Suzuki DL650K5 Service Manual

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FOREWORD

This manual contains an introductory description on

the SUZUKI DL650 and procedures for its inspec-

tion/service and overhaul of its main components.

Other information considered as generally known is

not included.

Read the GENERAL INFORMATION section to

familiarize yourself with the motorcycle and its main-

tenance. Use this section as well as other sections

to use as a guide for proper inspection and service.

This manual will help you know the motorcycle bet-

ter so that you can assure your customers of fast

and reliable service.

* This manual has been prepared on the basis

of the latest specifications at the time of publi-

cation. If modifications have been made since

then, differences may exist between the con-

tent of this manual and the actual motorcycle.

* Illustrations in this manual are used to show

the basic principles of operation and work

procedures. They may not represent the

actual motorcycle exactly in detail.

* This manual is written for persons who have

enough knowledge, skills and tools, including

special tools, for servicing SUZUKI motorcy-

cles. If you do not have the proper knowledge

and tools, ask your authorized SUZUKI

motorcycle dealer to help you.

Inexperienced mechanics or mechanics

without the proper tools and equipment

may not be able to properly perform the

services described in this manual.

Improper repair may result in injury to the

mechanic and may render the motorcycle

unsafe for the rider and passenger.

GROUP INDEX

GENERAL INFORMATION

PERIODIC MAINTENANCE

ENGINE

FI SYSTEM DIAGNOSIS

FUEL SYSTEM AND THROTTLE

BODY

COOLING AND LUBRICATION

SYSTEM

CHASSIS

ELECTRICAL SYSTEM

SERVICING INFORMATION

EMISSION CONTROL

INFORMATION

99500-36135-03E

Table of Contents

Chapters

Table of Contents

Troubleshooting

Summary of Contents for Suzuki DL650K5

Page 1: General Information
GROUP INDEX FOREWORD This manual contains an introductory description on the SUZUKI DL650 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 SUPPLEMENTS DL650K5 ('05- MODEL) DL650K6 ('06- MODEL) DL650/AK7 ('07- MODEL) DL650/AK8 ('08- MODEL) DL650/AK9 (’09-MODEL) WIRING DIAGRAM...
Page 4: 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 5 Apply oil. Use engine oil unless other- Use engine coolant. wise specified. Apply molybdenum oil solution. Use fork oil. (Mixture of engine oil and SUZUKI 99000-99001-SS8 MOLY PASTE in a ratio of 1:1) Apply SUZUKI SUPER GREASE “A”. 99000-25030 (USA) Apply or use brake fluid.
Page 6: 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 ECT Sensor : Engine Coolant Temperature : American Petroleum Institute Sensor (ECTS), Water Temp.
Page 7 MAL-Code : Malfunction Code (Diagnostic Code) : Maximum : Malfunction Indicator Lamp (LED) : Minimum : Nitrogen Oxides : Over Head Camshaft : Oil Pressure Switch : Positive Crankcase Ventilation (Crankcase Breather) : Right Hand : Read Only Memory : Society of Automotive Engineers STC System : Secondary Throttle Control System (STCS) STP Sensor...
Page 8 SAE-TO-FORMER SUZUKI TERM This table lists SAE (Society of Automotive Engineers) J1930 terms and abbreviations which may be used in this manual in compliance with SAE recommendations, as well as their former SUZUKI names. SAE TERM FORMER SUZUKI TERM FULL TERM...
Page 9 SAE TERM FORMER SUZUKI TERM FULL TERM ABBREVIATION Idle Speed Control ------- Ignition Control Electronic Spark Advance (ESA) Ignition Control Module ------- Intake Air Temperature Intake Air Temperature (IAT), Air Temperature Malfunction Indicator Lamp LED Lamp Malfunction Indicator Lamp (MIL)
Page 10 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 : Black with Orange tracer : Black with Red tracer...
Page 11: Table Of Contents
GENERAL INFORMATION GENERAL INFORMATION CONTENTS WARNING/CAUTION/NOTE .................1- 2 GENERAL PRECAUTIONS................1- 2 SUZUKI DL650K4 (’04-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 (FOR USA)................1- 5 ENGINE OIL (FOR OTHER COUNTRIES) ..........1- 5...
Page 12: Warning/Caution/Note
GENERAL INFORMATION WARNING/CAUTION/NOTE Please read this manual and follow its instructions carefully. To emphasize special information, the symbol and the words WARNING, CAUTION and NOTE have special meanings. Pay special attention to the mes- sages highlighted by these signal words. Indicates a potential hazard that could result in death or injury.
Page 13 GENERAL INFORMATION " * If parts replacement is necessary, replace the parts with Suzuki Genuine Parts or their equiva- lent. * When removing parts that are to be reused, keep them arranged in an orderly manner so that they may be reinstalled in the proper order and orientation.
Page 14: Suzuki Dl650K4 ('04-Model)
GENERAL INFORMATION SUZUKI DL650K4 (’04-MODEL) RIGHT SIDE LEFT SIDE • Difference between photographs and actual motorcycles depends 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.
Page 15: Engine Oil (For Usa)
GENERAL INFORMATION ENGINE OIL (FOR USA) SUZUKI recommends the use of SUZUKI PERFORMANCE 4 MOTOR OIL or an oil which is rated SF or SG under the API (American Petroleum Institute) service classification. The recommended viscosity is SAE 10W-40. If an SAE 10W-40 oil is not available, select and alternative according to the following chart.
Page 16: Anti-Freeze/Engine Coolant
Suzuki recommends the use of SUZUKI COOLANT anti-freeze/engine coolant. If this is not available, use an equivalent which is compatible with an aluminum radiator.
Page 17: Cylinder Identification
GENERAL INFORMATION CYLINDER IDENTIFICATION The two cylinders of this engine are identified as NO.1 and NO.2 cylinder, as viewed from front to rear . NO.2 NO.1...
Page 18: Information Labels
GENERAL INFORMATION INFORMATION LABELS DL650 DL650UE 1 Noise label A (For E-03, 24, 33) 2 Information label A (For E-03, 28, 33) 3 Vacuum hose routing label A (For E-33) 4 Fuel caution label A (For E-02, 24) 5 Manual notice label A (For E-03, 33) 6 Frame caution plate 7 Screen warning label...
Page 19: Specifications
GENERAL INFORMATION SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length ..............2 290 mm (90.2 in) Overall width ..............840 mm (33.1 in) Overall height ..............1 390 mm (54.7 in) ..Low windshield position (STD) 1 420 mm (55.9 in) ..Middle windshield position 1 450 mm (57.1 in) ..
Page 20: Chassis
1-10 GENERAL INFORMATION CHASSIS Front suspension ............Telescopic, coil spring, oil damped Rear suspension ............Link type, coil spring, oil damped Front fork stroke............150 mm (5.9 in) Rear wheel travel ............150 mm (5.9 in) Caster ................26 ° Trail ................
Page 21: Country And Area Codes
GENERAL INFORMATION 1-11 COUNTRY AND AREA CODES The following codes stand for the applicable country (-ies) and area (-s). MODEL CODE COUNTRY or AREA E-02 U.K. E-03 U.S.A. (Except for california) E-19 DL650 E-24 Australia E-28 Canada E-33 California (U.S.A.) DL650-UE E-19...
Page 23 PERIODIC MAINTENANCE PERIODIC MAINTENANCE CONTENTS PERIODIC MAINTENANCE SCHEDULE .............2- 2 PERIODIC MAINTENANCE CHART .............2- 2 LUBRICATION POINTS .................2- 4 MAINTENANCE AND TUNE-UP PROCEDURES ........2- 5 AIR CLEANER ..................2- 5 SPARK PLUG ..................2- 6 VALVE CLEARANCE ................2- 8 FUEL LINE .....................2-13 ENGINE OIL AND OIL FILTER ..............2-13 ENGINE IDLE SPEED ................2-15 THROTTLE CABLE PLAY ..............2-15...
Page 24: Periodic Maintenance Schedule
PERIODIC MAINTENANCE PERIODIC MAINTENANCE SCHEDULE The chart below lists the recommended intervals for all the required periodic service work necessary to keep the motorcycle operating at peak performance and economy. Mileages are expressed in terms of kilome- ters, miles and time for your convenience. IMPORTANT: The periodic maintenance intervals and service requirements have been established in accordance with EPA regulations.
Page 25 PERIODIC MAINTENANCE Interval 1 000 6 000 12 000 18 000 24 000 miles 4 000 7 500 11 000 14 500 Item months Brake fluid — Replace every 2 years. Tires — Steering — — Front forks — — —...
Page 26: Lubrication Points
PERIODIC MAINTENANCE LUBRICATION POINTS Proper lubrication is important for smooth operation and long life of each working part of the motorcycle. Major lubrication points are indicated below. 1 Clutch lever holder 2 Side-stand pivot and spring hook 3 Footrest pivot 4 Drive chain 5 Brake lever holder and throttle cables...
Page 27: Maintenance And Tune-Up Procedures
PERIODIC MAINTENANCE MAINTENANCE AND TUNE-UP PRO- CEDURES 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 28: Spark Plug
PERIODIC MAINTENANCE 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.1 (FRONT) SPARK PLUG REMOVAL •...
Page 29 PERIODIC MAINTENANCE NO.2 (REAR) SPARK PLUG REMOVAL • Remove the seat. (!7-4) • Lift and support the fuel tank. (!5-7) • Remove the spark plug cap. • Remove the spark plug with the special tool. $09930-10121: Spark plug socket wrench set HEAT RANGE •...
Page 30: Valve Clearance
PERIODIC MAINTENANCE SPARK PLUG AND PLUG CAP INSTALLATION " Before using a spark plug wrench, carefully turn the spark plug by finger into the threads of the cylinder head to prevent damage the aluminum threads. • Install the spark plugs to the cylinder heads by finger tight, and then tighten them to the specified torque.
Page 31 PERIODIC MAINTENANCE • Remove the generator cover plug 1 and timing inspection plug 2. • Turn the crankshaft to set the No.1 (Front) cylinder at TDC of compression stroke. (Align the “F | T” line on the generator rotor to the index mark of valve timing inspection hole and also bring the camshafts to the position as shown in page 2-8.) •...
Page 32 2-10 PERIODIC MAINTENANCE VALVE CLEARANCE ADJUSTMENT The clearance is adjusted by replacing the existing tappet shim by a thicker or thinner shim. • Remove the intake or exhaust camshafts. (!3-21, 23) • Remove the tappet and shim by fingers or magnetic hand. •...
Page 33 PERIODIC MAINTENANCE 2-11 (INTAKE SIDE)
Page 34 2-12 PERIODIC MAINTENANCE (EXHAUST SIDE)
Page 35: Fuel Line
PERIODIC MAINTENANCE 2-13 FUEL LINE Inspect every 6 000 km (4 000 miles, 12 months). Replace every 4 years. • Lift and support the fuel tank. (!5-7) • Inspect the fuel feed hose A for damage and fuel leakage. If any defects are found, the fuel hoses must be replaced.
Page 36 Filter change: 2.7 L (2.9/2.4 US/Imp qt) Engine overhaul: 3.1 L (3.3/2.7 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 37: Engine Idle Speed
PERIODIC MAINTENANCE 2-15 ENGINE IDLE SPEED Inspect initially at 1 000 km (600 miles, 2 month) and every 6 000 km (4 000 miles, 12 months) thereafter. NOTE: Make this adjustment when the engine is hot. • Start up the engine and set its idle speed to the specified range by turning the throttle stop screw 1.
Page 38: Throttle Valve Synchronization
2-16 PERIODIC MAINTENANCE MAJOR ADJUSTMENT • Remove the fuel tank. (!5-7) • Remove the air cleaner box. (!5-15) • Loosen the lock-nut 1 of the throttle returning cable. • Turn the returning cable adjuster 2 to obtain proper cable play. •...
Page 39: Clutch
PERIODIC MAINTENANCE 2-17 CLUTCH Inspect every 6 000 km (4 000 miles, 12 months). • Loosen the lock-nut 1 and turn the adjuster 2 all the way into the clutch lever assembly. • Remove the engine sprocket cover. • Loosen the lock-nut 3 and turn out the adjusting screw 4 two or three rotations.
Page 40: Cooling System
2-18 PERIODIC MAINTENANCE COOLING SYSTEM Inspect every 6 000 km (4 000 miles, 12 months). Replace engine coolant every 2 years. Replace radiator hoses every 4 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 41 PERIODIC MAINTENANCE 2-19 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 42: Drive Chain
2-20 PERIODIC MAINTENANCE RADIATOR HOSES • Remove the cowling. (!7-5) • Check to see the radiator hoses for crack, damage or engine coolant leakage. • If any defects are found, replace the radiator hoses with new ones. DRIVE CHAIN Inspect initially at 1 000 km (600 miles, 2 month) and every 6 000 km (4 000 miles, 12 months) thereafter.
Page 43 PERIODIC MAINTENANCE 2-21 • Count out 21 pins (20 pitches) on the chain and measure the distance between the two points. If the distance exceeds the 1 2 3 19 20 21 service limit, the chain must be replaced. % Drive chain 20-pitch length Service Limit: 319.4 mm (12.57 in) ADJUSTING •...
Page 44: Brake
* Do not use any oil sold commercially as “drive chain oil”. Such oil can damage the “O”-rings (or seals). * The standard drive chain is DID525V8. SUZUKI rec- ommends that this standard drive chain should be used for the replacement.
Page 45 PERIODIC MAINTENANCE 2-23 The brake system of this motorcycle is filled with a UPPER glycol-based brake fluid. Do not use or mix different LOWER types of fluid such as silicone-based or petro- leum-based. Do not use any brake fluid taken from old, used or unsealed containers.
Page 46 2-24 PERIODIC MAINTENANCE BRAKE PEDAL HEIGHT • Loosen the lock-nut 1 and rotate the push rod 2 to locate brake pedal 20 – 30 mm (0.59 – 0.98 in) A below the top face of the footrest. • Retighten the lock-nut 1 to secure the push rod 2 in the proper position.
Page 47 PERIODIC MAINTENANCE 2-25 AIR BLEEDING 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 48: Tire
R19M/C (59H) for front and 150/70 R17M/C (69H) 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 BRIDGESTONE (Front : TW101F Rear : TW152F)
Page 49: Front Fork
PERIODIC MAINTENANCE 2-27 FRONT FORK Inspect every 12 000 km (7 500 miles, 12 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. (!7-17) REAR SUSPENSION Inspect every 12 000 km (7 500 miles, 12 months).
Page 50: Chassis Bolt And Nut
2-28 PERIODIC MAINTENANCE CHASSIS BOLT AND NUT Tighten initially at 1 000 km (600 miles, 2 month) 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 2-29 for the loca- tions of the following nuts and bolts on the motorcycle.) ITEM N·m...
Page 51 PERIODIC MAINTENANCE 2-29...
Page 52: Compression Pressure Check
2-30 PERIODIC MAINTENANCE 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 53: Oil Pressure Check
PERIODIC MAINTENANCE 2-31 OIL PRESSURE CHECK Check periodically the oil pressure in the engine to judge roughly the condition of the moving parts. OIL PRESSURE SPECIFICATION Above 100 kPa (1.0 kgf/cm², 14 psi) at 3 000 r/min., Oil temp. at 60 °C (140 °F) Below 400 kPa (4.0 kgf/cm², 57 psi) If the oil pressure is lower or higher than the specification, the following causes may be considered.
Page 55 ENGINE ENGINE CONTENTS ENGINE COMPONENTS REMOVABLE WITH THE ENGINE IN PLACE ..3- 2 ENGINE REMOVAL AND INSTALLATION...........3- 3 ENGINE REMOVAL ................3- 3 ENGINE INSTALLATION................3-11 ENGINE DISASSEMBLY................3-19 ENGINE TOP SIDE .................3-19 ENGINE BOTTOM SIDE .................3-26 ENGINE COMPONENTS INSPECTION AND SERVICING ......3-36 CYLINDER HEAD COVER..............3-36 CAMSHAFT/CAMSHAFT JOURNAL .............3-37 CYLINDER HEAD ...................3-40...
Page 56: Engine Components Removable With The Engine In Place
ENGINE ENGINE COMPONENTS REMOVABLE WITH THE ENGINE IN PLACE Engine components which can be removed while the engine is installed on the chassis are listed below. For the installing and removing procedures, refer to respective paragraphs describing each component. ENGINE LEFT SIDE PARTS REMOVAL INSTALLATION...
Page 57: Engine Removal And Installation
ENGINE ENGINE REMOVAL AND INSTALLATION ENGINE REMOVAL Before taking the engine out of the frame, wash the engine using a steam cleaner. Engine removal is sequentially explained in the following steps. Reinstall the engine by reversing the removal procedure. • Drain the engine oil. (!2-13) •...
Page 58 ENGINE • Remove the throttle body. (!5-16) • Disconnect the spark plug caps. • Remove the left side frame cover. (!7-5) • Disconnect the gear position switch lead wire coupler 1. • Disconnect the generator lead wire coupler 2 and CKP sen- sor lead wire coupler 3.
Page 59 ENGINE • Remove the gearshift lever 1. • Remove the engine sprocket cover 2. • Remove the clutch release assembly 3, its support plate 4 and spring 5. • Remove the clutch push rod 6. • Remove the clutch cable from the generator cover. NOTE: If it is necessary to replace the clutch cable or clutch release lever, pry up and bend down the stopper A of the clutch release...
Page 60 ENGINE • Remove the cotter pin. (For E-03, 28, 33) • Loosen the rear axle nut 1. • Loosen the chain adjusters 2. • Remove the engine sprocket 3. • Disconnect the engine ground lead wire 4. • Disconnect the HO2 sensor lead wire coupler 5 and release the HO2 sensor lead wire from the clamp 6.
Page 61 ENGINE • Remove the muffler mounting bolt 1. • Loosen the front exhaust pipe mounting bolts 2. • Remove the front exhaust pipe 3. • Loosen the rear exhaust pipe mounting bolts. • Remove the muffler. • Remove the right footrest bracket mounting bolts. •...
Page 62 ENGINE • Disconnect the starter motor lead wire 1 and oil pressure switch lead wire 2. • Support the engine with an engine jack. • Remove the engine mounting nut 3 and bolt 4. • Loosen the engine mounting thrust adjuster lock-nut with the special tool.
Page 63 ENGINE • Remove the left engine mounting bracket 1. • Disconnect the ignition coil lead wires 2. • Disconnect the water hose clamp 3. • Remove the engine mounting nut. • Loosen the engine mounting thrust adjuster lock-nut. " 09940-14990: Engine mounting thrust adjuster socket wrench •...
Page 64 3-10 ENGINE • Loosen the pinch bolt 1. • Gradually lower the engine assembly by removing the bolt 2, Be careful not to damage the frame and engine when removing the engine from the frame.
Page 65: Engine Installation
ENGINE 3-11 ENGINE INSTALLATION Remount the engine in the reverse order of engine removal. Pay attention to the following points: NOTE: * The engine mounting nuts are self-locking. * Once the nut has been removed, it is no longer of any use. Be sure to use new nuts, and then tighten them to the specified torque.
Page 66 3-12 ENGINE • Before installing the engine assembly, install the spacer A, collar B and engine thrust adjuster C. • Install the collar 1 onto the crankcase properly as shown. • Install the left engine mounting bracket 2. • Apply THREAD LOCK to the engine mounting bracket bolts. •...
Page 67 ENGINE 3-13 • Put the drive chain on the driveshaft. • Gradually raise the engine assembly and align all the bolt holes. • Install the engine mounting bolts and tighten them tempo- rarily. • Tighten the engine mounting thrust adjusters to the specified torque.
Page 68 3-14 ENGINE • Install the washers and tighten the union bolt to the specified torque. $ Oil cooler union bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft) • Install the new gaskets. • Apply THREAD LOCK to the muffler mounting bolt. % 99000-32050: THREAD LOCK “1342”...
Page 69 ENGINE 3-15 Apply PARMATEX 1372 Apply PARMATEX 1372 ITEM N·m kgf-m lb-ft ABCD 16.5 • Adjust the brake pedal height. & Brake pedal height A Standard: 20 – 30 mm (0.79 – 1.18 in) • Install the gearshift arm as shown. 63.6 ˚...
Page 70 • Tighten the rear axle nut 2 to the specified torque. $ Rear axle nut: 100 N·m (10.0 kgf-m, 72.5 lb-ft) • Install the cotter pin. (For E-03, 28, 33) • Apply SUZUKI SUPER GREASE to the clutch push rod and install it. ' 99000-25030: SUZUKI SUPER GREASE “A” (USA)
Page 71 ENGINE 3-17 • Install the clutch cable to the generator cover temporarily. • Apply SUZUKI MOLY PASTE to the clutch release. ( 99000-25140: SUZUKI MOLY PASTE • Assemble the clutch release so that the lever arm A will be angle of 80 degree with axle B.
Page 72 3-18 ENGINE • After installing the engine, route the wire harness, cables and hoses properly. (!9-16) • Adjust the following items. * Engine oil (!2-14) * Engine coolant (!2-19) * Engine idle speed (!2-15) * Throttle cable play (!2-15) * Clutch cable play (!2-17) * Throttle body synchronization (!5-32)
Page 73: Engine Disassembly
ENGINE 3-19 ENGINE DISASSEMBLY ENGINE TOP SIDE Identify the position of each removed part. Organize the parts in their respective groups (e.g., intake, exhaust) so that they can be reinstalled in their origi- nal positions. • Remove the spark plugs. (!2-6) •...
Page 74 3-20 ENGINE • Remove the oil cooler bracket 7. • Remove the rear exhaust pipe 8 and gasket. • Remove the valve timing inspection plug 9 and generator cover plug 0. CYLINDER HEAD COVER • Remove the front cylinder head cover 1. •...
Page 75 ENGINE 3-21 • Remove the rear cylinder head cover 4. • Remove the dowel pin 5 and O-ring 6. FRONT CAMSHAFTS • Turn the crankshaft to bring the “F” line A on generator rotor to the index mark B of the valve inspection hole and also to bring the cams to the position as shown in illustration.
Page 76 3-22 ENGINE • Remove the spring holder bolt 2, spring and gasket. • Remove the cam chain tension adjuster 3. • Remove the intake camshaft journal holder 4. • Remove the exhaust camshaft journal holder 5. NOTE: Mark the cylinder location as “F” to the camshaft journal holders. •...
Page 77 ENGINE 3-23 • Remove the cylinder head gasket 5, dowel pins 6 and cam chain guide 7. FRONT CYLINDER • Remove the cylinder nuts 1. • Remove the cylinder 2. • Remove the cylinder base gasket 3 and dowel pins 4. NOTE: Make sure that the oil jet is inserted in the crankcase.
Page 78 3-24 ENGINE NOTE: * At the above condition, the rear cylinder is at ATDC 90 ° on expansion stroke. * Before removing the camshafts, inspect the valve clearance. ( ! 2-8) • Remove the cam chain guide 1. • Remove the cam chain tension adjuster cap bolt 2, spring and gasket.
Page 79 ENGINE 3-25 REAR CYLINDER HEAD • Remove the cylinder head bolt (M6) 1. • Remove the cylinder bolts (M6) 2. • Remove the cylinder head bolts 3 and washers. NOTE: When loosening the cylinder head bolts, loosen each bolt little by little diagonally.
Page 80: Engine Bottom Side
3-26 ENGINE REAR PISTON • Place a clean rag over the cylinder base so as not to drop the piston pin circlip into the crankcase. • Remove the piston pin circlip 1. • Remove the piston 2 by driving out the piston pin. NOTE: Scribe the cylinder number on the head of the piston.
Page 81 ENGINE 3-27 CLUTCH COVER • Remove the clutch cover 1. • Remove the dowel pins 2 and gasket 3. CLUTCH • Hold the generator rotor 1 with the special tool. " 09930-44530: Rotor holder • Remove the clutch springs. NOTE: Loosen the clutch spring set bolts little by little and diagonally.
Page 82 3-28 ENGINE • Remove the clutch push rod 6. NOTE: If it is difficult to pull out the push rod 6 , use a magnetic hand or a wire. • Remove the clutch drive plates and driven plates. • Remove the spring washer 7 and spring washer seat 8. •...
Page 83 ENGINE 3-29 • Remove the lock washer 9. • Remove the clutch sleeve hub 0. • Remove the thrust washer A. • Remove the primary driven gear assembly B. • Remove the spacer C. OIL PUMP • Remove the snap ring 1. •...
Page 84 3-30 ENGINE • Remove the oil pump 5. GEARSHIFT SYSTEM • Remove the snap ring 1 and washer 2. • Remove the gearshift shaft assembly 3 and washer 4. • Remove the gearshift cam plate bolt 5. • Remove the gearshift cam plate 6. •...
Page 85 ENGINE 3-31 • Remove the following parts. 8 Gearshift cam stopper bolt 9 Gearshift cam stopper spring 0 Washer OIL PIPE • Remove the oil pipe stopper 1. • Remove the oil pipe 2. PRIMARY DRIVE GEAR • Hold the generator rotor with the special tool. "...
Page 86 3-32 ENGINE • Remove the water pump drive gear 1 and primary drive gear REAR CAM CHAIN • Remove the cam chain tensioner 1. NOTE: Do not drop the washer 2 into the crankcase. • Remove the rear cam chain 3 and cam chain drive sprocket GENERATOR ROTOR •...
Page 87 ENGINE 3-33 • Remove the key 2. • Remove the starter driven gear 3. FRONT CAM CHAIN • Remove the cam chain tensioner 1. NOTE: Do not drop the washer 2 into the crankcase. • Remove the front cam chain 3. GEAR POSITION SWITCH •...
Page 88 3-34 ENGINE • Remove the O-ring 3. • Remove the switch contacts 4 and springs 5. CRANKCASE • Remove the oil plate 1. • Remove the crankcase bolts and clamp 2. NOTE: Loosen the crankcase bolts diagonally and smaller sizes first. •...
Page 89 ENGINE 3-35 • Remove the O-rings 3 and dowel pins 4. CRANKSHAFT • Remove the crankshaft 1. TRANSMISSION • Remove the gearshift fork shafts 1. • Remove the gearshift cam 2. • Remove the gear shift forks 3. • Remove the driveshaft assembly 4 and countershaft assem- bly 5.
Page 90: Engine Components Inspection And Servicing
3-36 ENGINE 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”, “No.2” “Exhaust”, “Intake”, so that each will be restored to the original location during assembly.
Page 91: Camshaft/Camshaft Journal
ENGINE 3-37 • Apply THREAD LOCK to the bolts and then install the PAIR reed valve cover. % 99000-32050: THREAD LOCK “1342” NOTE: The inlet pipe of the PAIR reed valve cover must face left side of the engine. CAMSHAFT/CAMSHAFT JOURNAL Be sure to identify each removed part as to its loca- tion, and lay the parts out in groups designated as “No.1”, “No.2”, “Exhaust”, “Intake”, so that each will...
Page 92 3-38 ENGINE CAM WEAR Worn-down cams are often the cause of mistimed valve opera- tion resulting in reduced power output. The limit of cam wear is specified for both intake and exhaust cams in terms of cam height H, which is to be measured with a micrometer.
Page 93: Camshaft Runout
ENGINE 3-39 If the camshaft journal oil clearance measured exceeds the limit, measure the inside diameter of the camshaft journal holder and outside diameter of the camshaft journal. Replace the camshaft or the cylinder head depending upon which one exceeds the specification.
Page 94: Cylinder Head
3-40 ENGINE CAM CHAIN GUIDE Check the contacting surface of the cam chain guide. If it is worn or damaged, replace it with a new one. CYLINDER HEAD VALVE AND VALVE SPRING DISASSEMBLY • Remove the tappets 1 and shims 2 by fingers or magnetic hand.
Page 95 ENGINE 3-41 • Pull out the valve from the other side. • Remove the oil seals 6 and spring seats 7. Do not reuse the removed oil seals. CYLINDER HEAD DISTORTION Decarbonize the combustion chambers. Check the gasketed surface of the cylinder head for distortion with a straightedge and thickness gauge, taking a clearance reading at several places indicated.
Page 96 3-42 ENGINE VALVE HEAD RADIAL RUNOUT Place the dial gauge at a right angle to the valve head face and measure the valve head radial runout. If it measures more than the service limit, replace the valve. & Valve head radial runout Service Limit: 0.03 mm (0.001 in) "...
Page 97 ENGINE 3-43 VALVE GUIDE SERVICING • Using the valve guide remover, drive the valve guide out toward the intake or exhaust camshaft side. " 09916-43210: Valve guide remover/installer NOTE: * Discard the removed valve guide subassemblies. * Only oversized valve guides are available as replacement parts.
Page 98 3-44 ENGINE VALVE SEAT WIDTH INSPECTION Visually check for valve seat width on each valve face. If the valve face has worn abnormally, replace the valve. • Coat the valve seat with Prussian Blue and set the valve in place.Rotate the valve with light pressure. •...
Page 99 ENGINE 3-45 INITIAL SEAT CUT • Using the 45 ° cutter, descale and clean up the seat. Rotate the cutter one or two turns. • Measure the valve seat width W after every cut. NOTE: Cut only the minimum amount necessary from the seat to pre- vent the possibility of the valve stem becoming too close to the camshaft.
Page 100 3-46 ENGINE FINAL SEAT CUT • If the contact area W is too low or too narrow, use the 45 ° cutter to raise and widen the contact area. NOTE: * After cutting the 15 °, 30 ° and 60 ° angles, it is possible that the valve seat (45 °) is too narrow.
Page 101 ENGINE 3-47 VALVE STEM END CONDITION • Check the valve stem end face for pitting and wear. VALVE SPRING The force of the coil springs keeps the valve seat tight. Weak- ened springs result in reduced engine power output, and often account for the chattering noise coming from the valve mecha- nism.
Page 102 3-48 ENGINE VALVE AND VALVE SPRING INSTALLATION • Install the valve spring seats 1. • Apply engine oil to each oil seal 2. • Install the oil seal. Do not reuse the removed oil seals. • Insert the valves, with their stems coated with MOLYBDE- NUM OIL SOLUTION all around and along the full stem length without any break.
Page 103 ENGINE 3-49 • Install the tappet shim and the tappet to their original position. NOTE: * Before installing them, apply engine oil to the shims and tap- pets all over, also to the tappet chambers on the cylinder head. * When seating the tappet shim, be sure the figure printed sur- face faces the tappet.
Page 104: Cylinder
3-50 ENGINE CYLINDER CYLINDER DISTORTION Check the gasketed surface of the cylinder for distortion with a straightedge and thickness gauge, taking a clearance reading at several places as indicated. If the largest reading at any position of the straightedge exceeds the limit, replace the cylinder.
Page 105: Piston And Piston Ring
ENGINE 3-51 PISTON AND PISTON RING PISTON DIAMETER • Using a micrometer, measure the piston outside diameter at 20 mm (0.79 in) A from the piston skirt end. If the measurement is less than the limit, replace the piston. & Piston diameter Service Limit: 80.88 mm (3.184 in) at 20 mm (0.79 in) from the skirt end "...
Page 106: Piston Ring Groove Width
3-52 ENGINE & Piston ring groove width Standard (1st) : 1.21 – 1.23 mm (0.0476 – 0.0484 in) (2nd): 1.01 – 1.03 mm (0.0398 – 0.0406 in) (Oil) : 2.01 – 2.03 mm (0.0791 – 0.0799 in) & Piston ring thickness Standard (1st) : 1.17 –...
Page 107: Conrod And Crankshaft
ENGINE 3-53 OVERSIZE OIL RING The following two types of oversize oil rings are available as optional parts. They bear the following identification marks. COLOR SIZE SIDE RAIL SPACER 0.5 mm O.S. BLUE BLUE • Measure the outside diameter to identify the size. 1 Oil ring spacer A Paint PISTON PINS AND PIN BORE...
Page 108 3-54 ENGINE CONROD BIG END SIDE CLEARANCE Check the conrod side clearance by using a thickness gauge. If the clearance exceeds the limit, replace conrod or crankshaft. & Conrod big end side clearance Service Limit: 0.50 mm (0.020 in) " 09900-20803: Thickness gauge CONROD BIG END WIDTH Check the conrod big end width.
Page 109 ENGINE 3-55 CONROD-CRANK PIN BEARING SELECTION • Place the plastigauge axially along the crank pin, avoiding the oil hole, at TDC or BDC side as shown. " 09900-22301: Plastigauge 09900-22302: Plastigauge • Tighten the conrod cap bolts to the specified torque, in two stages.
Page 110 3-56 ENGINE & Conrod I.D. Code I.D. specification 41.000 – 41.008 mm (1.6142 – 1.6145 in) 41.008 – 41.016 mm (1.6145 – 1.6148 in) & Crank pin O.D. Code O.D. specification 37.992 – 38.000 mm (1.4957 – 1.4961 in) 37.984 – 37.992 mm (1.4954 –...
Page 111: Crankcase
ENGINE 3-57 • When fitting the conrods on the crankshaft, make sure that I.D. codes A of the conrods face each cylinder intake valve sides. • Apply engine oil to the thread and flange of the bearing cap bolts. • Tighten the bearing cap bolt as following two steps. 90 ˚...
Page 112 + 99104-31140: SUZUKI BOND “1207B” (USA) 99000-31140: SUZUKI BOND “1207B” (Others) $ Oil pressure switch: 13 N·m (1.3 kgf-m, 9.5 lb-ft) NOTE: Be careful not to apply SUZUKI BOND to the hole of the thread end. OIL STRAINER • Remove the oil strainer plate 1.
Page 113 ENGINE 3-59 • Install the oil strainer 3. NOTE: Fit the projection A of the oil strainer 3 in the concave portion of the crankcase. • Install the oil strainer plate 2 and tighten the oil starainer plate screw to the specified torque. $ Oil strainer plate screw: 10 N·m (1.0 kgf-m, 7.0 lb-ft) OIL JET Removal...
Page 114 3-60 ENGINE Inspection and cleaning • Check the oil jets for clogging. • If they are clogged, clean their oil passage with a proper wire and compressed air. 1 Piston cooling oil jet (#13) 2 Oil jet (#14) (For transmission) 3 Oil jet (#14) (For each cylinder head) Installation •...
Page 115: Crankshaft Journal Bearing
ENGINE 3-61 CRANKSHAFT JOURNAL BEARING INSPECTION • Inspect the crankshaft journal bearings for any damage. • If any, replace them with a specified set of bearings. SELECTION • Inspect the crankshaft journal for any damage. • Measure the crankshaft journal O.D. with the special tool. &...
Page 116 3-62 ENGINE & Bearing thickness Color (Part No.) Thickness Green 1.996 – 1.999 mm (12229 – 27G00-0A0) (0.0786 – 0.0787 in) Black 1.999 – 2.002 mm (12229 – 27G00-0B0) (0.0787 – 0.0788 in) Brown 2.002 – 2.005 mm (12229 – 27G00-0C0) (0.0788 –...
Page 117 ENGINE 3-63 • Gradually press out the bearing with the special tool by using the hand-press. The removed bearings must be replaced with new ones. 1 Hand-press 2 Crankcase 3 Bearing NOTE: Using the hand-press is recommended to remove the crankshaft journal bearings.
Page 118 3-64 ENGINE • Tighten the special tool bolts to the specified torque. $ Special tool bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft) Before installing the bearings, lightly shave off the sharp edge part A of the crankcase chamfer by using an oilstone and wash the crankcase bore with enough engine oil.
Page 119 ENGINE 3-65 • Apply enough engine oil to the special tool and the bearings and then set the special tool carefully. • Gradually press 1 in the bearing 2 into the main journal bore by using the hand-press until the special tool 3 contacts the special tool 4.
Page 120: Crankcase Bearing And Oil Seal
3-66 ENGINE CRANKCASE BEARING AND OIL SEAL INSPECTION Rotate the bearing inner race by finger to inspect for abnormal play A, noise and smooth rotation while the bearings are in the crankcase. Replace the bearing with new ones, if there is anything unusual. Inspect the oil seals for any damage.
Page 121 ENGINE 3-67 • Remove the crankcase bearings by with the special tool. " 09921-20240: Bearing remover set NOTE: Select the suitable size attachment as following illustration. Bearing remover attachment 1 -25 mm 2 -17 mm 3 -20 mm A Left crankcase B Right crankcase...
Page 122 ---------- - 22 mm ---------- - 52 mm ---------- - 40 mm ---------- - 47 mm ---------- • Apply SUZUKI SUPER GREASE to the oil seal lip. ' 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others)
Page 123: Clutch
ENGINE 3-69 CLUTCH CLUTCH DRIVE PLATES NOTE: Wipe off engine oil from the clutch drive plates with a clean rag. • Measure the thickness of drive plates with a vernier calipers. • If each drive plate is not within the standard range, replace it with a new one.
Page 124: Primary Driven Gear Assembly
3-70 ENGINE CLUTCH BEARING INSPECTION Smooth engagement and disengagement of the clutch depends on the condition of this bearing. Inspect the clutch release bearing for any abnormality, particu- larly cracks, to decide whether it can be reused or should be replaced.
Page 125: Gearshift Shaft/Gearshift Arm
ENGINE 3-71 • Install the snap ring 2. GEARSHIFT SHAFT/GEARSHIFT ARM DISASSEMBLY • Remove the following parts from the gearshift shaft/gearshift arm. 1 Washer 5 Washer 2 Snap ring 6 Plate return spring 3 Gearshift shaft return spring 7 Gearshift cam drive plate 4 Snap ring INSPECTION Check the gearshift shaft/gearshift arm for wear or bend.
Page 126: Transmission
3-72 ENGINE TRANSMISSION COUNTERSHAFT DISASSEMBLY Be sure to identify each removed part as to its loca- tion, and lay the parts out in groups designated as “Drive” and “Driven”, so that each will be restored to the original location during assembly. •...
Page 127 ENGINE 3-73 • Remove the 5th drive gear bushing D. DRIVESHAFT DISASSEMBLY • Remove the washer 1 and 1st driven gear 2. • Remove the 1st driven gear bushing 3, washer 4 and 5th driven gear 5. • Remove the snap ring 6, washer 7 and 4th driven gear 8. •...
Page 128 3-74 ENGINE • Remove the 3rd driven gear bushing B and washer C. • Remove the snap ring D and 6th driven gear E. • Remove the snap ring F and 2nd driven gear bushing G. • Remove the 2nd driven gear H. INSPECTION Inspect the each gear and bushing for wear and damage.
Page 129 • Before installing the gears, lightly coat MOLY PASTE or engine oil to the driveshaft and countershaft. ( 99000-25140: SUZUKI MOLY PASTE • Before installing the O-ring, apply SUZUKI SUPER GREASE to it. ' 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A”...
Page 130 3-76 ENGINE When installing the 6th drive gear, 3rd driven gear and 4th driven gear bushings onto the shaft, align the shaft oil hole A with the bushing oil hole B. 1 6th drive gear bushing 2 3rd driven gear bushing 3 4th driven gear bushing •...
Page 131 ENGINE 3-77 1 1st (Low) drive gear/countershaft 7 5th driven gear 2 5th drive gear 8 4th driven gear 3 3rd/4th drive gear 9 3rd driven gear 4 6th (Top) drive gear 0 6th (Top) driven gear 5 2nd drive gear A 2nd driven gear 6 1st (Low) driven gear A 145 N·m (14.5 kgf·m, 105 lb-ft)
Page 132 3-78 ENGINE GEARSHIFT FORK TO GROOVE CLEARANCE Using a thickness gauge, check the gearshift fork clearance in the groove of its gear. The clearance for each gearshift fork plays an important role in the smoothness and positiveness of the shifting action. &...
Page 133: Starter Clutch
ENGINE 3-79 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 in one direction only. If a large resistance is felt for rotation, inspect the starter clutch or the starter clutch contacting surface on the starter driven gear for wear and damage.
Page 134: Generator And Signal Generator
3-80 ENGINE • Be sure to seat the flange A of the one way clutch 3 to the guide 4. • Install the guide 5 to the generator rotor with the arrow mark B faced upward. • Apply THREAD LOCK SUPER to the bolts and tighten them to the specified torque.
Page 135: Oil Pump
ENGINE 3-81 OIL PUMP INSPECTION Rotate the oil pump by hand and check that it moves smoothly. If it does not move smoothly, replace the oil pump assembly. * Do not attempt to disassemble the oil pump assem- bly. * The oil pump is available only as an assembly. CLUTCH RELEASE INSPECTION •...
Page 136: Engine Reassembly
3-82 ENGINE ENGINE REASSEMBLY Reassemble the engine in the reverse order of disassembly. The following steps require special attention or precautionary measures should be taken. NOTE: Apply engine oil to each running and sliding part before reas- sembling. ENGINE BOTTOM SIDE TRANSMISSION •...
Page 137 * Spread on surfaces thinly to form an even layer, and assemble the crankcases within few minutes. * Take extreme care not to apply any SUZUKI BOND to the oil hole, oil groove and bearing. * Apply to distorted surfaces as it forms a comparatively thick...
Page 138 * The grooved A side of the engine sprocket spacer 1 must face crankcase side. * Apply SUZUKI SUPER GREASE to the oil seal lip and O-ring. ' 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others)
Page 139 3-85 GEAR POSITION SWITCH • Install the gear position switch contacts 1 and springs. • Apply SUZUKI SUPER GREASE to the O-ring 2 and then install it onto the gear position switch. ' 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) •...
Page 140 3-86 ENGINE GENERATOR ROTOR • Install the starter driven gear 1. • Apply engine oil to the bushing of the starter driven gear. • Degrease the tapered portions A of the generator rotor assembly and the crankshaft. Use nonflammable cleaning solvent to wipe off oily or greasy matter and make these sur- faces completely dry.
Page 141 ENGINE 3-87 REAR CAM CHAIN • Install the rear cam chain 1. • Install the cam chain tensioner 2, washer 3 and cam chain tensioner bolt 4. • Tighten the cam chain tensioner bolt 4 to the specified torque. $ Cam chain tensioner bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft) NOTE: The front and rear cam chain tensioners are the same.
Page 142 3-88 ENGINE OIL PIPE • Install the oil pipe 1. • Tighten the oil pipe stopper screw 2 to the specified torque. $ Oil pipe stopper screw: 8 N·m (0.8 kgf-m, 6.0 lb-ft) NOTE: Align the projection A of the oil pipe with the groove B of its stopper.
Page 143 ENGINE 3-89 • Apply a small quantity of THREAD LOCK to the gearshift cam stopper plate bolt and tighten it to the specified torque. % 99000-32050: THREAD LOCK “1342” $ Gearshift cam stopper plate bolt: 13 N·m (1.3 kgf-m, 9.5 lb-ft) •...
Page 144 3-90 ENGINE • Install the washer 1 and pin 2. • Install the oil pump driven gear 3. • Install the snap ring 4. CLUTCH • Install the spacer 1 and apply ENGINE OIL to it. • Install the primary driven gear assembly 2 onto the counter- shaft.
Page 145 ENGINE 3-91 • Hold the clutch sleeve hub with the special tool. " 09920-53740: Clutch sleeve hub holder • Tighten the clutch sleeve hub nut to the specified torque. $ Clutch sleeve hub nut: 50 N·m (5.0 kgf-m, 36.0 lb-ft) •...
Page 146 3-92 ENGINE • Install the clutch push rod B into the countershaft. • Install the clutch push piece C, the bearing D and thrust washer E to the countershaft. NOTE: Thrust washer E is located between the pressure plate and bearing D .
Page 147 ENGINE 3-93 • Install the clutch cover. GENERATOR COVER • Apply MOLYBDENUM OIL SOLUTION to both ends of the shaft 1. * MOLYBDENUM OIL SOLUTION • Install the starter idle gear 2 and shaft 1. • Install the dowel pins 3 and gasket 4. Use the new gasket to prevent oil leakage.
Page 148: Engine Top Side
STARTER MOTOR • Install the new O-ring to the starter motor. Use the new O-ring to prevent oil leakage. • Apply SUZUKI SUPER GREASE to the O-ring. ' 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) •...
Page 149 ENGINE 3-95 • 1st ring 5 and 2nd ring 6 have letters “T” marked on the side. Be sure to bring the marked side to the top when fitting them to the piston. • Position the gaps of the three rings as shown. Before inserting each piston into the cylinder, check that the gaps are so located.
Page 150 Use the new O-rings to prevent oil leakage. CYLINDER • Coat SUZUKI BOND lightly to the mating surfaces at the part- ing line between the right and left crankcases as shown. + 99104-31140: SUZUKI BOND “1207B” (USA) .
Page 151 ENGINE 3-97 • Apply engine oil to the sliding surface of the cylinders. NOTE: The front and rear cylinders can be distinguished by the embossed-letters A . “FRONT” : Front cylinder “REAR” : Rear cylinder • Hold the piston rings in proper position, and insert each of the piston into the respective cylinders.
Page 152 3-98 ENGINE • Fit the dowel pins 2 and new cylinder head gasket 3 to the cylinder. Use the new gasket to prevent gas leakage. • Install the washers 4 to the cylinder head bolts (M10) 5 as shown. • Apply engine oil to the washers and thread portion of the bolts before installing the cylinder head bolts.
Page 153 ENGINE 3-99 • Install the front cylinder head in same manner as the rear cyl- inder head installation. CAM SHAFT • The cam shafts are identified by the embossed letters. INF : No.1 (Front) intake camshaft 1 EXF : No.1 (Front) exhaust camshaft 2 INR : No.2 (Rear) intake camshaft 3 EXR : No.2 (Rear) exhaust camshaft 4 •...
Page 154 3-100 ENGINE • The other arrow mark “2” on the exhaust camshaft sprocket should now be pointing straight up. Starting from the roller pin that is directly above the arrow mark “2” count out 16 roller pins (from the exhaust camshaft side going towards the intake “3”...
Page 155 ENGINE 3-101 • Tighten the camshaft journal holder bolts to the specified torque. $ Camshaft journal holder bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft) The camshaft journal holder bolts are made of a spe- cial material and much superior in strength, compared with other types of high strength bolts.
Page 156 3-102 ENGINE • Install the cam chain guide 7. No.2 (Rear) Camshafts • From the position where the front camshafts have now been installed, rotate the generator rotor 360 degrees (1 turn) coun- terclockwise and align the “F” line A on the generator rotor with the index mark B of the valve timing inspection hole.
Page 157 ENGINE 3-103 • The other arrow mark “2” on the intake camshaft sprocket should now be pointing straight up. Starting from the roller pin that is directly above the arrow mark “2” count out 16 roller pins (from the intake camshaft side going towards the exhaust camshaft side).
Page 158 3-104 ENGINE • Apply engine oil to the camshaft journal holders. • Install the camshaft journal holders, intake and exhaust. • Fasten the camshaft journal holders evenly by tightening the camshaft journal holder bolts sequentially and diagonally. NOTE: * Align the flange E of the camshafts with the groove F of the camshaft journal holders.
Page 159 ENGINE 3-105 No.1 (Front) cylinde TDC of compression stroke 1 Cam chain guide 2 Cam chain guide A Forward...
Page 160 • Install the dowel pins 1 and O-rings 2. • Install the new gaskets to each cylinder head cover. • Apply SUZUKI BOND to the cam end caps of the gaskets. + 99104-31140: SUZUKI BOND “1207B” (USA) . 99000-31110: SUZUKI BOND “1215” (Others) Use the new gaskets to prevent oil leakage.
Page 161 • When installing the water union, apply engine coolant to the O-ring. / ENGINE COOLANT INTAKE PIPE • Apply SUZUKI SUPER GREASE to the O-ring. ' 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) Use the new O-ring to prevent air from sucking through the joint.
Page 162 3-108 ENGINE GENERATOR COVER PLUG • Apply engine oil to the O-ring of the generator cover plug. • Tighten the valve timing inspection plug 1 and generator cover plug 2 to the specified torque. $ Valve timing inspection plug: 23 N·m (2.3 kgf-m, 16.3 lb-ft) Generator cover plug: 11 N·m (1.1 kgf-m, 8.0 lb-ft) Use the new O-ring to prevent oil leakage.
Page 164 FI SYSTEM DIAGNOSIS CONTENTS PRECAUTIONS IN SERVICING..............4- 2 ELECTRICAL PARTS................4- 2 FUSE .......................4- 3 ECM/VARIOUS SENSORS..............4- 3 ELECTRICAL CIRCUIT INSPECTION PROCEDURE ......4- 5 USING TESTERS..................4- 8 FI SYSTEM TECHNICAL FEATURES ............4- 9 INJECTION TIME (INJECTION VOLUME)..........4- 9 COMPENSATION OF INJECTION TIME (VOLUME)......4-10 INJECTION STOP CONTROL ..............4-10 FI SYSTEM PARTS LOCATION.............4-11...
Page 165 FI SYSTEM DIAGNOSIS SENSORS......................4-49 CKP SENSOR INSPECTION ..............4-49 CKP SENSOR REMOVAL AND INSTALLATION ........4-49 IAP SENSOR INSPECTION..............4-49 IAP SENSOR REMOVAL AND INSTALLATION........4-49 TP SENSOR INSPECTION ..............4-49 TP SENSOR REMOVAL AND INSTALLATION ........4-49 TPS ADJUSTMENT ................4-49 ECT SENSOR INSPECTION..............4-49 ECT SENSOR REMOVAL AND INSTALLATION ........4-49 IAT SENSOR INSPECTION ..............4-50 IAT SENSOR REMOVAL AND INSTALLATION........4-50 TO SENSOR INSPECTION..............4-50...
Page 166: Precautions In Servicing
FI SYSTEM DIAGNOSIS PRECAUTIONS IN SERVICING When handling the component parts or servicing the FI system, observe the following points for the safety of the system. ELECTRICAL PARTS CONNECTOR/COUPLER • When connecting a connector, be sure to push it in until a Click click is felt.
Page 167: Fuse
FI SYSTEM DIAGNOSIS • When connecting meter probe from the terminal side of the coupler (connection from harness side not being possible), 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 168 FI SYSTEM DIAGNOSIS • When disconnecting and connecting the ECM, make sure to turn OFF the ignition switch 1, 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 169: Electrical Circuit Inspection Procedure
FI SYSTEM DIAGNOSIS ELECTRICAL CIRCUIT INSPECTION PROCEDURE While there are various methods for electrical circuit inspection, described here is a general method to check for open and short circuit using an ohmmeter and a voltmeter. OPEN CIRCUIT CHECK Possible causes for the open circuits are as follows. As the cause can exist in the connector/coupler or terminal, they need to be checked carefully.
Page 170 FI SYSTEM DIAGNOSIS Continuity check • Measure resistance across coupler B (between A and C in the figure). If no continuity is indicated (infinity or over limit), the circuit is open between terminals A and C. 1 ECM • Disconnect the coupler B and measure resistance between couplers A and B.
Page 171 FI SYSTEM DIAGNOSIS SHORT CIRCUIT CHECK (WIRE HARNESS TO GROUND) • Disconnect the negative cable from the battery. • Disconnect the connectors/couplers at both ends of the circuit to be checked. NOTE: If the circuit to be checked branches to other parts as shown, disconnect all connectors/couplers of those parts.
Page 172: Using Testers
FI SYSTEM DIAGNOSIS USING TESTERS • Use the Suzuki multi-circuit tester set (09990-25008). • Use well-charged batteries in the tester. • Be sure to set the tester to the correct testing range. USING THE TESTER • Incorrectly connecting the + and - probes may cause the inside of the tester to burnout.
Page 173: Fi System Technical Features
FI SYSTEM DIAGNOSIS FI SYSTEM TECHNICAL FEATURES INJECTION TIME (INJECTION VOLUME) The factors to determine the injection time include the basic fuel injection time, which is calculated on the basis of intake air pressure, engine speed and throttle opening angle, and various compensations. These compensations are determined according to the signals from various sensors that detect the engine and driving conditions.
Page 174: Compensation Of Injection Time (Volume)
4-10 FI SYSTEM DIAGNOSIS COMPENSATION OF INJECTION TIME (VOLUME) The following different signals are output from the respective sensors for compensation of the fuel injection time (volume). SIGNAL DESCRIPTION ENGINE COOLANT TEMPERATURE SEN- When engine coolant temperature is low, injection time (vol- SOR SIGNAL ume) is increased.
Page 175: Fi System Parts Location
FI SYSTEM DIAGNOSIS 4-11 FI SYSTEM PARTS LOCATION A Speedometer F Fuel injector, No.1 B CKP sensor G Fuel injector, No.2 C TP sensor H Ignition coil, No.1 D Gear position sensor I STVA E STP sensor J TO sensor...
Page 176 4-12 FI SYSTEM DIAGNOSIS K IAP sensor N Fuel pump relay L IAT sensor O Ignition coil, No.2 M ECT sensor P PAIR control valve...
Page 177: Fi System Wiring Diagram
FI SYSTEM DIAGNOSIS 4-13 FI SYSTEM WIRING DIAGRAM...
Page 178: Self-Diagnosis Function
4-14 FI SYSTEM DIAGNOSIS SELF-DIAGNOSIS FUNCTION The self-diagnosis function is incorporated in the ECM. The function has two modes, “USER MODE” and “DEALER MODE”. The user can only be notified by the LCD (DISPLAY) panel and LED (FI light). To check the function of the individual FI system devices, the dealer mode is prepared.
Page 179: Dealer Mode
FI SYSTEM DIAGNOSIS 4-15 DEALER MODE The defective function is memorized in the computer. Use the special tool’s coupler to connect to the dealer mode coupler. ("4-20) The memorized malfunction code is displayed on LCD (DISPLAY) panel. Malfunc- tion means that the ECM does not receive signal from the devices. These affected devices are indicated in the code form.
Page 180: Tps Adjustment
4-16 FI SYSTEM DIAGNOSIS CODE MALFUNCTION PART REMARKS None No defective part Crankshaft position sensor (CKPS) Pick-up coil signal, signal generator Intake air pressure sensor (IAPS) Throttle position sensor (TPS) Engine coolant temperature sensor (ECTS) Intake air temperature sensor (IATS) Tip over sensor (TOS) Ignition signal #1 (IG coil #1) For #1 cylinder...
Page 181: Fail-Safe Function
FI SYSTEM DIAGNOSIS 4-17 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 Intake air pressure sensor Intake air pressure and atmospheric...
Page 182: Fi System Troubleshooting
4-18 FI SYSTEM DIAGNOSIS FI SYSTEM TROUBLESHOOTING CUSTOMER COMPLAINT ANALYSIS Record details of the problem (failure, complaint) and how it occurred as described by the customer. For this purpose, use of such an inspection form will facilitate collecting information to the point required for proper analysis and diagnosis.
Page 183 FI SYSTEM DIAGNOSIS 4-19 MOTORCYCLE/ENVIRONMENTAL CONDITION WHEN PROBLEM OCCURS Environmental condition Weather Fair Cloudy Rain Snow Always Other Temperature Warm Cool Cold ( °F/ °C) Always Frequency Always Sometimes ( times/ day, month) Only once Under certain condition Road Urban Suburb Highway Mountainous (...
Page 184: Self-Diagnostic Procedures
4-20 FI SYSTEM DIAGNOSIS SELF-DIAGNOSTIC PROCEDURES Don’t disconnect couplers from ECM, battery cable from battery, ECM ground wire harness from engine or main fuse before con- firming malfunction code (self-diagnostic trouble code) stored in memory. Such disconnection will erase memorized information in ECM memory.
Page 185: Malfunction Code And Defective Condition
FI SYSTEM DIAGNOSIS 4-21 MALFUNCTION CODE AND DEFECTIVE CONDITION MALFUNCTION DETECTED FAILURE CONDITION DETECTED ITEM CODE CHECK FOR NO FAULT ––––––––––– Crankshaft position The signal does not reach ECM for 3 sec. and more, after sensor receiving the IAP signal. The crankshaft position sensor wiring and mechanical parts.
Page 186 4-22 FI SYSTEM DIAGNOSIS MALFUNCTION DETECTED FAILURE CONDITION DETECTED ITEM CODE CHECK FOR When no actuator control signal is supplied from the ECM or Secondary throttle communication signal does not reach ECM or operation voltage valve actuator does not reach STVA motor, C28 is indicated. STVA can not operate.
Page 187: C12" Ckp Sensor Circuit Malfunction
FI SYSTEM DIAGNOSIS 4-23 “C12” CKP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE The signal does not reach ECM for 3 sec. and more, • Metal particles or foreign materiel being attached after receiving the IAP signal. on the CKP sensor and rotor tip. •...
Page 188 4-24 FI SYSTEM DIAGNOSIS Step2 1) Disconnect the CKP sensor coupler. 2) Crank the engine a few seconds with the starter motor, and measure the CKP sensor peak voltage at the coupler. % CKP sensor peak voltage: 3.7 V and more (+ White –...
Page 189: C13" Iap Sensor Circuit Malfunction
FI SYSTEM DIAGNOSIS 4-25 “C13” IAP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE IAP sensor voltage is out of the specified range. • 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.
Page 190 4-26 FI SYSTEM DIAGNOSIS Step 2 1) Connect the IAP sensor coupler. 2) Insert the needle pointed probes to the lead wire coupler. 3) Start the engine at idle speed. 4) Measure the IAP sensor output voltage at the wire side cou- pler (between G/B and B/Br wires).
Page 191 FI SYSTEM DIAGNOSIS 4-27 Output voltage (Vcc voltage 4.5 V, ambient temp. 25 °C, 77 °F) ALTITUDE ATMOSPHERIC OUTPUT (Reference) PRESSURE VOLTAGE (ft) (mmHg) Approx.     3.3 – 3.6 2 000 2 001 Approx.    ...
Page 192: C14" Tp Sensor Circuit Malfunction
4-28 FI SYSTEM DIAGNOSIS “C14” TP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE Output voltage is out of the specified range. • TP sensor maladjusted. • TP sensor circuit open or short. 0.1 V Sensor voltage < 4.8 V • TP sensor malfunction. •...
Page 193 FI SYSTEM DIAGNOSIS 4-29 Step 2 1) Remove the air cleaner box. ("5-15) 2) Turn the ignition switch OFF. 3) Disconnect the TP sensor coupler. 4) Check the continuity between A and ground. % TP sensor continuity: ∞ Ω (Infinity) (A –...
Page 194 4-30 FI SYSTEM DIAGNOSIS 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. Measure the TP sensor output voltage at the coupler (between + P/W and - B/Br) by turning the throttle grip. % TP sensor output voltage Throttle valve is closed : Approx.
Page 195: C15" Ect Sensor Circuit Malfunction
FI SYSTEM DIAGNOSIS 4-31 “C15” ECT SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE Output voltage is out of the specified range. • ECT sensor circuit open or short. • ECT sensor malfunction. 0.1 V Sensor voltage < 4.6 V • ECM malfunction. INSPECTION Step 1 1) Turn the ignition switch OFF.
Page 196 4-32 FI SYSTEM DIAGNOSIS Step 2 1) Turn the ignition switch OFF. 2) Measure the ECT sensor resistance. (Refer to page 6-10 for details.) % ECT sensor resistance: Approx. 2.45 kΩ at 20 °C (68 °F) (Terminal – Terminal) ! 09900-25008: Multi circuit tester set &...
Page 197: C21" Iat Sensor Circuit Malfunction
FI SYSTEM DIAGNOSIS 4-33 “C21” IAT SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE Output voltage is out of the specified range. • IAT sensor circuit open or short. • IAT sensor malfunction. 0.1 V Sensor voltage < 4.6 V • ECM malfunction. INSPECTION Step 1 1) Lift and support the fuel tank.
Page 198 4-34 FI SYSTEM DIAGNOSIS Step 2 1) Turn the ignition switch OFF. 2) Measure the IAT sensor resistance. % IAT sensor resistance: Approx. 2.45 kΩ at 20 °C (68 °F) (Terminal – Terminal) ! 09900-25008: Multi circuit tester set & Tester knob indication: Resistance (Ω) Is the resistance OK? •...
Page 199: C23" To Sensor Circuit Malfunction
FI SYSTEM DIAGNOSIS 4-35 “C23” TO SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE The sensor voltage should be the following for 2 sec. • TO sensor circuit open or short. and more after ignition switch turns ON. • TO sensor malfunction. •...
Page 200: C24" Or "C25" Ignition System Malfunction
4-36 FI SYSTEM DIAGNOSIS Step 2 1) Connect the TO sensor coupler. 2) Insert the needle pointed probe to the lead wire coupler. 3) Turn the ignition switch ON. 4) Measure the voltage at the wire side coupler between Br/W and B/Br wires of the TO sensor at horizontal.
Page 201: C28" Stv Actuator Circuit Malfunction
FI SYSTEM DIAGNOSIS 4-37 “C28” 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. INSPECTION Step 1 1) Remove the fuel tank and air cleaner box.
Page 202: C29" Stp Sensor Circuit Malfunction
4-38 FI SYSTEM DIAGNOSIS “C29” STP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE Signal voltage is out of the specified range. • STP sensor maladjusted. Difference between actual throttle opening and • STP sensor circuit open or short. opening calculated by ECM in larger than specified •...
Page 203 FI SYSTEM DIAGNOSIS 4-39 Step 2 1) Turn the ignition switch OFF. 2) Disconnect the STP sensor coupler. 3) Check the continuity between Yellow wire and ground. % STP sensor continuity: ∞ Ω (Infinity) (Yellow – Ground) 4) If OK, then measure the STP sensor resistance at the coupler (between Yellow and Black wires).
Page 204 4-40 FI SYSTEM DIAGNOSIS 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 coupler. 5) Turn the ignition switch ON. 6) Measure the STP sensor output voltage at the coupler (between + Yellow and - B/Br wires) when the secondary throttle valve is full closed and opened.
Page 205: C31" Gear Position (Gp) Switch Circuit Malfunction
FI SYSTEM DIAGNOSIS 4-41 “C31” GEAR POSITION (GP) SWITCH CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE No Gear Position switch voltage • Gear Position switch circuit open or short. Switch voltage is out of the specified range. • Gear Position switch malfunction. •...
Page 206: C32" Or "C33" Fuel Injector Circuit Malfunction
4-42 FI SYSTEM DIAGNOSIS “C32” or “C33” FUEL INJECTOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE Fuel injector voltage is 1.3 V and less. • Injector circuit open or short. • Injector malfunction. • ECM malfunction. INSPECTION Step 1 1) Remove the air cleaner box. ("5-15) 2) Turn the ignition switch OFF.
Page 207 FI SYSTEM DIAGNOSIS 4-43 Step 2 1) Disconnect the injector couplers. 2) Turn the ignition switch ON. 3) Measure the injector voltage between Y/R wire (No.1 injector coupler and No.2 injector coupler) and ground. % Injector voltage: Battery voltage (+ Y/R – - Ground) NOTE: Injector voltage can be detected only 2 seconds after ignition switch is turned ON.
Page 208: C41" Fp Relay Circuit Malfunction
4-44 FI SYSTEM DIAGNOSIS “C41” FP RELAY CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE No voltage is applied to the both injectors for 3 sec. • Fuel pump relay circuit open or short. after the contact of fuel pump relay is turned ON. •...
Page 209: C49" Pair Control Solenoid Valve Circuit Malfunction
FI SYSTEM DIAGNOSIS 4-45 “C49” PAIR CONTROL SOLENOID VALVE CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE PAIR control solenoid valve voltage is not input in • PAIR control solenoid valve circuit open or short. ECM. • PAIR control solenoid valve malfunction. •...
Page 210 4-46 FI SYSTEM DIAGNOSIS Step 2 1) Connect the PAIR control solenoid valve coupler. 2) Turn the ignition switch ON. 3) Insert the needle pointed probes to the PAIR control solenoid valve coupler. 4) Measure the voltage at the wire side coupler between Brown wire and ground.
Page 211: C44" Ho2 Sensor (Ho2S) Circuit Malfunction (E-02, 19)
FI SYSTEM DIAGNOSIS 4-47 “C44” HO2 SENSOR (HO2S) CIRCUIT MALFUNCTION (E-02, 19) DETECTED CONDITION POSSIBLE CAUSE The sensor voltage should be the following and less • HO2 sensor or its circuit open or short. after warming up condition. • Fuel system malfunction. •...
Page 212 4-48 FI SYSTEM DIAGNOSIS Step 2 1) Warm up the engine enough. 2) Insert the needle pointed probes to the HO2 sensor coupler. 3) Measure the HO2 sensor output voltage at the coupler (between W/G and B/Br wires) when idling condition. 4) Also, measure the HO2 sensor output voltage while holding the engine speed at 5 000 r/min.
Page 213: Sensors
FI SYSTEM DIAGNOSIS 4-49 SENSORS CKP SENSOR INSPECTION The crankshaft position sensor is installed in the generator cover. ("4-23) CKP SENSOR REMOVAL AND INSTALLA- TION • Remove the generator cover. ("3-26) • Install the generator cover in the reverse order of removal. IAP SENSOR INSPECTION The intake air pressure sensor is installed at the rear side of the air cleaner box.
Page 214: Iat Sensor Inspection
4-50 FI SYSTEM DIAGNOSIS IAT SENSOR INSPECTION The intake air temperature sensor is installed on the right side of the air cleaner box. ("4-33) IAT SENSOR REMOVAL AND INSTALLA- TION • Lift and support the fuel tank. ("5-7) • Remove the IAT sensor from the air cleaner box. •...
Page 215 FUEL SYSTEM AND THROTTLE BODY FUEL SYSTEM AND THROTTLE BODY CONTENTS FUEL SYSTEM ....................5- 2 FUEL DELIVERY SYSTEM..............5- 2 FUEL PUMP ....................5- 3 FUEL PRESSURE REGULATOR ............5- 5 FUEL INJECTOR ..................5- 5 FUEL PUMP CONTROL SYSTEM............5- 6 FUEL SYSTEM ....................5- 7 FUEL TANK LIFT-UP................5- 7 FUEL TANK REMOVAL................5- 7 FUEL TANK INSTALLATION ..............5- 7...
Page 216: Fuel System
FUEL SYSTEM AND THROTTLE BODY FUEL SYSTEM 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 217: Fuel Pump
FUEL SYSTEM AND THROTTLE BODY FUEL PUMP The electric fuel pump is mounted at the bottom of the fuel tank, which consists of the armature, magnet, impeller, brush, check valve and relief valve. The ECM controls its ON/OFF operation as controlled under the FUEL PUMP CONTROL SYSTEM.
Page 218 FUEL SYSTEM AND THROTTLE BODY When the impeller is driven by the motor, pressure differential occurs between the front part and the rear part of the blade groove as viewed in angular direction due to fluid friction. This process continuously takes place causing fuel pressure to be built up.
Page 219: Fuel Pressure Regulator
FUEL SYSTEM AND THROTTLE BODY FUEL PRESSURE REGULATOR The fuel pressure regulator consists of the spring and valve. It keeps absolute fuel pressure of 300 kPa (3.0 kgf/cm , 43 psi) to be applied to the injector at all times. When the fuel pressure rises more than 300 kPa (3.0 kgf/cm , 43 psi), the fuel pushes the valve in the regu- lator open and excess fuel returns to the fuel tank.
Page 220: Fuel Pump Control System
FUEL SYSTEM AND THROTTLE BODY FUEL PUMP CONTROL SYSTEM When the ignition switch is turned on, current from the battery flows to the fuel pump motor through the side- stand relay and the fuel pump relay causing the motor to turn. Since the ECM has a timer function, the fuel pump motor stops turning in three seconds after the switch has been turned on.
Page 221: Fuel System
FUEL SYSTEM AND THROTTLE BODY FUEL SYSTEM FUEL TANK LIFT-UP • Remove the seat. (!7-4) • Remove the cowring. (!7-5) • Remove the fuel tank mounting bolt and fuel tank mount stay • Lift and support the fuel tank with the fuel tank mount stay. FUEL TANK REMOVAL •...
Page 222: Fuel Pressure Inspection
FUEL SYSTEM AND THROTTLE BODY FUEL PRESSURE INSPECTION • Lift and support the fuel tank. (!5-7) • Place a rag under the fuel feed hose. • Remove the fuel feed hose and install the special tools between the fuel tank and fuel delivery pipe. $ 09940-40211: Fuel pressure gauge adaptor 09940-40220: Fuel pressure gauge hose attachment 09915-74511: Oil pressure gauge set...
Page 223: Fuel Pump Inspection
FUEL SYSTEM AND THROTTLE BODY FUEL PUMP INSPECTION Turn the ignition switch ON and check that the fuel pump oper- ates for few seconds. If the fuel pump motor does not make operating sound, replace the fuel pump assembly or inspect the fuel pump relay and tip over sensor.
Page 224: Fuel Pump Relay Inspection
5-10 FUEL SYSTEM AND THROTTLE BODY FUEL PUMP RELAY INSPECTION Fuel pump relay is located behind the ECM. • Remove the seat. (!7-4) • Remove the fuel pump relay. First, check the insulation between 1 and 2 terminals with pocket tester. Then apply 12 volts to 3 and 4 terminals, + to 3 and - to 4, and check the continuity between 1 and 2.
Page 225 FUEL SYSTEM AND THROTTLE BODY 5-11 • Remove the screws. • Remove the fuel pump assy 4 from the fuel pump plate 5. • Remove the fuel pump holder 6. • Remove the fuel mesh filter 7. • Remove the fuel pressure regulator holder 8 and the fuel pressure regulator 9.
Page 226: Fuel Mesh Filter Inspection And Cleaning
5-12 FUEL SYSTEM AND THROTTLE BODY FUEL MESH FILTER INSPECTION AND CLEANING If the fuel mesh filter is clogged with sediment or rust, fuel will not flow smoothly and loss in engine power may result. Blow the fuel mesh filter with compressed air. NOTE: If the fuel mesh filter is clogged with many sediment or rust, replace the fuel filter cartridge with a new one.
Page 227 FUEL SYSTEM AND THROTTLE BODY 5-13 • Install the new O-ring and apply SUZUKI SUPER GREASE to The O-ring must be replaced with a new one to prevent fuel leakage. & 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) •...
Page 228: Throttle Body And Stv Actuator
5-14 FUEL SYSTEM AND THROTTLE BODY THROTTLE BODY AND STV ACTUATOR CONSTRUCTION 1 TP sensor A STP sensor mounting screw 2 STP sensor B TP sensor mounting screw STVA Fuel delivery pipe mounting ITEM N·m kgf-m lb-ft screw 4 Fuel delivery pipe *1 Do not turn the screw.
Page 229: Air Cleaner And Throttle Body Removal
FUEL SYSTEM AND THROTTLE BODY 5-15 AIR CLEANER AND THROTTLE BODY REMOVAL AIR CLEANER BOX • Remove the fuel tank. (!5-7) • Disconnect the IAT sensor coupler 1. • Remove the IAP sensor vacuum hose 2. • Disconnect the IAP sensor coupler 3. •...
Page 230 5-16 FUEL SYSTEM AND THROTTLE BODY THROTTLE BODY • Remove the fuel tank. (!5-7) • Remove the air cleaner box. (!5-15) • Disconnect the various lead wire couplers. 1 TP sensor 2 STP sensor 3 STVA motor • Remove the injector lead wire coupler. •...
Page 231 FUEL SYSTEM AND THROTTLE BODY 5-17 • Disconnect the throttle cables from their drum. • Dismount the throttle body assembly. " * Be careful not to damage the throttle cable bracket and fast idle lever when dismounting or remounting the throttle body assembly. * After disconnecting the throttle cables, do not snap the throttle valve from full open to full close.
Page 232: Throttle Body Disassembly
5-18 FUEL SYSTEM AND THROTTLE BODY THROTTLE BODY DISASSEMBLY " * Be careful not to damage the throttle lever when dis- assembling the throttle body. * The throttle body is assembled precisely in factory. Do not disassemble it other than shown in this man- ual.
Page 233 FUEL SYSTEM AND THROTTLE BODY 5-19 • Remove the TPS 5 and STPS 6 with the special tool. $ 09930-11950: Torx wrench (TH 25) 09930-11960: Torx wrench (TH 20) NOTE: Prior to disassembly, mark each sensor’s original position with a paint or scribe for accurate reinstallation.
Page 234 5-20 FUEL SYSTEM AND THROTTLE BODY • Remove the throttle stop screw 9. NOTE: Measure the length A for accurate reinstallation. " Never loosen the throttle stop screw B on the No.2 throt- tle body. " Never remove the throttle valve and secondary throttle valve.
Page 235 FUEL SYSTEM AND THROTTLE BODY 5-21 " Never remove the throttle body link plates. • Remove the fast idle link lever 0. • Remove the spring A. • Remove the spring B, bushing C and plastic washer D.
Page 236: Throttle Body Cleaning
5-22 FUEL SYSTEM AND THROTTLE BODY THROTTLE BODY CLEANING Some carburetor cleaning chemicals, especially dip- type soaking solutions, are very corrosive and must be handled carefully. Always follow the chemical man- ufacturer’s instructions on proper use, handling and storage. • Clean all passageways with a spray type carburetor cleaner and blow dry with compressed air.
Page 237: Throttle Body Reassembly
Reassemble the throttle body in the reverse order of disassem- bly. Pay attention to the following points: • Apply SUZUKI SUPER GREASE to the throttle stop screw tip and the both ends of a spring. & 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A”...
Page 238 & 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) • Install the seal 9. • Apply a small quantity of SUZUKI SUPER GREASE to the shaft ends and seal lips. & 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A”...
Page 239 FUEL SYSTEM AND THROTTLE BODY 5-25 NOTE: Make sure the throttle valve open or close smoothly. • Align the boss A of the STP sensor with the groove B of the ST valve shaft. • Install the STP sensor. • Tighten the STP sensor mounting screws. $ 09930-11960: Torx wrench ' STP sensor mounting screw: 2.0 N·m (0.2 kgf-m, 1.5 lb-ft)
Page 240 5-26 FUEL SYSTEM AND THROTTLE BODY • Install the fuel injectors by pushing them straight to each throt- tle body. " Never turn the injector while pushing it. • Install the fuel delivery pipe assembly to the throttle body assembly. "...
Page 241: Stv Synchronization
FUEL SYSTEM AND THROTTLE BODY 5-27 STV SYNCHRONIZATION • Install the throttle body. (!5-27) • Turn the ignition switch OFF, if STV synchronization is per- formed on the vehicle. • Turn the STVA shaft with a finger so that the throttle valve height A will be same as B.
Page 242: Stp Sensor Adjustment
5-28 FUEL SYSTEM AND THROTTLE BODY • Connect the fuel injector couplers to the fuel injectors. NOTE: * The fuel injector coupler No.1 (FRONT) can be distinguished from that of the No.2 (REAR) by the “F” mark A . * Adjust the throttle cable play with the cable adjusters. Refer to page 2-15 for details.
Page 243: Tp Sensor Adjustment
FUEL SYSTEM AND THROTTLE BODY 5-29 TP SENSOR ADJUSTMENT After checking or adjusting the throttle valve synchronization, adjust the TP sensor positioning as follows: • After warming up engine, adjust the idling speed to 1 300 rpm. • Stop the warmed-up engine and connect the special tool to the dealer mode coupler.
Page 244: Fast Idle Inspection
5-30 FUEL SYSTEM AND THROTTLE BODY FAST IDLE INSPECTION The fast idle system is automatic type. When the fast idle cam is turned by the secondary throttle valve actuator, the cam pushes the lever on the throttle valve shaft causing the throttle valve to open and raise the engine speed. When the engine has warmed up, depending on the water tem- perature and ambient temperature as shown in the following table, the fast idle is cancelled allowing the engine to resume...
Page 245: Fast Idle Adjustment
FUEL SYSTEM AND THROTTLE BODY 5-31 FAST IDLE ADJUSTMENT • Remove the fuel tank. (!5-7) • Remove the air cleaner box. (!5-15) • Disconnect the STVA lead wire coupler and turn the ignition switch ON. • Open the STV fully with a finger. Measure the output voltage of the TP sensor.
Page 246: Throttle Valve Synchronization
5-32 FUEL SYSTEM AND THROTTLE BODY THROTTLE VALVE SYNCHRONIZATION Check and adjust the throttle valve synchronization between two cylinders. CALIBRATING EACH GAUGE (For vacuum balancer gauge) • Start up the engine and run it in idling condition for warming • Stop the warmed-up engine. •...
Page 247 FUEL SYSTEM AND THROTTLE BODY 5-33 • Turn the air screw 4 of the gauge so that the vacuum acting on the tube of that hose will bring the steel ball 5 in the tube to the center line 6. NOTE: The vacuum gauge is positioned approx.
Page 248 5-34 FUEL SYSTEM AND THROTTLE BODY • Connect a tachometer and start up the engine. • Bring the engine rpm to 1 300 rpm by the throttle step screw. • Check the vacuum of the two cylinders and balance the two throttle valves with the synchronizing screw 2 on the No.2 throttle body.
Page 250 COOLING AND LUBRICATION SYSTEM COOLING AND LUBRICATION SYSTEM CONTENTS ENGINE COOLANT..................6- 2 COOLING CIRCUIT..................6- 3 COOLING CIRCUIT INSPECTION ............6- 3 RADIATOR ....................6- 4 REMOVAL....................6- 4 INSPECTION AND CLEANING ..............6- 6 INSTALLATION ..................6- 6 RADIATOR CAP....................6- 7 INSPECTION................... 6- 7 WATER HOSE....................6- 7 INSPECTION...................
Page 251 COOLING AND LUBRICATION SYSTEM 6-1 OIL PUMP....................6-20 OIL PRESSURE SWITCH ...............6-20 OIL COOLER ....................6-21 REMOVAL ....................6-21 INSPECTION AND CLEANING ..............6-21 INSTALLATION..................6-22 ENGINE LUBRICATION FLOW CHART............6-23 ENGINE LUBRICATION CIRCUIT ..............6-24...
Page 252: Engine Coolant
COOLING AND LUBRICATION SYSTEM ENGINE COOLANT At the time of manufacture, the cooling system is filled with a 50:50 mixture of distilled water and ethylene glycol anti-freeze. This 50:50 mixture will provide the optimum corrosion protection and excellent heat pro- tection, and will protect the cooling system from freezing at temperatures above –31 °C (–24 °F).
Page 253: Cooling Circuit
COOLING AND LUBRICATION SYSTEM COOLING CIRCUIT 1 Thermostat 2 Reserve tank 3 Radiator 4 No.1 cylinder head 5 No.1 cylinder 6 No.2 cylinder 7 No.2 cylinder head 8 Water pump COOLING CIRCUIT INSPECTION Before removing the radiator and draining the engine coolant, inspect the cooling circuit for tightness.
Page 254: Radiator
COOLING AND LUBRICATION SYSTEM RADIATOR REMOVAL • Remove the cowling. (#7-5) • Drain the engine coolant. (#2-18) • Disconnect the right and left radiator hoses from the radiator. • Disconnect the siphon hose 1 from the radiator. • Disconnect the horn lead wire coupler 2.
Page 255 COOLING AND LUBRICATION SYSTEM • Remove the radiator lower mounting bolt. • Disconnect the cooling fan motor and thermo-switch lead wire coupler 3. • Remove the radiator upper mounting bolt. • Disconnect the speed sensor lead wire from the clamp 4. •...
Page 256: Inspection And Cleaning
COOLING AND LUBRICATION SYSTEM INSPECTION AND CLEANING Road dirt or trash stuck to the fins must be removed. Use of compressed air is recommended for this cleaning. Fins bent down or dented can be repaired by straightening them with the blade of a small screwdriver. INSTALLATION •...
Page 257: Radiator Cap
COOLING AND LUBRICATION SYSTEM RADIATOR CAP INSPECTION • Remove the radiator cap. (#6-3) • 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 – 1.25 kgf/cm², 13.5 –...
Page 258: Cooling Fan
COOLING AND LUBRICATION SYSTEM COOLING FAN INSPECTION • Remove the cowling. (#7-5) • Disconnect the cooling fan motor and thermo-switch lead wire coupler 1. Test the cooling fan motor for load current with an ammeter con- nected as shown in the illustration. The voltmeter is for making sure that the battery 2 applies 12 volts to the fan motor 3.
Page 259: Cooling Fan Thermo-Switch
COOLING AND LUBRICATION SYSTEM COOLING FAN THERMO-SWITCH REMOVAL • Remove the cowling. (#7-5) • Drain the engine coolant. (#2-18) • Disconnect the cooling fan thermo-switch lead wire coupler • 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 260: Ect Sensor
6-10 COOLING AND LUBRICATION SYSTEM ECT SENSOR REMOVAL • Drain the engine coolant. (#2-18) • Disconnect the ECT sensor lead wire coupler. • Place a rag under the ECT sensor and remove the ECT sen- sor 1. INSPECTION • Check the ECT sensor by testing it at the bench as shown in the figure.
Page 261: Installation
COOLING AND LUBRICATION SYSTEM 6-11 INSTALLATION • Install a new sealing washer 1. • Tighten the ECT sensor to the specified torque. $ ECT sensor: 19 N·m (1.9 kgf-m, 13.5 lb-ft) Take special care when handling the ECT sensor. It may cause damage if it gets a sharp impact.
Page 262: Thermostat Case Assembly
6-12 COOLING AND LUBRICATION SYSTEM THERMOSTAT CASE ASSEMBLY REMOVAL • Drain the engine coolant. (#2-18) • Place a rag under the thermostat case. • Remove the thermostat case cap 1. • Remove the thermostat 2. INSPECTION Inspect the thermostat pellet for signs of cracking. Test the thermostat at the bench for control action, in the follow- ing manner.
Page 263: Installation
COOLING AND LUBRICATION SYSTEM 6-13 • 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 8.0 mm (0.31 in). % Thermostat valve lift Standard: Over 8.0 mm at 100 °C (Over 0.31 in at 212 °F) •...
Page 264: Water Pump
6-14 COOLING AND LUBRICATION SYSTEM WATER PUMP REMOVAL AND DISASSEMBLY • Drain the engine coolant. (#2-18) • Drain the engine oil. (#2-13) • Disconnect the water hoses 1, 2. • Remove the water pump case and clutch cover. (#3-27) NOTE: Before draining engine oil and engine coolant, inspect engine oil and coolant leakage between the water pump and clutch cover.
Page 265 COOLING AND LUBRICATION SYSTEM 6-15 • Remove the water pump 6 from the clutch cover. • Remove the screws and separate the water pump. • Remove the O-rings 7. • Remove the E-ring from the impeller shaft. • Remove the impeller from the other side. •...
Page 266: Inspection
6-16 COOLING AND LUBRICATION SYSTEM • Remove the bearings with the special tool. & 09921-20240: Bearing remover set (10 mm) NOTE: If there is no abnormal noise, bearings removal is not neces- sary. The removed bearings must be replaced with the new ones.
Page 267: Reassembly And Installation
& 09913-70210: Bearing installer set () 22 mm) NOTE: The stamped mark on the oil seal faces impeller side. • Apply a small quantity of the SUZUKI SUPER GREASE to the oil seal lip. * 99000-25030: SUZUKI SUPER GREASE “A” (USA)
Page 268 NOTE: The paint marked side A of the mechanical seal ring faces to the impeller. • Apply SUZUKI SUPER GREASE to the impeller shaft. * 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) • Install the impeller to the water pump body.
Page 269 COOLING AND LUBRICATION SYSTEM 6-19 • Apply engine coolant to the O-ring 4. • Install a new O-ring. Use a new O-ring to prevent engine coolant leakage. • Connect the water hoses. • Pour engine coolant. (#2-18) • Pour engine oil. (#2-14) 4.5 N·m (0.45 kgf-m, 3.3 lb-ft)
Page 270: Lubrication System
6-20 COOLING AND LUBRICATION SYSTEM LUBRICATION SYSTEM OIL PRESSURE #2-31 OIL FILTER #2-14 OIL PRESSURE REGULATOR #3-57 OIL STRAINER #3-58 OIL JET #3-49, -59, -60 and -96 OIL PUMP #3-81 and -89 OIL PRESSURE SWITCH #3-58 and 8-34...
Page 271: Oil Cooler
COOLING AND LUBRICATION SYSTEM 6-21 OIL COOLER REMOVAL • Drain the engine oil. (#2-13) • Disconnect the oil cooler hoses. • Remove the oil cooler. • Remove the oil cooler fin guard net 1. • Remove the oil hoses 2. INSPECTION AND CLEANING Inspect the oil cooler and hose joints for oil leakage.
Page 272: Installation
6-22 COOLING AND LUBRICATION SYSTEM Fins bent down or dented can be repaired by straightening them with the blade of a small screwdriver. INSTALLATION • Install the new gasket washers 1. Use the new gasket washers to prevent engine oil leakage.
Page 273: Engine Lubrication Flow Chart
COOLING AND LUBRICATION SYSTEM 6-23 ENGINE LUBRICATION FLOW CHART EXHAUST EXHAUST STARTER CLUTCH CAMSHAFT JOURNAL CAMSHAFT JOURNAL STARTER CAM FACES CAM FACES DRIVEN GEAR BUSHING EXHAUST CAM CHAIN CAM CHAIN CAMSHAFT LEFT SIDE RIGHT SIDE CAM FACES CAM FACES CRANKSHAFT CRANKSHAFT JOURNAL JOURNAL...
Page 274: Engine Lubrication Circuit
6-24 COOLING AND LUBRICATION SYSTEM ENGINE LUBRICATION CIRCUIT FRONT CYLINDER...
Page 275 COOLING AND LUBRICATION SYSTEM 6-25 REAR CYLINDER...
Page 276 CHASSIS CONTENTS EXTERIOR PARTS ..................7- 2 CONSTRUCTION ...................7- 2 REMOVAL ....................7- 4 INSTALLATION ..................7- 8 FRONT WHEEL ....................7- 9 CONSTRUCTION ...................7- 9 REMOVAL ....................7-10 INSPECTION AND DISASSEMBLY ............7-10 REASSEMBLY AND REMOUNTING .............7-12 FRONT FORK ....................7-16 CONSTRUCTION ...................7-16 REMOVAL AND DISASSEMBLY ............7-17 INSPECTION ..................7-20 REASSEMBLY AND REMOUNTING .............7-21 SUSPENSION SETTING ................7-25...
Page 277 CHASSIS REMOUNTING ..................7-56 FINAL INSPECTION AND ADJUSTMENT ..........7-57 FRONT BRAKE .................... 7-58 CONSTRUCTION .................. 7-58 BRAKE PAD REPLACEMENT .............. 7-59 BRAKE FLUID REPLACEMENT ............7-60 CALIPER REMOVAL AND DISASSEMBLY ......... 7-61 CALIPER INSPECTION ................. 7-62 CALIPER REASSEMBLY AND REMOUNTING ........7-63 BRAKE DISC INSPECTION ..............
Page 278: Exterior Parts
7-2 CHASSIS EXTERIOR PARTS CONSTRUCTION 1 Wind screen cover 6 Cowling body 2 Wind screen 7 Combination meter panel 3 Wind screen brace 8 Cowling inner cover 4 Cowling brace 9 Left cowling ITEM N·m kgf-m lb-ft 5 Right cowling A Cowling brace mounting bolt 25.5...
Page 279 CHASSIS 1 Seat rail 4 Mud guard 2 Rear fender No.1 5 Frame cover ITEM N·m kgf-m lb-ft 3 Rear fender No.2 A Seat rail mounting bolt 36.0...
Page 280: Removal
CHASSIS REMOVAL SEAT • Remove the seat with the ignition key 1. FUEL TANK SIDE COVER • Remove the seat. ("7-4) • Remove the fuel tank side covers 1. NOTE: “ ✩ ” indicates hook location. CARRIER • Remove the seat. ("7-4) •...
Page 281 CHASSIS FRAME COVER • Remove the seat. ("7-4) • Remove the carrier. ("7-4) • Remove the fuel tank side cover. ("7-4) • Remove the frame covers 1. NOTE: “ ✩ ” indicates hook location. REAR FENDER • Remove the seat. ("7-4) •...
Page 282 CHASSIS • Remove the wind screen 2. • Remove the fuel tank top cover 3. • Remove the combination meter panel mounting screws 4. • Remove the combination meter panel 5. NOTE: “ ✩ ” indicates hook location. • Disconnect the speedometer lead wire coupler 6. •...
Page 283 CHASSIS • Remove the left cowling 8. • Remove the right cowling 9. • Remove the wind screen brace 0. • Disconnect the turn signal light lead wire couplers A. • Remove the screws B. • Remove the cowling body C. NOTE: “...
Page 284: Installation
CHASSIS • Disconnect the coupler D. • Remove the cowling blace E. • Remove the combination meter. ("8-29) INSTALLATION Install the exterior parts in the reverse order of removal. Pay attention to the following points: • Install the wind screen brace 1 as shown in the photograph. NOTE: Install the larger diameter bolts on the wind screen brace attach- ing section A .
Page 285: Front Wheel
CHASSIS FRONT WHEEL CONSTRUCTION 1 Brake disc 5 Front wheel 2 Dust seal 6 Tire valve ITEM N·m kgf-m lb-ft 3 Bearing A Front axle 47.0 4 Center spacer B Brake disc bolt 16.5...
Page 286: Removal
7-10 CHASSIS REMOVAL • Remove the right and left brake calipers. ("7-59) • Loosen the axle pinch bolt 1 on the right front fork leg. Do not operate the brake lever while removing the cal- ipers. • Slightly loosen the front axle with the special tool. $ 09900-18710: Hexagon bit 12 mm •...
Page 287 CHASSIS 7-11 • Remove the dust seal with the special tool. $ 09913-50121: Oil seal remover Do not reuse the removed dust seals. FRONT AXLE Using a dial gauge, check the front axle for runout and replace it if the runout exceeds the limit. $ 09900-20607: Dial gauge (1/100) 09900-20701: Magnetic stand 09900-21304: V-block set (100 mm)
Page 288: Reassembly And Remounting
7-12 CHASSIS REASSEMBLY AND REMOUNTING Reassemble and remount the front wheel in the reverse order of removal and disassembly. Pay attention to the following points: 39 N·m 3.9 kgf-m 28.0 lb-ft 39 N·m 3.9 kgf-m 28.0 lb-ft 23 N·m 2.3 kgf-m 16.5 lb-ft 23 N·m 2.3 kgf-m...
Page 289 CHASSIS 7-13 WHEEL BEARING • Apply SUZUKI SUPER GREASE to the wheel bearings. ' 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) • First install the left wheel bearing, then install the right wheel bearing and spacer with the special tools and used bearing.
Page 290 7-14 CHASSIS BRAKE DISC Make sure that the brake disc is clean and free of any greasy matter. • Apply THREAD LOCK to the disc mounting bolts and tighten them to the specified torque. NOTE: The stamped mark A on the brake disc should face to the out- side.
Page 291 CHASSIS 7-15 NOTE: Before tightening the axle pinch bolt on the right front fork leg, move the front fork up and down 4 or 5 times without applying front brake. • Tighten the axle pinch bolt 1 on the right front fork leg to the specified torque.
Page 292: Front Fork
7-16 CHASSIS FRONT FORK CONSTRUCTION 1 Spring adjuster B Oil seal 2 O-ring C Oil seal retainer 3 Washer D Guide metal 4 Spacer E Oil lock piece 5 Spring F Outer tube 6 Rebound spring G Cylinder 7 Inner tube H Washer 8 Slide metal A Front fork cap bolt...
Page 293: Removal And Disassembly
CHASSIS 7-17 REMOVAL AND DISASSEMBLY • Remove the front wheel. ("7-10) • Remove the speedometer lead wire mounting bolts 1. • Remove the front fender bolts and brake hose bolts. • Remove the front fender 2. • Loosen the front fork upper clamp bolts 3. NOTE: Slightly loosen the front fork cap bolts 4 before loosening the lower clamp bolts to facilitate later disassembly.
Page 294 7-18 CHASSIS • Invert the fork and drain the fork oil out of the fork by stroking. • Hold the fork inverted for a few minutes to drain the fork oil. • Remove the front axle pinch bolt. (For right front fork reg) •...
Page 295 CHASSIS 7-19 • Remove the oil seal stopper ring. • Pull the inner tube out of the outer tube. NOTE: Be careful not to damage the inner tube. The slide metals, oil seal and dust seal must be replaced with the new ones when reassembling the front fork.
Page 296: Inspection
7-20 CHASSIS INSPECTION INNER AND OUTER TUBES Inspect the inner tube outer surface and the outer tube inner sur- face for scratches. If any defects are found, replace them with the new ones. FORK SPRING Measure the fork spring free length. If it is shorter than the ser- vice limit, replace it with a new one.
Page 297: Reassembly And Remounting
CHASSIS 7-21 REASSEMBLY AND REMOUNTING Reassemble and remount the front fork in the reverse order of removal and disassembly. Pay attention to the following points: METALS AND SEALS • Hold the inner tube vertically and clean the metal groove and install the guide metal by hand as shown.
Page 298 7-22 CHASSIS • Install the oil seal stopper ring 6 and the dust seal 7. A Dust seal B Oil seal stopper ring C Oil seal D Oil seal retainer E Guide metal CYLINDER • Install the rebound spring 1 to the cylinder 2. •...
Page 299 • Place the front fork vertically without spring. • Compress the front fork fully. • Pour the specified front fork oil into the front fork. + 99000-99001-SS8: SUZUKI FORK OIL SS-08 % Front fork oil capacity (each leg): 524 ml (17.7/18.5 US/Imp oz) •...
Page 300 7-24 CHASSIS FORK SPRING • Install the fork spring 1 into the front fork. • Install the washer 2 and spacer 3. NOTE: The smaller spring pitch end A must face downward. • Apply fork oil lightly to the O-ring. Use a new O-ring to prevent oil leakage.
Page 301: Suspension Setting
CHASSIS 7-25 • Tighten the front fork cap bolt 4 to the specified torque. ! Front fork cap bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft) • Loosen the front fork lower clamp bolt. • Align the top of the inner tube to the upper surface of the steering stem upper bracket.
Page 302: Steering And Handlebar
7-26 CHASSIS STEERING AND HANDLEBAR CONSTRUCTION 1 Handlebars 0 Spacer 2 Steering stem upper bracket A Washer 3 Dust seal B Expander 4 Bearing upper A Handlebar clamp bolt ITEM N·m kgf-m lb-ft 5 Bearing lower B Steering stem head nut 16.5 6 Steering stem lower bracket C Front fork upper clamp bolt...
Page 303: Removal
CHASSIS 7-27 REMOVAL HANDLEBARS • Remove the handlebar balancers 1. • Remove the rear view mirrors 2. NOTE: Do not remove the handlebar balancer mounting screw before removing the handlebar balancer. Slightly loosen the mounting screw, and then pull the balancer assembly out of handlebars. •...
Page 304 7-28 CHASSIS • Remove the handlebars by removing the handlebar clamp bolts. • Remove the clutch lever holder B. STEERING STEM • Remove the front forks. ("7-17) • Remove the handlebars. ("7-27) • Remove the guides 1. • Remove the brake hose guide 2. •...
Page 305 CHASSIS 7-29 • Remove the steering stem upper bracket by removing the steering stem head nut. • Remove the steering stem lock-nut with the special tools. $ 09940-14911: Steering stem nut wrench 09940-14960: Steering stem nut wrench socket • Remove the washer 4. •...
Page 306: Inspection And Disassembly
7-30 CHASSIS • Remove the steering stem upper bearing 7. • Remove the steering stem lower bearing 8. INSPECTION AND DISASSEMBLY Inspect the removed parts for the following abnormalities. * Distortion of the steering stem * Bearing wear or damage * Abnormal bearing noise * Handlebars distriction * Race wear and brinelling...
Page 307: Reassembly And Remounting
• Press in the dust seal and lower bearing with the special tool. $ 09925-18011: Steering bearing installer • Apply SUZUKI SUPER GREASE to the bearings and dust seal. • Install the lower bearing to the steering stem lower bracket.
Page 308 7-32 CHASSIS • Install the washer. NOTE: When installing the washer, align the stopper lug to the groove of the steering stem. • Install the steering stem lock-nut and tighten it to the specified torque with the special tools. $ 09940-14911: Steering stem nut wrench 09940-14960: Steering stem nut wrench socket ! Steering stem lock-nut: 80 N·m (8.0 kgf-m, 58.0 lb-ft) •...
Page 309 1 and then tighten the bolt 2 . HANDLEBAR SWITCH BOX • Install the throttle cable case. • Apply SUZUKI SUPER GREASE to the throttle cables and their holes. ' 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) •...
Page 310: Steering Tension Adjustment
7-34 CHASSIS • Install the left handlebar switch box to the handlebars by engaging the stopper 3 with the handlebars hole 4. • Install the clutch master cylinder with the proper clutch hose routing. • Install the handlebar balancers and the rear view mirrors. (Handlebar balancer installation: "9-35) •...
Page 311: Rear Wheel
CHASSIS 7-35 REAR WHEEL CONSTRUCTION 1 Rear axle A Retainer 2 Dust seal B Sprocket mounting drum 3 Brake disc C Rear sprocket 4 Collar D Bearing 5 Bearing E Dust seal 6 Rear wheel F Collar 7 Tire valve A Brake disc bolt ITEM N·m kgf-m lb-ft...
Page 312: Removal
7-36 CHASSIS REMOVAL • Remove the cotter pin. (For E-03, 28, 33) • Loosen the rear axle nut. • Raise the rear wheel off the ground and support the motorcy- cle with a jack or wooden block. • Remove the axle nut and draw out the rear axle. Do not operate the brake pedal while removing the rear wheel.
Page 313: Inspection And Disassembly
CHASSIS 7-37 • Remove the rear sprocket 6 from the rear sprocket mounting drum. • Remove the brake disc 7. INSPECTION AND DISASSEMBLY TIRE: ("7-79) WHEEL: ("7-11 and 7-79) REAR AXLE Using a dial gauge, check the rear axle for runout. If the runout exceeds the limit, replace the rear axle.
Page 314 7-38 CHASSIS SPROCKET Inspect the rear sprocket teeth for wear. If they are worn as shown, replace the engine sprocket, rear sprocket and drive chain as a set. A Normal wear B Excessive wear DUST SEAL • Inspect the wheel dust seal lip and sprocket mounting drum dust seal lips for wear or damage.
Page 315 CHASSIS 7-39 BEARING Inspect the play of the wheel and sprocket mounting drum bear- ings by hand while they are in the wheel and drum. Rotate the inner race by hand to inspect for abnormal noise and smooth rotation. Replace the bearing if there is anything unusual. •...
Page 316: Reassembly And Remounting
7-40 CHASSIS REASSEMBLY AND REMOUNTING Reassemble and remount the rear wheel in the reverse order of removal and disassembly. Pay attention to the following points: 60 N·m 6.0 kgf-m 43.5 lb-ft 23 N·m 2.3 kgf-m 16.5 lb-ft 100 N·m 10.0 kgf-m 72.5 lb-ft E-03, 28, 33 A Left...
Page 317 CHASSIS 7-41 BEARING • Apply SUZUKI SUPER GREASE to the bearings before installing. ' 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) • Install the new bearing to the sprocket mounting drum with the special tool.
Page 318 NOTE: When installing the dust seals, the stamped mark of dust seal must face the special tool. • Apply SUZUKI SUPER GREASE to the dust seal lips before assembling rear wheel. ' 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others)
Page 319 CHASSIS 7-43 • Install the rear sprocket mounting drum assembly to the rear wheel hub. • Tighten the sprocket mounting nuts to the specified torque. ! Rear sprocket nut: 60 N·m (6.0 kgf-m, 43.5 lb-ft) • Install the collar. REAR AXLE •...
Page 320: Rear Shock Absorber
7-44 CHASSIS REAR SHOCK ABSORBER CONSTRUCTION Rear shock absorber Rear shock absorber lower mounting nut ITEM N·m kgf-m lb-ft Rear shock absorber upper mount- 36.0 ing nut 36.0...
Page 321: Removal
CHASSIS 7-45 REMOVAL • Raise the rear wheel off the ground and support the motorcy- cle with a jack or wooden block. • Remove the pre-load adjuster 1. • Remove the cushion lever rod bolts/nuts and the cushion rods • Disconnect the pre-load adjuster hose from the clamp 3. •...
Page 322: Inspection
7-46 CHASSIS INSPECTION Inspect the shock absorber body and bushing for damage and oil leakage. If any defects are found, replace the shock absorber with a new one. Do not attempt to disassemble the rear shock absorber unit. It is unserviceable. REAR SHOCK ABSORBER DISPOSAL * The rear shock unit contains high-pressure nitrogen gas.
Page 323: Remounting
CHASSIS 7-47 REMOUNTING Remount the rear shock absorbers in the reverse order of removal. Pay attention to the following points: • Install the rear shock absorber and tighten the rear shock absorber upper/lower mounting nuts. ! Rear shock absorber lower mounting nut: 50 N·m (5.0 kgf-m, 36.0 lb-ft) Rear shock absorber upper mounting nut: 50 N·m (5.0 kgf-m, 36.0 lb-ft)
Page 324: Suspension Setting
7-48 CHASSIS SUSPENSION SETTING After installing the rear suspension, adjust the spring pre-load and damping force as follows. SPRING PRE-LOAD ADJUSTMENT The pre-load is adjusted by turning the pre-load adjuster knob without tool. Position “0” provides the softest spring pre-load. Position “5”...
Page 325: Rear Swingarm
CHASSIS 7-49 REAR SWINGARM CONSTRUCTION 1 Rear shock absorber 0 Swingarm 2 Rear cushion rod A Center spacer 3 Rear cushion lever Rear shock absorber upper mounting nut ITEM N·m kgf-m lb-ft 4 Spacer B Cushion lever nut 36.0 5 Bearing C Cushion rod nut 56.5 6 Washer...
Page 326: Removal
7-50 CHASSIS REMOVAL • Remove the exhaust pipe and exhaust muffler. ("3-6) • Raise the rear wheel off the ground and support the motorcy- cle with a jack or wooden block. • Remove the rear wheel. ("7-36) • Remove the rear brake hose guides 1. •...
Page 327: Inspection And Disassembly
CHASSIS 7-51 • Remove the mud guard 8. • Remove the chain buffer 9. INSPECTION AND DISASSEMBLY SPACER • Remove the spacers 1 from swingarm and cushion lever. • Inspect the spacers for any flaws or other damage. If any defect is found, replace the spacers with the new ones.
Page 328 7-52 CHASSIS SWINGARM BEARING Insert the spacer into bearing and check the play when moving the spacer up and down. If excessive play is noted, replace the bearing with a new one. • Remove the swingarm pivot bearings and spacer with the special tool.
Page 329 CHASSIS 7-53 • Remove the cushion lever bearings with the special tool. $ 09921-20240: Bearing remover set (20 mm and 17 mm) The removed bearings must be replaced with the new ones. CUSHION ROD Inspect the cushion rods for damage and distortion.
Page 330: Reassembly
7-54 CHASSIS REASSEMBLY Reassemble the swingarm in the reverse order of disassembly and removal. Pay attention to the following points: 50 N·m 5.0 kgf-m 36.0 lb-ft 78 N·m 7.8 kgf-m 56.5 lb-ft 50 N·m 5.0 kgf-m 36.0 lb-ft 78 N·m 7.8 kgf-m 56.5 lb-ft 15 N·m...
Page 331 NOTE: When installing the bearing, the dust seal that is embedded in the bearing must face outside. • Apply SUZUKI SUPER GREASE to the bearings and spac- ers. ' 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others)
Page 332: Remounting
7-56 CHASSIS REMOUNTING Remount the swingarm in the reverse order of disassembly and removal. Pay attention to the following points: SWINGARM • Insert the swingarm pivot shaft and tighten it to the specified torque with the special tool. ! Swingarm pivot shaft: 15 N·m (1.5 kgf-m, 11.0 lb-ft) $ 09944-28320: Hexagon bit 19 mm •...
Page 333: Final Inspection And Adjustment
CHASSIS 7-57 CUSHION LEVER AND CUSHION ROD • Install the washers 1 and cushion lever 2. NOTE: Insert the cushion lever mounting bolt from the left side. ( " 7-54) • Install the cushion rod and rear shock absorber. NOTE: Insert the cushion rod mounting bolts and rear shock absorber mounting bolts from the left side.
Page 334: Front Brake
7-58 CHASSIS FRONT BRAKE CONSTRUCTION 1 Diaphragm 0 Dust seal 2 Dust boot A Piston 3 Piston/cup set B Caliper holder 4 Brake hose C Caliper 5 Pin Front brake master cylinder mounting bolt ITEM N·m kgf-m lb-ft 6 Pad mounting pin B Brake hose union bolt 7 Brake pad spring C Air bleeder valve...
Page 335: Brake Pad Replacement
CHASSIS 7-59 * This brake system is filled with an ethylene glycol-based DOT 4 brake fluid. Do not use mix different types of fluid such as silicone-based or petroleum-based. * Do not use any brake fluid taken from old, used or unsealed containers. Never reuse brake fluid left over from the last servicing or stored for long periods.
Page 336: Brake Fluid Replacement
7-60 CHASSIS • Install the inner pad so that the inner pad will be seated on the hatched part C. • Install the pad mounting pin 3. • Install the pin 4 securely. • Install the caliper. • Tighten the caliper mounting bolts to the specified torque. ! Front brake caliper mounting bolt: 39 N·m (3.9 kgf-m, 28.0 lb-ft) NOTE:...
Page 337: Caliper Removal And Disassembly
CHASSIS 7-61 * Never reuse the brake fluid left over from previous servicing and which has been stored for long peri- ods of time. * Bleed air from the brake system. ("2-25) CALIPER REMOVAL AND DISASSEMBLY • Drain the brake fluid. ("7-60) •...
Page 338: Caliper Inspection
7-62 CHASSIS • Place a rag over the pistons to prevent them from popping out and then force out the pistons using compressed air. Do not use high pressure air to prevent piston dam- age. • Remove the dust seals 3 and piston seals 4. Do not reuse the removed dust seals and piston seals to prevent fluid leakage.
Page 339: Caliper Reassembly And Remounting
CHASSIS 7-63 RUBBER PARTS Inspect the rubber parts for damage. If any damage is found, replace them with the new ones. CALIPER REASSEMBLY AND REMOUNTING Reassemble and remount the caliper in the reverse order of removal and disassembly. Pay attention to the following points: •...
Page 340 7-64 CHASSIS CALIPER HOLDER • Apply SUZUKI SILICONE GREASE to the caliper holder pin. - 99000-25100: SUZUKI SILICONE GREASE • Install the caliper holder to the caliper. • Install the pad spring 1. NOTE: When installing the pad spring, seated on the lug of pad spring to concaved part of brake caliper.
Page 341: Brake Disc Inspection
CHASSIS 7-65 BRAKE DISC INSPECTION Visually check the brake disc for damage or cracks. Measure the thickness with a micrometer. Replace the disc if the thickness is less than the service limit or if damage is found. % Front disc thickness: Service Limit: 4.5 mm (0.18 in) $ 09900-20205: Micrometer (0 –...
Page 342: Master Cylinder Inspection
7-66 CHASSIS • Remove the brake lever 3 and brake switch 4. • Pull out the dust boot 5 and remove the snap ring 6. • Remove the piston and return spring. 7 Piston 8 Secondary cup 9 Primary cup 0 Return spring MASTER CYLINDER INSPECTION Inspect the master cylinder bore for any scratches or other dam-...
Page 343: Master Cylinder Reassembly And Remounting
CHASSIS 7-67 MASTER CYLINDER REASSEMBLY AND REMOUNTING Reassemble and remount the master cylinder in the reverse order of removal and disassembly. Pay attention to the following points: * Wash the master cylinder components with fresh brake fluid before reassembly. Never use cleaning solvent or gasoline to wash them.
Page 344: Rear Brake
7-68 CHASSIS REAR BRAKE CONSTRUCTION 1 Brake hose C Brake pad spring 2 Diaphragm D Caliper bracket 3 Reservoir tank hose E Caliper 4 Piston/cup set A Brake hose union bolt 5 Push rod Rear brake master cylinder mounting bolt ITEM N·m kgf-m lb-ft 6 Dust boot...
Page 345: Brake Pad Replacement
CHASSIS 7-69 * This brake system is filled with an ethylene glycol-based DOT 4 brake fluid. Do not use or mix different types of fluid such as silicone-based or petroleum-based. * Do not use any brake fluid taken from old, used or unsealed containers. Never reuse brake fluid left over from the last servicing or stored for long periods.
Page 346 7-70 CHASSIS • Assemble the insulator 4 and shim 5 to the new brake pad Replace the brake pads as a set, otherwise braking performance will be adversely affected. • Install the new brake pads. NOTE: Make sure that the detent of the pad is seated onto the retainer on the caliper bracket.
Page 347: Brake Fluid Replacement
CHASSIS 7-71 BRAKE FLUID REPLACEMENT • Remove the right frame cover. ("7-5) • Remove the brake fluid reservoir cap. • Replace the brake fluid in the same manner as the front brake. ("7-60) , Specification and Classification: DOT 4 Bleed air from the brake system. ("2-25) CALIPER REMOVAL AND DISASSEMBLY •...
Page 348 7-72 CHASSIS • Pivot the caliper up and remove the caliper from the caliper bracket 2. • Remove the pad spring 3. • Remove the spacer 4 and boot 5 from the caliper. • Remove the brake caliper sliding pin 6. •...
Page 349: Caliper Inspection
CHASSIS 7-73 • Remove the dust seal 7 and piston seal 8. Do not reuse the dust seal and piston seal to prevent fluid leakage. CALIPER INSPECTION BRAKE CALIPER Inspect the brake caliper cylinder wall for nicks, scratches and other damage. If any damage is found, replace the caliper with a new one.
Page 350: Brake Disc Inspection
• Install the piston to the caliper. 1 Dust seal 2 Piston seal 3 Caliper BRAKE CALIPER SLIDING PIN • Install the boot 1. • Apply SUZUKI SILICONE GREASE to the inside of the boot. - 99000-25100: SUZUKI SILICONE GREASE • Install the spacer 2.
Page 351: Master Cylinder Removal And Disassembly
• Tighten the brake caliper sliding pin 3 to the specified torque. ! Brake caliper sliding pin: 27 N·m (2.7 kgf-m, 19.5 lb-ft) • Apply SUZUKI SILICONE GREASE to the brake caliper slid- ing pin. - 99000-25100: SUZUKI SILICONE GREASE •...
Page 352 7-76 CHASSIS • Loosen the lock-nut 2. • Remove the master cylinder mounting bolts 3. • Place a rag underneath the union bolt on the master cylinder to catch spilled drops of brake fluid. Remove the union bolt 4 and disconnect the brake hose. Immediately and completely wipe off any brake fluid contacting any parts of the motorcycle.
Page 353: Master Cylinder Inspection
2 Piston/primary cup 3 Push rod 4 Snap ring 5 Dust boot • Apply the SUZUKI MOLY PASTE to the push rod. . 99000-25140: SUZUKI MOLY PASTE • Install the O-ring 6, connector 7 and snap ring 8 to the master cylinder.
Page 354 7-78 CHASSIS • Install the master cylinder. • Tighten the lock-nut 9. ! Rear brake master cylinder rod lock-nut: 18 N·m (1.8 kgf-m, 13.0 lb-ft) • Install the reservoir tank. (Rear brake hose routing: "9-27) • Temporarily install the master cylinder to the frame. •...
Page 355: Tire And Wheel
CHASSIS 7-79 TIRE AND WHEEL TIRE REMOVAL The most critical factor of a 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 356: Valve Installation
7-80 CHASSIS VALVE • Inspect the valve after the tire is removed from the rim. Replace the valve with a new one if the seal rubber is peeling or has damage. • Inspect the valve core. If the seal 1 has abnormal deforma- tion, replace the valve with a new one.
Page 357: Tire Installation
CHASSIS 7-81 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. * Do not use oil, grease or gasoline on the tire bead in place of tire lubricant.
Page 358: Tire Pressure
7-82 CHASSIS • In this condition, check the “rim line” A cast on the tire side walls. The line must be equidistant from the wheel rim all around. If the distance between the rim line A 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 359: Drive Chain
CHASSIS 7-83 DRIVE CHAIN Use the special tool in the following procedures, to cut and rejoin the drive chain. $ 09922-22711: Drive chain cutting and joining tool set NOTE: When using the special tool, apply a small quantity of grease to the threaded parts of the special tool.
Page 360: Drive Chain Connecting
7-84 CHASSIS • Place the drive chain link being disjointed on the holder part 8 of the tool. • Turn in both the adjuster bolt 6 and pressure bolt “A” 3 so that each of their end hole fits over the chain joint pin properly. •...
Page 361 CHASSIS 7-85 • Apply grease on the recessed portion of the joint plate holder 3 and set the joint plate 0. NOTE: When positioning the joint plate 0 on the tool, its stamp mark must face the joint plate holder 3 side. •...
Page 362 7-86 CHASSIS • Stake the joint pin by turning (approximately 7/8 turn) the pressure bolt “A” 3 with the bar until the pin end diameter becomes the specified dimension. % Pin end diameter specification D 5.5 – 5.8 mm (0.217 – 0.228 in) * After joining of the chain has been completed, check to make sure that the link is smooth and no abnormal condition is found.
Page 363 ELECTRICAL SYSTEM ELECTRICAL SYSTEM CONTENTS CAUTIONS IN SERVICING ................8- 2 CONNECTOR ..................8- 2 COUPLER ....................8- 2 CLAMP ....................8- 2 FUSE ......................8- 2 SEMI-CONDUCTOR EQUIPPED PART ..........8- 3 BATTERY ....................8- 3 CONNECTING THE BATTERY ..............8- 3 WIRING PROCEDURE ................8- 3 USING THE MULTI CIRCUIT TESTER ..........8- 4 LOCATION OF ELECTRICAL COMPONENTS ..........8- 5 CHARGING SYSTEM ..................8- 7 TROUBLE SHOOTING ................8- 7...
Page 364: Cautions In Servicing
ELECTRICAL SYSTEM CAUTIONS IN SERVICING CONNECTOR • When connecting a connector, be sure to push it in until a click is felt. • Inspect the connector for corrosion, contamination and break- age in its cover. COUPLER • With a lock type coupler, be sure to release the lock before disconnecting it and push it in fully till the lock works when connecting it.
Page 365: Semi-Conductor Equipped Part
ELECTRICAL SYSTEM 8-3 SEMI-CONDUCTOR EQUIPPED PART • Be careful not to drop the part with a semi-conductor built in such as a ECM. • When inspecting this part, follow inspection instruction strictly. Neglecting proper procedure may cause damage to this part. BATTERY •...
Page 366: Using The Multi Circuit Tester
ELECTRICAL SYSTEM USING THE MULTI CIRCUIT TESTER • Properly use the multi circuit tester + and - probes. Improper use can cause damage to the motorcycle and tester. • If the voltage and current values are not known, begin mea- suring in the highest range.
Page 367: Location Of Electrical Components
ELECTRICAL SYSTEM 8-5 LOCATION OF ELECTRICAL COMPONENTS 1 Horn 7 Speed sensor (!8-35) 2 Fuel injector (!4-42) 8 Ignition coil (No.1) 3 STP sensor (!4-38) 9 CKP sensor (!4-23) 4 TP sensor (!4-28) 0 Generator (!8-10) 5 STV actuator (!4-37) A Gear position switch (!8-20) 6 Fuel pump (!5-9) B Side-stand switch (!8-20)
Page 368 ELECTRICAL SYSTEM 1 TO sensor (!4-35) 0 PAIR control valve (!10-7) 2 Fuel pump relay (!5-10) A Regulator/rectifier (!8-11) 3 ECM (Engine Control Module) B Cooling fan thermo-switch (!6-9) 4 Fuse box C HO2 sensor (!4-47) 5 Turn signal/side-stand relay (!8-37) D ECT sensor (!4-31) 6 Starter relay (!8-19) E Ignition coil (No.2)
Page 369: Charging System
ELECTRICAL SYSTEM 8-7 CHARGING SYSTEM 1 Generator 2 Regulator/rectifier 3 Ignition switch 4 Main fuse 5 Battery 6 Load TROUBLE SHOOTING Battery runs down quickly Step1 1) Check accessories which use excessive amounts of electricity. Are accessories being installed? Remove accessories. Go to Step2.
Page 370 ELECTRICAL SYSTEM Step4 1) Measure the continuity of the generator coil. (!8-10) Is the resistance of generator coil OK? Go to Step5. • Faulty generator coil. • Disconnected lead wires. Step5 1) Measure the generator no-load voltage. (!8-10) Is generator no-load performance OK? Go to Step6.
Page 371: Inspection
ELECTRICAL SYSTEM 8-9 INSPECTION BATTERY CURRENT LEAKAGE • Remove the seat. (!7-4) • Turn the ignition switch to the OFF position. • Disconnect the battery - lead wire. Measure the current between - battery terminal and the - bat- tery lead wire using the multi circuit tester. If the reading exceeds the specified value, leakage is evident.
Page 372 8-10 ELECTRICAL SYSTEM GENERATOR COIL RESISTANCE • Remove the right cowling. (!7-5) • Disconnect the generator coupler 1. Measure the resistance between the three lead wires. If the resistance is out of the specified value, replace the stator with a new one. Also, check that the generator core is insulated properly.
Page 373 ELECTRICAL SYSTEM 8-11 REGULATOR/RECTIFIER • Remove the right cowling. (!7-5) • Disconnect the regulator/rectifier couplers 1. • Remove the regulator/rectifier 2. Measure the voltage between the terminals using the multi cir- cuit tester as indicated in the table below. If the voltage is not within the specified value, replace the regulator/rectifier with a new one.
Page 374: Starter System And Side-Stand/Ignition Interlock System
8-12 ELECTRICAL SYSTEM STARTER SYSTEM AND SIDE-STAND/IGNITION INTERLOCK SYSTEM (30 A) (10 A) 1 Starter motor 2 Starter relay 3 Clutch switch 4 Starter button 5 Engine stop switch 6 Turn signal/side-stand relay 7 Ignition switch 8 Fuse 9 Side-stand switch 0 Gear position switch A Battery A To ECM and ignition coil.
Page 375 ELECTRICAL SYSTEM 8-13 Step3 1) Measure the starter relay voltage at the starter relay connectors (between B/Y and Y/G) when the starter button is pushed. Is a voltage OK? Go to Step4. • Faulty gear position switch. • Faulty starter button. •...
Page 376: Starter Motor Removal And Disassembly
8-14 ELECTRICAL SYSTEM STARTER MOTOR REMOVAL AND DISASSEMBLY • Remove the starter motor and disconnect the starter motor lead wire 1. • Disassemble the starter motor as shown in the illustration. 6 N·m (0.6 kgf-m, 4.3 lb-ft) 3.5 N·m (0.4 kgf-m, 2.45 lb-ft) 1 Housing end (rear bracket) 6 Armature A Thrust stopper...
Page 377: Starter Motor Inspection
ELECTRICAL SYSTEM 8-15 STARTER MOTOR INSPECTION CARBON BRUSH Inspect the brushes for abnormal wear, cracks, or smoothness in the brush holder. If any damage is found, replace the brush assembly with a new one. COMMUTATOR Inspect the commutator for discoloration, abnormal wear or undercut A.
Page 378: Starter Motor Reassembly
" Replace the O-rings with the new ones to prevent oil leakage and moisture. • Apply SUZUKI SUPER GREASE to the lip of the oil seal. - 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) • Apply a small quantity of SUZUKI MOLY PASTE to the arma- ture shaft.
Page 379 ELECTRICAL SYSTEM 8-17 • Install the washers 2 (12 × 6.5 × 2), washer 3 (16 × 6.5 × 1), washer 4 (14 × 6.5 × 1) and nut 5. " Replace the O-rings with the new ones to prevent oil leakage and moisture.
Page 380 8-18 ELECTRICAL SYSTEM • Apply SUZUKI SUPER GREASE to the starter motor O-rings. - 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) " Use new O-rings to prevent oil leakage. • Tighten the starter motor housing bolts to the specified torque.
Page 381: Starter Relay Inspection
ELECTRICAL SYSTEM 8-19 STARTER RELAY INSPECTION • Remove the seat. (!7-4) • Disconnect the battery - lead wire from the battery. • Remove the starter relay cover 1. • Disconnect the starter relay coupler 2. • Disconnect the starter motor lead wire 3 and battery lead wire 4.
Page 382: Side-Stand/Ignition Interlock System Parts Inspection
8-20 ELECTRICAL SYSTEM SIDE-STAND/IGNITION INTERLOCK SYSTEM PARTS INSPECTION Check the interlock system for proper operation. If the interlock system does not operate properly, check each component for damage or abnormalities. If any abnormality is found, replace the component with a new one. SIDE-STAND SWITCH •...
Page 383 ELECTRICAL SYSTEM 8-21 • Connect the gear position switch coupler to the wiring har- ness. • Turn the ignition switch to “ON” position and side-stand to upright position. • Insert the needle pointed probes to the gear position switch coupler. Measure the voltage between Pink and B/W lead wires using the multi circuit tester when shifting the gearshift lever from low to top.
Page 384 8-22 ELECTRICAL SYSTEM SIDE-STAND RELAY INSPECTION First check the insulation between D and E terminals with the tester. Then apply 12 V to terminals D and C (+ to D and - to C) and check the continuity between D and E. If there is no continuity, replace the turn signal/side-stand relay with a new one.
Page 385: Ignition System
ELECTRICAL SYSTEM 8-23 IGNITION SYSTEM (10 A) W/Bl (30 A) 1 CKP sensor 2 ECM 3 Wave form arrangement circuit 4 Power source circuit 5 CPU 6 TP sensor 7 ECT sensor 8 Gear position switch 9 Engine stop switch 0 Ignition coil #1 A Spark plug #1 B Ignition coil #2...
Page 386 8-24 ELECTRICAL SYSTEM Step3 1) Measure the ignition coil primary peak voltage. (!8-25) NOTE: The ignition coil peak voltage inspection method is applicable only with the multi circuit tester and peak volt adaptor. Is the peak voltage OK? Go to Step4. Go to Step5.
Page 387: Inspection
ELECTRICAL SYSTEM 8-25 INSPECTION IGNITION COIL PRIMARY PEAK VOLTAGE • Lift and support the fuel tank. (!5-7) • Remove the radiator lower mounting bolt and move the radia- tor lower side to forward. • Disconnect the two spark plug caps. •...
Page 388 8-26 ELECTRICAL SYSTEM • Repeat the above procedure a few times and measure the highest ignition coil primary peak voltage. ' Tester knob indication: Voltage (&) $ Ignition coil primary peak voltage: 150 V and more While testing, do not touch the tester probes and spark plugs to prevent receiving an electric shock.
Page 389 ELECTRICAL SYSTEM 8-27 CKP SENSOR PEAK VOLTAGE • Remove the seat. (!7-4) • Disconnect the ECM coupler. NOTE: Make sure that all of the couplers are connected properly and the battery used is in fully-charged condition. Measure the CKP sensor peak voltage in the following proce- dures.
Page 390 8-28 ELECTRICAL SYSTEM If the peak voltage on the CKP sensor lead wire coupler is OK but on the ECM coupler is out of specification, the wire harness must be replaced. If both peak voltages are out of specification, the CKP sensor must be replaced and re-checked. 5 CKP sensor 6 CKP sensor coupler 7 Peak volt adaptor...
Page 391: Combination Meter
ELECTRICAL SYSTEM 8-29 COMBINATION METER REMOVAL AND DISASSEMBLY • Disconnect the battery - lead wire. • Remove the combination meter panel. (!7-6). • Remove the combination meter 1. " When disconnecting and connecting the combination meter coupler, make sure to turn OFF the ignition switch, or electronic parts may get damaged.
Page 392: Inspection
8-30 ELECTRICAL SYSTEM INSPECTION LED (LIGHT EMITTING DIODE) Check that the LED lights immediately after turning the ignition switch on. If the LED fails in operation, replace the combination meter unit with a new one after checking its wire har- ness/coupler.
Page 393 ELECTRICAL SYSTEM 8-31 ODOMETER The odometer indicates “------” when the odometer is faulty. Replace the combination meter unit with a new one. TRIP METER The trip meter indicates “----.-” when the trip meter is faulty. In case the odometer works normaly, perform the trip meter reset.
Page 394: Indicators
8-32 ELECTRICAL SYSTEM INDICATORS ENGINE COOLANT TEMPERATURE METER INSPECTION • Disconnect the ECT sensor coupler 1. " When connecting and disconnecting the ECT sensor lead wire coupler, make sure to turn OFF the ignition switch, or electronic parts may get damaged. •...
Page 395 ELECTRICAL SYSTEM 8-33 FUEL LEVEL GAUGE INSPECTION • Remove the fuel tank. (!5-7) • Remove the fuel pump. (!5-10) Measure the resistance at each fuel level gauge float position. If the resistance is incorrect, replace the fuel level gauge with a new one.
Page 396 8-34 ELECTRICAL SYSTEM FUEL LEVEL METER INSPECTION • Remove the fuel tank left side cover. (!7-4) • Disconnect the fuel pump lead wire coupler. • Connect the each resistor between the Yellow/Black and Black/White lead wires at the wire harness. •...
Page 397 ELECTRICAL SYSTEM 8-35 SPEEDOMETER AND SPEED SENSOR If the speedometer, odometer or trip meter does not function properly, inspect the speed sensor and connection of coupler 1. If the speed sensor and connection are all right, replace the meter with a new one. SPEED SENSOR REMOVAL AND INSTALLATION •...
Page 398: Lamps
8-36 ELECTRICAL SYSTEM LAMPS HEADLIGHT, BRAKE LIGHT/TAILLIGHT AND TURN SIGNAL LIGHT HEADLIGHT 12 V 60/55 W 12 V 60/55 W + 5 W A ONLY E-02, 19 BRAKE LIGHT/TAIL LIGHT 12 V 21/5 W TURN SIGNAL LIGHT 12 V 21 W HEADLIGHT BEAM ADJUSTMENT •...
Page 399: Relays
ELECTRICAL SYSTEM 8-37 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 400: Switches
8-38 ELECTRICAL SYSTEM SWITCHES IGNITION SWITCH REMOVAL • Remove the fuel tank. (!5-7) • Remove the air cleaner box. (!5-15) • Disconnect the ignition switch coupler 1. • Remove the ignition switch mounting bolts with the special tools. # 09930-11920: Torx bit JT40H 09930-11940: Bit holder "...
Page 401: Inspection
ELECTRICAL SYSTEM 8-39 INSPECTION Inspect each switch for continuity with a tester. If any abnormality is found, replace the respective switch assemblies with new ones. IGNITION SWITCH REAR BRAKE SWITCH Color Color Position Position LOCK CLUTCH SWITCH Color DIMMER SWITCH Position Color µ...
Page 402: Battery
8-40 ELECTRICAL SYSTEM BATTERY SPECIFICATIONS Type designation YTX12 – BS Capacity 12 V, 36.0 kC (10 Ah)/10 HR 1 Upper cover breather 5 Terminal 2 Cathode plates 6 Safety valve 3 Stopper 7 Anode plates 4 Filter 8 Separator (Fiberglass plate) INITIAL CHARGING Filling electrolyte •...
Page 403 ELECTRICAL SYSTEM 8-41 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 404: Servicing
8-42 ELECTRICAL SYSTEM SERVICING Visually inspect the surface of the battery container. If any signs of cracking or electrolyte leakage from the sides of the battery have occurred, replace the battery with a new one. If the battery terminals are found to be coated with rust or an acidic white powdery substance, clean the battery terminals with sandpaper.
Page 405 SERVICING INFORMATION SERVICING INFORMATION CONTENTS TROUBLESHOOTING...................9- 2 MALFUNCTION CODE AND DEFECTIVE CONDITION ......9- 2 ENGINE ....................9- 4 RADIATOR (COOLING SYSTEM) ............9-10 CHASSIS ....................9-11 BRAKES....................9-12 ELECTRICAL ..................9-13 BATTERY ....................9-15 WIRE HARNESS, CABLE AND HOSE ROUTING........9-16 WIRE HARNESS ROUTING ..............9-16 HEATED OXYGEN SENSOR (HO2S) WIRE ROUTING (FOR E-02, 19) ..................9-18 ENGINE ELECTRICAL PARTS SET-UP ..........9-19 SPEED SENSOR LEAD WIRE ROUTING..........9-20...
Page 406: Troubleshooting
SERVICING INFORMATION TROUBLESHOOTING MALFUNCTION CODE AND DEFECTIVE CONDITION MALFUNCTION DETECTED FAILURE CONDITION DETECTED ITEM CODE CHECK FOR NO FAULT ––––––––––– Crankshaft position The signal does not reach ECM for 3 sec. and more, after sensor receiving the IAP signal. The crankshaft position sensor wiring and mechanical parts. (Crankshaft position sensor, lead wire/coupler connection) Intake air pressure The sensor should produce following voltage.
Page 407 SERVICING INFORMATION MALFUNCTION DETECTED FAILURE CONDITION DETECTED ITEM CODE CHECK FOR When no actuator control signal is supplied from the ECM or Secondary throttle communication signal does not reach ECM or operation voltage valve actuator does not reach STVA motor, C28 is indicated. STVA can not operate.
Page 408: Engine
SERVICING INFORMATION ENGINE ENGINE WILL NOT START OR IS HARD TO START Symptom, possible causes and remedy 1) Compression too low • Valve clearance out of adjustment. Adjust. • Worn valve guides or poor seating of valves. Repair or replace. •...
Page 409 SERVICING INFORMATION ENGINE IDLES POORLY Symptom, possible causes and remedy • Valve clearance out of adjustment. Adjust. • Poor seating of valves. Replace or repair. • Defective valve guides. Replace. • Worn down camshafts. Replace. • Too wide spark plug gaps. Adjust or replace.
Page 410 SERVICING INFORMATION NOISY ENGINE Symptom, possible causes and remedy 1) Excessive valve chatter • Too large valve clearance. Adjust. • Weakened or broken valve springs. Replace. • Worn tappet or cam surface. Replace. • Worn and burnt camshaft journal. Replace. 2) Noise seems to come from piston •...
Page 411 SERVICING INFORMATION ENGINE RUNS POORLY IN HIGH SPEED RANGE Symptom, possible causes and remedy 1) Defective engine internal/electrical parts • Weakened valve springs. Replace. • Worn camshafts. Replace. • Valve timing out of adjustment. Adjust. • Too narrow spark plug gaps. Adjust.
Page 412 SERVICING INFORMATION ENGINE LACKS POWER Symptom, possible causes and remedy 1) Defective engine internal/electrical parts • Loss of valve clearance. Adjust. • Weakened valve springs. Replace. • Valve timing out of adjustment. Adjust. • Worn piston rings or cylinders. Replace. •...
Page 413 SERVICING INFORMATION ENGINE OVERHEATS Symptom, possible causes and remedy 1) Defective engine internal parts • Heavy carbon deposit on piston crowns. Clean. • Not enough oil in the engine. Add oil. • Defective oil pump or clogged oil circuit. Replace or clean. •...
Page 414: Radiator (Cooling System)
9-10 SERVICING INFORMATION TRANSMISSION WILL NOT SHIFT BACK Symptom, possible causes and remedy • Broken return spring on shift shaft. Replace. • Rubbing or sticky shift shaft. Repair or replace. • Distorted or worn gearshift forks. Replace. TRANSMISSION JUMPS OUT OF GEAR Symptom, possible causes and remedy •...
Page 415: Chassis
SERVICING INFORMATION 9-11 CHASSIS HEAVY STEERING Symptom, possible causes and remedy • Overtightened steering stem nut. Adjust. • Broken bearing in steering stem. Replace. • Distorted steering stem. Replace. • Not enough pressure in tires. Adjust. WOBBLY HANDLEBARS Symptom, possible causes and remedy •...
Page 416: Brakes
9-12 SERVICING INFORMATION REAR SUSPENSION TOO SOFT Symptom, possible causes and remedy • Weakened spring of shock absorber. Replace. • Leakage of oil from shock absorber. Replace. • Improperly set rear spring unit adjuster. Adjust. REAR SUSPENSION TOO STIFF Symptom, possible causes and remedy •...
Page 417: Electrical
SERVICING INFORMATION 9-13 BRAKE DRAGS Symptom, possible causes and remedy • Rusty part. Clean and lubricate. • Insufficient brake lever or brake pedal pivot Lubricate. lubrication. ELECTRICAL NO SPARKING OR POOR SPARKING Symptom, possible causes and remedy • Defective ignition coils or spark plug caps. Replace.
Page 418 9-14 SERVICING INFORMATION GENERATOR DOES CHARGE, BUT CHARGING RATE IS BELOW THE SPECIFICATION Symptom, possible causes and remedy • Lead wires tend to get short- or open-circuited or Repair or retighten. loosely connected at terminals. • Grounded or open-circuited generator coil. Replace.
Page 419: Battery
SERVICING INFORMATION 9-15 BATTERY “SULFATION”, ACIDIC WHITE POWDERY SUBSTANCE OR SPOTS ON SURFACE OF CELL PLATES Symptom, possible causes and remedy • Cracked battery case. Replace the battery. • Battery has been left in a run-down condition for a Replace the battery. long time.
Page 420: Wire Harness, Cable And Hose Routing
9-16 SERVICING INFORMATION WIRE HARNESS, CABLE AND HOSE ROUTING WIRE HARNESS ROUTING Clamp Wiring harness Clamp Generator Starter motor Wiring harness Wiring harness Side-stand switch Gear position switch Clamp 1 IAT sensor lead wire Insert the protruded section each on the handle- 2 HO2 sensor lead wire bar switch lead wire coupler, ignition switch lead wire coupler and cooling fan motor lead wire cou-...
Page 421 SERVICING INFORMATION 9-17 Wiring harness No.2 Triangle mark of each spark plug cap must be brought to the exhaust side. 2 Magneto lead wire *4 Cut the clamp end. 3 Ignition coil No.2 *5 Do not slack the lead wire. *1 Clamp the turn signal light read wire.
Page 422: Heated Oxygen Sensor (Ho2S) Wire Routing (For E-02, 19)
9-18 SERVICING INFORMATION HEATED OXYGEN SENSOR (HO2S) WIRE ROUTING (FOR E-02, 19) HO2 sensor (For E-02, 19) Route the HO2 sensor lead wire along the fuel tank drain hose. HO2 sensor lead wire Pass through the HO2 sensor lead wire forward the swingarm.
Page 423: Engine Electrical Parts Set-Up
SERVICING INFORMATION 9-19 ENGINE ELECTRICAL PARTS SET-UP 90 ˚ Starter motor lead wire 90 ˚ Battery ground lead wire Bolt Generator lead wire Gear position switch lead wire Clamp Generator cover Starter motor lead wire mounting 45 ° and less ITEM N·m kgf-m lb-ft CKP sensor set bolt...
Page 424: Speed Sensor Lead Wire Routing
9-20 SERVICING INFORMATION SPEED SENSOR LEAD WIRE ROUTING 20 mm (0.79 in) 20 mm (0.79 in) 1 Speed sensor lead wire *1 Cut the clamp end. Clamp Route speed sensor lead wire to come outside the brake hose guide. Brake hose Route speed sensor lead wire on inside of front fork outer tube boss.
Page 425: Throttle Cable Routing
SERVICING INFORMATION 9-21 THROTTLE CABLE ROUTING 0 mm (0 in) 0 mm (0 in) 1 Throttle cable No.1 4 Wiring harness 2 Throttle cable No.2 *1 Fit the cable boots securely. 3 Front brake hose...
Page 426: Clutch Cable Routing
9-22 SERVICING INFORMATION CLUTCH CABLE ROUTING B – B C – C D – D E – E 1 Throttle cable (Pull) 7 Reserve tank bracket Throttle cable (Return) Route left handle switch wiring harness in the groove of radiator shroud. Handle switch wiring harness Route left handle switch wiring harness to come outside throttle and clutch cables.
Page 427: Throttle Body Installation/Hose Routing
SERVICING INFORMATION 9-23 THROTTLE BODY INSTALLATION/HOSE ROUTING 15 ˚ ~ 25 ˚ 40 ˚ ~ 50 ˚ 15 ˚ ~ 25 ˚ 2 ~ 5 mm (0.08 ~ 0.20 in) VIEW A 1 IAT sensor 9 Intake pipe clamp 2 Vacuum damper *1 To canister (For E-33) Throttle body assembly Pass through the vacuum hose inside the PAIR...
Page 428: Cooling System Hose Routing
9-24 SERVICING INFORMATION COOLING SYSTEM HOSE ROUTING 1 Clamp *3 Matching mark (Yellow) Wiring harness Clamp the water drain hose and oil pressure switch lead wire. Oil pressure switch Fill the bearing with engine oil until engine oil comes out from the hole of the be bearing hous- ing.
Page 429 SERVICING INFORMATION 9-25 0 ~ 90 ˚ 90 ˚ 90 ˚ 90 ˚ Marking position Installation point 1 Clamp *2 Matching mark (White) 2 Jiggle valve *3 Marking (Yellow) 3 Union *4 Clamp bolt head must face downward. 4 Radiator hose *5 Clamp bolt head must face left side.
Page 430: Front Brake Hose Routing
9-26 SERVICING INFORMATION FRONT BRAKE HOSE ROUTING Stopper 21 ˚ Brake hose Brake hose guide 42 ˚ Stopper Brake hose clamp Throttle cables Stopper 21 ˚ Stopper 21 ˚ Stopper After the brake hose union has contacted the Assemble the brake hose firmly. stopper, tighten the union bolt.
Page 431: Rear Brake Hose Routing
SERVICING INFORMATION 9-27 REAR BRAKE HOSE ROUTING 35 ˚ U P P E R LOWER 35 ˚ 42 ˚ A – A 1 Frame *1 Clamp ends should face forward. 2 Stopper *2 White paint faces outside. Brake hose After the brake hose union has contacted the stopper, tighten the union bolt.
Page 432: Fuel Tank Drain Hose Routing
9-28 SERVICING INFORMATION FUEL TANK DRAIN HOSE ROUTING Route fuel tank drain hose so that its curve faces Make sure to position the clamp in the specified forward. direction. Route fuel tank drain hose to come inside (left side) gear position sensor wiring harness.
Page 433: Fuel Tank Installation
SERVICING INFORMATION 9-29 FUEL TANK INSTALLATION 27 mm (1.06 in) 1 ~ 2 mm (0.04 ~ 0.08 in) Fuel tank center shield Align the front end of fuel tank center shield with this position. 2 Fuel tank side cushion...
Page 434: Pair (Air Supply) System Hose Routing
9-30 SERVICING INFORMATION PAIR (AIR SUPPLY) SYSTEM HOSE ROUTING Matching mark (White) Pass the PAIR hose between the cylinder head cover and intake pipe. 2 Matching mark (Yellow)
Page 435: Seat Lock Cable Routing
SERVICING INFORMATION 9-31 SEAT LOCK CABLE ROUTING VIEW OF TOP VIEW OF LEFT 1 Seat lock cable HEAD LAMP SET-UP Adhere cushion along the ridge line of lens. Right and left cushions shall be attached sym- metrically. *2 Start to adhere cushion from the corner of lens.
Page 436: Absorber Hose Routing
9-32 SERVICING INFORMATION ABSORBER HOSE ROUTING Absorber hose Rear fender (Front) Clamp BATTERY CUSHION INSTALLATION FRONT VIEW OF LEFT 12 Battery protector Adhere battery protector at the upper end.
Page 437: Side-Stand Set-Up
SERVICING INFORMATION 9-33 SIDE-STAND SET-UP ITEM N·m kgf-m lb-ft 29.0 36.0 10.0 72.5 BRAKE PEDAL/FOOTREST SET-UP A – A 1 Pin 3 Footrest 2 E-ring 4 Brake light switch...
Page 438: Engine Cap Installation
9-34 SERVICING INFORMATION ENGINE CAP INSTALLATION VIEW OF LEFT VIEW OF RIGHT Engine cap Push the center of cap so as to thoroughly remove looseness.
Page 439: Footrest Set-Up
SERVICING INFORMATION 9-35 FOOTREST SET-UP HANDLEBAR BALANCER INSTALLATION ITEM N·m kgf-m lb-ft 0.55 NOTE: After installing the RH balancer weight, check that throttle grip rotate smoothly by turning it.
Page 440: Special Tools
9-36 SERVICING INFORMATION SPECIAL TOOLS 09900-20101 09900-20202 09900-20204 09900-20205 09900-18710 09900-20102 Micrometer Micrometer Micrometer Hexagon bit 12 mm Vernier calipers (25 – 50 mm) (75 – 100 mm) (0 – 25 mm) 09900-20602 09900-20607 09900-20803 09900-20508 Dial gauge Dial gauge 09900-20701 09900-20806 Cylinder gauge set...
Page 441 SERVICING INFORMATION 9-37 09913-60221 09915-64512 09915-74511 Journal bearing 09913-70210 09915-40610 Compression Oil pressure gauge remover/installer Bearing installer set Oil filter wrench gauge 09915-74521 09915-74532 09915-77331 Oil pressure gauge Oil pressure gauge Meter 09916-10911 09916-14510 hose attachment (for high pressure) Valve lapper set Valve lifter 09916-14521 09916-20640...
Page 442 9-38 SERVICING INFORMATION 09917-47011 09920-13120 09920-53740 09924-84510 Vacuum pump Crankcase Clutch sleeve hub 09921-20240 Bearing installer gauge separating tool holder Bearing remover set 09925-18011 09930-10121 Steering bearing Spark plug socket 09930-11920 09930-11940 09930-11950 installer wrench set Torx bit JT40H Bit holder Torx wrench 09940-14911 09930-11960...
Page 443 SERVICING INFORMATION 9-39 09940-40211 09940-40220 09940-52861 09941-34513 Fuel pressure Fuel pressure gauge Front fork oil seal 09940-92720 Bearing/steering gauge adaptor hose attachment installer Spring scale race installer set 09941-54911 09943-74111 Bearing outer race Front fork oil level 09944-28320 remover gauge Hexagon bit 19 mm NOTE: When order the special tool, please confirm whether it is available or not.
Page 444: Tightening Torque
9-40 SERVICING INFORMATION TIGHTENING TORQUE ENGINE ITEM N·m kgf-m lb-ft Cylinder head cover bolt 10.0 Spark plug Camshaft journal holder bolt Cam chain tension adjuster cap bolt Cam chain tension adjuster mounting bolt Cylinder head bolt [M: 10] Initial 18.0 Final 30.5 Water drain bolt...
Page 445: Fi System Parts
SERVICING INFORMATION 9-41 ITEM N·m kgf-m lb-ft Exhaust pipe bolt/nut 16.5 Muffler mounting bolt/nut 16.5 Oil pipe stopper screw Engine sprocket nut 14.5 Engine mounting bolt/nut 40.0 Engine mounting nut [Center] 67.5 Engine mounting thrust adjuster Engine mounting thrust adjuster lock-nut 32.5 Engine mounting bracket bolt 25.5...
Page 446: Chassis
9-42 SERVICING INFORMATION CHASSIS N·m kgf-m lb-ft ITEM Steering stem head nut 65.0 Steering stem lock-nut 58.0 Front fork upper clamp bolt 16.5 Front fork lower clamp bolt 16.5 Front fork cap bolt 16.5 Front fork cylinder bolt 14.5 Front axle 47.0 Front axle pinch bolt 16.5...
Page 447: Tightening Torque Chart
SERVICING INFORMATION 9-43 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 448: Service Data
9-44 SERVICING INFORMATION SERVICE DATA VALVE + GUIDE Unit: mm (in) ITEM STANDARD LIMIT Valve diam. ---- (1.2) 25.5 ---- (1.0) Valve clearance (when cold) 0.10 – 0.20 ---- (0.004 – 0.008) 0.20 – 0.30 ---- (0.008 – 0.012) Valve guide to valve stem 0.020 –...
Page 449 SERVICING INFORMATION 9-45 CAMSHAFT + CYLINDER HEAD Unit: mm (in) ITEM STANDARD LIMIT Cam height 35.48 – 35.53 35.18 (1.3968 – 1.3988) (1.3850) 33.48 – 33.53 33.18 (1.3181 – 1.3201) (1.3063) Camshaft journal oil clearance 0.032 – 0.066 0.150 IN. & EX. (0.0013 –...
Page 450 9-46 SERVICING INFORMATION CYLINDER + PISTON + PISTON RING Unit: mm (in) ITEM STANDARD LIMIT Compression pressure 1 300 1 700 kPa 1 100 kPa – 17 kgf/cm 11 kgf/cm – ² ² 242 psi 156 psi – Compression pressure 200 kPa difference ----...
Page 451 SERVICING INFORMATION 9-47 CONROD + CRANKSHAFT Unit: mm (in) ITEM STANDARD LIMIT Conrod small end I.D. 20.010 – 20.018 20.040 (0.7878 – 0.7881) (0.7890) Conrod big end side clearance 0.170 – 0.320 (0.0067 – 0.0126) (0.02) Conrod big end width 20.95 –...
Page 452 9-48 SERVICING INFORMATION TRANSMISSION + DRIVE CHAIN Unit: mm (in) Except ratio ITEM STANDARD LIMIT Primary reduction ratio 2.088 (71/34) ---- Final reduction ratio 3.133 (47/15) ---- Gear ratios 2.461 (32/13) ---- 1.777 (32/18) ---- 1.380 (29/21) ---- 1.125 (27/24) ---- 0.961 (25/26) ----...
Page 453 SERVICING INFORMATION 9-49 THERMOSTAT + RADIATOR + FAN + COOLANT ITEM STANDARD NOTE Thermostat valve opening Approx. 88 °C (190 °F) ---- temperature Thermostat valve lift Over 8.0 mm (0.31 in) at 100 °C (212 °F) ---- ECT sensor resistance 20 °C Approx.
Page 454 9-50 SERVICING INFORMATION FI SENSORS+ SECONDARY THROTTLE VALVE ACTUATOR ITEM SPECIFICATION NOTE 130 – 240 Ω CKP sensor resistance W – G CKP sensor peak voltage 3.7 V (When cranking) and more IAP sensor input voltage 4.5 – 5.5 V + G/B –...
Page 455 SERVICING INFORMATION 9-51 ELECTRICAL Unit: mm (in) ITEM SPECIFICATION NOTE Firing order Spark plug NGK: CR8E Type DENSO: U24ESR-N 0.7 – 0.8 mm (0.028 – 0.031 in) Spark performance Over 8 mm (0.3 in) at 1 atm. 130 – 240 Ω CKP sensor resistance W –...
Page 456: Speedometer Light
9-52 SERVICING INFORMATION WATTAGE Unit: W SPECIFICATION ITEM E-03, 24, 28, 33 Others ← Headlight 12 V 60/55 W × 2 (H4) Position/Parking light 12 V 5 W × 2 ← Brake light/Taillight 12 V 21/5 W × 2 ← Turn signal light 12 V 21 W ←...
Page 457 SERVICING INFORMATION 9-53 BRAKE + WHEEL Unit: mm (in) ITEM STANDARD LIMIT Rear brake pedal height 15 – 25 (0.59 – 0.98) ---- Brake disc thickness Front (0.20) (0.18) Rear (0.20) (0.18) Brake disc runout ---- (0.012) Master cylinder bore 15.870 –...
Page 458 Front fork spring adjuster 3 groove from Top/Spring adjuster height 9 mm ---- (0.35 in) Front fork oil type SUZUKI FORK OIL SS-08 ---- or equivalent fork oil Front fork oil capacity (each leg) 524 ml ---- (17.7/18.5 US/Imp oz)
Page 459 SERVICING INFORMATION 9-55 FUEL + OIL ITEM STD/SPEC. NOTE Fuel type Use only unleaded gasoline of at least 87 pump R + M octane ( ) 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 corrosion...
Page 461 EMISSION CONTROL INFORMATION 10-1 EMISSION CONTROL INFORMATION CONTENTS EMISSION CONTROL SYSTEMS ..............10- 2 FUEL INJECTION SYSTEM ..............10- 2 CRANKCASE EMISSION CONTROL SYSTEM ........10- 3 EXHAUST EMISSION CONTROL SYSTEM (PAIR SYSTEM) ....10- 4 NOISE EMISSION CONTROL SYSTEM ..........10- 5 EVAPORATIVE EMISSION CONTROL SYSTEM (Only for E-33) ..10- 5 PAIR (AIR SUPPLY) SYSTEM INSPECTION ..........10- 6 HOSES ....................10- 6 PAIR REED VALVE ................10- 6...
Page 462: Emission Control Systems
10-2 EMISSION CONTROL INFORMATION EMISSION CONTROL SYSTEMS FUEL INJECTION SYSTEM DL650 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. 1 Fuel filter (For high pressure) A BEFORE-PRESSURIZED FUEL 2 Fuel pressure regulator...
Page 463: Crankcase Emission Control System
EMISSION CONTROL INFORMATION 10-3 CRANKCASE EMISSION CONTROL SYSTEM The engine is equipped with a PCV system. Blow-by gas in the engine is constantly drawn into the crank- case, which is returned to the combustion chamber through the breather hose, air cleaner and throttle body. 1 PAIR reed valve A FRESH AIR 2 Breather hose...
Page 464: Exhaust Emission Control System (Pair System)
10-4 EMISSION CONTROL INFORMATION EXHAUST EMISSION CONTROL SYSTEM (PAIR SYSTEM) The exhaust emission control system is composed of the PAIR system and THREE-WAY CATALYST sys- tem. (Except for E-03, -24 and-28) The fresh air is drawn into the exhaust port with the PAIR solenoid valve and PAIR reed valve.
Page 465: Noise Emission Control System
EMISSION CONTROL INFORMATION 10-5 NOISE EMISSION CONTROL SYSTEM TAMPERING WITH THE NOISE CONTROL SYSTEM PROHIBITED: Federal law prohibits the following acts or the causing thereof: 1. The removal or rendering inoperative by any person, other than for purposes of maintenance, repair or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use, or 2.
Page 466: Pair (Air Supply) System Inspection
10-6 EMISSION CONTROL INFORMATION (FOR E-33: K7) 1 IAP sensor 7 Fuel shut-off valve 2 Vacuum hose 8 EVAP canister 3 No.2 Throttle body A HC VAPOR 4 No.1 Throttle body B FRESH AIR 5 Purge hose C VACUUM 6 Surge hose PAIR (AIR SUPPLY) SYSTEM INSPECTION HOSES •...
Page 467: Pair Control Solenoid Valve
EMISSION CONTROL INFORMATION 10-7 PAIR CONTROL SOLENOID VALVE • Remove the air cleaner box. (!5-15) • Remove the PAIR control solenoid valve 1. • 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 468: Pair (Air Supply) System Hose Routing
10-8 EMISSION CONTROL INFORMATION PAIR (AIR SUPPLY) SYSTEM HOSE ROUTING !9-30 HEATED OXYGEN SENSOR (HO2S) WIRE ROUTING (E-02, 19) !9-18...
Page 469 EMISSION CONTROL INFORMATION 10-9 HEATED OXYGEN SENSOR (HO2S) INSPECTION (E-02, 19) • Remove the seat. (!7-4) • Disconnect the HO2 sensor coupler. • Remove the HO2 sensor unit. Do not remove the HO2 sensor while it is hot. & Be careful not to expose it to excessive shock. Do not use an impact wrench while removing or installing the HO2 sensor unit.
Page 470: Evaporative Emission Control System Inspection (Only For E-33)
10-10 EMISSION CONTROL INFORMATION EVAPORATIVE EMISSION CONTROL SYSTEM INSPECTION (Only for E-33) • Remove the frame cover. (!7-5) • Lift and support the fuel tank with its prop stay. (!5-7) HOSES Inspect the hoses for wear or damage. Make sure that the hoses are securely connected. EVAP CANISTER Inspect the canister for damage to the body.
Page 471: Evap Canister Hose Routing (Only For E-33)
EMISSION CONTROL INFORMATION 10-11 EVAP CANISTER HOSE ROUTING (Only for E-33) 1 Purge hose *2 Clamp ends should face outside. 2 Wiring harness *3 White paint mark should face top side. EVAP canister Pass through the purge hose between the frame and wiring harness.
Page 473 DL650K5 ('05 MODEL) 11- 1 DL650K5 ('05- MODEL) NOTE: The specifications and service data are the same as K4-MODEL. CONTENTS SPECIFICATIONS..................11- 2 SERVICE DATA..................11- 3 EXHAUST PIPE/MUFFLER INSTALLATON...........11-15 STARTER BUTTON INSPECTION INFORMATION.......11-15...
Page 474 11- 2 DL650K5 ('05 MODEL) SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length ..................2 290 mm (90.2 in) Overall width..................840 mm (33.1 in) Overall height ..................1 390 mm (54.7 in) ... Low windshield position (STD) 1 420 mm (55.9 in) ... Middle windshield position 1 450 mm (57.1 in) ...
Page 475 DL650K5 ('05 MODEL) 11- 3 SERVICE DATA 4 STROKE VALVE + GUIDE Unit: mm (in) ITEM STANDARD LIMIT Valve diam. ---- (1.2) 25.5 ---- (1.0) Valve clearance (when cold) 0.10 – 0.20 ---- (0.004 – 0.008) 0.20 – 0.30 ---- (0.008 –...
Page 476 11- 4 DL650K5 ('05 MODEL) CAMSHAFT + CYLINDER HEAD Unit: mm (in) ITEM STANDARD LIMIT Cam height 35.48 – 35.53 35.18 (1.3968 – 1.3988) (1.3850) 33.48 – 33.53 33.18 (1.3181 – 1.3201) (1.3063) Camshaft journal oil clearance 0.032 – 0.066 0.150...
Page 477 DL650K5 ('05 MODEL) 11- 5 CYLINDER + PISTON + PISTON RING Unit: mm (in) ITEM STANDARD LIMIT Compression pressure 1 100 kPa 1 300 – 1 700 kPa (11 kgf/cm², (13 – 17 kgf/cm², 185 – 242 psi) 156 psi)
Page 478 11- 6 DL650K5 ('05 MODEL) CONROD + CRANKSHAFT Unit: mm (in) ITEM STANDARD LIMIT Conrod small end I.D. 20.010 – 20.018 20.040 (0.7878 – 0.7881) (0.7890) Conrod big end side clearance 0.170 – 0.320 (0.0067 – 0.0126) (0.02) Conrod big end width 20.95 –...
Page 479 DL650K5 ('05 MODEL) 11- 7 TRANSMISSION + DRIVE CHAIN Unit: mm (in) Except ratio ITEM STANDARD LIMIT Primary reduction ratio 2.088 (71/34) ---- Final reduction ratio 3.133 (47/15) ---- Gear ratios 2.461 (32/13) ---- 1.777 (32/18) ---- 1.380 (29/21) ---- 1.125 (27/24)
Page 480 11- 8 DL650K5 ('05 MODEL) THERMOSTAT + RADIATOR + FAN + COOLANT ITEM STANDARD NOTE Thermostat valve opening Approx. 88 °C (190 °F) ---- temperature Thermostat valve lift Over 8.0 mm (0.31 in) at 100 °C (212 °F) ---- ECT sensor resistance 20 °C...
Page 481 DL650K5 ('05 MODEL) 11- 9 FI SENSORS+ SECONDARY THROTTLE VALVE ACTUATOR ITEM SPECIFICATION NOTE 130 – 240 Ω CKP sensor resistance W – G CKP sensor peak voltage 3.7 V (When cranking) and more IAP sensor input voltage 4.5 – 5.5 V + G/B –...
Page 482 11-10 DL650K5 ('05 MODEL) ELECTRICAL Unit: mm (in) ITEM SPECIFICATION NOTE Firing order Spark plug NGK: CR8E Type DENSO: U24ESR-N 0.7 – 0.8 mm (0.028 – 0.031 in) Spark performance Over 8 mm (0.3 in) at 1 atm. 130 – 240 Ω...
Page 483 DL650K5 ('05 MODEL) 11-11 WATTAGE Unit: W SPECIFICATION ITEM E-03, 24, 28, 33 Others ← Headlight 12 V 60/55 W × 2 (H4) Position/Parking light 12 V 5 W × 2 ← Brake light/Taillight 12 V 21/5 W × 2 ←...
Page 484 11-12 DL650K5 ('05 MODEL) BRAKE + WHEEL Unit: mm (in) ITEM STANDARD LIMIT Rear brake pedal height 15 – 25 (0.59 – 0.98) ---- Brake disc thickness Front (0.20) (0.18) Rear (0.20) (0.18) Brake disc runout ---- (0.012) Master cylinder bore 15.870 –...
Page 485 DL650K5 ('05 MODEL) 11-13 TIRE ITEM STD/SPEC. LIMIT Cold inflation tire pressure 225 kPa Front ---- (Solo riding) (2.25 kgf/cm², 33 psi) 250 kPa Rear ---- (2.50 kgf/cm², 36 psi) Cold inflation tire pressure 225 kPa Front ---- (Dual riding) (2.25 kgf/cm², 33 psi)
Page 486 11-14 DL650K5 ('05 MODEL) FUEL + OIL ITEM STD/SPEC. 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...
Page 487 DL650K5 ('05 MODEL) 11-15 EXHAUST PIPE/MUFFLER INSTALLATION Apply PARMATEX 1372 Apply PARMATEX 1372 ITEM N·m kgf-m lb-ft ABCD 16.5 STARTER BUTTON INSPECTION INFORMATION Inspect switch for continuity with a tester. If any abnormality is found, replace the respective switch assembies with new ones.
Page 489 This chapter describes service data , servicing procedures which differ from those of the DL650- K5 ('05 MODEL). NOTE: Any differences between DL650K5 ('05 MODEL) and DL650K6 ('06 MODEL) in Ø specifications and service data are clearly indicated with the asterisk marks (*).
Page 490 12- 2 DL650K6 ('06 MODEL) SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length ..................2 290 mm (90.2 in) Overall width ..................840 mm (33.1 in) Overall height ..................1 390 mm (54.7 in) ... Low windshield position (STD) 1 420 mm (55.9 in) ... Middle windshield position 1 450 mm (57.1 in) ...
Page 491 DL650K6 ('06 MODEL) 12- 3 SERVICE DATA 4 STROKE VALVE + GUIDE Unit: mm (in) ITEM STANDARD LIMIT Valve diam. ---- (1.2) 25.5 ---- (1.0) Valve clearance (when cold) 0.10 – 0.20 ---- (0.004 – 0.008) 0.20 – 0.30 ---- (0.008 –...
Page 492 12- 4 DL650K6 ('06 MODEL) CAMSHAFT + CYLINDER HEAD Unit: mm (in) ITEM STANDARD LIMIT Cam height 35.48 – 35.53 35.18 (1.3968 – 1.3988) (1.3850) 33.48 – 33.53 33.18 (1.3181 – 1.3201) (1.3063) Camshaft journal oil clearance 0.032 – 0.066 0.150 IN.
Page 493 DL650K6 ('06 MODEL) 12- 5 CYLINDER + PISTON + PISTON RING Unit: mm (in) ITEM STANDARD LIMIT Compression pressure 1 100 kPa 1 300 – 1 700 kPa (11 kgf/cm², (13 – 17 kgf/cm², 185 – 242 psi) 156 psi) Compression pressure 200 kPa difference...
Page 494: Clutch
12- 6 DL650K6 ('06 MODEL) CONROD + CRANKSHAFT Unit: mm (in) ITEM STANDARD LIMIT Conrod small end I.D. 20.010 – 20.018 20.040 (0.7878 – 0.7881) (0.7890) Conrod big end side clearance 0.170 – 0.320 (0.0067 – 0.0126) (0.02) Conrod big end width 20.95 –...
Page 495: 3Rd
DL650K6 ('06 MODEL) 12- 7 TRANSMISSION + DRIVE CHAIN Unit: mm (in) Except ratio ITEM STANDARD LIMIT Primary reduction ratio 2.088 (71/34) ---- Final reduction ratio 3.133 (47/15) ---- Gear ratios 2.461 (32/13) ---- 1.777 (32/18) ---- 1.380 (29/21) ---- 1.125 (27/24) ---- 0.961 (25/26)
Page 496 12- 8 DL650K6 ('06 MODEL) THERMOSTAT + RADIATOR + FAN + COOLANT ITEM STANDARD NOTE Thermostat valve opening Approx. 88 °C (190 °F) ---- temperature Thermostat valve lift Over 8.0 mm (0.31 in) at 100 °C (212 °F) ---- ECT sensor resistance 20 °C Approx.
Page 497 DL650K6 ('06 MODEL) 12- 9 FI SENSORS+ SECONDARY THROTTLE VALVE ACTUATOR ITEM SPECIFICATION NOTE 130 – 240 Ω CKP sensor resistance W – G CKP sensor peak voltage 3.7 V (When cranking) and more IAP sensor input voltage 4.5 – 5.5 V + G/B –...
Page 498: Electrical
12-10 DL650K6 ('06 MODEL) ELECTRICAL Unit: mm (in) ITEM SPECIFICATION NOTE Firing order Spark plug NGK: CR8E Type DENSO: U24ESR-N 0.7 – 0.8 mm (0.028 – 0.031 in) Spark performance Over 8 mm (0.3 in) at 1 atm. 130 – 240 Ω CKP sensor resistance W –...
Page 499: Position/Parking Light
DL650K6 ('06 MODEL) 11-11 WATTAGE Unit: W SPECIFICATION ITEM E-03, 24, 28, 33 Others ← Headlight 12 V 60/55 W × 2 (H4) Position/Parking light 12 V 5 W × 2 ← Brake light/Taillight 12 V 21/5 W × 2 ←...
Page 500 12-12 DL650K6 ('06 MODEL) BRAKE + WHEEL Unit: mm (in) ITEM STANDARD LIMIT Rear brake pedal height 15 – 25 (0.59 – 0.98) ---- Brake disc thickness Front (0.20) (0.18) Rear (0.20) (0.18) Brake disc runout ---- (0.012) Master cylinder bore 15.870 –...
Page 501 Front fork spring adjuster 3 groove from Top/Spring adjuster height 9 mm ---- (0.35 in) Front fork oil type SUZUKI FORK OIL SS-08 ---- or equivalent fork oil Front fork oil capacity (each leg) 524 ml ---- (17.7/18.5 US/Imp oz)
Page 502 12-14 DL650K6 ('06 MODEL) FUEL + OIL ITEM STD/SPEC. 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 corrosion...
Page 503 DL650K6 ('06 MODEL) 12-15 EMISSION CONTROL SYSTEM EXHAUST EMISSION CONTROL SYSTEM (PAIR SYSTEM) The exhaust emission control system is composed of the PAIR system and THREE-WAY CATALYST sys- tem. The fresh air is drawn into the exhaust port with the PAIR solenoid valve and PAIR reed valve. The PAIR solenoid valve is operated by the ECM, and the fresh air flow is controlled according to the TPS, ECTS, IATS and IAPS.
Page 505 • Please refer to chapters 1 through 12 for details which are not given in this chapter. CONTENTS ABBREVIATIONS USED IN THIS MANUAL .............13- 3 SAE-TO-FORMER SUZUKI TERM ..............13- 5 SPECIFICATIONS (DL650K7) ................13- 7 SPECIFICATIONS (DL650AK7).................13- 9 PERIODIC MAINTENANCE SCHEDULE ............13-11 PERIODIC MAINTENANCE CHART ............13-11...
Page 506 13- 2 DL650K7/AK7 (’07-MODEL) DL650K7/AK7 (’07-MODEL) CONTENTS ABS UNIT SYSTEM DIAGRAM ............... 13-78 ABS TROUBLESHOOTING ................13-79 TROUBLESHOOTING PROCEDURE............13-80 DTC (Diagnostic Trouble Code) OUTPUT ..........13-89 DTC DELETING AND ABS OPERATION CHECK ........13-91 USE OF SDS DIAGNOSTIC PROCEDURES........... 13-94 USE OF SDS DIAGNOSIS RESET PROCEDURE ........
Page 507 DL650K7/AK7 (’07-MODEL) 13- 3 ABBREVIATIONS USED IN THIS MANUAL : Fuel Injection, Fuel Injector ABDC : After Bottom Dead Center : Fuel Pump : Anti-lock brake system : Fuel Pressure Regulator : Alternating Current FP Relay : Fuel Pump Relay : Air Cleaner, Air Cleaner Box : American Petroleum Institute ATDC...
Page 508 : Pulsed Secondary Air Injection : 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 509 13- 5 SAE-TO-FORMER SUZUKI TERM This table lists SAE (Society of Automotive Engineers) J1930 terms and abbreviations which may be used in this manual in compliance with SAE recommendations, as well as their former SUZUKI names. SAE TERM FORMER SUZUKI TERM...
Page 510 13- 6 DL650K7/AK7 (’07-MODEL) SAE TERM FORMER SUZUKI TERM FULL TERM ABBREVIATION Idle Speed Control –––– Idle Speed Control Valve –––– ISC Valve Ignition Control Electronic Spark Advance (ESA) Ignition Control Module –––– Intake Air Temperature Intake Air Temperature (IAT), Air Tempera-...
Page 511 DL650K7/AK7 (’07-MODEL) 13- 7 SPECIFICATIONS (DL650K7) DIMENSIONS AND DRY MASS Overall length ............2 290 mm (90.2 in) Overall width ............840 mm (33.1 in) Overall height ............1 390 mm (54.7 in) ..Low windshield position (STD) 1 420 mm (55.9 in) ..Middle windshield position 1 450 mm (57.1 in) ..
Page 512: Oil Pressure/Coolant Temperature/Fuel Injection Indicator Light
13- 8 DL650K7/AK7 (’07-MODEL) CHASSIS Front suspension ..........Telescopic, coil spring, oil damped Rear suspension ..........Link type, coil spring, oil damped Front fork stroke........... 150 mm (5.9 in) Rear wheel travel ..........150 mm (5.9 in) Caster ..............26° Trail ..............
Page 513 DL650K7/AK7 (’07-MODEL) 13- 9 SPECIFICATIONS (DL650AK7) DIMENSIONS AND DRY MASS Overall length ............2 290 mm (90.2 in) Overall width ............840 mm (33.1 in) Overall height ............1 390 mm (54.7 in) ..Low windshield position (STD) 1 420 mm (55.9 in) ..Middle windshield position 1 450 mm (57.1 in) ..
Page 514 13-10 DL650K7/AK7 (’07-MODEL) CHASSIS Front suspension ..........Telescopic, coil spring, oil damped Rear suspension ..........Link type, coil spring, oil damped Front fork stroke........... 150 mm (5.9 in) Rear wheel travel ..........150 mm (5.9 in) Caster ..............26° Trail ..............110 mm (4.33 in) Steering angle............
Page 515: Periodic Maintenance Schedule
DL650K7/AK7 (’07-MODEL) 13- 11 PERIODIC MAINTENANCE SCHEDULE The chart below lists the recommended intervals for all the required periodic service work necessary to keep the motorcycle operating at peak performance and economy. Mileages are expressed in terms of kilome- ters, miles and time for your convenience. IMPORTANT: The periodic maintenance intervals and service requirements have been established in accordance with EPA regulations.
Page 516: Maintenance And Tune-Up Procedures
13-12 DL650K7/AK7 (’07-MODEL) MAINTENANCE AND TUNE-UP PROCEDURES This section describes the servicing procedures for each Peri- odic Maintenance item which differ from those of the DL650K6 (’06-MODEL). For details other than the following items, refer to the DL650 Service Manual. SPARK PLUG Inspect every 6 000 km (4 000 miles, 12 months) and replace every 12 000 km (7 500 miles, 24 months).
Page 517 DL650K7/AK7 (’07-MODEL) 13-13 NO.2 (REAR) SPARK PLUG REMOVAL • Lift and support the fuel tank. (!DL650K4 5-7) • Remove the spark plug caps. • Remove the spark plugs with the special tool. # 09930-10121: Spark plug socket wrench set HEAT RANGE •...
Page 518: Throttle Cable Play
13-14 DL650K7/AK7 (’07-MODEL) SPARK PLUG AND PLUG CAP INSTALLATION Before using a spark plug wrench, carefully turn the spark plug by finger into the threads of the cylinder head to prevent damage the aluminum threads. • Install the spark plugs to the cylinder heads by finger tight, and then tighten them to the specified torque.
Page 519: Fi System Diagnosis
DL650K7/AK7 (’07-MODEL) 13-15 FI SYSTEM DIAGNOSIS ECM TERMINAL TERMINAL TERMINAL CIRCUIT CIRCUIT GP switch signal (GP) — IAT sensor signal (IAT) ECT sensor signal (ECT) IAP sensor signal #1 (IAP. F) TO sensor signal (TOS) STP sensor signal (STP) TP sensor signal (TP) Power source for sensors (VCC) IAP sensor signal #2 (IAP.
Page 520: Fail-Safe Function
13-16 DL650K7/AK7 (’07-MODEL) 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 Intake air pressure sensor Intake air pressure is fixed to “YES”...
Page 521: Dtc Table And Defective Condition
DL650K7/AK7 (’07-MODEL) 13-17 DTC TABLE AND DEFECTIVE CONDITION DETECTED DTC No. DETECTED FAILURE CONDITION CHECK FOR ITEM NO FAULT ––––––––––– ––––––––––– CKP sensor The signal does not reach ECM for 2 CKP sensor wiring and mechan- sec. or more, after receiving the starter ical parts C12 (P0335) signal.
Page 522 13-18 DL650K7/AK7 (’07-MODEL) DETECTED DTC No. DETECTED FAILURE CONDITION CHECK FOR ITEM TO sensor The sensor voltage should be the fol- TO sensor, lead wire/coupler lowing for 2 sec. and more, after igni- connection tion switch is turned ON. C23 (P1651) 0.2 V <...
Page 523 DL650K7/AK7 (’07-MODEL) 13-19 DETECTED DTC No. DETECTED FAILURE CONDITION CHECK FOR ITEM Fuel injector CKP sensor (pickup coil) signal is pro- Fuel injector, wiring/coupler con- duced, but fuel injector signal is inter- nection, power supply to the C32 (P0201)/ rupted several times (Front 50 times, injector C33 (P0202) Rear 25 times) or more continuously.
Page 524: Dtc Troubleshooting
13-20 DL650K7/AK7 (’07-MODEL) DTC TROUBLESHOOTING “C12” (P0335) CKP SENSOR CIRCUIT MALFUNCTION On model K7, the connector terminals to be used for checking sensors for voltage, resistance or continuity at the ECM terminal ECM coupler (Harness side) are located as shown in the illustration. * Refer to the DL650 service manual 4-23 for details.
Page 525 DL650K7/AK7 (’07-MODEL) 13-21 3) Check the IAP sensor coupler (Front cylinder side 1 or Rear cylinder side 2) for loose or poor contacts. If OK, then measure the IAP sensor input voltage. 4) Disconnect the IAP sensor coupler. 5) Turn the ignition switch ON. 6) Measure the voltage at the Red wire 3 and ground.
Page 526 13-22 DL650K7/AK7 (’07-MODEL) Step 3 1) Turn the ignition switch OFF. 2) Remove the IAP sensor. 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 527 DL650K7/AK7 (’07-MODEL) 13-23 “C14” (P0120-H/L) TP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE Output voltage is not within the following • TP sensor maladjusted (P0120) range. • TP sensor circuit open or short Difference between actual throttle open- • TP sensor malfunction ing and opening calculated by ECM is •...
Page 528 13-24 DL650K7/AK7 (’07-MODEL) 6) Measure the voltage at the Red wire B and ground. 7) Also, measure the voltage at the Red wire B and B/Br wire C. $ TP sensor input voltage: 4.5 – 5.5 V (+ Red – - Ground) (+ Red –...
Page 529 DL650K7/AK7 (’07-MODEL) 13-25 “C15” (P0115-H/L) ECT SENSOR CIRCUIT MALFUNCTION On model K7, the connector terminals to be used for checking sensors for voltage, resistance or continuity at the ECM terminal ECM coupler (Harness side) are located as shown in the illustration. * Refer to the DL650 service manual 4-31 for details.
Page 530 13-26 DL650K7/AK7 (’07-MODEL) 5) Measure the voltage between Dg wire terminal and ground. 6) Also, measure the voltage between Dg wire terminal and B/Br wire terminal. $ IAT sensor input voltage: 4.5 – 5.5 V (+ Dg – - Ground) (+ Dg –...
Page 531 DL650K7/AK7 (’07-MODEL) 13-27 “C23” (P1651-H/L) TO SENSOR CIRCUIT MALFUNCTION On model K7, the connector terminals to be used for checking sensors for voltage, resistance or continuity at the ECM terminal ECM coupler (Harness side) are located as shown in the illustration. * Refer to the DL650 service manual 4-35 for details.
Page 532 13-28 DL650K7/AK7 (’07-MODEL) “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 533 DL650K7/AK7 (’07-MODEL) 13-29 Step 2 1) Turn the ignition switch OFF. 2) Disconnect the STVA coupler. 3) Remove the throttle body. (!Page 52) 4) Check the continuity between each terminal and ground. $ STVA continuity: ∞ Ω (Infinity) (Terminal – Ground) 5) If OK, then measure the STVA resistance (between terminal A and terminal B) and (between terminal C and terminal D).
Page 534 13-30 DL650K7/AK7 (’07-MODEL) 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 535 DL650K7/AK7 (’07-MODEL) 13-31 “C29” (P1654-H/L) STP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE Signal voltage is not within the following • STP sensor maladjusted. (P1654) range. • STP sensor circuit open or short. Difference between actual throttle open- • STP sensor malfunction. ing and opening calculated by ECM is •...
Page 536 13-32 DL650K7/AK7 (’07-MODEL) Step 2 1) Turn the ignition switch OFF. 2) Remove the air cleaner box. (!Page 51) 3) Connect the STP sensor coupler. 4) Insert the needle pointed probes to the STP sensor coupler. 5) Disconnect the STVA lead wire coupler. 6) Turn the ignition switch ON.
Page 537 DL650K7/AK7 (’07-MODEL) 13-33 “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 several times (Front 50 • Injector malfunction. times, Rear 25 times) or more.
Page 538 13-34 DL650K7/AK7 (’07-MODEL) 5) 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 539 DL650K7/AK7 (’07-MODEL) 13-35 “C40” (P0505 or P0506 and P0507) ISC VALVE CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE The circuit voltage of motor drive is • ISC valve circuit open or shorted to ground unusual. (P0505) • Power source circuit open Idle speed is higher than the normal •...
Page 540 13-36 DL650K7/AK7 (’07-MODEL) 4) Disconnect the ISC valve coupler and ECM coupler. 5) Check the continuity between terminals A and i, terminals B and 0, terminals C and g, terminals D and \, terminals E and 0, and terminals F and ^. When using the multi-circuit tester, do not strongly touch the terminal of the ECM coupler with a needle pointed tester probe to prevent the terminal damage...
Page 541 DL650K7/AK7 (’07-MODEL) 13-37 ACTIVE CONTROL INSPECTION (ISC RPM CONTROL) Check 1 1) Set up the SDS tool. (Refer to the SDS operation manual for further details.) 2) Check that the engine is running. 3) Click the “Active control”. 4) Click the “ISC rpm control” 1. 5) Check that the “Spec”...
Page 542 13-38 DL650K7/AK7 (’07-MODEL) Check 3 1) Click the button 1 and increase the “Spec” 2 to 1 400 rpm slowly. 2) Check that the “Desired idle speed” 3 is nearly equal to the “Spec” 2. Also, check that the number of steps 4 in the ISC valve position increases Check 4 1) Increase the “Spec”...
Page 543 DL650K7/AK7 (’07-MODEL) 13-39 “C41” (P0230) FP RELAY CIRCUIT MALFUNCTION On model K7, the connector terminals to be used for checking sensors for voltage, resistance or continuity at the ECM terminal ECM coupler (Harness side) are located as shown in the illustration. * Refer to the DL650 service manual 4-44 for details.
Page 544: For E
13-40 DL650K7/AK7 (’07-MODEL) “C44” (P0130/P0135) HO2 SENSOR (HO2S) CIRCUIT MALFUNCTION (FOR E-02, 19, 24, 41) 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 545 DL650K7/AK7 (’07-MODEL) 13-41 7) Disconnect the ECM coupler. 8) Check the continuity between W/G wire A and terminal 6. 9) Also, check the continuity between B/Br wire B and terminal B. When using the multi-circuit tester, do not strongly touch the terminal of the ECM coupler with a needle pointed tester probe to prevent the terminal damage or terminal bend.
Page 546 13-42 DL650K7/AK7 (’07-MODEL) Is the voltage OK? ECM coupler (Harness side) • W/G wire or B/Br wire open or shorted to ground, or poor 6 or B connection. • If wire and connection are OK, intermittent trou- ble or faulty ECM. •...
Page 547 DL650K7/AK7 (’07-MODEL) 13-43 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 and ground. 4) If the tester voltage indicates the battery voltage, it is good condition.
Page 548: Fuel Pump
13-44 DL650K7/AK7 (’07-MODEL) FUEL PUMP FUEL DISCHARGE AMOUNT INSPECTION " Gasoline is highly flammable and explosive. Keep heat, spark and flame away. • Lift and support the fuel tank. (!DL650K4 5-7) • Disconnect the fuel feed hose 1 from the fuel tank. •...
Page 549 DL650K7/AK7 (’07-MODEL) 13-45 FUEL PUMP CONSTRUCTION 1 Fuel level gauge 5 Fuel pump & 2 O-ring 6 Fuel mesh filter 3 Fuel pressure regulator 7 O-ring ITEM N·m kgf-m lb-ft 4 O-ring A Fuel pump mounting bolt...
Page 550: Fuel Pump Removal And Disassembly
13-46 DL650K7/AK7 (’07-MODEL) FUEL PUMP REMOVAL AND DISASSEMBLY REMOVAL • Remove the fuel tank. (!DL650K4 5-7) • Remove the fuel pump assembly by removing its mounting bolts diagonally. " Gasoline is highly flammable and explosive. Keep heat, spark and flame away. DISASSEMBLY •...
Page 551 DL650K7/AK7 (’07-MODEL) 13-47 • Remove the fuel pressure regulator 3. • Remove the O-ring 4 and fuel pump holder 5. • Remove the fuel mesh filter 6. • Remove the fuel pump 7. • Remove the fuel joint pipe 8.
Page 552 13-48 DL650K7/AK7 (’07-MODEL) FUEL MESH FILTER INSPECTION AND CLEANING If the fuel mesh filter is clogged with sediment or rust, fuel will not flow smoothly and loss in engine power may result. Blow the fuel mesh filter with compressed air. NOTE: If the fuel mesh filter is clogged with many sediment or rust, replace the fuel filter cartridge with a new one.
Page 553 DL650K7/AK7 (’07-MODEL) 13-49 • Install a new O-ring and apply SUZUKI SUPER GREASE to it. " The O-ring must be replaced with a new one to prevent fuel leakage. , 99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease) • When installing the fuel pump assembly, first tighten all the...
Page 554: Throttle Body
13-50 DL650K7/AK7 (’07-MODEL) THROTTLE BODY CONSTRUCTION Only for E-33 1 STP sensor 8 Secondary throttle link rod 2 TP sensor 9 Throttle link rod & 3 O-ring 0 STVA 4 Fuel delivery pipe/hose A STP sensor mounting screw ITEM N·m kgf-m lb-ft 5 Fuel injector...
Page 555 DL650K7/AK7 (’07-MODEL) 13-51 AIR CLEANER AND THROTTLE BODY REMOVAL AIR CLEANER BOX • Remove the fuel tank. (!DL650K4.5-7) • Remove the IAP sensor vacuum hoses (1, 2). • Disconnect the IAP sensor (R) coupler 3. • Remove the clamp and disconnect the IAP sensor (F) coupler •...
Page 556 13-52 DL650K7/AK7 (’07-MODEL) THROTTLE BODY • Disconnect the various lead wire couplers. 1 TP sensor 2 STP sensor 3 STVA • Remove the injector lead wire couplers. • Disconnect the ISC valve hoses. • Loosen the throttle body clamp screws.
Page 557 DL650K7/AK7 (’07-MODEL) 13-53 • Disconnect the throttle cables from their drum. • Dismount the throttle body assembly. * Be careful not to damage the throttle cable bracket and fast idle lever when dismounting or remounting the throttle body assembly. * After disconnecting the throttle cables, do not snap the throttle valve from full open to full close.
Page 558 13-54 DL650K7/AK7 (’07-MODEL) • Remove the fuel injectors. • Remove the TP sensor 7 and STP sensor 8 with the special tool. # 09930-11950: Torx wrench NOTE: Prior to disassembly, mark each sensor’s original position with a paint or scribe for accurate reinstallation. Never remove the STVA 9 and throttle body link plates 0.
Page 559 DL650K7/AK7 (’07-MODEL) 13-55 Never remove the throttle valve D and secondary throttle valve E. THROTTLE BODY CLEANING " Some carburetor cleaning chemicals, especially dip- type soaking solutions, are very corrosive and must be handled carefully. Always follow the chemical man- ufacturer’s instructions for proper use, handling and storage.
Page 560 * Apply thin coat of the engine oil to the 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. , 99000-25010: SUZUKI SUPER GREASE “A”...
Page 561 DL650K7/AK7 (’07-MODEL) 13-57 • Apply thin coat of the engine oil to the new cushion seal 3, and the O-ring 4. Replace the cushion seal and O-ring with the new ones. • Install the fuel injector 5 by pushing it straight to the delivery pipe 6.
Page 562: Air Cleaner Box And Throttle Body Installation
13-58 DL650K7/AK7 (’07-MODEL) AIR CLEANER BOX AND THROTTLE BODY INSTALLATION Installation is in the reverse order of removal. Pay attention to the following points: • Connect the throttle pulling cable 1 and throttle returning cable 2 to the throttle cable drum. •...
Page 563 DL650K7/AK7 (’07-MODEL) 13-59 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. (!Page 51) • Disconnect the STVA coupler. (!Page 28) •...
Page 564 13-60 DL650K7/AK7 (’07-MODEL) TP SENSOR ADJUSTMENT After all adjustments are completed, check or adjust the TPS setting condition. 1. Warm up the engine and check the engine idle r/min. 2. Remove the seat. (!DL650K4 7-4) 3. Connect the special tool (Mode select switch) to the dealer mode coupler at the wiring harness.
Page 565: Throttle Valve Synchronization
DL650K7/AK7 (’07-MODEL) 13-61 THROTTLE VALVE SYNCHRONIZATION USE OF SDS TOOL Check and adjust the throttle valve synchronization between two cylinders. Step 1 • Lift and support the fuel tank. (!DL650K4 5-7) • Remove the rubber caps 1 from each vacuum nipple on the throttle body.
Page 566 13-62 DL650K7/AK7 (’07-MODEL) • Click “Active control”. • Click “ISC air volume control” 3. • Click “ON” bottom 4 to fix the ISC air volume between two cylinders. NOTE: When making this synchronization, be sure that the water tem- perature is within 80 – 100 °C (176 – 212 °F). A Engine speed: Approx.
Page 567: Isc Valve
DL650K7/AK7 (’07-MODEL) 13-63 ISC VALVE REMOVAL • Remove the air cleaner box. (!Page 51) • Disconnect the ISC valve coupler 1. Be careful not to disconnect the ISC valve coupler at least 5 seconds after ignition switch is turned to OFF. If the ECM coupler or ISC valve coupler is discon- nected within 5 seconds after ignition switch is turned to OFF, there is a possibility of an usual valve posit-...
Page 568: Isc Valve Pre-Set
13-64 DL650K7/AK7 (’07-MODEL) ISC VALVE PRE-SET DL650 When removing or replacing the ISC valve, set the ISC valve using the following procedure: PROCEDURE 1) Turn the ignition switch to the OFF position. 2) Remove the seat. ( 7-4) 3) Connect the special tool to the dealer mode coupler and turn its switch to ON position.
Page 569: Ignition System
DL650K7/AK7 (’07-MODEL) 13-65 IGNITION SYSTEM INSPECTION IGNITION COIL PRIMARY PEAK VOLTAGE • Disconnect all the spark plug caps. (!Page 12) • Connect new spark plugs to each spark plug cap and ground them on the cylinder. NOTE: Be sure that all the spark plugs are connected properly and the battery used is in fully-charged condition.
Page 570 13-66 DL650K7/AK7 (’07-MODEL) • Shift the transmission into neutral, turn the ignition switch to the “ON” position and grasp the clutch lever. • Press the starter button and allow the engine to crank for a few seconds, and then measure the ignition coil primary peak voltage.
Page 571: Combination Meter
DL650K7/AK7 (’07-MODEL) 13-67 COMBINATION METER FUEL LEVEL GAUGE INSPECTION !DL650K4 8-33 FUEL LEVEL METER INSPECTION • Remove the fuel tank left side cover. (!DL650K4 7-4) • Disconnect the fuel pump lead wire coupler. • Connect the each resistor between the Yellow/Black and Black/White lead wires at the wire harness.
Page 572: Introduction Of Abs (For Dl650A)
13-68 DL650K7/AK7 (’07-MODEL) INTRODUCTION OF ABS (For DL650A) FRONT AND REAR WHEEL SPEED SENSORS Wheel speed sensor consists of wheel speed sensor 1 and sensor rotor 2. ABS CONTROL UNIT ABS control unit ABS control unit calculates signals input from each one of front and rear wheel speed sensors, monitors the slipping conditions of the wheels and, at the same time, sends control signal to Hydraulic Unit (HU).
Page 573 DL650K7/AK7 (’07-MODEL) 13-69 ABS CONTROL UNIT CALCULATING PROCESS The ABS controls and its calculations, in addition to the self-diagnosing and the fail-safe processes, occur during the ABS control unit calculating process. In addition, if a malfunction is detected by the self-diagnosis function, the brake stops being controlled by the ABS and a diagnostic trouble code is stored.
Page 574 13-70 DL650K7/AK7 (’07-MODEL) HYDRAULIC UNIT (HU) The hydraulic unit operates the solenoid valves based upon the signal which is output from the ABS control unit. The brake fluid pressure is then adjusted accordingly. The hydraulic unit controls the front and rear brake systems individually by operating separate components for the front and the rear, except for the pump drive motor, which is shared by both systems.
Page 575: Abs Indicator Light
DL650K7/AK7 (’07-MODEL) 13-71 FAIL-SAFE FUNCTION If malfunction occurs in the ABS electric system, this sets valve relay OFF. Consequently, motor relay will be set OFF and the indicator light ON, and no current will be applied to motor solenoid valve inactivating ABS and turning ABS indicator light ON.
Page 576: Cautions In Servicing
13-72 DL650K7/AK7 (’07-MODEL) CAUTIONS IN SERVICING ABS WIRING • The ABS parts are connected to various lead wires. The cou- pler and lead wire connections, as well as the lead wire and Click wire harness routing must be done correctly. Make sure that the proper clamps are used and positioned correctly.
Page 577 DL650K7/AK7 (’07-MODEL) 13-73 BATTERY • Only use a fully charged battery. • In order to prevent damage to the ABS control unit etc., be sure to connect the battery properly. • Never disconnect the battery or any other lead wires while the engine is running.
Page 578 • Only use the specified tires. TESTER 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. • Since the resistance may differ depending on the tester used and the temperature, the resistance should be set to the spec- ification.
Page 579: Abs Components
DL650K7/AK7 (’07-MODEL) 13-75 ABS COMPONENTS ABS COMPONENTS LOCATION 1 ABS indicator light 4 ABS control unit/HU 2 Front wheel speed sensor rotor 5 Rear wheel speed sensor rotor 3 Front wheel speed sensor 6 Rear wheel speed sensor...
Page 580: Abs Coupler Connection Diagram
13-76 DL650K7/AK7 (’07-MODEL) ABS COUPLER CONNECTION DIAGRAM...
Page 581: Abs Wiring Diagram
DL650K7/AK7 (’07-MODEL) 13-77 ABS WIRING DIAGRAM ABS CONTROL UNIT IGNITION SWITCH SPEEDOMETER COUPLER ABS INDICATOR LIGHT LOCK MODE SELECT COUPLER 1. HEAD HI 15 A 2. HEAD LO 15 A MOTOR VALVE 3. FUEL 10 A FUSE FUSE 4. IGNITION 10 A FWS RWS BATTERY...
Page 582: Abs Unit System Diagram
13-78 DL650K7/AK7 (’07-MODEL) ABS UNIT SYSTEM DIAGRAM...
Page 583: Abs Troubleshooting
DL650K7/AK7 (’07-MODEL) 13-79 ABS TROUBLESHOOTING ABS TROUBLESHOOTING DESCRIPTION Many of the ABS malfunction diagnosing operations are performed by checking the wiring continuity. Quick and accurate detection of malfunctions within the complex circuitry assures the proper operation of the ABS. Before beginning any repairs, thoroughly read and understand this Supplementary Service Manual. The ABS is equipped with a self-diagnosis function.
Page 584: Troubleshooting Procedure
13-80 DL650K7/AK7 (’07-MODEL) TROUBLESHOOTING PROCEDURE Troubleshooting should be proceed as follows. If the order is performed incorrectly or any part is omitted, a misdiagnosis may result. 1. Gather information from the customer. (!Page 82) 2. Perform the pre-diagnosis inspection. (!Page 83) 3.
Page 585 DL650K7/AK7 (’07-MODEL) 13-81 BASIC TROUBLESHOOTING DIAGRAM 1. Gather information from the customer. ( Page 82) 2. Perform the pre-diagnosis inspection. ( Page 83) 3. Inspect the ABS indicator light. ( Page 86) 4. Output the DTCs stored in the ABS control unit. ( Page 89) 5.
Page 586 13-82 DL650K7/AK7 (’07-MODEL) INFORMATION GATHERING To properly diagnose a malfunction, one must not make guesses or assumptions about the circumstances that caused it. Proper diagnosis and repair require duplicating the situation in which the malfunction occurred. If a diagnosis is made without duplicating the malfunction, even an experienced service technician may make a misdiagnosis and not perform the servicing procedure correctly, resulting in the malfunction not being repaired.
Page 587 80R19M/C 59H for front and 150/70R17M/C 69H for rear. The use of tires other than those specified may cause instability. It is highly recommended to use a SUZUKI Genuine Tire. * Replace the tire as a set, otherwise the DTC “25” (C1625) may be stored.
Page 588 13-84 DL650K7/AK7 (’07-MODEL) ABS COMPONENT Wheel speed sensor – sensor rotor clearance • Inspect the clearance between the wheel speed sensor and sensor rotor for each wheel using the thickness gauge. $ Wheel speed sensor – sensor rotor clearance: 0.3 – 1.5 mm (0.012 – 0.059 in) # 09900-20803: Thickness gauge 09900-20806: Thickness gauge ABS control unit/HU ground wire inspection...
Page 589 DL650K7/AK7 (’07-MODEL) 13-85 • Check for continuity between 1 terminal of coupler and bat- ABS control unit coupler (Harness end) tery - terminal, also 4 terminal of coupler and battery - ter- minal. # 09900-25008: Multi-circuit tester set + Tester knob indication: Continuity (*) If there are no continuity, repair the coupler or wire harness.
Page 590 13-86 DL650K7/AK7 (’07-MODEL) ABS INDICATOR LIGHT INSPECTION Step 1 1) Check if the ABS indicator light lights up when turning the ignition switch to ON. NOTE: If the ABS indicator light flashes, there may be a short-circuit existing in the mode select switch wire. Does the ABS indicator light up? Go to step 2.
Page 591 DL650K7/AK7 (’07-MODEL) 13-87 Step 4 ABS control unit coupler (Harness end) 1) Turn the ignition switch to OFF. 2) Disconnect the ABS control unit coupler. (!Page 84) 3) Turn the ignition switch to ON with the ABS control unit cou- pler disconnected, measure the voltage between B terminal and 4 terminal at the coupler.
Page 592 13-88 DL650K7/AK7 (’07-MODEL) Step 7 ABS control unit coupler (Harness end) 1) Turn the ignition switch to OFF and disconnect the ABS con- trol unit coupler. (!Page 84) 2) Turn the ignition switch to ON with the ABS control unit cou- pler disconnected, measure the voltage between H terminal and 4 terminal at the coupler.
Page 593: Dtc (Diagnostic Trouble Code) Output
DL650K7/AK7 (’07-MODEL) 13-89 DTC (Diagnostic Trouble Code) OUTPUT Connect the special tool to the mode select coupler to output the memorized DTCs on the ABS indicator light. • Turn the ignition switch to OFF. • Remove the seat. ( 7-4) •...
Page 594 13-90 DL650K7/AK7 (’07-MODEL) UNDERSTANDING THE DTC (Diagnostic Trouble Code) A two-digit DTC is shown through the flashing pattern of the ABS indicator light. A number between 1 and 9 is represented by the number of times that the ABS indicator light lights up in interval of 0.4 seconds and the separation between the tens and ones are indicated by the light staying off for 1.6 seconds.
Page 595: Dtc Deleting And Abs Operation Check
DL650K7/AK7 (’07-MODEL) 13-91 DTC DELETING AND ABS OPERATION CHECK DTC DELETING • Connect the special tool to the mode select coupler (O – B/W) and output the DTCs. 09930-82710: Mode select switch • While the DTCs are being output, set the special tool to OFF. The DTC deletion mode starts 12.5 seconds after the switch is set to OFF.
Page 596 13-92 DL650K7/AK7 (’07-MODEL) Ignition switch DTC indication 1 sec. 1 sec. 1 sec. Mode select switch Max. 12.5 seconds Cleaning start ABS indicator light (Malfunction exist) ABS OPERATION CHECK After deleting the DTCs, repeat the code output procedure and make sure that no DTCs remain (the ABS indicator light no longer flashes).
Page 597: Sds Check
DL650K7/AK7 (’07-MODEL) 13-93 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 598: Use Of Sds Diagnostic Procedures
13-94 DL650K7/AK7 (’07-MODEL) USE OF SDS DIAGNOSTIC PROCEDURES * Don’t disconnect couplers from ABS HU, the battery cable from the battery, ABS HU ground wire harness from the engine or main fuse before confirming the malfunction code (self-diagnostic trouble code) stored in memory. Such discon- nection will erase the memorized information in ABS HU mem- ory.
Page 599: Use Of Sds Diagnosis Reset Procedure
DL650K7/AK7 (’07-MODEL) 13-95 USE OF SDS DIAGNOSIS RESET PROCEDURE • After repairing the trouble, turn OFF the ignition switch and turn ON again. • Click the ABS button 1. • Click the “DTC inspection” button 2. • Check the DTC. •...
Page 600 13-96 DL650K7/AK7 (’07-MODEL) • Follow the displayed instructions. • Check that both “Current DTC” 4 and “Past DTC” 5 are deleted (NIL).
Page 601 DL650K7/AK7 (’07-MODEL) 13-97 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 “ABS” 1. 4) Click “Active control” 2. 5) Click “ABS HU operating” 3.
Page 602 13-98 DL650K7/AK7 (’07-MODEL) 6) It progresses to the next according to the following indication of screens. Return Next Cancel Help Return Next Cancel Help...
Page 603 DL650K7/AK7 (’07-MODEL) 13-99 Return Next Cancel Help NOTE: * If the front wheel is selected, lift the front wheel off the ground using a jack. * Two operators are needed in this work; One should apply a rotational force to the front wheel. Return Next Cancel...
Page 604 13-100 DL650K7/AK7 (’07-MODEL) Return Next Cancel Help NOTE: * In normal cases, the front brake lever feels a reaction force and the front wheel turns discontinuously. At the same time, the ABS HU operating sound will be heard. * The ABS HU motor operates for 6 seconds and then stops automatically. Return Finish Cancel...
Page 605: Dtc Table Of Abs
DL650K7/AK7 (’07-MODEL) 13-101 DTC TABLE OF ABS DTC parameter Indicator DTC No. Page status Possible cause None Normal ON *1 — Wheel speed sensor related malfunction Incorrect tire size, poor tire pressure, deformed wheel, wheel spinning, (C1625) Page 102 incorrect tooth count, interference at one or more wheels, permanent bad signal, etc.
Page 606: Dtc Troubleshooting
13-102 DL650K7/AK7 (’07-MODEL) DTC TROUBLESHOOTING DTC “25” (C1625): WHEEL SPEED SENSOR RELATED MALFUNCTION POSSIBLE CAUSE Incorrect tire size, poor tire pressure, deformed wheel, wheel spinning, incorrect tooth count, interference at one or more wheels, permanent bad signal, etc. Step 1 1) Check that the specified tires are installed.
Page 607 DL650K7/AK7 (’07-MODEL) 13-103 Step 4 1) Inspect the clearances of the front and rear wheel speed sen- sor – sensor rotor using the thickness gauge. $ Wheel speed sensor – sensor rotor clearance: 0.3 – 1.5 mm (0.012 – 0.059 in) # 09900-20803: Thickness gauge 09900-20806: Thickness gauge Are the clearances OK?
Page 608 13-104 DL650K7/AK7 (’07-MODEL) DTC “35” (C1635): ABS MOTOR MALFUNCTION POSSIBLE CAUSE Motor relay circuit open or short, broken fuse for motor relay, pump motor circuit open or short, faulty motor relay, faulty ABS motor, faulty ABS control unit, etc. Step 1 1) Inspect if the pump motor makes turning noise by setting the ignition switch to ON from OFF when the vehicle stands still.
Page 609 DL650K7/AK7 (’07-MODEL) 13-105 DTC “41” (C1641): WHEEL SPEED SENSOR SIGNAL MALFUNCTION (F) POSSIBLE CAUSE Too great air gap, worn or missing teeth, noise, interference between lines, loose contact in wheel speed sensor connector, wheel speed sensor not securely fastened, input amplifier in ABS control unit failure, etc.
Page 610 13-106 DL650K7/AK7 (’07-MODEL) DTC “42” (C1642): WHEEL SPEED SENSOR CIRCUIT OPEN (F) POSSIBLE CAUSE Wheel speed sensor circuit open or short, loosen contact in wheel speed sensor connector, input amplifier in ABS control unit failure, etc. Step 1 1) Turn the ignition switch to OFF. 2) Remove the air cleaner box cap.
Page 611 DL650K7/AK7 (’07-MODEL) 13-107 Step 4 ABS control unit coupler 1) Measure the resistance between 5 terminal and ground at (Harness end) the ABS control unit coupler. $ Normal value: ∞ Ω (Infinity) ) Tester knob indication: Resistance (Ω) Is the resistance between 5 and ground OK? Go to step 6.
Page 612 13-108 DL650K7/AK7 (’07-MODEL) Step 8 ABS control unit coupler (Harness end) 1) Connect the front wheel speed sensor coupler. 2) Connect three 1.5 V dry cells A in series as shown and make sure that their total voltage is more than 4.5 V. Measure the current between + dry cell terminal and F ter- minal on the ABS control unit coupler.
Page 613 DL650K7/AK7 (’07-MODEL) 13-109 DTC “44” (C1644): WHEEL SPEED SENSOR SIGNAL MALFUNCTION (R) POSSIBLE CAUSE Too great air gap, worn or missing teeth, noise, interference between lines, loose contact in wheel speed sensor connector, wheel speed sensor not securely fastened, input amplifier in ABS control unit failure, etc.
Page 614 13-110 DL650K7/AK7 (’07-MODEL) DTC “45” (C1645): WHEEL SPEED SENSOR CIRCUIT OPEN (R) POSSIBLE CAUSE Wheel speed sensor circuit open or short, loosen contact in wheel speed sensor connector, input amplifier in ABS control unit failure, etc. Step 1 1) Turn the ignition switch to OFF. 2) Remove the seat.
Page 615 DL650K7/AK7 (’07-MODEL) 13-111 Step 4 ABS control unit coupler 1) Measure the resistance between I terminal and ground at (Harness end) the ABS control unit coupler. $ Normal value: ∞ Ω (Infinity) ) Tester knob indication: Resistance (Ω) Is the resistance between I and ground OK? Go to step 6.
Page 616 13-112 DL650K7/AK7 (’07-MODEL) Step 8 ABS control unit coupler (Harness end) 1) Connect the rear wheel speed sensor coupler. 2) Connect three 1.5 V dry cells A in series as shown and make sure that their total voltage is more than 4.5 V. Measure the current between + dry cell terminal and 7 ter- minal on the ABS control unit coupler.
Page 617 DL650K7/AK7 (’07-MODEL) 13-113 DTC “47” (C1647): SUPPLY VOLTAGE (INCREASED) POSSIBLE CAUSE Faulty regulator/rectifier, faulty battery, faulty wire harness, etc. NOTE: When the voltage resumes the normal level, the ABS indicator light will go off. Step 1 1) Turn the ignition switch to OFF. 2) Remove the seat.
Page 618 13-114 DL650K7/AK7 (’07-MODEL) Step 3 ABS control unit coupler (Harness end) 1) Turn the ignition switch to OFF. 2) Remove the ABS control unit/HU cover. (!Page 84) 3) Check the ABS control unit coupler for loose or poor con- tacts. If OK, then disconnect the ABS control unit coupler. 4) Run the engine at 5 000 r/min with the dimmer switch set to 5) Measure the voltage between H terminal and 4 terminal at the coupler.
Page 619 DL650K7/AK7 (’07-MODEL) 13-115 DTC “48” (C1648): SUPPLY VOLTAGE (DECREASED) POSSIBLE CAUSE Faulty generator, faulty regulator/rectifier, faulty battery, faulty wire harness, etc. NOTE: When the voltage resumes the normal level, the ABS indicator light will go off. Step 1 1) Turn the ignition switch to OFF. 2) Remove the seat.
Page 620 13-116 DL650K7/AK7 (’07-MODEL) Step 3 ABS control unit coupler (Harness end) 1) Turn the ignition switch to OFF. 2) Remove the ABS control unit/HU cover. (!Page 84) 3) Check the ABS control unit coupler for loose or poor con- tacts. If OK, then disconnect the ABS control unit coupler. 4) Run the engine at 5 000 r/min with the dimmer switch set to 5) Measure the voltage between H terminal and 4 terminal at the coupler.
Page 621 DL650K7/AK7 (’07-MODEL) 13-117 DTC “55” (C1655): ABS CONTROL UNIT MALFUNCTION POSSIBLE CAUSE Faulty ABS control unit Step 1 1) Inspect the clearances of the front and rear wheel speed sen- sor – sensor rotor using the thickness gauge. $ Wheel speed sensor – sensor rotor clearance: 0.3 –...
Page 622 13-118 DL650K7/AK7 (’07-MODEL) DTC “61” (C1661): ABS SOLENOID MALFUNCTION POSSIBLE CAUSE Valve relay circuit open or short, broken fuse for valve relay, faulty valve relay, interruption of valve, failure output from ABS control unit, etc. Step 1 1) Turn the ignition switch to OFF. 2) Remove the seat.
Page 623: Abs Component Removal, Inspection And Installation
DL650K7/AK7 (’07-MODEL) 13-119 ABS COMPONENT REMOVAL, INSPECTION AND INSTALLATION FRONT WHEEL SPEED SENSOR/SENSOR ROTOR REMOVAL * The ABS is made up of many precision parts; never subject it to strong impacts or allow it to become dirty or dusty. * Do not hit the sensor rotor when dismounting the wheel.
Page 624 13-120 DL650K7/AK7 (’07-MODEL) • Remove the fuel tank. (!DL650K4 5-7) • Remove the air cleaner box cap. (!DL650K4 2-5) • Disconnect the sensor coupler and remove the front wheel speed sensor. (!Page 133) INSPECTION • Inspect the wheel speed sensor for damage. •...
Page 625 DL650K7/AK7 (’07-MODEL) 13-121 • Align the recess A on the speed sensor bracket with the stop- per B on the right front fork. • Check the clearance between the front wheel speed sensor and sensor rotor using the thickness gauge. $ Wheel speed sensor –...
Page 626 13-122 DL650K7/AK7 (’07-MODEL) FRONT WHEEL SPEED SENSOR INSTALLATION Right Left Front wheel speed sensor 0.3 – 1.5 mm (0.012 – 0.059 in)
Page 627 DL650K7/AK7 (’07-MODEL) 13-123 REAR WHEEL SPEED SENSOR/SENSOR ROTOR REMOVAL * The ABS is made up of many precision parts; never subject it to strong impacts or allow it to become dirty or dusty. * Do not hit the sensor rotor when dismounting the wheel.
Page 628 13-124 DL650K7/AK7 (’07-MODEL) INSPECTION • Inspect the wheel speed sensor for damage. • Clean the sensor if any metal particle or foreign material stuck on it. • Check that no wheel speed sensor rotor teeth are broken and that no foreign objects are caught in the wheel speed sensor. INSTALLATION Installation is in the reverse order of removal.
Page 629 DL650K7/AK7 (’07-MODEL) 13-125 REAR WHEEL SPEED SENSOR INSTALLATION Right Left 0.3 – 1.5 mm (0.012 – 0.059 in) Rear wheel speed sensor For E-03, 28, 33...
Page 630 13-126 DL650K7/AK7 (’07-MODEL) ABS CONTROL UNIT/HU REMOVAL " When storing the brake fluid, seal the container completely and keep away from children. * This brake system is filled with an ethylene glycol-based DOT 4 brake fluid. Do not mix differ- ent types of fluid such as silicone-based or petroleum-based.
Page 631 DL650K7/AK7 (’07-MODEL) 13-127 • Loosen the flare nuts 9 and disconnect the brake pipes. • Disconnect the ABS control unit coupler 0. • Remove the ABS control unit/HU by removing the mounting bolts. INSTALLATION Installation is in the reverse order of removal. Pay attention to the following points.
Page 632: Wire Harness, Hose Routing And Sensor Installation
12-128 DL650K7/AK7 (’07-MODEL) WIRE HARNESS, HOSE ROUTING AND SENSOR INSTALLATION WIRE HARNESS ROUTING Clamp Starter motor Wire harness Stop lamp switch Wiring harness ABS sensor (DL650A) IG coil coupler Clamp ISC valve coupler Clamp Fuel pump coupler Rectifier Taping clamp (Breather hose) IAP sensor Speed sensor...
Page 633 DL650K7/AK7 (’07-MODEL) 13-129 Taping clamp Clamp Clamp Clamp Ignition coil Reserver IN IN IN inlet hose ABS brake hose Frame Frame (DL650A only) #2 Ignition coil Magneto lead wire ICES label (E-28 only) Triangle mark of each spark plug cap *4 Do not slack the lead wire.
Page 634 13-130 DL650K7/AK7 (’07-MODEL) FRONT BRAKE HOSE ROUTING (For DL650) 21 ˚ 42 ˚ 21 ˚ 21 ˚ After positioning the brake hose junction with 1 Brake hose the stopper, tighten the bolt. After positioning the clamp with the stopper, 2 Brake hose guide tighten the clamp bolt.
Page 635 DL650K7/AK7 (’07-MODEL) 13-131 FRONT BRAKE HOSE ROUTING (For DL650A) 21˚ 49˚ 42˚ 21˚ 42˚ 42˚ 42˚ 35˚ 14˚ 14˚ 21˚ 1 Brake hose 7 ABS control unit/HU After the brake hose union has contacted the stopper, tighten the 2 Throttle cable (Return) union bolt.
Page 636 13-132 DL650K7/AK7 (’07-MODEL) REAR BRAKE HOSE ROUTING (For DL650A) *4, *5 42˚ 42˚ 1 ABS control unit *3 White paint outside. 2 Guide *4 Insert the reservoir hose into union to the root. Pass through the reservoir hose outside of the 3 Wheel speed sensor lead wire seat rail.
Page 637 DL650K7/AK7 (’07-MODEL) 13-133 FRONT WHEEL SPEED SENSOR INSTALLATION (For DL650A) 21˚ Sensor clamp 21˚ Pass through the wheel speed sensor lead wire Hold the wheel speed sensor lead wire with in front of the brake hose. Make clearance clamp on the top of the radiator. between the wheel speed sensor lead wire and the front fender.
Page 638 13-134 DL650K7/AK7 (’07-MODEL) REAR WHEEL SPEED SENSOR INSTALLATION (For DL650A) 1 Guide *1 Clamp the sensor lead wire to the brake hose at white painted marking. Wheel speed sensor *2 Pass through the sensor lead wire inside of brake hose guide. lead wire 3 Brake hose *3 Letters should face outside.
Page 639 DL650K7/AK7 (’07-MODEL) 13-135 FUEL TANK DRAIN HOSE ROUTING 90˚ 48 N . m 4.8 kgf-m 34.5 lb-ft 1 Fuel tank water drain hose 6 Brake pipe (For ABS model) 2 Reservoir tank overflow hose *1 Pass through the hoses under the brake pipe. (For ABS model) Pass through the hoses outside of brake pipe and reservoir tank 3 Reservoir tank inlet hose hose.
Page 640 13-136 DL650K7/AK7 (’07-MODEL) THROTTLE BODY INSTALLATION To canister (Purge hose E-33 only) Air cleaner side 25˚ Engine side 15 – 25˚ 19 N . m (1.9 kgf-m, 13.5 lb-ft) 10 N . m *5, *6 (1.0 kgf-m, 7.0 lb-ft) 48 N . m (4.8 kgf-m, 34.5 lb-ft) 1 ISC valve *4 Matching mark (Yellow) *1 Clamp ends should face back side.
Page 641 DL650K7/AK7 (’07-MODEL) 13-137 COOLING SYSTEM HOSE ROUTING Clamp the water drain hose and oil pressure switch lead 1 Clamp wire. Fill the bearing with engine oil until engine oil comes out 2 Wiring harness from the hole of the be bearing housing. 3 Oil pressure switch *6 Clamp bolt head upward.
Page 642 13-138 DL650K7/AK7 (’07-MODEL) 0 – 90˚ 90˚ 90˚ 90˚ Marking position Installation point 1 Clamp *3 Marking (Yellow) 2 Jiggle valve *4 Clamp bolt head downward. 3 Union *5 Clamp bolt head left side. 4 Radiator hose *6 Make clearance between bulge of union and clamp. *1 Marking *7 Clamp face left side.
Page 643 DL650K7/AK7 (’07-MODEL) 13-139 PAIR (AIR SUPPLY) SYSTEM HOSE ROUTING 1 Matching mark (White) 4 PAIR control solenoid valve Matching mark (Yellow) Pass through the PAIR hose between the cylin- der head cover and intake pipe. 3 Hose...
Page 644: Battery Protector Installation
13-140 DL650K7/AK7 (’07-MODEL) BATTERY PROTECTOR INSTALLATION 20 mm (0.79 in) 6.2 mm (0.24 in) 45 mm (1.77 in) 3.12 mm (0.12 in) Align the top of protector with the upper surface of the battery holder.
Page 645: Special Tools
DL650K7/AK7 (’07-MODEL) 13-141 SPECIAL TOOLS 09900-20803 09900-25008 09900-25009 09900-28630 09900-20806 Multi-circuit tester Needle pointed TPS test wire har- 09904-41010 Thickness gauge probe set ness SDS set tool 09913-10130 09917-47011 09930-10121 Carburetor adjuster Vacuum pump Spark plug socket 09930-11950 09930-82710 driver gauge wrench set Torx wrench...
Page 646: Service Data (Dl650K7)
13-142 DL650K7/AK7 (’07-MODEL) SERVICE DATA (DL650K7) VALVE + GUIDE Unit: mm (in) ITEM STANDARD LIMIT Valve diam. ---- (1.2) 25.5 ---- (1.0) Valve clearance (when cold) 0.10 – 0.20 ---- (0.004 – 0.008) 0.20 – 0.30 ---- (0.008 – 0.012) Valve guide to valve stem 0.020 –...
Page 647 DL650K7/AK7 (’07-MODEL) 13-143 CAMSHAFT + CYLINDER HEAD Unit: mm (in) ITEM STANDARD LIMIT Cam height 35.48 – 35.53 35.18 (1.3968 – 1.3988) (1.3850) 33.48 – 33.53 33.18 (1.3181 – 1.3201) (1.3063) Camshaft journal oil clearance 0.032 – 0.066 0.150 IN. & EX. (0.0013 –...
Page 648 13-144 DL650K7/AK7 (’07-MODEL) CYLINDER + PISTON + PISTON RING Unit: mm (in) ITEM STANDARD LIMIT Compression pressure 1 300 – 1 700 kPa 1 100 kPa (13 – 17 kgf/cm , 185 – 242 psi) (11 kgf/cm , 156 psi) Compression pressure 200 kPa ----...
Page 649 DL650K7/AK7 (’07-MODEL) 13-145 CONROD + CRANKSHAFT Unit: mm (in) ITEM STANDARD LIMIT Conrod small end I.D. 20.010 – 20.018 20.040 (0.7878 – 0.7881) (0.7890) Conrod big end side clearance 0.170 – 0.320 (0.0067 – 0.0126) (0.02) Conrod big end width 20.95 –...
Page 650 13-146 DL650K7/AK7 (’07-MODEL) TRANSMISSION + DRIVE CHAIN Unit: mm (in) Except ratio ITEM STANDARD LIMIT Primary reduction ratio 2.088 (71/34) ---- Final reduction ratio 3.133 (47/15) ---- Gear ratios 2.461 (32/13) ---- 1.777 (32/18) ---- 1.380 (29/21) ---- 1.125 (27/24) ---- 0.961 (25/26) ----...
Page 651 DL650K7/AK7 (’07-MODEL) 13-147 THERMOSTAT + RADIATOR + FAN + COOLANT ITEM STANDARD NOTE Thermostat valve opening Approx. 88 °C (190 °F) ---- temperature Thermostat valve lift Over 8.0 mm (0.31 in) at 100 °C (212 °F) ---- ECT sensor resistance 20 °C Approx.
Page 652 13-148 DL650K7/AK7 (’07-MODEL) FI SENSORS + STVA + ISC VALVE ITEM SPECIFICATION NOTE 130 – 240 Ω CKP sensor resistance W – G CKP sensor peak voltage 3.7 V (When cranking) and more IAP sensor input voltage (F & R) 4.5 –...
Page 653: Headlight
DL650K7/AK7 (’07-MODEL) 13-149 ELECTRICAL Unit: mm (in) ITEM SPECIFICATION NOTE Firing order Spark plug NGK: CR8E Type DENSO: U24ESR-N 0.7 – 0.8 mm (0.028 – 0.031 in) Spark performance Over 8 mm (0.3 in) at 1 atm. 130 – 240 Ω CKP sensor resistance W –...
Page 654: Position/Parking Light
13-150 DL650K7/AK7 (’07-MODEL) WATTAGE Unit: W SPECIFICATION ITEM E-03, 24, 28, 33 Others ← Headlight 12 V 60/55 W × 2 (H4) Position/Parking light 12 V 5 W × 2 ← Brake light/Taillight 12 V 21/5 W × 2 ← Turn signal light 12 V 21 W ←...
Page 655 DL650K7/AK7 (’07-MODEL) 13-151 BRAKE + WHEEL Unit: mm (in) ITEM STANDARD LIMIT Rear brake pedal height 15 – 25 (0.59 – 0.98) ---- Brake disc thickness Front (0.20) (0.18) Rear (0.20) (0.18) Brake disc runout ---- (0.012) Master cylinder bore * 14.000 –...
Page 656 Front fork spring adjuster 3 grooves from Top/Spring adjuster height 9 mm ---- (0.35 in) Front fork oil type SUZUKI FORK OIL SS-08 ---- or equivalent fork oil Front fork oil capacity (each leg) * 528 ml ---- (17.8/18.6 US/Imp oz)
Page 657 DL650K7/AK7 (’07-MODEL) 13-153 FUEL + OIL ITEM STD/SPEC. 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 658: Service Data (Dl650Ak7)
13-154 DL650K7/AK7 (’07-MODEL) SERVICE DATA (DL650AK7) VALVE + GUIDE Unit: mm (in) ITEM STANDARD LIMIT Valve diam. ---- (1.2) 25.5 ---- (1.0) Valve clearance (when cold) 0.10 – 0.20 ---- (0.004 – 0.008) 0.20 – 0.30 ---- (0.008 – 0.012) Valve guide to valve stem 0.020 –...
Page 659 DL650K7/AK7 (’07-MODEL) 13-155 CAMSHAFT + CYLINDER HEAD Unit: mm (in) ITEM STANDARD LIMIT Cam height 35.48 – 35.53 35.18 (1.3968 – 1.3988) (1.3850) 33.48 – 33.53 33.18 (1.3181 – 1.3201) (1.3063) Camshaft journal oil clearance 0.032 – 0.066 0.150 IN. & EX. (0.0013 –...
Page 660 13-156 DL650K7/AK7 (’07-MODEL) CYLINDER + PISTON + PISTON RING Unit: mm (in) ITEM STANDARD LIMIT Compression pressure 1 300 – 1 700 kPa 1 100 kPa (13 – 17 kgf/cm , 185 – 242 psi) (11 kgf/cm , 156 psi) Compression pressure 200 kPa ----...
Page 661 DL650K7/AK7 (’07-MODEL) 13-157 CONROD + CRANKSHAFT Unit: mm (in) ITEM STANDARD LIMIT Conrod small end I.D. 20.010 – 20.018 20.040 (0.7878 – 0.7881) (0.7890) Conrod big end side clearance 0.170 – 0.320 (0.0067 – 0.0126) (0.02) Conrod big end width 20.95 –...
Page 662 13-158 DL650K7/AK7 (’07-MODEL) TRANSMISSION + DRIVE CHAIN Unit: mm (in) Except ratio ITEM STANDARD LIMIT Primary reduction ratio 2.088 (71/34) ---- Final reduction ratio 3.133 (47/15) ---- Gear ratios 2.461 (32/13) ---- 1.777 (32/18) ---- 1.380 (29/21) ---- 1.125 (27/24) ---- 0.961 (25/26) ----...
Page 663 DL650K7/AK7 (’07-MODEL) 13-159 THERMOSTAT + RADIATOR + FAN + COOLANT ITEM STANDARD NOTE Thermostat valve opening Approx. 88 °C (190 °F) ---- temperature Thermostat valve lift Over 8.0 mm (0.31 in) at 100 °C (212 °F) ---- ECT sensor resistance 20 °C Approx.
Page 664 13-160 DL650K7/AK7 (’07-MODEL) FI SENSORS + STVA + ISC VALVE ITEM SPECIFICATION NOTE 130 – 240 Ω CKP sensor resistance W – G CKP sensor peak voltage 3.7 V (When cranking) and more IAP sensor input voltage (F & R) 4.5 –...
Page 665 DL650K7/AK7 (’07-MODEL) 13-161 ELECTRICAL Unit: mm (in) ITEM SPECIFICATION NOTE Firing order Spark plug NGK: CR8E Type DENSO: U24ESR-N 0.7 – 0.8 mm (0.028 – 0.031 in) Spark performance Over 8 mm (0.3 in) at 1 atm. 130 – 240 Ω CKP sensor resistance W –...
Page 666: Abs Indicator Light
13-162 DL650K7/AK7 (’07-MODEL) WATTAGE Unit: W SPECIFICATION ITEM E-03, 24, 28, 33 Others ← Headlight 12 V 60/55 W × 2 (H4) Position/Parking light 12 V 5 W × 2 ← Brake light/Taillight 12 V 21/5 W × 2 ← Turn signal light 12 V 21 W ←...
Page 667 DL650K7/AK7 (’07-MODEL) 13-163 BRAKE + WHEEL Unit: mm (in) ITEM STANDARD LIMIT Rear brake pedal height 15 – 25 (0.59 – 0.98) ---- Brake disc thickness Front (0.20) (0.18) Rear (0.20) (0.18) Brake disc runout ---- (0.012) Master cylinder bore 14.000 –...
Page 668 Front fork spring adjuster 3 grooves from Top/Spring adjuster height 9 mm ---- (0.35 in) Front fork oil type SUZUKI FORK OIL SS-08 ---- or equivalent fork oil Front fork oil capacity (each leg) 528 ml ---- (17.8/18.6 US/Imp oz)
Page 669 DL650K7/AK7 (’07-MODEL) 13-165 FUEL + OIL ITEM STD/SPEC. 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 671 DL650/AK8 (’08-MODEL) 14- 1 DL650/AK (’0 -MODEL) CONTENTS PAGE SERVICE DATA (DL650K8) ..............14- 2 SERVICE DATA (DL650A/AUEK8) ............14-14 NOTE: Specifications are the same as the K7-MODEL.
Page 672 14-2 DL650/AK8 (’08-MODEL) SERVICE DATA (DL650K8) VALVE + GUIDE Unit: mm (in) ITEM STANDARD LIMIT Valve diam. ---- (1.2) 25.5 ---- (1.0) Valve clearance (when cold) 0.10 – 0.20 ---- (0.004 – 0.008) 0.20 – 0.30 ---- (0.008 – 0.012) Valve guide to valve stem 0.020 –...
Page 673 DL650/AK8 (’08-MODEL) 14- 3 CAMSHAFT + CYLINDER HEAD Unit: mm (in) ITEM STANDARD LIMIT Cam height 35.48 – 35.53 35.18 (1.3968 – 1.3988) (1.3850) 33.48 – 33.53 33.18 (1.3181 – 1.3201) (1.3063) Camshaft journal oil clearance 0.032 – 0.066 0.150 IN.
Page 674 14-4 DL650/AK8 (’08-MODEL) CYLINDER + PISTON + PISTON RING Unit: mm (in) ITEM STANDARD LIMIT Compression pressure 1 300 – 1 700 kPa 1 100 kPa (13 – 17 kgf/cm , 185 – 242 psi) (11 kgf/cm , 156 psi) Compression pressure 200 kPa ----...
Page 675 DL650/AK8 (’08-MODEL) 14-5 CONROD + CRANKSHAFT Unit: mm (in) ITEM STANDARD LIMIT Conrod small end I.D. 20.010 – 20.018 20.040 (0.7878 – 0.7881) (0.7890) Conrod big end side clearance 0.170 – 0.320 (0.0067 – 0.0126) (0.02) Conrod big end width 20.95 –...
Page 676 14- 6 DL650/AK8 (’08-MODEL) TRANSMISSION + DRIVE CHAIN Unit: mm (in) Except ratio ITEM STANDARD LIMIT Primary reduction ratio 2.088 (71/34) ---- Final reduction ratio 3.133 (47/15) ---- Gear ratios 2.461 (32/13) ---- 1.777 (32/18) ---- 1.380 (29/21) ---- 1.125 (27/24) ---- 0.961 (25/26) ----...
Page 677 DL650/AK8 (’08-MODEL) 14- 7 THERMOSTAT + RADIATOR + FAN + COOLANT ITEM STANDARD NOTE Thermostat valve opening Approx. 88 °C (190 °F) ---- temperature Thermostat valve lift Over 8.0 mm (0.31 in) at 100 °C (212 °F) ---- ECT sensor resistance 20 °C Approx.
Page 678 14- 8 DL650/AK8 (’08-MODEL) FI SENSORS + STVA + ISC VALVE ITEM SPECIFICATION NOTE 130 – 240 Ω CKP sensor resistance W – G CKP sensor peak voltage 3.7 V (When cranking) and more IAP sensor input voltage (F & R) 4.5 –...
Page 679 DL650/AK8 (’08-MODEL) 14- 9 ELECTRICAL ITEM SPECIFICATION NOTE Firing order Spark plug NGK: CR8E Type DENSO: U24ESR-N 0.7 – 0.8 mm (0.028 – 0.031 in) Spark performance Over 8 mm (0.3 in) at 1 atm. 130 – 240 Ω CKP sensor resistance W –...
Page 680 14- 10 DL650/AK8 (’08-MODEL) WATTAGE Unit: W SPECIFICATION ITEM E-03, 24, 28, 33 Others ← Headlight 12 V 60/55 W × 2 (H4) Position/Parking light 12 V 5 W × 2 ← Brake light/Taillight 12 V 21/5 W × 2 ←...
Page 681 DL650/AK8 (’08-MODEL) 14- 11 BRAKE + WHEEL Unit: mm (in) ITEM STANDARD LIMIT Rear brake pedal height 15 – 25 (0.59 – 0.98) ---- Brake disc thickness Front (0.20) (0.18) Rear (0.20) (0.18) Brake disc runout ---- (0.012) Master cylinder bore 14.000 –...
Page 682 ---- outer tube fully compressed) Front fork spring adjuster 3 grooves from Top/Spring adjuster height 9 (0.35) ---- Front fork oil type SUZUKI FORK OIL SS-08 ---- or equivalent fork oil Front fork oil capacity (each leg) 528 ml ---- (17.8/18.6 US/Imp oz)
Page 683 DL650/AK8 (’08-MODEL) 14- 13 FUEL + OIL ITEM STD/SPEC. 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 684 14- 1 DL650/AK8 (’08-MODEL) SERVICE DATA (DL650A/AUEK8) VALVE + GUIDE Unit: mm (in) ITEM STANDARD LIMIT Valve diam. ---- (1.2) 25.5 ---- (1.0) Valve clearance (when cold) 0.10 – 0.20 ---- (0.004 – 0.008) 0.20 – 0.30 ---- (0.008 – 0.012) Valve guide to valve stem 0.020 –...
Page 685 DL650/AK8 (’08-MODEL) 14- 15 CAMSHAFT + CYLINDER HEAD Unit: mm (in) ITEM STANDARD LIMIT Cam height 35.48 – 35.53 35.18 (1.3968 – 1.3988) (1.3850) 33.48 – 33.53 33.18 (1.3181 – 1.3201) (1.3063) Camshaft journal oil clearance 0.032 – 0.066 0.150 IN.
Page 686 14- 1 DL650/AK8 (’08-MODEL) CYLINDER + PISTON + PISTON RING Unit: mm (in) ITEM STANDARD LIMIT Compression pressure 1 300 – 1 700 kPa 1 100 kPa (13 – 17 kgf/cm , 185 – 242 psi) (11 kgf/cm , 156 psi) Compression pressure 200 kPa ----...
Page 687 DL650/AK8 (’08-MODEL) 14- 17 CONROD + CRANKSHAFT Unit: mm (in) ITEM STANDARD LIMIT Conrod small end I.D. 20.010 – 20.018 20.040 (0.7878 – 0.7881) (0.7890) Conrod big end side clearance 0.170 – 0.320 (0.0067 – 0.0126) (0.02) Conrod big end width 20.95 –...
Page 688 14- 1 DL650/AK8 (’08-MODEL) TRANSMISSION + DRIVE CHAIN Unit: mm (in) Except ratio ITEM STANDARD LIMIT Primary reduction ratio 2.088 (71/34) ---- Final reduction ratio 3.133 (47/15) ---- Gear ratios 2.461 (32/13) ---- 1.777 (32/18) ---- 1.380 (29/21) ---- 1.125 (27/24) ---- 0.961 (25/26) ----...
Page 689 DL650/AK8 (’08-MODEL) 14- 19 THERMOSTAT + RADIATOR + FAN + COOLANT ITEM STANDARD NOTE Thermostat valve opening Approx. 88 °C (190 °F) ---- temperature Thermostat valve lift Over 8.0 mm (0.31 in) at 100 °C (212 °F) ---- ECT sensor resistance 20 °C Approx.
Page 690 DL650/AK8 (’08-MODEL) FI SENSORS + STVA + ISC VALVE ITEM SPECIFICATION NOTE 130 – 240 Ω CKP sensor resistance W – G CKP sensor peak voltage 3.7 V (When cranking) and more IAP sensor input voltage (F & R) 4.5 – 5.5 V IAP sensor output voltage (F &...
Page 691 DL650/AK8 (’08-MODEL) 14- 21 ELECTRICAL ITEM SPECIFICATION NOTE Firing order Spark plug NGK: CR8E Type DENSO: U24ESR-N 0.7 – 0.8 mm (0.028 – 0.031 in) Spark performance Over 8 mm (0.3 in) at 1 atm. 130 – 240 Ω CKP sensor resistance W –...
Page 692 DL650/AK8 (’08-MODEL) WATTAGE Unit: W SPECIFICATION ITEM E-03, 24, 28, 33 Others ← Headlight 12 V 60/55 W × 2 (H4) Position/Parking light 12 V 5 W × 2 ← Brake light/Taillight 12 V 21/5 W × 2 ← Turn signal light 12 V 21 W ←...
Page 693 DL650/AK8 (’08-MODEL) 14- 23 BRAKE + WHEEL Unit: mm (in) ITEM STANDARD LIMIT Rear brake pedal height 15 – 25 (0.59 – 0.98) ---- Brake disc thickness Front (0.20) (0.18) Rear (0.20) (0.18) Brake disc runout ---- (0.012) Master cylinder bore 14.000 –...
Page 694 ---- outer tube fully compressed) Front fork spring adjuster 3 grooves from Top/Spring adjuster height 9 (0.35) ---- Front fork oil type SUZUKI FORK OIL SS-08 ---- or equivalent fork oil Front fork oil capacity (each leg) 528 ml ---- (17.8/18.6 US/Imp oz)
Page 695 DL650/AK8 (’08-MODEL) 14- 25 FUEL + OIL ITEM STD/SPEC. 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 697 DL650/AK9 (’09-MODEL) 15- 1 DL650/AK9 (’09-MODEL) 6JKU EJCRVGT FGUETKDGU UGTXKEG URGEKHKECVKQPU UGTXKEG FCVC CPF UGTXKEKPI RTQEGFWTGTU YJKEJ FKHHGT HTQO VJQUG QH VJG &.- /1&'. CPF &.#- /1&'. 016' #P[ FKHHGTGPEGU DGVYGGP VJG &.- /1&'. QT &.#- /1&'. CPF &.- /1&'. CPF &.#- /1&'. KP URGEKHKECVKQPU CTG ENGCT[ KPFKECVGF YKVJ CP CUVGTKUM OCTM 2NGCUG TGHGT VQ VJG ECRVGTU VJTQWIJ HQT FGVCKNU YJKEJ CTG PQV IKXGP KP VJKU EJCRVGT...
Page 698 15-2 DL650/AK9 (’09-MODEL) SPECIFICATIONS DIMENSIONS AND CURB MASS Overall length ..................2 290 mm (90.2 in) Overall width..................840 mm (33.1 in) Overall height ..................1 390 mm (54.7 in) ... Low windshield position (STD) 1 420 mm (55.9 in) ... Middle windshield position 1 450 mm (57.1 in) ...
Page 699 15 A 15 A 10 A 10 A 15 A 15 A...
Page 700 DL650K7 (For E-03, 28, 33) : NEUTRAL INDICATOR LIGHT HANDLEBAR SWITCH (R) : HI-BEAM INDICATOR LIGHT : OIL INDICATOR LIGHT (OPTIONAL PARTS) ENGINE OIL PRESSURE : TURN SIGNAL INDICATOR LIGHT (R) STOP FRONT BRAKE SENSOR GRIP HEATER IGNITION SWITCH STARTER SPEEDOMETER SWITCH : TURN SIGNAL INDICATOR LIGHT (L)
Page 701 DL650AK7 (For E-03, 28, 33) : NEUTRAL INDICATOR LIGHT : HI-BEAM INDICATOR LIGHT : OIL INDICATOR LIGHT : TURN SIGNAL INDICATOR LIGHT (R) HANDLEBAR SWITCH (R) : TURN SIGNAL INDICATOR LIGHT (L) (OPTIONAL PARTS) ENGINE : ABS INDICATOR LIGHT OIL PRESSURE STOP FRONT BRAKE SENSOR...

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Suzuki DL650K5 Service Manual

General Information 1

Periodic Maintenance

Engine

Fi System Diagnosis

Fuel System and Throttle Body

Cooling and Lubrication Systemcooling and Lubrication System

Chassis

Electrical System

Quick Links

GENERAL INFORMATION

PERIODIC MAINTENANCE

ELECTRICAL SYSTEM

SERVICING INFORMATION

Chapters

Troubleshooting

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Summary of Contents for Suzuki DL650K5