Suzuki GW250 Service Manual

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SERVICE MANUAL

9 9 5 0 0 - 3 2 1 7 0 - 0 1 E

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Summary of Contents for Suzuki GW250

Page 1 SERVICE MANUAL 9 9 5 0 0 - 3 2 1 7 0 - 0 1 E...
Page 2: General Information
FOREWORD GROUP INDEX This manual contains an introductory description on the SUZUKI GW250 and procedures for its inspec- tion/service and overhaul of its main components. GENERAL INFORMATION Other information considered as generally known is not included. Read the GENERAL INFORMATION section to...
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 oil. Use engine oil or transmis- or equivalent. sion oil unless otherwise specified. 99000-99001-G10 Apply molybdenum oil solution. (Mixture of engine oil and SUZUKI Apply or use brake fluid. MOLY PASTE in a ratio of 1:1) Apply SUZUKI SUPER GREASE “A” or equivalent.
Page 5: Abbreviations Used In This Manual
ABBREVIATIONS USED IN THIS MANUAL ABDC : After Bottom Dead Center : Generator : Alternating Current : Ground : Air Cleaner, Air Cleaner Box GP Switch : Gear Position Switch : American Petroleum Institute ATDC : After Top Dead Center : Air Fuel Mixture : Hydrocarbons HO2 Sensor...
Page 6 : Power control module : Positive Crankcase Ventilation (Crankcase Breather) : Right Hand : Read Only Memory : Society of Automotive Engineers : Suzuki Diagnosis System TO Sensor : Tip-Over Sensor (TOS) TP Sensor : Throttle Position Sensor (TPS) WIRE COLOR...
Page 7: Table Of Contents
GENERAL INFORMATION CONTENTS WARNING/CAUTION/NOTICE/NOTE ............1- 2 GENERAL PRECAUTIONS ................. 1- 2 SUZUKI GW250L3 (’13-MODEL) ..............1- 4 SERIAL NUMBER LOCATION ..............1- 4 FUEL, OIL AND ENGINE COOLANT RECOMMENDATION...... 1- 5 FUEL...................... 1- 5 ENGINE OIL ..................1- 5 BRAKE FLUID..................
Page 8: Warning/Caution/Notice/Note
1-2 GENERAL INFORMATION WARNING/CAUTION/NOTICE/NOTE Please read this manual and follow its instructions carefully. To emphasize special information, the symbol and the words WARNING, CAUTION, NOTICE and NOTE have special meanings. Pay special attention to the messages highlighted by these signal words. ...
Page 9 * After servicing the fuel, oil, water, exhaust or brake systems, check all lines and fittings related to the system for leaks. * 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 10: Suzuki Gw250L3 ('13-Model)
1-4 GENERAL INFORMATION SUZUKI GW250L3 (’13-MODEL) RIGHT SIDE LEFT SIDE NOTE: Difference between illustration 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 11: Fuel, Oil And Engine Coolant Recommendation
Use oil with an API (American Petroleum Institute) classification of SG or higher with a JASO classification of MA. 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 right chart.
Page 12: Brake Fluid
There are two types of engine coolant: one used after diluting with distilled water and the other used as it is (without diluting). SUZUKI super long life coolant is the latter type and SUZUKI long life coolant is the former type.
Page 13: Break-In Procedures
GENERAL INFORMATION 1-7 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 14: Information Labels
1-8 GENERAL INFORMATION INFORMATION LABELS LABEL or PLATE NAME I.D. Plate (For-P21, 24, 71) Tire information label General warning label Brake Approval Label (For-P21, 24) Fuel limitation label (For-P12) Noise label (For-P24) Frame (RH) Chain case...
Page 15: Specifications
GENERAL INFORMATION 1-9 SPECIFICATIONS DIMENSIONS AND CURB MASS Overall length ................2 145 mm (84.4 in) Overall width ................760 mm (29.9 in) Overall height ................1 075 mm (42.3 in) Wheelbase ................1 430 mm (56.3 in) Ground clearance..............165 mm (6.4 in) Seat height ................
Page 16: Chassis
1-10 GENERAL INFORMATION CHASSIS Front suspension ..............Telescopic, coil spring, oil damped Rear suspension ..............Swingarm type, coil spring, oil damped Front fork stroke..............120 mm (4.7 in) Rear wheel travel ..............125 mm (4.9 in) Steering angle................. 40° Caster ..................26° Trail ..................
Page 17 PERIODIC MAINTENANCE 2-1 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 EXHAUST PIPE BOLTS AND MUFFLER BOLTS ....... 2- 5 SPARK PLUGS ..................
Page 18: Periodic Maintenance Schedule
Replace every 16 000 km (9 600 miles) or 48 months. COOLANT (Blue) SUZUKI LONG LIFE COOLANT Engine coolant (Green) or other than SUZUKI Replace every 8 000 km (5 000 miles) or 24 months. SUPER LONG LIFE COOLANT (Blue)
Page 19: Lubrication Points
PERIODIC MAINTENANCE 2-3 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. 1 Clutch lever pivot 5 Drive chain 2 Side-stand pivot and spring hook 6 Brake lever pivot 3 Gearshift lever pivot and front footrest pivot 7 Brake pedal pivot and front footrest pivot...
Page 20: Maintenance And Tune-Up Procedures
2-4 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 5 000 km (3 000 miles, 15 months). Replace every 15 000 km (9 000 miles, 45 months). •...
Page 21: Exhaust Pipe Bolts And Muffler Bolts
PERIODIC MAINTENANCE 2-5 EXHAUST PIPE BOLTS AND MUFFLER BOLTS Tighten initially at 1 000 km (600 miles, 3 months) and every 10 000 km (6 000 miles, 30 months) thereafter. • Tighten the exhaust pipe bolts, muffler support bolts, muffler chamber support bolt and exhaust connecting bolts to the specified torque.
Page 22: Spark Plugs
2-6 PERIODIC MAINTENANCE SPARK PLUGS Inspect every 5 000 km (3 000 miles, 15 months). Replace every 10 000 km (6 000 miles, 30 months). REMOVAL • Disconnect the spark plug caps. • Remove the spark plugs.  09930-10121: Spark plug wrench set HEAT RANGE •...
Page 23 PERIODIC MAINTENANCE 2-7 ELECTRODE’S CONDITION • Check the condition of the electrode. • If it is extremely worn or burnt, replace the spark plug. Replace the spark plug if it has a broken insulator, damaged thread, etc. Confirm the thread size and reach when replacing the plug.
Page 24: Valve Clearance
2-8 PERIODIC MAINTENANCE VALVE CLEARANCE Inspect initially at 1 000 km (600 miles, 3 months) and every 5 000 km (3 000 miles, 15 months) thereafter. • Remove the fuel tank covers. (8-5) • Remove the spark plugs 1. (2-6) •...
Page 25 PERIODIC MAINTENANCE 2-9 • Remove the generator cover plug 6 and valve timing inspec- tion plug 7. • Turn the crankshaft counterclockwise to set the #2 (Right) cyl- inder at TDC of compression stroke. (Align the “| R” line A on the generator rotor to the mark B of valve timing inspection hole and also bring the notch C on the left end of camshaft to the position as shown.)
Page 26 2-10 PERIODIC MAINTENANCE • Turn the crankshaft counterclockwise 540 degrees (1-1/2 turns) to set the #1 (Left) cylinder at TDC of compression stroke. Bring the notch C on the left end of camshaft to the position as shown. D Intake side •...
Page 27: Engine Oil Replacement
PERIODIC MAINTENANCE 2-11 ENGINE OIL AND OIL FILTER (ENGINE OIL) Replace initially at 1 000 km (600 miles, 3 months) and every 5 000 km (3 000 miles, 15 months) thereafter. (OIL FILTER) Replace initially at 1 000 km (600 miles, 3 months) and every 10 000 km (6 000 miles, 30 months) thereafter.
Page 28: Fuel Line
After contacting the gasket, tighten 2 turns. (20 N·m, 2.0 kgf-m, 14.5 lbf-ft) 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 29: Pair (Air Supply) System
PERIODIC MAINTENANCE 2-13 PAIR (AIR SUPPLY) SYSTEM Inspect initially at 5 000 km (3 000 miles, 15 months) and then every 10 000 km (6 000 miles, 30 months) thereafter. • Inspect the PAIR (air supply) system periodically. (11-3) THROTTLE CABLE PLAY Inspect initially at 1 000 km (600 miles, 3 months) and every 5 000 km (3 000 miles, 15 months) thereafter.
Page 30: Clutch Cable Play
2-14 PERIODIC MAINTENANCE CLUTCH CABLE PLAY Inspect initially at 1 000 km (600 miles, 3 months) and every 5 000 km (3 000 miles, 15 months) thereafter. • Slide the boot 1. • Loosen the lock-nut 2 and turn the adjuster 3 clockwise as far as it will go.
Page 31: Cooling System
PERIODIC MAINTENANCE 2-15 COOLING SYSTEM Replace engine coolant (SUZUKI super long life cool- ant: Blue) every 16 000 km (9 600 miles) or 48 months. Replace engine coolant (SUZUKI long life coolant: Green) every 8 000 km (5 000 miles) or 24 months.
Page 32 2-16 PERIODIC MAINTENANCE AIR BLEEDING THE COOLING CIRCUIT 1) Add engine coolant up to the radiator inlet. 2) Support the motorcycle upright. 3) Slowly swing the motorcycle, right and left, to bleed the air trapped in the cooling circuit. 4) Add engine coolant up to the radiator inlet. 5) Start up the engine and bleed air from the radiator inlet com- pletely.
Page 33: Drive Chain
NOTE: * When replacing the drive chain, replace the drive chain and sprockets as a set. * The standard drive chain is DID520VF (116 L). Suzuki recom- mends to use this standard drive chain as a replacement. CHECKING AND ADJUSTING •...
Page 34 • Lubricate both front and back plates of the drive chain. • Wipe off excess lubricant after lubricating all around of the drive chain. NOTE: The standard drive chain is DID520VF. Suzuki recommends to use this standard drive chain as a replacement.
Page 35: Brake
PERIODIC MAINTENANCE 2-19 BRAKE (BRAKE) Inspect initially at 1 000 km (600 miles, 3 months) and every 5 000 km (3 000 miles, 15 months) thereafter. (BRAKE HOSE AND BRAKE FLUID) Inspect every 5 000 km (3 000 miles, 15 months). Replace hoses every 4 years.
Page 36 2-20 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. (8-52) Replace the brake pads as a set, otherwise braking performance will be adversely affected.
Page 37 PERIODIC MAINTENANCE 2-21 BRAKE PEDAL HEIGHT • Loosen the lock-nut 1. • Turn the push rod 2 until the brake pedal height becomes 38 – 48 mm (1.5 – 1.9 in) A below the top of the footrest. • Tighten the lock-nut 1 securely. ...
Page 38 2-22 PERIODIC MAINTENANCE Front brake • Fill the master cylinder reservoir to the upper level. Place the reservoir cap to prevent dirt from entering. • Attach a hose to the air bleeder valve and insert the free end of the hose into a receptacle. •...
Page 39: Tires
PERIODIC MAINTENANCE 2-23 TIRES Inspect every 5 000 km (3 000 miles, 15 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 40: Steering
2-24 PERIODIC MAINTENANCE STEERING Inspect initially at 1 000 km (600 miles, 3 months) and every 10 000 km (6 000 miles, 30 months) thereafter. The steering should be adjusted properly for smooth turning of the handlebars and safe running. Overtighten steering prevents smooth turning of the handlebars and too loose steering will cause poor stability.
Page 41: Chassis Bolts And Nuts
PERIODIC MAINTENANCE 2-25 CHASSIS BOLTS AND NUTS Tighten initially at 1 000 km (600 miles, 3 months) and every 5 000 km (3 000 miles, 15 months) thereafter. Check that all chassis bolts and nuts are tightened to their specified torque. (Refer to page 2-26 for the loca- tions of the following nuts and bolts on the motorcycle.) Item N·m...
Page 42 2-26 PERIODIC MAINTENANCE...
Page 43: Compression Pressure Check
PERIODIC MAINTENANCE 2-27 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 44: Oil Pressure Check
2-28 PERIODIC MAINTENANCE 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 200 – 500 kPa (2 – 5 kgf/cm , 28 – 71 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 45: Sds Check
PERIODIC MAINTENANCE 2-29 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 46: Data At The Time Of Racing
2-30 PERIODIC MAINTENANCE Data at 3 000 r/min under no load Approx. 3 000 r/min Check the manifold absolute pressure. XX kPa Check the engine coolant temperature. XX ˚C Data at the time of racing Throttle: Quick wide open Throttle: Slowly open PAIR control solenoid valve OFF in accordance with the throttle valve opens...
Page 47 PERIODIC MAINTENANCE 2-31 Data of intake negative pressure during idling (100 °C) Check the engine coolant temperature. Approx. 100 ˚C Check the manifold absolute pressure. XX kPa Data of manifold absolute pressure operation at the time of starting Check the manifold absolute pressure. XX kPa...
Page 48 2-32 PERIODIC MAINTENANCE Example of trouble Three data; value 3 (current data 3), value 2 (past data 2) and value 1 (past data 1); can be made in 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 passing of time and identify what problem is currently occurring.
Page 49 ENGINE 3-1 ENGINE CONTENTS ENGINE COMPONENTS REMOVABLE WITH ENGINE IN PLACE ..3- 2 ENGINE REMOVAL AND INSTALLATION..........3- 3 ENGINE REMOVAL ................3- 3 ENGINE INSTALLATION ..............3- 8 ENGINE DISASSEMBLY ................3-12 ENGINE COMPONENTS INSPECTION AND SERVICE......3-25 CYLINDER HEAD COVER..............
Page 50: Engine Components Removable With Engine In Place
3-2 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...
Page 51: Engine Removal And Installation
ENGINE 3-3 ENGINE REMOVAL AND INSTALLATION ENGINE REMOVAL • Drain engine oil. (2-11) • Drain engine coolant. (2-15) • Remove the seat. (8-5) • Disconnect the battery - lead wire. • Remove the fuel tank 1. (5-2) • Remove the throttle body assembly 2. (5-12)
Page 52 3-4 ENGINE • Remove the exhaust pipes and mufflers 3. (6-2) • Disconnect the spark plug cap #2 4, PCV hose 5, starter motor lead wire 6 and battery - lead wire 7. • Disconnect the clamps 8, GP switch coupler 9, generator coupler 0, CKP sensor coupler A and side-stand switch cou- pler B.
Page 53 ENGINE 3-5 • Remove the oil pressure switch lead wire E. • Remove the engine sprocket cover F. • Loosen the clutch cable nuts G and clutch cable adjuster H. • Remove the clutch release arm I along with the clutch cable •...
Page 54 3-6 ENGINE • Move the speed sensor bracket O and remove the dowel pins • Remove the speed sensor rotor Q by removing it bolt while depressing the rear brake pedal. • Remove the engine sprocket nut R while depressing the rear brake pedal.
Page 55 ENGINE 3-7 • Disengage the gearshift link arm W by removing the bolt. NOTE: Mark the position of the gearshift link arm on the gearshift shaft before removing. • Remove the bolts X and washers Y. • Move the right footrest bracket assembly Z. •...
Page 56: Engine Installation
3-8 ENGINE • Remove the engine mounting bolts and nuts. • Gradually lower the engine. • Remove the engine assembly. ENGINE INSTALLATION Install the engine in the reverse order of engine removal. Pay attention to the following points: NOTE: The engine mounting nuts and frame down tube nuts are self-locking.
Page 57 ENGINE 3-9 • Tighten the gearshift link arm bolt 3 to the specified torque.  Gearshift link arm bolt: 10 N·m (1.0 kgf-m, 7.0 lbf-ft) • Inspect the gearshift lever height D between the gearshift lever top and footrest.  Gearshift lever height: Standard: 28 –...
Page 58 3-10 ENGINE • Install the clutch release camshaft retainer 9. (10-16) • Apply a small quantity of thread lock to the oil clutch release camshaft retainer bolt 0.  99000-32110: THREAD LOCK CEMENT SUPER “1322” or equivalent • When installing the clutch release arm A, align the groove E of clutch release arm A with the slit F of clutch release cam- shaft.
Page 59 ENGINE 3-11 • After finishing the engine installation, check the following items. * Wiring harness, cables and hoses routing (10-14 to 10-22 and 10-25) * Throttle cable play (2-13) * Clutch cable play (2-14) * Drive chain slack (2-18) * Engine oil (2-11) * Engine coolant (2-15) * Throttle valve synchronization (5-23)
Page 60: Engine Disassembly
3-12 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 1.  09930-10121: Spark plug wrench set •...
Page 61 ENGINE 3-13 • Turn the crankshaft counterclockwise to bring the “I R” line on generator rotor to the index mark A of the valve inspection hole and also to bring the camshaft to the position as shown. NOTE: At the above condition, the cylinder is at TDC of compression stroke and also the engraved lines B on the camshafts are par- allel with the mating surface of the cylinder head cover.
Page 62 3-14 ENGINE • Turn the crankshaft counterclockwise and remove the cam- shaft sprocket bolts 9. NOTE: Do not drop the camshaft sprocket bolts 9 into the cylinder head. • Slide and drop the camshaft sprocket 0 to the camshaft A. •...
Page 63 ENGINE 3-15 • Remove the cylinder head gasket 4, dowel pins 5 and cam chain guide 6. • Remove the water inlet connector 7. • Remove the cylinder bolts 1 and cylinder 8. NOTE: If the cylinder does not come off, lightly tap it with a plastic ham- mer.
Page 64 3-16 ENGINE CLUTCH COVER • Remove the clutch cover 1. • Remove the dowel pins 2 and gasket 3. CLUTCH • Remove the clutch spring bolts and clutch springs. NOTE: Loosen the clutch spring set bolts little by little and diagonally. •...
Page 65 ENGINE 3-17 • Remove the thrust washer 6, bearing 7 and clutch push piece 8. • Remove the clutch push rod 9. NOTE: If it is difficult to pull out the push rod 9, use a magnetic hand or a wire. •...
Page 66 3-18 ENGINE • Remove the thrust washer C and primary driven gear assem- bly D. • Remove the spacer E. OIL PUMP • Remove the snap ring 1, washer 2 and oil pump driven sprocket 3.  0990-06107: Snap ring pliers (Open type) NOTE: Do not drop the snap ring 1 and washer 2 into the crankcase.
Page 67 ENGINE 3-19 GEARSHIFT SYSTEM • Remove the snap ring 1 and washer 2 from the gearshift shaft.  0990-06107: Snap ring pliers (Open type) • Remove the gearshift shaft assembly 3 and washer 4. • Remove the gearshift cam stopper plate bolt 5 and gearshift cam stopper plate 6.
Page 68 3-20 ENGINE PRIMARY DRIVE GEAR • Hold the primary drive gear nut and remove the crank bal- ancer bolt 1 and washer 2. • Hold the generator rotor and remove the primary drive gear nut 3.  09930-44521: Rotor holder NOTE: The primary drive gear nut 3 has left-hand threads.
Page 69 ENGINE 3-21 GENERATOR ROTOR • Hold the generator rotor with the special tool.  09930-44521: Rotor holder • Loosen the generator rotor bolt 1. NOTE: When loosen the generator rotor bolt 1, do not remove it. The generator rotor bolt is used in conjunction with the generator rotor remover when removing the generator rotor.
Page 70 3-22 ENGINE GEAR POSITION SWITCH • Remove the gear position switch 1. • Remove the switch contacts 2 and springs 3. OIL FILTER AND OIL PRESSURE SWITCH • Remove the oil filter 1 with the special tool.  09915-40620: Oil filter wrench •...
Page 71 ENGINE 3-23 OIL STRAINER AND OIL PRESSURE REGULATOR • Remove the oil strainer 1. • Remove the oil pressure regulator 2. CRANKCASE • Remove the upper and lower crankcase bolts (M6). • Remove the upper and lower crankcase bolts (M8). NOTE: Loosen the crankcase bolts diagonally and the smaller sizes first.
Page 72 3-24 ENGINE TRANSMISSION • Remove the oil seal 1. • Remove the driveshaft assembly 2 and countershaft assem- bly 3. • Remove the C-rings 4 and pins 5. CRANK BALANCER AND CRANKSHAFT • Remove the crank balancer assembly 1. • Remove the crankshaft assembly 2 and thrust bearings 3. •...
Page 73: Engine Components Inspection And Service
ENGINE 3-25 ENGINE COMPONENTS INSPECTION AND SERVICE Identify the position of each removed part. Organize the parts in their respective groups (i.e., intake, exhaust) so that they can be installed in their original positions. CYLINDER HEAD COVER • Clean and check the gasket grooves A and PAIR reed valve gasket mating surfaces B of cylinder head cover.
Page 74: Camshaht Housing
3-26 ENGINE CAMSHAHT HOUSING DISASSEMBLY • Pull out the rocker arm shafts 1. • Remove the valve rocker arms 2 and wave washers 3. ROCKER ARM SHAFT OUTSIDE DIAMETER INSPECTION • Measure each rocker arm shaft out side diameter using the micrometer.
Page 75: Cylinder Head
ENGINE 3-27 CYLINDER HEAD DISASSEMBLY • Remove the intake pipes 1 and cylinder head water outlet pipe 2. • Remove the oil gallery plugs 3 if necessary. • Compress the valve spring using the special tools. Compressing of the valve spring must be limited to the extent only necessary to prevent the spring from fatigue.
Page 76 3-28 ENGINE • Remove the oil seal 9 and spring seat 0. • Remove the other valves in the same manner as described previously. CYLINDER HEAD DISTORTION • Decarbonize the combustion chambers. • Check the gasket surface of the cylinder head for distortion. Use a straightedge and thickness gauge.
Page 77 ENGINE 3-29 VALVE HEAD RADIAL RUNOUT • Place the dial gauge at a right angle to the valve head face and measure the valve head radial runout. • If it measures more than the service limit, replace the valve.  Valve head radial runout: Service Limit: 0.03 mm (0.001 in) ...
Page 78 3-30 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 (IN. & EX.): 0.9 – 1.1 mm (0.035 – 0.043 in) VALVE SEAT SERVICING •...
Page 79 ENGINE 3-31 VALVE STEM END CONDITION • Inspect the valve stem end face for pitting and wear. If pitting or wear is present, resurface the valve stem end. • Make sure that the length A is not less than 2.2 mm (0.09 in). If this length becomes less than 2.2 mm (0.09 in), replace the valve.
Page 80 3-32 ENGINE • Insert the valve, with its stem coated with molybdenum oil solution all around and along the full stem length without any break. When inserting the valve, take care not to damage the lip of the oil seal. ...
Page 81  Cylinder head water outlet pipe bolt: 10 N·m (1.0 kgf-m, 7.0 lbf-ft) • Apply grease to the new O-rings of the intake pipes 8.  99000-25010: SUZUKI SUPER GREASE “A” or equivalent • Install the intake pipes 8 with “UP” mark G faced upward.
Page 82: Camshaft
3-34 ENGINE CAMSHAFT CAM WEAR • Check the camshaft for wear or damage. • Measure the cam height H with the micrometer. Replace a camshaft if the cams are worn to the service limit.  Cam height H: Service Limit: (IN.) : 33.04mm (1.301 in) (EX.) : 32.75 mm (1.289 in) ...
Page 83: Camshaft Runout
ENGINE 3-35 • If the camshaft journal oil clearance exceeds the limit, mea- sure the inside diameter of the camshaft journal holder and outside diameter of the camshaft journal. • Replace the camshaft or the cylinder head depending upon which one exceeds the specification. ...
Page 84: Cam Chain Tension Adjuster
3-36 ENGINE CAM CHAIN TENSION ADJUSTER INSPECTION • Check that the push rod 1 can slide smoothly with the lock 2 of the ratchet mechanism released. • If it does not slide smoothly or the ratchet mechanism is worn or damaged, replace the cam chain tension adjuster with a new one.
Page 85: Piston
ENGINE 3-37 CYLINDER BORE • Measure the cylinder bore diameter at six places. • If any one of the measurements exceed the limit, overhaul the cylinder and replace the piston with an oversize piston, or replace the cylinder.  Cylinder bore: Service Limit: 53.590 mm (2.1098 in) ...
Page 86: Piston Ring Groove Width
3-38 ENGINE PISTON PIN AND PIN BORE • Measure the piston pin bore diameter using the small bore gauge. • If the measurement is out of specification, replace the piston.  Piston pin bore I.D.: Service Limit: 15.030 mm (0.5917 in) ...
Page 87: Piston Ring End Gap
ENGINE 3-39 PISTON RING FREE END GAP AND PISTON RING END GAP • Measure the piston ring free end gap using the vernier cali- pers. • Next, fit the piston ring squarely into the cylinder and measure the piston ring end gap using the thickness gauge. •...
Page 88: Clutch
3-40 ENGINE CLUTCH CLUTCH DRIVE PLATE INSPECTION NOTE: Wipe off engine oil from the clutch drive plates with a clean rag. Measure the thickness of drive plates with a vernier calipers. If the drive plate thickness is found to have reached the limit, replace it with a new one.
Page 89: Oil Pump
ENGINE 3-41 CLUTCH RELEASE BEARING INSPECTION Inspect the clutch release bearing for any abnormality, particu- larly cracks, to decide whether it can be reused or should be replaced. Smooth engagement and disengagement of the clutch depends on the condition of this bearing. CLUTCH SLEEVE HUB/PRIMARY DRIVEN GEAR ASSEMBLY Inspect the slot of the clutch sleeve hub 1 and primary driven gear assembly 2 for damage or wear caused by the clutch...
Page 90: Starter Clutch
3-42 ENGINE STARTER CLUTCH STARTER DRIVEN GEAR INSPECTION • Install the starter driven gear to the starter clutch and turn the starter driven gear by hand to inspect the starter clutch for a smooth movement. The gear turns one direction only. If a large resistance is felt to rotation, inspect the starter clutch for damage or inspect the starter clutch contacting surface of the starter driven gear for wear or damage.
Page 91 ENGINE 3-43 REASSEMBLY • Apply engine oil to the one way clutch 1. • When inserting the one way clutch 1 into the guide 2, fit the flange A in the step of the guide 2. NOTE: Be sure to seat the flange A of the one way clutch 1 to the guide 2.
Page 92: Generator
3-44 ENGINE PRIMARY DRIVE GEAR Rotate the primary drive scissors gear by finger to inspect for smooth rotation. If there are signs of any abnormalities, replace the springs. • When installing the primary drive scissors gear, align the punch mark A on the scissors gear with the rib B. GENERATOR INSPECTION (9-10 to -11) REASSEMBLY...
Page 93: Gearshift System
ENGINE 3-45 GEARSHIFT SYSTEM GEARSHIFT SHAFT DISASSEMBLY • Remove the following parts from the gearshift shaft. 1 Snap ring 4 Plate return spring 2 Gearshift shaft return spring 5 Washer 3 Gearshift cam drive plate GEARSHIFT SHAFT INSPECTION • Inspect the gearshift shaft for wear or bend. •...
Page 94: Clutch Release Camshaft
• Apply grease to the camshaft sliding surface of the clutch release camshaft 1 and new oil seal lip.  99000-25010: SUZUKI SUPER GREASE “A” or equivalent • Pass the new oil seal 2 into the upper crankcase 3 at 0 –...
Page 95: Oil Pressure Regulator
ENGINE 3-47 OIL PRESSURE REGULATOR Inspect the operation of the oil pressure regulator by pushing on the piston with a proper bar. If the piston does not operate, replace the oil pressure regulator with a new one. OIL STRAINER • Clean the oil strainer if necessary. •...
Page 96: Transmission
3-48 ENGINE TRANSMISSION DISASSEMBLY Disassemble the countershaft and driveshaft as shown in the illustration. NOTE: Identify the position of each removed part. Organize the parts in their respective groups (i.e., drive or driven) so that they can be reinstalled in their original positions. 1 Countershaft/1st drive gear 7 2nd driven gear 2 5th drive gear...
Page 97 * After installing a snap ring, make sure that it is completely seated in its groove and securely fitted.  99000-25010: SUZUKI SUPER GREASE “A” or equivalent • When installing a new snap ring 1, pay attention to its direc- tion.
Page 98 3-50 ENGINE TRANSMISSION PARTS LOCATION 1 Countershaft 2 Driveshaft...
Page 99: Crankcase
ENGINE 3-51 CRANKCASE GEARSHIFT FORK AND GEARSHIFT CAM Removal • Remove the gearshift cam bearing retainer No.1 1 and No.2 2 by removing the bearing retainer screws 3 from the lower crankcase. • Remove the gearshift fork shafts 4 and gearshift forks 5 from the lower crankcase.
Page 100 3-52 ENGINE GEARSHIFT FORK GROOVE WIDTH Measure the gearshift fork groove width using the vernier cali- pers.  Shift fork groove width: Standard: 5.0 – 5.1 mm (0.197 – 0.201 in)  09900-20101: Vernier calipers (150 mm) GEARSHIFT FORK THICKNESS Measure the gearshift fork thickness using the vernier calipers.
Page 101 The stamped mark side of the gearshift shaft bearing faces out- side. • Install the new oil seal with a suitable size socket wrench. • Apply grease to the oil seal lip.  99000-25010: SUZUKI SUPER GREASE “A” or equivalent...
Page 102 3-54 ENGINE GEARSHIFT FORK AND GEARSHIFT CAM Installation • Apply a small quantity of thread lock to the gearshift arm stop- per 1 and tighten it to the specified torque.  09900-32030: THREAD LOCK CEMENT SUPER “1303” or equivalent  Gearshift arm stopper: 19 N·m (1.9 kgf-m, 13.5 lbf-ft) •...
Page 103 ENGINE 3-55 OIL JET Removal • Remove the oil jet 1 (for cylinder head) from the upper crank- case. • Remove the crankshaft journal bearings 2. • Remove the piston cooling oil jets 3 from the upper crank- case. • Remove the oil jet 4 (for transmission) from the lower crank- case.
Page 104 3-56 ENGINE Installation Installation is in the reverse order of removal. Pay attention to the following points: • After tightening the oil jet 1 (for transmission), make sure that the oil jet end is flush with the crankcase mating surface. •...
Page 105 ENGINE 3-57 Installation Installation is in the reverse order of removal. Pay attention to the following points: • Fit the new gaskets 1 to the oil gallery plugs 2 as shown in the illustration. • Tighten the oil gallery plugs 2 to the specified torque. ...
Page 106: Crank Balancer
3-58 ENGINE CRANK BALANCER DISASSEMBLY • Remove the snap ring 1 and washer 2.  09900-06107: Snap ring pliers (Open type) • Remove the following parts from the crank balancer 3. 4 Balancer spring (6 pcs.) 5 Pin (3 pcs.) 6 Crank balancer driven gear 7 Wave washer Never remove the driven gear inner race 8 from the...
Page 107: Crank Balancer Journal Bearing
ENGINE 3-59 CRANK BALANCER JOURNAL BEARING INSPECTION • Inspect each bearing of upper and lower crankcases for any damage. SELECTION • Place the plastigage axially along the crank balancer journal as shown.  09900-22301: Plastigage (0.025 – 0.076 mm) • Mate the lower crankcase with the upper crankcase. •...
Page 108 3-60 ENGINE • Check the corresponding crankcase journal I.D. codes A, “A” or “B” which is stamped on the rear of upper crankcase. • Check the corresponding crank balancer journal O.D. codes B, “A”, “B” or “C” which is stamped on the crank balancer. ...
Page 109: Crankshaft And Conrod
ENGINE 3-61 INSTALLATION • When installing the bearings into the upper and lower crank- cases, be sure to install the tab A first, and then press in the other opposite side of the bearing. NOTE: Do not touch the bearing surfaces with your hands. Grasp by the edge of the bearing shell.
Page 110 3-62 ENGINE CONROD BIG END SIDE CLEARANCE • Inspect the conrod side clearance using a thickness gauge. • If the clearance exceeds the limit, remove the conrod and inspect the conrod big end width and the crank pin width. • If the width exceed the limit, replace conrod or crankshaft. ...
Page 111 ENGINE 3-63 • Tighten the conrod cap bolts to the specified torque, in two steps. (3-65) NOTE: * When installing the conrod cap bolts to the crank pin, make sure that I.D. code A on the conrod faces towards the intake side. * Never rotate the crankshaft or conrod when a piece of plasti- gage is installed.
Page 112 3-64 ENGINE  Crank pin O.D. Code O.D. specification 30.992 – 31.000 mm (1.2202 – 1.2205 in) 30.984 – 30.992 mm (1.2198 – 12202 in) 30.976 – 30.984 mm (1.2195 – 1.2198 in)  09900-20202: Micrometer (25 – 50 mm) ...
Page 113: Crankshaft Journal Bearing
ENGINE 3-65 • Apply engine oil to the thread portion and bearing surface of the bolts. • Tighten the conrod cap bolts in the following two steps.  Conrod cap bolt: 15 N·m (1.5 kgf-m, 11.0 lbf-ft) then turn 90° (1/4 turn) clockwise CRANKSHAFT JOURNAL BEARING INSPECTION •...
Page 114 3-66 ENGINE • Mate the lower crankcase with the upper crankcase. • Tighten each crankshaft journal bolt (M:8) to the specified torque. (3-73) NOTE: Never rotate the crankshaft when a piece of plastigage is installed.  Crankshaft journal bolt (M:8): Initial: 15 N·m (1.5 kgf-m, 11.0 lbf-ft) Final : 26 N·m (2.6 kgf-m, 19.0 lbf-ft) •...
Page 115 ENGINE 3-67  Crankshaft journal O.D. specification Code O.D. specification 29.992 – 30.000 mm (1.1808 – 1.1811 in) 29.984 – 29.992 mm (1.1805 – 1.1808 in) 29.976 – 29.984 mm (1.1802 – 1.1805 in)  09900-20202: Micrometer (25 – 50 mm) ...
Page 116: Crankshaft Thrust Bearing
3-68 ENGINE CRANKSHAFT THRUST BEARING INSPECTION • With the crankshaft, right-side thrust bearing and left-side thrust bearing inserted in the upper crankcase. • Measure the thrust clearance a between the left side thrust bearing and crankshaft using the thickness gauge. L: Left-side thrust bearing R: Right-side thrust bearing NOTE:...
Page 117 ENGINE 3-69  Thrust bearing selection table (Right side) Clearance before Color Thrust bearing inserting right-side Thrust clearance (Part No.) thickness thrust bearing 2.680 – 2.700 mm None 2.600 – 2.625 mm 0.055 – 0.100 mm (0.1055 – 0.1063 in) (12228-17E00-0L0) (0.1024 –...
Page 118: Engine Reassembly
3-70 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. CRANKSHAFT • Before installing the crankshaft assembly, apply a molybde- num oil solution to each crankshaft journal surface and bear- ing surface lightly.
Page 119 ENGINE 3-71 TRANSMISSION • Install the bearing pins 1 and the C-rings 2 on the upper crankcase. • Install the countershaft assembly to the upper crankcase. NOTE: Align the C-ring with the groove of bearing and the bearing pin with the indent on the bearing. •...
Page 120  99000-31140: SUZUKI BOND No.1207B or equivalent NOTE: • Use of SUZUKI bond is as follows: * Make surfaces free from moisture, oil, dust and other foreign materials. * Spread the sealant on surfaces thinly to form an even layer, and assemble the crankcases within few minutes.
Page 121 ENGINE 3-73 • Match the upper and lower crankcases. NOTE: Align the gearshift forks 1 with their grooves 2. • Fit the new gasket washers to the bolts 5 to 8 numbers. • Tighten the crankshaft journal bolts (M:8) in ascending order of numbers assigned to these bolts.
Page 122  Oil pressure regulator: 28 N·m (2.8 kgf-m, 20.0 lbf-ft) OIL STRAINER • Apply grease to the new O-ring 1.  99000-25010: SUZUKI SUPER GREASE “A” or equivalent • Install the oil strainer 2. • Apply thread lock to the oil strainer bolts 3 and tighten them to the specified torque.
Page 123  Oil pan bolt: 10 N·m (1.0 kgf-m, 7.0 lbf-ft) ENGINE SPROCKET SPACER • Apply grease to the new O-ring and oil seal lip.  99000-25010: SUZUKI SUPER GREASE “A” or equivalent • Install the engine sprocket spacer 1. NOTE: The grooved A side of the engine sprocket spacer 1 must face crankcase side.
Page 124 OIL PRESSURE SWITCH • Apply bond to the thread part of oil pressure switch and tighten oil pressure switch to the specified torque.  99000-31140: SUZUKI BOND No.1207B or equivalent  Oil pressure switch: 13 N·m (1.3 kgf-m, 9.5 lbf-ft) NOTE: Be careful not to apply bond to the hole of thread end.
Page 125 ENGINE 3-77 GENERATOR ROTOR • Apply engine oil to the bushing of the starter driven gear. • Fit the key 1 in the key slot on the crankshaft. • 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.
Page 126 • Apply engine oil to the starter idle gear shaft hole. • Apply bond lightly to the mating surfaces at the parting line between the upper and lower crankcases as shown.  99000-31140: SUZUKI BOND No.1207B or equivalent • Install the dowel pins 1 and new gasket 2.
Page 127 ENGINE 3-79 • Install the generator cover 3 and tighten the generator cover bolts to the specified torque.  Generator cover bolt: 10 N·m (1.0 kgf-m, 7.0 lbf-ft)  Be careful not to pinch finger between the generator cover and crankcase. GEARSHIFT SYSTEM •...
Page 128 3-80 ENGINE • Install the gearshift shaft assembly 7 with the washer 8. NOTE: Pinch the gearshift arm stopper 9 with return spring ends D. • Install the washer 0 and new snap ring A.  09900-06107: Snap ring pliers (Open type) OIL PUMP •...
Page 129 ENGINE 3-81 • Engage the oil pump drive chain 5 to the oil pump drive sprocket 6 and oil pump driven sprocket 7. • Install the oil pump drive chain 5 with the oil pump drive sprocket 6 and oil pump driven sprocket 7. NOTE: Teeth C on the oil pump drive sprocket 6 must face the clutch side.
Page 130 3-82 ENGINE • Apply engine oil to the inside and outside surface of the spacer 1. • Install the spacer 1 onto the countershaft. NOTE: The chamfer side A of spacer 1 crankcase inside. • Install the primary driven gear assembly 2 onto the countershaft.
Page 131 ENGINE 3-83 • Hold the clutch sleeve hub with the special tool.  09920-53740: Clutch sleeve hub holder • Tighten the clutch sleeve hub nut to the specified torque.  Clutch sleeve hub nut: 50 N·m (5.0 kgf-m, 36.0 lbf-ft) •...
Page 132 • Pour engine oil (30 ml – 40 ml) from the hole of the clutch pressure plate into the clutch sleeve hub. CLUTCH COVER • Apply bond lightly to the mating surfaces at the parting line between the upper and lower crankcases as shown.  99000-31140: SUZUKI BOND No.1207B or equivalent...
Page 133  Clutch cover bolt: 10 N·m (1.0 kgf-m, 7.0 lbf-ft) STARTER MOTOR • Apply grease to the new O-ring.  99000-25010: SUZUKI SUPER GREASE “A” or equivalent PISTON RING • Install the piston rings in the order of oil ring, 2nd ring and 1st ring.
Page 134 3-86 ENGINE • Install the 2nd ring 3 and the 1st ring 4 to the piston. NOTE: 1st ring and 2nd ring differ in shape. NOTE: Face the side with the stamped mark upward when assembling. 1st ring 2nd ring •...
Page 135 ENGINE 3-87 • Place a clean rag over the cylinder base so as not to drop the piston pin circlip 2 into the crankcase. • Install a piston pin circlip 2. NOTE: End gap of the circlip 2 should not be aligned with the cutaway in the piston pin bore.
Page 136 3-88 ENGINE • Place the cylinder head 4 on the cylinder. NOTE: When installing the cylinder head, keep the cam chain taut. • Apply engine oil to the washers A and thread portion of the bolts before installing the cylinder head bolts. •...
Page 137 ENGINE 3-89 CAMSHAFT • Turn the crankshaft counterclockwise and align the “I R” line on the generator rotor with the index mark A of valve timing inspection hole while keeping the cam chain pulled upward. NOTE: * Pull the cam chain upward, or the chain will be caught between crankcase and cam drive sprocket.
Page 138 3-90 ENGINE • Turn the crankshaft counterclockwise and tighten the cam- shaft sprocket bolts 5 to the specified torque.  Camshaft sprocket bolt: 15 N·m (1.5 kgf-m, 11.0 lbf-ft) • Turn the crankshaft counterclockwise to bring the “I R” line on generator rotor to the index mark E of the valve inspection hole and also to bring the camshaft to the position as shown.
Page 139 ENGINE 3-91 • Tighten the camshaft journal holder bolts in ascending order of numbers to the specified torque.  Camshaft journal holder bolt: 10 N·m (1.0 kgf-m, 7.0 lbf-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 140 3-92 ENGINE CAM CHAIN TENSION ADJUSTER • Retract the push rod by pushing the stopper 1. • Fit a new gasket 2. • Install the cam chain tension adjuster 3 and tighten its mounting bolts 4.  Cam chain tension adjuster mounting bolt: 10 N·m (1.0 kgf-m, 7.0 lbf-ft) •...
Page 141 • Install new gasket 1 to the cylinder head cover. • Apply bond to the cam end caps of the gaskets as shown.  99000-31140: SUZUKI BOND No.1207B or equivalent • Place the cylinder head cover on the cylinder head.
Page 142 FI SYSTEM DIAGNOSIS 4-1 FI SYSTEM DIAGNOSIS CONTENTS PRECAUTIONS IN SERVICING ..............4- 3 ELECTRICAL PARTS ................4- 3 FUSE...................... 4- 4 SWITCH ....................4- 4 ECM/VARIOUS SENSORS ..............4- 5 BATTERY ....................4- 5 ELECTRICAL CIRCUIT INSPECTION PROCEDURE......4- 6 USING THE MULTI CIRCUIT TESTER..........
Page 143 4-2 FI SYSTEM DIAGNOSIS FI SYSTEM DIAGNOSIS CONTENTS DTC “C41” (P0230-H/L): FP RELAY CIRCUIT MALFUNCTION ..4-66 DTC “C41” (P2505): ECM POWER INPUT SIGNAL MALFUNCTION..................4-69 DTC “C42” (P1650): IG SWITCH CIRCUIT MALFUNCTION....4-70 DTC “C44” (P0130/P0135): HO2 SENSOR (HO2S) CIRCUIT MALFUNCTION ....... 4-71 DTC “C49”...
Page 144: Precautions In Servicing
FI SYSTEM DIAGNOSIS 4-3 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 • Faulty FI system is often related to poor electrical contact of connector/coupler.
Page 145: Fuse
4-4 FI SYSTEM DIAGNOSIS • When taking measurements at electrical connectors using a tester probe, be sure to insert the probe from the wire harness side (rear) of the connector/coupler. 1 Coupler 2 Probe • 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.
Page 146: Ecm/Various Sensors
FI SYSTEM DIAGNOSIS 4-5 ECM/VARIOUS SENSORS • Since each component is a high-precision part, great care INCORRECT should be taken not to apply any severe impacts during removal and installation. • Be careful not to touch the electrical terminals of the elec- tronic parts (ECM, etc.).
Page 147: Electrical Circuit Inspection Procedure
4-6 FI SYSTEM DIAGNOSIS • Before measuring voltage at each terminal, check to make sure that battery voltage is 11 V or higher. Terminal voltage check with a low voltage battery will lead to erroneous diagno- sis. • Never connect any tester (voltmeter, ohmmeter, or whatever) to the electronic unit when its coupler is disconnected.
Page 148 FI SYSTEM DIAGNOSIS 4-7 • Using a test male terminal, check the female terminals of the circuit being checked for contact tension. Check each terminal visually for poor contact (possibly caused by dirt, corrosion, rust, entry of foreign object, etc.). At the same time, check to make sure that each terminal is fully inserted in the coupler and locked.
Page 149 4-8 FI SYSTEM DIAGNOSIS VOLTAGE CHECK If voltage is supplied to the circuit being checked, voltage check can be used as circuit check. • With all connectors/couplers connected and voltage applied to the circuit being checked, measure voltage between each terminal and body ground.
Page 150: Using The Multi Circuit Tester
1 ECM *1 To other parts USING THE MULTI CIRCUIT TESTER • Use the Suzuki multi circuit tester set. • Use well-charged batteries in the tester. • Be sure to set the tester to the correct testing range.  09900-25008: Multi circuit tester set USING THE TESTER •...
Page 151: Fi System Technical Features
4-10 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 152: Compensation Of Injection Time (Volume)
FI SYSTEM DIAGNOSIS 4-11 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 153: Fi System Parts Location
4-12 FI SYSTEM DIAGNOSIS FI SYSTEM PARTS LOCATION A ECM F Heated oxygen sensor (HO2S) B Ignition coil #2 (IG coil #2) G Tip-over sensor (TOS) C Engine coolant temperature sensor (ECTS) H Intake air pressure sensor #2 (IAPS #2) D Fuel injector #2 I PAIR control solenoid valve E Idle speed control valve (ISC valve)
Page 154 FI SYSTEM DIAGNOSIS 4-13 A ECM P Gear position switch (GP switch) J Combination meter Q Speed sensor K Ignition coil #1 (IG coil #1) R Fuel pump relay (FP relay) L Fuel injector #1 S Cooling fan relay M Throttle position sensor (TPS) T Fuel pump (FP) N Intake air temperature sensor (IATS) U Cooling fan...
Page 155: Fi System Wiring Diagram
4-14 FI SYSTEM DIAGNOSIS FI SYSTEM WIRING DIAGRAM Combination meter Cooling fan Cooling fan motor relay B/G Dg Speed sensor Regulator/ Rectifier Fuel Bl/Y pump Bl/G Generator CKPS Fuel injector FP relay 10 A O/Bl Bl/W Ignition IAPS #1 coil 10 A Ignition Engine...
Page 156: Ecm Terminal
FI SYSTEM DIAGNOSIS 4-15 ECM TERMINAL TERMINAL TERMINAL CIRCUIT CIRCUIT ISC valve signal (ISC 2A) — ISC valve signal (ISC 1A) Serial data for self-diagnosis HO2 sensor (HO2S) Power source for fuel injectors (VM) — ECM ground (E1) IAP sensor signal #1 (IAPS #1) Power source for back-up (BATT) —...
Page 157: Self-Diagnosis Function
4-16 FI SYSTEM DIAGNOSIS 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 (DISPLAY) panel and LED (FI indicator light). To check the function of the individual FI system devices, the dealer mode is provided.
Page 158: Dealer Mode
FI SYSTEM DIAGNOSIS 4-17 DEALER MODE The defective function is memorized in the computer. Use the special tool’s coupler to connect to the mode selection switch. 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 159 4-18 FI SYSTEM DIAGNOSIS CODE MALFUNCTION PART REMARKS None No defective part Crankshaft position sensor (CKPS) Pick-up coil signal, signal generator Intake air pressure sensor #2 (IAPS #2) For #2 cylinder Throttle position sensor (TPS) Engine coolant temperature sensor (ECTS) Intake air pressure sensor #1 (IAPS #1) For #1 cylinder Intake air temperature sensor (IATS)
Page 160: Tps Adjustment
FI SYSTEM DIAGNOSIS 4-19 TPS ADJUSTMENT 1. Connect the special tool (Mode selection switch) to the mode select coupler. (4-23) 2. Warm up the engine and keep it running in idling speed. 3. Turn the mode selection switch ON. 4. Check the position of the bar in the left of C code displayed on the LCD panel.
Page 161: Fail-Safe Function
4-20 FI SYSTEM DIAGNOSIS FAIL-SAFE FUNCTION FI system is provided with fail-safe function to allow the engine to start and the motorcycle to run in a mini- mum performance necessary even under malfunction condition. STARTING RUNNING ITEM FAIL-SAFE MODE ABILITY ABILITY IAP sensor Intake air pressure is fixed to 101...
Page 162: Fi System Troubleshooting
FI SYSTEM DIAGNOSIS 4-21 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 such an inspection form such as following will facilitate collecting information to the point required for proper analysis and diagnosis.
Page 163: Visual Inspection
4-22 FI SYSTEM DIAGNOSIS MOTORCYCLE/ENVIRONMENTAL CONDITION WHEN PROBLEM OCCURS Environmental condition Weather Fair Cloudy Rain Snow Always Other Temperature Warm Cool Cold ( °C/ °F) Always Frequency Always Sometimes ( times/ day, month) Only once Under certain condition Road Urban Suburb Highway Mountainous (...
Page 164: Self-Diagnostic Procedures
FI SYSTEM DIAGNOSIS 4-23 SELF-DIAGNOSTIC PROCEDURES NOTE: * Do not disconnect the couplers from ECM, battery cable from battery, ECM ground wire from engine or main fuse before confirming the DTC (Diagnostic Trouble Code) stored in mem- ory. Such disconnection will erase the memorized information in ECM memory.
Page 165: Use Of Sds Diagnostic Procedures
* How to use trigger, refer to the SDS operation manual for fur- ther details.  09904-41010: SUZUKI Diagnostic system set 99565-01010-028: CD-ROM Ver.28 • After repairing the trouble, clear to delete history code (past...
Page 166: Use Of Sds Diagnosis Reset Procedure
FI SYSTEM DIAGNOSIS 4-25 USE OF SDS DIAGNOSIS RESET PROCE- DURE • After repairing the trouble, turn OFF the ignition switch and turn 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 167: Show Failure Data (Displaying Data At The Time Of Dtc)
4-26 FI SYSTEM DIAGNOSIS SHOW FAILURE DATA (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 failure data”. Therefore, it is possible to know engine and driving conditions (e.g., whether the engine was warm or not, where the motorcycle was running or stopped) when a malfunction was detected by checking the show fail- ure data.
Page 168: Malfunction Code And Defective Condition
FI SYSTEM DIAGNOSIS 4-27 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 wiring and mechan- sec. or more, after receiving the starter ical parts signal.
Page 169 4-28 FI SYSTEM DIAGNOSIS DETECTED DTC No. DETECTED FAILURE CONDITION CHECK FOR ITEM TO sensor The sensor voltage should be the fol- TO sensor, lead wire/coupler lowing for 2 sec. and more, after igni- connection tion switch is turned ON. 0.2 V sensor voltage <...
Page 170 FI SYSTEM DIAGNOSIS 4-29 DETECTED DTC No. DETECTED FAILURE CONDITION CHECK FOR ITEM HO2 sensor HO2 sensor output voltage is not input Output state of HO2 sensor to ECM during engine operation and running condition. P0130 C44 (P0130) is indicated. The Heater can not operate so that HO2 sensor lead wire/coupler heater operation voltage is not supply...
Page 171: Dtc "C12" (P0335): Ckp Sensor Circuit Malfunction
4-30 FI SYSTEM DIAGNOSIS DTC “C12” (P0335): CKP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION AND POSSIBLE CAUSE 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.
Page 172 FI SYSTEM DIAGNOSIS 4-31 Step 1 CKP sensor signal circuit check 1) Turn the ignition switch OFF. 2) Remove the seat and right frame cover. (8-4 and 8-5) 3) Disconnect the CKP sensor coupler 1 and ECM couplers 2. 4) Check for proper terminal connection to the CKP sensor cou- pler and ECM couplers.
Page 173 4-32 FI SYSTEM DIAGNOSIS – Between the G wire and B wire at CKP sensor coupler: infinity • Voltage  09900-25008: Multi circuit tester set  Tester knob indication: Voltage () – Between G wire or B wire and ground: approx. 0 V (When ignition switch is ON) Is check result OK? Go to Step 2.
Page 174 FI SYSTEM DIAGNOSIS 4-33 Step 3 CKP sensor and signal rotor check 1) Remove the generator cover. (3-19) 2) Check that end face of the CKP sensor 1 and generator teeth 2 are free from any metal particles and damage. Is check result OK? Go to Step 4.
Page 175: Dtc "C13" (P1750-H/L) Or "C17" (P0105-H/L): Iap Sensor Circuit Malfunction
4-34 FI SYSTEM DIAGNOSIS DTC “C13” (P1750-H/L) or “C17” (P0105-H/L): IAP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION AND POSSIBLE CAUSE DETECTED CONDITION POSSIBLE CAUSE C13/C17 IAP sensor voltage is not within the fol- • Clogged vacuum passage between throttle body lowing range. and IAP sensor.
Page 176 FI SYSTEM DIAGNOSIS 4-35 Step 1 IAP sensor power supply circuit check 1) Turn the ignition switch OFF. 2) Remove the fuel tank. (5-2) 3) Disconnect the IAP sensor coupler related DTC. (#1 cylinder 1 or #2 cylinder 2) 4) Check for proper terminal connection to the IAP sensor cou- pler.
Page 177 4-36 FI SYSTEM DIAGNOSIS 3) Check for proper terminal connection to the ECM couplers. #1 Cylinder 4) If connections are OK, check the following points. • Resistance  09900-25008: Multi circuit tester set 09900-25009: Needle-point probe set  Tester knob indication: Resistance () –...
Page 178 FI SYSTEM DIAGNOSIS 4-37 Step 4 IAP sensor check 1 1) Turn the ignition switch OFF. 2) Connect the ECM couplers and IAP sensor coupler. 3) Insert the needle-point probes to the lead wire coupler. 4) Run the engine at idle speed and measure the IAP sensor output voltage between the Bl/W wire (#1) or W/R wire (#2) and B/Br wire.
Page 179: Dtc "C14" (P0120-H/L): Tp Sensor Circuit Malfunction
4-38 FI SYSTEM DIAGNOSIS DTC “C14” (P0120-H/L): TP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION AND POSSIBLE CAUSE DETECTED CONDITION POSSIBLE CAUSE Output voltage is not within the following • TP sensor maladjusted. range. • TP sensor circuit open or short. 0.2 V Sensor voltage <...
Page 180 FI SYSTEM DIAGNOSIS 4-39 Step 1 TP sensor power supply circuit check 1) Turn the ignition switch OFF. 2) Remove the left frame front cover. (8-4) 3) Disconnect the TP sensor coupler 1. 4) Check for proper terminal connection to the TP sensor cou- pler.
Page 181 4-40 FI SYSTEM DIAGNOSIS Step 3 TP sensor signal circuit check 1) Turn the ignition switch OFF. 2) Remove the seat. (8-5) 3) Disconnect the ECM couplers 1. 4) Check for proper terminal connection to the ECM couplers. 5) If connections are OK, check the following points. •...
Page 182 FI SYSTEM DIAGNOSIS 4-41 • Voltage  09900-25008: Multi circuit tester set  Tester knob indication: Voltage () – Between V wire and ground: approx. 0 V (When ignition switch is ON) Is check result OK? Go to Step 4. Repair or replace the V wire.
Page 183: Dtc "C15" (P0115-H/L): Ect Sensor Circuit Malfunction
4-42 FI SYSTEM DIAGNOSIS DTC “C15” (P0115-H/L): ECT SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION AND POSSIBLE CAUSE DETECTED CONDITION POSSIBLE CAUSE Output voltage is not within the following • ECT sensor circuit open or short. range. • ECT sensor malfunction. 0.15 V Sensor voltage <...
Page 184 FI SYSTEM DIAGNOSIS 4-43 Step 1 ECT sensor input voltage check 1) Turn the ignition switch OFF. 2) Remove the right fuel tank cover. (8-5) 3) Disconnect the ECT sensor coupler 1. 4) Check for proper terminal connection to the ECT sensor cou- pler.
Page 185 4-44 FI SYSTEM DIAGNOSIS – Between each of B/Bl and B/Br wire and ground: infinity – Between B/Bl wire terminal and B/Br wire at ECT sensor coupler: infinity • Voltage  09900-25008: Multi circuit tester set  Tester knob indication: Voltage () –...
Page 186 FI SYSTEM DIAGNOSIS 4-45 Step 3 ECT sensor check 1) Turn the ignition switch OFF. 2) Drain a small amount of engine coolant. (2-15) 3) Disconnect the ECT sensor coupler 1 and remove the ECT sensor 2. 4) Measure the ECT sensor resistance. NOTE: Refer to “ECT SENSOR INSPECTION”...
Page 187: Dtc "C21" (P0110-H/L): Iat Sensor Circuit Malfunction
4-46 FI SYSTEM DIAGNOSIS DTC “C21” (P0110-H/L): IAT SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION AND POSSIBLE CAUSE DETECTED CONDITION POSSIBLE CAUSE Output voltage is not within the following • IAT sensor circuit open or short. range. • IAT sensor malfunction. 0.15 V Sensor voltage <...
Page 188 FI SYSTEM DIAGNOSIS 4-47 Step 1 IAT sensor input voltage check 1) Turn the ignition switch OFF. 2) Disconnect the IAT sensor coupler 1. 3) Check for proper terminal connection to the IAT sensor cou- pler. 4) If connections are OK, turn the ignition switch ON. 5) Measure the input voltage between the Y/R wire and ground.
Page 189 4-48 FI SYSTEM DIAGNOSIS Step 2 IAT sensor circuit check 1) Turn the ignition switch OFF. 2) Remove the seat. (8-5) 3) Disconnect the ECM couplers 1. 4) Check for proper terminal connection to the ECM couplers. 5) If connections are OK, check the following points. •...
Page 190 FI SYSTEM DIAGNOSIS 4-49 • Voltage  09900-25008: Multi circuit tester set  Tester knob indication: Voltage () – Between Y/R wire or B/Br wire and ground: approx. 0 V (When ignition switch is ON) Is check result OK? Replace the ECM with a known good one, and inspect it again.
Page 191: Dtc "C23" (P1651-H/L): To Sensor Circuit Malfunction
4-50 FI SYSTEM DIAGNOSIS DTC “C23” (P1651-H/L): TO SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION AND POSSIBLE CAUSE DETECTED CONDITION POSSIBLE CAUSE The sensor voltage should be the follow- • TO sensor circuit open or short. ing for 2 sec. and more, after ignition •...
Page 192 FI SYSTEM DIAGNOSIS 4-51 Step 1 TO sensor power supply circuit check 1) Turn the ignition switch OFF. 2) Remove the seat. (8-5) 3) Remove the TO sensor 1 and disconnect the TO sensor coupler 2. (4-92) 4) Check for proper terminal connection to the TO sensor cou- pler.
Page 193 4-52 FI SYSTEM DIAGNOSIS Step 3 TO sensor signal circuit check 1) Turn the ignition switch OFF. 2) Remove the seat. (8-5) 3) Disconnect the ECM couplers 1. 4) Check for proper terminal connection to the ECM couplers. 5) If connections are OK, check the following points. •...
Page 194: Dtc "C24" (P0351) Or "C25" (P0352): Ignition System Malfunction
FI SYSTEM DIAGNOSIS 4-53 Step 4 TO sensor check 1) Turn the ignition switch OFF. 2) Connect the ECM couplers and TO sensor coupler. 3) Insert the needle-point probes to the lead wire coupler. 4) Turn the ignition switch ON. 5) Measure the TO sensor voltage between the Br wire and B/Br wire.
Page 195: Dtc "C31" (P0705): Gp Switch Circuit Malfunction
4-54 FI SYSTEM DIAGNOSIS DTC “C31” (P0705): GP SWITCH CIRCUIT MALFUNCTION DETECTED CONDITION AND POSSIBLE CAUSE DETECTED CONDITION POSSIBLE CAUSE No GP switch voltage • GP switch circuit open or short. GP switch voltage is not within the following range. •...
Page 196 FI SYSTEM DIAGNOSIS 4-55 4) Check for proper terminal connection to the GP switch cou- pler. 5) If connections are OK, turn the ignition switch ON. 6) Measure the input voltage between the P wire and ground. 7) If OK, measure the input voltage between the P wire and B/W wire.
Page 197 4-56 FI SYSTEM DIAGNOSIS – Between P wire terminal and other terminal at GP switch coupler: infinity • Voltage  09900-25008: Multi circuit tester set  Tester knob indication: Voltage () – Between P wire or B/W wire and ground: approx. 0 V (When ignition switch is ON) Is check result OK? Replace the ECM with a known good one, and...
Page 198: Dtc "C32" (P0201) Or "C33" (P0202): Fuel Injector Circuit Malfunction
FI SYSTEM DIAGNOSIS 4-57 DTC “C32” (P0201) or “C33” (P0202): FUEL INJECTOR CIRCUIT MALFUNCTION DETECTED CONDITION AND POSSIBLE CAUSE DETECTED CONDITION POSSIBLE CAUSE CKP signal is produced but fuel injector signal is • Injector circuit open or short. interrupted by 4 times or more continuity. •...
Page 199 4-58 FI SYSTEM DIAGNOSIS 4) Check for proper terminal connection to the injector coupler. 5) If connections are OK, turn the ignition switch ON. 6) Measure the voltage between O/Bl wire and ground. NOTE: Voltage can be detected only for 3 seconds after ignition switch is turned ON.
Page 200 FI SYSTEM DIAGNOSIS 4-59 – Between Bl/Y (#1) or Bl/G (#2) wire terminal and other ter- minal at injector coupler: infinity • Voltage  09900-25008: Multi circuit tester set  Tester knob indication: Voltage () – Between Bl/Y (#1) or Bl/G (#2) and ground wire: approx. 0 V (When ignition switch is ON) Is check result OK? Go to Step 3.
Page 201: Dtc "C40" (P0505): Isc Valve Circuit Malfunction
4-60 FI SYSTEM DIAGNOSIS DTC “C40” (P0505): ISC VALVE CIRCUIT MALFUNCTION DETECTED CONDITION AND POSSIBLE CAUSE DETECTED CONDITION POSSIBLE CAUSE The circuit voltage of motor drive is unusual. ISC valve circuit open or shorted to ground. WIRING DIAGRAM ISC valve ISC.
Page 202 FI SYSTEM DIAGNOSIS 4-61 Step 1 ISC valve drive circuit check 1) Turn the ignition switch OFF. 2) Remove the fuel tank. (5-2) 3) Disconnect the ISC valve coupler 1 and ECM couplers 2. 4) Check for proper terminal connection to the ISC valve coupler and ECM couplers.
Page 203 4-62 FI SYSTEM DIAGNOSIS – Between W/R wire terminal and other terminal at ISC valve coupler: infinity – Between B/R wire terminal and other terminal at ISC valve coupler: infinity – Between W/B wire terminal and other terminal at ISC valve coupler: infinity –...
Page 204 FI SYSTEM DIAGNOSIS 4-63 • Voltage  09900-25008: Multi circuit tester set  Tester knob indication: Voltage () – Between W/R, B/R, W/B or Lbl wires and ground: approx. 0 V (When ignition switch is ON) Is check result OK? Go to Step 2.
Page 205 4-64 FI SYSTEM DIAGNOSIS ACTIVE CONTROL INSPECTION (ISC RPM CONTROL) Check 1 1) Set up the SDS tools. (4-24 and refer to the SDS opera- tion manual for further details.) 2) Check that the engine is running. 3) Click the “Active control”. 4) Click the “ISC rpm control”...
Page 206 FI SYSTEM DIAGNOSIS 4-65 Check 3 1) Click the button 6 and increase the “Command value” 2 to 1 600 rpm slowly. 2) Check that the “Desired idle rpm” 3 is nearly equal to the “Command value” 2. Also, check that the number of steps 5 in the ISC valve position increases.
Page 207: Dtc "C41" (P0230-H/L): Fp Relay Circuit Malfunction
4-66 FI SYSTEM DIAGNOSIS DTC “C41” (P0230-H/L): FP RELAY CIRCUIT MALFUNCTION DETECTED CONDITION AND POSSIBLE CAUSE DETECTED CONDITION POSSIBLE CAUSE No voltage is applied to fuel pump. • FP relay circuit open or short. • FP relay malfunction. P0230 Voltage is applied to fuel pump although •...
Page 208 FI SYSTEM DIAGNOSIS 4-67 Step 1 FP relay power supply circuit check 1) Turn the ignition switch OFF. 2) Remove the frame upper cover assembly. (8-6) 3) Disconnect the FP relay coupler 1. 4) Check for proper terminal connection to the FP relay coupler. 5) If connections are OK, turn the ignition switch ON.
Page 209 4-68 FI SYSTEM DIAGNOSIS Step 3 FP relay drive circuit check 1) Turn the ignition switch OFF. 2) Disconnect the ECM couplers 1. 3) Check for proper terminal connection to the ECM couplers. 4) If connections are OK, check the following points. •...
Page 210: Dtc "C41" (P2505): Ecm Power Input Signal Malfunction
FI SYSTEM DIAGNOSIS 4-69 DTC “C41” (P2505): ECM POWER INPUT SIGNAL MALFUNCTION DETECTED CONDITION AND POSSIBLE CAUSE DETECTED CONDITION POSSIBLE CAUSE No voltage is applied to the ECM. • Lead wire/coupler connection of ECM terminal to fuel fuse. • Fuel fuse. WIRING DIAGRAM To combination meter Fuel pump...
Page 211: Dtc "C42" (P1650): Ig Switch Circuit Malfunction
4-70 FI SYSTEM DIAGNOSIS Step 1 ECM power supply circuit check 1) Turn the ignition switch OFF. 2) Remove the seat. (8-5) 3) Disconnect the ECM couplers 1. 4) Check for proper terminal connection to the ECM couplers. 5) If connections are OK, Measure the voltage between R/Y and ground.
Page 212: Dtc "C44" (P0130/P0135): Ho2 Sensor (Ho2S) Circuit Malfunction
FI SYSTEM DIAGNOSIS 4-71 DTC “C44” (P0130/P0135): HO2 SENSOR (HO2S) CIRCUIT MALFUNCTION DETECTED CONDITION AND POSSIBLE CAUSE DETECTED CONDITION POSSIBLE CAUSE HO2 sensor output voltage is not input • Output state of HO2 sensor. to ECM specified running condition. P0130 The heater can not operate so that •...
Page 213 4-72 FI SYSTEM DIAGNOSIS Step 1 HO2 sensor heater power supply circuit check 1) Turn the ignition switch OFF. 2) Disconnect the HO2 sensor coupler 1. (4-93) 3) Check for proper terminal connection to the HO2 sensor cou- pler. 4) If connections are OK, turn the ignition switch ON. 5) Measure the voltage between O/W wire and ground.
Page 214 FI SYSTEM DIAGNOSIS 4-73 4) Check for proper terminal connection to the ECM couplers. 5) If connections are OK, check the following points. • Resistance  09900-25008: Multi circuit tester set 09900-25009: Needle-point probe set  Tester knob indication: Resistance () –...
Page 215 4-74 FI SYSTEM DIAGNOSIS • Voltage  09900-25008: Multi circuit tester set  Tester knob indication: Voltage () – Between W, B or B/Br wires and ground: approx. 0 V (When ignition switch is ON) Is check result OK? Go to Step 3. Repair or replace the defective wire harness.
Page 216 FI SYSTEM DIAGNOSIS 4-75 Step 4 HO2 sensor output voltage check 1) Connect the ECM coupler and HO2 sensor coupler. 2) Warm up the engine enough. 3) Insert the needle-point probes to the lead wire coupler. 4) Measure the HO2 sensor output voltage between the B wire and B/Br wire, in idling condition.
Page 217 4-76 FI SYSTEM DIAGNOSIS P0130 for HO2 sensor (Use of SDS) Step 1 HO2 sensor circuit check 1) Turn the ignition switch OFF. 2) Remove the seat. (8-5) 3) Disconnect the HO2 sensor coupler 1 (4-93) and ECM couplers 2. 4) Check for proper terminal connection to the HO2 sensor cou- pler and the ECM couplers.
Page 218 FI SYSTEM DIAGNOSIS 4-77 – Between B/Br wire terminal and other terminal at HO2 sen- sor coupler: infinity • Voltage  09900-25008: Multi circuit tester set  Tester knob indication: Voltage () – Between B wire or B/Br wire and ground: approx. 0 V (When ignition switch is ON) Is check result OK? Go to Step 2.
Page 219 4-78 FI SYSTEM DIAGNOSIS 6) Measure the HO2 sensor output voltage while holding the engine speed at 5 000 r/min.  HO2 sensor output voltage at 5 000 r/min: 0.6 V or more (+ terminal: B – - terminal: B/Br) Is check result OK? Replace the ECM with a known good one, and inspect it again.
Page 220 FI SYSTEM DIAGNOSIS 4-79 Step 2 HO2 sensor heater drive circuit check 1) Turn the ignition switch OFF. 2) Remove the seat. (8-5) 3) Disconnect the ECM couplers 1. 4) Check for proper terminal connection to the ECM couplers. 5) If connections are OK, check the following points. •...
Page 221 4-80 FI SYSTEM DIAGNOSIS Step 3 HO2 sensor heater check 1) Measure the resistance between terminals. NOTE: * Temperature of the HO2 sensor affects resistance value largely. * Make sure that the HO2 sensor heater is in atmospheric tem- perature. ...
Page 222: Dtc "C49" (P1656)
FI SYSTEM DIAGNOSIS 4-81 DTC “C49” (P1656): PAIR CONTROL SOLENOID VALVE CIRCUIT MALFUNCTION DETECTED CONDITION AND POSSIBLE CAUSE DETECTED CONDITION POSSIBLE CAUSE PAIR control solenoid valve voltage is not input to • PAIR control solenoid valve circuit open or short. ECM.
Page 223 4-82 FI SYSTEM DIAGNOSIS Step 1 PAIR control solenoid valve power supply circuit check 1) Turn the ignition switch OFF. 2) Remove the fuel tank. (5-2) 3) Disconnect the PAIR control solenoid valve coupler 1. 4) Check for proper terminal the PAIR control solenoid valve coupler.
Page 224 FI SYSTEM DIAGNOSIS 4-83 – Between Br/Y wire and ground: infinity – Between Br/Y wire terminal and other terminal at PAIR con- trol solenoid valve coupler: infinity • Voltage  09900-25008: Multi circuit tester set  Tester knob indication: Voltage () –...
Page 225 4-84 FI SYSTEM DIAGNOSIS ACTIVE CONTROL INSPECTION 1) Set up the SDS tools. (4-24 and refer to the SDS opera- tion manual for further details.) 2) Turn the ignition switch ON. 3) Click “PAIR control solenoid drive control” 1. 4) Click each button 2. At this time, if an operation sound is heard from the PAIR control solenoid valve, the function is normal.
Page 226: Dtc "C60" (P0480)
FI SYSTEM DIAGNOSIS 4-85 DTC “C60” (P0480): COOLING FAN RELAY CIRCUIT MALFUNCTION DETECTED CONDITION AND POSSIBLE CAUSE DETECTED CONDITION POSSIBLE CAUSE Cooling fan relay signal is not input to ECM. • Cooling fan relay circuit open or short. • Cooling fan relay. •...
Page 227 4-86 FI SYSTEM DIAGNOSIS Step 1 Cooling fan relay power supply circuit check 1) Turn the ignition switch OFF. 2) Remove the frame upper cover assembly. (8-6) 3) Disconnect the cooling fan relay coupler 1. 4) Check for proper terminal connection to the cooling fan relay coupler.
Page 228 FI SYSTEM DIAGNOSIS 4-87 Step 3 Cooling fan relay drive circuit check 1) Turn the ignition switch OFF. 2) Disconnect the ECM couplers 1. 3) Check for proper terminal connection to the ECM couplers. 4) If connections are OK, check the following points. •...
Page 229 4-88 FI SYSTEM DIAGNOSIS ACTIVE CONTROL INSPECTION 1) Set up the SDS tools. (4-24 and refer to the SDS opera- tion manual for further details.) 2) Start the engine and run it idling condition. 3) Click “Cooling fan relay control” 1. 4) Click the “Operate”...
Page 230: Dtc "C65" (P0506/P0507): Idle Speed Malfunction
FI SYSTEM DIAGNOSIS 4-89 DTC “C65” (P0506/P0507): IDLE SPEED MALFUNCTION DETECTED CONDITION AND POSSIBLE CAUSE DETECTED CONDITION POSSIBLE CAUSE Idle speed rose higher than or dropped • Air passage clogged. lower than desired idle speed by more • ISC valve is fixed. than specified range.
Page 231 4-90 FI SYSTEM DIAGNOSIS Step 3 Air intake system check 1) Check air intake system for clogging and leakage. Is check result OK? Go to Step 4. Repair or replace defective parts. Step 4 Engine mechanical systems check 1) Check the following points related to engine mechanical sys- tem.
Page 232: Sensors
FI SYSTEM DIAGNOSIS 4-91 SENSORS CKP SENSOR INSPECTION The signal rotor is mounted on the generator rotor 1 and CKP sensor 2 is installed at the inside of the generator cover. (9-25) CKP SENSOR REMOVAL AND INSTALLATION • Remove the generator cover. (3-19) •...
Page 233: Ect Sensor Inspection
4-92 FI SYSTEM DIAGNOSIS ECT SENSOR INSPECTION The ECT sensor 1 is installed at the thermostat connector. (7-10) ECT SENSOR REMOVAL AND INSTALLATION • Remove the ECT sensor 1. (7-9) • Install the ECT sensor in the reverse order of removal. ...
Page 234: Ho2 Sensor Inspection
FI SYSTEM DIAGNOSIS 4-93 HO2 SENSOR INSPECTION The heated oxygen sensor is installed to the muffler chamber. (4-71) HO2 SENSOR REMOVAL AND INSTALLATION • Remove the left and right fuel tank covers. (8-5) • Remove the reservoir tank mounting bolt 1 and radiator mounting bolts 2.
Page 235 4-94 FI SYSTEM DIAGNOSIS • Install the HO2 sensor is in the reverse order of removal. Pay attention to the following points: Do not apply oil or other materials to the sensor air hole. • Apply anti-seize compound to thread part a of HO2 sensor. •...
Page 236 FUEL SYSTEM AND THROTTLE BODY 5-1 FUEL SYSTEM AND THROTTLE BODY CONTENTS FUEL SYSTEM..................... 5- 2 FUEL TANK REMOVAL................ 5- 2 FUEL TANK INSTALLATION ............... 5- 3 FUEL PRESSURE INSPECTION ............5- 3 FUEL PUMP INSPECTION ..............5- 4 FUEL DISCHARGE AMOUNT INSPECTION ........5- 4 FUEL PUMP RELAY INSPECTION ............
Page 237: Fuel System
5-2 FUEL SYSTEM AND THROTTLE BODY FUEL SYSTEM FUEL TANK REMOVAL • Remove the seat. (8-5) • Remove the fuel tank covers. (8-5) • Remove the fuel tank bolts and brackets 1. • Lift and support the fuel tank. NOTE: Do not lift the fuel tank too much, or the fuel feed hose 3 will be bent or twisted.
Page 238: Fuel Tank Installation
FUEL SYSTEM AND THROTTLE BODY 5-3 FUEL TANK INSTALLATION • Installation is in the reverse order of removal. Pay attention to the following point: NOTE: Connect the fuel feed hose to the fuel pump until it locks securely (a click is heard). •...
Page 239: Fuel Pump Inspection
5-4 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 240: Fuel Pump Relay Inspection
FUEL SYSTEM AND THROTTLE BODY 5-5 • Connect proper lead wires to the fuel pump lead wire coupler (fuel pump side) and apply 12 V to the fuel pump (between Y/R wire and B/W wire) for 10 seconds and measure the amount of fuel discharged.
Page 241: Fuel Pump And Fuel Level Gauge Removal
5-6 FUEL SYSTEM AND THROTTLE BODY FUEL PUMP AND FUEL LEVEL GAUGE REMOVAL CONSTRUCTION  1 Fuel pressure regulator assembly 5 Fuel mesh filter 2 Joint 6 Dust cover ITEM N·m kgf-m lbf-ft 3 Fuel pump A Fuel pump mounting bolt 4 Reservoir cup...
Page 242 FUEL SYSTEM AND THROTTLE BODY 5-7 REMOVAL • Remove the fuel tank. (5-2) • Remove the fuel pump assembly 1 by removing its mounting bolts diagonally.  * Keep away from fire or spark. * Spilled gasoline should be wiped off immediately. * Work in a well-ventilated area.
Page 243: Fuel Pump Disassembly
5-8 FUEL SYSTEM AND THROTTLE BODY FUEL PUMP DISASSEMBLY • Remove the fuel pump assembly. (5-7) • Disconnect the lead wires 1 and lead wire coupler 2. • Remove the dust cover 3. • Remove the screw 4. • Remove the fuel pump 5. •...
Page 244: Fuel Mesh Filter Inspection And Cleaning
FUEL SYSTEM AND THROTTLE BODY 5-9 • Remove the fuel mesh filter 0. • Remove the lead wires A. • Remove the fuel pump B from the reservoir cup. FUEL MESH FILTER INSPECTION AND CLEANING If the fuel mesh filter is clogged with foreign particles, it hinders smooth gasoline flow resulting in loss of engine power.
Page 245 NOTE: Push the lock position C fully until the clicking sound heard. • Install a new O-ring 5 and apply grease to it.  99000-25010: SUZUKI SUPER GREASE “A” or equivalent • Connect the fuel level gauge lead wire coupler.
Page 246: Throttle Body
FUEL SYSTEM AND THROTTLE BODY 5-11 THROTTLE BODY CONSTRUCTION 1 TP sensor 6 ISC valve 2 Fuel delivery pipe 7 ISC valve hose  3 O-ring 8 Air screw 4 Fuel injector A Fuel delivery pipe mounting screw ITEM N·m kgf-m lbf-ft 5 Cushion seal...
Page 247: Throttle Body Removal
5-12 FUEL SYSTEM AND THROTTLE BODY THROTTLE BODY REMOVAL • Remove the fuel tank. (5-2) • Disconnect the fuel injector lead wire couplers 1. • Disconnect the PAIR hose 2 from the air cleaner box and ISC valve coupler 3. •...
Page 248: Throttle Body Disassembly
FUEL SYSTEM AND THROTTLE BODY 5-13 • Loosen the throttle body clamp screws. • Move the air cleaner box backward. • Remove the throttle body assembly. THROTTLE BODY DISASSEMBLY NOTE: Identify the position of each removed part. Organize the parts in their respective groups so that they can be reinstalled in their original positions.
Page 249 5-14 FUEL SYSTEM AND THROTTLE BODY • Remove the fuel injectors 3 from the fuel delivery pipe. • Remove the ISC valve 4. • Remove the TP sensor 5 with the special tool.  09930-11950: Torx wrench (T25H) NOTE: Prior to disassembly, mark the TP sensor original position with a paint or scribe for accurate reinstallation.
Page 250: Throttle Body Cleaning
FUEL SYSTEM AND THROTTLE BODY 5-15 THROTTLE BODY CLEANING  Some carburetor cleaning chemicals, especially dip-type soaking solutions, are very corrosive and must be handled carefully. Always follow the chemical manufacturer’s instructions on proper use, handling and storage. • Use a swab moistened with a carburetor cleaner (petroleum solvent) to clean the passageways, throttle valve, and main bore and then dry the cleaned surfaces with compressed air.
Page 251: Throttle Body Reassembly
TP sensor mounting screws. NOTE: * Align the throttle shaft end A with the groove B of TP sensor. * Apply grease to the throttle shaft end A if necessary.  99000-25010: SUZUKI SUPER GREASE “A” or equivalent  09930-11950: Torx wrench (T25H) •...
Page 252: Throttle Body Installation
FUEL SYSTEM AND THROTTLE BODY 5-17 THROTTLE BODY INSTALLATION Install the throttle body assembly in the following points: 1) Install the throttle body assembly 1 into the intake pipes 2. NOTE: Never tighten the intake pipe clamp screws 3. 2) Install the air cleaner box 4 to the throttle body assembly 1. 3) Tighten the outlet tube clamp screws 5 and then intake pipe clamp screws 3.
Page 253: Fuel Injector Removal
5-18 FUEL SYSTEM AND THROTTLE BODY FUEL INJECTOR REMOVAL • Remove the fuel delivery pipe assembly with the fuel injec- tors. (5-19) • Remove the fuel injectors 1. FUEL INJECTOR INSPECTION Check fuel injector filter for evidence of dirt and contamination. If present, clean and check for presence of dirt in the fuel lines and fuel tank.
Page 254 FUEL SYSTEM AND THROTTLE BODY 5-19 • Loosen the outlet tube clamp screws 2. • Move the air cleaner box 3 backward. • Disconnect the fuel feed hose 4. • Disconnect the fuel injector lead wire couplers 5. • Remove the fuel delivery pipe mounting screws 6. •...
Page 255: Isc Valve Inspection
5-20 FUEL SYSTEM AND THROTTLE BODY ISC VALVE INSPECTION • Inspect the ISC valve for any carbon deposition defects. Clean or replace the ISC valve if necessary. *Refer to the ISC VALVE INSPECTION for details. (4-60) ISC VALVE INSTALLATION Install the ISC valve in the reverse order of removal. Pay attention to the following point: •...
Page 256: Isc Valve Reset
FUEL SYSTEM AND THROTTLE BODY 5-21 ISC VALVE RESET When removing ISC valve or replacing the throttle body assem- bly, reset the ISC valve learned value in the following proce- dures: 1) Set up the SDS tool. (4-24) 2) Turn the ignition switch ON. 3) Click “Active control”.
Page 257: Tp Reset
5-22 FUEL SYSTEM AND THROTTLE BODY TP RESET When replacing the throttle body assembly or TP sensor with a new one or reinstalling the TP sensor, reset the TP fully closed learned value in the following procedures: 1) Set up the SDS tool. (4-24) 2) Turn the ignition switch ON.
Page 258: Throttle Valve Synchronization
FUEL SYSTEM AND THROTTLE BODY 5-23 THROTTLE VALVE SYNCHRONIZATION Check and adjust the throttle valve synchronization among two cylinders. Step 1 • Lift up support the fuel tank. (5-2) • Disconnect the respective vacuum hoses 1 from each vac- uum nipples on the throttle body. •...
Page 259 5-24 FUEL SYSTEM AND THROTTLE BODY • Click “Active control”. • Click “ISC air volume control” 1. • Click “ON” button 2 to fix the ISC air volume of two cylinders. NOTE: When making this synchronization, be sure that the water tem- perature is within 80 –...
Page 260 FUEL SYSTEM AND THROTTLE BODY 5-25 Step 3 • Repeat the procedures of step 2 when air screws were cleaned. • Close the SDS tool and turn the ignition switch OFF. • Disconnect the vacuum tester and reinstall the removed parts. •...
Page 261 EXHAUST SYSTEM 6-1 EXHAUST SYSTEM CONTENTS EXHAUST SYSTEM..................6- 2 REMOVAL ....................6- 2 INSPECTION ..................6- 3 INSTALLATION..................6- 3...
Page 262: Exhaust System
6-2 EXHAUST SYSTEM EXHAUST SYSTEM REMOVAL  To avoid the risk of being burned, do not touch the exhaust system when the system is hot. Any service on the exhaust system should be performed when the system is cool. Make sure that the exhaust pipe and mufflers have enough clearance from the rubber parts and plastic parts to avoid melting.
Page 263: Inspection
EXHAUST SYSTEM 6-3 • Remove the clamps 4. • Remove the exhaust pipe/muffler assembly 5 by removing the exhaust pipe bolts 6, muffler support bolts/nuts 7 and chamber support bolt 8. NOTE: Support the exhaust pipe/muffler assembly to prevent it from falling.
Page 264 COOLING AND LUBRICATION SYSTEM 7-1 COOLING AND LUBRICATION SYSTEM CONTENTS ENGINE COOLANT ..................7- 2 COOLING CIRCUIT ..................7- 4 COOLING CIRCUIT INSPECTION............7- 4 RADIATOR AND COOLING FAN MOTOR ..........7- 5 RADIATOR AND COOLING FAN MOTOR REMOVAL......7- 5 RADIATOR AND COOLING FAN MOTOR INSTALLATION ....
Page 265: Engine Coolant
* Ethanol or methanol base coolant or water alone should not be used in cooling system at any time as damage to cooling system could occur. * Do not mix the distilled water, SUZUKI long life coolant (coolant color: Green) or equivalent. FOR SUZUKI LONG LIFE COOLANT The cooling system is filled with a 50:50 mixture of distilled water and ethylene glycol anti-freeze.
Page 266 COOLING AND LUBRICATION SYSTEM 7-3 * Use a high quality ethylene glycol base anti-freeze, mixed with distilled water. Do not mix an alcohol base anti-freeze and different brands of anti-freeze. * Do not put in 60% and more anti-freeze or 50% and less. (Refer to Fig. 1 and 2.) * Do not use a radiator anti-leak additive.
Page 267: Cooling Circuit
7-4 COOLING AND LUBRICATION SYSTEM COOLING CIRCUIT RESERVOIR TANK THERMOSTAT CONNEECTOR CYLINDER HEAD THERMOSTAT CYLINDER ECT SENSOR RADIATOR WATER PUMP COOLING CIRCUIT INSPECTION Before removing the radiator and draining the engine coolant, inspect the cooling circuit for tightness. • Remove the right fuel tank cover. (8-5) •...
Page 268: Radiator And Cooling Fan Motor
COOLING AND LUBRICATION SYSTEM 7-5 RADIATOR AND COOLING FAN MOTOR RADIATOR AND COOLING FAN MOTOR REMOVAL • Remove the left and right fuel tank covers. (8-5) • Drain the engine coolant. (2-15) • Disconnect the reservoir tank over flow hose 1 and reservoir tank inlet hose 2.
Page 269: Radiator And Cooling Fan Motor Installation
7-6 COOLING AND LUBRICATION SYSTEM • Remove the cooling fan motor assembly A. RADIATOR AND COOLING FAN MOTOR INSTALLATION Install the radiator and cooling fan motor in the reverse order of removal. Pay attention to the following points: • Tighten the cooling fan motor assembly mounting bolts 1 to the specified torque.
Page 270: Water Hose Inspection
COOLING AND LUBRICATION SYSTEM 7-7 • Apply thread lock to the reservoir tank mounting bolts 3 and tighten them to the specified torque as shown in the cooling system hose routing. (10-20)  Reservoir tank mounting bolt: 6 N·m (0.6 kgf-m, 4.5 lbf-ft) ...
Page 271: Radiator Inspection And Cleaning
7-8 COOLING AND LUBRICATION SYSTEM RADIATOR INSPECTION AND CLEANING • Remove the left and right fuel tank covers. (8-5) • Inspect the radiator for water leaks. If any defects are found, replace the radiator with a new one. If the fins are bent or dented, repair them by carefully straightening them with the blade of a small screwdriver.
Page 272: Cooling Fan Relay Inspection
COOLING AND LUBRICATION SYSTEM 7-9 COOLING FAN RELAY INSPECTION Cooling fan relay is located inside of the left frame upper cover. • Remove the frame upper cover assembly. (8-6) • Disconnect the cooling fan relay coupler 1 and remove the cooling fan relay 2.
Page 273: Inspection
7-10 COOLING AND LUBRICATION SYSTEM INSPECTION • Check the ECT sensor by testing it at the bench as shown in the figure. Connect the ECT sensor 1 to a circuit tester and place it in the oil 2 contained in a pan, which is placed on a stove.
Page 274: Thermostat
COOLING AND LUBRICATION SYSTEM 7-11 THERMOSTAT REMOVAL • Remove the right fuel tank cover. (8-5) • Drain a small amount of engine coolant. (2-15) • Place a rag under the connector cap 1. • Move the connector cap 1 by removing the connector cap bolts.
Page 275: Installation
7-12 COOLING AND LUBRICATION SYSTEM • Keep on heating the water to raise its temperature. • Just when the water temperature reaches specified value, the thermostat valve should have lifted by at least 4.5 mm (0.18 in).  Thermostat valve lift A: Standard: 4.5 mm and over at 100 °C (0.18 in and over at 212 °F)
Page 276: Water Pump
COOLING AND LUBRICATION SYSTEM 7-13 WATER PUMP CONSTRUCTION  Water pump cover O-ring O-ring Impeller shaft ITEM N·m kgf-m lbf-ft Impeller Water pump air bleeder bolt Mechanical seal Impeller securing bolt Oil seal Water pump cover screw 0.55 Water pump body Water pump mounting bolt...
Page 277: Removal And Disassembly
7-14 COOLING AND LUBRICATION SYSTEM 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 278 COOLING AND LUBRICATION SYSTEM 7-15 • Remove the impeller securing bolt 7 by holding the impeller 8 with a water pump pliers. • Remove the mechanical seal ring 9 and rubber seal 0 from the impeller. • Remove the impeller shaft A and washer B. •...
Page 279: Inspection
7-16 COOLING AND LUBRICATION SYSTEM INSPECTION MECHANICAL SEAL • Visually inspect the mechanical seal for damage, with particu- lar attention given to the sealing face. Replace the mechanical seal that shows indications of leak- age. Also replace the seal ring if necessary. OIL SEAL •...
Page 280: Reassembly And Installation
The stamped mark on the oil seal faces mechanical seal side. • Apply a small quantity of the grease to the oil seal lip.  99000-25010: SUZUKI SUPER GREASE “A” or equivalent • Install the new mechanical seal using a suitable size socket wrench.
Page 281 7-18 COOLING AND LUBRICATION SYSTEM • Install the rubber seal 3 into the impeller 4. • After wiping off the oily or greasy matter from the mechanical seal ring 5, install it into the impeller. NOTE: The paint marked side B of mechanical seal ring faces the rub- ber seal.
Page 282 COOLING AND LUBRICATION SYSTEM 7-19 • Apply grease to the new O-ring C.  99000-25010: SUZUKI SUPER GREASE “A” or equivalent • Install the water pump with the slot on the pump shaft end E securely engaged with the flat F of the oil pump shaft.
Page 283: Lubrication System
7-20 COOLING AND LUBRICATION SYSTEM LUBRICATION SYSTEM OIL PRESSURE 2-28 OIL FILTER 2-12 OIL PRESSURE REGULATOR 3-23 and 3-47 OIL STRAINER 3-23 and 3-47 OIL JET 3-55 OIL PUMP 3-18 and 3-41 OIL PRESSURE SWITCH 9-34...
Page 284: Engine Lubrication System Chart
COOLING AND LUBRICATION SYSTEM 7-21 ENGINE LUBRICATION SYSTEM CHART #2 CAMSHAFT CAMSHAFT RIGHT-SIDE JOURNAL HOLDER #2 CAMSHAFT JOURNALS AND CAMFACES #1 CAMSHAFT CAMSHAFT LEFT-SIDE JOURNAL HOLDER #1 CAMSHAFT JOURNALS AND #1 ROCKER ARM #2 ROCKER ARM CAMFACES SHAFT SHAFT #1 ROCKER ARM #2 ROCKER ARM CAM CHAIN #1 CYLINDER HEAD #2 CYLINDER HEAD...
Page 285 CHASSIS 8-1 CHASSIS CONTENTS EXTERIOR PARTS ..................8- 3 FASTENER.................... 8- 3 FRAME COVER..................8- 4 FRAME FRONT COVER ............... 8- 4 FUEL TANK CENTER COVER ............. 8- 4 FUEL TANK COVER ................8- 5 SEAT...................... 8- 5 FRAME UPPER COVER ............... 8- 6 PILLION RIDER HANDLE..............
Page 286 8-2 CHASSIS CHASSIS CONTENTS INSALLATION ..................8-44 SUSPENSION SETTING ............... 8-44 REAR SUSPENSION ................... 8-45 CONSTRUCTION .................. 8-45 REMOVAL ..................... 8-46 INSPECTION AND DISASSEMBLY ............. 8-47 REASSEMBLY ..................8-49 INSTALLATION..................8-50 FRONT BRAKE.................... 8-51 CONSTRUCTION .................. 8-51 BRAKE PAD REPLACEMENT ............. 8-52 BRAKE FLUID REPLACEMENT ............
Page 287: Exterior Parts
CHASSIS 8-3 EXTERIOR PARTS FASTENER 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. • 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 288: Frame Cover
8-4 CHASSIS FRAME COVER REMOVAL NOTE: The left and right side frame covers are installed symmetrically and therefore the removal procedure for one side is the same as that for the other side. • Remove the frame cover 1 by removing the screw 2. : Hooked point INSTALLATION •...
Page 289: Fuel Tank Cover
CHASSIS 8-5 FUEL TANK COVER REMOVAL NOTE: The left and right side fuel tank covers are installed symmetri- cally and therefore the removal procedure for one side is the same as that for the other side. • Remove the frame front cover. (8-4) •...
Page 290: Frame Upper Cover
8-6 CHASSIS FRAME UPPER COVER REMOVAL • Remove the seat. (8-5) • Remove the left and right frame front covers. (8-4) • Remove the pillion rider handle. (8-6) • Disconnect the clamp 1 and seat lock cable 2. • Remove the screws 3 and fasteners 4. •...
Page 291: Front Wheel
CHASSIS 8-7 FRONT WHEEL CONSTRUCTION  1 Front axle 5 Front wheel 2 Brake disc 6 Spacer ITEM N·m kgf-m lbf-ft 3 Dust seal 7 Collar 47.0 4 Bearing A Brake disc bolt 13.0...
Page 292: Removal
8-8 CHASSIS REMOVAL NOTE: Do not operate the brake lever with the caliper removed. • Loosen the front axle pinch bolt 1. • Loosen the front axle 2 using the special tool.  09900-18710: Hexagon socket (12 mm) • Raise the front wheel off the ground and support the motorcy- cle with a jack or a wooden block.
Page 293 CHASSIS 8-9 • Remove the brake disc 1. • Remove the dust seals 2 on both sides using the special tool.  09913-50121: Oil seal remover AXLE SHAFT Using a dial gauge, check the axle shaft for runout and replace it if the runout exceeds the limit.
Page 294 8-10 CHASSIS WHEEL BEARING Inspect the play of wheel bearings by finger while they are in the wheel. Rotate the inner race by finger to inspect for abnormal noise and smooth rotation. Replace the bearing in the following procedure if there is any- thing unusual.
Page 295: Reassembly And Installation
(0.08 – 0.20 in) (0.08 – 0.20 in) 18 N . m (1.8 kgf-m, 13.0 lbf-ft) A LH B RH a Clearance WHEEL BEARING • Apply grease to the new wheel bearings.  99000-25010: SUZUKI SUPER GREASE “A” or equivalent...
Page 296 4 Removed wheel bearing B RH DUST SEAL • Install the new dust seals using the special tool.  09913-70210: Bearing installing set (10 – 75) • Apply grease to the dust seal lips.  99000-25010: SUZUKI SUPER GREASE “A” or equivalent...
Page 297 CHASSIS 8-13 BRAKE DISC • Make sure that the brake disc is clean and free of any greasy matter. • Apply thread lock to the brake disc bolts and tighten them to the specified torque.  99000-32130: THREAD LOCK CEMENT SUPER “1360” or equivalent ...
Page 298 8-14 CHASSIS • Tighten the front axle pinch bolt 3 to the specified torque.  Front axle pinch bolt: 23 N·m (2.3 kgf-m, 16.5 lbf-ft) • Then, tighten the front stabilizer bolts 2.  After installing the front wheel, pump the brake lever until the pistons push the pads correctly.
Page 299: Front Fork
CHASSIS 8-15 FRONT FORK CONSTRUCTION 1 O-ring A Dust seal 2 Spacer B Oil seal stopper ring 3 Washer C Oil seal 4 Spring D Spacer 5 Damper rod ring E Outlet tube slide bushing  6 Rebound spring F Outer tube (RH) 7 Damper rod G Outer tube (LH) ITEM...
Page 300: Removal And Disassembly
8-16 CHASSIS REMOVAL AND DISASSEMBLY NOTE: The left and right front forks are installed symmetrically and therefore the removal and disassembly procedure for one side is the same as that for the other side. • Remove the front wheel. (8-8) * Make sure that the motorcycle is supported securely.
Page 301 CHASSIS 8-17 • Remove the front fork cap bolt 8.  Take care so that the cap bolt does not spring out by the force of the spring. • Remove the spacer A, washer B and fork spring C. • Invert the front fork and stroke it several times to drain out fork oil.
Page 302: Inspection
8-18 CHASSIS • Remove the dust seal F and oil seal stopper ring G. Be careful not to damage the inner tube. • Pull the inner tube out of the outer tube. • Remove the oil lock piece H. • Remove the following parts from the inner tube. I Outer tube slide bushing J Spacer K Oil seal...
Page 303: Reassembly And Installation
• Apply fork oil to the inner tube slide bushing 1, outer tube slide bushing 2 and the lip of oil seal 4.  99000-99044-10G: SUZUKI FORK OIL G-10 or equivalent • Insert the oil lock piece 5 into the inner tube.
Page 304  Damper rod bolt: 30 N·m (3.0 kgf-m, 21.5 lbf-ft) FORK OIL • Pour the specified fork oil into the inner tube.  Front fork oil capacity (each leg): 338 ml (11.4/11.9 US/lmp oz)  99000-99044-10G: SUZUKI FORK OIL G-10 or equivalent...
Page 305 The smaller pitch end A of fork spring must face downward. FRONT FORK CAP BOLT • Apply fork oil to the new O-ring.  99000-99044-10G: SUZUKI FORK OIL G-10 or equivalent • Temporarily tighten the front fork cap bolt. • Set the front fork with the upper surface of the inner tube posi- tioned 244 mm (9.6 in) A from the upper surface of the lower...
Page 306 8-22 CHASSIS • Tighten the front fork lower clamp bolt 1 to the specified torque.  Front fork lower clamp bolt: 33 N·m (3.3 kgf-m, 24.0 lbf-ft) • Tighten the front fork cap bolt 2 and front fork upper clamp bolt 3 to the specified torque.
Page 307: Steering
CHASSIS 8-23 STEERING CONSTRUCTION For P-12 only  1 Steering stem upper bracket 8 Lower bearing inner race 2 Dust seal 9 Lower seal ITEM N·m kgf-m lbf-ft 3 Upper bearing inner race 0 Steering stem lower bracket 47.0 4 Steering stem upper bearing A Steering stem head nut 23 N·m (2.3 kgf-m, 16.5 lbf-ft) 5 Upper bearing outer race B Steering stem nut...
Page 308: Removal
8-24 CHASSIS REMOVAL • Remove the combination meter and headlight assembly. (9-27 and 9-36) • Remove the front wheel. (8-8) • Remove the front forks. (8-16) • Remove the clamps 1. • Disconnect the ignition switch coupler 2. • Remove the brake hose clamp bolt 3 and cable guide bolt 4. •...
Page 309: Inspection And Disassembly
CHASSIS 8-25 • Remove the ignition switch D if necessary. INSPECTION AND DISASSEMBLY Inspect the removed parts for the following abnormalities. * Distortion of the steering stem * Bearing wear or damage * Abnormal bearing noise * Race wear or damage * Dust seal wear or damage If any abnormal points are found, replace defective parts with new ones.
Page 310: Reassembly
 09941-34513: Bearing installer INNER RACE • Apply grease to the new lower seal 1.  99000-25010: SUZUKI SUPER GREASE “A” or equivalent • Press in the new lower bearing inner race using the special tool.  09925-18011: Bearing installer INSTALLATION Install the steering in the reverse order of removal.
Page 311: Steering Tension Adjustment
CHASSIS 8-27 STEERING STEM UPPER BRACKET • Temporarily install the steering stem upper bracket 1. • Temporarily install the front forks 2. • Tighten the steering stem head nut 3 to the specified torque.  Steering stem head nut: 65 N·m (6.5 kgf-m, 47.0 lbf-ft) •...
Page 312: Handlebars
8-28 CHASSIS HANDLEBARS CONSTRUCTION Apply handle grip bond  1 Handlebars 5 Throttle grip Handlebar 2 Rear view mirror 6 Handlebar holders holder bolt ITEM N·m kgf-m lbf-ft 3 Handlebar balancer 7 Right handlebar switch box Handlebar 16.5 4 Left handlebar grip 8 Left handlebar switch box clamp bolt 11.5...
Page 313: Removal
CHASSIS 8-29 REMOVAL HANDLEBAR LEFT SIDE PARTS • Remove the rear view mirror 1. • Remove the handlebar switch box 2. • Disconnect the clutch lever position switch coupler 3. • Remove the handlebar balancer 4. • Remove the handlebar grip 5. •...
Page 314: Installation
8-30 CHASSIS INSTALLATION Install the handlebars in the reverse order of removal. Pay atten- tion to the following points: • Insert the boss A of the handlebar holder into the hole B of the upper bracket. • Tighten the handlebar holder bolts 1 to the specified torque. ...
Page 315 • Insert the projection E of the right handlebar switch box into hole of the right handlebar. • Apply grease to the throttle cables and cable pulley.  99000-25010: SUZUKI SUPER GREASE “A” or equivalent • Align the clutch lever holder’s mating surface F with the punch mark G on the left handlebars.
Page 316: Rear Wheel
8-32 CHASSIS REAR WHEEL CONSTRUCTION 1 Rear axle 0 Rear sprocket 2 Brake disc A Retainer 3 Collar B Bearing 4 Dust seal C Dust seal  5 Bearing D Spacer 6 Rear wheel A Brake disc bolt ITEM N·m kgf-m lbf-ft 7 Wheel damper...
Page 317: Removal
CHASSIS 8-33 REMOVAL • Loosen the axle nut 1. • Raise the rear wheel off the ground and support the motorcy- cle with a jack or wooden block. Make sure that the motorcycle is supported securely. • Remove the axle nut 1 and draw out the rear axle 2. •...
Page 318: Inspection And Disassembly
8-34 CHASSIS • Remove the rear sprocket mounting drum retainer B. INSPECTION AND DISASSEMBLY TIRE............(2-23, 8-73) WHEEL ............(8-9 and 8-73) AXLE SHAFT ..........(8-9) BRAKE DISC..........(8-58) (Use the front wheel specifications and procedure.) DUST SEAL Inspect the wheel and sprocket mounting drum dust seal for wear or damage.
Page 319 CHASSIS 8-35 SPROCKET Inspect the sprocket teeth for wear. If they are worn as shown, replace the two sprockets and drive chain as a set. A Normal wear B Excessive wear BEARING Inspect the play wheel bearing and sprocket mounting drum bearing by hand while they are installed in place.
Page 320: Reassembly And Installation
8-36 CHASSIS REASSEMBLY AND INSTALLATION Reassemble and install the rear wheel in the reverse order of removal and disassembly. Pay attention to the following points: 2 – 5 mm 2 – 5 mm (0.08 – 0.20 in) (0.08 – 0.20 in) 49 N .
Page 321 CHASSIS 8-37 BEARING • Apply grease to the new bearings.  99000-25010: SUZUKI SUPER GREASE “A” or equivalent • Install the bearing to the sprocket mounting drum using the special tool.  09913-70210: Bearing installing set (10 – 75) • First install the right wheel bearing 1, then install the spacer 2 and left wheel bearing 3 using the special tool and removed wheel bearings 4.
Page 322 • Install the new dust seals using the special tool.  09913-70210: Bearing installing set (10 – 75) • Apply grease to the dust seal lips.  99000-25010: SUZUKI SUPER GREASE “A” or equivalent WHEEL DAMPER • Insert the protrusion on the wheel damper firmly. (8-36) REAR SPROCKET AND SPROCKET MOUNTING DRUM •...
Page 323 CHASSIS 8-39 • Tighten the rear sprocket nuts to the specified torque.  Rear sprocket nut: 49 N·m (4.9 kgf-m, 35.5 lbf-ft) NOTE: Stamped mark A on the sprocket must face outside. • Install the spacer 2. BRAKE DISC • Make sure that the brake disc is clean and free of any greasy matter.
Page 324: Rear Shock Absorber
8-40 CHASSIS REAR SHOCK ABSORBER CONSTRUCTION  Rear shock absorber mounting 1 Rear shock absorber nut (Lower) ITEM N·m kgf-m lbf-ft 36.0 Rear shock absorber mounting nut (Upper) 61.0...
Page 325: Removal
CHASSIS 8-41 REMOVAL • Remove the seat, frame covers, frame front covers, pillion rider handle and frame upper cover assembly. (8-4 to -6) • Remove the left muffler. (6-2) • Remove the rear wheel. (8-33) • Unhook the return spring 1 and remove the right front foot- rest bracket 2.
Page 326: Bearing Replacement
• Remove the rear shock absorber bearing 2 using the special tools.  09923-73210: Bearing remover 09930-30104: Rotor remover sliding shaft • Press the new bearing using the special tool.  09924-84510: Bearing installer set • Apply grease to the bearing.  99000-25010: SUZUKI SUPER GREASE “A” or equivalent...
Page 327: Rear Shock Absorber Disposal
CHASSIS 8-43 REAR SHOCK ABSORBER DISPOSAL  The rear shock unit contains high-pressure nitrogen gas. * Mishandling can cause explosion. * Keep away from fire and heat. High gas pressure caused by heat can cause an explosion. * Release gas pressure before disposing. GAS PRESSURE RELEASE •...
Page 328: Insallation
8-44 CHASSIS INSALLATION Install the rear shock absorber in the reverse order of removal. Pay attention to the following points: • Install the rear shock absorber and tighten the rear shock absorber mounting nuts to the specified torque.  Rear shock absorber mounting nut (Upper): 50 N·m (5.0 kgf-m, 36.0 lbf-ft) Rear shock absorber mounting nut (Lower): 84 N·m (8.4 kgf-m, 61.0 lbf-ft)
Page 329: Rear Suspension
CHASSIS 8-45 REAR SUSPENSION CONSTRUCTION 1 Swingarm pivot shaft 6 Spacer 2 Chain buffer 7 Swingarm  3 Dust cover 8 Chain case 4 Spacer 9 Chain adjuster ITEM N·m kgf-m lbf-ft 5 Bearing A Swingarm pivot nut 47.0...
Page 330 8-46 CHASSIS REMOVAL • Remove the right frame cover. (8-4) • Remove the right front footrest bracket. (8-41) • Support the motorcycle with a jack to be no load for the swin- garm. Make sure that the motorcycle is supported securely. •...
Page 331 CHASSIS 8-47 • Remove the chain adjusters 5 and brake hose guides 1. • Remove the dust covers 6, washers 7 and chain buffer 8. INSPECTION AND DISASSEMBLY SPACER • Remove the spacers from swingarm. • Inspect the spacers for wear and damage. If any defects are found, replace the spacer with a new one.
Page 332 8-48 CHASSIS • Remove the swingarm pivot bearings 1 using the special tools.  09923-74511: Bearing remover 09930-30104: Rotor remover sliding shaft SWINGARM PIVOT SHAFT Using a dial gauge, check the pivot shaft runout and replace it if the runout exceeds the limit. ...
Page 333 CHASSIS 8-49 REASSEMBLY Reassemble the rear suspension in the reverse order of disassembly. Pay attention to the following points:  1 Washer B RH ITEM N·m kgf-m lbf-ft 2 Dust cover C Rear shock absorber mounting nut (Upper) 36.0 3 Spacer D Rear shock absorber mounting nut (Lower) 61.0 A LH...
Page 334: Installation
When installing the bearing, stamped mark on bearing must face outside.  09941-34513: Bearing installer • Apply grease to the bearings and dust covers.  99000-25010: SUZUKI SUPER GREASE “A” or equivalent INSTALLATION Install the rear suspension in the reverse order of removal. Pay attention to the following points: •...
Page 335: Front Brake
CHASSIS 8-51 FRONT BRAKE CONSTRUCTION  ITEM 1 Brake lever B Brake pad mounting pin plug N·m kgf-m lbf-ft 2 Brake light switch C Brake pad mounting pin 3 Piston cup set D Brake caliper air bleeder valve 0.25 4 Piston seal E Brake caliper sliding pin A 13.0 5 Dust seal...
Page 336: Brake Pad Replacement
8-52 CHASSIS  * 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. * 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 period of time.
Page 337 CHASSIS 8-53 • Remove the pad mounting pin 2 and brake pads 4. Do not operate the brake lever with the pads removed. NOTE: When the brake caliper is removed, care must be used so as not to cause stress to the brake hose. (Hang the brake caliper on the frame with a string etc.) •...
Page 338: Brake Fluid Replacement
8-54 CHASSIS BRAKE FLUID REPLACEMENT • Place the motorcycle on a level surface and keep the handle- bars straight. • Remove the brake fluid reservoir cap 1 and diaphragm. • Suck up the old brake fluid as much as possible. •...
Page 339: Caliper Disassembly
CHASSIS 8-55 CALIPER DISASSEMBLY • Remove the brake pads. (8-52) • Remove the brake caliper holder 1. • Remove the pad spring 2. • Remove the rubber boots 3. • Place a clean rag over the pistons to prevent it from popping out and then force out the pistons using compressed air.
Page 340: Caliper Inspection
8-56 CHASSIS CALIPER INSPECTION BRAKE CALIPER Inspect the brake caliper cylinder wall for nicks, scratches and other damage. If any damage is found, replace the caliper with a new one. BRAKE CALIPER PISTON Inspect the brake caliper piston surface for any scratches and other damage.
Page 341: Caliper Reassembly
• Install the each seal as shown in the illustration. 1 Piston seal 2 Dust seal 3 Caliper body • Apply grease to the brake caliper sliding pins.  99000-25100: SUZUKI SILICONE GREASE or equivalent • Install the brake pads. (8-53)
Page 342: Caliper Installation
8-58 CHASSIS CALIPER INSTALLATION Install the caliper in the reverse order of removal. Pay attention to the following points: • Tighten the brake caliper mounting bolts 1 to the specified torque.  Front brake caliper mounting bolt: 26 N·m (2.6 kgf-m, 19.0 lbf-ft) •...
Page 343: Master Cylinder Removal And Disassembly
CHASSIS 8-59 MASTER CYLINDER REMOVAL AND DISAS- SEMBLY • Remove the right rear view mirror 1. • Drain brake fluid. (8-54) • Place a clean rag underneath the brake hose union bolt 2 on the master cylinder to catch any split brake fluid. Spilled brake fluid can damage painted surfaces and plastic parts.
Page 344: Master Cylinder Inspection
8-60 CHASSIS • Pull out the dust boot 0 and remove the snap ring A.  09900-06108: Snap ring pliers (Close type) • Remove the stopper plate B, piston cup set C and spring D. MASTER CYLINDER INSPECTION MASTER CYLINDER Inspect the master cylinder bore for any scratches or other dam- age.If any damage is found, replace the master cylinder with a new one.
Page 345: Master Cylinder Reassembly And Installation
• Apply grease to the brake lever pivot bolt. • Apply grease to the contact point between piston and brake lever.  99000-25100: SUZUKI SILICONE GREASE or equivalent • Tighten the brake lever pivot bolt 1 and lock-nut 2 to the specified torque.
Page 346 8-62 CHASSIS • When installing the brake light switch, align the projection on the switch with the hole in the master cylinder. • When installing the master cylinder 3 onto the handlebar 4, align the master cylinder holder’s mating surface A with the punch mark B on the handlebar 4 and tighten the upper holder bolt first.
Page 347: Rear Brake
CHASSIS 8-63 REAR BRAKE CONSTRUCTION  1 Brake pedal A Piston cup set 2 Brake caliper bracket A Brake caliper mounting bolt ITEM N·m kgf-m lbf-ft 3 Brake pad spring B Brake pad mounting pin 16.5 4 Caliper piston C Brake pad mounting pin plug 13.0 5 Dust seal D Brake caliper sliding pin...
Page 348: Brake Pad Replacement
8-64 CHASSIS  * 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. * 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 period of time.
Page 349: Brake Fluid Replacement
CHASSIS 8-65 • Push the piston all the way into brake caliper. • Install the new brake pads 5. NOTE: * Replace the brake pads as a set, otherwise braking perfor- mance will be adversely affected. * Make sure that the detent A of the pad is seated onto the pad guide on the caliper bracket.
Page 350: Caliper Removal
8-66 CHASSIS CALIPER REMOVAL • Drain the brake fluid. (8-54) • Place a clean rag underneath the union bolt on the brake cali- per to catch any split brake fluid. • Remove the brake hose from the caliper by removing the union bolt 1 and catch the brake fluid in a suitable recepta- cle.
Page 351: Caliper Inspection
CHASSIS 8-67 CALIPER INSPECTION BRAKE CALIPER Inspect the brake caliper cylinder wall for nicks, scratches and other damage. If any damage is found, replace the caliper with a new one. BRAKE CALIPER PISTON Inspect the brake caliper piston surface for any scratches and other damage.
Page 352: Caliper Reassembly
• Install the each seal as shown in the illustration. 1 Piston seal 2 Dust seal 3 Caliper body • Apply grease to the inside of boot. • Apply grease to the brake caliper sliding pin.  99000-25100: SUZUKI SILICONE GREASE or equivalent...
Page 353: Caliper Installation
CHASSIS 8-69 CALIPER INSTALLATION Install the caliper in the reverse order of removal. Pay attention to the following points: • Install the brake pads and tighten the brake caliper mounting bolt 1 to the specified torque. (8-65)  Rear brake caliper mounting bolt: 23 N·m (2.3 kgf-m, 16.5 lbf-ft) •...
Page 354 8-70 CHASSIS • Place a clean rag underneath the union bolt 2 on the master cylinder to catch spilled drops of brake fluid. Spilled brake fluid can damage painted surfaces and plastic parts. Be careful not to spill any fluid. Wipe spilled fluid up immediately.
Page 355: Master Cylinder Inspection
CHASSIS 8-71 • Remove the push rod 5, piston cup set C and spring D. MASTER CYLINDER INSPECTION MASTER CYLINDER Inspect the master cylinder bore for any scratches or other dam- age. If any damage is found, replace the master cylinder with a new one.
Page 356 8-72 CHASSIS • Apply grease to the push rod end.  99000-25100: SUZUKI SILICONE GREASE or equivalent • Install a new O-ring 1. • Tighten the master cylinder mounting bolts 2 and lock-nut 3 to the specified torque.  Rear brake master cylinder mounting bolt: 10 N·m (1.0 kgf-m, 7.0 lbf-ft)
Page 357: Tire And Wheel
CHASSIS 8-73 TIRE AND WHEEL TIRE REMOVAL • The most critical factor of tubeless tire is the seal between the wheel rim and the tire bead. For this reason, it is recom- mended to use a tire changer that can satisfy this sealing requirement and can make the operation efficient as well as functional.
Page 358 8-74 CHASSIS VALVE • Inspect the valve after the tire is removed from the rim. Replace the valve with a new one if the seal A rubber is peel- ing or has damage. NOTE: If the external appearance of the valve shows no abnormal con- dition, removing of the valve is not necessary.
Page 359: Tire Installation
CHASSIS 8-75 TIRE INSTALLATION • Apply tire lubricant to the tire bead. Never use oil, grease or gasoline on the tire bead in place of tire lubricant. When installing the tire onto the wheel, observe the following points: • When installing the tire, the arrow A on the side wall should point to the direction of wheel rotation.
Page 360: Balancer Weight Installation
8-76 CHASSIS • In this condition, check the “rim line” B cast on the tire side walls. The line must be equidistant from the wheel rim all around. If the distance between the rim line and wheel rim varies, this indicates that the bead is not properly seated. If this is the case, deflate the tire completely and unseat the bead for both sides.
Page 361: Drive Chain
CHASSIS 8-77 DRIVE CHAIN Use the special tool in the following procedures, to cut and rejoin the drive chain.  09922-22711: Drive chain cutting and joining tool set NOTE: When using the special tool, apply a small quantity of grease to the threaded parts of the special tool.
Page 362: Drive Chain Connecting
8-78 CHASSIS • Place the drive chain link being disjointed on the chain holder 8 of the tool. • Turn in both the adjuster bolt 6 and pressure bolt “A” 3 so that each of their end hole fits over the chain joint pin properly. •...
Page 363 CHASSIS 8-79 • Apply grease on the recessed portion of the joint plate holder 3. Then install the joint plate 0 on the tool, its stamp mark must face the joint plate holder 3 side. • Set the drive chain on the tool as illustrated and turn in the adjuster bolt 5 to secure the wedge holder &...
Page 364 8-80 CHASSIS • Stake the joint pin by turning (approximately 7/8 turn) the pressure bolt “A” 3 with the bar until the pin end diameter becomes the specified dimension. • After joining of the chain has been completed, check to make sure that the link is smooth and no abnormal condition is found.
Page 365 ELECTRICAL SYSTEM 9-1 ELECTRICAL SYSTEM CONTENTS CAUTIONS IN SERVICING ................. 9- 3 CONNECTOR ..................9- 3 COUPLER....................9- 3 CLAMP ....................9- 3 FUSE...................... 9- 3 SWITCH ....................9- 4 SEMI-CONDUCTOR EQUIPPED PART ..........9- 4 BATTERY ....................9- 4 CONNECTING THE BATTERY.............
Page 366 9-2 ELECTRICAL SYSTEM ELECTRICAL SYSTEM CONTENTS RELAYS ...................... 9-42 TURN SIGNAL RELAY INSPECTION ..........9-42 STARTER RELAY INSPECTION ............9-42 FUEL PUMP RELAY INSPECTION ............9-42 COOLING FAN RELAY INSPECTION..........9-42 SWITCHES ....................9-42 IGNITION SWITCH REMOVAL AND INSTALLATION......9-42 SWITCHES INSPECTION ..............
Page 367: Cautions In Servicing
ELECTRICAL SYSTEM 9-3 CAUTIONS IN SERVICING CONNECTOR • When connecting a connector, be sure to push it in until a click is felt. • 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 in fully to engage the lock when con- necting.
Page 368: Switch
9-4 ELECTRICAL SYSTEM SWITCH • Never apply grease material to switch contact points to pre- vent damage. 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.
Page 369: Using The Multi Circuit Tester
ELECTRICAL SYSTEM 9-5 USING THE MULTI CIRCUIT TESTER • Properly use the multi circuit tester + and - probes. Improper use can cause damage to the motorcycle and tester. • If the voltage and current values are not known, begin mea- suring in the highest range.
Page 370: Location Of Electrical Components
9-6 ELECTRICAL SYSTEM LOCATION OF ELECTRICAL COMPONENTS 1 Fuel injector (#1) (4-57) 8 ISC valve (4-60) E Generator 2 TP sensor (4-38) 9 ECM F CKP sensor (4-30) 3 IAT sensor (4-46) 0 TO sensor (4-50) G Speed sensor (9-33 to -34) 4 Starter motor A Fuel pump relay (5-5) H GP switch (4-54)
Page 371 ELECTRICAL SYSTEM 9-7 1 Battery (9-9 to -10) 6 Horn A HO2 sensor (4-71) 2 Fuse box 7 Oil pressure switch (9-34) B Mode select coupler 3 Fuel pump (5-4) 8 Ignition coil (#2) (9-23 to -24) C Side-stand diode (9-19) 4 Fuel level gauge (9-32) 9 Fuel injector (#2) (4-57) 5 ECT sensor (7-10)
Page 372: Charging System
9-8 ELECTRICAL SYSTEM CHARGING SYSTEM IG. switch Generator Regulator/Rectifier 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. (9-9) Is the battery for current leaks OK? Go to Step 3.
Page 373: Inspection
ELECTRICAL SYSTEM 9-9 Step 5 1) Measure the generator no-load performance. (9-11) Is the generator no-load performance OK? Go to Step 6. Faulty generator. Step 6 1) Inspect the regulator/rectifier. (9-11) Is the regulator/rectifier OK? Go to Step 7. Faulty regulator/rectifier. Step 7 1) Inspect wirings.
Page 374 9-10 ELECTRICAL SYSTEM REGULATED VOLTAGE • Remove the seat. (8-5) • Start the engine and keep it running at 5 000 r/min with the dimmer switch turned HI position. • Measure the DC voltage between the + and - battery termi- nals using the multi circuit tester.
Page 375 ELECTRICAL SYSTEM 9-11 GENERATOR NO-LOAD PERFORMANCE • Disconnect the generator coupler. (9-10) • Start the engine and keep it running at 5 000 r/min. • Using the multi circuit tester, measure the voltage between three lead wires. If the tester reads under the specified value, replace the gen- erator with a new one.
Page 376: Starter System
9-12 ELECTRICAL SYSTEM STARTER SYSTEM Engine stop Ignition Engine stop Ignition switch switch switch switch Fuse (30 A) Fuse (30 A) To Ignition To Ignition coil coil Starter Starter Fuse motor Fuse motor (10 A) (10 A) Battery Battery Side-stand Side-stand relay relay...
Page 377: Starter Motor Removal
ELECTRICAL SYSTEM 9-13 Step 3 1) Measure the starter relay voltage at the starter relay connectors (between Y/G + and B/Y -) when the starter button is pushed. Is a voltage OK? Go to Step 4. • Faulty engine stop switch. •...
Page 378: Starter Motor Disassembly
9-14 ELECTRICAL SYSTEM STARTER MOTOR DISASSEMBLY • Disassemble the starter motor as shown in the illustration.  ITEM N·m kgf-m lbf-ft 1 O-ring 4 Starter motor case 7 Housing end (outside) 2 Housing end (inside) 5 Armature A Starter motor mounting bolt 3 Oil seal 6 Brush B Starter motor lead wire bolt...
Page 379: Starter Motor Reassembly
Pay attention to the following points: • Apply grease to the lip of the oil seal and bearing.  99000-25010: SUZUKI SUPER GREASE “A” or equivalent • Apply a small quantity of moly paste to the armature shaft.  99000-25140: SUZUKI MOLY PASTE or equivalent...
Page 380 • Align the match mark on the starter motor case with the match mark on the housing end (inside). • Apply grease to the new O-ring 2.  99000-25010: SUZUKI SUPER GREASE “A” or equivalent • Tighten the starter motor mounting bolt 3 with the battery - lead wire 4.
Page 381: Starter Relay Inspection
ELECTRICAL SYSTEM 9-17 STARTER RELAY INSPECTION • Remove the seat. (8-5) • Remove the left frame cover. (8-4) • Disconnect the battery - lead wire from the battery. • Disconnect the starter motor lead wire 1, battery + lead wire 2 and starter relay coupler 3.
Page 382: Side-Stand/Ignition Interlock System Parts
9-18 ELECTRICAL SYSTEM SIDE-STAND/IGNITION INTERLOCK SYSTEM PARTS INSPECTION Check the interlock system for proper operation. If the interlock system does not operate properly, check each component for damage or abnormalities. If any abnormality is found, replace the component with a new one. SIDE-STAND SWITCH INSPECTION •...
Page 383 ELECTRICAL SYSTEM 9-19 DIODE INSPECTION • Remove the right frame front cover. (8-4) • Remove the diode 1. Measure the voltage between the terminals using the multi cir- cuit tester. + Probe of tester to: B, c 0.4 – 0.6 V 1.4 V and more B, c (Tester’s battery voltage)
Page 384 9-20 ELECTRICAL SYSTEM GEAR POSITION SWITCH INSPECTION • Remove the right frame cover. (8-4) • Disconnect the gear position switch coupler 1 and check the continuity between Bl and B/W lead wires with the transmis- sion in “NEUTRAL”.  09900-25008: Multi circuit tester set ...
Page 385: Ignition System
ELECTRICAL SYSTEM 9-21 IGNITION SYSTEM Engine stop switch Side-stand relay sensor Fuse Ignition switch Fuse Battery sensor sensor switch TROUBLESHOOTING No spark or poor spark NOTE: * Check that the transmission is in neutral and the engine stop switch is in the RUN position. Grasp the clutch lever.
Page 386 9-22 ELECTRICAL SYSTEM Step 3 1) Measure the ignition coil primary peak voltage. (9-23) NOTE: This inspection method is applicable only with the multi circuit tester and the peak volt adaptor. Is the peak voltage OK? Go to Step 4. Go to Step 5.
Page 387: Inspection
ELECTRICAL SYSTEM 9-23 INSPECTION IGNITION COIL PRIMARY PEAK VOLTAGE • Remove the fuel tank. (5-2) • Disconnect the spark plug caps. (2-6) • Connect new spark plugs to the spark plug caps and ground them to the cylinder head. NOTE: Make sure that spark plug cap and spark plug are connected properly and the battery is used in fully-charged condition.
Page 388 9-24 ELECTRICAL SYSTEM IGNITION COIL RESISTANCE • Remove the fuel tank. (5-2) • Disconnect the ignition coil lead wires and plug cap. • Measure the ignition coil resistance in both the primary and Ω secondary windings. If the resistance is not within the stan- kΩ...
Page 389 ELECTRICAL SYSTEM 9-25 CKP SENSOR PEAK VOLTAGE NOTE: Be sure that all couplers are connected properly and the battery used is in fully-charged condition. • Remove the right frame cover. (8-4) • Disconnect the CKP sensor coupler 1 and connect the multi circuit tester with the peak volt adaptor as follows.
Page 390: Combination Meter
9-26 ELECTRICAL SYSTEM COMBINATION METER DESCRIPTION This combination meter mainly consists of the stepping motor, LCD (Liquid Crystal Display) and LED (Light Emitting Diode). The rpm pointer is driven by the stepping motor. The LCDs indicate Speed, Odo/Trip 1/Trip 2/Clock/Gear position, Eco/Norm and Fuel level indicator respec- tively.
Page 391: Removal And Disassembly
ELECTRICAL SYSTEM 9-27 REMOVAL AND DISASSEMBLY • Remove the headlight upper cover 1 upward. : Hooked point • Move the combination meter assembly 2 upward. : Hooked point • Disconnect the boot 3 and combination meter assembly cou- pler 4. •...
Page 392: Inspection
9-28 ELECTRICAL SYSTEM INSPECTION LED (LIGHT EMITTING DIODE) Check that the LED lights [FI light, Engine rpm indicator light, Oil pressure indicator light and Engine coolant temperature indicator light] immediately after turning the ignition switch ON. Also, other LED lights (Neutral indicator light, High-beam indicator light and Turn signal indicator light) can be checked by depending on each switch position.
Page 393 ELECTRICAL SYSTEM 9-29 ENGINE RPM INDICATOR LIGHT While in ECO mode A or NORM mode B, when the tachometer shows engine rpm within the specified range the engine rpm indicator light 1 turns on or blinks. ECO mode A: Engine rpm indicator light 1 Engine rpm (r/min) No light engine rpm <...
Page 394 9-30 ELECTRICAL SYSTEM MAINTENANCE The maintenance comes on to notify engine oil replacement timing. The display comes on at initial 1 000 km (600 miles) and the display comes on at every time 5 000 km (3 000 miles) thereafter. After the initial 1 000 Km (600 miles) reset, interval can be varied in the range between 500 km (300 miles) to 5 000 km (3 000 miles) with a step of 500 km (300 miles).
Page 395 ELECTRICAL SYSTEM 9-31 FUEL LEVEL INDICATOR INSPECTION • Lift and support the fuel tank. (5-2) • Disconnect the fuel pump lead wire coupler 1. • Connect variable resistor between the R/Bl and B/W lead wires at the wire harness. • Turn the ignition switch to the “ON” position when the motor- cycle is held upright.
Page 396 9-32 ELECTRICAL SYSTEM FUEL LEVEL GAUGE INSPECTION • Remove the fuel level gauge. (5-7) • Measure the resistance at each fuel level gauge float position. If the resistance is incorrect, replace the fuel level gauge with a new one. Float position Resistance 9 –...
Page 397 ELECTRICAL SYSTEM 9-33 ENGINE COOLANT TEMPERATURE INDICATOR LIGHT ECT sensor inspection (7-10) • Remove the right fuel tank cover. (8-5) • Disconnect the ECT sensor coupler 1. • Connect the variable resistor A between the terminals. • Turn the ignition switch ON. •...
Page 398 9-34 ELECTRICAL SYSTEM • Move a screwdriver back and forth across the pickup surface of the speed sensor. The voltage readings should cycle as fol-   lows (0 V 12 V or 12 V 0 V). If the voltage reading does not change, replace the speed sensor with a new one.
Page 399: Lamps
ELECTRICAL SYSTEM 9-35 LAMPS HEADLIGHT AND POSITION LIGHT For – P21, 24, 71 For – P12 Headlight bulb 1: 12 V 60/55 W Position light bulb 2: 12 V 5 W  Remove the bulb when it gets cool, since it may be heated to an extremely high temperature when the headlight is turned ON.
Page 400 9-36 ELECTRICAL SYSTEM HEADLIGHT BULB REPLACEMENT • Remove the combination meter assembly. (9-27) • Remove the headlight mounting screws 1. • Move the headlight assembly 2 forward. • Disconnect the headlight coupler 3. NOTE: When removing the headlight assembly 4, disconnect the posi- tion light coupler 5.
Page 401 ELECTRICAL SYSTEM 9-37 HEADLIGHT BEAM ADJUSTMENT Adjust the headlight beam in the following procedures: Adjust the headlight beam vertically. POSITION LIGHT BULB REPLACEMENT NOTE: The right and left position light bulbs are installed symmetrically and therefore the replacement procedure for one side is the same as that for the other side.
Page 402: License Plate Light
9-38 ELECTRICAL SYSTEM LICENSE PLATE LIGHT License plate light bulb 1: 12 V 5 W When you touch the bulb with your bare hands, clean the bulb with a cloth moistened with alco- hol or soapy water to prevent premature bulb failure. NOTE: Do not use bulb other than those with predetermined wattage.
Page 403: Brake/Tail Light
ELECTRICAL SYSTEM 9-39 BRAKE/TAIL LIGHT Brake/Tail light 1: 12 V 21/5 W When you touch the bulb with your bare hands, clean the bulb with a cloth moistened with alco- hol or soapy water to prevent premature bulb failure. NOTE: Do not use bulb other than those with predetermined wattage.
Page 404: Turn Signal Light
9-40 ELECTRICAL SYSTEM TURN SIGNAL LIGHT Turn signal light 1: 12 V 10 W When you touch the bulb with your bare hands, clean the bulb with a cloth moistened with alco- hol or soapy water to prevent premature bulb failure. NOTE: Do not use bulb other than those with predetermined wattage.
Page 405 ELECTRICAL SYSTEM 9-41 REAR TURN SIGNAL LIGHT BULB REPLACEMENT NOTE: The right and left rear turn signal light bulbs are installed sym- metrically and therefore the replacement procedure for one side is the same as that for the other side. •...
Page 406: Turn Signal Relay Inspection
9-42 ELECTRICAL SYSTEM RELAYS TURN SIGNAL RELAY INSPECTION The turn signal relay 1 is located under the fuel tank. If the turn signal light does not light, inspect the bulb or repair the circuit connection. If the bulb and circuit connection are OK, the turn signal relay 1 may be faulty, replace it with a new one.
Page 407: Switches Inspection
ELECTRICAL SYSTEM 9-43 SWITCHES INSPECTION Inspect each switch for continuity with a tester. If any abnormality is found, replace the respective switch assemblies with new ones.  09900-25008: Multi circuit tester set  Tester knob indication: Continuity test () IGNITION SWITCH (For-P21) HORN BUTTON Color Color...
Page 408: Initial Charging
9-44 ELECTRICAL SYSTEM BATTERY SPECIFICATIONS Type designation YTX9-BS Capacity 12 V, 28.8 kC (8 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 409 ELECTRICAL SYSTEM 9-45 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 410: Recharging Operation
9-46 ELECTRICAL SYSTEM SERVICING Visually inspect the surface of the battery container. If any signs of cracking or electrolyte leakage from the sides of the battery have occurred, replace the battery with a new one. If the battery terminals are found to be coated with rust or an acidic white powdery substance, clean the battery terminals with sandpaper.
Page 411 SERVICING INFORMATION 10-1 SERVICING INFORMATION CONTENTS TROUBLESHOOTING ................10- 3 FI SYSTEM MALFUNCTION CODE AND DEFECTIVE CONDITION..............10- 3 ENGINE ....................10- 3 RADIATOR (COOLING SYSTEM) ............10- 9 CHASSIS ....................10-10 BRAKES ....................10-11 ELECTRICAL ..................10-12 BATTERY ..................... 10-13 WIRING HARNESS, CABLE AND HOSE ROUTING.........
Page 412 10-2 SERVICING INFORMATION SERVICING INFORMATION CONTENTS REGULATOR/RECTIFIER INSTALLATION ........10-40 SPECIAL TOOLS ................. 10-41 TIGHTENING TORQUE ................10-44 ENGINE ....................10-44 FI SYSTEM AND INTAKE AIR SYSTEM ..........10-46 COOLING SYSTEM................10-46 CHASSIS ....................10-46 TIGHTENING TORQUE CHART ............10-48 SERVICE DATA ..................
Page 413: Troubleshooting
SERVICING INFORMATION 10-3 TROUBLESHOOTING FI SYSTEM MALFUNCTION CODE AND DEFECTIVE CONDITION (4-27 to -29) 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.
Page 414 10-4 SERVICING INFORMATION 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 gaps Adjust or replace.
Page 415 SERVICING INFORMATION 10-5 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 or cam surface Replace. 4. Worn and burnt camshaft journal Replace.
Page 416 10-6 SERVICING INFORMATION 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 gaps Adjust.
Page 417 SERVICING INFORMATION 10-7 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 cylinders Replace.
Page 418 10-8 SERVICING INFORMATION Complaint Symptom and possible causes Remedy Dirty or heavy 1. Too much engine oil in the engine Check with inspection exhaust smoke window, drain out excess oil. 2. Worn piston rings or cylinders Replace. 3. Worn valve guides Replace.
Page 419: Radiator (Cooling System)
SERVICING INFORMATION 10-9 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 relay, or open- or short- Repair or replace.
Page 420: Chassis
10-10 SERVICING INFORMATION CHASSIS Complaint Symptom and possible causes Remedy Heavy steering 1. Overtightened steering stem nut Adjust. 2. Broken bearing in steering stem Replace. 3. Distorted steering stem Replace. 4. Not enough pressure in tires Adjust. Wobbly handlebars 1. Loss of balance between right and left front forks Adjust.
Page 421: Brakes
SERVICING INFORMATION 10-11 BRAKES Complaint Symptom and possible causes Remedy Insufficient brake 1. Leakage of brake fluid from hydraulic system Repair or replace. power 2. Worn pads Replace. 3. Friction surfaces of pad are dirty oil or dust Clean disc/pads or replace. 4.
Page 422: Electrical
10-12 SERVICING INFORMATION ELECTRICAL Complaint Symptom and possible causes Remedy No sparking or poor 1. Defective ignition coils Replace. sparking 2. Defective spark plugs Replace. 3. Defective CKP sensor Replace. 4. Defective ECM Replace. 5. Defective TO sensor Replace. 6. Open-circuited wiring connections Check and repair.
Page 423: Battery
SERVICING INFORMATION 10-13 BATTERY Complaint Symptom and possible causes Remedy “Sulfation”, acidic 1. Cracked battery case Replace the battery. white powdery sub- 2. Battery has been left in a run-down condition for Replace the battery. stance or spots on a long time surface of cell plates Battery runs down...
Page 424: Wiring Harness, Cable And Hose Routing
10-14 SERVICING INFORMATION WIRING HARNESS, CABLE AND HOSE ROUTING WIRING HARNESS ROUTING Pass the left handlebar switch lead wire to inside of the clutch cable. Insert the front brake switch terminal firmly. Fix the cover of the front brake switch terminal firmly. Clamp the wiring harness Pass the left handlebar switch lead wire at white tape position.
Page 425 SERVICING INFORMATION 10-15 Clamp Clamp Regulator/rectifier Regulator/rectifier Speed sensor Speed sensor Generator Side-stand switch Side-stand switch Clamp the protector upper of the cable guide. Clamp Face the lock part of HO2 sensor clamp left side. Wiring harness (White tape point) VIEW A Oil pressure switch coupler TO sensor...
Page 426 10-16 SERVICING INFORMATION Route the generator lead wire between the crankcase and starter motor and pass it over 10 N·m the crankcase. Gear position switch (1.0 kgf-m, 7.0 lbf-ft) lead wire Do not pinch the lead wires 20˚ – 40˚ Generator lead wire Pass the starter motor lead wire under the frame.
Page 427: Cable Routing
SERVICING INFORMATION 10-17 CABLE ROUTING VIEW A 1 Throttle cable No.1 9 Left handlebar switch *7 3 mm (0.12 in) 2 Throttle cable No.2 0 Frame Pass the clutch cable into the clutch cable Pass the throttle cables over the water bypass 3 Clutch cable hose 5.
Page 428: Intake System Hose Routing
10-18 SERVICING INFORMATION INTAKE SYSTEM HOSE ROUTING 1, 6 VIEW A VIEW B VIEW C  1 Fuel feed hose 6 Washer 2 ISC valve hose *1 White mark ITEM N·m kgf-m lbf-ft 3 Intake pipe clamp *2 Clamp end should face left side. Pass the IAP sensor hose #1 4 Outlet tube clamp 0.55...
Page 429: Fuel Tank Drain Hose Routing
SERVICING INFORMATION 10-19 FUEL TANK DRAIN HOSE ROUTING 95 mm (3.74 in) 70 mm (2.76 in) VIEW A 1 Fuel tank water drain hose *2 Pass the hoses to the forward of frame. Connect the reservoir tank overflow hose 6 to the 2 Fuel tank breather hose No.1 narrow side of 3 way joint 5.
Page 430: Cooling System Hose Routing
10-20 SERVICING INFORMATION COOLING SYSTEM HOSE ROUTING Frame 6 N·m 2 – 8 mm (0.6 kgf-m, 4.5 lbf-ft) (0.08 – 0.31 in) Wiring Clearance Reservoir tank harness overflow hose The clamp end should face Marking Stopper Clamp downward. Pass the drain hose Yellow mark between the air cleaner, The clamp end...
Page 431 SERVICING INFORMATION 10-21 10 N·m (1.0 kgf-m, 7.0 lbf-ft) Yellow mark The clamp screw head should face left diagonal White mark backward. The clamp screw head should face The clamp screw left side. head should face Connect the 3 way left side.
Page 432: Ignition Coil Installation
10-22 SERVICING INFORMATION IGNITION COIL INSTALLATION 0 – 30˚ 0 – 30˚  1 Ignition coil #1 Pass the high tension cord behind the throt- 2 Ignition coil #2 tle cable guide. ITEM N·m kgf-m lbf-ft 3 Spark plug cap Pass the high tension cord under the fuel 0.65 4 High tension cord...
Page 433: Front Brake Hose Routing
SERVICING INFORMATION 10-23 FRONT BRAKE HOSE ROUTING 21˚ 21˚ VIEW A VIEW B 21˚  1 Brake hose After the brake hose union has *1 Pass the brake hose as shown. contacted the stopper, tighten the ITEM N·m kgf-m lbf-ft union bolt.
Page 434: Rear Brake Hose Routing
10-24 SERVICING INFORMATION REAR BRAKE HOSE ROUTING 14° 21°  1 Rear brake master cylinder *1 Clamp ends should face as shown. 2 Rear brake hose ITEM N·m kgf-m lbf-ft Insert the reservoir tank hose to the union firmly. 16.5 Rear brake reservoir tank hose White paint faces outside before...
Page 435: Pair (Air Supply) System Hose Routing
SERVICING INFORMATION 10-25 PAIR (AIR SUPPLY) SYSTEM HOSE ROUTING MIN. 10 mm (0.4 in) MIN. 10 mm (0.4 in)  PAIR control solenoid valve *2 The clamp end should face downward. PAIR reed valve *3 The clamp end should face left side. ITEM N·m kgf-m lbf-ft Air cleaner box *4 The clamp end should face upward.
Page 436: Fuel Tank Installation
10-26 SERVICING INFORMATION FUEL TANK INSTALLATION 1 Fuel tank *2 Hung on projection part firmly. 2 Fuel tank center cover *3 Clean the surface before attaching the cushion. 3 Fuel tank cover – – Keep clearance 2 4 mm (0.08 0.16 in) between the fuel tank and fuel tank covers 2, 3, 4.
Page 437: Muffler & Exhaust Pipe Installation
SERVICING INFORMATION 10-27 MUFFLER & EXHAUST PIPE INSTALLATION 4 – 6 mm (0.16 – 0.24 in) VIEW A 0 – 2 mm (0 – 0.8 in) 3 – 5 mm (0.12 – 0.20 in) VIEW C VIEW B  1 HO2 sensor The chamfer side of connector face the muffler 2 Muffler side.
Page 438: Seat Lock Cable Routing
10-28 SERVICING INFORMATION SEAT LOCK CABLE ROUTING VIEW A 1 Seat lock cable *2 The tip of the cable is cylindrical shaped. 2 Clamp *3 The tip of the cable is spherical shaped. 3 Flame *4 Set the cable firmly. *1 The lock part of clamp over the frame.
Page 439: Front Fender Installation
SERVICING INFORMATION 10-29 FRONT FENDER INSTALLATION 1 Front fender 3 Washer (RH only) 2 Front stabilizer *1 The embossed lettering of the front stabilizer must face lower side FRONT LICENSE PLATE INSTALLATION (Only for P-12) 1 Front license plate 2 Clamp...
Page 440: Front Side Reflex Reflector Installation (Only For P-24)
10-30 SERVICING INFORMATION FRONT SIDE REFLEX REFLECTOR INSTALLATION (Only for P-24)  ITEM 1 Reflex reflector 3 Washer N·m kgf-m lbf-ft 2 Reflector bolt 4 Front fork 0.45 0.18...
Page 441: Frame Cover Installation
SERVICING INFORMATION 10-31 FRAME COVER INSTALLATION *1 *1 1 Frame upper cover (LH) 9 Frame head cover (RH) 2 Frame upper cover (RH) 0 Rear fender 3 Frame upper cover (CENTER) A Pillion rider handle 4 Frame front cover (LH) *1 To footrest bracket.
Page 442: Frame Installation
10-32 SERVICING INFORMATION FRAME INSTALLATION  ITEM Frame down tube N·m kgf-m lbf-ft Frame 43.5 Engine mounting bracket 36.0 SIDE-STAND INSTALLATION  ITEM Install the spring as shown. N·m kgf-m lbf-ft 29.0...
Page 443: Center Stand Installation (For P-12)
SERVICING INFORMATION 10-33 CENTER STAND INSTALLATION (For P-12) To muffler  ITEM 1 Center stand 3 Center stand cushion N·m kgf-m lbf-ft Do not apply grease to the 2 Center stand spring 43.5 flange and thread part.
Page 444: Rear Brake Pedal Installation
10-34 SERVICING INFORMATION REAR BRAKE PEDAL INSTALLATION 38 – 48 mm (1.50 – 1.89 in) 25 mm (0.98 in)  1 Brake pedal Rear brake master cylinder 2 Footrest bracket Circlip ITEM N·m kgf-m lbf-ft 3 Brake pedal spring Washer 4 Brake switch spring Measuring position.
Page 445: Handlebars Installation
SERVICING INFORMATION 10-35 HANDLEBARS INSTALLATION 50 – 52 mm 1.5 – 2.5 mm 52 mm 50 – 52 mm 1.5 – 2.5 mm 52 mm (2.0 (2.0 – 2.1 in) (0.06 – 0.10 in) 2.1 in) (2.0 (2.0 – 2.1 in) (0.06 –...
Page 446: Headlight Cover Installation
10-36 SERVICING INFORMATION HEADLIGHT COVER INSTALLATION 1 Headlight lower cover 4 Headlight side cover (RH) 2 Headlight upper cover 5 Headlight housing brace 3 Headlight side cover (LH) 6 Cushion...
Page 447: Headlight Installation
SERVICING INFORMATION 10-37 HEADLIGHT INSTALLATION  1 Headlight unit 4 Headlight side cover (LH) 2 Combination meter assembly 5 Headlight side cover (RH) ITEM N·m kgf-m lbf-ft 3 Headlight upper cover 6 Headlight housing brace...
Page 448: Front Turn Signal Light Installation
10-38 SERVICING INFORMATION FRONT TURN SIGNAL LIGHT INSTALLATION VIEW B VIEW A Pass the front turn signal lead wire 1 Front turn signal light (RH) 3 Radiator reservoir tank behind the front turn signal light. 2 Front turn signal light (LH) *1 Coupler position.
Page 449: Rear Combination Light Installation
SERVICING INFORMATION 10-39 REAR COMBINATION LIGHT INSTALLATION VIEW A 1 Brake/Tail light Cut the tip of clamp after clamping the lead wires. 2 Rear fender After clamping the rear turn signal light lead wire and license plate light lead 3 Rear frame center cover wire, pass the lead wires inside the hole of the rear fender.
Page 450: Regulator/Rectifier Installation
10-40 SERVICING INFORMATION REGULATOR/RECTIFIER INSTALLATION VIEW A Pass the regulator/rectifier lead wire 1 Regulator/Rectifier 4 Clamp along the frame. Do not slacken. Clamp the regulator/rectifier lead 2 Bracket 5 ECM wire at root of the connector. 3 Clamp *1 Install the clamp to the bracket.
Page 451: Special Tools
Small bore gauge Multi circuit tester V blocks (0.025 – 0.076 mm) (0.051 – 0.152 mm) (18 – 35 mm) 09900-25009 09904-41010 09910-60611 09913-10750 Needle-point probe SUZUKI Diagnostic Universal clamp Compression 09913-50121 system set wrench gauge adapter Oil seal remover...
Page 452 10-42 SERVICING INFORMATION 09913-70210 09915-64512 09915-72410 Bearing installing set 09915-40620 Compression Oil pressure gauge 09915-74521 (10 – 75 ) Oil filter wrench gauge attachment Adapter hose 09915-77331 09916-14910 Oil pressure gauge 09916-10911 09916-14510 Valve lifter 09916-84511 (1 000 kPa) Valve lapper set Valve lifter attachment Tweezer...
Page 453 SERVICING INFORMATION 10-43 09930-82720 09940-14911 09940-34581 09940-40211 Mode selection Steering stem nut 09940-34520 Front fork assembling Fuel pressure switch socket wrench T type handle attachment (F) gauge adapter 09940-40220 09940-52861 09941-54911 Fuel pressure Front fork oil seal 09940-92720 09941-34513 Bearing outer race gauge attachment installer set Spring scale...
Page 454: Tightening Torque
10-44 SERVICING INFORMATION TIGHTENING TORQUE ENGINE ITEM N·m kgf-m lbf-ft Cylinder head cover bolt (Initial) (Final) 10.0 Cylinder head bolt 18.0 Cylinder head cover cap bolt Cylinder side bolt Primary drive gear nut 50.5 Exhaust pipe bolt 16.5 Exhaust connecting bolt 12.5 Muffler support bolt 16.5...
Page 455 SERVICING INFORMATION 10-45 ITEM N·m kgf-m lbf-ft Shift cam bearing retainer screw Oil pressure switch Oil filter 14.5 Oil pressure switch lead wire bolt 0.15 Gearshift arm stopper 13.5 Gearshift fork shaft plug 18.0 Oil pressure regulator 20.0 Oil filter union bolt 11.0 Oil separator plate bolt Engine sprocket cover bolt...
Page 456: Fi System And Intake Air System
10-46 SERVICING INFORMATION FI SYSTEM AND INTAKE AIR SYSTEM ITEM N·m kgf-m lbf-ft GP switch mounting bolt 0.65 CKP sensor mounting bolt 0.55 Fuel delivery pipe mounting screw Fuel pump mounting bolt HO2 sensor 18.0 EVAP canister bracket mounting bolt EVAP canister holder screw 0.55 EVAP system purge control solenoid valve mounting nut...
Page 457 SERVICING INFORMATION 10-47 Front brake master cylinder holder bolt Front brake caliper mounting bolt 19.0 Front brake caliper sliding pin A 16.5 Front brake caliper sliding pin B Front brake pad mounting pin 13.0 Front brake pad pin plug 0.25 Brake hose union bolt 16.5 Front brake lever pivot bolt...
Page 458: Tightening Torque Chart
10-48 SERVICING INFORMATION TIGHTENING TORQUE CHART Each fastener should be tightened to the torque specified in “TIGHTENING LIST”. If no description or speci- fication is provided, refer to the following tightening torque chart for the applicable torque for each fastener. Thread diameter (Nominal diameter) A [mm] Strength Unit...
Page 459: Service Data
SERVICING INFORMATION 10-49 SERVICE DATA VALVE + GUIDE Unit: mm (in) ITEM STANDARD LIMIT Valve diam. 27.0 — (1.06) 22.5 — (0.89) Valve 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 460 10-50 SERVICING INFORMATION CAMSHAFT + CYLINDER HEAD Unit: mm (in) ITEM STANDARD LIMIT Cam height 33.34 – 33.38 33.04 (1.313 – 1.314) (1.301) 33.05 – 33.09 32.75 (1.301 – 1.303) (1.289) Camshaft journal oil clearance 0.032 – 0.066 0.150 (0.0013 – 0.0026) (0.0059) Camshaft journal holder I.D.
Page 461 SERVICING INFORMATION 10-51 CYLINDER + PISTON + PISTON RING Unit: mm (in) ITEM STANDARD LIMIT Compression pressure 1 300 – 1 700 kPa 1 000 kPa (13 – 17 kgf/cm², 185 – 242 psi) (10 kgf/cm , 142 psi) Compression pressure difference 200 kPa —...
Page 462 10-52 SERVICING INFORMATION CONROD + CRANKSHAFT Unit: mm (in) ITEM STANDARD LIMIT Conrod small end I.D. 15.006 – 15.014 15.040 (0.5908 – 0.5911) (0.5921) Conrod big end side clearance 0.10 – 0.20 0.30 (0.004 – 0.008) (0.012) Conrod big end width 19.95 –...
Page 463 SERVICING INFORMATION 10-53 CLUTCH Unit: mm (in) ITEM STANDARD / SPECIFICATION LIMIT Clutch cable play 10 – 15 — (0.39 – 0.59) Clutch release screw 1 turn counterclockwise — Drive plate thickness 2.92 – 3.08 2.62 No. 1 and 2 (0.115 –...
Page 464 10-54 SERVICING INFORMATION THERMOSTAT + RADIATOR + FAN + COOLANT ITEM STANDARD/SPECIFICATION NOTE Thermostat valve opening temper- Approx. 88 °C (190 °F) — ature Thermostat valve lift 4.5 mm (0.18 in) and over at 100 °C (212 °F) — ECT sensor resistance 20 °C Approx.
Page 465 SERVICING INFORMATION 10-55 FI SENSORS ITEM STANDARD NOTE CKP sensor resistance 150 – 230 CKP sensor peak voltage 1.5 V or more When cranking IAP sensor input voltage 4.5 – 5.5 V IAP sensor output voltage Approx. 2.6 V at idle speed TP sensor input voltage 4.5 –...
Page 466 10-56 SERVICING INFORMATION ELECTRICAL Unit: mm (in) ITEM STANDARD / SPECIFICATION NOTE Firing order Spark plug NGK: CR7E Type DENSO: U22ESR-N 0.7 – 0.8 (0.028 – 0.031) Spark performance Over 8 (0.3) at 1 atm. 150 – 230  CKP sensor resistance CKP sensor peak voltage 1.5 V or more Ignition coil resistance...
Page 467 SERVICING INFORMATION 10-57 BRAKE + WHEEL Unit: mm (in) ITEM STANDARD / SPECIFICATION LIMIT Rear brake pedal height 38 – 48 — (1.5 – 1.9) Brake disc thickness 4.8 – 5.2 Front (0.189 – 0.205) (0.18) 4.3 – 4.7 Rear (0.169 –...
Page 468 Front fork oil level (without spring, 136 (5.4) — outer tube fully compressed) Front fork oil type SUZUKI FORK OIL G10 or equivalent — Front fork oil capacity (each leg) 338 ml (11.4/11.9 US/Imp oz) — Front fork inner tube O.D.
Page 469 EMISSION CONTROL INFORMATION 11-1 EMISSION CONTROL INFORMATION CONTENTS EMISSION CONTROL SYSTEMS ............... 11-2 NOISE EMISSION CONTROL SYSTEM..........11-2 HO2 SENSOR INSPECTION..............11-2 HO2 SENSOR REMOVAL AND INSTALLATION ........ 11-2 PAIR (AIR SUPPLY) SYSTEM AND EMISSION CONTROL SYSTEM INSPECTION....................11-3 PAIR HOSES ..................11-3 PAIR REED VALVE................
Page 470: Emission Control Systems
11-2 EMISSION CONTROL INFORMATION EMISSION CONTROL SYSTEMS NOISE EMISSION CONTROL SYSTEM TAMPERING WITH THE NOISE CONTROL SYSTEM PROHIBITED: Local law or federal law prohibits the following acts or the causing thereof: 1. The removal or rendering inoperative by any person, other than for purposes of maintenance, repair or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use, or 2.
Page 471: Pair (Air Supply) System And Emission Control System Inspection
EMISSION CONTROL INFORMATION 11-3 PAIR (AIR SUPPLY) SYSTEM AND EMISSION CONTROL SYSTEM INSPECTION PAIR HOSES • Remove the fuel tank. (5-2) • Inspect the PAIR hoses 1 for wear or damage. If it is worn or damaged, replace the PAIR hoses 1 with a new one. PAIR REED VALVE •...
Page 472: Pcv Hose
11-4 EMISSION CONTROL INFORMATION PCV HOSE • Inspect the PCV hose 1 for wear and damage. If it is worn or damaged, replace the PCV hose 1 with a new one. PAIR CONTROL SOLENOID VALVE REMOVAL • Remove the fuel tank. (5-2) •...
Page 473 EMISSION CONTROL INFORMATION 11-5 • Check the resistance between the terminals of the PAIR con- trol solenoid valve.  PAIR control solenoid valve resistance: 18 – 22  at 20 °C (68 °F)  09900-25008: Multi circuit tester set  Tester knob indication: Resistance () INSTALLATION Installation is in the reverse order of removal.
Page 474: Pair (Air Supply) System Hose Routing
11-6 EMISSION CONTROL INFORMATION PAIR (AIR SUPPLY) SYSTEM HOSE ROUTING MIN. 10 mm (0.4 in) MIN. 10 mm (0.4 in)  PAIR control solenoid valve *2 The clamp end should face downward. PAIR reed valve *3 The clamp end should face left side. ITEM N·m kgf-m lbf-ft Air cleaner box *4 The clamp end should face upward.
Page 475 WIRING DIAGRAM P-21 Wiring diagrams wire color, refer to section “WIRE COLOR”. HANDLEBAR SWITCH (R) STARTER BUTTON PUSH FUSE BOX REGULATOR/ RECTIFIER 1. HEAD ENGINE FRONT IGNITION IGNITION IGNITION 2. SIGNAL STOP BRAKE COIL #2 COIL #1 SWITCH 3. FUEL SWITCH SWITCH 4.
Page 476 P-12, 24, 71 HANDLEBAR SWITCH (R) STARTER BUTTON PUSH FUSE BOX REGULATOR/ RECTIFIER ENGINE 1. HEAD FRONT IGNITION IGNITION 2. SIGNAL STOP BRAKE IGNITION COIL #2 COIL #1 3. FUEL SWITCH SWITCH SWITCH 4. IGNITION 10A SPARE SPEED SPARE PRESSURE SENSOR SWITCH REAR...
Page 477 Prepared by CHANGZHOU HAOJUE SUZUKI MOTORCYCLE CO.,LTD. Supplied by April, 2012 Part No. 99500-32170-01E Printed in Japan...
Page 478 CHANGZHOU HAOJUE SUZUKI MOTORCYCLE CO.,LTD. Printed in Japan...

This manual is also suitable for:

Gw250l3

Suzuki GW250 Service Manual

General Information 1

Periodic Maintenance

Engine

Fi System Diagnosis

Fuel System and Throttle Body

Exhaust System

Chassis

Exterior Parts

Front Wheel

Front Fork

Steering

Steering Tension Adjustment

Handlebars

Rear Wheel

Rear Shock Absorber

Rear Suspension

Front Brake

Rear Brake

Tire and Wheel

Drive Chain

Quick Links

Chapters

Troubleshooting

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Summary of Contents for Suzuki GW250