutch in the reverse order of removal. specified torque. Pay attention to the following points: : Thread lock cement 99000–32030 • When inserting the one way clutch (1) into the guide (THREAD LOCK CEMENT SUPER 1303 or (2), fit the flange “A”...
Page 285: Starter Driven Gear Bearing Removal And Installation
Starting System: 1I-12 Starter Driven Gear Bearing Removal and Starter Related Parts Inspection B931H21906016 Installation Refer to “Starter Idle Gear / Starter Clutch Removal and B931H21906015 Installation (Page 1I-10)”. Removal 1) Remove the starter driven gear. Refer to “Starter Idle Starter Clutch Gear / Starter Clutch Removal and Installation 1) Install the starter driven gear onto the starter clutch.
Page 286: Starter Button Inspection
1I-13 Starting System: Starter Idle Gear 2) Disconnect the handlebar switch coupler (1). Inspect the starter idle gear No. 1 (1) and No. 2 (2) for wear or damage. If any damage is found, replace it with a new one. I931H1190036-01 3) Measure the voltage between Y/G and O lead wires.
Page 287: Tightening Torque Specifications
For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List: in Section 0C”. Special Tools and Equipment Recommended Service Material B931H21908001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010...
Page 288: Charging System
1J-1 Charging System: Charging System Engine Schematic and Routing Diagram Charging System Diagram B931H21A02001 Regulator/Rectifier Ignition switch Generator I718H11A0001-01 Component Location Charging System Components Location B931H21A03001 Refer to “Electrical Components Location: in Section 0A”. Diagnostic Information and Procedures Charging System Symptom Diagnosis B931H21A04001 Condition Possible cause...
Page 289: Battery Runs Down Quickly
Charging System: 1J-2 Condition Possible cause Correction / Reference Item Battery overcharges Faulty regulator/rectifier. Replace. Faulty battery. Replace. Poor contact of generator lead wire Repair. coupler. Battery runs down quickly Trouble in charging system. Check the generator, regulator/rectifier and circuit connections and make necessary adjustments to obtain specified charging operation.
Page 290: Repair Instructions
1J-3 Charging System: Repair Instructions Battery Current Leakage Inspection 3) Measure the DC voltage between the (+) and (–) B931H21A06001 battery terminals using the multi-circuit tester. If the Inspect the battery current leakage in the following voltage is not within the specified value, inspect the procedures: generator and regulator/rectifier.
Page 291: Generator Removal And Installation
Charging System: 1J-4 3) Measure the resistance between the three lead 3) Disconnect the generator coupler (1). wires. If the resistance is out of specified value, replace the stator with a new one. Also, check that the generator core is insulated properly. NOTE When making this test, it is not necessary to remove the generator.
Page 292 1J-5 Charging System: 7) Disconnect the gearshift lever arm (1) and speed 12) Remove the generator cover (9). sensor coupler (2). 8) Remove the recoil cover (3). I931H11A0009-02 13) Remove the gasket (10) and dowel pins. I931H11A0006-01 9) Disconnect the CKP sensor coupler (4) and generator coupler (5) and remove the clamp (6).
Page 293 Charging System: 1J-6 16) Remove the generator rotor assembly (11) with the Installation special tool. Install the generator in the reverse order of removal. Pay attention to the following points: NOTE • Tighten the generator stator set bolts and CKP sensor Remove the starter clutch if necessary.
Page 294 Generator rotor nut (d): 140 N·m (14.0 kgf-m, 101.5 lbf-ft) I931H11A0020-01 • Apply grease to the O-ring (5) and oil seal lip. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) CAUTION I931H11A0018-01 • Install the dowel pins and new gasket (4).
Page 295: Regulator / Rectifier Inspection
Charging System: 1J-8 Regulator / Rectifier Inspection B931H21A06005 Inspect the regulator/rectifier in the following procedures: 1) Turn the ignition switch OFF. 2) Remove the rear fender. Refer to “Rear Side Exterior Parts Removal and Installation: in Section 9D”. 3) Disconnect the regulator/rectifier coupler (1) and remove the regulator/rectifier (2). I931H11A0023-01 4) Measure the voltage between the terminals using the multi-circuit tester as indicated in the following table.
Page 296: Battery Components
1J-9 Charging System: Battery Components B931H21A06006 “B” I649G11A0040-03 3) Insert the nozzles of the electrolyte container (3) into I649G11A0046-03 the electrolyte filler holes of the battery. 1. Anode plates 5. Stopper 4) Hold the electrolyte container firmly so that it does 2.
Page 297 Charging System: 1J-10 NOTE Correct If no air bubbles come out from a filler port, tap the bottom of the electrolyte container two or three times. Never remove the container from the battery. Incorrect I310G11A0024-01 6) After confirming that the electrolyte has entered the battery completely, remove the electrolyte containers from the battery.
Page 298: Battery Removal And Installation
1J-11 Charging System: Battery Recharging Battery Removal and Installation B931H21A06008 Removal CAUTION 1) Remove the seat. Refer to “Seat Removal and Do not remove the caps on the battery top Installation: in Section 9D”. while recharging. 2) Remove the battery stay (1). NOTE When the vehicle is not used for a long period, check the battery every 1 month to...
Page 299: Battery Visual Inspection
Charging System: 1J-12 Installation Battery Visual Inspection B931H21A06009 Install the battery in the reverse order of removal. Inspect the battery in the following procedures: Pay attention to the following point: 1) Remove the seat. Refer to “Seat Removal and CAUTION Installation: in Section 9D”.
Page 300: Tightening Torque Specifications
For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List: in Section 0C”. Special Tools and Equipment Recommended Service Material B931H21A08001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010...
Page 301: Exhaust System
Exhaust System: 1K-1 Exhaust System Engine Precautions Precautions for Exhaust System B931H21B00001 WARNING To avoid the risk of being burned, do not touch the exhaust system when the system is hot. Any service on the exhaust system should be performed when the system is cool. CAUTION Make sure that the exhaust pipe and muffler have enough clearance from the rubber parts and plastic parts to avoid melting.
Page 302: Exhaust Pipe / Muffler Removal And Installation
1K-2 Exhaust System: Exhaust Pipe / Muffler Removal and Installation 7) Remove the muffler (3). B931H21B06002 NOTE Removal Support the muffler to prevent it from falling. 1) Remove the inner fenders and side covers, left and right. Refer to “Front Side Exterior Parts Removal and Installation: in Section 9D”.
Page 303: Exhaust System Inspection
Exhaust System: 1K-3 • Install the exhaust pipe gasket (2) and connector (3). CAUTION Replace the gasket and connector with new ones. I931H11B0009-01 Exhaust System Inspection B931H21B06003 Inspect the exhaust pipe connection and muffler connection for exhaust gas leakage and mounting condition.
Page 304 1K-4 Exhaust System:...
Page 305: Suspension General Diagnosis
Table of Contents 2- i Section 2 Suspension CONTENTS Precautions ..........2-1 Rear Suspension ........2C-1 Precautions............. 2-1 Repair Instructions ..........2C-1 Precautions for Suspension ........2-1 Rear Suspension Components ......2C-1 Rear Suspension Assembly Construction...2C-2 Suspension General Diagnosis....2A-1 Rear Shock Absorber Removal and Diagnostic Information and Procedures....2A-1 Installation ............2C-3 Rear Suspension Inspection .......2C-4...
Page 306: Precautions
2-1 Precautions: Precautions Suspension Precautions Precautions for Suspension B931H22000001 Refer to “General Precautions: in Section 00”. WARNING All suspensions, bolts and nuts are an important part in that it could affect the performance of vital parts. They must be tightened to the specified torque periodically and if the suspension effect is lost, replace it with a new one.
Page 307: Suspension General Diagnosis
Suspension General Diagnosis: 2A-1 Suspension General Diagnosis Suspension Diagnostic Information and Procedures Suspension and Wheel Symptom Diagnosis B931H22104001 Condition Possible cause Correction / Reference Item Wobbly front wheel Distorted wheel rim. Replace. Worn hub bearings. Replace. Defective or incorrect tire. Replace.
Page 308: Front Suspension
2B-1 Front Suspension: Front Suspension Suspension Repair Instructions Front Suspension Components B931H22206001 I931H1220054-02 1. Front shock absorber mounting bolt 10. Suspension arm pivot bolt (Lower) 19. Cotter pin 2. Front shock absorber 11. Suspension arm pivot nut (Lower) : 55 N⋅m (5.5 kgf-m, 40.0 lbf-ft) 3.
Page 309: Front Suspension Assembly Construction
Front Suspension: 2B-2 Front Suspension Assembly Construction B931H22206002 “ a ” “ a ” I931H1220055-01 1. Front shock absorber mounting bolt 11. Inner dust seal : Align the surface of dust seal with the edge of suspension arm. 2. Front shock absorber mounting nut “a”: 6.8 –...
Page 310: Front Shock Absorber Removal And Installation
2B-3 Front Suspension: Front Shock Absorber Removal and Installation Installation B931H22206003 Install the front shock absorber in the reverse order of CAUTION removal. Pay attention to the following point: • Tighten the mounting bolt and nut to the specified Make sure that the vehicle is supported torque.
Page 311: Spring Pre-Load Adjustment
Front Suspension: 2B-4 3) Install the front shock absorber. Refer to “Front 3) Remove the front drive shaft cover (3). Shock Absorber Removal and Installation (Page 2B- 3)”. Spring Pre-load Adjustment B931H22206006 WARNING Be sure to adjust the spring pre-load on the both suspensions equally.
Page 312 2B-5 Front Suspension: 8) Disengage the tie-rod end (8) with the special tool. 11) Remove the steering knuckle (11). WARNING When using the tie-rod end remover, keep clear of the tie-rod end because it may come loose with some force and could strike you. Special tool (A): 09942–72410 (Tie-rod end remover) I931H1220011-03...
Page 313 Front Suspension: 2B-6 • Install the cotter pins (3). • Install the cotter pin (8). CAUTION CAUTION The removed cotter pins (3) must be replaced The removed cotter pin (8) must be replaced with new ones. with a new one. I931H1220013-02 I931H1220015-02 •...
Page 314: Front Hub Bearing Inspection
2B-7 Front Suspension: • Install the wheel hub (10), washer (11) and front hub Front Hub Bearing Inspection B931H22206008 nut (12). Inspect the inner race play of the front hub bearing by hand while they are in the steering knuckle. NOTE Rotate the inner races by hand to inspect for abnormal The conical side of washer (11) faces out...
Page 315 Front Suspension: 2B-8 3) Remove the inner dust seal (3) with the special tool. • Install the snap ring (2) with the special tool. Special tool CAUTION (A): 09913–50121 (Oil seal remover) Never reuse snap ring (2). Special tool : 09900–06108 (Snap ring remover (Close type)) I931H1220021-01 4) Remove the wheel hub bearing (4), using the...
Page 316: Front Suspension Upper / Lower Arm Removal And Installation
2B-9 Front Suspension: • Install a new outer dust seal (4) using a suitable size 5) Remove the suspension upper arm (2) by removing socket wrench. the suspension upper arm pivot bolt (3) and pivot nut (4). CAUTION Replace the outer dust seal (4) with a new one.
Page 317: Steering Knuckle End Inspection
Front Suspension: 2B-10 3) Set the steering knuckle (3) and install the 10) Keep a vehicle on a level ground. Next loosen each suspension upper arm (4). pivot nut and tighten them to the specified torque again. 4) Tighten the suspension upper arm pivot nut (5) and shock absorber mounting nut (6).
Page 318: Steering Knuckle End Removal And Installation
2B-11 Front Suspension: Steering Knuckle End Removal and Installation Lower B931H22206012 • Remove the snap ring (1) with the special tool. Refer to “Front Wheel Hub / Steering Knuckle Removal and Installation (Page 2B-4)” and “Front Suspension Special tool Upper / Lower Arm Removal and Installation (Page 2B- : 09900–06107 (Snap ring remover (Open 9)”.
Page 319: Front Suspension Arm Related Parts Inspection
Front Suspension: 2B-12 • Install the snap ring (2) with the special tool. CAUTION Replace the snap ring (2) with a new one. Special tool : 09900–06107 (Snap ring remover (Open type)) I931H1220042-01 Front Suspension Arm Related Parts Inspection B931H22206013 Refer to “Front Suspension Upper / Lower Arm Removal and Installation (Page 2B-9)”.
Page 320: Front Suspension Upper Arm Bushing And Inner Dust Seal Removal And Installation
2B-13 Front Suspension: Lower arm Inspect the front lower arm (1) and bushings (2) for bend or damage. If any defects are found, replace the defective parts with new ones. Refer to “Front Suspension Lower Arm Bushing Removal and Installation (Page 2B-14)”. I931H1220047-01 Installation 1) Install the front upper arm bushings (1) and inner...
Page 321: Front Suspension Lower Arm Bushing Removal And Installation
Front Suspension: 2B-14 2) Apply grease to the lip of inner dust seals, spacer (1) Installation and inside of dust seals (2). Install the front suspension lower arm bushings with the special tool and hydraulic press. : Grease 99000–25160 (Water resistance grease or equivalent) CAUTION 3) Install the washers (3) to the dust seals (2) and...
Page 322: Specifications
For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List: in Section 0C”. Special Tools and Equipment Recommended Service Material B931H22208001 Material SUZUKI recommended product or Specification Note Grease Water resistance grease or P/No.: 99000–25160...
Page 323: Special Tool
Front Suspension: 2B-16 Special Tool B931H22208002 09900–06107 09900–06108 Snap ring remover (Open Snap ring remover (Close type) type) (Page 2B-11) / (Page 2B-7) / (Page 2B- (Page 2B-11) / (Page 2B-12) / (Page 2B-12) 09913–50121 09913–70210 Oil seal remover Bearing installer set (10 – (Page 2B-7) / (Page 2B- (Page 2B-8) /...
Page 324: Rear Suspension
2C-1 Rear Suspension: Rear Suspension Suspension Repair Instructions Rear Suspension Components B931H22306001 I931H1230056-06 1. Rear shock absorber 9. Spacer 17. Rear stabilizer joint nut 2. Rear stabilizer bar 10. Rear suspension arm (Lower) 18. Rear suspension knuckle nut 3. Rear stabilizer bushing 11.
Page 325: Rear Suspension Assembly Construction
Rear Suspension: 2C-2 Rear Suspension Assembly Construction B931H22306002 “ a ” “ a ” “ a ” “ a ” I931H1230060-04 1. Rear suspension arm pivot nut (Upper) 8. Rear hub bearing 2. Rear suspension arm pivot nut (Lower) “a”: 6.8 – 7.2 mm (0.27 –0.28 in) 3.
Page 326: Rear Shock Absorber Removal And Installation
2C-3 Rear Suspension: “a ” “ a ” “ a ” “ a ” I931H1230061-05 1. Suspension knuckle nut (Upper) 8. Stabilizer bushing 2. Suspension knuckle nut (Lower) “a”: 6.8 – 7.2 mm (0.27 – 0.28 in) 3. Inner dust seal : 60 N⋅m (6.0 kgf-m, 43.5 lbf-ft) : Align the surface of dust seal with the edge of suspension arm.
Page 327: Rear Suspension Inspection
Rear Suspension: 2C-4 4) Remove the shock absorber (2) by removing the 2) Inspect the rear shock absorber for damage and oil shock absorber upper and lower mounting bolt and leakage, and absorber bushing for wear or damage. nut. If any defects are found, replace the rear shock absorber with a new one.
Page 328: Rear Wheel Hub / Suspension Knuckle Removal And Installation
2C-5 Rear Suspension: Rear Wheel Hub / Suspension Knuckle Removal 4) Remove the suspension knuckle upper and lower bolts and nuts. and Installation B931H22306007 5) Remove the rear suspension knuckle (6). NOTE The right and left suspension parts are installed procedure for one side is the same as that for the other side.
Page 329: Rear Hub Bearing Inspection
Rear Suspension: 2C-6 • Tighten the rear knuckle nuts (3) to the specified torque. Tightening torque Rear suspension knuckle nut (Upper and Lower) (a): 60 N·m (6.0 kgf-m, 43.5 lbf-ft) I931H1230013-01 Rear Hub Bearing Inspection B931H22306008 Inspect the inner race play of the rear hub bearing by hand while it is in the rear knuckle.
Page 330 2C-7 Rear Suspension: 2) Remove the snap ring (2) with the special tool. Installation Install the hub bearing in the reverse order of removal. Special tool Pay attention to the following points: : 09900–06108 (Snap ring remover (Close • Install the hub bearing (1) using the hydraulic press type)) and special tool.
Page 331: Rear Suspension Arm Upper / Lower Removal And Installation
Rear Suspension: 2C-8 • Install the snap ring (2) with the special tool. • Apply grease to the lip of outer dust seal (4). : Grease 99000–25160 (Water resistance CAUTION grease or equivalent) Never reuse snap ring (2). Special tool : 09900–06108 (Snap ring remover (Close type)) I831G1230023-02...
Page 332 2C-9 Rear Suspension: 5) Disconnect the stabilizer joint (3) from the rear • Apply thread lock to the shock absorber mounting suspension lower arm (4). bolts. 6) Remove the shock absorber mounting lower bolt (5) : Thread lock cement 99000–32030 and nut (6).
Page 333: Rear Suspension Arm Related Parts Inspection
Rear Suspension: 2C-10 • Keep a vehicle on a level ground. Next loosen each Lower Arm pivot nut and tighten them to the specified torque 1) Inspect the following parts for wear or damage. If any again. defects are found, replace defective parts with new ones.
Page 334: Rear Suspension Upper Arm Bushing And Inner Dust Seal Removal And Installation
2C-11 Rear Suspension: Suspension Knuckle Rear Suspension Upper Arm Bushing and Inner Dust Seal Removal and Installation 1) Inspect the following parts for wear or damage. If any B931H22306012 defects are found, replace defective parts with new Refer to “Rear Suspension Arm Upper / Lower Removal ones.
Page 335: Rear Suspension Lower Arm Bushing And Inner Dust Seal Removal And Installation
Rear Suspension: 2C-12 Installation 2) Apply grease to the lip of inner dust seals, spacer (3) and inside of dust seals (4). 1) Install the rear suspension upper arm bushings (1) and inner dust seals (2) with the special tool and : Grease 99000–25160 (Water resistance suitable socket wrench.
Page 336 2C-13 Rear Suspension: 2) Remove the rear suspension lower arm bushings (4) along with the inner dust seals (5) with the special tools. Special tool : 09923–73210 (Bearing remover) : 09930–30104 (Rotor remover slide shaft) I931H1230040-01 I931H1230038-01 3) Remove the another inner dust seal (6) with the special tool.
Page 337: Rear Suspension Knuckle Bushing And Inner Dust Seal Removal And Installation
Rear Suspension: 2C-14 Rear Suspension Knuckle Bushing and Inner Installation Dust Seal Removal and Installation 1) Install the suspension knuckle bushings (1) and B931H22306014 inner dust seals (2) with the special tool and suitable socket wrench. Refer to “Rear Wheel Hub / Suspension Knuckle Removal and Installation (Page 2C-5)”.
Page 338: Rear Stabilizer Removal And Installation
2C-15 Rear Suspension: 2) Apply grease to the lip of the inner dust seals, spacer 4) Remove the stabilizer bar (3). (1) and inside of dust seals (2). : Grease 99000–25160 (Water resistance grease or equivalent) 3) Install the spacers (1), dust seals (2) and washers (3).
Page 339: Stabilizer Parts Inspection
Rear Suspension: 2C-16 • Install the washers (1) as shown. Stabilizer Bushing / Plate Inspect the bushing and plate for wear or damage. If any defects are found, replace the bushing and/or plate with a new one. I931H1230059-02 • Tighten the stabilizer joint nuts (2) to the specified torque.
Page 340: Specifications
For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List: in Section 0C”. Special Tools and Equipment Recommended Service Material B931H22308001 Material SUZUKI recommended product or Specification Note Grease Water resistance grease or P/No.: 99000–25160...
Page 341: Special Tool
Rear Suspension: 2C-18 Special Tool B931H22308002 09900–06108 09913–50121 Snap ring remover (Close Oil seal remover type) (Page 2C-7) / (Page 2C- (Page 2C-6) / (Page 2C- 09913–70210 09913–75520 Bearing installer set (10 – Bearing installing tool (Page 2C-7) (Page 2C-7) 09923–73210 09924–84510 Bearing remover...
Page 342: Wheels And Tires
2D-1 Wheels and Tires: Wheels and Tires Suspension Precautions Precautions for Wheel and Tire B931H22400001 WARNING • Proper tire pressure and proper tire loading are important factors. Over loading tire can lead to tire failure and loss of vehicle control. •...
Page 343: Front / Rear Wheel Removal And Installation
Wheels and Tires: 2D-2 Front / Rear Wheel Removal and Installation • Tighten the wheel set nuts to the specified torque. B931H22406002 NOTE NOTE Tighten the wheel set nuts diagonally. The front and rear wheels are installed symmetrically and therefore the removal Tightening torque procedure for one side is the same as that for Wheel set nut (Front and Rear) (a): 60 N·m (6.0...
Page 344 2D-3 Wheels and Tires: 4) Separate the tire from the rim using a set of tire 3) Mount the tire on the rim by hand as shown in the levers and rim protectors. figure. CAUTION When using the tire levers, do not scratch or hit the sealing portion (hump) of the wheel or it may cause air-leakage.
Page 345: Specifications
Wheels and Tires: 2D-4 NOTE 6) Adjust the tire pressure to the specified pressure. Check the “rim line” “B” cast on the tire Cold inflation tire pressure sidewalls. It must be equidistant from the Front: 35 kPa (0.35 kgf/cm , 5.1 psi) wheel rim all the way around.
Page 346 2D-5 Wheels and Tires:...
Page 347 Table of Contents 3- i Section 3 Driveline / Axle CONTENTS Precautions ..........3-1 Final Gear Components ........3B-23 Final Gear Construction ........3B-24 Precautions............. 3-1 Final Gear Oil Level Inspection ......3B-25 Precautions for Driveline / Axle ......3-1 Final Gear Oil Replacement......3B-25 Drive Chain / Drive Train / Drive Shaft...
Page 348: Propeller Shafts
3-ii Table of Contents Special Tool ............3C-16 Driven / Drive Bevel Gear Shim Inspection and Adjustment ..........3D-12 Propeller Shafts ........3D-1 Front Propeller Shaft Components....3D-15 Front Propeller Shaft Removal and Repair Instructions ..........3D-1 Installation ............3D-16 Front Output Shaft Components ......3D-1 Front Output Shaft Removal and Installation ..3D-1 Front Propeller Shaft Related Parts Inspection............3D-17...
Page 349: Precautions
Precautions: Precautions Driveline / Axle Precautions Precautions for Driveline / Axle B931H23000001 Refer to “General Precautions: in Section 00”. WARNING Support the vehicle with a jack or wooden block when servicing the drive shafts and drive train.
Page 350: Drive Chain / Drive Train / Drive Shaft
3A-1 Drive Chain / Drive Train / Drive Shaft: Drive Chain / Drive Train / Drive Shaft Driveline / Axle Diagnostic Information and Procedures Drive Shaft Symptom Diagnosis B931H23104001 Condition Possible cause Correction / Reference Item Noisy Drive Shaft Worn drive shaft joints. Replace.
Page 351: Front Drive Shaft Assembly Removal And Installation
1) Remove the boot band of the differential side joint. • Apply grease to the spline of the front drive shafts. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) • Apply grease to the lip of the oil seal and install the front drive shafts to the front differential gear case.
Page 352 3A-3 Drive Chain / Drive Train / Drive Shaft: 2) Slide the boot toward the center of the front drive 6) Remove the boot band of the small diameter side. shaft and remove the stopper ring from the outer race. I931H1310004-02 Assembly CAUTION...
Page 353 Drive Chain / Drive Train / Drive Shaft: 3A-4 2) Install the cage (1) on the shaft. CAUTION Install the cage with the large diameter side “A” facing the shaft end. “B” “A” I831G1310014-01 5) Insert the cage into the outer race and install the new stopper ring to the groove of the outer race.
Page 354: Front Drive Shaft Inspection
3A-5 Drive Chain / Drive Train / Drive Shaft: 8) Install the circlip (2) into the groove of front drive Front Drive Shaft Inspection B931H23106004 shaft spline. Inspect the front drive shaft in the following procedures: CAUTION 1) Remove the front drive shaft assembly. Refer to “Front Drive Shaft Assembly Removal and The removed circlip must be replaced with a Installation (Page 3A-2)”.
Page 355: Rear Drive Shaft Components
Drive Chain / Drive Train / Drive Shaft: 3A-6 Rear Drive Shaft Components B931H23106005 I931H1310013-04 1. Circlip 6. Inner boot band (Small) : Apply grease. 2. Snap ring 7. Drive shaft : Apply water resistance grease. 3. Stopper ring 8. Outer boot band (Small) : Do not reuse.
Page 356: Rear Drive Shaft Disassembly And Assembly
“ a ” new one. • Apply grease to the spline of the rear drive shafts. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) • Apply grease to the lip of the oil seal and install the rear drive shafts to the rear final gear case.
Page 357: Special Tools And Equipment
Drive Chain / Drive Train / Drive Shaft: 3A-8 Special Tools and Equipment Recommended Service Material B931H23108001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010 (Page 3A-2) / (Page 3A- equivalent Water resistance grease or P/No.: 99000–25160...
Page 358: Differential
3B-1 Differential: Differential Driveline / Axle Diagnostic Information and Procedures Drive Train Symptom Diagnosis B931H23204001 Condition Possible cause Correction / Reference Item Engine noisy (Noise Worn or damage drive and driven bevel Replace. seems to came from front/ gears. rear output shaft bevel Excessive backlash.
Page 359: Repair Instructions
Differential: 3B-2 Repair Instructions Front Drive (Differential) Components B931H23206001 I931H1320095-04 1. Front drive (differential) gear case 16. Snap ring 31. Breather rubber case 2. Front drive (differential) gear case cover 17. O-ring 32. Oil drain plug 3. Shim (Right side) 18.
Page 360: Front Drive (Differential) Construction
3B-3 Differential: Front Drive (Differential) Construction B931H23206002 “A” I931H1320001-03 1. Shim : 1.3 N⋅m (0.13 kgf-m, 0.94 lbf-ft) : Apply thread lock to the thread part. 2. Front drive (differential) case cover bolt : 22 N⋅m (2.2 kgf-m, 16.0 lbf-ft) : Apply bond to matching surface.
Page 361: Front Drive (Differential) Gear Oil Level Inspection
Differential: 3B-4 Front Drive (Differential) Gear Oil Level 6) Remove the clamps and disconnect the 4WD/diff- lock actuator lead wire coupler (2). Inspection B931H23206003 Refer to “Front Differential Gear Oil Inspection: in Section 0B”. Front Drive (Differential) Gear Oil Replacement B931H23206004 Refer to “Front Differential Gear Oil Inspection: in Section 0B”.
Page 362: Front Drive (Differential) Assembly Disassembly And Assembly
3B-5 Differential: Installation • After installing the front drive (differential), check the Install the front drive (differential) assembly in the wiring harness routing and pour the front differential reverse order of removal. Pay attention to the following gear oil. Refer to “Wiring Harness Routing points: Diagram: in Section 9A”...
Page 363 Differential: 3B-6 4) Remove the front drive (differential) case housing (3) 6) Remove the diff-lock sleeve (5). with the special tool. 7) Remove the diff-lock fork shaft (6) and diff-lock fork (7). Special tool (A): 09912–34510 (Cylinder disassembly ring tool) I931H1320016-02 8) Remove the snap ring (8).
Page 364 3B-7 Differential: 11) Remove the snap ring (11) and bearing (12). 14) Remove the dust seal cap (16) and dust seal (17). NOTE There is no abnormal noise, the bearing removal is not necessary. Special tool : 09900–06107 (Snap ring remover (Open type)) I931H1320023-01 15) Remove the snap ring (18) and input shaft (19).
Page 365 Differential: 3B-8 17) Remove the snap ring (21) and input shaft bearing (22) with the special tool. NOTE If there is no abnormal noise, the bearing removal is not necessary. Special tool : 09900–06107 (Snap ring remover (Open type)) (D): 09913–60910 (Bearing and gear puller) I931H1320028-02 20) Remove the pinion gear pilot bearing (26) with the special tools.
Page 366 3B-9 Differential: Assembly 4) Install the pinion gear (4) into the front drive (differential) gear case and fix the snap ring (5). CAUTION Special tool The removed oil seals, snap rings and : 09900–06108 (Snap ring remover (Close bearings must be replaced with new ones. type)) 1) Install the bearings (1) with the special tool.
Page 367 (A): 09913–70210 (Bearing installer set (10 – 75)) “ a ” I931H1320093-01 9) Apply a small quantity of grease to the dust seal lip. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) 10) Install the dust seal with the special tool. I931H1320039-01 Special tool “a”: 4 mm (0.1574 in)
Page 368 3B-11 Differential: 14) Install the differential fork (14) and screw shaft (15). 17) Install the diff-lock fork (17) and diff-lock sleeve (18). NOTE When installing the screw shaft (15), align the convex part “A” of differential fork (14) and groove “B” of screw shaft (15). I931H1320043-01 18) Install the front drive (differential) gear assembly (19).
Page 369 21) Apply bond to the mating surface of the front drive 24) Apply grease to the O-ring and lip of oil seal. (differential) case. CAUTION : Sealant 99000–31110 (SUZUKI BOND Replace the O-ring with a new one. No.1215 or equivalent) : Grease 99000–25010 (SUZUKI SUPER...
Page 370: Front Drive (Differential) Related Parts Inspection
3B-13 Differential: Front Drive (Differential) Related Parts Differential Fork and Diff-lock Fork Inspect the shifting forks for wear or damage. If any Inspection B931H23206007 defects are found, replace the shifting forks with new Refer to “Front Drive (Differential) Assembly ones. Disassembly and Assembly (Page 3B-5)”.
Page 371 Differential: 3B-14 Diff-lock Cam Input Shaft Inspect the diff-lock cam for wear or damage. If any Inspect the input shaft for wear or damage. defects are found, replace the diff-lock cam with a new Inspect the input shaft bearing for abnormal noise and one.
Page 372: Breather Rubber Case Inspection
3B-15 Differential: Breather Rubber Case Inspection NOTE B931H23206008 At this time, it is not necessary to apply a Inspect the breather rubber case for wear or damage. If sealant to the mating surface of the gear any defects are found, replace the breather rubber case case.
Page 373 Differential: 3B-16 • Remove the dial gauge and turn the front drive Left Side Shim Selection (differential) gear 120°, then measure the backlash. • Install the right side shim(s) (1) and front drive Repeat this procedure once more and compare the (differential) gear assembly.
Page 374 3B-17 Differential: • Remove the front drive (differential) case. Tooth Contact • Measure the thickness of compressed solder (2) with CAUTION the micrometer. Make sure to check the backlash after the Special tool tooth contact has been adjusted, since it may (A): 09900–20205 (Micrometer (0 –...
Page 375: 2Wd / 4Wd / Diff-Lock System Inspection
Differential: 3B-18 • Rotate the final drive (differential) gear several turns in 2WD / 4WD / Diff-lock System Inspection B931H23206010 each direction. This will provide a contact pattern on Actuator the coated teeth of final drive (differential) gear. Refer to “Front Drive (Differential) Assembly Removal •...
Page 376 3B-19 Differential: 2) Inspect the diff-lock actuator diode (1) as shown in 3) Inspect the 2WD/4WD/diff-lock switch for continuity the neutral relay diode inspection. Refer to “Neutral with a tester. If any abnormality is found, replace the Relay Diode Inspection: in Section 1I”. left handlebar switch assembly with a new one.
Page 377 Differential: 3B-20 3) Click the “Date monitor” button (3). I831G1320073-02 4) Check that both “Differential lock position switch signal” and “Differential lock switch signal” are “Open”. I931H1320097-01 5) Turn the transfer selecting switch (diff-lock position switch and diff-lock switch) ON position. 6) Check that both “Differential lock position switch signal”...
Page 378 3B-21 Differential: Drive Relay Diff-lock Relay 1) Remove the seat. Refer to “Front Side Exterior 1) Remove the left side cover and engine side cover. Parts Removal and Installation: in Section 9D”. Refer to “Front Side Exterior Parts Removal and Installation: in Section 9D”...
Page 379: Rear Drive Breather Hose Routing Diagram
Differential: 3B-22 Rear Drive Breather Hose Routing Diagram B931H23206011 “A” “ a ” “B” I831G1320145-02 1. Breather hose 6. V-belt cooling duct 2. Rear drive assembly “A”: Press the breather hose between the fuel tank lower cover and belt cooling duct. 3.
Page 380: Final Gear Components
3B-23 Differential: Final Gear Components B931H23206012 I831G1320080-08 1. Final gear case 11. Shim : 100 N⋅m (10.0 kgf-m, 72.0 lbf-ft) 2. Final gear case cover 12. Final drive gear : 26 N⋅m (2.6 kgf-m, 19.0 lbf-ft) 3. Final driven gear 13.
Page 381: Final Gear Construction
Differential: 3B-24 Final Gear Construction B931H23206013 “A” “A” I931H1320084-05 1. Shim (Left side) 6. Lock-nut : 55 N⋅m (5.5 kgf-m, 40.0 lbf-ft) 2. Shim (Right side) “A”: Matching surface : Apply grease. 3. Final drive gear shim(s) : 26 N⋅m (2.6 kgf-m, 19.0 lbf-ft) : Apply water resistance grease.
Page 382: Final Gear Oil Level Inspection
3B-25 Differential: Final Gear Oil Level Inspection 9) Remove the V-belt outlet cooling duct. Refer to “V- B931H23206014 belt Cooling Duct Removal and Installation: in Refer to “Final Gear Oil Inspection: in Section 0B”. Section 5A”. 10) Disconnect the breather hose (3). Final Gear Oil Replacement B931H23206015 Refer to “Final Gear Oil Inspection: in Section 0B”.
Page 383: Final Gear Assembly Disassembly And Assembly
Differential: 3B-26 Installation • Adjust the rear brake pedal free travel. Refer to “Rear Install the final gear assembly in the reverse order of Brake Pedal / Rear Brake (Parking Brake) Lever removal. Pay attention to the following points: Inspection and Adjustment: in Section 0B”. •...
Page 384 3B-27 Differential: 3) Remove the final gear cover (2) from the final gear 7) Remove the final driven gear bearing (7) with the case, by using two 5 mm screws. special tool. NOTE If there is no abnormal condition, the bearing removal is not necessary.
Page 385 Differential: 3B-28 10) Remove the final driven gear bearing (9) with the 13) Remove the final drive gear (12) and shim(s) (13). suitable tool. NOTE If there is no abnormal condition, the bearing removal is not necessary. I831G1320104-01 14) Unlock the final drive gear nut (14) with a chisel. I831G1320101-01 11) Unlock the final drive stopper (10) with a chisel.
Page 386 3B-29 Differential: 16) Remove the washer (15). 19) Remove the final drive gear bearing (18) with the special tool. NOTE If there is no abnormal condition, the bearing removal is not necessary. Special tool (I): 09921–20240 (Bearing remover set) I831G1320107-02 17) Remove the bearing (16) and the upper inner race from the pinion gear with the special tool and suitable tool.
Page 387 Differential: 3B-30 • Install the final drive gear bearing (1) to the final gear • Tighten the final drive gear nut (4) to the specified case with the special tool. torque with the special tool. Special tool Tightening torque (A): 09913–70210 (Bearing installer set (10 – Final drive gear nut (a): 100 N·m (10.0 kgf-m, 72.5 75)) lbf-ft)
Page 388 3B-31 Differential: • Tighten the final drive gear bearing stopper (7) to the • Install the oil seal to the final gear case with the specified torque with the special tool. special tool. Special tool CAUTION (G): 09951–15810 (Brake disk dust cover The removed final drive gear bearing stopper installer) must be replaced with a new one.
Page 389: Final Gear Related Parts Inspection
• Install the O-ring to the final gear cover (11). defects are found, replace the oil seals with new ones. • Apply a small quantity of grease to the O-ring. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I831G1320127-01...
Page 390: Final Gear Shim Inspection And Selection
3B-33 Differential: Final Driven / Drive Gear Bering Final Driven Gear Inspect the bearings for abnormal noise and smooth Inspect the final driven gear for wear or damage. If any rotation. Replace the bearings if there is anything defects are found, replace drive and driven gear as a unusual.
Page 391 Differential: 3B-34 • Install the left side shim(s) and final driven gear. Left Side Shim Selection • Put a few pieces of solder (O.D.: 1.2 – 1.5 mm x L: 6 mm) on the back side of final driven gear, as shown in the figure.
Page 392 3B-35 Differential: • Remove the final gear cover. • Clean and degrease several teeth on the final drive gear and final driven gear, and then apply a coating of • Measure the thickness of compressed solder with the machinist’s layout dye or paste to several teeth of the micrometer.
Page 393 Differential: 3B-36 • Install the final gear cover, and then tighten the bolts CAUTION to the specified torque diagonally. Refer to “Final Gear Make sure to check the backlash and shim Assembly Disassembly and Assembly (Page 3B-26)”. thickness after the tooth contact has been NOTE adjusted, since it may have changed.
Page 394: Specifications
3B-37 Differential: Specifications Service Data B931H23207001 Drive Train Unit: mm (in) Item Standard Limit Front drive (differential) gear backlash 0.05 – 0.20 (0.0020 – 0.0080) — Without gear cover 0.02 – 0.06 (0.0008 – 0.0024) — Front gear specification backlash Gear cover assembled 0.08 –...
Page 395: Special Tools And Equipment
Differential: 3B-38 Special Tools and Equipment Recommended Service Material B931H23208001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010 (Page 3B-10) / equivalent (Page 3B-12) / (Page 3B-32) Water resistance grease P/No.: 99000–25160 (Page 3B-5) /...
Page 396 3B-39 Differential: 09913–60910 09913–61510 Bearing and gear puller Bearing puller (Page 3B-8) / (Page 3B- (Page 3B-29) 8) / (Page 3B-29) 09913–70210 09913–75520 Bearing installer set (10 – Bearing installing tool (Page 3B-7) / (Page 3B- (Page 3B-30) 8) / (Page 3B-9) / (Page 3B-9) / (Page 3B-...
Page 397: Transfer
Transfer: 3C-1 Transfer Driveline / Axle Diagnostic Information and Procedures Transfer Symptom Diagnosis B931H23304001 Condition Possible cause Correction / Reference Item Engine is noisy (Noise Worn or rubbing gear. Replace. seems to come from the Worn transfer driveshaft or countershaft. Replace shaft. transfer) Worn bearing.
Page 398: Repair Instructions
3C-2 Transfer: Repair Instructions Transfer Components B931H23306001 I931H1330001-04 1. Washer 15. Select sliding dog 29. Drive gear No. 2 2. Reverse idle gear 16. Reverse select spacer 30. Snap ring 3. Reverse idle gear shaft 17. Reverse driven gear 31. Output shaft bearing (Right side) 4.
Page 399: Transfer Removal And Installation
Transfer: 3C-3 Transfer Removal and Installation 6) Remove the countershaft assembly (4) and reverse B931H23306002 idle gear (5). Removal 1) Remove the engine assembly from the frame. Refer to “Engine Assembly Removal: in Section 1D”. 2) Remove the engine top side. Refer to “Engine Top Side Disassembly: in Section 1D”.
Page 400 3C-4 Transfer: 9) Remove the drive bevel gear (9). Refer to “Rear • Install the transfer output shaft assembly (1) with a Output Shaft / Drive Bevel Gear Removal and plastic mallet. Installation: in Section 3D”. I931H1330011-01 I931H1330008-01 • Install the shim(s) (2), drive bevel gear (3) and washer 10) Remove the transfer output shaft assembly (10) with (4).
Page 401 Transfer: 3C-5 NOTE • Install the gearshift fork (9) and reverse gearshift fork (10). After the backlash and tooth contact have been checked or adjusted, lock the drive NOTE bevel gear nut with a center punch. Refer to Identify the shape of the shift forks and “Driven / Drive Bevel Gear Shim Inspection install them properly.
Page 402: Transfer Construction
3C-6 Transfer: Transfer Construction B931H23306003 I931H1330052-01 1. Countershaft 2. Driveshaft 3. Snap ring : Assembly snap ring with edge side out. Transfer Disassembly and Assembly • Remove the lock washer (1) by aligning the teeth “A” B931H23306004 of the lock washer with the spline grooves “B”. Refer to “Transfer Removal and Installation (Page 3C- 3)”.
Page 403 Transfer: 3C-7 Assembly • Fit the lock washer (4) onto the lock washer (3). NOTE • When reassembling the driven gears, attention must be given to the locations and positions of washers. The cross sectional view shows the correct position of the snap ring.
Page 404: Transfer Related Bearing Removal And Installation
3C-8 Transfer: Transfer Related Bearing Removal and Installation B931H23306005 Refer to “Oil Seal / Bearing (Crankcase and Generator Cover) Removal and Installation: in Section 1D” and “Transfer Disassembly and Assembly (Page 3C-6)”. Transfer Related Parts Inspection B931H23306006 Refer to “Transfer Removal and Installation (Page 3C-3)” and “Transfer Disassembly and Assembly (Page 3C-6)”.
Page 405: Gearshift Cam Components
Transfer: 3C-9 Driveshaft bearing / Countershaft bearing / Gearshift Oil Seal Refer to “Oil Seal / Bearing (Crankcase and bearing Refer to “Oil Seal / Bearing (Crankcase and Generator Cover) Removal and Installation: in Generator Cover) Removal and Installation: in Section 1D”.
Page 406: Gearshift System Construction
3C-10 Transfer: Gearshift System Construction B931H23306008 I931H1330054-01 1. Gearshift shaft No. 1 3. Snap ring : Assemble snap ring with sharp edge side out. 2. Gearshift cam Gearshift Cam Disassembly and Assembly 1) Remove the snap ring (1) and gearshift cam (2). B931H23306009 Special tool Refer to “Transfer Removal and Installation (Page 3C-...
Page 407: Gear Position (Gp) Switch Inspection
Transfer: 3C-11 2) Remove the spring (3) and washer (4). • When installing a new snap ring (2), pay attention to its direction. Fit it to the side where the thrust is as shown in the figure. Special tool : 09900–06107 (Snap ring remover (Open type)) “A”...
Page 408: Hi / Lo Position Diode Inspection
(2). • Apply grease to the O-ring. CAUTION Replace the O-ring with a new one. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I931H1330035-01 3) Inspect the HI position diode (1) and LO position diode (2) as shown in the neutral relay diode inspection.
Page 409: Gearshift Shaft No. 2 / Gearshift Cam Plate Removal And Installation
Transfer: 3C-13 Gearshift Shaft No. 2 / Gearshift Cam Plate 5) Remove the gearshift cam stopper plate (7). Removal and Installation 6) Remove the gearshift cam stopper (8). B931H23306013 Removal Refer to “Shift Lever Assembly Removal and Installation: in Section 5A”. 1) Drain engine oil.
Page 410: Gearshift Linkage Inspection
3C-14 Transfer: • Check the gearshift cam stopper moves smoothly. • Locate the gearshift cam in the neutral position. • Install the gearshift cam stopper plate (5). NOTE • Align the gearshift cam pin “B” with the gearshift cam stopper plate hole “C”. •...
Page 411: Gearshift Shaft Oil Seal Removal And Installation
Transfer: 3C-15 Gearshift Shaft Oil Seal Installation Inspect the gearshift shaft oil seal lip for damage or Install the oil seal in the reverse order of removal. Pay wear. If any defect are found, replace the oil seal with a attention to the following points: new one.
Page 412: Tightening Torque Specifications
For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List: in Section 0C”. Special Tools and Equipment Recommended Service Material B931H23308001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010...
Page 413: Propeller Shafts
Propeller Shafts: 3D-1 Propeller Shafts Driveline / Axle Repair Instructions Front Output Shaft Components B931H23406001 I931H1340001-01 1. Front output shaft bearing (Rear) 7. Front drive collar assembly 2. Front output shaft : Apply grease. 3. Front output shaft housing : Apply water resistance grease. 4.
Page 414: Front Output Shaft Disassembly And Assembly
2) Remove the front drive collar assembly (3), front output shaft housing (4) and O-ring (5). CAUTION Replace the O-ring (1) with a new one. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I931H1340008-01 3) Remove the front drive collar (6) from the output oil seal plate (7) with the special tool.
Page 415 Propeller Shafts: 3D-3 5) Remove the oil seal (9) with the special tool. 8) Remove the front output shaft bearing (rear) with the special tools. Special tool (B): 09913–50121 (Oil seal remover) NOTE If there is no abnormal noise, the bearing removed is not necessary.
Page 416 – 75)) – 75)) 7) Install the O-ring (8) to the front drive collar (6). 8) Apply grease to the O-ring (8). : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I931H1340015-01 3) Install the washer (3) and snap ring (4).
Page 417: Front Output Shaft Related Parts Inspection
Propeller Shafts: 3D-5 Front Output Shaft Related Parts Inspection Oil Seal B931H23406004 Visually inspect the oil seal for damage, with particular Refer to “Front Output Shaft Disassembly and Assembly attention given to the lip. (Page 3D-2)”. Replace the oil seal that shows indications of leakage. Front Output Shaft Inspect the front output shaft for distortion.
Page 418: Rear Output Shaft Components
3D-6 Propeller Shafts: Rear Output Shaft Components B931H23406005 I931H1340023-02 1. Rear output shaft drive bevel gear 7. Shim 13. Yoke 2. Shim(s) 8. Bearing : 100 N⋅m (10.0 kgf-m 72.5 lbf-ft) 3. Rear output shaft driven bevel gear 9. Oil seal : Apply water resistance grease.
Page 419 Propeller Shafts: 3D-7 4) Remove the rear output shaft (1). 4) Remove the washer (2), drive bevel gear (3) and shim(s) (4). I931H1340025-01 5) Remove the C-ring (2). I931H1340028-01 5) Remove the transfer output shaft assembly (5) with a plastic mallet. I931H1340026-01 Drive bevel gear I931H1340029-01...
Page 420: Rear Output Shaft Disassembly And Assembly
3D-8 Propeller Shafts: • Hold the transfer output driven gear with the special • After installed rear output shaft, check the backlash tools and tighten the drive bevel gear nut (2) to the and tooth contact. Refer to “Rear Output Shaft / Drive specified torque.
Page 421 Propeller Shafts: 3D-9 6) Remove the universal joint (3). 10) Unlock the rear output shaft driven gear nut with a chisel. I931H1340035-01 7) Unlock the rear output shaft nut with a chisel. I931H1340039-01 11) With the rear output shaft held immovable with a vise, remove the rear output shaft driven gear nut.
Page 422 3D-10 Propeller Shafts: Assembly • Lock the rear output shaft driven gear nut (3) with a Assemble the rear output shaft in the reverse order of center punch. disassembly. Pay attention to the following points: NOTE Apply engine oil to each running part before reassembling.
Page 423 If a large resistance is felt to • Apply grease to the bearings and their lip of dust seal. movement, tap the bearing with a plastic mallet lightly. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I931H1340052-04...
Page 424: Rear Output Shaft Related Parts Inspection
3D-12 Propeller Shafts: Rear Output Shaft Related Parts Inspection Bearing B931H23406008 Inspect the rear output shaft bearing and rear driven Refer to “Rear Output Shaft Disassembly and Assembly bevel gear bearing for abnormal noise and smooth (Page 3D-8)”. rotation. If any defects are found, replace the bearing with a new one.
Page 425 Propeller Shafts: 3D-13 2) Set the dial gauge on the drive bevel gear as shown. Rear output shaft bevel gear backlash Standard: 0.03 – 0.15 mm (0.0001 – 0.006 in) Special tool Backlash Shim adjustment (B): 09900–20607 (Dial gauge) Under 0.03 mm (C): 09900–20701 (Dial gauge chuck) Increase shim thickness (0.001 in)
Page 426 3D-14 Propeller Shafts: Tooth Contact Tooth contact Shim adjustment Contact at tooth top [A] Increase shim thickness CAUTION Contact at tooth root [C] Decrease shim thickness Make sure to check the backlash after the tooth contact has been adjusted, since it may have changed.
Page 427: Front Propeller Shaft Components
Propeller Shafts: 3D-15 Part No. Shim thickness Part No. Shim thickness 24935-03G50-055 0.550 mm (0.0217 in) 24935-03G50-110 1.100 mm (0.0433 in) 24935-03G50-058 0.575 mm (0.0226 in) 24935-03G50-113 1.125 mm (0.0443 in) 24935-03G50-060 0.600 mm (0.0236 in) 24935-03G50-115 1.150 mm (0.0453 in) 24935-03G50-063 0.625 mm (0.0246 in) 24935-03G50-118...
Page 428: Front Propeller Shaft Removal And Installation
3D-16 Propeller Shafts: Front Propeller Shaft Removal and Installation B931H23406011 Removal 1) Remove the front drive (differential) assembly. Refer to “Front Drive (Differential) Assembly Removal and Installation: in Section 3B”. 2) Remove the front propeller shaft spring (1) and front propeller shaft boot (2).
Page 429: Front Propeller Shaft Related Parts Inspection
Propeller Shafts: 3D-17 4) Apply grease (approx. 4 grams) to the spline. Front Propeller Shaft Related Parts Inspection B931H23406012 : Grease 99000–25160 (Water resistance grease or equivalent) Front Propeller Shaft Inspect the front propeller shaft for wear or damage. If any defects are found, replace the front propeller shaft with a new one.
Page 430: Rear Propeller Shaft Components
3D-18 Propeller Shafts: Universal Joint Boots Inspect the play by turning the universal joint. If Inspect the front propeller shaft boot and universal joint excessive play is noted, replace it with a new one. boot for crack or damage. If any defects are found, replace the defect part with a new one.
Page 431: Rear Propeller Shaft Removal And Installation
Propeller Shafts: 3D-19 Rear Propeller Shaft Removal and Installation 5) Draw out the rear propeller shaft (4). B931H23406014 Removal 1) Remove the final gear assembly. Refer to “Final Gear Assembly Removal and Installation: in Section 3B”. 2) Remove the rear propeller shaft joint (1). I931H1340077-01 6) Loosen the boot clamp screw and remove the rear propeller shaft boot (5).
Page 432 3D-20 Propeller Shafts: 9) Remove the circlips (8) from the universal joint. Installation CAUTION The removed lock-nut, circlips and O-ring must be replaced with new ones. 1) Apply grease to lip of the oil seal. : Grease 99000–25160 (Water resistance grease or equivalent) I931H1340081-01 10) Remove the bearings (9) by tapping with the special...
Page 433 Propeller Shafts: 3D-21 6) Install the yoke (4). 10) Install the O-ring (9) to the rear propeller shaft. 7) Install the bearings (5) by tapping with the special tool. Special tool (A): 09913–70210 (Bearing installer set (10 – 75)) I931H1340088-02 11) Fit the rear propeller shaft joint boot (10) to the rear propeller shaft groove.
Page 434: Rear Propeller Shaft Related Parts Inspection
3D-22 Propeller Shafts: 16) Install the O-ring (13) to the rear propeller shaft joint (14). 17) Apply grease (approx. 4 grams) to the spline of rear propeller shaft joint. : Grease 99000–25160 (Water resistance grease or equivalent) I931H1340095-01 Boots Inspect the rear output joint boot and propeller shaft joint boot for crack or damage.
Page 435: Specifications
Propeller Shafts: 3D-23 2) Insert the universal joint to the bearing and check the Rear Propeller Shaft Spring play by turning the universal joint, as shown in the Inspect the rear propeller shaft spring for wear or figure. If excessive play is found, replace the damage.
Page 436: Special Tools And Equipment
3D-24 Propeller Shafts: Special Tools and Equipment Recommended Service Material B931H23408001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010 (Page 3D-2) / (Page 3D- equivalent 4) / (Page 3D-4) / (Page 3D-11) Water resistance grease or P/No.: 99000–25160...
Page 437: Special Tool
Propeller Shafts: 3D-25 Special Tool B931H23408002 09900–06107 09900–06108 Snap ring remover (Open Snap ring remover (Close type) type) (Page 3D-2) (Page 3D-3) / (Page 3D- 09900–20607 09900–20701 Dial gauge Dial gauge chuck (Page 3D-13) (Page 3D-13) 09913–50121 09913–70210 Oil seal remover Bearing installer set (10 –...
Page 438 3D-26 Propeller Shafts:...
Page 439: Brake Control System And Diagnosis
Table of Contents 4- i Section 4 Brake CONTENTS Precautions ..........4-1 Repair Instructions ..........4B-1 Front Brake Components ........4B-1 Precautions............. 4-1 Front Brake Pad Inspection.........4B-2 Precautions for Brake System ......4-1 Front Brake Pad Replacement......4B-2 Brake Fluid Information ......... 4-1 Front Brake Caliper Removal and Installation..4B-3 Front Brake Caliper Disassembly and Brake Control System and Diagnosis ...
Page 440 4-ii Table of Contents Parking / Rear Brake Lever Removal and Specifications ............4D-5 Installation ............4D-4 Tightening Torque Specifications......4D-5 Parking / Rear Brake Light Switch Inspection ..4D-4 Special Tools and Equipment ......4D-5 Parking / Rear Brake Relay Inspection ....4D-4 Recommended Service Material ......4D-5...
Page 441: Precautions
Precautions: Precautions Brake Precautions Precautions for Brake System B931H24000001 Refer to “General Precautions: in Section 00”. Brake Fluid Information B931H24000002 WARNING • This brake system is filled with an ethylene glycol-based DOT 4 brake fluid. Do not use or mix different types of fluid, such as silicone-based or petroleum-based.
Page 442: Brake Control System And Diagnosis
4A-1 Brake Control System and Diagnosis: Brake Control System and Diagnosis Brake Schematic and Routing Diagram Front Brake Hose Routing Diagram B931H24102001 “A” “D” “B” “C” “D” “F” “E” “D” I931H1410043-05 1. Master cylinder 11. Suspension upper arm 2. Front brake hose No. 1 12.
Page 443: Rear Brake Cable Routing Diagram
Brake Control System and Diagnosis: 4A-2 Rear Brake Cable Routing Diagram B931H24102002 “A” I931H1410044-02 1. Rear brake cable 3. Rear brake pedal 5. Washer “A”: Fix the rear brake cable to the footrest bar with clamp. 2. Adjust nut 4. Pin 6.
Page 444: Diagnostic Information And Procedures
4A-3 Brake Control System and Diagnosis: Diagnostic Information and Procedures Brake Symptom Diagnosis B931H24104001 Condition Possible cause Correction / Reference Item Insufficient brake power Leakage of brake fluid from hydraulic Repair or replace. system. Worn pads or friction plate. Replace. Oil adhesion on friction surface of pads.
Page 445: Rear Brake Light Switch Inspection
Brake Control System and Diagnosis: 4A-4 Rear Brake Light Switch Inspection Parking / Rear Brake Light Switch Inspection B931H24106003 B931H24106005 Inspect the rear brake light switch in the following Inspect the parking/rear brake light switch in the procedures: following procedures: 1) Remove the left front inner fender.
Page 446: Air Bleeding From Front Brake Fluid Circuit
4A-5 Brake Control System and Diagnosis: Air Bleeding from Front Brake Fluid Circuit 4) Loosen the air bleeder valve by turning it a quarter of B931H24106009 a turn so that the brake fluid runs into the receptacle, Air trapped in the brake fluid circuit acts like a cushion to this will remove the tension of the brake lever absorb a large proportion of the pressure developed by causing it to touch the handlebar grip.
Page 447: Brake Fluid Replacement
Brake Control System and Diagnosis: 4A-6 Brake Fluid Replacement 7) Loosen the air bleeder valve and pump the brake B931H24106010 lever until the old brake fluid flows out of the brake CAUTION system. • Make sure that the vehicle is supported securely.
Page 448: Front Brake Hose Removal And Installation
4A-7 Brake Control System and Diagnosis: Front Brake Hose Removal and Installation 3) Bleed air from the front brake system. Refer to “Air B931H24106011 Bleeding from Front Brake Fluid Circuit (Page 4A- Removal 5)”. 4) Install the front fender. Refer to “Front Side CAUTION Exterior Parts Removal and Installation: in Make sure that the vehicle is supported...
Page 449 Brake Control System and Diagnosis: 4A-8 6) Remove the rear brake cable (6). Installation 1) Install the rear brake cable as shown in the rear brake cable routing diagram. Refer to “Rear Brake Cable Routing Diagram (Page 4A-2)”. 2) Install the spring as shown in the figure. NOTE The large diameter “a”...
Page 450: Front Brake Master Cylinder Components
4A-9 Brake Control System and Diagnosis: Front Brake Master Cylinder Components B931H24106013 I931H1410047-01 1. Reservoir tank cap 7. Brake hose union bolt : 6 N⋅m (0.6 kgf-m, 4.5 lbf-ft) 2. Diaphragm 8. Brake lever : Apply silicone grease. 3. Plate 9.
Page 451 Brake Control System and Diagnosis: 4A-10 4) Place a rag underneath the brake hose union bolt (2) on the master cylinder to catch any spilt brake fluid. “A” 5) Remove the brake hose union bolt (2) and disconnect the brake hose. “B”...
Page 452: Front Brake Master Cylinder / Brake Lever Disassembly And Assembly
4A-11 Brake Control System and Diagnosis: Front Brake Master Cylinder / Brake Lever 4) Remove the following parts from the master cylinder. Disassembly and Assembly • Secondary cup (7) B931H24106015 • Piston (8) Refer to “Front Brake Master Cylinder Assembly Removal and Installation (Page 4A-9)”.
Page 453: Front Brake Master Cylinder Parts Inspection
• Apply grease to the brake lever pivot bolt. • Apply grease to the contact point between piston and brake lever. I649G1410027-02 : Grease 99000–25100 (SUZUKI Silicone Piston Grease or equivalent) Inspect the piston surface for any scratches or other damage.
Page 454: Rear Brake Pedal Construction
4A-13 Brake Control System and Diagnosis: Rear Brake Pedal Construction B931H24106017 “b” “ c ” “B” “A” “B” “A” “ a ” I931H1410048-03 1. Rear brake pedal 6. Rear brake pedal screw “B”: Anchoring point (Pedal side) 2. Rear brake light switch “a”: 12.5 –...
Page 455 Brake Control System and Diagnosis: 4A-14 5) Remove the rear brake pedal shaft (3). CAUTION 6) Remove the rear brake pedal (4) and rear brake Never reuse the removed dust seals with new pedal spring (5). ones. : Grease 99000–25160 (Water resistance grease or equivalent) I931H1410033-01 7) Remove the dust seals (6) if necessary.
Page 456: Specifications
4A-15 Brake Control System and Diagnosis: Specifications Service Data B931H24107001 Brake Unit: mm (in) Item Standard Limit Rear brake pedal height 12.5 – 22.5 (0.5 – 0.9) — Front master cylinder bore 12.700 – 12.743 (0.5000 – 0.5017) — Front master cylinder piston diam. 12.657 –...
Page 457: Special Tool
Brake Control System and Diagnosis: 4A-16 Special Tools and Equipment Recommended Service Material B931H24108001 Material SUZUKI recommended product or Specification Note Brake fluid DOT 4 — (Page 4A-6) / (Page 4A- Grease SUZUKI Silicone Grease or P/No.: 99000–25100 (Page 4A-12)
Page 458: Front Brakes
4B-1 Front Brakes: Front Brakes Brake Precautions Precautions for Front Brakes B931H24200001 WARNING When servicing the front brake system, place the vehicle on a level ground and support the vehicle with a jack. NOTE The right and left calipers, brake pads and discs are installed symmetrically and therefore the removal procedure for one side is the same as that for the other side.
Page 459: Front Brake Pad Inspection
Front Brakes: 4B-2 Front Brake Pad Inspection CAUTION B931H24206002 The extent of brake pads wear can be checked by Do not operate the brake lever while observing the grooved limit line “A” on the pads. When dismounting the pads. the wear exceeds the grooved limit line, replace the pads with new ones.
Page 460: Front Brake Caliper Removal And Installation
4B-3 Front Brakes: 7) Apply a small quantity of thread lock to the brake pad 4) Remove the brake caliper by removing the brake mounting pins (1). caliper mounting bolts (2). : Thread lock cement 99000–32050 (THREAD LOCK CEMENT 1342 or equivalent) 8) Tighten the front brake pad mounting pins (1) to the specified torque.
Page 461: Front Brake Caliper Disassembly And Assembly
Front Brakes: 4B-4 • After setting the brake hose union to the stopper, 3) Remove the caliper holder (2) and rubber boots (3) tighten the union bolt (3) to the specified torque. from brake caliper. CAUTION The seal washers (4) should be replaced with the new ones to prevent fluid leakage.
Page 462 I931H1420026-01 • Apply silicon grease to the two pins. : Grease 99000–25100 (SUZUKI SILICONE GREASE or equivalent) • Install the brake caliper holder (6) to the brake caliper (7).
Page 463: Front Brake Caliper Parts Inspection
Front Brakes: 4B-6 Front Brake Caliper Parts Inspection Brake Pad Mounting Pin B931H24206006 Inspect the brake pad mounting pin for wear or other Refer to “Front Brake Caliper Disassembly and damage. If any damage is found, replace the mounting Assembly (Page 4B-4)”. pin with a new one.
Page 464: Front Brake Disc Removal And Installation
4B-7 Front Brakes: Front Brake Disc Removal and Installation 2) Check the brake disc for damage or cracks and B931H24206007 measure the thickness using the micrometer. 3) Replace the brake disc if the thickness is less than Removal the service limit or if detect is found. 1) Remove the front wheel assembly.
Page 465: Specifications
For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List: in Section 0C”. Special Tools and Equipment Recommended Service Material B931H24208001 Material SUZUKI recommended product or Specification Note Brake fluid DOT 4 — (Page 4B-5) /...
Page 466: Special Tool
4B-9 Front Brakes: Special Tool B931H24208002 09900–20205 09900–20607 Micrometer (0 – 25 mm) Dial gauge (Page 4B-7) (Page 4B-7) 09900–20701 Dial gauge chuck (Page 4B-7)
Page 467: Rear Brakes
Rear Brakes: 4C-1 Rear Brakes Brake Precautions Precautions for Rear Brake B931H24300001 WARNING When servicing the rear brake system, place the vehicle on a level ground and support the vehicle with a jack. Repair Instructions Rear Brake Components B931H24306001 I931H1430023-01 1.
Page 468: Rear Brake Friction Plate Inspection
4C-2 Rear Brakes: Rear Brake Friction Plate Inspection Installation B931H24306002 • Fit the rear brake case gasket (1). Refer to “Rear Brake Friction Plate Wear Limit Inspection: in Section 0B”. CAUTION Replace the gasket (1) with a new one. Rear Brake Friction Plate Replacement B931H24306003 Refer to “Rear Brake Disassembly and Assembly (Page 4C-3)”.
Page 469: Rear Brake Disassembly And Assembly
Rear Brakes: 4C-3 • Install the return spring (3) and lining indicator (4). Rear Brake Disassembly and Assembly B931H24306005 Refer to “Rear Brake Assembly Removal and Installation NOTE (Page 4C-2)”. Align the boss of lining indicator (4) with wide spline on the brake cam shaft. Disassembly 1) Remove the gasket (1) and dowel pins (2).
Page 470 4C-4 Rear Brakes: 5) Unlock the nut with a chisel. 8) Remove the oil seal (9) with the special tool. Special tool (B): 09913–50121 (Oil seal remover) 9) Remove the oil seal (10). I831G1430014-01 6) Remove the rear drive gear shaft nut (6) with the special tool and remove the washer (7).
Page 471 Rear Brakes: 4C-5 12) Remove the side plate stopper (13). 13) Remove the side plate (14), pins (15) and springs (16). “A” I831G1430022-04 1. Separator plate 4. Side plate stopper 2. Friction plate “A”: Direction of out side 3. Side plate I831G1430043-03 •...
Page 472 4C-6 Rear Brakes: • Apply grease to the lip of oil seals. • Install the rear propeller shaft coupling (11). • Install the washer (12) and rear drive gear shaft nut : Grease 99000–25160 (Water resistance (13). grease) CAUTION The removed nut (13) must be replaced with a new one.
Page 473: Rear Brake Parts Inspection
Rear Brakes: 4C-7 • Install the balls and rear brake pressure plate (14). Rear Brake Parts Inspection B931H24306006 Refer to “Rear Brake Disassembly and Assembly NOTE (Page 4C-3)”. When installing the rear brake pressure plate (14), align its groove “A” with the cam “B” of Rear Brake Cam Lever rear brake cam shaft (10).
Page 474 4C-8 Rear Brakes: Rear Brake Cam Shaft Inspect the rear brake cam shaft for wear or damage. If any wear or damage is found, replace it with a new one. I831G1430039-01 • Measure the outer distance “a” between the side plates as shown in the figure.
Page 475: Specifications
Rear Brakes: 4C-9 Rear Brake Pressure Plate Inspect the rear brake pressure plate for wear or damage. If any wear or damage is found, replace it with a new one. Inspect the balls for wear or damage. If any wear or damage is found, replace them with new ones.
Page 476: Special Tool
4C-10 Rear Brakes: Special Tools and Equipment Recommended Service Material B931H24308001 Material SUZUKI recommended product or Specification Note Grease Water resistance grease P/No.: 99000–25160 (Page 4C-6) / (Page 4C- Thread lock cement THREAD LOCK CEMENT SUPER P/No.: 99000–32130 (Page 4C-2)
Page 477: Parking Brake
Parking Brake: 4D-1 Parking Brake Brake Schematic and Routing Diagram Parking / Rear Brake Cable Routing Diagram B931H24402001 “A” “B” I931H1440001-03 1. Parking brake cable 4. Wiring harness 2. Parking brake cable guide “A”: Pass the parking brake cable under the wiring harness. 3.
Page 478 4D-2 Parking Brake: “C” I931H1440002-02 1. Parking brake cable 6. Clamp 2. Parking brake cable guide 7. Parking brake cable adjust nut 3. Frame 8. Rear brake assembly 4. Wiring harness “C”: Fix the rubber of parking brake cable with clamp. 5.
Page 479: Repair Instructions
Parking Brake: 4D-3 Repair Instructions Parking / Rear Brake Inspection and 6) Remove the parking brake cable (5) from the cable guide (6). Adjustment B931H24406001 Refer to “Rear Brake Pedal / Rear Brake (Parking Brake) Lever Inspection and Adjustment: in Section 0B”.
Page 480: Parking / Rear Brake Lever Components
4D-4 Parking Brake: Parking / Rear Brake Lever Components B931H24406003 I831G1440007-01 1. Brake lever lock 4. Brake lever pivot bolt 7. Lock-nut 2. Brake lever cover 5. Brake lever pivot nut : 6 N⋅m (0.6 kgf-m, 4.5 lbf-ft) 3. Brake lever 6.
Page 481 Parking Brake: 4D-5 Specifications Tightening Torque Specifications B931H24407001 NOTE The specified tightening torque is described in the following. “Parking / Rear Brake Lever Components (Page 4D-4)” Reference: For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List: in Section 0C”. Special Tools and Equipment Recommended Service Material B931H24408001...
Page 482 4D-6 Parking Brake:...
Page 483 Table of Contents 5- i Section 5 Transmission / Transaxle CONTENTS Precautions ..........5-1 Drive V-belt Inspection ........5A-14 Movable / Fixed Drive Face Parts Inspection..5A-14 Precautions............. 5-1 Movable / Fixed Driven Face Parts Inspection ..5A-15 Precautions for Transmission / Transaxle..... 5-1 Clutch Shoe Removal and Installation ....5A-15 Automatic Transmission......
Page 484: Precautions
5-1 Precautions: Precautions Transmission / Transaxle Precautions Precautions for Transmission / Transaxle B931H25000001 Refer to “General Precautions: in Section 00”.
Page 485: Automatic Transmission
Automatic Transmission: 5A-1 Automatic Transmission Transmission / Transaxle Schematic and Routing Diagram Drive Train System B931H25102001 “A” I931H1510001-03 1. Crankshaft 6. Fixed driven face 11. Low driven gear 2. Movable drive face 7. Transfer input shaft 12. High driven gear 3.
Page 486: Diagnostic Information And Procedures
5A-2 Automatic Transmission: Diagnostic Information and Procedures Automatic Transmission Symptom Diagnosis B931H25104001 Condition Possible cause Correction / Reference Item Excessive engine noise Gear worn or abnormal contact. Replace. Spline worn. Replace. Bearing worn or burned. Replace. V-belt slipping V-belt slipping. Replace.
Page 487: Repair Instructions
Automatic Transmission: 5A-3 Repair Instructions Automatic Transmission Components B931H25106001 I931H1510106-03 1. Drive face bolt 11. Driven face bolt 21. Spring 2. Movable drive plate 12. Clutch housing 22. Spring plate 3. Damper 13. One way clutch 23. Movable driven face ring nut 4.
Page 488 5A-4 Automatic Transmission: V-belt Cooling Duct Construction B931H25106002 I931H1510105-02 1. Heat shield 3. Inlet belt cooling duct No. 1 5. Inlet belt cooling duct connector 7. Outlet belt cooling duct No. 2 2. Clamp 4. Inlet belt cooling duct No. 2 6.
Page 489: Clutch Engagement And Lock-Up Speed Inspection
Automatic Transmission: 5A-5 5) Remove the outlet belt cooling duct No. 1 (4) along Movable drive face with outlet belt cooling duct connector (5). 1) Remove the cap (1) and movable drive face cover (2). I931H1510005-01 I931H1510007-01 Installation 2) Hold the movable drive face with the special tool and 1) Install the V-belt cooling duct as shown in the V-belt remove the drive face bolt (3) and collar (4).
Page 490 5A-6 Automatic Transmission: Movable driven face V-belt inner cover 1) Hold the movable driven face with the special tool • Install the V-belt inner cover (1). and its remove the driven face bolt (1). CAUTION 2) Remove the driven face assembly (2) and drive belt (3).
Page 491 79.5 lbf-ft) Special tool (A): 09930–40113 (Flywheel rotor holder) I931H1510012-01 • Apply grease in the groove of fixed driven face. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I931H1510015-01 Movable Drive Face • Install the movable drive face assembly (1).
Page 492: Movable Drive Face Disassembly And Assembly
5A-8 Automatic Transmission: • Install the collar (2) and drive face bolt (3). V-belt Outer Cover • Install the V-belt outer cover (1). NOTE CAUTION The deep concave of the collar (2) faces outside. If there are wear or damage, replace the gasket (2) with a new one.
Page 493 2) Apply grease to the lip of oil seals and inside grease I931H1510023-01 3) Remove the dampers (4). groove “A” of the movable drive face. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) CAUTION • Wipe off any excess grease thoroughly.
Page 494: Movable Driven Face Disassembly And Assembly
I931H1510029-02 Do not remove the movable driven face ring 6) Apply grease to the inside groove of the spacer (5). nut before attaching the clutch spring : Grease 99000–25010 (SUZUKI SUPER compressor. GREASE A or equivalent) Special tool (A): 09917–23711 (Ring nut socket wrench) (B): 09924–52450 (Fixed driven face holder)
Page 495 Automatic Transmission: 5A-11 3) Remove the movable driven face ring nut (2). 3) Remove the spring seat (5) and O-rings (6). I931H1510032-01 I931H1510035-01 4) Remove the pins (7) and rollers (8). “B” “A” I931H1510033-01 I931H1510036-01 WARNING 5) Remove the movable driven face (9). Since a high spring force applies to the movable driven face, care must be used so as not to cause the movable driven face to...
Page 496 • Apply grease to the pin grooves of the movable driven • Install the oil seals (1) with the special tool. face. Special tool : Grease 99000–25010 (SUZUKI SUPER (A): 09913–70210 (Bearing installer set (10 – GREASE A or equivalent) 75))
Page 497 Automatic Transmission: 5A-13 • Install the spring (8) and spring plate (9) by aligning • Tighten the movable driven face ring nut (10) the spring ends with the holes. temporarily. • Remove the special tool from the movable driven face NOTE assembly.
Page 498: Drive V-Belt Inspection
5A-14 Automatic Transmission: Drive V-belt Inspection Roller B931H25106008 Inspect each roller and their sliding surface for wear or Inspect that the drive belt is free from any greasy damage. substance. If any defects are found, replace the rollers as a set. Inspect the contact surface of the drive belt for cracks or damage and measure the width of the drive belt with the NOTE...
Page 499: Movable / Fixed Driven Face Parts Inspection
Automatic Transmission: 5A-15 Movable / Fixed Driven Face Parts Inspection O-ring and Oil Seal B931H25106010 Inspect the O-rings and oil seals for wear or damage. If any defects are found, replace the O-rings and oil Movable / Fixed Driven Face seals with new ones.
Page 500 5A-16 Automatic Transmission: 6) Remove the dowel pins (6) and gasket (7). 10) Remove the clutch shoe (11) with the special tools. 7) Remove the one way clutch (8). Special tool (C): 09930–30104 (Rotor remover slide shaft) (D): 09920–33540 (Clutch shoe remover) I931H1510057-01 8) Hold the clutch shoe with the special tools and remove the clutch shoe nut (9).
Page 501 Automatic Transmission: 5A-17 • Apply a small quantity of thread lock to the clutch shoe nut (3). : Thread lock cement 99000–32030 (THREAD LOCK CEMENT SUPER 1303 or equivalent) • Install the clutch shoe nut (3). NOTE The clutch shoe nut (3) has left-hand threads. “A”...
Page 502: Clutch Cover Disassembly And Assembly
5A-18 Automatic Transmission: • Install the outlet belt cooling duct connector (9). • Remove the oil seal (3) with the special tool. Special tool (A): 09913–50121 (Oil seal remover) I931H1510070-02 Clutch Cover Disassembly and Assembly I931H1510073-01 B931H25106012 Refer to “Clutch Shoe Removal and Installation •...
Page 503 5A-19 Assembly • Apply grease to the lip of the oil seal (4). • Install the bearing (1) with the special tool. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) Special tool (A): 09913–70210 (Bearing installer set (10 –...
Page 504: Clutch Related Parts Inspection
5A-20 Automatic Transmission: • After installed the clutch housing, check if the clutch Clutch housing housing rotates smoothly. Inspect the clutch housing for any abnormal surface damage. Measure the inside diameter of the clutch housing. If the measurement exceeds the service limit, replace the clutch housing with a new one.
Page 505: Movable Drive Face Cover Disassembly And Assembly
Automatic Transmission: 5A-21 • Remove the bearing (3) with the special tool. • Install the clutch shoe (3) onto the clutch housing and turn the clutch shoe by hand to inspect the one way NOTE clutch for a smooth movement. The clutch shoe turns If there is no abnormal noise, the bearing one direction only.
Page 506: Movable Driven Face Cover Parts Inspection
5A-22 Automatic Transmission: • Apply grease to the bearing. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I931H1510089-01 Movable Driven Face Cover Parts Inspection B931H25106015 I931H1510087-01 • Install the snap ring (2). Right Clutch Housing Bearing Rotate the inner race by finger to inspect for abnormal CAUTION play, noise and smooth rotation.
Page 507: Shift Lever Assembly Components
Automatic Transmission: 5A-23 Shift Lever Assembly Components Installation B931H25106016 Install the gearshift knob in the reverse order of removal. NOTE Tighten the lock-nut securely. Shift Lever Assembly Removal and Installation B931H25106018 Removal 1) Keep the vehicle on a level ground. 2) Remove the left inner fender.
Page 508: Shift Lever Disassembly And Assembly
“A” Install the gearshift lever in the reverse order of removal. Pay attention to the following points: • Apply grease to pivot. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I931H1510099-01 “A”: Mating position • Install the removed parts. Refer to “Front Side Exterior Parts Removal and Installation: in Section 9D”.
Page 509: Shift Rod Adjustment
Automatic Transmission: 5A-25 Shift Rod Adjustment 2) Turn shift rod in or out and set the gearshift link arm B931H25106020 angle as shown in the figure. Adjust the shift rod length along each angle of the gearshift link arm. 1) Loosen the lock-nuts (1). “...
Page 510: Tightening Torque Specifications
For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List: in Section 0C”. Special Tools and Equipment Recommended Service Material B931H25108001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010...
Page 511: Special Tool
Automatic Transmission: 5A-27 Special Tool B931H25108002 09900–20101 09913–50121 Vernier calipers (150 mm) Oil seal remover (Page 5A-14) (Page 5A-18) / (Page 5A-21) 09913–70210 09917–23711 Bearing installer set (10 – Ring nut socket wrench (Page 5A-9) / (Page 5A- (Page 5A-10) / 12) / (Page 5A-19) / (Page 5A-13)
Page 512 5A-28 Automatic Transmission:...
Page 513: Steering General Diagnosis
Table of Contents 6- i Section 6 Steering CONTENTS Precautions ..........6-1 Component Location ...........6C-8 EPS Components Location .........6C-8 Precautions............. 6-1 Diagnostic Information and Procedures ....6C-8 Precautions for Steering ........6-1 EPS Troubleshooting ..........6C-8 Steering General Diagnosis....6A-1 Pre-diagnosis Inspection........6C-9 EPS System Check...........6C-11 Diagnostic Information and Procedures....6A-1 DTC (Diagnostic Trouble Code) Output ....6C-18 Steering Symptom Diagnosis......
Page 514: Precautions
6-1 Precautions: Precautions Steering Precautions Precautions for Steering B931H26000001 Refer to “General Precautions: in Section 00”.
Page 515: Steering General Diagnosis
Steering General Diagnosis: 6A-1 Steering General Diagnosis Steering Diagnostic Information and Procedures Steering Symptom Diagnosis B931H26104001 Condition Possible cause Correction / Reference Item Heavy Steering Distorted steering shaft. Replace. Improper front wheel alignment. Adjust. Insufficiently lubricated. Lubricate. Not enough pressure in tires. Adjust.
Page 516: Steering / Handlebar
6B-1 Steering / Handlebar: Steering / Handlebar Steering Repair Instructions Steering / Handlebars Components B931H26206001 “A” “A” “A” “A” I931H1620036-08 1. Handlebars 10. Lower dust seal 19. Handlebar left switch assembly 2. Handlebar upper clamp 11. Steering arm plate 20. Handle grip 3.
Page 517: Steering / Handlebars Assembly Construction
Steering / Handlebar: 6B-2 Steering / Handlebars Assembly Construction B931H26206002 “B” VIEW A I931H1620037-06 1. Handlebar holder nut : 60 N⋅m (6.0 kgf-m, 43.5 lbf-ft) 2. Tie-rod end nut : 29 N⋅m (2.9 kgf-m, 21.0 lbf-ft) 3. Steering shaft lower nut : 162 N⋅m (16.2 kgf-m, 117.0 lbf-ft) 4.
Page 518 6B-3 Steering / Handlebar: Handlebars Removal and Installation B931H26206003 Removal 1) Remove the combination meter. Refer to “Combination Meter Removal and Installation: in Section 9C”. 2) Remove the clamp. 3) Disconnect the brake hose from the hose guide. I931H1620003-01 6) Disconnect the parking brake cable (6) from left brake lever.
Page 519 Steering / Handlebar: 6B-4 9) Remove the left brake lever (9) from the handlebars • Tighten the handlebar clamp bolts (4) to the specified (left side). torque. NOTE First tighten the handlebar clamp bolts (4) (front ones) to the specified torque. Tightening torque Handlebar clamp bolt (b): 26 N·m (2.6 kgf-m, 19.0 lbf-ft)
Page 520: Handlebars Inspection
6B-5 Steering / Handlebar: • Tighten the left handlebar switch screws (6). Handlebars Inspection B931H26206004 Refer to “Handlebars Removal and Installation (Page 6B-3)”. Inspect the handlebars for distortion or damage. If any defects are found, replace the handlebars with a new one.
Page 521 Steering / Handlebar: 6B-6 4) Remove the cotter pin (1), nut (2) and washer (3). I931H1620020-02 Installation I931H1620016-01 Install the steering shaft in the reverse order of removal. 5) Remove the steering arm plate (4) and steering shaft Pay attention to the following points: (5).
Page 522 6B-7 Steering / Handlebar: • Apply grease to the lower dust seal (3) and O-ring (4). • Apply a small quality thread lock to the thread part of steering shaft. CAUTION : Thread lock cement 99000–32030 The removed O-ring must be replaced with a (THREAD LOCK CEMENT SUPER 1303 or new one.
Page 523: Tie-Rod / Tie-Rod End Removal And Installation
Steering / Handlebar: 6B-8 Tie-rod / Tie-rod End Removal and Installation 4) Remove the other tie-rod end in the same manner as B931H26206006 described previously. WARNING 5) Separate the tie-rod ends (2), nuts (3),(4) and tie- rods (5). When using the tie-rod end remover, keep clear of the tie-rod end because it may come CAUTION loose with some force and could strike you.
Page 524: Steering Related Parts Inspection
6B-9 Steering / Handlebar: • Install the washers (2) and tighten the rod end nuts (3) Tie-rod End Inspect the tie-rod ends for smooth movement. If there (steering arm plate side) to the specified torque. are any abnormalities, replace the tie-rod ends with new Tightening torque ones.
Page 525: Tightening Torque Specifications
For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List: in Section 0C”. Special Tools and Equipment Recommended Service Material B931H26208001 Material SUZUKI recommended product or Specification Note Grease Water resistance grease P/No.: 99000–25160...
Page 526: Special Tool
6B-11 Steering / Handlebar: Special Tool B931H26208002 09924–84521 09930–30721 Bearing installer set Rotor remover (Page 6B-6) / (Page 6B- (Page 6B-6) 09942–72410 Tie-rod end remover (Page 6B-5) / (Page 6B- 8) / (Page 6B-8)
Page 527: Power Assisted Steering System
Power Assisted Steering System: 6C-1 Power Assisted Steering System Steering Precautions Precautions for EPS B931H26300001 Refer to “Precautions for Electrical Circuit Service: in Section 00”. NOTE When repairing EPS system, remove the front fender. Refer to “Front Side Exterior Parts Removal and Installation: in Section 9D”.
Page 528: General Description
6C-2 Power Assisted Steering System: General Description P/S System Description B931H26301001 This electronic power steering (EPS) system consists of a EPS control unit (2), a torque sensor (3), a EPS motor (4). In this system, the EPS control unit determines the level and direction of the assist force for the handlebars (1) according to the signal from the torque sensor and the vehicle speed signal from speed sensor (9).
Page 529 Power Assisted Steering System: 6C-3 Detecting Principle The column shaft is connected to the input shaft by means of serration. The output shaft and input shaft are connected via torsion bar. When torque is inputted from the column shaft, a relative angular displacement occurs between the input shaft and the output shaft due to twist of the torsion bar.
Page 530 6C-4 Power Assisted Steering System: Control System In the EPS control unit, the steering assist control determines the basic power assist force and the convergence control improves the steering operation feeling. The controller determines the target motor current by the calculation of these controls and the maximum current limiting control and it also regulates the motor current so that the target motor current and the actual current are matched.
Page 531: Eps Diagnosis General Description
Power Assisted Steering System: 6C-5 EPS Diagnosis General Description B931H26301002 The P/S system in this vehicle is controlled by the EPS control unit. The EPS control unit has an self diagnostic system which detects a malfunction in this system. When diagnosing troubles, be sure to have full understanding of the outline of “Self Diagnostic System Description (Page 6C-5)”...
Page 532: Schematic And Routing Diagram
6C-6 Power Assisted Steering System: Schematic and Routing Diagram EPS Wiring Diagram B931H26302001 Refer to “Wire Color Symbols: in Section 0A”. I931H2630001-01...
Page 533: Eps Control Unit Diagram
Power Assisted Steering System: 6C-7 EPS Control Unit Diagram B931H26302002 Refer to “Wire Color Symbols: in Section 0A”. Ignition EPS unit switch 30 A Speedometer MAIN 40 A Fail-safe relay Bl/B Speed sensor (Vehicle speed) motor Motor drive circuit Gr/R Mode selsct switch Torque sensor I931H1630007-05...
Page 534: Eps System Wiring Harness Routing Diagram
6C-8 Power Assisted Steering System: EPS System Wiring Harness Routing Diagram B931H26302003 Refer to “Wiring Harness Routing Diagram: in Section 9A”. Component Location EPS Components Location B931H26303001 Refer to “Electrical Components Location: in Section 0A”. Diagnostic Information and Procedures EPS Troubleshooting CAUTION B931H26304001 The EPS is equipped with a self-diagnosis function.
Page 535: Pre-Diagnosis Inspection
AT25 x 10 –12 for rear. The use of tires other than those Tire specified may cause instability. It is highly Tire type recommended to use a SUZUKI Genuine Tire. Tire type Front: DUNLOP KT411 Rear: DUNLOP KT415...
Page 536 6C-10 Power Assisted Steering System: Steering Related Parts 4) Remove the front fender. Refer to “Front Side Refer to “Steering Related Parts Inspection: in Exterior Parts Removal and Installation: in Section 6B”. Section 9D”. 5) Disconnect the EPS control unit coupler (1). Battery Battery voltage inspection 1) Turn the ignition switch OFF.
Page 537: Eps System Check
Power Assisted Steering System: 6C-11 EPS System Check B931H26304003 WARNING Carry out test drive in light traffic area to prevent an accident. Step Action 1) Perform “Customer Complaint Analysis”. Go to Step 2. Perform customer complaint analysis. Was customer complaint analysis performed according to instruction? 1) Check for operation of the “EPS”...
Page 538 6C-12 Power Assisted Steering System: Step Action (The EPS indicator light does not light up) Go to Step 5. Inspect the wire harness. (Faulty ignition 1) Turn the ignition switch OFF. or ground wire) 2) Disconnect the EPS control unit coupler (1) and (2). I931H1630017-03 3) Turn the ignition switch ON with the EPS control unit coupler disconnected, measure the voltage between...
Page 539 Power Assisted Steering System: 6C-13 Step Action 1) Turn the ignition switch ON with the EPS control unit Go to Step 6. • Inspect the wire coupler disconnected, measure the voltage between harness. (Faulty terminal “A” and terminal “B” at the coupler. indicator light wire) •...
Page 540 6C-14 Power Assisted Steering System: Step Action (The EPS indicator light does not go off) Go to Step 8. Replace the EPS fuse. 1) Remove the seat. Refer to “Seat Removal and Installation: in Section 9D”. 2) Open the fuse box and inspect the ignition fuse (1). CAUTION If a fuse is blown, find the cause of the problem and correct it before replacing the fuse.
Page 541 Power Assisted Steering System: 6C-15 Step Action 1) Turn the ignition switch OFF. Go to Step 9. Inspect the wire harness. (Faulty ignition 2) Disconnect the EPS control unit coupler (1) and (2). or ground wire) I931H1630017-03 3) Turn the ignition switch ON with the EPS control unit coupler disconnected, measure the voltage between terminal “A”...
Page 542 6C-16 Power Assisted Steering System: Step Action 1) Turn the ignition switch ON with the EPS control unit Go to Step 10. Inspect the wire coupler disconnected, measure the voltage between harness. (Faulty terminal “A” and terminal “B” at the coupler. indicator light wire) Special tool (A): 09900–25008 (Multi-circuit tester set)
Page 543 Power Assisted Steering System: 6C-17 Step Action 10 1) Turn the ignition switch OFF. Replace the EPS Inspect the wire control unit. harness. (Faulty mode 2) Short the mode select coupler terminals using the select switch wire) special tool. Special tool (A): 09930–82710 (Mode select switch) I931H1630024-01 3) Check for continuity between terminal “A”...
Page 544: Dtc (Diagnostic Trouble Code) Output
6C-18 Power Assisted Steering System: DTC (Diagnostic Trouble Code) Output 4) Switch the special tool to ON. B931H26304004 NOTE • Even through the EPS is operating correctly, a DTC is memorized in any of the following conditions. – Previous malfunctions were repaired, but the DTCs were not deleted.
Page 545 2) Set up the SDS tool. (Refer to the SDS operation manual for further details.) NOTE Special tool • Don’t disconnect couplers from EPS (A): 09904–41010 (SUZUKI Diagnostic control unit, the battery cable from the system set) battery, EPS control unit ground wire (B): 99565–01010–019 (CD-ROM Ver.19)
Page 546 6C-20 Power Assisted Steering System: I931H1630032-01 4) Close the SDS tool and turn the ignition switch OFF. DTC (Diagnostic Trouble Code) Deleting B931H26304005 Use of Mode Select Switch 1) Remove the seat. Refer to “Seat Removal and Installation: in Section 9D”. I705H1110116-03 3) Read the DTC (Diagnostic Trouble Code) and show data when trouble (displaying data at the time of...
Page 547 Special tool : 09904–41010 (SUZUKI Diagnostic system 6) Afterwards, start the engine and turn the handlebars set) to check that the EPS activates correctly.
Page 548 6C-22 Power Assisted Steering System: 5) Click the EPS button (1). 8) Click “Clear” (3) to delete history code (Past DTC). NOTE The DTC is memorized in the EPS control unit also when the wire coupler of any sensor is disconnected. Therefore, when a wire coupler has been disconnected at the time of diagnosis, erase the stored malfunction history code using SDS.
Page 549: Sds Check
Code) Deleting (Page 6C-20)”. • A number of different data under a fixed condition as shown should be saved or filed as sample. Special tool : 09904–41010 (SUZUKI Diagnostic system set) : 99565–01010–019 (CD-ROM Ver.19) DATA sampled from EPS system...
Page 550: Dtc Table
6C-24 Power Assisted Steering System: Scroll the screen Check the motor current XX A Check the motor current XX A Check the motor current XX A I931H1630105-02 DTC Table B931H26304007 Indicator Malfunction cause Reference status None Normal ON * — Refer to “DTC “C1111”: Torque C1111 Torque sensor (main) circuit voltage failure...
Page 551: Dtc "C1111": Torque Sensor (Main) Circuit Malfunction
Power Assisted Steering System: 6C-25 DTC “C1111”: Torque Sensor (Main) Circuit Malfunction B931H26304008 Possible Cause • Faulty torque sensor signal circuit. • Faulty torque sensor. • Faulty EPS control unit. Troubleshooting CAUTION Never remove the torque sensor to prevent accident and damage. NOTE •...
Page 552 6C-26 Power Assisted Steering System: Step Action 1) Turn the ignition switch OFF. Go to Step 2. • Loose or poor contacts on the 2) Check the torque sensor coupler for loose or poor torque sensor. contact. If OK, measure the torque sensor input voltage. •...
Page 553 Power Assisted Steering System: 6C-27 Step Action 1) Turn the ignition switch OFF. • Replace the EPS • R wire terminal or G control unit with a wire terminal circuit 2) Connect the torque sensor coupler. known good one, and open (torque sensor 3) Insert the needle pointed probes to lead wire coupler.
Page 554: Dtc "C1113": Torque Sensor (Main / Sub) Circuit Correlation Malfunction
6C-28 Power Assisted Steering System: DTC “C1113”: Torque Sensor (Main / Sub) Circuit Correlation Malfunction B931H26304009 Possible Cause • Faulty torque sensor signal circuit. • Faulty torque sensor. • Faulty EPS control unit. Troubleshooting CAUTION Never remove the torque sensor to prevent accident and damage. NOTE •...
Page 555 Power Assisted Steering System: 6C-29 Step Action 1) Turn the ignition switch OFF. Go to Step 2. • Loose or poor contacts on the 2) Check the torque sensor coupler for loose or poor torque sensor. contact. If OK, measure the torque sensor input voltage. •...
Page 556 6C-30 Power Assisted Steering System: Step Action 6) Next, measure the voltage between G wire “C” and Go to Step 2. • Loose or poor ground, G wire “C” and B wire “B”, W wire “D” and contacts on the ground and W wire “D”...
Page 557 Power Assisted Steering System: 6C-31 Step Action 1) Turn the ignition switch OFF. • G, W and B wire open If check result is not or shorted to ground satisfactory, replace the 2) Connect the torque sensor coupler. or poor torque sensor torque sensor (EPS 3) Insert the needle pointed probes to lead wire coupler.
Page 558: Dtc "C1114": Torque Sensor Power Supply Circuit Malfunction
6C-32 Power Assisted Steering System: DTC “C1114”: Torque Sensor Power Supply Circuit Malfunction B931H26304010 Possible Cause • Faulty torque sensor signal circuit. • Faulty torque sensor. • Faulty EPS control unit. Troubleshooting CAUTION Never remove the torque sensor to prevent accident and damage. NOTE After repairing the trouble, clear the DTC using a SDS tool or mode coupler switch.
Page 559 Power Assisted Steering System: 6C-33 Step Action 1) Turn the ignition switch OFF. • If wire and • Power supply circuit connection are OK, (R wire) shorted to 2) Check the EPS control unit power source couplers for intermittent trouble or ground.
Page 560: Dtc "C1115": Torque Sensor (Sub) Circuit Malfunction
6C-34 Power Assisted Steering System: DTC “C1115”: Torque Sensor (Sub) Circuit Malfunction B931H26304011 Possible Cause • Faulty torque sensor signal circuit. • Faulty torque sensor. • Faulty EPS control unit. Troubleshooting CAUTION Never remove the torque sensor to prevent accident and damage. NOTE After repairing the trouble, clear the DTC using a SDS tool or mode coupler switch.
Page 561 Power Assisted Steering System: 6C-35 Step Action 1) Turn the ignition switch OFF. Go to step 2. • Loose or poor contacts on the 2) Check the torque sensor coupler for loose or poor torque sensor. contact. If OK, measure the torque sensor input voltage. •...
Page 562 6C-36 Power Assisted Steering System: Step Action 1) Turn the ignition switch OFF. • Replace the EPS • R wire terminal or W control unit with a wire terminal circuit 2) Connect the torque sensor coupler. known good one, and open (torque sensor 3) Insert the needle pointed probes to lead wire coupler.
Page 563: Dtc "C1121": Vehicle Speed Signal Circuit Malfunction
Power Assisted Steering System: 6C-37 DTC “C1121”: Vehicle Speed Signal Circuit Malfunction B931H26304012 Possible Cause • Faulty vehicle speed signal circuit. • Faulty speed sensor. • Faulty EPS control unit. Troubleshooting NOTE After repairing the trouble, clear the DTC using a SDS tool or mode coupler switch. Refer to “DTC (Diagnostic Trouble Code) Deleting (Page 6C-20)”.
Page 564 6C-38 Power Assisted Steering System: Step Action 6) Disconnect the EPS control unit coupler [B], speed Go to step 2. Bl/B wire open. sensor coupler [C] and combination meter coupler [A]. Refer to “Speed Sensor Removal and Installation: in Section 9C” and “Combination Meter Removal and Installation: in Section 9C”.
Page 565 Power Assisted Steering System: 6C-39 Step Action 1) Connect the combination meter coupler and speed Go to step 3. Bl/B wire shorted to sensor coupler. ground. 2) Measure the voltage between the Bl/B wire “A” and ground. Special tool (A): 09900–25008 (Multi-circuit tester set) Tester knob indication Voltage ( Vehicle speed signal voltage...
Page 566: Dtc "C1122": Engine Speed Signal Circuit Malfunction
6C-40 Power Assisted Steering System: DTC “C1122”: Engine Speed Signal Circuit Malfunction B931H26304013 Possible Cause • Faulty engine speed signal circuit. • Faulty ECM. • Faulty EPS control unit. Troubleshooting NOTE Start the engine after repairing the DTC and check that the indicator light is turned OFF. Refer to “Precautions in Diagnosing Troubles (Page 6C-1)”.
Page 567 Power Assisted Steering System: 6C-41 Step Action 1) Setup the SDS tool (Refer to the SDS operation manual Go to step 2. Inspect the CKP sensor. for further details.) or connect the mode select switch. Refer to “DTC “C12” (P0335): CKP Sensor 2) Click “Engine”...
Page 568 6C-42 Power Assisted Steering System: Step Action 1) Connect the ECM coupler. Replace the EPS Replace the ECM with a control unit with a new new one. Refer to “EPS 2) Start the engine. one. Refer to “EPS Control Unit Removal 3) Measure the voltage between W wire “A”...
Page 569: Dtc "C1141", "C1142", "C1143", "C1145" Eps Motor Circuit Malfunction
Power Assisted Steering System: 6C-43 DTC “C1141”, “C1142”, “C1143”, “C1145” EPS Motor Circuit Malfunction B931H26304014 Possible Cause • Faulty EPS motor circuit. • Faulty EPS motor. • EPS control unit malfunction. Troubleshooting Step Action 1) Turn the ignition switch OFF. Go to step 2.
Page 570 6C-44 Power Assisted Steering System: Step Action 1) Turn the ignition switch OFF. Replace the EPS Replace the EPS motor control unit with a (EPS body assembly) 2) Disconnect the EPS motor coupler. known good one, and with a new one. Refer to inspect it again.
Page 571: Dtc "C1153" Eps Control Unit Supply Voltage Circuit Malfunction
Power Assisted Steering System: 6C-45 DTC “C1153” EPS Control Unit Supply Voltage Circuit Malfunction B931H26304015 Possible Cause • Faulty regulator/rectifier. • Faulty EPS control unit. • Faulty wire harness, etc. Troubleshooting Step Action 1) Remove the seat. Refer to “Seat Removal and Go to Step 2.
Page 572 6C-46 Power Assisted Steering System: Step Action 1) Turn the ignition switch OFF. Replace the EPS Inspect the wire control unit. harness. (Faulty ignition 2) Check the EPS control unit coupler for loose or poor or ground wire) contacts. If OK, then disconnect the EPS control unit coupler.
Page 573: Dtc "C1152", "C1154", "C1155" Eps Control Unit Malfunction
Power Assisted Steering System: 6C-47 DTC “C1152”, “C1154”, “C1155” EPS Control Unit Malfunction B931H26304016 Possible Cause C1152 • Relay welding (EPS control unit internal circuit) C1154 • Relay malfunction (EPS control unit internal circuit) C1155 • EPS control unit malfunction Troubleshooting •...
Page 574: Eps Control Unit Removal And Installation
6C-48 Power Assisted Steering System: EPS Control Unit Removal and Installation 6) Release the clip part “A” of the EPS control unit plate B931H26306002 with the special tool. Removal Special tool 1) Disconnect the battery (–) lead wire. (A): 09942–83110 (Clip remover) 2) Remove the front fender.
Page 575: Eps Body Assembly Components
Power Assisted Steering System: 6C-49 • Connect the torque sensor lead wire (2). 4) Remove the holder cover (1) by removing the fastener (2). I931H1630099-02 • Connect the EPS motor coupler (3) and clamp (4). I931H1630066-02 5) Remove the center cover (3). •...
Page 576 6C-50 Power Assisted Steering System: 12) Remove the cable guide (11). 8) Remove the steering shaft plate (7) with the special tool. Special tool (A): 09944–36011 (Steering wheel remover) I931H1630071-06 13) Remove the EPS body assembly. CAUTION I931H1630112-02 Never disassemble the EPS body assembly. 9) Remove the front brake hose union (8) from the cable guide (9).
Page 577 Power Assisted Steering System: 6C-51 • Install the cable guide (1) and tighten the bolts (2) to • Install the front brake hose union (5) to the cable the specified torque. guide. Tightening torque EPS body assembly mounting bolt (a): 26 N·m ( 2.6 kgf-m, 19.0 lbf-ft) I931H1630079-01 •...
Page 578: Eps Motor Inspection
6C-52 Power Assisted Steering System: • Install the handlebar holder (7) and tighten the nuts to • Install the front fender. Refer to “Front Side Exterior the specified torque. Parts Removal and Installation: in Section 9D”. • Install the handlebars. Refer to “Handlebars Tightening torque Removal and Installation: in Section 6B”.
Page 579: Specifications
For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List: in Section 0C”. Special Tools and Equipment Recommended Service Material B931H26308001 Material SUZUKI recommended product or Specification Note Grease Water resistance grease or P/No.: 99000–25160...
Page 580: Special Tool
(Page 6C-43) / (Page 6C-45) / (Page 6C-45) / (Page 6C-46) / (Page 6C-52) / (Page 6C-52) 09904–41010 09930–82710 SUZUKI Diagnostic system Mode select switch (Page 6C-19) / (Page 6C-17) / (Page 6C-21) / (Page 6C-18) (Page 6C-23) 09930–82720 09942–83110...
Page 581 Table of Contents 9- i Section 9 Body and Accessories CONTENTS Precautions ..........9-1 Engine Coolant Temperature Removal and Installation ............9C-4 Precautions............. 9-1 Fuel Level Indicator Inspection ......9C-4 Precautions for Electrical System ......9-1 Fuel Level Gauge Inspection ......9C-5 Component Location ..........9-1 Speedometer Inspection ........9C-6 Electrical Components Location ......
Page 582 9-ii Table of Contents Specifications............9E-7 Special Tools and Equipment ......9E-7 Tightening Torque Specifications......9E-7...
Page 583: Precautions
Precautions: Precautions Body and Accessories Precautions Precautions for Electrical System B931H29000001 Refer to “General Precautions: in Section 00” and “Precautions for Electrical Circuit Service: in Section 00”. Component Location Electrical Components Location B931H29003001 Refer to “Electrical Components Location: in Section 0A”.
Page 584: Wiring Systems
9A-1 Wiring Systems: Wiring Systems Body and Accessories Schematic and Routing Diagram Wiring Diagram B931H29102001 Refer to “Wire Color Symbols: in Section 0A”.
Page 585 Wiring Systems: 9A-2 For P-17 I931H2910901-02...
Page 586 9A-3 Wiring Systems: For P-24, 28, 33 I931H2910902-02...
Page 587: Wiring Harness Routing Diagram
Wiring Systems: 9A-4 Wiring Harness Routing Diagram B931H29102002 “ a ” “b” “c” “C” “ b ” “B” “A” “A” VIEW A I931H1910901-07 1. Clamp 9. Throttle cable 2. Clamp “A”: Pass the wiring harness and cooling fan lead wire over the radiator : Bind the wiring harness and hose with the clamp.
Page 588 9A-5 Wiring Systems: “E” “D” “C” VIEW A VIEW F “F” “B” “A” I931H1910902-07 1. Starter motor 13. ECT sensor coupler 2. Starter motor terminal 14. Injector coupler 3. Engine earth 15. IAP/TP/IAT sensor coupler 4. Clamp 16. ISC valve coupler : Bind the wiring harness and rear brake cable with the clamp.
Page 589 Wiring Systems: 9A-6 “A” “C” “B” VIEW “A” “ a ” “D” I931H1910903-05 1. Clamp 10. ECM : Bind the left handlebar switch lead wire, rear brake lever switch lead wire, horn lead wire (For P-17, 24) and emergency switch lead wire (For P-17) with the clamp. Cut the tip of clamp after clamping.
Page 590: Specifications
9A-7 Wiring Systems: “ a ” I931H1910908-01 1. Starter motor 3. Generator stator 5. Starter motor lead wire 7. Clamp 2. Gear position switch 4. Ground wire 6. Grommet “a”: 30° Specifications Service Data B931H2910S001 Electrical Unit: mm Item Specification Note 10 A Headlight...
Page 591: Lighting Systems
Lighting Systems: 9B-1 Lighting Systems Body and Accessories Repair Instructions Headlight Components B931H29206001 I931H1920011-02 1. Headlight bulb (12 V 35/35 W) Headlight Removal and Installation 3) Remove the headlight assembly (2) by removing B931H29206002 screw (3), fastener (4) and bolts (5). Removal 1) Remove the front grill upper cover.
Page 592: Headlight Bulb Replacement
9B-2 Lighting Systems: Installation 3) Replace the headlight bulb (4) by unhooking the bulb Install the headlight in the reverse order of removal. Pay holder spring (5). attention to the following point: • After installing, be sure to inspect the headlight beam. Refer to “Headlight Beam Adjustment (Page 9B-2)”.
Page 593: Rear Combination Light Removal And Installation
Lighting Systems: 9B-3 Rear Combination Light Removal and 1) Remove the rear combination light. Installation B931H29206006 Removal 1) Remove the rear combination light mounting bolts. I931H1920006-01 2) Remove the bulb socket by turning it counterclockwise. I931H1920006-01 2) Remove the rear combination light assembly by disconnecting the clamp (1) and coupler (2).
Page 594: Reversing Light Bulb Replacement (For
9B-4 Lighting Systems: Reversing Light Bulb Replacement (For P-17) B931H29206008 Remove the reversing light bulb (1) as shown in the figure. I831G1920025-03 1. Reversing light bulb (12 V/21 W) Reversing Light Relay Inspection (For P-17) 2) Disconnect the handlebar switch coupler (1). B931H29206009 First, check the insulation between “A”...
Page 595: Specifications
Lighting Systems: 9B-5 Specifications Service Data B931H29207001 Wattage Unit: W Specification Item P-24, 28, 33 P-17 ← 35 x 2 Headlight ← 35 x 2 ← Brake light/Taillight 21/5 Reversing light — Special Tools and Equipment Special Tool B931H29208001 09900–25008 Multi circuit tester set (Page 9B-4) / (Page 9B-...
Page 596: Combination Meter / Fuel Meter / Horn
9C-1 Combination Meter / Fuel Meter / Horn: Combination Meter / Fuel Meter / Horn Body and Accessories General Description Combination Meter System Description B931H29301001 This combination meter mainly consists of LCD (Liquid Crystal Display) and LED (Light Emitting Diode). The LCDs indicate Speed, Odo / Trip A / Trip B, Fuel level, Diff-lock, 4WD, Gear position, Engine coolant temperature, FI and Clock / Hour / FI (DTC) respectively.
Page 597: Repair Instructions
Combination Meter / Fuel Meter / Horn: 9C-2 Repair Instructions Combination Meter Components B931H29306001 I931H1930019-01 1. Upper case 2. Combination meter 3. Lower case Combination Meter Removal and Installation Removal B931H29306002 1) Remove the combination meter cover (1) by CAUTION removing the screws (2), fastener (3) and ignition switch ring nut (4).
Page 598: Combination Meter Disassembly And Assembly
9C-3 Combination Meter / Fuel Meter / Horn: 2) Remove the combination meter mounting bolt. Combination Meter Disassembly and Assembly B931H29306003 Refer to “Combination Meter Removal and Installation (Page 9C-2)”. CAUTION Do not attempt to disassemble the combination meter unit. Disassembly Disassemble the combination meter as shown in the combination meter components.
Page 599: Engine Coolant Temperature Removal And Installation
Combination Meter / Fuel Meter / Horn: 9C-4 3) Disconnect the ECT sensor coupler (1). 6) Check the LCD and LED operations when the resistance is adjusted to the specified values. If either one or all indications are abnormal, replace the combination meter with a new one.
Page 600: Fuel Level Gauge Inspection
9C-5 Combination Meter / Fuel Meter / Horn: 3) Connect the variable resister (2) between the Y/B and B lead wires from the wire harness. I931H1930009-01 4) Turn the ignition switch ON. 5) Check the display of fuel level indicator (LCD) as shown in the figure. If any abnormality is found, replace the combination meter with a new one.
Page 601: Speedometer Inspection
Combination Meter / Fuel Meter / Horn: 9C-6 Speedometer Inspection B931H29306009 If the speedometer, odometer or trip meter does not function properly, inspect the speed sensor and the coupler connections. If the speed sensor and coupler connections are OK, replace the combination meter unit with a new one.
Page 602: Ignition Switch Inspection
9C-7 Combination Meter / Fuel Meter / Horn: 3) Move a screwdriver back and forth across the pick- 4) After finishing the ignition switch inspection, reinstall up surface of the speed sensor. The voltage the removed parts. readings should cycle as follows (0 V → 12 V or 12 V →...
Page 603: Horn Removal And Installation (For
For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List: in Section 0C”. Special Tools and Equipment Recommended Service Material B931H29308001 Material SUZUKI recommended product or Specification Note Grease Water resistance grease or P/No.: 99000–25160...
Page 604: Exterior Parts
9D-1 Exterior Parts: Exterior Parts Body and Accessories Repair Instructions Exterior Parts Construction B931H29406001 Front Side I931H1940040-04 1. Front fender 3. Air cleaner box cover 5. Front grill cover 7. Right inner fender 2. Front box 4. Side cover 6. Left inner fender...
Page 605 Exterior Parts: 9D-2 Rear Side I931H1940041-02 1. Rear fender 2. Right mud guard 3. Left mud guard 4. Engine side cover 5. Rear box...
Page 606: Rear Fender Heat Shield Construction
9D-3 Exterior Parts: Rear Fender Heat Shield Construction B931H29406002 “ c ” “ d ” “ a ” “ b ” “ a ” “A” I931H1940042-01 1. Rear fender “a”: 1 – 3 mm (0.04 – 0.12 in) “c”: 67 mm (2.64 in) “A”: Inside of the rear fender.
Page 607: Fuel Tank Lower Cover Heat Shield Installation
Exterior Parts: 9D-4 Fuel Tank Lower Cover Heat Shield Installation B931H29406003 “ a ” I931H1940044-01 1. Heat shield 2. Cushion 3. Fuel tank lower cover “a”: Max. 5 mm (0.2 in)
Page 608: Fastener Removal And Installation
9D-5 Exterior Parts: Fastener Removal and Installation Type B B931H29406004 Removal Type A 1) Pry up the head of fastener center piece (1) with a Removal screw driver. 1) Depress the head of fastener center piece (1). 2) Pull out the fastener “A”. 2) Pull out the fastener (2).
Page 609: Front Side Exterior Parts Removal And Installation
Exterior Parts: 9D-6 Front Side Exterior Parts Removal and Installation Install the air cleaner box cover in the reverse order of Installation B931H29406005 removal. Front Grill Cover Front Box Removal Removal Remove the front grill cover (1) by removing the 1) Remove the front box cap (1).
Page 610 9D-7 Exterior Parts: 5) Remove the front box holder (4) and cushions (5). Inner Fender Removal Remove the inner fenders (1) by removing the fasteners (2), left and right. I931H1940006-01 I931H1940010-02 I931H1940007-01 Installation Install the front box in the reverse order of removal. Pay I931H1940011-03 attention to the following points: Installation...
Page 611 Exterior Parts: 9D-8 6) Remove the front fender (2) by removing the screws (3) and fasteners (4). I931H1940013-02 “B”: Right side I931H1940015-02 Installation Install the side cover in the reverse order of removal. Front Fender Removal 1) Remove the front carrier. Refer to “Front Carrier Removal and Installation: in Section 9E”.
Page 612: Rear Side Exterior Parts Removal And Installation
9D-9 Exterior Parts: Rear Side Exterior Parts Removal and Mud Guard Installation Removal B931H29406006 Remove the mud guards (1) by removing the bolts (2), screws (3) and fasteners (4), left and right. Engine Side Cover Removal Remove the engine side cover (1). I931H1940020-03 “A”: Left side I931H1940018-02...
Page 613 Exterior Parts: 9D-10 2) Remove the fasteners (3), bolt (4) and screw (5). 5) Remove the screws (1) and fasteners (2). I931H1940023-01 I931H1940025-02 3) Move the rear fender upside. 4) Remove the fuel tank outer cover (6). I931H1940026-02 6) Remove the battery. Refer to “Battery Removal and Installation: in Section 1J”.
Page 614: Seat Removal And Installation
9D-11 Exterior Parts: 9) Remove the parking brake cable (8) from the cable Seat Removal and Installation B931H29406007 guide. Removal Pull the seat lock lever (1) upward, and remove the seat (2). I931H1940029-02 10) Remove the fuel tank cap (9). I931H1940031-01 CAUTION To prevent the fuel tank from contamination...
Page 615: Under Cover Components
Exterior Parts: 9D-12 Under Cover Components B931H29406008 I831G1940034-02 1. Front under cover 2. Engine under cover 3. Rear under cover Under Cover Removal and Installation B931H29406009 Front Under Cover Removal Remove the front under cover (1) by removing the bolts (2) and fasteners (3).
Page 616 9D-13 Exterior Parts: 2) Install the front under cover. 2) Install the engine under cover. Engine Under Cover Rear Under Cover Removal Removal Remove the engine under cover (1). Remove the rear under cover (1). I931H1940035-01 I931H1940038-01 Installation 1) Fix the engine under cover (1) with the front under cover (2) and rear under cover (3).
Page 617: Body Structure
Body Structure: 9E-1 Body Structure Body and Accessories Repair Instructions Body Frame Construction B931H29506001 I931H1950018-02 1. Frame 3. Washer : Apply thread lock to the thread part. 2. Battery plate 4. Spacer...
Page 618: Footrest Construction
9E-2 Body Structure: Footrest Construction B931H29506002 I831G1950001-04 1. Footrest (R) 3. Footrest plate : 55 N⋅m (5.5 kgf-m, 40.0 lbf-ft) 2. Footrest (L) : 26 N⋅m (2.6 kgf-m, 19.0 lbf-ft) : Apply thread lock to the thread part. Footrest Removal and Installation Installation B931H29506003 Install the footrest in the reverse order of removal.
Page 619: Carrier Construction
Body Structure: 9E-3 Carrier Construction B931H29506004 I931H1950017-02 1. Front carrier 2. Rear carrier : Apply thread lock to the thread part. Front Carrier Removal and Installation B931H29506005 Removal 1) Remove the front grill upper cover. Refer to “Front Side Exterior Parts Removal and Installation: in Section 9D”.
Page 620: Rear Carrier Removal And Installation
9E-4 Body Structure: Installation Install the front carrier in the reverse order of removal. Pay attention to the following point: • Apply thread lock to the front carrier mounting bolts. : Thread lock cement 99000–32030 (THREAD LOCK CEMENT SUPER 1303 or equivalent) I931H1950010-01 I931H1950007-02...
Page 621: Front Grip Bar Construction
Body Structure: 9E-5 Front Grip Bar Construction B931H29506007 I931H1950013-01 1. Front grip bar : Apply thread lock to thread part. Front Grip Bar Removal and Installation Installation B931H29506008 Install the front grip bar in the reverse order of removal. Pay attention to the following point: Removal •...
Page 622: Trailer Towing Construction
9E-6 Body Structure: Trailer Towing Construction B931H29506009 “ a ” “ b ” I831G1950020-04 1. Trailer towing warning label (P-17, 28) : 60 N⋅m (6.0 kgf-m, 43.5 lbf-ft) 2. Trailer towing warning label “a“: 5 mm (0.2 in) 3. Trailer towing “b“: 30 mm (1.2 in) Trailer Towing Removal and Instruction Installation...
Page 623 For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List: in Section 0C”. Special Tools and Equipment Recommended Service Material B931H29508001 Material SUZUKI recommended product or Specification Note Thread lock cement THREAD LOCK CEMENT SUPER P/No.: 99000–32030...
Page 624 Prepared by December, 2008 Part No. 99500-44080-03E Printed in U.S.A.

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2009 lt-a500xp Lt-a500xz

Suzuki kq500 Service Manual

Table of Contents

Section 1 Engine

Precautions

Engine General Information and Diagnosis

General Description

Schematic and Routing Diagram

Component Location

Diagnostic Information and Procedures

Specifications

Special Tools and Equipment

Emission Control Devices

Precautions

Repair Instructions

Repair Instructions

Precautions

Diagnostic Information and Procedures

Component Location

Special Tools and Equipment

Specifications

Engine Mechanical

Schematic and Routing Diagram

Diagnostic Information and Procedures

Repair Instructions

Specifications

Schematic and Routing Diagram

Precautions

Engine Lubrication System

Diagnostic Information and Procedures

Repair Instructions

Specifications

Special Tools and Equipment

Engine Cooling System

Precautions

General Description

Schematic and Routing Diagram

Diagnostic Information and Procedures

Repair Instructions

Specifications

Special Tools and Equipment

Fuel System

Precautions

General Description

Schematic and Routing Diagram

Diagnostic Information and Procedures

Repair Instructions

Specifications

Special Tools and Equipment

Ignition System

Schematic and Routing Diagram

General Description

Diagnostic Information and Procedures

Repair Instructions

Specifications

Special Tools and Equipment

Starting System

Schematic and Routing Diagram

Diagnostic Information and Procedures

Component Location

Repair Instructions

Specifications

Special Tools and Equipment

Diagnostic Information and Procedures

Component Location

Schematic and Routing Diagram

Charging System

Repair Instructions

Specifications

Special Tools and Equipment

Exhaust System

Precautions

Repair Instructions

Specifications

Quick Links

Chapters

Troubleshooting

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