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VZ800
9 9 5 0 0 - 3 8 0 5 0 - 0 1 E

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Table of Contents

   Also See for Suzuki VZ800

   Summary of Contents for Suzuki VZ800

  • Page 1 VZ800 9 9 5 0 0 - 3 8 0 5 0 - 0 1 E...
  • Page 2: General Information

    FOREWORD GROUP INDEX This manual contains an introductory description on the SUZUKI VZ800 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 molybdenum oil solution. Use fork oil. (Mixture of engine oil and SUZUKl 99000-99044-L01 MOLY PASTE in a ratio of 1 : 1) Apply SUZUKI SUPER GREASE “A”. 99000-25030 (USA) Apply or use brake fluid. 99000-25010 (Others) Apply SUZUKI MOLY PASTE.
  • Page 5: Abbreviations Used In This Manual

    ABBREVIATIONS USED IN THIS MANUAL : Engine Control Module ABDC : After Bottom Dead Center Engine Control Unit (ECU) : Alternating Current (FI Control Unit) : Air Cleaner, Air Cleaner Box EOT Sensor : Engine Oil Temperature : American Petroleum Institute Sensor (EOTS), Oil Temp.
  • Page 6 : Oil Pressure Switch : Positive Crankcase Ventilation (Crankcase Breather) : Right Hand : Read Only Memory : Society of Automotive Engineers : Suzuki Diagnosis System STC System : Secondary Throttle Control System (STCS) STP Sensor : Secondary Throttle Position Sensor (STPS)
  • Page 7 WIRE COLOR : Black : Gray : Red : Blue : Light blue : White : Brown : Light green : Yellow : Dark green : Orange : Green : Pink B/Bl : Black with Blue tracer B/Br : Black with Brown tracer : Black with Green tracer B/Lg : Black with Light green tracer...
  • Page 8: Table Of Contents

    GENERAL INFORMATION CONTENTS WARNING/CAUTION/NOTE .................1- 2 GENERAL PRECAUTIONS ................1- 2 SUZUKI VZ800K5 (’05-MODEL) ..............1- 4 SERIAL NUMBER LOCATION ..............1- 4 FUEL, OIL AND ENGINE COOLANT RECOMMENDATION .......1- 4 FUEL (FOR USA AND CANADA) ............1- 4 FUEL (FOR OTHER COUNTRIES) ............1- 4 ENGINE OIL ...................1- 5...
  • Page 9: General Precautions

    1-2 GENERAL INFORMATION WARNING/CAUTION/NOTE Please read this manual and follow its instructions carefully. To emphasize special information, the symbol and the words WARNING, CAUTION and NOTE have special meanings. Pay special attention to the mes- sages highlighted by these signal words. ...
  • Page 10 GENERAL INFORMATION 1-3  * If parts replacement is necessary, replace the parts with Suzuki Genuine Parts or their equiva- lent. * When removing parts that are to be reused, keep them arranged in an orderly manner so that they may be reinstalled in the proper order and orientation.
  • Page 11: Serial Number Location

    1-4 GENERAL INFORMATION SUZUKI VZ800K5 (’05-MODEL) RIGHT SIDE LEFT SIDE * 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 12: Engine Oil

    Suzuki recommends the use of SUZUKI COOLANT anti-freeze/engine coolant. If this is not available, use an equivalent which is compatible with an aluminum radiator.
  • Page 13: Cylinder Identification

    1-6 GENERAL INFORMATION BREAK-IN PROCEDURES During manufacturing only the best possible materials are used and all machined parts are finished to a very high standard. It is still necessary to allow the moving parts to “BREAK-IN” before subjecting the engine to maximum stresses.
  • Page 14: Information Labels

    GENERAL INFORMATION 1-7 INFORMATION LABELS VZ800 1 Noise label For E-03, 24, 33 2 Information label For E-03, 28, 33 3 Vacuum hose routing label For E-33 4 Manual notice label For E-03, 33 5 Fuel caution label For E-02, 24...
  • Page 15: Specifications

    1-8 GENERAL INFORMATION SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length............2 370 mm (93.3 in) Overall width ............920 mm (36.2 in) Overall height............1 125 mm (44.3 in) Wheelbase ............1 655 mm (65.2 in) Ground clearance ..........140 mm (5.5 in) Seat height............
  • Page 16 GENERAL INFORMATION 1-9 CHASSIS Front suspension..........Inverted telescopic, coil spring, oil damped Rear suspension ..........Swingarm type, coil spring, oil damped Front suspension stroke........140 mm (5.5 in) Rear wheel travel ..........105 mm (4.1 in) Caster..............33° 15’ Trail ..............141 mm (5.6 in) Steering angle .............
  • 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 SPARK PLUG ..................2- 5 VALVE CLEARANCE ................2- 7 FUEL HOSE ...................2-10 ENGINE OIL AND OIL FILTER ..............2-11 ENGINE IDLE SPEED ................2-13 THROTTLE CABLE PLAY ..............2-14...
  • Page 18: Periodic Maintenance Schedule

    2-2 PERIODIC MAINTENANCE PERIODIC MAINTENANCE SCHEDULE The chart below lists the recommended intervals for all the required periodic service work necessary to keep the motorcycle operating at peak performance and economy. Mileages are expressed in terms of kilome- ters, miles and time for your convenience. NOTE: More frequent servicing may be performed on motorcycles that are used under severe conditions.
  • 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. Clutch lever holder Side-stand pivot and spring hook Gearshift link pivot Brake lever holder Throttle cable Brake pedal pivot and brake rod link...
  • 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 6 000 km (4 000 miles, 12 months) and replace every 18 000 km (11 000 miles, 36 months). •...
  • Page 21: Spark Plug

    PERIODIC MAINTENANCE 2-5 NOTE: When cleaning the air cleaner element, drain water from the air cleaner by removing the drain plug. SPARK PLUG Inspect every 6 000 km (4 000 miles, 12 months) and replace every 12 000 km (7 500 miles, 24 months). No.
  • Page 22 2-6 PERIODIC MAINTENANCE No. 2 (REAR) SPARK PLUG REMOVAL • Remove the rear and front seats. (8-3) • Remove the fuel tank. (6-3) • Remove the spark plug cap. • Remove the spark plug with a spark plug wrench. HEAT RANGE •...
  • Page 23: Valve Clearance

    PERIODIC MAINTENANCE 2-7 SPARK PLUG AND PLUG CAP INSTALLATION • Install the spark plugs to the cylinder heads by finger tight, and then tighten them to the specified torque.  Spark plug: 11 N·m (1.1 kgf-m, 8.0 lb-ft)  When installing a spark plug, carefully turn the spark plug wrench by finger into the threads of the cylinder head to prevent damage the aluminum threads.
  • Page 24 2-8 PERIODIC MAINTENANCE • Remove the cylinder head cover caps (1, 2). • Remove the PAIR pipe. • Remove the gasket 3.  Do not reuse the removed gasket.
  • Page 25 PERIODIC MAINTENANCE 2-9 • Remove all the inspection caps. • Remove all the spark plugs. • Remove the generator cover plug 4. • Remove the cap 5 and the timing inspection plug 6. • Rotate the generator rotor to set the No. 1 engine’s piston at TDC of the compression stroke.
  • Page 26: Fuel Hose

    2-10 PERIODIC MAINTENANCE  Both right and left valve clearances should be as closely set as possible. • Rotate the generator rotor 450 degrees (1 and 1/4 turns) and align the “F I T” line on the rotor with the center of hole on the generator cover.
  • Page 27: Engine Oil Replacement

    PERIODIC MAINTENANCE 2-11 ENGINE OIL AND OIL FILTER (ENGINE OIL) Replace initially at 1 000 km (600 miles, 2 months) and every 6 000 km (4 000 miles, 12 months) thereafter. (OIL FILTER) Replace initially at 1 000 km (600 miles, 2 months) and every 18 000 km (11 000 miles, 36 months) thereafter.
  • Page 28 3.4 L (3.6/3.0 US/Imp qt) Overhaul engine: 3.7 L (3.9/3.3 US/Imp qt)  ONLY USE A GENUINE SUZUKI MOTORCYCLE OIL FILTER. Other manufacturer’s oil filters may differ in thread specifications (thread diameter and pitch), fil- tering performance and durability which may lead to engine damage or oil leaks.
  • Page 29: Engine Idle Speed

    PERIODIC MAINTENANCE 2-13 ENGINE IDLE SPEED Inspect initially at 1 000 km (600 miles, 2 months) and every 6 000 km (4 000 miles, 12 months) thereafter. NOTE: Warm up the engine before adjusting the engine idle speed. • Connect the multi-circuit tester to the high-tension cord. •...
  • Page 30: Throttle Cable Play

    2-14 PERIODIC MAINTENANCE THROTTLE CABLE PLAY Inspect initially at 1 000 km (600 miles, 2 months) and every 6 000 km (4 000 miles, 12 months) thereafter. Adjust the throttle cable play A with the following three steps. MINOR ADJUSTMENT First step: •...
  • Page 31: Throttle Valve Synchronization

    PERIODIC MAINTENANCE 2-15 MAJOR ADJUSTMENT • Remove the rear and front seats. (8-3) • Remove the fuel tank. (6-3) • Loosen the lock nut 1 of the throttle returning cable. • Turn the returning cable adjuster 2 to obtain proper cable play.
  • Page 32: Clutch

    2-16 PERIODIC MAINTENANCE CLUTCH Inspect every 6 000 km (4 000 miles, 12 months). • Loosen the lock nut 1. • Turn in the adjuster 2 all the way into the clutch lever assem- bly. • Remove the left frame cover. (8-3) •...
  • Page 33: Cooling System

    PERIODIC MAINTENANCE 2-17 COOLING SYSTEM RADIATOR HOSE Inspect every 6 000 km (4 000 miles, 12 months). ENGINE COOLANT Replace engine coolant every 2 years. ENGINE COOLANT LEVEL CHECK • Keep the motorcycle upright. • Check the engine coolant level by observing the full and lower lines on the engine coolant reserve tank.
  • Page 34 2-18 PERIODIC MAINTENANCE AIR BLEEDING THE COOLING CIRCUIT • Add engine coolant up to the radiator inlet. • Support the motorcycle upright. • Slowly swing the motorcycle, right and left, to bleed the air trapped in the cooling circuit. • Add engine coolant up to the radiator inlet. •...
  • Page 35: Final Gear Oil

    PERIODIC MAINTENANCE 2-19 FINAL GEAR OIL Replace initially at 1 000 km (600 miles, 2 months) and inspect every 12 000 km (7 500 miles, 24 months) thereafter. • Keep the motorcycle upright. • Place an oil pan under the final gear case. •...
  • Page 36 2-20 PERIODIC MAINTENANCE FRONT BRAKE PADS The extent of brake pad wear can be checked by observing the grooved limit A on the pad. When the wear exceeds the grooved limit, replace the pads with new ones. (8-52)  Replace the brake pads as a set, otherwise braking performance will be adversely affected.
  • Page 37 PERIODIC MAINTENANCE 2-21 REAR BRAKE ADJUSTING • Adjust the free travel A to 20 – 30 mm by turning the adjust- ing nut 1.  Rear brake pedal free travel A: 20 – 30 mm (0.8 – 1.2 in) REAR BRAKE SHOE WEAR This motorcycle is equipped with brake lining wear limit indicator on the rear brake.
  • Page 38 2-22 PERIODIC MAINTENANCE AIR BLEEDING FROM THE BRAKE FLUID CIRCUIT Air trapped in the fluid circuit acts like a cushion to absorb a large proportion of the pressure developed by the master cylin- der and thus interferes with the full braking performance of the brake caliper.
  • Page 39: Tire

    The standard tire fitted on this motorcycle is 130/90-16M/C (67H) for front and 170/80-15M/C (77H) for rear. The use of tires other than those specified may cause instability. It is highly recommended to use a SUZUKI Genuine Tire. TIRE TYPE IRC (FRONT) : GS-23F A IRC (REAR)
  • Page 40: Front Fork

    2-24 PERIODIC MAINTENANCE FRONT FORK Inspect every 12 000 km (7 500 miles, 24 months). Inspect the front forks for oil leakage, scoring or scratches on the outer surface of the inner tubes. Replace any defective parts, if necessary. (8-13) REAR SUSPENSION Inspect every 12 000 km (7 500 miles, 24 months).
  • Page 41: Chassis Bolt And Nut

    PERIODIC MAINTENANCE 2-25 CHASSIS BOLT AND NUT Tighten initially at 1 000 km (600 miles, 2 months) and every 6 000 km (4 000 miles, 12 months) thereafter. Check that all chassis bolts and nuts are tightened to their specified torque. (Refer to page 2-26 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 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 (Automatic de-comp.
  • Page 44: Oil Pressure Check

    2-28 PERIODIC MAINTENANCE OIL PRESSURE CHECK Check periodically the oil pressure in the engine to judge roughly the condition of the moving parts. OIL PRESSURE SPECIFICATION Above 350 kPa (3.5 kgf/cm², 50 psi) at 3 000 r/min, Oil temp. at 60°C (140°F) Below 650 kPa (6.5 kgf/cm², 92 psi) 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, take the sample of data from the new motorcycle and at the time of periodic maintenance at your dealership. Save the data in the computer or by printing and filing the hard copies. The saved or filed data are useful for troubleshooting as they can be compared periodically with changes over time or failure conditions of the motorcycle.
  • Page 46: Data At 3 000 R/min Under No Load

    2-30 PERIODIC MAINTENANCE Data at 3 000 r/min under no load XXXX r/min XXXX r/min Check the manifold absolute pressure. Check the manifold absolute pressure. XXX mmHg XXX mmHg Secondary valve moves approx. XX degree. Secondary valve moves approx. XX degree. Data at the time of racing Throttle : Throttle : Slo...
  • Page 47 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 ...............3-11 ENGINE COMPONENTS INSPECTION AND SERVICING ......3-27 CYLINDER HEAD COVER ..............3-27 CAMSHAFT ....................3-28 CAM CHAIN TENSIONER AND GUIDE ..........3-30 CYLINDER HEAD ..................3-30...
  • Page 48: 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 the page listed in this section for removal and reinstallation instructions. ENGINE CENTER PARTS REMOVAL INSTALLATION...
  • Page 49: Engine Removal And Installation

    ENGINE 3-3 ENGINE REMOVAL AND INSTALLATION ENGINE REMOVAL Before taking the engine out of the frame, wash the engine using a steam cleaner. Engine removal is sequentially explained in the following steps. Reinstall the engine by reversing the removal procedure. •...
  • Page 50 3-4 ENGINE • Remove the engine coolant reservoir tank. • Disconnect the water hoses 3. • Disconnect the side-stand switch lead wire coupler 4. • Disconnect the neutral switch lead wire coupler 5. • Disconnect the generator lead wire coupler 6 and the signal generator lead wire coupler 7.
  • Page 51 ENGINE 3-5 • Remove the PAIR (AIR SUPPLY) cover. • Remove the PAIR mounting bolts. • Disconnect the PAIR hoses B and lead wire coupler C. • Remove the air cleaner box D and air intake pipe E. (5-47) • Remove the air cleaner box bracket. •...
  • Page 52 3-6 ENGINE • Disconnect the ECT sensor lead wire coupler G. • Disconnect the spark plug caps. • Remove the right frame cover. (8-4) • Disconnect the HO2 sensor lead wire coupler H. (For E-02, 19, 24) • Remove the No. 1 muffler I. •...
  • Page 53 ENGINE 3-7 • Remove the rear clutch cover J. • Remove the rear brake link K. • Disconnect the horn lead wire coupler L and rear brake switch lead wire coupler M. • Remove the cooling fan N. (7-8) • Remove the engine frame mounting bolt O. •...
  • Page 54: Engine Installation

    3-8 ENGINE ENGINE INSTALLATION Install the engine in the reverse order of engine removal. Pay attention to the following points: • Install the universal joint. NOTE: Be sure to face the short portion A backward when installing it. • Install the boot. NOTE: Make sure that the “UP”...
  • Page 55 ENGINE 3-9 NOTE: * The engine mounting nuts are self-locking. Once the nut has been removed, they are no longer of any use. * Be sure to use new nuts and tighten them to the specified torque. 50 N . m (5.0 kgf-m, 36.0 lb-ft) 79 N .
  • Page 56 3-10 ENGINE • Apply grease to the push rod and install it.  99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) • Apply grease to the clutch release mechanism and install it.  99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A”...
  • Page 57: Engine Disassembly

    ENGINE 3-11 ENGINE DISASSEMBLY • Remove the PAIR pipes. • Remove the spark plugs.  09930-10121: Spark plug wrench set • Remove the gaskets. • Remove the cylinder head cover caps (1, 2). • Remove the water outlet union 3. •...
  • Page 58 3-12 ENGINE • Remove the valve inspection caps. (F & R) • Remove the intake pipes 6. (F & R) CYLINDER HEAD COVER • Remove the valve timing inspection plug 1 and the generator cover cap 2. • Position “R I T” line on the generator with the center of the valve timing inspection hole.
  • Page 59 ENGINE 3-13 • Remove the dowel pins and camshaft end cap 3. • Rotate the generator rotor 450 degrees (1 and 1/4 turns) and align the “F I T” line on the generator with the center of the valve timing inspection hole. •...
  • Page 60 3-14 ENGINE CYLINDER HEAD/CYLINDER • Loosen the water hose clamp screws. • Remove the cylinder head bolts. (Front cylinder) • After unlocking the ratchet, push the cam chain tension adjuster rod fully. • Insert the special tool between the ratchet and the adjuster body.
  • Page 61 ENGINE 3-15 • Separate the cylinder head/cylinder assembly. (Front cylin- der) • Remove the cam chain guide 4. • Remove the dowel pins and gasket 5. • Remove the cylinder head bolts. (Rear cylinder) • Push the cam chain tension adjuster rod and insert the spe- cial tool.
  • Page 62 3-16 ENGINE • Remove the dowel pins and gasket 7. • Remove the cam chain guide 8. • Remove the water hose and pipe. • Remove the cylinder 9. (Rear cylinder) • Remove the dowel pins and gasket 0. PISTON •...
  • Page 63 ENGINE 3-17 • Draw out each piston pin 2 and remove the pistons 3. (F & R) NOTE: Scribe the cylinder position on the head. STARTER MOTOR • Remove the starter motor cover 1. • Remove the starter motor 2. CLUTCH •...
  • Page 64 3-18 ENGINE • Remove the clutch spring mounting bolts and springs diago- nally. • Remove the pressure plate 2. • Remove the thrust washer 3, bearing 4, push piece 5 and push rod 6. • Remove the clutch drive and driven plates 7. •...
  • Page 65 ENGINE 3-19 • Remove the clutch sleeve hub nut with the special tool.  09920-53740: Clutch sleeve hub holder • Remove the washer 0 and the clutch sleeve hub A. • Remove the thrust washer B, spacer C, and needle roller bearing D.
  • Page 66 3-20 ENGINE OIL PUMP • Remove the oil pump by removing the snap ring.  09900-06107: Snap ring pliers • Remove the pin 1 and washer 2. • Remove the oil pump 3. GEARSHIFT • Draw out the gearshift shaft 1. •...
  • Page 67 ENGINE 3-21 PRIMARY DRIVE GEAR • Remove the primary drive gear by removing the primary drive gear bolt with the special tool.  09930-40113: Rotor holder  This bolt has left-hand thread. Turning it counter-clockwise may cause damage. • Remove the cam chain tensioner 1, washers, spacer 2 and the chain 3.
  • Page 68 3-22 ENGINE NEUTRAL SWITCH • Remove the oil pressure switch lead wire. • Remove the neutral switch assembly. • Remove the neutral switch contacts 1 and spring 2. GENERATOR • Remove the generator cover. • Remove the dowel pins and gasket 1. •...
  • Page 69 ENGINE 3-23 • Loosen the generator rotor bolt. NOTE: When loosen the rotor bolt, do not remove it. The rotor bolt is used in conjunction with the rotor remover when removing the rotor. • Remove the generator rotor assembly with the special tool. ...
  • Page 70 3-24 ENGINE • Remove the water pump assembly and gasket 1. SECONDARY DRIVEN GEAR • Remove the secondary driven gear housing bolts. • Remove the secondary driven gear case. • Remove the secondary driven gear assembly 1 and shims • Remove the bearing 3, pin 4, oil jet 5, and dowel pins.
  • Page 71 ENGINE 3-25 OIL JET • Remove the oil jets. CRANKCASE • Remove the crankcase bolts. • Separate the crankcase into two parts with the special tool.  09920-13120: Crankcase separator • Remove the dowel pins and O-ring.
  • Page 72 3-26 ENGINE • Remove the thrust shim 1 and crankshaft 2. • Remove the gearshift fork shafts 3 gearshift forks 4 and gearshift cam 5. • Remove the transmission. • Remove the washer. SECONDARY DRIVE BEVEL GEAR • Remove the over driving gear 1 and bush 2. •...
  • Page 73: Engine Components Inspection And Servicing

    ENGINE 3-27 ENGINE COMPONENTS INSPECTION AND SERVICING CYLINDER HEAD COVER DISASSEMBLY  Be sure to identify each removed part as to its loca- tion, and lay the parts out in groups designated as “No. 1 cylinder”, “No. 2 cylinder”, “Exhaust”, “Intake”, so that each will be restored to the original location during assembly.
  • Page 74: Camshaft

    3-28 ENGINE REASSEMBLY • Apply SUZUKI MOLY PASTE to the rocker arms and their shafts.  99000-25140: SUZUKI MOLY PASTE  Rocker arm shaft: 27 N·m (2.7 kgf-m, 19.5 lb-ft) CAMSHAFT “F” “R” The camshafts should be checked for wear and also for runout of cams and journals if the engine has been noted to produce abnormal noise or vibration or to lack output power.
  • Page 75 To properly measure the oil clearance with plastigauge, all gas- ket material must be removed from fitting surfaces of cylinder head and cover. Do not apply SUZUKI BOND “1216B” until after the oil clearance has been determined. • Tighten the cylinder head cover bolts evenly and diagonally to the specified torque.
  • Page 76: Cam Chain Tensioner And Guide

    3-30 ENGINE CAM CHAIN TENSIONER AND GUIDE CAM CHAIN TENSIONER For driving the camshafts, two cam chain tensioners are used on the respective cam drive chains. Unlock the ratchet mecha- nism, and move the push rod in place to see if it slides smoothly. If any stickiness is noted or ratchet mechanism is faulty, replace the cam chain tensioner assembly with a new one.
  • Page 77 ENGINE 3-31 • Pull out the valve 5 from the other side. • Remove the valve stem seal 6 and valve spring seat 7. NOTE: Removal of valves completes ordinary disassembling work. If valve guides have to be removed for replacement after inspect- ing related parts, carry out the steps shown in valve guide ser- vicing.
  • Page 78 3-32 ENGINE VALVE HEAD RADIAL RUNOUT Place the dial gauge at right angles to the valve head face, and measure the valve head radial runout. If it measures more than limit, replace the valve.  Valve head radial runout Service Limit: 0.03 mm (0.001 in) ...
  • Page 79 ENGINE 3-33 • Re-finish the valve guide holes in cylinder head with a 10.8 mm reamer and handle.  09916-34580: Valve guide hole reamer 09916-34542: Reamer handle • Cool down the new valve guides in a freezer for about one hour and heat the cylinder head to 100 –...
  • Page 80 3-34 ENGINE • The ring-like dye impression left on the valve face must be continuous – without any break. In addition, the width of the dye ring, which is the visualized seat “width”, must be within the following specification:  Valve seat width W Standard: 0.9 –...
  • Page 81 ENGINE 3-35 • Insert the solid pilot 1 (09916-24450: N-100-5.52) with a slight rotation. Seat the pilot snugly. Install the 45° cutter, attachment and T-handle. INITIAL SEAT CUT • Using the 45° cutter, descale and clean up the seat. Rotate the cutter one or two turns.
  • Page 82 3-36 ENGINE BOTTOM NARROWING CUT • If the contact area W is too wide or too low, use the 60° (intake side only) to narrow and raise the contact area. 60˚ (Intake only) FINAL SEAT CUT Contact area too low and •...
  • Page 83 ENGINE 3-37 • Clean and assemble the head and valve components. Fill the intake and exhaust ports with gasoline to check for leaks. • If any leaks occur, inspect the valve seat and face for burrs or other things that could prevent the valve from sealing. ...
  • Page 84  Do not reuse the oil seal. • Insert the valves, with their stems coated with high quality molybdenum disfluid lubricant (SUZUKI MOLY PASTE) all around and along the full stem length without any break.  99000-25140: SUZUKI MOLY PASTE ...
  • Page 85 ENGINE 3-39 NOTE: When installing the water union to the cylinder head, apply grease to the new O-rings.  99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others)
  • Page 86: Cylinder

     Cylinder bore Service Limit: 83.085 mm (3.2711 in)  09900-20508: Cylinder gauge set NOTE: When installing the water union to the cylinder, apply grease to the new O-rings.  99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others)
  • Page 87: Piston

    ENGINE 3-41 PISTON PISTON DIAMETER Using a micrometer, measure the piston outside diameter at the place shown in Fig. If the measurement is less than the limit, replace the piston.  Piston diameter Service Limit: 82.880 mm (3.2630 in) 15 mm (0.6 in) ...
  • Page 88: Piston Ring End Gap

    3-42 ENGINE PISTON RING FREE END GAP AND END GAP Before installing piston rings, measure the free end gap of each ring using vernier calipers. Next, fit the ring in the cylinder, and measure each ring end gap using a thickness gauge. If any ring has an excess end gap, replace the ring.
  • Page 89 ENGINE 3-43 PISTON PIN AND PIN BORE Using a small bore gauge, measure the piston pin bore inside diameter, and using a micrometer, measure the piston pin out- side diameter. If the reading exceeds following limit, replace both piston and piston pin. ...
  • Page 90: Conrod/crankshaft

    3-44 ENGINE • 1st ring and 2nd ring have letter “R” marked on the side. Be sure to bring the marked side to the top when fitting them to the piston. 1st ring 2nd ring • Position the gaps of the three rings as shown. Before inserting each piston into the cylinder, check that the gaps are so 2nd ring located.
  • Page 91 ENGINE 3-45  Conrod big end width Standard: 21.95 – 22.00 mm (0.864 – 0.866 in) Crank pin width Standard: 22.10 – 22.15 mm (0.870 – 0.872 in)  09900-20205: Micrometer (0 – 25 mm) 09900-20605: Dial calipers (10 – 34 mm) CONROD-CRANK PIN BEARING SELECTION •...
  • Page 92 3-46 ENGINE • Remove the caps and measure the width of compressed plas- tigauge with envelope scale. This measurement should be taken at the widest part.  Conrod big end oil clearance Standard: 0.024 – 0.042 mm (0.0009 – 0.0017 in) Service Limit: 0.080 mm (0.0031 in) •...
  • Page 93 ENGINE 3-47 Bearing thickness specification Color code Color (Part No.) Thickness Green 1.485 – 1.488 mm (12164-38E00-0A0) (0.0585 – 0.0586 in) Black 1.488 – 1.491 mm (12164-38E00-0B0) (0.0586 – 0.0587 in) Brown 1.491 – 1.494 mm (12164-38E00-0C0) (0.0587 – 0.0588 in) Yellow 1.494 –...
  • Page 94 3-48 ENGINE CRANKCASE/CRANKSHAFT BEARING INSPECTION • Inspect the crankshaft and crankshaft journal bearings for any damage. If any, replace them with a specified set of bearings. • Measure the crankshaft journal O.D. 1 by using the special tool.  Crankshaft journal O.D. 1 Standard: 47.965 –...
  • Page 95 ENGINE 3-49 Bearing thickness Color code Color (Part No.) Thickness Green 2.006 – 2.009 mm (12229-39G00-0A0) (0.0789 – 0.0790 in) Black 2.009 – 2.012 mm (12229-39G00-0B0) (0.0790 – 0.0792 in) Brown 2.012 – 2.015 mm (12229-39G00-0C0) (0.0792 – 0.0793 in) ...
  • Page 96 3-50 ENGINE NOTE: Bearing Using the hand-press is recommended to remove the crankshaft journal bearings. However, the crankshaft journal bearings can be removed by using with the following special tools.  09924-84510: Bearing installer set 09924-74570: Final drive gear bearing remover/installer •...
  • Page 97 ENGINE 3-51 • Set the bearings installed in the special tool to the crankcase half as shown.  * Be sure the bearing protruded side B faces the crankcase bore. * Align the special tool mating surface with the line mark C on the crankcase.
  • Page 98 3-52 ENGINE NOTE: Using the hand-press is recommended to install the crankshaft journal bearings. However, the crankshaft journal bearings can be installed by using the following special tools.  09924-84510: Bearing installer set 09924-74570: Final drive gear bearing remover/installer Clearance 1 mm (0.04 in) •...
  • Page 99: Clutch

    ENGINE 3-53 • If the thrust clearance exceeds the standard range, adjust the thrust clearance by the following procedures: • Remove the thrust shim, and measure its thickness with a micrometer. • Change the thrust shim with the other shim if the thrust clear- ance is incorrect.
  • Page 100: Generator/signal Generator/ Starter Clutch

    3-54 ENGINE Measure each driven plate for distortion with a thickness gauge and surface plate. Replace driven plates which exceed the limit.  Clutch driven plate distortion Service Limit: 0.10 mm (0.004 in)  09900-20803: Thickness gauge CLUTCH SPRING FREE LENGTH Measure the free length of each coil spring with a vernier cali- pers, and compare the elastic strength of each with the specified limit.
  • Page 101 ENGINE 3-55 STARTER CLUTCH INSPECTION Install the starter driven gear onto 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 dam- age or inspect the starter clutch contacting surface of the starter driven gear for wear or damage.
  • Page 102: Oil Pump

    3-56 ENGINE • When installing the starter clutch guide 2, make sure that the flange B side faces out. • Apply THREAD LOCK SUPER “1303” to the securing bolts and tighten them to the specified torque while holding the rotor with off-set wrench. ...
  • Page 103: Transmission

    ENGINE 3-57 TRANSMISSION DISASSEMBLY • Disassemble the transmission gears as shown in the illustration. (USA) (Others) (USA) (Others) 1 Driveshaft bolt 8 2nd driven gear 2 Over driving gear 9 Countershaft/1st drive gear 3 1st driven gear 0 4th drive gear 4 4th driven gear A 3rd drive gear ...
  • Page 104 NOTE: Before installing the gears, coat lightly moly paste or engine oil to the driveshaft and countershaft.  99000-25140: SUZUKI MOLY PASTE  * Never reuse a circlip. After a circlip has been removed from a shaft, it should be discarded and a new snap ring must be installed.
  • Page 105 ENGINE 3-59  When installing the 1st and 3rd driven gear bushings, align the bushing oil hole C with the driveshaft oil hole D. TRANSMISSION GEARS AND RELATED PARTS...
  • Page 106: Gearshift Fork

    3-60 ENGINE GEARSHIFT FORK GEARSHIFT FORK TO GROOVE CLEARANCE Using a thickness gauge, check the shifting fork clearance in the groove of its gear. The clearance for each of the three shifting forks plays an impor- tant role in the smoothness and positiveness of shifting action. If the clearance checked is noted to exceed the limit specified, replace the fork or its gear, or both.
  • Page 107: Crankcase

    • Remove the oil sump filter. • Clean the oil sump filter using compressed air. • When installing the new O-ring, apply grease to it.  99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) OIL PIPE...
  • Page 108 • When installing the oil pipe, use the new O-rings. • Apply grease to the O-rings.  99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) • Apply a small quantity of the THREAD LOCK “1342” to the oil pipe retainer bolts and tighten them securely.
  • Page 109 ENGINE 3-63 BEARING DISASSEMBLY • Remove the bearing retainers. • Remove the bearing with the special tools.  09913-70210: Bearing installer set 09921-20240: Bearing remover set NOTE: If abnormal noise does not occur, it is not necessary to remove the bearing. BEARING REASSEMBLY •...
  • Page 110 3-64 ENGINE • When installing the switch, apply SUZUKI BOND “1207B”.  Oil pressure switch: 14 N·m (1.4 kgf-m, 10.0 lb-ft)  99000-31140: SUZUKI BOND ‘‘1207B” OIL SEAL • Remove the oil seal with the special tool.  09913-70210: Bearing installer set •...
  • Page 111: Engine Reassembly

    ENGINE 3-65 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. SECONDARY DRIVE BEVEL GEAR •...
  • Page 112 • Install the crankshaft into the left crankcase half. NOTE: Coat lightly moly paste to the crankshaft journal bearings and the thrust shim.  99000-25140: SUZUKI MOLY PASTE  Never strike the crankshaft with a plastic hammer when inserting it into the crankcase. It will be easy to...
  • Page 113  Use the new O-ring to prevent oil leakage. • Clean the mating surfaces of the left and right crankcase halves. • Apply SUZUKI BOND “1207B” to the mating surface of the right crankcase.  99000-31140: SUZUKI BOND ‘‘1207B” NOTE: Use of SUZUKI BOND “1207B”...
  • Page 114 99000-25010: SUZUKI SUPER GREASE “A” (Others) • Clean the mating surfaces of the crankcase and the second- ary gear case. • Apply SUZUKI BOND “1207B” to the mating surface of the secondary gear case.  99000-31140: SUZUKI BOND ‘‘1207B” NOTE: * Make surfaces free from moisture, oil, dust and other foreign materials.
  • Page 115 • Install the new O-ring and new gasket. • Tighten the water pump mounting screws.  Use the new O-ring to prevent oil leakage. NOTE: Apply grease to the O-ring.  99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others)
  • Page 116 NOTE: * Fit the clamp to the bolt A. * Apply grease to the O-ring.  99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) CAM CHAIN/CAM CHAIN TENSIONER • Install the cam chain tensioner 1, washers 2, spacer 3 and cam chain.
  • Page 117 • Install the generator cover. NOTE: Fit the new gaskets to the bolts A. NEUTRAL SWITCH • Install the springs 1 and switch contacts 2. NOTE: Apply grease to the O-ring.  99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others)
  • Page 118 3-72 ENGINE • Install the neutral switch. • Install the oil pressure switch lead wire. OIL FILTER • Apply engine oil lightly to the gasket of the oil filter before installation. • Install the oil filter turning it by hand until feeling that the filter gasket contacts the mounting surface.
  • Page 119 ENGINE 3-73 • Install the primary drive gear and tighten the primary drive gear bolt to the specified torque with the special tool.  Primary drive gear bolt: 95 N·m (9.5 kgf-m, 68.5 lb-ft)  09930-40113: Rotor holder NOTE: This bolt has left-hand thread. GEARSHIFT •...
  • Page 120 3-74 ENGINE • Install the gearshift return spring properly. • Install the gearshift shaft with the center of shift gear on the shaft aligned the center of gearshift cam driven gear. OIL PUMP • Install the oil pump.  Oil pump mounting bolt: 11 N·m (1.1 kgf-m, 8 lb-ft) NOTE: Set the oil pump shaft end A to the water pump shaft B.
  • Page 121 ENGINE 3-75 • Install the primary driven gear assembly and engage the chain with the oil pump driven gear. • Apply engine oil to the primary driven gear bearing 3 and install it. • Install the spacer 4 and thrust washer 5. •...
  • Page 122 3-76 ENGINE 95 N . m (9.5 kgf-m, 68.5 lb-ft) Clutch drive plate No. 2 Clutch drive plate No. 1 60 N . m (6.0 kgf-m, 43.5 lb-ft) Wave washer Clutch driven plate seat Wave washer A No. 2 Drive plate Thickness: 3.5 mm (0.14 in) ..1 pc.
  • Page 123 ENGINE 3-77 • Install the clutch drive plate No. 2 A first. • Install the drive and driven plate one by one into the clutch sleeve hub. • Install the push rod. • Install the clutch push piece 0, bearing A and thrust washer •...
  • Page 124 • Apply engine oil to the new O-ring and install the oil jets. PISTON • Apply a light coat of SUZUKI MOLY PASTE to the piston pins.  99000-25140: SUZUKI MOLY PASTE • When installing the piston, the arrow mark on the piston head is located to the exhaust side.
  • Page 125  09918-53810: Chain tensioner lock tool  Cam chain tension adjuster mounting bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft) • Coat SUZUKI BOND “1207B” lightly to the mating surfaces among the crankcase mating surfaces.  99000-31140: SUZUKI BOND ‘‘1207B” • Fit the dowel pins and the new gasket 1.
  • Page 126 3-80 ENGINE CYLINDER HEAD • Install the cam chain guide. 1 For front cylinder 2 For rear cylinder • Fit the dowel pins and the new gasket 3.  Use a new gasket to prevent gas leakage. • Install the cylinder head and tighten the cylinder head bolts diagonally to the specified torque.
  • Page 127 Pull the cam chains upward, or the chain will be caught between crankcase and cam drive sprocket. • Before installing the camshafts onto each cylinder head, apply SUZUKI MOLY PASTE onto the camshaft journals. Also, apply engine oil onto the camshaft journal holders.  99000-25140: SUZUKI MOLY PASTE NOTE: The camshaft is identified by the embossed letters “F”...
  • Page 128 3-82 ENGINE • Align the arrow marks on the front and rear camshafts so it is parallel with the surface of the cylinder heads. NOTE: Arrow marks are located to forward. Front • Engage the chains on the cam sprockets with the locating pin holes A as shown in the photograph.
  • Page 129 ENGINE 3-83 • Apply SUZUKI BOND “1216B” to the mating surface of the cylinder head cover. • Fit the camshaft end caps 1. • Apply grease to the new O-ring 2 and install it. (Front cylin- der only) 99000-31230: SUZUKI BOND “1216B”...
  • Page 130 L: 250 FRONT REAR NOTE: * Before installing the bolt 1, apply SUZUKI BOND “1207B” to the thread of the bolt. * Allen bolt: 2 * Fit the gasket to the bolt 3. • Remove the tensioner lock tools. NOTE: Click sound is heard when the cam chain tension adjuster is released.
  • Page 131 “F” • Apply grease to the new O-ring and install the water outlet union.  99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) • Install the gasket and the breather cover. • Apply grease to the new O-rings and install the valve inspec- tion caps.
  • Page 132 3-86 ENGINE • Install the new gaskets. • Install the PAIR pipes. • Install the spark plugs.  09930-10121: Spark plug wrench set...
  • Page 133 SHAFT DRIVE 4-1 SHAFT DRIVE CONTENTS SECONDARY BEVEL GEARS ...............4- 2 CONSTRUCTION ...................4- 2 REMOVAL ....................4- 4 DISASSEMBLY ..................4- 4 INSPECTION ..................4- 5 SECONDARY GEAR SHIMS ADJUSTMENT ........4- 6 REASSEMBLY ..................4-10 INSTALLATION ..................4-10 FINAL BEVEL GEARS ..................4-11 CONSTRUCTION ...................4-11 FINAL GEAR CASE REMOVAL ............4-13 FINAL GEAR CASE DISASSEMBLY ............4-13 FINAL GEAR SHIMS ADJUSTMENT ............4-17 FINAL GEAR CASE REASSEMBLY .............4-21...
  • Page 134: Secondary Bevel Gears

    4-2 SHAFT DRIVE SECONDARY BEVEL GEARS CONSTRUCTION Bush Shims (5 kinds) Oil seal Overdriving driven gear Driven bevel gear bearing Bearing stopper Circlip O-ring Universal joint Output cam dog Shims (5 kinds) Secondary drive gear shaft nut Secondary drive bevel gear bear- Damper spring O-ring ing retainer bolt...
  • Page 135 SHAFT DRIVE 4-3 0.05 – 0.32 mm Backlash (0.002 – 0.013 in) Standard clearance A: 1.00 mm (0.039 in) B: 1.00 mm (0.039 in) Adjust backlash by selecting shims. (Use two pieces of shims.) Shim 1 size table Part number Thickness 24945-05A-0A0 0.30 mm (0.012 in)
  • Page 136: Removal

    4-4 SHAFT DRIVE REMOVAL SECONDARY DRIVE BEVEL GEAR The crankcase must be separated to service the secondary drive bevel gear. The secondary drive bevel gear service requires engine removal and disassembly. Refer to the engine removal and the engine disassembly sections for secondary drive bevel gear assembly removal.
  • Page 137: Inspection

    SHAFT DRIVE 4-5 SECONDARY DRIVEN BEVEL GEAR • Remove the bearing stopper with the special tool.  09921-21820: Bearing retainer wrench • Remove the oil seal 1 and O-ring 2. INSPECTION Inspect the removed parts for the following abnormalities. * Drive and driven bevel gears damage or wear * Improper tooth contact * Abnormal noise of bearings * Bearing damage or wear...
  • Page 138: Secondary Gear Shims Adjustment

    Secondary driven bevel gear bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft) NOTE: * Hollow portion A of the secondary driven bevel gear assembly faces inside. * It is not necessary to apply SUZUKI BOND “1207B” to the matching surface at this stage.
  • Page 139 SHAFT DRIVE 4-7 • Measure the backlash as follows. • Set-up a dial gauge as shown in photo.  09900-20606: Dial gauge (1/100 mm, 10 mm) 09900-20701: Magnetic stand • Adjust the dial gauge so that it touches the secondary drive bevel gear cam dog;...
  • Page 140 4-8 SHAFT DRIVE Driven bevel gear side Part No. Shim thickness 24945-05A00-0A0 0.30 mm (0.012 in) 24945-05A00-0B0 0.35 mm (0.014 in) 24945-05A00-0C0 0.40 mm (0.016 in) 24945-05A00-0D0 0.50 mm (0.020 in) 24945-05A00-0E0 0.60 mm (0.024 in) NOTE: The shims (driven bevel gear side) are available as a set (24945-05810).
  • Page 141 SHAFT DRIVE 4-9 SHIM SPECIFICATIONS Drive bevel gear side Part No. Shim thickness 24935-38A01-030 0.30 mm (0.012 in) 24935-38A01-035 0.35 mm (0.014 in) 24935-38A01-040 0.40 mm (0.016 in) 24935-38A01-050 0.50 mm (0.020 in) 24935-38A01-060 0.60 mm (0.024 in) NOTE: The shims (drive bevel gear side) are available as a set (24935-38810).
  • Page 142: Reassembly

    REASSEMBLY SECONDARY DRIVEN BEVEL GEAR • Apply grease to the lip of oil seal.  99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) • Tighten the bearing stopper to the specified torque with the special tool.
  • Page 143: Final Bevel Gears

    SHAFT DRIVE 4-11 FINAL BEVEL GEARS CONSTRUCTION 1 Oil seal A Oil seal K Final drive coupling 2 Final gear bearing case B Final gear case L Snap ring 3 O-ring C Shims (5 kinds) M Oil seal 4 Plate D Stopper plate (2 kinds) N Spring 5 Final driven gear bearing...
  • Page 144 4-12 SHAFT DRIVE 0.03 – 0.064 mm Backlash (0.001 – 0.025 in) Standard clearance A: 1.00 mm (0.039 in) Standard clearance C: 1.00 mm (0.039 in) Shim 1 size table Shim 3 size table Part number Thickness Part number Thickness 27445-38A00-030 0.30 mm (0.012 in) 27327-34200...
  • Page 145: Final Gear Case Removal

    SHAFT DRIVE 4-13 FINAL GEAR CASE REMOVAL After draining final gear oil, the following components must be removed in the described order before removing the final gear case. NOTE: Refer to the following pages for the details of each step. •...
  • Page 146 4-14 SHAFT DRIVE 4 Spring 5 Propeller shaft 6 Snap ring • Using a chisel, unlock the nut. • Remove the final drive bevel gear coupling nut with the spe- cial tool.  09924-62430: 22 mm Long socket 09924-64510: Final drive gear coupling holder •...
  • Page 147 SHAFT DRIVE 4-15 • Remove the bearing from the final drive bevel gear with the special tool.  09913-50121: Bearing puller  The removed bearing must be replaced with a new one. NOTE: If no abnormal noise, the bearing removal is not necessary. •...
  • Page 148 4-16 SHAFT DRIVE • Remove the bearing retainer screws, using an impact driver set.  09900-09004: Impact driver set • Remove the final driven gear bearing C and oil seal D with the special tools.  09941-64511: Bearing remover 09930-30104: Sliding shaft ...
  • Page 149: Final Gear Shims Adjustment

     Final gear case bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft) NOTE: It is not necessary to apply SUZUKI BOND “1207B” to the matching surface at this stage. • Measure the clearance between the shims and bearing. If it is not within the specification, the shims must be changed.
  • Page 150 4-18 SHAFT DRIVE BACKLASH After assembling the final gear case, measure the final bevel gear backlash as follows. • Install the backlash measuring tool on the drive bevel gear coupling, and set-up a dial gauge as shown in photo.  09924-34510: Backlash measuring tool (27 – 50 mm) 09900-20607: Dial gauge (1/100 mm, 10 mm) 09900-20701: Magnetic stand •...
  • Page 151 SHAFT DRIVE 4-19 Shims 2 specifications Part No. Shim thickness 27327-34200 0.35 mm (0.014 in) 27327-34210 0.40 mm (0.016 in) 27327-34220 0.50 mm (0.020 in) 27327-34230 0.60 mm (0.024 in) The shims 1 are available as a set (27327-34810). EXAMPLE: Final gear to case shims 1;...
  • Page 152 4-20 SHAFT DRIVE • Remove the final gear bearing case and final driven bevel 3 INCORRECT (Contact at tooth root) gear, and inspect the coated teeth of the driven bevel gear. The contact patch should be as shown at right: •...
  • Page 153: Final Gear Case Reassembly

    SHAFT DRIVE 4-21 FINAL GEAR CASE REASSEMBLY Reassemble the final gear case in the reverse order of disas- sembly. Pay attention to the following points. • Install a new oil seal 1 and O-ring 2 to the bearing stopper.  Use new O-ring and oil seat to prevent oil leakage.
  • Page 154 • Apply grease to the lip of the oil seal.  99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) • Apply SUZUKI BOND to the mating surface of the final gear case and final gear bearing case. ...
  • Page 155 • Apply grease to the O-ring and the oil seal. • Install the bearing stopper 3.  99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) • Tighten the bearing stopper to the specified torque with the special tool.
  • Page 156 • Apply grease to the lip of the oil seal.  Use a new oil seal to prevent oil leakage.  99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) • Install the stopper plate 9. ...
  • Page 157: Final Gear Case Installation

    SHAFT DRIVE 4-25 FINAL GEAR CASE INSTALLATION Installation is in the reverse order of removal. NOTE: Refer to the following pages for the details of each step. • Install the final gear case. • Tighten the final gear case bolts to the specified torque. ...
  • Page 158 FI SYSTEM 5-1 FI SYSTEM CONTENTS PRECAUTIONS IN SERVICING ..............5- 3 CONNECTOR/COUPLER ...............5- 3 FUSE .......................5- 4 ECM/VARIOUS SENSORS ..............5- 4 ELECTRICAL CIRCUIT INSPECTION PROCEDURE......5- 6 USING THE MULTI-CIRCUIT TESTER ..........5- 9 FI SYSTEM TECHNICAL FEATURES ............5-10 INJECTION TIME (INJECTION VOLUME) ..........5-10 COMPENSATION OF INJECTION TIME (VOLUME) ......5-11 INJECTION STOP CONTROL ..............5-11 FI SYSTEM PARTS LOCATION ..............5-12...
  • Page 159 5-2 FI SYSTEM FI SYSTEM CONTENTS “C32” (P0201) or “C33” (P0202) FUEL INJECTOR CIRCUIT MALFUNCTION ..................5-66 “C41” (P0230) FP RELAY CIRCUIT MALFUNCTION......5-68 “C42” (P01650) IG SWITCH CIRCUIT MALFUNCTION......5-68 “C44” (P0130/P0135) HO2 SENSOR (HO2S) CIRCUIT MALFUNCTION (FOR E-02, 19, 24)............5-69 “C49”...
  • Page 160: Precautions In Servicing

    FI SYSTEM 5-3 PRECAUTIONS IN SERVICING When handling the FI component parts or servicing the FI sys- tem, observe the following points for the safety of the system. CONNECTOR/COUPLER • When connecting a connector, be sure to push it in until a click is felt.
  • Page 161: Fuse

    5-4 FI SYSTEM • When connecting meter probe from the terminal side of the coupler where (connection from harness side not being possi- ble), use extra care not to force and cause the male terminal to bend or the female terminal to open. Connect the probe as shown to avoid opening of female ter- minal.
  • Page 162 FI SYSTEM 5-5 Ignition S/W • When disconnecting and connecting the ECM couplers, make sure to turn OFF the ignition switch, or electronic parts may get damaged. INCORRECT • Battery connection in reverse polarity is strictly prohibited. Such a wrong connection will damage the components of the FI system instantly when reverse power is applied.
  • Page 163: Electrical Circuit Inspection Procedure

    5-6 FI SYSTEM ELECTRICAL CIRCUIT INSPECTION PROCEDURE While there are various methods for electrical circuit inspection, described here is a general method to check for open and short circuit using an ohmmeter and a voltmeter. OPEN CIRCUIT CHECK Possible causes for the open circuit are as follows. As the cause can exist in the connector/coupler or terminal, they need to be checked carefully.
  • Page 164 FI SYSTEM 5-7 Continuity check • Measure resistance across coupler B (between A and C in the figure). If no continuity is indicated (infinity or over limit), the circuit is open between terminals A and C. • Disconnect the coupler B and measure resistance between couplers A and B.
  • Page 165 5-8 FI SYSTEM SHORT CIRCUIT CHECK (WIRE HARNESS TO GROUND) • Disconnect the negative cable from the battery. To other • Disconnect the connectors/couplers at both ends of the circuit parts to be checked. NOTE: If the circuit to be checked branches to other parts as shown, disconnect all connectors/couplers of those parts.
  • Page 166: Using The Multi-circuit Tester

    FI SYSTEM 5-9 USING THE MULTI-CIRCUIT TESTER • Use the Suzuki multi-circuit tester (09900-25008). • Use well-charged batteries in the tester. • Be sure to set the tester to the correct testing range. USING THE TESTER MULTI-CIRCUIT TESTER • Incorrectly connecting the + and - probes may cause the inside of the tester to burnout.
  • Page 167: Fi System Technical Features

    5-10 FI SYSTEM 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 the 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 168: Compensation Of Injection Time (volume)

    FI SYSTEM 5-11 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 169: Fi System Parts Location

    5-12 FI SYSTEM FI SYSTEM PARTS LOCATION A Speedometer H Gear position switch B Starter relay I Crankshaft position sensor (CKPS) C Starter motor J Fuel injector #2 (FI) D Intake air pressure sensor #1 (IAPS) K Fuel injector #1 (FI) E Fuel pump relay (FP RELAY) L Ignition coil #1 (IG COIL) F Fuel pump...
  • Page 170 FI SYSTEM 5-13 N Intake air pressure sensor #2 (IAPS) R Intake air temperature sensor (IATS) O Secondary throttle position sensor (STPS) S Ignition coil #2 (IG COIL) P Throttle position sensor (TPS) T Engine coolant temperature sensor (ECTS) Q Secondary throttle valve actuator (STVA) U HO2 sensor (HO2S) [For E-02, 19, 24]...
  • Page 171: Fi System Wiring Diagram

    5-14 FI SYSTEM FI SYSTEM WIRING DIAGRAM...
  • Page 172: Ecm Terminal

    FI SYSTEM 5-15 ECM TERMINAL TERMINAL TERMINAL CIRCUIT CIRCUIT GP switch signal (GP) Ignition switch signal (AT) IAT sensor signal (IAT) ECT sensor signal (ECT) Rear cylinder IAP sensor signal (IAP. R) TO sensor signal (TOS) STP sensor signal (STP) TP sensor signal (TP) Blank Front cylinder IAP sensor signal (IAP.
  • Page 173: Self-diagnosis Function

    5-16 FI SYSTEM 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 light). To check the function of the individual FI system devices, the dealer mode is prepared.
  • Page 174: Dealer Mode

    FI SYSTEM 5-17 DEALER MODE The defective function is memorized in the computer. Use the special tool’s coupler to connect to the dealer mode coupler. The memorized malfunction code is displayed on the 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 175 5-18 FI SYSTEM 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 Front cylinder Throttle position sensor (TPS) Engine coolant temp. sensor (ECTS) Intake air pressure sensor #1 (IAPS #1) For Rear cylinder Intake air temp.
  • Page 176: Tps Adjustment

    FI SYSTEM 5-19 TPS ADJUSTMENT 1. Warm up the engine and adjust the engine idle speed to 1 100 ± 100 r/min. (2-13) 2. Connect the special tool (Mode select switch) and select the dealer mode. 3. Remove the fuel tank. (6-3) 4.
  • Page 177: Fail-safe Function

    5-20 FI SYSTEM 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 760 “YES”...
  • Page 178: Fi System Troubleshooting

    FI SYSTEM 5-21 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 an inspection form such as below will facilitate collecting information required for proper analysis and diagnosis.
  • Page 179: Visual Inspection

    5-22 FI SYSTEM 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 ( Uphill...
  • Page 180: Self-diagnostic Procedures

    FI SYSTEM 5-23 SELF-DIAGNOSTIC PROCEDURES NOTE: * Don’t disconnect couplers from the ECM, the battery cable from the battery, ECM ground wire harness from the engine or main fuse before confirming the malfunction code (self-diag- nostic trouble code) stored in memory. Such disconnection will erase the memorized information in ECM memory.
  • Page 181: Use Of Sds Diagnostic Procedures

    5-24 FI SYSTEM USE OF SDS DIAGNOSTIC PROCEDURES * Don’t disconnect couplers from ECM, the battery cable from the battery, ECM ground wire harness from the engine or main fuse before confirming the malfunction code (self-diagnostic trouble code) stored in memory. Such disconnection will erase the memorized information in ECM memory.
  • Page 182: Use Of Sds Diagnosis Reset Procedure

    FI SYSTEM 5-25 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 183: Show Data When Trouble (displaing Data At The Time Of Dtc)

    5-26 FI SYSTEM SHOW DATA WHEN TROUBLE (DISPLAING DATA AT THE TIME OF DTC) ECM stores the engine and driving conditions (in the form of data as shown in the figure) at the moment of the detection of a malfunction in its memory. This data is called “Show data when trouble”. Therefore, it is possible to know engine and driving conditions (e.g., whether the engine was warm or not, where the motorcycle was running or stopped) when a malfunction was detected by checking the show data when trouble.
  • Page 184: Malfunction Code And Defective Condition

    FI SYSTEM 5-27 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 185 5-28 FI SYSTEM DETECTED DTC No. DETECTED FAILURE CONDITION CHECK FOR ITEM IAT sensor The sensor voltage should be the fol- IAT sensor, lead wire/coupler lowing. connection 0.1 V sensor voltage < 4.6 V In other than the above range, C21 (P0110) is indicated.
  • Page 186 FI SYSTEM 5-29 DETECTED DTC No. DETECTED FAILURE CONDITION CHECK FOR ITEM Gear posi- Gear position signal voltage should be GP switch, lead wire/coupler tion signal higher than the following for 3 seconds connection, Gearshift cam, etc. and more. Gear position sensor voltage > 0.6 V If lower than the above value, C31 P0705 (P0705) is indicated.
  • Page 187: C12" (p0335) Ckp Sensor Circuit Malfunction

    5-30 FI SYSTEM “C12” (P0335) CKP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE The signal does not reach ECM for 3 sec. or more, • Metal particles or foreign material being stuck on after receiving the starter signal. the CKP sensor and rotor tip •...
  • Page 188 FI SYSTEM 5-31 4) Remove the tool box 3. 5) Turn the ignition switch OFF. 6) Check the CKP sensor coupler for loose or poor contacts. If OK, then measure the CKP sensor resistance. 7) Disconnect the CKP sensor coupler and measure the resis- tance.
  • Page 189 5-32 FI SYSTEM Step 2 1) Crank the engine a few seconds with the starter motor, and measure the CKP sensor peak voltage at the coupler. 2) Repeat the above test procedure a few times and measure the highest peak voltage. ...
  • Page 190: C13" (p1750) Or "c17" (p0105) Iap Sensor Circuit Malfunction

    FI SYSTEM 5-33 “C13” (P1750) or “C17” (P0105) IAP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE IAP sensor voltage low or high • Clogged vacuum passage between throttle body and IAP sensor (0.1 V Sensor voltage < 4.8 V) • Air being drawn from vacuum passage between NOTE: throttle body and IAP sensor Note that atmospheric pressure varies depending on...
  • Page 191 5-34 FI SYSTEM Is the voltage OK? Go to Step 2. • Loose or poor contacts on the ECM coupler (terminal 6 or D) • Open or short circuit in the Red wire or B/Br wire 8) After repairing the trouble, clear the DTC using SDS tool. (5-25) Step 2 1) Connect the IAP sensor coupler.
  • Page 192 FI SYSTEM 5-35 Step 3 1) Turn the ignition switch OFF. 2) Remove the IAP sensor. (5-75) 3) Connect the vacuum pump gauge to the vacuum port of the IAP sensor. 4) Arrange 3 new 1.5 V batteries in series 1 (check that total - voltage is 4.5 –...
  • Page 193 5-36 FI SYSTEM Output voltage (VCC voltage 4.5 – 5.0 V, ambient temp. 20 – 30 °C, 68 – 86 °F) ALTITUDE ATMOSPHERIC OUTPUT (Reference) PRESSURE VOLTAGE (ft) (mmHg)     3.4 – 4.0 2 000 2 001 ...
  • Page 194: C14" (p0120-h/l) Tp Sensor Circuit Malfunction

    FI SYSTEM 5-37 “C14” (P0120-H/L) TP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE Output voltage is not within the following • TP sensor maladjusted range. • TP sensor circuit open or short Difference between actual throttle open- • TP sensor malfunction ing and opening calculated by ECM is •...
  • Page 195 5-38 FI SYSTEM Step 1 (When indicating P0120-H:) 1) Remove the fuel tank. (6-3) 2) Turn the ignition switch OFF. 3) Check the TP sensor coupler for loose or poor contacts. If OK, then check the TP sensor lead wire continuity. 4) Disconnect the TP sensor coupler.
  • Page 196 FI SYSTEM 5-39 Step 1 (When indicating P0120-L:) 1) Remove the fuel tank. (6-3) 2) Turn the ignition switch OFF. 3) Check the TP sensor coupler for loose or poor contacts. If OK, then measure the TP sensor lead wire continuity. 4) Disconnect the TP sensor coupler.
  • Page 197 5-40 FI SYSTEM Step 2 1) Turn the ignition switch OFF. 2) Disconnect the TP sensor coupler. 3) Check the continuity between Yellow wire and ground.  TP sensor continuity: ∞ Ω (Infinity) (Yellow – Ground) 4) If OK, then measure the TP sensor resistance at the termi- nals (between Yellow wire and Black wire).
  • Page 198 FI SYSTEM 5-41 Step 3 1) Connect the TP sensor coupler. 2) Insert the needle pointed probes to the lead wire coupler. 3) Turn the ignition switch ON. 4) Measure the TP sensor output voltage at the coupler (between Bl/B wire A and B/Br wire B) by turning the throttle grip.
  • Page 199: C15" (p0115-h/l) Ect Sensor Circuit Malfunction

    5-42 FI SYSTEM “C15” (P0115-H/L) ECT SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE Output voltage is not within the following • ECT sensor circuit open or short range. • ECT sensor malfunction Sensor voltage < 4.6 V • ECM malfunction P0115 Sensor voltage is higher than specified •...
  • Page 200 FI SYSTEM 5-43 Step 1 (When indicating P0115-H:) 1) Remove the fuel tank. (6-3) 2) Turn the ignition switch OFF. 3) Check the ECT sensor coupler for loose or poor contacts. If OK, then check the ECT sensor lead wire continuity. 4) Remove the right frame cover.
  • Page 201 5-44 FI SYSTEM Step 1 (When indicating P0115-L:) 1) Remove the fuel tank. (6-3) 2) Turn the ignition switch OFF. 3) Check the ECT sensor coupler for loose or poor contacts. If OK, then check the ECT sensor lead wire continuity. 4) Disconnect the ECT sensor coupler.
  • Page 202 FI SYSTEM 5-45 Step 2 1) Turn the ignition switch OFF. 2) Loosen the inlet pipe screw. 3) Lift up the inlet pipe 1. 4) Disconnect the ECT sensor coupler. 5) Measure the ECT sensor resistance.  ECT sensor resistance: Approx.
  • Page 203: Ect Sensor Inspection

    5-46 FI SYSTEM ECT SENSOR INSPECTION • Remove the ECT sensor. (5-77) • 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 204: C21" (p0110-h/l) Iat Sensor Circuit Malfunction

    FI SYSTEM 5-47 “C21” (P0110-H/L) IAT SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE Output voltage is not within the following • IAT sensor circuit open or short range. • IAT sensor malfunction Sensor voltage < 4.6 V • ECM malfunction P0110 Sensor voltage is higher than specified •...
  • Page 205 5-48 FI SYSTEM 6) Measure the voltage between Dg wire terminal 3 and ground. 7) Also, measure the voltage between Dg wire terminal 3 and B/Br wire terminal 4.  IAT sensor input voltage: 4.5 – 5.5 V (+ Dg – - Ground) (+ Dg –...
  • Page 206 FI SYSTEM 5-49 Step 1 (When indicating P0110-H:) 1) Loosen the inlet pipe screw. (5-47) 2) Remove the air cleaner box. (6-13) 3) Turn the ignition switch OFF. 4) Check the IAT sensor coupler for loose or poor contacts. If OK, then check the IAT sensor lead wire continuity. 5) Remove the right frame cover.
  • Page 207 5-50 FI SYSTEM Step 1 (When indicating P0110-L:) 1) Loosen the inlet pipe screw. (5-47) 2) Remove the air cleaner box. (6-13) 3) Turn the ignition switch OFF. 4) Check the IAT sensor coupler for loose or poor contacts. If OK, then check the IAT sensor lead wire continuity. 5) Disconnect the IAT sensor coupler.
  • Page 208 FI SYSTEM 5-51 Step 2 1) Turn the ignition switch OFF. 2) Disconnect the IAT sensor coupler. 3) Measure the IAT sensor resistance.  IAT sensor resistance: Approx. 2.6 kΩ at 20 °C (68 °F) (Terminal – Terminal)  09900-25008: Multi-circuit tester set ...
  • Page 209: C23" (p1651-h/l) To Sensor Circuit Malfunction

    5-52 FI SYSTEM “C23” (P1651-H/L) TO SENSOR CIRCUIT MALFUNCTION 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 • TO sensor malfunction switch is turned ON. •...
  • Page 210 FI SYSTEM 5-53 Step 1 (When indicating P1651-H:) 1) Remove the right frame cover. (8-4) 2) Turn the ignition switch OFF. 3) Check the TO sensor coupler for loose or poor contacts. If OK, then check the TO sensor lead wire continuity. 4) Disconnect the TO sensor coupler.
  • Page 211 5-54 FI SYSTEM Step 1 (When indicating P1651-L:) 1) Remove the right frame cover. (8-4) 2) Turn the ignition switch OFF. 3) Check the TO sensor coupler for loose or poor contacts. If OK, then check the TO sensor lead wire continuity. 4) Disconnect the TO sensor coupler.
  • Page 212: C24" (p0351) Or "c25" (p0352) Ignition System Malfunction

    FI SYSTEM 5-55 Step 2 1) Connect the TO sensor coupler. 2) Insert the needle pointed probes to the lead wire coupler. 3) Turn the ignition switch ON. 4) Measure the voltage at the wire side coupler between Br/W 1 and B/Br 2 wires.
  • Page 213: C28" (p1655) Stv Actuator Circuit Malfunction

    5-56 FI SYSTEM “C28” (P1655) STV ACTUATOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE The operation voltage does not reach the STVA. • STVA malfunction ECM does not receive communication signal from • STVA circuit open or short the STVA. • STVA motor malfunction STVA B/Lg STVA.
  • Page 214 FI SYSTEM 5-57 Step 2 1) Turn the ignition switch OFF. 2) Disconnect the STVA lead wire coupler. 3) Check the continuity between each terminal and ground.  STVA continuity: ∞ Ω (Infinity) (Terminal – Ground) 4) If OK, then measure the STVA resistance (between Black wire A and Pink wire B) and (between Green wire C and W/ Bl wire D).
  • Page 215 5-58 FI SYSTEM ACTIVE CONTROL INSPECTION 1) Set up the SDS tool. (Refer to the SDS operation manual for further details) 2) Turn the ignition switch ON. 3) Click “Secondary throttle operating control” 1. 4) Click each button 2. At this time, if an operation sound is heard from the STVA, the function is normal.
  • Page 216: C29" (p1654-h/l) Stp Sensor Circuit Malfunction

    FI SYSTEM 5-59 “C29” (P1654-H/L) STP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE Signal voltage is not within the following • STP sensor maladjusted range. • STP sensor circuit open or short Difference between actual throttle open- • STP sensor malfunction ing and opening calculated by ECM is •...
  • Page 217 5-60 FI SYSTEM Step 1 (When indicating P1654-H:) 1) Remove the fuel tank. (6-3) 2) Turn the ignition switch OFF. 3) Check the STP sensor coupler for loose or poor contacts. If OK, then check the STP sensor lead wire continuity. 4) Disconnect the STP sensor coupler.
  • Page 218 FI SYSTEM 5-61 Step 1 (When indicating P1654-L:) 1) Remove the fuel tank. (6-3) 2) Turn the ignition switch OFF. 3) Check the STP sensor coupler for loose or poor contacts. If OK, then check the STP sensor lead wire continuity. 4) Disconnect the TO sensor coupler.
  • Page 219 5-62 FI SYSTEM Step 2 1) Turn the ignition switch OFF. 2) Disconnect the STP sensor coupler. 3) Check the continuity between each terminal and ground.  STP sensor continuity: ∞ Ω (Infinity) (Terminal – Ground) 4) If OK, then measure the STP sensor resistance at the wire terminals (between Yellow wire A and Black wire B).
  • Page 220 FI SYSTEM 5-63 Step 3 1) Turn the ignition switch OFF. 2) Connect the STP sensor coupler. 3) Insert the needle pointed probes to the STP sensor coupler. 4) Disconnect the STVA lead wire coupler. 5) Loosen the inlet pipe screw. (2-7) Lift the inlet pipe.
  • Page 221: C31" (p0705) Gp Switch Circuit Malfunction

    5-64 FI SYSTEM “C31” (P0705) GP SWITCH CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE No Gear Position switch voltage. • Gear Position switch circuit open or short Switch voltage is not within the following range. • Gear Position switch malfunction Switch voltage > 0.6 V •...
  • Page 222 FI SYSTEM 5-65 Is the voltage OK? ECM coupler (Harness side) • Pink wire open or shorted to ground • If wire and connection are OK, intermittent trou- ble or faulty ECM. • Recheck each terminal and wire harness for open circuit and poor connection.
  • Page 223: C32" (p0201) Or "c33" (p0202) Fuel Injector Circuit Malfunction

    5-66 FI SYSTEM “C32” (P0201) or “C33” (P0202) FUEL INJECTOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE CKP signals produced but fuel injector signal is • Injector circuit open or short interrupted continuous by 4 times or more. • Injector malfunction •...
  • Page 224 FI SYSTEM 5-67 6) If OK, then check the continuity between each terminal and ground.  STP sensor continuity: ∞ Ω (Infinity)  09900-25008: Multi-circuit tester set  Tester knob indication: Resistance (Ω) Are the resistance and continuity OK? Go to Step 2. Replace the injector with a new one.
  • Page 225: C41" (p0230) Fp Relay Circuit Malfunction

    5-68 FI SYSTEM “C41” (P0230) FP RELAY CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE No voltage is applied to fuel pump although fuel • Fuel pump relay circuit open or short pump relay is turned ON, or voltage is applied to fuel •...
  • Page 226: C44" (p0130/p0135) Ho2 Sensor (ho2s) Circuit Malfunction (for E-02, 19, 24)

    FI SYSTEM 5-69 “C44” (P0130/P0135) HO2 SENSOR (HO2S) CIRCUIT MALFUNCTION (FOR E-02, 19, 24) DETECTED CONDITION POSSIBLE CAUSE HO2 sensor output voltage is not input • HO2 sensor circuit open or shorted to ground (P0130) to ECM during engine operation and •...
  • Page 227 5-70 FI SYSTEM 7) Remove the right frame cover. (8-4) 8) Remove the ECM bracket (5-38) and disconnect the ECM coupler. 9) Check the continuity between W/Bl wire A and terminal 7. 10)Also, check the continuity between B/Br wire B and terminal ...
  • Page 228 FI SYSTEM 5-71 Is the voltage OK? ECM coupler (Harness side) • W/Bl wire or B/Br wire open or shorted to ground, or poor 7 or D connection • If wire and connection are OK, intermittent trou- ble or faulty ECM. •...
  • Page 229 5-72 FI SYSTEM Step 2 (When indicating C44/P0135:) 1) Connect the HO2 sensor coupler. 2) Insert the needle pointed probes to the HO2 sensor coupler. 3) Turn the ignition switch ON and measure the heater voltage between W/B wire A and ground. 4) If the tester voltage indicates the battery voltage, it is good condition.
  • Page 230: C49" (p1656) Pair Control Solenoid Valve Circuit Malfunction

    FI SYSTEM 5-73 “C49” (P1656) PAIR CONTROL SOLENOID VALVE CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE PAIR control solenoid valve voltage is not input to • PAIR valve circuit open or short ECM. • PAIR valve malfunction • ECM malfunction Engine stop Side-stand Ignition switch...
  • Page 231 5-74 FI SYSTEM Step 2 1) Turn the ignition switch ON. 2) Measure the voltage between O/W wire A and ground.  PAIR valve voltage: Battery voltage (+ O/W A – - Ground)  09900-25008: Multi-circuit tester set  Tester knob indication: Voltage () Is the voltage OK? ECM coupler (Harness side) •...
  • Page 232: Sensors

    FI SYSTEM 5-75 SENSORS IAP SENSOR INSPECTION The intake air pressure sensor is located on the air inlet pipe. (5-33) IAP SENSOR REMOVAL/INSTALLATION • Remove the fuel tank. (6-3) • Remove the IAP sensors 1 and disconnect the couplers 2 and vacuum hoses 3.
  • Page 233: Stp Sensor Inspection

    5-76 FI SYSTEM STP SENSOR INSPECTION The secondary throttle position sensor is installed on the No. 2 throttle body. (5-59) STP SENSOR REMOVAL/INSTALLATION • Remove the fuel tank. (6-3) • Disconnect the coupler 1. • Remove the screw with a torx wrench (T25) and STP sensor •...
  • Page 234: Iat Sensor Inspection

    FI SYSTEM 5-77 IAT SENSOR INSPECTION The intake air temperature sensor is installed at the back side of the air cleaner box. (5-47) IAT SENSOR REMOVAL/INSTALLATION • Remove the air cleaner box. (5-47) • Disconnect the IAT sensor coupler 1 and remove the IAT sensor 2.
  • Page 235: Ho2 Sensor Inspection (for E-02, 19, 24)

    5-78 FI SYSTEM HO2 SENSOR INSPECTION (FOR E-02, 19, 24) The heated oxygen sensor is installed on the pre-muffler. (5-69) HO2 SENSOR REMOVAL/INSTALLATION • Remove the right frame cover. (8-4) • Disconnect the coupler 1 and remove the HO2 sensor unit. ...
  • Page 236 FUEL SYSTEM AND THROTTLE BODY 6-1 FUEL SYSTEM AND THROTLE BODY CONTENTS FUEL DELIVERY SYSTEM ................6- 2 FUEL SYSTEM ....................6- 3 FUEL TANK REMOVAL................6- 3 FUEL TANK INSTALLATION ..............6- 3 FUEL PRESSURE INSPECTION............6- 4 FUEL PUMP INSPECTION ..............6- 5 FUEL DISCHARGE AMOUNT INSPECTION .........6- 5 FUEL PUMP RELAY INSPECTION ............6- 6 FUEL PUMP REMOVAL AND DISASSEMBLY ........6- 7 FUEL MESH FILTER INSPECTION AND CLEANING ......6-11...
  • Page 237: Fuel Delivery System

    6-2 FUEL SYSTEM AND THROTTLE BODY FUEL DELIVERY SYSTEM The fuel delivery system consists of the fuel tank, fuel pump, fuel filters, fuel feed hose, fuel delivery pipe (including fuel injectors) and fuel pressure regulator. There is no fuel return hose. The fuel in the fuel tank is pumped up by the fuel pump and pressurized fuel flows into the injector installed in the fuel delivery pipe.
  • Page 238: Fuel System

    FUEL SYSTEM AND THROTTLE BODY 6-3 FUEL SYSTEM FUEL TANK REMOVAL • Remove the seats. (8-3) • Remove the fuel tank mounting bolt. • Lift and support the fuel tank about 10 cm (3.94 in) with the proper stay. NOTE: Be careful not to lift the fuel more than about 10 cm (3.94 in), or hoses will be twisted.
  • Page 239: Fuel Pressure Inspection

    6-4 FUEL SYSTEM AND THROTTLE BODY FUEL PRESSURE INSPECTION • Lift and support the fuel tank. (6-3) • Place a rag under the fuel feed hose. • Remove the fuel feed hose 1. • Install the special tools between the fuel tank and fuel delivery pipe.
  • Page 240: Fuel Pump Inspection

    FUEL SYSTEM AND THROTTLE BODY 6-5 FUEL PUMP INSPECTION Turn the ignition switch ON and check that the fuel pump operates 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 241: Fuel Pump Relay Inspection

    6-6 FUEL SYSTEM AND THROTTLE BODY FUEL PUMP RELAY INSPECTION Fuel pump relay is located inside the secondary gear case cover. • Remove the secondary gear case cover. (2-16) • Remove the fuel pump relay. First, check the insulation between A and B terminals with pocket tester.
  • Page 242: Fuel Pump Removal And Disassembly

    FUEL SYSTEM AND THROTTLE BODY 6-7 FUEL PUMP REMOVAL AND DISASSEMBLY CONSTRUCTION 1 Thermistor 6 O-ring  2 Fuel pump 7 Cover 3 Vessel 8 Fuel mesh filter ITEM N·m kgf-m lb-ft 4 Rubber cushion A Fuel pump mounting bolt 5 Fuel pump holder...
  • Page 243 6-8 FUEL SYSTEM AND THROTTLE BODY • Remove the fuel tank. (6-3) • Remove the fuel pump assembly mounting bolts diagonally.  Gasoline is highly flammable and explosive. Keep heat, spark and flame away. • Lift the fuel pump assembly 1 as shown in the photograph. •...
  • Page 244 FUEL SYSTEM AND THROTTLE BODY 6-9 • With the fuel pump assembly 1 being turned approximately 30° counterclockwise as shown in the photograph, pull the Front side Front side fuel pump wiring coupler 3 out of the tank opening while taking care not to cause it to interfere with the tank opening.
  • Page 245 6-10 FUEL SYSTEM AND THROTTLE BODY • Remove the thermistor 7. • Disconnect fuel pump coupler 8. • Remove the fuel pump 9. • Remove the rubber cushion 0 and vessel A. • Remove the fuel pump holder B. • Remove the cover C and fuel mesh filter D.
  • Page 246: Fuel Mesh Filter Inspection And Cleaning

    A ..Thermistor (HIGH) B ..Thermistor (LOW) C ..Positive terminal for fuel pump • Install a new O-ring and apply SUZUKI SUPER GREASE “A” to it.  99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) ...
  • Page 247: Throttle Body

    6-12 FUEL SYSTEM AND THROTTLE BODY THROTTLE BODY CONSTRUCTION 1 STP sensor 9 Three way joint (For E-33) 2 TP sensor 0 Hose (For E-33) 3 IAP sensor A Vacuum hoses 4 STVA B Throttle stop screw  5 Fuel delivery pipe C Idle adjusting screw 6 O-ring A STP sensor mounting screw...
  • Page 248: Air Cleaner Box Removal

    FUEL SYSTEM AND THROTTLE BODY 6-13 AIR CLEANER BOX REMOVAL • Remove the fuel tank. (6-3) • Remove the bolts. : Hooked part • Loosen the clamp screw 1. • Disconnect the IAP sensor lead wire coupler 2. • Disconnect the PAIR hose 3. •...
  • Page 249: Throttle Body Disassembly

    6-14 FUEL SYSTEM AND THROTTLE BODY • Disconnect the fuel injector lead wire couplers 9. • Disconnect the vacuum hoses 0. • Loosen the throttle body clamp screw at the intake pipe side. • Disconnect the throttle cables from their drum. ...
  • Page 250 FUEL SYSTEM AND THROTTLE BODY 6-15 • Remove the fuel delivery hose 4. • Remove the fuel delivery pipes 5. • Remove the fuel injectors 6. • Remove the TP sensor 7 and STP sensor 8 with the special tool. ...
  • Page 251 6-16 FUEL SYSTEM AND THROTTLE BODY  * Do not loosen the nut 0. * The fast idle screw A is factory-adjusted at the time of delivery and therefore avoid removing or turning it unless otherwise necessary. * Do not turn the screw B. ...
  • Page 252: Throttle Body Cleaning

    FUEL SYSTEM AND THROTTLE BODY 6-17 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 for proper use, handling and storage. • Clean all passageways with a spray-type carburetor cleaner and blow dry with compressed air.
  • Page 253 * Apply thin coat of the engine oil to the new O-ring. * Align the throttle shaft end C with the groove D of TP sensor. * Apply SUZUKI SUPER GREASE “A” to the throttle shaft end C if necessary.
  • Page 254 FUEL SYSTEM AND THROTTLE BODY 6-19 • Install the O-rings and dust seals to each fuel injector. • Apply thin coat of the engine oil to the new O-rings and dust seal.  Replace the O-rings and dust seals with the new ones. •...
  • Page 255: Throttle Body Installation

    6-20 FUEL SYSTEM AND THROTTLE BODY • Install the fuel delivery pipe joint hose 6 to the delivery pipes. • Tighten the fuel delivery pipe hose mounting screws to the specified torque.  Fuel delivery pipe joint hose mounting screw: 3.5 N·m (0.35 kgf-m, 2.5 lb-ft) THROTTLE BODY INSTALLATION Installation is in the reverse order of removal.
  • Page 256: Stp Sensor Adjustment

    FUEL SYSTEM AND THROTTLE BODY 6-21 STP SENSOR ADJUSTMENT If the STP sensor adjustment is necessary, measure the sensor out put voltage and adjust the STP sensor position as follows: • Remove the air cleaner box. (6-13) • Disconnect the STVA coupler. (6-13) •...
  • Page 257: Fuel Injector Installation

    6-22 FUEL SYSTEM AND THROTTLE BODY FUEL INJECTOR INSTALLATION • Apply thin coat of the engine oil to new injector dust seals and O-rings. (6-19) • Install the injector by pushing it straight to the throttle body. Never turn the injector while pushing it. (6-19) FAST IDLE The fast idle system is automatic type.
  • Page 258 FUEL SYSTEM AND THROTTLE BODY 6-23 • Turn the ignition switch OFF. • Disconnect the STVA coupler. • Turn the ignition switch ON. • Open the secondary throttle valve fully by moving the fast idle link with your finger. • With the secondary throttle valve held at this position, mea- sure the output voltage of the TP sensor as shown.
  • Page 259: Throttle Valve Synchronization

    6-24 FUEL SYSTEM AND THROTTLE BODY THROTTLE VALVE SYNCHRONIZATION Check and adjust the throttle valve synchronization among two cylinders. USE OF VACUUM BALANCER GAUGE Calibrating each vacuum gauge • Start up the engine and run it in idling condition for warming •...
  • Page 260: Throttle Position Sensor (tps) Setting

    FUEL SYSTEM AND THROTTLE BODY 6-25 • After making sure that the steel ball stays steady at the center line, disconnect the hose from the No. 1 throttle body vacuum nipple and connect the next hose to this vacuum nipple. •...
  • Page 261 COOLING AND LUBRICATION SYSTEM 7-1 COOLING AND LUBRICATION SYSTEM CONTENTS ENGINE COOLANT ..................7- 2 COOLING CIRCUIT ..................7- 3 COOLING CIRCUIT INSPECTION............7- 3 RADIATOR AND WATER HOSES ..............7- 4 RADIATOR REMOVAL ................7- 4 RADIATOR CAP INSPECTION ..............7- 5 RADIATOR INSPECTION AND CLEANING ..........7- 5 RADIATOR REMOUNTING ..............7- 5 WATER HOSE AND RESERVOIR TANK INSPECTION......7- 6 COOLING FAN ....................7- 7...
  • Page 262: Engine Coolant

    7-2 COOLING AND LUBRICATION SYSTEM ENGINE COOLANT At the time of manufacture, the cooling system is filled with a Anti-freeze Freezing point 50:50 mixture of distilled water and ethylene glycol anti-freeze. density This 50:50 mixture will provide the optimum corrosion protection –30 ˚C (–24 ˚F) and excellent heat protection, and will protect the cooling system –40 ˚C (–44 ˚F)
  • Page 263: Cooling Circuit

    COOLING AND LUBRICATION SYSTEM 7-3 COOLING CIRCUIT RESERVOIR ENGINE COOLANT THERMOSTAT TEMPERATURE CYLINDER HEAD TANK SENSOR CYLINDER COOLING FAN THERMO RADIATOR SWITCH WATER PUMP COOLING CIRCUIT INSPECTION Before removing the radiator and draining the engine coolant, inspect the cooling circuit for tightness. •...
  • Page 264: Radiator And Water Hoses

    7-4 COOLING AND LUBRICATION SYSTEM RADIATOR AND WATER HOSES RADIATOR REMOVAL • Remove the fuel tank. (6-3) • Remove the frame head covers. (3-3) • Drain the engine coolant. (2-17) • Remove the radiator cover 1. • Remove the radiator mounting bolts. •...
  • Page 265: Radiator Cap Inspection

    COOLING AND LUBRICATION SYSTEM 7-5 RADIATOR CAP INSPECTION • Fit the cap 1 to the radiator cap tester 2. • Build up pressure slowly by operating the tester. Make sure that the pressure build-up stops at 95 – 125 kPa (0.95 – 12.5 kgf/cm², 13.5 –...
  • Page 266: Water Hose And Reservoir Tank Inspection

    7-6 COOLING AND LUBRICATION SYSTEM WATER HOSE AND RESERVOIR TANK INSPECTION • Remove the fuel tank. (6-3) • Remove the secondary gear case cover. (8-40) • Remove the frame head covers. (3-3) • Any water hose and reservoir tank 1 found in a cracked con- dition or flattened must be replaced.
  • Page 267: Cooling Fan

    COOLING AND LUBRICATION SYSTEM 7-7 COOLING FAN INSPECTION • Disconnect the cooling fan lead wire coupler 1. • Test the cooling fan motor for load current with an ammeter connected as shown in the illustration. • The voltmeter is for making sure that the battery applies 12 volts to the motor.
  • Page 268: Installation

    7-8 COOLING AND LUBRICATION SYSTEM • Remove the cooling fan 1 by disconnecting the cooling fan lead wire coupler. INSTALLATION Install the cooling fan in the reverse order of removal. Pay atten- tion to the following points: • Put the cooling fan 1 between the down tube and the engine. •...
  • Page 269: Cooling Fan Thermo-switch

    COOLING AND LUBRICATION SYSTEM 7-9 COOLING FAN THERMO-SWITCH REMOVAL • Drain the engine coolant. (2-17) • Disconnect the cooling fan thermo-switch coupler 1. • Remove the cooling fan thermo-switch 2. INSPECTION • Check the thermo-switch closing or opening temperatures by testing it at the bench as shown in the figure.
  • Page 270: Engine Coolant Temperature Sensor

    7-10 COOLING AND LUBRICATION SYSTEM ENGINE COOLANT TEMPERATURE SENSOR REMOVAL • Lift and support the fuel tank. (6-3) • Remove the frame head covers. (3-3) • Disconnect the engine coolant temperature sensor coupler • Keep the motorcycle upright. • Place a rag under the sensor and remove the engine coolant temperature sensor 2.
  • Page 271: Installation

    COOLING AND LUBRICATION SYSTEM 7-11 INSTALLATION Install the engine coolant temperature sensor order of removal. Pay attention to the following points: • Tighten the engine coolant temperature sensor to the speci- fied torque.  Engine coolant temperature sensor: 18 N·m (1.8 kgf-m, 13.0 lb-ft) ...
  • Page 272: Thermostat

    7-12 COOLING AND LUBRICATION SYSTEM THERMOSTAT REMOVAL • Drain engine coolant. (2-17) • Remove the reservoir tank. (3-4) • Remove the water hoses 1 and water pump case 2. • Remove the thermostat case 3. • Remove the thermostat 4. INSPECTION Inspect the thermostat pellet for signs of cracking.
  • Page 273: Installation

    COOLING AND LUBRICATION SYSTEM 7-13 • 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 6.0 mm (0.24 in).  Thermostat valve lift A Standard: 6.0 mm and over at 90 °C (0.24 in and over at 194 °F) •...
  • Page 274: Water Pump

    7-14 COOLING AND LUBRICATION SYSTEM WATER PUMP REMOVAL AND DISASSEMBLY • Drain the engine oil. (2-11) • Drain engine coolant. (2-17) • Remove the water pump case. (7-12) 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.
  • Page 275: Inspection

    COOLING AND LUBRICATION SYSTEM 7-15 • Remove the bearings with the special tool.  09921-20240: Bearing remover set NOTE: If there is no abnormal noise condition, bearing removal is not necessary.  The removed bearing must be replaced with a new one.
  • Page 276: Reassembly And Installation

     09913-70210: Bearing installer set NOTE: The stamped mark on the oil seal faces outside. • Apply a small quantity of the SUZUKI SUPER GREASE “A” to the oil seal lip.  99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others)
  • Page 277  09913-70210: Bearing installer set NOTE: The stamped mark on the bearing faces crankcase side. • Apply SUZUKI SUPER GREASE “A” to the impeller shaft.  99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) • Install the impeller shaft to the water pump body.
  • Page 278 • Install the impeller 2 and impeller shaft 3 to the water pump body. • Install the pin 4 and E-ring 5.  99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) • Install the new gasket 6.
  • Page 279: Lubrication System

    COOLING AND LUBRICATION SYSTEM 7-19 LUBRICATION SYSTEM OIL PRESSURE 2-28 OIL FILTER 2-12 OIL PRESSURE REGULATOR 3-62 OIL STRAINER 3-61 OIL JET 3-60 OIL PUMP 3-56 OIL PRESSURE SWITCH 3-63...
  • Page 280: Engine Lubrication System Chart

    7-20 COOLING AND LUBRICATION SYSTEM ENGINE LUBRICATION SYSTEM CHART ROCKER ARM SHAFT (EX.) ROCKER ARM SHAFT (EX.) CAMSHAFT R. JOURNAL CAMSHAFT L. JOURNAL CAM FACES CAM FACES (IN. & EX.) (IN. & EX.) VALVES AND VALVES AND SPRINGS (IN. & EX.) SPRINGS (IN.
  • Page 281 CHASSIS 8-1 CHASSIS CONTENTS EXTERIOR PARTS..................8- 3 REMOVAL ....................8- 3 REMOUNTING ..................8- 4 FRONT WHEEL .....................8- 5 CONSTRUCTION ..................8- 5 REMOVAL AND DISASSEMBLY ............8- 7 INSPECTION ...................8- 8 REASSEMBLY AND REMOUNTING............8- 9 FRONT FORK....................8-12 CONSTRUCTION ..................8-12 REMOVAL AND DISASSEMBLY ............8-13 INSPECTION ...................8-16 REASSEMBLY AND REMOUNTING............8-17 HANDLEBAR....................8-21...
  • Page 282 8-2 CHASSIS CHASSIS CONTENTS BRAKE PAD REPLACEMENT............... 8-52 BRAKE FLUID REPLACEMENT............8-53 BRAKE CALIPER REMOVAL AND DISASSEMBLY..................8-53 BRAKE CALIPER INSPECTION ............8-54 BRAKE CALIPER REASSEMBLY AND REMOUNTING....... 8-55 BRAKE DISC INSPECTION ..............8-56 MASTER CYLINDER REMOVAL AND DISASSEMBLY ....... 8-57 MASTER CYLINDER INSPECTION ............
  • Page 283: Exterior Parts

    CHASSIS 8-3 EXTERIOR PARTS REMOVAL SEAT • Remove the rear seat by removing the bolt.  Be careful not to scratch the rear fender. • Remove the rear seat grip band by removing the bolts. • Remove the seat.  Be careful not to scratch the rear fender.
  • Page 284: Remounting

    8-4 CHASSIS • Remove the right frame covers 2 by removing the bolts.  * Wait until the engine and exhaust pipe are cool enough to touch with bare hands before draining oil. * Be careful not to scratch the frame covers. : Hooked part REAR FENDER •...
  • Page 285: Front Wheel

    CHASSIS 8-5 FRONT WHEEL CONSTRUCTION  1 Bearing (R) 5 Brake disc 2 Front wheel 6 Spacer ITEM N·m kgf-m lb-ft 3 Spacer A Front axle 47.0 4 Bearing (L) B Brake disc mounting bolt 16.5...
  • Page 286 8-6 CHASSIS Right Left  A Front axle B Brake disc bolt ITEM N·m kgf-m lb-ft 47.0 16.5...
  • Page 287: Removal And Disassembly

    CHASSIS 8-7 REMOVAL AND DISASSEMBLY • Loosen the front axle pinch bolt 1. • Loosen the front axle with the special tool.  09900-18710: Hexagon socket (12 mm) • Raise the front wheel off the ground with a jack or a wooden block.
  • Page 288: Inspection

    8-8 CHASSIS INSPECTION WHEEL BEARINGS Inspect the play of the wheel bearings by finger while they are in the wheel. Rotate the inner race by finger to inspect for abnor- mal noise and smooth rotation. Replace the bearing in the following procedure if there is any- thing unusual.
  • Page 289: Reassembly And Remounting

    Reassemble and remount the front wheel in the reverse order of removal and disassembly. Pay special attention to the following points: WHEEL BEARING • Apply SUZUKI SUPER GREASE “A” to the bearings before installing.  99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) •...
  • Page 290  99000-32130: THREAD LOCK SUPER “1360”  Brake disc bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft) SPEED SENSOR • Apply SUZUKI SUPER GREASE “A” to the speed sensor dust seal.  99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) •...
  • Page 291 CHASSIS 8-11 • Tighten the front axle to the specified torque. • Tighten the front axle pinch bolt 3 on the specified torque.  Front axle: 65 N·m (6.5 kgf-m, 47.0 lb-ft) Front axle pinch bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft) ...
  • Page 292: Front Fork

    8-12 CHASSIS FRONT FORK CONSTRUCTION 1 O-ring 6 Oil seal A Front fork cap bolt 2 Spacer 7 Oil seal stopper ring B Inner rod lock-nut 3 Spring 8 Dust seal C Front axle pinch bolt 4 Outer tube 9 Inner rod/Damper rod (cartridge) D Caliper rod bolt 5 Oil seal retainer 0 Inner tube...
  • Page 293: Removal And Disassembly

    CHASSIS 8-13 REMOVAL AND DISASSEMBLY • Remove the front wheel. (8-7) • Remove the front brake caliper. (8-52) • Remove the front fender. • Loosen the front fork upper clamp bolts 1. NOTE: Slightly loosen the front fork cap bolts 2 before loosening the lower clamp bolts to facilitate later disassembly.
  • Page 294 8-14 CHASSIS • Remove the front fork cap bolt from the inner rod by loosening the lock nut. • Compress the fork spring with the special tool and remove the special tool. • Remove the spacer 3 and spring 4. •...
  • Page 295 CHASSIS 8-15 • Extract the outer tube from the inner tube. NOTE: Be careful not to damage the “ANTI-FRICTION” metals. • Remove the dust seal 6. • Remove the oil seal stopper ring 7. • Remove the oil seal 8 with the special tool. ...
  • Page 296: Inspection

    8-16 CHASSIS INSPECTION INNER AND OUTER TUBES • Inspect the inner tube outer surface and outer tube inner sur- face for scratches. • Inspect the “ANTI-FRICTION” metal surfaces for scratches. • If any defects are found, replace them with a new one. ...
  • Page 297: Reassembly And Remounting

    CHASSIS 8-17 REASSEMBLY AND REMOUNTING Reassemble and remount the front fork in the reverse order of removal and disassembly. Pay attention to the following points: OIL SEAL AND DUST SEAL • Install the dust seal, oil seal stopper ring, oil seal and oil seal retainer onto the inner tube.
  • Page 298 • Pour specified front fork oil up to the top level of the outer tube.  Capacity (each leg): 490 ml (16.6/17.3 US/lmp oz)  99000-99044-L01: SUZUKI FORK OIL L01 or an equivalent fork oil • Move the inner rod slowly with the special tool ten times and more until no more bubbles come out from the oil.
  • Page 299  Inner rod lock-nut: 15 N·m (1.5 kgf-m, 11.0 lb-ft) • Remove the special tools. • Fit the O-ring to the front fork cap bolt and apply grease.  99000-25010: SUZUKI SUPER GREASE “A”  Use a new O-ring to prevent oil leakage.
  • Page 300 8-20 CHASSIS • Install the front fork to the steering stem, turn signal clamps (10-22 and -23) and steering stem upper bracket. • Align the upper surface of the outer tube with the upper sur- face of the steering stem upper bracket. •...
  • Page 301: Handlebar

    CHASSIS 8-21 HANDLEBAR CONSTRUCTION 1 Handlebars 3 Left handle grip 5 Right handle grip 2 Handlebar balancer 4 Left handle switch 6 Right handle switch...
  • Page 302: Removal And Disassembly

    8-22 CHASSIS REMOVAL AND DISASSEMBLY • Remove the brake master cylinder 1. (8-57) • Remove the right handle switch 2. • Remove the handle balancer 3. • Remove the throttle grip 4. • Remove the left rear view mirror 5. •...
  • Page 303  Handlebar set bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft) • Install the handlebar set bolt caps. Punch mark Clearance • Apply the SUZUKI SUPER GREASE “A” to the throttle cables and their holder.  99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) •...
  • Page 304: Steering

    8-24 CHASSIS STEERING CONSTRUCTION 1 Handlebar set bolt cap 6 Steering stem upper bearing C Front fork upper clamp bolt 2 Handlebar clamp/holder 7 Steering stem lower bearing D Handlebar holder nut 3 Steering stem upper bracket 8 Steering stem E Front fork lower clamp bolt 4 Steering stem nut A Handlebar set bolt...
  • Page 305: Removal And Disassembly

    CHASSIS 8-25 REMOVAL AND DISASSEMBLY • Remove the front forks. (8-13) • Remove the brake hose union bolt 1. (8-57) • Disconnect the clamps. • Remove the handlebar. (8-22) • Remove the steering stem head nut 2 and washer. • Remove the steering stem upper bracket 3. •...
  • Page 306 8-26 CHASSIS • Remove the steering stem nut with the special tool.  09940-14911: Steering stem nut wrench • Remove the steering stem lower bracket. NOTE: Hold the steering stem lower bracket to prevent it from falling. • Remove the dust seal 5, steering stem upper bearing inner race 6 and bearing 7.
  • Page 307: Inspection And Disassembly

    CHASSIS 8-27 INSPECTION AND DISASSEMBLY Inspect the removed parts for the following abnormalities. * Handlebars distortion * Race wear and brinelling * Bearing wear or damage * Abnormal noise of bearing If any abnormal points are found, replace defective parts with the new ones.
  • Page 308 8-28 CHASSIS BEARING • Apply SUZUKI SUPER GREASE “A” to the bearings and bearing races.  99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) • Install the lower bearing to the steering stem lower bracket. • Install the upper bearing and bearing inner race.
  • Page 309 CHASSIS 8-29 HANDLEBAR HOLDER • Install the handlebar holders and related parts to the steering stem head. • Tighten the handlebar holder nuts to the specified torque.  Handlebar holder nut: 54 N·m (5.4 kgf-m, 39.0 lb-ft) FRONT FORK AND STEERING STEM UPPER BRACKET •...
  • Page 310: Steering Tension Adjustment

    8-30 CHASSIS STEERING TENSION ADJUSTMENT Check the steering movement in the following procedure. • By supporting the motorcycle with a jack, lift the front wheel until it is off the floor by 20 – 30 mm (0.8 – 1.2 in). •...
  • Page 311: Rear Wheel

    CHASSIS 8-31 REAR WHEEL CONSTRUCTION 1 Rear axle 8 Bearing (LH) E Brake cam lever 2 Spacer (LH) 9 Spacer (RH) F Cotter pin (For E-03, 28, 33) 3 Lock washer 0 Bearing (RH) A Driven joint stopper bolt 4 Driven joint stopper A Rear wheel B Rear brake cam lever bolt 5 Driven joint...
  • Page 312 8-32 CHASSIS Left Right For E-03, 28, 33  A Rear axle nut B Brake cam lever nut ITEM N·m kgf-m lb-ft ITEM N·m kgf-m lb-ft C Rear torque link nut (F) 47.0 25.5 D Rear torque link nut (R) 18.0...
  • Page 313: Removal

    CHASSIS 8-33 REMOVAL • Raise the rear wheel off the ground and support the motorcy- cle with a jack or wooden block. • Remove the rear brake rod 1. • Remove the torque link rod 2. • Remove the left frame cover. (8-3) •...
  • Page 314: Disassembly

    8-34 CHASSIS • Remove the cotter pin 4. (For E-03, 28, 33) • Remove the axle nut 5 and draw out the rear axle. NOTE: The rear fender removal is not necessary when the rear part of motorcycle can be lifted high enough to take the rear wheel out smoothly.
  • Page 315: Inspection And Disassembly

    CHASSIS 8-35 INSPECTION AND DISASSEMBLY WHEEL (8-66) TIRE (2-23 and 8-66) WHEEL BEARINGS Inspect the play of the wheel bearings by finger while they are in the wheel. Rotate the inner race by finger to inspect for abnor- mal noise and smooth rotation. Replace the bearing in the following procedure if there is anything unusual.
  • Page 316: Reassembly And Remounting

    Pay attention to the following points: WHEEL BEARING • Apply grease to the bearings before installation.  99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) • Install the wheel bearings with the special tool.
  • Page 317 NOTE: Apply grease to the O-ring and the final gear spline before installing the driven joint.  99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) • Apply THREAD LOCK SUPER to the thread of driven joint stopper bolts.
  • Page 318: Rear Suspension

    8-38 CHASSIS REAR SUSPENSION CONSTRUCTION 1 Rear shock absorber 6 Swingarm pivot bearing B Rear cushion rod mounting nut 2 Rear cushion rod 7 Swingarm bearing C Rear cushion lever mounting nut 3 Spacer 8 Swingarm D Rear swingarm pivot bolt lock nut 4 Rear cushion lever bearing 9 Boot E Rear swingarm pivot bolt (Right)
  • Page 319 CHASSIS 8-39 Left Right 50 N . m 5.0 kgf-m 43.5 lb-ft 1 mm 1 mm 78 N . m 7.8 kgf-m 56.5 lb-ft 1 mm 1 mm 100 N . m 10.0 kgf-m 100 N . m 72.5 lb-ft 10.0 kgf-m 72.5 lb-ft 9.5 N .
  • Page 320: Removal

    8-40 CHASSIS REMOVAL • Remove the rear wheel. (8-33) • Remove the final gear case with propeller shaft. • Remove the fuel tank. (6-3) • Remove the battery 1 and disconnect the coupler 2. • Remove the set mounting bracket 3. •...
  • Page 321 CHASSIS 8-41 • Remove the right frame lower cover 8, clutch rear cover 9. : Hooked part • Remove the tool box cover 0. • Remove the tool box. • Remove the fuse box and relay stay. • Remove the cushion lever mounting bolt and nut and cushion rods A (L &...
  • Page 322 8-42 CHASSIS • Remove the shock absorber B. • Remove the right side swingarm pivot bolt lock nut C. • Remove the left and right side swingarm pivot bolts D. NOTE: Slightly loosen the cushion rod mounting nuts and the shock absorber lower mounting nut before removing the swingarm to facilitate later disassembly.
  • Page 323: Inspection And Disassembly

    CHASSIS 8-43 INSPECTION AND DISASSEMBLY SPACER • Remove spacer from swingarm. • Remove the spacers from the cushion lever. • Inspect the spacers for any flaws or other damage. If any defects are found, replace the spacers with new ones. SWINGARM BEARING Insert the spacer into swingarm cushion rod upper side bearing and check the play to move the spacer up and down.
  • Page 324 8-44 CHASSIS CUSHION LEVER BEARING Insert the spacer into bearing and check the play to move the spacer up and down. If an excessive play is noted, replace the bearing with a new ones. • Remove the cushion rod lower side bearings by with the spe- cial tool.
  • Page 325: Reassembly

    • Install the bearings into the cushion lever by with the special tool. (8-39)  09924-84521: Bearing installer NOTE: When installing the bearings, stamped mark of bearing must face outside. • Apply grease to the spacers and bearings.  99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others)
  • Page 326: Remounting

    • Install the swingarm assembly, its pivot bearings and bolts (1, 2). NOTE: Apply grease to the swingarm pivot bearings.  99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) 1: For left side swingarm pivot bolt 2: For right side swingarm pivot bolt •...
  • Page 327  Cushion lever mounting nut: 78 N·m (7.8 kgf-m, 56.5 lb-ft) FINAL GEAR CASE • Install the plate to the final gear case 1. Apply SUZUKI BOND to the mating surface of swingarm and final gear case.  99000-31140: SUZUKI BOND ‘‘1207B”...
  • Page 328 8-48 CHASSIS • Apply Lithium Base Molybdenum grease (NLGI #2) to the pro- peller shaft spline. NOTE: To install the final gear case easily, move the dust boot front and the universal joint back. Engage the universal joint to the propel- ler shaft first and then engage it to the secondary driven bevel gear shaft.
  • Page 329: Rear Shock Absorber Disposal

    CHASSIS 8-49 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 330: Front Brake

    8-50 CHASSIS FRONT BRAKE CONSTRUCTION 1 Cap 6 Caliper holder A Insulator 2 Diaphragm 7 Caliper A Master cylinder mounting bolt 3 Master cylinder 8 Pad set B Brake hose union bolt 4 Piston set 9 Piston C Brake caliper mounting bolt 5 Brake hose 0 Piston and dust seal ...
  • Page 331 CHASSIS 8-51  * The brake system is filled with an glycol-based brake fluid, which is classified DOT 4. Do not use or mix other types of brake fluid, such as silicone-based and petroleum-based brake flu- ids when refilling the brake system, otherwise serious damage to the brake system will result. * Do not use any brake fluid taken from old, used, or unsealed containers.
  • Page 332: Brake Pad Replacement

    8-52 CHASSIS BRAKE PAD REPLACEMENT • Remove the reflex reflector 1. (For E-03, 28, 33) • Remove the brake caliper by removing the brake caliper mounting bolts. • Remove the pin 2. • Remove the pad pin 3. • Remove the brake pads 4. ...
  • Page 333: Brake Fluid Replacement

    CHASSIS 8-53 BRAKE FLUID REPLACEMENT • Place the motorcycle on a level surface and keep the handle- bar straight. • Remove the master cylinder reservoir cap and diaphragm. • Remove as much old brake fluid as possible. • Fill the reservoir with new brake fluid. ...
  • Page 334: Brake Caliper Inspection

    8-54 CHASSIS • Remove the brake pads. (8-52) • Remove the insulator 3. • Remove the brake caliper holder 4. • Remove the spring 5. • Place a rag over the brake caliper pistons to prevent them from popping out, and then force out the pistons using com- pressed air.
  • Page 335: Brake Caliper Reassembly And Remounting

    CHASSIS 8-55 RUBBER PARTS Replace the removed rubber parts with new ones. BRAKE CALIPER REASSEMBLY AND REMOUNTING Reassemble and remount the brake caliper in the reverse order of removal and disassembly. Pay special attention to the follow- ing points: • Wash the caliper bores and pistons with the specified brake fluid.
  • Page 336: Brake Disc Inspection

    • Apply SUZUKI SILICONE GREASE to the insulators.  99000-25100: SUZUKI SILICONE GREASE BRAKE CALIPER HOLDER • Apply SUZUKI SILICONE GREASE to the brake caliper holder.  99000-25100: SUZUKI SILICONE GREASE • Tighten the brake caliper mounting bolts 1, and brake hose union bolt 2 to the specified torque.
  • Page 337: Master Cylinder Removal And Disassembly

    CHASSIS 8-57 Measure the runout using the dial gauge. If the runout exceeds the service limit, replace the brake disc with a new one.  09900-20607: Dial gauge (1/100 mm) 09900-20701: Magnetic stand  Brake disc runout Service Limit: 0.3 mm (0.012 in) •...
  • Page 338: Master Cylinder Inspection

    8-58 CHASSIS • Pull the dust boot 6 out and remove the snap ring 7. • Remove the piston assembly. MASTER CYLINDER INSPECTION MASTER CYLINDER Inspect the master cylinder bore for any scratches or damage. If any damages are found, replace the master cylinder with a new one.
  • Page 339: Master Cylinder Reassembly And Remounting

    • When installing the brake light switch, align the projection on the switch with the hole in the master cylinder. • Apply SUZUKI SUPER GREASE “A” to the bolt.  99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others)
  • Page 340 8-60 CHASSIS • When remounting the master cylinder onto the handlebars, align the master cylinder holder’s mating surface 1 with the punch mark 2 on the handlebars and tighten the upper clamp bolt first.  Master cylinder mount bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft) Master cylinder Handlebar Upper...
  • Page 341: Rear Brake

    CHASSIS 8-61 REAR BRAKE CONSTRUCTION  1 Brake shoe 2 Brake camshaft ITEM N·m kgf-m lb-ft 3 Brake panel 47.0 4 Brake cam lever 5 Cotter pin (For E-03, 28, 33) A Rear axle nut B Rear brake cam lever bolt...
  • Page 342: Removal And Disassembly

    8-62 CHASSIS REMOVAL AND DISASSEMBLY • Remove the rear wheel. (8-33) • Remove the rear brake panel 1. • Remove the brake shoes 2. • Remove the rear brake cam lever 3 by removing bolt. • Remove the washer 4, spring 5 and O-ring 6. •...
  • Page 343: Reassembly And Remounting

    REASSEMBLY AND REMOUNTING BRAKE CAMSHAFT • When installing the brake camshaft, apply SUZUKI SUPER GREASE “A” to the camshaft and cam face.  99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) •...
  • Page 344: Rear Brake Rod

    8-64 CHASSIS REAR BRAKE ROD REMOVAL AND DISASSEMBLY • Remove the exhaust pipes and mufflers assembly. (3-6) • Remove the right frame lower cover 1, clutch rear cover 2. : Hooked part • Remove the rear brake switch spring 3. •...
  • Page 345: Reassembly Remounting

    • Apply grease to the rear brake link pivot bolt and tighten it to the specified torque.  99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others)  Rear brake link pivot bolt: 29 N·m (2.9 kgf-m, 21 lb-ft) •...
  • Page 346: Tire And Wheel

    8-66 CHASSIS 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 recommended to use a tire changer that can satisfy this sealing requirement and can make the operation efficient as well as functional.
  • Page 347: Valve Inspection

    CHASSIS 8-67 VALVE INSPECTION Inspect the valve after the tire is removed from the rim. Replace the valve with a new one if the seal A rubber is peeling or has damage. NOTE: If the external appearance of the valve shows no abnormal con- dition, removing of the valve is not necessary.
  • Page 348: Tire Installation

    8-68 CHASSIS TIRE INSTALLATION • Apply tire lubricant to the tire bead. • When installing the tire onto the wheel, observe the following points.  * Do not reuse the valve which has been once removed. * Never use oil, grease or gasoline on the tire bead in place of tire lubricant.
  • Page 349: Balancer Weight Installation

    CHASSIS 8-69 • 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 350 ELECTRICAL SYSTEM 9-1 ELECTRICAL SYSTEM CONTENTS CAUTIONS IN SERVICING ................9- 3 CONNECTOR..................9- 3 COUPLER ....................9- 3 CLAMP ....................9- 3 FUSE .......................9- 3 SEMI-CONDUCTOR EQUIPPED PART ..........9- 4 BATTERY ....................9- 4 CONNECTING THE BATTERY...............9- 4 WIRING PROCEDURE................9- 4 USING THE MULTI-CIRCUIT TESTER ..........9- 5 LOCATION OF ELECTRICAL COMPONENTS ...........9- 6 CHARGING SYSTEM ...................9- 8 TROUBLESHOOTING ................9- 8...
  • Page 351 9-2 ELECTRICAL SYSTEM ELECTRICAL SYSTEM CONTENTS SWITCHES ....................9-35 BATTERY ..................... 9-37 SPECIFICATIONS .................. 9-37 INITIAL CHARGING ................9-37 SERVICING..................... 9-39 RECHARGING OPERATION..............9-39...
  • Page 352: 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. Click • Inspect the connector for corrosion, contamination and break- age in its cover. COUPLER Click • With a lock type coupler, be sure to release the lock before disconnecting and push it in fully till the lock works when con- necting.
  • Page 353: Semi-conductor Equipped Part

    9-4 ELECTRICAL SYSTEM SEMI-CONDUCTOR EQUIPPED PART • Be careful not to drop the part with a semi-conductor built in INCORRECT such as a ECM. • When inspecting this part, follow inspection instruction strictly. Neglecting proper procedure may cause damage to this part. BATTERY •...
  • Page 354: 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 355: Location Of Electrical Components

    9-6 ELECTRICAL SYSTEM LOCATION OF ELECTRICAL COMPONENTS 1 IAP sensor (#2) (5-33) 0 TP sensor (5-37) 2 IAP sensor (#1) (5-33) A TO sensor (5-52) 3 Fuel injector (#1) (5-66) B Starter motor 4 ECM (Engine Control Module) C Ignition switch 5 Speed sensor D Horn 6 Ignition coil (#2)
  • Page 356 ELECTRICAL SYSTEM 9-7 1 Fuel level switch 9 Starter relay/Main fuse 2 Fuel pump (6-5) 0 Turn signal/Side-stand relay 3 Battery A Regulator/Rectifier 4 ECT sensor (5-42) B Oil pressure switch 5 Fuse box C Generator 6 Ignition coil (#1) D CKP sensor (5-30) 7 Fuel pump relay (6-6) E GP switch (5-64)
  • Page 357: Charging System

    9-8 ELECTRICAL SYSTEM CHARGING SYSTEM Regulator/rectifier IG.switch Generator TROUBLESHOOTING Battery runs down quickly Step 1 1) Check accessories which use excessive amounts of electricity. Are accessories being installed? Remove accessories. Go to Step 2. Step 2 1) Check the battery for current leaks. (9-9) Is the battery for current leaks OK? Go to Step 3.
  • Page 358: Inspection

    ELECTRICAL SYSTEM 9-9 Step 5 1) Measure the generator no-load voltage. (9-11) Is the generator no-load voltage 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 359 9-10 ELECTRICAL SYSTEM REGULATED VOLTAGE • Remove the seat. (8-3) • Start the engine and keep it running at 5 000 r/min. with light- ing switch turned ON and dimmer switch turned HI position. Measure the DC voltage between the + and - battery termi- nals using the multi circuit tester.
  • Page 360 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 genera- tor with a new one.
  • Page 361: Starter System And Side-stand/ignition Interlock System

    9-12 ELECTRICAL SYSTEM STARTER SYSTEM AND SIDE-STAND/IGNITION INTERLOCK SYSTEM Engine stop Ignition switch switch Fuse (30 A) To Ignition coil Starter motor Fuse Gear position (15 A) switch (Neutral) Starter relay Starter Turn signal/ Clutch lever button side-stand relay position switch side-stand switch TROUBLESHOOTING...
  • Page 362 ELECTRICAL SYSTEM 9-13 Step 3 1) Measure the starter relay voltage at the starter relay connectors (between Y/G + and Y/B -) when the starter button is pushed. Is a voltage OK? Go to Step 4. • Faulty engine stop switch •...
  • Page 363: Starter Motor Removal And Disassembly

    9-14 ELECTRICAL SYSTEM STARTER MOTOR REMOVAL AND DISAS- SEMBLY • Disconnect the battery - lead wire. • Drain engine coolant. (2-17) • Remove the mufflers and exhaust pipe. (3-6) • Remove the engine coolant pipe 1. • Remove the starter motor cover 2. •...
  • Page 364: Starter Motor Inspection

    Reassemble the starter motor in the reverse order of disassem- bly. Pay attention to the following points: • Apply SUZUKI SUPER GREASE “A” to the lip of the oil seal.  99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others)
  • Page 365: Starter Relay Inspection

    9-16 ELECTRICAL SYSTEM • Apply a small quantity of SUZUKI MOLY PASTE to the arma- ture shaft.  99000-25140: SUZUKI MOLY PASTE • Align the torque 1 on the brush holder with the groove 2 on the housing end. • Align the torque 3 on the brush holder with the mark 4 on the starter motor case.
  • Page 366: Side Stand/ignition Interlock System Parts Inspection

    ELECTRICAL SYSTEM 9-17 Apply 12 V to A and B terminals and check for continuity between the positive and negative terminals using the multi cir- cuit tester. If the starter relay clicks and continuity is found, the relay is ok. ...
  • Page 367 9-18 ELECTRICAL SYSTEM GEAR POSITION SWITCH • Remove the secondary gear case cover. (8-40) • Disconnect the gear position switch coupler and check the continuity between Blue and Black/White with the transmis- sion in “NEUTRAL”.  09900-25008: Multi circuit tester set ...
  • Page 368 ELECTRICAL SYSTEM 9-19 TURN SIGNAL/SIDE-STAND RELAY The turn signal/side-stand relay is composed of the turn signal relay, side-stand relay and diode. • Remove the secondary gear case cover. (8-40) • Remove the turn signal/side-stand relay. SIDE-STAND RELAY INSPECTION First check the insulation between D and E terminals with the tester.
  • Page 369: Spark Plug

    9-20 ELECTRICAL SYSTEM IGNITION SYSTEM Engine stop switch Ignition Side- coil stand Spark plug relay sensor Fuse Ignition switch Fuse Throttle Gear Engine Battery position position oil temp. sensor switch sensor NOTE: The fuel cut-off circuit is incorporated in this ECM in order to prevent over-running of engine. When engine speed reaches 8 000 r/min during running, this circuit cuts off fuel at the fuel injector.
  • Page 370 ELECTRICAL SYSTEM 9-21 Step 2 1) Measure the battery voltage between input lead wires at the ECM with the ignition switch in the “ON” position. (E-02, 19, 24: O/G and B/W, E-03, 28, 33: O/W and B/W) Is the voltage OK? Go to Step 3.
  • Page 371: Inspection

    9-22 ELECTRICAL SYSTEM INSPECTION IGNITION COIL PRIMARY PEAK VOLTAGE • Remove the fuel tank. (6-3) • Remove the frame head covers. (3-3) • Disconnect the spark plug caps. • Connect new spark plugs to each spark plug cap and ground them to the cylinder head.
  • Page 372 ELECTRICAL SYSTEM 9-23 IGNITION COIL RESISTANCE • Remove the fuel tank. (6-3) • Remove the frame head covers. (3-3) • Disconnect the spark plug caps. Ω • Measure the ignition coil resistance in both the primary and kΩ secondary windings. If the resistance is not within the stan- dard range, replace the ignition coil with a new one.
  • Page 373 9-24 ELECTRICAL SYSTEM • Shift the transmission into the neutral and turn ignition switch “ON”. CKP sensor coupler • Crank the engine a few seconds with the starter motor by coupler depressing starter button and check the CKP sensor peak voltage.
  • Page 374: Speedometer And Pilot Lamp Box

    ELECTRICAL SYSTEM 9-25 SPEEDOMETER AND PILOT LAMP BOX DESCRIPTION This speedometer mainly consists of the stepping motor, LCD (Liquid Crystal Display) and LED (Light Emit- ting Diode). This speedometer is light, thin and of high response compared to those currently in use because of this composition.
  • Page 375: Speedometer Removal And Disassembly

    9-26 ELECTRICAL SYSTEM SPEEDOMETER REMOVAL AND DISASSEMBLY • Remove the headlight. • Disconnect the speedometer lead wire couplers. • Remove the speedometer cover 1. : Hooked part • Remove the speedometer.  When disconnecting and reconnecting the speedome- ter coupler, make sure to turn OFF the ignition switch, or electronic parts may get damaged.
  • Page 376 ELECTRICAL SYSTEM 9-27 • Disassemble the speedometer as follows.  Do not attempt to disassemble the speedometer unit. 1 Speedometer cover 2 Speedometer unit 3 Speedometer case...
  • Page 377: Pilot Lamp Box Removal And Disassembly

    9-28 ELECTRICAL SYSTEM PILOT LAMP BOX REMOVAL AND DISASSEMBLY • Lift and support the fuel tank. (6-3) • Remove the coupler 1.  When disconnecting and reconnecting the pilot lamp box coupler, make sure to turn OFF the ignition switch, or electronic parts may get damaged. •...
  • Page 378: Inspection

    ELECTRICAL SYSTEM 9-29 INSPECTION LED (LIGHT EMITTING DIODE) Check that the LED lights (FI light, Oil pressure indicator light, Engine coolant indicator light and Fuel level 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 posi- tion.
  • Page 379 9-30 ELECTRICAL SYSTEM ENGINE COOLANT TEMPERATURE METER AND INDICATOR ECT sensor inspection. (!7-10) • Remove the fuel tank. (!6-3) • Remove the frame head covers. (!3-3) • Disconnect the ECT sensor coupler 1. " When connecting and disconnecting the engine cool- ant temperature sensor lead wire coupler, make sure to turn OFF the ignition switch, or electronic parts may get damaged.
  • Page 380 ELECTRICAL SYSTEM 9-31 • When the switch is immersed in kerosene under the above condition, the bulb should go out. If the bulb remains lit, Test Battery bulb replace the unit with a new one. Kerosene FUEL LEVEL INDICATOR LIGHT INSPECTION If the fuel level indicator light does not function properly, check the fuel level indicator switch and its lead wire/coupler.
  • Page 381 9-32 ELECTRICAL SYSTEM • Connect 12 V battery (between O/R and B/W), 10 kΩ resistor (between O/R and P) and the multi circuit tester (+ probe of tester to O/R and - to P) as shown right illustration. O/R : Orange with Red tracer 12 V B/W : Black with White tracer 10 kΩ...
  • Page 382: 21 W

    ELECTRICAL SYSTEM 9-33 LAMPS HEADLIGHT, BRAKE LIGHT/TAILLIGHT, LICENSE PLATE LIGHT AND TURN SIGNAL LIGHT HEADLIGHT 12 V 60/55 W POSITION LIGHT 12 V 5 W (E-02, 19) BRAKE LIGHT/TAILLIGHT LICENCE PLATE LIGHT 4 12 V 5 W TURN SIGNAL LIGHT 5 Front 12 V 21/5 W ......
  • Page 383 9-34 ELECTRICAL SYSTEM HEADLIGHT BEAM ADJUSTMENT • Adjust the headlight beam. A: Vertical adjuster B: Horizontal adjuster NOTE: To adjust the headlight beam, adjust the beam horizontally first, then adjust vertically.
  • Page 384: Relays

    ELECTRICAL SYSTEM 9-35 RELAYS TURN SIGNAL/SIDE-STAND RELAY The turn signal/side-stand relay is composed of the turn signal relay, side-stand relay and diode. INSPECTION Before removing the turn signal/side-stand relay, check the operation of the turn signal light. If the turn signal light does not illuminate, inspect the bulb, turn signal switch and circuit connection.
  • Page 385 9-36 ELECTRICAL SYSTEM Inspect each switch for continuity with a tester. If any STARTER BUTTON abnormality is found, replace the respective switch Color Position assemblies with new ones. PUSH HAZARD SWITCH HORN BUTTON Color Position Color B/Bl (OFF) Position (ON) PUSH IGNITION SWITCH FRONT BRAKE SWITCH...
  • Page 386: Battery

    ELECTRICAL SYSTEM 9-37 Filter BATTERY Stopper Upper SPECIFICATIONS cover breather Terminal Type designation FTX12-BS Cathode plates Safety valve Capacity 12 V, 36 kC (10 Ah)/10 HR Anode plates Separator (fiberglass plate) INITIAL CHARGING Filling electrolyte • Remove the aluminum tape 1 sealing the battery electrolyte filler holes.
  • Page 387 9-38 ELECTRICAL SYSTEM 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 388: Servicing

    ELECTRICAL SYSTEM 9-39 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 389 SERVICING INFORMATION 10-1 SERVICING INFORMATION CONTENTS TROUBLESHOOTING .................10- 2 FI SYSTEM MALFUNCTION CODE AND DEFECTIVE CONDITION ..10- 2 ENGINE ....................10- 5 RADIATOR (COOLING SYSTEM) ............10-10 CHASSIS ....................10-11 SHAFT DRIVE ..................10-12 BRAKES....................10-12 ELECTRICAL ..................10-13 BATTERY ....................10-14 WIRING HARNESS, CABLE AND HOSE ROUTING........10-15 WIRING HARNESS ROUTING .............10-15 CABLE ROUTING .................10-18 THROTTLE BODY INSTALLATION .............10-19...
  • Page 390: Troubleshooting

    10-2 SERVICING INFORMATION TROUBLESHOOTING FI SYSTEM MALFUNCTION CODE AND DEFECTIVE CONDITION DETECTED DTC No. DETECTED FAILURE CONDITION CHECK FOR ITEM NO FAULT ––––––––––– ––––––––––– CKP sensor The signal does not reach ECM for 3 CKP sensor wiring and mechan- sec. or more, after receiving the starter ical parts signal.
  • Page 391 SERVICING INFORMATION 10-3 DETECTED DTC No. DETECTED FAILURE CONDITION CHECK FOR ITEM IAT sensor The sensor voltage should be the fol- IAT sensor, lead wire/coupler lowing. connection 0.1 V sensor voltage < 4.6 V In other than the above range, C21 (P0110) is indicated.
  • Page 392 10-4 SERVICING INFORMATION DETECTED DTC No. DETECTED FAILURE CONDITION CHECK FOR ITEM Gear posi- Gear position signal voltage should be GP switch, lead wire/coupler tion signal higher than the following for 3 seconds connection. Gearshift cam, etc. and more. Gear position sensor voltage > 0.6 V If lower than the above value, C31 P0705 (P0705) is indicated.
  • Page 393: Engine

    SERVICING INFORMATION 10-5 ENGINE Complaint Symptom and possible causes Remedy Engine will not start Compression too low or is hard to start. 1. Out of adjustment valve clearance Adjust. 2. Worn valve guides or poor seating of valves Repair or replace. 3.
  • Page 394 10-6 SERVICING INFORMATION Complaint Symptom and possible causes Remedy Engine idles poorly. 1. Out of adjustment valve clearance Adjust. 2. Poor seating of valves Replace or repair. 3. Defective valve guides Replace. 4. Worn down camshafts Replace. 5. Too wide spark plug gaps Adjust or replace.
  • Page 395 SERVICING INFORMATION 10-7 Complaint Symptom and possible causes Remedy Noisy engine Excessive valve chatter Adjust. 1. Too large valve clearance 2. Weakened or broken valve springs Replace. 3. Worn tappet or cam surface Replace. 4. Worn and burnt camshaft journal Replace.
  • Page 396 10-8 SERVICING INFORMATION Complaint Symptom and possible causes Remedy Engine runs poorly Defective engine internal/electrical parts Replace. in high speed range. 1. Weakened valve springs 2. Worn camshafts Replace. 3. Valve timing out of adjustment Adjust. 4. Too narrow spark plug gaps Adjust.
  • Page 397 SERVICING INFORMATION 10-9 Complaint Symptom and possible causes Remedy Engine lacks power. Defective engine internal/electrical parts Adjust. 1. Loss of valve clearance 2. Weakened valve springs Replace. 3. Out of adjustment valve timing Adjust. 4. Worn piston rings or cylinders Replace.
  • Page 398: Radiator (cooling System)

    10-10 SERVICING INFORMATION Complaint Symptom and possible causes Remedy Dirty or heavy 1. Too much engine oil in the engine Check with inspection win- exhaust smoke dow drain out excess oil. 2. Worn piston rings or cylinders Replace. 3. Worn valve guides Replace.
  • Page 399: Chassis

    SERVICING INFORMATION 10-11 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 400: Shaft Drive

    10-12 SERVICING INFORMATION SHAFT DRIVE Complaint Symptom and possible causes Remedy Noisy shaft drive Noise seems to come from secondary bevel gear and final bevel gear assemblies. 1. Oil level too low Refill. (Check oil jet./Replace oil seal.) 2. Drive and driven bevel gears damaged or worn Replace.
  • Page 401: Electrical

    SERVICING INFORMATION 10-13 ELECTRICAL Complaint Symptom and possible causes Remedy No sparking or poor 1. Defective ignition coils or CKP sensor Replace. sparking 2. Defective spark plugs Replace. 3. Defective ECM Replace. 4. Defective tip over sensor Replace. 5. Open-circuited wiring connections Check and repair.
  • Page 402: Battery

    10-14 SERVICING INFORMATION 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.
  • Page 403: Wiring Harness, Cable And Hose Routing

    SERVICING INFORMATION 10-15 WIRING HARNESS, CABLE AND HOSE ROUTING WIRING HARNESS ROUTING Clamp Clamp Handlebar switch (L) Handlebar switch (R) Clamp Cushion Speedometer Clamp Handlebar switch (L & R) Wiring harness Front turn signal light (L & R) Speed sensor Regulator/Rectifier Clamp Clamp...
  • Page 404 10-16 SERVICING INFORMATION Indicator lamp Turn Resorvoir harness down. Breaser hose hose match mark Tapping clamp To brake switch, etc. To ECT sensor To Horn To horn Set inside of the frame. Frame No use. TO sensor Set under the starter relay. Cleaner Tapping Harness...
  • Page 405 SERVICING INFORMATION 10-17...
  • Page 406: Cable Routing

    10-18 SERVICING INFORMATION CABLE ROUTING Throttle cable No. 1 Throttle cable No. 2 Clamp Clip Clutch cable White tape Outside Frame High-tension cord Guide Clutch Solenoid cable harness Cushion Clamp Outside High-tension cord Frame High-tension cord Clutch cable Clutch cable Outside Clutch cable Fuel tank cushion bar...
  • Page 407: Throttle Body Installation

    SERVICING INFORMATION 10-19 THROTTLE BODY INSTALLATION Intake pipe side Air cleaner side 67 mm  1 IAP sensor (Front cylinder) 7 IAT sensor 2 IAP sensor (Rear cylinder) 8 Purge hose (E-33 only) ITEM N·m kgf-m lb-ft 3 PCV (Breather) hose *1 Match mark 13.0 Pass through the PCV (Breather)
  • Page 408: Cooling System Hose Routing

    10-20 SERVICING INFORMATION COOLING SYSTEM HOSE ROUTING Pass through the reservoir hose between frame and *4 Set the hose with dent of engine case. throttle valve actuator. A The end of the clamp should face... *2 Clamp the hose with frame and harness. *3 Be careful not to dent hose with frame cover.
  • Page 409: Front Brake Routing

    SERVICING INFORMATION 10-21 FRONT BRAKE ROUTING 28 ˚ After the brake hose union touching to the stop- *3 Clamp the sleeve firmly. per, tighten the union bolt. *2 Pass through the brake hose firmly. *4 Set the clamp with stopper before tightening.
  • Page 410: Speed Sensor Harness Routing

    10-22 SERVICING INFORMATION SPEED SENSOR HARNESS ROUTING Pass through the speed sensor harness in front of the brake hose 5 Clamp and guide. 2 Pass through the speed sensor harness in front of the brake hose. 6 Clip 3 Do not catch the speed sensor harness to the caliper boss. 7 Yellow mark 4 Touch the stopper 8 Guide...
  • Page 411: Front Turn Signal Lead Wire Routing

    SERVICING INFORMATION 10-23 FRONT TURN SIGNAL LEAD WIRE ROUTING Brake hose guide Left handle switch harness Clamp Wiring harness Right front turn signal Speed sensor Clamp Left front turn signal Right front turn signal *1 Cut after clamping. MUFFLER & EXHAUST PIPE INSTALLATION 5 mm (0.12 in) 5 mm...
  • Page 412: Handlebar Balancer

    10-24 SERVICING INFORMATION HANDLEBAR BALANCER 5.5 N·m (0.5 kgf-m, 4.0 lb-ft) Clearance : Right side 0 mm (0 in) : Left side 1 Handlebar 4 Handle balancer expander 2 Nut 5 Handlebar balancer 3 Throttle grip 6 Screw BATTERY PROTECTOR 1 Stick protectors to upper end of this surface.
  • Page 413: Lubrication Points

    SERVICING INFORMATION 10-25 LUBRICATION POINTS 5.3 mm (2.1 in)
  • Page 414: Fuel Tank Installation

    10-26 SERVICING INFORMATION FUEL TANK INSTALLATION Inside 1 Cut after clamping. 2 Frame...
  • Page 415: Rear Combination Lamp Installation

    SERVICING INFORMATION 10-27 REAR COMBINATION LAMP INSTALLATION 1.8 N . m (0.18 kgf-m, 1.3 lb-ft) 1.8 N . m (0.18 kgf-m, 1.3 lb-ft) 1 Pass through the left turn signal harness. 4 Reflex reflector 2 Reflex reflector 5 Right reflex reflector (For E-03, 28, 33) 3 License plate bracket (For E-02, 19, 24) 6 Left reflex reflector (For E-03, 28, 33)
  • Page 416: Frame Head Cover Cushion Installation

    10-28 SERVICING INFORMATION FRAME HEAD COVER CUSHION INSTALLATION 1 Cushion 7 10 mm (0.39 in) 5 mm (0.20 in) 2 3 mm (0.12 in) 15 mm (0.59 in) 3 12 mm (0.47 in) 20 mm (0.79 in) LEFT SIDE COVER CUSHION INSTALLATION 1 Cushion 2 27 mm (1.06 in) 3 35 mm (1.38 in)
  • Page 417: Rear Fender Cushion Installation

    SERVICING INFORMATION 10-29 REAR FENDER CUSHION INSTALLATION...
  • Page 418: Left Side Cover Installation

    10-30 SERVICING INFORMATION LEFT SIDE COVER INSTALLATION...
  • Page 419: Lid Cushion Instsallation

    SERVICING INFORMATION 10-31 LID CUSHION INSTSALLATION 1 Cushion 3 45 mm (1.77 in) 10 mm (0.39 in)
  • Page 420: Tail Lamp Installation

    10-32 SERVICING INFORMATION TAIL LAMP INSTALLATION Clamp Grommet Pass through the tail lamp harness and left turn Pass through the wiring harness outside of signal harness over the right side mounting cushions. boss. Pass through the wiring harness between rear *2 Assemble to the rear fender.
  • Page 421: Pair (air Supply) System Diagram

    SERVICING INFORMATION 10-33 PAIR (AIR SUPPLY) SYSTEM DIAGRAM 1 PAIR control solenoid valve *1 From air cleaner 2 PAIR reed valve *2 To #1 cylinders A FRESH AIR *3 To #2 cylinders...
  • Page 422: Pair (air Supply) System Hose Routing

    10-34 SERVICING INFORMATION PAIR (AIR SUPPLY) SYSTEM HOSE ROUTING 1 PAIR control solenoid valve *2 Matching mark 2 Throttle body *3 Do not contact the hose and throttle cable drum. 3 Bolt *4 The sealant side should face PAIR pipe side. With the bolt lightly contacted with the PAIR pipe, *1 To air cleaner box tighten the bolt.
  • Page 423: Special Tools

    SERVICING INFORMATION 10-35 SPECIAL TOOLS 09900-18710 09900-20101 09900-06107 09900-06108 09900-09004 Hexagon socket 09900-20102 Snap ring pliers Snap ring pliers Impact driver set (12 mm) Vernier calipers 09900-20202 09900-20203 09900-20204 09900-20205 Micrometer Micrometer Micrometer Micrometer 09900-20508 (25 – 50 mm) (50 – 75 mm) (75 –...
  • Page 424 10-36 SERVICING INFORMATION 09913-60230 09913-60241 09913-70210 Journal bearing Journal bearing 09913-60910 Bearing installer 09913-75821 remover/installer remover/installer Bearing puller Bearing installer 09915-74511 09913-76010 09913-84510 09915-40610 09915-63210 Oil pressure Bearing installer Bearing installer Oil filter wrench Adaptor gauge hose 09915-74532 09915-64512 09915-77331 Oil pressure Compression Meter (for high...
  • Page 425 SERVICING INFORMATION 10-37 09917-47011 09918-03810 09918-53810 09920-13120 09920-53740 Vacuum pump Compression Chain tensioner Crankcase & Shaft Clutch sleeve hub holder gauge gauge adaptor lock tool remover 09924-62410 09921-21820 09921-20240 09924-34510 Final drive gear Bearing retainer Bearing remover 09923-73210 Backlash measur- bearing holder wrench Bearing remover...
  • Page 426 10-38 SERVICING INFORMATION 09940-14911 09940-30221 09940-40211 09940-40220 09940-50120 Steering stem nut Front fork assem- Fuel pressure Fuel pressure gauge Front fork inner wrench bling tool gauge adaptor hose attachment rod holder 09940-52861 09940-94922 09940-51410 09940-52841 Front fork oil seal 09940-92720 Front fork spring Bearing installer Inner rod holder...
  • Page 427: Tightening Torque

    SERVICING INFORMATION 10-39 TIGHTENING TORQUE ENGINE ITEM N·m kgf-m lb-ft Rocker arm shaft 19.5 Cylinder head cover bolt 6 mm 8 mm 18.0 Cylinder head bolt and nut Initial 8 mm Final 18.0 Initial 18.0 10 mm Final 27.5 Cam sprocket bolt 11.0 Cam chain tension adjuster mounting bolt Cam chain tensioner bolt...
  • Page 428: Secondary And Final

    10-40 SERVICING INFORMATION SECONDARY AND FINAL N·m kgf-m lb-ft ITEM Secondary drive bevel gear bearing retainer bolt 16.5 Secondary driven bevel gear bolt 16.5 Secondary driven bevel gear bearing stopper 10.5 76.0 Secondary drive gear shaft nut 10.5 76.0 Final gear case nut 29.0 Final drive bevel gear coupling nut 10.0...
  • Page 429: Chassis

    SERVICING INFORMATION 10-41 CHASSIS N·m kgf-m lb-ft ITEM Front axle 47.0 Front axle pinch bolt 16.5 Brake disc bolt 16.5 Front fork cap bolt 16.5 Front fork spring stopper nut 25.5 Front fork damper rod bolt 29.0 Front fork upper clamp bolt 16.5 Front fork lower clamp bolt 21.5...
  • Page 430: Tightening Torque Chart

    10-42 SERVICING INFORMATION TIGHTENING TORQUE CHART For other nuts and bolts not listed in the preceding page, refer to this chart: Bolt Diameter Conventional or “4” marked bolt “7” marked bolt A (mm) N·m kgf-m lb-ft N·m kgf-m lb-ft 0.15 0.23 0.45 0.55...
  • Page 431: Service Data

    SERVICING INFORMATION 10-43 SERVICE DATA VALVE + GUIDE Unit: mm (in) ITEM STANDARD LIMIT Valve diam. — (1.18) — (1.02) Valve clearance (when cold) 0.08 – 0.13 — (0.003 – 0.005) 0.17 – 0.22 — (0.007 – 0.009) Valve guide to valve stem 0.010 –...
  • Page 432 10-44 SERVICING INFORMATION CAMSHAFT + CYLINDER HEAD Unit: mm (in) ITEM STANDARD LIMIT Cam height 35.50 – 35.54 35.20 (1.398 – 1.399) (1.386) 36.58 – 36.62 36.28 (1.440 – 1.442) (1.428) Camshaft journal oil clearance 0.032 – 0.066 0.150 (0.0013 – 0.0026) (0.0059) Camshaft journal holder I.D.
  • Page 433 SERVICING INFORMATION 10-45 ITEM STANDARD LIMIT Piston ring groove width 1.01 – 1.03 — (0.0398 – 0.0406) 1.21 – 1.23 — (0.0476 – 0.0484) 2.51 – 2.53 — (0.0988 – 0.0996) Piston ring thickness 0.970 – 0.990 — (0.0382 – 0.0390) 1.170 –...
  • Page 434 10-46 SERVICING INFORMATION CLUTCH Unit: mm (in) ITEM STANDARD LIMIT Clutch lever play 10 – 15 — (0.4 – 0.6) Clutch release screw 1/4 turn back — Drive plate thickness 2.92 – 3.08 2.62 No. 1 (0.115 – 0.121) (0.103) 3.42 –...
  • Page 435 SERVICING INFORMATION 10-47 THERMOSTAT + RADIATOR + FAN + ENGINE COOLANT ITEM STANDARD/SPECIFICATION NOTE Thermostat valve opening Approx. 75 °C (167 °F) — temperature Thermostat valve lift Over 6 mm (0.24 in) at 90 °C (194 °F) — ECT sensor resistance 20 °C Approx.
  • Page 436 10-48 SERVICING INFORMATION FI SENSORS+ SECONDARY THROTTLE VALVE ACTUATOR ITEM SPECIFICATION NOTE 184 – 276 Ω CKP sensor resistance CKP sensor peak voltage 4.0 V and more When cranking IAP sensor input voltage 4.5 – 5.5 V IAP sensor output voltage Approx.
  • Page 437 SERVICING INFORMATION 10-49 ELECTRICAL Unit: mm (in) ITEM SPECIFICATION NOTE Firing order 1·2 Spark plug NGK: DPR7EA-9 Type DENSO: X22EPR-U9 0.8 – 0.9 (0.031 – 0.035) Spark performance Over 8 (0.3) at 1 atm. 184 – 276 Ω CKP sensor resistance CKP sensor peak voltage 4.0 V and more Ignition coil resistance...
  • Page 438: Speedometer Light

    10-50 SERVICING INFORMATION WATTAGE Unit: W SPECIFICATION ITEM E-03, 28, 33 E-24 Others ← ← Headlight ← ← Position/Parking light ← ← Brake light/Taillight Turn signal light 21/5 (Front), ← 21 (Rear) ← ← Licence plate light ← ← Speedometer light ←...
  • Page 439 380.4 (14.98) (14.6) Front fork oil level (without spring) ---- (6.02) Front fork oil type SUZUKI FORK OIL L01 ---- or an equivalent fork oil Front fork oil capacity (each leg) 490 ml ---- (16.6/17.3 US/Imp oz) Front fork inner tube outside diam.
  • Page 440 10-52 SERVICING INFORMATION FUEL + OIL ITEM SPECIFICATION NOTE Fuel type Use only unleaded gasoline of at least 87 pump octane (R/2 + M/2) or 91 octane or higher rated by the research method. Gasoline containing MTBE (Methyl Tertiary Butyl E-03, 28, 33 Ether), less than 10% ethanol, or less than 5% methanol with appropriate cosolvents and corro-...
  • Page 441: Emission Control Information

    EMISSION CONTROL INFORMATION 11-1 EMISSION CONTROL INFORMATION CONTENTS EMISSION CONTROL SYSTEMS ...............11- 2 FUEL INJECTION SYSTEM..............11- 2 EXHAUST EMISSION CONTROL SYSTEM (PAIR SYSTEM).....11- 3 NOISE EMISSION CONTROL SYSTEM..........11- 4 EVAPORATIVE EMISSION CONTROL SYSTEM (Only for E-33) ..11- 4 PAIR (AIR SUPPLY) SYSTEM INSPECTION ..........11- 5 HOSES ....................11- 5 PAIR REED VALVE ................11- 5 PAIR CONTROL SOLENOID VALVE...........11- 6...
  • Page 442: Emission Control Systems

    11-2 EMISSION CONTROL INFORMATION EMISSION CONTROL SYSTEMS FUEL INJECTION SYSTEM VZ800 motorcycles are equipped with a fuel injection system for emission level control. This fuel injection system is precision designed, manufactured and adjusted to comply with the applicable emission limits.
  • Page 443: Exhaust Emission Control System (pair System)

    EMISSION CONTROL INFORMATION 11-3 EXHAUST EMISSION CONTROL SYSTEM (PAIR SYSTEM) The exhaust emission control system is composed of the PAIR system and THREE-WAY CATALYST sys- tem (For E-02, 19, 24, 33). The fresh air is drawn into the exhaust port with the PAIR control solenoid valve and PAIR reed valve.
  • Page 444: Noise Emission Control System

    11-4 EMISSION CONTROL INFORMATION NOISE EMISSION CONTROL SYSTEM TAMPERING WITH THE NOISE CONTROL SYSTEM PROHIBITED: Local 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 445: Pair (air Supply) System Inspection

    EMISSION CONTROL INFORMATION 11-5 PAIR (AIR SUPPLY) SYSTEM INSPECTION HOSES • Remove the PAIR cover. (3-5) • Inspect the hoses for wear or damage. • Inspect that the hoses for secure connection. PAIR REED VALVE • Remove the PAIR control solenoid valve. (3-5) •...
  • Page 446: Pair Control Solenoid Valve

    11-6 EMISSION CONTROL INFORMATION PAIR CONTROL SOLENOID VALVE • Remove the PAIR control solenoid valve. (3-5) • Check that air flows through the air inlet port to the air outlet port. • If air does not flow out, replace the PAIR control solenoid valve with a new one.
  • Page 447: Pair (air Supply) System Hose Routing

    EMISSION CONTROL INFORMATION 11-7 PAIR (AIR SUPPLY) SYSTEM HOSE ROUTING 1 PAIR control solenoid valve *2 Matching mark 2 Throttle body *3 Do not contact the hose and throttle cable drum. 3 Bolt *4 The sealant side should face PAIR pipe side. With the bolt lightly contacted with the PAIR pipe, *1 To air cleaner box.
  • Page 448: Heated Oxgen Sensor (ho2s) Inspection (for E-02, 19, 24)

    11-8 EMISSION CONTROL INFORMATION HEATED OXGEN SENSOR (HO2S) INSPECTION (FOR E-02, 19, 24) • Disconnect the HO2 sensor lead wire coupler. (5-69) • Inspect the HO2 sensor and its circuit referring to flow table of the malfunction code C44 (P0130/P0135). •...
  • Page 449: Evaporative Emission Control System Inspection (only For E-33)

    EMISSION CONTROL INFORMATION 11-9 EVAPORATIVE EMISSION CONTROL SYSTEM INSPECTION (Only for E-33) • Remove the seats 1. (8-3) • Remove the fuel tank 2. (6-3) • Remove the right frame cover 3. (8-4) HOSES (EVAP hose) Inspect the hoses for wear or damage. Make sure that the hoses are securely connected.
  • Page 450: Evap Canister Hose Routing (only For E-33)

    11-10 EMISSION CONTROL INFORMATION EVAP CANISTER HOSE ROUTING (Only for E-33) 1 Three way joint *2 White paint mark should face upside. 2 Wiring harness *3 To three way joint. 3 Fuel shut-off valve *4 Face the clamp end right side. 4 EVAP canister *5 Face the clamp end right side.
  • Page 451 WIRING DIAGRAM E-02, 19, 24 Wiring diagrams wire color, refer to section “WIRE COLOR”. TEMP : ENGINE COOLANT TEMP. WARNING LIGHT : FI LIGHT : FUEL WARNING LIGHT : TURN SIGNAL INDICATOR LIGHT : HI-BEAM INDICATOR LIGHT HANDLEBAR SWITCH (R) : NEUTRAL INDICATOR LIGHT ENGINE : OIL INDICATOR LIGHT...
  • Page 452 E-03, 28, 33 TEMP : ENGINE COOLANT TEMP. WARNING LIGHT : FI LIGHT : FUEL WARNING LIGHT HANDLEBAR SWITCH (R) : TURN SIGNAL INDICATOR LIGHT : HI-BEAM INDICATOR LIGHT ENGINE : NEUTRAL INDICATOR LIGHT PILOT LAMP HAZARD STOP STARTER FRONT BRAKE : OIL INDICATOR LIGHT SWITCH SWITCH...
  • Page 453 Prepared by December, 2004 Part No. 99500-38050-01E Printed in Japan...
  • Page 454 Printed in Japan...

This manual is also suitable for:

Vz800k5M50Boulevard m50Intruder vz800

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  • Freddie Aug 27, 2019 07:31:
    I lost my key and broke my ignition my bike was throughing a c42 code i chaged my ignition module but that was not the problem i need to know how to bypass the ignition and still have spark i have none it wont start it just cranks over
  • Ben Thomas Dec 08, 2017 06:18:
    Just bought the motorcycle and need repair and owners manual for it
  • pete best Aug 16, 2015 07:56:
    bloody brilliant manual....​. saved me giving any labour money to Marbella muppit brained mechanics.​..finding manualslib made my freakin week......​. manuals are easy to follow and very well documented​, not hard or to tecy to understand​... no sales points, this I find refreshing​.. this manual is a real breeze.... if you cant follow thease manuals you shouldn't be breathing ok.... now stop getting ripped off and being force fed mumbo/jumb​o from workshops and buy some tools, turn up the sounds, and do your own servicing ect eh.... pete best.