Suzuki GSX1300R Manual
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Suzuki GSX1300R Manual

Suzuki gsx1300r motorcycle
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Table of Contents

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Download this manual See also: Supplementary Service Manual, Owner's Manual
This manual contains an introductory description on the SUZUKI GSX1300R and procedures for its inspection/
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 maintenance. 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 better 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 publication. If modifi-
cations have been made since then, differences may exist between the content 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 motorcycles. If you do not have the proper knowledge and tools, ask your authorized
SUZUKI motorcycle dealer to help you.
WARNING
!
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.
© COPYRIGHT SUZUKI MOTOR CORPORATION 2007
FOREWORD

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Do you have a question about the GSX1300R and is the answer not in the manual?

Questions and answers

Clifton r Hinds
May 31, 2025

laid it down now wont start

0
1 comments:
Mr. Anderson
May 31, 2025

The Suzuki GSX1300R may not start after being laid down due to potential issues such as melted wires on the regulator/rectifier (RNR), which can affect the electrical system. Additionally, the engine will not start unless certain conditions are met: the ignition circuit must be on, the transmission must be in neutral or the clutch disengaged with the side stand up. If these conditions are not satisfied, or if there is electrical damage from the fall, the engine may not start.

This answer is automatically generated

0
Fred
January 25, 2025

My 2004 Hayabusa fuel pump has a three prong fuel pump connection .. How can I connect or convert my four prong fuel pump connection to my bike? Or can I replace my our prong connector with a three prong any suggestions for the wiring?

0
1 comments:
Mr. Anderson
February 10, 2025

The fuel pump assembly mentioned is specifically designed for a three-pin connection. If your 2004 Suzuki GSX1300R Hayabusa has a three-prong fuel pump connection, connecting a four-prong fuel pump would require modifying the wiring. However, this is not recommended as it may affect performance or cause compatibility issues. Instead, it is best to use a compatible three-prong fuel pump to ensure proper function and avoid electrical or operational problems.

This answer is automatically generated

0

Related Manuals for Suzuki GSX1300R

Summary of Contents for Suzuki GSX1300R

  • Page 1 FOREWORD This manual contains an introductory description on the SUZUKI GSX1300R and procedures for its inspection/ 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 maintenance. Use this section as well as other sections to use as a guide for proper inspection and service.
  • Page 3 TABLE OF CONTENTS Precautions............... 00-i Precautions ............00-1 General Information ........... 0-i General Information ..........0A-1 Maintenance and Lubrication ......... 0B-1 Service Data............0C-1 Engine ................. 1-i Precautions .............. 1-1 Engine General Information and Diagnosis ... 1A-1 Emission Control Devices ........1B-1 Engine Electrical Devices........1C-1 Engine Mechanical..........1D-1 Engine Lubrication System ........
  • Page 5 SUPPLEMENTS GSX1300RK9...
  • Page 7 Table of Contents 00- i Section 00 Precautions CONTENTS Precautions ..........00-1 General Precautions ........... 00-1 Precautions for Electrical Circuit Service .... 00-2 Precautions............00-1 Warning / Caution / Note........00-1...
  • Page 8 CAUTION Indicates a potential hazard that could result • If parts replacement is necessary, replace in death or injury. the parts with Suzuki Genuine Parts or their equivalent. CAUTION • When removing parts that are to be reused, keep them arranged in an orderly manner...
  • Page 9 Precautions: 00-2 • Never reuse a circlip. When installing a • Before refitting the sealed coupler, make sure its seal new circlip, take care not to expand the rubber is positioned properly. The seal rubber may end gap larger than required to slip the possibly come off the position during disconnecting circlip over the shaft.
  • Page 10 00-3 Precautions: • Check the male connector for bend and female Switch connector for excessive opening. Also check the Never apply grease material to switch contact points to coupler for locking (looseness), corrosion, dust, etc. prevent damage. ECM / Various sensors •...
  • Page 11 Precautions: 00-4 Battery • Never connect any tester (voltmeter, ohmmeter, or whatever) to the electronic unit when its coupler is • Battery connection in reverse polarity is strictly disconnected. Otherwise, damage to electronic unit prohibited. Such a wrong connection will damage the may result.
  • Page 12 00-5 Precautions: 3) Using a test male terminal, check the female Continuity check terminals of the circuit being checked for contact 1) Measure resistance across coupler “B” (between “A” tension. and “C” in figure). Check each terminal visually for poor contact If no continuity is indicated (infinity or over limit), the (possibly caused by dirt, corrosion, rust, entry of circuit is open between terminals “A”...
  • Page 13 Precautions: 00-6 3) Also, if measured values are as listed following, a Short circuit check (Wire harness to ground) resistance (abnormality) exists which causes the 1) Disconnect the negative (–) cable from the battery. voltage drop in the circuit between terminals “A” and 2) Disconnect the connectors/couplers at both ends of “B”.
  • Page 14 : 09900–25008 (Multi-circuit tester set) I705H1000009-02 “D”: To other parts Using The Multi-Circuit Testers • Use the Suzuki multi-circuit tester set. • Use well-charged batteries in the tester. • Be sure to set the tester to the correct testing range. Special tool (A): 09900–25008 (Multi-circuit tester set)

  • Page 15: General Information

    Fuel Line Inspection ..........0B-10 Symbols .............. 0A-1 Engine Oil and Filter Replacement ....0B-10 Abbreviations ............0A-1 Throttle Cable Play Inspection and SAE-to-Former SUZUKI Term ......0A-2 Adjustment ............0B-12 Vehicle Side View ..........0A-3 Throttle Valve Synchronization ......0B-12 Vehicle Identification Number ......0A-4 Evaporative Emission Control System Fuel and Oil Recommendation ......
  • Page 16 Apply oil. Use engine oil unless otherwise specified. Apply molybdenum oil solution. (Mixture of engine oil and SUZUKl MOLY PASTE in a ratio of 1:1). Apply SUZUKI SUPER GREASE “A” or equivalent. 99000-25010 Apply SUZUKI MOLY PASTE or equivalent. 99000-25140 Apply SUZUKI SILICONE GREASE or equivalent.
  • Page 17 J1930 terms and abbreviations which may be used in FPR: Fuel Pressure Regulator this manual in compliance with SAE recommendations, FP Relay: Fuel Pump Relay as well as their former SUZUKI names. Ex. SAE term (Abbreviation): Former SUZUKI term GEN: Generator GND: Ground...
  • Page 18 Manifold Absolute Pressure (MAP): Intake Air motorcycles may exist depending on the Pressure (IAP), Intake Vacuum markets. Mass Air Flow (MAF): Air Flow SUZUKI GSX1300R (2008-model) On-Board Diagnostic (OBD): Self-Diagnosis Function, Diagnostic Open Loop (OL): — Right Side Power Control Module (PCM): —...
  • Page 19 Use of SF/SG or SH/SJ in API with MA in JASO. head pipe. The engine serial number “B” is located on Suzuki recommends the use of SAE 10W-40 engine oil. the upper crankcase. These numbers are required If SAE 10W-40 engine oil is not available, select an especially for registering the machine and ordering alternative according to the chart.
  • Page 20 2) Upon reaching an odometer reading of 1 600 km (1 Suzuki recommends the use of SUZUKI COOLANT anti- 000 miles) you can subject the motorcycle to full freeze/engine coolant. If this is not available, use an throttle operation.
  • Page 21 General Information: 0A-6 Country and Area Codes B815H20101009 The following codes stand for the applicable country(-ies) and area(-s). Code Country or Area Effective Frame No. GSX1300R K8 (E-02) U.K. JS1CK111200100001 – GSX1300R K8 (E-19) E.U. JS1CK111100100001 – GSX1300RUF K8 (E-19) E.U.
  • Page 22 0A-7 General Information: Warning, Caution and Information Labels Location B815H20101011 1, 2 7, 8, 9 10, 11 1, 2, 20 14, 15, 16, 17 19, 21 12, 13 I815H1010008-01 1. Noise label (For E-03, 24, 33) 15. General warning label (French) (For GSX1300RUF E-19) 2.
  • Page 23 General Information: 0A-8 Component Location Electrical Components Location B815H20103001 I815H1010007-02 1. STV actuator 7. PAIR control solenoid valve 13. Starter motor 2. STP sensor 8. Cooling fan (RH) 14. GP switch 3. TP sensor 9. IAP sensor 15. HO2 sensor 4.
  • Page 24 0A-9 General Information: I815H1010006-03 17. Turn signal/Side-stand relay 25. ECT sensor 33. Horn 18. Fuse box 26. Ignition switch 34. Cooling fan (LH) 19. Cooling fan relay 27. AP sensor 35. IAT sensor 20. Secondary fuel injector 28. Battery 36. CKP sensor 21.
  • Page 25 General Information: 0A-10 Specifications Specifications B815H20107001 NOTE These specifications are subject to change without notice. Dimensions and dry mass Item Specification Remark Overall length 2 190 mm (86.2 in) Overall width 735 mm (28.9 in) Overall height 1 165 mm (48.9 in) Wheelbase 1 480 mm (52.3 in) Ground clearance...

  • Page 26: Front Suspension

    0A-11 General Information: Chassis Item Specification Remark Front suspension Inverted telescopic, coil spring, oil damped Rear suspension Link type, coil spring, oil damped Front suspension stroke 120 mm (4.7 in) Rear wheel travel 140 mm (5.5 in) Caster 23° 25’ Tail 93 mm (3.7 in) Steering angle...
  • Page 27 General Information: 0A-12 Special Tools and Equipment Special Tool B815H20108001 09900–06104 09900–06107 09900–06108 09900–18740 09900–20102 Snap ring pliers Snap ring pliers Snap ring pliers Hexagon socket (24 Vernier calipers (1/20 mm, 200 mm) 09900–20202 09900–20204 09900–20205 09900–20530 09900–20602 Micrometer (1/100 Micrometer (75 –...
  • Page 28 0A-13 General Information: 09913–70210 09915–40610 09915–63311 09915–64512 09915–74521 Bearing installer set Oil filter wrench Compression gauge Compression gauge Oil pressure gauge attachment hose 09915–74540 09915–77331 09916–10911 09916–14510 09916–14522 Oil pressure gauge Meter (for high Valve lapper set Valve spring Valve spring attachment pressure) compressor...
  • Page 29 General Information: 0A-14 09924–84510 09924–84521 09925–18011 09930–10121 09930–11920 Bearing installer set Bearing installer set Steering bearing Spark plug wrench set Torx bit (JT40H) installer 09930–11930 09930–11940 09930–11950 09930–30104 09930–30450 Torx bit (JT30H) Bit holder Torx wrench Rotor remover slide Rotor remover bolt shaft 09930–44530 09930–73140...
  • Page 30 0A-15 General Information: 09940–94930 09941–34513 09941–54911 09941–74911 09943–74111 Front fork spacer Steering race installer Bearing outer race Steering bearing Fork oil level gauge holder remover installer 99565–01010–012 CD-ROM Ver.12...

  • Page 31: Maintenance And Lubrication

    Maintenance and Lubrication: 0B-1 Maintenance and Lubrication General Information Precautions Precautions for Maintenance B815H20200001 The “Periodic Maintenance Schedule Chart” lists the recommended intervals for all the required periodic service work necessary to keep the motorcycle operating at peak performance and economy. Maintenance intervals are expressed in terms of kilometers, miles and months for your convenience.
  • Page 32 0B-2 Maintenance and Lubrication: Interval 1 000 6 000 12 000 18 000 24 000 Item miles 4 000 7 500 11 000 14 500 months Brakes — Brake fluid Replace every 2 years. — Brake hoses Replace every 4 years. Tires —...
  • Page 33 Maintenance and Lubrication: 0B-3 Repair Instructions Air Cleaner Element Replacement B815H20206001 Replace air cleaner element Every 18 000 km (11 000 miles, 36 months) Refer to “Air Cleaner Element Removal and Installation in Section 1D (Page 1D-6)”. Air Cleaner Element Inspection B815H20206002 Inspect air cleaner element Every 6 000 km (4 000 miles, 12 months)

  • Page 34: Exterior Parts

    0B-4 Maintenance and Lubrication: Valve Clearance Inspection and Adjustment 6) Remove the ignition coil/caps (4) and spark plugs. B815H20206004 Refer to “Ignition Coil / Plug Cap and Spark Plug Removal and Installation in Section 1H (Page 1H- Inspect valve clearance 6)”.
  • Page 35 Maintenance and Lubrication: 0B-5 11) Remove the cylinder head cover. Refer to “Engine 13) Turn the crankshaft clockwise to bring the line “C” on Top Side Disassembly in Section 1D (Page 1D-27)”. the starter clutch to the slit “D” of valve timing inspection hole and also to bring the notches “E”...
  • Page 36 0B-6 Maintenance and Lubrication: 15) Turn the crankshaft clockwise 360° (one full rotation) Adjustment and position the notches “E” on the left end of both The clearance is adjusted by replacing the existing camshafts to the positions as shown in the figure. tappet shim with a thicker or thinner shim.
  • Page 37 Maintenance and Lubrication: 0B-7 (INTAKE SIDE) I823H1020070-02...
  • Page 38 0B-8 Maintenance and Lubrication: (EXHAUST SIDE) I823H1020071-02...
  • Page 39 Maintenance and Lubrication: 0B-9 6) Install the camshafts and cam chain tension adjuster. Spark Plug Gap Refer to “Engine Top Side Assembly in Section 1D 1) Remove the spark plugs. Refer to “Ignition Coil / (Page 1D-31)”. Plug Cap and Spark Plug Removal and Installation in 7) Rotate the engine so that the tappet is depressed Section 1H (Page 1H-6)”.
  • Page 40 0B-10 Maintenance and Lubrication: Fuel Line Inspection Engine Oil and Filter Replacement B815H20206007 B815H20206008 Inspect fuel line Replace engine oil Every 6 000 km (4 000 miles, 12 months) Initially at 1 000 km (600 miles, 2 months) and every 6 000 km (4 000 miles, 12 months) thereafter Inspect the fuel line in the following procedures: Replace oil filter...
  • Page 41 2) Start up the engine and allow it to run for several leaks. Also, do not use a genuine Suzuki minutes at idle speed. automobile oil filter on this motorcycle.
  • Page 42 0B-12 Maintenance and Lubrication: 5) Install the new oil filter. Turn it by hand until you feel Throttle Cable Play Inspection and Adjustment B815H20206009 that the oil filter O-ring contacts the oil filter mounting surface. Then, tighten the oil filter two full turns (or to Inspect throttle cable play specified torque) using the special tool.
  • Page 43 Maintenance and Lubrication: 0B-13 Evaporative Emission Control System Engine Coolant Change Refer to “Engine Coolant Description in Section 1F Inspection (E-33 only) B815H20206011 (Page 1F-1)”. Inspect evaporative emission control system WARNING Every 12 000 km (7 500 miles, 24 months) Do not open the radiator cap when the engine Inspect the evaporative emission control system is hot, as you may be injured by escaping hot...
  • Page 44 0B-14 Maintenance and Lubrication: Air Bleeding From the Cooling Circuit Clutch System Inspection B815H20206014 1) Remove the right cowling. Refer to “Exterior Parts Inspect clutch hose and clutch fluid Removal and Installation in Section 9D (Page 9D- Every 6 000 km (4 000 miles, 12 months) 14)”.
  • Page 45 Maintenance and Lubrication: 0B-15 Clutch Hose Inspection Drive Chain Inspection and Adjustment B815H20206017 1) Remove the left side cowling. Refer to “Exterior Inspect drive chain Parts Removal and Installation in Section 9D Initially at 1 000 km (600 miles, 2 months) and every (Page 9D-14)”.
  • Page 46 0B-16 Maintenance and Lubrication: Drive Chain Length Inspection 4) Loosen or tighten both chain adjuster bolts (3) until there is 20 – 30 mm (0.8 – 1.2 in) of slack “a” at the 1) Loosen the axle nut (1). middle of the chain between the engine and rear 2) Loosen the chain adjuster lock-nuts (2).
  • Page 47 Brake Fluid Level Check • The standard drive chain is a RK 1) Keep the motorcycle upright and place the GB50GSVZ4. SUZUKI recommends to use handlebars straight. this standard drive chain as a replacement. 2) Check the brake fluid level by observing the lower limit lines on the front and rear brake fluid reservoirs.
  • Page 48 0B-18 Maintenance and Lubrication: Brake Pads Check Front and Rear Brake Hose Inspection The extent of brake pad wear can be checked by Inspect the brake hoses and hose joints for crack, observing the grooved limit line “A” on the pad. When the damage or brake oil leakage.
  • Page 49 Maintenance and Lubrication: 0B-19 Brake Hose Replacement Tire Pressure If the tire pressure is too high or too low, steering will be Replace brake hose adversely affected and tire wear increased. Therefore, Every 4 years maintain the correct tire pressure for good roadability or Refer to “Front Brake Hose Removal and Installation in shorter tire life will result.
  • Page 50 0B-20 Maintenance and Lubrication: Steering System Inspection Rear Suspension Inspection B815H20206021 B815H20206023 Inspect steering system Inspect rear suspension Initially at 1 000 km (600 miles, 2 months) and every Every 12 000 km (7 500 miles, 24 months) 12 000 km (7 500 miles, 24 months) thereafter Inspect the rear shock absorber for oil leakage and Steering should be adjusted properly for smooth turning check that there is no play in the swingarm.
  • Page 51 Maintenance and Lubrication: 0B-21 Chassis Bolt and Nut Inspection B815H20206024 Tighten chassis bolt and nut Initially at 1 000 km (600 miles, 2 months) and every 6 000 km (4 000 miles, 12 months) thereafter Check that all chassis bolts and nuts are tightened to their specified torque.
  • Page 52 0B-22 Maintenance and Lubrication: I815H1020059-02 I815H1020061-03 Union bolt (Front brake) 23 N⋅m (2.3 kgf-m, 16.5 lb-ft) Union bolt (Rear brake) 23 N⋅m (2.3 kgf-m, 16.5 lb-ft) Front axle bolt 100 N⋅m (10.0 kgf-m, 72.5 lb-ft) Front footrest bolt 23 N⋅m (2.3 kgf-m, 16.5 lb-ft) Brake disc bolt (Front) 23 N⋅m (2.3 kgf-m, 16.5 lb-ft) Rear brake master cylinder mounting bolt 10 N⋅m (1.0 kgf-m, 7.0 lb-ft)
  • Page 53 Maintenance and Lubrication: 0B-23 Compression Pressure Check B815H20206025 Refer to “Compression Pressure Check in Section 1D (Page 1D-3)”. Oil Pressure Check B815H20206026 Refer to “Oil Pressure Check in Section 1E (Page 1E- 5)”. SDS Check B815H20206027 Refer to “SDS Check in Section 1A (Page 1A-17)”. I815H1020065-02 Rear sprocket nut 60 N⋅m (6.0 kgf-m, 43.5 lb-ft) Specifications...
  • Page 54 0B-24 Maintenance and Lubrication: Special Tools and Equipment Recommended Service Material B815H20208001 Material SUZUKI recommended product or Specification Note Brake fluid DOT 4 — (Page 0B-14) / (Page 0B-17) NOTE Required service material is also described in the following. “Lubrication Points (Page 0B-2)”...

  • Page 55: Service Data

    Service Data: 0C-1 Service Data General Information Specifications Service Data B815H20307001 Valve + Guide Unit: mm (in) Item Standard Limit 33 (1.30) — Valve diam. 27.5 (1.08) — 0.08 – 0.18 (0.003 – 0.007) — Valve clearance (when cold) 0.18 – 0.28 (0.007 – 0.011) —...
  • Page 56 0C-2 Service Data: Cylinder + Piston + Piston Ring Unit: mm (in) Item Standard Limit 1 000 kPa Compression pressure 1 400 – 1 800 kPa (14 – 18 kgf/cm , 199 – 256 psi) (10 kgf/cm , 142 psi) 200 kPa Compression pressure difference —...
  • Page 57 Service Data: 0C-3 Oil Pump Item Standard Limit 200 – 500 kPa Oil pressure (at 60 °C, 140 °F) (2.0 – 5.0 kgf/cm , 28.4 – 71.1 psi) — at 3 000 r/min Clutch Unit: mm (in) Item Standard Limit No.
  • Page 58 0C-4 Service Data: Thermostat + Radiator + Fan + Coolant Item Standard/Specification Note Thermostat valve opening Approx. 82 °C (180 °F) — temperature Over 8 mm (0.31 in) and at 95 °C (203 °F) Thermostat valve lift — 20 °C Approx.
  • Page 59 Service Data: 0C-5 FI Sensors Item Standard/Specification Note 180 – 280 Ω CKP sensor resistance CKP sensor peak voltage 3.0 V and more When cranking IAP sensor input voltage 4.5 – 5.5 V IAP sensor output voltage Approx. 2.7 V at idle speed TP sensor input voltage 4.5 –...
  • Page 60 0C-6 Service Data: Throttle Body Item Specification Bore size 44 mm (1.73 in) I.D. No. 15H1 (For E-33), 15H0 (For the others) 1 150 ± 100 r/min Idle r/min Throttle cable play 2.0 – 4.0 mm (0.08 – 0.16 in) Electrical Unit: mm Item...
  • Page 61 Service Data: 0C-7 Wattage Unit: W Specification Item E-02, 19, 24 The other countries ← Headlight ← ← Position/Parking light 5 x 2 ← Brake light/Taillight ← Turn signal light 21 x 4 ← License plate light ← Tachometer light ←...
  • Page 62 Front fork oil level (Without spring, 95 (3.7) — outer tube fully compressed) Front fork oil type SUZUKI FORK OIL L01 or an equivalent fork oil — Front fork oil capacity (Each leg) 532 ml (18.0/18.7 US/lmp oz) — Front fork inner tube O.D 43 (1.7)
  • Page 63 Service Data: 0C-9 Tightening Torque List B815H20307002 Engine Item N⋅m kgf-m lb-ft Exhaust pipe bolt 16.5 Exhaust pipe mounting bolt 16.5 Muffler mounting bolt 18.0 Muffler connecting bolt 16.5 Muffler joint nut 18.0 Speed sensor rotor bolt 20.0 Engine sprocket nut 14.5 105.0 Speed sensor bolt...
  • Page 64 0C-10 Service Data: Item N⋅m kgf-m lb-ft Bearing retainer screw Cam chain guide retainer screw Balancer shaft arm bolt Balancer cover bolt Balancer pipe bolt Oil strainer bolt Oil pan bolt Oil pipe bolt (Camshaft housing) Oil pipe bolt [M6] Oil pipe union bolt [M14] 17.5...
  • Page 65 Service Data: 0C-11 Item N⋅m kgf-m lb-ft Handlebar clamp bolt Master cylinder holder bolt (Upper and Lower) Front brake caliper mounting bolt 28.0 Front brake caliper housing bolt 16.0 Front brake pad mounting pin 11.0 Brake hose union bolt 16.5 Clutch master cylinder mounting bolt Clutch hose union bolt 16.5...
  • Page 66 0C-12 Service Data:...

  • Page 67: Table Of Contents

    Table of Contents 1- i Section 1 Engine CONTENTS Precautions ..........1-1 DTC “C24” (P0351), “C25” (P0352), “C26” (P0353) or “C27” (P0354): Ignition System Precautions............. 1-1 Malfunction............1A-71 Precautions for Engine.......... 1-1 DTC “C28” (P1655): Secondary Throttle Engine General Information and Valve Actuator (STVA) Malfunction....1A-71 DTC “C29”...
  • Page 68 1-ii Table of Contents Exhaust Emission Control System STP Sensor Removal and Installation ....1C-8 Description ............1B-3 STV Actuator Inspection ........1C-9 Noise Emission Control System Description..1B-6 STV Actuator Removal and Installation ....1C-9 Evaporative Emission Control System ISC Valve Inspection...........1C-9 Diagram (Only for E-33) ........
  • Page 69 Table of Contents 1-iii Piston Ring Removal and Installation ....1D-60 General Description ..........1F-1 Piston and Piston Ring Inspection ....1D-61 Engine Coolant Description......... 1F-1 Engine Bottom Side Disassembly .....1D-63 Schematic and Routing Diagram ......1F-2 Engine Bottom Side Assembly......1D-71 Cooling Circuit Diagram ........1F-2 Crank Balancer Disassembly and Assembly ..1D-88 Water Hose Routing Diagram ......
  • Page 70 1-iv Table of Contents Fuel Mesh Filter Inspection and Cleaning..1G-14 Turn Signal / Side-stand Relay Removal and Fuel Injector / Fuel Delivery Pipe / T-joint Installation ............1I-7 Removal and Installation........ 1G-14 Side-stand / Ignition Interlock System Parts Fuel Injector Inspection and Cleaning....1G-14 Inspection............
  • Page 71 Precautions: Precautions Engine Precautions Precautions for Engine B815H21000001 Refer to “General Precautions in Section 00 (Page 00-1)” and “Precautions for Electrical Circuit Service in Section 00 (Page 00-2)”.

  • Page 72: Engine General Information And Diagnosis

    1A-1 Engine General Information and Diagnosis: Engine General Information and Diagnosis Engine General Description Injection Timing Description B815H21101001 Injection Time (Injection Volume) The factors to determine the injection time include the basic fuel injection time, which is calculated on the basis of the intake air pressure, engine speed and throttle opening angle, and various compensations.
  • Page 73 Engine General Information and Diagnosis: 1A-2 Signal Descriptions During acceleration, the fuel injection time (volume) is increased, ACCELERATION SIGNAL/ DECELERATION in accordance with the throttle opening speed and engine rpm. SIGNAL During deceleration, the fuel injection time (volume) is decreased. Injection Stop Control Signal Descriptions...
  • Page 74 1A-3 Engine General Information and Diagnosis: NOTE The FI light “B” turns ON about 3 seconds after turning the ignition switch ON. “B” “A” I815H1110002-03 Dealer Mode The defective function is memorized in the computer. Use the special tool’s coupler to connect to the mode select switch.
  • Page 75 Engine General Information and Diagnosis: 1A-4 Combination Cooling meter Cooling fan relay Cooling B/G Y/Bl O/R IG switch/Immobilizer signal R/Bl O/Bl Speed sensor R/Bl (E-02, 19, 24) Lg/W (E-03, 28, 33) CMPS Lg/G Lg/Bl Gr/W Gr/B Gr/Y Gr/R Secondary Secondary Secondary CKPS fuel...
  • Page 76 1A-5 Engine General Information and Diagnosis: Terminal Alignment of ECM Coupler B815H21102002 I823H1110002-01 TERMINAL NO. CIRCUIT TERMINAL NO. CIRCUIT STVA signal (STVA, 2A) ISC valve signal (ISC, 2A) STVA signal (STVA, 1A) ISC valve signal (ISC, 1A) — Drive mode selector (DMS 1) —...

  • Page 77: Fi System Parts Location

    Engine General Information and Diagnosis: 1A-6 Component Location FI System Parts Location B815H21103001 I815H1110006-03 “A”: ECM “G”: Cooling fan relay “M”: Fuel pump relay (FP relay) “B”: Secondary fuel infector “H”: Cooling fan “N”: Fuel pump “C”: Primary fuel infector “I”: Engine coolant temperature sensor (ECTS) “O”: Ignition coil (IG coil) “D”: Intake air temperature sensor (IATS)
  • Page 78 1A-7 Engine General Information and Diagnosis: I815H1110007-03 “A”: ECM “V”: Tip-over sensor (TOS) “Q”: Idle speed control valve (ISC valve) “W”: Heated oxygen sensor (HO2S) “R”: Secondary throttle position sensor (STPS) “X”: Gear position switch (GP switch) “S”: Throttle position sensor (TPS) “Y”: Drive mode selector (DMS) “T”: Secondary throttle valve actuator (STVA) “Z”: EVAP system purge control valve (For E-33)
  • Page 79 Engine General Information and Diagnosis: 1A-8 Diagnostic Information and Procedures Engine Symptom Diagnosis B815H21104001 Condition Possible cause Correction / Reference Item Engine will not start or is Valve clearance out of adjustment. Adjust. hard to start Worn valve guide or poor seating of Repair or replace.
  • Page 80 1A-9 Engine General Information and Diagnosis: Condition Possible cause Correction / Reference Item Engine stalls often Defective IAP sensor or circuit. Repair or replace. (Incorrect fuel/air mixture) Clogged fuel filter. Clean or replace. Defective fuel pump. Replace. Defective fuel pressure regulator. Replace.
  • Page 81 Engine General Information and Diagnosis: 1A-10 Condition Possible cause Correction / Reference Item Noisy engine (Noise Too much play on pump shaft bearing. Replace. seems to come from Worn or damaged impeller shaft. Replace. water pump) Worn or damaged mechanical seal. Replace.
  • Page 82 1A-11 Engine General Information and Diagnosis: Condition Possible cause Correction / Reference Item Engine lacks power Low fuel pressure. Repair or replace. (Defective control circuit Defective TP sensor. Replace. or sensor) Defective IAT sensor. Replace. Defective CKP sensor. Replace. Defective GP switch. Replace.

  • Page 83: Engine General Information And

    Engine General Information and Diagnosis: 1A-12 Self-Diagnostic Procedures 5) Check the DTC to determine the malfunction part. B815H21104002 Refer to “DTC Table (Page 1A-20)”. Use of Mode Select Switch Special tool NOTE (A): 09930–82720 (Mode select switch) • Do not disconnect the coupler from ECM, battery cable from battery, ECM ground wire from engine or main fuse before confirming DTC (Diagnostic Trouble Code)
  • Page 84 1A-13 Engine General Information and Diagnosis: Use of SDS 2) Set up the SDS tools. (Refer to the SDS operation manual for further details.) NOTE Special tool • Do not disconnect the coupler from ECM, (A): 09904–41010 (SDS Set) battery cable from battery, ECM ground (B): 99565–01010–012 (CD-ROM Ver.12) wire from the engine or main fuse before confirming DTC (Diagnostic Trouble Code)

  • Page 85: Show Data When Trouble

    Engine General Information and Diagnosis: 1A-14 3) Click the DTC inspection button (1). Use of SDS Diagnosis Reset Procedures B815H21104003 NOTE The malfunction code is memorized in the ECM also when the lead wire coupler of any sensor is disconnected. Therefore, when a lead wire coupler has been disconnected at the time of diagnosis, erase the stored malfunction history code using SDS.
  • Page 86 1A-15 Engine General Information and Diagnosis: 6) Follow the displayed instructions. 7) Check that both “Current DTC” (3) and “Past DTC” (4) are deleted (NIL). I705H1110006-01 I705H1110008-01 8) Close the SDS tool and turn the ignition switch OFF. 9) Disconnect the SDS tool and install the front seat. I705H1110009-01 Show Data When Trouble (Displaying Data at the Time of DTC) B815H21104004...
  • Page 87 Engine General Information and Diagnosis: 1A-16 1) Click “Show data when trouble” (1) to display the data. I718H1110269-02 2) Click the drop down button (2), either “Failure #1” or “Failure #2” can be selected. I718H1110270-01...
  • Page 88 1A-17 Engine General Information and Diagnosis: SDS Check B815H21104005 Using SDS, sample the data at the time of new and periodic vehicle inspections. After saving the sampled data in the computer, file them by model and by user. The periodically filed data help improve the accuracy of troubleshooting since they can indicate the condition of vehicle functions that has changed with time.
  • Page 89 Engine General Information and Diagnosis: 1A-18 Data at 3 000 r/min under no load Approx. 3 000 r/min Check the water temperature. XX ˚C Check the manifold absolute pressure. XXX kPa I823H1110209-02 Data at the time of racing Throttle: Quick wide open Throttle: Slowly open Secondary throttle valve opens...
  • Page 90 1A-19 Engine General Information and Diagnosis: Data of intake negative pressure during idling (100 °C) Check the manifold absolute pressure. XXX kPa Check the engine coolant temperature. XX ˚C I823H1110211-01 Data of manifold absolute pressure operation at the time of starting Check the manifold absolute pressure.

  • Page 91: Dtc Table

    Engine General Information and Diagnosis: 1A-20 Example of Trouble Three data; value 1 (current data 1), value 2 (past data 2) and value 3 (past data 3); can be made in comparison by showing them in the graph. Read the change of value by comparing the current data to the past data that have been saved under the same condition, then you may determine how changes have occurred with the passing of time and identify what problem is currently occurring.
  • Page 92 1A-21 Engine General Information and Diagnosis: Code Malfunction Part Remarks C23 (P1651-H/L) Tip-over sensor (TOS) (Page 1A-64) C24 (P0351) Ignition signal #1 (IG coil #1) For #1 cylinder (Page 1A-71) C25 (P0352) Ignition signal #2 (IG coil #2) For #2 cylinder (Page 1A-71) C26 (P0353) Ignition signal #3 (IG coil #3)
  • Page 93 Engine General Information and Diagnosis: 1A-22 Fail-Safe Function Table B815H21104007 FI system is provided with fail-safe function to allow the engine to start and the motorcycle to run in a minimum performance necessary even under malfunction condition. Item Fail-Safe Mode Starting Ability Running Ability When camshaft position signal has failed...
  • Page 94 1A-23 Engine General Information and Diagnosis: The engine can start and can run even if the signal in the table is not received from each sensor. But, the engine running condition is not complete, providing only emergency help (by fail-safe circuit). In this case, it is necessary to bring the motorcycle to the workshop for complete repair.
  • Page 95 Engine General Information and Diagnosis: 1A-24 FI System Troubleshooting B815H21104008 Customer Complaint Analysis Record details of the problem (failure, complaint) and how it occurred as described by the customer. For this purpose, use of such an inspection form such as following will facilitate collecting information to the point required for proper analysis and diagnosis.

  • Page 96: Malfunction Code And Defective Condition

    1A-25 Engine General Information and Diagnosis: Visual Inspection Prior to diagnosis using the mode select switch or SDS, perform the following visual inspections. The reason for visual inspection is that mechanical failures (such as oil leakage) cannot be displayed on the screen with the use of mode select switch or SDS.
  • Page 97 Engine General Information and Diagnosis: 1A-26 Malfunction Detected Item Detected Failure Condition Check For Code The sensor voltage should be the following. 0.15 V ≤ Sensor voltage < 4.85 V ECT sensor, lead wire/coupler In other than the above range, C15 (P0115) is connection indicated.
  • Page 98 1A-27 Engine General Information and Diagnosis: Malfunction Detected Item Detected Failure Condition Check For Code Gear position signal voltage should be higher than the following for 3 seconds and more. GP switch, wiring/coupler Gear position sensor voltage ≥ 0.6 V Gear position signal P0705 connection, gearshift cam, etc.
  • Page 99 Engine General Information and Diagnosis: 1A-28 * : Immobilizer system equipped model only. (E-02, 19, 24) DTC “C11” (P0340) CMP Sensor Circuit Malfunction B815H21104010 Detected Condition and Possible Cause Detected Condition Possible Cause The signal does not reach ECM for 4 sec. or more, after •...
  • Page 100 1A-29 Engine General Information and Diagnosis: Step Action 1) Turn the ignition switch OFF. • B/Y, R or B/Br wire • Inspect that metal open or shorted to particles or foreign 2) Lift and support the fuel tank. Refer to “Fuel Tank the ground.

  • Page 101: Dtc "C12" (P0335): Ckp Sensor Circuit Malfunction

    Engine General Information and Diagnosis: 1A-30 DTC “C12” (P0335): CKP Sensor Circuit Malfunction B815H21104011 Detected Condition and Possible Cause Detected Condition Possible Cause The signal does not reach ECM for 4 sec. or more, after • Metal particles or foreign material being stuck on the receiving the starter signal.
  • Page 102 1A-31 Engine General Information and Diagnosis: Step Action 1) Turn the ignition switch OFF. Go to Step 2. Replace the CKP sensor with a new one. 2) Lift and support the fuel tank. Refer to “Fuel Tank Removal and Installation in Section 1G (Page 1G-9)”. 3) Check the CKP sensor coupler (1) for loose or poor contacts.
  • Page 103 Engine General Information and Diagnosis: 1A-32 Step Action 5) If OK, then check the continuity between each terminal Go to Step 2. Replace the CKP and ground. sensor with a new one. Special tool (A): 09900–25008 (Multi-circuit tester set) CKP sensor continuity ∞...

  • Page 104: Dtc "C13" (P0105-H/L): Iap Sensor Circuit Malfunction

    1A-33 Engine General Information and Diagnosis: DTC “C13” (P0105-H/L): IAP Sensor Circuit Malfunction B815H21104012 Detected Condition and Possible Cause Detected Condition Possible Cause IAP sensor voltage is not within the • Clogged vacuum passage between throttle body and following range. IAP sensor.
  • Page 105 Engine General Information and Diagnosis: 1A-34 C13 (Use of mode select switch) Step Action 1) Turn the ignition switch OFF. Go to Step 2. • Loose or poor contacts on the ECM 2) Lift and support the fuel tank. Refer to “Fuel Tank coupler.
  • Page 106 1A-35 Engine General Information and Diagnosis: P0105-H for IAP sensor (Use of SDS) Step Action 1) Turn the ignition switch OFF. Go to Step 3. G/B wire shorted to VCC, or B/Br wire open. 2) Lift and support the fuel tank. Refer to “Fuel Tank Removal and Installation in Section 1G (Page 1G-9)”.
  • Page 107 Engine General Information and Diagnosis: 1A-36 Step Action 6) Disconnect the ECM coupler. Refer to “ECM Removal Go to Step 3. G/B wire shorted to and Installation in Section 1C (Page 1C-2)”. VCC, or B/Br wire open. 7) Insert the needle pointed probes to the lead wire coupler. 8) Check the continuity between the G/B wire and terminal “9”.
  • Page 108 1A-37 Engine General Information and Diagnosis: P0105-L for IAP sensor (Use of SDS) Step Action 1) Turn the ignition switch OFF. Go to Step 2. R and G/B wire open, G/ B wire shorted to the 2) Lift and support the fuel tank. Refer to “Fuel Tank ground.
  • Page 109 Engine General Information and Diagnosis: 1A-38 Step Action 6) Disconnect the ECM coupler. Refer to “ECM Removal Go to Step 2. R and G/B wire open, G/ and Installation in Section 1C (Page 1C-2)”. B wire shorted to the ground. 7) Insert the needle pointed probes to the lead wire coupler.
  • Page 110 1A-39 Engine General Information and Diagnosis: Step Action 1) Turn the ignition switch OFF. • G/B, R or B/Br wire If check result is not open or shorted to satisfactory, replace the 2) Remove the IAP sensor. Refer to “IAP Sensor Removal the ground, or poor IAP sensor with a new and Installation in Section 1C (Page 1C-3)”.

  • Page 111: Dtc "C14" (P0120-H/L): Tp Sensor Circuit Malfunction

    Engine General Information and Diagnosis: 1A-40 DTC “C14” (P0120-H/L): TP Sensor Circuit Malfunction B815H21104013 Detected Condition and Possible Cause Detected Condition Possible Cause Output voltage is not within the following • TP sensor maladjusted. range. • TP sensor circuit open or short. Difference between actual throttle opening •...
  • Page 112 1A-41 Engine General Information and Diagnosis: C14 (Use of mode select switch) Step Action 1) Turn the ignition switch OFF. Go to Step 3. • Loose or poor contacts on the ECM 2) Lift and support the fuel tank. Refer to “Fuel Tank coupler.
  • Page 113 Engine General Information and Diagnosis: 1A-42 P0120-H (Use of SDS) Step Action 1) Turn the ignition switch OFF. Go to Step 3. P/B wire shorted to VCC, or B/Br wire open. 2) Lift and support the fuel tank. Refer to “Fuel Tank Removal and Installation in Section 1G (Page 1G-9)”.
  • Page 114 1A-43 Engine General Information and Diagnosis: Step Action 7) Check the continuity between the P/B wire and terminal Go to Step 3. P/B wire shorted to “8”. Also, check the continuity between the B/Br wire and VCC, or B/Br wire open. terminal “29”.
  • Page 115 Engine General Information and Diagnosis: 1A-44 P0120-L (Use of SDS) Step Action 1) Turn the ignition switch OFF. Go to Step 2. R and P/B wire open, or P/B wire shorted to the 2) Lift and support the fuel tank. Refer to “Fuel Tank ground.
  • Page 116 1A-45 Engine General Information and Diagnosis: Step Action 6) Disconnect the ECM coupler. Refer to “ECM Removal Go to Step 2. R and P/B wire open, or and Installation in Section 1C (Page 1C-2)”. P/B wire shorted to the ground. 7) Check the continuity between the P/B wire and terminal “8”.
  • Page 117 Engine General Information and Diagnosis: 1A-46 Step Action 1) Turn the ignition switch OFF. • P/B, R or B/Br wire If check result is not open or shorted to satisfactory, replace TP 2) Connect the special tool between the TP sensor and its the ground, or poor sensor with a new one.

  • Page 118: Dtc "C15" (P0115-H/L): Ect Sensor Circuit Malfunction

    1A-47 Engine General Information and Diagnosis: DTC “C15” (P0115-H/L): ECT Sensor Circuit Malfunction B815H21104014 Detected Condition and Possible Cause Detected Condition Possible Cause Output voltage is not with in the following • ECT sensor circuit open or short. range. • ECT sensor malfunction. 0.15 V ≤...
  • Page 119 Engine General Information and Diagnosis: 1A-48 C15 (Use of mode select switch) Step Action 1) Turn the ignition switch OFF. Go to Step 2. • Loose or poor contacts on the ECM 2) Lift and support the fuel tank. Refer to “Fuel Tank coupler.
  • Page 120 1A-49 Engine General Information and Diagnosis: P0115-H (Use of SDS) Step Action 1) Turn the ignition switch OFF. Go to Step 2. B/Bl or B/Br wire open. 2) Lift and support the fuel tank. Refer to “Fuel Tank Removal and Installation in Section 1G (Page 1G-9)”. 3) Check the ECT sensor coupler (1) for loose or poor contacts.
  • Page 121 Engine General Information and Diagnosis: 1A-50 P0115-L (Use of SDS) Step Action 1) Turn the ignition switch OFF. Go to Step 2. • B/Bl wire shorted to the ground. 2) Lift and support the fuel tank. Refer to “Fuel Tank Removal and Installation in Section 1G (Page 1G-9)”.
  • Page 122 1A-51 Engine General Information and Diagnosis: Step Action 9) Measure the output voltage between the B/Bl wire and Go to Step 2. • B/Bl wire shorted to ground. the ground. • If wire is OK, go to Special tool Step 2. (A): 09900–25008 (Multi-circuit tester set) (B): 09900–25009 (Needle pointed probe set) Tester knob indication...

  • Page 123: Dtc "C21" (P0110-H/L): Iat Sensor Circuit Malfunction

    Engine General Information and Diagnosis: 1A-52 DTC “C21” (P0110-H/L): IAT Sensor Circuit Malfunction B815H21104015 Detected Condition and Possible Cause Detected Condition Possible Cause Output voltage is not with in the following • IAT sensor circuit open or short. range. • IAT sensor malfunction. 0.15 V ≤...
  • Page 124 1A-53 Engine General Information and Diagnosis: C21 (Use of mode select switch) Step Action 1) Turn the ignition switch OFF. Go to Step 2. • Loose or poor contacts on the ECM 2) Lift and support the fuel tank. Refer to “Fuel Tank coupler.
  • Page 125 Engine General Information and Diagnosis: 1A-54 P0110-H (Use of SDS) Step Action 1) Turn the ignition switch OFF. Connect the ECM Dg or B/Br wire open. coupler and go to Step 2) Lift and support the fuel tank. Refer to “Fuel Tank Removal and Installation in Section 1G (Page 1G-9)”.
  • Page 126 1A-55 Engine General Information and Diagnosis: P0110-L (Use of SDS) Step Action 1) Turn the ignition switch OFF. Go to Step 2. • Dg wire shorted to the ground. 2) Lift and support the fuel tank. Refer to “Fuel Tank Removal and Installation in Section 1G (Page 1G-9)”.
  • Page 127 Engine General Information and Diagnosis: 1A-56 Step Action 9) Measure the output voltage between the Dg wire and Go to Step 2. • Dg wire shorted to ground. the ground. • If wire is OK, go to Special tool Step 2. (A): 09900–25008 (Multi-circuit tester set) (B): 09900–25009 (Needle pointed probe set) Tester knob indication...

  • Page 128: Dtc "C22" (P01450-H/L): Ap Sensor Circuit Malfunction

    1A-57 Engine General Information and Diagnosis: DTC “C22” (P01450-H/L): AP Sensor Circuit Malfunction B815H21104016 Detected Condition and Possible Cause Detected Condition Possible Cause AP sensor voltage is not within the • Clogged vacuum passage with dust. following range. • AP sensor circuit open or shorted to the ground. 0.5 V ≤...
  • Page 129 Engine General Information and Diagnosis: 1A-58 C22 (Use of mode select switch) Step Action 1) Turn the ignition switch OFF. Go to Step 2. • Loose or poor contacts on the ECM 2) Remove the front seat. Refer to “Exterior Parts Removal coupler.
  • Page 130 1A-59 Engine General Information and Diagnosis: P1450-H (Use of SDS) Step Action 1) Turn the ignition switch OFF. Go to Step 2. G/Y wire shorted to VCC, or B/Br wire open. 2) Remove the front seat. Refer to “Exterior Parts Removal and Installation in Section 9D (Page 9D-14)”.
  • Page 131 Engine General Information and Diagnosis: 1A-60 Step Action 6) Disconnect the ECM coupler. Refer to “ECM Removal Go to Step 2. G/Y wire shorted to and Installation in Section 1C (Page 1C-2)”. VCC, or B/Br wire open. 7) Insert the needle pointed probes to the lead wire coupler. 8) Check the continuity between the G/Y wire and terminal “26”.
  • Page 132 1A-61 Engine General Information and Diagnosis: P01450-L (Use of SDS) Step Action 1) Turn the ignition switch OFF. Go to Step 2. R and G/Y wire open, G/ Y wire shorted to the 2) Remove the front seat. Refer to “Exterior Parts Removal ground.
  • Page 133 Engine General Information and Diagnosis: 1A-62 Step Action 6) Disconnect the ECM coupler. Refer to “ECM Removal Go to Step 2. R and G/Y wire open, G/ and Installation in Section 1C (Page 1C-2)”. Y wire shorted to the ground. 7) Insert the needle pointed probes to the lead wire coupler.
  • Page 134 1A-63 Engine General Information and Diagnosis: Step Action 1) Turn the ignition switch OFF. • G/Y, R or B/Br wire If check result is not open or shorted to satisfactory, replace the 2) Remove the AP sensor. Refer to “IAP Sensor Removal the ground, or poor AP sensor with a new and Installation in Section 1C (Page 1C-3)”.

  • Page 135: Dtc "C23" (P1651-H/L): To Sensor Circuit Malfunction

    Engine General Information and Diagnosis: 1A-64 DTC “C23” (P1651-H/L): TO Sensor Circuit Malfunction B815H21104017 Detected Condition and Possible Cause Detected Condition Possible Cause The sensor voltage should be the • TO sensor circuit open or short. following for 2 sec. and more, after ignition •...
  • Page 136 1A-65 Engine General Information and Diagnosis: C23 (Use of mode select switch) Step Action 1) Turn the ignition switch OFF. Go to Step 2. Replace the TO sensor with a new one. Refer to 2) Lift and support the fuel tank. Refer to “Fuel Tank “TO Sensor Removal Removal and Installation in Section 1G (Page 1G-9)”.
  • Page 137 Engine General Information and Diagnosis: 1A-66 P1651-H (Use of SDS) Step Action 1) Turn the ignition switch OFF. Go to Step 2. B wire shorted to VCC, or B/Br wire open. 2) Lift and support the fuel tank. Refer to “Fuel Tank Removal and Installation in Section 1G (Page 1G-9)”.
  • Page 138 1A-67 Engine General Information and Diagnosis: Step Action 6) Disconnect the ECM coupler. Refer to “ECM Removal Go to Step 2. B wire shorted to VCC, and Installation in Section 1C (Page 1C-2)”. or B/Br wire open. 7) Insert the needle pointed probes to the lead wire coupler. 8) Check the continuity between the B wire and terminal “22”.
  • Page 139 Engine General Information and Diagnosis: 1A-68 P1651-L (Use of SDS) Step Action 1) Turn the ignition switch OFF. Go to Step 2. R or B wire open, or B wire shorted to the 2) Lift and support the fuel tank. Refer to “Fuel Tank ground.
  • Page 140 1A-69 Engine General Information and Diagnosis: Step Action 6) Disconnect the ECM coupler. Refer to “ECM Removal Go to Step 2. R or B wire open, or B and Installation in Section 1C (Page 1C-2)”. wire shorted to the ground. 7) Insert the needle pointed probes to the lead wire coupler.
  • Page 141 Engine General Information and Diagnosis: 1A-70 Step Action 1) Connect the ECM coupler and TO sensor coupler. • R, B or B/Br wire • Loosen or poor open or shorted to contacts on the ECM 2) Remove the TO sensor. Refer to “TO Sensor Removal the ground, or poor coupler.

  • Page 142: Dtc "C24" (P0351), "C25" (P0352), "C26" (P0353) Or "C27" (P0354): Ignition System Malfunction

    1A-71 Engine General Information and Diagnosis: DTC “C24” (P0351), “C25” (P0352), “C26” (P0353) or “C27” (P0354): Ignition System Malfunction B815H21104018 NOTE Refer to “No Spark or Poor Spark in Section 1H (Page 1H-5)” for details. DTC “C28” (P1655): Secondary Throttle Valve Actuator (STVA) Malfunction B815H21104019 Detected Condition and Possible Cause Detected Condition...
  • Page 143 Engine General Information and Diagnosis: 1A-72 Troubleshooting CAUTION 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. NOTE After repairing the trouble, clear the DTC using SDS tool. Refer to “Use of SDS Diagnosis Reset Procedures (Page 1A-14)”.
  • Page 144 1A-73 Engine General Information and Diagnosis: Step Action 1) Turn the ignition switch OFF. • B/Lg, P/W, G and W/ • Loose or poor B wire open or contacts on the ECM 2) Disconnect the STVA lead wire coupler. shorted to the coupler.
  • Page 145 Engine General Information and Diagnosis: 1A-74 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). I815H1110013-01 4) Click each button (2). At this time, if an operation sound is heard from the STVA, the function is normal.

  • Page 146: Dtc "C29" (P1654-H/L): Secondary Throttle Position Sensor (Stps) Circuit Malfunction

    1A-75 Engine General Information and Diagnosis: DTC “C29” (P1654-H/L): Secondary Throttle Position Sensor (STPS) Circuit Malfunction B815H21104020 Detected Condition and Possible Cause Detected Condition Possible Cause Output voltage is not within the following • STP sensor maladjusted. range. • STP sensor circuit open or short. Difference between actual throttle opening •...
  • Page 147 Engine General Information and Diagnosis: 1A-76 C29 (Use of mode select switch) Step Action 1) Turn the ignition switch OFF. Go to Step 3. • Loose or poor contacts on the ECM 2) Lift and support the fuel tank. Refer to “Fuel Tank coupler.
  • Page 148 1A-77 Engine General Information and Diagnosis: P1654-H (Use of SDS) Step Action 1) Turn the ignition switch OFF. Go to Step 3. Y/W wire shorted to VCC, or B/Br wire open. 2) Lift and support the fuel tank. Refer to “Fuel Tank Removal and Installation in Section 1G (Page 1G-9)”.
  • Page 149 Engine General Information and Diagnosis: 1A-78 Step Action 6) Disconnect the ECM coupler. Refer to “ECM Removal Go to Step 3. Y/W wire shorted to and Installation in Section 1C (Page 1C-2)”. VCC, or B/Br wire open. 7) Check the continuity between the Y/W wire and terminal “20”.
  • Page 150 1A-79 Engine General Information and Diagnosis: P1654-L (Use of SDS) Step Action 1) Turn the ignition switch OFF. Go to Step 2. R or Y/W wire open, or Y/W wire shorted to the 2) Lift and support the fuel tank. Refer to “Fuel Tank ground.
  • Page 151 Engine General Information and Diagnosis: 1A-80 Step Action 7) Check the continuity between the Y/W wire and terminal Go to Step 2. R or Y/W wire open, or “20”. Also, check the continuity between the R wire and Y/W wire shorted to the terminal “11”.
  • Page 152 1A-81 Engine General Information and Diagnosis: Step Action 1) Turn the ignition switch OFF. • R, Y/W or B/Br wire If check result is not open or shorted to satisfactory, replace the 2) Connect the ECM coupler and STP sensor coupler. the ground, or poor STP sensor with a new 3) Disconnect the STVA lead wire coupler.

  • Page 153: Dtc "C31" (P0705): Gp Switch Circuit Malfunction

    Engine General Information and Diagnosis: 1A-82 DTC “C31” (P0705): GP Switch Circuit Malfunction B815H21104021 Detected Condition and Possible Cause Detected Condition Possible Cause No Gear Position switch voltage • GP switch circuit open or short. GP switch voltage is not within the following range. •...
  • Page 154 1A-83 Engine General Information and Diagnosis: Step Action 1) Turn the ignition switch OFF. • P wire open or • R or B wire open, or shorted to the R wire shorted to the 2) Lift and support the fuel tank. Refer to “Fuel Tank ground.

  • Page 155: Dtc "C32" (P0201), "C33" (P0202), "C34" (P0203) Or "C35" (P0204): Primary Fuel Injector Circuit Malfunction

    Engine General Information and Diagnosis: 1A-84 DTC “C32” (P0201), “C33” (P0202), “C34” (P0203) or “C35” (P0204): Primary Fuel Injector Circuit Malfunction B815H21104022 Detected Condition and Possible Cause Detected Condition Possible Cause CKP signal is produced but fuel injector signal is •...
  • Page 156 1A-85 Engine General Information and Diagnosis: Step Action 1) Turn the ignition switch OFF. Go to Step 2. Replace the injector with a new one. Refer to 2) Lift and support the fuel tank. Refer to “Fuel Tank “Throttle Body Removal and Installation in Section 1G (Page 1G-9)”.
  • Page 157 Engine General Information and Diagnosis: 1A-86 Step Action 5) If OK, then check the continuity between each terminal Go to Step 2. Replace the injector and ground. with a new one. Refer to “Throttle Body Special tool Disassembly and (A): 09900–25008 (Multi-circuit tester set) Assembly in Section 1D Injector continuity (Page 1D-12)”.
  • Page 158 1A-87 Engine General Information and Diagnosis: Step Action 1) Turn the ignition switch ON. • Gr/W wire open or Open circuit in the Y/R shorted to the wire. 2) Measure the injector voltage between the Y/R wire and ground, or poor “48” ground.

  • Page 159: Dtc "C36" (P1764), "C37" (P1765), "C38" (P1766) Or "C39" (P1767): Secondary Fuel Injector Circuit Malfunction

    Engine General Information and Diagnosis: 1A-88 DTC “C36” (P1764), “C37” (P1765), “C38” (P1766) or “C39” (P1767): Secondary Fuel Injector Circuit Malfunction B815H21104023 Detected Condition and Possible Cause Detected Condition Possible Cause Some failure exists in the fuel injector signal in a high •...
  • Page 160 1A-89 Engine General Information and Diagnosis: Step Action 1) Turn the ignition switch OFF. Go to Step 2. Replace the injector with a new one. Refer to 2) Lift and support the fuel tank. Refer to “Fuel Tank “Throttle Body Removal and Installation in Section 1G (Page 1G-9)”.
  • Page 161 Engine General Information and Diagnosis: 1A-90 Step Action 5) If OK, then check the continuity between each terminal Go to Step 2. Replace the injector and ground. with a new one. Refer to “Throttle Body Special tool Disassembly and (A): 09900–25008 (Multi-circuit tester set) Assembly in Section 1D Injector continuity (Page 1D-12)”.
  • Page 162 1A-91 Engine General Information and Diagnosis: Step Action 1) Turn the ignition switch ON. • Lg wire open or Open circuit in the Y/R shorted to the wire. 2) Measure the injector voltage between the Y/R wire and ground, or poor “64” ground.

  • Page 163: Dtc "C40" (P0505 / P0506 / P0507): Isc Valve Circuit Malfunction

    Engine General Information and Diagnosis: 1A-92 DTC “C40” (P0505 / P0506 / P0507): ISC Valve Circuit Malfunction B815H21104024 Detected Condition and Possible Cause Detected Condition Possible Cause The circuit voltage of motor drive is • ISC valve circuit open or shorted to the ground. C40/P0505 unusual.
  • Page 164 1A-93 Engine General Information and Diagnosis: Step Action 1) Turn the ignition switch OFF. Go to Step 2. Bl, Y, G or Br wire open. 2) Remove the air cleaner box. Refer to “Air Cleaner Box Removal and Installation in Section 1D (Page 1D-6)”. 3) Check the ISC valve coupler (1) for loose or poor contacts.
  • Page 165 Engine General Information and Diagnosis: 1A-94 Step Action 1) Check the continuity between each ISC valve terminal If wire is OK, Replace the ISC valve and ground. intermittent trouble or with a new one. Refer to faulty ECM. “Throttle Body Special tool Disassembly and (A): 09900–25008 (Multi-circuit tester set)
  • Page 166 1A-95 Engine General Information and Diagnosis: ACTIVE CONTROL INSPECTION (ISC RPM Check 2 CONTROL) 1) Click the button (4) and decrease the “Spec” (2) to 1 Check 1 050 rpm slowly. 1) Set up the SDS tool. (Refer to the SDS operation 2) Check that the “Desired idle speed”...
  • Page 167 Engine General Information and Diagnosis: 1A-96 Check 3 Check 4 1) Click the button (6) and increase the “Spec” (2) to 1 1) Click the button (6) and increase the “Spec” (2) to 1 500 rpm slowly. 900 rpm. 2) Check that the “Desired idle speed” (3) is nearly 2) Check that the “Desired idle speed”...

  • Page 168: Dtc "C41" (P0230-H/L): Fp Relay Circuit Malfunction

    1A-97 Engine General Information and Diagnosis: DTC “C41” (P0230-H/L): FP Relay Circuit Malfunction B815H21104025 Detected Condition and Possible Cause Detected Condition Possible Cause No voltage is applied to fuel pump. • Fuel pump relay circuit open or short. • Fuel pump relay malfunction. Voltage is applied to fuel pump although •...
  • Page 169 Engine General Information and Diagnosis: 1A-98 C41 (Use of mode select switch) Step Action 1) Turn the ignition switch OFF. • ECM power input Replace the FP relay signal malfunction. with a new one. 2) Remove the frame cover. Refer to “Exterior Parts Removal and Installation in Section 9D (Page 9D-14)”.
  • Page 170 1A-99 Engine General Information and Diagnosis: P0230-L (Use of SDS) Step Action 1) Turn the ignition switch OFF. • Y/B wire open or poor Replace the FP relay “39” connection. with a new one. 2) Remove the frame cover. Refer to “Exterior Parts Removal and Installation in Section 9D (Page 9D-14)”.

  • Page 171: Dtc "C41" (P2505): Ecm Power Input Signal Malfunction

    Engine General Information and Diagnosis: 1A-100 DTC “C41” (P2505): ECM Power Input Signal Malfunction B815H21104026 Detected Condition and Possible Cause Detected Condition Possible Cause No voltage is applied to the ECM. • Lead wire/coupler connection of ECM terminal to fuel fuse.
  • Page 172 1A-101 Engine General Information and Diagnosis: Step Action 1) Turn the ignition switch OFF. • Fuel pump relay Open or short circuit in circuit malfunction. the R/Bl wire. 2) Remove the front seat. Refer to “Exterior Parts Removal and Installation in Section 9D (Page 9D-14)”. Refer to “DTC “C41”...

  • Page 173: Dtc "C42" (P1650): Ig Switch Circuit Malfunction

    Engine General Information and Diagnosis: 1A-102 DTC “C42” (P1650): IG Switch Circuit Malfunction B815H21104027 Detected Condition and Possible Cause Detected Condition Possible Cause Ignition switch signal is not input to the ECM. • Ignition system circuit open or short. • ECM malfunction. When the ID agreement is not verified.
  • Page 174 1A-103 Engine General Information and Diagnosis: Troubleshooting (When Indicating C44/P0130:) CAUTION 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. NOTE After repairing the trouble, clear the DTC using SDS tool.
  • Page 175 Engine General Information and Diagnosis: 1A-104 Step Action 7) Check the continuity between the W/G wire terminal “A” Go to Step 2. W/G wire shorted to the and terminal “12”. Also, check the continuity between the power source, or W/G B/Br wire terminal “B”...
  • Page 176 1A-105 Engine General Information and Diagnosis: Step Action 1) Connect the ECM coupler and HO2 sensor coupler. • W/G or B/Br wire Replace the HO2 open or shorted to sensor with a new one. 2) Warm up the engine enough. the power source, or Refer to “Heated 3) Insert the needle pointed probes to the lead wire coupler.
  • Page 177 Engine General Information and Diagnosis: 1A-106 Troubleshooting (When Indicating C44/P0135:) NOTE After repairing the trouble, clear the DTC using SDS tool. Refer to “Use of SDS Diagnosis Reset Procedures (Page 1A-14)”. Step Action 1) Turn the ignition switch OFF. Go to Step 2. Replace the HO2 sensor with a new one.
  • Page 178 1A-107 Engine General Information and Diagnosis: Step Action 1) Connect the HO2 sensor coupler. • O/W or W/B wire • Open or short circuit open or shorted to in the W/B wire or O/ 2) Insert the needle pointed probes to the lead wire coupler. the ground, or poor W wire.

  • Page 179: Dtc "C49" (P1656): Pair Control Solenoid Valve Circuit Malfunction

    Engine General Information and Diagnosis: 1A-108 DTC “C49” (P1656): PAIR Control Solenoid Valve Circuit Malfunction B815H21104029 Detected Condition and Possible Cause Detected Condition Possible Cause PAIR control solenoid valve voltage is not input to ECM. • PAIR control solenoid valve circuit open or short. •...
  • Page 180 1A-109 Engine General Information and Diagnosis: Step Action 1) Turn the ignition switch OFF. Go to Step 2. Replace the PAIR control solenoid with a 2) Remove the air cleaner box. Refer to “Air Cleaner Box new one. Refer to “PAIR Removal and Installation in Section 1D (Page 1D-6)”.
  • Page 181 Engine General Information and Diagnosis: 1A-110 Step Action 1) Turn the ignition switch ON. • Gr wire open or Open or short circuit in shorted to the the O/W wire. 2) Measure the voltage between the O/W wire and ground. ground, or poor “44”...
  • Page 182 1A-111 Engine General Information and Diagnosis: Active Control Inspection 1) Set up the SDS tool. (Refer to SDS operation manual for further details.) 2) Turn the ignition switch ON. 3) Click “PAIR Sol operating control” (1). I815H1110018-01 4) Click each button (2). At this time, if an operating sound is heard from the PAIR control solenoid valve, the function is normal.

  • Page 183: Dtc "C60" (P0480): Cooling Fan Relay Circuit Malfunction

    Engine General Information and Diagnosis: 1A-112 DTC “C60” (P0480): Cooling Fan Relay Circuit Malfunction B815H21104030 Detected Condition and Possible Cause Detected Condition Possible Cause Cooling fan relay signal is not input to ECM. • Cooling fan relay circuit open or short. •...
  • Page 184 1A-113 Engine General Information and Diagnosis: Troubleshooting CAUTION 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. NOTE After repairing the trouble, clear the DTC using SDS tool. Refer to “Use of SDS Diagnosis Reset Procedures (Page 1A-14)”.
  • Page 185 Engine General Information and Diagnosis: 1A-114 Active Control Inspection 1) Set up the SDS tool. (Refer to SDS operation manual for further details.) 2) Start the engine and run it in idling condition. 3) Click “Cooling fan relay control” (1). I815H1110020-01 4) Click the “Operate”...

  • Page 186: Dtc "C62" (P0443): Evap System Purge Control Solenoid Valve Circuit Malfunction (E-33 Only)

    1A-115 Engine General Information and Diagnosis: DTC “C62” (P0443): EVAP System Purge Control Solenoid Valve Circuit Malfunction (E-33 only) B815H21104031 Detected Condition and Possible Cause Detected Condition Possible Cause EVAP system purge control valve voltage is not input to • EVAP system purge control valve circuit open or short. ECM.
  • Page 187 Engine General Information and Diagnosis: 1A-116 Step Action 1) Turn the ignition switch OFF. Go to Step 2. Replace the EVAP system purge control 2) Lift and support the fuel tank. Refer to “Fuel Tank with a new one. Refer to Removal and Installation in Section 1G (Page 1G-9)”.
  • Page 188 1A-117 Engine General Information and Diagnosis: Step Action 1) Turn the ignition switch ON. • Dbr wire open or Open or short circuit in shorted to the the O/W wire. 2) Measure the voltage between the O/W wire and ground. ground, or poor “15”...

  • Page 189: Specifications

    Engine General Information and Diagnosis: 1A-118 4) Click each button (2). At this time, if an operating sound is heard from the EVAP system purge control valve, the function is normal. I823H1110219-01 Specifications Service Data B815H21107001 Injector + Fuel Pump + Fuel Pressure Regulator Item Specification Note...
  • Page 190 1A-119 Engine General Information and Diagnosis: Special Tools and Equipment Special Tool B815H21108001 09900–25008 09900–25009 Multi-circuit tester set Needle pointed probe set (Page 1A-29) / (Page 1A-36) / (Page 1A-31) / (Page 1A-38) / (Page 1A-32) / (Page 1A-38) / (Page 1A-110) / (Page 1A-43) / (Page 1A-116) /...
  • Page 191 Engine General Information and Diagnosis: 1A-120 09900–28630 09904–41010 TPS test wire harness SDS set (Page 1A-46) (Page 1A-13) / (Page 1A-17) 09917–47011 09930–82720 Vacuum pump gauge Mode select switch (Page 1A-39) / (Page 1A-3) / (Page 1A- (Page 1A-63) 12) / (Page 1A-12) 99565–01010–012 CD-ROM Ver.12...
  • Page 192 Fuel Injection System Description B815H21201001 GSX1300R 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. With varying engine conditions, all of the fuel injection volumes are precisely controlled by the programmed injection maps in the ECM to reduce CO, NOX and HC.
  • Page 193 Emission Control Devices: 1B-2 Crankcase Emission Control System Description B815H21201002 The engine is equipped with a PCV system to prevent discharging crankcase emissions into the atmosphere. Blow-by gas in the engine is constantly drawn into the crankcase, which is returned to the combustion chamber through the PCV (breather) hose, air cleaner and throttle body.

  • Page 194: Exhaust Emission Control System Description

    1B-3 Emission Control Devices: Exhaust Emission Control System Description B815H21201003 The exhaust emission control system is composed of the PAIR system, HO2 sensor, three-way catalyst system and ISC system. The fresh air is drawn into the exhaust port through the PAIR control solenoid valve and PAIR reed valve. The PAIR control solenoid valve is operated by the ECM, which is controlled according to the signals from TPS, ECTS, IATS, IAPS and CKPS.
  • Page 195 Emission Control Devices: 1B-4 PAIR System Diagram “A” “B” I815H1120004-01 1. PAIR control solenoid valve 2. PAIR reed valve “A”: Fresh air “B”: Exhaust gas...
  • Page 196 1B-5 Emission Control Devices: Pair System Hose Routing Diagram “B” “ a” “A” “B” “ b” “ b” “A” “ b ” “ b” “A” I815H1120005-03 1. PAIR control solenoid valve 3. Marking (Yellow) “B”: Top side “b”: 0° 2. PAIR reed valve “A”: To the air cleaner box “a”: 45°...

  • Page 197: Noise Emission Control System Description

    Emission Control Devices: 1B-6 Noise Emission Control System Description B815H21201004 TAMPERING WITH THE NOISE CONTROL SYSTEM PROHIBITED: Local law or federal law prohibits the following acts or the causing thereof: • 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 •...

  • Page 198: Evaporative Emission Control System Diagram (Only For

    1B-7 Emission Control Devices: Evaporative Emission Control System Diagram (Only for E-33) B815H21201005 “A” “B” “C” “D” I815H1120006-01 1. Fuel tank 6. Fuel tank pressure control valve 11. IAP sensor 2. Fuel pump 7. EVAP canister “A”: Fuel 3. Fuel feed hose 8.

  • Page 199: Schematic And Routing Diagram

    Emission Control Devices: 1B-8 Schematic and Routing Diagram EVAP Canister Hose Routing Diagram (Only for E-33) B815H21202001 “A” “B” I815H1120007-01 1. Fuel shut-off valve 8. Clamp : The ends of the clamp should face upward. 2. TPC valve 9. Clamp : The ends of the clamp should face backward.

  • Page 200: Repair Instructions

    1B-9 Emission Control Devices: Repair Instructions Heated Oxygen Sensor (HO2S) Removal and Installation Install the HO2 sensor in the reverse order of removal. Installation B815H21206001 Pay attention to the following points: Removal CAUTION WARNING Do not apply oil or other materials to the Do not remove the HO2 sensor while it is hot.

  • Page 201: Pair Control Solenoid Valve Removal And Installation

    Emission Control Devices: 1B-10 4) Remove the PAIR reed valves (3). PAIR Control Solenoid Valve Removal and Installation B815H21206004 Removal 1) Lift and support the fuel tank. Refer to “Fuel Tank Removal and Installation in Section 1G (Page 1G- 9)”. 2) Remove the air cleaner box.

  • Page 202: Pair System Inspection

    1B-11 Emission Control Devices: PAIR System Inspection 3) Reinstall the PAIR reed valves. Refer to “PAIR Reed B815H21206005 Valve Removal and Installation (Page 1B-9)”. PAIR Hose 1) Lift and support the fuel tank. Refer to “Fuel Tank PAIR Control Solenoid Valve Removal and Installation in Section 1G (Page 1G- 1) Remove the PAIR control solenoid valve.

  • Page 203: Crankcase Breather (Pcv) Hose Inspection

    Emission Control Devices: 1B-12 4) Check the resistance between the terminals of the Crankcase Breather (PCV) Hose / Reed Valve / PAIR control solenoid valve. Cover Removal and Installation B815H21206007 Special tool Removal : 09900–25008 (Multi-circuit tester set) 1) Lift and support the fuel tank. Refer to “Fuel Tank Removal and Installation in Section 1G (Page 1G- Tester knob indication 9)”.

  • Page 204: Crankcase Breather (Pcv) Cover Inspection

    • Apply bond to the mating surface of the PCV cover. 1) Remove the PCV cover. Refer to “Crankcase : Sealant 99000–31140 (SUZUKI BOND Breather (PCV) Hose / Reed Valve / Cover Removal No.1207B or equivalent) and Installation (Page 1B-12)”.

  • Page 205: Evaporative Emission Control System Removal And Installation (Only For

    Emission Control Devices: 1B-14 Evaporative Emission Control System Removal EVAP System Purge Control Solenoid Valve and Installation (Only for E-33) Removal B815H21206009 1) Lift and support the fuel tank. Refer to “Fuel Tank Hose Removal and Installation in Section 1G (Page 1G- Removal 9)”.

  • Page 206: Evaporative Emission Control System Inspection (For E-33 Only)

    1B-15 Emission Control Devices: Fuel Shut-off Valve EVAP System Purge Control Solenoid Valve Removal NOTE 1) Remove the fuel tank. Refer to “Fuel Tank Removal EVAP system purge control solenoid valve and Installation in Section 1G (Page 1G-9)”. can be checked without removing it from the 2) Disconnect the surge hose (1).
  • Page 207 Emission Control Devices: 1B-16 3) Check the resistance between the terminals of the 2) When air pressure is applied lightly to the tank EVAP system purge control solenoid valve. If the pressure control valve from the side “B”, air should resistance is not within the standard range, replace flow out through the valve difficulty.

  • Page 208: Specifications

    1B-17 Emission Control Devices: 2) When air is blown into the fuel shut-off valve with its side “A” positioned sideways, the air cannot pass through to the canister side. If the fuel shut-off valve operates otherwise, it must be replaced. “A”...

  • Page 209: Special Tools And Equipment

    Emission Control Devices: 1B-18 Special Tools and Equipment Recommended Service Material B815H21208001 Material SUZUKI recommended product or Specification Note Sealant SUZUKI BOND No.1207B or P/No.: 99000–31140 (Page 1B-13) equivalent Thread lock cement THREAD LOCK CEMENT SUPER P/No.: 99000–32110 (Page 1B-10)

  • Page 210: Engine Electrical Devices

    1C-1 Engine Electrical Devices: Engine Electrical Devices Engine Precautions Precautions for Engine Electrical Device B815H21300001 Refer to “General Precautions in Section 00 (Page 00-1)” and “Precautions for Electrical Circuit Service in Section 00 (Page 00-2)”. Component Location Engine Electrical Components Location B815H21303001 Refer to “Electrical Components Location in Section 0A (Page 0A-8)”.

  • Page 211: Repair Instructions

    Engine Electrical Devices: 1C-2 Repair Instructions ECM Removal and Installation Installation B815H21306001 Install the CMP sensor in the reverse order of removal. Removal Pay attention to the following points: 1) Remove the front seat. Refer to “Exterior Parts CAUTION Removal and Installation in Section 9D (Page 9D- 14)”.

  • Page 212: Iap Sensor Inspection

    1C-3 Engine Electrical Devices: Installation TP Sensor Removal and Installation B815H21306009 Install the CKP sensor in the reverse order of removal. Refer to “Throttle Body Disassembly and Assembly in Refer to “Generator Removal and Installation in Section Section 1D (Page 1D-12)”. 1J (Page 1J-6)”.

  • Page 213: Tp Sensor Adjustment

    3) Turn the mode select switch ON. necessary. 4) Check the position of the bar in the left of C code displayed on the LCD panel. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) Special tool : 09930–11950 (Torx wrench) “A”...

  • Page 214: Ect Sensor Removal And Installation

    1C-5 Engine Electrical Devices: ECT Sensor Removal and Installation ECT Sensor Inspection B815H21306011 B815H21306012 Removal Refer to “DTC “C15” (P0115-H/L): ECT Sensor Circuit Malfunction in Section 1A (Page 1A-47)”. 1) Lift and support the fuel tank. Refer to “Fuel Tank Inspect the ECT sensor in the following procedures: Removal and Installation in Section 1G (Page 1G- 9)”.

  • Page 215: Iat Sensor Removal And Installation

    Engine Electrical Devices: 1C-6 IAT Sensor Removal and Installation NOTE B815H21306013 IAT sensor resistance measurement method Removal is the same way as that of the ECT sensor. 1) Remove the air cleaner box. Refer to “Air Cleaner Refer to “ECT Sensor Inspection (Page 1C- Box Removal and Installation in Section 1D 5)”.

  • Page 216: To Sensor Removal And Installation

    1C-7 Engine Electrical Devices: TO Sensor Removal and Installation STP Sensor Inspection B815H21306018 B815H21306019 Removal Refer to “DTC “C29” (P1654-H/L): Secondary Throttle Position Sensor (STPS) Circuit Malfunction in Section 1) Lift and support the fuel tank. Refer to “Fuel Tank 1A (Page 1A-75)”.

  • Page 217: Stp Sensor Removal And Installation

    Engine Electrical Devices: 1C-8 5) Close the secondary throttle valve by finger and STP Sensor Removal and Installation B815H21306021 measure the STP sensor output voltage. Removal Special tool 1) Remove the throttle body. Refer to “Throttle Body (A): 09900–25008 (Multi-circuit tester set) Removal and Installation in Section 1D (Page 1D- (B): 09900–25009 (Needle pointed probe 10)”.

  • Page 218: Stv Actuator Inspection

    1C-9 Engine Electrical Devices: : Grease 99000–25010 (SUZUKI SUPER ISC Valve Inspection B815H21306024 GREASE A or equivalent) Refer to “DTC “C40” (P0505 / P0506 / P0507): ISC Valve Special tool Circuit Malfunction in Section 1A (Page 1A-92)”. : 09930–11950 (Torx wrench)

  • Page 219: Ho2 Sensor Inspection

    Engine Electrical Devices: 1C-10 5) Click the “Reset” button to clear the ISC leaned HO2 Sensor Inspection B815H21306027 value. Refer to “DTC “C44” (P0130/P0135): HO2 Sensor (HO2S) Circuit Malfunction in Section 1A (Page 1A- 102)”. HO2 Sensor Removal and Installation B815H21306028 Refer to “Heated Oxygen Sensor (HO2S) Removal and Installation in Section 1B (Page 1B-9)”.

  • Page 220: Specifications

    1C-11 Engine Electrical Devices: Specifications Service Data B815H21307001 FI Sensors Item Standard/Specification Note 180 – 280 Ω CKP sensor resistance CKP sensor peak voltage 3.0 V and more When cranking IAP sensor input voltage 4.5 – 5.5 V IAP sensor output voltage Approx.

  • Page 221: Tightening Torque Specifications

    For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List in Section 0C (Page 0C-9)”. Special Tools and Equipment Recommended Service Material B815H21308001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010 (Page 1C-4) /...

  • Page 222: Engine Mechanical

    1D-1 Engine Mechanical: Engine Mechanical Engine Schematic and Routing Diagram Camshaft and Sprocket Assembly Diagram B815H21402001 I823H1140001-01...

  • Page 223: Throttle Cable Routing Diagram

    Engine Mechanical: 1D-2 Throttle Cable Routing Diagram B815H21402002 “A” “B” “B” “ a ” “ a ” I815H1140001-01 1. Throttle cable No. 1 5. Front brake hose 2. Throttle cable No. 2 “A”: Pass through the throttle cables No. 1 and No. 2 between the air clearner box and guide the of screw. 3.

  • Page 224: Diagnostic Information And Procedures

    1D-3 Engine Mechanical: Diagnostic Information and Procedures Engine Mechanical Symptom Diagnosis 6) Keep the throttle grip in the fully-opened position. B815H21404001 Refer to “Engine Symptom Diagnosis in Section 1A (Page 1A-8)”. Compression Pressure Check B815H21404002 The compression pressure reading of a cylinder is a good indicator of its internal condition.

  • Page 225: Repair Instructions

    Engine Mechanical: 1D-4 Repair Instructions Engine Components Removable with the Engine in Place B815H21406001 Engine components which can be removed while the engine is installed on the frame are as follows. For the installing and removing procedures, refer to respective paragraphs describing each component. Center of Engine Item Removal...
  • Page 226 1D-5 Engine Mechanical: Engine Right Side Item Removal Inspection Installation Refer to “Clutch Removal in Refer to “Clutch Installation Clutch cover — Section 5C (Page 5C-14)”. in Section 5C (Page 5C-17)”. Refer to “Clutch Parts Refer to “Clutch Removal in Refer to “Clutch Installation Clutch plates Inspection in Section 5C...

  • Page 227: Air Cleaner Element Removal And Installation

    Engine Mechanical: 1D-6 Air Cleaner Element Removal and Installation 3) Disconnect the ISC valve hose (2) and PCV hose B815H21406002 (3). Removal 1) Lift and support the fuel tank. Refer to “Fuel Tank Removal and Installation in Section 1G (Page 1G- 9)”.

  • Page 228: Air Cleaner Element Inspection And Cleaning

    1D-7 Engine Mechanical: Installation Throttle Cable Inspection B815H21406006 Install the air cleaner box in the reverse order of Check that the throttle grip moves smoothly from full removal. Pay attention to the following point: open to full close. If it does not move smoothly, lubricate •...

  • Page 229: Throttle Body Components

    Engine Mechanical: 1D-8 Throttle Body Components B815H21406008 I815H1140013-03 1. TP sensor 8. Secondary fuel injector 15. Fuel delivery pipe 2. STP sensor 9. Primary fuel injector 16. Fuel delivery pipe T-joint 3. O-ring 10. Cushion seal 17. EVAP system purge control solenoid valve 4.

  • Page 230: Throttle Body Construction

    1D-9 Engine Mechanical: Throttle Body Construction B815H21406009 “ a” “ a” “ a” “a ” “C” “A” “B” I815H1140014-05 1. Fuel feed hose 5. EVAP purge control solenoid valve (E-33 only) “a”: Approx. 45° 2. ISC valve hose “A”: To the IAP sensor : 1.5 N⋅m (0.15 kgf-m, 1.0 lb-ft) 3.

  • Page 231: Throttle Body Removal And Installation

    Engine Mechanical: 1D-10 Throttle Body Removal and Installation 5) Disconnect the TP sensor lead wire coupler (2), STP B815H21406010 sensor lead wire coupler (3) and STVA lead wire Removal coupler (4). 1) Remove the side cowlings. Refer to “Exterior Parts 6) Remove the clamp (5).
  • Page 232 1D-11 Engine Mechanical: 9) Disconnect the vacuum hose (9) from the IAP Installation sensor. Installs in the reverse order of removal. Pay attention to the following points: 10) Disconnect the purge hose (10) from the EVAP system purge control solenoid valve. (E-33 only) •...

  • Page 233: Throttle Body Disassembly And Assembly

    Engine Mechanical: 1D-12 Throttle Body Disassembly and Assembly 4) Remove the primary fuel injectors (6) and secondary B815H21406011 fuel injectors (7) from the fuel delivery pipe. Refer to “Throttle Body Removal and Installation (Page 1D-10)”. Disassembly CAUTION Identify the position of each removed part. Organize the parts in their respective groups so that they can be reinstalled in their original positions.
  • Page 234 1D-13 Engine Mechanical: 8) Remove the TP sensor (12) and STP sensor (13) CAUTION with the special tool. These adjusting screws (17), (18) and (19) are Special tool factory-adjusted at the time of delivery and : 09930–11950 (Torx wrench) do not turn or remove them. NOTE Prior to disassembly, mark the each sensor’s original position with a paint or scribe for...
  • Page 235 • Align the secondary throttle shaft end “A” with the groove “B” of the STP sensor. • Apply grease to the secondary throttle shaft end “A” if necessary. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) Special tool I823H1140593-01 •...
  • Page 236 1D-15 Engine Mechanical: NOTE • Assemble the fuel delivery pipes as shown in the figure. • Make sure the throttle valves smoothly open and close. CAUTION • For TP sensor setting procedure, refer to Be careful not to twist the fuel delivery pipe “TP Sensor Adjustment in Section 1C T-joint when installing the fuel delivery pipes, (Page 1C-4)”.

  • Page 237: Throttle Body Inspection And Cleaning

    Engine Mechanical: 1D-16 ISC Valve Visual Inspection B815H21406013 Visually inspect the ISC valve if necessary. • Inspect the ISC valve for any carbon deposition defects. Clean or replace the ISC valve if necessary. I815H1140041-01 Throttle Body Inspection and Cleaning B815H21406012 Refer to “Throttle Body Disassembly and Assembly (Page 1D-12)”.
  • Page 238 1D-17 Engine Mechanical: 4) Connect the respective vacuum tester hoses to each 9) Click “Active control”. vacuum nipple. 10) Click “ISC air volume control” (3). I815H1140044-02 5) Set up the SDS tool. (Refer to the SDS operation manual for further details.) 6) Start the engine.

  • Page 239: Isc Valve Reset

    Engine Mechanical: 1D-18 12) Check for the synchronization of vacuum from #1 to ISC Valve Reset B815H21406015 #4 cylinders. When removing or replacing the throttle body assembly, reset the ISC valve learned value in the following procedures: 1) Turn the ignition switch ON position. 2) Set up the SDS tools.

  • Page 240: Tp Reset

    1D-19 Engine Mechanical: NOTE Engine Assembly Removal B815H21406017 The learned value of the ISC valve is set at Before taking the engine out of the frame, wash the RESET position. engine using a steam cleaner. Engine removal is sequentially explained in the following steps: 1) Remove th side cowlings.
  • Page 241 Engine Mechanical: 1D-20 9) Remove the oil hoses (2) and (3). 12) Remove the radiator with oil cooler by removing their mounting bolts. CAUTION Be careful not to bend the radiator and oil cooler fins. I815H1140067-01 I815H1140071-01 I815H1140068-01 10) Disconnect the water/air bleed hose (4) and cylinder head outlet hose (5).
  • Page 242 1D-21 Engine Mechanical: 15) Disconnect the HO2 sensor lead wire coupler (9) 19) Remove the exhaust pipe assembly. and oil pressure switch lead wire (10). I815H1140079-01 20) Remove the exhaust pipe gaskets (11). I815H1140075-01 16) Loosen the muffler connecting bolts. I815H1140080-01 21) Disconnect the starter motor lead wire (12) and I815H1140076-01...
  • Page 243 Engine Mechanical: 1D-22 23) Disconnect the CKP sensor lead wire coupler (15), 26) Remove the ignition coil/plug caps (22). generator lead wire coupler (16) and GP switch lead CAUTION wire coupler (17). • Do not pry up the ignition coil/plug cap with a screwdriver or a bar to avoid its damage.
  • Page 244 1D-23 Engine Mechanical: 29) Jack up the motorcycle and fix it for safety. 36) Loosen the engine mounting thrust adjuster lock-nut (32) with the special tool. 30) Remove the side-stand (25) with its bracket. 37) Loosen the engine mounting thrust adjuster (33) 31) Remove the engine sprocket (26).

  • Page 245: Engine Assembly Installation

    Engine Mechanical: 1D-24 39) Loosen the engine mounting thrust adjuster lock- 41) Remove the engine mounting bolts and gradually nuts (36) and (37) with the special tool. lower the front side of the engine. Then, take off the driven chain from the driveshaft. 40) Loosen the engine mounting thrust adjusters (38) and (39) fully.
  • Page 246 1D-25 Engine Mechanical: • Tighten the engine mounting thrust adjusters (1) to the • Tighten the engine mounting thrust adjuster lock-nuts specified torque with the special tool. (2) to the specified torque withe the special tool. Tightening torque Tightening torque Engine mounting thrust adjuster (a): 10 N·m (1.0 Engine mounting thrust adjuster lock-nut (b): 45 kgf-m, 7.0 lb-ft)
  • Page 247 Engine Mechanical: 1D-26 1 “b” “a” “e” “b” “h” “a” 2 “ d ” 2 “ d ” “ g ” “c” “ g ” 1 “f” 3 “ h ” “ g ” “ g ” I815H1140106-01 1: Bolt “b”: 60 mm (2.36 in) “g”: 43 mm (1.69 in) : 10 N⋅m (1.0 kgf-m, 7.0 lb-ft)

  • Page 248: Engine Top Side Disassembly

    1D-27 Engine Mechanical: NOTE • Install the engine sprocket. Refer to “Engine Sprocket Removal and Installation in Section 3A (Page 3A-2)”. Before servicing the engine top side components (until camshafts removal) with • Install the exhaust pipe assembly and muffler. Refer to the engine inplace, remove the following “Exhaust Pipe / Muffler Removal and Installation in parts:...
  • Page 249 Engine Mechanical: 1D-28 3) Turn the crankshaft to bring the line “A” on the starter 5) Remove the gasket (4). clutch to the slit “B” of the valve timing inspection hole and also to bring the cams to the position as shown in the figure.
  • Page 250 1D-29 Engine Mechanical: 8) Remove the dowel pins. 2) Remove the oil hoses (2) and (3). 9) Remove the intake camshaft (9) and exhaust camshaft (10). I823H1140041-01 I823H1140039-01 Cylinder Head NOTE The cylinder head can not be serviced with the engine installed in the frame. 1) Remove the water hose (1).
  • Page 251 Engine Mechanical: 1D-30 4) Remove the cylinder head bolts (M6) (6). Cam Chain Guide No. 1 5) Remove the cylinder head bolt (M6) (7). NOTE 6) Loosen the cylinder nuts (8). The cam chain guide can not be serviced with the engine installed in the frame. Remove the cam chain guide No.

  • Page 252: Engine Top Side Assembly

    1D-31 Engine Mechanical: 4) Remove the dowel pins and cylinder base gasket Engine Top Side Assembly B815H21406020 (3). Assemble the engine top side in the reverse order of disassembly. Pay attention to the following points: Piston • When installing the pistons, apply molybdenum oil solution onto each piston pin.
  • Page 253 Engine Mechanical: 1D-32 NOTE Cylinder • Fit the dowel pins and a new gasket (1) to the End gap of the circlip “B” should not be crankcase. aligned with the cutaway in the piston pin bore. CAUTION Use a new gasket to prevent oil leakage. •...
  • Page 254 1D-33 Engine Mechanical: • Insert the No. 2 and No. 3 pistons into the cylinder. Cylinder Head • Pull the cam chain out of the cylinder and install the NOTE cam chain guide No. 1 (1). Some light resistance must be overcome to CAUTION lower the cylinder.
  • Page 255 Engine Mechanical: 1D-34 • Place the cylinder head on the cylinder. • After firmly tightening the cylinder head bolts (M10), install the cylinder head bolts (M6) (3). NOTE • Tighten the cylinder head bolts (3) and the cylinder nuts (4) to the specified torque. •...
  • Page 256 1D-35 Engine Mechanical: • With the oil hose union contacted to the stopper “C”, • Turn the crankshaft clockwise and align the line “A” on tighten the bolts to the specified torque. the starter clutch with the index mark “B” of the valve timing inspection hole while keeping the cam chain Tightening torque pulled upward.
  • Page 257 Engine Mechanical: 1D-36 • Pull the cam chain lightly. • Bind the cam chain and the sprocket with a proper clamp (4) to prevent the cam chain disengagement • Turn the exhaust camshaft so that the arrow is aligned while installing the camshaft journal holders. with the gasket surface of the cylinder head.
  • Page 258 1D-37 Engine Mechanical: I823H1140077-02 • Install the dowel pins. • Tighten the camshaft journal holder bolts in ascending order of numbers to the specified torque. • Install the camshaft journal holders. Tightening torque Camshaft journal holder bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft) CAUTION The camshaft journal holder bolts are made...
  • Page 259 Engine Mechanical: 1D-38 5 (1) 6 (2) 6 (2) 5 (1) I823H1140079-03 • Install the oil pipe (4) and tighten oil pipe bolts to the • Install the cam chain guide No. 2 (8). specified torque. Tightening torque Cam chain guide No. 2 bolt: 10 N·m (1.0 kgf-m, NOTE 7.0 lb-ft) •...
  • Page 260 1D-39 Engine Mechanical: • Fit a new gasket (1). • Unhook the outer circlip “A” from its groove by pushing in the stepped part (4) of the plunger head CAUTION with a (–) screwdriver. Use a new gasket to prevent oil leakage. •...
  • Page 261 Engine Mechanical: 1D-40 “B” I823H1140577-02 NOTE The cam chain tension adjuster can be serviced with the engine installed in the frame. • After installing the cam chain tension adjuster, turn the crankshaft approx. 180° counterclockwise to make the plunger come out from the adjuster against the cam chain, via chain tensioner.
  • Page 262 Make sure that the adjuster works properly • Apply bond to the cam end caps of the gasket as by checking no slack at point “B”. shown in the figure. : Sealant 99000–31140 (SUZUKI BOND No.1207B or equivalent) CAUTION “B”...

  • Page 263: Camshaft Inspection

    Engine Mechanical: 1D-42 • Tighten the head cover bolts (1) to the specified Cam Wear torque. Check the camshaft for wear or damage. Measure the cam height “a” with a micrometer. Tightening torque Replace a camshaft if the cams are worn to the service Head cover bolt (a): 14 N·m (1.4 kgf-m, 10.0 lb-ft) limit.
  • Page 264 1D-43 Engine Mechanical: Camshaft Journal Wear 5) Tighten the camshaft journal holder bolts in Inspect the camshaft journal wear in the following ascending order of numbers to the specified torque. procedures: Refer to “Engine Top Side Assembly (Page 1D-31)”. 1) Remove the water bypass union. Refer to “Cylinder NOTE Head Disassembly and Assembly (Page 1D-47)”.

  • Page 265: Camshaft Sprocket / Bearing Inspection

    Engine Mechanical: 1D-44 8) If the camshaft journal oil clearance exceeds the Camshaft Sprocket / Bearing Inspection B815H21406022 limit, measure the inside diameter of the camshaft Inspect the camshaft sprockets/bearings in the following journal holder and the outside diameter of the procedures: camshaft journal.

  • Page 266: Cam Chain Tension Adjuster Inspection

    1D-45 Engine Mechanical: Cam Chain Tension Adjuster Inspection B815H21406023 The cam chain tension adjuster is maintained at the proper tension by an automatically adjusted. 1) Remove the cam chain tension adjuster. Refer to “C” “Engine Top Side Disassembly (Page 1D-27)”. 2) Holding the cam chain tension adjuster as shown in the figure, compress the plunger by turning the adjuster body until the outer circlip “A”...

  • Page 267: Cam Chain Guide Removal And Installation

    Engine Mechanical: 1D-46 Cam Chain Guide Removal and Installation Cam Chain Guide Inspection B815H21406024 B815H21406025 Removal Inspect the cam chain guide in the following procedures: 1) Remove the cylinder head cover. Refer to “Engine 1) Remove the cam chain guides. Refer to “Cam Chain Top Side Disassembly (Page 1D-27)”.

  • Page 268: Cylinder Head Disassembly And Assembly

    1D-47 Engine Mechanical: 4) Check the contacting surface of the cam chain 2) Insert the special tool (A) between the valve spring tensioner. If it is worn or damaged, replace it with a and cylinder head. new one. 3) Using the special tools, compress the valve spring and remove the two cotter halves (3) from the valve stem.
  • Page 269 Engine Mechanical: 1D-48 4) Remove the valve spring retainer (4) and valve 9) Remove the thermostat cover (10). spring (5). 10) Remove the thermostat (11). 5) Pull out the valve (6) from the combustion chamber side. I823H1140115-01 11) Remove the intake pipes (12). I823H1140112-01 6) Remove the oil seal (7) and spring seat (8).
  • Page 270 Assembly is in the reverse order of disassembly. Pay union (3) and tighten it to the specified torque. attention to the following points: : Sealant 99000–31140 (SUZUKI BOND • Tighten the cam chain tension adjuster service cap (1) No.1207B or equivalent) and oil gallery plug (2) to the specified torque.
  • Page 271 Engine Mechanical: 1D-50 • Set the clamp screws as shown in the figure. “B” “D” “E” “ a ” “a ” “ a” “a ” “C” I823H1140121-03 “B”: Upper “C”: Lower “D”: Left “E”: Right “a”: 45° • Install the thermostat. •...
  • Page 272 1D-51 Engine Mechanical: • Install the valve spring seat. • Put on the valve spring retainer (7), and using the special tools, press down the spring, fit the cotter • Apply engine oil to the oil seal (6), and press-fit it into halves to the stem end, and release the lifter to allow the position.

  • Page 273: Cylinder Head Related Parts Inspection

    Engine Mechanical: 1D-52 • Be sure that the rounded lip “K” of the cotter fits Cylinder Head Related Parts Inspection B815H21406028 snugly into the groove “L” in the stem end. Refer to “Cylinder Head Disassembly and Assembly (Page 1D-47)”. “K” “L”...
  • Page 274 1D-53 Engine Mechanical: Valve Head Radial Runout Valve Stem Deflection Place the dial gauge at a right angle to the valve head Lift the valve about 10 mm (0.39 in) from the valve seat. face and measure the valve head radial runout. If it Measure the valve stem deflection in two directions, “X”...
  • Page 275 Engine Mechanical: 1D-54 Valve Stem Wear Valve Spring Measure the valve stem O.D. using the micrometer. If it The force of the coil spring keeps the valve seat tight. A is out of specification, replace the valve with a new one. weakened spring results in reduced engine power output If the valve stem O.D.
  • Page 276 1D-55 Engine Mechanical: Valve Seat Width Valve Seat Sealing Condition 1) Visually check for valve seat width on each valve 1) Clean and assemble the cylinder head and valve face. If the valve face has worn abnormally, replace components. the valve. 2) Fill the intake and exhaust ports with gasoline to 2) Coat the valve seat with a red lead (Prussian Blue) check for leaks.

  • Page 277: Valve Guide Replacement

    Engine Mechanical: 1D-56 Valve Guide Replacement 5) Cool down the new valve guides in a freezer for B815H21406029 about one hour and heat the cylinder head to 100 – 150 °C (212 – 302 °F) with a hot plate. 1) Remove the cylinder head. Refer to “Engine Top Side Disassembly (Page 1D-27)”.

  • Page 278: Valve Seat Repair

    1D-57 Engine Mechanical: 8) After installing the valve guides, refinish their guiding Valve Seat Repair B815H21406030 bores using the reamer. Be sure to clean and oil the The valve seats (1) for both the intake and exhaust guides after reaming. valves are machined to three different angles.

  • Page 279: Cylinder Disassembly And Assembly

    Engine Mechanical: 1D-58 Cylinder Disassembly and Assembly • Apply engine coolant to O-ring of water inlet B815H21406031 connector. Refer to “Engine Top Side Disassembly (Page 1D-27)”. Refer to “Engine Top Side Assembly (Page 1D-31)”. CAUTION Replace the O-ring with a new one. Disassembly 1) Remove the water inlet connector (1).

  • Page 280: Cylinder Inspection

    1D-59 Engine Mechanical: Cylinder Inspection Cylinder Bore B815H21406032 Measure the cylinder bore diameter at six places. If any Refer to “Engine Top Side Disassembly (Page 1D-27)”. one of the measurements exceed the limit, overhaul the Refer to “Engine Top Side Assembly (Page 1D-31)”. cylinder and replace the piston with an oversize piston.

  • Page 281: Piston Ring Removal And Installation

    Engine Mechanical: 1D-60 Piston Ring Removal and Installation CAUTION B815H21406033 Removal When installing the spacer, be careful not to allow its two ends to overlap in the groove. 1) Draw out the piston pin and remove the piston. Refer to “Engine Top Side Disassembly (Page 1D-27)”. 2) Carefully spread the ring opening with your thumbs and then push up the opposite side of the 1st ring to “A”...

  • Page 282: Piston And Piston Ring Inspection

    1D-61 Engine Mechanical: 2) Position the gaps of the three rings and side rails as Piston-to-cylinder Clearance shown. Before inserting piston into the cylinder, Subtract the piston diameter from the cylinder bore check that the gaps are so located. diameter. If the piston-to-cylinder clearance exceeds the service limit, replace both the cylinder and the piston.
  • Page 283 Engine Mechanical: 1D-62 Piston ring thickness Piston Pin and Pin Bore Standard (1st): 0.76 – 0.81 mm (0.0299 – 0.0319 in) Measure the piston pin bore inside diameter using the Standard (1st): 1.08 – 1.10 mm (0.0425 – 0.0433 in) small bore gauge.

  • Page 284: Engine Bottom Side Disassembly

    1D-63 Engine Mechanical: Engine Bottom Side Disassembly 2) Remove the reed valve (2). B815H21406035 NOTE The crankcase must be separated to service the crankshaft and conrod. 1) Remove the engine assembly from the frame. Refer to “Engine Assembly Removal (Page 1D-19)”. 2) Remove the engine top side.
  • Page 285 Engine Mechanical: 1D-64 Starter Torque Limiter Oil Pump Remove the starter torque limiter (1) and starter idle gear 1) Remove the snap ring (1). (2). Refer to “Starter Torque Limiter / Starter Clutch 2) Remove the oil pump driven gear (2). Removal and Installation in Section 1I (Page 1I-10)”.
  • Page 286 1D-65 Engine Mechanical: Gear Position Switch Cam Chain Tensioner Remove the cam chain tensioner (1). 1) Remove the gear position switch lead wire clamps. 2) Remove the gear position switch (1). I823H1140165-01 I823H1140162-01 Generator Remove the generator component parts (1). Refer to Starter Clutch “Generator Removal and Installation in Section 1J Remove the starter clutch (1).
  • Page 287 Engine Mechanical: 1D-66 Gearshift System 4) Remove the gearshift cam plate bolt (5). 1) Remove the gearshift cover (1). 5) Remove the gearshift cam plate (6). I823H1140168-01 I823H1140171-01 2) Remove the gasket (2) and dowel pins. 6) Remove the gearshift cam stopper (7) and gearshift arm stopper (8).
  • Page 288 1D-67 Engine Mechanical: Oil Pipe Oil Pressure Regulator Remove the oil pressure regulator (1). 1) Remove the oil pipe (1). 2) Remove the cushion (2). I823H1140178-01 I823H1140175-01 Oil Strainer 1) Remove the oil strainer (1). Oil Pressure Switch Remove the oil pressure switch (1). I815H1140120-01 2) Remove the O-ring (2).
  • Page 289 Engine Mechanical: 1D-68 Crank Balancer Crankcase 1) Remove the oil separator (1). 1) Remove the crankcase bolts. NOTE Loosen the crankcase bolts diagonally and the smaller sizes first. I823H1140182-01 2) Remove the balancer shaft arm (2). I823H1140186-02 I823H1140183-02 3) Remove the balancer shaft (3). I815H1140060-01 2) Remove the crankshaft journal bolts.
  • Page 290 1D-69 Engine Mechanical: 3) Make sure that all of the bolts are removed. Then, Transmission tap the sides of the lower crankcase using a plastic Remove the transmission component. Refer to hammer to separate the upper and lower crankcase “Transmission Removal in Section 5B (Page 5B-3)”. halves and then lift the lower crankcase off of the upper crankcase.
  • Page 291 Engine Mechanical: 1D-70 3) Remove the oil jet (3) (for generator) from the upper Crankshaft Journal Bearing crankcase. Remove the crankshaft journal bearings, upper and lower. CAUTION • When removing the crankshaft journal bearings, be careful not to scratch the crankcase and the crankshaft journal bearings.

  • Page 292: Engine Bottom Side Assembly

    1D-71 Engine Mechanical: Oil Gallery Plug 2) Remove the oil gallery plugs (M6) (5), (M8) (6), (M10) (7), (M6) (8) and (M16) (9) from the lower 1) Remove the oil gallery plug (M6) (1), (M14) (2), crankcase. (M14) (3) and (M6) (4) from the upper crankcase. I823H1140201-01 I823H1140198-01 I823H1140202-01...
  • Page 293 Engine Mechanical: 1D-72 Tightening torque Oil gallery plug (M6) and (M8) (a): 10 N·m (1.0 kgf- m, 7.0 lb-ft) Oil gallery plug (M10) (b): 18 N·m (1.8 kgf-m, 13.0 lb-ft) Oil gallery plug (M14) (c): 23 N·m (2.3 kgf-m, 16.5 lb-ft) Oil gallery plug (M16) (d): 35 N·m (3.5 kgf-m, 25.5 lb-ft)
  • Page 294 1D-73 Engine Mechanical: Oil Jet • Install the oil jets (for transmission (2) and oil spray (3)). • Fit the new O-rings (1) to each piston cooling oil jet and apply engine oil to them. CAUTION Use the new O-rings to prevent oil pressure leakage.
  • Page 295 Selection (Page 1D-96)”. • Apply sealant to distorted surfaces as it forms a comparatively thick film. • Apply sealant to both mating surface of crankcases at hatched parts. : Sealant 99000–31140 (SUZUKI BOND No.1207B or equivalent) “A” “A” I823H1140214-02...
  • Page 296 1D-75 Engine Mechanical: “A” I823H1140306-01 “A”: Apply bond to both surfaces of the upper and lower cases. : Apply bond.
  • Page 297 Engine Mechanical: 1D-76 • Match the upper and lower crankcases. • Tighten the other crankcase bolts a little at a time to equalize the pressure. NOTE CAUTION Align the gearshift forks with each gearshift groove. Fit the new copper washers to the bolts “B”. Tightening torque Crankcase bolt (M6): 11 N·m (1.1 kgf-m, 8.0 lb-ft) Crankcase bolt (M8): 26 N·m (2.6 kgf-m, 19.0 lb-ft)
  • Page 298 1D-77 Engine Mechanical: • Also check that the driveshaft and countershaft rotate • Hold the crankshaft and install the crank balancer smoothly. assembly. I815H1140126-01 I823H1140221-01 NOTE Align the engraved line “C” on the crank balancer, punch mark “D” on the balancer gear and triangle mark “E”...
  • Page 299 Engine Mechanical: 1D-78 • Install the balancer shaft arm. • Slowly turn the balancer shaft (2) clockwise until it stops (position “F”) with a (–) screwdriver. NOTE • From this position, turn the balancer shaft (2) Apply a small quantity of thread lock to the counterclockwise by 1.5 –...
  • Page 300 Apply a small quantity of thread lock to the balancer cover bolt and tighten it to the Apply grease to the O-ring. specified torque. : Grease 99000–25010 (SUZUKI SUPER : Thread lock cement 99000–32110 GREASE A or equivalent) (THREAD LOCK CEMENT SUPER 1322 or...
  • Page 301 • Apply grease to the new O-ring and press in the oil NOTE pressure regulator to the crankcase. Fit the new gasket washer to the oil pan bolt : Grease 99000–25010 (SUZUKI SUPER (2). GREASE A or equivalent) Tightening torque CAUTION Oil pan bolt (a): 10 N·m (1.0 kgf-m, 7.0 lb-ft)
  • Page 302 (3). Use a new O-ring to prevent oil leakage. • Apply engine oil to the oil pipe union bolt (4). : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) : Thread lock cement 99000–32110 (THREAD LOCK CEMENT SUPER 1322 or...
  • Page 303 Engine Mechanical: 1D-82 Gearshift System • Install the gearshift cam stopper plate (5). • Install the gearshift cam stopper (1), bolt (2), washer NOTE (3) and return spring (4). Align the gearshift cam pin “B” with the • Apply a small quantity of thread lock to the gearshift gearshift cam stopper plate hole “C”.
  • Page 304 Use a new gasket to prevent oil leakage. Use the new O-ring to prevent oil leakage. • Apply grease to the lip of the gearshift cover oil seal. : Grease 99000–25010 (SUZUKI SUPER : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent)
  • Page 305 Engine Mechanical: 1D-84 Cam Chain Tensioner • Install the cam chain (2) onto the cam chain drive sprocket. • Install the cam chain tensioner (1). • Apply thread lock to the cam chain tensioner bolt (2). Tightening torque Cam chain tensioner bolt (a): 23 N·m (2.3 kgf-m, 16.5 lb-ft) I823H1140251-01 Starter Clutch...
  • Page 306 • Apply a bond lightly to the groove of gear position switch lead wire grommet. CAUTION : Sealant 99000–31140 (SUZUKI BOND Use the new O-ring to prevent oil leakage. No.1207B or equivalent) : Grease 99000–25010 (SUZUKI SUPER...
  • Page 307 Engine Mechanical: 1D-86 • Install the washer (1) and pin (2). Starter Torque Limiter • Install the starter idle gear and starter torque limiter. NOTE Refer to “Starter Torque Limiter / Starter Clutch Be careful not to drop the washer or pin into Removal and Installation in Section 1I (Page 1I-10)”.
  • Page 308 • Apply to distorted surfaces as it forms a comparatively thick film. I823H1140264-02 • Install the reed valve cover (4). : Sealant 99000–31140 (SUZUKI BOND No.1207B or equivalent) Tightening torque PCV reed valve cover bolt (b): 10 N·m (1.0 kgf-m, 7.0 lb-ft)

  • Page 309: Crank Balancer Disassembly And Assembly

    Engine Mechanical: 1D-88 Crank Balancer Disassembly and Assembly Assembly B815H21406037 Assemble the crank balancer in the reverse order of Refer to“Engine Bottom Side Disassembly (Page 1D- disassembly. Pay attention to the following points: 63)”. • Apply molybdenum oil solution to the dampers. Refer to “Engine Bottom Side Assembly (Page 1D-71)”.

  • Page 310: Crank Balancer Inspection

    1D-89 Engine Mechanical: • Apply molybdenum oil solution to the bearings, Balancer Shaft spacers and washers. Inspect the balancer shaft for wear or damage. Replace the balancer shaft if there is anything unusual. M/O: Molybdenum oil (MOLYBDENUM OIL SOLUTION) I823H1140275-01 I823H1140272-04 Conrod Removal and Installation B815H21406039...
  • Page 311 Engine Mechanical: 1D-90 4) Remove the bearings (1). 3) When fitting the conrod cap, make sure that I.D. code “B” on each conrod faces intake side. NOTE • Do not remove the bearings (1) unless absolutely necessary. “B” • Make a note of where the bearings are removed from so that they can be reinstalled in their original positions.

  • Page 312: Conrod And Crankshaft Inspection

    1D-91 Engine Mechanical: Conrod and Crankshaft Inspection 2) If the clearance exceeds the limit, remove the conrod B815H21406040 and measure the conrod big end width and crank pin Refer to “Conrod Removal and Installation (Page 1D- width. Refer to “Conrod Removal and Installation 89)”.

  • Page 313: Conrod Crank Pin Bearing Inspection And Selection

    Engine Mechanical: 1D-92 Conrod Crank Pin Bearing Inspection and 4) Remove the conrod caps and measure the width of the compressed plastigauge using the envelope Selection B815H21406041 scale. This measurement should be taken at the Refer to “Conrod Removal and Installation (Page 1D- widest part of the compressed plastigauge.
  • Page 314 1D-93 Engine Mechanical: 2) Check the corresponding crank pin O.D. code 4) Select the specified bearings from the bearing numbers ([1], [2] or [3]) “B”. selection table. CAUTION The bearings should be replaced as a set. Bearing selection table Crank pin O.D. “B ”...

  • Page 315: Crankshaft Journal Bearing Inspection And Selection

    Engine Mechanical: 1D-94 Crankshaft Journal Bearing Inspection and 2) Set the crankshaft onto the upper crank case. Selection 3) Install the plastigauge onto each crankshaft journal B815H21406042 as shown in the figure. Refer to “Engine Bottom Side Disassembly (Page 1D- 63)”.
  • Page 316 1D-95 Engine Mechanical: 6) Remove the lower crankcase and measure the width 2) Check the corresponding crankshaft journal O.D. of compressed plastigauge using the envelope codes “B” ([A], [B] or [C]), which are stamped on the scale. This measurement should be taken at the crankshaft.

  • Page 317: Crankshaft Thrust Clearance Inspection And Selection

    Engine Mechanical: 1D-96 4) Select the specified bearings from the bearing Crankshaft Thrust Clearance Inspection and selection table. Selection Bearing selection table B815H21406043 Refer to “Engine Bottom Side Disassembly (Page 1D- 63)”. Crankshaft O.D. “B” Refer to “Engine Bottom Side Assembly (Page 1D-71)”. Code Green Black...
  • Page 318 1D-97 Engine Mechanical: Selection 2) If the right-side thrust bearing is within the standard range, reinsert the right-side thrust bearing and 1) Remove the right-side thrust bearing and measure remove the left-side thrust bearing. its thickness using the micrometer. If the thickness of the right-side thrust bearing is below standard, 3) With the left-side thrust bearing removed, measure replace it with a new bearing and measure the thrust...

  • Page 319: Specifications

    Engine Mechanical: 1D-98 Specifications Service Data B815H21407001 Valve + Guide Unit: mm (in) Item Standard Limit 33 (1.30) — Valve diam. 27.5 (1.08) — 0.08 – 0.18 (0.003 – 0.007) — Valve clearance (when cold) 0.18 – 0.28 (0.007 – 0.011) —...
  • Page 320 1D-99 Engine Mechanical: Cylinder + Piston + Piston Ring Unit: mm (in) Item Standard Limit 1 000 kPa Compression pressure 1 400 – 1 800 kPa (14 – 18 kgf/cm , 199 – 256 psi) (10 kgf/cm , 142 psi) 200 kPa Compression pressure difference —...

  • Page 321: Tightening Torque Specifications

    Engine Mechanical: 1D-100 Tightening Torque Specifications B815H21407002 Tightening torque Fastening part Note N⋅m kgf-m lb-ft STP sensor mounting screw 0.35 (Page 1D-14) ISC valve mounting screw (Page 1D-14) TP sensor mounting screw 0.35 (Page 1D-14) Fuel delivery pipe mounting screw 0.35 (Page 1D-15) Engine mounting thrust adjuster...

  • Page 322: Special Tools And Equipment

    For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List in Section 0C (Page 0C-9)”. Special Tools and Equipment Recommended Service Material B815H21408001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010 (Page 1D-14) /...

  • Page 323: Special Tool

    Engine Mechanical: 1D-102 NOTE Required service material is also described in the following. “Throttle Body Components (Page 1D-8)” “Engine Bottom Side Assembly (Page 1D-71)” Special Tool B815H21408002 09900–06107 09900–20102 Snap ring pliers Vernier calipers (1/20 mm, 200 mm) (Page 1D-86) (Page 1D-54) / (Page 1D-62) 09900–20202...
  • Page 324 1D-103 Engine Mechanical: 09900–22301 09900–22302 Plastigauge (0.025 – 0.076 Plastigauge (0.051 – 0.152 (Page 1D-43) / (Page 1D-43) (Page 1D-92) / (Page 1D-94) 09900–22403 09915–40610 Small bore gauge (18 – 35 Oil filter wrench (Page 1D-44) / (Page 1D-66) / (Page 1D-62) / (Page 1D-81) (Page 1D-91)
  • Page 325 Engine Mechanical: 1D-104 09916–84511 09919–28620 Valve adjuster driver Sleeve protector (Page 1D-47) / (Page 1D-47) / (Page 1D-51) (Page 1D-51) 09930–11950 09940–14990 Torx wrench Engine mounting thrust adjuster socket wrench (Page 1D-13) / (Page 1D-23) / (Page 1D-14) / (Page 1D-24) / (Page 1D-14) (Page 1D-25)

  • Page 326: Engine Lubrication System

    1E-1 Engine Lubrication System: Engine Lubrication System Engine Precautions Precautions for Engine Oil B815H21500001 Refer to “Fuel and Oil Recommendation in Section 0A (Page 0A-4)”. Schematic and Routing Diagram Engine Lubrication System Chart Diagram B815H21502001...

  • Page 327: Oil Pan

    Engine Lubrication System: 1E-2 CAMSHAFT JOURNALS, CAMFACES AND TAPPETS RH-BEARING AND INTAKE CAMSHAFT INTAKE CAMSHAFT CAM CHAIN CAM SPROCKET HOUSING TENSION OIL PIPE ADJUSTER EXHAUST CAMSHAFT RH-BEARING AND EXHAUST CAMSHAFT HOUSING CAM SPROCKET CYLINDER HEAD CAMSHAFT JOURNALS, CAMFACES AND TAPPETS CAM DRIVE CHAIN OIL HOSE SUB GALLERY...

  • Page 328: Engine Lubrication Circuit Diagram

    1E-3 Engine Lubrication System: Engine Lubrication Circuit Diagram B815H21502002 I823H1150042-01 1. Main gallery...
  • Page 329 Engine Lubrication System: 1E-4 I823H1150043-02 1. Main gallery...

  • Page 330: Diagnostic Information And Procedures

    1E-5 Engine Lubrication System: Diagnostic Information and Procedures Engine Lubrication Symptom Diagnosis B815H21504001 Condition Possible cause Correction / Reference Item Engine overheats Insufficient amount of engine oil. Check level and add. Defective oil pump. Replace. Clogged oil circuit. Clean. Clogged oil cooler. Clean or replace.

  • Page 331: Repair Instructions

    Engine Lubrication System: 1E-6 7) Stop the engine and remove the oil pressure gauge and attachment. 8) Reinstall the main oil gallery plug (1) and tighten it to the specified torque. CAUTION Use a new gasket to oil leakage. Tightening torque Main oil gallery plug (M16) (a): 35 N·m (3.5 kgf- m, 25.5 lb-ft) I815H1150003-01...

  • Page 332: Oil Pressure Regulator / Oil Strainer Inspection

    Use the new O-rings to prevent oil leakage. Oil Pressure Regulator / Oil Strainer Inspection B815H21506004 : Grease 99000–25010 (SUZUKI SUPER Refer to “Oil Pan / Oil Strainer / Oil Pressure Regulator GREASE A or equivalent) Removal and Installation (Page 1E-6)”.

  • Page 333: Oil Cooler / Oil Cooler Hose Inspection And Cleaning

    Engine Lubrication System: 1E-8 Oil Cooler / Oil Cooler Hose Inspection and Cleaning B815H21506005 Refer to “Exterior Parts Removal and Installation in Section 9D (Page 9D-14)”. Oil Cooler Hose Inspection Inspect the oil cooler hoses for any damage and oil leakage.

  • Page 334: Oil Pressure Switch Removal And Installation

    Installation 1) Install the oil pressure switch (1), apply a bond lightly to its thread and tighten it to the specified torque. : Sealant 99000–31140 (SUZUKI Bond 1207B or equivalent) Tightening torque Oil pressure switch (a): 14 N·m (1.4 kgf-m, 10.0...

  • Page 335: Oil Pressure Switch Inspection

    Engine Lubrication System: 1E-10 2) Connect the oil pressure switch lead wire securely. Installation Refer to “Wiring Harness Routing Diagram in Installation is in the reverse order of removal. Pay Section 9A (Page 9A-5)”. attention to the following points: • Fit the new O-ring (1) to each piston cooling oil jet and Tightening torque apply engine oil to them.
  • Page 336 1E-11 Engine Lubrication System: Oil Jet (For Transmission) Installation Installation is in the reverse order of removal. Pay Removal attention to the following point: 1) Remove the engine assembly. Refer to “Engine • Tighten the oil jet (for generator) to the specified Assembly Removal in Section 1D (Page 1D-19)”.

  • Page 337: Oil Jet / Oil Gallery Jet Inspection

    Engine Lubrication System: 1E-12 Oil Jet / Oil Gallery Jet Inspection Oil Pump Removal and Installation B815H21506010 B815H21506011 Refer to “Oil Jet / Oil Gallery Jet Removal and NOTE Installation (Page 1E-10)”. Be careful not to drop any parts into the crankcase.

  • Page 338: Oil Pump Inspection

    CAUTION Special tool : 09900–06107 (Snap ring pliers) Use a new O-ring to prevent oil leakage. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) • Install the oil pump. NOTE Set the oil pump shaft end “A” to the water pump shaft.

  • Page 339: Specifications

    Engine Lubrication System: 1E-14 Specifications Service Data B815H21507001 Oil Pump Item Standard Limit 200 – 500 kPa Oil pressure (at 60 °C, 140 °F) (2.0 – 5.0 kgf/cm , 28.4 – 71.1 psi) — at 3 000 r/min Item Specification Note Engine oil type SAE 10W-40, API SF/SG or SH/SJ with JASO MA...

  • Page 340: Special Tools And Equipment

    1E-15 Engine Lubrication System: Special Tools and Equipment Recommended Service Material B815H21508001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010 (Page 1E-7) / (Page 1E- equivalent Sealant SUZUKI Bond 1207B or equivalent P/No.: 99000–31140...

  • Page 341: Engine Cooling System

    Engine Cooling System: 1F-1 Engine Cooling System Engine Precautions Precautions for Engine Cooling System B815H21600001 WARNING • You can be injured by boiling fluid or steam if you open the radiator cap when the engine is hot. After the engine cools, wrap a thick cloth around cap and carefully remove the cap by turning it a quarter turn to allow pressure to escape and then turn the cap all the way off.

  • Page 342: Engine Coolant Description

    1F-2 Engine Cooling System: Schematic and Routing Diagram Cooling Circuit Diagram B815H21602001 ENGINE COOLANT RESERVOIR THERMOSTAT TEMPERATURE CYLINDER HEAD TANK SENSOR CYLINDER RADIATOR WATER PUMP I823H1160001-01...

  • Page 343: Water Hose Routing Diagram

    Engine Cooling System: 1F-3 Water Hose Routing Diagram B815H21602002 “C” “B” “A” “C” “D” “G” “F” “B” “ b ” “H” “ a ” “ a ” “A” “ a ” “K” “H” “ d ” “I” “ c” “A” “E”...

  • Page 344: Diagnostic Information And Procedures

    1F-4 Engine Cooling System: Diagnostic Information and Procedures Engine Cooling Symptom Diagnosis B815H21604001 Condition Possible cause Correction / Reference Item Engine overheats Not enough engine coolant. Add engine coolant. Radiator core clogged with dirt or scale. Clean. Faulty cooling fan. Repair or replace.

  • Page 345: Radiator Cap Inspection

    Engine Cooling System: 1F-5 Radiator Cap Inspection Radiator Cleaning B815H21606002 Blow out any foreign matter that is stuck in the radiator Inspect the radiator cap in the following procedures: fins using compressed air. 1) Remove the radiator cap. Refer to “Cooling Circuit CAUTION Inspection (Page 1F-4)”.

  • Page 346: Radiator / Cooling Fan Motor Removal And Installation

    1F-6 Engine Cooling System: 6) Move the radiator forward. 6) Disconnect the cooling fan motor lead wire coupler (left) (6) and radiator outlet hose (7). 7) Always apply compressed air from the engine side. I815H1160010-01 I815H1160007-01 7) Remove the radiator assembly (8) by removing the 8) Reinstall the removed parts.

  • Page 347: Water Hose Inspection

    Engine Cooling System: 1F-7 Installation 3) Any leakage from the connecting section should be Install the radiator in the reverse order of removal. Pay corrected by proper tightening. Refer to “Water Hose attention to the following points: Routing Diagram (Page 1F-3)”. •...

  • Page 348: Water Hose Removal And Installation

    1F-8 Engine Cooling System: Water Hose Removal and Installation Cooling Fan Inspection B815H21606006 B815H21606009 Removal Cooling fan operating temperature 1) Remove the side cowlings. Refer to “Exterior Parts Standard Removal and Installation in Section 9D (Page 9D- (ON → OFF): Approx. 100 °C (212 °F) 14)”.

  • Page 349: Cooling Fan Relay Inspection

    Engine Cooling System: 1F-9 Cooling Fan Relay Inspection Thermostat Cover / Thermostat Removal and B815H21606010 Installation Inspect the fan relay in the following procedures: B815H21606013 Removal 1) Remove the upper panel. Refer to “Exterior Parts Removal and Installation in Section 9D (Page 9D- 1) Drain a small amount of engine coolant.

  • Page 350: Thermostat Inspection

    1F-10 Engine Cooling System: Installation Thermostat Inspection B815H21606014 Install the thermostat in the reverse order of removal. Inspect the thermostat in the following procedures: Pay attention to the following points: 1) Remove the thermostat. Refer to “Thermostat Cover • Install the thermostat. / Thermostat Removal and Installation (Page 1F-9)”.

  • Page 351: Water Pump Components

    Engine Cooling System: 1F-11 6) Read the thermometer just when opening the 8) Just when the water temperature reaches specified thermostat. If this reading, which is the temperature value, the thermostat valve should have been lifted level at which the thermostat valve begins to open, is by at least 8 mm (0.31 in).

  • Page 352: Water Pump Construction

    1F-12 Engine Cooling System: Water Pump Construction B815H21606016 I823H1160028-03 1. Impeller 5. O-ring : Apply thread lock. 2. Mechanical seal : 8 N⋅m (0.8 kgf-m, 6.0 lb-ft) : Apply molybudenum oil solution. 3. Oil seal : Apply grease. : Do not reuse. 4.

  • Page 353: Water Pump Disassembly And Assembly

    CAUTION 1) Remove the water pump case (1). Replace the O-ring with the a new one. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) • Install the water pump assembly with the slot on the pump shaft end “A” securely engaged with the flat “B”...
  • Page 354 Special tool (A): 09921–20240 (Bearing remover set) I823H1160039-01 2) Apply a small quantity of the grease to the oil seal lip. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I823H1160037-02 6) Remove the oil seal. NOTE If there is no abnormal condition, the oil seal removal is not necessary.
  • Page 355 “D” I823H1160042-01 4) Apply molybudenum solution to the impeller shaft (1) and washer (2). M/O: Moly paste 99000–25140 (SUZUKI MOLY PASTE or equivalent) I823H1160045-03 9) Install the impeller and tighten the impeller securing 5) Install the impeller shaft (1) and washer (2) to the bolt (8) to the specified torque.

  • Page 356: Water Pump Related Parts Inspection

    Replace the mechanical seal that shows indications of • Apply engine coolant to the O-ring (9). leakage. • Apply grease to the O-ring (10). : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I823H1160049-01 Oil Seal Visually inspect the oil seal for damage, with particular I815H1160032-01 attention given to the lip.

  • Page 357: Specifications

    Engine Cooling System: 1F-17 Impeller / Shaft Impeller Shaft Journal Visually inspect the impeller and its shaft for damage. Visually inspect the journal for damage or scratch. Replace the impeller or shaft if necessary. Replace the water pump body if necessary. I823H1160052-01 I823H1160053-01 Specifications...

  • Page 358: Tightening Torque Specifications

    (Page 1F-13) / equivalent (Page 1F-14) / (Page 1F-16) Moly paste SUZUKI MOLY PASTE or equivalent P/No.: 99000–25140 (Page 1F-15) NOTE Required service material is also described in the following. “Water Pump Components (Page 1F-11)” “Water Pump Construction (Page 1F-12)”...

  • Page 359: Fuel System

    Fuel System: 1G-1 Fuel System Engine Precautions Precautions for Fuel System B815H21700001 WARNING • Keep away from fire or spark. • During disassembling, use care to minimize spillage of gasoline. • Spilled gasoline should be wiped off immediately. • Work in a well-ventilated area. •...

  • Page 360: General Description

    1G-2 Fuel System: General Description Fuel Injection System Description B815H21701001 Fuel System The fuel delivery system consists of the fuel tank (1), fuel pump (2), fuel filters (3) and (4), fuel feed hose (5), fuel delivery pipes (6) including fuel injectors (7) and (8), fuel pressure regulator (9). 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 injectors installed in the fuel delivery pipe.

  • Page 361: Schematic And Routing Diagram

    Fuel System: 1G-3 Schematic and Routing Diagram Fuel Tank Drain Hose and Breather Hose Routing Diagram B815H21702001 “D” “A” “B” “ a ” “ a” “ b ” “C” I815H1170001-03 1. Fuel tank drain hose “A”: Pass the breather hose and drain hose to right side of the rear shock absorber. 2.

  • Page 362: Diagnostic Information And Procedures

    1G-4 Fuel System: Diagnostic Information and Procedures Fuel System Diagnosis B815H21704001 Condition Possible cause Correction / Reference Item Engine will not start or is Clogged fuel filter or fuel hose. Clean or replace. hard to start (No fuel Defective fuel pump. Replace.

  • Page 363: Repair Instructions

    Fuel System: 1G-5 Repair Instructions Fuel Pressure Inspection 4) Turn the ignition ON and check for fuel pressure. B815H21706001 Fuel pressure WARNING Approx. 300 kPa (3.0 kgf/cm , 43 psi) • Keep away from fire or spark. If the fuel pressure is lower than the specification, •...

  • Page 364: Fuel Pump Inspection

    1G-6 Fuel System: Fuel Pump Inspection 3) Connect a proper fuel hose (2) to the fuel pump. B815H21706002 4) Place the measuring cylinder and insert the fuel Turn the ignition switch ON and check that the fuel pump hose end into the measuring cylinder. operates for a few seconds.

  • Page 365: Fuel Pump Relay Inspection

    Fuel System: 1G-7 Fuel Pump Relay Inspection Fuel Hose Inspection B815H21706004 B815H21706005 Refer to “Electrical Components Location in Section 0A Refer to “Fuel Line Inspection in Section 0B (Page 0B- (Page 0A-8)”. 10)”. Inspect the fuel pump relay in the following procedures: Fuel Level Gauge Inspection 1) Remove the frame cover.

  • Page 366: Fuel Tank Construction

    1G-8 Fuel System: Fuel Tank Construction B815H21706007 “ a ” “ b ” “ c” I815H1170009-02 1. Fuel tank cushion “a”: 5 mm (0.20 in) : Apply adhesive agent. 2. Dent mark “b”: 2 mm (0.08 in) : Align the fuel tank cushion with the dent mark (2). 3.

  • Page 367: Fuel Tank Heat Shield Construction

    Fuel System: 1G-9 Fuel Tank Heat Shield Construction B815H21706008 I815H1170010-01 1. Fuel tank heat shield No. 1 4. Clamp : The end of the clamp should face backward. 2. Fuel tank heat shield No. 2 5. Adhesive tape : Clean the adhesive surface before adhering the adhesive tape. 3.
  • Page 368 1G-10 Fuel System: 3) Remove the bolts. 7) Disconnect the fuel tank drain hose (4). 8) Disconnect the surge hose (5). (For E-33) 9) Disconnect the fuel tank breather hose. (Except for E-33) I815H1170012-01 4) Lift and support the fuel tank with the prop stay. I815H1170014-01 10) Remove the fuel tank by removing its bracket bolts.

  • Page 369: Fuel Pump Components

    Fuel System: 1G-11 Fuel Pump Components B815H21706010 I815H1170017-03 1. Fuel level gauge 6. Fuel pump holder : 10 N⋅m (1.0 kgf-m, 7.0 lb-ft) 2. Fuel filter cartridge 7. Fuel mesh filter : Apply grease. 3. Bushing 8. O-ring : Apply engine oil. 4.

  • Page 370: Fuel Pump Disassembly And Assembly

    1G-12 Fuel System: Fuel Pump Disassembly and Assembly 5) Disconnect the ground read wire (4). B815H21706011 6) Remove the fuel pump plate (5). Disassembly 1) Remove the fuel tank. Refer to “Fuel Tank Removal and Installation (Page 1G-9)”. 2) Remove the fuel pump assembly (1) by removing its mounting bolts diagonally.
  • Page 371 3. Fuel pump (–) lead wire (B) 4. Fuel level gauge (–) lead wire (B) 5. Ground lead wire • Install a new O-ring and apply grease to it. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) WARNING I823H1170019-01 The O-ring must be replaced with a new one to prevent fuel leakage.

  • Page 372: Fuel Mesh Filter Inspection And Cleaning

    1G-14 Fuel System: • When installing the fuel pump assembly, first tighten Fuel Injector / Fuel Delivery Pipe / T-joint all the fuel pump mounting bolts lightly and then to the Removal and Installation specified torque. B815H21706013 Refer to “Throttle Body Disassembly and Assembly in Tightening torque Section 1D (Page 1D-12)”.

  • Page 373: Specifications

    Fuel System: 1G-15 Specifications Service Data B815H21707001 Injector + Fuel Pump + Fuel Pressure Regulator Item Specification Note 11 – 13 Ω at 20 °C (68 °F) Injector resistance Fuel pump discharge amount 220 ml (7.4/7.7 US/lmp oz) and more/10 sec. Fuel pressure regulator operating Approx.

  • Page 374: Special Tools And Equipment

    1G-16 Fuel System: Special Tools and Equipment Recommended Service Material B815H21708001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010 (Page 1G-13) equivalent NOTE Required service material is also described in the following. “Fuel Pump Components (Page 1G-11)”...

  • Page 375: Ignition System

    Ignition System: 1H-1 Ignition System Engine General Description Immobilizer Description (For E-02, 19, 24) Operation B815H21801001 When the ignition switch is turned ON with the engine The immobilizer, an anti-theft system, is installed as a stop switch in ON, the immobi-antenna and ECM are standard equipment.

  • Page 376: Drive Mode Selector Description

    1H-2 Ignition System: NOTE 1) Turn on the ignition switch and engine stop switch. 2) Start the engine. If the indicator light flashes fast, turn the ignition switch OFF then ON to make 3) Push the driving mode switch for 2 seconds until the judgment again as there is possible driving mode indicator shows A.

  • Page 377: Schematic And Routing Diagram

    Ignition System: 1H-3 Schematic and Routing Diagram Ignition System Diagram B815H21802001 Refer to “Wire Color Symbols in Section 0A (Page 0A-6)”. Engine stop switch Side-stand relay Fuse sensor Ignition switch Fuse Battery sensor sensor switch I823H1180025-01 Ignition System Components Location B815H21802002 Refer to “Electrical Components Location in Section 0A (Page 0A-8)”.

  • Page 378: Diagnostic Information And Procedures

    1H-4 Ignition System: Diagnostic Information and Procedures Ignition System Symptom Diagnosis B815H21804001 Condition Possible cause Correction / Reference Item Spark plug not sparking Damaged spark plug. Replace. Fouled spark plugs. Clean or replace. Wet spark plugs. Clean and dry or replace. Defective ignition coil/plug caps.

  • Page 379: No Spark Or Poor Spark

    Ignition System: 1H-5 No Spark or Poor Spark B815H21804002 Troubleshooting NOTE Check that the transmission is in neutral and the engine stop switch is in the “RUN” position. Grasp the clutch lever. Check that the fuse is not blown and the battery is fully-charged before diagnosing. Step Action Check the ignition system couplers for poor connections.

  • Page 380: Repair Instructions

    1H-6 Ignition System: Repair Instructions Ignition Coil / Plug Cap and Spark Plug Removal 5) Remove the spark plugs with a spark plug wrench. and Installation Special tool B815H21806001 (A): 09930–10121 (Spark plug wrench set) Removal WARNING The hot engine can burn you. Wait until the engine is cool enough to touch.

  • Page 381: Spark Plug Inspection And Cleaning

    Ignition System: 1H-7 • Install the ignition coil/plug caps and connect their Spark Plug Inspection and Cleaning B815H21806002 lead wire couplers. Refer to “Spark Plug Inspection and Cleaning in Section 0B (Page 0B-9)”. CAUTION Do not hit the ignition coil/plug cap with a Ignition Coil / Plug Cap Inspection plastic hammer when installing it.
  • Page 382 1H-8 Ignition System: 4) Connect all the ignition coil/plug cap lead wire 5) Insert the needle pointed probe to the lead wire couplers to the ignition coil/plug caps respectively, coupler. and ground them on the cylinder head (each spark CAUTION plug hole).
  • Page 383 Ignition System: 1H-9 7) Measure the ignition coil primary peak voltage in the Ignition Coil / Plug Cap Resistance following procedures: 1) Remove the ignition coil/plug caps. Refer to “Ignition Coil / Plug Cap and Spark Plug Removal and WARNING Installation (Page 1H-6)”.

  • Page 384: Ckp Sensor Inspection

    1H-10 Ignition System: CKP Sensor Inspection 4) Measure the CKP sensor peak voltage in the B815H21806004 following procedures: Refer to “Electrical Components Location in Section 0A a) Shift the transmission into neutral, turn the (Page 0A-8)”. ignition switch ON and grasp the clutch lever. b) Press the starter button and allow the engine to CKP Sensor Peak Voltage crank for a few seconds, and then measure the...

  • Page 385: Ckp Sensor Removal And Installation

    Ignition System: 1H-11 CKP Sensor Resistance CKP Sensor Removal and Installation B815H21806005 1) Lift and support the fuel tank. Refer to “Fuel Tank Refer to “Generator Removal and Installation in Section Removal and Installation in Section 1G (Page 1G- 1J (Page 1J-6)”. 9)”.

  • Page 386: Ignition Switch Inspection

    1H-12 Ignition System: Ignition Switch Inspection Installation B815H21806007 Install the ignition switch in the reverse order of removal. Refer to “Ignition Switch Inspection in Section 9C Pay attention to the following points: (Page 9C-8)”. • Tighten the ignition switch mounting bolts (1), right and left with the special tools.

  • Page 387: Drive Mode Selector Inspection

    Ignition System: 1H-13 Drive Mode Selector Inspection B815H21806009 Inspect the drive mode selector in the following procedures: 1) Set up the SDS tool. (Refer to the SDS operation manual for further details.) 2) Turn the ignition switch ON. 3) Click “Date monitor”. 4) Make sure each of “Driving mode selection”...

  • Page 388: Immobilizer Antenna Removal And Installation (For

    1H-14 Ignition System: Immobilizer Antenna Removal and Installation 4) Remove the ignition switch. Refer to “Ignition Switch Removal and Installation (Page 1H-12)”. (For E-02, 19, 24) B815H21806010 5) Remove the immobilizer antenna (2). Removal 1) Turn the ignition switch OFF. 2) Remove the upper cover and body cowling cover.

  • Page 389: Special Tools And Equipment

    Ignition System: 1H-15 Special Tools and Equipment Recommended Service Material B815H21808001 Material SUZUKI recommended product or Specification Note Thread lock cement THREAD LOCK CEMENT SUPER P/No.: 99000–32110 (Page 1H-12) 1322 or equivalent Special Tool B815H21808002 09900–25008 09900–25009 Multi-circuit tester set...

  • Page 390: Starting System

    1I-1 Starting System: Starting System Engine Schematic and Routing Diagram Starting System Diagram B815H21902001 Refer to “Wire Color Symbols in Section 0A (Page 0A-6)”. Ignition Engine stop switch switch Fuse (30 A) ignition coil Gear Fuse position Starter Starter (15 A) switch button motor...

  • Page 391: Starter Motor Will Not Run

    Starting System: 1I-2 Starter Motor Will Not Run B815H21904002 NOTE Make sure the fuses are not blown and the battery is fully-charged before diagnosing. Troubleshooting Step Action 1) Shift the transmission into neutral. Go to Step 2. Go to Step 3. 2) Grasp the clutch lever, turn on the ignition switch with the engine stop switch in the “RUN”...

  • Page 392: Repair Instructions

    1I-3 Starting System: Repair Instructions Starter Motor Components B815H21906001 I823H1190037-06 1. O-ring 5. O-ring : 5 N⋅m (0.5 kgf-m, 3.5 lb-ft) 2. Housing end (Inside) 6. Starter motor case : 6 N⋅m (0.6 kgf-m, 4.5 lb-ft) 3. O-ring 7. Housing end assembly (Outside) : Apply grease to sliding surface.

  • Page 393: Starter Motor Removal And Installation

    CAUTION Replace the O-rings with new ones to prevent oil leakage and moisture. • Apply grease to the lip of the oil seal. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I815H1190002-01 Installation Install the starter motor in the reverse order of removal.

  • Page 394: Starter Motor Inspection

    1I-5 Starting System: • Tighten the starter motor housing bolts to the Starter Motor Inspection B815H21906004 specified torque. Refer to “Starter Motor Disassembly and Assembly Tightening torque (Page 1I-4)”. Starter motor housing bolt (a): 5 N·m (0.5 kgf-m, 3.5 lb-ft) Carbon Brush Inspect the carbon brushes for abnormal wear, cracks or smoothness in the brush holder.

  • Page 395: Starter Relay Removal And Installation

    Starting System: 1I-6 Armature Coil Starter Relay Removal and Installation B815H21906005 Inspect for continuity between each segment. Removal Inspect for continuity between each segment and the 1) Turn the ignition switch OFF. armature shaft. If there is no continuity between the segments or there is 2) Disconnect the battery (–) lead wire from the battery.

  • Page 396: Starter Relay Inspection

    1I-7 Starting System: Starter Relay Inspection 3) Measure the relay coil resistance between the B815H21906006 terminals using the multi-circuit tester. If the Inspect the starter relay in the following procedures: resistance is not within the specified value, replace 1) Remove the starter relay. Refer to “Starter Relay the starter relay with a new one.

  • Page 397: Side-Stand / Ignition Interlock System Parts Inspection

    Starting System: 1I-8 Side-stand / Ignition Interlock System Parts 5) Connect the side-stand switch coupler. Inspection 6) Install the left side cowling. Refer to “Exterior Parts B815H21906008 Removal and Installation in Section 9D (Page 9D- Check the interlock system for proper operation. If the 14)”.
  • Page 398 1I-9 Starting System: 4) Install the turn signal/side-stand relay. Refer to “Turn Gear Position Switch Signal / Side-stand Relay Removal and Installation 1) Lift and support the fuel tank. Refer to “Fuel Tank (Page 1I-7)”. Removal and Installation in Section 1G (Page 1G- 9)”.

  • Page 399: Starter Torque Limiter / Starter Clutch Removal And Installation

    Starting System: 1I-10 7) Measure the voltage between R and B lead wires 4) Remove the gasket (2) and dowel pins. using the multi-circuit tester when shifting the 5) Remove the starter torque limiter (3) and its shaft (4). gearshift lever from low to top. Special tool (A): 09900–25008 (Multi-circuit tester set) (B): 09900–25009 (Needle pointed probe...
  • Page 400 • Apply a bond lightly to the mating surfaces at the parting line between the upper and lower crankcases. CAUTION : Sealant 99000–31140 (SUZUKI BOND Replace the gaskets with new ones to No.1207B or equivalent) prevent oil leakage.

  • Page 401: Starter Torque Limiter Inspection

    Starting System: 1I-12 Starter Torque Limiter Inspection Starter Clutch Inspection B815H21906010 B815H21906011 Refer to “Starter Torque Limiter / Starter Clutch Removal CAUTION and Installation (Page 1I-10)”. • Do not attempt to disassemble the starter Starter Clutch torque limiter. 1) Install the starter driven gear onto the starter clutch. •...

  • Page 402: Starter Button Inspection

    1I-13 Starting System: Starter Button Inspection 3) Inspect the starter button for continuity with the B815H21906012 tester. Inspect the starter button in the following procedures: If any abnormality is found, replace the right handle 1) Remove the left upper panel. Refer to “Exterior Parts switch assembly with a new one.

  • Page 403: Special Tools And Equipment

    Starting System: 1I-14 Special Tools and Equipment Recommended Service Material B815H21908001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010 (Page 1I-4) / (Page 1I-4) equivalent (Page 1I-4) / (Page 1I- Sealant SUZUKI BOND No.1207B or P/No.: 99000–31140...

  • Page 404: Charging System

    1J-1 Charging System: Charging System Engine Schematic and Routing Diagram Charging System Diagram B815H21A02001 Regulator/Rectifier Ignition switch Generator I718H11A0001-01 Component Location Charging System Components Location B815H21A03001 Refer to “Electrical Components Location in Section 0A (Page 0A-8)”. Diagnostic Information and Procedures Charging System Symptom Diagnosis B815H21A04001 Condition...

  • Page 405: Battery Runs Down Quickly

    Charging System: 1J-2 Condition Possible cause Correction / Reference Item Battery overcharges Faulty regulator/rectifier. Replace. Faulty battery. Replace. Poor contact of generator lead wire Repair. coupler. Battery runs down quickly Trouble in charging system. Check the generator, regulator/rectifier and circuit connections and make necessary adjustments to obtain specified charging operation.

  • Page 406: Repair Instructions

    1J-3 Charging System: Repair Instructions Battery Cushion Rubber Attachment Construction B815H21A06001 “ a ” VIEW OF TOP “ a ” “ b ” “ b” VIEW OF SIDE I815H11A0001-06 “a”: 25 mm (1.0 in) “b”: 30 mm (1.2 in)

  • Page 407: Battery Current Leakage Inspection

    Charging System: 1J-4 Battery Current Leakage Inspection Regulated Voltage Inspection B815H21A06002 B815H21A06003 Inspect the battery current leakage in the following Inspect the regulated voltage in the following procedures: procedures: 1) Turn the ignition switch OFF. 1) Remove the seat. Refer to “Exterior Parts Removal and Installation in Section 9D (Page 9D-14)”.

  • Page 408: Generator Inspection

    1J-5 Charging System: Generator Inspection No-load Performance B815H21A06004 1) Lift and support the fuel tank. Refer to “Fuel Tank Generator Coil Resistance Removal and Installation in Section 1G (Page 1G- 1) Lift and support the fuel tank. Refer to “Fuel Tank 9)”.

  • Page 409: Generator Removal And Installation

    Charging System: 1J-6 Generator Removal and Installation 8) Hold the generator rotor with the special tool. B815H21A06005 Special tool Removal (A): 09930–44530 (Rotor holder) 1) Disconnect the battery (–) lead wire. Refer to “Battery Removal and Installation (Page 1J-14)”. 9) Remove the generator rotor bolt and washer. 2) Drain engine oil.
  • Page 410 1J-7 Charging System: 11) Remove the key (7). Installation Install the generator in the reverse order of removal. Pay attention to the following points: • Tighten the generator stator set bolts and CKP sensor mounting bolts to the specified torque. NOTE Be sure the grommet (1) is set to the generator cover.
  • Page 411 • Apply a bond lightly to the mating surfaces at the Be careful not to pinch the finger between the parting line between the upper and lower crankcases generator cover and crankcase. as shown. : Sealant 99000–31140 (SUZUKI BOND No.1207B or equivalent) I815H11A0014-01 I815H11A0012-01...

  • Page 412: Regulator / Rectifier Construction

    1J-9 Charging System: Regulator / Rectifier Construction B815H21A06006 “ b ” “ c ” “ a ” I815H11A0015-01 1. Regulator/Rectifier “a”: 15 mm (0.6 in) 2. Clamp “b”: 50 mm (2.0 in) 3. Bracket “c”: 30 mm (1.2 in) 4. Protection tape : 10 N⋅m (1.0 kgf-m, 7.0 lb-ft) : Before adhering the protection tape, clean its adhesive surface of the frame.

  • Page 413: Regulator / Rectifier Removal And Installation

    Charging System: 1J-10 Regulator / Rectifier Removal and Installation B815H21A06007 Removal 1) Turn the ignition switch OFF. 2) Remove the rear under cowling. Refer to “Exterior Parts Removal and Installation in Section 9D (Page 9D-14)”. 3) Disconnect the regulator/rectifier couplers. 4) Remove the regulator/rectifier as shown in the regulator/rectifier construction.

  • Page 414: Battery Components

    1J-11 Charging System: Battery Components 2) Remove the caps (2) from the electrolyte container. B815H21A06009 NOTE • Do not remove or pierce the sealed areas “B” of the electrolyte container. • After filling the electrolyte completely, use the removed cap (2) as sealing caps of battery-filler holes.
  • Page 415 Charging System: 1J-12 5) Make sure that air bubbles (4) rise to the top of each 6) After confirming that the electrolyte has entered the electrolyte container, and leave in this position for battery completely, remove the electrolyte containers about more than 20 minutes. from the battery.
  • Page 416 1J-13 Charging System: Charging 3) After recharging, wait at least 30 minutes and then For initial charging, use the charger specially designed measure the battery voltage using the multi-circuit for MF battery. tester. If the battery voltage is less than 12.5 V, recharge CAUTION the battery again.

  • Page 417: Battery Removal And Installation

    Charging System: 1J-14 Battery Removal and Installation Installation B815H21A06011 Install the battery in the reverse order of removal. Removal Pay attention to following points: 1) Remove the seat. Refer to “Exterior Parts Removal CAUTION and Installation in Section 9D (Page 9D-14)”. 2) Disconnect the battery (–) lead wire (1).

  • Page 418: Specifications

    1J-15 Charging System: Specifications Service Data B815H21A07001 Electrical Unit: mm Item Specification Note 0.2 – 0.7 Ω Generator coil resistance Generator maximum output Approx. 400 W at 5 000 r/min Generator no-load voltage (When 70 V (AC) and more at 5 000 r/min engine is cold) Regulated voltage 13.5 –...

  • Page 419: Special Tools And Equipment

    Charging System: 1J-16 Special Tools and Equipment Recommended Service Material B815H21A08001 Material SUZUKI recommended product or Specification Note Sealant SUZUKI BOND No.1207B or P/No.: 99000–31140 (Page 1J-8) equivalent Special Tool B815H21A08002 09900–25008 09930–30450 Multi-circuit tester set Rotor remover bolt (Page 1J-4) /...

  • Page 420: Exhaust System

    1K-1 Exhaust System: Exhaust System Engine Precautions Precautions for Exhaust System B815H21B00001 WARNING To avoid the risk of being burned, do not touch the exhaust system when the system is hot. Any service on the exhaust system should be performed when the system is cool. CAUTION Make sure that the exhaust pipes and mufflers have enough clearance from the rubber parts and plastic parts to avoid melting.

  • Page 421: Repair Instructions

    Exhaust System: 1K-2 Repair Instructions Exhaust System Construction B815H21B06001 “ a ” I815H11B0001-06 1. Gasket 5. HO2 sensor : 9 N⋅m (0.9 kgf-m, 6.5 lb-ft) 2. Connector “a”: 30 – 45° : 4 N⋅m (0.4 kgf-m, 3.0 lb-ft) 3. Gasket : 23 N⋅m (2.3 kgf-m, 16.5 lb-ft) : Apply muffler seal.

  • Page 422: Exhaust Pipe / Muffler Removal And Installation

    1K-3 Exhaust System: Exhaust Pipe / Muffler Removal and Installation 4) Separate the muffler body and muffler joint pipe (5). B815H21B06002 Removal 1) Loosen the muffler connecting bolt(-s) (1). 2) Remove the muffler assembly(-ies) (2) by removing the mounting bolt(-s) (3) and nut(-s). NOTE Support the muffler to prevent it from falling.
  • Page 423 Exhaust System: 1K-4 8) Remove the radiator/oil cooler mounting bolts. 12) Remove the exhaust pipe assembly by removing the exhaust pipe bolts and exhaust pipe mounting bolt. 9) Remove the oil cooler bracket (8). 10) Move the radiator/oil cooler forward. CAUTION Take care not to bend the radiator/oil cooler fins.
  • Page 424 1K-5 Exhaust System: 13) Remove the exhaust pipe gaskets (10). Installation Installation is in the reverse order of removal. Pay attention to the following points: • Tighten the HO2 sensor (1) to the specified torque. Tightening torque HO2 sensor (a): 25 N·m (2.5 kgf-m, 18.0 lb-ft) CAUTION •...
  • Page 425 Exhaust System: 1K-6 • Tighten the exhaust pipe bolts (3) and exhaust pipe • Install the connectors (5). mounting bolt (4) to the specified torque. CAUTION Tightening torque Replace the connectors with new ones. Exhaust pipe bolt (b): 23 N·m (2.3 kgf-m, 16.5 lb- NOTE Exhaust pipe mounting bolt (c): 23 N·m (2.3 kgf- m, 16.5 lb-ft)

  • Page 426: Exhaust System Inspection

    1K-7 Exhaust System: Exhaust System Inspection B815H21B06003 Inspect the exhaust pipe connection and muffler connection for exhaust gas leakage and mounting condition. If any defect is found, replace the exhaust pipe assembly or muffler with a new one. Check the exhaust pipe bolts, muffler connecting bolts and muffler mounting bolts are tightened to their specified torque.

  • Page 427: Special Tools And Equipment

    For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List in Section 0C (Page 0C-9)”. Special Tools and Equipment Recommended Service Material B815H21B08001 Material SUZUKI recommended product or Specification Note Muffler seal MUFFLER SEAL LOCTITE 5920 — (Page 1K-6)
  • Page 428 1K-9 Exhaust System:...
  • Page 429 Table of Contents 2- i Section 2 Suspension CONTENTS Precautions ..........2-1 Swingarm Related Parts Inspection ....2C-11 Swingarm Bearing Removal and Installation ..2C-12 Precautions............. 2-1 Specifications .............2C-13 Precautions for Suspension ........2-1 Service Data............2C-13 Suspension General Diagnosis....2A-1 Tightening Torque Specifications......2C-13 Special Tools and Equipment ......2C-14 Diagnostic Information and Procedures....2A-1 Recommended Service Material .......2C-14...

  • Page 430: Precautions

    2-1 Precautions: Precautions Suspension Precautions Precautions for Suspension B815H22000001 Refer to “General Precautions in Section 00 (Page 00-1)”. WARNING All suspensions, bolts and nuts are an important part in that it could affect the performance of vital parts. They must be tightened to the specified torque periodically and if the suspension effect is lost, replace it with a new one.

  • Page 431: Suspension General Diagnosis

    Suspension General Diagnosis: 2A-1 Suspension General Diagnosis Suspension Diagnostic Information and Procedures Suspension and Wheel Symptom Diagnosis B815H22104001 Condition Possible cause Correction / Reference Item Wobbly front wheel Distorted wheel rim. Replace. Worn front wheel bearings. Replace. Defective or incorrect tire. Replace.

  • Page 432: Front Suspension

    2B-1 Front Suspension: Front Suspension Suspension Repair Instructions Front Fork Components B815H22206001 I815H1220001-03 1. Front fork cap bolt 9. Inner rod/Damper rod (cartridge) 17. Front axle pinch bolt 2. O-ring 10. Oil seal retainer : 15 N⋅m (1.5 kgf-m, 11.0 lb-ft) 3.

  • Page 433: Front Fork Removal And Installation

    Front Suspension: 2B-2 Front Fork Removal and Installation 6) Loose the front fork upper clamp bolt (3). B815H22206002 NOTE NOTE The right and left front forks are installed • Slightly loosen the front fork cap bolt (4) to symmetrically and therefore the removal facilitate later disassembly.
  • Page 434 2B-3 Front Suspension: Installation 5) Tighten the front fork lower clamp bolts (1). 1) Set the front fork to the front fork lower bracket Tightening torque temporarily by tightening the lower clamp bolts (1). Front fork lower clamp bolt (b): 23 N·m (2.3 kgf- m, 16.5 lb-ft) I823H1220005-01 2) Tighten the front fork cap bolt (2) to the specified...
  • Page 435 Front Suspension: 2B-4 9) Install the handlebar holder assembly. 11) Install the front wheel assembly. Refer to “Front Wheel Assembly Removal and Installation in Section 10) Tighten the handlebar holder mounting bolts and 2D (Page 2D-4)”. nuts (6). NOTE Tightening torque Handlebar holder mounting nut (d): 35 N·m (3.5 Before tightening the front axle and front axle kgf-m, 25.5 lb-ft)

  • Page 436: Front Suspension Adjustment

    2B-5 Front Suspension: Front Suspension Adjustment Damping Force Adjustment B815H22206003 After installing the front fork, adjust the spring pre-load NOTE and two kinds of damping force as follows: Make sure to check the 1st click position by the last click sound when turning in the WARNING adjuster.

  • Page 437: Front Fork Disassembly And Assembly

    Front Suspension: 2B-6 Front Fork Disassembly and Assembly 4) Remove the front fork cap bolt (1) from the inner rod B815H22206004 by loosening the lock-nut (2). Refer to “Front Fork Removal and Installation (Page 2B- 2)”. CAUTION NOTE • Do not disassemble the front fork cap bolt (1).
  • Page 438 2B-7 Front Suspension: 9) Remove the outer tube from the inner tube. 12) Remove the inner rod/damper rod (cartridge) (8). CAUTION Do not disassemble the inner rod/damper rod (cartridge). I815H1220019-01 10) Remove the outside of the front axle pinch bolt (7). I815H1220022-01 13) Remove the dust seal (9) and oil seal stopper ring (10).
  • Page 439 14) Remove the oil seal (11) with the special tool. • Apply fork oil to the oil seal lip. 15) Remove the oil seal retainer (12). : Fork Oil 99000–99044–L01 (SUZUKI FORK Special tool OIL L01 or equivalent) (D): 09913–50121 (Oil seal remover)
  • Page 440 2B-9 Front Suspension: • Apply thread lock to the damper rod bolt (2) and • Install the oil seal stopper ring (2). tighten it to the specified torque with the special tools. CAUTION CAUTION Make sure that the oil seal stopper ring is Use a new damper rod bolt gasket (3) to fitted securely.
  • Page 441 • Keep the front fork vertically and wait 5 – 6 minutes. outer tube. NOTE : Fork Oil 99000–99044–L01 (SUZUKI FORK OIL L01 or equivalent) • Always keep oil level over the cartridge top end, or air may enter the cartridge during Front fork oil capacity (each leg) this procedure.
  • Page 442 (1) to the softest position before “ a ” installing the cap bolt. • Use a new O-ring to prevent oil leakage. : Fork Oil 99000–99044–L01 (SUZUKI FORK OIL L01 or equivalent) I823H1220029-02 “a”: 11 mm (0.43 in) I815H1220031-01...

  • Page 443: Front Fork Parts Inspection

    Front Suspension: 2B-12 • Slowly turn the cap bolt completely by hand until the Fork Spring end of the cap bolt seats on the lock-nut. Measure the fork spring free length. If it is shorter than the service limit, replace it with a new one. •...

  • Page 444: Specifications

    Front fork oil level (Without spring, 95 (3.7) — outer tube fully compressed) Front fork oil type SUZUKI FORK OIL L01 or an equivalent fork oil — Front fork oil capacity (Each leg) 532 ml (18.0/18.7 US/lmp oz) — Front fork inner tube O.D 43 (1.7)

  • Page 445: Special Tools And Equipment

    Special Tools and Equipment Recommended Service Material B815H22208001 Material SUZUKI recommended product or Specification Note Fork Oil SUZUKI FORK OIL L01 or equivalent P/No.: 99000–99044– (Page 2B-8) / (Page 2B- 8) / (Page 2B-10) / (Page 2B-11) Thread lock cement THREAD LOCK CEMENT SUPER P/No.: 99000–32110...

  • Page 446: Rear Suspension

    2C-1 Rear Suspension: Rear Suspension Suspension Repair Instructions Rear Suspension Components B815H22306001 I815H1230001-03 1. Rear shock absorber 8. Swingarm pivot shaft : 50 N⋅m (5.0 kgf-m, 36.0 lb-ft) 2. Rear shock absorber mounting nut 9. Swingarm pivot nut : 78 N⋅m (7.8 kgf-m, 56.5 lb-ft) 3.

  • Page 447: Rear Suspension Assembly Construction

    Rear Suspension: 2C-2 Rear Suspension Assembly Construction B815H22306002 I815H1230002-02 1. Rear shock absorber mounting nut (Upper) 6. Swingarm pivot shaft : 15 N⋅m (1.5 kgf-m, 11.0 lb-ft) 2. Rear shock absorber mounting nut (Lower) 7. Swingarm pivot nut : 100 N⋅m (10.0 kgf-m, 72.5 lb-ft) 3.

  • Page 448: Rear Shock Absorber / Cusion Lever Removal And Installation

    2C-3 Rear Suspension: Rear Shock Absorber / Cusion Lever Removal 8) Remove the rear shock absorber downward. and Installation B815H22306003 Removal 1) Remove the rear under cowling and side cowlings. Refer to “Exterior Parts Removal and Installation in Section 9D (Page 9D-14)”. 2) Support the motorcycle with a jack to relieve load on the rear shock absorber.

  • Page 449: Rear Suspension Inspection

    Rear Suspension: 2C-4 Rear Suspension Inspection Rear Suspension Adjustment B815H22306004 B815H22306006 Refer to “Rear Suspension Inspection in Section 0B After installing the rear suspension, adjust the spring (Page 0B-20)”. pre-load and damping force as follows: Spring Pre-load Adjustment Rear Shock Absorber Inspection B815H22306005 •...

  • Page 450: Rear Shock Absorber Disposal

    2C-5 Rear Suspension: Compression side 1) Mark the drill center at the location “A” using a center Turn the damping force adjuster (2) to the desired punch. position. STD position 8 clicks out of from stiffest position “ a ” “A”...

  • Page 451: Cushion Lever Removal And Installation

    Rear Suspension: 2C-6 Cushion Lever Removal and Installation Cushion Lever Inspection B815H22306008 B815H22306009 Refer to “Cushion Lever Removal and Installation Removal (Page 2C-6)”. 1) Support the motorcycle with a jack to relieve load on Spacer the cushion lever. 1) Remove the spacers from the cushion lever. 2) Remove the cushion lever by removing its related bolts, nuts and washers.

  • Page 452: Cushion Lever Bearing Removal And Installation

    (A): 09921–20240 (Bearing remover set) (B): 09913–70210 (Bearing installer set) I815H1230022-01 2) Apply grease to the bearings. I815H1230019-01 : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I815H1230020-01 I815H1230023-01 3) Install the cushion lever. Refer to “Cushion Lever Removal and Installation (Page 2C-6)”.

  • Page 453: Swingarm / Cushion Rod Removal And Installation

    Rear Suspension: 2C-8 Swingarm / Cushion Rod Removal and 6) Remove the swingarm pivot shaft lock-nut with the special tool. Installation B815H22306011 Special tool (A): 09940–14970 (Swingarm pivot thrust Removal adjuster socket wrench) 1) Cut the drive chain. Refer to “Drive Chain Replacement in Section 3A (Page 3A-7)”.
  • Page 454 2C-9 Rear Suspension: 8) Remove the swingarm pivot shaft. Installation Install the swingarm in the reverse order of removal. Pay 9) Remove the swingarm. attention to the following points: 10) Remove the cushion lever (5) and cushion rods (6). • Temporarily install the cushion rod mounting nut. NOTE The stamped marks “A”...
  • Page 455 Rear Suspension: 2C-10 – Hold the swingarm pivot shaft and tighten the – Tighten the cushion lever, cushion rod and rear swingarm pivot nut (2) to the specified torque. shock absorber mounting nut to the specified torque. Tightening torque Swingarm pivot nut (b): 100 N·m (10.0 kgf-m, Tightening torque 72.5 lb-ft) Rear shock absorber mounting nut (d): 50 N·m...

  • Page 456: Swingarm Related Parts Inspection

    2C-11 Rear Suspension: Swingarm Related Parts Inspection Swingarm B815H22306012 Inspect the swingarm for damage. If any defect is found, Refer to “Swingarm / Cushion Rod Removal and replace the swingarm with a new one. Installation (Page 2C-8)”. Spacers 1) Remove the dust seal and spacers from the swingarm.

  • Page 457: Swingarm Bearing Removal And Installation

    4) Remove the swingarm cushion rod bearings (3) (B): 09941–34513 (Steering race installer) using the special tools. Special tool (A): 09921–20240 (Bearing remover set) I815H1230046-01 4) Apply grease to the bearings. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I815H1230044-02...

  • Page 458: Specifications

    2C-13 Rear Suspension: 5) Install the swingarm. Refer to “Swingarm / Cushion Rod Removal and Installation (Page 2C-8)”. I815H1230047-01 Specifications Service Data B815H22307001 Suspension Unit: mm (in) Item Standard Limit Rear shock absorber spring pre-set 195 (7.7) — length Rear shock absorber damping force Rebound 12 clicks out from stiffed position —...

  • Page 459: Special Tools And Equipment

    Rear Suspension: 2C-14 Special Tools and Equipment Recommended Service Material B815H22308001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010 (Page 2C-7) / (Page 2C- equivalent NOTE Required service material is also described in the following.

  • Page 460: Wheels And Tires

    2D-1 Wheels and Tires: Wheels and Tires Suspension Precautions Precautions for Wheel and Tire B815H22400001 WARNING • Proper tire pressure and proper tire loading are important factors. Over loading tire can lead to tire failure and loss of motorcycle control. •...

  • Page 461: Repair Instructions

    Wheels and Tires: 2D-2 Repair Instructions Front Wheel Components B815H22406001 I815H1240001-01 1. Front axle bolt 5. Bearing 9. Wheel balancer : 100 N⋅m (10.0 kgf-m, 72.5 lb-ft) 2. Collar 6. Tire 10. Spacer : Apply grease. 3. Brake disc 7. Front wheel 11.

  • Page 462: Front Wheel Assembly Construction

    2D-3 Wheels and Tires: Front Wheel Assembly Construction B815H22406002 “ a ” I815H1240003-01 1. Brake disc bolt “a”: Clearance : Apply grease. 2. Brake caliper mounting bolt : 23 N⋅m (2.3 kgf-m, 16.5 lb-ft) : Apply thread lock to the thread part. 3.

  • Page 463: Front Wheel Assembly Removal And Installation

    Wheels and Tires: 2D-4 Front Wheel Assembly Removal and Installation 7) Remove the brake calipers, left and right. B815H22406003 CAUTION Removal Do not operate the brake lever with the 1) Remove the rear under cowling and side cowlings. caliper removed. Refer to “Exterior Parts Removal and Installation in Section 9D (Page 9D-14)”.
  • Page 464 2D-5 Wheels and Tires: Installation 4) Hold the front axle with the special tool and tighten the front axle bolt (3) to the specified torque. 1) Install the collar (1) to the right side of the wheel. Special tool (A): 09900–18740 (Hexagon socket (24 mm)) Tightening torque Front axle bolt (b): 100 N·m (10.0 kgf-m, 72.5 lb-...

  • Page 465: Front Wheel Related Parts Inspection

    Wheels and Tires: 2D-6 8) Install the front fender, side cowlings and rear under Wheel cowlings. 1) Remove the brake pads. Refer to “Front Brake Pad Replacement in Section 4B (Page 4B-2)”. Front Wheel Related Parts Inspection 2) Make sure that the wheel runout checked as shown B815H22406004 in the figure does not exceed the service limit.

  • Page 466: Front Wheel Dust Seal / Bearing Removal And Installation

    1) Remove the front wheel assembly. Refer to “Front Wheel Assembly Removal and Installation 1) Apply grease to the wheel bearings. (Page 2D-4)”. : Grease 99000–25010 (SUZUKI SUPER 2) Remove the dust seals (1) using the special tool. GREASE A or equivalent) Special tool (A): 09913–50121 (Oil seal remover)
  • Page 467 (A): 09924–84510 (Bearing installer set) CAUTION The sealed cover of the bearing must face outside. I823H1240016-01 4) Apply grease to the lip of dust seals. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I649G1240020-03 Right Left I823H1240017-01 5) Install the front wheel assembly. Refer to“Front Wheel Assembly Removal and Installation (Page 2D-4)”.

  • Page 468: Rear Wheel Components

    2D-9 Wheels and Tires: Rear Wheel Components B815H22406006 I815H1240002-05 1. Rear axel nut 9. Wheel damper : 100 N⋅m (10.0 kgf-m, 72.5 lb-ft) 2. Rear brake disc 10. Wheel balancer : 35 N⋅m (3.5 kgf-m, 25.5 lb-ft) 3. Collar 11. Air valve : 60 N⋅m (6.0 kgf-m, 43.5 lb-ft) 4.

  • Page 469: Rear Wheel Assembly Construction

    Wheels and Tires: 2D-10 Rear Wheel Assembly Construction B815H22406007 “ a ” “A” I815H1240011-01 1. Rear sprocket nut : 100 N⋅m (10.0 kgf-m, 72.5 lb-ft) 2. Rear axle nut : 35 N⋅m (3.5 kgf-m, 25.5 lb-ft) 3. Brake disc bolt : 33 N⋅m (3.3 kgf-m, 24.0 lb-ft) 4.

  • Page 470: Rear Wheel Assembly Removal And Installation

    2D-11 Wheels and Tires: Rear Wheel Assembly Removal and Installation Installation B815H22406008 1) Install the spacer (1) and collar (2). Removal 1) Loosen the axle nut (1). 2) Raise the rear wheel off the ground and support the motorcycle with a jack or wooden block. CAUTION Make sure that the motorcycle is supported securely.

  • Page 471: Rear Wheel Related Parts Inspection

    Wheels and Tires: 2D-12 Rear Wheel Related Parts Inspection Wheel Axle B815H22406009 Using a dial gauge, check the wheel axle for runout, If Refer to “Rear Wheel Assembly Removal and the runout exceeds the limit, replace the axle shaft. Installation (Page 2D-11)”. Wheel axle runout Service limit: 0.25 mm (0.010 in) Tire...

  • Page 472: Rear Wheel Dust Seal / Bearing Removal And Installation

    2) Remove the spacer (1). 3) Remove the rear sprocket mounting drum assembly 1) Apply grease to the wheel bearings. (2) from the rear wheel. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I823H1240023-03 I649G1240019-02 4) Remove the dust seal (3).
  • Page 473 (B): 09924–84510 (Bearing installer set) CAUTION The sealed cover of the bearing must face outside. I823H1240025-01 4) Apply grease to the dust seal lip. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I649G1240030-02 Left Right I823H1240026-01 5) Install the rear sprocket mounting drum assembly.

  • Page 474: Tire Removal And Installation

    2D-15 Wheels and Tires: Tire Removal and Installation Installation B815H22406011 Removal CAUTION The most critical factor of a tubeless tire is the seal Do not reuse the valve which has been once between the wheel rim and the tire bead. For this removed.

  • Page 475: Wheel / Tire / Air Valve Inspection And Cleaning

    Wheels and Tires: 2D-16 3) Bounce the tire several times while rotating. This Wheel / Tire / Air Valve Inspection and Cleaning B815H22406012 makes the tire bead expand outward to contact the Refer to “Tire Removal and Installation (Page 2D-15)”. wheel, thereby facilitating air inflation.

  • Page 476: Air Valve Removal And Installation

    2D-17 Wheels and Tires: Air Valve Installation Inspect the air valve for peeling and damage. If any Install the air valve in the reverse order of removal. Pay defect is found, replace the air valve with a new one. attention to the following points: Refer to “Air Valve Removal and Installation (Page 2D- •...

  • Page 477: Wheel Balance Check And Adjustment

    Wheels and Tires: 2D-18 Wheel Balance Check and Adjustment 4) When installing the balancer weight to the wheel, set B815H22406014 the balancer weight on center rib of the wheel. Check and adjust the wheel balance in the following procedures: 1) Removal the wheel assembly. Refer to “Front Wheel Assembly Removal and Installation (Page 2D-4)”...

  • Page 478: Tightening Torque Specifications

    For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List in Section 0C (Page 0C-9)”. Special Tools and Equipment Recommended Service Material B815H22408001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010 (Page 2D-7) /...
  • Page 479 Wheels and Tires: 2D-20 09913–50121 09913–70210 Oil seal remover Bearing installer set (Page 2D-7) / (Page 2D- (Page 2D-8) / (Page 2D- 09921–20240 09924–84510 Bearing remover set Bearing installer set (Page 2D-7) / (Page 2D- (Page 2D-8) / (Page 2D- 09941–34513 Steering race installer (Page 2D-14)
  • Page 480 2D-21 Wheels and Tires:...
  • Page 481 Table of Contents 3- i Section 3 Driveline / Axle CONTENTS Precautions ..........3-1 Rear Sprocket / Rear Sprocket Mounting Drum Removal and Installation ......3A-4 Precautions............. 3-1 Drive Chain Related Parts Inspection ....3A-5 Precautions for Driveline / Axle ......3-1 Sprocket Mounting Drum Dust Seal / Bearing Drive Chain / Drive Train / Drive Shaft...

  • Page 482: Precautions

    • Lubricate the drive chain with a heavy weight motor oil. Wipe off any excess oil or chain lubricant. Do not use any oil sold commercially as “drive chain oil”. Such oil can damage the O-rings. • The standard drive chain is RK GB50GSVZ4. Suzuki recommends to use this standard drive chain as a replacement.

  • Page 483: Drive Chain / Drive Train / Drive Shaft

    Drive Chain / Drive Train / Drive Shaft: 3A-1 Drive Chain / Drive Train / Drive Shaft Driveline / Axle Diagnostic Information and Procedures Drive Chain and Sprocket Symptom Diagnosis B815H23104001 Condition Possible cause Correction / Reference Item Noisy Drive Chain Worn sprocket.

  • Page 484: Engine Sprocket Removal And Installation

    3A-2 Drive Chain / Drive Train / Drive Shaft: Engine Sprocket Removal and Installation 6) Remove the speed sensor rotor (4) by removing its B815H23106002 bolt while depressing the rear brake pedal. Removal 1) Remove the side cowlings. Refer to “Exterior Parts Removal and Installation in Section 9D (Page 9D- 14)”.
  • Page 485 20.0 lb-ft) • Before installing the engine sprocket cover, apply a small quantity of grease to the clutch push rod. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I815H1310010-01 • Adjust the drive chain slack. Refer to “Drive Chain Inspection and Adjustment in Section 0B (Page 0B- 15)”.

  • Page 486: Rear Sprocket / Rear Sprocket Mounting Drum Removal And Installation

    1) Remove the rear wheel assembly by disengaging rear wheel hub and rear sprocket mounting drum. the drive chain. Refer to “Rear Wheel Assembly : Grease 99000–25010 (SUZUKI SUPER Removal and Installation in Section 2D (Page 2D- GREASE A or equivalent) 11)”.

  • Page 487: Drive Chain Related Parts Inspection

    Drive Chain / Drive Train / Drive Shaft: 3A-5 Drive Chain Related Parts Inspection Wheel Damper B815H23106004 Inspect the dampers for wear and damage. Replace the Refer to “Rear Sprocket / Rear Sprocket Mounting Drum damper if there is anything unusual. Removal and Installation (Page 3A-4)”.
  • Page 488 3) Apply grease to the dust seal lip. 1) Apply grease to the bearing before installing. 4) Apply grease to the retainer before installing the rear sprocket mounting drum. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent)

  • Page 489: Drive Chain Replacement

    Drive Chain / Drive Train / Drive Shaft: 3A-7 5) Install the rear sprocket mounting drum assembly to Drive Chain Cutting rear wheel hub. Refer to “Rear Sprocket / Rear 1) Set up the special tool as shown in the figure. Sprocket Mounting Drum Removal and Installation (Page 3A-4)”.
  • Page 490 3A-8 Drive Chain / Drive Train / Drive Shaft: 2) Place the drive chain link being disjointed on the 6) Remove the joint pin (9) of the other side of joint holder part (8) of the tool. plate. 3) Turn in both the adjuster bolt (6) and pressure bolt CAUTION [A] (3) so that each of their end hole fits over the chain joint pin properly.
  • Page 491 Drive Chain / Drive Train / Drive Shaft: 3A-9 2) Apply grease to the joint pins (8), O-rings (9) and 6) Turn in the pressure bolt [A] (6) and align two joint plates (10). pins (11) properly with the respective holes of the joint plate (10).
  • Page 492 3A-10 Drive Chain / Drive Train / Drive Shaft: Joint pin staking 2) Stake the joint pin by turning (approximately 7/8 turn) the pressure bolt [A] (3) with the bar until the pin end 1) Set up the special tool as shown in the figure. diameter becomes the specified dimension.

  • Page 493: Specifications

    For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List in Section 0C (Page 0C-9)”. Special Tools and Equipment Recommended Service Material B815H23108001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010 (Page 3A-3) /...

  • Page 494: Special Tool

    3A-12 Drive Chain / Drive Train / Drive Shaft: Special Tool B815H23108002 09913–50121 09913–70210 Oil seal remover Bearing installer set (Page 3A-5) (Page 3A-6) 09921–20240 09922–22711 Bearing remover set Drive chain cutting and joining tool (Page 3A-6) (Page 3A-7) 09924–84510 Bearing installer set (Page 3A-6)
  • Page 495 Table of Contents 4- i Section 4 Brake CONTENTS Precautions ..........4-1 Tightening Torque Specifications......4A-18 Special Tools and Equipment ......4A-19 Precautions............. 4-1 Recommended Service Material .......4A-19 Precautions for Brake System ......4-1 Special Tool ............4A-19 Brake Fluid Information ......... 4-1 Front Brakes ..........4B-1 Brake Control System and Diagnosis ...

  • Page 496: Precautions

    4-1 Precautions: Precautions Brake Precautions Precautions for Brake System B815H24000001 Refer to “General Precautions in Section 00 (Page 00-1)”. Brake Fluid Information B815H24000002 WARNING • 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.

  • Page 497: Brake Control System And Diagnosis

    Brake Control System and Diagnosis: 4A-1 Brake Control System and Diagnosis Brake Schematic and Routing Diagram Front Brake Hose Routing Diagram B815H24102001 “ a ” “ a ” “ b ” “ b ” “ b ” I815H1410003-04 1. Front brake hose No.1 7.

  • Page 498: Rear Brake Hose Routing Diagram

    4A-2 Brake Control System and Diagnosis: Rear Brake Hose Routing Diagram B815H24102002 “ b ” “ a ” “A” “ b” I815H1410004-02 1. Brake hose clamp “b”: 21° : Brake hose clamp ends should face outside. 2. Brake hose clamp : 23 N⋅m (2.3 kgf-m, 16.5 lb-ft) : Brake hose clamp ends should face backward.

  • Page 499: Diagnostic Information And Procedures

    Brake Control System and Diagnosis: 4A-3 Diagnostic Information and Procedures Brake Symptom Diagnosis B815H24104001 Condition Possible cause Correction / Reference Item Insufficient brake power Leakage of brake fluid from hydraulic Repair or replace. system. Worn pads and disc. Replace. Oil adhesion on friction surface of pads. Clean disc and pads. Air in hydraulic system.

  • Page 500: Rear Brake Light Switch Inspection

    4A-4 Brake Control System and Diagnosis: Rear Brake Light Switch Inspection Brake Fluid Level Check B815H24106003 B815H24106005 Inspect the rear brake light switch in the following Refer to “Brake System Inspection in Section 0B procedures: (Page 0B-17)”. 1) Disconnect the rear brake light switch lead wire Brake Hose Inspection coupler (1).
  • Page 501 Brake Control System and Diagnosis: 4A-5 3) Squeeze and release the brake lever several times 8) Fill the reservoir with brake fluid to the upper mark of in rapid succession and squeeze the lever fully the reservoir. without releasing it. I815H1410013-01 9) Install the reservoir cap.

  • Page 502: Brake Fluid Replacement

    4A-6 Brake Control System and Diagnosis: • Fill the reservoir with brake fluid to the upper mark of 6) Loosen the air bleeder valve and pump the brake the reservoir. lever until the old brake fluid flows out of the brake system.
  • Page 503 Brake Control System and Diagnosis: 4A-7 8) Fill the reservoir with brake fluid to the upper mark of 7) Loosen the air bleeder valve and pump the brake the reservoir. pedal until the old brake fluid flows out of the brake system.

  • Page 504: Front Brake Hose Removal And Installation

    4A-8 Brake Control System and Diagnosis: 9) Fill the reservoir with brake fluid to the upper mark of Rear Brake Hose Removal and Installation B815H24106010 the reservoir. Removal 1) Remove the frame cover. Refer to “Exterior Parts Removal and Installation in Section 9D (Page 9D- 14)”.

  • Page 505: Front Brake Master Cylinder Components

    Brake Control System and Diagnosis: 4A-9 Front Brake Master Cylinder Components B815H24106011 I815H1410054-01 1. Reservoir cap 7. Brake hose union bolt : 6.0 N⋅m (0.6 kgf-m, 4.5 lb-ft) 2. Plate 8. Brake lever : Apply brake fluid. 3. Diaphragm 9. Brake lever pivot bolt : Apply silicone grease.

  • Page 506: Front Brake Master Cylinder Assembly Removal And Installation

    4A-10 Brake Control System and Diagnosis: Front Brake Master Cylinder Assembly Removal and Installation B815H24106012 “A” Removal “B” 1) Drain brake fluid. Refer to “Brake Fluid Replacement (Page 4A-6)”. 2) Disconnect the front brake light switch lead wire coupler (1). I815H1410031-01 “B”...

  • Page 507: Front Brake Master Cylinder / Brake Lever Disassembly And Assembly

    Brake Control System and Diagnosis: 4A-11 Front Brake Master Cylinder / Brake Lever 5) Remove the following parts from the master cylinder. Disassembly and Assembly • Secondary cup (9) B815H24106013 • Piston (10) Refer to “Front Brake Master Cylinder Assembly Removal and Installation (Page 4A-10)”.

  • Page 508: Front Brake Master Cylinder Parts Inspection

    • Apply grease to the brake lever pivot bolt. • Apply grease to the contacting surfaces between piston and brake lever. I815H1410041-01 : Grease 99000–25100 (SUZUKI Silicone Grease or equivalent) Piston / Rubber Parts Inspect the piston surface for any scratches or other damage.

  • Page 509: Rear Brake Master Cylinder Components

    Brake Control System and Diagnosis: 4A-13 Rear Brake Master Cylinder Components B815H24106015 I815H1410043-01 1. Reservoir tank 6. Master cylinder : 18 N⋅m (1.8 kgf-m, 13.0 lb-ft) 2. Reservoir hose 7. Piston/Cup set : Apply silicone grease. 3. Brake hose union bolt 8.

  • Page 510: Rear Brake Master Cylinder Assembly Removal And Installation

    4A-14 Brake Control System and Diagnosis: Rear Brake Master Cylinder Assembly Removal Installation Install the rear brake master cylinder in the reverse order and Installation B815H24106016 of removal. Pay attention to the following points: Removal CAUTION 1) Remove the frame cover. Refer to “Exterior Parts The seal washers should be replaced with the Removal and Installation in Section 9D (Page 9D- new ones to prevent fluid leakage.

  • Page 511: Rear Brake Master Cylinder Disassembly And Assembly

    Brake Control System and Diagnosis: 4A-15 Rear Brake Master Cylinder Disassembly and 5) Remove the push rod (7), piston/cup set (8) and spring (9). Assembly B815H24106017 Refer to “Front Brake Master Cylinder Assembly Removal and Installation (Page 4A-10)”. Disassembly 1) Disconnect the reservoir hose (1). 2) Remove the lock-nut (2).

  • Page 512: Rear Brake Master Cylinder Parts Inspection

    Rear Brake Master Cylinder Parts Inspection • Apply grease to the push rod end. B815H24106018 Refer to “Rear Brake Master Cylinder Disassembly and : Grease 99000–25100 (SUZUKI Silicone Assembly (Page 4A-15)”. Grease or equivalent) Master Cylinder Inspect the master cylinder bore for any scratches or other damage.

  • Page 513: Rear Brake Pedal Construction

    Brake Control System and Diagnosis: 4A-17 Rear Brake Pedal Construction B815H24106019 I815H1410053-02 1. Washer 3. Rear brake return spring hook : Apply grease. : Do not reuse. 2. Snap ring : 5.5 N⋅m (0.55 kgf-m, 4.0 lb-ft) : Apply thread lock to the thread part. Rear Brake Pedal Removal and Installation Installation B815H24106020...

  • Page 514: Specifications

    4A-18 Brake Control System and Diagnosis: Specifications Service Data B815H24107001 Brake Unit: mm (in) Item Standard Limit Rear brake pedal height 50 – 60 (2.0 – 2.4) — Front 14.000 – 14.043 (0.5512 – 0.5529) — Master cylinder bore Rear 12.700 –...

  • Page 515: Special Tools And Equipment

    Brake Control System and Diagnosis: 4A-19 Special Tools and Equipment Recommended Service Material B815H24108001 Material SUZUKI recommended product or Specification Note Brake fluid DOT 4 — (Page 4A-6) / (Page 4A- 7) / (Page 4A-11) / (Page 4A-15) Grease SUZUKI Silicone Grease or P/No.: 99000–25100...

  • Page 516: Front Brakes

    4B-1 Front Brakes: Front Brakes Brake Repair Instructions Front Brake Components B815H24206001 I815H1420001-04 1. O-ring 7. Front brake disc : Apply thread lock to the thread part. 2. Piston seal : 22 N⋅m (2.2 kgf-m, 16.0 lb-ft) : Apply brake fluid. 3.

  • Page 517: Front Brake Pad Inspection

    Front Brakes: 4B-2 Front Brake Pad Inspection 4) Clean up the caliper especially around the caliper B815H24206002 piston. The extent of brake pads wear can be checked by 5) Install the spring to caliper, bring its wider side of observing the grooved limit line “A” on the pads. When pawl “A”...

  • Page 518: Front Brake Caliper Removal And Installation

    4B-3 Front Brakes: 7) Install the brake caliper. Removal 8) Tighten the front brake caliper mounting bolts (4) and 1) Drain brake fluid. Refer to “Brake Fluid Replacement front brake pad mounting pins (5) to the specified in Section 4A (Page 4A-6)”. torque.

  • Page 519: Front Brake Caliper Disassembly And Assembly

    Front Brakes: 4B-4 Installation Front Brake Caliper Disassembly and Assembly B815H24206005 Install the brake caliper in the reverse order of removal. Refer to “Front Brake Caliper Removal and Installation Pay attention to the following points: (Page 4B-3)”. • Tighten each bolt to the specified torque. NOTE Tightening torque The right and left calipers are installed...
  • Page 520 4B-5 Front Brakes: 4) Place a rag over the pistons to prevent it from Assembly popping out and then force out the pistons using Assemble the caliper in the reverse order of compressed air. disassembly. Pay attention to the following points: •...

  • Page 521: Front Brake Caliper Parts Inspection

    Front Brakes: 4B-6 • Install a new O-ring and reassemble caliper halves. Front Brake Caliper Parts Inspection B815H24206006 Refer to “Front Brake Caliper Disassembly and CAUTION Assembly (Page 4B-4)”. Replace the O-ring with a new one. Brake Caliper Cylinder Inspect the brake caliper cylinder wall for nicks, scratches or other damage.

  • Page 522: Front Brake Disc Removal And Installation

    4B-7 Front Brakes: Brake Pad Spring Installation Inspect the brake pad spring for damage and excessive Install the front brake disc in the reverse order of bend. If any damage is found, replace it with a new one. removal. Pay attention to the following points: •...

  • Page 523: Specifications

    Front Brakes: 4B-8 Brake Disc Runout 1) Dismount the front brake caliper. Refer to “Front Brake Caliper Removal and Installation (Page 4B- 3)”. 2) Measure the runout using the dial gauge. Replace the disc if the runout exceeds the service limit.

  • Page 524: Special Tools And Equipment

    4B-9 Front Brakes: Special Tools and Equipment Recommended Service Material B815H24208001 Material SUZUKI recommended product or Specification Note Brake fluid DOT 4 — (Page 4B-5) / (Page 4B- Thread lock cement Thread Lock Cement Super 1360 or P/No.: 99000–32130 (Page 4B-7)

  • Page 525: Rear Brakes

    Rear Brakes: 4C-1 Rear Brakes Brake Repair Instructions Rear Brake Components B815H24306001 I823H1430025-04 1. Rear caliper 7. Rear brake disc : 35 N⋅m (3.5 kgf-m, 2.5 lb-ft) 2. Piston seal 8. Brake pad spring : Apply silicone grease to sliding surface. 3.

  • Page 526: Rear Brake Pad Inspection

    4C-2 Rear Brakes: Rear Brake Pad Inspection 3) Remove the brake pads (3) with the rear caliper B815H24306002 pivoted up. The extent of brake pads wear can be checked by observing the grooved limit line “A” on the pads. When NOTE the wear exceeds the grooved limit line, replace the When removing the pads, push the piston all...

  • Page 527: Rear Brake Caliper Removal And Installation

    Rear Brakes: 4C-3 6) Tighten the caliper mounting bolt (4) and pad 3) Remove the brake pads. Refer to “Rear Brake Pad mounting pin (5) to the specified torque. Replacement (Page 4C-2)”. 4) Pivot the caliper up and remove the caliper from the Tightening torque caliper bracket.

  • Page 528: Rear Brake Caliper Disassembly And Assembly

    4C-4 Rear Brakes: Rear Brake Caliper Disassembly and Assembly 5) Remove the dust seal (7) and piston seal (8). B815H24306005 Refer to “Rear Brake Caliper Removal and Installation (Page 4C-3)”. Disassembly 1) Remove the pad spring (1), rubber boot (2) and sliding pin (3).
  • Page 529 • Apply the brake fluid to piston seal (1) and dust seal • Tighten the sliding pin (3) and apply grease to the (2). sliding pin. : Grease 99000–25100 (SUZUKI Silicone CAUTION Grease or equivalent) Replace the piston seal (1) and dust seal (2) Tightening torque with new ones.

  • Page 530: Rear Brake Caliper Parts Inspection

    4C-6 Rear Brakes: Rear Brake Caliper Parts Inspection Boot and Spacer B815H24306006 Inspect the boots and spacer for damage and wear. If Refer to “Rear Brake Caliper Disassembly and any defects are found, replace them with new ones. Assembly (Page 4C-4)”. Brake Caliper Cylinder Inspect the brake caliper cylinder wall for nicks, scratches or other damage.

  • Page 531: Rear Brake Disc Inspection

    Rear Brakes: 4C-7 Installation Brake Disc Runout Install the rear brake disc in the reverse order of 1) Dismount the rear brake caliper. Refer to “Rear removal. Pay attention to the following points: Brake Caliper Removal and Installation (Page 4C- •...

  • Page 532: Specifications

    4C-8 Rear Brakes: Specifications Service Data B815H24307001 Brake Unit: mm (in) Item Standard Limit Brake disc thickness Rear 5.3 – 5.7 (0.21 – 0.22) 5.0 (0.20) Brake disc runout — 0.30 (0.012) Brake caliper cylinder bore Rear 38.180 – 38.256 (1.5031 – 1.5061) —...

  • Page 533: Special Tools And Equipment

    Rear Brakes: 4C-9 Special Tools and Equipment Recommended Service Material B815H24308001 Material SUZUKI recommended product or Specification Note Brake fluid DOT 4 — (Page 4C-4) / (Page 4C- Grease SUZUKI Silicone Grease or P/No.: 99000–25100 (Page 4C-5) / (Page 4C-...
  • Page 534 4C-10 Rear Brakes:...
  • Page 535 Table of Contents 5- i Section 5 Transmission / Transaxle CONTENTS Precautions ..........5-1 Clutch ............5C-1 Precautions............. 5-1 Precautions............5C-1 Precautions for Transmission / Transaxle..... 5-1 Precautions for Clutch System......5C-1 Clutch Fluid (Brake Fluid) Information....5C-1 Manual Transmission......5B-1 Schematic and Routing Diagram ......5C-2 Diagnostic Information and Procedures....5B-1 Clutch Hose Routing Diagram......5C-2 Manual Transmission Symptom Diagnosis ..

  • Page 536: Precautions

    5-1 Precautions: Precautions Transmission / Transaxle Precautions Precautions for Transmission / Transaxle B815H25000001 Refer to “General Precautions in Section 00 (Page 00-1)”.

  • Page 537: Manual Transmission

    Manual Transmission: 5B-1 Manual Transmission Transmission / Transaxle Diagnostic Information and Procedures Manual Transmission Symptom Diagnosis B815H25204001 Condition Possible cause Correction / Reference Item Engine is noisy (Noise Worn or rubbing gear. Replace. seems to come from the Worn countershaft spline. Replace countershaft.

  • Page 538: Repair Instructions

    5B-2 Manual Transmission: Repair Instructions Transmission Components B815H25206001 I815H1520016-01 1. 2nd drive gear 12. 5th driven gear : 145 N⋅m (14.5 kgf-m, 105.0 lb-ft) 2. 6th drive gear 13. 1st driven gear : 10 N⋅m (1.0 kgf-m, 7.0 lb-ft) 3. 3rd/4th drive gears 14.

  • Page 539: Transmission Removal

    Manual Transmission: 5B-3 Transmission Removal Gearshift Fork and Gearshift Cam B815H25206002 1) Remove the gearshift cam bearing retainer (1) from 1) Remove the engine assembly from the frame. Refer the lower crankcase. to “Engine Assembly Removal in Section 1D (Page 1D-19)”. 2) Remove the engine top side.

  • Page 540: Transmission Installation

    5B-4 Manual Transmission: Bearing Transmission Installation B815H25206003 1) Remove the gearshift shaft bearing using the special Install the transmission in the reverse order of removal. tool. Pay attention to the following points: Special tool Bearing (A): 09921–20240 (Bearing remover set) CAUTION Replace the removed bearings with new ones.
  • Page 541 Manual Transmission: 5B-5 • Install the gearshift cam along with the bearing. • Install the bearing retainer (4). NOTE NOTE The stamped mark side of the gearshift cam Apply a small quantity of thread lock to the bearing faces outside. bearing retainer screws and tighten them to the specified torque.
  • Page 542 5B-6 Manual Transmission: • Install the driveshaft assembly on the upper • Install the oil seal (4). crankcase. • Turn each bearing to set the bearing dowel pin “F” and “G” in position. NOTE Align the bearing ring “A” with the groove “B”...

  • Page 543: Transmission Construction

    Manual Transmission: 5B-7 Transmission Construction B815H25206004 I823H1520086-02 1. Countershaft 2. Driveshaft Countershaft Gear / Driveshaft Gear Countershaft Disassembly and Assembly • Remove the 6th drive gear snap ring (1) from its B815H25206005 groove and slide it towards the 3rd/4th drive gears (2). Refer to “Transmission Removal (Page 5B-3)”...
  • Page 544 5B-8 Manual Transmission: • Slide the 6th (3) and 2nd (4) drive gears toward the • Remove the driveshaft bearing (2) along with the 3rd/4th drive gears (2), then remove the 2nd drive spacer (3) using a hydraulic press. gear circlip (5). •...
  • Page 545 • Before installing the oil seal, apply grease to the oil seal lip. M/O: Molybdenum oil (MOLYBDENUM OIL SOLUTION) : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I823H1520023-02 • When installing a new snap ring (1), pay attention to •...

  • Page 546: Transmission Related Parts Inspection

    5B-10 Manual Transmission: • When installing the gear bushings onto the driveshaft, • When installing the gear bushing onto the align the shaft oil holes “A” with the bushing oil hole countershaft, align the shaft oil hole “A” with the “B”.

  • Page 547: Gear Position (Gp) Switch Inspection

    Manual Transmission: 5B-11 Gearshift Fork Groove Width Gear Position (GP) Switch Inspection B815H25206007 Measure the gearshift fork groove width using the Refer to “Side-stand / Ignition Interlock System Parts vernier calipers. Inspection in Section 1I (Page 1I-8)”. Special tool (A): 09900–20102 (Vernier calipers (1/20 mm, Gear Position (GP) Switch Removal and 200 mm)) Installation...
  • Page 548 • Apply a bond lightly to the gear position switch bolt Install the gear position switch in the reverse order of lead wire grommet (1). removal. Pay attention to the following points: : Sealant 99000–31140 (SUZUKI BOND NOTE No.1207B or equivalent) Align the gear position switch pin “A” with NOTE the gearshift cam hole “B”.

  • Page 549: Gearshift Lever Construction

    Manual Transmission: 5B-13 Gearshift Lever Construction B815H25206009 “ a” “ b” I815H1520012-01 “a”: Approx. 14° : 10 N⋅m (1.0 kgf-m, 7.0 lb-ft) : Apply grease. “b”: 50 – 60 mm (2.0 – 2.4 in) : 40 N⋅m (4.0 kgf-m, 29.0 lb-ft)

  • Page 550: Gearshift Lever Removal And Installation

    5B-14 Manual Transmission: Gearshift Lever Removal and Installation 2) Loosen the lock-nuts (1). B815H25206010 3) Turn the gearshift link rod (2) until the gearshift lever Removal is 50 – 60 mm (2.0 – 2.4 in) below the top of the Remove the gearshift lever as shown in the gearshift footrest.

  • Page 551: Gearshift Shaft Construction

    Manual Transmission: 5B-15 Gearshift Shaft Construction B815H25206013 I815H1520013-02 1. Gearshift shaft 6. Gearshift cam drive plate : Apply thread lock to the thread part. 2. Washer : 10 N⋅m (1.0 kgf-m, 7.0 lb-ft) : Apply thread lock to the thread part. 3.

  • Page 552: Gearshift Shaft / Gearshift Cam Plate Removal And Installation

    5B-16 Manual Transmission: Gearshift Shaft / Gearshift Cam Plate Removal Installation Refer to “Engine Bottom Side Assembly in Section 1D and Installation B815H25206014 (Page 1D-71)”. Refer to “Engine Assembly Removal in Section 1D Install the gearshift shaft and gearshift cam plate in the (Page 1D-19)”.

  • Page 553: Gearshift Linkage Inspection

    Manual Transmission: 5B-17 Gearshift Linkage Inspection Gearshift Shaft Oil Seal / Bearing Removal and B815H25206015 Installation Refer to “Gearshift Shaft / Gearshift Cam Plate Removal B815H25206016 and Installation (Page 5B-16)”. Removal 1) Remove the gearshift shaft. Refer to “Gearshift Shaft Gearshift Shaft / Gearshift Cam Plate Removal and Installation Check the gearshift shaft for bend or wear.
  • Page 554 (A): 09913–70210 (Bearing installer set) CAUTION • Apply grease to the oil seal lip. The removed oil seal and bearings must be : Grease 99000–25010 (SUZUKI SUPER replaced with new ones. GREASE A or equivalent) • Install the bearings with the special tool.

  • Page 555: Specifications

    Manual Transmission: 5B-19 Specifications Service Data B815H25207001 Drive Train Unit: mm (in) Except ratio Item Standard Limit Primary reduction ratio 1.596 (83/52) — Final reduction ratio 2.388 (43/18) — 2.615 (34/13) — 1.937 (31/16) — 1.526 (29/19) — Gear ratios 1.285 (27/21) —...

  • Page 556: Special Tools And Equipment

    5B-20 Manual Transmission: Special Tools and Equipment Recommended Service Material B815H25208001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010 (Page 5B-9) / (Page 5B- equivalent Molybdenum oil MOLYBDENUM OIL SOLUTION — (Page 5B-9) Sealant SUZUKI BOND No.1207B or...

  • Page 557: Clutch

    Clutch: 5C-1 Clutch Transmission / Transaxle Precautions Precautions for Clutch System B815H25300001 Refer to “General Precautions in Section 00 (Page 00-1)”. Clutch Fluid (Brake Fluid) Information B815H25300002 WARNING • This clutch 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.

  • Page 558: Schematic And Routing Diagram

    5C-2 Clutch: Schematic and Routing Diagram Clutch Hose Routing Diagram B815H25302001 “ b” “ b” “ a ” I815H1530001-05 1. Stopper “a”: 28° : After the clutch hose union has contacted the stopper, tighten the union bolt. 2. Hose guide “b”: Clearance : Install the hose guide (2) to the grommet (4) on the clutch oil hose properly.

  • Page 559: Diagnostic Information And Procedures

    Clutch: 5C-3 Diagnostic Information and Procedures Clutch System Symptom Diagnosis B815H25304001 Condition Possible cause Correction / Reference Item Engine is noisy (Noise Worn countershaft spline. Replace countershaft. seems to come from the Worn clutch hub spline. Replace clutch hub. clutch) Worn clutch plate teeth.

  • Page 560: Air Bleeding From Clutch Fluid Circuit

    5C-4 Clutch: Air Bleeding from Clutch Fluid Circuit 9) Close the air bleeder valve and disconnect the hose. B815H25306004 Tightening torque CAUTION Air bleeder valve (Clutch): 6 N·m (0.6 kgf-m, 4.5 Handle brake fluid with care: the fluid reacts lb-ft) chemically with paint, plastics, rubber 10) Fill the reservoir with brake fluid to the upper mark materials, etc.

  • Page 561: Clutch Hose Removal And Installation

    Clutch: 5C-5 6) Connect a clear hose to the air bleeder valve and 9) Fill the reservoir with brake fluid to the upper mark insert the other end of hose into a receptacle. “A” of the reservoir. “A” I815H1530003-01 I815H1530008-01 7) Loosen the air bleeder valve and pump the clutch 10) Reinstall the removed parts.

  • Page 562: Clutch Control System Components

    5C-6 Clutch: Clutch Control System Components B815H25306007 I815H1530009-03 1. Push rod 7. Push rod : Apply brake fluid. 2. Piston/Cup set 8. Clutch release cylinder set : Apply grease. 3. Clutch hose 9. Air bleeder valve : Apply silicone grease. 4.

  • Page 563: Clutch Master Cylinder Assembly Removal And Installation

    Clutch: 5C-7 Clutch Master Cylinder Assembly Removal and Installation Install the clutch master cylinder in the reverse order of Installation B815H25306008 removal. Pay attention to the following points: • When installing the clutch master cylinder (1) onto the Removal left handlebar (2), align the master cylinder holder’s 1) Drain clutch fluid.

  • Page 564: Clutch Master Cylinder / Clutch Lever Disassembly And Assembly

    5C-8 Clutch: • After setting the clutch hose union to the stopper, 2) Remove the clutch lever (4). tighten the union bolt (3) to the specified torque. CAUTION The seal washers should be replaced with new ones to prevent fluid leakage. Tightening torque Clutch hose union bolt (b): 23 N·m (2.3 kgf-m, 16.5 lb-ft)
  • Page 565 5C-9 6) Remove the piston/cup set from the master cylinder. • Apply silicone grease to the push rod ends. • Secondary cup (9) : Grease 99000–25100 (SUZUKI Silicone • Piston (10) Grease or equivalent) • Primary cup (11) • Spring (12) I815H1530021-01 •...

  • Page 566: Clutch Master Cylinder Components Inspection

    5C-10 Clutch: Clutch Master Cylinder Components Inspection Clutch Release Cylinder / Push Rod Removal B815H25306010 and Installation Refer to “Clutch Master Cylinder / Clutch Lever B815H25306011 Disassembly and Assembly (Page 5C-8)”. Removal 1) Drain clutch fluid. Refer to “Clutch Fluid Master Cylinder Replacement (Page 5C-4)”.
  • Page 567 5C-11 9) Remove the clutch release cylinder (6) from the • Apply a small quantity of grease to the push rod. engine sprocket cover. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I815H1530029-01 10) Remove the push rod (7).

  • Page 568: Clutch Push Rod Inspection

    5C-12 Clutch: Clutch Push Rod Inspection Assembly B815H25306012 Assemble the clutch release cylinder in the reverse order Inspect the push rod in the following procedures: of disassembly. Pay attention to the following points: 1) Remove the clutch push rod. Refer to “Clutch •...

  • Page 569: Clutch Components

    Clutch: 5C-13 Clutch Components B815H25306015 “A” I823H1530059-06 1. Clutch pressure plate 7. No. 1 driven plate (8 – 5 pcs.) 13. Push rod 2. Clutch push piece 8. No. 2 driven plate (1 – 4 pcs.) “A”: The No. 1 and No. 2 driven plates are 9 in total. 3.

  • Page 570: Clutch Removal

    5C-14 Clutch: Clutch Removal 6) Remove the gasket (6) and dowel pins. B815H25306016 1) Drain engine oil. Refer to “Engine Oil and Filter Replacement in Section 0B (Page 0B-10)”. 2) Remove the right side cowling. Refer to “Exterior Parts Removal and Installation in Section 9D (Page 9D-14)”.
  • Page 571 Clutch: 5C-15 9) Remove the spring washer (10) and its seat (11). 12) Unlock the clutch sleeve hub nut. I815H1530043-01 I815H1530046-01 10) Remove the thrust washer (12), bearing (13) and 13) Hold the clutch sleeve hub with the special tool. clutch push piece (14).
  • Page 572 5C-16 Clutch: 16) Remove the clutch sleeve hub (17), clutch lifter drive 19) Remove the oil pump drive gear (24) from the cam (18) and its driven cam (19). primary driven gear assembly. I815H1530049-01 I815H1530062-01 17) Remove the thrust washer (20), spacer (21) and 20) Remove the thrust washer (25).

  • Page 573: Clutch Installation

    Clutch: 5C-17 Clutch Installation • Install the primary driven gear assembly. B815H25306017 Installation is in the reverse order of removal. Pay NOTE attention to the following points: • If it is difficult to install the primary driven • Install the thrust washer onto the countershaft. gear, rotate the crankshaft.
  • Page 574 5C-18 Clutch: • Install the clutch lifter drive cam (4), driven cam (5) to • Install the clutch sleeve hub along with the clutch lifter the clutch sleeve hub (6). drive and driven cams onto the countershaft. • Install the conical spring washer (8). NOTE NOTE •...
  • Page 575 Clutch: 5C-19 • Tighten the clutch sleeve hub nut to the specified torque. Tightening torque Clutch sleeve hub nut: 150 N·m (15.0 kgf-m, 108.5 lb-ft) “G” • Lock the clutch sleeve hub nut with a center punch. 14/15 I823H1530049-03 11. No. 3 drive plate 12.
  • Page 576 • Install the cushion (18) and clutch outer cover (19) to the clutch cover. I815H1530057-01 • Apply a bond lightly to the mating surfaces at the parting line between the upper and lower crankcase as shown in the figure. : Sealant 99000–31140 (SUZUKI BOND No.1207B or equivalent) I815H1530060-01 I815H1530058-01...

  • Page 577: Clutch Parts Inspection

    Clutch: 5C-21 • Tighten the clutch outer cover bolts (20) with the Clutch Parts Inspection B815H25306018 washers (21) securely. Refer to “Clutch Removal (Page 5C-14)” and “Clutch Installation (Page 5C-17)”. Clutch Drive and Driven Plate NOTE Wipe off the engine oil from the drive and driven plates with a clean rag.
  • Page 578 5C-22 Clutch: Clutch drive plate claw width Clutch Release Bearing Service limit (No. 1 drive plate): 13.05 mm (0.514 in) Inspect the clutch release bearing for any abnormality, Service limit (No. 2 and No. 3 drive plate): 13.10 mm especially cracks. When removing the bearing from the (0.516 in) clutch, decide whether it can be reused or if it should be replaced.

  • Page 579: Specifications

    Clutch: 5C-23 Specifications Service Data B815H25307001 Clutch Unit: mm (in) Item Standard Limit No. 1 2.92 – 3.08 (0.115 – 0.121) 2.62 (0.103) Clutch drive plate thickness No. 2 & 3 3.72 – 3.88 (0.146 – 0.153) 3.42 (0.135) No. 1 13.85 –...

  • Page 580: Special Tools And Equipment

    5C-24 Clutch: Special Tools and Equipment Recommended Service Material B815H25308001 Material SUZUKI recommended product or Specification Note Brake fluid DOT 4 — (Page 5C-4) / (Page 5C- 4) / (Page 5C-9) / (Page 5C-12) Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010...
  • Page 581 Table of Contents 6- i Section 6 Steering CONTENTS Precautions ..........6-1 Steering Components .........6B-5 Steering Damper Construction......6B-6 Precautions............. 6-1 Steering Removal and Installation ......6B-6 Precautions for Steering ........6-1 Steering Related Parts Inspection.....6B-10 Steering General Diagnosis....6A-1 Steering System Inspection ......6B-10 Steering Stem Bearing Removal and Diagnostic Information and Procedures....6A-1 Installation ............6B-11...

  • Page 582: Precautions

    6-1 Precautions: Precautions Steering Precautions Precautions for Steering B815H26000001 Refer to “General Precautions in Section 00 (Page 00-1)”.

  • Page 583: Steering General Diagnosis

    Steering General Diagnosis: 6A-1 Steering General Diagnosis Steering Diagnostic Information and Procedures Steering Symptom Diagnosis B815H26104001 Condition Possible cause Correction / Reference Item Heavy steering Over tightened steering stem nut. Adjust. Broken bearing in steering stem. Replace. Distorted steering stem. Replace.

  • Page 584: Steering / Handlebar

    6B-1 Steering / Handlebar: Steering / Handlebar Steering Repair Instructions Handlebar Components B815H26206001 “A” I815H1620001-02 I815H1620002-01 1. Throttle grip 6. Handlebar holder : 5.5 N⋅m (0.55 kgf-m, 4.0 lb-ft) 2. Grip rubber 7. Left handlebar : 35 N⋅m (3.5 kgf-m, 25.5 lb-ft) 3.

  • Page 585: Handlebar Construction

    Steering / Handlebar: 6B-2 Handlebar Construction B815H26206002 “A” “A” “ a ” “ a ” “B” “B” I815H1620038-02 1. Front brake master cylinder “B”: UP mark : 5.5 N⋅m (0.55 kgf-m, 4.0 lb-ft) 2. Clutch master cylinder “a”: Clearance : Apply thread lock to the thread part. 3.

  • Page 586: Handlebar Removal And Installation

    6B-3 Steering / Handlebar: Handlebar Removal and Installation 3) Remove the handlebar clamp bolts (9). B815H26206003 4) Detach the right and left handlebars (10). Removal 1) Remove the following parts from the left handlebar. a) Clutch master cylinder/clutch lever (1) CAUTION Do not turn the clutch master cylinder upside down.

  • Page 587: Handlebars Inspection

    • Insert the projection “D” of the left handlebar switch cable pulley. box into the hole of the handlebars. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) • Insert the projection “B” of the right handlebar switch box into the hole of the handlebars.

  • Page 588: Steering Components

    6B-5 Steering / Handlebar: Steering Components B815H26206005 I815H1620011-02 1. Handlebar holder 9. Washer : 10 N⋅m (1.0 kgf-m, 7.0 lb-ft) 2. Handlebars 10. Steering stem nut : 35 N⋅m (3.5 kgf-m, 25.5 lb-ft) 3. Handlebar damper 11. Dust seal cover : 90 N⋅m (9.0 kgf-m, 65.0 lb-ft) 4.

  • Page 589: Steering Damper Construction

    Steering / Handlebar: 6B-6 Steering Damper Construction B815H26206006 I815H1620012-02 1. Steering damper 2. Dust seal 3. Bearing : 23 N⋅m (2.3 kgf-m, 16.5 lb-ft) : Apply grease. Steering Removal and Installation 5) Disconnect the ignition switch lead wire coupler (2), B815H26206007 left handle switch lead wire coupler (3), right handle switch lead wire coupler (4), drive mode selector...
  • Page 590 6B-7 Steering / Handlebar: 7) Remove the handlebars and handlebar holder. Refer 13) Remove the steering stem lock-nut, washer and to “Handlebar Removal and Installation (Page 6B-3)” steering stem nut with the special tools. and “Front Fork Removal and Installation in Section NOTE 2B (Page 2B-2)”.
  • Page 591 • Apply grease to the bearings, bearing races and dust (B): 09940–14960 (Steering nut wrench seals before remounting the steering stem. socket) : Grease 99000–25010 (SUZUKI SUPER Tightening torque GREASE A or equivalent) Steering stem nut (a): 45 N⋅m (4.5 kgf-m, 32.5 lb- ft) then turn back 1/2 –...
  • Page 592 1) Temporarily install the upper bracket, washer (1) and • Install the handlebars. Refer to “Handlebar Removal steering stem head nut (2). and Installation (Page 6B-3)”. Steering damper • Apply grease to the bearings and dust seals. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I815H1620025-01 I823H1620019-02...

  • Page 593: Steering Related Parts Inspection

    Steering / Handlebar: 6B-10 • Install the steering damper and tighten the bolt (1) and If any abnormal points are found, replace defective parts nut (2). with new ones. Tightening torque Steering damper bolt (a): 23 N·m (2.3 kgf-m, 16.5 lb-ft) Steering damper nut (b): 23 N·m (2.3 kgf-m, 16.5 lb-ft)

  • Page 594: Steering Stem Bearing Removal And Installation

    6B-11 Steering / Handlebar: Steering Stem Bearing Removal and Installation Installation B815H26206010 Install the steering stem bearings in the reverse order of removal. Pay attention to the following points: Removal CAUTION 1) Remove the steering stem lower bracket. Refer to “Steering Removal and Installation (Page 6B-6)”.

  • Page 595: Steering Tension Adjustment

    Steering / Handlebar: 6B-12 Steering Tension Adjustment 6) If the initial force read on the scale when the B815H26206011 handlebar starts turning is either too heavy or too Check the steering movement in the following light, adjust it till it satisfies the specification. procedures: a) First, loosen the front fork upper and lower clamp 1) By supporting the motorcycle with a jack, lift the front...

  • Page 596: Specifications

    For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List in Section 0C (Page 0C-9)”. Special Tools and Equipment Recommended Service Material B815H26208001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010 (Page 6B-4) /...

  • Page 597: Special Tool

    Steering / Handlebar: 6B-14 Special Tool B815H26208002 09910–60611 09925–18011 Universal clamp wrench Steering bearing installer (Page 6B-12) (Page 6B-11) 09940–14911 09940–14960 Steering stem nut wrench Steering nut wrench socket (Page 6B-7) / (Page 6B- (Page 6B-7) / (Page 6B- 8) / (Page 6B-9) 8) / (Page 6B-9)
  • Page 598 6B-15 Steering / Handlebar:...
  • Page 599 Table of Contents 9- i Section 9 Body and Accessories CONTENTS Precautions ..........9-1 Dimmer Switch Inspection.........9B-11 Specifications .............9B-12 Precautions............. 9-1 Service Data............9B-12 Precautions for Electrical System ......9-1 Tightening Torque Specifications......9B-12 Component Location ..........9-1 Special Tools and Equipment ......9B-12 Electrical Components Location ......
  • Page 600 9-ii Table of Contents Intake Cover Protection Tape Attachment ..9D-3 Special Tools and Equipment ......9D-22 Inner Under Cowling Cushion Attachment ..9D-4 Recommended Service Material .......9D-22 Under Cowling Heat Shield Attachment....9D-4 Special Tool ............9D-22 Pillion Rider Handlebar Construction ....9D-5 Body Structure......... 9E-1 Panel Cushion Attachment........9D-6 Rear Fender Construction........9D-7 Repair Instructions ..........9E-1...

  • Page 601: Precautions

    Precautions: Precautions Body and Accessories Precautions Precautions for Electrical System B815H29000001 Refer to “General Precautions in Section 00 (Page 00-1)” and “Precautions for Electrical Circuit Service in Section 00 (Page 00-2)”. Component Location Electrical Components Location B815H29003001 Refer to “Electrical Components Location in Section 0A (Page 0A-8)”.

  • Page 602: Wiring Systems

    9A-1 Wiring Systems: Wiring Systems Body and Accessories Schematic and Routing Diagram Wiring Diagram B815H29102001 Refer to “Wire Color Symbols in Section 0A (Page 0A-6)”.
  • Page 603 Wiring Systems: 9A-2 For E-02, 19, 24 I815H1910901-04...
  • Page 604 9A-3 Wiring Systems: For E-03, 28 I815H1910902-04...
  • Page 605 Wiring Systems: 9A-4 For E-33 I815H1910903-04...

  • Page 606: Wiring Harness Routing Diagram

    9A-5 Wiring Systems: Wiring Harness Routing Diagram B815H29102002 “B” “A” I815H1910904-06 1. Clamp 15. Clutch pipe : Bind the wiring harness, starter motor lead wire, generator lead wire, gear position switch lead wire and HO2 sensor lead wire with the clamp. 2.
  • Page 607 Wiring Systems: 9A-6 8. Clamp 22. IAP sensor : Bind the handlebar switch lead wires (LH/RH), ignition switch lead wire and immobilizer antenna lead wire (E-02, 19, 24) with the clamp. 9. Guide 23. Combination meter coupler : Pass the handlebar switch lead wires (LH/RH) and immobilizer antenna lead wire (E-02, 19, 24) into the guide.
  • Page 608 9A-7 Wiring Systems: “ a ” “A” “ b ” “c ” “c ” I815H1910908-01 1. Clamp 13. Seat rail : Bind the wiring harness, starter motor lead wire, generator lead wire, gear position switch lead wire and HO2 sensor lead wire with the clamp. 2.
  • Page 609 Wiring Systems: 9A-8 “ a ” “ a ” “ a ” “ b ” “A” I815H1910905-01...

  • Page 610: Specifications

    9A-9 Wiring Systems: 1. Gear position switch 8. Battery (–) lead wire : 120 N⋅m (12.0 kgf-m, 87 lb-ft) 2. Oil pressure switch “A”: When tightening the starter motor mounting bolts, tighten rear one first. : 10 N⋅m (1.0 kgf-m, 7.0 lb-ft) 3.

  • Page 611: Lighting Systems

    Lighting Systems: 9B-1 Lighting Systems Body and Accessories Repair Instructions Headlight Components B815H29206001 I815H1920001-03 1. Headlight Low beam bulb (12 V 55 W, H7) 3. Position light bulb (12 V 5 W x 2) 2. Socket 4. Headlight High beam bulb (12 V 65 W, H9)

  • Page 612: Headlight Removal And Installation

    9B-2 Lighting Systems: Headlight Removal and Installation 3) Unhook the bulb holder spring (3) and remove the B815H29206002 headlight bulb/socket (Low beam) (4). Removal 1) Remove the body cowlings. Refer to “Exterior Parts Removal and Installation in Section 9D (Page 9D- 14)”.

  • Page 613: Headlight Beam Adjustment

    Lighting Systems: 9B-3 9) Remove the position light socket (9). Headlight Beam Adjustment B815H29206004 Insert a (+) screwdriver as shown in the figure and adjust the headlight beam horizontally and vertically. “A” I815H1920009-01 10) Replace the position light bulb (10) with a new one. I815H1920011-01 “A”: Vertical adjuster “B”...

  • Page 614: Front Turn Signal Light Removal And Installation

    9B-4 Lighting Systems: Front Turn Signal Light Removal and Front Turn Signal Light Bulb Replacement B815H29206007 Installation B815H29206006 CAUTION Removal When you touch the bulb with your bare 1) Remove the body cowlings. Refer to “Exterior Parts hands, clean the bulb with a cloth moistened Removal and Installation in Section 9D (Page 9D- with alcohol or soap water to prevent 14)”.

  • Page 615: Rear Lighting System Construction

    Lighting Systems: 9B-5 Rear Lighting System Construction B815H29206008 I815H1920017-02 1. Spacer x 2 pcs. 5. License plate light 9. Combination light 2. Washer x 2 pcs. 6. Turn signal light x 2 pcs. : 5 N⋅m (0.5 kgf-m, 3.5 lb-ft) 3.

  • Page 616: Rear Combination Light Replacement

    9B-6 Lighting Systems: 5) Remove the combination light brackets (upper and NOTE lower) (4). When reusing the removed bolts (1), apply a small quantity of the thread lock to them. Tightening torque Combination light mounting bolt (a): 2.8 N·m ( 0.28 kgf-m, 2.0 lb-ft) : Thread lock cement 99000–32110 (THREAD LOCK CEMENT SUPER 1322 or...

  • Page 617: License Plate Light Removal And Installation

    Lighting Systems: 9B-7 License Plate Light Removal and Installation License Plate Light Bulb Replacement B815H29206012 B815H29206013 Removal 1) Remove the license plate light mounting nuts (1). 1) Remove the frame cover. Refer to “Exterior Parts Removal and Installation in Section 9D (Page 9D- 14)”.

  • Page 618: Rear Turn Signal Light Components

    9B-8 Lighting Systems: Rear Turn Signal Light Components B815H29206014 I815H1920029-01 1. Rear turn signal light 2. Rear turn signal light bulb (12 V 21 W x 2) 3. Socket Rear Turn Signal Light Removal and Installation Installation B815H29206015 Install the rear turn signal light in the reverse order of Removal removal.

  • Page 619: Reflex Reflector Construction

    Lighting Systems: 9B-9 2) Remove the socket (2) by turning it 3) Replace the bulb (3). counterclockwise. I815H1920034-01 4) Reinstall the removed parts. I815H1920033-01 Reflex Reflector Construction B815H29206017 I815H1920035-07 1. Front reflex reflector x 2 pcs. (For E-03, 24, 28, 33) 3.

  • Page 620: Hazard Switch Inspection

    9B-10 Lighting Systems: 2) Remove the turn signal/side-stand relay (1). Turn Signal Switch Inspection B815H29206021 Inspect the turn signal switch in the following procedures: 1) Remove the left upper panel. Refer to “Exterior Parts Removal and Installation in Section 9D (Page 9D- 14)”.

  • Page 621: Passing Light Switch Inspection

    Lighting Systems: 9B-11 Passing Light Switch Inspection Dimmer Switch Inspection B815H29206022 B815H29206023 Inspect the passing light switch in the following Inspect the dimmer switch in the following procedures: procedures: 1) Remove the left upper panel. Refer to “Exterior Parts 1) Remove the left upper panel. Refer to “Exterior Parts Removal and Installation in Section 9D (Page 9D- Removal and Installation in Section 9D (Page 9D- 14)”.

  • Page 622: Specifications

    For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List in Section 0C (Page 0C-9)”. Special Tools and Equipment Recommended Service Material B815H29208001 Material SUZUKI recommended product or Specification Note Thread lock cement THREAD LOCK CEMENT SUPER P/No.: 99000–32110 (Page 9B-6)

  • Page 623: Combination Meter / Fuel Meter / Horn

    Combination Meter / Fuel Meter / Horn: 9C-1 Combination Meter / Fuel Meter / Horn Body and Accessories General Description Combination Meter System Description B815H29301001 This combination meter mainly consists of the stepping motor, LCD (Liquid Crystal Display) and LED (Light Emitting Diode).

  • Page 624: Repair Instructions

    9C-2 Combination Meter / Fuel Meter / Horn: Repair Instructions Combination Meter Components B815H29306001 I815H1930002-02 1. Combination meter unit 2. Combination meter case 3. Combination meter cover Combination Meter Removal and Installation 3) Disconnect the coupler (1) and remove the B815H29306002 combination meter assembly.

  • Page 625: Combination Meter Disassembly And Assembly

    Combination Meter / Fuel Meter / Horn: 9C-3 Combination Meter Disassembly and Assembly NOTE B815H29306003 Refer to “Combination Meter Removal and Installation • The pointers may not return to the proper (Page 9C-2)”. position even turning the ignition switch on under low temperature condition. In Disassembly that case, you can reset the pointers to the Disassemble the combination meter as shown in the...

  • Page 626: Engine Coolant Temperature Meter And Indicator Light Inspection

    9C-4 Combination Meter / Fuel Meter / Horn: Engine Coolant Temperature Meter and 4) Turn the ignition switch ON. Indicator Light Inspection 5) Check the engine coolant temperature meter (3) and B815H29306005 indicator light (LED) (4) operations when the Inspect the engine coolant temperature meter and resistance is adjusted to the specified values.

  • Page 627: Ect Sensor Removal And Installation

    Combination Meter / Fuel Meter / Horn: 9C-5 ECT Sensor Removal and Installation 4) Turn the ignition switch ON. B815H29306006 5) Check the fuel meter (3) and indicator light (LED) (4) Refer to “ECT Sensor Removal and Installation in operations when the resistance is adjusted to the Section 1C (Page 1C-5)”.

  • Page 628: Fuel Level Gauge Inspection

    9C-6 Combination Meter / Fuel Meter / Horn: Fuel Level Gauge Inspection Speed Sensor Removal and Installation B815H29306008 B815H29306010 Inspect the fuel level gauge in the following procedures: Removal 1) Remove the fuel pump. Refer to “Fuel Pump 1) Remove the left side cowling. Refer to “Exterior Disassembly and Assembly in Section 1G (Page 1G- Parts Removal and Installation in Section 9D 12)”.

  • Page 629: Speed Sensor Inspection

    Combination Meter / Fuel Meter / Horn: 9C-7 Speed Sensor Inspection Oil Pressure Indicator Inspection B815H29306011 B815H29306012 Inspect the speed sensor in the following procedures: Inspect the oil pressure indicator in the following procedures: 1) Remove the speed sensor. Refer to “Speed Sensor Removal and Installation (Page 9C-6)”.

  • Page 630: Oil Pressure Switch Inspection

    9C-8 Combination Meter / Fuel Meter / Horn: Oil Pressure Switch Inspection 3) Inspect the ignition switch for continuity with a tester. B815H29306014 If any abnormality is found, replace the ignition Inspect the oil pressure switch in the following switch with a new one. procedures: Special tool NOTE...

  • Page 631: Horn Inspection

    Combination Meter / Fuel Meter / Horn: 9C-9 Horn Inspection Horn Inspection B815H29306017 1) Disconnect the horn coupler (1). NOTE If the horn sound condition is normal, it is not necessary to inspect the horn button continuity. Horn Button Inspection 1) Remove the left fuel tank cover.

  • Page 632: Specifications

    9C-10 Combination Meter / Fuel Meter / Horn: Specifications Service Data B815H29307001 Wattage Unit: W Item Specification Tachometer light Speedometer light Turn signal indicator light High beam indicator light Neutral position indicator light Oil pressure indicator light FI indicator light Engine coolant temp.

  • Page 633: Exterior Parts

    Exterior Parts: 9D-1 Exterior Parts Body and Accessories Schematic and Routing Diagram Seat Lock Cable Routing Diagram B815H29402001 I815H1940012-03 1. Frame cover 3. Seat lock cable guide 2. Seat lock cable 4. Plate : Set the plate in the reverse side of the guide.

  • Page 634: Repair Instructions

    9D-2 Exterior Parts: Repair Instructions Exterior Parts Construction B815H29406001 “B” “A” I815H1940005-02 “A”: To the steering under bracket “B”: To the frame...

  • Page 635: Rear Under Cowling Head Shield Attachment

    Exterior Parts: 9D-3 Rear Under Cowling Head Shield Attachment B815H29406002 “a ” “ a ” I815H1940013-01 1. Head shield, rear under cowling “a”: 3 mm (0.12 in) Intake Cover Protection Tape Attachment B815H29406003 “ a ” “ b” “e ” “...

  • Page 636: Inner Under Cowling Cushion Attachment

    9D-4 Exterior Parts: Inner Under Cowling Cushion Attachment B815H29406004 “ a ” “b ” I815H1940015-01 1. Cushion 2. Under cowling, inner (LH) “a”: 3 mm (0.12 in) “b”: 5 mm (0.20 in) Under Cowling Heat Shield Attachment B815H29406005 “A” “A” I815H1940016-03 1.

  • Page 637: Pillion Rider Handlebar Construction

    Exterior Parts: 9D-5 Pillion Rider Handlebar Construction B815H29406006 “ a ” “b ” I815H1940017-04 1. Pillion rider handle 3. Cushion, frame cover 5. Frame, seat rail “b”: 2.5 mm (0.10 in) 2. Cushion, pillion rider handle 4. Frame cover “a”: 1.5 mm (0.06 in) : 33 N⋅m (3.3 kgf-m, 24.0 lb-ft)

  • Page 638: Panel Cushion Attachment

    9D-6 Exterior Parts: Panel Cushion Attachment B815H29406007 “ a” “ a ” “ c” “ b ” “ b ” “ d ” I815H1940001-04 “a”: 20 mm (0.79 in) “b”: 30 mm (1.18 in) “c”: 5 mm (0.20 in) “d”: 3 mm (0.12 in)

  • Page 639: Rear Fender Construction

    Exterior Parts: 9D-7 Rear Fender Construction B815H29406008 I815H1940002-03...

  • Page 640: Frame Cover Construction

    9D-8 Exterior Parts: Frame Cover Construction B815H29406009 I815H1940004-04 : 33 N⋅m (3.3 kgf-m, 24.0 lb-ft)

  • Page 641: Cowling Cushion Attachment

    Exterior Parts: 9D-9 Cowling Cushion Attachment B815H29406010 “ a ” “ a ” “ a ” “ a ” “ a ” “ a ” I815H1940006-03 “a”: 5 mm (0.2 in)

  • Page 642: Flame Cover Cushion Attachment

    9D-10 Exterior Parts: Flame Cover Cushion Attachment B815H29406011 “A” “ a ” “B” I815H1940007-02 1. Cushion rubber : Clean the adhesive surface before adhering the cusion rubber. 2. Protection tape : Clean the adhesive surface before adhering the protection tape. “A”: Align the corner of the cushion rubber to the end of the rib.

  • Page 643: Mudguard Construction

    Exterior Parts: 9D-11 “ b ” “ a ” I815H1940008-02 1. Cushion rubber “a”: 30 mm (1.2 in) “b”: 6.5 mm (0.26 in) : Align the cushion rubber with the edge. Mudguard Construction B815H29406012 “A” I815H1940009-03 1. Mudguard “A”: Clean the adhesive surface before adhering the cushion rubber. 2.

  • Page 644: Rear Fender Cushion Attachment

    9D-12 Exterior Parts: Rear Fender Cushion Attachment B815H29406013 “ a ” I815H1940010-02 1. Rear fender 3. Cushion rubber No. 2 : Clean the adhesive surface before adhering the cushion rubber. 2. Cushion rubber No. 1 “a”: 5 mm (0.2 in) : Clean the adhesive surface before adhering the cushion rubber.

  • Page 645: Fastener Removal And Installation

    Exterior Parts: 9D-13 Fastener Removal and Installation Type B B815H29406015 Removal Type A 1) Pry up the head of fastener center piece (1) with a Removal screw driver. 1) Depress the head of fastener center piece (1). 2) Pull out the fastener “A”. 2) Pull out the fastener (2).

  • Page 646: Exterior Parts Removal And Installation

    9D-14 Exterior Parts: Exterior Parts Removal and Installation Installation B815H29406016 Slide the seat hooks into the seat hook retainers and Front Seat push down firmly until the seat snaps into the locked Removal position. Remove the front seat by removing the bolts. I823H1940008-02 Seat Tail Cover I823H1940004-02...
  • Page 647 Exterior Parts: 9D-15 Removal Upper Meter Panel Remove the seat tail cover in the reverse order of Removal installation. 1) Remove the lower meter panel. 2) Remove the fasteners. Windscreen 3) Remove the upper meter panel (1). Removal 1) Remove the bolts and nuts (1). 2) Remove the windscreen (2) upward.
  • Page 648 9D-16 Exterior Parts: Body Cowling Cover Center Under Cowling Removal Removal 1) Remove the fasteners (6 pcs.). 1) Remove the body cowling cover and inner under cowlings. 2) Remove the body cowling cover (1). 2) Remove the center under cowling (1). I823H1940016-02 I823H1940019-01 Installation...
  • Page 649 Exterior Parts: 9D-17 Rear Under Cowling 4) Remove the following bolts and fasteners. Removal 1) Remove the fasteners. I823H1940023-01 I823H1940021-01 2) Remove the rear under cowling (1) backward. I823H1940024-01 I815H1940020-01 Installation Install the rear under cowling in the reverse order of removal.
  • Page 650 9D-18 Exterior Parts: Body Cowling Installation Install the body cowling in the reverse order of removal. Removal Pay attention to the following points: 1) Remove the side cowlings. (LH & RH) • Push in the hooked points on the body cowling to the 2) Remove the upper panels.
  • Page 651 4) Remove the wire clamps (2). I823H1940037-01 • Before installing the steering damper mounting bolt, apply grease to the steering damper bearing and dust seals. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I823H1940034-01 5) Remove the steering damper mounting bolt (3). I823H1940038-01...
  • Page 652 9D-20 Exterior Parts: • Tighten the steering damper mounting bolt to the Frame Cover specified torque. Removal 1) Remove the front and rear seats. Tightening torque Steering damper mounting bolt (b): 23 N·m (2.3 2) Remove the pillion rider handle. kgf-m, 16.5 lb-ft) 3) Disconnect the rear combination light coupler (1) and seat lock cable (2).
  • Page 653 Exterior Parts: 9D-21 6) Remove the seat rail hooks (4) using the special tools. Front Fender Removal Special tool Refer to “Front Fork Removal and Installation in Section : 09930–11930 (Torx bit (JT30H)) 2B (Page 2B-2)”. : 09930–11940 (Bit holder) Installation Refer to “Front Fork Removal and Installation in Section 2B (Page 2B-2)”.

  • Page 654: Specifications

    For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List in Section 0C (Page 0C-9)”. Special Tools and Equipment Recommended Service Material B815H29408001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010 (Page 9D-19)

  • Page 655: Body Structure

    Body Structure: 9E-1 Body Structure Body and Accessories Repair Instructions Body Frame Construction B815H29506001 I815H1950001-03 1. Frame 5. Adjuster : 10 N⋅m (1.0 kgf-m, 7.0 lb-ft) 2. Seat rail 6. Adjuster lock-nut : 45 N⋅m (4.5 kgf-m, 32.5 lb-ft) 3. Seat rail bolt 7.

  • Page 656: Front Footrest Bracket Construction

    9E-2 Body Structure: Front Footrest Bracket Construction B815H29506002 “ a ” I815H1950002-03 1. Washer 2. Washer 2. Bushing “a”: 2.0 mm (0.08 in) : 23 N⋅m (2.3 kgf-m, 16.5 lb-ft)

  • Page 657: Side-Stand Construction

    Body Structure: 9E-3 Side-stand Construction B815H29506003 I815H1950003-02 : 50 N⋅m (5.0 kgf-m, 36.0 lb-ft) : 95 N⋅m (9.5 kgf-m, 68.5 lb-ft) : 60 N⋅m (6.0 kgf-m, 43.5 lb-ft) : Apply grease to sliding surface. Pillion Footrest Bracket Construction B815H29506004 I815H1950004-01 : 35 N⋅m (3.5 kgf-m, 25.5 lb-ft)

  • Page 658: Footrest Construction

    9E-4 Body Structure: Footrest Construction B815H29506005 I815H1950005-02 1. Front footrest 2. Pillion footrest : Apply grease to sliding surface.

  • Page 659: Side-Stand Removal And Installation

    Body Structure: 9E-5 Side-stand Removal and Installation B815H29506006 Removal 1) Support the motorcycle with a jack or wooden block. CAUTION • Do not support the motorcycle with the exhaust pipes. • Make sure that the motorcycle is supported securely. 2) Remove the side-stand as shown in the side-stand construction. Refer to “Side-stand Construction (Page 9E-3)”. Installation Install the side-stand as shown in the side-stand construction.
  • Page 660  ...
  • Page 661 GSX1300RK9 (’09 MODEL) 10-1 GSX1300RK9 (2009 MODEL) NOTE: * Difference between K9-MODEL and K8-MODEL specification is indicated as an asterisk mark (*). * The service data is the same as the K8-MODEL.
  • Page 662 10-2 GSX1300RK9...
  • Page 663 GSX1300RK9 10-3 “A” “ b ” “B” “D” “ c ” “ c ” “C” “D”...

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