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Table of Contents
GSX-R750
9 9 5 0 0 - 3 7 1 3 0 - 0 1 E

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Table of Contents

   Summary of Contents for Suzuki GSX-R750

  • Page 1 GSX-R750 9 9 5 0 0 - 3 7 1 3 0 - 0 1 E...
  • Page 2: General Information

    FOREWORD GROUP INDEX This manual contains an introductory description on the SUZUKI GSX-R750 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 motorcycle and its main- tenance.
  • 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 Use engine coolant. wise specified. 99000-99032-11X (Except USA) Apply molybdenum oil solution. Use fork oil. (Mixture of engine oil and SUZUKI 99000-99001-SS5 MOLY PASTE in a ratio of 1:1) Apply SUZUKI SUPER GREASE “A” or equivalent grease. Apply or use brake fluid.
  • Page 5: Abbreviations Used In This Manual

    ABBREVIATIONS USED IN THIS 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 : Oil Pressure Switch : Positive Crankcase Ventilation (Crankcase Breather) : Right Hand : Read Only Memory : Society of Automotive Engineers : Suzuki Diagnosis System STC System : Secondary Throttle Control System (STCS) STP Sensor : Secondary Throttle Position Sensor...
  • Page 7 WIRE COLOR : Black : Green :Pink : Blue : Gray : Red : Brown : Light blue : White : Dark green : Light green : Yellow : Dark gray : Orange B/Bl : Black with Blue tracer B/Br : Black with Brown tracer : Black with Green tracer B/Lg...
  • Page 8: Table Of Contents

    GENERAL INFORMATION CONTENTS WARNING/CAUTION/NOTE................. 1- 2 GENERAL PRECAUTIONS ................1- 2 SUZUKI GSX-R750K6 (’06-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)................
  • Page 9: 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. ...
  • Page 10 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 11: Suzuki Gsx-r750k6 ('06-model)

    GENERAL INFORMATION SUZUKI GSX-R750K6 (’06-MODEL) RIGHT SIDE LEFT SIDE • Difference between illustrations and actual motorcycle 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 right side of the steering head pipe.
  • Page 12: 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 13: Front Fork Oil

    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 14: 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 15: Information Labels

    GENERAL INFORMATION INFORMATION LABELS GSX-R750 GSX-R750UF 1 Noise label A (For E-03, 24, 33) 2 Information label A (For E-03, 28, 33) 3 Vacuum hose routing label A (For E-33) 4 Fuel caution label A (For E-02, 24) 5 Fuel information label...
  • Page 16: Specifications

    GENERAL INFORMATION SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length ................2 040 mm (80.3 in) Overall width ................715 mm (28.1 in) Overall height ................1 125 mm (44.3 in) Wheelbase ................1 400 mm (55.1 in) Ground clearance..............130 mm (5.1 in) Seat height ................
  • Page 17: Chassis

    1-10 GENERAL INFORMATION CHASSIS Front suspension ..............Inverted telescopic, coil spring, oil damped Rear suspension ..............Link type, coil spring, oil damped Front fork stroke..............120 mm (4.7 in) Rear wheel travel ..............130 mm (5.1 in) Steering angle................. 27° Caster ..................
  • Page 18 PERIODIC MAINTENANCE PERIODIC MAINTENANCE CONTENTS PERIODIC MAINTENANCE SCHEDULE ............ 2- 2 PERIODIC MAINTENANCE CHART............. 2- 2 LUBRICATION POINTS ................ 2- 3 MAINTENANCE AND TUNE-UP PROCEDURES ........2- 4 AIR CLEANER..................2- 4 SPARK PLUG..................2- 5 VALVE CLEARANCE................2- 7 ENGINE OIL AND OIL FILTER .............
  • Page 19: 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 motorcycle operating at peak performance and economy. Mileages are expressed in terms of kilome- ters, miles and time for your convenience. IMPORTANT (For E-28): The periodic maintenance intervals and service requirements have been estab- lished in accordance with EPA regulations.
  • Page 20: Lubrication Points

    PERIODIC MAINTENANCE LUBRICATION POINTS Proper lubrication is important for smooth operation and long life of each working part of the motorcycle. Major lubrication points are indicated below. Brake lever holder Brake pedal pivot and footrest pivot Clutch lever holder Footrest pivot and Side-stand pivot Drive chain gearshift lever pivot...
  • Page 21: Maintenance And Tune-up Procedures

    PERIODIC MAINTENANCE MAINTENANCE AND TUNE-UP PROCEDURES This section describes the servicing procedures for each item of the Periodic Maintenance requirements. AIR CLEANER Inspect every 6 000 km (4 000 miles, 12 months). Replace every 18 000 km (11 000 miles, 36 months). •...
  • Page 22: Spark Plug

    PERIODIC MAINTENANCE SPARK PLUG Inspect every 6 000 km (4 000 miles, 12 months). Replace every 12 000 km (7 500 miles, 24 months). SPARK PLUG AND IGNITION COIL/PLUG CAP REMOVAL • Remove the front seat. (8-7) • Lift and support the fuel tank. (5-3) •...
  • Page 23 PERIODIC MAINTENANCE SPARK PLUG GAP • Measure the spark plug gap with a thickness gauge. • Adjust the spark plug gap if necessary.  Spark plug gap: Standard: 0.7 – 0.8 mm (0.028 – 0.031 in)  09900-20803: Thickness gauge ELECTRODE’S CONDITION •...
  • Page 24: Valve Clearance

    PERIODIC MAINTENANCE VALVE CLEARANCE Inspect every 24 000 km (14 500 miles, 48 months). • Remove the right under cowling. (8-5) • Lift and support the fuel tank. (5-3) • Remove the air cleaner box. (5-14) • Disconnect the CMP sensor coupler 1. •...
  • Page 25 PERIODIC MAINTENANCE • Turn the crankshaft to bring the line A on the CKP sensor rotor to the rib B behind the clutch cover and also to bring the notches A on the left ends of both camshafts (Ex. and In.) to the positions as shown.
  • Page 26 PERIODIC MAINTENANCE VALVE CLEARANCE ADJUSTMENT The clearance is adjusted by replacing the existing tappet shim by a thicker or thinner shim. • Remove the intake or exhaust camshafts. (3-14) • Remove the tappet and shim by fingers or magnetic hand. •...
  • Page 27 2-10 PERIODIC MAINTENANCE (INTAKE SIDE)
  • Page 28 PERIODIC MAINTENANCE 2-11 (EXHAUST SIDE)
  • Page 29: Engine Oil And Oil Filter

    2-12 PERIODIC MAINTENANCE ENGINE OIL AND OIL FILTER (ENGINE OIL) Replace initially at 1 000 km (600 miles, 2 months) and every 6 000 km (4 000 miles, 12 months) thereafter. (OIL FILTER) Replace initially at 1 000 km (600 miles, 2 months) and every 18 000 km (11 000 miles, 36 months) thereafter.
  • Page 30: Exhaust Control Valve

    Oil and filter change : 2.5 L (2.6/2.2 US/Imp qt) Engine overhaul : 2.9 L (3.1/2.6 US/Imp qt)  ONLY USE A GENUINE SUZUKI MOTORCYCLE OIL FILTER. Other manufacturer’s oil filters may differ in thread specifications (thread diameter and pitch), fil- tering performance and durability which may lead to engine damage or oil leaks.
  • Page 31: Fuel Line

    2-14 PERIODIC MAINTENANCE • Remove the under cowlings. (8-5) • Check the lock-nuts tightness. If the lock-nuts are loose, adjust the cable play and tighten the lock-nuts. FUEL LINE Inspect initially 6 000 km (4 000 miles, 12 months). • Inspect the fuel feed hose 1 for damage and fuel leakage. If any defects are found, the fuel feed hose must be replaced.
  • Page 32: Throttle Valve Synchronization

    PERIODIC MAINTENANCE 2-15 THROTTLE VALVE SYNCHRONIZATION Inspect initially at 1 000 km (600 miles, 2 months) (E-33 only) and every 12 000 km (7 500 miles, 24 moths). • Inspect the throttle valve synchronization periodically. (5-26) EVAPORATIVE EMISSION CONTROL SYSTEM (E-33 ONLY) Inspect every 12 000 km (7 500 miles, 24 months).
  • Page 33: Clutch

    2-16 PERIODIC MAINTENANCE CLUTCH Inspect every 6 000 km (4 000 miles, 12 months). • Lift and support the fuel tank with its prop stay. (5-3) • Turn in the adjuster 1 all the way into the clutch lever assem- bly.
  • Page 34: Cooling System

    PERIODIC MAINTENANCE 2-17 COOLING SYSTEM Inspect every 6 000 km (4 000 miles, 12 months). Replace engine coolant every 2 years. ENGINE COOLANT LEVEL CHECK • Keep the motorcycle upright. • Check the engine coolant level by observing the full and lower lines on the engine coolant reservoir.
  • Page 35 2-18 PERIODIC MAINTENANCE AIR BLEEDING THE COOLING CIRCUIT • Add engine coolant up to the radiator inlet. • Support the motorcycle upright. • Slowly swing the motorcycle, right and left, to bleed the air trapped in the cooling circuit. • Add engine coolant up to the radiator inlet. •...
  • Page 36 PERIODIC MAINTENANCE 2-19 RADIATOR HOSES • Remove the under cowlings. (8-5) • Lift and support the fuel tank. (5-3) • Check the radiator hoses for crack, damage or engine coolant leakage. • If any defect is found, replace the radiator hose with new one.
  • Page 37: Drive Chain

    2-20 PERIODIC MAINTENANCE DRIVE CHAIN Inspect initially at 1 000 km (600 miles, 2 months) and every 6 000 km (4 000 miles, 12 months) thereafter. Clean and lubricate every 1 000 km (600 miles). Visually check the drive chain for the possible defects listed below.
  • Page 38 PERIODIC MAINTENANCE 2-21 • Count out 21 pins (20 pitches) on the chain and measure the distance between the two points. If the distance exceeds the 1 2 3 19 20 21 service limit, the chain must be replaced.  Drive chain 20-pitch length: Service limit: 319.4 mm (12.57 in) ADJUSTING •...
  • Page 39 • After washing and drying the chain, oil it with a heavyweight motor oil.  * Do not use any oil sold commercially as “drive chain oil”. Such oil can damage the O-rings. * The standard drive chain is RK525ROZ5Y. Suzuki recommends to use this standard drive chain as a replacement.
  • Page 40: Brake

    PERIODIC MAINTENANCE 2-23 BRAKE (BRAKE) Inspect initially at 1 000 km (600 miles, 2 months) and every 6 000 km (4 000 miles, 12 months) thereafter. (BRAKE HOSE AND BRAKE FLUID) Inspect every 6 000 km (4 000 miles, 12 months). Replace hoses every 4 years.
  • Page 41 2-24 PERIODIC MAINTENANCE BRAKE PADS Front brake The extent of brake pad wear can be checked by observing the grooved limit line A on the pad. When the wear exceeds the grooved limit line, replace the pads with the new ones. (8-65) ...
  • Page 42 PERIODIC MAINTENANCE 2-25 BRAKE LIGHT SWITCH • Adjust the rear brake light switch so that the brake light will come on just before pressure is felt when the brake pedal is depressed. AIR BLEEDING FROM BRAKE FLUID CIRCUIT Air trapped in the brake fluid circuit acts like a cushion to absorb a large proportion of the pressure developed by the master cyl- inder and thus interferes with the full braking performance of the brake caliper.
  • Page 43 2-26 PERIODIC MAINTENANCE FRONT BRAKE (Master cylinder side) • Bleed air from the master cylinder in the same manner as front brake (caliper side).  Air bleeder valve: 6.0 N·m (0.6 kgf-m, 4.3 Ib-ft) NOTE: If air is trapped in the master cylinder, bleed air from the master cylinder first.
  • Page 44: Tires

    PERIODIC MAINTENANCE 2-27 TIRES Inspect every 6 000 km (4 000 miles, 12 months). TIRE TREAD CONDITION Operating the motorcycle with excessively worn tires will decrease riding stability and consequently invite a dangerous situation. It is highly recommended to replace a tire when the remaining depth of tire tread reaches the following specification.
  • Page 45: Front Fork

    2-28 PERIODIC MAINTENANCE FRONT FORK Inspect every 12 000 km (7 500 miles, 24 months). • Inspect the front forks for oil leakage, scoring or scratches on the outer surface of the inner tubes. Replace any defective parts, if necessary. (8-18) REAR SUSPENSION Inspect every 12 000 km (7 500 miles, 24 months).
  • Page 46: Exhaust Pipe Bolt And Nut

    PERIODIC MAINTENANCE 2-29 EXHAUST PIPE BOLT AND NUT Tighten initially at 1 000 km (600 miles, 2 months) and every 12 000 km (7 500 miles, 24 months) thereafter. • Tighten the exhaust pipe bolts, muffler mounting bolt and nut to the specified torque.
  • Page 47: Chassis Bolts And Nuts

    2-30 PERIODIC MAINTENANCE CHASSIS BOLTS AND NUTS Tighten initially at 1 000 km (600 miles, 2 months) and every 6 000 km (4 000 miles, 12 months) thereafter. Check that all chassis bolts and nuts are tightened to their specified torque. (Refer to page 2-31 for the loca- tions of the following nuts and bolts on the motorcycle.) Item N·m...
  • Page 48 PERIODIC MAINTENANCE 2-31...
  • Page 49: 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. COMPRESSION PRESSURE SPECIFICATION Standard Limit...
  • Page 50: 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 SPECIFICATION 100 – 400 kPa (1.0 – 4.0 kgf/cm , 14 – 57 psi) at 3 000 r/min, Oil temp. at 60 °C (140 °F) If the oil pressure is lower or higher than the specification, the following causes may be considered.
  • Page 51: Sds Check

    2-34 PERIODIC MAINTENANCE SDS CHECK Using SDS, take the sample of data from the new motorcycle and at the time of periodic maintenance at your dealership. Save the data in the computer or by printing and filing the hard copies. The saved or filed data are useful for troubleshooting as they can be compared periodically with changes over time or failure conditions of the motorcycle.
  • Page 52: Data At The Time Of Racing

    PERIODIC MAINTENANCE 2-35 Data at 3 000 r/min under no load 3 000 r/min Check the manifold absolute pressure. XXX mmHg Data at the time of racing Throttle: Slowly open Throttle: Quick wide open Secondary throttle valve opens closes in according with the engine r/min.
  • Page 53 2-36 PERIODIC MAINTENANCE Data of intake negative pressure during idling (100 °C) Check the manifold absolute pressure. Approx. XXX mmHg Data of secondary throttle valve operation at the time of starting Closes fully in approx. XX sec.
  • Page 54 ENGINE ENGINE CONTENTS ENGINE COMPONENTS REMOVABLE WITH ENGINE IN PLACE ..3- 2 ENGINE REMOVAL AND INSTALLATION..........3- 3 ENGINE REMOVAL ................3- 3 ENGINE INSTALLATION ..............3-10 ENGINE DISASSEMBLY ................3-14 ENGINE COMPONENTS INSPECTION AND SERVICE......3-27 CYLINDER HEAD COVER..............3-27 CMP SENSOR ..................
  • Page 55: Engine Components Removable With Engine In Place

    ENGINE ENGINE COMPONENTS REMOVABLE WITH ENGINE IN PLACE The parts listed below can be removed and reinstalled without removing the engine from the frame. Refer to page listed in each section for removal and reinstallation instructions. ENGINE CENTER ITEM REMOVAL INSPECTION INSTALLATION 11-7...
  • Page 56: Engine Removal And Installation

    ENGINE ENGINE REMOVAL AND INSTALLATION 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. Reinstall the engine by reversing the removal procedure. • Remove the under cowlings. (8-5) •...
  • Page 57 ENGINE RADIATOR • Disconnect the by-pass hose 1 and radiator inlet hose 2. • Disconnect the oil cooler outlet hose 3. • Disconnect the cooling fan coupler 4. • Remove the radiator mounting bolts. • Remove the radiator 5.  Be careful not to bent the radiator fins.
  • Page 58 ENGINE EXHAUST PIPE AND MUFFLER • Remove the EXCV cables along with the bracket 1. • Loosen the muffler connecting bolt. • Remove the HO2 sensor 2 (For E-02, 19). (4-107) • Remove the exhaust pipe bolts. • Remove the exhaust pipe. •...
  • Page 59 ENGINE • Disconnect the following couplers. 3 GP switch lead wire 4 CKP sensor lead wire 5 Ground lead wire 6 Starter motor lead wire 7 Speed sensor lead wire 8 ECT sensor • Disconnect the ignition coil/plug cap lead wire couplers. ...
  • Page 60 ENGINE ENGINE SPROCKET AND GEARSHIFT LEVER • Disengage the gearshift lever 1. • Remove the engine sprocket cover 2. • Remove the clutch push rod 3. • Remove the speed sensor rotor 4. • Remove the engine sprocket nut 5 and the washer 6. •...
  • Page 61 ENGINE • Remove the engine sprocket 0. ENGINE MOUNTING • Support the engine using an engine jack. • Remove the engine mounting bolt A. • Loosen the engine mounting pinch bolt 1. • Remove the engine mounting bolt B.
  • Page 62 ENGINE • Remove the engine mounting nut 2. • Remove the engine mounting thrust adjuster lock-nut 3 with the special tool. • Loosen the engine mounting thrust adjuster 4 fully.  09940-14980: Engine mounting thrust adjuster socket wrench • Remove the engine mounting nut 5. •...
  • Page 63: Engine Installation

    3-10 ENGINE ENGINE INSTALLATION Install the engine in the reverse order of engine removal. Pay attention to the following points: NOTE: Be careful not to damage the frame and engine when installing the engine. • Before installing the engine, install the spacers 1. •...
  • Page 64 ENGINE 3-11  LENGTH ITEM N·m kgf-m lb-ft ITEM 40.0 1.77 16.5 2.17 Bolt 16.5 8.46 32.5 8.07 54.0 Spacer 30.5 1.20 Adjuster 1.57 a LH b RH...
  • Page 65 • Tighten the speed sensor rotor bolt 4 to the specified torque.  Speed sensor rotor bolt: 25 N·m (2.5 kgf-m, 18.0 lb-ft) • Apply SUZUKI SUPER GREASE “A” to the clutch push rod end.  99000-25010: SUZUKI SUPER GREASE “A”...
  • Page 66 ENGINE 3-13 • Tighten the muffler mounting bolts, exhaust pipe bolts and muffler connecting bolt to the specified torque.  Muffler mounting bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft) Muffler connecting bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft) Exhaust pipe bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft) •...
  • Page 67: Engine Disassembly

    3-14 ENGINE ENGINE DISASSEMBLY  Identify the position of each removed part. Organize the parts in their respective groups (e.g., intake, exhaust) so that they can be reinstalled in their origi- nal positions. • Remove the spark plugs. (2-5) STARTER MOTOR •...
  • Page 68 ENGINE 3-15 • Turn the crankshaft to bring the line A on the CKP sensor rotor to the rib B behind the clutch cover and also to bring the cams to the position as shown. • Remove the cam chain tension adjuster 2. •...
  • Page 69 3-16 ENGINE CYLINDER HEAD • Remove the thermostat cover 1. • Remove the thermostat 2 and thermostat conector 3. THERMOSTAT INSPECTION (7-9) • Remove the ECT sensor 4. ECT SENSOR INSPECTION (7-7) • Remove the cylinder head bolts (M6) 5. •...
  • Page 70 ENGINE 3-17 • Hold the clutch housing with the special tool.  Do not damage the clutch plates by the special tool.  09920-53740: Clutch sleeve hub holder • Remove the clutch springs. NOTE: Loosen the clutch spring set bolts little by little and diagonally. •...
  • Page 71 3-18 ENGINE • Hold the clutch sleeve hub with the special tool.  09920-53740: Clutch sleeve hub holder • Remove the clutch sleeve hub nut. • Remove the washers C, D and E from the clutch sleeve hub. • Remove the wave spring washers F and clutch lifter driven cam G.
  • Page 72 ENGINE 3-19 OIL PUMP DRIVE SPROCKET • Remove the spacer 1. • Remove the oil pump drive sprocket 2 and chain 3. • Remove the thrust washer 4. GEARSHIFT SYSTEM • With the snap ring 1 and washer removed, remove the gear- shift shaft assembly 2.
  • Page 73 3-20 ENGINE • Remove the shaft 4, bearing 5 and thrust washer 6. • Remove the generator cover. • Remove the dowel pins and gasket. • Remove the starter idle gear No. 2 7 and shaft 8. CAM CHAIN/CAM CHAIN TENSIONER/CAM CHAIN GUIDE •...
  • Page 74 ENGINE 3-21 GENERATOR ROTOR AND STARTER DRIVEN GEAR • Hold the generator rotor with the special tool.  09930-44520: Rotor holder • Remove the generator rotor bolt. • Install a bolt A of suitable size to the left end of crankshaft. SUITABLE BOLT A [M12, length: 28 –...
  • Page 75 3-22 ENGINE GEAR POSITION SWITCH • Remove the gear position switch 1. CRANKCASE BREATHER (PCV) COVER • Remove the crankcase breather cover 1. • Remove the gasket 2. OIL PRESSURE SWITCH • Remove the oil pressure switch 1. OIL FILTER •...
  • Page 76 ENGINE 3-23 OIL COOLER • Remove the oil cooler 1. OIL PAN • Remove the plate 1 and oil pan. • Remove the gasket. OIL PRESSURE REGULATOR • Remove the oil pressure regulator 1. OIL STRAINER • Remove the oil strainer 2. OIL PUMP •...
  • Page 77 3-24 ENGINE • Remove the upper crankcase bolts. • Remove the lower crankcase bolts (M8). • Remove the crankshaft journal bolts (M9). • Remove the lower crankcase assembly. • Remove the dowel pins and O-ring 2. BALANCER SHAFT • Remove the balancer shaft 1 and oil seal 2. COUNTERSHAFT •...
  • Page 78 ENGINE 3-25 • Remove the C-ring 6 and bearing pin 7. CRANKSHAFT • Loosen the conrod bearing cap bolts by using a 10 mm, 12-point socket wrench, and tap the bearing cap bolts lightly with a plastic hammer to remove the bearing cap. •...
  • Page 79 3-26 ENGINE • Separate the piston and conrod by driving out the piston pin. NOTE: Scribe the cylinder number on the piston head.
  • Page 80: Engine Components Inspection And Service

    ENGINE 3-27 ENGINE COMPONENTS INSPECTION AND SERVICE  Identify the position of each removed part. Organize the parts in their respective groups (i.e., intake, exhaust, No.1 or No.2) so that they can be installed in their original locations. CYLINDER HEAD COVER •...
  • Page 81: Crankcase Breather Reed Valve

    3-28 ENGINE INSPECTION • Inspect the reed valve for the carbon deposit. • If the carbon deposit is found in the reed valve, replace the PAIR reed valve with a new one. CRANKCASE BREATHER REED VALVE REMOVAL • Remove the crankcase breather reed valve 1 from the crank- case breather cover.
  • Page 82: Camshaft

    ENGINE 3-29 CAMSHAFT CAMSHAFT IDENTIFICATION The exhaust camshaft can be distinguished from that of the intake by the embossed letters “EX” (for exhaust) as against let- ters “IN” (for intake). CAM WEAR • Check the camshaft for wear or damage. •...
  • Page 83: Camshaft Runout

    3-30 ENGINE NOTE: Do not rotate the camshaft with the plastigauge in place. • Remove the camshaft holders, and read the width of the com- pressed plastigauge with envelope scale. • This measurement should be taken at the widest part. •...
  • Page 84: Cam Chain Tension Adjuster

    ENGINE 3-31 CAM CHAIN TENSION ADJUSTER INSPECTION • Holding the cam chain tension adjuster as shown, compress the plunger by turning the adjuster body until the outer circlip A fits the groove B. NOTE: * Wipe off engine oil from the plunger head and thumb so that they may not to be slippery.
  • Page 85: Cam Chain Guide

    3-32 ENGINE CAM CHAIN GUIDE INSPECTION • Check the contacting surfaces of the cam chain guide No. 1 and No. 2. • If they are worn or damaged, replace them with the new ones. CYLINDER HEAD AND VALVE VALVE AND VALVE SPRING DISASSEMBLY •...
  • Page 86 ENGINE 3-33 CYLINDER HEAD DISTORTION • Decarbonize the combustion chambers. • Check the gasketed 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 87 3-34 ENGINE VALVE STEM DEFLECTION • Lift the valve about 10 mm from the valve seat. • Measure the valve stem deflection in two directions, perpen- dicular to each other, by positioning the dial gauge as shown. • If the deflection measured exceeds the limit, then determine whether the valve or the guide should be replaced with a new one.
  • Page 88 ENGINE 3-35 • Cool down the new valve guides in a freezer for about one hour and heat the cylinder head to 100 °C – 150 °C (212 °F – 302 °F) with a hot plate.  Do not use a burner to heat the valve guide hole to prevent cylinder head distortion.
  • Page 89 3-36 ENGINE • If the seat width W measured exceeds the standard value or seat width is not uniform, reface the seat using the seat cutter.  Valve seat width W: Standard: 0.9 – 1.1 mm (0.035 – 0.043 in) If the valve seat is out of specification, re-cut the seat.
  • Page 90 ENGINE 3-37 VALVE SPRING The force of the coil spring keeps the valve seat tight. Weak- ened spring result in reduced engine power output, and often account for the chattering noise coming from the valve mecha- nism. • Check the valve spring for proper strength by measuring its free length and also by the force required to compress it.
  • Page 91 3-38 ENGINE • Put on the valve spring retainer 2, and using the special tool 3, press down the spring, fit the cotter halves 4 to the stem end, and release the lifter to allow the cotter halves to wedge in between retainer and stem.
  • Page 92: Clutch

    ENGINE 3-39 • Apply SUZUKI SUPER GREASE “A” to the O-rings.  99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease) • Install the intake pipes. • Apply THREAD LOCK to the bolts.  99000-32050: THREAD LOCK “1342” CLUTCH CLUTCH DRIVE PLATE INSPECTION...
  • Page 93: Clutch Lifter

    3-40 ENGINE CLUTCH SPRING INSPECTION • Measure the free length of each coil spring with a vernier cali- pers, and compare the length with the specified limit. • Replace all the springs if any spring is not within the limit. ...
  • Page 94 ENGINE 3-41 CLUTCH LIFTER PIN ADJUSTMENT NOTE: When adjusting the clutch lifter, it is not necessary to install the clutch onto the countershaft. • Assemble the following parts into the primary driven gear assembly. (3-90 to -93) * Clutch sleeve hub * Spring washer seat, Spring washer * Clutch drive plates, Clutch driven plates * Pressure plate...
  • Page 95: Oil Pump

    3-42 ENGINE WAVE SPRING WASHER INSPECTION • Measure the free height H of each wave spring washer with a vernier calipers. • If each wave spring washer height H is not within the speci- fied limit, replace it with a new one. ...
  • Page 96 ENGINE 3-43 DISASSEMBLY • With holding the rotor with the special tool remove the starter clutch bolts.  09930-44520: Rotor holder • Remove the one way clutch 1 and guide 2 from the rotor. REASSEMBLY • When fitting the one way clutch 1 to the guide 2, position flange side A of one way clutch to the rotor side.
  • Page 97: Generator

    3-44 ENGINE GENERATOR INSPECTION (9-10) REASSEMBLY • When installing the generator stator set bolts, tighten them to the specified torque.  Generator stator set bolt: 11 N·m (1.1 kgf-m, 8.0 lb-ft) NOTE: Be sure to install the grommet 1 to the generator cover. WATER PUMP 7-11 GEARSHIFT SYSTEM...
  • Page 98: Oil Pressure Regulator

    ENGINE 3-45 • Install the following parts to the gearshift shaft/gearshift arm as shown in the illustration. 1 Washer 5 Plate return spring 2 Snap ring 6 Washer 3 Gearshift shaft return spring 7 Screw 4 Gearshift cam drive plate OIL PRESSURE REGULATOR •...
  • Page 99: Transmission

    3-46 ENGINE TRANSMISSION DRIVESHAFT REMOVAL (3-52) DISASSEMBLY Disassemble the countershaft and driveshaft. Pay attention to the following points: • Remove the 6th drive gear snap ring 1 from its groove and slide it towards the 3rd/4th drive gears 2. • Slide the 6th 3 and 2nd 4 drive gears toward the 3rd/4th drive gears 2, then remove the 2nd drive gear circlip 5.
  • Page 100 Replace the bearings if there is anything unusual. * Before installing the gears, apply engine oil to the driveshaft and countershaft. * When installing the oil seal, apply SUZUKI SUPER GREASE “A” to it.  99000-25010: SUZUKI SUPER GREASE “A”...
  • Page 101 3-48 ENGINE TRANSMISSION PARTS LOCATION 1 Countershaft 2 Driveshaft...
  • Page 102: Cylinder

    ENGINE 3-49 CYLINDER CRANKCASE SERVICING (3-52) CYLINDER DISTORTION • Check the gasketed surface of the cylinder for distortion with a straightedge and thickness gauge, taking a clearance read- ing at several places as indicated. • If the largest reading at any position of the straightedge exceeds the limit, replace the crankcase set.
  • Page 103: Piston And Piston Ring

    3-50 ENGINE PISTON AND PISTON RING PISTON DIAMETER • Using a micrometer, measure the piston outside diameter at 15 mm (0.6 in) A from the piston skirt end. • If the measurement is less than the limit, replace the piston. ...
  • Page 104: Piston Ring Groove Width

    ENGINE 3-51 PISTON RING-TO-GROOVE CLEARANCE • Measure the side clearances of the 1st and 2nd piston rings using the thickness gauge. • If any of the clearances exceeds the limit, replace both the piston and piston rings.  09900-20803: Thickness gauge 09900-20205: Micrometer (0 –...
  • Page 105: Crankcase

    3-52 ENGINE CRANKCASE DRIVESHAFT AND GEARSHIFT CAM Removal • Remove the screws. • Remove the gearshift fork shaft 1, gearshift cam 2 and gearshift forks 3. • Remove the spacer 4. • Remove the driveshaft left bearing dust seal 5. •...
  • Page 106 ENGINE 3-53 • Remove the driveshaft assembly 8. GEARSHIFT FORK-TO-GROOVE CLEARANCE • Using a thickness gauge, check the gearshift fork clearance in the groove of its gear. • The clearance for each gearshift fork plays an important role in the smoothness and positiveness of the shifting action. ...
  • Page 107 3-54 ENGINE BEARING AND DUST SEAL Inspection • Inspect the gearshift cam bearing 1 for abnormal noise and smooth rotation. • Replace the bearings if there is anything unusual. • Inspect the gearshift cam bearing 2, gearshift shaft bearings 3 (LH) and 4 (RH) for abnormal noise and smooth rotation while they are in the crankcase.
  • Page 108 ENGINE 3-55 • Inspect the driveshaft left bearing dust seal for wear and dam- age. • Replace the dust seal if there is anything unusual. Removal • Remove the gearshift cam bearing with the special tools.  09923-74511: Bearing remover 09930-30104: Sliding shaft ...
  • Page 109 • Install new oil seal with the special tool.  09913-70210: Bearing installer set (22) • Apply SUZUKI SUPER GREASE “A” to the oil seal lip.  99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease) • Install the bearing with the special tool.
  • Page 110  99000-32050: THREAD LOCK “1342”  Bearing retainer screw: 10 N·m (1.0 kgf-m, 7.0 lb-ft) • Install the dowel pin. • Apply SUZUKI SUPER GREASE “A” to the O-ring and fit the driveshaft left bearing case 6.  Replace the O-ring with a new one.
  • Page 111   Driveshaft left bearing case bolt: 12 N·m (1.2 kgf-m, 8.7 lb-ft) • Apply SUZUKI SUPER GREASE “A” to the dust seal lip and O-ring. • Apply THREAD LOCK to the bolts and tighten them to the specified torque.
  • Page 112 ENGINE 3-59 • Remove the oil jet 2 (for transmission) from the lower crank- case. • Remove the oil jet 3 (for cam chain tension adjuster) from the cylinder head. Inspection and cleaning • Check the oil jets for clogging. •...
  • Page 113 3-60 ENGINE • Install the oil jet (for transmission). • Apply engine oil to the O-ring.  Use new O-ring to prevent oil pressure leakage. • Install the oil jet (for cam chain tension adjuster). PLUG Removal • Remove the oil gallery plugs 1 and 2. •...
  • Page 114 • Apply engine coolant to the O-rings of the water jacket plugs 5 and 6.  99000-99032-11X: SUZUKI COOLANT (Except USA) • Tighten each plug to the specified torque.  1 Oil gallery plug: 10 N·m (1.0 kgf-m, 7.0 lb-ft) 2 Oil gallery plug: 22 N·m (2.2 kgf-m, 16.0 lb-ft)
  • Page 115: Balancer Shaft

    3-62 ENGINE BALANCER SHAFT DISASSEMBLY • Remove the balancer gear along with the dampers from the balancer shaft. INSPECTION • Inspect the damper for wear and damage, replace it if any defects are found. REASSEMBLY • Apply MOLYBDENUM OIL SOLUTION to each part. ...
  • Page 116 ENGINE 3-63 • Remove the middle crankcase and measure the width of the compressed plastigauge using the envelope scale. This mea- surement should be taken at the widest part of the com- pressed plastigauge.  Balancer shaft journal oil clearance: Standard: 0.028 –...
  • Page 117 3-64 ENGINE INSTALLATION • When fitting the balancer shaft journal bearings to the upper and middle crankcases, be sure to fix the stopper part A first and press the other end.  Do not touch the bearing surfaces with your hands. Grasp by the edge of the bearing shell.
  • Page 118: Crankshaft And Conrod

    ENGINE 3-65 CRANKSHAFT AND CONROD CRANKSHAFT RUNOUT • Support the crankshaft with V-blocks as shown, with the two end journals resting on the blocks. • Set up the dial gauge, as shown. • Rotate the crankshaft slowly to read the runout. •...
  • Page 119 3-66 ENGINE CONROD-BIG END BEARING INSPECTION • Inspect the bearing surfaces for any sign of fusion, pitting, burn, or flaws. If any, replace them with a specified set of bearings. CONROD-BIG END BEARING SELECTION • Place the plastigauge axially along the crank pin, avoiding the oil hole, as shown.
  • Page 120 ENGINE 3-67 • Check the corresponding conrod I.D. code number (“1” or “2”) • Check the corresponding crank pin O.D. code number (“1”, “2” or “3”) B.  Bearing selection table Crank pin O.D. B Code Green Black Brown Conrod I.D A Black Brown...
  • Page 121 3-68 ENGINE  Crank pin O.D. Code O.D. specification 32.992 – 33.000 mm (1.2989 – 1.2992 in) 32.984 – 32.992 mm (1.2986 – 1.2989 in) 32.976 – 32.984 mm (1.2983 – 1.2986 in)  09900-20202: Micrometer (25 – 50 mm) ...
  • Page 122: Crankshaft Journal Bearing

    ENGINE 3-69 CRANKSHAFT JOURNAL BEARING INSPECTION • Inspect each bearing of upper and lower crankcases for any damage. SELECTION • Place the plastigauge axially along the crankshaft journal, avoiding the oil hole, as shown.  09900-22301: Plastigauge  Never rotate the crankshaft when a piece of plasti- gauge is installed.
  • Page 123 3-70 ENGINE • Check the corresponding crankcase journal I.D. code number A, “A”, “B” or “C” which is stamped on the rear of upper crankcase. • Check the corresponding crankshaft journal O.D. code num- ber B, “A”, “B” or “C” which is stamped on the crankshaft. ...
  • Page 124 ENGINE 3-71  Crankshaft journal O.D. specification Code O.D. specification 31.994 – 32.000 mm (1.2596 – 1.2598 in) 31.988 – 31.994 mm (1.2594 – 1.2596 in) 31.982 – 31.988 mm (1.2591 – 1.2594 in)  09900-20202: Micrometer (25 – 50 mm) ...
  • Page 125: Crankshaft Thrust Bearing

    3-72 ENGINE CRANKSHAFT THRUST BEARING • With the crankshaft, right-side thrust bearing and left-side thrust bearing inserted in the upper crankcase, measure the thrust clearance on the left side by using the thickness gauge. L: Left-side thrust bearing R: Right-side thrust bearing NOTE: Pull the crankshaft to the generator side, so that there is no clearance on the right-side thrust bearing.
  • Page 126 ENGINE 3-73  Thrust bearing selection table Clearance before Color Thrust bearing inserting left-side Thrust clearance (Part No.) thickness thrust bearing 2.560 – 2.585 mm White 2.475 – 2.500 mm 0.060 – 0.110 mm (0.1008 – 0.1018 in) (12228-17E00-0F0) (0.0974 – 0.0984 in) (0.0024 –...
  • Page 127: Engine Reassembly

    3-74 ENGINE ENGINE REASSEMBLY • Reassemble the engine in the reverse order of disassembly. • The following steps require special attention or precautionary measures should be taken. NOTE: Apply engine oil to each running and sliding part before reas- sembling. •...
  • Page 128 ENGINE 3-75 • 1st ring 4 and 2nd ring 3 have letters “IR” and “R” marked on one side. Be sure to bring the marked side upward when fitting them to the piston. • Position the gaps of the three ring as shown. Before inserting each piston into the cylinder, check that the gaps are so located.
  • Page 129 3-76 ENGINE • Install the pistons and conrods into the cylinders from upside. NOTE: When installing the pistons, the indent C of each piston head must be brought to the exhaust side.  Be careful not to damage the cylinder wall and piston jet by the conrod.
  • Page 130 ENGINE 3-77 • Set the crankshaft to the conrods and upper crankcase. • Apply engine oil to the crank pin and bearing surface.  Be sure to clean the conrod big end. • When fitting the conrod cap, make sure that I.D. code A on each conrod faces intake side.
  • Page 131 3-78 ENGINE • Insert the right and left thrust bearings with oil groove B fac- ing the crank web. NOTE: Right thrust bearing has green painting. BALANCER SHAFT • Install the thrust washers 1, 2 and oil seal 3. • Apply a MOLYBDENUM OIL SOLUTION to each balancer shaft journal and bearing lightly.
  • Page 132 ENGINE 3-79 • Turn the bearing to fit the bearing dowel pin in the position A. • Install the dowel pin and oil seal 3. • Install the gearshift shaft and fork 4, bushing 5 and retainer...
  • Page 133 • Install the dowel pins. • Install the dowel pins, O-ring 1 and cap 2.  Replace the O-ring with a new one. • Apply SUZUKI BOND to the mating surface of the lower crankcase.  99000-31110: SUZUKI BOND “1215” (or equivalent bond)
  • Page 134 ENGINE 3-81 • Tighten the crankshaft journal bolts (M9) in ascending order of numbers assigned to these bolts. Tighten each bolt a little at a time to equalize the pressure in the following two steps.  Crankshaft journal bolt: (M9) Initial : 18 N·m (1.8 kgf-m, 13.0 lb-ft) Final : 50°...
  • Page 135  Oil pump mounting bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft) OIL STRAINER AND OIL PRESSURE REGULATOR • Apply SUZUKI SUPER GREASE “A” to the O-rings and press in the oil strainer and oil pressure regulator to the crankcase.  99000-25010: SUZUKI SUPER GREASE “A”...
  • Page 136  99000-31140: SUZUKI BOND “1207B”  Oil pressure switch: 14 N·m (1.4 kgf-m, 10.0 lb-ft) NOTE: Be careful not to apply SUZUKI BOND to the hole of thread end. OIL COOLER • Apply SUZUKI SUPER GREASE “A” to the O-ring and install the oil cooler.
  • Page 137 • Install the crankcase breather cover 2.  Crankcase breather cover bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft) GEAR POSITION SWITCH • Apply SUZUKI SUPER GREASE “A” to the O-ring. NOTE: Align the gear position switch pin A with the gearshift cam hole ...
  • Page 138 ENGINE 3-85 WATER PUMP • Apply SUZUKI SUPER GREASE “A” to the O-ring.  Use a new O-ring to prevent oil leakage.  99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease) • Install the water pump. NOTE: Set the water pump shaft end A to the oil pump shaft B as shown.
  • Page 139 3-86 ENGINE GENERATOR ROTOR AND STARTER DRIVEN GEAR • Degrease the tapered portion A of generator rotor and also the crankshaft B. Use nonflammable cleaning solvent to wipe off oily or greasy matter and make these surfaces completely dry. • Install the generator rotor onto the crankshaft. •...
  • Page 140 STARTER IDLE GEAR • Install the starter idle gear No. 2 1 and shaft 2. • Apply SUZUKI BOND lightly to the mating surfaces A at the parting line between the upper and lower crankcases.  99000-31140: SUZUKI BOND “1207B”...
  • Page 141 • Install the starter idle gear No. 1 shaft 5, thrust washer 6, bearing 7, starter idle gear No. 1 8, washer 9, and spring washer 0. • Apply SUZUKI SUPER GREASE “A” to the O-ring.  99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease) •...
  • Page 142 ENGINE 3-89 • Install the gearshift cam stopper plate 5. NOTE: Align the gearshift cam pin B with the gearshift cam stopper plate hole C . • Apply a small quantity of THREAD LOCK to the gearshift cam stopper plate bolt and tighten it to the specified torque. ...
  • Page 143 3-90 ENGINE • Install the oil pump drive sprocket 1 to the countershaft. NOTE: Teeth A on the sprocket must face the clutch side. • Pass the chain between the oil pump drive and driven sprock- ets. CLUTCH • Install the primary driven gear assembly 1. NOTE: * Before assembling the clutch, adjust the clutch lifter.
  • Page 144 ENGINE 3-91 • Install the clutch sleeve hub assembly onto the countershaft. • Install the washer 9 and spring washer 0. NOTE: * Before installing the washer 9 , visually inspect the washer surface for wear and damage. If necessary, replace it with a new one.
  • Page 145 3-92 ENGINE • Install the clutch push rod C into the countershaft. • Install the clutch push piece D, bearing E and thrust washer F to the countershaft. NOTE: Thrust washer F is located between the pressure plate and bearing E . •...
  • Page 146 ENGINE 3-93 *1: Direction of outside *2: Paint DRIVE PLATE: a No. 2 Drive plate ..1 pc. [Black paint/I.D. 111 mm (4.4 in)] b No. 1 Drive plate ..7 pcs. [Purple paint/I.D. 111 mm (4.4 in)] c No. 3 Drive plate ..1 pc. [NIL/I.D. 118 mm (4.6 in)] NOTE: No.3 drive plate can be distinguished by the inside diameter (I.D.).
  • Page 147 3-94 ENGINE CLUTCH COVER • Apply SUZUKI BOND lightly to the mating surfaces at the parting line between the upper and lower crankcases as shown.  99000-31140: SUZUKI BOND “1207B” • Install new gasket 1 and dowel pin.  Use a new gasket to prevent oil leakage.
  • Page 148 ENGINE 3-95 • Place the cylinder head on the cylinder. NOTE: When installing the cylinder head, keep the cam chain taut. • Tighten the cylinder head bolts (M10) in the following four-step. Step 1: • Tighten the cylinder head bolts to the specified torque with a torque wrench sequentially and diagonally.
  • Page 149 3-96 ENGINE • Apply engine coolant to the O-ring. • Install the thermostat conector 3.  Use a new O-ring to prevent engine coolant leakage.  Thermostat conector bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft) • Install the thermostat 4. NOTE: The jiggle valve A of thermostat faces upside.
  • Page 150 ENGINE 3-97 The camshafts are identified by the embossed letters. • Before replacing the camshafts on cylinder head, apply MOLYBDENUM OIL SOLUTION to their journals and cam faces. • Apply a MOLYBDENUM OIL SOLUTION to the camshaft jour- nal holders. ...
  • Page 151 3-98 ENGINE • Install the dowel pins. • Install O-rings 3 to the camshaft journal holders.  Replace the O-rings with new ones. • Install the camshaft journal holders. NOTE: * Each camshaft journal holder is identified with an embossed letter.
  • Page 152 ENGINE 3-99 • Tighten the camshaft journal holder bolts in the ascending order of numbers to the specified torque.  Camshaft journal holder bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft)  The camshaft journal holder bolts are made of a spe- cial material and much superior in strength, compared with other types of high strength bolts.
  • Page 153 3-100 ENGINE • Fit a new gasket 1.  Use a new gasket to prevent oil leakage. • Install the cam chain tension adjuster.  Cam chain tension adjuster mounting bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft) • Turn the crankshaft approx. 180° counterclockwise to make 180˚...
  • Page 154 ENGINE 3-101 10 N·m (1.0 kgf-m, 7.0 lb-ft)
  • Page 155  Replace the gaskets with new ones. • Install a new gasket to the cylinder head cover. • Apply SUZUKI BOND to the cam end cap points of the gasket as shown.  99000-31140: SUZUKI BOND “1207B” ...
  • Page 156 • Tighten the head cover bolts to the specified torque.  Head cover bolt: 14 N·m (1.4 kgf-m, 10.0 lb-ft) STARTER MOTOR • Apply SUZUKI SUPER GREASE “A” to the O-ring.  99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease) •...
  • Page 157 FI SYSTEM DIAGNOSIS FI SYSTEM DIAGNOSIS CONTENTS PRECAUTIONS IN SERVICING ..............4- 3 ELECTRICAL PARTS ................4- 3 FUSE....................... 4- 4 ECM/VARIOUS SENSORS ..............4- 4 ELECTRICAL CIRCUIT INSPECTION PROCEDURE......4- 6 USING THE MULTI-CIRCUIT TESTER..........4- 9 FI SYSTEM TECHNICAL FEATURES............4-10 INJECTION TIME (INJECTION VOLUME) ..........
  • Page 158 FI SYSTEM DIAGNOSIS FI SYSTEM DIAGNOSIS CONTENTS “C31” (P0705) GP SWITCH CIRCUIT MALFUNCTION......4-75 “C32” (P0201), “C3