Suzuki LT-A450X Manual

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FOREWORD

This manual contains an introductory description on

the SUZUKI LT-A450X and procedures for its

inspection, service and overhaul of its main compo-

nents.

Other information considered as generally known is

not included.

Read the GENERAL INFORMATION section to

familiarize yourself with the vehicle and its mainte-

nance. 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 reli-

able service.

* This manual has been prepared on the basis

of the latest specifications at the time of publi-

cation. If modifications have been made since

then, differences may exist between the con-

tent 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 motorcy-

cle dealer to help you.

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.

GROUP INDEX

GENERAL INFORMATION

PERIODIC MAINTENANCE

ENGINE

DRIVE TRAIN

FI SYSTEM DIAGNOSIS

FUEL SYSTEM AND

THROTTLE BODY

COOLING AND

LUBRICATION SYSTEM

CHASSIS

ELECTRICAL SYSTEM

SERVICING INFORMATION

EMISSION CONTROL

INFORMATION

Table of Contents

Chapters

Table of Contents

Troubleshooting

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Summary of Contents for Suzuki LT-A450X

Page 1: General Information
FOREWORD GROUP INDEX This manual contains an introductory description on the SUZUKI LT-A450X and procedures for its inspection, service and overhaul of its main compo- GENERAL INFORMATION nents. Other information considered as generally known is not included. PERIODIC MAINTENANCE Read the GENERAL INFORMATION section to familiarize yourself with the vehicle and its mainte- nance.
Page 2 SUPPLEMENTS LT-A450XK8 (’ LT-A450XK9 (’09 MODEL) WIRING DIAGRAM...
Page 3: How To Use This Manual
HOW TO USE THIS MANUAL TO LOCATE WHAT YOU ARE LOOKING FOR: 1. The text of this manual is divided into sections. 2. The section titles are listed in the GROUP INDEX. 3. Holding the manual as shown at the right will allow you to find the first page of the section easily.
Page 4 Apply molybdenum oil solution. Measure in voltage range. (mixture of engine oil and SUZUKl MOLY PASTE in a ratio of 1 : 1) Apply SUZUKI SUPER GREASE “A” or Measure in resistance range. equivalent grease. 99000-25010 Apply SUZUKI SILICONE GREASE.
Page 5 ABBREVIATIONS USED IN T HIS MANUAL ABDC : After Bottom Dead Center : Engine Control Module : Alternating Current Engine Control Unit (ECU) : Air Cleaner, Air Cleaner Box (FI Control Unit) : American Petroleum Institute ECT Sensor : Engine Coolant Temperature ATDC : After Top Dead Center Sensor (ECTS), Water Temp.
Page 6 : Over Head Camshaft : Positive Crankcase Ventilation (Crankcase Breather) : Rectifier : Regulator : Right Hand : Read Only Memory : Society of Automotive Engineers : Suzuki Diagnosis System TO Sensor : Tip-Over Sensor (TOS) TP Sensor : Throttle Position Sensor (TPS)
Page 7 SAE-TO-FORMER SUZUKI TERM This table lists SAE (Society of Automotive Engineers) J1930 terms and abbreviations which may be used in this manual in compliance with SAE recommendations, as well as their former SUZUKI names. SAE TERM FORMER SUZUKI TERM FULL TERM...
Page 8 SAE TERM FORMER SUZUKI TERM FULL TERM ABBREVIATION On-Board Diagnostic Self-Diagnosis Function Diagnostic Programmable Read Only Memory PROM ------- Random Access Memory ------- Read Only Memory Throttle Body Throttle Body (TB) Throttle Body Fuel Injection Throttle Body Fuel Injection (TBI)
Page 9: Table Of Contents
GENERAL INFORMATION GENERAL INFORMATION CONTENTS WARNING/CAUTION/NOTE .................1- 2 GENERAL PRECAUTIONS................1- 2 SUZUKI LT-A450XK7 (’07-MODEL) .............1- 4 SERIAL NUMBER LOCATION..............1- 4 FUEL, OIL AND ENGINE COOLANT RECOMMENDATION......1- 5 FUEL (FOR USA AND CANADA)............1- 5 FUEL (FOR OTHER COUNTRIES)............1- 5 ENGINE OIL (FOR USA).................1- 5 ENGINE OIL (FOR OTHER COUNTRIES) ..........1- 5...
Page 10: Warning/Caution/Note
GENERAL INFORMATION WARNING/CAUTION/NOTE Please read this manual and follow its instructions carefully. To emphasize special information, the symbol and the words WARNING, CAUTION and NOTE have special meanings. Pay special attention to the mes- sages highlighted by these signal words. Indicates a potential hazard that could result in death or injury.
Page 11 GENERAL INFORMATION * If parts replacement is necessary, replace the parts with Suzuki Genuine Parts or their equiva- lent. * When removing parts that are to be reused, keep them arranged in an orderly manner so that they may be reinstalled in the proper order and orientation.
Page 12: Suzuki Lt-A450Xk7 ('07-Model)
GENERAL INFORMATION SUZUKI LT-A450XK7 (’07-MODEL) RIGHT SIDE LEFT SIDE • Difference between illustration and actual vehicle may exist depending on the markets. SERIAL NUMBER LOCATION The frame serial number or V.I.N. (Vehicle Identification Number) 1 is stamped, on the left side of the front frame pipe.
Page 13: Fuel, Oil And Engine Coolant Recommendation
Suzuki recommends the use of SUZUKI PERFORMANCE 4 MOTOR OIL or 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 an alternative according to the following chart.
Page 14: Engine Coolant
Suzuki recommends the use of SUZUKI COOLANT anti-freeze/engine coolant. If this is not available, use an equivalent which is compatible with an aluminum radiator.
Page 15: Break-In Procedures
GENERAL INFORMATION BREAK-IN PROCEDURES During manufacture only the best possible materials are used and all machined parts are finished to a very high standard but it is still necessary to allow the moving parts to “BREAK-IN” before subjecting the engine to maximum stresses.
Page 16: Information Labels
GENERAL INFORMATION INFORMATION LABELS 1 Certification plate A (For E-24, 33) 2 Information label A (For E-33) 3 Gearshift label 4 Gearshift label A (For E-28) 5 Tire air pressure label 6 Tire air pressure label and warning no-passenger label A (For E-28) 7 General warning &...
Page 17: Specifications
GENERAL INFORMATION SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length ................2 115 mm (83.3 in) ..E-28, 33 2 135 mm (84.1 in) ..E-17, 24 Overall width ................1 210 mm (47.6 in) ..E-28, 33 1 215 mm (47.8 in) ..E-17, 24 Overall height ................
Page 18: Chassis
1-10 GENERAL INFORMATION CHASSIS 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 ..................
Page 19 PERIODIC MAINTENANCE PERIODIC MAINTENANCE CONTENTS PERIODIC MAINTENANCE SCHEDULE .............2- 2 PERIODIC MAINTENANCE CHART .............2- 2 MAINTENANCE AND TUNE-UP PROCEDURES ........2- 3 AIR CLEANER ELEMENT ..............2- 3 EXHAUST PIPE NUTS AND MUFFLER MOUNTING BOLTS ....2- 5 VALVE CLEARANCE ................2- 5 SPARK PLUG ..................2- 7 SPARK ARRESTER ................2- 8 FUEL LINE .....................2- 8 ENGINE OIL AND OIL FILTER ..............2- 9...
Page 20: Periodic Maintenance Schedule
PERIODIC MAINTENANCE PERIODIC MAINTENANCE SCHEDULE The chart below 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, and are dependent on whichever comes first. NOTE: More frequent servicing may be performed on vehicles that are used under severe conditions.
Page 21: Maintenance And Tune-Up Procedures
PERIODIC MAINTENANCE MAINTENANCE AND TUNE-UP PROCEDURES This section describes the servicing procedures for each item mentioned in the Periodic Maintenance chart. Before performing the servicing procedures mentioned in the periodic maintenance chart, remove following parts to ease ser- vicing work; •...
Page 22 PERIODIC MAINTENANCE • Using compressed air, blow the dust from the cleaner ele- ment. Always ap ply c ompressed ai r to th e i nside o f the ai r cleaner e lement. If c ompressed a ir i s applied to t he outside, dirt will be forc ed in to th e p ores of th e a ir cleaner el ement, r estricting ai r flow t hrough the ai r cleaner element.
Page 23: Exhaust Pipe Nuts And Muffler Mounting Bolts
PERIODIC MAINTENANCE EXHAUST PIPE NUTS AND MUFFLER MOUNTING BOLTS Tighten i nitially at 2 00 km (100 mi les, 1 mo nth) a nd every 1 000 km (600 miles, 3 months) thereafter. • Remove the rear fender. ($8-15) • Remove the left inner fender. ($8-10) •...
Page 24 PERIODIC MAINTENANCE • Remove the recoil starter. ($3-11) • Remove the valve timing inspection plug 1. INSPECTION The valve clearance specification is same for both valves. Valve clearance adjustment must be checked and adjusted, 1) at the time of periodic inspection, 2) when the valve mechanism is ser- viced, and 3) when the camshaft is disturbed by removing it for servicing.
Page 25: Spark Plug
PERIODIC MAINTENANCE SPARK PLUG Replace every 6 000 km (4 000 miles). • Remove the right side cover. ($8-10) • Disconnect the spark plug cap 1 and remove the spark plug. Standard Cold type CR6E CR7E DENSO U20ESR-N U22ESR-N CARBON DEPOSITS Check to see if there are carbon deposits on the spark plug.
Page 26: Spark Arrester
PERIODIC MAINTENANCE SPARK ARRESTER Clean every 2 000 km (1 200 miles, 6 months). • Remove the muffler end cover 1. • Extract the spark arrester pipe 2 from the muffler. • Clean the spark arrester pipe 2 by brush. •...
Page 27: Engine Oil And Oil Filter
PERIODIC MAINTENANCE ENGINE OIL AND OIL FILTER Replace i nitially at 2 00 km ( 100 miles, 1 month) a nd every 2 000 km (1 200 miles, 6 months) thereafter. The oil should be changed while the engine is warm. Oil filter replacement at the above intervals should be done together with the engine oil change.
Page 28 (thread d iameter an d pi tch), filtering performance and durability which may lead to e ngine damage or oi l le aks. Als o, do no t us e a G ENUINE SUZUKI AUTOMOBILE OIL FILTER on this vehicle.
Page 29: Front Differential Gear Oil
PERIODIC MAINTENANCE 2-11 FRONT DIFFERENTIAL GEAR OIL Inspect every 2 000 km (1 200 miles, 6 months). Replace every 2 years. FRONT DIFFERENTIAL GEAR OIL INSPECTION • Place the vehicle on level ground. • Remove the oil level plug 1 and oil filler plug 2, and inspect the oil level.
Page 30: Final Gear Oil
2-12 PERIODIC MAINTENANCE FINAL GEAR OIL Inspect every 2 000 km (1 200 miles, 6 months). Replace every year. FINAL GEAR OIL INSPECTION • Place the vehicle on level position. • Remove the filler plug 1, and inspect the oil level. If the oil level is below, add fresh oil until the oil level reaches the bot- tom tip of the thread.
Page 31: Throttle Cable Play
PERIODIC MAINTENANCE 2-13 THROTTLE CABLE PLAY Inspect ini tially at 2 00 km (1 00 mi les, 1 mo nth) an d every 1 000 km (600 miles, 3 months) thereafter. Adjust the throttle cable play A as follows. • Loosen the lock-nut 1 of the throttle cable. •...
Page 32: Engine Coolant
2-14 PERIODIC MAINTENANCE ENGINE COOLANT Replace the engine coolant every 2 years. ENGINE COOLANT LEVEL CHECK • Inspect the engine coolant level by observing the upper A and lower B lines on the engine coolant reservoir tank. • If the level is below the lower line, add engine coolant until the level reaches the upper line.
Page 33: Radiator
PERIODIC MAINTENANCE 2-15 • Install the radiator cap securely. • After warming up and cooling down the engine, add the spec- ified engine coolant until the level is between the upper and lower lines on the engine coolant reservoir tank. Repeat t he ab ove p rocedure several t imes an d m ake sure the rad iator is filled with en gine coolant to the upper line of the engine coolant reservoir tank.
Page 34: Drive Belt
2-16 PERIODIC MAINTENANCE DRIVE BELT Inspect every 2 000 km (1 200 miles, 6 months). REMOVAL • Remove the right inner fender. ($8-10) • Remove the right mud guard. ($8-10) • Remove the rear brake cable clamp 1. • Remove the right footrest 2. •...
Page 35 PERIODIC MAINTENANCE 2-17 • Remove the movable drive face bolt 6 and collar 7 with the special tool. % 09930-40113: Rotor holder • Remove the movable drive face 8. • Remove the movable driven face bolt with the special tool. •...
Page 36 2-18 PERIODIC MAINTENANCE INSTALLATION Install the drive belt in reverse order of removal. Pay attention to the following points: • Install the drive belt, as low as possible, between the movable driven face and fixed driven face by tapping with a plastic mal- let.
Page 37 PERIODIC MAINTENANCE 2-19 Install the collar 4 and movable drive face bolt 5. NOTE: Be careful direction of the collar 4 . • Tighten the movable drive face bolt to the specified torque with the special tool. " Movable drive face bolt: 110 N·m (11.0 kgf-m, 79.5 lb-ft) % 09930-40113: Rotor holder NOTE: Turn the fixed drive face until the belt is seated in and both the...
Page 38: Drive Shaft Boots
2-20 PERIODIC MAINTENANCE • Install the clutch cover gasket and clutch cover. The removed c lutch c over g asket must b e replaced with a new one. • Tighten the clutch cover bolts to the specified torque. " Clutch cover bolt: 8 N·m (0.8 kgf-m, 5.7 lb-ft) Tighten the clutch cover bolts A firs t a nd the n o ther ones diagonally.
Page 39: Brakes
PERIODIC MAINTENANCE 2-21 BRAKES Inspect ini tially at 2 00 km (1 00 mi les, 1 mo nth) an d every 1 000 km (600 miles, 3 months) thereafter. FRONT BRAKE PADS • Remove the front wheels. ($8-18) The extent of front brake pad wear can be checked by observing the limit line A on the brake pads.
Page 40 2-22 PERIODIC MAINTENANCE REAR BRAKE PEDAL FREE TRAVEL Adjust the rear brake pedal free travel as follows: MAJOR ADJUSTMENT • Turn the adjuster nut 1 so the rear brake pedal has 20 – 30 mm (0.8 – 1.2 in) free travel at the rear brake pedal end before pressure is felt.
Page 41: Rear Brake Plates
PERIODIC MAINTENANCE 2-23 REAR BRAKE LEVER PLAY Adjust the rear brake lever play as follows: MAJOR ADJUSTMENT • Turn the adjust nut 1 so the rear brake lever has 6 – 8 mm (0.2 – 0.3 in) play at the rear brake lever end before pressure is felt.
Page 42: Brake Fluid
2-24 PERIODIC MAINTENANCE BRAKE FLUID Inspect every 1 000 km (600 miles, 3 months). Replace every 2 years. BRAKE FLUID LEVEL • Place the handlebar straight. • Inspect the brake fluid level by observing the lower limit line on the front brake fluid reservoir. •...
Page 43 PERIODIC MAINTENANCE 2-25 AIR BLEEDING THE BRAKE FLUID CIRCUIT Air trapped in the brake fluid circuit acts like a cushion absorb a large proportion of the pressure developed by the master cylin- der and thus interferes with the full braking performance of the brake caliper.
Page 44: Brake Hoses
2-26 PERIODIC MAINTENANCE BRAKE HOSES Inspect every 2 000 km (1 200 miles, 6 months). Replace every 4 years. • Inspect the brake hoses for leakage, cracks, wear and dam- age. If any damages are found, replace the brake hoses with new ones.
Page 45: Steering
PERIODIC MAINTENANCE 2-27 STEERING Inspect ini tially at 2 00 km (1 00 mi les, 1 mo nth) an d every 1 000 km (600 miles, 3 months) thereafter. Steering system should be adjusted properly for smooth manip- ulation of the handlebars and safe running. •...
Page 46: Chassis Nuts And Bolts
2-28 PERIODIC MAINTENANCE CHASSIS NUTS AND BOLTS Tighten in itially a t 200 k m (1 00 mi les, 1 mo nth) an d every 1 000 km (600 miles, 3 months) thereafter. Check that all chassis nuts and bolts are tightened to their specified torque. (Refer to page 2-29 for the loca- tions of the following nuts and bolts.) Item N·m...
Page 47 PERIODIC MAINTENANCE 2-29...
Page 48 2-30 PERIODIC MAINTENANCE...
Page 49: General Lubrication
PERIODIC MAINTENANCE 2-31 GENERAL LUBRICATION Lubricate every 1000 km (600 miles, 3 months). Proper lubrication is important for smooth operation and long life of each working part of the vehicle. Major lubrication points are indicated below. ) Grease 1 Steering shaft holder 5 Drive shaft joint spline 2 Brake lever holder and throttle lever 6 Drive belt cover bearing (inner race)
Page 50: Compression Pressure Check
2-32 PERIODIC MAINTENANCE COMPRESSION PRESSURE CHECK The compression pressure reading of a cylinder is a good indicator of its internal condition. The decision to overhaul the cylinder is often based on the results of a compression test. Periodic mainte- nance records kept at your dealership should include compression readings for each maintenance service. &...
Page 51: Oil Pressure Check
PERIODIC MAINTENANCE 2-33 OIL PRESSURE CHECK Check the engine oil pressure periodically. This will give a good indication of the condition of the moving parts. & Oil pressure: Above 80 kPa (0.8 kgf/cm², 11.5 psi) Below 120 kPa (1.2 kgf/cm², 17.0 psi) If the oil pressure lower or higher than the specification, the following causes may be considered.
Page 52: Initial Engagement And Clutch Lock-Up Inspection
2-34 PERIODIC MAINTENANCE INITIAL ENGAGEMENT AND CLUTCH LOCK-UP INSPECTION The LT-A450X is equipped with a centrifugal type automatic clutch. To insure proper performance and longevity of the clutch assemblies it is essential that the clutches engage smoothly and gradually. Before checking the initial engagement and clutch lock-up two inspection checks must be performed to thoroughly check the operation of the drive train.
Page 53: Clutch Lock-Up Inspection
PERIODIC MAINTENANCE 2-35 CLUTCH LOCK-UP INSPECTION Perform this inspection to determine if the clutch is engaging fully and not slipping. • Connect a tachometer onto the spark plug high-tension code. • Start the engine. • Shift the range lever to the “High” position. •...
Page 54: Sds Check
2-36 PERIODIC MAINTENANCE SDS CHECK 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. The periodically filed data help improve the accuracy of troubleshooting since they can indicate the condition of vehicle functions that has changed with time.
Page 55 PERIODIC MAINTENANCE 2-37 Data at 3 000 r/min under no load 3 000 r/min Check the manifold absolute pressure. XXX kPa (XXX mmHg) Data at the time of racing Throttle: Throttle: Slowly open Quick wide open...
Page 56 2-38 PERIODIC MAINTENANCE 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 compar- ison 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 pass of time and identify what problem is currently occurring.
Page 57 ENGINE ENGINE CONTENTS ENGINE COMPONENTS REMOVABLE WITH ENGINE IN PLACE ...3- 2 ENGINE LEFT SIDE ................3- 2 ENGINE RIGHT SIDE ................3- 2 ENGINE CENTER ..................3- 2 ENGINE REMOVAL AND REMOUNTING ...........3- 3 ENGINE REMOVAL ................3- 3 ENGINE REMOUNTING .................3- 8 ENGINE DISASSEMBLY ................3-11 ENGINE COMPONENTS INSPECTION AND SERVICE ......3-29 CYLINDER HEAD COVER ..............3-29...
Page 58: Engine Components Removable With Engine In Place
ENGINE ENGINE COMPONENTS REMOVABLE WITH ENGINE IN PLACE The parts listed below can be removed and installed without removing the engine from the frame. Refer to the page listed in each section for removal and installation instructions. ENGINE LEFT SIDE PARTS REMOVAL INSTALLATION...
Page 59: Engine Removal And Remounting
ENGINE ENGINE REMOVAL AND REMOUNTING ENGINE REMOVAL Before taking the engine out of the frame, wash the engine using a steam cleaner. Engine removal is sequentially explained in the following steps. • Drain engine oil. ($2-9) • Drain engine coolant. ($2-14) •...
Page 60 ENGINE • Remove the air cleaner box. ($6-10) • Disconnect the ECT sensor coupler 5. • Remove the throttle body assembly. ($6-11) • Remove the transfer gear shift lever assembly. ($8-97) • Remove the transfer gear shift shaft lever 6. •...
Page 61 ENGINE • Remove the belt cooling ducts. (Intake A and outlet B) • Loosen the muffler connect bolt C. • Remove the exhaust pipe D. • Remove the muffler E. • Remove the rear brake cable clamp F. • Remove the right footrest G.
Page 62 ENGINE • Remove the rear brake pedal assembly. ($10-29) • Remove the front drive train (differential) gear case mounting bolts/nuts. • Slide the front differential assembly H forward. • Remove the front propeller shaft spring I.
Page 63 ENGINE • Remove the engine mounting nuts. • Remove the engine from the right side.
Page 64: Engine Remounting
ENGINE ENGINE REMOUNTING Remount the engine in the reverse order of engine removal. Pay attention to the following points: " ITEM N·m kgf-m lb-ft 43.5 43.5 • Tighten the engine mounting nuts to the specified torque. " Engine mounting nut: 60 N·m (6.0 kgf-m, 43.5 lb-ft)
Page 65 ENGINE • Tighten the engine mounting damper stopper bolts to the specified torque. " Engine mounting damper stoper bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft) NOTE: When installing the engine mounting damper stopper 1 , keep that the clearance ( A and B ) are equal. •...
Page 66 3-10 ENGINE • Apply a small quantity THREAD LOCK SUPER “1303” to the footrest mounting bolts, and tighten them to the specified torque. * 99000-32030: THREAD LOCK SUPER “1303” " Footrest mounting bolt (M8): 26 N·m (2.6 kgf-m, 19.0 lb-ft) (M10): 55 N·m (5.0 kgf-m, 40.0 lb-ft) •...
Page 67: Engine Disassembly
ENGINE 3-11 ENGINE DISASSEMBLY STARTER MOTOR • Remove the starter motor 1. SPARK PLUG • Remove the spark plug. % 09930-10121: Spark plug wrench set WATER HOSE • Remove the water bypass hose. RECOIL STARTER • Remove the recoil starter 1. CAM CHAIN TENSION ADJUSTER •...
Page 68 3-12 ENGINE • Turn the adjusting screw clockwise with a - screwdriver until the push rod locked. • Remove the cam chain tension adjuster 2 and gasket 3. CYLINDER HEAD COVER • Remove the valve clearance inspection caps 1. • Remove the cylinder head cover bolts and washers. •...
Page 69 ENGINE 3-13 • Remove the cylinder head cover plug 3. CAMSHAFT AND CAMSHAFT SPROCKET • Remove the valve timing inspection plug 1. • Turn the generator rotor until the “TDC” line A on the genera- tor rotor is aligned with the index mark B of the generator cover.
Page 70 3-14 ENGINE • Remove the C-ring 5 and draw out the camshaft 6 from the camshaft sprocket. • Remove the camshaft sprocket 7. OIL FILTER • Remove the oil filter with special tool. % 09915-40610: Oil filter wrench CYLINDER HEAD •...
Page 71 ENGINE 3-15 • Remove the cylinder head bolts (M10) in diagonal stages, and then remove the cylinder head 3. NOTE: If the cylinder head dose not come off easily, lightly tap it using a plastic mallet. CYLINDER • Remove the cylinder head gasket 1 and dowel pins 2. •...
Page 72 3-16 ENGINE • Draw out the piston pin 2 and remove the piston 3. WATER PUMP • Remove the water pump 1. GENERATOR COVER • Remove the starter cup nut 1 with a suitable bar 2. • Remove the starter cup 3. •...
Page 73 ENGINE 3-17 STARTER IDLE GEAR NO.1 AND NO.2 • Remove the starter idle gear No.1 1 and shaft 2. • Remove starter idle gear No.2 3 and shaft 4. GEARSHIFT SHAFT • Remove the and washers 1 and gearshift shaft 2. •...
Page 74 3-18 ENGINE TRANSFER OUTPUT DRIVE GEAR • Remove the transfer output drive gear 1 by removing the snap ring 2. • Remove the spacer 3. STARTER CLUTCH AND GENERATOR ROTOR • Remove the generator rotor nut 1. • Install the special tool to the crankshaft end. % 09930-31921: Rotor remover attachment •...
Page 75 ENGINE 3-19 CAM CHAIN • Remove the cam chain 1. CRANK BALANCER SHAFT DRIVE/DRIVEN GEAR AND OIL PUMP DRIVE GEAR • Install the special tools to the crank balancer drive gear 1. % 09920-53740: Clutch sleeve hub holder 09920-31020: Extension handle •...
Page 76 3-20 ENGINE • Remove the washer 6 and crank balancer drive gear 7. • Remove the pin 8. • Remove the spacer 9. OIL PUMP • Remove the snap ring 1. • Remove the oil pump driven gear 2. • Remove the pin 4 and washer 5. •...
Page 77 ENGINE 3-21 • Remove the cap 2. MOVABLE DRIVE FACE • Remove the movable drive face cover 1. • Remove the dowel pins 2. • Remove the movable drive face bolt 3 and collar 4 with the special tool. % 09930-40113: Rotor holder •...
Page 78 3-22 ENGINE MOVABLE DRIVEN FACE AND DRIVE BELT • Remove the movable driven face bolt with the special tool. • Remove the movable driven face assembly 1 and drive belt % 09930-40113: Rotor holder FIXED DRIVE FACE • Remove the fixed drive face 1. •...
Page 79 ENGINE 3-23 • Remove the switch contacts 2 and springs 3. CLUTCH HOUSING CASE • Remove the clutch housing case 1 together with the clutch housing 2. • Remove the dowel pins 3 and clutch housing case gasket 4. • Remove the oil jet 5. •...
Page 80 3-24 ENGINE • Remove the spacer 7 from the clutch housing case. CLUTCH SHOE • Remove the one way clutch 1. • Remove the clutch shoe nut 2 with the special tool. NOTE: The clutch shoe nut has left-hand thread. % 09930-40113: Rotor holder 09930-40120: Rotor holder attachment A •...
Page 81 ENGINE 3-25 • Separate the crankcase with the special tool. NOTE: Fit the crank case separating tool to the right crankcase, so that the tool plate is paralleled with the end of the crankcase. % 09920-13120: Crankcase and shaft remover •...
Page 82 3-26 ENGINE TRANSFER • Remove the gearshift fork shaft 1 and gearshift cam 2. • Remove the gearshift forks 3. • Remove the transfer output shaft assembly 4 and reverse idle gear 5. • Install a suitable washer 6 and the removed movable drive face bolt 7 to the transfer input shaft.
Page 83 ENGINE 3-27 • Hold the transfer output driven gear 2 with the special tool. • Remove the drive bevel gear nut. % 09920-53740: Clutch sleeve hub holder • Remove the washer 3 and rear output shaft drive bevel gear • Remove the shim 5. •...
Page 84 3-28 ENGINE • Remove the crankshaft with the special tool. % 09920-13120: Crankcase and shaft remover • Remove the generator cover.
Page 85: Engine Components Inspection And Service
ENGINE 3-29 ENGINE COMPONENTS INSPECTION AND SERVICE CYLINDER HEAD COVER Identify t he po sition of eac h r emoved part. Organize the pa rts in th eir re spective gro ups (i .e., in take or exhaust) so that they can be installed in their original locations.
Page 86 3-30 ENGINE ROCKER ARM I.D. Measure the inside diameter of the rocker arm and check the wear of the camshaft contacting surface. & Rocker arm I.D. Standard (IN & EX): 12.000 – 12.018 mm (0.4724 – 0.4731 in) % 09900-20605: Dial calipers (1/100 mm, 10 – 34 mm) REASSEMBLY Reassemble the cylinder head cover in the reverse order of dis- assembly.
Page 87: Cylinder Head
ENGINE 3-31 CYLINDER HEAD DISASSEMBLY Identify t he po sition of eac h r emoved part. Organize the pa rts in th eir re spective gro ups (i .e., in take or exhaust) so that they can be installed in their original locations.
Page 88 3-32 ENGINE • Remove the valve spring retainer 9 and valve spring 0. • Pull out the valve A from the combustion chamber side. • Remove the oil seal B and valve spring seat C. • Remove the other valves in the same manner as described previously.
Page 89 ENGINE 3-33 CYLINDER HEAD DISTORTION Decarbonize the combustion chambers. Inspect the gasket surface of the cylinder head for distortion with a straightedge and thickness gauge, taking a clearance reading at several places indicated. If the largest reading at any position of the straightedge exceeds the limit, replace the cylinder head.
Page 90 3-34 ENGINE VALVE STEM AND VALVE FACE WEAR CONDITION Visually inspect each valve stem and valve face for wear and pit- ting. If it is worn or damaged, replace the valve with a new one. VALVE STEM DEFLECTION Lift the valve about 10 mm (0.39 in) from the valve seat. Measure the valve stem deflection in two directions, perpendicu- lar to each other, by positioning the dial gauge as shown.
Page 91 ENGINE 3-35 VALVE GUIDE SERVICING • Using the valve guide remover, drive the valve guide out toward the intake or exhaust camshaft side. % 09916-44310: Valve guide remover/installer NOTE: * Discard the removed valve guide subassemblies. * Only oversized valve guides are available as replacement parts.
Page 92 3-36 ENGINE • After installing the valve guides, re-finish their guiding bores using the reamer. • Clean and engine oil the guides after reaming. % 09916-34570: Valve guide reamer (5.0 mm) 09916-34542: Reamer handle NOTE: * Be sure to cool down the cylinder head to ambient air tempera- ture.
Page 93 ENGINE 3-37 VALVE SEAT SERVICING 45˚ 15˚ • The valve seats 1 for both the intake valve 2 and exhaust valve 3 are machined to three different angles. The seat con- tact surface is cut at 45°. INTAKE EXHAUST · seat angle 15°, 45°...
Page 94 3-38 ENGINE VALVE SPRING The force of the coil spring keeps the valve seat tight. Weak- ened spring results in reduced engine power output, and often accounts for the chattering noise coming from the valve mecha- nism. Inspect the valve spring for proper strength by measuring its free length and also by the force required to compress it.
Page 95 • Tighten the cam chain tensioner bolt to the specified torque. " Cam chain tensioner bolt: 13 N·m (1.3 kgf-m, 9.5 Ib-ft) • Install the ECT sensor. ($7-12) • Apply SUZUKI SUPER GREASE “A” to the O-ring. , 99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease)
Page 96: Automatic Decomp
3-40 ENGINE • Apply THREAD LOCK SUPER “1303” to the intake pipe bolts. • Install the intake pipe and tighten the bolts to the specified torque. NOTE: Make sure that the “up mark” A comes to the upper side. * 99000-32030: THREAD LOCK SUPER “1303” "...
Page 97: Cam Sprocket
ENGINE 3-41 NOTE: “10” “12” Install the cylinder head cover to its original position. “8” “3” • Tighten the cylinder head cover bolts to the specified torque “1” “6” and in the proper tightening sequence. " Cylinder head cover bolt: 10 N·m (1.0 kgf-m, 7.0 Ib-ft) “4”...
Page 98: Cam Chain Tension Adjuster
3-42 ENGINE CAM CHAIN TENSION ADJUSTER Insert the - screwdriver into the slotted end of cam chain ten- sion adjuster and turn it clockwise to lessen the tension and release the - screwdriver. Then check the push rod movement. If the push rod is stuck or spring mechanism failed, replace the cam chain tension adjuster assembly with a new one.
Page 99: Piston And Piston Ring
ENGINE 3-43 CYLINDER BORE Inspect the cylinder wall for any scratches, nicks or other dam- age. Measure the cylinder bore diameter at six places. If any one of the measurements exceed the limit, replace the cyl- inder. & Cylinder bore Standard: 84.000 –...
Page 100 3-44 ENGINE PISTON PIN AND PIN BORE Measure the piston pin bore diameter using the small bore gauge. If the measurement is out of specifications replace the piston. & Piston pin bore I.D.: Service Limit: 20.030 mm (0.7885 in) % 09900-20602: Dial gauge (1/1000 mm, 1 mm) 09900-22403: Small bore gauge (18 –...
Page 101: Conrod
ENGINE 3-45 PISTON RING END GAP Fit the piston ring squarely into the cylinder and measure the piston ring end gap using the thickness gauge. If any of the measurements exceeds the service limit, replace the piston ring with a new one. &...
Page 102: Crankshaft
3-46 ENGINE CRANKSHAFT DISASSEMBLY • Disassemble the crankshaft as shown. 1 Crankshaft (R) 5 Washer 2 Washer 6 Crank pin 3 Conrod 7 Crankshaft (L) 4 Bearing REASSEMBLY • Measure the width between the crankshaft webs “a” referring to the figure when rebuilding the crankshaft. &...
Page 103: Crank Balancer, Balancer Driven Gear And Drive Gear
ENGINE 3-47 CRANKSHAFT RUNOUT Support the crankshaft using V-blocks and measure the crank- shaft runout using the dial gauge, as shown. If the runout exceeds the service limit, replace the crankshaft with a new one. NOTE: * Place the crankshaft onto the V-blocks so that it becomes hori- zontally.
Page 104 3-48 ENGINE REASSEMBLY • Install the starter clutch in the proper direction as shown. NOTE: When installing the starter clutch onto the rotor, make sure that the arrow mark A in the bearing faces to the rotor. • Apply engine oil to the starter clutch. •...
Page 105: Starter Idle Gear No.1 And No.2
ENGINE 3-49 • Install the bearing with the special tool. % 09913-70210: Bearing installer set (-37) The rem oved be aring must be replaced w ith a new one. STARTER IDLE GEAR NO.1 AND NO.2 INSPECTION Inspect the starter idle gear No.1 1, No.2 2, starter idle gear shafts 3 and 4 for wear or damage.
Page 106: Movable Drive Face And Driven Face
3-50 ENGINE MOVABLE DRIVE FACE AND DRIVEN FACE 1 Movable drive plate A Movable driven face 2 Damper (4 pcs) B Pin (4 pcs) 3 Spacer C Spacer (4 pcs) 4 Roller (8 pcs) D O-ring (2 pcs) 5 Oil seal (2 pcs) E Spring seat "...
Page 107 ENGINE 3-51 MOVABLE DRIVE FACE DISASSEMBLY • Remove the movable drive face plate 1 and rollers 2. • Remove the spacer 3. • Remove the oil seals 4 and 5. NOTE: If there are abnormal conditions, the oil seals removal are not necessary.
Page 108 The r emoved oi l seals mus t be r eplaced wi th n ew ones. • Apply SUZUKI SUPER GREASE “A” to the lip of oil seals and inside grease groove of the movable drive face. , 99000-25010: SUZUKI SUPER GREASE “A”...
Page 109 ENGINE 3-53 MOVABLE DRIVEN FACE DISASSEMBLY • Hold the movable driven face assembly with the special tools and vise, loosen the movable driven face ring nut with the special tools. Do not remove the movable driven face ring nut before attaching the clutch spring compressor.
Page 110 3-54 ENGINE • Remove the spring seat 4 and O-rings 5. • Remove the pins 6 and rollers 7. • Remove the movable driven face 8. • Remove the oil seals 9 and 0 from the movable driven face. NOTE: If there are abnormal conditions, the oil seals removal are not necessary.
Page 111 The r emoved o il s eals m ust be replaced wit h ne w ones. • Install the O-rings 1 to the movable driven face. • Apply SUZUKI SUPER GREASE “A” to the oil seal lips and movable driven face inside grease groove. , 99000-25010: SUZUKI SUPER GREASE “A”...
Page 112 3-56 ENGINE • Install the spring seat 6 by aligning the hole A with the hole • Install the spring 7 and spring plate 8 by aligning the spring ends with the holes. • Compress the spring with the special tool. % 09922-31430: Movable driven face spring compressor •...
Page 113: Drive Belt
ENGINE 3-57 DRIVE BELT INSPECTION Inspect that the drive belt is free from any greasy substance. Inspect the contact surface of the drive belt for cracks or dam- age and measure the width of the drive belt with the vernier cali- pers.
Page 114: Oil Pump
3-58 ENGINE ONE WAY CLUTCH INSPECTION • Install the one way clutch 1 onto the proper direction as shawn. NOTE: When installing the one way clutch 1 onto the clutch housing 2 , make sure that the “OUTSIDE” mark A in the one way clutch faces to the clutch housing.
Page 115: Transfer
ENGINE 3-59 TRANSFER DISASSEMBLY • Disassemble the transfer as shown. 1 Washer C Low driven gear O Wave washer 2 Reverse idle gear D Low driven gear bush P Washer 3 Reverse idle gear shaft E Dog Q Counter shaft 4 Spacer F Spacer R Bearing...
Page 116 3-60 ENGINE REASSEMBLY Reassemble the transfer in the reverse order of disassembly. Pay attention to the following points: * Never reuse a sn ap ring. After a sn ap ring has been removed from a sh aft, it should be discarded and a new snap ring must be installed.
Page 117 ENGINE 3-61 • Install the reverse drive gear bush 3 and low driven gear bush 4. When installing t he bu sh o nto t he t ransfer output shaft, align the shaft oil hole B with the bush oil hole...
Page 118: Gearshift Fork And Gear
3-62 ENGINE GEARSHIFT FORK AND GEAR GEARSHIFT FORK-TO-GROOVE CLEARANCE Using a thickness gauge, inspect the shifting fork clearance in the groove of its gear. The clearance for each gearshift fork plays an important role in the smoothness and positiveness of shifting action. If the clearance exceeds the limit, replace the fork or its gear, or both.
Page 119: Gearshift Cam
ENGINE 3-63 GEARSHIFT CAM DISASSEMBLY • Disassemble the gearshift cam as shown. 1 Gear position switch 7 Washer C Gearshift fork (for Reverse) 2 O-ring 8 Spring D Gearshift fork (for High/Low) 3 Gearshift shaft 9 Dog (for High/Low) E Gearshift fork shaft 4 Snap ring 0 Snap ring F Gearshift shaft...
Page 120 3-64 ENGINE REASSEMBLY • Install the dogs 1 and 2 as shown. NOTE: Align the punched marks A of the dog with the punched mark B on the shaft.
Page 121: Gearshift Shaft
ENGINE 3-65 GEARSHIFT SHAFT DISASSEMBLY • Disassemble the following parts from the gearshift shaft 1. 2 Return spring 3 Gearshift arm 4 Snap ring INSPECTION Inspect the gearshift shaft for bend or damage. Inspect the return spring for damage or fatigue. Replace the defective parts with a new one if necessary.
Page 122: Front Output Shaft
3-66 ENGINE FRONT OUTPUT SHAFT CONSTRUCTION 1 Bearing 4 Shim (S) 2 Front output shaft 5 Oil seal 3 Front output shaft housing 6 Front drive collar assembly REMOVAL AND DISASSEMBLY • Remove the front output shaft 1 from the right case. •...
Page 123 ENGINE 3-67 • Remove the front drive collar assembly 4 and front output shaft housing 5. • Remove the front drive collar 6 from the output oil seal plate 7 with special tool. % 09913-70210: Bearing installer set • Remove the O-ring 8. •...
Page 124 3-68 ENGINE FRONT OUTPUT SHAFT INSPECTION Inspect the front output shaft for distortion. If distortion is found, replace the rear output shaft with a new one. Inspect the gear of the front output shaft for wear or damage. If any defects are found, replace the drive and driven bevel gears as a set.
Page 125 • Install the oil seal 4 with the special tool. % 09913-70210: Bearing installer set The removed oil seal must be replaced with a new one. • Apply SUZUKI SUPER GREASE “A” to the O-ring and lip of the oil seal. , 9900-25010: SUZUKI SUPER GREASE “A”...
Page 126: Rear Output Shaft
3-70 ENGINE REAR OUTPUT SHAFT CONSTRUCTION 1 Rear output shaft drive bevel gear 7 Bearing " 2 Shim (s) 8 Oil seal ITEM N·m kgf-m lb-ft 3 Rear output shaft driven bevel gear A Drive bevel gear nut 4 Front output shaft drive gear B Rear output shaft nut 10.0 72.5...
Page 127 ENGINE 3-71 • Unlock the nut with a chisel. • Remove the rear output shaft nut. • Remove the washer 3, front output shaft drive gear 4, bear- ing 5 and rear output shaft driven bevel gear 6. REAR OUTPUT SHAFT INSPECTION Inspect the rear output shaft 1 for distortion.
Page 128: Transfer Output Drive/Driven Gear
3-72 ENGINE REASSEMBLY Reassemble the rear output shaft in the reverse order of disas- sembly. Pay attention to the following points: • Install the rear output shaft driven bevel gear 1 and bearing NOTE: The wider side A of the bearing should be positioned bevel gear side.
Page 129: Shim Adjustment
ENGINE 3-73 SHIM ADJUSTMENT BACKLASH • Install the rear output shaft drive bevel gear. ($3-93) • Place the rear output shaft on the left crankcase half and hold bearings with the special tool. % 09921-21910: Bearing holder • Set a dial gauge on the rear output shaft drive bevel gear as shown.
Page 130 3-74 ENGINE For rear output shaft driven bevel Measure the backlash by turning the drive bevel gear shaft in gear ( 3-72) each direction, reading the total backlash with the dial gauge. If Part No. Shim thickness the backlash is not within specification, the shim must be 0.550 mm (0.022 in) 24945-03G50-055 changed and the backlash should be re-checked until correct.
Page 131 ENGINE 3-75 TOOTH CONTACT After backlash adjustment is carried out, the tooth contact must be checked. Pay attention to the following procedures: • Remove the rear output shaft from the left crankcase. • Clean and degrease several teeth of the drive and driven bevel gears.
Page 132 3-76 ENGINE Shim thickness Part No. 0.550 mm (0.0217 in) 24935-03G50-055 0.575 mm (0.0226 in) 24935-03G50-058 0.600 mm (0.0236 in) 24935-03G50-060 0.625 mm (0.0246 in) 24935-03G50-063 0.650 mm (0.0256 in) 24935-03G50-065 0.675 mm (0.0266 in) 24935-03G50-068 0.700 mm (0.0276 in) 24935-03G50-070 0.725 mm (0.0285 in) 24935-03G50-073...
Page 133: Crankcase
ENGINE 3-77 CRANKCASE OIL SEAL INSPECTION Inspect the oil seal lips for wear on damage. It any defects are found, replace the oil seal with new ones. OIL SEAL REMOVAL • Remove the oil seal with the special tool. % 09913-50121: Oil seal remover •...
Page 134 NOTE: The plate side of the oil seal faces to the outside. % 09913-70210: Bearing installer set (-52) • Apply SUZUKI SUPER GREASE “A” to the lip of the oil seals. , 9900-25010: SUZUKI SUPER GREASE “A” (or equivalent grease) •...
Page 135 ENGINE 3-79 • Remove the bearing 1 with the special tool. % 09921-20240: Bearing remover set Bearing 1: Remover -25 • Remove the bearings with the special tool. % 09913-70210: Bearing installer set Bearing 2: -35 Attachment Bearing 3: -75 Attachment Bearing 4: -32 Attachment Bearing 5: -52 Attachment Bearing 6: -68 Attachment...
Page 136 3-80 ENGINE RIGHT CRANKCASE BEARING REMOVAL NOTE: If there is no abnormal noise, the bearing removal is not neces- sary. • Remove the bearing retainers. • Remove the bearings with the special tool. % 09921-20240: Bearing remover set Bearing 1, 2: Remover -20 •...
Page 137 ENGINE 3-81 RIGHT CRANKCASE BEARING INSTALLATION • Press the bearings with the special tool. % 09913-70210: Bearing installer set Bearing 1: -30 Attachment Bearing 2: -42 Attachment Bearing 3: -75 Attachment Bearing 4: -55 Attachment Bearing 5: -35 Attachment The re moved bearings m ust be rep laced with n ew ones.
Page 138: Generator Cover
3-82 ENGINE GENERATOR COVER DISASSEMBLY • Remove the speed sensor 1. • Remove the oil seals 2 and 3 with the special tool. % 09913-50121: Oil seal remover • Remove the generator stator 4, CKP sensor 5, bracket 6 and grommet 7. •...
Page 139 The r emoved o il s eals m ust be replaced wit h ne w ones. % 09913-70210: Bearing installer set Oil seal 4: -42 Attachment Oil seal 5: -20 Attachment • Apply SUZUKI SUPER GREASE “A” to the lip of the oil seals. , 09900-25010: SUZUKI SUPER GREASE “A” (or equivalent grease)
Page 140: Clutch Housing Case
3-84 ENGINE • Apply SUZUKI SUPER GREASE “A” to the O-ring. The removed O-ring must be replaced with a new one. , 99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease) • Install the speed sensor and tighten the speed sensor bolt to the specified torque.
Page 141: Movable Drive Face Cover
• Install the oil seal 2 with the special tool. % 09913-70210: Bearing installer set (-55) The removed oil seal must be replaced with a new one. • Apply SUZUKI SUPER GREASE “A” to the lip of the oil seal. , 99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease)
Page 142 • Install the oil seal 3 with the special tool. % 09913-70210: Bearing installer set (-47) The removed oil seal must be replaced with a new one. • Apply SUZUKI SUPER GREASE “A” to the lip of oil seal. , 99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease)
Page 143: Recoil Starter
ENGINE 3-87 RECOIL STARTER 1 O-ring 5 Reel 2 Starter cup 6 Spiral spring 3 Starter cup nut 7 Rope assembly 4 Ratchet set DISASSEMBLY • Remove the nut 1 and friction plate 2. • Remove the ratchet guide 3, ratchet 4 and ratchet pin 5.
Page 144 3-88 ENGINE • Remove the spring cover 6, spring 7 and spacer 8. • Remove the cap 9 from the knob 0. • Untie a knot at the rope. • Hook the rope to groove A of the reel A. •...
Page 145 Wear hand and eye protection when installing the reel, since the sp ring may q uickly unwind an d ca use an injury. • Apply SUZUKI SUPER GREASE “A” to the spiral spring. , 99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease) •...
Page 146 • Install the ratchet pin, spacer, spring cover, ratchet and ratchet guide. NOTE: • Apply SUZUKI SUPER GREASE “A” to the shaft and ratchet guide. , 99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease)
Page 147: Engine Reassembly
ENGINE 3-91 ENGINE REASSEMBLY Reassemble the engine in the reverse order of disassembly. The following steps require special attention or precautionary measures should be taken. Always keep the drive belt, drive face and driven face away from any greasy matter. NOTE: Apply engine oil to each running and sliding part before reas- sembling.
Page 148 3-92 ENGINE • Install the spacer 2. • Install the shim 3. • Install the rear output shaft drive bevel gear 4 and washer 5. • Hold the transfer output gear with the special tool. % 09920-53740: Clutch sleeve hub holder •...
Page 149 ENGINE 3-93 • Install the transfer output shaft assembly 2 and reverse idle gear 3. • Install the gearshift forks 4. • Install the gearshift cam 5 and gearshift fork shaft 6. REAR OUTPUT SHAFT • Install the C-ring 1. •...
Page 150 • Install the dowel pins 1 to the left crankcase. • Apply engine oil to the conrod big end and each gear. • Apply SUZUKI BOND “1215” to the mating surface of the right crankcase as shown. . 99000-31110: SUZUKI BOND “1215”...
Page 151 3-95 • After the crankcase bolts have been tightened, check if the each shaft rotates smoothly. • Apply SUZUKI SUPER GREASE “A” to the O-ring. , 99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease) The removed O-ring must be replaced with a new one to prevent oil leakage.
Page 152 “OUTSIDE” mark A in the one way clutch faces to the clutch housing. • Install the clutch housing. CLUTCH HOUSING CASE • Apply SUZUKI SUPER GREASE “A” to the O-ring. • Install the oil jet 1 as shown. , 99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease) The removed O-ring must be replaced with a new one to prevent oil pressure leakage.
Page 153 • Install the collar 4. GEAR POSITION SWITCH • Install the springs 1 and switch contacts 2. • Apply SUZUKI SUPER GREASE “A” to the O-ring 3. , 99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease) Removed O -ring m ust be re placed w ith a ne w o ne to prevent oil leakage.
Page 154 3-98 ENGINE • Install the clutch inner cover gasket and clutch inner cover 2. The r emoved cl utch in ner cov er ga sket must b e replaced with a new one. • Tighten the clutch inner cover bolts to the specified torque. Tighten the cl utch in ner co ver bo lts A first and then other ones diagonally.
Page 155 ENGINE 3-99 • Tighten the movable driven face bolt 2 to the specified torque with the special tool. " Movable driven face bolt: 110 N·m (11.0 kgf-m, 79.5 lb-ft) % 09930-40113: Rotor holder • Install the movable drive face assembly 3. Degrease the movable drive face assembly.
Page 156 3-100 ENGINE • Install the movable drive face cover 7 and tighten the bolts securely. • Install the cap 8. CLUTCH COVER • Install the clutch cover gasket and clutch cover 1. The removed c lutch c over g asket must b e replaced with a new one.
Page 157 ENGINE 3-101 • Install the oil pump driven gear 4. • Install the snap ring 5. NOTE: Be careful not to drop the snap ring into the crankcase. CRANK BALANCER SHAFT DRIVE/DRIVEN GEAR AND OIL PUMP DRIVE GEAR • Install the pin 1. •...
Page 158 3-102 ENGINE • Install the key 4. • Install the oil pump drive gear 5. NOTE: Be careful direction of the oil pump drive gear. OUTSIDE INSIDE • Install the crank balancer driven gear 6. NOTE: Align the matching marks A as shown.
Page 159 ENGINE 3-103 • Apply a small quantity of THREAD LOCK SUPER “1303” to the balancer driven gear bolts. * 99000-32030: THREAD LOCK SUPER “1303” • Hold the crank balancer drive gear with the special tool and tighten the crank balancer driven gear bolt 7 to the specified torque.
Page 160 3-104 ENGINE • Install the generator rotor. Make su re t hat t he st arter cl utch o n t he c rankshaft rotor is fitted into the generator rotor properly. • Hold the generator rotor and tighten the generator rotor nut 5 to the specified torque with the special tool.
Page 161 ENGINE 3-105 • Install the washer 6. • Install the gearshift shaft 7 and washer 8. NOTE: Align the matching mark A of the gear shift shaft with matching mark B of the gearshift cam stopper plate. STARTER IDLE GEAR NO.1 AND NO.2 •...
Page 162 • Install the generator cover 3 and tighten the bolts securely. NOTE: Fit the clamp to the bolt A . STARTER CUP • Apply SUZUKI SUPER GREASE “A” to the O-ring and lip of the oil seal. , 99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease) The removed O-ring must be replaced with a new one.
Page 163 ENGINE 3-107 When installing the spacer, be careful not to allow its two ends to overlap in the groove. A INCORRECT B CORRECT • Install the 2nd ring 3 and the 1st ring 4 to the piston. NOTE: 1st ring and 2nd ring differ in shape. •...
Page 164 • Thoroughly wipe off oil from the fitting surface of the crank- case. • Apply SUZUKI BOND “1215” to the crankcase B as shown. % 99000-31110: SUZUKI BOND “1215” (or equivalent bond) • Apply molybdenum oil solution to the sliding surface of the piston and piston rings.
Page 165 ENGINE 3-109 • Install the cam chain guide 3. NOTE: Make sure that the cam chain guide 3 is inserted properly or binding of the cam chain and guide may result. • Install the dowel pins 4 and cylinder head gasket 5. The removed gasket must be replaced with a new one to prevent gas leakage.
Page 166 3-110 ENGINE CAMSHAFT AND CAMSHAFT SPROCKET • Turn the generator rotor until the “TDC” line A on the genera- tor rotor is aligned with the index mark B of the generator cover. If th e crankshaft is tu rned without d rawing th e c am chain upward, the cam chain will catch between crank- case and camshaft sprocket.
Page 167 ENGINE 3-111 • Fit the lock washer 4. • Apply a small quantity of THREAD LOCK SUPER “1303” to the camshaft sprocket bolts and tighten them to the specified torque. " Camshaft sprocket bolt: 15 N·m (1.5 kgf-m, 11.0 lb-ft) * 99000-32030: THREAD LOCK SUPER “1303”...
Page 168 • Thoroughly wipe off oil from the fitting surfaces of the cylinder head and cover. 1216 • Apply SUZUKI BOND uniformly to the mating surface of the cylinder head cover and install it with in a few minutes. 0 99000-31230: SUZUKI BOND “1216B”...
Page 169 ENGINE 3-113 • Apply the SUZUKI SUPER GREASE “A” to the O-rings. • Install the valve clearance inspection caps and tighten the valve clearance inspection cap bolts to the specified torque. " Valve clearance inspection cap bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft) , 9900-25010: SUZUKI SUPER GREASE “A”...
Page 170 ENGINE WATER HOSE • Install the water bypass hose. STARTER MOTOR • Apply SUZUKI SUPER GREASE “A” to the O-ring. , 99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease) The removed O-ring must be replaced with a new one. • Install the starter motor and tighten the starter motor mounting bolts to the specified torque.
Page 171 DRIVE TRAIN DRIVE TRAIN CONTENTS FRONT DRIVE TRAIN (DIFFERENTIAL) .............4- 2 CONSTRUCTION ...................4- 2 REMOVAL ....................4- 3 DISASSEMBLY ..................4- 4 INSPECTION ..................4- 9 REASSEMBLY ..................4-11 REMOUNTING ..................4-17 SHIM ADJUSTMENT ................4-18 REASSEMBLY INFORMATION .............4-21 FRONT PROPELLER SHAFT ..............4-22 REMOVAL ..
Page 172: Front Drive Train (Differential)
DRIVE TRAIN FRONT DRIVE TRAIN (DIFFERENTIAL) CONSTRUCTION Front drive train (differential) Snap ring gear case Front drive train (differential) 2WD/4WD shifting sleeve gear case cover 3 Shim (right side) I Snap ring 4 Bearing J Bearing 5 Front drive train (differential) gear K Snap ring 6 Bearing L Oil seal 7 Shim (left side)
Page 173: Removal
DRIVE TRAIN REMOVAL • Remove the front wheels. ($8-18) • Drain the front differential gear oil. ($2-11) • Remove the front brake caliper. ($8-29) • Remove the front suspension. ($8-41) • Hold the inboard joint 1 of the front drive shaft and tug the drive shaft horizontally.
Page 174: Disassembly
DRIVE TRAIN • Remove the front drive train (differential) gear case mounting bolts/nuts. • Remove the front drive train (differential) gear case assembly out of the frame. DISASSEMBLY 4WD/DIFF-LOCK ACTUATOR • Remove the 4WD/diff-lock actuator assembly. BREATHER CASE • Remove the breather case. FRONT DRIVE TRAIN (DIFFERENTIAL) GEAR •...
Page 175 DRIVE TRAIN • Align the shifting fork pin 3 with the groove of the sifting cam • Remove the front drive train (differential) gear assembly 5, diff-lock shifting fork 6 and shifting fork shaft 7. • Remove the right side shim 8 and left side shim 9. •...
Page 176 DRIVE TRAIN • Remove the 2WD/4WD shifting cam 2. • Remove the snap ring 3. • Remove the 2WD/4WD shifting cam bearing with the special tool. % 09921-20240: Bearing remover set (-17) NOTE: If there is no abnormal noise, the bearing removal is not neces- sary.
Page 177 DRIVE TRAIN • Remove the snap ring 5. • Remove the input shaft 6. • Remove the 2WD/4WD shifting sleeve 7. • Remove the snap ring 8. • Remove the input shaft bearing with the special tool. % 09913-60910: Bearing and gear puller NOTE: If there is no abnormal noise, the bearing removal is not neces- sary.
Page 178 DRIVE TRAIN DRIVE BEVEL GEAR • Remove the snap ring 1. • Remove the drive bevel gear 2. • Remove the drive bevel gear bearing with the special tool. % 09913-60910: Bearing and gear puller NOTE: If there is no abnormal noise, the bearing removal is not neces- sary.
Page 179: Inspection
DRIVE TRAIN INSPECTION SHIFTING FORK SHAFT Inspect the shifting fork shafts for wear or damage. If any defects are found, replace the shifting fork shafts with new ones. DIFF-LOCK SHIFTING FORK AND 2WD/4WD SHIFTING FORK Inspect the diff-lock shifting fork 1 and 2WD/4WD shifting fork 2 for wear or damage.
Page 180 4-10 DRIVE TRAIN BEARING INSPECTION Rotate the bearing inner race by finger to inspect for abnormal Play play, noise and smooth rotation. If there is anything unusual, Play replace the bearing with a new one. DRIVE BEVEL GEAR Inspect the drive bevel gear for wear or damage. If any defects are found, replace the drive bevel gear with a new one.
Page 181: Reassembly
The removed oil seal must be replaced with a new one. NOTE: Insert the oil seal until the specified value as shown. • Apply SUZUKI SUPER GREASE “A” to the lip of oil seal. , 99000-25010: SUZUKI SUPER GREASE “A” 4 mm (or equivalent) (0.1574 in)
Page 182 The removed oil seal must be replaced with a new one. NOTE: Insert the oil seal until the specified value as shown. • Apply SUZUKI SUPER GREASE “A” to the lip of oil seal. 4 mm , 99000-25010: SUZUKI SUPER GREASE “A”...
Page 183 DRIVE TRAIN 4-13 INPUT SHAFT • Install the bearing onto the input shaft with the special tool. The remove bearing must be replaced with a new one. % 09913-70210: Bearing installer set (-40) • Install the snap ring 1. • Install the snap ring 2 to the input shaft 3. •...
Page 184 • Install the oil seal 5 with a suitable tool. The removed oil seal must be replaced with a new one. • Apply SUZUKI SUPER GREASE “A” to the lip of oil seal. , 99000-25010: SUZUKI SUPER GREASE “A” (or equivalent) •...
Page 185 • Align the shifting fork pin A with the groove of the shifting cam B. • After the backlash and tooth contact have been checked or adjusted, apply SUZUKI BOND “1215” to the mating surface of the case. . 99000-31110: SUZUKI BOND “1215”...
Page 186 After the backlash and tooth contact have been checked or adjusted, apply thread lock to the case cover bolts. 4WD/DIFF-LOCK ACTUATOR • Apply SUZUKI SUPER GREASE “A” to the O-rings. , 99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease) The removed O-rings must be replaced with new ones to prevent front differential gear oil leakage.
Page 187: Remounting
The rem oved st opper ring m ust be re placed with a new one. • Apply SUZUKI SUPER GREASE “A” to the spline. , 99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease) Be careful not to damage the front drive train (differen- tial) gear case oil seals.
Page 188: Shim Adjustment
4-18 DRIVE TRAIN SHIM ADJUSTMENT BACKLASH • Install the removed left and right side shim(s) and front drive train (differential) gear assembly. • Assemble the gear case cover. ($4-15) NOTE: At this time, it is not necessary to apply a sealant to the mating surface of the gear case.
Page 189 DRIVE TRAIN 4-19 LEFT SIDE SHIM SELECTION • Install the removed right side shim(s) and front drive train (dif- ferential) assembly. • Put a few pieces of solder (O.D.: 1.2 – 1.5 mm × L: 6 mm) on the bearing outer race, as shown. NOTE: * Do not install the left side shim(s) at this time.
Page 190 4-20 DRIVE TRAIN TOOTH CONTACT After backlash adjustment and left side shim selection are car- ried out, the tooth contact must be checked. Pay attention to the following points: • Remove the front drive train (differential) gear assembly. • Clean and degrease several teeth on the ring gear and drive bevel gear, and then apply a coating of machinist’s layout dye or paste to several teeth of the drive bevel gear.
Page 191: Reassembly Information
DRIVE TRAIN 4-21 REASSEMBLY INFORMATION 22 N·m Mating surfaces (2.2 kgf-m, 16.0 lb-ft) shim shim 3-5 gram 3-5 gram 1.3 N·m (0.13 kgf-m, 0.94 lb-ft) 3-5 gram...
Page 192: Front Propeller Shaft
4-22 DRIVE TRAIN FRONT PROPELLER SHAFT REMOVAL • Remove the front drive train (differential) gear case assembly. ($4-3) • Remove the front propeller shaft spring 1 and front propeller shaft boot 2. • Loosen the boot clamp screw and remove the universal joint boot 3.
Page 193: Reassembly
DRIVE TRAIN 4-23 UNIVERSAL JOINT • Inspect the play by turning the universal joint. If excessive play is noted, replace it with a new one. Do not attempt to disassemble the universal joint. BOOTS Inspect the front propeller shaft boot 1 and universal joint boot 2 for crack or damage.
Page 194 4-24 DRIVE TRAIN • Connect the universal joint to the joint portion (at the engine side). • Tighten the boot clamp screw. • Install the front propeller shaft spring. • Apply small quantity of WATER RESISTANCE GREASE to the spline of the front propeller shaft and front propeller shaft spring.
Page 195: Rear Drive Train
DRIVE TRAIN 4-25 REAR DRIVE TRAIN CONSTRUCTION 1 Final gear case E Rear propeller shaft coupling 2 Final gear case cover F Washer 3 Ring gear G Lock-nut 4 Shim (right side) H Snap ring 5 Shim (left side) I Propeller shaft joint 6 Bearing J Spring plate 7 Oil seal...
Page 196: Removal
4-26 DRIVE TRAIN REMOVAL • Remove the rear wheels. ($8-18) • Drain the final gear oil. ($2-12) • Remove the rear brake cable. ($8-73) • Remove the rear suspension. ($8-84) • Hold the inboard joint 1 of the rear drive shaft and tug the rear drive shaft horizontally.
Page 197: Disassembly
DRIVE TRAIN 4-27 • Remove the final gear case mounting bolt/nuts. • Remove the final gear case assembly out of the frame. DISASSEMBLY FINAL GEAR AND FINAL GEAR CASE • Remove the rear brake. ($8-73) • Remove the final gear case bolts diagonally and evenly. •...
Page 198 4-28 DRIVE TRAIN • Remove the oil seal with the special tool. % 09913-50121: Oil seal remover • Remove the final gear case cover bearing 6 with the special tool. % 09913-70210: Bearing installer set 09944-66010: Bearing installer NOTE: If there is no abnormal condition, the bearing removal is not nec- essary.
Page 199 DRIVE TRAIN 4-29 REAR PINION GEAR • Unlock the rear drive bearing lock-nut 1 with a chisel. • Remove the rear drive bearing lock-nut with the special tool. % 09924-41830: Bearing lock-nut wrench • Remove the rear pinion gear 2 and shim 3. •...
Page 200 4-30 DRIVE TRAIN • Remove the rear pinion gear lock-nut 4 and washer 5 with the special tools. % 09924-52470: Fixed final drive gear holder 09940-92430: Rear axle wrench A • Remove the rear pinion gear bearing outer race 6 with the special tool and suitable tool A.
Page 201: Inspection
DRIVE TRAIN 4-31 INSPECTION RING GEAR Inspect the ring gear for wear or damage. If any defects are found, replace right gear with a new one. REAR PINION GEAR Inspect the rear pinion gear for wear or damage. If any defects are found, replace the pinion gear with a new one. BEARING INSPECTION Rotate the bearing inner race by finger to inspect for abnormal Play...
Page 202: Reassembly
• Install the oil seal to the final gear case with the special tool. % 09951-15810: Bearing installer • Apply SUZUKI SUPER GREASE “A” to the lip of the oil seal. , 99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease) The removed oil seal must be replaced with a new one.
Page 203 DRIVE TRAIN 4-33 • Tighten the rear pinion gear lock-nut with the special tools to the specified torque. The rem oved rea r pin ion ge ar lo ck-nut mu st be replaced with a new one. % 09924-52470: Fixed final drive gear holder 09940-92430: Rear axle wrench A "...
Page 204 The remove bearing must be replaced with a new one. • Install the oil seal with the special tool. % 09951-15810: Bearing installer • Apply SUZUKI SUPER GREASE “A” to the lip of the oil seal. , 99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease) The remove bearing must be with a new one.
Page 205: Remounting
DRIVE TRAIN 4-35 • Apply a small quantity of THREAD LOCK SUPER “1303” to the final gear case bolts and tighten them to the specified torque diagonally. * 99000-32030: THREAD LOCK SUPER “1303” " Final gear case bolt (M8): 26 N·m (2.6 kgf-m, 19.0 lb-ft) Final gear case bolt (M10): 55 N·m (5.5 kgf-m, 40.0 lb-ft) NOTE: After the backlash and tooth contact have been checked or...
Page 206: Shim Adjustment
4-36 DRIVE TRAIN SHIM ADJUSTMENT BACKLASH • Install the removed shim(s), pinion gear and new bearing lock-nut. ($4-33) • Tighten the bearing lock-nut to the specified torque. ($4- NOTE: At this time, it is not necessary to bend the bearing lock-nut col- lar.
Page 207 DRIVE TRAIN 4-37 LEFT SIDE SHIM SELECTION • After the backlash has been checked or adjusted, put a few pieces of solder (O.D.: 1.2 – 1.5 mm × L: 6 mm) on the back side of ring gear, as shown. NOTE: * Do not install the left side shim(s) at this time.
Page 208 4-38 DRIVE TRAIN TOOTH CONTACT After backlash adjustment and left shim selection are carried out, the tooth contact must be checked. Pay attention to the fol- lowing procedures: • Remove the ring gear. • Clean and degrease several teeth on the ring gear and pinion gear, and then apply a coating of machinist’s layout dye or paste to several teeth of the pinion gear.
Page 209: Reassembly Information
DRIVE TRAIN 4-39 REASSEMBLY INFORMATION 2.0 N·m (0.2 kgf-m, 1.5 lb-ft) 100 N·m (10.0 kgf-m, 72.5 lb-ft) 3 – 5 gram 3 – 5 gram 100 N·m (10 kgf-m, 22.5 lb-ft) 100 N·m (10 kgf-m, 22.5 lb-ft) 100 N·m (10 kgf-m, 72.5 lb-ft) Pinion gear shim (S) shim (right side) shim (left side)
Page 210: Rear Propeller Shaft
4-40 DRIVE TRAIN REAR PROPELLER SHAFT REMOVAL AND DISASSEMBLY • Remove the rear final gear case assembly. ($4-26) • Remove the rear propeller shaft joint 1. • Remove the O-ring 2. • Remove the rear propeller shaft spring 3. • Loosen the boot clamp screw. •...
Page 211 DRIVE TRAIN 4-41 • Remove the rear propeller shaft joint boot 5 and universal joint boot 6. • Remove the O-ring 7. • Remove the circlips from the universal joint. • Remove the bearings 8 by tapping with the special tool. % 09913-70210: Bearing installer set (-20) •...
Page 212: Inspection
4-42 DRIVE TRAIN • Unlock the rear output shaft nut with a chisel. • Remove the rear output shaft yoke A. INSPECTION REAR PROPELLER SHAFT Inspect the rear propeller shaft for wear or damage. If any defects are found, replace rear propeller shaft with a new one.
Page 213: Reassembly And Installation
DRIVE TRAIN 4-43 REASSEMBLY AND INSTALLATION • Reassemble and install the rear propeller shaft assembly in the reverse order of removal and disassembly. • Install the rear output shaft yoke 1 and rear output shaft nut The r emoved r ear output s haft nut m ust be r eplaced with a new one.
Page 214 4-44 DRIVE TRAIN • Install the rear propeller shaft joint boot 6 and universal joint boot 7 to the rear propeller shaft. • Apply WATER RESISTANCE GREASE to the hole inside of the boots and spline of rear propeller shaft. 1 99000-25160: WATER RESISTANSE GREASE •...
Page 215 ...
Page 216 FI SYSTEM DIAGNOSIS CONTENTS PRECAUTIONS IN SERVICING..............5- 2 ELECTRICAL PARTS................5- 2 FUSE .......................5- 3 ECM/VARIOUS SENSORS..............5- 3 ELECTRICAL CIRCUIT INSPECTION PROCEDURE ......5- 5 USING THE MULTI-CIRCUIT TESTER ..........5- 8 FI SYSTEM TECHNICAL FEATURES ............5- 9 INJECTION TIME (INJECTION VOLUME)..........5- 9 COMPENSATION OF INJECTION TIME (VOLUME)......5-10 INJECTION STOP CONTROL ..............5-10 FI SYSTEM PARTS LOCATION.............5-11...
Page 217 FI SYSTEM DIAGNOSIS SENSORS ..................... 5-59 CKP SENSOR INSPECTION..............5-59 CKP SENSOR REMOVAL AND INSTALLATION ......... 5-59 IAP SENSOR INSPECTION ..............5-59 TP SENSOR INSPECTION..............5-59 IAT SENSOR INSPECTION ..............5-59 ECT SENSOR INSPECTION ..............5-59 ECT SENSOR REMOVAL AND INSTALLATION ........5-59 TO SENSOR INSPECTION ..............
Page 218: Precautions In Servicing
FI SYSTEM DIAGNOSIS PRECAUTIONS IN SERVICING When handling the component parts or servicing the FI system, observe the following points for the safety of the system. ELECTRICAL PARTS CONNECTOR/COUPLER • When connecting a connector, be sure to push it in until a Click click is felt.
Page 219: Fuse
FI SYSTEM DIAGNOSIS • When connecting meter probe from the terminal side of the coupler (where connection from harness side not being possi- ble), use extra care not to force and cause the male terminal to bend or the female terminal to open. Connect the probe as shown to avoid opening of female ter- minal.
Page 220 FI SYSTEM DIAGNOSIS • When disconnecting and connecting the ECM, make sure to turn OFF the ignition switch 1, or electronic parts may get damaged. • Do not disconnect the ECM coupler within 3 seconds, after turning OFF the ignition switch. INCORRECT •...
Page 221: Electrical Circuit Inspection Procedure
FI SYSTEM DIAGNOSIS ELECTRICAL CIRCUIT INSPECTION PROCEDURE While there are various methods for electrical circuit inspection, described here is a general method to check for open and short circuit using an ohmmeter and a voltmeter. OPEN CIRCUIT CHECK Possible causes for the open circuits are as follows. As the cause can exist in the connector/coupler or terminal, they need to be checked carefully.
Page 222 FI SYSTEM DIAGNOSIS Continuity check • Measure resistance across coupler B (between A and C in the figure). If no continuity is indicated (infinity or over limit), the circuit is open between terminals A and C. 1 ECM • Disconnect the coupler B and measure resistance between couplers A and B.
Page 223 FI SYSTEM DIAGNOSIS SHORT CIRCUIT CHECK (WIRE HARNESS TO GROUND) • Disconnect the negative cable from the battery. • Disconnect the connectors/couplers at both ends of the circuit to be checked. NOTE: If the circuit to be checked branches to other parts as shown, disconnect all connectors/couplers of those parts.
Page 224: Using The Multi-Circuit Tester
FI SYSTEM DIAGNOSIS USING THE MULTI-CIRCUIT TESTER • Use the Suzuki multi-circuit tester set (09900-25008). • Use well-charged batteries in the tester. • Be sure to set the tester to the correct testing range. USING THE TESTER • Incorrectly connecting the + and - probes may cause the inside of the tester to burnout.
Page 225: Fi System Technical Features
FI SYSTEM DIAGNOSIS FI SYSTEM TECHNICAL FEATURES INJECTION TIME (INJECTION VOLUME) The factors to determine the injection time include the basic fuel injection time, which is calculated on the basis of intake air pressure, engine speed and throttle opening angle, and various compensations. These compensations are determined according to the signals from various sensors that detect the engine and driving conditions.
Page 226: Compensation Of Injection Time (Volume)
5-10 FI SYSTEM DIAGNOSIS COMPENSATION OF INJECTION TIME (VOLUME) The following different signals are output from the respective sensors for compensation of the fuel injection time (volume). SIGNAL DESCRIPTION ENGINE COOLANT TEMPERATURE SEN- When engine coolant temperature is low, injection time (vol- SOR SIGNAL ume) is increased.
Page 227: Fi System Parts Location
FI SYSTEM DIAGNOSIS 5-11 FI SYSTEM PARTS LOCATION A Speed sensor E Crankshaft position sensor (CKPS) B Throttle position sensor (TPS) F Combination meter C Intake air pressure sensor (IAPS) G Diff-lock relay D Intake air temperature sensor (IATS) H Engine coolant temperature sensor (ECTS) NOTE: B , C and D devices are combined into one.
Page 228 5-12 FI SYSTEM DIAGNOSIS I Tip-over sensor (TOS) L Fuel pump relay (FP RELAY) J Fuel injector M Fuel pump (FP) K Ignition coil...
Page 229: Fi System Wiring Diagram
FI SYSTEM DIAGNOSIS 5-13 FI SYSTEM WIRING DIAGRAM...
Page 230: Ecm Terminal
5-14 FI SYSTEM DIAGNOSIS ECM TERMINAL TERMINAL TERMINAL CIRCUIT CIRCUIT Ignition coil (IG1) CKP sensor signal (CKP-) Fuel injector (#11) Fuel pump relay (FP Relay) Power source (+B) Injector power voltage (VM) Back up power (BATT) Diff-lock relay (DL Relay) Brake switch (BRK) Serial data for self-diagnosis (SDL) Power source for sensors (VCC)
Page 231: Self-Diagnosis Function
FI SYSTEM DIAGNOSIS 5-15 SELF-DIAGNOSIS FUNCTION The self-diagnosis function is incorporated in the ECM. The function has two modes, “User mode” and “Dealer mode”. The user can only be notified by the LCD (FI) panel and LED (FI light). To check the function of the individual FI system devices, the dealer mode is prepared.
Page 232: Dealer Mode
5-16 FI SYSTEM DIAGNOSIS DEALER MODE The defective function is memorized in the computer. Use the special tool’s coupler to connect to the dealer mode coupler. The memorized malfunction code is displayed on LCD (DISPLAY) panel. Malfunction means that the ECM does not receive signal from the devices. These affected devices are indicated in the code form.
Page 233: Tps Adjustment
FI SYSTEM DIAGNOSIS 5-17 CODE MALFUNCTION PART REMARKS None No defective part Crankshaft position sensor (CKPS) Pick-up coil signal, signal generator Intake air pressure sensor (IAPS) Throttle position sensor (TPS) Engine coolant temperature sensor (ECTS) Diff-lock relay Intake air temperature sensor (IATS) Tip-over sensor (TOS) Ignition signal (IG coil) Fuel injector signal (FI)
Page 234: Fail-Safe Function
5-18 FI SYSTEM DIAGNOSIS FAIL-SAFE FUNCTION FI system is provided with fail-safe function to allow the engine to start and the vehicle to run in a minimum performance necessary even under malfunction condition. STARTING RUNNING ITEM FAIL-SAFE MODE ABILITY ABILITY IAP sensor Intake air pressure is fixed to 760 “YES”...
Page 235: Fi System Troubleshooting
FI SYSTEM DIAGNOSIS 5-19 FI SYSTEM TROUBLESHOOTING 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.
Page 236: Visual Inspection
5-20 FI SYSTEM DIAGNOSIS VEHICLE/ENVIRONMENTAL CONDITION WHEN PROBLEM OCCURS Environmental condition Weather Fair Cloudy Rain Snow Always Other Temperature Warm Cool Cold ( °F/ °C) Always Frequency Always Sometimes ( times/ day, month) Only once Under certain condition Road Mountainous ( Uphill Downhill) Gravel...
Page 237: Self-Diagnostic Procedures
FI SYSTEM DIAGNOSIS 5-21 SELF-DIAGNOSTIC PROCEDURES NOTE: * Don’t disconnect the coupler from ECM, the battery cable from the battery, or main fuse from the fuse box before confirming the malfunction code (self-diagnostic trouble code) stored in the memory. Such disconnection will erase the memorized information in ECM memory.
Page 238: Use Of Sds Diagnostic Procedures
5-22 FI SYSTEM DIAGNOSIS USE OF SDS DIAGNOSTIC PROCEDURES NOTE: * Don’t disconnect the coupler from ECM, the battery cable from the battery, or main fuse from the fuse box before confirming the malfunction code (self-diagnostic trouble code) stored in memory.
Page 239: Use Of Sds Diagnosis Reset Procedure
FI SYSTEM DIAGNOSIS 5-23 USE OF SDS DIAGNOSIS RESET PROCE- DURE • After repairing the trouble, turn the ignition switch to OFF and turn to ON again. • Click the “DTC inspection” button 1. • Check the DTC. • The previous malfunction history code (Past DTC) still remains stored in the ECM.
Page 240: Show Data When Trouble (Displaying Data At The Time Of Dtc)
5-24 FI SYSTEM DIAGNOSIS SHOW DATA WHEN TROUBLE (DISPLAYING DATA AT THE TIME OF DTC) 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. This data is called “Show data when trouble”. Therefore, it is possible to know engine and driving conditions (e.g., whether the engine was warm or not, where the vehicle was running or stopped) when a malfunction was detected by checking the “Show data when trouble”.
Page 241: Malfunction Code And Defective Condition
FI SYSTEM DIAGNOSIS 5-25 MALFUNCTION CODE AND DEFECTIVE CONDITION DETECTED DTC No. DETECTED FAILURE CONDITION CHECK FOR ITEM NO FAULT ––––––––––– ––––––––––– CKP sensor The signal does not reach ECM for 3 CKP sensor lead wire/coupler sec. or more, after receiving the starter and mechanical parts.
Page 242 5-26 FI SYSTEM DIAGNOSIS DETECTED DTC No. DETECTED FAILURE CONDITION CHECK FOR ITEM IAT sensor The sensor voltage should be the fol- IAT sensor, lead wire/coupler lowing. connection. 0.15 V < sensor voltage 4.85 V In other than the above value, C21 (P0110) is indicated.
Page 243: C12" (P0335) Ckp Sensor Circuit Malfunction
FI SYSTEM DIAGNOSIS 5-27 “C12” (P0335) CKP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE The signal does not reach ECM for 3 sec. or more, • Metal particles or foreign material being stuck on after receiving the starter signal. the CKP sensor and rotor tip. •...
Page 244 5-28 FI SYSTEM DIAGNOSIS 4) If OK, then check the continuity between each terminal and ground. & CKP sensor continuity: ∞ Ω (Infinity) (Blue – Ground) (White – Ground) % 09900-25008: Multi-circuit tester set 2 Tester knob indication: Resistance (Ω) Are the resistance and continuity OK? Go to step 2.
Page 245 FI SYSTEM DIAGNOSIS 5-29 Step 2 1) Crank the engine a few seconds with the starter motor, and measure the CKP sensor peak voltage at the coupler. 2) Repeat the above test procedure a few times and measure the highest peak voltage. &...
Page 246: C13" (P0105-H/L) Iap Sensor Circuit Malfunction
5-30 FI SYSTEM DIAGNOSIS “C13” (P0105-H/L) IAP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE IAP sensor voltage is not within the fol- • Clogged vacuum passage between throttle body lowing value. and IAP sensor. 0.5 V < Sensor voltage 4.85 V •...
Page 247 FI SYSTEM DIAGNOSIS 5-31 4) Disconnect the IAP sensor coupler. 5) Turn the ignition switch to ON. 6) Measure the voltage at the Red wire A and ground. 7) If OK, then measure the voltage at the Red wire A and B/O wire C.
Page 248 5-32 FI SYSTEM DIAGNOSIS 6) Disconnect the ECM coupler. 7) Check the continuity between G/B wire B and terminal B. 8) Also, then check the continuity between B/O wire C and ter- minal J. & IAPS lead wire continuity: Continuity (5) % 09900-25008: Multi-circuit tester set 09900-25009: Needle pointed probe set 6 Tester knob indication: Continuity test (5)
Page 249 FI SYSTEM DIAGNOSIS 5-33 7) Disconnect the ECM coupler. 8) Check the continuity between Red wire A and terminal 6. & IAPS lead wire continuity: Continuity (5) % 09900-25008: Multi-circuit tester set 09900-25009: Needle pointed probe set 6 Tester knob indication: Continuity test (5) ECM coupler (Harness side) When us ing the m ulti-circuit te ster, do no t s trongly touch the t erminal o f t he E CM co upler w ith a ne edle...
Page 250 5-34 FI SYSTEM DIAGNOSIS Step 2 1) Connect the IAP sensor coupler and ECM coupler. 2) Insert the needle pointed probes to the lead wire coupler. 3) Start the engine at idle speed and measure the IAP sensor output voltage at the wire side coupler (between G/B wire B and B/O wire C).
Page 251: C14" (P0120-H/L) Tp Sensor Circuit Malfunction
FI SYSTEM DIAGNOSIS 5-35 “C14” (P0120-H/L) TP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE Output voltage is not within the following • TP sensor circuit open or short. value. • TP sensor malfunction. Difference between actual throttle open- • ECM malfunction. ing and opening calculated by ECM is larger than specified value.
Page 252 5-36 FI SYSTEM DIAGNOSIS 4) Disconnect the TP sensor coupler. 5) Turn the ignition switch to ON. 6) Measure the voltage at the Red wire A and ground. 7) If OK, then measure the voltage at the Red wire A and B/O wire C.
Page 253 FI SYSTEM DIAGNOSIS 5-37 6) Disconnect the ECM coupler. 7) Check the continuity between B/O wire C and terminal J. & TPS lead wire continuity: Continuity (5) % 09900-25008: Multi-circuit tester set 09900-25009: Needle pointed probe set 6 Tester knob indication: Continuity test (5) ECM coupler (Harness side) When us ing the m ulti-circuit te ster, do no t s trongly touch the t erminal o f t he E CM co upler w ith a ne edle...
Page 254 5-38 FI SYSTEM DIAGNOSIS Step 1 (When indicating P0120-L:) 1) Remove the left side cover. ($8-9) 2) Turn the ignition switch to OFF. 3) Check the TP sensor coupler for loose or poor contacts. If OK, then check the TP sensor lead wire continuity. 4) Disconnect the TP sensor coupler.
Page 255 FI SYSTEM DIAGNOSIS 5-39 Step 2 1) Connect the TP sensor coupler and ECM coupler. 2) Insert the needle pointed probes to the lead wire coupler. 3) Turn the ignition switch to ON. 4) Measure the TP sensor output voltage at the coupler (between + Yellow wire B and - B/O wire C) by pushing the throttle lever.
Page 256: C15" (P0115-H/L) Ect Sensor Circuit Malfunction
5-40 FI SYSTEM DIAGNOSIS “C15” (P0115-H/L) ECT SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE Output voltage is not within the following • ECT sensor circuit open or short. value. • ECT sensor malfunction. 0.15 < Sensor voltage 4.85 V • ECM malfunction. P0115 Sensor voltage is higher than specified •...
Page 257 FI SYSTEM DIAGNOSIS 5-41 Step 1 (When indicating P0115-H:) 1) Remove the right side cover. ($8-10) 2) Turn the ignition switch to OFF. 3) Check the ECT sensor coupler for loose or poor contacts. If OK, then check the ECT sensor lead wire continuity. 4) Disconnect the ECT sensor coupler and ECM coupler.
Page 258 5-42 FI SYSTEM DIAGNOSIS Step 1 (When indicating P0115-L:) 1) Remove the right side cover. ($8-10) 2) Turn the ignition switch to OFF. 3) Check the ECT sensor coupler for loose or poor contacts. If OK, then check the ECT sensor lead wire continuity. 4) Disconnect the ECT sensor coupler.
Page 259 FI SYSTEM DIAGNOSIS 5-43 Step 2 1) Turn the ignition switch to OFF. 2) Disconnect the ECT sensor coupler. 3) Measure the ECT sensor resistance. & ECT sensor resistance: Approx. 2.45 kΩ at 20 °C (68 °F) (Terminal – Terminal) % 09900-25008: Multi-circuit tester set 2 Tester knob indication: Resistance (Ω) Refer to page 7-11 for details.
Page 260: C20" (P1752) Diff-Lock Relay Circuit Malfunction
5-44 FI SYSTEM DIAGNOSIS “C20” (P1752) DIFF-LOCK RELAY CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE No voltage is applied to diff-lock motor, although • Diff-lock relay circuit open or short. ignition switch is turned ON, or voltage is applied to • Diff-lock relay malfunction. diff-lock motor, although ignition switch is turned •...
Page 261 FI SYSTEM DIAGNOSIS 5-45 SDS operation check (4WD/diff-lock switch) 1) Check that the 4WD/diff-lock switch (4WD switch 1 and diff-lock switch 2) is turned OFF. 2) Set up the SDS tool. (Refer to the SDS operation manual for further details.) 3) Open the “Data monitor”.
Page 262 5-46 FI SYSTEM DIAGNOSIS 5) Turn the 4WD/ddiff-lock switch (4WD switch and diff-lock switch) to ON position. 6) Check that both “Differential lock position switch signal” 5 and “Differential lock switch signal” 6 are “GND”. If the 4WD/diff-lock switch dose not function properly, inspect the 4WD/diff-lock switch for details.
Page 263: C21" (P0110-H/L) Iat Sensor Circuit Malfunction
FI SYSTEM DIAGNOSIS 5-47 “C21” (P0110-H/L) IAT SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE Output voltage is not within the following • IAT sensor circuit open or short. value. • IAT sensor malfunction. 0.15 < Sensor voltage 4.85 V • ECM malfunction. P0110 Sensor voltage is higher than specified •...
Page 264 5-48 FI SYSTEM DIAGNOSIS Step 1 (When indicating P0110-H:) 1) Remove the left side cover. ($8-9) 2) Turn the ignition switch to OFF. 3) Check the IAT sensor coupler for loose or poor contacts. If OK, then check the IAT sensor lead wire continuity. 4) Disconnect the IAT sensor coupler and ECM coupler.
Page 265 FI SYSTEM DIAGNOSIS 5-49 Step 1 (When indicating P0110-L:) 1) Remove the left side cover. ($8-9) 2) Turn the ignition switch to OFF. 3) Check the IAT sensor coupler for loose or poor contacts. If OK, then check the IAT sensor lead wire continuity. 4) Disconnect the IAT sensor coupler.
Page 266 5-50 FI SYSTEM DIAGNOSIS Step 2 1) Turn the ignition switch to OFF. 2) Disconnect the IAT sensor coupler. 3) Measure the IAT sensor resistance. & IAT sensor resistance: 2.22 – 3.11 kΩ at 20 °C (68 °F) (A Terminal – B Terminal) % 09900-25008: Multi-circuit tester set 2 Tester knob indication: Resistance (Ω) Is the resistance OK?
Page 267: C23" (P1651-H/L) To Sensor Circuit Malfunction
FI SYSTEM DIAGNOSIS 5-51 “C23” (P1651-H/L) TO SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE The sensor voltage should be the fol- • TO sensor circuit open or short. lowing for 2 sec. and more, after ignition • TO sensor malfunction. switch is turned ON.
Page 268 5-52 FI SYSTEM DIAGNOSIS Step 1 (When indicating P1651-H:) 1) Remove the air cleaner box. ($6-10) 2) Turn the ignition switch to OFF. 3) Check the TO sensor coupler for loose or poor contacts. If OK, then check the TO sensor lead wire continuity. 4) Disconnect the TO sensor coupler.
Page 269 FI SYSTEM DIAGNOSIS 5-53 Step 1 (When indicating P1651-L:) 1) Remove the air cleaner box. ($6-10) 2) Turn the ignition switch to OFF. 3) Check the TO sensor coupler for loose or poor contacts. If OK, then check the TO sensor lead wire continuity. 4) Disconnect the TO sensor coupler.
Page 270: C24" (P0351) Ignition Coil Circuit Malfunction
5-54 FI SYSTEM DIAGNOSIS Step 2 1) Connect the TO sensor coupler and ECM coupler. 2) Insert the needle pointed probes to the lead wire coupler. 3) Turn the ignition switch to ON. 4) Measure the voltage at the wire side coupler (between Br/W wire B and B/O wire C).
Page 271: C32" (P0201) Fuel Injector Circuit Malfunction
FI SYSTEM DIAGNOSIS 5-55 “C32” (P0201) FUEL INJECTOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE CKP signal is produced but fuel injector signal is • Injector circuit open or short. interrupted 4 times or more continuously. • Injector malfunction. • ECM malfunction. Fuel Main Fuel pump relay...
Page 272 5-56 FI SYSTEM DIAGNOSIS Step 2 1) Turn the ignition switch to ON. 2) Measure the injector voltage between Y/R wire A and ground. & Injector voltage: Battery voltage (+ Y/R – - Ground) NOTE: Injector voltage can be detected only 3 for seconds after ignition switch is turned ON.
Page 273: C41" (P0230-H/L) Fp Relay Circuit Malfunction
FI SYSTEM DIAGNOSIS 5-57 “C41” (P0230-H/L) FP RELAY CIRCUIT MALFUNCTION 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, • Fuel pump relay malfunction. or voltage is applied to fuel pump, •...
Page 274 5-58 FI SYSTEM DIAGNOSIS Step 1 (When indicating P0230-H:) 1) Remove the seat. ($8-6) 2) Turn the ignition switch to OFF. 3) Check the FP relay coupler for loose or poor contacts. If OK, then check the FP relay. ($5-6) Is the FP relay OK? ECM coupler (wiring harness side) •...
Page 275: Ckp Sensor Inspection
FI SYSTEM DIAGNOSIS 5-59 SENSORS CKP SENSOR INSPECTION The crankshaft position sensor is installed on the generator cover. ($3-82) CKP SENSOR REMOVAL AND INSTALLATION • Remove the generator cover. ($3-16) • Remove the CKP sensor. ($3-82) • Install the generator cover in the reverse order of removal. IAP SENSOR INSPECTION The intake air pressure sensor is installed at the left side of the throttle body.
Page 276: To Sensor Inspection
5-60 FI SYSTEM DIAGNOSIS TO SENSOR INSPECTION The tip-over sensor is located in front of the throttle body. ($5-51) TO SENSOR REMOVAL AND INSTALLATION • Remove the air cleaner box. ($6-10) • Remove the TO sensor from its bracket. ($5-51) •...
Page 277 FUEL SYSTEM AND THROTTLE BODY FUEL SYSTEM AND THROTTLE BODY CONTENTS FUEL DELIVERY SYSTEM ................6- 2 FUEL SYSTEM ....................6- 3 FUEL TANK REMOVAL................6- 3 FUEL TANK INSTALLATION ..............6- 3 FUEL PRESSURE INSPECTION............6- 4 FUEL PUMP INSPECTION ..............6- 5 FUEL DISCHARGE AMOUNT INSPECTION .........6- 5 FUEL PUMP RELAY INSPECTION ............6- 6 FUEL PUMP AND FUEL MESH FILTER ..........6- 7 FUEL TANK PRESSURE CONTROL (FTPC) VALVE...
Page 278: Fuel Delivery System
FUEL SYSTEM AND THROTTLE BODY FUEL DELIVERY SYSTEM The fuel delivery system consists of the fuel tank, fuel pump, fuel filter, fuel feed hose, fuel delivery pipe (including fuel injector) and fuel pressure regulator. There is no fuel return hose. The fuel in the fuel tank is pumped up by the fuel pump and pressurized fuel flows into the injector installed in the fuel delivery pipe.
Page 279: Fuel System
FUEL SYSTEM AND THROTTLE BODY FUEL SYSTEM FUEL TANK REMOVAL • Remove the rear fender. ($8-15) • Remove the fuel tank cover. ($8-15) • Place a rag under the fuel feed hose 1 and disconnect the fuel feed hose 1 from the fuel pump 2. Gasoline is highly flammable and explosive.
Page 280: Fuel Pressure Inspection
FUEL SYSTEM AND THROTTLE BODY FUEL PRESSURE INSPECTION • Remove the left side cover. ($8-9) • Place a rag under the fuel feed hose 1 and remove the fuel feed hose 1 from the fuel delivery pipe. • Install the special tools between the fuel feed hose and fuel delivery pipe.
Page 281: Fuel Pump Inspection
FUEL SYSTEM AND THROTTLE BODY FUEL PUMP INSPECTION Turn the ignition switch ON and check that the fuel pump oper- ates for few seconds. If the fuel pump motor does not make operating sound, inspect the fuel pump circuit connections or inspect the fuel pump relay and tip-over sensor.
Page 282: Fuel Pump Relay Inspection
FUEL SYSTEM AND THROTTLE BODY • Connect a proper lead wire into the fuel pump lead wire cou- pler (fuel pump side) 4 and apply 12 volts to the fuel pump (between terminal A and terminal B) for 10 seconds and measure the amount of fuel discharged.
Page 283: Fuel Pump And Fuel Mesh Filter
FUEL SYSTEM AND THROTTLE BODY FUEL PUMP AND FUEL MESH FILTER FUEL PUMP REMOVAL AND DISASSEMBLY • Remove the fuel tank. ($6-3) • Loosen the fuel pump retainer 1 with the special tool. % 09942-51011: Ring locknut wreuch Gasoline is highly flammable and explosive. Keep heat, spark and flame away.
Page 284: Fuel Tank Pressure Control (Ftpc) Valve Inspection
FUEL SYSTEM AND THROTTLE BODY FUEL PUMP REASSEMBLY AND INSTALLATION Reassemble and install the fuel pump in the reverse order of removal and disassembly. Pay attention to the following points: • Install the fuel pump gasket 1 to the fuel pump. The removed fuel pump gasket must be replaced with a new one to prevent fuel leakage.
Page 285: Throttle Body
FUEL SYSTEM AND THROTTLE BODY THROTTLE BODY CONSTRUCTION 1 Throttle body 5 Injector seal " 2 Fuel delivery pipe 6 Starter valve ITEM N·m kgf-m lb-ft 3 O-ring 7 Throttle cable cover 4 Fuel injector A Fuel delivery pipe mounting screw...
Page 286: Air Cleaner Box Removal
6-10 FUEL SYSTEM AND THROTTLE BODY AIR CLEANER BOX REMOVAL • Remove the front fender. ($8-9) • Disconnect the PCV hose 1. • Loosen the throttle body clamp screw. • Remove the air cleaner box mounting bolts. • Remove the air cleaner box. AIR CLEANER BOX INSTALLATION Install the air cleaner box in the reverse order of removal.
Page 287: Throttle Body Removal
FUEL SYSTEM AND THROTTLE BODY 6-11 THROTTLE BODY REMOVAL • Remove the air cleaner box. ($6-10) • Place a rug under the fuel feed hose 1 and disconnect the fuel feed hose 1 from the fuel delivery pipe. Gasoline is highly flammable and explosive. Keep heat, spark and flame away.
Page 288: Throttle Body Disassembly
6-12 FUEL SYSTEM AND THROTTLE BODY • Remove the starter valve 6, spring 7 and O-ring 8 from the starter cable. • Loosen the throttle body clamp screw and remove the throttle body assembly. THROTTLE BODY DISASSEMBLY • Remove the fuel delivery pipe 1. •...
Page 289 FUEL SYSTEM AND THROTTLE BODY 6-13 * Avoid removing the idle air screw 5. * Never remove the TP/IAP/IAT sensor 6. * Never remove the throttle valve 7. * Never us e car buretor cl eaning chemicals t o t he throttle body assembly.
Page 290: Throttle Body Inspection
6-14 FUEL SYSTEM AND THROTTLE BODY THROTTLE BODY INSPECTION Check following items for any damage or clogging. * O-ring * Throttle valve * Idle air screw THROTTLE BODY REASSEMBLY Reassemble the throttle body in the reverse order of disassem- bly. Pay attention to the following points: •...
Page 291: Fuel Injector Removal
FUEL SYSTEM AND THROTTLE BODY 6-15 • Align the lug on the throttle body with the intake pipe’s cutout. • Adjust the throttle cable play. ($2-13) FUEL INJECTOR REMOVAL • Remove the air cleaner box. ($6-10) • With battery negative cable disconnected, disconnect the injector coupler.
Page 292: Cooling And Lubrication System
COOLING AND LUBRICATION SYSTEM COOLING AND LUBRICATION SYSTEM CONTENTS ENGINE COOLANT ..................7- 2 COOLING CIRCUIT ..................7- 3 COOLING CIRCUIT INSPECTION ............7- 3 RADIATOR AND WATER HOSE ..............7- 4 RADIATOR REMOVAL ................7- 4 RADIATOR CAP INSPECTION .............7- 5 RADIATOR INSPECTION AND CLEANING .........7- 6 RADIATOR INSTALLATION ..............7- 6 WATER HOSE INSPECTION ..............7- 7 RADIATOR RESERVOIR TANK ............7- 7...
Page 293: Engine Coolant
COOLING AND LUBRICATION SYSTEM ENGINE COOLANT At the time of manufacture, the cooling system is filled with a 50:50 mixture of distilled water and ethylene glycol anti-freeze. This 50:50 mixture will provide the optimum corrosion protection and excellent heat pro- tection, and will protect the cooling system from freezing at temperatures above -31 °C (-24 °F).
Page 294: Cooling Circuit
COOLING AND LUBRICATION SYSTEM COOLING CIRCUIT ENGINE COOLANT RESERVOIR THERMOSTAT TEMPERATURE CYLINDER HEAD TANK SENSOR CYLINDER BYPASS COOLING FAN THERMO RADIATOR SWITCH WATER PUMP COOLING CIRCUIT INSPECTION Before removing the radiator and draining the engine coolant, inspect the cooling circuit for tightness. •...
Page 295: Radiator And Water Hose
COOLING AND LUBRICATION SYSTEM RADIATOR AND WATER HOSE RADIATOR REMOVAL • Remove the front fender. ($8-15) • Drain engine coolant. ($2-14) • Disconnect the cooling fan thermo-switch coupler 1 and cool- ing fan motor lead wire coupler 2. • Disconnect the inlet hose 3. •...
Page 296: Radiator Cap Inspection
COOLING AND LUBRICATION SYSTEM • Disconnect the siphon hose 5 and remove the reservoir tank • Remove the cooling fan 7. • Remove the cooling fan thermo-switch 8. • Remove the radiator cover 9. RADIATOR CAP INSPECTION • Remove the radiator cap 1 from the radiator. •...
Page 297: Radiator Inspection And Cleaning
COOLING AND LUBRICATION SYSTEM RADIATOR INSPECTION AND CLEANING • Road dirt or trash stuck on the fins must be removed. • Use of compressed air is recommended for this cleaning. • Fins bent down or dented can be repaired by straightening them with the blade of a small - screwdriver.
Page 298: Water Hose Inspection
COOLING AND LUBRICATION SYSTEM WATER HOSE INSPECTION • Remove the front fender. ($8-15) • Any water hose found in a cracked condition or flattened must be replaced. • Any leakage from the connecting section should be corrected by proper tightening. RADIATOR RESERVOIR TANK REMOVAL AND REMOUNTING •...
Page 299: Cooling Fan
COOLING AND LUBRICATION SYSTEM COOLING FAN REMOVAL • Remove the front fender. ($8-15) • Disconnect the cooling fan motor lead wire coupler 1. • Remove the cooling fan unit 2. • Remove the cushion 3. • Remove the cooling fan 4.
Page 300: Installation
COOLING AND LUBRICATION SYSTEM • Remove the cooling fan motor 5. INSTALLATION Install the cooling fan unit in the reverse order of removal. Pay attention to the following points: • Apply a small quantity of the THREAD LOCK SUPER “1303” on the cooling fan motor shaft.
Page 301: Cooling Fan Thermo-Switch
7-10 COOLING AND LUBRICATION SYSTEM COOLING FAN THERMO-SWITCH REMOVAL • Remove the front fender. ($8-15) • Drain engine coolant. ($2-14) • Disconnect the cooling fan thermo-switch coupler 1. • Remove the cooling fan thermo-switch 2. INSPECTION Check the thermo-switch closing or opening temperatures by testing it at the bench as shown in the figure.
Page 302: Ect Sensor
COOLING AND LUBRICATION SYSTEM 7-11 ECT SENSOR REMOVAL • Remove the left side cover. ($8-4) • Disconnect the ECT sensor coupler 1. • Place a rag under the ECT sensor 2. • Remove the ECT sensor 2. INSPECTION • Check the ECT sensor by testing it at the bench as shown in the figure.
Page 303: Installation
7-12 COOLING AND LUBRICATION SYSTEM INSTALLATION Install the ECT sensor in the reverse order of removal. Pay attention to the following points: • Apply engine coolant to the gasket 1. The removed gasket must be replaced with a new one to prevent engine coolant leakage.
Page 304: Inspection
COOLING AND LUBRICATION SYSTEM 7-13 INSPECTION Inspect the thermostat pellet for signs of cracking. Test the thermostat at the bench for control action, in the follow- ing manner. • Pass a string 1 between flange 2 of thermostat, as shown. •...
Page 305: Installation
7-14 COOLING AND LUBRICATION SYSTEM INSTALLATION Install the thermostat in the reverse order of removal. Pay attention to the following points: • Apply engine coolant to the rubber seal on the thermostat. • Install the thermostat. NOTE: Align the lug on the thermostat A with the groove on the cylin- der head B .
Page 306: Water Pump
COOLING AND LUBRICATION SYSTEM 7-15 WATER PUMP REMOVAL AND DISASSEMBLY NOTE: Before draining engine oil and engine coolant, inspect engine oil and coolant leakage between the water pump and crankcase. If engine oil is leaking, visually inspect the oil seal and O-ring. If engine coolant is leaking, visually inspect the mechanical seal and seal ring.
Page 307 7-16 COOLING AND LUBRICATION SYSTEM • Remove the water pump cover 6. • Remove the O-ring 7. • Remove the E-ring 8, pin holder 9, pin 0 and washer A. • Remove the impeller B from the water pump body C. •...
Page 308: Inspection
COOLING AND LUBRICATION SYSTEM 7-17 • Place a rag over the water pump body. • Remove the oil seal E with a suitable bar. NOTE: If there is no abnormal condition, the oil seal removal is not nec- essary. • Remove the mechanical seal ring F and rubber seal G from the impeller.
Page 309: Reassembly And Installation
The removed oil seal must be replaced with a new one. NOTE: The stamped mark on the oil seal faces outside. • Apply a small quantity of the SUZUKI SUPER GREASE “A” to the oil seal lip. , 99000-25010: SUZUKI SUPER GREASE “A”...
Page 310 , 99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease) • Install the impeller shaft 3 to the water pump body. • Apply SUZUKI SUPER GREASE “A” to the washer and pin holder. , 99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease)
Page 311 7-20 COOLING AND LUBRICATION SYSTEM • Apply engine coolant to the O-ring 8. • Apply SUZUKI SUPER GREASE “A” to the O-ring 9. , 99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease) The removed O-rings must be replaced with new ones.
Page 312 COOLING AND LUBRICATION SYSTEM 7-21 • Tighten the water pump mounting bolts to the specified torque. " Water pump mounting bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft) • Connect the outlet hose and water bypass hose. • Pour engine coolant. ($2-14) •...
Page 313: Lubrication System
7-22 COOLING AND LUBRICATION SYSTEM LUBRICATION SYSTEM OIL FILTER $2-10 OIL PRESSURE $2-33 OIL PUMP $3-58 OIL SUMP FILTER $3-58...
Page 314: Engine Lubrication System Chart
COOLING AND LUBRICATION SYSTEM 7-23 ENGINE LUBRICATION SYSTEM CHART CHAIN CAM FACE ROCKER CYLINDER WALL CYLINDER CLUCH SHOE HEAD COVER & PISTON CONROD ONE-WAY CAMSHAFT BIG END BEARING CLUCH CAMSHAFT CRANKSHAFT (R) JOURNAL CRANKSHAFT BEARING (R) CYLINDER HEAD CRANK CRANK CYLINDER CASE (R) CASE (L)
Page 315: Engine Lubrication System
7-24 COOLING AND LUBRICATION SYSTEM ENGINE LUBRICATION SYSTEM To cylinder head OIL PUMP...
Page 316 COOLING AND LUBRICATION SYSTEM 7-25 EXHAUST SIDE INTAKE SIDE...
Page 317 ...
Page 318 CHASSIS CONTENTS EXTERIOR PARTS ..................8- 2 CONSTRUCTION ...................8- 2 FASTENER REMOVAL AND INSTALLATION ........8- 4 REMOVAL ....................8- 6 FRONT AND REAR WHEELS ..............8-18 CONSTRUCTION ...................8-18 REMOVAL ....................8-18 INSTALLATION ..................8-18 TIRES ......................8-19 TIRE REPLACEMENT ................8-19 FRONT DRIVE SHAFT .................8-21 CONSTRUCTION ...................8-21 REMOVAL AND DISASSEMBLY ............
Page 319 CHASSIS STEERING ....................8-57 CONSTRUCTION .................. 8-57 REMOVAL ..................... 8-58 INSPECTION AND DISASSEMBLY ............8-60 REASSEMBLY AND INSTALLATION ..........8-62 TOE ADJUSTMENT ................8-65 FRONT WHEEL, FRONT BRAKE, FRONT SUSPENSION FRONT DRIVE SHAFT AND STEERING REASSEMBLING INFORMATION ..8-66 REAR DRIVE SHAFT ...................
Page 320: Exterior Parts
CHASSIS EXTERIOR PARTS CONSTRUCTION 1 Front fender 5 Right inner fender 2 Radiator cap lid 6 Left inner fender 3 Right side cover 7 Front box 4 Left side cover 8 Front grill upper cover...
Page 321 CHASSIS 1 Rear fender 4 Left upper mud guard 2 Right mud guard 5 Rear box 3 Left lower mud guard...
Page 322: Fastener Removal And Installation
CHASSIS FASTENER REMOVAL AND INSTALLATION FASTENER (Type A) Removal • Depress the head of fastener center piece 1. • Pull out the fastener a. Installation • Let the center piece stick out toward the head so that the pawls 2 close. •...
Page 323 CHASSIS FASTENER (Type B) Removal • Pry up the head of fastener center piece 1 with a screw driver. • Pull out the fastener a. Installation • Insert the fastener into the installation hole. NOTE: To prevent the pawl 2 from damage, insert the fastener all the way into the installation hole.
Page 324: Removal
CHASSIS REMOVAL SEAT • Move the seat lock 1 upward, and remove the seat. FRONT GRILL AND FRONT CARRIER • Remove the front grill lower cover 1 by removing the right and left clips 2 and bolts 3. • Remove the front grill upper cover clips 4, left and right. •...
Page 325 CHASSIS • Remove the right front carrier mounting bolt. • Remove the front carrier mounting bolts, left and right. • Remove the front carrier B. FRONT FENDER MUD GUARD (For E-17, E-24) • Remove the front fender mud guard clips 1, left and right.
Page 326 CHASSIS • Remove the front fender mud guard 2 left and right. HEADLIGHT • Remove the front grill. ($8-6) • Remove the headlight housing screws, left and right. • Disconnect the headlight couplers, left and right. • Remove the headlight 1, left and right. FRONT GRIP BAR •...
Page 327 CHASSIS • Remove the front grip bar 1. FRONT FENDER • Remove the seat. ($8-6) • Remove the front carrier. ($8-6) • Remove the air cleaner box cover 1. • Remove the left upper mud guard. • Remove the left side cover. •...
Page 328 8-10 CHASSIS • Remove the left inner fender 5. • Remove the right side cover 6. • Remove the right mud guard clips 7, screws 8 and bolt 9. • Remove the right inner fender 0. • Disconnect the power source socket coupler A.
Page 329 CHASSIS 8-11 • Remove the front fender. FRONT BOX • Remove the front box cap 1. • Disconnect the front box cap wire. • Remove the front box mounting screw. • Turn the front box counterclockwise and remove it. • Remove the cushion 2 from the front box as shown in the illustration.
Page 330 8-12 CHASSIS • Remove the left side cover 2. • Remove the right side cover 3. MUD GUARD • Remove the left side cover. ($above) • Remove the left mud guard 1.
Page 331 CHASSIS 8-13 • Remove the right side cover. ($8-12) • Remove the right mud guard 2. FOOTREST • Remove the side cover. ($8-12) • Remove the mud guard. ($above) • Remove the rear brake cable clamp 1. • Remove the right footrest 2. REAR FENDER MUD GUARD (For E-17, E-24) •...
Page 332 8-14 CHASSIS REAR CARRIER • Remove the rear carrier. REAR BOX • Remove the rear box 1.
Page 333 CHASSIS 8-15 REAR FENDER AND FUEL TANK COVER • Remove the seat. ($8-6) • Remove the rear carrier. ($8-14) • Remove the mud guard, left and right. • Remove the side cover, left and right. • Disconnect the - battery cable first, and then + battery cable. •...
Page 334 8-16 CHASSIS INSTALLATION Install the exterior parts in the reverse order of removal. Pay attention the to following points. • Apply a small quantity of THREAD LOCK “1342” to the front grip bar mounting bolts. / 99000-32050: THREAD LOCK “1342” •...
Page 335 CHASSIS 8-17 • Apply a small quantity of THREAD LOCK “1342” to the rear carrier mounting bolts. / 99000-32050: THREAD LOCK “1342”...
Page 336: Front And Rear Wheels
8-18 CHASSIS FRONT AND REAR WHEELS CONSTRUCTION " 1 Front tire 5 Rear wheel ITEM N·m kgf-m lb-ft 2 Front wheel 6 Rear wheel air valve 3 Front wheel air valve A Front wheel set nut 43.5 4 Rear tire B Rear wheel set nut 43.5 REMOVAL...
Page 337: Tires
CHASSIS 8-19 TIRES TIRE REPLACEMENT • Remove the front and rear wheels. ($8-18) • After removing the air valve caps, release the tire pressure by depressing the valves. • Dismount the bead from the rim completely as shown. • Separate the tire from the rim using a set of tire levers and rim protectors.
Page 338 8-20 CHASSIS • When installing each tire, make sure the arrow A on the tire points in the direction of rotation. Also, make sure the outer side of the wheel rim is facing outward. NOTE: For inspecting the tires, refer to page 2-26. Inspect the valve cores, before installing.
Page 339: Front Drive Shaft
CHASSIS 8-21 FRONT DRIVE SHAFT CONSTRUCTION 1 Circlip 6 Inner boot band (small) 2 Snap ring 7 Drive shaft 3 Stopper ring 8 Outer boot band (small) 4 Inner boot band (large) 9 Outer boot 5 Inner boot 0 Outer boot band (large) REMOVAL AND DISASSEMBLY •...
Page 340 8-22 CHASSIS • Remove the boot bands of the differential side joint. • Slide the boot toward the center of the front drive shaft and remove the stopper ring from the outer race. • Separate the outer race from the front drive shaft. •...
Page 341: Inspection And Reassembly
CHASSIS 8-23 INSPECTION AND REASSEMBLY Inspect the boots for wear or damage. If any defects are found, replace them with new ones. Inspect the axle play by using a push-and-pull motion as shown. NOTE: * Clean the disassembled parts (except for the boots). After Cleaning, completely dry the parts using compressed air.
Page 342 8-24 CHASSIS • Install the snap ring. • Apply grease to the entire surface of the cage and the inside of the outer race. Position Wheel side Differential side Grease Quantity 40 g 70 g NOTE: The tube of joint grease is included in the wheel side boot set or differential side joint set of spare parts.
Page 343: Installation
The rem oved st opper ring m ust be re placed with a new one. • Apply SUZUKI SUPER GREASE “A” to the spline. , 99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease) Be careful not to damage the front drive train (differen- tial) gear case oil seal.
Page 344: Front Brake
8-26 CHASSIS FRONT BRAKE CONSTRUCTION Brake master cylinder reser- Dust seal voir cap 2 Diaphragm E Front brake caliper 3 Brake master cylinder clamp F Brake caliper holder " 4 Boot G Front brake pad ITEM N·m kgf-m lb-ft 5 Piston/cup set H Pad spring 6 Cup A Brake master cylinder clamp bolt...
Page 345 CHASSIS 8-27 * 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 brake fluids. * Do not use any brake fluid taken from old, used or unsealed containers. Never reuse brake fluid left over from the last servicing or which has been stored for a long periods of time.
Page 346: Brake Pad Replacement
8-28 CHASSIS BRAKE PAD REPLACEMENT • Place the vehicle on level ground. • Support the vehicle with a jack or wooden block. • Remove the front wheel. ($8-18) • Remove the brake caliper mounting bolts 1 and brake pad mounting pins 2. NOTE: Before installing the brake pads, inspect the pad mounting pins for wear.
Page 347: Brake Fluid Replacement
CHASSIS 8-29 BRAKE FLUID REPLACEMENT • Place the vehicle on level ground and keep the handlebar straight. • Remove the brake master cylinder reservoir cap and dia- phragm. • Suck up the old brake fluid as much as possible. • Fill the reservoir with new brake fluid. ( Specification and classification: DOT 4 •...
Page 348 8-30 CHASSIS • Remove the caliper holder 1. • Remove the pad spring 2. • Place a rag over the brake caliper piston to prevent it from popping out and then force out the piston using compressed air. Do not use high pressure air to prevent brake caliper piston damage.
Page 349: Brake Caliper Inspection
CHASSIS 8-31 BRAKE CALIPER INSPECTION BRAKE CALIPER Inspect the brake caliper cylinder wall for nicks, scratches or other damage. If any defects are found, replace the brake cali- per with a new one. BRAKE CALIPER PISTON Inspect the brake caliper piston for any scratches or damage. If any defects are found, replace the piston with a new one.
Page 350: Brake Caliper Reassembly And Installation
* Apply brake fluid to the dust seal, brake caliper bore and piston before reassembly. PISTON SEAL • Apply SUZUKI SILICONE GREASE to the piston seal. 8 99000-25100: SUZUKI SILICONE GREASE • Install the piston seal as shown. 1 Dust seal...
Page 351 " Caliper holder pin: 17 N·m (1.7 kgf-m, 12.5 lb-ft) Caliper holder slide pin: 22 N·m (2.2 kgf-m, 16.0 lb-ft) • Apply SUZUKI SILICON GREASE to the brake caliper holder pin and brake caliper holder slide pin. 8 99000-25100: SUZUKI SILICONE GREASE •...
Page 352: Brake Disc Removal And Disassembly
8-34 CHASSIS • Install the front brake hose union bolt 8 with the front brake hose washers 9. • Tighten the front brake hose union bolt 8 to the specified torque. " Front brake hose union bolt: 25 N·m (2.5 kgf-m, 18.0 lb-ft) * The r emoved f ront br ake ho se w ashers mu st b e replaced wit h ne w ones t o pr event brake f luid l eak- age.
Page 353: Brake Disc Inspection
CHASSIS 8-35 BRAKE DISC INSPECTION • Remove the front wheel. ($8-18) • Remove the brake caliper. ($8-29) Inspect the brake disc for cracks or damage and measure the thickness with the micrometer. If any defects are found, if the thickness is less than the service limit, replace the brake disc with a new one.
Page 354: Master Cylinder Removal And Disassembly
8-36 CHASSIS MASTER CYLINDER REMOVAL AND DISASSEMBLY • Place a rag underneath the front brake hose union bolt on the brake master cylinder to catch any spilled brake fluid. Remove the front brake hose union bolt and disconnect the front brake hose. Immediately a nd c ompletely wi pe o ff an y brake fluid contacting any p art o f the veh icle.
Page 355 CHASSIS 8-37 • Remove the dust boot 7 and circlip 8. • Remove the piston/secondary cup, primary cup and spring. 9 Secondary cup 0 Piston A Primary cup B Spring...
Page 356: Brake Master Cylinder Inspection
8-38 CHASSIS BRAKE MASTER CYLINDER INSPECTION BRAKE MASTER CYLINDER Inspect the brake master cylinder bore for any scratches or damage. If any defects are found, replace the brake master cyl- inder with a new one. PISTON AND RUBBER PARTS Inspect the piston surface, primary cup, secondary cup and dust boot for any scratches, wear or damage.
Page 357 CHASSIS 8-39 • Align the brake master cylinder holder mating surface A with the punched mark B on the handlebars and tighten the upper clamp bolt C first and lower clamp bolt D. " Brake master cylinder clamp bolt: 11 N·m (1.1 kgf-m, 8.0 lb-ft) C Upper clamp bolt D Lower clamp bolt E Clearance...
Page 358: Front Suspension
8-40 CHASSIS FRONT SUSPENSION CONSTRUCTION 1 Front shock absorber A Snap ring Front upper wishbone Cotter pin Front lower wishbone Front shock absorber mounting upper bolt " Steering knuckle Front shock absorber mounting ITEM N·m kgf-m lb-ft lower nut 5 Tie rod C Front wishbone arm pivot nut (upper) 40.0 6 Tie rod end...
Page 359: Removal
CHASSIS 8-41 REMOVAL • Remove the front grill lower cover. ($8-6) • Remove the front wheel. ($8-18) • Remove the cotter pin. • Loosen the hub nut 1. • Remove the front brake caliper. ($8-29) • Remove the front hub nut 1. •...
Page 360 8-42 CHASSIS • Remove the tie rod end 6 with a commercially available bear- ing joint remover 7. • Remove the cotter pins and steering knuckle end nuts. • Remove the steering knuckle 8 with a commercially available bearing joint remover 9. •...
Page 361: Inspection And Disassembly
CHASSIS 8-43 INSPECTION AND DISASSEMBLY FRONT DRIVE SHAFT COVER Inspect the front drive shaft cover for wear or damage. If any defects are found, replace the front drive shaft cover with a new one. BRAKE DISC COVER Inspect the brake disc cover for damage. If any defects are found, replace the brake disc cover with a new one.
Page 362 8-44 CHASSIS Inspect the front upper wishbone arm bush for wear or damage. If any defects are found, replace the front upper wishbone arm bush with new ones. FRONT UPPER WISHBONE ARM DUST SEAL Inspect the front upper wishbone arm dust seal for wear or dam- age.
Page 363 CHASSIS 8-45 • Remove the front upper wishbone arm knuckle end 2 with the special tool. % 09913-70210: Bearing installer set (-30) FRONT LOWER WISHBONE ARM Inspect the front lower wishbone arm for bend or damage. If any defects are found, replace the front lower wishbone arm with new one.
Page 364 8-46 CHASSIS • Remove the front lower knuckle end 2 with the special tools and vise as shown. % 09913-70210: Bearing installer set -30 09941-53610: Front fork installer hammer STEERING KNUCKLE DUST SEAL • Remove the steering knuckle dust seals with the special tool. % 09913-50121: Oil seal remover FRONT HUB BEARING Inspect the inner race play of the front hub bearing by hand...
Page 365: Reassembly And Installation
CHASSIS 8-47 • Remove the hub bearing with the special tool. % 09921-20240: Bearing remover set (-30) REASSEMBLY AND INSTALLATION Reassemble and install the front suspension in the reverse order of removal and disassembly. Pay attention to the following points: STEERING KNUCKLE •...
Page 366 % 09913-70210: Bearing installer set (-55) The r emoved d ust se al mus t be r eplaced wi th a n ew one. • Apply SUZUKI SUPER GREASE “A” to the lip of the dust seals. , 99000-25010: SUZUKI SUPER GREASE “A”...
Page 367 • Install the front upper wishbone arm bush with the special tool. % 09913-70210: Bearing installer set (-30) • Apply SUZUKI SUPER GREASE “A” to the inside of the front upper wishbone arm bush, lip of dust seals and spacer. , 99000-25010: SUZUKI SUPER GREASE “A”...
Page 368 9 99000-32130: THREAD LOCK SUPER “1360” " Front brake disk cover mounting bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft) • Apply SUZUKI SUPER GREASE “A” to the wheel hub spline. , 99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease) • Install the wheel hub 1, washer 2 and front hub nut 3.
Page 369 CHASSIS 8-51 NOTE: Install the washer 2 as shown in the illustration. Front wheel Front wheel side hub side • Install the front brake caliper. ($8-33) • Tighten the front wheel set nuts 4 to the specified torque. " Front wheel set nut: 60 N·m (6.0 kgf-m, 43.5 lb-ft) SPRING PRE-LOAD ADJUSTMENT After installing the front shock absorbers, adjust the spring pre- load.
Page 370: Handlebars
8-52 CHASSIS HANDLEBARS CONSTRUCTION 1 Handlebar 9 Rear brake lever 2 Handlebar upper clamp 0 Grip " 3 Steering shaft A Handlebar upper clamp bolt ITEM N·m kgf-m lb-ft 4 Throttle cable B Rear brake lever holder clamp bolt 5 Rear brake cable C Throttle lever case bolt 19.0 6 Starter cable...
Page 371: Removal
CHASSIS 8-53 REMOVAL • Remove the right grip 1. • Remove the throttle lever case 2. • Remove the brake master cylinder 3 from the handlebars. ($8-36) • Disconnect the brake hose clamp. • Remove the left grip 4. • Remove the left handlebar switch box 5. •...
Page 372: Inspection
8-54 CHASSIS • Remove the handlebars 9. INSPECTION Inspect the handlebars for distortion or damage. If any defects are found, replace the handlebars with a new one. INSTALLATION Install the handlebars in the reverse order of removal. Pay atten- Apply handle tion to the following points: grip bond.
Page 373 " Rear brake lever holder clamp bolt: 10 N·m (1.0 kgf-m, 7.5 lb-ft) • Apply the grease to the end of starter cable. , 99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease) • When installing the left handle switch, engage the stopper F...
Page 374 8-56 CHASSIS • Tighten the left handle switch screw. • Install the brake master cylinder. ($8-38) • Align the punch mark H on the handlebars with the mating surface I of throttle lever case. • Tighten the throttle lever case bolts to the specified torque. "...
Page 375: Steering
CHASSIS 8-57 STEERING CONSTRUCTION " 1 Handlebar 9 Tie rod ITEM N·m kgf-m lb-ft 2 Handlebar upper clamp 0 Tie rod end 3 Steering shaft A Handleber upper clamp bolt 19.0 4 Steering shaft holder B Handleber holder nut 43.5 5 Dust seal C Steering shaft holder bolt 16.5...
Page 376: Removal
8-58 CHASSIS REMOVAL • Remove the front wheels. ($8-18) • Remove the front fender. ($8-9) • Remove the handlebars. ($8-53) • Remove the handlebar holder nuts, washers and handlebar holder 1. • Remove the cotter pins, tie rod end nuts and spring washers. •...
Page 377 CHASSIS 8-59 • Remove the cotter pins, tie rod end nuts and spring washers. • Remove the steering arm plate 6 with a commercially avail- able ball bearing joint remover 3. • Disconnect the brake hose clamp. • Remove the cable clamp. •...
Page 378: Inspection And Disassembly
8-60 CHASSIS INSPECTION AND DISASSEMBLY STEERING SHAFT HOLDER BUSH Inspect the bush for wear or damage. If any defects are found, replace the bushing with a new one. TIE ROD Inspect the tie rod for distortion or damage. If any defects are found, replace the tie rod with a new one.
Page 379 CHASSIS 8-61 STEERING SHAFT HOLDER Inspect the steering shaft holders for wear or damage. If any defects are found, replace the steering shaft holders with new ones. STEERING SHAFT BUSH AND DUST SEAL Inspect the steering shaft bush 1 and dust seal 2 for wear and damage.
Page 380: Reassembly And Installation
, 99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease) • Install the steering shaft holder bush to the steering shaft. • Apply SUZUKI SUPER GREASE “A” to the bush and dust seal. , 99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease) •...
Page 381 CHASSIS 8-63 • Apply SUZUKI SUPER GREASE “A” to the dust seal and O- ring. The removed O-ring must be replaced with a new one. , 99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease) • Install the dust seal and O-ring to the steering shaft.
Page 382 8-64 CHASSIS TIE ROD • Tighten the tie rod end nuts to the specified torque. " Tie rod end nut: 29 N·m (2.9 kgf-m, 21.0 lb-ft) • Install the cotter pins. The r emoved co tter pi ns mu st be r eplaced wi th n ew ones.
Page 383: Toe Adjustment
CHASSIS 8-65 TOE ADJUSTMENT Adjust the toe-out as follows: • Place the vehicle on level ground and set the handlebars straight. • Make sure all the tires are inflated to the standard pressure. ($2-26) • Place 75 kg (165 lbs) weight on the seat. Forward •...
Page 384: Front Wheel, Front Brake, Front Suspension Front Drive Shaft And Steering Reassembling Information
8-66 CHASSIS FRONT WHEEL, FRONT BRAKE, FRONT SUSPENSION FRONT DRIVE SHAFT AND STEERING REASSEMBLING INFORMATION " ITEM N·m kgf-m lb-ft ITEM N·m kgf-m lb-ft ITEM N·m kgf-m lb-ft 19.0 32.5 21.0 43.5 40.0 43.5 16.5 43.5 11.0 49.5 21.0 47.0 21.0 17.0 123.0...
Page 385: Rear Drive Shaft
CHASSIS 8-67 REAR DRIVE SHAFT CONSTRUCTION 1 Circlip 6 Inner boot band (small) 2 Snap ring 7 Drive shaft 3 Stopper ring 8 Outer boot band (small) 4 Inner boot band (large) 9 Outer boot 5 Inner boot 0 Outer boot band (large) REMOVAL •...
Page 386 8-68 CHASSIS • Remove the boot bands of the final gear side joint. • Slide the boot toward the center of the rear drive shaft and remove the stopper ring from the outer race. • Separate the outer race from the rear drive shaft. •...
Page 387: Inspection And Reassembly
CHASSIS 8-69 INSPECTION AND REASSEMBLY Inspect the boots for wear or damage. If any defects are found, replace them with new ones. Inspect the axle play by using a push-and-pull motion as shown. NOTE: * Clean the disassembled parts (except for the boot). After cleaning, completely dry the parts using compressed air.
Page 388 8-70 CHASSIS • Install the snap ring. • Apply grease to the entire surface of the cage and the inside of the outer race. Position Wheel side Final gear side Grease Quantity 40 g 65 g NOTE: The tube of joint grease is included in the wheel side boot set or final gear side joint set of spare parts.
Page 389: Installation
• Install the stopper ring 3 into the groove of drive shaft spline. The rem oved st opper ring m ust be re placed with a new one. • Apply SUZUKI SUPER GREASE “A” to the spline. , 99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease) Be careful not to damage the front drive case oil seal.
Page 390: Rear Brake
8-72 CHASSIS REAR BRAKE CONSTRUCTION 1 Steel plates 8 Rear brake cam lever 2 Friction plates 9 Rear brake case 3 Rear brake return spring 0 Bearing " 4 Rear brake pressure plate A Snap ring ITEM N·m kgf-m lb-ft 5 Ball B Oil seal 6 Gasket...
Page 391: Removal And Disassembly
CHASSIS 8-73 REMOVAL AND DISASSEMBLY • Drain the final gear oil. ($2-12) • Remove the rear suspension. ($8-84) • Remove the rear drive shaft. ($8-67) • Remove the rear brake adjust nuts 1 and 2. • Remove the rear brake cables •...
Page 392 8-74 CHASSIS • Remove the trailer towing 5. • Remove the rear final gear case assembly mounting bolts. • Remove the final gear case assembly for a while back. • Remove the rear brake cam lever 6, limit indicator 7 and return spring 8.
Page 393 CHASSIS 8-75 • Remove the rear brake friction plate and steel plate A. • Remove the rear brake pressure plate B and balls. • Remove the rear brake cam shaft C. • Unlock the rear drive gear shaft lock-nut with a chisel. •...
Page 394 8-76 CHASSIS • Remove the rear drive gear shaft F, with plastic mallet. • Remove the oil seals with the special tool. % 09913-50121: Oil seal remover • Remove the snap ring. BEARING INSPECTION Rotate the bearing inner race by finger to inspect for abnormal Play play, noise and smooth rotation while the bearing is in the rear Play...
Page 395: Inspection
CHASSIS 8-77 INSPECTION REAR BRAKE CAM LEVER Inspect the rear brake cam lever for wear or damage. If any defects are found, replace rear brake came lever with a new one. REAR BRAKE CAM SHAFT Inspect the rear brake cam shaft for wear or damage. If any defects are found, replace rear brake cam shaft with a new one.
Page 396 8-78 CHASSIS BRAKE PLATE RETURN SPRING Measure the free length A. If the free length A is shorter than the limit, replace the spring with a new one. & Brake plate return spring: Service Limit: 20.2 mm (0.80 in) Replace the removed plate stopper 1 with a new one. REAR BRAKE PRESSURE PLATE Inspect the rear blake pressure plate for wear or damage.
Page 397: Reassembly
• Apply WATER RESISTANCE GREASE to the oil seals. 1 99000-25160: WATER RESISTANCE GREASE • Install the rear brake cam shaft 2. • Apply SUZUKI SUPER GREASE “A” to the rear brake cam shaft. ,99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease)
Page 398 8-80 CHASSIS • Install the rear propeller shaft coupling 5. • Install the washer and rear drive gear shaft lock-nut 6. • Tighten the rear drive gear shaft lock-nut 6 to the specified torque with the special tool. % 09924-52480: Fixed propeller shaft holder "...
Page 399: Remounting
CHASSIS 8-81 • Install the rear brake case. • Apply a small quantity THREAD LOCK SUPER “1360” to the rear brake case bolts. • Tighten the bolts diagonally to the specified torque. " Rear brake case bolt: 26 N·m (2.6 kgf-m, 19.0 lb-ft) 9 99000-32130: THREAD LOCK SUPER “1360”...
Page 400 8-82 CHASSIS • Install the final gear case assembly to the frame. • Tighten the rear final gear case mounting nut 1 to the speci- fied torque. " Final gear case mounting nut: 65 N·m (6.5 kgf-m, 47.0 lb-ft) • Tighten the trailer towing bolts to the specified torque. "...
Page 401: Rear Suspension
CHASSIS 8-83 REAR SUSPENSION CONSTRUCTION 1 Rear shock absorber 9 Rear knuckle 2 Rear stabilizer bar 0 Hub bearing 3 Rear stabilizer bush A Snap ring " 4 Rear stabilizer bracket B Dust seal ITEM N·m kgf-m lb-ft 5 Rear stabilizer link A Rear shock absorber mounting nut 6 Upper wishbone arm B Rear wishbone arm pivot nut...
Page 402: Removal
8-84 CHASSIS REMOVAL • Remove the rear wheel. ($8-18) • Remove the rear drive shaft cover 1. • Remove the cotter pin and rear hub nut. • Remove the rear wheel hub 2. • Remove the rear stabilizer link nuts. •...
Page 403 CHASSIS 8-85 • Remove the rear shock absorber 6. • Remove the rear knuckle 7. • Remove the rear upper wishbone arm 8. • Remove the rear lower wishbone arm 9.
Page 404: Inspection And Disassembly
8-86 CHASSIS INSPECTION AND DISASSEMBLY REAR DRIVE SHAFT COVER Inspect the rear drive shaft cover for wear or damage. If any defects are found, replace the rear drive shaft cover with a new one. REAR SHOCK ABSORBER Inspect the rear shock absorber for oil leakage or damage. If any defects are found, replace the rear shock absorber with a new one.
Page 405 CHASSIS 8-87 REAR UPPER WISHBONE ARM Inspect the rear upper wishbone arm wear or damage. If any defects are found, replace the rear upper wishbone arm with a new one. REAR UPPER WISHBONE ARM BUSH Inspect the rear upper wishbone arm bush for wear or damage. If any defects are found, replace the rear upper wishbone arm bush with new ones.
Page 406 8-88 CHASSIS REAR WISHBONE ARM DUST SEAL Inspect the rear wishbone arm dust seal for wear or damage. If any defects are found, replace the rear wishbone arm dust seal with a new one. REAR KNUCKLE Inspect the rear knuckle for wear or damage. If any defects are found, rear knuckle with a new one.
Page 407 CHASSIS 8-89 • Remove the snap ring 1. • Remove the rear hub bearing 2 with the special tool. % 09921-20240: Bearing remover set REAR KNUCKLE DUST SEAL Inspect the rear knuckle dust seal for wear or damage. If any defects are found, replace the rear knuckle dust seal with a new one.
Page 408: Reassembly And Installation
Press fit the rear upper wishbone arm bush with the special tool. % 09924-84521: Bearing installer set • Apply SUZUKI SUPER GREASE “A” to the inside of rear upper wishbone arm bush, lip of the dust seals and spacer. , 99000-25010: SUZUKI SUPER GREASE “A”...
Page 409 % 09924-74510: Bearing and oil seal instaler handle 09926-27610: Oil seal installer 09944-66030: Oil seal installer • Apply SUZUKI SUPER GREASE “A” to the lip of oil seals. , 99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease) • Apply SUZUKI SUPER GREASE “A” to the inside of rear knuckle bush, lip of the dust seals and spacer.
Page 410 8-92 CHASSIS REAR SUSPENSION • Install the rear wishbone arm (upper and lower) and tighten the rear wishbone arm pivot nut (upper and lower) to the specified torque. " Rear wishbone arm pivot nut (upper and lower): 60 N·m (6.0 kgf-m, 43.5 lb-ft) •...
Page 411 • Tighten the rear stabilizer link nuts to the specified torque. " Rear stabilizer link nut: 34 N·m (3.4 kgf-m, 24.5 lb-ft) • Apply SUZUKI SUPER GREASE “A” to the wheel hub spline. , 99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease) •...
Page 412 8-94 CHASSIS • Tighten the rear wheel set nuts 6 to the specified torque. " Rear wheel set nut: 60 N·m (6.0 kgf-m, 43.5 lb-ft) SPRING PRE-LOAD ADJUSTMENT After installing the rear shock absorber, adjust the spring pre- load. Position “1” provides the minimum spring pre-load. Position “5”...
Page 413: Rear Wheel Rear Suspension And Rear Drive Shaft Reassembling Information
CHASSIS 8-95 REAR WHEEL REAR SUSPENSION AND REAR DRIVE SHAFT REASSEMBLING INFORMATION " ITEM N·m kgf-m lb-ft ITEM N·m kgf-m lb-ft 43.5 43.5 43.5 43.5 13.0 94.0 43.5 43.5 43.5 24.5...
Page 414: Transfer Gear Shift Lever
8-96 CHASSIS TRANSFER GEAR SHIFT LEVER CONSTRUCTION " 1 Transfer gear shift lever assembly 3 Knob ITEM N·m kgf-m lb-ft 2 Rod 4 Mounting bolt...
Page 415: Removal
CHASSIS 8-97 REMOVAL • Remove the front fender. ($8-9) • Remove the transfer gear shift lever mounting bolts. • Keep the gear shift arm 1 in the “N” position. 30 ˚ 33 ˚ 33 ˚ • Loosen the bolt 2 and remove the gear shift arm 1. •...
Page 416: Installation
INSTALLATION Install the transfer gearshift lever in the reverse order of removal. Pay attention to the following points: • Apply SUZUKI SUPER GREASE to the pivot of the shift lever assembly. , 99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease) •...
Page 417 ...
Page 418: Electrical System
ELECTRICAL SYSTEM CONTENTS CAUTIONS IN SERVICING ................9- 2 CONNECTOR ..................9- 2 COUPLER ....................9- 2 CLAMP....................9- 2 FUSE .......................9- 2 SEMI-CONDUCTOR EQUIPPED PART..........9- 3 BATTERY....................9- 3 CONNECTING THE BATTERY ..............9- 3 WIRING PROCEDURE ................9- 3 USING THE MULTI-CIRCUIT TESTER ..........9- 4 LOCATION OF ELECTRICAL COMPONENTS ...........
Page 419 ELECTRICAL SYSTEM LAMPS ......................9-33 HEADLIGHT ....................9-33 HEADLIGHT INSTALLATION..............9-34 BRAKE LIGHT/TAILLIGHT..............9-35 REVERSING LIGHT (FOR E-17) ............9-35 DIODE ......................9-36 REVERSING LIGHT RELAY (FOR E-17) .............9-36 SWITCHES ....................9-37 BATTERY .....................9-38 SPECIFICATIONS...................9-38 INITIAL CHARGING................9-38 SERVICING .....................9-40 RECHARGING OPERATION ..............9-40...
Page 420: Cautions In Servicing
ELECTRICAL SYSTEM CAUTIONS IN SERVICING CONNECTOR • When connecting a connector, be sure to push it in until a click is felt. Click • Inspect the connector for corrosion, contamination and break- age in its cover. COUPLER Click • With a lock type coupler, be sure to release the lock when dis- connecting, and push it in fully till the lock works when con- necting.
Page 421: Battery
ELECTRICAL SYSTEM SEMI-CONDUCTOR EQUIPPED PART • Be careful not to drop the part with a semi-conductor built in INCORRECT such as a ECM. • When inspecting this part, follow inspection instruction strictly. Neglecting proper procedure may cause damage to this part. BATTERY •...
Page 422: Using The Multi-Circuit Tester
ELECTRICAL SYSTEM USING THE MULTI-CIRCUIT TESTER • Properly use the multi-circuit tester + and - probes. Improper use can cause damage to the vehicle and tester. • If the voltage and current values are not known, begin mea- suring in the highest range. •...
Page 423: Main Fuse
ELECTRICAL SYSTEM LOCATION OF ELECTRICAL COMPONENTS 1 Battery 9 Starter motor 2 Main fuse 0 4WD/diff-lock switch 3 Starter relay A Brake lever switch (R) 4 Fuse box B Ignition switch 5 Neutral relay C Ignition coil 6 Fuel pump relay D Rear brake switch 7 ECM E Gear position switch...
Page 424 ELECTRICAL SYSTEM 1 Cooling fan thermo-switch A Regulator/rectifier 2 4WD/diff-lock actuator diode B Parking brake relay 3 Neutral relay diode C Diff-lock relay 4 Starter button D Cooling fan 5 Dimmer switch E 4WD/diff-lock actuator 6 Engine stop switch F Speed sensor 7 Over ride switch G Generator 8 Brake lever switch (L)
Page 425: Charging System
ELECTRICAL SYSTEM CHARGING SYSTEM Regulator/Rectifier IG. switch Generator TROUBLESHOOTING Battery runs down quickly Step 1 1) Check accessories which use excessive amounts of electricity. Are accessories being installed? Remove accessories. Go to Step 2. Step 2 1) Check the battery for current leaks. ($9-8) Is the battery current leakage OK? Go to Step 3.
Page 426: Inspection
ELECTRICAL SYSTEM Step 5 1) Measure the generator no-load performance. ($9-10) Is the generator no-load performance OK? Go to Step 6. Faulty generator. Step 6 1) Inspect the regulator/rectifier. ($9-10) Is the regulator/rectifier OK? Go to Step 7. Faulty regulator/rectifier. Step 7 1) Inspect wirings.
Page 427 ELECTRICAL SYSTEM REGULATED VOLTAGE • Remove the seat. ($8-6) • Remove the battery stay 1. • Start the engine, turn the ignition switch to LIGHT (<) and the dimmer switch to HI and run the engine at 5 000 r/min. Measure the DC voltage between the + and - battery termi- nals with the multi-circuit tester.
Page 428 9-10 ELECTRICAL SYSTEM GENERATOR NO-LOAD PERFORMANCE • Remove the rear fender. ($8-15) • Disconnect the generator coupler. • Start the engine and keep it running at 5 000 r/min. Measure the voltage between three lead wires with the multi-cir- cuit tester. If the tester indicates under the specified value, replace the gen- erator with a new one.
Page 429: Fuse
ELECTRICAL SYSTEM 9-11 STARTER SYSTEM Starter Engine Ignition stop switch Ignition button switch fuse Main Neutral relay fuse Starter motor Neutral indicator light Parking B/Bl brake Bl/B Starter relay relay Bl/B Neutral Gear diode position switch Parking brake switch TROUBLESHOOTING Make sure that the fuses are not blown and the battery is fully-charged before diagnosing.
Page 430: Starter Motor Removal
9-12 ELECTRICAL SYSTEM Step 3 1) Measure the starter relay voltage at the starter relay connectors (between Y/B + and B/W -) when the starter button is pushed. Is a voltage OK? Go to Step 4. • Faulty engine stop switch. •...
Page 431: Starter Motor Disassembly
ELECTRICAL SYSTEM 9-13 STARTER MOTOR DISASSEMBLY • Disassemble the starter motor as shown in the illustration. " 1 O-ring 5 Housing end (outside) ITEM N·m kgf-m lb-ft 2 Housing end (inside) A Lead wire connecting nut 3 Starter motor case B Mounting bolt 4 Armature...
Page 432: Starter Motor Inspection
9-14 ELECTRICAL SYSTEM STARTER MOTOR INSPECTION CARBON BRUSH Inspect the brushes for abnormal wear, cracks, or smoothness in the brush holder. If any damages are found, replace the brush assembly with a new one. Measure the length A of the carbon brushes using a vernier cal- ipers.
Page 433: Starter Motor Reassembly
STARTER MOTOR REASSEMBLY Reassemble the starter motor in the reverse order of disassem- bly. Pay attention to the following points: • Apply SUZUKI SUPER GREASE “A” to the lip of the oil seal. , 99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease) •...
Page 434: Starter Relay Inspection
9-16 ELECTRICAL SYSTEM STARTER RELAY INSPECTION • Remove the seat. ($8-6) • Disconnect the battery - lead wire from the battery. • Remove the starter relay cover 1. • Disconnect the starter motor lead wire, battery lead wire and starter relay coupler 2. •...
Page 435: Parking Brake Relay Inspection
ELECTRICAL SYSTEM 9-17 PARKING BRAKE RELAY INSPECTION • Remove the rear fender. ($8-15) First, check the insulation between A and B terminals with the multi-circuit tester. Then apply 12 V to terminals C and D (+ to C and - to D) and check the continuity between A and B. If there is no continuity, replace the parking brake relay with a new one.
Page 436: Ignition System
9-18 ELECTRICAL SYSTEM IGNITION SYSTEM Engine Ignition stop Fuse Fuse switch Ignition coil switch (30A) (15A) Regulator /rectifier Generator switch sensor NOTE: The fuel cut-off circuit is incorporated in this ECM in order to prevent over-running of engine. When engine speed reaches 8 000 r/min, or engine speed reaches 5 000 r/min at diff-lock switch is in ON and transfer is in low, or engine speed reaches 4 000 r/min at diff-lock switch is in ON and transfer is in high, this circuit cuts off fuel at the fuel injector.
Page 437 ELECTRICAL SYSTEM 9-19 Step 2 1) Measure the battery voltage between input lead wires (O/W and B/W) at the ECM with the ignition switch in the “ON” position. Is the voltage OK? Go to Step 3. • Faulty ignition switch. •...
Page 438: Inspection
9-20 ELECTRICAL SYSTEM INSPECTION IGNITION COIL PRIMARY PEAK VOLTAGE • Remove the right side cover. ($8-10) • Remove the spark plug cap. • Connect a new spark plug 1 to spark plug cap and ground it to the cylinder head bolt. NOTE: Make sure that the spark plug cap and spark plug are connected properly and the battery is fully-charged.
Page 439 ELECTRICAL SYSTEM 9-21 IGNITION COIL RESISTANCE • Remove the right side cover. ($8-10) • Disconnect the ignition coil lead wire and spark plug cap. Measure the ignition coil resistance in both the primary and sec- ondary windings with the multi-circuit tester. If the resistance in both the primary and secondary windings is close to the speci- fied values, the windings are in sound condition.
Page 440 9-22 ELECTRICAL SYSTEM CKP SENSOR PEAK VOLTAGE • Disconnect the CKP sensor coupler 1. • Connect the multi-circuit tester with the peak volt adaptor as follows. + probe: White - probe: Blue % 09900-25008: multi-circuit tester set When us ing the multi-circuit t ester an d peak v olt adaptor, refer to the appropriate instruction manual.
Page 441 ELECTRICAL SYSTEM 9-23 CKP SENSOR RESISTANCE • Disconnect the CKP sensor coupler. • Measure the resistance between the lead wires and ground. If the resistance is not as specified, the CKP sensor must be replaced. % 09900-25008: Multi-circuit tester set 2 Tester knob indication: Resistance (Ω) &...
Page 442: 4Wd/Diff-Lock System
9-24 ELECTRICAL SYSTEM 4WD/DIFF-LOCK SYSTEM INSPECTION When the diff-lock light blinks and the diff-lock indicator flickers, inspect the following items for any abnormalities. • Short circuit of wire harness. • Poor contact of couplers. • Faulty 4WD/diff-lock switch. ($9-37) • Faulty 4WD/diff-lock relay. ($9-25) •...
Page 443 ELECTRICAL SYSTEM 9-25 4WD/DIFF-LOCK RELAY • Remove the seat. ($8-6) • Remove the 4WD/diff-lock relay 1. First, check the continuity between A and D, between D and F terminals with the multi-circuit tester. Check the insulation between A and E, between E and F. Apply 12 V to the terminals C and E (+ to E and - to C), check the insulation between D and F.
Page 444: Combination Meter
9-26 ELECTRICAL SYSTEM COMBINATION METER DESCRIPTION This combination meter mainly consists of LCD (Liquid Crystal Display) and LED (Light Emitting Diode). This combination meter is light, thin and of high response compared to those currently in use because of this composition.
Page 445: Operating Procedure
ELECTRICAL SYSTEM 9-27 OPERATING PROCEDURE INITIAL DISPLAY When the ignition switch is set to ON, all LCD, ECT/FI, neutral indicator, reverse indicator and diff-lock indicator light. light up for two seconds. NOTE: If the power supply is cut (e.g., when the battery is replaced); * The odometer, tripmeter and clock are displayed after the ini- tial display appears.
Page 446: Removal And Disassembly
9-28 ELECTRICAL SYSTEM CLOCK Displays the time (hour and minutes) on a 12-hour clock. Setting the time Hold down the button over two seconds and then flashing the minute display. @ Select the correct minutes by min. pressing the button. Decide the minutes by pressing the ODO/TRIP button, and then flashing the hour display.
Page 447 ELECTRICAL SYSTEM 9-29 • Disconnect combination meter coupler 4 and remove the combination meter assembly. * When disconnecting and reconnecting the combina- tion m eter c oupler, m ake s ure t o tu rn OF F th e ign i- tion switch, or electronic parts may get damaged.
Page 448: Inspection
9-30 ELECTRICAL SYSTEM INSPECTION LED (LIGHT EMITTING DIODE) Check that the LED lights (diff-lock, reverse, neutral and ECT/FI) immediately after turning the ignition switch ON. Also, check them for lighting in accordance with their switch positions. If the LED fails in operation, replace the combination meter unit with a new one after checking its wire har- ness/coupler.
Page 449 ELECTRICAL SYSTEM 9-31 FUEL METER • Remove the rear fender. ($8-15) • Connect each resistor between the terminals as shown. • Turn the ignition switch to “ON” position and wait for approx. 13 seconds. Check the display of fuel meter as shown below, If any abnor- mality is found, replace the combination meter with a new one.
Page 450 9-32 ELECTRICAL SYSTEM SPEEDOMETER If the speedometer, odometer or trip meter does not function properly, inspect the speed sensor and connection of coupler. If the speed sensor and connection are functioning properly, replace the combination meter with a new one. SPEED SENSOR •...
Page 451: Headlight
ELECTRICAL SYSTEM 9-33 LAMPS HEADLIGHT HEADLIGHT BULB 12 V 35/35 W × 2 1 If yo u ha ve to uched an d th e bu lb with y our b are ha nds, clean it w ith a cl oth moistened with alcohol or soapy water to maintain lens clarity.
Page 452: Headlight Installation
9-34 ELECTRICAL SYSTEM HEADLIGHT INSTALLATION Head light coupler Head light (R) Adjusting point...
Page 453: Brake Light/Taillight
ELECTRICAL SYSTEM 9-35 BRAKE LIGHT/TAILLIGHT BRAKE LIGHT/TAILLIGHT BULB 12 V 21/5 W 1 If yo u ha ve to uched an d th e bu lb with y our b are ha nds, clean it w ith a cl oth moistened with alcohol or soapy water to maintain lens clarity.
Page 454: Diode
9-36 ELECTRICAL SYSTEM DIODE • The 4WD/diff-lock actuator diode 1 and neutral relay diode 2 are located near the radiator. • The high position diode 3 and low position 4 diode are located above the generator cover. Measure the voltage between A and B terminals using the multi-circuit tester as indicated in the table below.
Page 455: Switches
ELECTRICAL SYSTEM 9-37 SWITCHES Inspect each switch for continuity with a multi-circuit tester. If any abnormality is found, replace the respec- tive switch assemblies with new ones. % 09900-25008: Multi-circuit tester set REAR BRAKE SWITCH IGNITION SWITCH Color Color Position Position PARKING BRAKE SWITCH DIMMER SWITCH...
Page 456: Battery
9-38 ELECTRICAL SYSTEM BATTERY SPECIFICATIONS Type designation YTX14-BS Capacity 12 V, 43.2 kC (12 Ah)/10 HR 1 Upper cover breather 5 Terminal 2 Cathode plates 6 Safety valve 3 Stopper 7 Anode plates 4 Filter 8 Separator (Fiberglass plate) INITIAL CHARGING Filling electrolyte •...
Page 457 ELECTRICAL SYSTEM 9-39 NOTE: If no air bubbles are coming up from a filler port, tap the bottom of the electrolyte container two or three times. Never remove the container from the battery. • After confirming that the electrolyte has entered the battery completely, remove the electrolyte containers from the bat- tery.
Page 458: Servicing
9-40 ELECTRICAL SYSTEM Measure the battery voltage using multi circuit tester. The tester (at 25 ˚ C) should indicate more than 12.5 – 12.6 V (DC) as shown in the 30 second Fig. If the battery voltage is lower than the specification, charge the battery with a battery charger.
Page 459: Servicing Information
SERVICING INFORMATION 10-1 SERVICING INFORMATION CONTENTS TROUBLESHOOTING.................10- 2 FI SYSTEM MALFUNCTION CODE AND DEFECTIVE CONDITION ..10- 2 ENGINE ....................10- 4 DRIVE TRAIN ..................10-10 RADIATOR (COOLING SYSTEM) ............10-11 CHASSIS ....................10-11 BRAKES....................10-13 ELECTRICAL ..................10-14 BATTERY ....................10-15 WIRING HARNESS, CABLE AND HOSE ROUTING........10-16 WIRING HARNESS ROUTING .............10-16 CABLE ROUTING .................10-18 FUEL HOSE ROUTING.................10-20...
Page 460: Troubleshooting
10-2 SERVICING INFORMATION TROUBLESHOOTING FI SYSTEM MALFUNCTION CODE AND DEFECTIVE CONDITION DETECTED DTC No. DETECTED FAILURE CONDITION CHECK FOR ITEM NO FAULT ––––––––––– ––––––––––– CKP sensor The signal does not reach ECM for 3 CKP sensor lead wire/coupler sec. or more, after receiving the starter and mechanical parts.
Page 461 SERVICING INFORMATION 10-3 DETECTED DTC No. DETECTED FAILURE CONDITION CHECK FOR ITEM IAT sensor The sensor voltage should be the fol- IAT sensor, lead wire/coupler lowing. connection. 0.15 V < sensor voltage 4.85 V In other than the above value, C21 (P0110) is indicated.
Page 462: Engine
10-4 SERVICING INFORMATION ENGINE Complaint Symptom and possible causes Remedy Engine will not start Compression too low or is hard to start. 1. Valve clearance out of adjustment Adjust. 2. Worn valve guides or poor seating of valves Repair or replace. 3.
Page 463 SERVICING INFORMATION 10-5 Complaint Symptom and possible causes Remedy Engine idles poorly. 1. Valve clearance out of adjustment Adjust. 2. Poor seating of valves Replace or repair. 3. Defective valve guides Replace. 4. Worn down camshaft Replace. 5. Too wide spark plug gap Adjust or replace.
Page 464 10-6 SERVICING INFORMATION Complaint Symptom and possible causes Remedy Noisy engine Excessive valve chatter 1. Too large valve clearance Adjust. 2. Weakened or broken valve springs Replace. 3. Worn rocker arm and rocker arm shaft Replace. 4. Worn and burnt camshaft journal Replace.
Page 465 SERVICING INFORMATION 10-7 Complaint Symptom and possible causes Remedy Engine runs poorly Defective engine internal/electrical parts in high speed range. 1. Weakened valve springs Replace. 2. Worn camshaft Replace. 3. Valve timing out of adjustment Adjust. 4. Too narrow spark plug gap Adjust.
Page 466 10-8 SERVICING INFORMATION Complaint Symptom and possible causes Remedy Engine lacks power. Defective engine internal/electrical parts 1. Loss of valve clearance Adjust. 2. Weakened valve springs Replace. 3. Valve timing out of adjustment Adjust. 4. Worn piston rings or cylinder Replace.
Page 467 SERVICING INFORMATION 10-9 Complaint Symptom and possible causes Remedy Engine overheats Defective engine internal parts 1. Heavy carbon deposit on piston crowns Clean. 2. Not enough oil in the engine Add oil. 3. Defective oil pump or clogged oil circuit Replace or clean.
Page 468: Drive Train
10-10 SERVICING INFORMATION DRIVE TRAIN Complaint Symptom and possible causes Remedy Power will not To the rear wheel transmit from the 1. Broken drive and driven bevel gear teeth. Replace. engine 2. Broken rear output shaft. Replace. 3. Worn or broken rear drive shaft serration. Replace.
Page 469: Radiator (Cooling System)
SERVICING INFORMATION 10-11 RADIATOR (COOLING SYSTEM) Complaint Symptom and possible causes Remedy Engine overheats 1. Not enough engine coolant Add coolant. 2. Radiator core clogged with dirt or scale Clean. 3. Faulty cooling fan Repair or replace. 4. Defective cooling fan thermo-switch Replace.
Page 470 10-12 SERVICING INFORMATION Complaint Symptom and possible causes Remedy Tires rapidly or 1. Worn or loose front wheel hub bearings Replace. unevenly wear. 2. Improper front wheel alignment Adjust. Steering too noisy. 1. Loose nuts and bolts Tighten. 2. Damaged or worn front wheel hub bearings Replace.
Page 471: Brakes
SERVICING INFORMATION 10-13 BRAKES Complaint Symptom and possible causes Remedy Insufficient brake Front power 1. Leakage of brake fluid from hydraulic system Repair or replace. 2. Worn pads Replace. 3. Oil adhesion of engaging surface of pads/shoe Clean disc and pads. 4.
Page 472: Electrical
10-14 SERVICING INFORMATION ELECTRICAL Complaint Symptom and possible causes Remedy No sparking or poor 1. Defective ignition coil Replace. sparking 2. Defective spark plug Replace. 3. Defective CKP sensor Replace. 4. Defective ECM Replace. 5. Defective TO sensor Replace. 6. Open-circuited wiring connections Check and repair.
Page 473: Battery
SERVICING INFORMATION 10-15 Complaint Symptom and possible causes Remedy 4WD button dose 1. Defective 4WD/diff-lock relay Replace. not work 2. Defective 4WD button Replace. 3. Open- or short-circuited lead wires, or loose lead Repair or replace or connections retighten. Diff-lock button 1.
Page 474: Wiring Harness, Cable And Hose Routing
10-16 SERVICING INFORMATION WIRING HARNESS, CABLE AND HOSE ROUTING WIRING HARNESS ROUTING 60~80 mm (2.3 – 3.1 in) Clamp Wiring harness Ignition coil Wiring harness Clamp To power source Clamp Wiring harness Clamp Clamp Hose Wiring harness Brake light/taillight Clamp Wiring harness Cooling fan thermo switch TP/IAP/IAT...
Page 475 SERVICING INFORMATION 10-17 Clamp Horn switch (E-17, E-24) Set sag under Emergency switch (E-17) combination meter Handle switch (L) To combination meter Handle switch (L) Parking brake switch Parking brake switch Brake lever switch (L) Brake lever switch (L) Brake lever switch (R) Horn switch (E-17, E-24) 4WD/diff-lock switch Pass combination meter wire...
Page 476: Cable Routing
10-18 SERVICING INFORMATION CABLE ROUTING Frame Throttle cable Parking brake cable Wiring harness Parking brake cable Stater cable Frame Parking brake cable Location of cable and harness: as shown Sterter cable Wiring harness Parking brake cable Parking brake cable guide Fix foot brake cable to the footrest bar Handlebar...
Page 477 SERVICING INFORMATION 10-19 Wiring harness Parking brake cable Rear fender Parking brake cable Tie protector with clamp as shown. Screw Frame Protector Frame Parking brake cable Rear fender Foot brake pedal Parking brake cable Washer Adjust nut Front side Cotter pin Rear brake assy Foot brake cable Fix foot brake cable...
Page 478: Fuel Hose Routing
10-20 SERVICING INFORMATION FUEL HOSE ROUTING...
Page 479: Fuel Tank Breather Hose Routing
SERVICING INFORMATION 10-21 FUEL TANK BREATHER HOSE ROUTING Frame Fuel tank breather hose Check valve hose Check valve hose Valve (Black) Valve (Orange) Fuel tank Fuel tank breather hose Fuel tank pressure control valve Valve (Orange) Fuel tank breather hose...
Page 480: Cooling System Hose Routing
10-22 SERVICING INFORMATION COOLING SYSTEM HOSE ROUTING Thermostat Reservoir tank Radiator Bypass hose Radiator upper hose Bypass hose Radiator lower hose Water pump...
Page 481: Rear Drive Breather Hose Routing
SERVICING INFORMATION 10-23 REAR DRIVE BREATHER HOSE ROUTING Breather hose Breather hose Fuel tank lower cover Fuel tank 20˚ – 30˚ Belt cooling outlet duct Rear drive assy Rear drive assy...
Page 482: Front Brake Hose And Pipe Routing
10-24 SERVICING INFORMATION FRONT BRAKE HOSE AND PIPE ROUTING Master cylinder reservoir tank Master cylinder reservoir tank Tighten bolt with the Union bolt end-fitting contacted with the tank. Assemble front brake hose firmly into the guide. Front brake hose 25 N·m Through front brake hose (2.5 kgf-m, 18.0 lb-ft) rear of the throttle cable...
Page 483: Fender Installation
SERVICING INFORMATION 10-25 FENDER INSTALLATION Front fender Right inner fender Left mud guard Left inner fender...
Page 484 10-26 SERVICING INFORMATION Rear box Rear fender Right mud guard Left mud guard...
Page 485: Rear Fender Heat Shield Installation
SERVICING INFORMATION 10-27 REAR FENDER HEAT SHIELD INSTALLATION Rear fender 1 – 3 mm (0.04 – 0.12 in) 1 – 3 mm (0.04 – 0.12 in) Heat shield 5 mm (0.20 in) Heat shield 8 mm (0.32 in) 67 mm (2.64 in) Heat shield 30 mm (1.181 in) Heat shield...
Page 486: Belt Cooling Duct Installation
10-28 SERVICING INFORMATION BELT COOLING DUCT INSTALLATION...
Page 487: Rear Brake Pedal
SERVICING INFORMATION 10-29 REAR BRAKE PEDAL...
Page 488: Rear Side Reflex Reflector Installation (For E-28)
10-30 SERVICING INFORMATION REAR SIDE REFLEX REFLECTOR INSTALLATION (FOR E-28) Rear fender Reflex reflector bracket Reflex reflector...
Page 489: Trailer Tow Plate Installation
SERVICING INFORMATION 10-31 TRAILER TOW PLATE INSTALLATION Trailer tow warning label (E-17 (CH), 28) Trailer tow warning label Trailer tow plate mounting bolt 60 N·m (6.0 kgf-m, 43.5 lb-ft) Trailer tow plate...
Page 490: Engine Mounting
10-32 SERVICING INFORMATION ENGINE MOUNTING Engine mounting Thermostat case Thermostat case bolt 23 N·m (2.3 kgf-m, 16.5 lb-ft) Water hose clamp screw 1.5 N·m Recoil starter (0.15 kgf-m, 1.0 lb-ft) 10 N·m Engine mounting bolt 10 N·m (1.0 kgf-m, 7.0 lb-ft) (1.0 kgf-m, 7.0 lb-ft) Engine mounting bolt Engine mounting nut...
Page 491: Radiator Guard Installation (For E-24)
SERVICING INFORMATION 10-33 RADIATOR GUARD INSTALLATION (For E-24) Radiator Radiator net Clamp Radiator guard 0 – 3 mm (0 – 0.12 in) Frame...
Page 492: Special Tools
10-34 SERVICING INFORMATION SPECIAL TOOLS 09900-20101 09900-20202 09900-20204 09900-20205 09900-20102 Micrometer Micrometer Micrometer 09900-20530 Vernier calipers (25 – 50 mm) (75 – 100 mm) (0 – 25 mm) Cylinder gauge set 09900-20602 09900-20605 09900-20607 09900-20803 Dial gauge Dial calipers Dial gauge 09900-20701 09900-20806 (1/1000 mm, 1 mm)
Page 493 SERVICING INFORMATION 10-35 09913-60910 09913-10750 09913-50121 Bearing and gear 09913-70210 09915-40610 Adaptor Oil seal remover puller Bearing installer set Oil filter wrench 09915-64512 09915-70610 09915-72410 09915-74511 09915-74521 Compression Oil pressure gauge Oil pressure gauge Oil pressure gauge Oil pressure gauge gauge set attachment attachment...
Page 494 10-36 SERVICING INFORMATION 09917-13210 09917-23711 09917-47011 09920-13120 Valve clearance Ring nut socket Vacuum pump 09917-50410 Crankcase and adjusting driver wrench gauge Bearing remover shaft remover 09920-33540 09920-53740 09920-31020 Clutch shoe Clutch sleeve hub 09921-20240 09921-21910 Extension handle remover holder Bearing remover set Bearing holder 09922-31430 09924-21920...
Page 495 SERVICING INFORMATION 10-37 09924-52480 09924-62430 09924-74510 09924-84521 Fixed propeller Long socket Bearing and oil seal 09924-84510 Bearing installer shaft holder (22 mm) installer handle Bearing installer set 09930-10121 09926-27610 Spark plug wrench 09930-30104 09930-30721 09930-40113 Oil seal installer Sliding shaft Rotor remover Rotor holder 09930-40120...
Page 496: Tightening Torque
10-38 SERVICING INFORMATION TIGHTENING TORQUE ENGINE ITEM N·m kgf-m lb-ft Spark plug Cylinder head cover bolt Rocker arm shaft bolt 27.5 2.75 20.0 Intake pipe bolt 27.5 2.75 20.0 Cylinder head bolt (M8) 18.0 Initial 18.0 Cylinder head bolt (M10) Final 27.0 Cylinder base nut...
Page 497: Drive Train
SERVICING INFORMATION 10-39 DRIVE TRAIN ITEM N·m kgf-m lb-ft 4WD/diff-lock actuator mounting bolt 16.0 16.0 Front drive train (differential) gear case bolt Front drive train (differential) gear case mounting nut 36.0 Front differential gear oil level plug Front differential gear oil filler plug 34.5 3.45 25.0...
Page 498: Chassis
10-40 SERVICING INFORMATION CHASSIS ITEM N·m kgf-m lb-ft Handlebar upper 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 17.0 123.0 Front wishbone arm pivot nut (upper) 43.5 Front wishbone arm pivot nut (lower) 47.0...
Page 499: Tightening Torque Chart
SERVICING INFORMATION 10-41 TIGHTENING TORQUE CHART For other nuts and bolts 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 500: Service Data
10-42 SERVICING INFORMATION SERVICE DATA VALVE + VALVE GUIDE Unit: mm (in) ITEM STANDARD LIMIT Valve diam. 30.6 ---- (1.20) 27.0 ---- (1.06) Tappet clearance (when cold) 0.05 – 0.10 ---- (0.002 – 0.004) 0.17 – 0.22 ---- (0.007 – 0.009) Valve guide to valve stem 0.010 –...
Page 501 SERVICING INFORMATION 10-43 CAMSHAFT + CYLINDER HEAD Unit: mm (in) ITEM STANDARD LIMIT Cam height 33.450 – 33.504 33.15 (1.3169 – 1.3190) (1.3051) 33.470 – 33.524 33.17 (1.3177 – 1.3198) (1.3059) Camshaft journal oil clearance 0.028 – 0.059 (0.0011 – 0.0023) 0.150 (0.0059) 0.032 –...
Page 502 10-44 SERVICING INFORMATION ITEM STANDARD LIMIT Piston ring end gap 0.10 – 0.25 0.50 (0.004 – 0.010) (0.020) 0.10 – 0.30 0.50 (0.004 – 0.011) (0.020) Piston ring to groove clearance 0.180 ---- (0.0071) 0.150 ---- (0.0059) Piston ring groove width 1.21 –...
Page 503 SERVICING INFORMATION 10-45 CLUTCH Unit: mm (in) ITEM STANDARD LIMIT Clutch wheel I.D. 140.0 – 140.2 140.5 (5.512 – 5.520) (5.53) Clutch shoe No groove at — any part Clutch engagement r/min. 1 700 – 2 200 r/min. — Clutch lock-up r/min. 3 750 –...
Page 504 10-46 SERVICING INFORMATION THERMOSTAT + RADIATOR + FAN + COOLANT ITEM STANDARD/SPECIFICATION NOTE Thermostat valve opening Approx. 82 °C (180 °F) temperature Thermostat valve lift 8 mm (0.315 in) and over at 95 °C (203 °F) Radiator cap valve opening 110 –...
Page 505 SERVICING INFORMATION 10-47 FI SENSORS ITEM SPECIFICATION NOTE 200 – 250 Ω CKP sensor resistance CKP sensor peak voltage 65 V and more When cranking IAP sensor input voltage 4.5 – 5.5 V IAP sensor output voltage 2.17 – 3.15 V at idle speed TP sensor input voltage 4.5 –...
Page 506 10-48 SERVICING INFORMATION THROTTLE BODY ITEM STANDARD/SPECIFICATION Bore size 35 mm I.D. No. 11H0 Idle r/min. 1 500 ± 100 r/min. Throttle cable play 3 – 5 mm (0.1 – 0.2 in) ELECTRICAL Unit: mm (in) ITEM STANDARD/SPECIFICATION NOTE Spark plug NGK: CR6E Type DENSO: U20ESR-N...
Page 507: Reversing Light
SERVICING INFORMATION 10-49 WATTAGE Unit: W STANDARD/SPECIFICATION ITEM E-24, -28, -33 E-17 ← Headlight 35 × 2 ← 35 × 2 ← Brake light/Taillight 21/5 Reversing light ← Speedometer light High beam indicator light ← Neutral indicator light FI indicator light/Engine coolant ←...
Page 508 10-50 SERVICING INFORMATION ITEM STANDARD LIMIT Steering angle 46 ° (right & left) ---- Turning radius 3.1 m (10.2 ft) ---- Toe (with 75 kg, 165 lbs) -10 ± 4 mm (0.39 ± 0.16 in) ---- Camber 0.64 ° ---- Caster 1.6 °...
Page 509 SERVICING INFORMATION 10-51 FUEL + OIL ITEM SPECIFICATION NOTE Fuel type Use only unleaded gasoline of at least 87 pump octane (R/2 + M/2) or 91 octane or higher rated by the Research Method. Gasoline containing MTBE (Methyl Tertiary E-28, 33 Butyl Ether), less than 10 % ethanol, or less than 5 % methanol with appropriate cosolvents and corrosion inhibitor is permissible.
Page 510 ...
Page 511: Emission Control Information
EMISSION CONTROL INFORMATION 11-1 EMISSION CONTROL INFORMATION CONTENTS EMISSION CONTROL SYSTEMS...............11- 2 FUEL INJECTION SYSTEM..............11- 2 CRANKCASE EMISSION CONTROL SYSTEM........11- 3...
Page 512: Emission Control Systems
11-2 EMISSION CONTROL INFORMATION EMISSION CONTROL SYSTEMS FUEL INJECTION SYSTEM LT-A450 vehicles are equipped with a fuel injection system for emission level control. This fuel injection system is precision designed, manufactured and adjusted to comply with the applicable emission limits. With a view to reducing CO, NOX and HC, all of the fuel injection volumes are stringently controlled with the programmed injection maps in the ECM by varying engine conditions.
Page 513: Crankcase Emission Control System
EMISSION CONTROL INFORMATION 11-3 CRANKCASE EMISSION CONTROL SYSTEM The engine is equipped with a PCV system. Blow-by gas in the engine is constantly drawn into the crank- case, which is returned to the combustion chamber through the PCV (breather) hose, air cleaner and throttle body.
Page 514 ...
Page 515 LT-A450XK8 (’08 MODEL) LT-A450XK8 ( ’08 MODEL) CONTENTS PAGE INFORMATION LABELS ................12- 2 FRONT SUSPENSION................12- 3 FRONT SUSPENSION REASSEMBLING INFORMATION ......12- 4 REAR SUSPENSION .................12- 5 REAR SUSPENSION REASSEMBLING INFORMATION......12- 6 FUEL LEVEL GAUGE INSPECTION............12- 7 NOTE: The specifications and service data are the same as the K-7MODEL.
Page 516: Information Labels
12-2 LT- A450XK8 (’08 MODEL) INFORMATION LABELS APPLIED SPECIFICATION LABEL or PLATE NAME P-17 P-24 P-28 P-33 1 Certification plate E 2 Information label E 3 Gearshift label E 4 Gearshift label F 5 Tire air pressure label E 6 Tire air pressure label and warning no-passenger label F 7 General warning &...
Page 517: Front Suspension
LT- - A450XK8 (’08 MODEL) 1 -3 FRONT SUSPENSION CONSTRUCTION 1 Front shock absorber 7 Seal Front upper wishbone Front shock absorber mounting upper bolt ITEM N·m kgf-m lb-ft Front lower wishbone Front shock absorber mounting lower nut 40.0 4 Bush C Front wishbone arm pivot nut (upper) 43.5 5 Dust seal...
Page 518: Front Suspension Reassembling Information
12-4 LT- A450XK8 (’08 MODEL) FRONT SUSPENSION REASSEMBLING INFORMATION 7 mm (0.28 in) 7 mm (0.28 in) “A” “A” ITEM N·m kgf-m lb-ft 43.5 : Apply grease to the inside bush, dust seal and seal. “A” : Press fitting position of the bush.
Page 519: Rear Suspension
LT- - A450XK8 (’08 MODEL) 1 1 2-5 REAR SUSPENSION CONSTRUCTION 1 Rear shock absorber 0 Hub bearing 2 Rear stabilizer bar A Snap ring 3 Rear stabilizer bush B Dust seal 4 Rear stabilizer bracket C Seal 5 Rear stabilizer link D Spacer ITEM N·m...
Page 520: Rear Suspension Reassembling Information
12-6 LT- A450XK8 (’08 MODEL) REAR SUSPENSION REASSEMBLING INFORMATION 7 mm 7 mm “A” “A” 7 mm 7 mm “A” “A” ITEM N·m kgf-m lb-ft ITEM N·m kgf-m lb-ft 43.5 43.5 43.5 43.5 43.5 24.5 : Apply grease to the inside bush, dust seal and seal. “A”...
Page 521: Fuel Level Gauge Inspection
LT- - A450XK8 (’08 MODEL) 1 1 2-7 FUEL LEVEL GAUGE INSPECTION 166 mm (6.54 in) • Remove the fuel pump assembly. 27.7 mm • Measure the resistance at each fuel level gauge float position. (1.09 in) If the resistance is incorrect, replace the fuel pump assembly with a new one.
Page 522 LT-A450XK9 (’09-MODEL) 13-1 LT-A450XK9 (’09-MODEL) This chapter describes the service specifications, service data and servicing procedures which differ from those of the LT-A450XK8 (’08-MODEL). NOTE: * Any differences between the LT-A450XK8 (’08-MODEL) and LT-A450XK9 (’09-MODEL) in specifications are clearly indicated with an asterisk (*) mark. * Please refer to the chapters 1 through 12 for details which are not given in this chapter.
Page 523 13-2 LT-A450XK9 (’09-MODEL) SPECIFICATIONS (LT-A450XK9) DIMENSIONS AND CURB MASS Overall length ..................2 115 mm (83.3 in)... P-28, 33 2 135 mm (84.1 in)... P-17, 24 Overall width ..................1 210 mm (47.6 in)... P-28, 33 1 250 mm (49.2 in)... P-17, 24 Overall height ..................
Page 524 LT-A450XK9 (’09-MODEL) 13-3 REAR SUSPENSION Effective frame No. From 5SAAL42AX97103961 (ADDITION) (CHANGE) (CHANGE) 1 Rear suspention arm (lower) 4 Washer 2 Rear stabilizer joint A Rear stabilizer joint nut ITEM N·m kgf-m lb-ft 3 Rear stabilizer 43.5 REAR STABILIZER BUSH Do not apply grease.
Page 525 WIRE COLOR : Black : Gray : Blue : Orange : Brown : Red : Dark green : White : Green : Yellow B/Bl : Black with Blue tracer B/Br : Black with Brown tracer : Black with Green tracer : Black with Red tracer : Black with White tracer : Black with Yellow tracer...
Page 526 WIRING DIAGRAM For Sweden Model Wiring diagram wire color, refer to section “WIRE COLOR”. : DIFF-LOCK INDICATOR LIGHT ENGINE : REVERSE INDICATOR LIGHT STATER STOP : NEUTRAL INDICATOR LIGHT DIMMER SWITCH BUTTON OVER RIDE EMERGENCY BRAKE : HI-BEAM INDICATOR LIGHT SWITCH SWITCH SWITCH...
Page 527 For Australia Model ENGINE : DIFF-LOCK INDICATOR LIGHT STATER STOP BUTTON : REVERSE INDICATOR LIGHT DIMMER SWITCH OVER RIDE BRAKE SWITCH SWITCH : NEUTRAL INDICATOR LIGHT LEVER REAR : WATER TEMP WARNING SWITCH BRAKE PUSH PUSH SWITCH COMBINATION METER BRAKE LEVER SWITCH SWITCH(R)
Page 528 For Canada, USA Models ENGINE STATER : DIFF-LOCK INDICATOR LIGHT STOP REAR BUTTON SWITCH OVER RIDE BRAKE : REVERSE INDICATOR LIGHT BRAKE SWITCH SWITCH : NEUTRAL INDICATOR LIGHT LEVER : WATER TEMP WARNING DIMMER SWITCH PUSH BRAKE SWITCH COMBINATION METER LEVER SWITCH(R) PUSH...

Suzuki LT-A450X Manual

General Information 1

Electrical

Engine

Drive Train

Fi System Diagnosis

Fuel System and Throttle Body

Cooling and Lubrication System

Chassis

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GENERAL INFORMATION

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SERVICING INFORMATION

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