Suzuki kq750 Service Manual

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This manual contains an introductory description on the SUZUKI LT-A750X/P 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

and passenger.

FOREWORD

99500-47021-03E

Table of Contents

Chapters

Table of Contents

Troubleshooting

Summary of Contents for Suzuki kq750

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 Body and Accessories..........9-i Precautions............... 00-i Precautions ............00-1 Precautions .............. 9-1 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 SUPPLEMENTS LT-A750XK9 (’09 MODEL) LT-A750XPK9 (’09 MODEL)
Page 6: 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 7: 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 8 Precautions: 00-2 • Never reuse a circlip. When installing a • Before refitting the sealed coupler, make sure its seal new circlip, take care not to expand the rubber is positioned properly. The seal rubber may end gap larger than required to slip the possibly come off the position during disconnecting circlip over the shaft.
Page 9 00-3 Precautions: • Check the male connector for bend and female Switch connector for excessive opening. Also check the Never apply grease material to switch contact points to coupler for locking (looseness), corrosion, dust, etc. prevent damage. ECM / Various sensors •...
Page 10 Precautions: 00-4 Battery • Never connect any tester (voltmeter, ohmmeter, or whatever) to the electronic unit when its coupler is • Battery connection in reverse polarity is strictly disconnected. Otherwise, damage to electronic unit prohibited. Such a wrong connection will damage the may result.
Page 11 00-5 Precautions: 3) Using a test male terminal, check the female 2) Disconnect the coupler “B” and measure resistance terminals of the circuit being checked for contact between couplers “A” and “B-1”. tension. If no continuity is indicated, the circuit is open Check each terminal visually for poor contact between couplers “A”...
Page 12 Precautions: 00-6 3) Also, if measured values are as listed following, a 3) Measure resistance between terminal at one end of resistance (abnormality) exists which causes the circuit (“A” terminal in figure) and body ground. If voltage drop in the circuit between terminals “A” and continuity is indicated, there is a short circuit to “B”.
Page 13 00-7 Precautions: Using The Multi-Circuit Testers NOTE • Use the Suzuki multi-circuit tester set. • When connecting the multi-circuit tester, • Use well-charged batteries in the tester. use the needle pointed probe to the back side of the lead wire coupler and connect •...
Page 14: Table Of Contents
Symbols .............. 0A-1 Front Differential Gear Oil Replacement ...0B-13 Abbreviations ............0A-1 Final Gear Oil Inspection........0B-14 SAE-to-Former SUZUKI Term ......0A-2 Final Gear Oil Replacement......0B-14 Vehicle Side View ..........0A-3 Throttle Cable Play Inspection and Vehicle Identification Number ......0A-3 Adjustment ............0B-15...
Page 15: 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 16 Throttle Position Sensor (TP Sensor): TP Sensor this manual in compliance with SAE recommendations, (TPS) as well as their former SUZUKI names. Ex. SAE term (Abbreviation): Former SUZUKI term Voltage Regulator (VR): Voltage Regulator Air Cleaner (ACL): Air Cleaner, Air Cleaner Box...
Page 17: Vehicle Identification Number
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 18 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 19 0A-5 General Information: Country and Area Codes B931G20101009 The following codes stand for the applicable country(-ies) and area(-s). Model Code Country or Area Effective Frame No. P-17 Sweden P-24 Australia LT-A750XK8 P-28 Canada P-33 U.S.A. 5SAAR41A 87100001 – P-17 Sweden P-24 Australia LT-A750XZK8...
Page 20 General Information: 0A-6 Warning, Caution and Information Labels Location B931G20101011 12, 13 1, 21 23, 24 15, 16 17, 18 I831G1010005-06 1. Certification plate For P-24, 33 13. Max AMP caution label For P-17, 28 2. Information label For P-33 14.
Page 21 0A-7 General Information: Component Location Electrical Components Location B931G20103001 I831G1010006-02 1. Battery 7. 4WD/Diff-lock relay 13. Ignition switch 2. Starter relay/Main fuse 8. Mode selection switch coupler 14. Power source 3. Fuse box 9. Starter motor 15. Ignition coil 4. Neutral relay 10.
Page 22 General Information: 0A-8 I831G1010007-03 18. Cooling fan thermo-switch 24. Parking brake switch 30. High position diode 19. Resister 25. Brake lever switch 31. Low position diode 20. 4WD/Diff-lock actuator diode 26. Regulator/Rectifier 32. Speed sensor 21. Neutral relay diode 27. Parking brake relay 33.
Page 23: Fuel System
0A-9 General Information: Specifications Specifications (LT-A750X/ZK8) B931G20107001 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 2 135 mm (84.1 in) P-17, 24 1 210 mm (47.6 in) P-28, 33 Overall width 1 250 mm (49.2 in)
Page 24: 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 180 mm (7.1 in) Rear wheel travel 200 mm (7.9 in) Caster 1.6°...
Page 25 0A-11 General Information: Specifications (LT-A750X/ZK9) B931G20107002 NOTE • These specifications are subject to change without notice. • Any differences between the LT-A750X/ZK8 (’08-model) and LT-A750X/ZK9 (’09-model) in specifications are indicated with an asterisk mark (*). Dimensions and curb mass Item Specification Remark 2 115 mm (83.3 in)
Page 26 General Information: 0A-12 09900–22301 09900–22302 09900–22403 09900–25008 09900–25009 Plastigauge (0.025 – Plastigauge (0.051 – Small bore gauge (18 Multi-circuit tester set Needle pointed probe 0.076 mm) 0.152 mm) – 35 mm) 09900–26006 09904–41010 09910–32812 09910–32860 09912–34510 Engine tachometer SDS set Crankshaft installer Attachment Cylinder...
Page 27 0A-13 General Information: 09916–14521 09916–14910 09916–34542 09916–34550 09916–34580 Valve spring Valve spring Reamer handle Valve guide reamer Valve guide reamer compressor compressor (5.5 mm) (10.8 mm) attachment attachment 09916–44910 09916–57360 09916–84511 09917–23711 09917–47011 Valve guide remover/ Attachment Tweezers Ring nut wrench Vacuum pump gauge installer 09919–28610...
Page 28 General Information: 0A-14 09924–52470 09924–74520 09924–74570 09924–84521 09930–10121 Fixed final drive gear Oil seal installer/ Final drive gear Bearing installer set Spark plug wrench set holder remover bearing installer/ remover 09930–11950 09930–30104 09930–30721 09930–31921 09930–40113 Torx wrench Rotor remover sliding Rotor remover Rotor remover Rotor holder...
Page 29 0A-15 General Information: 99565–01010–013 CD-ROM Ver.13...
Page 30: Maintenance And Lubrication
Maintenance and Lubrication: 0B-1 Maintenance and Lubrication General Information Precautions Precautions for Maintenance B931G20200001 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: Lubrication Points
0B-2 Maintenance and Lubrication: 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: Repair Instructions
Maintenance and Lubrication: 0B-3 Repair Instructions Air Cleaner Element Inspection and Cleaning 3) Carefully use compressed air to clean the air cleaner B931G20206001 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: Exhaust Pipe Bolt And Muffler Bolt Inspection
0B-4 Maintenance and Lubrication: Exhaust Pipe Bolt and Muffler Bolt Inspection Valve Clearance Inspection and Adjustment B931G20206002 B931G20206003 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 Maintenance and Lubrication: 0B-5 5) Drain a small amount of engine coolant and 8) Turn the crankshaft to bring the “TDC” line “A” on the disconnect the radiator upper hose of thermostat generator rotor to the lug mark “B”. side. Refer to “Cooling System Inspection (Page 0B- 15)”.
Page 35 0B-6 Maintenance and Lubrication: 10) Insert the thickness gauge between the tappet and 3) Check the figures printed on the shim. These figures the cam. If the clearance is out of specification, indicate the thickness of the shim, as illustrated. adjust it to the specified range.
Page 36 Maintenance and Lubrication: 0B-7 (INTAKE SIDE) I831G1020017-02...
Page 37 0B-8 Maintenance and Lubrication: (EXHAUST SIDE) I831G1020018-02...
Page 38: Spark Plug Replacement
Maintenance and Lubrication: 0B-9 6) Install the camshafts. Refer to “Engine Top Side 3) After finishing the spark plug inspection, reinstall the Assembly in Section 1D (Page 1D-21)”. removed parts. 7) Rotate the engine so that the tappet is depressed Spark Plug Gap fully.
Page 39: Spark Arrester Cleaning
0B-10 Maintenance and Lubrication: Spark Arrester Cleaning Fuel Line Inspection B931G20206006 B931G20206007 Spark arrester cleaning Inspect fuel line Every 2 000 km (1 200 miles, 6 months) Every 1 000 km (600 miles, 3 months) 1) Remove the muffler end cover (1). Replace fuel line Every 4 years Inspect the fuel line in the following procedures:...
Page 40 Maintenance and Lubrication: 0B-11 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 41: Front Differential Gear Oil Inspection
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 42: Front Differential Gear Oil Replacement
Maintenance and Lubrication: 0B-13 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 43: Final Gear Oil Inspection
0B-14 Maintenance and Lubrication: Final Gear Oil Inspection 4) Drain oil by removing the oil drain plug (1) and oil B931G20206011 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 44: Throttle Cable Play Inspection And Adjustment
Maintenance and Lubrication: 0B-15 Throttle Cable Play Inspection and Adjustment Cooling System Inspection B931G20206013 B931G20206015 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 45 0B-16 Maintenance and Lubrication: 3) Remove the left inner fender. Refer to “Front Side 9) Bleed air from the cooling circuit. Exterior Parts Removal and Installation in Section 10) After changing engine coolant, reinstall the removed 9D (Page 9D-6)”. parts. 4) Remove the front under cover.
Page 46: Drive V-Belt Inspection And Replacement
Maintenance and Lubrication: 0B-17 Drive Shaft Boots Inspection Radiator Hoses Inspection B931G20206017 Inspect radiator hoses Inspect drive shaft Every 2 000 km (1 200 miles, 6 months) Initially at 200 km (100 miles, 1 month) and every 1 Inspect the radiator hoses for damage and engine 000 km (600 miles, 3 months) thereafter coolant leakage.
Page 47 0B-18 Maintenance and Lubrication: Brake Fluid Level Check Front Brake Pads Check The extent of front brake pad wear can be checked by Inspect brake fluid level observing the grooved limit line “A” on the pad. When the Every 1 000 km (600 miles, 3 months) wear exceeds the grooved limit line, replace the pads 1) Place the vehicle on a level ground.
Page 48: Rear Brake Pedal / Rear Brake
Maintenance and Lubrication: 0B-19 Front Brake Hose Replacement Brake Pedal Free Travel Inspection Replace brake hose Inspect and adjust the rear brake pedal free travel “a” as Every 4 years follows. Refer to “Front Brake Hose Removal and Installation in Rear brake pedal free travel “a”...
Page 49 0B-20 Maintenance and Lubrication: Rear Brake (Parking Brake) Lever Play Adjustment 5) After adjusting the play, check that the rear wheels roll freely without applying the brake, the 1) After adjusting the brake pedal, check the rear brake transmission in neutral and the rear wheels off the lever play “a”...
Page 50: Tire Inspection
Maintenance and Lubrication: 0B-21 Tire Inspection CAUTION B931G20206021 The standard tire fitted on this vehicle is an Inspect tire AT25 x 8-12 for the front and a AT25 x 10- Every 1 000 km (600 miles, 3 months) for the rear. The use of tires other than Tire Tread Condition those specified may cause instability.
Page 51: Toe Adjustment
0B-22 Maintenance and Lubrication: If the toe-out is out of specification, bring it into the 5) After adjustment has been made, tighten the four specified range. Refer to “Toe Adjustment (Page 0B- lock-nuts to the specified torque. 22)”. Tightening torque Tie-rod lock-nut (a): 45 N·m (4.5 kgf-m, 32.5 lbf- Toe Adjustment B931G20206023...
Page 52: Chassis Bolt And Nut Inspection
Maintenance and Lubrication: 0B-23 Chassis Bolt and Nut Inspection B931G20206025 Tighten chassis bolt and nut Initially at 200 km (100 miles, 1 month) and every 1 000 km (600 miles, 3 months) thereafter Check that all chassis bolts and nuts are tightened to their specified torque.
Page 53 0B-24 Maintenance and Lubrication: I831G1020067-04 I831G1020070-03 Rear wheel set nut 60 N⋅m (6.0 kgf-m, 43.5 lb-ft) Front brake air bleeder valve 6 N⋅m (0.6 kgf-m, 4.5 lb-ft) Rear hub nut 121 N⋅m (12.1 kgf-m, 87.5 lb-ft) Front brake caliper mounting bolt 26 N⋅m (2.6 kgf-m, 19.0 lb-ft) I831G1020068-04 I831G1020071-03 Tie-rod end nut 29 N⋅m (2.9 kgf-m, 21.0 lb-ft)
Page 54 Maintenance and Lubrication: 0B-25 I831G1020074-04 I831G1020077-02 Rear brake pedal pivot bolt 11 N⋅m (1.1 kgf-m, 8.0 lb-ft) Rear knuckle nut 60 N⋅m (6.0 kgf-m, 43.5 lb-ft) I831G1020075-05 I831G1020078-04 Rear brake case bolt 26 N⋅m (2.6 kgf-m, 19.0 lb-ft) Rear stabilizer joint nut [Up to 5SAAR41A497105526: 34 N⋅m (3.4 kgf-m, 24.5 lb-ft)] Rear brake cam lever nut 11 N⋅m (1.1 kgf-m, 8.0 lb-ft) [From 5SAAR41A497105527: 60 N⋅m (6.0 kgf-m, 43.5 lb-ft)]...
Page 55: Compression Pressure Check
0B-26 Maintenance and Lubrication: Compression Pressure Check 3) Start the engine. B931G20206026 4) Shift the range lever to the “High” position. Refer to “Compression Pressure Check in Section 1D 5) Slowly open the throttle and note the engine speed (Page 1D-2)”. (r/min) when the vehicle begins to move forward.
Page 56: Tightening Torque Specifications
For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List in Section 0C (Page 0C-7)”. Special Tools and Equipment Recommended Service Material B931G20208001 Material SUZUKI recommended product or Specification Note Brake fluid DOT 4 — (Page 0B-18) NOTE Required service material is also described in the following.
Page 57 0B-28 Maintenance and Lubrication: 09915–40610 Oil filter wrench (Page 0B-12) / (Page 0B-12)
Page 58: Service Data
Service Data: 0C-1 Service Data General Information Specifications Service Data B931G20307001 Valve + Valve Guide Unit: mm (in) Item Standard Limit 36.0 (1.42) — Valve diam. 33.0 (1.30) — 0.10 – 0.20 (0.004 – 0.008) — Tappet clearance (When cold) 0.20 –...
Page 59 0C-2 Service Data: Cylinder + Piston + Piston Ring Unit: mm (in) Item Standard Limit Compression pressure (Automatic- Approx. 1 000 kPa (10.0 kgf/cm , 142 psi) — decomp. actuated) Piston-to-cylinder clearance 0.030 – 0.040 (0.0012 – 0.0016) 0.120 (0.0047) Nicks or Cylinder bore 104.000 –...
Page 60 Service Data: 0C-3 Drive Train Unit: mm (in) Except ratio Item Standard Limit Primary reduction ratio (Automatic Variable change (2.763 – 0.780) — drive) Secondary reduction ratio 2.158 (40/21 x 17/15) — Front 3.600 (36/10) — Final reduction ratio Rear 3.600 (36/10) —...
Page 61 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 62 Service Data: 0C-5 Electrical Unit: mm (in) Item 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. 150 – 250 Ω CKP sensor resistance CKP sensor peak voltage 5.0 V and more Terminal –...
Page 63 0C-6 Service Data: Brake + Wheel Unit: mm (in) Item Standard Limit Front brake disc thickness — 3.0 (0.12) Front brake disc runout — 0.30 (0.012) Front master cylinder bore 14.000 – 14.043 (0.5512 – 0.5529) — Front master cylinder piston diam. 13.957 –...
Page 64: Tightening Torque List
Service Data: 0C-7 Tightening Torque List B931G20307002 Engine Item N⋅m kgf-m lb-ft Spark plug Initial Cylinder head cover bolt Final 10.5 Cam drive idle gear/sprocket shaft 29.5 Intake pipe bolt Cylinder head bolt (M6) Initial 18.0 Cylinder head bolt (L200) Final 27.0 Cylinder head bolt (L: 70)
Page 65 0C-8 Service Data: Drive Train Item N⋅m kgf-m lb-ft 4WD/Diff-lock actuator mounting bolt 16.0 Front drive (Differential) gear case bolt 16.0 Front drive (Differential) gear case mounting nut 36.0 Front drive (Differential) gear oil level plug 0.85 Front drive (Differential) gear oil filler plug 25.5 Front drive (Differential) gear oil drain plug 23.0...
Page 66 Service Data: 0C-9 Chassis Item N⋅m kgf-m lb-ft Handlebar clamp bolt 19.0 Handlebar holder nut 43.5 Rear brake lever holder clamp bolt Throttle lever case bolt Steering shaft holder bolt 16.5 Steering shaft lower nut 16.2 117.0 Front suspension arm pivot nut (Upper) 43.5 Front suspension arm pivot nut (Lower) 47.0...
Page 67 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 lb-ft N⋅m kgf-m lb-ft 0.15 0.23 0.45 0.55...
Page 68 0C-11 Service Data:...
Page 69: Engine General Information And Diagnosis
Table of Contents 1- i Section 1 Engine CONTENTS Precautions ..........1-1 DTC “C40” (P05057): ISC Valve Circuit Malfunction............1A-62 Precautions............. 1-1 DTC “C41” (P230-H/L): FP Relay Circuit Precautions for Engine.......... 1-1 Malfunction............1A-67 Engine General Information and Specifications .............1A-69 Diagnosis ..........1A-1 Service Data............1A-69 Special Tools and Equipment ......1A-70 General Description ..........1A-1...
Page 70: Engine Mechanical
1-ii Table of Contents Service Data............1C-6 Recommended Service Material .......1D-69 Tightening Torque Specifications......1C-6 Special Tool ............1D-69 Special Tools and Equipment ......1C-7 Engine Lubrication System ....1E-1 Recommended Service Material ......1C-7 Precautions............1E-1 Special Tool ............1C-7 Precautions for Engine Oil ........1E-1 Engine Mechanical ........1D-1 Schematic and Routing Diagram ......1E-1 Schematic and Routing Diagram......1D-1 Engine Lubrication System Chart Diagram ..1E-1...
Page 71: Ignition System
Table of Contents 1-iii Water Pump Disassembly and Assembly ..1F-14 Spark Plug Cap and Spark Plug Removal and Water Pump Related Parts Inspection ....1F-18 Installation ............1H-3 Spark Plug Inspection and Cleaning ....1H-3 Specifications............. 1F-19 Ignition Coil and Plug Cap Inspection ....1H-3 Service Data .............
Page 72 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 73: Precautions
Precautions: Precautions Engine Precautions Precautions for Engine B831G21000001 Refer to “General Precautions in Section 00 (Page 00-1)” and “Precautions for Electrical Circuit Service in Section 00 (Page 00-2)”.
Page 74: Engine General Information And Diagnosis
1A-1 Engine General Information and Diagnosis: Engine General Information and Diagnosis Engine General Description Injection Timing Description B831G21101001 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 75 Engine General Information and Diagnosis: 1A-2 Compensation of Injection Time (Volume) The following different signals are output from the respective sensors for compensation of the fuel injection time (volume). Signal Descriptions ENGINE COOLANT TEMPERATURE SENSOR When engine coolant temperature is low, injection time (volume) SIGNAL is increased.
Page 76 1A-3 Engine General Information and Diagnosis: If “CHEC” is indicated, the LCD does not indicate the trouble code. It is necessary to check the wiring harness between ECM and speedometer couplers. The possible cause of this indication is as follows; Engine stop switch is in OFF position.
Page 77: Schematic And Routing Diagram
Engine General Information and Diagnosis: 1A-4 Schematic and Routing Diagram FI System Wiring Diagram B831G21102001 I831G1110002-04...
Page 78: Terminal Alignment Of Ecm Coupler
1A-5 Engine General Information and Diagnosis: Terminal Alignment of ECM Coupler B831G21102002 I831G1110003-03 TERMINAL NO. CIRCUIT TERMINAL NO. CIRCUIT Ignition coil (IG1) CKP sensor signal (CKP-) Fuel injector (#1) Fuel pump relay (FP relay) Power source (+B) Injector power voltage (VM) Back up power (BATT) Diff-lock relay (DL relay) Brake switch (BRK)
Page 79: Component Location
Engine General Information and Diagnosis: 1A-6 Component Location FI System Parts Location B831G21103001 “H” “D” “E” “I” “B” “C” “F” “G” I831G1110004-02 “A”: ECM “C”: TP sensor “E”: IAT sensor “G”: Speed sensor “I”: Diff-lock relay “B”: ISC valve “D”: IAP sensor “F”: CKP sensor “H”: Combination meter...
Page 80 1A-7 Engine General Information and Diagnosis: “L” “J” “M” “N” “K” “I” I831G1110005-03 “A”: ECM “J”: TO sensor “L”: Ignition coil “N”: Fuel pump “I”: ECT sensor “K”: Fuel injector “M”: FP relay...
Page 81: Diagnostic Information And Procedures
Engine General Information and Diagnosis: 1A-8 Diagnostic Information and Procedures Engine Symptom Diagnosis B831G21104001 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 82 1A-9 Engine General Information and Diagnosis: 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 83 Engine General Information and Diagnosis: 1A-10 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 84: Self-Diagnostic Procedures
1A-11 Engine General Information and Diagnosis: Self-Diagnostic Procedures 5) Check the DTC to determine the malfunction part. B831G21104002 Refer to “DTC Table (Page 1A-19)”. Use of Mode Select Switch Special tool NOTE (A): 09930–82720 (Mode select 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 85 Engine General Information and Diagnosis: 1A-12 Use of SDS NOTE • Do not disconnect the coupler from ECM, the battery cable from the battery, ECM ground wire harness from the engine or main fuse before confirming DTC (Diagnostic Trouble Code) stored in memory.
Page 86: Use Of Sds Diagnosis Reset Procedures
1A-13 Engine General Information and Diagnosis: 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 87: Show Data When Trouble (Displaying Data At The Time Of Dtc)
Engine General Information and Diagnosis: 1A-14 Show Data When Trouble (Displaying Data at the Time of DTC) B831G21104004 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 88: Sds Check
1A-15 Engine General Information and Diagnosis: 2) Click the drop down button (2), either “Failure #1” or “Failure #2” can be selected. I831G1110017-01 SDS Check B831G21104005 Using SDS, sample the data at the time of new and periodic vehicle inspections. After saving the sampled data in the computer, file them by model and by user.
Page 89 Engine General Information and Diagnosis: 1A-16 Sample Data sampled from cold starting through warm-up Check the engine r/min. 1 300 r/min Check the engine coolant temperature. XX° C Check the manifold absolute pressure. XXX kPa I831G1110009-03 Data at 3 000 r/min under no load Approx.
Page 90 1A-17 Engine General Information and Diagnosis: Data at the time of racing Throttle: Quick wide open Throttle: Slowly open I831G1110011-01...
Page 91 Engine General Information and Diagnosis: 1A-18 Example of Trouble Three data; value 1 (current data 1), value 2 (past data 2) and value 3 (past data 3); 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 92: Dtc Table
1A-19 Engine General Information and Diagnosis: DTC Table B831G21104006 Code Malfunction Part Remarks None No defective part C12 (P0335) Crankshaft position sensor (CKP sensor) Pick-up coil signal, signal generator (Page 1A-24) C13 (P0105-H/L) Intake air pressure sensor (IAP sensor) (Page 1A-27) C14 (P0120-H/L) Throttle position sensor (TP sensor) (Page 1A-34)
Page 93: Fi System Troubleshooting
Engine General Information and Diagnosis: 1A-20 FI System Troubleshooting B831G21104008 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 94 1A-21 Engine General Information and Diagnosis: 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 95: Malfunction Code And Defective Condition Table
Engine General Information and Diagnosis: 1A-22 Malfunction Code and Defective Condition Table B831G21104009 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 96 1A-23 Engine General Information and Diagnosis: 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 97: Dtc "C12" (P0335): Ckp Sensor Circuit Malfunction
Engine General Information and Diagnosis: 1A-24 DTC “C12” (P0335): CKP Sensor Circuit Malfunction B831G21104010 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 98 1A-25 Engine General Information and Diagnosis: Step Action 1) Turn the ignition switch OFF. Go to Step 2. Replace the CKP sensor with a new one. 2) Check the CKP sensor coupler for loose or poor contacts. If OK, then measure the CKP sensor resistance. I831G1110020-02 3) Disconnect the CKP sensor coupler and measure the resistance.
Page 99 Engine General Information and Diagnosis: 1A-26 Step Action 4) 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 100: Dtc "C13" (P0105-H/L): Iap Sensor Circuit Malfunction
1A-27 Engine General Information and Diagnosis: DTC “C13” (P0105-H/L): IAP Sensor Circuit Malfunction B831G21104011 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 101 Engine General Information and Diagnosis: 1A-28 C13 (Use of mode select switch) Step Action 1) Remove the front fender. Refer to “Front Side Exterior Go to Step 2. • Loose or poor Parts Removal and Installation in Section 9D (Page 9D- contacts on the ECM 6)”.
Page 102 1A-29 Engine General Information and Diagnosis: 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 front fender. Refer to “Front Side Exterior Parts Removal and Installation in Section 9D (Page 9D- 6)”.
Page 103 Engine General Information and Diagnosis: 1A-30 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 (Page 1C-1)”. 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 104 1A-31 Engine General Information and Diagnosis: P0105-L for IAP sensor (Use of SDS) Step Action 1) Turn the ignition switch OFF. Go to Step 2. R and G/B wire open, G/ B wire shorted to the 2) Remove the front fender. Refer to “Front Side Exterior ground.
Page 105 Engine General Information and Diagnosis: 1A-32 Step Action 6) Disconnect the ECM coupler. Refer to “ECM Removal Go to Step 2. R and G/B wire open, G/ and Installation in Section 1C (Page 1C-1)”. B wire shorted to the ground. 7) Insert the needle pointed probes to the lead wire coupler.
Page 106 1A-33 Engine General Information and Diagnosis: 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) Remove the IAP sensor. Refer to “IAP Sensor Removal ground, or poor “6”, sensor with a new one.
Page 107: Dtc "C14" (P0120-H/L): Tp Sensor Circuit Malfunction
Engine General Information and Diagnosis: 1A-34 DTC “C14” (P0120-H/L): TP Sensor Circuit Malfunction B831G21104012 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. Difference between actual throttle opening •...
Page 108 1A-35 Engine General Information and Diagnosis: C14 (Use of mode select switch) Step Action 1) Remove the left side cover. Refer to “Front Side Exterior Go to Step 2. • Loose or poor Parts Removal and Installation in Section 9D (Page 9D- contacts on the ECM 6)”.
Page 109 Engine General Information and Diagnosis: 1A-36 P0120-H (Use of SDS) Step Action 1) Remove the left side cover. Refer to “Front Side Exterior Go to Step 2. R wire shorted to VCC Parts Removal and Installation in Section 9D (Page 9D- or B/Br wire open.
Page 110 1A-37 Engine General Information and Diagnosis: Step Action 7) Disconnect the ECM coupler. Refer to “ECM Removal Go to Step 2. R wire shorted to VCC and Installation in Section 1C (Page 1C-1)”. or B/Br wire open. 8) Check the continuity between R wire “A” and terminal “6”.
Page 111 Engine General Information and Diagnosis: 1A-38 P0120-L (Use of SDS) Step Action 1) Remove the left side cover. Refer to “Front Side Exterior Go to Step 2. Y or R wire open, or Y Parts Removal and Installation in Section 9D (Page 9D- wire shorted to ground.
Page 112 1A-39 Engine General Information and Diagnosis: Step Action 7) Disconnect the ECM coupler. Refer to “ECM Removal Go to Step 2. Y or R wire open, or Y and Installation in Section 1C (Page 1C-1)”. wire shorted to ground. 8) Check the continuity between Y wire “B” and terminal “14”.
Page 113 Engine General Information and Diagnosis: 1A-40 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 114: Dtc "C15" (P0115-H/L): Ect Sensor Circuit Malfunction
1A-41 Engine General Information and Diagnosis: DTC “C15” (P0115-H/L): ECT Sensor Circuit Malfunction B831G21104013 Detected Condition and Possible Cause Detected Condition Possible Cause Output voltage is not with in the following • ECT sensor circuit open or short. range. • ECT sensor malfunction. 0.15 V ≤...
Page 115 Engine General Information and Diagnosis: 1A-42 C15 (Use of mode select switch) Step Action 1) Remove the left side cover. Refer to “Front Side Exterior Go to Step 2. • Loose or poor Parts Removal and Installation in Section 9D (Page 9D- contacts on the ECM 6)”.
Page 116 1A-43 Engine General Information and Diagnosis: P0115-H (Use of SDS) Step Action 1) Remove the left side cover. Refer to “Front Side Exterior Go to Step 2. B/Bl or B/Br wire open. Parts Removal and Installation in Section 9D (Page 9D- 6)”.
Page 117 Engine General Information and Diagnosis: 1A-44 P0115-L (Use of SDS) Step Action 1) Remove the left side cover. Refer to “Front Side Exterior Go to Step 2. • B/Bl wire shorted to Parts Removal and Installation in Section 9D (Page 9D- ground.
Page 118 1A-45 Engine General Information and Diagnosis: Step Action 8) Turn the ignition switch ON. Go to Step 2. • B/Bl wire shorted to ground. 9) Measure the output voltage between B/Bl wire and ground. • If wire is OK, go to Step 2.
Page 119 Engine General Information and Diagnosis: 1A-46 Step Action 1) Turn the ignition switch OFF. • B/Br or B/Bl wire Replace the ECT open or shorted to sensor with a new one. 2) Connect the ECM coupler. ground, or poor “24” Refer to “ECT Sensor 3) Disconnect the ECT sensor coupler.
Page 120: Dtc "C20" (P1752): Diff-Lock Relay Circuit Malfunction
1A-47 Engine General Information and Diagnosis: DTC “C20” (P1752): Diff-lock Relay Circuit Malfunction B831G21104014 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 121 Engine General Information and Diagnosis: 1A-48 Step Action 1) Remove the rear fender. Refer to “Front Side Exterior • Inspect the 4WD/diff- Replace the diff-lock Parts Removal and Installation in Section 9D (Page 9D- lock switch. relay with a new one. 6)”.
Page 122: Dtc "C21" (P0110-H/L): Iat Sensor Circuit Malfunction
1A-49 Engine General Information and Diagnosis: DTC “C21” (P0110-H/L): IAT Sensor Circuit Malfunction B831G21104015 Detected Condition and Possible Cause Detected Condition Possible Cause Output voltage is not with in the following • IAT sensor circuit open or short. range. • IAT sensor malfunction. 0.15 V ≤...
Page 123 Engine General Information and Diagnosis: 1A-50 C21 (Use of mode select switch) Step Action 1) Remove the left side cover. Refer to “Front Side Exterior Go to Step 2. • Loose or poor Parts Removal and Installation in Section 9D (Page 9D- contacts on the ECM 6)”.
Page 124 1A-51 Engine General Information and Diagnosis: P0110-H (Use of SDS) Step Action 1) Remove the left side cover. Refer to “Front Side Exterior Connect the ECM Dg or B/Br wire open. Parts Removal and Installation in Section 9D (Page 9D- coupler and go to step 6)”.
Page 125 Engine General Information and Diagnosis: 1A-52 Step Action 1) Turn the ignition switch OFF. • Dg or B/Br wire open Replace the IAT sensor or shorted to ground, with a new one. Refer to 2) Measure the IAT sensor resistance. or poor “28”...
Page 126: Dtc "C23" (P1651-H/L): To Sensor Circuit Malfunction
1A-53 Engine General Information and Diagnosis: DTC “C23” (P1651-H/L): TO Sensor Circuit Malfunction B831G21104016 Detected Condition and Possible Cause Detected Condition Possible Cause The sensor voltage should be the • TO sensor circuit open or short. following for 2 sec. and more, after ignition •...
Page 127 Engine General Information and Diagnosis: 1A-54 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 (Page 1D-5)”. with a new one.
Page 128 1A-55 Engine General Information and Diagnosis: 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 (Page 1D-5)”. VCC, or B/Br wire open. 2) Turn the ignition switch OFF.
Page 129 Engine General Information and Diagnosis: 1A-56 Step Action 7) Disconnect the ECM coupler. Go to Step 2. Br/W wire shorted to VCC, or B/Br wire open. 8) Check the continuity between Br/W wire “B” and terminal “10”. Also, check the continuity between B/Br wire “C” and terminal “24”.
Page 130 1A-57 Engine General Information and Diagnosis: Step Action 4) Remove the TO sensor. Go to Step 2. R or B wire open, or Br/ W wire shorted to the 5) Disconnect the TO sensor coupler. ground. 6) Insert the needle pointed probes to the lead wire coupler. 7) Check the continuity between Br/W wire “B”...
Page 131 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 132: Dtc "C24" (P0351): Ignition Coil Circuit Malfunction
1A-59 Engine General Information and Diagnosis: DTC “C24” (P0351): Ignition Coil Circuit Malfunction B831G21104017 NOTE Refer to “No Spark or Poor Spark in Section 1H (Page 1H-2)” for details. DTC “C32” (P0201): Fuel Injector Circuit Malfunction B831G21104018 Detected Condition and Possible Cause Detected Condition Possible Cause CKP signal is produced but fuel injector signal is...
Page 133 Engine General Information and Diagnosis: 1A-60 Step Action 1) Remove the side cover. Refer to “Front Side Exterior Go to Step 2. Replace the injector Parts Removal and Installation in Section 9D (Page 9D- with a new one. Refer to 6)”.
Page 134 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 1D Injector continuity (Page 1D-10)”.
Page 135: Dtc "C40" (P05057): Isc Valve Circuit Malfunction
Engine General Information and Diagnosis: 1A-62 DTC “C40” (P05057): ISC Valve Circuit Malfunction B831G21104019 Detected Condition and Possible Cause Detected Condition Possible Cause No voltage is applied to ISC valve motor, although ignition • ISC valve circuit open or shorted to the ground. switch is turned ON, or voltage is applied to ISC valve •...
Page 136 1A-63 Engine General Information and Diagnosis: Step Action 1) Remove the left side cover. Refer to “Front Side Exterior Go to Step 2. B/Lg, R/B, P/W, G or W/ Parts Removal and Installation in Section 9D (Page 9D- Bl wire open. 6)”.
Page 137 Engine General Information and Diagnosis: 1A-64 Step Action 1) Measure the resistance between terminals “A” and “C”, If wire is OK, Replace the ISC valve terminals “B” and “D”. intermittent trouble or with a new one. faulty ECM. Special tool (A): 09900–25008 (Multi-circuit tester set) ISC valve resistance Approx.
Page 138 1A-65 Engine General Information and Diagnosis: 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 139 Engine General Information and Diagnosis: 1A-66 Check 3 1) Click the button (6) and increase the “Spec” (2) to 1 400 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 140: Dtc "C41" (P230-H/L): Fp Relay Circuit Malfunction
1A-67 Engine General Information and Diagnosis: DTC “C41” (P230-H/L): FP Relay Circuit Malfunction B831G21104020 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 141 Engine General Information and Diagnosis: 1A-68 C41 (Use of mode select switch) Step Action 1) Remove the seat. Refer to “Front Side Exterior Parts • Y/Bl or O/W wire Replace the FP relay Removal and Installation in Section 9D (Page 9D-6)”. open or shorted to with a new one.
Page 142: Specifications
1A-69 Engine General Information and Diagnosis: 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 9D-6)”.
Page 143: Special Tools And Equipment
Engine General Information and Diagnosis: 1A-70 Special Tools and Equipment Special Tool B831G21108001 09900–25008 09900–25009 Multi-circuit tester set Needle pointed probe set (Page 1A-25) / (Page 1A-30) / (Page 1A-26) / (Page 1A-32) / (Page 1A-26) / (Page 1A-32) / (Page 1A-28) / (Page 1A-35) / (Page 1A-29) /...
Page 144: Emission Control Devices
1B-1 Emission Control Devices: Emission Control Devices Engine Precautions Precautions for Emission Control Devices B831G21200001 Refer to “General Precautions in Section 00 (Page 00-1)”. Repair Instructions Crankcase Breather (PCV) Hose Inspection Crankcase Breather (PCV) Hose Removal and B831G21206001 Installation Inspect the PCV hose in the following procedures: B831G21206002 Removal 1) Remove the seat.
Page 145: Engine Electrical Devices
Engine Electrical Devices: 1C-1 Engine Electrical Devices Engine Precautions Precautions for Engine Electrical Device B831G21300001 Refer to “General Precautions in Section 00 (Page 00-1)” and “Precautions for Electrical Circuit Service in Section 00 (Page 00-2)”. Component Location Engine Electrical Components Location B831G21303001 Refer to “Electrical Components Location in Section 0A (Page 0A-7)”.
Page 146: Iap Sensor Removal And Installation
• Align the throttle shaft end “A” with the groove “B” of TP sensor. • Apply grease to the throttle shaft end “A” if necessary. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I831G1130003-01 Tightening torque TP sensor mounting screw: 2 N·m (0.2 kgf-m, 1.5...
Page 147: Tp Sensor Adjustment
Engine Electrical Devices: 1C-3 TP Sensor Adjustment 7) Tighten the TP sensor mounting screw. B831G21306008 Tightening torque Adjust the TP sensor in the following procedures: TP sensor mounting screw: 2 N·m (0.2 kgf-m, 1) Connect the special tool to the mode select switch. 1.5 lb-ft) Refer to “Self-Diagnostic Procedures in Section 1A (Page 1A-11)”.
Page 148: Ect Sensor Removal And Installation
1C-4 Engine Electrical Devices: ECT Sensor Removal and Installation ECT Sensor Inspection B831G21306011 B831G21306012 Removal Refer to “DTC “C15” (P0115-H/L): ECT Sensor Circuit Malfunction in Section 1A (Page 1A-41)”. 1) Drain engine coolant. Refer to “Cooling System Inspect the ECT sensor in the following procedures: Inspection in Section 0B (Page 0B-15)”.
Page 149: To Sensor Inspection
Engine Electrical Devices: 1C-5 TO Sensor Inspection ISC Valve Removal and Installation B831G21306013 B831G21306016 Refer to “DTC “C23” (P1651-H/L): TO Sensor Circuit Removal Malfunction in Section 1A (Page 1A-53)”. CAUTION TO Sensor Removal and Installation Be careful not to disconnect the ISC valve B831G21306014 coupler at least 3 seconds after ignition Removal...
Page 150: Gp Switch Inspection
1C-6 Engine Electrical Devices: Installation GP Switch Inspection B831G21306017 Refer to “Gear Position Switch Inspection in Section 1I NOTE (Page 1I-9)”. When replacing the ISC valve, turn the ignition switch ON and OFF. GP Switch Removal and Installation B831G21306018 Install the ISC valve in the reverse order of removal. Refer to “Gear Position (GP) Switch Removal and Pay attention to the following points: Installation in Section 3C (Page 3C-13)”.
Page 151: Recommended Service Material
For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List in Section 0C (Page 0C-7)”. Special Tools and Equipment Recommended Service Material B831G21308001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010 (Page 1C-2)
Page 152: Engine Mechanical
1D-1 Engine Mechanical: Engine Mechanical Engine Schematic and Routing Diagram Throttle Cable Routing Diagram B831G21402001 “B” “A” I831G1140002-02 1. Throttle cable 5. Throttle cable guide 2. Brake hose “A”: Pass through the throttle cable inside of pin. 3. Handlebar “B”: Pass through the throttle cable inside of brake hose. 4.
Page 153: Diagnostic Information And Procedures
Engine Mechanical: 1D-2 Diagnostic Information and Procedures Engine Mechanical Symptom Diagnosis 5) Install the compression gauge and adaptor in the B831G21404001 spark plug hole. Make sure that the connection is Refer to “Engine Symptom Diagnosis in Section 1A tight. (Page 1A-8)”. Special tool (A): 09915–64512 (Compression gauge) Compression Pressure Check...
Page 154: Repair Instructions
1D-3 Engine Mechanical: Repair Instructions Engine Components Removable with the Engine in Place B831G21406001 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 155 Engine Mechanical: 1D-4 Engine Right Side Item Removal Inspection Installation Refer to “V-belt Type Refer to “V-belt Type Continuously Variable Refer to “Movable / Fixed Continuously Variable Fixed drive face Automatic Transmission Drive Face Parts Inspection Automatic Transmission Removal and Installation in in Section 5A (Page 5A-15)”.
Page 156: Air Cleaner Element Removal And Installation
1D-5 Engine Mechanical: Air Cleaner Element Removal and Installation 2) Disconnect the IAP sensor lead wire coupler (1) and B831G21406002 vacuum hose (2). Removal 1) Remove the seat. Refer to “Seat Removal and Installation in Section 9D (Page 9D-11)”. 2) Remove the air cleaner box cover (1). I831G1140011-01 3) Remove the air cleaner box mounting bolts.
Page 157: Throttle Cable Removal And Installation
Engine Mechanical: 1D-6 5) Remove the IAT sensor coupler (5) and PCV hose Throttle Cable Removal and Installation B831G21406005 (6). Removal 1) Remove the front fender. Refer to “Front Side Exterior Parts Removal and Installation in Section 9D (Page 9D-6)”. 2) Remove the right handlebar switch box.
Page 158: Throttle Body Components
1D-7 Engine Mechanical: Throttle Body Components B831G21406008 I831G1140016-05 1. TP sensor 6. Fuel injector 11. TP sensor mounting screw : Apply grease. 2. ISC valve 7. Cushion seal 12. ISC valve mounting screw : Apply engine oil. 3. IAP sensor 8.
Page 159: Throttle Body Construction
Engine Mechanical: 1D-8 Throttle Body Construction B831G21406009 “A” “A” I831G1140018-01 1. Air cleaner box 4. IAP sensor hose 2. Fuel hose 5. Clamp 3. PCV hose “A”: Pass through the fuel hose between air cleaner guide ribs. Throttle Body Removal and Installation B831G21406010 Removal 1) Remove the air cleaner box.
Page 160 1D-9 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). I831G1140022-01 I831G1140020-01 Installation 5) Remove the throttle cable cover (5). NOTE When replacing the throttle body, turn the ignition switch ON and OFF.
Page 161: Throttle Body Disassembly And Assembly
Engine Mechanical: 1D-10 • Connect the throttle cable. 2) Remove the fuel delivery pipe assembly (2) by removing its mounting screws. I831G1140027-01 • Tighten the throttle body clamp screws. Refer to I831G1140031-01 “Throttle Body Construction (Page 1D-8)”. 3) Remove the fuel injector (3). I831G1140028-01 I831G1140033-01 •...
Page 162 • Align the secondary throttle shaft end “A” with the groove “B” of TP sensor. • Apply grease to the secondary throttle shaft end “A” if necessary. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) Special tool : 09930–11950 (Torx wrench)
Page 163 Engine Mechanical: 1D-12 • Apply a thin coat of engine oil to the O-ring and install • Install the fuel injector (4) by pushing it straight to the the ISC valve assembly. throttle body. CAUTION CAUTION Replace the O-ring with a new one. Never turn the injector while pushing it.
Page 164: Throttle Body Inspection And Cleaning
1D-13 Engine Mechanical: Throttle Body Inspection and Cleaning ISC Valve Visual Inspection B831G21406012 Check the ISC valve for carbon deposits or other Refer to “Throttle Body Disassembly and Assembly damage. If carbon is deposited, remove it with a brush (Page 1D-10)”. and clean with a compressed air.
Page 165 Engine Mechanical: 1D-14 5) Remove the following parts from the vehicle. 9) Disconnect the radiator inlet hose (7) and outlet hose (8). • Front fender (1). Refer to “Front Side Exterior Parts Removal and Installation in Section 9D (Page 9D-6)”. •...
Page 166 1D-15 Engine Mechanical: 13) Disconnect the generator coupler (10), CKP sensor 19) Remove the rear propeller shaft (15). Refer to “Rear coupler (11) and gear position sensor coupler (12). Propeller Shaft Removal and Installation in Section 3D (Page 3D-17)”. I831G1140060-02 14) Remove the V-belt cooling ducts.
Page 167: Engine Assembly Installation
Engine Mechanical: 1D-16 23) Support engine with a jack and remove the engine • When installing the engine mounting damper stopper mounting bolts and nuts. (2), keep that the clearance are equal. “ a ” “ a ” I831G1140068-03 “a”: Clearance I831G1140066-01 •...
Page 168: Engine Top Side Disassembly
1D-17 Engine Mechanical: • Install the rear brake cable clamp (5). Engine Top Side Disassembly B831G21406015 It is unnecessary to remove the engine assembly from the frame when servicing the engine top side. CAUTION Identify the position of each removed part. Organize the parts in their respective groups (e.g., intake, exhaust) so that they can be reinstalled in their original positions.
Page 169 Engine Mechanical: 1D-18 8) Disconnect the ECT sensor coupler (1). 3) Remove the water pump outlet hose (3). I831G1140073-01 I831G1140081-03 9) Remove the engine mounting dumper stopper (2). Exhaust Pipe Remove the exhaust pipe. Refer to “Exhaust Pipe / Muffler Removal and Installation in Section 1K (Page 1K-2)”.
Page 170 1D-19 Engine Mechanical: Cylinder Head Cover 3) Remove the camshaft journal holders (1). Remove the cylinder head cover (1) and its gasket. CAUTION Be sure to loosen the camshaft journal holder bolts evenly by shifting the wrench diagonally. I831G1140084-02 Cam Shaft 1) Remove the valve timing inspection plug.
Page 171 Engine Mechanical: 1D-20 Cylinder Head 4) Remove the cylinder head (7). 1) Remove the cam drive idle gear/sprocket (1) by NOTE removing its shaft (2) with the idle shaft gasket (3) If the cylinder head does not come off easily, and cam chain idle shim (4).
Page 172: Engine Top Side Assembly
1D-21 Engine Mechanical: 4) Remove the dowel pins (6) and gasket (7). Engine Top Side Assembly B831G21406016 Assemble the engine top side in the reverse order of NOTE disassembly. Pay attention to the following points: Be careful not to drop the dowel pins (6) into the crankcase.
Page 173 M/O: Molybdenum oil (MOLYBDENUM OIL SOLUTION) • Apply bond lightly to the mating surfaces of crankcases. : Sealant 99000–31110 (SUZUKI BOND No.1215 or equivalent) • Fit the dowel pins (1) and the new gasket (2). CAUTION Replace the cylinder gasket (2) with a new one.
Page 174 1D-23 Engine Mechanical: Cam Chain Guide • Apply the engine oil to the threads and both sides of washers. • Install the cam chain guide (1). CAUTION Be sure that the cam chain guide (1) is installed properly. I831G1140113-01 • Tighten the cylinder head bolts to the specified two- step torque with a torque wrench sequentially and diagonally.
Page 175 Engine Mechanical: 1D-24 • Tighten the cylinder base nuts (5) to the specified • Install the cam drive idle gear/sprocket shaft (2), torque. copper washer (3) and shim (4). Tightening torque CAUTION Cylinder base nut (c): 10 N·m (1.0 kgf-m, 7.0 lb-ft) When checking the positions, remove the cam chain slack at the cam chain guide side by holding the cam drive idle gear/sprocket...
Page 176 1D-25 Engine Mechanical: • Tighten the cam drive idle gear/sprocket shaft (2) to the specified torque. CORRECT Tightening torque Cam drive idle gear/sprocket shaft (a): 41 N·m ( “F” 4.1 kgf-m, 29.5 lb-ft) “E” “E” “C” “D” I831G1140120-03 INCORRECT I831G1140328-01 “G”...
Page 177 Engine Mechanical: 1D-26 • Install the new O-ring (2), spring (3) and bar (4). • Apply engine oil to the camshaft journal holders. NOTE CAUTION Before installing the camshaft, check that the Use a new O-ring to prevent oil leakage. tappets are installed correctly.
Page 178: Valve Clearance Inspection And Adjustment
CAUTION Use a new gasket (1) to prevent oil leakage. • Apply bond to the cam end caps of the gasket as shown in the figure. : Sealant 99000–31230 (SUZUKI BOND No.1216B or equivalent) I831G1140131-01 Spark plug • Install the spark plug. Refer to “Spark Plug Cap and Spark Plug Removal and Installation in Section 1H (Page 1H-3)”.
Page 179: Camshaft Inspection
Engine Mechanical: 1D-28 Camshaft Inspection Cam height “a” B831G21406018 Service limit (IN.): 36.030 mm (1.4185 in) Refer to “Engine Top Side Disassembly (Page 1D-17)”. Service limit (EX.): 35.000 mm (1.3780 in) Refer to “Engine Top Side Assembly (Page 1D-21)”. Camshaft Identification The exhaust camshaft has the automatic decompression (1).
Page 180 1D-29 Engine Mechanical: 2) Use the plastigauge to read the clearance at the 6) This measurement should be taken at the widest widest portion, which is specified as follows. part of the compressed plastigauge. Special tool Camshaft journal oil clearance (IN. & EX.) (A): 09900–22301 (Plastigauge (0.025 –...
Page 181: Camshaft Sprocket Inspection
Engine Mechanical: 1D-30 Camshaft Sprocket Inspection Cam Chain Guide Removal and Installation B831G21406019 B831G21406021 Inspect the camshaft sprocket in the following Removal procedures: 1) Remove the cylinder head. Refer to “Engine Top 1) Remove the intake and exhaust camshafts. Refer to Side Disassembly (Page 1D-17)”.
Page 182: Cam Chain Tensioner Inspection
1D-31 Engine Mechanical: Cam Chain Tensioner Inspection Disassembly B831G21406023 1) Remove the tappet (1) and shim (2) by fingers or Inspect the cam chain tensioner in the following magnetic hand. procedures: 1) Remove the cylinder head. Refer to “Engine Top Side Disassembly (Page 1D-17)”.
Page 183 Engine Mechanical: 1D-32 4) Pull out the valve (6) from the combustion chamber 9) Remove the oil gallery plug (cylinder head) (10). side. I831G1140152-01 10) Remove the ECT sensor. Refer to “ECT Sensor I831G1140148-01 Removal and Installation in Section 1C (Page 1C- 5) Remove the oil seal (7) and spring seat (8).
Page 184 CAUTION Tightening torque Replace the O-ring with new ones. Water bypass union (c): 12 N·m (1.2 kgf-m, 8.5 lb- : Grease 99000–25010 (SUZUKI SUPER : Thread lock cement 99000–32050 GREASE A or equivalent) (THREAD LOCK CEMENT 1342 or equivalent) I831G1140156-01 I831G1140158-04 •...
Page 185 Engine Mechanical: 1D-34 • Insert the valve, with its stem coated with • Put on the valve spring retainer (3), and using the molybdenum oil all around and along the full stem special tools, press down the spring, fit the cotter length without any break.
Page 186: Cylinder Head Related Parts Inspection
1D-35 Engine Mechanical: • Install the other valves and springs in the same Valve Stem Runout manner as described previously. Support the valve using V-blocks, as shown, and check its runout using the dial gauge. If the runout exceeds the •...
Page 187 Engine Mechanical: 1D-36 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 188 1D-37 Engine Mechanical: 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 189: Valve Guide Replacement
Engine Mechanical: 1D-38 Valve Seat Sealing Condition Valve Guide Replacement B831G21406026 1) Clean and assemble the cylinder head and valve 1) Remove the cylinder head. Refer to “Engine Top components. Side Disassembly (Page 1D-17)”. 2) Fill the intake and exhaust ports with gasoline to 2) Remove the valves.
Page 190 1D-39 Engine Mechanical: 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 191: Valve Seat Repair
Engine Mechanical: 1D-40 Valve Seat Repair Cam Drive Idle Gear / Sprocket Thrust B831G21406027 Clearance Inspection and Adjustment The valve seats (1) for both the intake and exhaust B831G21406028 valves are machined to three different angles. The seat Inspection contact surface is cut at 45°. •...
Page 192: Cylinder Disassembly And Assembly
1D-41 Engine Mechanical: Adjustment Cylinder Disassembly and Assembly B831G21406029 If the thrust clearance is exceed the standard, adjust the Disassembly thrust clearance by the following procedures: Refer to “Engine Top Side Disassembly (Page 1D-17)”. • Remove the shim, and measure its thickness with a micrometer.
Page 193: Piston Ring Removal And Installation
Engine Mechanical: 1D-42 Cylinder Bore 3) Remove the 2nd ring and oil ring in the same Inspect the cylinder wall for any scratches, nicks or other manner. damage. If any defects are found, replace the cylinder with a new one. Installation Measure the cylinder bore diameter at six places.
Page 194: Piston And Piston Ring Inspection
1D-43 Engine Mechanical: b) Install the 2nd ring (3) and 1st ring (4) to piston. Piston and Piston Ring Inspection B831G21406032 Refer to “Piston Ring Removal and Installation NOTE (Page 1D-42)”. 1st ring (4) and 2nd ring (3) differ in shape. Piston Diameter Measure the piston diameter using the micrometer at 15 mm (0.6 in) “a”...
Page 195 Engine Mechanical: 1D-44 Piston Ring-to-groove Clearance Piston Ring Free End Gap and Piston Ring End Gap Measure the side clearances of the 1st and 2nd piston Measure the piston ring free end gap using vernier rings using the thickness gauge. If any of the clearances calipers.
Page 196: Engine Bottom Side Disassembly
1D-45 Engine Mechanical: Piston Pin and Pin Bore Engine Bottom Side Disassembly B831G21406033 Measure the piston pin bore inside diameter using the Remove the engine assembly. Refer to “Engine small bore gauge. If measurement is out of specification, Assembly Removal (Page 1D-13)”. replace the piston.
Page 197 Engine Mechanical: 1D-46 Water Pump Starter Torque Limiter / Starter Idle Gear Remove the water pump (1). 1) Remove the starter torque limiter (1) with the washers (2). 2) Remove the starter idle gear (3) and shaft (4). I831G1140192-01 Starter Cup I831G1140196-02 1) Remove the starter cup nut (1) with a suitable bar.
Page 198 1D-47 Engine Mechanical: Gear Shift System 2) Remove the drive gear spacer (3) and output shaft spacer (4). 1) Remove the washers (1) and gearshift shaft (2). 2) Remove the cam driven gear (3) by removing its bolt (4). I831G1140204-01 Cam Chain / Cam Chain Tensioner I831G1140198-02 1) Remove the cam chain tensioner bolt (1), cam chain...
Page 199 Engine Mechanical: 1D-48 3) Remove the pin (4) and washer (5). 4) Remove the keys (5). 4) Remove the oil pump (6). NOTE Do not drop the pin (4) and washer (5) into the crankcase. I831G1140212-01 5) Unlock the crank balancer drive gear nut. I831G1140209-01 Balancer Shaft Drive / Driven Gear 1) Remove the balancer shaft driven gear bolts (1) by...
Page 200 1D-49 Engine Mechanical: 7) Remove the washer (6) and crank balancer drive Oil Jet gear (7). Remove the oil jet (1) from crankcase. I831G1140215-01 I831G1140218-01 8) Remove the pin (8). Oil Gallery Plug Remove the oil gallery plug (1) and gasket (2). I831G1140216-01 Automatic Transmission I831G1140219-01...
Page 201 Engine Mechanical: 1D-50 Crankcase Oil Strainer Remove the oil strainer (1). 1) Remove the crankcase bolts “A” and clamp (1). 2) Remove the crankcase bolts “B”. NOTE Loosen the crankcase bolts diagonally with the smaller sizes first. “A” I831G1140229-01 “B” “A”...
Page 202: Engine Bottom Side Assembly
1D-51 Engine Mechanical: Crankshaft Engine Bottom Side Assembly B831G21406034 1) Install the removed generator cover (1) and tighten Assemble the engine bottom side in the reverse order of the bolts at three places. disassembly. Pay attention to the following points: NOTE Apply engine oil to each running and sliding part before reassembling.
Page 203 I831G1140248-03 • Apply bond to the mating surface of the right crankcase. I831G1140246-01 : Sealant 99000–31110 (SUZUKI BOND Transfer / Rear Output Shaft / Rear Output Shaft No.1215 or equivalent) Bevel Gear • Install the rear output shaft bevel gear (1) and rear output shaft (2).
Page 204 CAUTION • Tighten the crankcase bolts to the specified torque. Use the new O-ring to prevent oil leakage. NOTE : Grease 99000–25010 (SUZUKI SUPER • Tighten the larger diameter crankcase GREASE A or equivalent) bolts first and then smaller ones diagonally and evenly.
Page 205 Engine Mechanical: 1D-54 • Tighten the gear position switch mounting bolts. Oil Jet When installing the oil jet, apply grease to the O-ring. CAUTION CAUTION • Be careful not to tighten the bolts too Use a new O-ring to prevent oil pressure leak. much.
Page 206 1D-55 Engine Mechanical: • Install the crank balancer drive gear (2) and washer • Install the keys (4). (3). I831G1140268-01 • Install the crank balancer driven gears (5) water pump I831G1140265-02 • Hold the crank balancer drive gear with the special drive gear (6) and oil pump drive gear (7).
Page 207 Engine Mechanical: 1D-56 • Apply thread lock to the balancer driven gear bolts. • Install the oil pump drive gear (3) with chain (4). • Install the snap ring (5). : Thread lock cement 99000–32030 (THREAD LOCK CEMENT SUPER 1303 or NOTE equivalent) Be careful not to drop the snap ring (5) into...
Page 208 1D-57 Engine Mechanical: • Install the snap ring (3). • Install the gearshift cam stopper plate (5). NOTE CAUTION Align the gearshift cam pin “B” with the The removed snap ring must be replaced gearshift cam stopper plate hole “C”. with a new one.
Page 209 Apply molybdenum oil solution to the inside of the bushings. • Apply grease to the O-ring and lip of the oil seal. • Install the starter cup (1). M/O: Molybdenum oil (MOLYBDENUM OIL : Grease 99000–25010 (SUZUKI SUPER SOLUTION) GREASE A or equivalent) I831G1140285-01 I831G1140288-01...
Page 210: Conrod And Crankshaft Inspection
34 mm)) CAUTION Conrod small end I.D. Replace the O-ring with a new one. Service limit: 23.040 mm (0.9071 in) : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I831G1140292-02 I831G1140290-01 • Tighten the water pump mounting bolts (1) to the specified torque.
Page 211: Width Between Crankshaft Webs
Engine Mechanical: 1D-60 Conrod Deflection Crankshaft Runout Wear On the big end of the conrod can be estimated by • Measure the crankshaft runout with V-blocks and dial checking the movement of the small end of the rod. This gauge. method can also check the extent of ware on the parts of NOTE the conrod’s big end.
Page 212: Crankshaft Oil Seal Inspection
1D-61 Engine Mechanical: Crankshaft Oil Seal Inspection Generator cover B831G21406037 Check the oil seal for damage. If any damage is found, replace the oil seal with a new one. Refer to “Engine Bottom Side Disassembly (Page 1D-45)” and “Bearing Removal and Installation (Page 1D-61)”. I831G1140301-03 Bearing Removal and Installation B831G21406039...
Page 213 Engine Mechanical: 1D-62 3) Remove the other bearings (2) with the special tool. 3) Remove the each bearing (2) with the special tool. Special tool Special tool (B): 09913–70210 (Bearing installer set) (B): 09921–20240 (Bearing remover set) I831G1140304-01 I831G1140307-03 4) Remove the front output shaft bearing (3) with the Right crankcase special tools.
Page 214 1D-63 Engine Mechanical: 6) Remove the oil seal (5) with the special tool. 4) Remove the oil seal (3) with the special tool. Special tool Special tool (F): 09913–70210 (Bearing installer set) (B): 09913–50121 (Oil seal remover) I831G1140310-01 I831G1140313-01 5) Remove the speed sensor (4). Generator cover 1) Remove the magnet stator.
Page 215 CAUTION CAUTION Replace the O-ring with a new one. Use the special tool suitable size for each : Grease 99000–25010 (SUZUKI SUPER bearing to prevent damage. GREASE A or equivalent) Special tool 5) Tighten the bolt to the specified torque.
Page 216 1D-65 Engine Mechanical: Right crankcase Left crankcase 1) Install the oil seals (1) with the special tool. 1) Install the bearings (1) with the special tool. Special tool CAUTION : 09913–70210 (Bearing installer set) Use the special tool suitable size for each bearing to prevent damage.
Page 217: Specifications
Engine Mechanical: 1D-66 Specifications Service Data B831G21407001 Valve + Valve Guide Unit: mm (in) Item Standard Limit 36.0 (1.42) — Valve diam. 33.0 (1.30) — 0.10 – 0.20 (0.004 – 0.008) — Tappet clearance (when cold) 0.20 – 0.30 (0.008 – 0.012) —...
Page 218 1D-67 Engine Mechanical: Cylinder + Piston + Piston Ring Unit: mm (in) Item Standard Limit Compression pressure (Automatic- Approx. 1 000 kPa (10.0 kgf/cm , 142 psi) — decomp. actuated) Piston-to-cylinder clearance 0.030 – 0.040 (0.0012 – 0.0016) 0.120 (0.0047) Cylinder bore 104.000 –...
Page 219: Tightening Torque Specifications
Engine Mechanical: 1D-68 Tightening Torque Specifications B831G21407002 Tightening torque Fastening part Note N⋅m kgf-m lb-ft Air cleaner box mounting bolt 0.45 (Page 1D-6) TP sensor mounting screw (Page 1D-11) ISC valve mounting screw (Page 1D-12) Fuel delivery pipe mounting screw (Page 1D-12) Engine mounting nut 43.5...
Page 220: Special Tools And Equipment
1D-69 Engine Mechanical: Special Tools and Equipment Recommended Service Material B831G21408001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010 (Page 1D-11) / equivalent (Page 1D-33) / (Page 1D-52) / (Page 1D-53) / (Page 1D-53) /...
Page 221 Engine Mechanical: 1D-70 09900–20530 09900–20602 Cylinder gauge set Dial gauge (1/1000 mm, 1 (Page 1D-42) (Page 1D-29) / (Page 1D-45) 09900–20605 09900–20607 Dial calipers (1/100 mm, 10 Dial gauge (1/100 mm, 10 – 34 mm) (Page 1D-59) (Page 1D-28) / (Page 1D-35) / (Page 1D-35) / (Page 1D-36) /...
Page 222 1D-71 Engine Mechanical: 09915–40610 09915–63311 Oil filter wrench Compression gauge attachment (Page 1D-45) (Page 1D-2) 09915–64512 09916–10911 Compression gauge Valve lapper set (Page 1D-2) (Page 1D-37) 09916–14510 09916–14521 Valve spring compressor Valve spring compressor attachment (Page 1D-31) / (Page 1D-31) (Page 1D-34) 09916–14910 09916–34542...
Page 223 Engine Mechanical: 1D-72 09920–53740 09921–20240 Clutch sleeve hub holder Bearing remover set (Page 1D-48) / (Page 1D-61) / (Page 1D-55) (Page 1D-62) / (Page 1D-63) 09923–74511 09924–52460 Bearing remover Socket (52 mm) (Page 1D-62) (Page 1D-48) / (Page 1D-48) / (Page 1D-55) / (Page 1D-56) 09930–11950...
Page 224: Engine Lubrication System
1E-1 Engine Lubrication System: Engine Lubrication System Engine Precautions Precautions for Engine Oil B831G21500001 Refer to “Fuel and Oil Recommendation in Section 0A (Page 0A-3)”. Schematic and Routing Diagram Engine Lubrication System Chart Diagram B831G21502001 CAM FACE & TAPPET CAMSHAFT CYLINDER WALL ONE-WAY CLUCH SHOE...
Page 225: Diagnostic Information And Procedures
Engine Lubrication System: 1E-2 Diagnostic Information and Procedures Engine Lubrication Symptom Diagnosis B831G21504001 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-3 Engine Lubrication System: 7) After warm up, increase the engine speed to 3 000 r/ 8) Stop the engine and remove the oil pressure gauge min (Observe the tachometer), and read the oil and attachment. pressure gauge. 9) Reinstall the main oil gallery plug (1) and tighten it to If the oil pressure is lower or higher than the the specified torque.
Page 227: Oil Sump Filter Inspection And Cleaning
Engine Lubrication System: 1E-4 Installation Oil Sump Filter Inspection and Cleaning B831G21506004 Install the oil sump filter in the reverse order of removal. Inspect the oil sump filter in the following procedures: Pay attention to the following points: 1) Remove the oil sump filter. Refer to “Oil Sump Filter •...
Page 228: Oil Jet Inspection
1E-5 Engine Lubrication System: Installation 3) Remove the starter torque limiter and starter idle Install the oil jet in the reverse order of removal. Pay gear (2). Refer to “Starter Torque Limiter / Starter attention to the following point: Clutch Removal and Installation in Section 1I (Page 1I-10)”.
Page 229 Engine Lubrication System: 1E-6 7) Remove the snap ring (7) and oil pump driven gear • Install the new snap ring (1). (8). Special tool Special tool : 09900–06107 (Snap ring pliers) : 09900–06107 (Snap ring pliers) • Install the oil pump drive gear (2) with chain. 8) Remove the pin (9), washer (10) and oil pump (11).
Page 230: Oil Pump Inspection
1E-7 Engine Lubrication System: Oil Pump Inspection • Hold the crank balancer driven gear with the special B831G21506008 tool and tighten the oil pump drive gear bolt (3) to the Inspect the oil pump in the following procedures: specified torque. 1) Remove the oil pump.
Page 231: Special Tools And Equipment
Engine Lubrication System: 1E-8 Special Tools and Equipment Recommended Service Material B831G21508001 Material SUZUKI recommended product or Specification Note Thread lock cement THREAD LOCK CEMENT SUPER P/No.: 99000–32030 (Page 1E-6) 1303 or equivalent THREAD LOCK CEMENT 1342 or P/No.: 99000–32050...
Page 232: Engine Cooling System
1F-1 Engine Cooling System: Engine Cooling System Engine Precautions Precautions for Engine Cooling System B831G21600001 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 233: Engine Coolant Description
Engine Cooling System: 1F-2 Schematic and Routing Diagram Cooling Circuit Diagram B831G21602001 ENGINE COOLANT RESERVOIR THERMOSTAT TEMPERATURE CYLINDER HEAD TANK SWITCH CYLINDER BYPASS COOLING FAN THERMO RADIATOR SWITCH WATER PUMP I831G1160001-02...
Page 234: Water Hose Routing Diagram
1F-3 Engine Cooling System: Water Hose Routing Diagram B831G21602002 “ D ” “A” “B” “A” “A” “B” “C” “A” I831G1160002-05 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 lb-ft) 3.
Page 235: Diagnostic Information And Procedures
Engine Cooling System: 1F-4 Diagnostic Information and Procedures Engine Cooling Symptom Diagnosis B831G21604001 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 236: Radiator Cap Inspection
1F-5 Engine Cooling System: Radiator Cap Inspection Radiator Cleaning B831G21606002 Blow out any foreign matter that is stuck in the radiator Inspect the radiator cap in the following procedures: fins using compressed air. 1) Remove the radiator cap. Refer to “Cooling Circuit CAUTION Inspection (Page 1F-4)”.
Page 237 Engine Cooling System: 1F-6 4) Disconnect the cooling fan motor coupler (3). 7) Disconnect the inlet hose (6) and outlet hose (7). I831G1160055-01 I831G1160009-01 5) Remove the cooling fan assembly (4) by removing 8) Remove the radiator (8) by removing the bolts. the bolts.
Page 238: Water Hose Removal And Installation
1F-7 Engine Cooling System: Cooling Fan Inspection Installation Install the cooling fan assembly and radiator in the B931G21606006 Inspect the cooling fan in the following procedures: reverse order of removal. Pay attention to the following 1) Disconnect the cooling fan motor coupler (1). points: •...
Page 239: Radiator Reservoir Tank Removal And Installation
Engine Cooling System: 1F-8 Radiator Reservoir Tank Removal and Radiator Reservoir Tank Inspection B831G21606008 Installation Inspect the radiator reservoir tank cooling leaks. If any B831G21606007 defects are found, replace the radiator reservoir tank Removal with a new one. 1) Remove the right inner fender. Refer to “Front Side Exterior Parts Removal and Installation in Section 9D (Page 9D-6)”.
Page 240: Ect Sensor Removal And Installation
1F-9 Engine Cooling System: 3) Any leakage from the connecting section should be ECT Sensor Removal and Installation B831G21606010 corrected by proper tightening. Refer to “Water Hose Refer to “ECT Sensor Removal and Installation in Routing Diagram (Page 1F-3)”. Section 1C (Page 1C-4)”. ECT Sensor Inspection B831G21606011 Refer to “ECT Sensor Inspection in Section 1C...
Page 241: Cooling Fan Thermo-Switch Inspection
Engine Cooling System: 1F-10 Installation Cooling Fan Thermo-switch Inspection B831G21606013 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-11 Engine Cooling System: Thermostat Removal and Installation Installation B831G21606014 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 0B- thermostat.
Page 243: Thermostat Inspection
Engine Cooling System: 1F-12 5) Heat the water by placing the beaker on a stove and • Pour engine coolant. Refer to “Cooling System observe the rising temperature on a thermometer Inspection in Section 0B (Page 0B-15)”. (2). • Bleed air from the cooling circuit. Refer to “Cooling System Inspection in Section 0B (Page 0B-15)”.
Page 244: Water Pump Components
1F-13 Engine Cooling System: Water Pump Components B831G21606016 I831G1160033-05 1. Water pump cover 4. Mechanical seal : 6 N⋅m (0.6 kgf-m, 4.5 lb-ft) : Apply engine coolant. 2. O-ring 5. Oil seal : 13 N⋅m (1.3 kgf-m, 9.5 Ib-ft) : Do not reuse. 3.
Page 245: Water Pump Disassembly And Assembly
1) Remove the O-rings (1), snap ring (2), washer (3) Replace the O-rings with the new ones. and water pump driven gear (4). : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) • Set the water pump driven gear (1) to the water pump drive gear (2) and install the water pump assembly (3).
Page 246 1F-15 Engine Cooling System: 4) Remove the pin (7) and washer (8). 7) Remove the mechanical seal with the special tool. NOTE If there is no abnormal condition, the mechanical seal removal is not necessary. Special tool (A): 09921–20240 (Bearing remover set) I831G1160040-02 5) Remove the impeller (9).
Page 247 I831G1160047-01 I831G1160045-01 2) Apply a small quantity of the grease to the oil seal lip. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I831G1160048-01 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 6) Apply grease to the impeller shaft. 9) Install the water pump driven gear (5), washer (6) and snap ring (7). : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) CAUTION 7) Install the impeller shaft to the water pump body.
Page 249: Water Pump Related Parts Inspection
Engine Cooling System: 1F-18 11) Fit the water pump cover and tighten the water pump Oil Seal cover screws (9) to the specified torque. Visually inspect the oil seal for damage, with particular attention given to the lip. Tightening torque Replace the oil seal that shows indications of leakage.
Page 250: Specifications
1F-19 Engine Cooling System: Specifications Service Data B831G21607001 Thermostat + Radiator + Fan + Coolant Item Standard Note Thermostat valve opening Approx. 82 °C (180 °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-20 Special Tools and Equipment Recommended Service Material B831G21608001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010 (Page 1F-14) / equivalent (Page 1F-16) / (Page 1F-17) NOTE Required service material is also described in the following.
Page 252: Fuel System
1G-1 Fuel System: Fuel System Engine Precautions Precautions for Fuel System B831G21700001 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 B831G21701001 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 B831G21702001 Intake pipe Outlet tube VIEW A I831G1170002-04 1. Fuel hose 4. IAP sensor hose 2. Air cleaner box 5. Pass the fuel hose between the air cleaner guide. 3.
Page 255: Fuel Tank Breather Hose Routing Diagram
Fuel System: 1G-4 Fuel Tank Breather Hose Routing Diagram B831G21702002 “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 lb-ft) 3.
Page 256: Diagnostic Information And Procedures
1G-5 Fuel System: Diagnostic Information and Procedures Fuel System Diagnosis B831G21704001 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. B831G21706001 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 Discharge Amount Inspection
1G-7 Fuel System: Fuel Discharge Amount Inspection 6) Connect a proper lead wire into the fuel pump lead B831G21706003 wire coupler (fuel pump side) and apply 12 V to the WARNING fuel pump (between (+) Y/R wire and (–) B/W wire) for 10 seconds and measure the amount of fuel •...
Page 259: Fuel Hose Inspection
Fuel System: 1G-8 3) First, check for insulation with the tester between Fuel Level Gauge Inspection B831G21706007 terminals “A” and “B”. Next, check for continuity Refer to “Fuel Level Gauge Inspection in Section 9C between “A” and “B” with 12 V voltage applied, (Page 9C-6)”.
Page 260: Fuel Pump Components
1G-9 Fuel System: 7) Remove the fuel tank lower cover (4). Fuel Pump Assembly Removal and Installation B831G21706011 Removal WARNING • Spilled gasoline should be wiped off immediately. • Keep away from fire or spark. • Work in a well-ventilated area. 1) Remove the fuel tank.
Page 261: Fuel Pump Disassembly And Assembly
Fuel System: 1G-10 Fuel Pump Disassembly and Assembly Fuel Injector Inspection and Cleaning B831G21706012 B831G21706014 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: 4) Disconnect the injector coupler (2). Installation Install the fuel injector / fuel delivery pipe in the reverse order of removal. Pay attention to the following points: • Apply a thin coat of engine oil to the new cushion seal (1) and O-ring (2).
Page 263: Fuel Tank Pressure Control (Ftpc) Valve Removal And Installation
Fuel System: 1G-12 • Install the fuel delivery pipe assembly (5) to the 5) Remove the mad guard mounting fasteners (1) and throttle body assembly. screws (2). CAUTION Never turn the fuel injector while installing it. • Tighten the fuel delivery pipe mounting screws to the specified torque.
Page 264: Fuel Tank Pressure Control (Ftpc) Valve Inspection
1G-13 Fuel System: 7) Move the rear fender upside. Fuel Tank Pressure Control (FTPC) Valve Inspection 8) Disconnect the breather hoses (4) and remove the B831G21706017 FTPC valve (5). 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)”.
Page 265: Tightening Torque Specifications
Fuel System: 1G-14 Tightening Torque Specifications B831G21707002 Tightening torque Fastening part Note N⋅m kgf-m lb-ft Fuel pump retainer 25.5 (Page 1G-9) Fuel delivery pipe mounting screw (Page 1G-12) NOTE The specified tightening torque is also described in the following. “Fuel Tank Breather Hose Routing Diagram (Page 1G-4)” Reference: For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List in Section 0C (Page 0C-7)”.
Page 266: Ignition System
1H-1 Ignition System: Ignition System Engine General Description Override Switch Description B831G21801001 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 B831G21804001 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 and Go to Step 5. Faulty spark plug. Cleaning in Section 0B (Page 0B-9)”. Is the spark plug OK? Inspect the ignition coil. Refer to “Ignition Coil and Plug Cap Go to step 6.
Page 269 Ignition System: 1H-4 3) Connect the new spark plug to spark plug cap and ground it to the cylinder head. NOTE Be sure that the spark plug is connected properly and the battery used is in fully- charged condition. I831G1180006-01 “B”...
Page 270: Ckp Sensor Inspection
1H-5 Ignition System: 3) Measure the ignition coil resistance in both the 3) Connect the multi-circuit tester with the peak volt primary and secondary coils. If the resistance is not adaptor as follows: within the standard range, replace the ignition coil CAUTION with a new one.
Page 271: Ckp Sensor Removal And Installation
Ignition System: 1H-6 CKP Sensor Resistance Engine Stop Switch Inspection B831G21806006 1) Remove the left side cover and engine side cover. Inspect the engine stop switch in the following Refer to “Front Side Exterior Parts Removal and procedures: Installation in Section 9D (Page 9D-6)”. 1) Turn the ignition switch OFF.
Page 272: Ignition Switch Removal And Installation
1H-7 Ignition System: Ignition Switch Removal and Installation Override Switch Inspection B831G21806008 B831G21806009 Removal 1) Remove the left inner fender. Refer to “Front Side 1) Remove the left inner fender. Refer to “Front Side Exterior Parts Removal and Installation in Section Exterior Parts Removal and Installation in Section 9D (Page 9D-6)”.
Page 273: Specifications
Ignition System: 1H-8 Specifications Service Data B831G21807001 Electrical Unit: mm (in) Item Specification Note NGK: CR6E Type DENSO: U20ESR-N Spark plug 0.7 – 0.8 (0.028 – 0.031) Spark performance Over 8 (0.3) at 1 atm. 150 – 250 Ω CKP sensor resistance CKP sensor peak voltage 5.0 V and more 0.1 –...
Page 274: Starting System
1I-1 Starting System: Starting System Engine Schematic and Routing Diagram Starting System Diagram B831G21902001 Refer to “Wire Color Symbols in Section 0A (Page 0A-5)”. Starter Engine Ignition stop switch Ignition button switch fuse Main Neutral relay fuse Starter motor Neutral indicator light Parking...
Page 275: Starter Motor Will Not Run
Starting System: 1I-2 Starter Motor will not Run B831G21904002 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 B831G21906001 I831G1190002-04 1. O-ring 5. Starter motor case : Apply grease to sliding surface. 2. Housing end (Inside) 6. Housing end (Outside) : Apply moly paste to sliding surface. 3. Armature : 6 N⋅m (0.6 kgf-m, 4.5 lb-ft) : Do not reuse.
Page 277: Starter Motor Removal And Installation
Pay attention to the following points: Disassembly • Apply grease to the starter motor O-ring. Disassemble the starter motor as shown in the starter : Grease 99000–25010 (SUZUKI SUPER motor components diagram. Refer to “Starter Motor GREASE A or equivalent) Components (Page 1I-3)”.
Page 278: Starter Motor Inspection
Brush length “a” • Apply a small quantity of moly paste to the armature Service limit: 6.0 mm (0.24 in) shaft. Special tool : Moly paste 99000–25140 (SUZUKI Moly : 09900–20102 (Vernier calipers (1/20 mm, 200 paste or equivalent) mm)) “a”...
Page 279: Starter Relay Removal And Installation
Starting System: 1I-6 Commutator Bearing Inspect the commutator for discoloration, abnormal wear Check the bearing of housing end for damage. or undercut “A”. If any damage is found, replace the housing end. If the commutator is abnormally worn, replace the armature.
Page 280: Starter Relay Inspection
1I-7 Starting System: Installation 3) Measure the relay coil resistance between the Install the starter relay in the reverse order of removal. terminals using the multi-circuit tester. If the resistance is not within the specified value, replace the starter relay with a new one. Starter Relay Inspection B831G21906006 Special tool...
Page 281: Neutral Relay Inspection
Starting System: 1I-8 Neutral Relay Inspection B831G21906008 Inspect the neutral relay in the following procedures: “A” 1) Remove the neutral relay. Refer to “Neutral Relay Removal and Installation (Page 1I-7)”. 2) Check the insulation between “A” and “B” terminals using the multi-circuit tester. 3) Apply 12 V to terminals “C”...
Page 282: Parking Brake Relay Inspection
1I-9 Starting System: Parking Brake Relay Inspection 3) Inspect the parking brake switch for continuity with a B831G21906011 tester. If any abnormality is found, replace the Inspect the parking brake relay in the following parking brake switch with a new one. Refer to procedures: “Handlebars Removal and Installation in Section 6B 1) Remove the parking brake relay.
Page 283: Starter Torque Limiter / Starter Clutch Removal And Installation
Starting System: 1I-10 4) After finishing the gear position switch inspection, 5) Remove the idle gear shaft (5) and starter idle gear reinstall the removed parts. (6). 6) Remove the generator rotor assembly (7). Refer to Starter Torque Limiter / Starter Clutch Removal “Generator Removal and Installation in Section 1J and Installation (Page 1J-4)”.
Page 284 1I-11 Starting System: Installation • Apply thread lock to the bolts, and then tighten them Install the starter clutch in the reverse order of removal. to the specified torque. Pay attention to the following points: : Thread lock cement 99000–32030 •...
Page 285: Starter Driven Gear Bearing Removal And Installation
Starting System: 1I-12 • Fit the washers (3) onto the starter torque limiter (4). Starter Related Parts Inspection B831G21906016 • Install the starter torque limiter (4) to the crankcase. Refer to “Starter Torque Limiter / Starter Clutch Removal and Installation (Page 1I-10)”. Starter Clutch 1) Install the starter driven gear onto the starter clutch.
Page 286: Starter Button Inspection
1I-13 Starting System: Starter Torque Limiter Starter Button Inspection B831G21906017 Inspect the starter button in the following procedures: CAUTION 1) Remove the left inner fender. Refer to “Front Side Do not attempt to disassemble the starter Exterior Parts Removal and Installation in Section torque limiter.
Page 287: Recoil Starter Components
Starting System: 1I-14 Recoil Starter Components B831G21906018 I831G1190046-04 1. Ratchet set 3. Spiral spring : Apply grease. 2. Reel 4. Rope assembly : Apply thread lock to the thread part. Recoil Starter Assembly Removal and Installation Install the recoil starter assembly in the reverse order of Installation removal.
Page 288: Recoil Starter Disassembly And Assembly
1I-15 Starting System: Recoil Starter Disassembly and Assembly 4) Disengage the rope (9) from the handle (10). B831G21906020 Refer to “Recoil Starter Assembly Removal and Installation (Page 1I-14)”. Disassembly WARNING Wear hand and eye protection when removing the reel, since the spring may quickly unwind and cause an injury.
Page 289 • Apply grease to the spiral spring. I831G1190058-02 • Install the ratchet related parts. : Grease 99000–25010 (SUZUKI SUPER • Apply grease to the shaft and ratchet guide. GREASE A or equivalent) : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) “A”...
Page 290: Recoil Starter Inspection
1I-17 Starting System: Recoil Starter Inspection Rope B831G21906021 Inspect the rope for damage. If any defects are found, replace the rope with a new one. Ratchet Set Inspect the ratchet set for wear or damage. If any defects are found, replace the ratchet set with a new one.
Page 291: Specifications
For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List in Section 0C (Page 0C-7)”. Special Tools and Equipment Recommended Service Material B831G21908001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010 (Page 1I-4) /...
Page 292: Special Tool
1I-19 Starting System: Special Tool B831G21908002 09900–20102 09900–25008 Vernier calipers (1/20 mm, Multi-circuit tester set 200 mm) (Page 1I-5) (Page 1I-6) / (Page 1I-7) (Page 1I-7) / (Page 1I- 8) / (Page 1I-8) / (Page 1I-9) / (Page 1I-9) (Page 1I-9) / (Page 1I- 09913–70210 09930–73140...
Page 293: Charging System
Charging System: 1J-1 Charging System Engine Schematic and Routing Diagram Charging System Diagram B831G21A02001 Regulator/Rectifier Ignition switch Generator I718H11A0001-01 Component Location Charging System Components Location B831G21A03001 Refer to “Electrical Components Location in Section 0A (Page 0A-7)”. Diagnostic Information and Procedures Charging System Symptom Diagnosis B831G21A04001 Condition...
Page 294: Battery Runs Down Quickly
1J-2 Charging System: 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 295: Repair Instructions
Charging System: 1J-3 Repair Instructions Battery Current Leakage Inspection 3) Measure the DC voltage between the (+) and (–) B831G21A06001 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 296: Generator Removal And Installation
1J-4 Charging System: 3) Measure the resistance between the three lead 4) Start the engine and keep it running at 5 000 r/min. wires. 5) Using the multi-circuit tester, measure the voltage If the resistance is out of specified value, replace the between three lead wires.
Page 297 Charging System: 1J-5 8) Disconnect the gearshift lever arm (3) and speed 13) Remove the gasket (9) and dowel pins. sensor coupler (4). I831G11A0009-01 14) Hold the generator rotor with a 41 mm offset wrench. I831G11A0015-01 9) Disconnect the CKP sensor coupler (5) and 15) Remove the generator rotor nut.
Page 298 1J-6 Charging System: 17) Remove the generator rotor assembly (10) 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 299 M/O: Molybdenum oil (MOLYBDENUM OIL SOLUTION) I831G11A0021-02 • Apply grease to the O-ring (4) and oil seal lip. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) CAUTION Replace the O-ring (4) with a new one. I831G11A0019-01 • Install the dowel pins and new gasket (3).
Page 300: Regulator / Rectifier Inspection
1J-8 Charging System: • Tighten the starter cup nut (5) to the specified torque. • Apply a small quantity of thread lock to the bolts. Tightening torque : Thread lock cement 99000–32050 Starter cup nut (e): 38 N·m (3.8 kgf-m, 27.5 lb-ft) (THREAD LOCK CEMENT 1342 or equivalent) I831G11A0025-02 I831G11A0023-05...
Page 301: Battery Components
Charging System: 1J-9 4) Measure the voltage between the terminals using the multi-circuit tester as indicated in the following table. If the voltage is not within the specified value, replace the regulator/rectifier with a new one. NOTE If the tester reads 1.4 V and below when the tester probes are not connected, replace its battery. Special tool : 09900–25008 (Multi-circuit tester set) Tester knob indication...
Page 302 1J-10 Charging System: 2) Remove the caps (2) from the electrolyte container. NOTE If no air bubbles come out from a filler port, NOTE tap the bottom of the electrolyte container • Do not remove or pierce the sealed areas two or three times.
Page 303 Charging System: 1J-11 2) Measure the battery voltage using the multi-circuit tester. Correct If the voltage reading is less than the 12 V (DC), recharge the battery with a battery charger. Recharging time 1.8 A for 5 to 10 hour 3) After recharging, wait at least 30 minutes and then measure the battery voltage using the multi-circuit tester.
Page 304: Battery Removal And Installation
1J-12 Charging System: Battery Removal and Installation 5) Remove the battery (4). B831G21A06008 Removal 1) Remove the seat. Refer to “Seat Removal and Installation in Section 9D (Page 9D-11)”. 2) Remove the battery stay (1). I831G11A0029-02 Installation Install the battery in the reverse order of removal. Pay attention to following point: I831G11A0028-02 CAUTION...
Page 305: Tightening Torque Specifications
For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List in Section 0C (Page 0C-7)”. Special Tools and Equipment Recommended Service Material B831G21A08001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010 (Page 1J-7)
Page 306: Exhaust System
1K-1 Exhaust System: Exhaust System Engine Precautions Precautions for Exhaust System B831G21B00001 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 307: Exhaust Pipe / Muffler Removal And Installation
Exhaust System: 1K-2 Exhaust Pipe / Muffler Removal and Installation 7) Remove the muffler (3). B831G21B06002 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 9D-6)”.
Page 308: Exhaust System Inspection
1K-3 Exhaust System: • Install the exhaust pipe gasket (2) and connector (3). Exhaust System Inspection B831G21B06003 Inspect the exhaust pipe connection and muffler CAUTION connection for exhaust gas leakage and mounting Replace the gasket and connector with new condition. If any defect are found, replace the exhaust ones.
Page 309: Specifications
Exhaust System: 1K-4 Specifications Tightening Torque Specifications B831G21B07001 Tightening torque Fastening part Note N⋅m kgf-m lb-ft Muffler mounting bolt (Page 1K-2) / 16.5 (Page 1K-3) Exhaust pipe nut (Page 1K-3) / 16.5 (Page 1K-3) Muffler connecting bolt (Page 1K-3) / 16.5 (Page 1K-3) NOTE...
Page 310 1K-5 Exhaust System:...
Page 311: Suspension General Diagnosis
Table of Contents 2- i Section 2 Suspension CONTENTS Precautions ..........2-1 Repair Instructions ..........2C-1 Rear Suspension Components ......2C-1 Precautions............. 2-1 Rear Suspension Assembly Construction...2C-2 Precautions for Suspension ........2-1 Rear Shock Absorber Removal and Suspension General Diagnosis....2A-1 Installation ............2C-3 Rear Suspension Inspection .......2C-4 Diagnostic Information and Procedures....2A-1 Rear Shock Absorber Inspection ......2C-4...
Page 312: Precautions
2-1 Precautions: Precautions Suspension Precautions Precautions for Suspension B831G22000001 Refer to “General Precautions in Section 00 (Page 00-1)”. 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 313: Suspension General Diagnosis
Suspension General Diagnosis: 2A-1 Suspension General Diagnosis Suspension Diagnostic Information and Procedures Suspension and Wheel Symptom Diagnosis B831G22104001 Condition Possible cause Correction / Reference Item Wobbly front wheel Distorted wheel rim. Replace. Worn hub bearings. Replace. Defective or incorrect tire. Replace.
Page 314: Front Suspension
2B-1 Front Suspension: Front Suspension Suspension Repair Instructions Front Suspension Components B831G22206001 I831G1220002-08 1. Front shock absorber mounting bolt 10. Suspension arm bolt (Lower) 19. Cotter pin 2. Front shock absorber 11. Suspension arm pivot nut (Lower) : 55 N⋅m (5.5 kgf-m, 40.0 lb-ft) 3.
Page 315: Front Suspension Assembly Construction
Front Suspension: 2B-2 Front Suspension Assembly Construction B831G22206002 “ a ” “ a ” I831G1220001-06 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 12.
Page 316: Front Shock Absorber Removal And Installation
2B-3 Front Suspension: Front Shock Absorber Removal and Installation Front Suspension Inspection B831G22206003 B831G22206004 Refer to “Suspensions Inspection in Section 0B CAUTION (Page 0B-22)”. Make sure that the vehicle is supported securely. Front Shock Absorber Inspection B831G22206005 Removal Inspect the front shock absorber in the following procedures: 1) Remove the front wheel.
Page 317: Spring Pre-Load Adjustment
Front Suspension: 2B-4 Spring Pre-load Adjustment 3) Remove the front drive shaft cover (3). B831G22206006 WARNING Be sure to adjust the spring pre-load on the both suspensions equally. • Turn the spring tension ring (1) to the desired position. NOTE Position 1 provides the softest spring tension and position 5 provides the stiffest.
Page 318 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) I831G1220015-02...
Page 319 Front Suspension: 2B-6 • Install the cotter pins (4). • Apply thread lock to the brake disc cover mounting bolts (9) and tighten them to the specified torque. CAUTION : Thread lock cement 99000–32130 The removed cotter pins (4) must be replaced (THREAD LOCK CEMENT SUPER 1360 or with new ones.
Page 320: Front Hub Bearing Inspection
2B-7 Front Suspension: • Install the brake caliper. Refer to “Front Brake Caliper Front Hub Bearing Removal and Installation B831G22206009 Removal and Installation in Section 4B (Page 4B-3)”. Refer to “Front Wheel Hub / Steering Knuckle Removal • Install the front wheel assembly. Refer to “Front / Rear and Installation (Page 2B-4)”.
Page 321 Front Suspension: 2B-8 4) Remove the wheel hub bearing (4), using the • Install the snap ring (2) with the special tool. hydraulic press and special tool. CAUTION Special tool Never reuse snap ring (2). (B): 09913–70210 (Bearing installer set) Special tool : 09900–06108 (Snap ring pliers) I831G1220028-02...
Page 322: Front Suspension Upper / Lower Arm Removal And Installation
2B-9 Front Suspension: • Install a new outer dust seal (4) using a suitable size 6) Remove the suspension upper arm (3) by removing socket wrench. the suspension upper bolt (4) and pivot nut (5). CAUTION Replace the outer dust seal (4) with a new one.
Page 323: Steering Knuckle End Inspection
Front Suspension: 2B-10 3) Set the steering knuckle (3) and install the Steering Knuckle End Inspection B831G22206011 suspension upper arm (4). • Inspect the steering knuckle end for wear or damage. 4) Temporarily tighten the suspension arm pivot nut If any defects are found, replace the front lower (upper) (5) and shock absorber mounting nut (6).
Page 324: Steering Knuckle End Removal And Installation
2B-11 Front Suspension: Steering Knuckle End Removal and Installation Lower B831G22206012 • 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 pliers) 9)”.
Page 325: Front Suspension Arm Related Parts Inspection
Front Suspension: 2B-12 • Install the snap ring (2) with the special tool. Front Suspension Arm Related Parts Inspection B831G22206013 Refer to “Front Suspension Upper / Lower Arm Removal CAUTION and Installation (Page 2B-9)”. Replace the snap ring (2) with a new one. Upper arm Special tool 1) Inspect the following parts for wear or damage.
Page 326: Front Suspension Upper Arm Bushing And Inner Dust Seal Removal And Installation
2B-13 Front Suspension: Lower arm 2) Remove the front upper arm bushings along with Inspect the front lower arm (1) and bushings (2) for bend inner dust seals. or damage. If any defects are found, replace the Special tool defective parts with new ones. Refer to “Front (A): 09923–73210 (Bearing remover) Suspension Lower Arm Bushing Removal and (B): 09930–30104 (Rotor remover slide...
Page 327: 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) CAUTION 3) Install the washers (3) to the dust seals (2) and...
Page 328: Specifications
For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List in Section 0C (Page 0C-7)”. Special Tools and Equipment Recommended Service Material B831G22208001 Material SUZUKI recommended product or Specification Note Grease Water resistance grease P/No.: 99000–25160 (Page 2B-5) /...
Page 329: Special Tool
Front Suspension: 2B-16 Special Tool B831G22208002 09900–06107 09900–06108 Snap ring pliers Snap ring pliers (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 (Page 2B-7) / (Page 2B- (Page 2B-8) / (Page 2B-...
Page 330: Rear Suspension
2C-1 Rear Suspension: Rear Suspension Suspension Repair Instructions Rear Suspension Components B931G22306001 “A” I931G1230003-02 1. Rear shock absorber 10. Rear suspension arm (lower) 19. Washer [From 5SAAR41A497105527] 2. Rear stabilizer bar 11. Rear suspension knuckle “A”: Do not apply grease. [From 5SAAR41A197105887] 3.
Page 331: Rear Suspension Assembly Construction
Rear Suspension: 2C-2 Rear Suspension Assembly Construction B931G22306002 “ a ” “ a ” “ a ” “ a ” “ a ” “ a ” “A” “ a ” “ a ” I931G1230001-04...
Page 332: Rear Shock Absorber Removal And Installation
2C-3 Rear Suspension: 1. Rear suspension arm pivot nut (upper) 11. Rear shock absorber mounting nut (lower) 2. Rear suspension arm pivot nut (lower) 12. Stabilizer joint nut 3. Rear wheel hub nut “A”: Do not apply grease. [From 5SAAR41A197105887] 4.
Page 333: Rear Suspension Inspection
Rear Suspension: 2C-4 Rear Suspension Inspection Spring Pre-load Adjustment B931G22306004 B931G22306006 Refer to “Suspensions Inspection in Section 0B WARNING (Page 0B-22)”. Be sure to adjust the spring pre-load on the both suspensions equally. Rear Shock Absorber Inspection B931G22306005 Inspect the rear shock absorber in the following After installing the rear suspension, adjust the spring procedures: pre-load as follows:...
Page 334 2C-5 Rear Suspension: • Apply grease to the lip of outer dust seal and rear 2) Remove the rear wheel assembly. Refer to “Front / Rear Wheel Removal and Installation in Section 2D wheel hub spline. (Page 2D-2)”. : Grease 99000–25160 (Water resistance grease or equivalent) CAUTION Make sure that the vehicle is supported...
Page 335: Rear Hub Bearing Inspection
Rear Suspension: 2C-6 Rear Hub Bearing Removal and Installation • Install the rear wheel assembly. Refer to “Front / Rear Wheel Removal and Installation in Section 2D B931G22306009 (Page 2D-2)”. Removal • Tighten the hub nut (5) to the specified torque. 1) Remove the outer dust seal (1) with the special tool.
Page 336 2C-7 Rear Suspension: 4) Remove the hub bearing (4) using the hydraulic • Install the snap ring (2) with the special tool. press and special tool. CAUTION Special tool Never reuse snap ring (2). (B): 09913–70210 (Bearing installer set) Special tool : 09900–06108 (Snap ring pliers) I831G1230064-02 Installation...
Page 337: Rear Suspension Arm Upper / Lower Removal And Installation
Rear Suspension: 2C-8 • Apply grease to the lip of outer dust seal (4). 5) Disconnect the stabilizer joint (3) from the rear suspension lower arm (4). : Grease 99000–25160 (Water resistance 6) Remove the shock absorber mounting lower bolt (5) grease or equivalent) and nut (6).
Page 338: Rear Suspension Arm Related Parts Inspection
2C-9 Rear Suspension: • Install the rear suspension knuckle arm and wheel • Tighten the shock absorber mounting lower bolt and nut to the specified torque. hub. Refer to “Rear Wheel Hub / Suspension Knuckle Removal and Installation (Page 2C-4)”. Tightening torque Rear shock absorber mounting nut (b): 60 N·m ( Rear Suspension Arm Related Parts Inspection...
Page 339 Rear Suspension: 2C-10 Lower Arm Suspension Knuckle 1) Inspect the following parts for wear or damage. If any 1) Inspect the following parts for wear or damage. If any defects are found, replace defective parts with new defects are found, replace defective parts with new ones.
Page 340: Rear Suspension Upper Arm Bushing Removal And Installation
2C-11 Rear Suspension: Rear Suspension Upper Arm Bushing Removal Installation and Installation 1) Install the rear suspension upper arm bushing and B931G22306012 inner dust seal with the special tool and suitable Refer to “Rear Suspension Arm Upper / Lower Removal socket wrench.
Page 341: Rear Suspension Lower Arm Bushing Removal And Installation
Rear Suspension: 2C-12 Rear Suspension Lower Arm Bushing Removal 3) Remove the another inner dust seal (6) with the special tool. and Installation B931G22306013 Special tool Refer to “Rear Suspension Arm Upper / Lower Removal (B): 09943–88211 (Bearing remover/ and Installation (Page 2C-8)”. installer) Removal 1) Remove the following parts from the rear suspension...
Page 342: Rear Suspension Knuckle Bushing Removal And Installation
2C-13 Rear Suspension: 2) Apply grease to the lip of inner dust seals, spacer (3) 2) Remove the suspension knuckle bushings along and inside of dust seals (4). with inner dust seals with the special tools. : Grease 99000–25160 (Water resistance Special tool grease or equivalent) (A): 09923–73210 (Bearing remover)
Page 343: Rear Stabilizer Removal And Installation
Pay attention to the following points: 1) Remove the rear wheels. Refer to “Front / Rear • Apply grease to the inside of stabilizer bushing. Wheel Removal and Installation in Section 2D : Grease 99000–25100 (SUZUKI SILICONE (Page 2D-2)”. GREASE or equivalent) CAUTION Make sure that the vehicle is supported securely.
Page 344: Stabilizer Parts Inspection
2C-15 Rear Suspension: • Apply thread lock to the stabilizer plate mounting bolts and tighten the bolts securely. : Thread lock cement 99000–32030 (THREAD LOCK CEMENT SUPER 1303 or equivalent) I831G1230058-01 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.
Page 345: Specifications
For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List in Section 0C (Page 0C-7)”. Special Tools and Equipment Recommended Service Material B931G22308001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SILICONE GREASE or P/No.: 99000–25100 (Page 2C-14)
Page 346: Special Tool
2C-17 Rear Suspension: Special Tool B931G22308002 09900–06108 09913–50121 Snap ring pliers Oil seal remover (Page 2C-6) / (Page 2C- (Page 2C-6) / (Page 2C- 09913–70210 09913–75520 Bearing installer set Bearing installer (Page 2C-7) (Page 2C-7) 09923–73210 09930–30104 Bearing remover Rotor remover sliding shaft (Page 2C-11) / (Page 2C-11) / (Page 2C-12) /...
Page 347: Wheels And Tires
Wheels and Tires: 2D-1 Wheels and Tires Suspension Precautions Precautions for Wheel and Tire B831G22400001 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 348: Front / Rear Wheel Removal And Installation
2D-2 Wheels and Tires: Front / Rear Wheel Removal and Installation • Tighten the wheel nuts to the specified torque. B831G22406002 NOTE NOTE Tighten the wheel 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 nut (a): 60 N·m (6.0 kgf-m, 43.5 lb-ft)
Page 349 Wheels and Tires: 2D-3 5) After removing the tire, inspect the wheel if 4) When installing each tire, make sure the arrow “A” necessary. on the tire points in the direction of rotation. Also, make sure the outer side of the wheel rim is facing Installation outward.
Page 350: Specifications
2D-4 Wheels and Tires: 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 351 Table of Contents 3- i Section 3 Driveline / Axle CONTENTS Precautions ..........3-1 Final Gear Components ........3B-21 Final Gear Construction ........3B-22 Precautions............. 3-1 Final Gear Oil Level Inspection ......3B-23 Precautions for Driveline / Axle ......3-1 Final Gear Oil Replacement......3B-23 Drive Chain / Drive Train / Drive Shaft...
Page 352: Propeller Shafts
3-ii Table of Contents Recommended Service Material .......3C-18 Rear Output Shaft Drive Bevel Gear Shim Special Tool ............3C-18 Inspection and Adjustment......3D-11 Front Propeller Shaft Components....3D-14 Propeller Shafts ........3D-1 Front Propeller Shaft Removal and Installation ............3D-14 Repair Instructions ..........3D-1 Front Output Shaft Components ......3D-1 Front Propeller Shaft Related Parts Inspection............3D-16 Front Output Shaft Removal and Installation ..3D-1...
Page 353: Precautions
Precautions: Precautions Driveline / Axle Precautions Precautions for Driveline / Axle B831G23000001 Refer to “General Precautions in Section 00 (Page 00-1)”. WARNING Support the vehicle with a jack or wooden block when servicing the drive shafts and drive train.
Page 354: 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 B831G23104001 Condition Possible cause Correction / Reference Item Noisy Drive Shaft Worn drive shaft joints. Replace.
Page 355: Front Drive Shaft Assembly Removal And Installation
Drive Chain / Drive Train / Drive Shaft: 3A-2 Front Drive Shaft Assembly Removal and CAUTION Installation Be careful not to damage the front differential B831G23106002 Removal gear case oil seals. 1) Drain the front differential gear oil. Refer to “Front NOTE Differential Gear Oil Inspection in Section 0B (Page 0B-12)”.
Page 356 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. I831G1310011-02 Assembly CAUTION...
Page 357 Drive Chain / Drive Train / Drive Shaft: 3A-4 3) Install the new snap ring to the cage. 5) Insert the cage into the outer race and install the new stopper ring to the groove of the outer race. CAUTION CAUTION Replace the snap ring with a new one.
Page 358: 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 B831G23106004 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 359: Rear Drive Shaft Components
Drive Chain / Drive Train / Drive Shaft: 3A-6 Rear Drive Shaft Components B831G23106005 I831G1310002-05 1. Circlip 5. Inner boot 9. Outer boot 2. Snap ring 6. Inner boot band (Small) 10. Outer boot band (Large) 3. Stopper ring 7. Drive shaft : Apply grease.
Page 360: Rear Drive Shaft Disassembly And Assembly
Rear drive shaft inspection as the same manner of front drive shaft. Special Tools and Equipment Recommended Service Material B831G23108001 Material SUZUKI recommended product or Specification Note Grease Water resistance grease P/No.: 99000–25160 (Page 3A-2) / (Page 3A- NOTE Required service material is also described in the following.
Page 361: Differential
Differential: 3B-1 Differential Driveline / Axle Diagnostic Information and Procedures Drive Train Symptom Diagnosis B831G23204001 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 362: Repair Instructions
3B-2 Differential: Repair Instructions Front Drive (Differential) Components B831G23206001 I831G1320001-06 1. Front drive (differential) gear case 12. O-ring 23. Input shaft 2. Front drive (differential) gear case cover 13. 4WD/Diff-lock Actuator 24. Breather rubber case 3. Shim (Right side) 14. Bearing 25.
Page 363: Front Drive (Differential) Construction
Differential: 3B-3 Front Drive (Differential) Construction B831G23206002 “A” I831G1320002-07 1. Shim : 1.3 N⋅m (0.13 kgf-m, 0.94 lb-ft) : Apply thread lock to the thread part. 2. Front drive (differential) case cover bolt : Apply grease. : Apply bond to matching surface. “A”: Matching surface : Apply water resistance grease.
Page 364: Front Drive (Differential) Gear Oil Level Inspection
3B-4 Differential: Front Drive (Differential) Gear Oil Level 7) Disconnect the 2WD/4WD/diff-lock actuator lead wire coupler (1). Inspection B831G23206003 Refer to “Front Differential Gear Oil Inspection in Section 0B (Page 0B-12)”. Front Drive (Differential) Gear Oil Replacement B831G23206004 Refer to “Front Differential Gear Oil Inspection in Section 0B (Page 0B-12)”.
Page 365: Front Drive (Differential) Assembly Disassembly And Assembly
Differential: 3B-5 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 Diagram in points: Section 9A (Page 9A-4)”...
Page 366 3B-6 Differential: 4) Align the concave part of 2WD/4WD shifting cam 9) Remove the oil seals. and convex part of diff-lock shift fork. Special tool 5) Remove the front drive (differential) gear assembly (B): 09913–70210 (Bearing installer set) (2), diff-lock shifting fork (3) and shifting fork shaft (4).
Page 367 Differential: 3B-7 13) Remove the oil seal cap (10) and oil seal (11). 15) Remove the input shaft bearing (15) with the special tool. NOTE If there is no abnormal noise, the bearing removal is not necessary. Special tool (D): 09913–60910 (Bearing remover) I831G1320017-01 •...
Page 368 3B-8 Differential: 18) Remove the pinion gear pilot bearing with the special Assembly tools. CAUTION NOTE The removed oil seals, snap rings and If there is no abnormal noise, the bearing bearings must be replaced with new ones. removal is not necessary. 1) Install the bearings (1) to the front drive (differential) Special tool gear assembly with the special tool.
Page 369 11) Install the 4WD/diff-lock shifting fork (8), onto the groove of the 2WD/4WD shifting sleeve “A”. I831G1320029-01 7) Install the input shaft. 8) Apply a small quantity of grease to the oil seal lip. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) “A” I831G1320032-01...
Page 370 3B-10 Differential: 12) Apply front differential gear oil to the 2WD/4WD 16) Install the oil seals (12) into the front drive sifting fork shaft (9). (differential) gear case cover with the special tool. NOTE Insert the oil seal until the specified value as shown in the figure.
Page 371 Tightening torque Front drive (differential) case cover bolt (a): 22 N·m (2.2 kgf-m, 16.0 lb-ft) I831G1320040-01 22) Apply bond to the mating surface of the front drive (differential) case. : Sealant 99000–31110 (SUZUKI BOND “B” No.1215 or equivalent) I831G1320043-02 I831G1320041-01...
Page 372: Front Drive (Differential) Related Parts Inspection
Refer to “Front Drive (Differential) Assembly Replace the O-rings with new ones. Disassembly and Assembly (Page 3B-5)”. : Grease 99000–25010 (SUZUKI SUPER Front Drive Gear Oil Seals GREASE A or equivalent) Inspect the lip of oil seal for wear or damage. If any defect is found, replace the oil seal with a new one.
Page 373 Differential: 3B-13 Diff-lock Shifting Shaft and 2WD/4WD Shifting Shaft 2WD/4WD Shifting Cam Inspect the 2WD/4WD shifting fork shafts for wear or Inspect the 2WD/4WD shifting cam for wear or damage. damage. If any defects are found, replace the shifting If any defects are found, replace the 2WD/4WD shifting fork shafts with new ones.
Page 374: Breather Rubber Case Inspection
3B-14 Differential: Pinion Gear Front Drive (Differential) Gear Shim Inspection Inspect the pinion gear for wear or damage. and Selection Inspect the pinion gear bearing for abnormal noise and B831G23206009 Refer to “Front Drive (Differential) Assembly smooth rotation. If any defects are found, replace Disassembly and Assembly (Page 3B-5)”.
Page 375 Differential: 3B-15 • Remove the oil filler cap and measure the backlash of List of shims (for right side) the differential ring gear using the horizontal type dial Part No. Shim thickness gauge and drive shaft (3) as shown in the figure. 0.75 mm (0.0295 in) 0.80 mm (0.0315 in) •...
Page 376 3B-16 Differential: • Install the front drive (differential) case (2) and tighten • After selecting the proper size of shim(s), check or the bolts to the special torque diagonally. adjust the backlash and tooth contact. Tightening torque Tooth Contact Front drive (differential) case bolt (a): 22 N·m (2.2 kgf-m, 16.0 lb-ft) CAUTION Make sure to check the backlash after the...
Page 377: 2Wd/4Wd/Diff-Lock System Inspection
Differential: 3B-17 • Rotate the final drive (differential) gear several turns in 2WD/4WD/Diff-lock System Inspection B831G23206010 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 378 3B-18 Differential: 3) Inspect the 2WD/4WD/diff-lock switch for continuity with a tester. If any abnormality is found, replace the Color Bl/R W/Bl B/Y B/W Position left handlebar switch assembly with a new one. Refer to “Handlebars Removal and Installation in Section 6B (Page 6B-3)”.
Page 379 Differential: 3B-19 4) Check that both “Differential lock position switch signal” and “Differential lock switch signal” are “Open”. I831G1320074-01 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” and “Differential lock switch signal” are “GND”. I831G1320075-01 If the transfer selecting switch dose not function properly, inspect the 4WD/diff-lock switch for continuity check.
Page 380: Rear Drive Breather Hose Routing Diagram
3B-20 Differential: 4) Apply 12 V to the terminal “B” and “E” ((+) to “E” and Diff-lock Relay (–) to “B”), check the insulation between “A” and “D”. Check the insulation between “A” and “B” terminals with If any abnormality is found, replace the 4WD/diff-lock the multi-circuit tester.
Page 381: Final Gear Components
Differential: 3B-21 Final Gear Components B831G23206012 I831G1320080-08 1. Final gear case 11. Shim : 100 N⋅m (10.0 kgf-m, 72.0 lb-ft) 2. Final gear case cover 12. Pinion gear : 26 N⋅m (2.6 kgf-m, 19.0 lb-ft) 3. Ring gear 13. Bearing : 55 N⋅m (5.5 kgf-m, 40.0 lb-ft) 4.
Page 382: Final Gear Construction
3B-22 Differential: Final Gear Construction B831G23206013 “A” “A” I831G1320081-04 1. Shim (Left side) 6. Lock-nut : Apply water resistance grease. 2. Shim (Right side) “A”: Matching surface : Apply thread lock to thread part. 3. Pinion gear shim(s) : 26 N⋅m (2.6 kgf-m, 19.0 lb-ft) : Apply bond.
Page 383: Final Gear Oil Level Inspection
Differential: 3B-23 Final Gear Oil Level Inspection 9) Loosen the outlet pipe connecting screws (4). B831G23206014 Refer to “Final Gear Oil Inspection in Section 0B (Page 0B-14)”. Final Gear Oil Replacement. B831G23206015 Refer to “Final Gear Oil Inspection in Section 0B (Page 0B-14)”.
Page 384: Final Gear Assembly Disassembly And Assembly
3B-24 Differential: Installation • Adjust the parking brake lever play. Refer to “Rear Installation the final gear assembly in the reverse order Brake Pedal / Rear Brake (Parking Brake) Lever of removal. Pay attention to the following points: Inspection and Adjustment in Section 0B (Page 0B- 19)”.
Page 385 Differential: 3B-25 4) Remove the O-ring (3) and final driven gear (4). 7) Remove the final driven gear bearing (7) with the special tool. NOTE If there is no abnormal condition, the bearing removal is not necessary. Special tool (B): 09913–70210 (Bearing installer set) (C): 09944–66010 (Bearing installer) I831G1320095-01 5) Remove the shim(s) (5).
Page 386 3B-26 Differential: 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 rear final drive nut (14) with a chisel. I831G1320101-01 11) Unlock the final drive stopper (10) with a chisel.
Page 387 Differential: 3B-27 17) Remove the bearing (16) and the upper inner race 19) Remove the final drive gear bearing (18) with the from the pinion gear with the special tool and special tool. suitable tool. NOTE NOTE If there is no abnormal condition, the bearing If there is no abnormal condition, the bearing removal is not necessary.
Page 388 3B-28 Differential: • Install the final drive gear bearing (1) to the final gear • Tighten the lock-nut (4) to the specified torque with case with the special tool. the special tool. Special tool Tightening torque (A): 09913–70210 (Bearing installer set) Final drive lock-nut (a): 100 N·m (10.0 kgf-m, 72.5 lb-ft) Special tool...
Page 389 Differential: 3B-29 • Tighten the final drive gear bearing stopper (7) to the • Apply a small quantity of grease to the oil seal lip. specified torque with the special tool. : Grease 99000–25160 (Water resistance grease) CAUTION The removed final drive gear bearing stopper must be replaced with a new one.
Page 390: Final Gear Related Parts Inspection
• Install the shim(s) (10). • Install the O-ring to the final gear cover (11). • Apply a small quantity of grease to the O-ring. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I831G1320127-01 Final Driven / Drive Gear Bering Inspect the bearings for abnormal noise and smooth rotation.
Page 391: Final Gear Shim Inspection And Selection
Differential: 3B-31 Final Drive Gear Inspect the final drive gear for wear or damage. Inspect the final drive gear bearing for abnormal noise and smooth rotation. If any defects are found, replace defective parts. I831G1320132-01 • Install the left side shim(s) and final driven gear. I831G1320130-01 Final Driven Gear Inspect the final driven gear for wear or damage.
Page 392 3B-32 Differential: 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. NOTE Do not install the left side shim(s) at this time. I831G1320136-01 •...
Page 393 Differential: 3B-33 • Install the left and right side shim(s) (2) and final Tooth contact Shim adjustment driven gear assembly (1). Contact at tooth top [A] Decrease shim thickness Contact at tooth top [C] Increase shim thickness CAUTION Make sure to check the backlash and shim thickness after the tooth contact has been adjusted, since it may have changed.
Page 394: Specifications
3B-34 Differential: Specifications Service Data B831G23207001 Drive Train Unit: mm (in) Item Standard Limit Front drive (differential) gear backlash 0.05 – 0.10 (0.0020 – 0.0040) — 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-35 Special Tools and Equipment Recommended Service Material B831G23208001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010 (Page 3B-9) / (Page 3B- equivalent 12) / (Page 3B-30) Water resistance grease P/No.: 99000–25160...
Page 396 3B-36 Differential: 09913–61510 09913–70210 Bearing puller Bearing installer set (Page 3B-27) (Page 3B-6) / (Page 3B- 8) / (Page 3B-8) / (Page 3B-8) / (Page 3B- 9) / (Page 3B-9) / (Page 3B-10) / (Page 3B-10) / (Page 3B-25) / (Page 3B-27) / (Page 3B-28) 09913–84510...
Page 397: Transfer
Transfer: 3C-1 Transfer Driveline / Axle Diagnostic Information and Procedures Transfer Symptom Diagnosis B831G23304001 Condition Possible cause Correction / Reference Item Engine is noisy (Noise Worn or rubbing gear. Replace. seems to come from the Worn transfer input/output shaft. Replace shaft. transfer) Worn bearing.
Page 398: Repair Instructions
3C-2 Transfer: Repair Instructions Transfer Components B831G23306001 I831G1330001-09 1. Washer 14. Driven gear bushing 27. Counter shaft bearing (Left side) 2. Reverse idle gear 15. Select sliding dog 28. Spacer 3. Reverse idle gear shaft 16. Reverse select spacer 29. Drive gear No. 2 4.
Page 399: Transfer Removal And Installation
Transfer: 3C-3 Transfer Removal and Installation 6) Remove the gearshift forks (3). B831G23306002 Removal 1) Remove the engine assembly from the frame. Refer to “Engine Assembly Removal in Section 1D (Page 1D-13)”. 2) Disassemble the engine top side. Refer to “Engine Top Side Disassembly in Section 1D (Page 1D-17)”.
Page 400 3C-4 Transfer: 9) Remove the drive shaft (9) with a plastic mallet by CAUTION installing a suitable washer with the drive face bolt. • Do not disassemble the transfer output shaft. • The transfer output driven gear and transfer output shaft is available only as an assembly.
Page 401 Transfer: 3C-5 • Install the transfer output shaft assembly and reverse • Install the gearshift cam (4). idle gear. Refer to “Transfer Components (Page 3C- 2)”. • Install the gearshift fork (2) and reverse gearshift fork (3). NOTE Identify the shape of the shift forks and install them properly.
Page 402: Transfer Construction
3C-6 Transfer: Transfer Construction B831G23306003 I831G1330002-03 1. Counter shaft 2. Drive shaft 3. Snap ring : Assembly snap ring with edge side out. Counter Shaft / Reverse Idle Gear Disassembly Counter shaft and Assembly 1) Remove the counter shaft assembly. Refer to B831G23306004 “Transfer Removal and Installation (Page 3C-3)”.
Page 403 Transfer: 3C-7 3) Remove the low driven gear bushing (3) and select 7) Remove the high gearshift dog (10) and select sliding dog (4). spacer (11). I831G1330021-01 I831G1330025-01 8) Remove the high driven gear (12) with the wave 4) Remove the reverse select spacer (5), reverse gear (6) and reverse driven gear bushing (7).
Page 404 3C-8 Transfer: Reverse idle gear • Before installing the high driven gear (1), set the wave 1) Remove the washers (1). washer (2) as shown in the figure. I831G1330028-01 I831G1330030-01 2) Remove the reverse idle gear shaft (2) and bering •...
Page 405: Gearshift Cam Components
Transfer: 3C-9 • When installing the gear bushing onto the counter shaft, align the shaft oil hole “C” with the bushing oil hole “D” as shown in the figure. “D” “C” “D” “C” I831G1330034-03 I831G1330033-05 Gearshift Cam Components B831G23306005 I831G1330003-05 1.
Page 406: Gearshift System Construction
3C-10 Transfer: 6. Snap ring 15. Gearshift fork shaft : Apply engine oil. 7. Washer 16. Gearshift cam stopper : Do not reuse. 8. Spring 17. Gearshift arm 9. Gearshift cam 18. Washer Gearshift System Construction B831G23306006 I831G1330004-04 1. Gearshift shaft 3.
Page 407: Gearshift Cam Disassembly And Assembly
Transfer: 3C-11 Gearshift Cam Disassembly and Assembly • Remove the reverse gearshift cam (6) and snap ring B831G23306007 (7). Disassembly Special tool CAUTION : 09900–06107 (Snap ring pliers) Identify the position of each removed part. Organize the parts in their respective groups so that they can be reinstalled in their original positions.
Page 408: Transfer Gear Bearing Removal And Installation
3C-12 Transfer: • Install the snap ring (1) and gearshift cam (2). Transfer Gear Bearing Inspection B831G23306009 CAUTION • Inspect the reverse idle gear shaft bearing for abnormal noise and smooth rotation. Replace the • Align the punch mark “A” of the gearshift bearing if there is anything unusual.
Page 409: Transfer Related Bearing Inspection
Transfer: 3C-13 Gearshift Fork Groove Width Gear Position (GP) Switch Removal and Measure the gearshift fork groove width using the Installation vernier calipers. B831G23306013 Removal Special tool 1) Turn the ignition switch OFF. (A): 09900–20102 (Vernier calipers (1/20 mm, 2) Remove the left and right side cover. Refer to “Front 200 mm)) Side Exterior Parts Removal and Installation in Gearshift fork groove width...
Page 410: Gearshift Shaft No. 2 / Gearshift Cam Plate Removal And Installation
Replace the O-ring with a new one. Replacement in Section 0B (Page 0B-10)”. 2) Drain engine coolant. Refer to “Cooling System : Grease 99000–25010 (SUZUKI SUPER Inspection in Section 0B (Page 0B-15)”. GREASE A or equivalent) 3) Remove the gearshift arm (1).
Page 411 Transfer: 3C-15 6) Remove the following parts from the gearshift shaft • Tighten the gearshift cam stopper bolt (2) securely. (4). • Gearshift return spring (5) • Shift gear (6) • Snap ring (7) Special tool : 09900–06107 (Snap ring pliers) I831G1330051-01 “A”...
Page 412 3C-16 Transfer: • Install the gearshift cam stopper plate (5). • Install the snap ring (6) and washer (7). NOTE CAUTION • Align the gearshift cam pin “B” with the the removed snap ring (6) must be replaced with new one. gearshift cam stopper plate hole “C”.
Page 413: Gearshift Linkage Inspection
Transfer: 3C-17 Gearshift Linkage Inspection Gearshift Shaft Oil Seal Removal and B831G23306015 Installation Refer to “Gearshift Shaft No. 2 / Gearshift Cam Plate B831G23306016 Removal and Installation (Page 3C-14)”. Removal • Remove the generator cover. Refer to “Generator Gearshift Shaft Removal and Installation in Section 1J (Page 1J-4)”.
Page 414: Specifications
Reverse 5.30 – 5.40 (0.209 – 0.213) — Special Tools and Equipment Recommended Service Material B831G23308001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010 (Page 3C-14) equivalent NOTE Required service material is also described in the following.
Page 415: Propeller Shafts
Propeller Shafts: 3D-1 Propeller Shafts Driveline / Axle Repair Instructions Front Output Shaft Components B831G23406001 I831G1340001-03 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 416: Front Output Shaft Disassembly And Assembly
• Apply a small quantity of grease to the O-ring (1). CAUTION Replace a O-ring (1) with a new one. : Grease 99000–25010 (SUZUKI SUPER I831G1340005-02 2) Remove the front drive collar (3), front drive output GREASE A or equivalent) shaft housing (4) and O-ring (5).
Page 417 Propeller Shafts: 3D-3 3) Remove the O-ring (6). 6) Remove the front output shaft bearing (front) with the special tool. NOTE If there is no abnormal noise, the bearing removed is not necessary. Special tool (B): 09921–20240 (Bearing remover set) I831G1340007-02 4) Remove the oil seal (7) with the special tool.
Page 418 (A): 09913–70210 (Bearing installer set) I831G1340015-04 6) Install the O-ring (5) to the front drive collar. 7) Apply grease to the O-ring (5). : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I831G1340012-01 2) Install the front output shaft bearing (front) to the front output shaft housing with the special tool.
Page 419: Front Output Shaft Related Parts Inspection
Propeller Shafts: 3D-5 11) Install the front output shaft to the right crankcase. Oil Seal Visually inspect the oil seal for damage, with particular 12) Tighten the front output shaft bolts (10). attention given to the lip. Replace the oil seal that shows indications of leakage. I831G1340018-03 13) Assemble the engine.
Page 420: Rear Output Shaft Components
3D-6 Propeller Shafts: Rear Output Shaft Components B831G23406005 I831G1340022-05 1. Rear output shaft drive bevel gear 7. Shim(s) 13. Rear output shaft yoke 2. Shim(s) 8. Bearing : 100 N⋅m (10.0 kgf-m 72.5 lb-ft) 3. Rear output shaft driven bevel gear 9.
Page 421 Propeller Shafts: 3D-7 4) Remove the rear output shaft (1). 9) Remove the washer (3), drive bevel gear (4) and shim (5). I831G1340023-01 5) Remove the C-ring (2). I831G1340026-02 Installation Install the rear output shaft in the reverse order of removal.
Page 422: Rear Output Shaft Disassembly And Assembly
3D-8 Propeller Shafts: • Install the rear output shaft (1). 2) Remove the washer (1), rear output shaft driven gear (2), bearing (3) and rear output shaft driven NOTE bevel gear (4). Be sure to fit the C-ring (2) and bearing knock-pin “A”...
Page 423 Propeller Shafts: 3D-9 Assembly • After installed rear output shaft yoke to the rear output Assemble the rear output shaft in the reverse order of shaft, install the washer (5) and tighten the output disassembly. Pay attention to the following points: shaft nut (6) to the specified torque.
Page 424: Rear Output Shaft Related Parts Inspection
3D-10 Propeller Shafts: • Lock the rear output shaft driven gear nut (9) with a Rear Output Shaft Gear center punch. Inspect the rear output shaft gear for wear or damage. If any defects are found, replace the rear output shaft gear with the new one.
Page 425: Rear Output Shaft Drive Bevel Gear Shim Inspection And Adjustment
Propeller Shafts: 3D-11 Rear Output Shaft Drive Bevel Gear Shim • Place the rear output shaft on the left crankcase half and hold bearings with the special tool. Inspection and Adjustment B831G23406009 Special tool Refer to “Rear Output Shaft Removal and Installation (C): 09921–21910 (Bearing holder) (Page 3D-6)”.
Page 426 3D-12 Propeller Shafts: List of shims (for driven bevel gear) Tooth Contact Part No. Shim thickness CAUTION 24945-03G50-055 0.550 mm (0.022 in) 24945-03G50-058 0.575 mm (0.023 in) Make sure to check the backlash after the 24945-03G50-060 0.600 mm (0.024 in) tooth contact has been adjusted, since it may 24945-03G50-063 0.625 mm (0.025 in)
Page 427 Propeller Shafts: 3D-13 Part No. Shim thickness 24935-03G50-055 0.550 mm (0.0217 in) 24935-03G50-058 0.575 mm (0.0226 in) 24935-03G50-060 0.600 mm (0.0236 in) 24935-03G50-063 0.625 mm (0.0246 in) 24935-03G50-065 0.650 mm (0.0256 in) 24935-03G50-068 0.675 mm (0.0266 in) 24935-03G50-070 0.700 mm (0.0276 in) 24935-03G50-073 0.725 mm (0.0285 in) 24935-03G50-075...
Page 428: Front Propeller Shaft Components
3D-14 Propeller Shafts: Front Propeller Shaft Components B831G23406010 I831G1340045-04 1. Boot 5. Universal joint 2. Front propeller shaft spring 6. Boot 3. Front propeller shaft : Apply water resistance grease. 4. Circlip : Do not reuse. Front Propeller Shaft Removal and Installation 3) Using a (–) screwdriver or the like into a notch of the B831G23406011 universal joint and remove the front propeller shaft...
Page 429 Propeller Shafts: 3D-15 Installation 5) Connect the universal joint to the joint portion (at the engine side). CAUTION 6) Attach the boot to the front drive collar and tighten The removed circlips must be replaced with the boot clamp screw to the specified torque. new ones.
Page 430: Front Propeller Shaft Related Parts Inspection
3D-16 Propeller Shafts: Front Propeller Shaft Related Parts Inspection Universal Joint B831G23406012 Inspect the play by turning the universal joint. If Refer to “Front Propeller Shaft Removal and Installation excessive play is noted, replace it with a new one. (Page 3D-14)”. CAUTION Front Propeller Shaft Do not attempt to disassemble the universal...
Page 431: Rear Propeller Shaft Components
Propeller Shafts: 3D-17 Rear Propeller Shaft Components B831G23406013 I831G1340057-04 1. O-ring 9. Universal joint set 2. Rear propeller shaft joint 10. Rear output shaft yoke 3. Rear propeller shaft boot 11. Oil seal 4. Rear propeller shaft spring : 100 N⋅m (10.0 kgf-m, 72.5 lb-ft) 5.
Page 432 3D-18 Propeller Shafts: 4) Remove the rear propeller shaft spring (3). 8) Remove the O-ring (7). I831G1340061-01 I831G1340065-01 5) Draw out the rear propeller shaft (4) horizontally. 9) Remove the circlips from the universal joint. I831G1340062-01 I831G1340066-03 6) Loosen the boot clamp screw and remove the rear 10) Remove the bearings (8) by tapping with the special propeller shaft boot (5).
Page 433 I831G1340069-02 15) Remove the oil seal. I831G1340072-02 7) Apply grease to the bearings and dust seal lip. I831G1340070-01 : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) Installation CAUTION The removed oil seal, nut, circlips and O-ring must be replaced with a new ones.
Page 434 3D-20 Propeller Shafts: 8) Install the universal joint (4) to the yoke (5) and 12) Install the circlips to the universal joint. bearings (6) with the special tool. Special tool (A): 09913–70210 (Bearing installer set) I831G1340077-02 13) Install the O-ring (7) to the rear propeller shaft. I831G1340074-03 9) Install the circlips.
Page 435 Propeller Shafts: 3D-21 15) Fit the rear propeller shaft joint boot (9) to the rear 20) Install the O-ring (11) to the rear propeller shaft joint. propeller shaft groove. 21) Apply grease (approx. 4 grams) to the spline of rear propeller shaft joint.
Page 436: Rear Propeller Shaft Related Parts Inspection
3D-22 Propeller Shafts: Rear Propeller Shaft Related Parts Inspection Universal Joint B831G23406015 Inspect the universal joint in the following procedures: Refer to “Rear Propeller Shaft Removal and Installation 1) Inspect the universal joint and outer surface of the (Page 3D-17)”. bearing for scuffing, wear or damage.
Page 437: Specifications
For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List in Section 0C (Page 0C-7)”. Special Tools and Equipment Recommended Service Material B831G23408001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010 (Page 3D-2) /...
Page 438: Special Tool
3D-24 Propeller Shafts: Special Tool B831G23408002 09900–06107 09900–06108 Snap ring pliers Snap ring pliers (Page 3D-2) (Page 3D-3) / (Page 3D- 09900–20607 09900–20701 Dial gauge (1/100 mm, 10 Magnetic stand (Page 3D-11) (Page 3D-11) 09913–50121 09913–70210 Oil seal remover Bearing installer set (Page 3D-3) (Page 3D-4) / (Page 3D-...
Page 439: Front Brakes
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 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 B831G24000001 Refer to “General Precautions in Section 00 (Page 00-1)”. Brake Fluid Information B831G24000002 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 B831G24102001 “A” “D” “B” “C” “D” “H” “E” “F” “G” “D” “J” “I” VIEW A I831G1410001-09 1. Master cylinder reservoir “B”: Pass the brake hose inside the throttle cable.
Page 443: Rear Blake Cable Routing Diagram
Brake Control System and Diagnosis: 4A-2 Rear Blake Cable Routing Diagram B831G24102002 “A” Front side I831G1410035-05 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.
Page 444: Diagnostic Information And Procedures
4A-3 Brake Control System and Diagnosis: Diagnostic Information and Procedures Brake Symptom Diagnosis B831G24104001 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: Repair Instructions
Brake Control System and Diagnosis: 4A-4 Repair Instructions Brake Pedal Height Inspection and Adjustment Rear Brake Light Switch Inspection B831G24106001 B831G24106003 Refer to “Rear Brake Pedal / Rear Brake (Parking Brake) Inspect the rear brake light switch in the following Lever Inspection and Adjustment in Section 0B procedures: (Page 0B-19)”.
Page 446: Parking / Rear Brake Light Switch Inspection
4A-5 Brake Control System and Diagnosis: Parking / Rear Brake Light Switch Inspection Air Bleeding from Front Brake Fluid Circuit B831G24106005 B831G24106009 Inspect the parking/rear brake light switch in the Air trapped in the brake fluid circuit acts like a cushion to following procedures: absorb a large proportion of the pressure developed by the master cylinder and thus interferes with the full...
Page 447: Brake Fluid Replacement
Brake Control System and Diagnosis: 4A-6 4) Loosen the air bleeder valve by turning it a quarter of Brake Fluid Replacement B831G24106010 a turn so that the brake fluid runs into the receptacle, CAUTION this will remove the tension of the brake lever causing it to touch the handlebar grip.
Page 448: Front Brake Hose Removal And Installation
4A-7 Brake Control System and Diagnosis: 7) Loosen the air bleeder valve and pump the brake Front Brake Hose Removal and Installation B831G24106011 lever until the old brake fluid flows out of the brake Removal system. CAUTION Make sure that the vehicle is supported securely.
Page 449: Rear Brake Cable Removal And Installation
Brake Control System and Diagnosis: 4A-8 Rear Brake Cable Removal and Installation 6) Remove the rear brake cable bolt (7) from the right B831G24106012 footrest. Removal 1) Remove the right inner fender. Refer to “Front Side Exterior Parts Removal and Installation in Section 9D (Page 9D-6)”.
Page 450: Front Brake Master Cylinder Components
4A-9 Brake Control System and Diagnosis: Front Brake Master Cylinder Components B831G24106013 I831G1410019-04 1. Reservoir cap 7. Brake hose union bolt : 6 N⋅m (0.6 kgf-m, 4.5 lb-ft) 2. Diaphragm 8. Brake lever : Apply silicone grease. 3. Plate 9. Brake lever pivot bolt : Apply brake fluid.
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) B831G24106015 • 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 B831G24106017 “ a ” I831G1410038-04 1. Brake pedal 4. Brake pedal pivot bolt : Apply water resistance grease. 2. Brake light switch “a”: 17.5 mm (0.69 in) : Apply thread lock to the thread part. 3.
Page 455: Rear Brake Pedal Removal And Installation
Brake Control System and Diagnosis: 4A-14 Rear Brake Pedal Removal and Installation • Apply grease to the pivot part of brake pedal. B831G24106018 : Grease 99000–25160 (Water resistance Removal grease) 1) Remove the right inner fender. Refer to “Front Side Exterior Parts Removal and Installation in Section 9D (Page 9D-6)”.
Page 456: Specifications
4A-15 Brake Control System and Diagnosis: Specifications Service Data B831G24107001 Brake Unit: mm (in) Item Standard Limit Rear brake pedal height 12.5 – 22.5 (0.5 – 0.9) — Front master cylinder bore 14.000 – 14.043 (0.5512 – 0.5529) — Front master cylinder piston diam. 13.957 –...
Page 457: Special Tools And Equipment
Brake Control System and Diagnosis: 4A-16 Special Tools and Equipment Recommended Service Material B831G24108001 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 B831G24200001 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 1. Front brake caliper 7. Brake caliper mounting bolt : 23 N⋅m (2.3 kgf-m, 16.5 lb-ft) 2. Piston seal 8. Front brake disk : Apply thread lock to the thread part. 3. Dust seal : 6 N⋅m (0.6 kgf-m, 4.5 lb-ft) : Apply thread lock to the thread part.
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 (2). caliper mounting bolts (2). : Thread lock cement 99000–32050 (THREAD LOCK CEMENT 1342 or equivalent) 8) Tighten the front brake pad mounting pins (2) 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) Place a rag over the brake caliper piston to prevent it tighten the union bolt (3) to the specified torque. from popping out and then force out the piston using compressed air.
Page 462 4B-5 Front Brakes: Brake Caliper Holder Brake caliper • Remove the caliper holder pin (1) and caliper holder • Wash the caliper bores and pistons with specified slide pin (2) from caliper holder (3). brake fluid. Particularly wash the dust seal groove and piston seal groove.
Page 463: Front Brake Caliper Parts Inspection
4B-6 • Apply silicon grease to the two pins. Front Brake Caliper Parts Inspection B831G24206006 : Grease 99000–25100 (SUZUKI SILICONE Refer to “Front Brake Caliper Disassembly and GREASE or equivalent) Assembly (Page 4B-4)”. • Install the brake caliper holder (3) to the brake caliper Brake Caliper Cylinder (4).
Page 464: Front Brake Disc Removal And Installation
4B-7 Front Brakes: Brake Pad Mounting Pin Front Brake Disc Removal and Installation B831G24206007 Inspect the brake pad mounting pin for wear or other damage. If any damage is found, replace the mounting Removal pin with a new one. 1) Remove the front wheel assembly. Refer to “Front / Rear Wheel Removal and Installation in Section 2D (Page 2D-2)”.
Page 465: Front Brake Disc Inspection
Front Brakes: 4B-8 Front Brake Disc Inspection Brake Disc Runout B831G24206008 1) Dismount the front brake caliper. Refer to “Front Brake Disc Thickness Brake Caliper Removal and Installation (Page 4B- 1) Dismount the front brake caliper. Refer to “Front 3)”. Brake Caliper Removal and Installation (Page 4B- 2) Measure the runout using the dial gauge.
Page 466: Tightening Torque Specifications
For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List in Section 0C (Page 0C-7)”. Special Tools and Equipment Recommended Service Material B831G24208001 Material SUZUKI recommended product or Specification Note Brake fluid DOT 4 — (Page 4B-5) /...
Page 467: Rear Brakes
Rear Brakes: 4C-1 Rear Brakes Brake Precautions Precautions for Rear Brake B831G24300001 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 B831G24306001 I831G1430001-06 1.
Page 468: Rear Brake Friction Plate Inspection
4C-2 Rear Brakes: Rear Brake Friction Plate Inspection Installation B831G24306002 • Fit the rear brake case gasket (1). Refer to “Rear Brake Friction Plate Wear Limit Inspection in Section 0B (Page 0B-20)”. CAUTION Replace the gasket (1) with a new one. Rear Brake Friction Plate Replacement B831G24306003 Refer to “Rear Brake Disassembly and Assembly...
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 B831G24306005 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: 4) Remove the rear bake cam shaft (6). 7) Remove the rear drive gear shaft (9), with plastic mallet. I831G1430013-01 5) Unlock the nut with a chisel. I831G1430016-01 8) Remove the oil seal (10) with the special tool. Special tool (B): 09913–50121 (Oil seal remover) 9) Remove the oil seal (11).
Page 471 Rear Brakes: 4C-5 11) Remove the bearing with the special tool. Assembly Special tool CAUTION (C): 09921–20240 (Bearing remover set) The removed oil seal, bearing and snap ring must be replaced with new ones. • Install the rear brake in the reverse order of disassembly.
Page 472 4C-6 Rear Brakes: • Install the oil seals (7) and (8) with the special tool. • Install the rear brake cam shaft (10). • Apply grease to the rear brake cam shaft. Special tool (A): 09913–70210 (Bearing installer set) : Grease 99000–25160 (Water resistance grease) I831G1430024-05 •...
Page 473: Rear Brake Parts Inspection
Rear Brakes: 4C-7 • Bend the collar of the nut to the notch on the shaft of • Install the dowel pins and gasket (16). the rear propeller shaft coupling. CAUTION The removed gasket must be replaced with a new one. I831G1430029-01 •...
Page 474 4C-8 Rear Brakes: Bearing Rear Brake Side Plate / Rear Brake Friction Plate / Inspect the inner race play of the bearing by hand while Steel Plate it is in the rear brake case. • Inspect the rear brake side plates (1), rear brake Turn the inner race by hand to inspect for abnormal friction plates (2) and separator plates (3) for wear or noise or smooth rotation.
Page 475: Specifications
Rear Brakes: 4C-9 Brake Side Plate Spring Rear Brake Pressure Plate Inspect the rear brake pressure plate for wear or • Measure the free length “a”. damage. If any wear or damage is found, replace it with • If the free length “a” is shorter than the limit, replace a new one.
Page 476: Special Tools And Equipment
4C-10 Rear Brakes: Special Tools and Equipment Recommended Service Material B831G24308001 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 B831G24402001 “A” “B” I831G1440001-02 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” I831G1440002-03 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 B831G24406001 Refer to “Rear Brake Pedal / Rear Brake (Parking Brake) Lever Inspection and Adjustment in Section 0B (Page 0B-19)”.
Page 480: Parking / Rear Brake Lever Components
4D-4 Parking Brake: Parking / Rear Brake Lever Components B831G24406003 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 lb-ft) 3. Brake lever 6.
Page 481 Parking Brake: 4D-5 Specifications Tightening Torque Specifications B831G24407001 NOTE The specified tightening torque is also 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 (Page 0C-7)”.
Page 482 4D-6 Parking Brake:...
Page 483 Table of Contents 5- i Section 5 Transmission / Transaxle CONTENTS Precautions ..........5-1 Movable / Fixed Drive Face Parts Inspection..5A-15 Movable / Fixed Driven Face Parts Inspection ..5A-15 Precautions............. 5-1 Clutch Shoe Removal and Installation ....5A-16 Precautions for Transmission / Transaxle..... 5-1 Clutch Housing Case Disassembly and Automatic Transmission......
Page 484: Precautions
5-1 Precautions: Precautions Transmission / Transaxle Precautions Precautions for Transmission / Transaxle B831G25000001 Refer to “General Precautions in Section 00 (Page 00-1)”.
Page 485: Automatic Transmission
Automatic Transmission: 5A-1 Automatic Transmission Transmission / Transaxle Schematic and Routing Diagram Drive Train System B831G25102001 “A” I831G1510001-04 1. Crankshaft 6. Fixed driven face 11. High driven gear 2. Movable drive face 7. Transfer input shaft 12. Transfer output drive gear 3.
Page 486: Diagnostic Information And Procedures
5A-2 Automatic Transmission: Diagnostic Information and Procedures Automatic Transmission Symptom Diagnosis B831G25104001 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 B831G25106001 I831G1510002-03 1. Movable drive face bolt 11. Movable 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 B831G25106002 I831G1510003-06 1. Heat shield 3. Belt cooling inlet duct No. 1 5. Belt cooling inlet duct connector 7. Belt cooling outlet duct No. 2 2. Clamp 4. Belt cooling inlet duct No. 2 6.
Page 489: V-Belt Cooling Duct Removal And Installation
Automatic Transmission: 5A-5 V-belt Cooling Duct Removal and Installation 5) Remove the outlet belt cooling duct No. 1 (4) along B831G25106003 with outlet belt cooling duct connector (5). Removal 1) Remove the right inner fender. Refer to “Front Side Exterior Parts Removal and Installation in Section 9D (Page 9D-6)”.
Page 490 5A-6 Automatic Transmission: 6) Remove the V-belt outer cover (1). 3) Remove the movable drive face cover (1) and collar (2). I831G1510008-01 I831G1510011-01 Movable drive face 4) Remove the dowel pins (3). 1) Remove the cap (1). 5) Remove the movable drive face (4). I831G1510009-01 I831G1510012-01 2) Remove the movable drive face bolt with the special...
Page 491 I831G1510015-01 Fixed drive face • Apply grease in the groove of fixed driven face. Install the fixed drive face (1). : Grease 99000–25010 (SUZUKI SUPER CAUTION GREASE A or equivalent) Degrease the fixed drive face. Use nonflammable cleaning solvent to wipe off oily or greasy matter and make its surfaces completely dry.
Page 492 5A-8 Automatic Transmission: • Tighten the movable driven face bolt (3) to the • Install the dowel pins (4). specified torque with the special tool. Tightening torque Movable driven face bolt (a): 110 N·m (11.0 kgf- m, 79.5 lb-ft) Special tool (A): 09930–40113 (Rotor holder) I831G1510020-02 •...
Page 493: Movable Drive Face Disassembly And Assembly
Automatic Transmission: 5A-9 V-belt Outer Cover 2) Remove the movable drive plate (2) and rollers (3). • Install the V-belt outer cover (1). CAUTION If there are wear or damage, replace the gasket (2) with a new one. I831G1510025-01 3) Remove the dampers (4). I831G1510023-01 •...
Page 494 (3). I831G1510028-01 2) Apply grease to the lip of oil seals and inside grease groove “A” of the movable drive face. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) CAUTION I831G1510031-01 • Wipe off any excess grease thoroughly.
Page 495: Movable Driven Face Disassembly And Assembly
Automatic Transmission: 5A-11 7) Install the spacer (6). 2) Set the special tool to the movable driven face assembly (1) and compress the movable driven face NOTE assembly by turning in the special tool handle. When installing the spacer, press down the NOTE movable drive face plate so as not to cause the rollers to come out of position.
Page 496 5A-12 Automatic Transmission: 4) Loosen the special tool handle slowly and remove 9) Remove the oil seals (10) and (11) from the movable the special tool. driven face. 5) Remove the spring plate (3) and spring (4). NOTE If there are no abnormal conditions, the oil seals removal are not necessary.
Page 497 • Apply grease to the oil seal lips, O-rings and inside groove of movable driven face. CAUTION Replace the O-rings (1) with new ones. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) CAUTION • Wipe off any excess grease thoroughly.
Page 498: Drive V-Belt Inspection
5A-14 Automatic Transmission: • Compress the spring (7) with the special tool. • Tighten the movable driven face ring nut (10) to the specified torque with the special tools. Special tool (B): 09922–31430 (Clutch spring Tightening torque compressor) Movable driven face ring nut (a): 110 N·m (11.0 kgf-m, 79.5 lb-ft) NOTE Special tool...
Page 499: Movable / Fixed Drive Face Parts Inspection
Automatic Transmission: 5A-15 Movable / Fixed Drive Face Parts Inspection Oil Seal B831G25106009 Inspect the lip of the oil seal for wear or damage. If any damages are found, replace the oil seal with a new Movable / Fixed Drive Face one.
Page 500: Clutch Shoe Removal And Installation
5A-16 Automatic Transmission: Movable Driven Spring 4) Remove the inlet cooling duct connector (3) from the Measure the spring free length with the vernier calipers. clutch housing case (4). • If the length is shorter than the service limit, replace 5) Remove the clutch housing case (4) along with the the spring with a new one.
Page 501 Automatic Transmission: 5A-17 9) Remove the washer (10). “ b ” “ a ” I831G1510068-01 “a”: Clutch shoe side “b”: Clutch shoe nut side • Apply a small quantity of thread lock to the clutch shoe nut (3). I831G1510065-02 10) Remove the clutch shoe (11) with the special tools. : Thread lock cement 99000–32030 (THREAD LOCK CEMENT SUPER 1303 or Special tool...
Page 502 5A-18 Automatic Transmission: • Apply molybdenum oil solution to the inside of the one • Install the clutch housing case (7) and inlet belt way clutch (4). cooling duct connector (8) and tighten the bolts diagonally. M/O: Molybdenum oil (MOLYBDENUM OIL SOLUTION) •...
Page 503: Clutch Housing Case Disassembly And Assembly
Automatic Transmission: 5A-19 Clutch Housing Case Disassembly and • Remove the retainers (4). Assembly B831G25106012 Refer to “Clutch Shoe Removal and Installation (Page 5A-16)”. Disassembly • Remove the clutch housing (1) from clutch housing case. I831G1510077-01 • Remove the bearing (5) with the special tool. Special tool (B): 09921–20240 (Bearing remover set) NOTE...
Page 504: Clutch Parts Inspection
• Apply a small quantity of thread lock to the bearing • Apply grease to the O-ring (6). retainer screws (2), and tighten them securely. : Grease 99000–25010 (SUZUKI SUPER : Thread lock cement 99000–32030 GREASE A or equivalent) (THREAD LOCK CEMENT SUPER 1303 or...
Page 505 Automatic Transmission: 5A-21 Clutch Shoe Left Clutch Housing Bearing Inspect the boss and centrifugal weight fulcrum sections Rotate the inner race by finger to inspect for abnormal for looseness, damage and operation. play, noise and smooth rotation. If there is anything Inspect the clutch shoe for damage and fouling with oil unusual, replace the bearing with a new one.
Page 506: Movable Drive Face Cover Disassembly And Assembly
I831G1510090-01 • Remove the snap ring (2). I831G1510094-01 • Apply grease to the bearing. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I831G1510091-01 • Remove the bearing (3) with the special tool. NOTE If there is no abnormal noise, the bearing removal is not necessary.
Page 507: Clutch Housing Cover Parts Inspection
(A): 09913–70210 (Bearing installer set) CAUTION The removed oil seal must be replaced with a new one. • Apply grease to the lip of oil seal. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I831G1510101-01 Shift Lever Assembly Components B831G25106016...
Page 508: Gear Shift Knob Removal And Installation
5A-24 Automatic Transmission: Gear Shift Knob Removal and Installation 4) Loosen the bolt (2) and remove the gear shift arm B831G25106017 (1). Removal 1) Loosen the lock-nut (1). 2) Remove the gear shift knob (2). I831G1510105-03 5) Remove the transfer gear shift lever mounting bolts (3).
Page 509: Shift Lever Disassembly And Assembly
Pay attention to the following points: (Page 9D-6)”. • Apply grease to pivot. Shift Lever Disassembly and Assembly : Grease 99000–25010 (SUZUKI SUPER B831G25106019 GREASE A or equivalent) 1) Removed the shift lever assembly. Refer to “Shift Lever Assembly Removal and Installation (Page 5A- 24)”.
Page 510: Specifications
5A-26 Automatic Transmission: NOTE Shift arm side Be careful not to separate the rod from the joint by turning the rod too much. Shift lever side I831G1510118-01 I831G1510117-01 Specifications Service Data B831G25107001 Clutch Unit: mm (in) Item Standard Limit Clutch wheel I.D. 140.0 –...
Page 511 For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List in Section 0C (Page 0C-7)”. Special Tools and Equipment Recommended Service Material B831G25108001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010 (Page 5A-7) /...
Page 512: Special Tool
5A-28 Automatic Transmission: Special Tool B831G25108002 09900–20101 09913–50121 Vernier calipers (1/15 mm, Oil seal remover 150 mm) (Page 5A-14) (Page 5A-19) / (Page 5A-22) 09913–70210 09917–23711 Bearing installer set Ring nut wrench (Page 5A-10) / (Page 5A-11) / (Page 5A-12) / (Page 5A-14) (Page 5A-19) / (Page 5A-20) /...
Page 513 Table of Contents 6- i Section 6 Steering CONTENTS Precautions ..........6-1 Handlebars Removal and Installation ....6B-3 Handlebars Inspection ........6B-5 Precautions............. 6-1 Steering Shaft Removal and Installation .....6B-6 Precautions for Steering ........6-1 Tie-rod / Tie-rod End Removal and Steering General Diagnosis....6A-1 Installation ............6B-9 Steering Parts Inspection ........6B-10 Diagnostic Information and Procedures....6A-1...
Page 514: Precautions
6-1 Precautions: Precautions Steering Precautions Precautions for Steering B831G26000001 Refer to “General Precautions in Section 00 (Page 00-1)”.
Page 515: Steering General Diagnosis
Steering General Diagnosis: 6A-1 Steering General Diagnosis Steering Diagnostic Information and Procedures Steering Symptom Diagnosis B831G26104001 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 B831G26206001 “A” “A” “A” “A” I831G1620001-17...
Page 517: Steering / Handlebars Assembly Construction
Steering / Handlebar: 6B-2 1. Handlebars 11. O-ring 21. Handle grip 2. Handlebar upper clamp 12. Washer “A”: Apply grip bond. 3. Handlebar clamp bolt 13. Steering shaft lower nut : 26 N⋅m (2.6 kgf-m, 19.0 lb-ft) 4. Steering shaft 14.
Page 518: Handlebars Removal And Installation
6B-3 Steering / Handlebar: Handlebars Removal and Installation 5) Remove the parking brake lever from the handlebar B831G26206003 by removing mounting bolt. Removal 1) Remove the combination meter. Refer to “Combination Meter Removal and Installation in Section 9C (Page 9C-3)”. 2) Remove the following parts from left handlebar.
Page 519 Steering / Handlebar: 6B-4 8) Remove the following parts from the right handlebar. • Set the handlebars so that its punch mark “A” aligns with the mating surface of the left handlebar holder. a) Right grip (4) b) Front brake master cylinder/Front brake lever (5) CAUTION Do not turn the front brake master cylinder upside down.
Page 520: Handlebars Inspection
6B-5 Steering / Handlebar: • Apply adhesive agent to the handlebar right and left • Install the master cylinder. Refer to “Front Brake end and right and left grip inner wall. Master Cylinder Assembly Removal and Installation in Section 4A (Page 4A-9)”. : Handle grip bond (Handle Grip Bond •...
Page 521: Steering Shaft Removal And Installation
Steering / Handlebar: 6B-6 Steering Shaft Removal and Installation 9) Disconnect the brake hose (3) from the hose guide. B831G26206005 10) Remove the read wire clamps. Removal 1) Remove the front wheels. Refer to “Front / Rear Wheel Removal and Installation in Section 2D (Page 2D-2)”.
Page 522 6B-7 Steering / Handlebar: 15) Remove the steering shaft bushing (10) and dust • Apply grease to the dust seal (3) and O-ring (4). seal (11) with the special tools and suitable socket CAUTION wrench. The removed O-ring must be replaced with a Special tool new one.
Page 523 Steering / Handlebar: 6B-8 • Apply grease to the steering shaft holders before • When installing the steering arm plate, align the wide installing the shaft holders. spline “B” of steering shaft (7) with slit “C” of steering arm plate (8). : Grease 99000–25160 (Water resistance grease) CAUTION...
Page 524: Tie-Rod / Tie-Rod End Removal And Installation
6B-9 Steering / Handlebar: • Connect the tie-rod ends. Refer to “Front Wheel Hub / Tie-rod / Tie-rod End Removal and Installation B831G26206006 Steering Knuckle Removal and Installation in Section Removal 2B (Page 2B-4)”. 1) Remove the tie-rod end (steering knuckle side). •...
Page 525: Steering Parts Inspection
Steering / Handlebar: 6B-10 Installation • After installed wheels, inspect the toe-out. If the toe- Install the tie-rod in the reverse order of removal. Pay out is out of specification, bring it into the specified attention to the following points: range.
Page 526: Specifications
6B-11 Steering / Handlebar: Tie-rod End Steering Shaft Holder Inspect the tie-rod ends for smooth movement. If there Inspect the steering shaft holders for wear or damage. If are any abnormalities, replace the tie-rod ends with new any defects are found, replace the steering shaft holders ones.
Page 527: Tightening Torque Specifications
For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List in Section 0C (Page 0C-7)”. Special Tools and Equipment Recommended Service Material B831G26208001 Material SUZUKI recommended product or Specification Note Grease Water resistance grease P/No.: 99000–25160 (Page 6B-7) /...
Page 528 6B-13 Steering / Handlebar:...
Page 529 Table of Contents 9- i Section 9 Body and Accessories CONTENTS Precautions ..........9-1 Engine Coolant Temperature Indicator Light Inspection............9C-4 Precautions............. 9-1 Engine Coolant Temperature Removal and Precautions for Electrical System ......9-1 Installation ............9C-4 Component Location ..........9-1 Fuel Level Indicator Inspection ......9C-5 Electrical Components Location ......
Page 530 9-ii Table of Contents Trailer Towing Construction ........ 9E-7 Tightening Torque Specifications......9E-8 Trailer Towing Removal and Instruction....9E-7 Special Tools and Equipment ......9E-8 Specifications............9E-8 Recommended Service Material ......9E-8...
Page 531: Precautions
Precautions: Precautions Body and Accessories Precautions Precautions for Electrical System B831G29000001 Refer to “General Precautions in Section 00 (Page 00-1)” and “Precautions for Electrical Circuit Service in Section 00 (Page 00-2)”. Component Location Electrical Components Location B831G29003001 Refer to “Electrical Components Location in Section 0A (Page 0A-7)”.
Page 532: Wiring Systems
9A-1 Wiring Systems: Wiring Systems Body and Accessories Schematic and Routing Diagram Wiring Diagram B831G29102001 Refer to “Wire Color Symbols in Section 0A (Page 0A-5)”.
Page 533 Wiring Systems: 9A-2 For P-17 I831G1910901-10...
Page 534 9A-3 Wiring Systems: For P-24, 28, 33 I831G1910902-13...
Page 535: Wiring Harness Routing Diagram
Wiring Systems: 9A-4 Wiring Harness Routing Diagram B831G29102002 Clamp 60 – 80 mm (2.36 – 3.15 in) Wiring harness Ignition coil Wiring harness Clamp To power source Clamp Wiring harness Clamp Clamp Hose Wiring harness Clamp Cooling fan thermo switch Brake light/taillight Wiring harness ISC valve...
Page 536 9A-5 Wiring Systems: Clamp Set the writing harness as shown. Horn button (P-17, 24) To combination meter Emergency switch (P-17) Handle switch Parking brake switch Front brake switch Ignition switch Handle switch 4WD/Diff-lock switch Pass the writing harness behind the upper. Parking brake switch Combination meter Horn button (P-17, 24)
Page 537: Specifications
Wiring Systems: 9A-6 “ a ” I831G1910905-05 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 B831G29107001 Electrical Unit: mm Item Specification Note 10 A Headlight...
Page 538: Lighting Systems
9B-1 Lighting Systems: Lighting Systems Body and Accessories Repair Instructions Headlight Components B831G29206001 I831G1920002-03 1. Headlight bulb (12 V 35/35 W) Headlight Removal and Installation 3) Remove the headlight assembly (2) by removing B831G29206002 screw (3), fastener (4) and bolts (5). Removal 1) Remove the front grill upper cover.
Page 539: Headlight Bulb Replacement
Lighting Systems: 9B-2 Installation 2) Disconnect the headlight coupler (3). Install the headlight in the reverse order of removal. Pay 3) Replace the headlight bulb (4) by unhooking the bulb attention to the following point: holder spring (5). • After installing, be sure to inspect the headlight beam. Refer to “Headlight Beam Adjustment (Page 9B-2)”.
Page 540: Auxiliary Headlight Components
9B-3 Lighting Systems: Auxiliary Headlight Components B831G29206005 I831G1920009-05 1. Auxiliary headlight bulb (12 V 35/35 W) Auxiliary Headlight Removal and Installation 2) Remove the auxiliary headlight cover (2) by B831G29206006 removing the fasteners (3). Removal 1) Remove the screws (1). I831G1920011-01 I831G1920010-01 I831G1920012-01...
Page 541: Auxiliary Headlight Bulb Replacement
Lighting Systems: 9B-4 3) Remove the auxiliary headlight mounting bolt (4). Auxiliary Headlight Bulb Replacement B831G29206007 CAUTION • If you touch the bulb with your bare hands, clean the bulb with a cloth moistened with alcohol or soapy water to prevent premature bulb failure.
Page 542: Auxiliary Headlight Beam Adjustment
9B-5 Lighting Systems: 4) Properly fit the bulb socket cap (1). Auxiliary Headlight Beam Adjustment B831G29206008 NOTE • Loosen the auxiliary headlight mounting bolt (1). Make sure that the “TOP” mark “A” face to upper side. “A” I831G1920029-01 • Adjust the auxiliary headlight beam. •...
Page 543: Rear Combination Light Removal And Installation
Lighting Systems: 9B-6 Rear Combination Light Removal and 1) Remove the rear combination light. Installation B831G29206010 Removal 1) Remove the rear combination light mounting bolts. I831G1920022-02 2) Remove the bulb socket by turning it counterclockwise. I831G1920020-01 2) Remove the rear combination light assembly by disconnecting the clamp (1) and coupler (2).
Page 544: Reversing Light Bulb Replacement (For
9B-7 Lighting Systems: Reversing Light Bulb Replacement (For P-17) B831G29206012 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). B831G29206013 First, check the insulation between “A”...
Page 545: Specifications
Lighting Systems: 9B-8 Specifications Service Data B831G29207001 Wattage Unit: W Specification Item P-24, 28, 33 P-17 ← 35 x 2 Headlight ← 35 x 2 ← Auxiliary headlight 35/35 ← Brake light/Taillight 21/5 Revercing light — Special Tools and Equipment Special Tool B831G29208001 09900–25008...
Page 546: 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 B831G29301001 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 547: Repair Instructions
Combination Meter / Fuel Meter / Horn: 9C-2 Repair Instructions Combination Meter Components B831G29306001 I831G1930002-04 1. Upper case 2. Combination meter 3. Lower case...
Page 548: Combination Meter Removal And Installation
9C-3 Combination Meter / Fuel Meter / Horn: Combination Meter Removal and Installation 3) Disconnect the combination meter coupler (5) and B831G29306002 remove the combination meter assembly (6). CAUTION When disconnecting and reconnecting the combination meter coupler, make sure to turn OFF the ignition switch, or electronic parts may get damaged.
Page 549: Combination Meter Inspection
Combination Meter / Fuel Meter / Horn: 9C-4 Combination Meter Inspection 4) Connect the variable resistor (2) between the B831G29306004 terminals. LED Inspection Check that the LEDs (Diff-lock indicator light, Reverse indicator light and FI indicator light / Engine coolant temperature indicator light) immediately light up for two seconds when the ignition switch is turned to ON.
Page 550: Fuel Level Indicator Inspection
9C-5 Combination Meter / Fuel Meter / Horn: Fuel Level Indicator Inspection B831G29306007 Inspect the fuel level indicator in the following procedures: 1) Move the rear fender upside. Refer to “Fuel Tank Pressure Control (FTPC) Valve Removal and Installation in Section 1G (Page 1G-12)”.
Page 551: Fuel Level Gauge Inspection
Combination Meter / Fuel Meter / Horn: 9C-6 Fuel Level Gauge Inspection Speed Sensor Removal and Installation B831G29306008 B831G29306010 Inspect the fuel level gauge in the following procedures: Removal 1) Remove the fuel pump. Refer to “Fuel Pump 1) Remove the engine side cover. Refer to “Rear Side Assembly Removal and Installation in Section 1G Exterior Parts Removal and Installation in Section (Page 1G-9)”.
Page 552: Speed Sensor Inspection
9C-7 Combination Meter / Fuel Meter / Horn: Speed Sensor Inspection Ignition Switch Inspection B831G29306011 B831G29306012 Inspect the speed sensor in the following procedures: Inspect the ignition switch in the following procedures: 1) Remove the speed sensor. Refer to “Speed Sensor 1) Remove the left inner fender.
Page 553: Horn Inspection (For
Combination Meter / Fuel Meter / Horn: 9C-8 Horn Inspection (For P-17, 24) 3) Connect the horn couplers. B831G29306014 NOTE Horn Inspection If the horn sound condition is normal, it is not 1) Disconnect the horn couplers as shown in the wiring necessary to inspect the horn button harness routing diagram.
Page 554: Special Tools And Equipment
9C-9 Combination Meter / Fuel Meter / Horn: Special Tools and Equipment Recommended Service Material B831G29308001 Material SUZUKI recommended product or Specification Note Grease Water resistance grease P/No.: 99000–25160 (Page 9C-6) Special Tool B831G29308002 09900–25008 Multi-circuit tester set (Page 9C-6) /...
Page 555: Exterior Parts
Exterior Parts: 9D-1 Exterior Parts Body and Accessories Repair Instructions Exterior Parts Construction B831G29406001...
Page 556 9D-2 Exterior Parts: Front Side I831G1940001-08 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 557 Exterior Parts: 9D-3 Rear Side I831G1940002-02 1. Rear fender 2. Right mud guard 3. Left mud guard 4. Engine side cover 5. Rear box...
Page 558: Rear Fender Heat Shield Construction
9D-4 Exterior Parts: Rear Fender Heat Shield Construction B831G29406002 “ a ” “ b ” “ a ” “ d ” “ c” I831G1940003-07 1. Rear fender “a”: 1 – 3 mm (0.04 – 0.12 in) “c”: 67 mm (2.64 in) 2.
Page 559: Fuel Tank Lower Cover Heat Shield Installation
Exterior Parts: 9D-5 Fuel Tank Lower Cover Heat Shield Installation B831G29406003 “ a ” I831G1940045-02 1. Heat shield 2. Cushion 3. Fuel tank lower cover “a”: Max. 5 mm (0.2 in)
Page 560: Fastener Removal And Installation
9D-6 Exterior Parts: Fastener Removal and Installation Front Side Exterior Parts Removal and B831G29406004 Installation Removal B831G29406005 1) Depress the head of fastener center piece (1). Front Grill Cover 2) Pull out the fastener (2). Removal Remove the front grill cover (1) by removing the fasteners (2).
Page 561 Exterior Parts: 9D-7 Air Cleaner Box Cover 5) Remove the front box holder (4) and cushions (5). Removal 1) Remove the seat. Refer to “Seat Removal and Installation (Page 9D-11)”. 2) Remove the air cleaner box cover (1) by removing the fasteners (2).
Page 562 9D-8 Exterior Parts: Inner Fender Removal Remove the inner fenders (1) by removing the screw (2), 1 “B” bolt (3) and fastener (4), left and right. I831G1940016-01 “B”: Right side Installation Install the side cover in the reverse order of removal. I831G1940013-02 Front Fender Removal...
Page 563: Rear Side Exterior Parts Removal And Installation
Exterior Parts: 9D-9 5) Remove the front fender (2) by removing the screws Rear Side Exterior Parts Removal and (3) and fasteners (4). Installation B831G29406006 Engine Side Cover Removal Remove the engine side cover (1). I831G1940018-01 I831G1940021-01 Installation Install the engine side cover in the reverse order of removal.
Page 564 9D-10 Exterior Parts: Mud Guard 2) Remove the fasteners (3), bolt (4) and screw (5). Removal Remove the mud guards (1) by removing the bolts (2), screws (3) and fastener (4), left and right. I831G1940026-01 3) Move the rear fender upside. “A”...
Page 565: Seat Removal And Installation
Exterior Parts: 9D-11 5) Remove the fasteners (1) and screws (2). 9) Remove the parking brake cable (5) from the cable guide. I831G1940028-01 I831G1940031-01 10) Remove the fuel tank cap (6). CAUTION To prevent the fuel tank from contamination with foreign particles, install the fuel tank cap, after removing the rear fender.
Page 566: Under Cover Components
9D-12 Exterior Parts: Under Cover Components B831G29406008 I831G1940034-02 1. Front under cover 2. Engine under cover 3. Rear under cover Under Cover Removal and Installation B831G29406009 Front Under Cover Removal Remove the front under cover (1) by removing the bolts (2) and fasteners (3).
Page 567 Exterior Parts: 9D-13 Engine Under Cover Removal Remove the engine under cover (1). I831G1940042-01 2) Install the engine under cover. Rear Under Cover I831G1940038-01 Removal Remove the rear under cover (1). I831G1940039-01 I831G1940043-01 I831G1940040-01 Installation I831G1940044-01 1) Fix the engine under cover (1) with the front under Installation cover (2) and rear under cover (3).
Page 568: Body Structure
9E-1 Body Structure: Body Structure Body and Accessories Repair Instructions Body Frame Construction B831G29506001 I831G1950005-06 1. Frame 2. Battery plate Footrest Construction B831G29506002 I831G1950001-04 1. Footrest (R) 3. Footrest plate : 55 N⋅m (5.5 kgf-m, 40.0 lb-ft) 2. Footrest (L) : 26 N⋅m (2.6 kgf-m, 19.0 lb-ft) : Apply thread lock to the thread part.
Page 569: Footrest Removal And Installation
Body Structure: 9E-2 Footrest Removal and Installation Installation B831G29506003 Install the footrest in the reverse order of removal. Pay attention to the following point: Removal • Apply thread lock to the footrest mounting bolts and 1) Remove the mud guard. Refer to “Rear Side Exterior tighten them to the special torque.
Page 570: Carrier Construction
9E-3 Body Structure: Carrier Construction B831G29506004 I831G1950006-06 1. Front carrier 2. Rear carrier : Apply thread lock to the thread part.
Page 571: Front Carrier Removal And Installation
Body Structure: 9E-4 Front Carrier Removal and Installation Installation B831G29506005 Install the front carrier in the reverse order of removal. Pay attention to the following point: Removal • Apply thread lock to the front carrier mounting bolts. 1) Remove the front grill upper cover. Refer to “Front : Thread lock cement 99000–32110 Side Exterior Parts Removal and Installation in (THREAD LOCK CEMENT SUPER 1322 or...
Page 572: Rear Carrier Removal And Installation
9E-5 Body Structure: Rear Carrier Removal and Installation Installation B831G29506006 Install the rear carrier in the reverse order of removal. Pay attention to the following point: Removal • Apply thread lock to the rear carrier mounting bolts. 1) Remove the rear carrier (1) by removing the bolts (2) : Thread lock cement 99000–32110 and screw (3).
Page 573: Front Grip Bar Construction
Body Structure: 9E-6 Front Grip Bar Construction B831G29506007 I831G1950016-01 1. Front grip bar : Apply thread lock to thread part. Front Grip Bar Removal and Installation Installation B831G29506008 Install the front grip bar in the reverse order of removal. Pay attention to the following point: Removal •...
Page 574: Trailer Towing Construction
9E-7 Body Structure: Trailer Towing Construction B831G29506009 “ a ” “ b ” I831G1950020-04 1. Trailer towing warning label (P-17, 28) : 60 N⋅m (6.0 kgf-m, 43.5 lb-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 575: Special Tools And Equipment
For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List in Section 0C (Page 0C-7)”. Special Tools and Equipment Recommended Service Material B831G29508001 Material SUZUKI recommended product or Specification Note Thread lock cement THREAD LOCK CEMENT SUPER P/No.: 99000–32110 (Page 9E-2) /...
Page 576 LT-A750XK9 ('09-MODEL) 10-1 LT-A750XK9 ('09-MODEL) NOTE: * Asterisk mark (*) indicates the New K9-model specification. * The service data is the same as the K8-model.
Page 577 10-2 LT-A750XK9 ('09-MODEL)
Page 578 LT-A750XPK9 ('09-MODEL) LT-A750XPK9 ('09-MODEL) This chapter describes service data, service specifications and servicing procedures which differ from those of the LT-A750X/ZK9.
Page 579 * 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 580: General Information ................................................... 0-I General Information
TABLE OF CONTENTS NOTE For the screen toned sections with asterisk (*) in the “TABLE OF CONTENTS” below, refer to the same sections of the service manual mentioned in the “FOREWORD” of this manual. Precautions............... 00-i Body and Accessories..........9-i Precautions ............
Page 582 Table of Contents 00- i Section 00 Precautions CONTENTS NOTE For the items with asterisk (*) in the “CONTENTS” below, refer to the same section of the service manual mentioned in the “FOREWORD” of this manual. Precautions ..........00-1 General Precautions ..........00-* Precautions for Electrical Circuit Service .....00-* Precautions............
Page 583 00-1 Precautions: Precautions Precautions Precautions Precautions for EPS (LT-A750XP/ZK9) • Since each component is a high-precision part, great B931G40000004 care should be taken not to apply any service impacts EPS Wiring during removal and installation. • The EPS parts are connected to various lead wires. The coupler and lead wire connections, as well as the lead wire and wire harness routings must be done correctly.
Page 584 Front Differential Gear Oil Inspection....0B-* Symbols ...............0A-* Front Differential Gear Oil Replacement ..... 0B-* Abbreviations ............0A-* Final Gear Oil Inspection........0B-* SAE-to-Former SUZUKI Term ......0A-* Final Gear Oil Replacement........ 0B-* Vehicle Side View ..........0A-* Throttle Cable Play Inspection and Vehicle Identification Number ......0A-* Adjustment ............
Page 585 Vehicle Side View (LT-A750XP/ZK9) Left Side B931G40101013 NOTE Difference between illustration and actual motorcycles may exist depending on the markets. SUZUKI LT-A750XP (2009-model) Right Side I931G3010002-01 I931G3010001-01 Country and Area Codes (LT-A750XP/ZK9) B931G40101014 The following codes stand for the applicable country(-ies) and area(-s).
Page 586 General Information: 0A-2 Warning, Caution and Information Labels Location (LT-A750XP/ZK9) B931G40101015 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 587 0A-3 General Information: Specifications Specifications (LT-A750XP/ZK9) B931G40107003 NOTE These specifications are subject to change without notice. Dimensions and curb 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 588 General Information: 0A-4 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 170.5 mm (6.7 in) Rear wheel travel 195 mm (7.7 in) Caster 3.3q Trail 16.7 mm (0.66 in)
Page 589 Special Tool B931G40108002 09900–06107 09900–20102 09900–25008 09900–25009 09904–41010 Snap ring remover Vernier calipers (200 Multi circuit tester set Needle-point probe SUZUKI Diagnostic (Open type) system set 09924–84521 09930–30721 09930–44530 09930–82710 09930–82720 Bearing installer set Rotor remover Rotor holder Mode select switch Mode selection switch 09942–72410...
Page 590 Maintenance and Lubrication: 0B-1 Maintenance and Lubrication General Information Repair Instructions Air Cleaner Element Inspection and Cleaning 5) Immerse the element in motor oil, and then squeeze out the excess oil leaving the element slightly wet. (LT-A750XP/ZK9) B931G40206030 Clean element “A”...
Page 591 0B-2 Maintenance and Lubrication: 5) Measure the distances (“A” and “B”) between the front wheels. Subtract the measurement of “A” from “ a ” that of “B” to find the toe-out. If the toe-out is not within specification, adjust the tie-rod to the right or left until the toe-out is within the specified range.
Page 592 Maintenance and Lubrication: 0B-3 Chassis Bolt and Nut Inspection (LT-A750XP/ ZK9) B931G40206033 Tighten chassis bolt and nut Initially at 200 km (100 miles, 1 month) and every 1 000 km (600 miles, 3 months) thereafter Check that all chassis bolts and nuts are tightened to their specified torque.
Page 593 0B-4 Maintenance and Lubrication: Specifications Tightening Torque Specifications B931G40207001 Tightening torque Fastening part Note N˜m kgf-m lbf-ft )(Page 0B-2) Tie-rod lock-nut 21.0 NOTE The specified tightening torque is described in the following. “Chassis Bolt and Nut Inspection (LT-A750XP/ZK9) (Page 0B-3)” Reference: For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List (LT-A750XP/ZK9) in Section 0C (Page 0C-7)”.
Page 594 Service Data: 0C-1 Service Data General Information Specifications Service Data (LT-A750XP/ZK9) B931G40307003 Valve + Valve Guide Unit: mm (in) Item Standard Limit 36.0 (1.42) — Valve diam. 33.0 (1.30) — 0.10 – 0.20 (0.004 – 0.008) — Tappet clearance (When cold) 0.20 –...
Page 595 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 104.000 –...
Page 596 Service Data: 0C-3 Drive Train Unit: mm (in) Except ratio Item Standard Limit Automatic transmission ratio Variable change (2.763 – 0.780) — Secondary reduction ratio 2.158 (40/21 x 17/15) — Front 3.600 (36/10) — Final reduction ratio Rear 3.600 (36/10) —...
Page 597 0C-4 Service Data: Injector + Fuel Pump + Fuel Pressure Regulator Item Specification Note 11 – 13 : at 20 qC (68 qF) 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 598 Service Data: 0C-5 Electrical Unit: mm (in) Item 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. 150 – 250 : CKP sensor resistance CKP sensor peak voltage 5.0 V and more Terminal –...
Page 599 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 — 3.0 (0.20) Front brake disc runout —...
Page 600 Service Data: 0C-7 Tightening Torque List (LT-A750XP/ZK9) B931G40307004 Engine Item N˜m kgf-m lbf-ft Spark plug Initial Cylinder head cover bolt Final 10.5 Cam drive idle gear/sprocket shaft 29.5 Intake pipe bolt Cylinder head bolt (M6) Initial 18.0 Cylinder head bolt (L200) Final 27.0 Cylinder head bolt (L: 70)
Page 601 0C-8 Service Data: Drive Train Item N˜m kgf-m lbf-ft 4WD/Diff-lock actuator mounting bolt 16.0 Front drive (Differential) gear case bolt 16.0 Front drive (Differential) gear case mounting nut 36.0 Front drive (Differential) gear oil level plug 0.85 Front drive (Differential) gear oil filler plug 25.5 Front drive (Differential) gear oil drain plug 23.0...
Page 602 Service Data: 0C-9 Chassis Item N˜m kgf-m lbf-ft Handlebar clamp bolt 19.0 Handlebar holder nut 43.5 Rear brake lever holder clamp bolt Throttle lever case bolt Steering shaft upper nut 12.0 87.0 Steering shaft bolt 19.0 EPS control unit mounting nut EPS body assembly mounting bolt 19.0 EPS body assembly mounting nut...
Page 603 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 604 Table of Contents 1- i Section 1 Engine CONTENTS NOTE For the items with asterisk (*) in the “CONTENTS” below, refer to the same section of the service manual mentioned in the “FOREWORD” of this manual. Precautions ..........1-* DTC “C40” (P05057): ISC Valve Circuit Malfunction............
Page 605 1-ii Table of Contents Service Data............1C-* Recommended Service Material ......1D-* Tightening Torque Specifications......1C-* Special Tool ............1D-* Special Tools and Equipment ......1C-* Engine Lubrication System ..... 1E-* Recommended Service Material ......1C-* Precautions............1E-* Special Tool ............1C-* Precautions for Engine Oil ........
Page 606 Table of Contents 1-iii Water Pump Disassembly and Assembly ....1F-* Spark Plug Cap and Spark Plug Removal and Water Pump Related Parts Inspection ....1F-* Installation ............1H-* Spark Plug Inspection and Cleaning ....1H-* Specifications............1F-* Ignition Coil and Plug Cap Inspection ....1H-* Service Data ............1F-* CKP Sensor Inspection ........
Page 607 1-iv Table of Contents Starter Motor Related Parts Inspection (LT- Battery Charging ..........1J-* A750XP/ZK9) ............. 1I-3 Battery Removal and Installation ......1J-* Battery Visual Inspection........1J-* Specifications............1I-5 Generator Removal and Installation (LT- Service Data............1I-* A750XP/ZK9) ............ 1J-1 Service Data (LT-A750XP/ZK9) ......1I-5 Battery Removal and Installation (LT- Tightening Torque Specifications......
Page 608 Starting System: 1I-1 Starting System Engine Repair Instructions Starter Motor Components (LT-A750XP/ZK9) B931G41906022 I931G3190012-03 1. O-ring 6. Starter motor case : 5 N˜m (0.5 kgf-m, 3.5 lbf-ft) 2. Housing end (Inside) 7. Housing end (Outside) : Apply grease to sliding surface. 3.
Page 609 Pay attention to the following points: Disassemble the starter motor as shown in the starter • Apply grease to the starter motor O-ring. motor components diagram. Refer to “Starter Motor : Grease 99000–25010 (SUZUKI SUPER Components in related manual”. GREASE “A” or equivalent) Assembly...
Page 610 • Apply a small quantity of moly paste to the armature Starter Motor Related Parts Inspection (LT- shaft. A750XP/ZK9) B931G41906025 : Moly paste 99000–25140 (SUZUKI Moly Refer to “Starter Motor Disassembly and Assembly in paste or equivalent) related manual”. Carbon Brush Inspect the carbon brushes for abnormal wear, cracks or smoothness in the brush holder.
Page 611 1I-4 Starting System: Armature Coil Bearing Measure for continuity between each segment. Measure Check the bearing of housing end for damage. for continuity between each segment and the armature If any damage is found, replace the housing end. shaft. If there is no continuity between the segments or there is continuity between the segments and shaft, replace the armature with a new one.
Page 612 For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List (LT-A750XP/ZK9) in Section 0C (Page 0C-7)”. Special Tools and Equipment Recommended Service Material B931G41908001 Material SUZUKI recommended product or Specification Note )(Page 1I-2) / )(Page 1I-2) Grease SUZUKI SUPER GREASE “A” or P/No.: 99000–25010...
Page 613 Be careful not to pinch the finger between the generator cover and the crankcase. • Apply grease to the O-ring (1) and oil seal lip. : Grease 99000–25010 (SUZUKI SUPER GREASE “A” or equivalent) I931G31A0001-01 9) Disconnect the CKP sensor coupler (5) and CAUTION generator coupler (6) and remove the clamp (7).
Page 614 Charging System: 1J-2 • Tighten the crankshaft spacer nut (2) to the specified 3) Disconnect the battery (–) lead wire (2). torque with the special tool. 4) Disconnect the battery (+) lead wire (3). Special tool NOTE (A): 09930–44530 (Rotor holder) Be sure to disconnect the battery (–) lead Tightening torque wire (2) first, then disconnect the battery (+)
Page 615 For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List (LT-A750XP/ZK9) in Section 0C (Page 0C-7)”. Special Tools and Equipment Recommended Service Material B931G41A08001 Material SUZUKI recommended product or Specification Note )(Page 1J-1) Grease SUZUKI SUPER GREASE “A” or P/No.: 99000–25010...
Page 616 Table of Contents 3- i Section 3 Driveline / Axle CONTENTS NOTE For the items with asterisk (*) in the “CONTENTS” below, refer to the same section of the service manual mentioned in the “FOREWORD” of this manual. Precautions ..........3-* Front Drive (Differential) Gear Oil Replacement .............
Page 617 3-ii Table of Contents Transfer Related Parts Inspection....... 3C-* Front Output Shaft Related Parts Inspection ..3D-* Transfer Related Bearing Inspection....3C-* Rear Output Shaft Components......3D-* Gear Position (GP) Switch Inspection....3C-* Rear Output Shaft Removal and Installation ..3D-* Gear Position (GP) Switch Removal and Rear Output Shaft Disassembly and Installation ............
Page 618 Drive Chain / Drive Train / Drive Shaft: 3A-1 Drive Chain / Drive Train / Drive Shaft Driveline / Axle Repair Instructions Front Drive Shaft Components (LT-A750XP/ZK9) B931G43106009 I931H1310012-03 1. Circlip 6. Inner boot band (Small) : Apply grease. 2. Snap ring 7.
Page 619 3A-2 Drive Chain / Drive Train / Drive Shaft: Front Drive Shaft Disassembly and Assembly 3) Remove the outer race from the front drive shaft. (LT-A750XP/ZK9) B931G43106010 Refer to “Front Drive Shaft Assembly Removal and Installation in related manual”. Disassembly CAUTION Do not disassemble the wheel side joint.
Page 620 Drive Chain / Drive Train / Drive Shaft: 3A-3 Assembly 3) Install the new snap ring to the cage. CAUTION CAUTION Replace the snap ring with a new one. • Wash all parts before installation, clean the inside and outside of the boots with a Special tool cloth.
Page 621 3A-4 Drive Chain / Drive Train / Drive Shaft: 5) Insert the cage into the outer race and install the new stopper ring to the groove of the outer race. CAUTION • Replace the stopper ring with a new one. •...
Page 622 Drive Chain / Drive Train / Drive Shaft: 3A-5 Rear Drive Shaft Components (LT-A750XP/ZK9) B931G43106012 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.
Page 623 3A-6 Drive Chain / Drive Train / Drive Shaft: Special Tools and Equipment Recommended Service Material B931G43108001 NOTE Required service material is also described in the following. “Front Drive Shaft Components (LT-A750XP/ZK9) (Page 3A-1)” “Rear Drive Shaft Components (LT-A750XP/ZK9) (Page 3A-5)” Special Tool B931G43108002 09900–06107...
Page 624 Table of Contents 4- i Section 4 Brake CONTENTS NOTE For the items with asterisk (*) in the “CONTENTS” below, refer to the same section of the service manual mentioned in the “FOREWORD” of this manual. Precautions ..........4-* Special Tools and Equipment ......4A-5 Special Tool ............
Page 625 4-ii Table of Contents Parking / Rear Brake Cable Routing Diagram ..4D-* Parking / Rear Brake Lever Removal and Installation ............4D-* Repair Instructions ..........4D-* Parking / Rear Brake Light Switch Inspection ..4D-* Parking / Rear Brake Inspection and Parking / Rear Brake Relay Inspection ....
Page 626 Brake Control System and Diagnosis: 4A-1 Brake Control System and Diagnosis Brake Schematic and Routing Diagram Front Brake Hose Routing Diagram (LT-A750XP/ZK9) B931G44102003 “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 627 4A-2 Brake Control System and Diagnosis: Repair Instructions Front Brake Hose Removal and Installation (LT- Installation A750XP/ZK9) CAUTION B931G44106019 Removal The seal washers should be replaced with the new ones to prevent fluid leakage. CAUTION Make sure that the vehicle is supported 1) Install the front brake hose as shown in the front securely.
Page 628 Brake Control System and Diagnosis: 4A-3 Rear Brake Pedal Construction (LT-A750XP/ZK9) B931G44106020 “ b ” “ c ” “B” “A” “B” “A” “ a ” I931G3410002-01 1. Rear brake pedal 6. Rear brake pedal screw “B”: Anchoring point (Pedal side) 2.
Page 629 4A-4 Brake Control System and Diagnosis: 5) Remove the rear brake pedal shaft (3). Installation Install the rear brake pedal in the reverse order of 6) Remove the rear brake pedal (4) and rear brake removal. Pay attention to the following points: pedal spring (5).
Page 630 For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List (LT-A750XP/ZK9) in Section 0C (Page 0C-7)”. Special Tools and Equipment Recommended Service Material B931G44108003 Material SUZUKI recommended product or Specification Note )(Page 4A-4) / )(Page 4A- Grease Water resistance grease or P/No.: 99000–25160...
Page 631 4A-6 Brake Control System and Diagnosis:...
Page 632 Table of Contents 6- i Section 6 Steering CONTENTS NOTE For the items with asterisk (*) in the “CONTENTS” below, refer to the same section of the service manual mentioned in the “FOREWORD” of this manual. Precautions ..........6-1 P/S System Note (LT-A750XP/ZK9) ....6C-1 Precautions in Diagnosing Troubles (LT- Precautions.............
Page 633 6-ii Table of Contents DTC “C1153” EPS Control Unit Supply EPS Body Assembly Components (LT- Voltage Circuit Malfunction (LT-A750XP/ A750XP/ZK9) ..........6C-50 ZK9) ..............6C-46 EPS Body Assembly Removal and DTC “C1152”, “C1154”, “C1155” EPS Control Installation (LT-A750XP/ZK9) ......6C-50 Unit Malfunction (LT-A750XP/ZK9)....6C-47 EPS Motor Inspection (LT-A750XP/ZK9) ..6C-53 Repair Instructions ..........6C-48 Specifications .............6C-54...
Page 634 Precautions: Precautions Steering Precautions Precautions for Steering (LT-A750XP/ZK9) B931G46000002 Refer to “General Precautions in Section 00 in related manual” and “Precautions for EPS (LT-A750XP/ZK9) in Section 00 (Page 00-1)”.
Page 635 6A-1 Steering General Diagnosis: Steering General Diagnosis Steering Diagnostic Information and Procedures Steering Symptom Diagnosis (LT-A750XP/ZK9) B931G46104002 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 636 Steering / Handlebar: 6B-1 Steering / Handlebar Steering Repair Instructions Steering / Handlebars Components (LT-A750XP/ZK9) B931G46206008 “A” “A” “A” “A” I931G3620028-02 1. Handlebars 10. Lower dust seal 19. Handlebar left switch assembly 2. Handlebar upper clamp 11. Steering arm plate 20.
Page 637 6B-2 Steering / Handlebar: Steering / Handlebars Assembly Construction (LT-A750XP/ZK9) B931G46206009 “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 638 Steering / Handlebar: 6B-3 Handlebars Removal and Installation (LT- 6) Remove the following parts from left handlebars (left side). A750XP/ZK9) B931G46206010 a) Left grip (4) b) Left switch box (5) Removal c) Horn button (For P-17, 24) 1) Remove the auxiliary headlight cover. Refer to “Auxiliary Headlight Removal and Installation in d) Emergency switch (For P-17) Section 9B in related manual”...
Page 639 6B-4 Steering / Handlebar: 9) Remove the handlebar upper clamps (7) and • Install the washers (3) and bolts (4) as shown in the handlebars (8). steering/handlebars construction. Refer to “Steering / Handlebars Assembly Construction (LT-A750XP/ZK9) (Page 6B-2)”. • Set the handlebars so that its punch mark “B” aligns with the mating surface of the left handlebar holder.
Page 640 Steering / Handlebar: 6B-5 • Apply adhesive agent to the handlebar right and left • Install the master cylinder. Refer to “Front Brake end and right and left grip inner wall. Master Cylinder Assembly Removal and Installation in Section 4A in related manual”. : Handle grip bond (Handle Grip Bond •...
Page 641 6B-6 Steering / Handlebar: Steering Shaft Removal and Installation (LT- 5) Remove the steering arm plate (4) and steering shaft (5). A750XP/ZK9) B931G46206012 Removal 1) Remove the EPS control unit. Refer to “EPS Control Unit Removal and Installation (LT-A750XP/ZK9) in Section 6C (Page 6C-48)”.
Page 642: Steering / Handlebar
Steering / Handlebar: 6B-7 Installation • Apply grease to the steering shaft. Install the steering shaft in the reverse order of removal. : Grease 99000–25160 (Water resistance Pay attention to the following points: grease or equivalent) • Install the steering shaft bushing (1) along with dust seal (2) with the special tool.
Page 643 6B-8 Steering / Handlebar: • Install the cotter pin (8). Removal 1) Remove the tie-rod end with the special tool. Refer CAUTION to “Front Wheel Hub / Steering Knuckle Removal The removed cotter pin (8) must be replaced and Installation in Section 2B in related manual”. with a new one.
Page 644: Installation
Steering / Handlebar: 6B-9 4) Remove the other tie-rod end in the same manner as • Install the washers (2) and tighten the rod end nuts (3) described previously. (steering arm plate side) to the specified torque. 5) Separate the tie-rod ends (2), nuts (3), (4) and tie- Tightening torque rods (5).
Page 645: Service Data (Lt-A750Xp/Zk9)
6B-10 Steering / Handlebar: Tie-rod End Steering Shaft Inspect the tie-rod ends for smooth movement. If there Inspect the steering shaft for distortion or bend. If any are any abnormalities, replace the tie-rod ends with new defects are found, replace the steering shaft with a new ones.
Page 646 For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List (LT-A750XP/ZK9) in Section 0C (Page 0C-7)”. Special Tools and Equipment Recommended Service Material B931G46208001 Material SUZUKI recommended product or Specification Note )(Page 6B-7) / )(Page 6B- Grease Water resistance grease or P/No.: 99000–25160...
Page 647: 6C-1 Power Assisted Steering System
6C-1 Power Assisted Steering System: Power Assisted Steering System Steering Precautions Precautions for EPS (LT-A750XP/ZK9) B931G46300001 Refer to “General Precautions in Section 00 in related manual” and “Precautions for EPS (LT-A750XP/ZK9) in Section 00 (Page 00-1)”. NOTE When repairing EPS system, remove the front fender. Refer to “Front Side Exterior Parts Removal and Installation in Section 9D in related manual”.
Page 648: General Description
Power Assisted Steering System: 6C-2 General Description P/S System Description (LT-A750XP/ZK9) B931G46301001 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 649 6C-3 Power Assisted Steering System: 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 650 Power Assisted Steering System: 6C-4 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 651: Eps Diagnosis General Description (Lt-A750Xp/Zk9)
6C-5 Power Assisted Steering System: EPS Diagnosis General Description (LT-A750XP/ZK9) B931G46301002 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 (LT-A750XP/ZK9) (Page 6C-5)”...
Page 652: Schematic And Routing Diagram
Power Assisted Steering System: 6C-6 Schematic and Routing Diagram EPS Wiring Diagram (LT-A750XP/ZK9) B931G46302001 Refer to “Wire Color Symbols in Section 0A in related manual”. I931G3630070-01...
Page 653: Eps Control Unit Diagram (Lt-A750Xp/Zk9)
6C-7 Power Assisted Steering System: EPS Control Unit Diagram (LT-A750XP/ZK9) B931G46302002 Refer to “Wire Color Symbols in Section 0A in related manual”. Ignition EPS countrol unit switch 30 A Speedometer MAIN 40 A Fail-safe relay Bl/B Speed sensor (Vehicle speed) TACHO motor Motor drive circuit...
Page 654: Eps System Wiring Harness Routing
Power Assisted Steering System: 6C-8 EPS System Wiring Harness Routing Diagram (LT-A750XP/ZK9) B931G46302003 Refer to “Wiring Harness Routing Diagram (LT-A750XP/ZK9) in Section 9A (Page 9A-4)”. Component Location EPS Components Location (LT-A750XP/ZK9) B931G46303001 I931G3630002-02 1. EPS control unit 3. Fuse (EPS) 2.
Page 655: Diagnostic Information And Procedures
6C-9 Power Assisted Steering System: Diagnostic Information and Procedures EPS Troubleshooting (LT-A750XP/ZK9) CAUTION B931G46304001 The EPS is equipped with a self-diagnosis function. The Each time a resistance is measured, the detected malfunction is stored as a diagnostic trouble ignition switch should be set to OFF. code which causes the EPS indicator light to light up or flash in set patterns to indicate the malfunction.
Page 656: Pre-Diagnosis Inspection (Lt-A750Xp/Zk9)
AT25 x 8 – 12 œœ for front and AT25 x 10 – 12 Tire for rear. The use of tires other than those Tire type specified may cause instability. It is highly Tire type recommended to use a SUZUKI Genuine Tire. Front: DUNLOP KT411 Rear: DUNLOP KT415...
Page 657 6C-11 Power Assisted Steering System: Steering Related Parts 4) Remove the front fender. Refer to “Front Side Refer to “Steering Parts Inspection in Section 6B in Exterior Parts Removal and Installation in Section related manual”. 9D in related manual”. 5) Disconnect the EPS control unit coupler (1). Battery Battery voltage inspection 1) Turn the ignition switch OFF.
Page 658: Eps System Check (Lt-A750Xp/Zk9)
Power Assisted Steering System: 6C-12 EPS System Check (LT-A750XP/ZK9) B931G46304003 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 659 6C-13 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). I931G3630008-01 3) Turn the ignition switch ON with the EPS control unit coupler disconnected, measure the voltage between...
Page 660 Power Assisted Steering System: 6C-14 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 661 6C-15 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 in related manual”. 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 662 Power Assisted Steering System: 6C-16 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) I931G3630008-01 3) Turn the ignition switch ON with the EPS control unit coupler disconnected, measure the voltage between terminal “A”...
Page 663 6C-17 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 664 Power Assisted Steering System: 6C-18 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) I931G3630013-01 3) Check for continuity between terminal “A”...
Page 665: Dtc (Diagnostic Trouble Code) Output (Lt- A750Xp/Zk9)
6C-19 Power Assisted Steering System: DTC (Diagnostic Trouble Code) Output (LT- 4) Switch the special tool to ON. A750XP/ZK9) B931G46304004 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 666 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): 99565–01010–020 (CD-ROM Ver.20)
Page 667: Dtc (Diagnostic Trouble Code) Deleting (Lt- A750Xp/Zk9)
6C-21 Power Assisted Steering System: I931H1630032-01 4) Close the SDS tool and turn the ignition switch OFF. DTC (Diagnostic Trouble Code) Deleting (LT- A750XP/ZK9) B931G46304005 Use of Mode Select Switch 1) Remove the seat. Refer to “Seat Removal and Installation in Section 9D in related manual”. I705H1110116-03 3) Read the DTC (Diagnostic Trouble Code) and show data when trouble (displaying data at the time of...
Page 668 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 669 6C-23 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 670: Sds Check (Lt-A750Xp/Zk9)
Code) Deleting (LT-A750XP/ZK9) (Page 6C-21)”. • 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) : 99565–01010–020 (CD-ROM Ver.20) DATA sampled from EPS system...
Page 671: Dtc Table (Lt-A750Xp/Zk9)
6C-25 Power Assisted Steering System: Scroll the screen I931G3630066-01 DTC Table (LT-A750XP/ZK9) B931G46304007 Indicator Malfunction cause Reference status None Normal ON * — Refer to “DTC “C1111”: Torque C1111 Torque sensor (main) circuit voltage failure Sensor (Main) Circuit Malfunction (LT-A750XP/ZK9) (Page 6C-26)”. Refer to “DTC “C1113”: Torque Torque sensor (main) and (sub) circuit voltage Sensor (Main / Sub) Circuit...
Page 672: Dtc "C1111": Torque Sensor (Main) Circuit Malfunction (Lt-A750Xp/Zk9)
Power Assisted Steering System: 6C-26 DTC “C1111”: Torque Sensor (Main) Circuit Malfunction (LT-A750XP/ZK9) B931G46304008 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 673 6C-27 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 674 Power Assisted Steering System: 6C-28 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-point probes to lead wire coupler.
Page 675: Dtc "C1113": Torque Sensor (Main / Sub) Circuit Correlation Malfunction (Lt-A750Xp/Zk9)
6C-29 Power Assisted Steering System: DTC “C1113”: Torque Sensor (Main / Sub) Circuit Correlation Malfunction (LT-A750XP/ZK9) B931G46304009 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 676 Power Assisted Steering System: 6C-30 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 677 6C-31 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 678 Power Assisted Steering System: 6C-32 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-point probes to lead wire coupler.
Page 679: Dtc "C1114": Torque Sensor Power Supply Circuit Malfunction (Lt-A750Xp/Zk9)
6C-33 Power Assisted Steering System: DTC “C1114”: Torque Sensor Power Supply Circuit Malfunction (LT-A750XP/ZK9) B931G46304010 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 680 Power Assisted Steering System: 6C-34 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 681: Dtc "C1115": Torque Sensor (Sub) Circuit Malfunction (Lt-A750Xp/Zk9)
6C-35 Power Assisted Steering System: DTC “C1115”: Torque Sensor (Sub) Circuit Malfunction (LT-A750XP/ZK9) B931G46304011 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 682 Power Assisted Steering System: 6C-36 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 683 6C-37 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-point probes to lead wire coupler.
Page 684: Dtc "C1121": Vehicle Speed Signal Circuit Malfunction (Lt-A750Xp/Zk9)
Power Assisted Steering System: 6C-38 DTC “C1121”: Vehicle Speed Signal Circuit Malfunction (LT-A750XP/ZK9) B931G46304012 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 (LT-A750XP/ZK9) (Page 6C-21)”.
Page 685 6C-39 Power Assisted Steering System: Step Action 3) 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 in related manual” and “Combination Meter Removal and Installation in Section 9C in related manual”.
Page 686 Power Assisted Steering System: 6C-40 Step Action 1) Connect the combination meter coupler and speed Go to step 3. Bl/B wire shorted to sensor coupler. ground. 2) Turn the ignition switch ON. 3) Measure the voltage between the Bl/B wire “A” and ground.
Page 687: Dtc "C1122": Engine Speed Signal Circuit Malfunction (Lt-A750Xp/Zk9)
6C-41 Power Assisted Steering System: DTC “C1122”: Engine Speed Signal Circuit Malfunction (LT-A750XP/ZK9) B931G46304013 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 (LT-A750XP/ZK9) (Page 6C-1)”.
Page 688 Power Assisted Steering System: 6C-42 Step Action 1) Turn the ignition switch OFF. Go to step 3. W wire open. 2) Check the EPS control unit coupler for loose or poor contact. If OK, then measure the engine speed signal lead wire continuity.
Page 689 6C-43 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 690: Dtc "C1141", "C1142", "C1143", "C1145" Eps Motor Circuit Malfunction (Lt-A750Xp/Zk9)
Power Assisted Steering System: 6C-44 DTC “C1141”, “C1142”, “C1143”, “C1145” EPS Motor Circuit Malfunction (LT-A750XP/ZK9) B931G46304014 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 691 6C-45 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 692: Dtc "C1153" Eps Control Unit Supply Voltage Circuit Malfunction (Lt-A750Xp/Zk9)
Power Assisted Steering System: 6C-46 DTC “C1153” EPS Control Unit Supply Voltage Circuit Malfunction (LT-A750XP/ZK9) B931G46304015 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 693: Dtc "C1152", "C1154", "C1155" Eps Control Unit Malfunction (Lt-A750Xp/Zk9)
6C-47 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 694: Eps Control Unit Construction
Power Assisted Steering System: 6C-48 Repair Instructions EPS Control Unit Construction (LT-A750XP/ZK9) B931G46306001 “B” “A” I931H1630056-02 1. EPS control unit 4. Torque sensor coupler 2. EPS control unit plate : 12 N˜m (1.2 kgf-m, 8.5 lbf-ft) 3. Cushion “B”: Install the clip of the torque sensor coupler to the hole “A” of the EPS control unit plate.
Page 695 6C-49 Power Assisted Steering System: 4) Disconnect the torque sensor coupler (1). 7) Remove the fastener (4) and bolt (5). 8) Remove the EPS control unit (6) along with the EPS control unit plate (7). I931G3630042-01 5) Remove the clamp (2) and release the EPS motor lead wire (3).
Page 696: Eps Body Assembly Components (Lt- A750Xp/Zk9)
Power Assisted Steering System: 6C-50 • Connect the EPS motor coupler (3) and clamp (4). 5) Remove the center cover (2). • Connect the other EPS control unit couplers. I931G3630050-01 6) Remove the handlebar holder (3) by removing the I931G3630048-01 nuts (4).
Page 697 6C-51 Power Assisted Steering System: 9) Remove the front brake hose union (7) and throttle 13) Remove the EPS body assembly. cable (8) from the cable guide (9). CAUTION Never disassemble the EPS body assembly. I931G3630053-01 10) Remove the steering shaft bolt (10). I931G3630057-02 Installation Refer to “Steering / Handlebars Assembly Construction...
Page 698 Power Assisted Steering System: 6C-52 • Install the cable guide (1) and tighten the bolts (2) to • Install the front brake hose union (5) and throttle cable the specified torque. (6) to the cable guide. Tightening torque EPS body assembly mounting bolt (a): 26 N·m ( 2.6 kgf-m, 19.0 lbf-ft) I931G3630062-02 •...
Page 699: Eps Motor Inspection (Lt-A750Xp/Zk9)
6C-53 Power Assisted Steering System: • Install the handlebar holder (8) and tighten the nuts to EPS Motor Inspection (LT-A750XP/ZK9) B931G46306005 the specified torque. 1) Disconnect the EPS motor coupler. Tightening torque 2) First, check for insulation with the tester between Handlebar holder nut (e): 60 N·m (6.0 kgf-m, 43.5 terminals “A”...
Page 700 For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List (LT-A750XP/ZK9) in Section 0C (Page 0C-7)”. Special Tools and Equipment Recommended Service Material B931G46308001 Material SUZUKI recommended product or Specification Note )(Page 6C-51) / Grease Water resistance grease or P/No.: 99000–25160...
Page 701 )(Page 6C-44) / )(Page 6C-46) / )(Page 6C-46) / )(Page 6C-47) / )(Page 6C-53) / )(Page 6C-53) 09904–41010 09930–82710 SUZUKI Diagnostic system Mode select switch )(Page 6C-20) / )(Page 6C-18) / )(Page 6C-22) / )(Page 6C-19) )(Page 6C-24) 09930–82720 09942–83110...
Page 702 Table of Contents 9- i Section 9 Body and Accessories CONTENTS NOTE For the items with asterisk (*) in the “CONTENTS” below, refer to the same section of the service manual mentioned in the “FOREWORD” of this manual. Precautions ..........9-* Combination Meter Removal and Installation ..
Page 703 9-ii Table of Contents Front Carrier Removal and Installation ....9E-* Body Frame Construction (LT-A750XP/ZK9) ..9E-1 Rear Carrier Removal and Installation ....9E-* Specifications ............9E-* Front Grip Bar Construction ........ 9E-* Tightening Torque Specifications......9E-* Front Grip Bar Removal and Installation ..... 9E-* Special Tools and Equipment ......9E-1 Trailer Towing Construction ........
Page 704 Wiring Systems: 9A-1 Wiring Systems Body and Accessories Schematic and Routing Diagram Wiring Diagram (LT-A750XP/ZK9) B931G49102003 Refer to “Wire Color Symbols in Section 0A in related manual”.
Page 705 9A-2 Wiring Systems: For P-17 I931G3910901-02...
Page 706 Wiring Systems: 9A-3 For P-24, 28, 33 I931G3910902-03...
Page 707 9A-4 Wiring Systems: Wiring Harness Routing Diagram (LT-A750XP/ZK9) B931G49102004 “ a ” “ b” “c ” “D” “ b ” “C” “A” “B” VIEW A I931G3910905-02 1. Clamp 9. Throttle cable 2. Clamp “B”: Pass the wiring harness and cooling fan lead wire over the radiator : Bind the wiring harness and hose with the clamp.
Page 708 Wiring Systems: 9A-5 “E” “D” VIEW A “C” VIEW F “F” “B” “A” I931G3910903-02 1. Starter motor 14. Injector coupler 2. Starter motor terminal 15. TP sensor coupler 3. Engine earth 16. ISC valve coupler 4. Clamp 17. TO sensor : Bind the wiring harness and rear brake cable with the clamp.
Page 709 9A-6 Wiring Systems: “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.
Page 710 Wiring Systems: 9A-7 “ a ” I931G3910904-01 1. Starter motor 3. Generator stator 5. Grommet “a”: 90q 2. Gear position switch 4. Ground wire 6. Clamp Specifications Tightening Torque Specifications B931G4910S002 NOTE The specified tightening torque is described in the following. “Wiring Harness Routing Diagram (LT-A750XP/ZK9) (Page 9A-4)”...
Page 711 9E-1 Body Structure: Body Structure Body and Accessories Repair Instructions Body Frame Construction (LT-A750XP/ZK9) B931G49506011 I931G3950001-04 1. Frame 3. Washer : Apply thread lock to the thread part. 2. Battery plate 4. Spacer Special Tools and Equipment Recommended Service Material B931G49508001 NOTE Required service material is also described in the following.

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Suzuki kq750 Service Manual

Section 0 General Information

General Description

Maintenance and Lubrication

Precautions

Scheduled Maintenance

Repair Instructions

Special Tools and Equipment

Service Data

Specifications

Section 1 Engine

Precautions

General Description

Engine General Information and Diagnosis

Schematic and Routing Diagram

Component Location

Diagnostic Information and Procedures

Specifications

Special Tools and Equipment

Precautions

Emission Control Devices

Repair Instructions

Repair Instructions

Diagnostic Information and Procedures

Component Location

Precautions

Engine Electrical Devices

Specifications

Schematic and Routing Diagram

Engine Mechanical

Diagnostic Information and Procedures

Repair Instructions

Specifications

Special Tools and Equipment

Engine Lubrication System

Precautions

Schematic and Routing Diagram

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

General Description

Ignition System

Schematic and Routing Diagram

Diagnostic Information and Procedures

Repair Instructions

Specifications

Special Tools and Equipment

Starting System

Schematic and Routing Diagram

Component Location

Diagnostic Information and Procedures

Repair Instructions

Specifications

Special Tools and Equipment

Diagnostic Information and Procedures

Component Location

Charging System

Schematic and Routing Diagram

Repair Instructions

Specifications

Special Tools and Equipment

Exhaust System

Precautions