Suzuki SFV650 Service Manual
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Suzuki SFV650 Service Manual

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Table of Contents

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SFV650
SERVICE MANUAL
9 9 5 0 0 - 3 6 1 9 0 - 0 1 E

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Summary of Contents for Suzuki SFV650

  • Page 1 SFV650 SERVICE MANUAL 9 9 5 0 0 - 3 6 1 9 0 - 0 1 E...
  • Page 2 FOREWORD This manual contains an introductory description on the SUZUKI SFV650 and procedures for its inspection/ser- vice 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 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 6 CAUTION special meanings. Pay special attention to the messages highlighted by these signal words. • If parts replacement is necessary, replace the parts with Suzuki Genuine Parts or WARNING their equivalent. Indicates a potential hazard that could result • When removing parts that are to be reused, in death or injury.
  • Page 7 Precautions: 00-2 • Use a torque wrench to tighten fasteners • Before refitting the sealed coupler, make sure its seal to the specified torque. Wipe off grease rubber is positioned properly. The seal rubber may and oil if a thread is smeared with them. possibly come off the position during disconnecting work and if the coupler is refitted with the seal rubber •...
  • Page 8 00-3 Precautions: • Check the male connector for bend and female Fuse connector for excessive opening. Also check the • When a fuse blows, always investigate the cause to coupler for locking (looseness), corrosion, dust, etc. correct it and then replace the fuse. •...
  • Page 9 Precautions: 00-4 • When disconnecting and connecting the coupler, • Before measuring voltage at each terminal, check to make sure to turn OFF the ignition switch, or make sure that battery voltage is 11 V or higher. electronic parts may get damaged. Terminal voltage check with a low battery voltage will lead to erroneous diagnosis.
  • Page 10 00-5 Precautions: 1) Disconnect the negative (–) cable from the battery. Continuity check 2) Check each connector/coupler at both ends of the 1) Measure resistance across coupler “B” (between “A” circuit being checked for loose connection. Also and “C” in figure). check for condition of the coupler lock if equipped.
  • Page 11 Precautions: 00-6 3) Also, if measured values are as listed following, a 3) Measure resistance between terminal at one end of resistance (abnormality) exists which causes the circuit (“A” terminal in figure) and body ground. If voltage drop in the circuit between terminals “A” and continuity is indicated, there is a short circuit to “B”.
  • Page 12 00-7 Precautions: Using The Multi-Circuit Testers NOTE • Use the Suzuki multi-circuit tester set. • When connecting the multi-circuit tester, • Use well-charged batteries in the tester. use the needle pointed probe to the back side of the lead wire coupler and connect •...

  • Page 13: General Information

    Table of Contents 0- i Section 0 General Information CONTENTS General Information ........ 0A-1 Exhaust Pipe Bolts and Muffler Bolts Inspection............0B-4 General Description ..........0A-1 Valve Clearance Inspection and Adjustment ..0B-4 Symbols .............. 0A-1 Spark Plug Replacement ........0B-9 Abbreviations ............0A-2 Spark Plug Inspection and Cleaning ....0B-9 Vehicle Side View ..........
  • Page 14 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 15 BBDC: Before Bottom Dead Center ROM: Read Only Memory BTDC: Before Top Dead Center B+: Battery Positive Voltage SAE: Society of Automotive Engineers SDS: Suzuki Diagnosis System CKP Sensor: Crankshaft Position Sensor (CKPS) STC System: Secondary Throttle Control System CKT: Circuit (STCS)

  • Page 16: Vehicle Side View

    PERFORMANCE 4 MOTOR OIL or an equivalent engine oil. Use of SF/SG or SH/SJ in API with MA in JASO. Suzuki recommends the use of SAE 10W-40 engine oil. If SAE 10W-40 engine oil is not available, select and alternative according to the chart.

  • Page 17: Cylinder Identification

    1 850 ml (2.0/1.6 US/Imp qt) oil. Use of SF/SG or SH/SJ in API with MA in JASO. Suzuki recommends the use of SAE 10W-40 engine oil. For engine coolant mixture information, refer to “Engine If SAE 10W-40 engine oil is not available, select an Coolant Description in Section 1F (Page 1F-1)”.
  • Page 18 Country and Area Codes B944H10101009 The following codes stand for the applicable country(-ies) and area(-s). Code Country or Area Effective Frame No. SFV650 K9 (E-02) U.K. JS1CX111100100001 – SFV650 K9 (E-03) U.S.A (Except for California) JS1VP55A 92100001 – SFV650 K9 (E-19) E.U.
  • Page 19 Warning, Caution and Information Labels Location B944H10101011 7, 8, 9 2, 3 1, 10 11, 12 5, 6 I944H1010008-02 SFV650 SFV650U 1. Noise label For E-03, 24, 33 For E-24 2. Information label For E-03, 28, 33 — 3. Vacuum hose routing label For E-33 —...
  • Page 20 0A-7 General Information: Component Location Electrical Components Location B944H10103001 I944H1010006-04 1. IAP sensor (#1) 7. ECT sensor 13. Starter motor 2. IAP sensor (#2) 8. Ignition coil (#2) 14. Oil pressure switch 3. IAT sensor 9. Ignition coil (#1) 15. Cooling fan 4.
  • Page 21 General Information: 0A-8 I944H1010007-04 17. Fuel injector (#1) 23. TO sensor 29. CKP sensor 18. Fuel injector (#2) 24. Turn signal/Side-stand relay 30. Speed sensor 19. Fuel pump/Fuel level gauge 25. Fuse box 31. GP switch 20. Starter relay/main fuse 26.
  • Page 22 0A-9 General Information: Specifications Specifications B944H10107001 NOTE These specifications are subject to change without notice. Dimensions and curb mass Item Specification Remark Overall length 2 130 mm (83.9 in) Overall width 760 mm (29.9 in) Overall height 1 090 mm (42.9 in) Wheelbase 1 445 mm (56.9 in) Ground clearance...
  • Page 23 General Information: 0A-10 Chassis Item Specification Remark Front suspension Telescopic, coil spring, oil damped Rear suspension Link type, coil spring, oil damped Front suspension stroke 125 mm (4.9 in) Rear wheel travel 130 mm (5.1 in) Caster 25° Trail 106 mm (4.17 in) Steering angle 33°...
  • Page 24 Plastigauge Plastigauge Small bore gauge (18 Multi circuit tester set Needle pointed probe – 35 mm) 09900–28630 09904–41010 09910–60611 09913–50121 09913–60221 TP Sensor test lead SUZUKI Diagnostic Universal clamp Oil seal remover Journal bearing system set wrench installer & holder...
  • Page 25 General Information: 0A-12 09913–70210 09915–40620 09915–63311 09915–64512 09915–70610 Bearing installer set Oil filter wrench Compression gauge Compression gauge Oil pressure gauge (10 – 75) attachment attachment 09915–74521 09915–77331 09916–10911 09916–14510 09916–14522 Adapter hose Oil pressure gauge Valve lapper set Valve lifter Valve lifter attachment (1000 kPa) 09916–33210...
  • Page 26 0A-13 General Information: 09930–11940 09930–11950 09930–30450 09930–40113 09930–44530 Torx bit holder Torx wrench (5 mm) Rotor remover bolt Flywheel rotor holder Rotor holder 09930–82720 09940–14911 09940–34520 09940–34531 09940–40211 Mode selection switch Steering stem nut T type handle Front fork assembling Fuel pressure gauge socket wrench attachment (A)

  • Page 27: Maintenance And Lubrication

    Maintenance and Lubrication: 0B-1 Maintenance and Lubrication General Information Precautions Precautions for Maintenance B944H10200001 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 28: Lubrication Points

    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 Rear suspension — — — Chassis bolts and nuts Lubrication Points B944H10205002 Proper lubrication is important for smooth operation and long life of each working part of the motorcycle. Major lubrication points are indicated as follows.
  • Page 29 Maintenance and Lubrication: 0B-3 Repair Instructions Air Cleaner Element Replacement CAUTION B944H10206001 Always apply compressed air to the inside of Replace air cleaner element the air cleaner element. If compressed air is Every 18 000 km (11 000 miles, 36 months) applied to the outside, dirt will be forced into Refer to “Air Cleaner Element Removal and Installation the pores of the air cleaner element,...
  • Page 30 0B-4 Maintenance and Lubrication: Exhaust Pipe Bolts and Muffler Bolts Inspection Valve Clearance Inspection and Adjustment B944H10206003 B944H10206006 Tighten exhaust pipe bolts, muffler bolts and nut Inspect valve clearance Initially at 1 000 km (600 miles, 2 months) and every Every 24 000 km (14 500 miles, 48 months) thereafter 12 000 km (7 500 miles, 24 months) thereafter Inspection...
  • Page 31 Maintenance and Lubrication: 0B-5 NOTE • The tappet clearance should be taken when each cylinder is at Top Dead Center (TDC) of compression stroke. • The cams (IN. & EX.) on the front cylinder at position “A” show the front cylinder at TDC of compression stroke.
  • Page 32 0B-6 Maintenance and Lubrication: 7) Turn the crankshaft 270 degrees (3/4 turns) to set 2) Remove the tappet (1) and shim (2) by fingers or the #2 (Rear) cylinder at TDC of compression stroke. magnetic hand. (Align the “| R” line on the generator rotor to the center of timing inspection hole and also bring the camshafts to the position “B”...
  • Page 33 Maintenance and Lubrication: 0B-7 (INTAKE SIDE) I944H1020019-01...
  • Page 34 0B-8 Maintenance and Lubrication: (EXHAUST SIDE) I944H1020020-01...
  • Page 35 Maintenance and Lubrication: 0B-9 6) Install the intake or exhaust cam chain tension Spark Plug Gap adjuster. Refer to “Engine Top Side Assembly in 1) Remove the spark plugs. Refer to “Spark Plug Cap Section 1D (Page 1D-31)”. and Spark Plug Removal and Installation in Section 7) Rotate the engine so that the tappet is depressed 1H (Page 1H-5)”.
  • Page 36 0B-10 Maintenance and Lubrication: Fuel Line Inspection Engine Oil Replacement B944H10206007 1) Keep the motorcycle upright. Inspect fuel line 2) Place an oil pan below the engine, and drain engine Every 6 000 km (4 000 miles, 12 months) oil by removing the oil drain plug (1) and filler cap (2).
  • Page 37 Also, do not use a genuine Suzuki 3) Turn off the engine and wait about three minutes, automobile oil filter on this motorcycle.
  • Page 38 0B-12 Maintenance and Lubrication: Throttle Cable Play Inspection and Adjustment Throttle Valve Synchronization B944H10206009 B944H10206010 Inspect throttle cable play Inspect throttle valve synchronization Initially at 1 000 km (6 000 miles, 2 months) and Initially 1 000 km (600 miles, 2 months) (E-33 only) every 6 000 km (4 000 miles, 12 months) thereafter and every 12 000 km (7 500 miles, 24 months) Inspect and adjust the throttle cable play “a”...
  • Page 39 Maintenance and Lubrication: 0B-13 WARNING Do not open the radiator cap when the engine is hot, as you may be injured by escaping hot liquid or vapor. Engine coolant may be harmful if swallowed or if it comes in contact with skin or eyes.
  • Page 40 0B-14 Maintenance and Lubrication: 10) Reinstall the removed parts. 3) From that position, turn out the release screw (2) 1 turn and tighten the lock-nut (1) securely by holding Radiator Hose Inspection the release screw (2). Check the radiator hoses for crack, damage or engine Clutch release screw coolant leakage.
  • Page 41 Maintenance and Lubrication: 0B-15 Drive Chain Inspection and Adjustment 4) Count out 21 pins (20 pitches) on the chain and B944H10206016 measure the distance between the two points. If the distance exceeds the service limit, the chain must be Inspect drive chain replaced.
  • Page 42 • Do not use any oil sold commercially as “drive chain oil”. Such oil can damage the O-rings. • The standard drive chain is a DID520VM2. SUZUKI recommends to use this standard drive chain as a replacement. I944H1020043-01 I944H1020042-01 I944H1020044-01...
  • Page 43 Maintenance and Lubrication: 0B-17 Brake Pads Check The extent of brake pad wear can be checked by observing the grooved limit line “A” on the pad. When the wear exceeds the grooved limit line, replace the pads with new ones. Refer to “Front Brake Pad Replacement in Section 4B (Page 4B-2)”...
  • Page 44 0B-18 Maintenance and Lubrication: Brake Fluid Replacement Tire Pressure If the tire pressure is too high or too low, steering will be Replace brake fluid adversely affected and tire wear increased. Therefore, Every 2 years maintain the correct tire pressure for good roadability or Refer to “Brake Fluid Replacement in Section 4A shorter tire life will result.
  • Page 45 Maintenance and Lubrication: 0B-19 2) Support the motorcycle so that the front wheel is off the ground, with the wheel facing straight ahead, grasp the lower fork tubes near the axle and pull forward. If play is found, readjust the steering. Refer to “Steering Tension Adjustment in Section 6B (Page 6B-9)”.
  • Page 46 0B-20 Maintenance and Lubrication: I944H1020056-01 I944H1020059-02 Front brake hose union bolt 23 N⋅m (2.3 kgf-m, 16.5 lbf-ft) Rear axle nut 100 N⋅m (10.0 kgf-m, 72.5 lbf-ft) Front brake master cylinder mounting bolt 10 N⋅m (1.0 kgf-m, Rear sprocket nut 60 N⋅m (6.0 kgf-m, 43.5 lbf-ft) 7.0 lbf-ft) I944H1020060-01 I944H1020057-01...
  • Page 47 Maintenance and Lubrication: 0B-21 Compression Pressure Check B944H10206024 Refer to “Compression Pressure Check in Section 1D (Page 1D-3)”. Oil Pressure Check B944H10206025 Refer to “Oil Pressure Check in Section 1E (Page 1E- 5)”. SDS Check B944H10206026 Refer to “SDS Check in Section 1A (Page 1A-18)”. I944H1020062-02 Rear shock absorber mounting bolt (Lower) 50 N⋅m (5.0 kgf-m, 36.0 lbf-ft)
  • Page 48 0B-22 Maintenance and Lubrication: Special Tools and Equipment Recommended Service Material B944H10208001 Material SUZUKI recommended product or Specification Note Brake fluid DOT 4 — (Page 0B-16) NOTE Required service material is also described in the following. “Lubrication Points (Page 0B-2)”...
  • Page 49 Service Data: 0C-1 Service Data General Information Specifications Service Data B944H10307001 Valve + Guide Unit: mm (in) Item Standard Limit 31 (1.22) — Valve diam. 25.5 (1.00) — 0.10 – 0.20 (0.004 – 0.008) — Valve clearance (when cold) 0.20 – 0.30 (0.008 – 0.012) —...
  • Page 50 0C-2 Service Data: Cylinder + Piston + Piston Ring Unit: mm (in) Item Standard Limit 1 300 – 1 700 kPa 1 100 kPa Compression pressure (13.0 – 17.0 kgf/cm , 185 – 242 psi) (11.0 kgf/cm , 156 psi) 200 kPa Compression pressure difference —...
  • Page 51 Service Data: 0C-3 Transmission + Drive Chain Unit: mm (in) Except ratio Item Standard Limit Primary reduction ratio 2.088 (71/34) — Final reduction ratio 3.066 (46/15) — 2.461 (32/13) — 1.777 (32/18) — 1.380 (29/21) — Gear ratios 1.125 (27/24) —...
  • Page 52 0C-4 Service Data: FI Sensors + Secondary Throttle Valve Actuator Item Standard/Specification Note 160 – 240 Ω CKP sensor resistance CKP sensor peak voltage 4.6 V and more When cranking IAP sensor (#1 & #2) input voltage 4.5 – 5.5 V IAP sensor (#1 &...
  • Page 53 Service Data: 0C-5 Electrical Unit: mm (in) Item Specification Note 1 ⋅ 2 Firing order NGK: CR8EIA-9 Type Spark plug DENSO: IU24D 0.8 – 0.9 (0.031 – 0.035) Spark performance Over 8 (0.3) at 1 atm. 160 – 240 Ω CKP sensor resistance CKP sensor peak voltage 4.6 V and more...
  • Page 54 Front fork oil level (Without spring, 96 (3.78) — outer tube fully compressed) Front fork oil type SUZUKI FORK OIL SS-08 or an equivalent fork oil — Front fork oil capacity (Each leg) 517 ml (17.5/18.2 US/Imp oz) — Front fork spring adjuster 3th groove from top —...
  • Page 55 Service Data: 0C-7 Fuel + Oil Item Specification Note Use only unleaded gasoline of at least 87 pump octane (R/2 + M/2). Gasoline containing MTBE (Methyl Tertiary Butyl Ether), less E-03, 28, 33 Fuel type than 10% ethanol, or less than 5% methanol with appropriate cosolvents and corrosion inhibitor is permissible.
  • Page 56 0C-8 Service Data: Item N⋅m kgf-m lbf-ft Gear position switch mounting bolt 0.65 Oil pressure switch 10.0 Oil pressure switch lead wire bolt 0.15 [M6] Crankcase bolt [M8] 19.0 (Cylinder head) [M6] [M6] Oil gallery plug [M8] 13.0 [M12] 15.0 [M16] 25.5 Oil drain plug...
  • Page 57 Service Data: 0C-9 Chassis Item N⋅m kgf-m lbf-ft Steering stem head nut 65.0 Tighten 45 N⋅m (4.5 kgf-m, 32.5 lbf-ft) then turn back 1/2 Steering stem nut – 1/4. Front fork upper clamp bolt 16.5 Front fork lower clamp bolt 16.5 Front fork cap bolt 16.5...
  • Page 58 0C-10 Service Data: Tightening Torque Chart For other bolts and nuts not listed in the preceding page, refer to this chart: Bolt Diameter Conventional or “4” marked bolt “7” marked bolt “a” (mm) N⋅m kgf-m lbf-ft N⋅m kgf-m lbf-ft 0.15 0.23 0.45 0.55...

  • Page 59: Table Of Contents

    Table of Contents 1- i Section 1 Engine CONTENTS Precautions ..........1-1 DTC “C31” (P0705): GP Switch Circuit Malfunction............1A-84 Precautions............. 1-1 DTC “C32” (P0201), “C33” (P0202): Fuel Precautions for Engine.......... 1-1 Injector Circuit Malfunction......1A-88 Engine General Information and DTC “C40” (P0505 / P0506 / P0507): ISC Valve Circuit Malfunction.........1A-91 Diagnosis ..........
  • Page 60 1-ii Table of Contents Engine Symptom Diagnosis ........1C-1 Engine Top Side Disassembly ......1D-25 Engine Top Side Assembly .......1D-31 Repair Instructions ..........1C-1 Valve Clearance Inspection and Adjustment ..1D-43 ECM Removal and Installation......1C-1 Camshaft Inspection .........1D-44 CKP Sensor Inspection ........1C-1 Cam Chain Tension Adjuster Inspection ...1D-45 CKP Sensor Removal and Installation ....1C-2 Cam Chain Guide Inspection ......1D-46 IAP Sensor Inspection.........1C-2...
  • Page 61 Table of Contents 1-iii Special Tool ............1E-15 Fuel Hose Removal and Installation ....1G-7 Fuel Level Gauge Inspection ......1G-7 Engine Cooling System ......1F-1 Fuel Tank Removal and Installation....1G-7 Fuel Pump Components ........1G-9 Precautions............1F-1 Fuel Pump Assembly Removal and Precautions for Engine Cooling System....
  • Page 62 1-iv Table of Contents Starter Motor Disassembly and Assembly ... 1I-4 Generator Removal and Installation....1J-4 Starter Motor Related Parts Inspection ....1I-6 Regulator / Rectifier Construction ....... 1J-8 Starter Relay Removal and Installation....1I-6 Regulator / Rectifier Inspection ......1J-8 Starter Relay Inspection........
  • Page 63 Precautions: Precautions Engine Precautions Precautions for Engine B944H11000001 Refer to “General Precautions in Section 00 (Page 00-1)” and “Precautions for Electrical Circuit Service in Section 00 (Page 00-2)”.

  • Page 64: Engine General Information And Diagnosis

    1A-1 Engine General Information and Diagnosis: Engine General Information and Diagnosis Engine General Description Injection Timing Description B944H11101001 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 65 Engine General Information and Diagnosis: 1A-2 Compensation of Injection Time (Volume) The following different signals are output from the respective sensors for compensation of the fuel injection time (volume). Signal Descriptions ENGINE COOLANT TEMPERATURE SENSOR When engine coolant temperature is low, injection time (volume) SIGNAL is increased.
  • Page 66 1A-3 Engine General Information and Diagnosis: Self-Diagnosis Function B944H11101002 The self-diagnosis function is incorporated in the ECM. The function has two modes, “User mode” and “Dealer mode”. The user can only be notified by the LCD (DISPLAY) panel and LED (FI indicator light). To check the function of the individual FI system devices, the dealer mode is provided.
  • Page 67 Engine General Information and Diagnosis: 1A-4 Dealer Mode The defective function is memorized in the computer. Use the special tool’s coupler to connect to the mode select switch. The memorized malfunction code is displayed on LCD (DISPLAY) panel. Malfunction means that the ECM does not receive signal from the devices.

  • Page 68: Fi System Wiring Diagram

    1A-5 Engine General Information and Diagnosis: Schematic and Routing Diagram FI System Wiring Diagram B944H11102001 Combination meter Cooling fan motor Cooling fan relay 15 A Br/B CKPS 31 36 Fuel injector Fuel Pump O/Bl Gr/W Gr/B FP relay 10 A Engine stop B/Br switch...
  • Page 69 Engine General Information and Diagnosis: 1A-6 Terminal Alignment of ECM Coupler B944H11102002 I944H1110003-01 TERMINAL NO. CIRCUIT TERMINAL NO. CIRCUIT GP switch signal (GP) CKP sensor signal (CKP+) IAT sensor signal (IAT) — IAP sensor signal #1 (IAP.F) — STP sensor signal (STP) —...

  • Page 70: Fi System Parts Location

    1A-7 Engine General Information and Diagnosis: Component Location FI System Parts Location B944H11103001 I944H1110004-06 “A”: ECM “G”: Throttle position sensor (TPS) “B”: Speedometer “H”: Crank shaft position sensor (CKPS) “C”: Intake air pressure sensor #2 (IAPS) “I”: Speedometer sensor “D”: Intake air temperature sensor (IATS) “J”: Gear position switch (GP switch) “E”: Secondary throttle position sensor (STPS) “K”: Heated oxygen sensor (HO2S)
  • Page 71 Engine General Information and Diagnosis: 1A-8 I944H1110005-02 “A”: ECM “R”: Fuel pump relay (FP relay) “M”: Cooling fan “S”: Fuel injector (Front) “N”: Intake air pressure sensor #1 (IAPS) “T”: Fuel injector (Rear) “O”: Fuel pump “U”: Engine coolant temperature sensor (ECTS) “P”: Tip-over sensor (TOS) “V”: Ignition coil (Rear) “Q”: Cooling fan relay...

  • Page 72: Engine Symptom Diagnosis

    1A-9 Engine General Information and Diagnosis: Diagnostic Information and Procedures Engine Symptom Diagnosis B944H11104001 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 73 Engine General Information and Diagnosis: 1A-10 Condition Possible cause Correction / Reference Item Engine stalls often Defective IAP sensors 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 74 1A-11 Engine General Information and Diagnosis: Condition Possible cause Correction / Reference Item Engine runs poorly in Weakened valve spring. Replace. high speed range Worn camshafts. Replace. (Defective engine internal/ Valve timing out of adjustment. Adjust. electrical parts) Too narrow spark plug gaps. Adjust.
  • Page 75 Engine General Information and Diagnosis: 1A-12 Condition Possible cause Correction / Reference Item Engine overheats Heavy carbon deposit on piston crown. Clean. (Defective engine internal Not enough oil in the engine. Add oil. parts) Defective oil pump or clogged oil circuit. Replace or clean. Sucking air from intake pipes.
  • Page 76 1A-13 Engine General Information and Diagnosis: Self-Diagnostic Procedures 5) Check the DTC “A” to determine the malfunction B944H11104002 part. Refer to “DTC Table (Page 1A-22)”. 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 77: Engine General Information And

    Engine General Information and Diagnosis: 1A-14 Use of SDS NOTE • Do not disconnect the coupler from ECM, battery cable from battery, ECM ground wire from the engine or main fuse before confirming DTC (Diagnostic Trouble Code) stored in memory. Such disconnection may erase the memorized information in ECM memory.

  • Page 78: Show Data When Trouble

    1A-15 Engine General Information and Diagnosis: 4) Start the engine or crank the engine for more than 4 4) Click the DTC inspection button (1). seconds. 5) Check the DTC to determine the malfunction part. Refer to “DTC Table (Page 1A-22)”. NOTE •...
  • Page 79 Engine General Information and Diagnosis: 1A-16 9) Check that both “Current DTC” (3) and “Past DTC” 10) Close the SDS tool and turn the ignition switch OFF. (4) are deleted (NIL). 11) Disconnect the SDS tool. 12) Reinstall the removed parts. I705H1110008-01 Show Data When Trouble (Displaying Data at the Time of DTC) B944H11104004...
  • Page 80 1A-17 Engine General Information and Diagnosis: 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 81 Engine General Information and Diagnosis: 1A-18 SDS Check B944H11104005 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 82 1A-19 Engine General Information and Diagnosis: Data at 3 000 r/min under no load Approx. 3 000 r/min. Check the manifold absolute pressure. XXX kPa Check the engine coolant temperature. I944H1110108-02 Data at the time of racing Throttle: Quick wide open Throttle: Slowly open Secondary throttle valve open...
  • Page 83 Engine General Information and Diagnosis: 1A-20 Data of intake negative pressure during idling (100 °C) Check the engine coolant temperature. Check the monifold absolute pressure. XXX kPa I944H1110110-01 Data of manifold absolute pressure operation at the time of starting Check the monifold absolute pressure. XXX kPa I944H1110111-01...
  • Page 84 1A-21 Engine General Information and Diagnosis: Example of Trouble Three data; value 3 (current data 3), value 1 (past data 1) and value 2 (past data 2); 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 85 Engine General Information and Diagnosis: 1A-22 DTC Table B944H11104006 Code Malfunction Part Remarks None No defective part C12 (P0335) Crankshaft position sensor (CKPS) Pick-up coil signal, signal generator (Page 1A-27) C13 (P1750) Intake air pressure sensor #2 (IAPS) For #2 cylinder (Page 1A-30) C14 (P0120-H/L) Throttle position sensor (TPS)
  • Page 86 1A-23 Engine General Information and Diagnosis: Fail-Safe Function Table B944H11104007 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 Intake air pressure value is fixed to 101 kPa...
  • Page 87 Engine General Information and Diagnosis: 1A-24 FI System Troubleshooting B944H11104008 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 88: 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 89 Engine General Information and Diagnosis: 1A-26 Malfunction Detected Item Detected Failure Condition Check For Code The sensor voltage should be the following. 0.2 V ≤ Sensor voltage < 4.8 V TO sensor, lead wire/coupler In other than the above value, C23 (P1651) is connection indicated.
  • Page 90 1A-27 Engine General Information and Diagnosis: Malfunction Detected Item Detected Failure Condition Check For Code After engine is started few minutes. (Sensor output voltage ≥ 2.5 V) Engine is cold and stopped. HO2 sensor is circuit open or P0130 (Sensor output voltage < 0.1 V) shorted to ground In other than the above value, C44 HO2 sensor...
  • Page 91 Engine General Information and Diagnosis: 1A-28 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 terminal damage. NOTE After repairing the trouble, clear the DTC using SDS tool. Refer to “Use of SDS Diagnosis Reset Procedures (Page 1A-15)”.
  • Page 92 1A-29 Engine General Information and Diagnosis: Step Action 1) Turn the ignition switch OFF. Go to Step 3. Short circuit in the W wire. 2) Disconnect the ECM coupler. Refer to “ECM Removal and Installation in Section 1C (Page 1C-1)”. 3) Insert the needle pointed probes to the lead wire coupler.

  • Page 93: Dtc "C13" (P1750) Or "C17" (P0105): Iap Sensor Circuit Malfunction

    Engine General Information and Diagnosis: 1A-30 DTC “C13” (P1750) or “C17” (P0105): IAP Sensor Circuit Malfunction B944H11104011 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.
  • Page 94 1A-31 Engine General Information and Diagnosis: When indicating C13 for IAP sensor (#2) / When indicating C17 for IAP sensor (#1) (Use of mode select switch) Step Action 1) Turn the ignition switch OFF. Go to Step 2. Open circuit in the R or B/Br wire.
  • Page 95 Engine General Information and Diagnosis: 1A-32 Step Action 1) Turn the ignition switch OFF. Go to Step 3. Short circuit in the R wire. 2) Disconnect the ECM coupler. Refer to “ECM Removal and Installation in Section 1C (Page 1C-1)”. 3) Insert the needle pointed probes to the lead wire coupler.
  • Page 96 1A-33 Engine General Information and Diagnosis: Step Action 1) Insert the needle pointed probes to the lead wire coupler. Go to Step 4. • Open or short circuit in the G/B wire (#1 2) Check there is continuity between the G/B wire “A” and cylinder).
  • Page 97 Engine General Information and Diagnosis: 1A-34 Step Action 3) If there is continuity, check there is no continuity Go to Step 4. • Open or short circuit between the G/B wire “A” and ground, G/Y wire “B” and in the G/B wire (#1 ground.
  • Page 98 1A-35 Engine General Information and Diagnosis: Step Action 1) Remove the IAP sensor. Refer to “IAP Sensor Removal Replace the ECM with a If check result is not and Installation in Section 1C (Page 1C-2)”. new one. Refer to “ECM satisfactory, replace the Removal and IAP sensor with a new...

  • Page 99: Dtc "C14" (P0120-H/L): Tp Sensor Circuit

    Engine General Information and Diagnosis: 1A-36 DTC “C14” (P0120-H/L): TP Sensor Circuit Malfunction B944H11104012 Detected Condition and Possible Cause Detected Condition Possible Cause Output voltage is not within the following • TP sensor maladjusted. range. • TP sensor circuit open or short. 0.1 V ≤...
  • Page 100 1A-37 Engine General Information and Diagnosis: C14 (Use of mode select switch) Step Action 1) Turn the ignition switch OFF. Go to Step 2. Open circuit in the R or B/Br wire. 2) Lift and support the fuel tank. Refer to “Fuel Tank Removal and Installation in Section 1G (Page 1G-7)”.
  • Page 101 Engine General Information and Diagnosis: 1A-38 Step Action 1) Turn the ignition switch OFF. Go to Step 3. Short circuit in the R wire. 2) Disconnect the ECM coupler. Refer to “ECM Removal and Installation in Section 1C (Page 1C-1)”. 3) Check there is no continuity between the R wire “A”...
  • Page 102 1A-39 Engine General Information and Diagnosis: Step Action 1) Disconnect the ECM coupler. Refer to “ECM Removal Go to Step 4. Short circuit in the P/W and Installation in Section 1C (Page 1C-1)”. wire. 2) Check the continuity between the P/W wire “A” and terminal “21”.
  • Page 103 Engine General Information and Diagnosis: 1A-40 Step Action 1) Turn the ignition switch OFF. Replace the ECM with a If check result is not new one. Refer to “ECM satisfactory, replace TP 2) Connect the ECM coupler. Refer to “ECM Removal and Removal and sensor with a new one.
  • Page 104 1A-41 Engine General Information and Diagnosis: P0120-H (Use of SDS) Step Action 1) Turn the ignition switch OFF. Go to Step 2. Open circuit in the R wire. 2) Lift and support the fuel tank. Refer to “Fuel Tank Removal and Installation in Section 1G (Page 1G-7)”. 3) Check the TP sensor coupler (1) for loose or poor contacts.
  • Page 105 Engine General Information and Diagnosis: 1A-42 Step Action 1) Disconnect the ECM coupler. Refer to “ECM Removal Go to Step 3. Short circuit in the P/W and Installation in Section 1C (Page 1C-1)”. wire. 2) Check the continuity between the P/W wire “A” and terminal “21”.
  • Page 106 1A-43 Engine General Information and Diagnosis: Step Action 1) Turn the ignition switch OFF. Replace the ECM with a If check result is not new one. Refer to “ECM satisfactory, replace TP 2) Connect the ECM coupler. Refer to “ECM Removal and Removal and sensor with a new one.
  • Page 107 Engine General Information and Diagnosis: 1A-44 P0120-L (Use of SDS) Step Action 1) Turn the ignition switch OFF. Go to Step 2. Short circuit in the R wire. 2) Lift and support the fuel tank. Refer to “Fuel Tank Removal and Installation in Section 1G (Page 1G-7)”. 3) Check the TP sensor coupler (1) for loose or poor contacts.
  • Page 108 1A-45 Engine General Information and Diagnosis: Step Action 1) Disconnect the ECM coupler. Refer to “ECM Removal Go to Step 3. Short circuit in the P/W and Installation in Section 1C (Page 1C-1)”. wire. 2) Check the continuity between the P/W wire “A” and terminal “21”.
  • Page 109 Engine General Information and Diagnosis: 1A-46 Step Action 1) Turn the ignition switch OFF. Replace the ECM with a If check result is not new one. Refer to “ECM satisfactory, replace TP 2) Connect the ECM coupler. Refer to “ECM Removal and Removal and sensor with a new one.

  • Page 110: Dtc "C15" (P0115-H/L): Ect Sensor Circuit

    1A-47 Engine General Information and Diagnosis: DTC “C15” (P0115-H/L): ECT Sensor Circuit Malfunction B944H11104013 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. 0.1 V ≤...
  • Page 111 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. Short circuit in the B/Bl wire or B/Br wire. 2) Remove the throttle body. Refer to “Throttle Body Removal and Installation in Section 1D (Page 1D-10)”.
  • Page 112 1A-49 Engine General Information and Diagnosis: Step Action 6) If OK, then check there is ECT sensor lead wire no Go to Step 2. Short circuit in the B/Bl continuity. wire or B/Br wire. 7) Turn the ignition switch OFF. 8) Disconnect the ECM coupler.
  • Page 113 Engine General Information and Diagnosis: 1A-50 P0115-H (Use of SDS) Step Action 1) Turn the ignition switch OFF. Go to Step 2. Open circuit in the B/Bl or B/Br wire. 2) Remove the throttle body. Refer to “Throttle Body Removal and Installation in Section 1D (Page 1D-10)”. 3) Check the ECT sensor coupler (1) for loose or poor contacts.
  • Page 114 1A-51 Engine General Information and Diagnosis: P0115-L (Use of SDS) Step Action 1) Turn the ignition switch OFF. Go to Step 2. Short circuit in the B/Bl or B/Br wire. 2) Remove the throttle body. Refer to “Throttle Body Removal and Installation in Section 1D (Page 1D-10)”. 3) Check the ECT sensor coupler (1) for loose or poor contacts.
  • Page 115 Engine General Information and Diagnosis: 1A-52 Step Action 1) Turn the ignition switch OFF. Replace the ECM with a Replace the ECT new one. Refer to “ECM sensor with a new one. 2) Disconnect the ECT sensor coupler. Removal and Refer to “ECT Sensor 3) Measure the ECT sensor resistance.

  • Page 116: Dtc "C21" (P0110-H/L): Iat Sensor Circuit

    1A-53 Engine General Information and Diagnosis: DTC “C21” (P0110-H/L): IAT Sensor Circuit Malfunction B944H11104015 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. 0.1 V ≤...
  • Page 117 Engine General Information and Diagnosis: 1A-54 C21 (Use of mode select switch) Step Action 1) Turn the ignition switch OFF. Go to Step 2. Short circuit in the Dg wire or B/Br wire. 2) Lift and support the fuel tank. Refer to “Fuel Tank Removal and Installation in Section 1G (Page 1G-7)”.
  • Page 118 1A-55 Engine General Information and Diagnosis: Step Action 8) Disconnect the ECM coupler. Refer to “ECM Removal Go to Step 2. Short circuit in the Dg and Installation in Section 1C (Page 1C-1)”. wire or B/Br wire. 9) Check there is no continuity between the Dg wire “A” and ground, B/Br wire “B”...
  • Page 119 Engine General Information and Diagnosis: 1A-56 P0110-H (Use of SDS) Step Action 1) Turn the ignition switch OFF. Go to Step 2. Open circuit in the Dg or B/Br wire. 2) Lift and support the fuel tank. Refer to “Fuel Tank Removal and Installation in Section 1G (Page 1G-7)”.
  • Page 120 1A-57 Engine General Information and Diagnosis: P0110-L (Use of SDS) Step Action 1) Turn the ignition switch OFF. Go to Step 2. Short circuit in the Dg or B/Br wire. 2) Lift and support the fuel tank. Refer to “Fuel Tank Removal and Installation in Section 1G (Page 1G-7)”.
  • Page 121 Engine General Information and Diagnosis: 1A-58 Step Action 1) Turn the ignition switch OFF. Replace the ECM with a Replace the IAT sensor new one. Refer to “ECM with a new one. Refer to 2) Disconnect the IAT sensor coupler. Removal and “IAP Sensor Removal 3) Measure the IAT sensor resistance.

  • Page 122: Dtc "C23" (P1651-H/L): To Sensor Circuit

    1A-59 Engine General Information and Diagnosis: DTC “C23” (P1651-H/L): TO Sensor Circuit Malfunction B944H11104016 Detected Condition and Possible Cause Detected Condition Possible Cause The sensor voltage should be the • TO sensor circuit open or short. following. • TO sensor malfunction. 0.2 V ≤...
  • Page 123 Engine General Information and Diagnosis: 1A-60 C23 (Use of mode select switch) Step Action 1) Turn the ignition switch OFF. Go to Step 2. Open circuit in the R wire or B/Br wire. 2) Remove the seat. Refer to “Exterior Parts Removal and Installation in Section 9D (Page 9D-4)”.
  • Page 124 1A-61 Engine General Information and Diagnosis: Step Action 7) If OK, then measure the voltage between the R wire “A” Go to Step 2. Open circuit in the R and ground. wire or B/Br wire. Special tool (A): 09900–25008 (Multi circuit tester set) Tester knob indication Voltage ( “A”...
  • Page 125 Engine General Information and Diagnosis: 1A-62 P1651-H (Use of SDS) Step Action 1) Turn the ignition switch OFF. Go to Step 2. Open circuit in the R wire or B/Br wire. 2) Remove the seat. Refer to “Exterior Parts Removal and Installation in Section 9D (Page 9D-4)”.
  • Page 126 1A-63 Engine General Information and Diagnosis: Step Action 1) Insert the needle pointed probes to the lead wire coupler. Go to Step 3. Open circuit in the Br/W wire. 2) Check the continuity between the B/W wire “A” and terminal “20”. Special tool (A): 09900–25008 (Multi circuit tester set) (B): 09900–25009 (Needle pointed probe set)
  • Page 127 Engine General Information and Diagnosis: 1A-64 P1651-L (Use of SDS) Step Action 1) Turn the ignition switch OFF. Go to Step 2. Short circuit in the R wire. 2) Remove the seat. Refer to “Exterior Parts Removal and Installation in Section 9D (Page 9D-4)”. 3) Check the TO sensor coupler (1) for loose or poor contacts.
  • Page 128 1A-65 Engine General Information and Diagnosis: Step Action 1) Check there is no continuity between the Br/W wire “B” Go to Stop 3. Short circuit in the Br/W and ground. wire. Also the Br/W wire “B” and another wire. Special tool (A): 09900–25008 (Multi circuit tester set) Tester knob indication Continuity (...
  • Page 129 Engine General Information and Diagnosis: 1A-66 Step Action 1) Connect the ECM coupler and TO sensor coupler. • Replace the ECM • Replace the TO with a new one. Refer sensor with a new 2) Remove the TO sensor. Refer to “TO Sensor Removal to “ECM Removal one.

  • Page 130: Dtc "C24" (P0351) Or "C25" (P0352): Ignition System Malfunction

    1A-67 Engine General Information and Diagnosis: DTC “C24” (P0351) or “C25” (P0352): Ignition System Malfunction B944H11104017 NOTE • Refer to “No Spark or Poor Spark in Section 1H (Page 1H-3)” for details. • When indicating “C24” (P0351) for #1 front cylinder side. •...
  • Page 131 Engine General Information and Diagnosis: 1A-68 Step Action 1) Remove the air cleaner box. Refer to “Air Cleaner Box Go to Step 2. Open or short circuit in Removal and Installation in Section 1D (Page 1D-6)”. the W/B, B/Lg, G or P/W wire.
  • Page 132 1A-69 Engine General Information and Diagnosis: Step Action 7) If the sound is heard from the tester, then check there is Go to Step 2. Open or short circuit in no continuity among the STVA lead wire coupler each the W/B, B/Lg, G or P/W terminal and ground.
  • Page 133 Engine General Information and Diagnosis: 1A-70 Step Action 1) Remove the throttle body assembly. Refer to “Throttle Go to Step 3. Replace the throttle Body Removal and Installation in Section 1D (Page 1D- body assembly with a 10)”. new one. Refer to “Throttle Body Removal 2) Check the continuity between each terminal and ground.
  • Page 134 1A-71 Engine General Information and Diagnosis: Step Action 1) Install the throttle body assembly. Refer to “Throttle Body Replace the ECM with a Replace the throttle Removal and Installation in Section 1D (Page 1D-10)”. new one. Refer to “ECM body assembly with a Removal and new one.
  • Page 135 Engine General Information and Diagnosis: 1A-72 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). I944H1110140-02 4) Click each button (2). At this time, if an operation sound is heard from the STVA, the function is normal.

  • Page 136: Dtc "C29" (P1654-H/L): Secondary Throttle Position Sensor (Stps) Circuit Malfunction

    1A-73 Engine General Information and Diagnosis: DTC “C29” (P1654-H/L): Secondary Throttle Position Sensor (STPS) Circuit Malfunction B944H11104019 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. 0.1 V ≤...
  • Page 137 Engine General Information and Diagnosis: 1A-74 C29 (Use of mode select switch) Step Action 1) Turn the ignition switch OFF. Go to Step 2. Open circuit in the R wire or B/Br wire. 2) Remove the air cleaner box. Refer to “Air Cleaner Box Removal and Installation in Section 1D (Page 1D-6)”.
  • Page 138 1A-75 Engine General Information and Diagnosis: Step Action 1) Turn the ignition switch OFF. Go to Step 3. Short circuit in the R wire. 2) Disconnect the ECM coupler. Refer to “ECM Removal and Installation in Section 1C (Page 1C-1)”. 3) Check there is no continuity between the R wire “A”...
  • Page 139 Engine General Information and Diagnosis: 1A-76 Step Action 1) Disconnect the ECM coupler. Refer to “ECM Removal Go to Step 4. Short circuit in the Y and Installation in Section 1C (Page 1C-1)”. wire. 2) Check the continuity between the Y wire “A” and terminal “4”.
  • Page 140 1A-77 Engine General Information and Diagnosis: Step Action 1) Turn the ignition switch OFF. Replace the ECM with a Replace the STP sensor new one. Refer to “ECM with a new one. Refer to 2) Connect the ECM coupler. Removal and “STP Sensor Removal 3) Connect the special tool between the STP sensor and its Installation in Section...
  • Page 141 Engine General Information and Diagnosis: 1A-78 P1654-H (Use of SDS) Step Action 1) Turn the ignition switch OFF. Go to Step 2. Open circuit in the R wire. 2) Remove the air cleaner box. Refer to “Air Cleaner Box Removal and Installation in Section 1D (Page 1D-6)”. 3) Check the STP sensor coupler (1) for loose or poor contacts.
  • Page 142 1A-79 Engine General Information and Diagnosis: Step Action 1) Disconnect the ECM coupler. Refer to “ECM Removal Go to Step 3. Short circuit in the Y and Installation in Section 1C (Page 1C-1)”. wire. 2) Check the continuity between the Y wire “A” and terminal “4”.
  • Page 143 Engine General Information and Diagnosis: 1A-80 Step Action 1) Turn the ignition switch OFF. Replace the ECM with a Replace the STP sensor new one. Refer to “ECM with a new one. Refer to 2) Connect the ECM coupler. Removal and “STP Sensor Removal 3) Connect the special tool between the STP sensor and its Installation in Section...
  • Page 144 1A-81 Engine General Information and Diagnosis: P1654-L (Use of SDS) Step Action 1) Turn the ignition switch OFF. Go to Step 2. Short circuit in the R wire. 2) Remove the air cleaner box. Refer to “Air Cleaner Box Removal and Installation in Section 1D (Page 1D-6)”. 3) Check the STP sensor coupler (1) for loose or poor contacts.
  • Page 145 Engine General Information and Diagnosis: 1A-82 Step Action 1) Disconnect the ECM coupler. Refer to “ECM Removal Go to Step 3. Short circuit in the Y and Installation in Section 1C (Page 1C-1)”. wire. 2) Check the continuity between the Y wire “A” and terminal “4”.
  • Page 146 1A-83 Engine General Information and Diagnosis: Step Action 1) Turn the ignition switch OFF. Replace the ECM with a Replace the STP sensor new one. Refer to “ECM with a new one. Refer to 2) Connect the ECM coupler. Removal and “STP Sensor Removal 3) Connect the special tool between the STP sensor and its Installation in Section...

  • Page 147: Dtc "C31" (P0705): Gp Switch Circuit Malfunction

    Engine General Information and Diagnosis: 1A-84 DTC “C31” (P0705): GP Switch Circuit Malfunction B944H11104020 Detected Condition and Possible Cause Detected Condition Possible Cause Gear position signal voltage should be higher than the • GP switch circuit open or short. following. •...
  • Page 148 1A-85 Engine General Information and Diagnosis: Step Action 1) Turn the ignition switch OFF. Go to Step 2. Open circuit in the P, Bl or B/W wire. 2) Lift and support the fuel tank. Refer to “Fuel Tank Removal and Installation in Section 1G (Page 1G-7)”. 3) Check the GP switch coupler (1) for loose or poor contacts.
  • Page 149 Engine General Information and Diagnosis: 1A-86 Step Action 1) Disconnect the ECM coupler. Refer to “ECM Removal Go to Step 3. Short circuit in the P and Installation in Section 1C (Page 1C-1)”. wire or B/W wire. 2) Insert the needle pointed probes to the lead wire coupler. 3) Check there is continuity between the P wire “A”...
  • Page 150 1A-87 Engine General Information and Diagnosis: Step Action 1) Connect the ECM coupler. Refer to “ECM Removal and Go to Step 4. Short circuit in the Bl Installation in Section 1C (Page 1C-1)”. wire. 2) Turn the ignition switch ON. 3) Measure the voltage between the Bl wire “A”...

  • Page 151: Dtc "C32" (P0201), "C33" (P0202): Fuel Injector Circuit Malfunction

    Engine General Information and Diagnosis: 1A-88 DTC “C32” (P0201), “C33” (P0202): Fuel Injector Circuit Malfunction B944H11104021 Detected Condition and Possible Cause Detected Condition Possible Cause CKP signal is produced but fuel injector signal is • Injector circuit open or short. interrupted by 8 times or more continuity.
  • Page 152 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) Remove the air cleaner box. Refer to “Air Cleaner Box “Throttle Body Removal and Installation in Section 1D (Page 1D-6)”.
  • Page 153 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-11)”.

  • Page 154: Dtc "C40" (P0505 / P0506 / P0507): Isc Valve Circuit Malfunction

    1A-91 Engine General Information and Diagnosis: DTC “C40” (P0505 / P0506 / P0507): ISC Valve Circuit Malfunction B944H11104022 Detected Condition and Possible Cause Detected Condition Possible Cause C40/P0505 ISC valve circuit malfunction. • Secondary throttle valve is fixed in opening position. Idle speed is lower than the desired •...
  • Page 155 Engine General Information and Diagnosis: 1A-92 Active Control Inspection (ISC RPM Control) Check 2 Check 1 1) Click the button (4) and decrease the “Spec” (2) to 1 200 rpm slowly. 1) Set up the SDS tool. (Refer to the SDS operation manual for further details.) 2) Check that the “Desired idle speed”...

  • Page 156: Dtc "C41" (P0230-H/L): Fp Relay Circuit Malfunction

    1A-93 Engine General Information and Diagnosis: DTC “C41” (P0230-H/L): FP Relay Circuit Malfunction B944H11104023 Detected Condition and Possible Cause Detected Condition Possible Cause No voltage is applied to the fuel pump, although fuel Fuel pump relay, lead wire/coupler connection, power pump relay is turned ON, or voltage is applied to fuel source to fuel pump relay and fuel injectors.
  • Page 157 Engine General Information and Diagnosis: 1A-94 C41 (Use of mode select switch) Step Action 1) Turn the ignition switch OFF. Go to Step 2. Replace the FP relay with a new one. 2) Remove the right rear frame cover. Refer to “Exterior Parts Removal and Installation in Section 9D (Page 9D- 4)”.
  • Page 158 1A-95 Engine General Information and Diagnosis: Step Action 4) If the sound is heard from the tester, then check there is Go to Step 3. Open or short circuit in no continuity between the Y/B wire “A” and ground, Y/R the Y/B or Y/R wire.
  • Page 159 Engine General Information and Diagnosis: 1A-96 Step Action 1) Measure the fuel pump relay switch side voltage Replace the ECM with a Open circuit in the R/W between the R/W wire “C” and ground. new one. Refer to “ECM wire or O/W wire. Removal and Special tool Installation in Section...

  • Page 160: Dtc "C42" (P1650): Ig Switch Circuit

    1A-97 Engine General Information and Diagnosis: DTC “C42” (P1650): IG Switch Circuit Malfunction B944H11104025 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. Troubleshooting NOTE •...
  • Page 161 Engine General Information and Diagnosis: 1A-98 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 terminal damage. Step Action 1) Turn the ignition switch OFF.
  • Page 162 1A-99 Engine General Information and Diagnosis: Step Action 1) Disconnect the ECM coupler. Refer to “ECM Removal Go to Step 3. Short circuit in the W/G and Installation in Section 1C (Page 1C-1)”. wire. 2) Check there is no continuity between the W/G wire “A” and ground.
  • Page 163 Engine General Information and Diagnosis: 1A-100 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 164 1A-101 Engine General Information and Diagnosis: 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-15)”. Step Action 1) Turn the ignition switch OFF. Go to Step 2.
  • Page 165 Engine General Information and Diagnosis: 1A-102 Step Action 1) Disconnect the ECM coupler. Refer to “ECM Removal Go to Step 3. Open circuit in the W/B and Installation in Section 1C (Page 1C-1)”. wire. 2) Insert the needle pointed probes to the lead wire coupler. 3) Check there is continuity between the W/B wire “A”...
  • Page 166 1A-103 Engine General Information and Diagnosis: Step Action 1) Connect the HO2 sensor coupler and ECM coupler. Replace the ECM with a Open circuit in the O/W Refer to “ECM Removal and Installation in Section 1C new one. Refer to “ECM wire.

  • Page 167: Dtc "C60" (P0480): Cooling Fan Relay Circuit Malfunction

    Engine General Information and Diagnosis: 1A-104 DTC “C60” (P0480): Cooling Fan Relay Circuit Malfunction B944H11104028 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 168 1A-105 Engine General Information and Diagnosis: Step Action 1) Turn the ignition switch OFF. Go to Step 2. Replace the cooling fan relay with a new one. 2) Remove the right rear frame cover. Refer to “Exterior Parts Removal and Installation in Section 9D (Page 9D- 4)”.
  • Page 169 Engine General Information and Diagnosis: 1A-106 Step Action 1) Turn the ignition switch ON. Go to Step 3. Open circuit in the O/Bl wire or O/W wire. 2) Measure the cooling fan relay switch side voltage between the O/Bl wire “A” and ground. Special tool (A): 09900–25008 (Multi circuit tester set) Tester knob indication...
  • Page 170 1A-107 Engine General Information and Diagnosis: Step Action 1) Remove the right frame body cover. Refer to “Exterior Go to Step 4. Replace the cooling fan Parts Removal and Installation in Section 9D (Page 9D- motor with a new one. 4)”.
  • Page 171 Engine General Information and Diagnosis: 1A-108 Step Action 1) Disconnect the ECM coupler. Refer to “ECM Removal Replace the ECM with a Open circuit in the G/W and Installation in Section 1C (Page 1C-1)”. new one. Refer to “ECM wire or B wire. Removal and 2) Insert the needle pointed probes to the lead wire coupler.
  • Page 172 1A-109 Engine General Information and Diagnosis: 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). I944H1110157-02 4) Click the “Operate”...

  • Page 173: Specifications

    Engine General Information and Diagnosis: 1A-110 Specifications Service Data B944H11107001 Injector Item Specification Note 11 – 13 Ω at 20 °C (68 °F) Injector resistance Fuel pump discharge amount 166 ml (5.6/5.8 US/lmp oz) and more/10 sec. Fuel pressure regulator operating Approx.

  • Page 174: Special Tool

    (Page 1A-60) / (Page 1A-98) / (Page 1A-61) / (Page 1A-99) (Page 1A-61) 09900–28630 09904–41010 TP Sensor test lead SUZUKI Diagnostic system (Page 1A-40) / (Page 1A-14) / (Page 1A-43) / (Page 1A-18) (Page 1A-46) / (Page 1A-77) / (Page 1A-80) /...
  • Page 175 Engine General Information and Diagnosis: 1A-112 09917–47011 09930–82720 Vacuum pump gauge set Mode selection switch (Page 1A-35) (Page 1A-4) / (Page 1A- 13) / (Page 1A-13) 99565–01010–019 CD-ROM Ver.19 (Page 1A-14) / (Page 1A-18)

  • Page 176: 1B-1 Emission Control Devices

    Fuel Injection System Description B944H11201001 SFV650 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 177: Crankcase Emission Control System Description

    Emission Control Devices: 1B-2 Crankcase Emission Control System Description B944H11201002 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 178: Noise Emission Control System Description

    1B-3 Emission Control Devices: Noise Emission Control System Description B944H11201004 TAMPERING WITH THE NOISE CONTROL SYSTEM PROHIBITED: Local 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 179: Heated Oxygen Sensor (Ho2S) Inspection

    Emission Control Devices: 1B-4 4) Remove the HO2 sensor (3). Crankcase Breather (PCV) Hose Inspection B944H11206006 Inspect the PCV hose (1) for wear and damage. If it is worn or damaged, replace the PCV hose with a new one. Refer to “Crankcase Breather (PCV) Hose Removal and Installation (Page 1B-4)”.

  • Page 180: Specifications

    1B-5 Emission Control Devices: Specifications Service Data B944H11207001 FI Sensors Item Specification Note Approx. 8 Ω at 23 °C (73 F°) HO2 sensor heater resistance Approx. 0.45 V and less at idle speed HO2 sensor output voltage 0.6 V and more at 6 000 r/min Tightening Torque Specifications B944H11207002 Tightening torque...

  • Page 181: Engine Electrical Devices

    Engine Electrical Devices: 1C-1 Engine Electrical Devices Engine Precautions Precautions for Engine Electrical Device B944H11300001 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 B944H11303001 Refer to “Electrical Components Location in Section 0A (Page 0A-7)”.

  • Page 182: Ckp Sensor Removal And Installation

    1C-2 Engine Electrical Devices: CKP Sensor Removal and Installation B944H11306003 Removal 1) Remove the generator cover. Refer to “Generator Removal and Installation in Section 1J (Page 1J-4)”. 2) Remove the CKP sensor (1) along with generator stator (2). I944H1130005-01 Installation Install the IAP sensors in the reverse order of removal.

  • Page 183: Iat Sensor Removal And Installation

    Engine Electrical Devices: 1C-3 6) Loosen the TP sensor mounting screw (1) using the Installation special tool and turn the TP sensor to bring the bar Install the IAT sensor in the reverse order of removal. to the correct position. IAT Sensor Inspection Special tool B944H11306026...

  • Page 184: Ect Sensor Inspection

    1C-4 Engine Electrical Devices: 4) Remove the ECT sensor (2). ECT Sensor Inspection B944H11306009 Refer to “DTC “C15” (P0115-H/L): ECT Sensor Circuit CAUTION Malfunction in Section 1A (Page 1A-47)”. Take special care when handling the ECT Inspect the ECT sensor in the following procedures: sensor.

  • Page 185: To Sensor Removal And Installation

    Engine Electrical Devices: 1C-5 TO Sensor Removal and Installation STP Sensor Adjustment B944H11306010 B944H11306013 Removal Adjust the STP sensor in the following procedures: 1) Remove seat (1). Refer to “Exterior Parts Removal 1) Remove the air cleaner box. Refer to “Air Cleaner and Installation in Section 9D (Page 9D-4)”.

  • Page 186: Stp Sensor Removal And Installation

    • Apply grease to the secondary throttle accurate reinstallation. shaft end “A”, if necessary. Special tool : Grease 99000–25010 (SUZUKI SUPER : 09930–11950 (Torx wrench) GREASE A or equivalent) Special tool : 09930–11950 (Torx wrench) Tightening torque STP sensor mounting screw: 3.5 N·m (0.35 kgf-...

  • Page 187: Stv Actuator Inspection

    Engine Electrical Devices: 1C-7 ISC Learned Value Reset and Opening Initialization B944H11306019 When removing or replacing the throttle body assembly, “B” set the ISC valve to the following procedures: 1) Set up the SDS tool. (Refer to the SDS operation manual for further details.) 2) Turn the ignition switch ON.

  • Page 188: Ho2 Sensor Inspection

    1C-8 Engine Electrical Devices: HO2 Sensor Inspection NOTE B944H11306020 Refer to “DTC “C44” (P0130 / P0135): HO2 Sensor The ISC leaned value of the ISC valve is set at (HO2S) Circuit Malfunction in Section 1A (Page 1A-97)”. preset position. HO2 Sensor Removal and Installation B944H11306021 Refer to “Heated Oxygen Sensor (HO2S) Removal and Installation in Section 1B (Page 1B-3)”.

  • Page 189: Tightening Torque Specifications

    For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List in Section 0C (Page 0C-7)”. Special Tools and Equipment Recommended Service Material B944H11308001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010 (Page 1C-6)

  • Page 190: Engine Mechanical

    ISC Valve System Description ISC Valve is Opened Position B944H11401001 SFV650 motorcycles are equipped with a ISC valve system of secondary throttle valve interlinked. In the throttle body is provided a bypass through which air volume is varied when the cutaway on the secondary throttle shaft is moved, causing the engine idle speed to be adjusted.

  • Page 191: Throttle Cable Routing Diagram

    Engine Mechanical: 1D-2 Throttle Cable Routing Diagram B944H11402002 “B” “ b ” “A” “C” “ b ” “ a ” “E” “F” “D” I944H1140330-02 1. Throttle cable No. 1 “B”: The adjustment of clutch cable play should be made on the adjuster on which the clutch cable cap is installed with 3-5 mm of threads left on the clutch lever adjuster.

  • Page 192: Diagnostic Information And Procedures

    1D-3 Engine Mechanical: Diagnostic Information and Procedures Engine Mechanical Symptom Diagnosis 5) Keep the throttle grip in the fully-opened position. B944H11404002 Refer to “Engine Symptom Diagnosis in Section 1A (Page 1A-9)”. Compression Pressure Check B944H11404001 The compression pressure reading of a cylinder is a good indicator of its internal condition.

  • Page 193: Repair Instructions

    Engine Mechanical: 1D-4 Repair Instructions Engine Components Removable with the Engine in Place B944H11406001 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 194 1D-5 Engine Mechanical: Engine Right Side Item Removal Inspection Installation Refer to “Exhaust Pipe / Refer to “Exhaust Pipe / Refer to “Exhaust System Muffler Removal and Muffler Removal and Exhaust pipe/Muffler Construction in Section 1K Installation in Section 1K Installation in Section 1K (Page 1K-2)”.

  • Page 195: Air Cleaner Element Removal And Installation

    Engine Mechanical: 1D-6 Air Cleaner Element Removal and Installation Air Cleaner Box Removal and Installation B944H11406034 B944H11406036 Removal Removal 1) Lift and support the fuel tank. Refer to “Fuel Tank 1) Lift and support the fuel tank. Refer to “Fuel Tank Removal and Installation in Section 1G (Page 1G- Removal and Installation in Section 1G (Page 1G- 7)”.

  • Page 196: Throttle Body Components

    1D-7 Engine Mechanical: 5) Disconnect the crankcase breather hose (5). Installation Install the air cleaner box in the reverse order of removal. Pay attention to the following points: • Fit the air cleaner outlet tube clamps properly. Refer to “Throttle Body Construction (Page 1D-8)”. •...

  • Page 197: Throttle Body Construction

    Engine Mechanical: 1D-8 Throttle Body Construction B944H11406041 Outlet tube clamp Outlet tube clamp “ a ” “ b” Intake pipe clamp “C” “ d ” “D” “ c ” “B” “C” “A” I944H1140342-02 1. Clean inlet sheet “B”: Face the tip of the front side clamp to upper. “b”: 15 –...
  • Page 198 1D-9 Engine Mechanical: “B” “A” “ a ” “ a ” I944H1140343-03 1. Clamp “A”: Yellow mark : 10 N⋅m (1.0 kgf-m, 7.0 lbf-ft) : The end of clamp should face forward. 2. HO2 sensor lead wire “B”: The end clamp should face backward. 3.

  • Page 199: Throttle Body Removal And Installation

    Engine Mechanical: 1D-10 Throttle Body Removal and Installation 7) Loosen the throttle body clamp screws (6). B944H11406042 Removal 1) Disconnect the battery (–) lead wire. Refer to “Battery Removal and Installation in Section 1J (Page 1J-12)”. 2) Lift and support the fuel tank. Refer to “Fuel Tank Removal and Installation in Section 1G (Page 1G- 7)”.

  • Page 200: Throttle Body Disassembly And Assembly

    1D-11 Engine Mechanical: Installation • Connect the fuel injector couplers. Install the throttle body in the reverse order of removal. NOTE Pay attention to the following points: Make sure that each coupler is installed in • Connect the throttle pulling cable (1) and throttle the correct position.
  • Page 201 Engine Mechanical: 1D-12 2) Remove the throttle link rod (3) and secondary 4) Remove the fuel injectors (6) from the fuel delivery throttle link rod (4). pipes (7). I944H1140270-02 I944H1140272-02 3) Remove the fuel delivery pipe assemblies (5). 5) Remove the TP sensor (8) and STP sensor (9) by removing each screw (10) and (11).
  • Page 202 1D-13 Engine Mechanical: : Grease 99000–25010 (SUZUKI SUPER CAUTION GREASE A or equivalent) Never remove the throttle valve (14) and Special tool secondary throttle valve (15). : 09930–11950 (Torx wrench) Tightening torque STP sensor mounting screw: 3.5 N·m (0.35 kgf- m, 2.5 lbf-ft)
  • Page 203 Engine Mechanical: 1D-14 Special tool • Wipe off the mounting surface on the delivery pipe (6) : 09930–11950 (Torx wrench) where the fuel injector (5) will be seated with a clean rag. Tightening torque • Install the fuel injector (5) by pushing it straight to the TP sensor mounting screw: 3.5 N·m (0.35 kgf-m, delivery pipe (6).

  • Page 204: Throttle Body Inspection And Cleaning

    1D-15 Engine Mechanical: • Tighten the fuel delivery pipe mounting screws (8) to Inspection the specified torque. Check following items for any defects or clogging. Replace the throttle body, if necessary. Tightening torque • O-ring Fuel delivery pipe mounting screw (b): 5 N·m (0.5 kgf-m, 3.5 lbf-ft) •...
  • Page 205 Engine Mechanical: 1D-16 8) Click “Active control”. 9) Click “ISC air volume control” (3). I944H1140345-02 10) Click “ON” button (4) to fix the ISC air volume between 2 cylinders. NOTE When making this synchronization, be sure that the water temperature is within 80 – 105 °C (176 – 221 °F) “A”.

  • Page 206: Isc Learned Value Reset

    1D-17 Engine Mechanical: 13) If the adjustment is not yet correct, remove each air 6) Click “Reset” button (2) to clear the ISC learned screw and clean them with a spray-type carburetor value. cleaner and blow dry with a compressed air. Also, clean the air screw passageways.

  • Page 207: Engine Assembly Removal

    Engine Mechanical: 1D-18 Engine Assembly Removal 8) Remove the rear frame body cover (4) and radiator B944H11406059 inlet hose (5). Before taking the engine out of the frame, wash the engine using a stream cleaner. Engine removal is sequentially explained in the following steps: 1) Drain engine oil.
  • Page 208 1D-19 Engine Mechanical: 12) Remove the front spark plug caps (11). 18) Disconnect the starter motor lead wire (17). I944H1140293-01 I944H1140297-01 13) Remove the rear spark plug caps (12). 19) Disconnect the oil pressure switch lead wire (18) and clamps (19). I944H1140294-01 14) Disconnect the clamp (13).
  • Page 209 Engine Mechanical: 1D-20 22) Disengage the gearshift link arm (23) by removing 26) Remove the engine sprocket inner cover (29). the bolt (24). NOTE Mark the gearshift shaft head at which the gearshift link arm slit is set for correct reinstallation.
  • Page 210 1D-21 Engine Mechanical: 34) Loosen the chain adjuster bolts (36) to provide 39) Disconnect the reservoir tank over flow hose (44). additional chain slack, left and right. I944H1140311-02 40) Support the engine with a proper jack (45). I944H1140307-02 35) Remove the washer (37) and engine sprocket (38). CAUTION Do not support at the oil filter (46).

  • Page 211: Engine Assembly Installation

    Engine Mechanical: 1D-22 42) Remove the front left engine mounting bolt (50). Engine Assembly Installation B944H11406061 43) Remove the front right engine mounting bolt (51) and Reinstall the engine in the reverse order of engine spacer (52). removal. Pay attention to the following points: Install the engine in the reverse order of engine removal.
  • Page 212 1D-23 Engine Mechanical: • Install the front right engine mounting bolt (6) and • Tighten all engine mounting bolts and nuts to the spacer (7) temporarily. specified torque, as shown in the following illustration. • Apply thread lock to the front left engine mounting bolt (8) and tighten it.
  • Page 213 Engine Mechanical: 1D-24 • When installing the clutch release arm, align the • Tighten the speed sensor rotor bolt (12) to the punch mark “A” of clutch release arm with slit “B” of specified torque. camshaft. Tightening torque • Tighten the clutch release arm bolt (9) to the specified Speed sensor rotor bolt (e): 25 N·m (2.5 kgf-m, torque.

  • Page 214: Engine Top Side Disassembly

    1D-25 Engine Mechanical: • Adjust the drive chain slack. Refer to “Drive Chain Engine Top Side Disassembly B944H11406006 Inspection and Adjustment in Section 0B (Page 0B- It is unnecessary to remove the engine assembly from 15)”. the frame when servicing the engine top side. •...
  • Page 215 Engine Mechanical: 1D-26 Intake Pipe / Water Union Front Camshaft Remove the intake pipe (1) and water unions (2). 1) Remove the valve timing inspection plug (1) and generator cover plug (2). I944H1140136-01 I944H1140139-01 Exhaust Pipe 2) Turn the crankshaft to bring the “I F” line “A” on Remove the rear exhaust pipe (1) and gasket (2).
  • Page 216 1D-27 Engine Mechanical: 4) Remove the front cam chain tension adjuster (6) and Front Cylinder Head gasket. 1) Remove the front cylinder head bolt (M6) (L40) (1). I944H1140142-01 I944H1140145-01 5) Remove the cam chain guide No. 2 (7). 2) Remove the front cylinder head (2) by removing the 6) Remove the camshaft journal holders (8).
  • Page 217 Engine Mechanical: 1D-28 Front Cylinder Front Piston 1) Remove the front cylinder (1) by removing the 1) Place a clean rag over the cylinder base so as not to cylinder nuts (2). drop the piston pin circlips into the crankcase. 2) Remove the piston pin circlip (1).
  • Page 218 1D-29 Engine Mechanical: Rear Camshaft 4) Remove the cam chain guide No. 2 (5). 1) Rotate the generator 360 degrees (1 turn) 5) Remove the camshaft journal holder (6). counterclockwise and align the “I F” line “A” on the generator rotor with the index mark “B” of the valve timing inspection hole.
  • Page 219 Engine Mechanical: 1D-30 2) Remove the rear cylinder head (2) by the removing 3) Remove the rear cylinder gasket (4) and dowel pins cylinder head bolts (M6) (L70) (3) and (M10) (4). (5). NOTE Loosen the cylinder head bolts little by little diagonally with the smaller sizes first.

  • Page 220: Engine Top Side Assembly

    “A” • Coat bond lightly to the mating surfaces at the parting line between the right and left crankcases as shown. : Sealant 99000–31110 (SUZUKI BOND No.1215 or equivalent) I944H1140163-01 • Place a clean rag over the cylinder base so as not to drop the piston pin circlips (1) into the crankcase.
  • Page 221 Engine Mechanical: 1D-32 • Apply molybdenum oil solution to the sliding surface NOTE of the pistons and cylinder walls. • The cylinders can be distinguished by the M/O: Molybdenum oil (MOLYBDENUM OIL embossed-letters, “FRONT” and “REAR”. SOLUTION) • When installing the cylinders, keep the cam chains taut.
  • Page 222 1D-33 Engine Mechanical: NOTE The front and rear cam chain guides are the same. I944H1140328-01 • Tighten the cylinder head bolts (M10) (4) to the specified two-step torque with a torque wrench sequentially and diagonally. I944H1140171-01 Tightening torque • Place the cylinder heads on the cylinders. Cylinder head bolt (M10) (Initial) (a): 25 N·m (2.5 kgf-m, 18.0 lbf-ft) NOTE...
  • Page 223 Engine Mechanical: 1D-34 • Tighten the cylinder nuts (7) to the specified torque. • Apply molybdenum oil solution to the camshaft journal holders. Tightening torque Cylinder nut (M6) (d): 10 N·m (1.0 kgf-m, 7.0 lbf-ft) M/O: Molybdenum oil (MOLYBDENUM OIL SOLUTION) NOTE Before installing the camshaft, check that the...
  • Page 224 1D-35 Engine Mechanical: • Engage the 16th roller pin “E” on the cam chain with the arrow marked “3” on the intake sprocket. “E” NOTE The cam chain should now be on all three sprockets. Be careful not to move the “D”...
  • Page 225 Engine Mechanical: 1D-36 • Fasten the camshaft journal holders evenly by • Install the cam chain tension adjuster (4) with “F-UP” tightening the crankshaft journal holder bolts mark “A” faced to the top of cylinder head. sequentially and diagonally. • Tighten the cam chain tension adjuster bolts (5) to the specified torque.
  • Page 226 1D-37 Engine Mechanical: • Install the cam chain guide (9) by tightening its bolts CAUTION (10). After installing the cam chain tension adjuster, check to be sure that the adjuster works properly by checking the slack of cam chain. I944H1140189-02 I944H1140188-01 16 15 14 13 12 11 10 9 8 7 6 5 16 15 14 13 12 11 10 9 8 7 6 5...
  • Page 227 Engine Mechanical: 1D-38 • Before replacing the camshafts on cylinder head, • Engage the 16th roller pin “E” on the cam chain with apply molybdenum oil solution to their journals and the marked “3” on the exhaust sprocket. cam faces. NOTE •...
  • Page 228 1D-39 Engine Mechanical: 16151413 1211 10 9 8 7 6 5 4 3 2 1 I944H1140194-01 • Install the dowel pins (1). “F” “G” I944H1140196-01 • Fasten the camshaft journal holders evenly by I944H1140195-01 • Apply molybdenum oil to the camshaft journal holders. tightening the camshaft journal holder bolts sequentially and diagonally.
  • Page 229 Engine Mechanical: 1D-40 Rear Cam Chain Tension Adjuster • The rear cam chain tension adjuster are identified by the embossed letters “R-UP”. • Retract the push rod (1) by pushing the stopper (2). I944H1140200-01 • Tighten the cam chain tension adjuster cap bolt (8) to the specified torque.
  • Page 230 Valve timing inspection plug (d): 23 N·m (2.3 kgf- Use new gaskets to prevent oil leakage. m, 16.5 lbf-ft) • Apply bond to the cam end caps of the gaskets as shown in the figure. : Sealant 99000–31140 (SUZUKI BOND No.1207B or equivalent) I944H1140336-02 I944H1140205-01...
  • Page 231 Engine Mechanical: 1D-42 • The cylinder head covers can be distinguished by Spark Plug radiator mounting hole “A”. Install the spark plugs. Refer to “Spark Plug Cap and Spark Plug Removal and Installation in Section 1H (Page 1H-5)”. Exhaust Pipe “A”...

  • Page 232: Valve Clearance Inspection And Adjustment

    Refer to “Water Hose Routing Diagram in Section 1F CAUTION (Page 1F-3)”. Use a new O-ring to prevent mixture air from soaking through the joint. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) NOTE • Face the “UP” mark “A” on the intake pipe to upper.

  • Page 233: Camshaft Inspection

    Engine Mechanical: 1D-44 Camshaft Inspection Camshaft Journal Wear B944H11406009 Inspect the camshaft journal wear in the following Refer to “Engine Top Side Disassembly (Page 1D-25)”. procedures: Refer to “Engine Top Side Assembly (Page 1D-31)”. 1) Determine whether or not each journal is worn down to the limit by measuring the oil clearance with the Camshaft Identification camshaft installed in place.

  • Page 234: Cam Chain Tension Adjuster Inspection

    1D-45 Engine Mechanical: 5) This measurement should be taken at the widest part of the compressed plastigauge. Camshaft journal oil clearance (IN. & EX.) Service limit: 0.150 mm (0.0059 in) I944H1140220-01 Camshaft Runout Measure the runout using the dial gauge. Replace the camshaft if the runout exceeds the limit.

  • Page 235: Cam Chain Guide Inspection

    Engine Mechanical: 1D-46 2) Unlock the ratchet (1), and move the push rod in Cam Chain Tensioner Inspection B944H11406015 place to see if it slides smoothly. If any stickiness is Inspect the cam chain tensioner in the following noted or ratchet mechanism is faulty, replace the procedures: cam chain tension adjuster assembly with a new 1) Remove the cam chain tensioner No.
  • Page 236 1D-47 Engine Mechanical: Valve / Valve spring 1) Remove the tappet (1) and shim (2) by fingers or magnetic hand. I944H1140228-01 5) Remove the valve spring retainer (4) and valve spring (5). 6) Pull out the valve (6) from the combustion chamber I944H1140226-01 2) When compressing the valve spring use a sleeve side.
  • Page 237 Engine Mechanical: 1D-48 Valve / Valve spring • Put on the valve spring retainer (3), and using the special tools, press down the spring, fit the cotter • Install the valve spring seat (1). halves to the stem end, and release the lifter to allow •...

  • Page 238: Cylinder Head Related Parts Inspection

    1D-49 Engine Mechanical: • Install the tappet shims and the tappets to their Cylinder Head Related Parts Inspection B944H11406050 original positions. Refer to “Cylinder Head Disassembly and Assembly (Page 1D-46)”. NOTE • Apply engine oil to the stem. Cylinder Head Distortion •...
  • Page 239 Engine Mechanical: 1D-50 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 240 1D-51 Engine Mechanical: NOTE If valve guides have to be removed for replacement after inspecting related parts, carry out the steps shown in valve guide replacement. Refer to “Valve Guide “a” Replacement (Page 1D-52)”. I649G1140246-02 Valve Seat Sealing Condition 1) Clean and assemble the cylinder head and valve components.

  • Page 241: Valve Guide Replacement

    Engine Mechanical: 1D-52 Valve Guide Replacement 5) Cool down the new valve guides in a freezer for B944H11406052 about one hour and heat the cylinder head to 100 – 1) Remove the cylinder head. Refer to “Engine Top 150 °C (212 – 302 °F) with a hot plate. Side Disassembly (Page 1D-25)”.

  • Page 242: Valve Seat Repair

    1D-53 Engine Mechanical: 8) After installing the valve guides, refinish their guiding CAUTION bores using the reamer. Be sure to clean and oil the • The valve seat contact area must be guides after reaming. inspected after each cut. Special tool •...

  • Page 243: Cylinder Inspection

    Engine Mechanical: 1D-54 Valve Spring Cylinder Inspection B944H11406020 The force of the coil spring keeps the valve seat tight. Refer to “Engine Top Side Disassembly (Page 1D-25)”. Weakened spring results in reduced engine power Refer to “Engine Top Side Assembly (Page 1D-31)”. output and often accounts for the chattering noise coming from the valve mechanism.

  • Page 244: Piston Ring Removal And Installation

    1D-55 Engine Mechanical: Piston Ring Removal and Installation B944H11406022 Removal “A” 1) Draw out the piston pin and remove the piston. Refer to “Engine Top Side Disassembly (Page 1D-25)”. 2) Carefully spread the ring opening with your thumbs and then push up the opposite side of the 1st ring to remove it.

  • Page 245: Piston And Piston Ring Inspection

    Engine Mechanical: 1D-56 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 246 1D-57 Engine Mechanical: Piston Pin / Pin Bore Measure the piston pin bore inside diameter using the small bore gauge. If measurement is out of specification, replace the piston. Special tool (A): 09900–20602 (Dial gauge (1/1000 mm, 1 mm)) (B): 09900–22403 (Small bore gauge (18 – 35 mm)) Piston pin bore I.D.

  • Page 247: Engine Bottom Side Disassembly

    Engine Mechanical: 1D-58 Engine Bottom Side Disassembly 2) Remove the gasket (4), dowel pins (5) and clutch B944H11406024 push rod (6). Refer to “Engine Assembly Removal (Page 1D-18)”. Refer to “Engine Top Side Disassembly (Page 1D-25)”. CAUTION Identify the position of each removed part. Organize the parts in their respective groups (e.g., intake, exhaust) so that they can be reinstalled in their original positions.
  • Page 248 1D-59 Engine Mechanical: 2) Remove the oil pump driven gear (2). 2) Remove the oil pipe (3). I944H1140006-01 I944H1140009-02 3) Remove the pin (3) and washer (4). Gearshift System NOTE NOTE Do not drop the pin (3) and washer (4) into Do not drop the each parts into the the crankcase.
  • Page 249 Engine Mechanical: 1D-60 Oil Filter Primary Drive Gear Remove the oil filter (1) with the special tool. 1) Hold the generator rotor with the special tool. Special tool Special tool (A): 09915–40620 (Oil filter wrench) (A): 09930–44530 (Rotor holder) I944H1140012-01 I944H1140015-01 2) Remove the primary drive gear bolt (1).
  • Page 250 1D-61 Engine Mechanical: Rear Cam Chain Starter Driven Gear Remove the key (1) and starter driven gear (2). 1) Remove the cam chain tensioner (1). NOTE Do not drop the washer (2) into the crankcase. I944H1140021-01 Front Cam Chain 1) Remove the cam chain tensioner (1). NOTE I944H1140018-01 Do not drop the washer (2) into the...
  • Page 251 Engine Mechanical: 1D-62 Gear Position Switch 1) Remove the driveshaft oil seal retainer (1) by removing its bolts (2). I944H1140027-02 I944H1140024-02 2) Remove the gear position switch (3) by removing its bolts (4). 3) Remove the O-ring (5). I944H1140028-02 4) Separate the crankcase into two parts, right and left with the special tool.
  • Page 252 1D-63 Engine Mechanical: 5) Remove the O-rings (5) and dowel pins (6). Crankshaft Remove the crankshaft (1). I944H1140030-02 I944H1140033-01 Oil Strainer Transmission / Gearshift 1) Remove the oil strainer plate (1). 1) Remove the transmission component. Refer to 2) Remove the oil strainer (2). “Transmission Removal and Installation in Section 5B (Page 5B-3)”.
  • Page 253 Engine Mechanical: 1D-64 Oil Gallery Jet (for Cylinder) Crankshaft Journal Bearing Remove the oil gallery jets (1) (for cylinder) from left and 1) Set the special tool as shown to remove the right crankcase halves. crankshaft journal bearings (1) with the special tool. NOTE Remove the crankshaft journal bearings in only one direction, from inside to outside of...

  • Page 254: Engine Bottom Side Assembly

    1D-65 Engine Mechanical: Oil Gallery Plug Transmission Oil Seal / Bearing Remove the transmission oil seals (1) and bearings (2) if 1) Remove the oil gallery plugs (M6) (1), (M8) (2) and necessary. Refer to “Transmission Removal and (M12) (3) from the left crankcase. Installation in Section 5B (Page 5B-3)”...
  • Page 255 Engine Mechanical: 1D-66 Oil Gallery Plug Crankcase Journal Bearing • Tighten each plug to the specified torque. • Set the specified crankshaft journal bearings (1) to the special tool. CAUTION CAUTION Use each new gasket. Before setting the bearing, apply molybdenum oil solution to the special tool Tightening torque and bearings.
  • Page 256 1D-67 Engine Mechanical: • Tighten the special tool bolts to the specified torque. Special tool “C” (A): 09913–60221 (Journal bearing installer and holder) “D” Tightening torque Special tool bolt (a): 23 N·m (2.3 kgf-m, 16.5 lbf-ft) I944H1140055-01 • Apply enough molybdenum oil solution to the special tool and the bearings and then set the special tool carefully.
  • Page 257 • Fit the new O-rings to each oil jets. Special tool CAUTION (A): 09913–70210 (Bearing installer set) Use the new O-rings to prevent oil leakage. • Apply grease to new O-ring. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent)
  • Page 258 • Apply grease to the lip of oil seal. • Apply a small quantity of thread lock to the bolts (7) and tighten them to the specified torque. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) : Thread lock cement 99000–32110...
  • Page 259 Engine Mechanical: 1D-70 • Install the crankshaft assembly into the left crankcase. Oil Strainer • Install the oil strainer (1). CAUTION CAUTION Never strike the crankshaft with a plastic hammer when inserting it into the crankcase. • The lip “A” of the oil strainer should be positioned downward.
  • Page 260 Replace the O-rings with new ones. NOTE : Grease 99000–25010 (SUZUKI SUPER Fit the clamp (3) to the bolt as shown. GREASE A or equivalent) • Install the O-rings (1) and dowel pins (2).
  • Page 261 CAUTION CAUTION Use the new O-ring to prevent oil leakage. Replace the O-ring with a new one. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) NOTE Align the gear position switch pin “A” with the gearshift cam hole “B”.
  • Page 262 1D-73 Engine Mechanical: Front Cam Chain Generator Rotor • Install the front cam chain (1). • Install the generator rotor (1). Refer to “Generator Removal and Installation in Section 1J (Page 1J-4)”. I944H1140082-01 • Install the cam chain tensioner (2), washer (3) and I944H1140085-01 cam chain tensioner bolt (4).
  • Page 263 Cam chain tensioner bolt (a): 10 N·m (1.0 kgf-m, 7.0 lbf-ft) NOTE Be careful not to apply bond to the hole of thread end. : Sealant 99000–31140 (SUZUKI BOND No.1207B or equivalent) Tightening torque Oil pressure switch (a): 14 N·m (1.4 kgf-m, 10.0 lbf-ft)
  • Page 264 1D-75 Engine Mechanical: • Tighten the union bolt (1) to the specified torque. • Tighten the gearshift cam stopper bolt (2) to the specified torque. Tightening torque Oil cooler union bolt (a): 70 N·m (7.0 kgf-m, 50.5 NOTE lbf-ft) Hook the return spring end “A” to the stopper (1).
  • Page 265 Engine Mechanical: 1D-76 • Apply thread lock to the gearshift cam stopper plate bolt (6) and tighten it to the specified torque. : Thread lock cement 99000–32110 (THREAD LOCK CEMENT SUPER 1322 or equivalent) Tightening torque Gearshift cam stopper plate bolt (b): 13 N·m (1.3 kgf-m, 9.5 lbf-ft) I944H1140101-01 “D”...
  • Page 266 1D-77 Engine Mechanical: • Tighten the oil pipe stopper screw (2) to the specified torque. NOTE Align the projection “A” of the oil pipe with the groove “B” of its stopper. Tightening torque Oil pipe stopper screw (a): 8 N·m (0.8 kgf-m, 6.0 lbf-ft) I944H1140107-02 “A”...
  • Page 267 Starter Motor • Install the dowel pins (1), gasket (2) and clutch push • Apply grease to the O-ring. rod (3). : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) CAUTION Use the new gasket to prevent oil leakage. CAUTION Replace the O-ring with a new one.

  • Page 268: Conrod Removal And Installation

    1D-79 Engine Mechanical: Conrod Removal and Installation NOTE B944H11406054 Inspect and select the conrod crank pin Removal bearing if necessary. Refer to “Conrod Crank 1) Remove the crankshaft assembly from the Pin Bearing Inspection and Selection crankcase. Refer to “Engine Bottom Side (Page 1D-81)”.

  • Page 269: Conrod / Crankshaft Inspection

    Engine Mechanical: 1D-80 4) Apply engine oil to the conrod cap bolts. Conrod / Crankshaft Inspection B944H11406055 Refer to “Conrod Removal and Installation (Page 1D- 79)”. Conrod Small End I.D. Measure the conrod small end inside diameter using the small bore gauge. If the conrod small end inside diameter exceeds the service limit, replace the conrod.

  • Page 270: Conrod Crank Pin Bearing Inspection And Selection

    1D-81 Engine Mechanical: Conrod big end width 3) Tighten the conrod cap bolts to the specified torque, Standard: 20.95 – 21.00 mm (0.825 – 0.827 in) in two stages. Refer to “Conrod Removal and Installation (Page 1D-79)”. Crank pin width “a” Standard: 42.17 –...
  • Page 271 Engine Mechanical: 1D-82 Selection 1) Check the corresponding conrod I.D. code numbers ([1] or [2]) “A”. “ b ” “A” “ a ” I944H1140126-01 “a”: 10.5 mm (0.413 in) “b”: 31.5 mm (1.240 in) I822H1140296-01 4) Select the specified bearings from the bearing Conrod I.D.

  • Page 272: Crankshaft Journal Bearing Inspection And Selection

    1D-83 Engine Mechanical: Crankshaft Journal Bearing Inspection and Selection Selection 1) Select the specified bearings from the crankcase B944H11406029 journal I.D. codes. The crankcase journal I.D. codes Refer to “Engine Bottom Side Disassembly (Page 1D- ((A), (B) or (C)) “A”, is stamped on the inside of each 58)”.

  • Page 273: Specifications

    Engine Mechanical: 1D-84 “B” I944H1140133-01 Specifications Service Data B944H11407001 Valve + Guide Unit: mm (in) Item Standard Limit 31 (1.22) — Valve diam. 25.5 (1.00) — 0.10 – 0.20 (0.004 – 0.008) — Valve clearance (when cold) 0.20 – 0.30 (0.008 – 0.012) —...
  • Page 274 1D-85 Engine Mechanical: Cylinder + Piston + Piston Ring Unit: mm (in) Item Standard Limit 1 300 – 1 700 kPa 1 100 kPa Compression pressure (13.0 – 17.0 kgf/cm , 185 – 242 psi) (11.0 kgf/cm , 156 psi) 200 kPa Compression pressure difference —...

  • Page 275: Tightening Torque Specifications

    Engine Mechanical: 1D-86 Tightening Torque Specifications B944H11407002 Tightening torque Fastening part Note N⋅m kgf-m lbf-ft STP sensor mounting screw 0.35 (Page 1D-13) TP sensor mounting screw 0.35 (Page 1D-14) Fuel delivery pipe mounting screw (Page 1D-15) Clutch release arm bolt (Page 1D-24) Engine sprocket nut 14.5...

  • Page 276: 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-7)”. Special Tools and Equipment Recommended Service Material B944H11408001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010 (Page 1D-13) /...
  • Page 277 Engine Mechanical: 1D-88 Special Tool B944H11408002 09900–06107 09900–20101 Snap ring remover (Open Vernier calipers (150 mm) type) (Page 1D-58) / (Page 1D-57) / (Page 1D-59) / (Page 1D-80) (Page 1D-76) / (Page 1D-77) 09900–20102 09900–20202 Vernier calipers (200 mm) Micrometer (25 – 50 mm) (Page 1D-50) / (Page 1D-44) / (Page 1D-54)
  • Page 278 1D-89 Engine Mechanical: 09900–22403 09913–60221 Small bore gauge (18 – 35 Journal bearing installer & holder (Page 1D-45) / (Page 1D-64) / (Page 1D-57) / (Page 1D-66) / (Page 1D-80) (Page 1D-67) / (Page 1D-67) 09913–70210 09915–40620 Bearing installer set (10 – Oil filter wrench (Page 1D-68) (Page 1D-60) /...
  • Page 279 Engine Mechanical: 1D-90 09920–13120 09930–11950 Crankshaft remover Torx wrench (5 mm) (Page 1D-62) (Page 1D-12) / (Page 1D-13) / (Page 1D-14) 09930–44530 Rotor holder (Page 1D-60) / (Page 1D-74)

  • Page 280: Engine Lubrication System

    1E-1 Engine Lubrication System: Engine Lubrication System Engine Precautions Precautions for Engine Oil B944H11500001 Refer to “Fuel and Oil Recommendation in Section 0A (Page 0A-3)”.

  • Page 281: Schematic And Routing Diagram

    Engine Lubrication System: 1E-2 Schematic and Routing Diagram Engine Lubrication System Chart Diagram B944H11502001 EXHAUST EXHAUST STARTER CLUTCH COMSHAFT JOURNAL COMSHAFT JOURNAL STARTER CAM FACES CAM FACES DRIVEN GEAR BUSHING EXHAUST CAM CHAIN CAM CHAIN CAMSHAFT LEFT SIDE RIGHT SIDE CAM FACES CAM FACES CRANKSHAFT...

  • Page 282: Engine Lubrication Circuit Diagram

    1E-3 Engine Lubrication System: Engine Lubrication Circuit Diagram B944H11502002 FRONT CYLINDER I944H1150042-03...
  • Page 283 Engine Lubrication System: 1E-4 REAR CYLINDER I944H1150043-02...

  • Page 284: Diagnostic Information And Procedures

    1E-5 Engine Lubrication System: Diagnostic Information and Procedures Engine Lubrication Symptom Diagnosis B944H11504001 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 285: Repair Instructions

    Engine Lubrication System: 1E-6 7) 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 (M12) (a): 21 N·m (2.1 kgf- m, 15.0 lbf-ft) I944H1150046-01 8) Check the engine oil level.

  • Page 286: Oil Strainer Inspection And Cleaning

    1E-7 Engine Lubrication System: 2) If the oil strainer is clogged with sediment or rust, clean the oil strainer using compressed air. “B” NOTE When the strainer is dirtied excessively, “A” replace the oil strainer with a new one. “C” I944H1150007-01 “A”...

  • Page 287: Oil Pressure Switch Removal And Installation

    When installing the oil cooler, fit the concave part “A” of the oil cooler onto the convex part I944H1150015-01 “B” of the crankcase. 4) Remove the oil pressure switch (1). : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) “A” “B” I944H1150016-01...

  • Page 288: Oil Pressure Switch Inspection

    2) Remove the oil jets (1). 1) Install the oil pressure switch (1), apply the bond to its thread part and tighten it to the specified torque. : Sealant 99000–31140 (SUZUKI BOND No.1207B or equivalent) Tightening torque Oil pressure switch (a): 14 N·m (1.4 kgf-m, 10.0...
  • Page 289 (2) (for cylinder) as shown. CAUTION Use new O-rings to prevent oil pressure leakage. • Apply grease to O-rings. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I944H1150023-02 5) Remove the clutch push rod oil seal (2). I944H1150022-02...
  • Page 290 • Apply grease to lip of clutch push rod oil seal. • Apply grease to the O-ring. : Grease 99000–25010 (SUZUKI SUPER CAUTION GREASE A or equivalent) Use a new O-ring to prevent oil leakage.

  • Page 291: Oil Jet / Oil Gallery Jet Inspection

    Engine Lubrication System: 1E-12 Oil Jet / Oil Gallery Jet Inspection 4) Remove the pin (3) and washer (4). B944H11506010 Refer to “Oil Jet Removal and Installation (Page 1E-9)”. Oil Jet Make sure that the oil jets are not clogged. If they are clogged, clean their oil passage using a wire of the proper size and compressed air.

  • Page 292: Oil Pump Inspection

    1E-13 Engine Lubrication System: • Install the oil pump driven gear (4) and snap ring (5). Oil Pipe Removal and Installation B944H11506014 Removal CAUTION 1) Drain engine oil. Refer to “Engine Oil and Filter Never reuse a snap ring. Replacement in Section 0B (Page 0B-10)”. 2) Remove the clutch.

  • Page 293: Oil Pipe Inspection

    Engine Lubrication System: 1E-14 • Tighten the oil pipe stopper screw (2) to the specified Oil Pipe Inspection B944H11506015 torque. Inspect the oil pipe the following procedures: NOTE 1) Remove the oil pipe. Refer to “Oil Pipe Removal and Installation (Page 1E-13)”. Align the projection “A”...

  • Page 294: Special Tools And Equipment

    1E-15 Engine Lubrication System: Special Tools and Equipment Recommended Service Material B944H11508001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010 (Page 1E-8) / (Page 1E- equivalent 9) / (Page 1E-10) / (Page 1E-11) /...

  • Page 295: Engine Cooling System

    Engine Cooling System: 1F-1 Engine Cooling System Engine Precautions Precautions for Engine Cooling System B944H11600001 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 296: Schematic And Routing Diagram

    1F-2 Engine Cooling System: Schematic and Routing Diagram Cooling Circuit Diagram B944H11602001 RESERVE TANK OIL COOLER RADIATOR NO. 1 CYLINDER HEAD NO. 1 CYLINDER WATER PUMP THERMOSTAT NO. 2 CYLINDER NO. 2 CYLINDER HEAD I944H1160001-02...

  • Page 297: Water Hose Routing Diagram

    Engine Cooling System: 1F-3 Water Hose Routing Diagram B944H11602002 “E” “J” “ e ” “I” “ d ” “ e ” “A” “ e ” “ e ” “E” “D” “F” “A” “B” “K” “B” “ a ” “ a ” “L”...

  • Page 298: Diagnostic Information And Procedures

    1F-4 Engine Cooling System: Diagnostic Information and Procedures Engine Cooling Symptom Diagnosis B944H11604001 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 299: Radiator Cap Inspection

    Engine Cooling System: 1F-5 Radiator Cap Inspection Radiator Cleaning B944H11606002 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 300 1F-6 Engine Cooling System: 4) Remove the radiator assembly (5) by removing the 7) Disconnect the coupler (9) and remove the cooling bolts (6). fan motor (10). I944H1160005-02 I944H1160009-02 8) Remove the radiator under rubber (11). I944H1160006-02 5) Remove the cooling fan assembly (7). I944H1160010-02 Installation Install the radiator/cooling fan motor in the reverse order...

  • Page 301: Water Hose Inspection

    Engine Cooling System: 1F-7 Water Hose Inspection Water Hose Removal and Installation B944H11606005 B944H11606006 Inspect the water hose in the following procedures: Removal 1) Remove the frame body covers, left and right. Refer 1) Drain engine coolant. Refer to “Cooling System to “Exterior Parts Removal and Installation in Section Inspection in Section 0B (Page 0B-12)”.

  • Page 302: Radiator Reservoir Tank Removal And Installation

    1F-8 Engine Cooling System: Radiator Reservoir Tank Removal and Installation Installation 1) Install the reservoir tank (1) as shown in the water B944H11606008 hose routing diagram. Refer to “Water Hose Routing Removal Diagram (Page 1F-3)”. 1) Lift and support the fuel tank. Refer to “Fuel Tank 2) Fill the reservoir tank to the upper level “A”.

  • Page 303: Cooling Fan Relay Inspection

    Engine Cooling System: 1F-9 NOTE “C” “A” • When making this test, it is not necessary to remove the cooling fan. • The voltmeter is for making sure that the battery applies 12 V to the motor. With the fan motor with electric motor fan running at full speed, the ammeter should be “D”...

  • Page 304: Thermostat Inspection

    1F-10 Engine Cooling System: Installation 4) Immerse the thermostat (1) in the water contained in Install the thermostat in the reverse order of removal, a beaker and note that the immersed thermostat is in pay attention to the following points: suspension.

  • Page 305: Water Pump Components

    Engine Cooling System: 1F-11 Water Pump Components B944H11606015 I944H1160056-01 1. Snap ring 6. Bearing 11. Water pump cover screw : Apply engine coolant. 2. Water pump driven gear 7. O-ring 12. Water drain bolt : Apply engine oil. 3. Pin 8.

  • Page 306: Water Pump Removal And Installation

    Before draining engine oil and engine coolant, inspect engine oil and coolant leakage between the water pump and : Grease 99000–25010 (SUZUKI SUPER crankcase. If engine oil is leaking, visually GREASE A or equivalent) inspect the oil seal and O-ring. If engine 2) Install the water pump assembly to the clutch cover.

  • Page 307: Water Pump Disassembly And Assembly

    Engine Cooling System: 1F-13 Water Pump Disassembly and Assembly 4) Remove the E-ring (5) and impeller (6). B944H11606018 Refer to “Water Pump Removal and Installation (Page 1F-12)”. Disassembly 1) Remove the O-rings (1). I944H1160031-02 5) Remove the mechanical seal ring (7) and rubber seal (8) from the impeller.
  • Page 308 I944H1160037-01 3) Apply a small quantity of the grease to the oil seal lip. I944H1160035-01 : Grease 99000–25010 (SUZUKI SUPER Assembly GREASE A or equivalent) 1) Apply engine oil to the bearings and install the bearings with the special tool.
  • Page 309 Use a new O-ring to prevent engine coolant leakage. I944H1160040-02 7) Apply grease to the impeller shaft. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I944H1160043-02 11) Fit the water pump cover and tighten the water pump cover screws (5) to the specified torque.

  • Page 310: Water Pump Related Parts Inspection

    1F-16 Engine Cooling System: 12) Install the new O-rings (6). Impeller Visually inspect the impeller and its shaft for damage. CAUTION Replace the impeller if necessary. Use the new O-rings to prevent engine coolant leakage. I944H1160047-01 Bearing Inspect the play of the bearings by hand while it is in the I944H1160044-04 water pump case.

  • Page 311: Specifications

    Engine Cooling System: 1F-17 Specifications Service Data B944H11607001 Thermostat + Radiator + Fan + Coolant Item Standard Note Thermostat valve opening Approx. 76.5 °C (170 °F) — temperature 8 mm (0.31 in) and over at 100 °C (212 °F) Thermostat valve lift —...

  • Page 312: Special Tools And Equipment

    1F-18 Engine Cooling System: Special Tools and Equipment Recommended Service Material B944H11608001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010 (Page 1F-12) / equivalent (Page 1F-14) / (Page 1F-15) NOTE Required service material is also described in the following.

  • Page 313: Fuel System

    Fuel System: 1G-1 Fuel System Engine Precautions Precautions for Fuel System B944H11700001 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. CAUTION •...

  • Page 314: General Description

    1G-2 Fuel System: General Description Fuel System Description B944H11701001 Fuel System The fuel delivery system consists of the fuel tank (1), fuel pump (2), fuel mesh filter (3), fuel feed hose (4), fuel delivery pipe (5), fuel injectors (8) and fuel pressure regulator (6). There is no fuel return hose. The fuel in the fuel tank (1) is pumped up by the fuel pump (2) and pressurized fuel flows into the injector (8) installed in the fuel delivery pipe (5).

  • Page 315: Schematic And Routing Diagram

    Fuel System: 1G-3 Schematic and Routing Diagram Fuel Tank Drain Hose and Breather Hose Routing Diagram B944H11702001 “D” “D” “ a ” “E” “C” “A” “B” I944H1170039-03 1. Fuel tank water drain hose “A”: Pass the reservoir tank overflow hose above the high-tension cord and below the water hose.

  • Page 316: Diagnostic Information And Procedures

    1G-4 Fuel System: Diagnostic Information and Procedures Fuel System Diagnosis B944H11704001 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 317: Repair Instructions

    Fuel System: 1G-5 Repair Instructions Fuel Pressure Inspection B944H11706001 WARNING • Keep away from fire or spark. • Spilled gasoline should be wiped off immediately. • Work in a well-ventilated area. Inspect the fuel pressure in the following procedures: 1) Lift and support the fuel tank. Refer to “Fuel Tank Removal and Installation (Page 1G-7)”.

  • Page 318: Fuel Pump Inspection

    1G-6 Fuel System: Fuel Pump Inspection 6) Connect a proper lead wire into the fuel pump lead B944H11706002 wire coupler (fuel pump side) and apply 12 V to the Turn the ignition switch ON and check that the fuel pump fuel pump (between (+) Y/R wire and (–) B/W wire) operates for a few seconds.

  • Page 319: Fuel Hose Inspection

    Fuel System: 1G-7 3) First, check for insulation with the tester between terminals “A” and “B”. Next, check for continuity between “A” and “B” with 12 V voltage applied, positive (+) to terminal “C” and negative (–) to terminal “D”. If continuity does not exist, replace the relay with a new one.
  • Page 320 1G-8 Fuel System: 3) Lift and support the fuel tank with the fuel tank prop 8) Remove the fuel tank bracket (8). stay (2). CAUTION Lifting up the fuel tank by force can damage the hoses and wiring harness. I944H1170014-03 9) Remove the fuel tank stay and its rubber cushion (9).

  • Page 321: Fuel Pump Components

    Fuel System: 1G-9 Fuel Pump Components B944H11706011 I944H1170041-02 1. Fuel level gauge 5. Fuel pump : 10 N⋅m (1.0 kgf-m, 7.0 lbf-ft) 2. Fuel pressure regulator assembly 6. Fuel mesh filter : Apply engine oil. 3. O-ring 7. Fuel feed hose : Apply grease.

  • Page 322: Fuel Pump Assembly Removal And Installation

    1) Install the new O-ring (1) and apply grease to it. CAUTION To O-ring must be replaced with a new one to prevent fuel leakage. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I944H1170020-01 2) Remove the fuel level gauge (2) by removing the screws (3).
  • Page 323 Fuel System: 1G-11 3) Remove the fuel pressure regulator assembly (4). 9) Remove the joint (10). CAUTION Never remove the fuel pressure regulator (11) from the holder. I944H1170022-02 4) Disconnect the fuel pump (+) lead wire (5). 5) Remove the fuel pump assembly (6). I944H1170026-02 Assembly Refer to “Fuel Mesh Filter Inspection and Cleaning...

  • Page 324: Fuel Mesh Filter Inspection And Cleaning

    1G-12 Fuel System: Fuel Injector / Fuel Delivery Pipe Removal and Installation B944H11706015 Removal 1) Remove the air cleaner box. Refer to “Air Cleaner Box Removal and Installation in Section 1D (Page 1D-6)”. 2) Place a rug under the fuel feed hoses (1) and disconnect the fuel feed hoses (1) from the fuel delivery pipes.
  • Page 325 Fuel System: 1G-13 Installation • Install the fuel delivery pipes along with the fuel Install the fuel injector / fuel delivery pipe in the reverse injectors to the throttle body assembly. order of removal. Pay attention to the following points: CAUTION NOTE •...

  • Page 326: Fuel Injector Inspection And Cleaning

    1G-14 Fuel System: Fuel Injector Inspection and Cleaning B944H11706016 Inspect the fuel injector in the following procedures: 1) Remove the fuel injector. Refer to “Fuel Injector / Fuel Delivery Pipe Removal and Installation (Page 1G-12)”. 2) Check the fuel injector filter for evidence of dirt and contamination.

  • Page 327: Special Tools And Equipment

    Fuel System: 1G-15 Special Tools and Equipment Recommended Service Material B944H11708001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010 (Page 1G-10) equivalent NOTE Required service material is also described in the following. “Fuel Pump Components (Page 1G-9)”...

  • Page 328: Ignition System

    1H-1 Ignition System: Ignition System Engine Schematic and Routing Diagram Ignition System Diagram B944H11802001 Refer to “Wire Color Symbols in Section 0A (Page 0A-5)”. Engine stop switch Side-stand relay sensor #1 (F) Fuse Ignition switch #2 (R) Fuse Battery sensor sensor switch I944H1180001-05...

  • Page 329: Component Location

    Ignition System: 1H-2 Component Location Ignition System Components Location B944H11803003 Refer to “Electrical Components Location in Section 0A (Page 0A-7)”. Diagnostic Information and Procedures Ignition System Symptom Diagnosis B944H11804001 Condition Possible cause Correction / Reference Item Spark plug not sparking Damaged spark plugs.

  • Page 330: No Spark Or Poor Spark

    1H-3 Ignition System: No Spark or Poor Spark B944H11804002 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 331: Repair Instructions

    Ignition System: 1H-4 Repair Instructions Ignition Coil Construction B944H11806011 “C” “B” “A” “ a ” “B” I944H1180002-10 1. Ignition coil #1 8. FC mark 2. Ignition coil #2 9. RC mark 3. Regulator/rectifier 10. Clamp: Contact the clamp with the horn bracket on its left side and clamp down the high-tension cord at the marked position.

  • Page 332: Spark Plug Cap And Spark Plug Removal And Installation

    1H-5 Ignition System: Spark Plug Cap and Spark Plug Removal and 2) Lift and support the fuel tank. Refer to “Fuel Tank Removal and Installation in Section 1G (Page 1G- Installation 7)”. B944H11806012 WARNING 3) Disconnect the spark plug caps (1). The hot engine can burn you.

  • Page 333: Ignition Coil Removal And Installation

    Ignition System: 1H-6 Ignition Coil Removal and Installation Ignition Coil and Plug Cap Inspection B944H11806009 B944H11806003 Refer to “Electrical Components Location in Section 0A Ignition Coil Primary Peak Voltage (Page 0A-7)”. 1) Disconnect the all spark plug caps. Refer to “Spark Plug Cap and Spark Plug Removal and Installation Removal (Page 1H-5)”.
  • Page 334 1H-7 Ignition System: Tester knob indication: Voltage ( a) Shift the transmission to the neutral, turn the ignition switch ON and grasp the clutch lever. ((+) Probe) ((–) Probe) Ignition coil #1 O/W lead wire W/Bl lead wire b) Press the starter button and allow the engine to Black lead wire crank for a few seconds, and then measure the Ignition coil #2...

  • Page 335: Ckp Sensor Inspection

    Ignition System: 1H-8 CKP Sensor Inspection 4) Measure the CKP sensor peak voltage in the B944H11806004 following procedures: Refer to “Electrical Components Location in Section 0A a) Shift the transmission to the neutral, turn the (Page 0A-7)”. 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 336: Ckp Sensor Removal And Installation

    1H-9 Ignition System: 3) Measure the resistance between the lead wires and 3) Inspect the engine stop switch for continuity with a ground. If the resistance is not within the standard tester. range, replace the CKP sensor with a new one. If any abnormality is found, replace the right Refer to “CKP Sensor Removal and Installation handlebar switch assembly with a new one.

  • Page 337: Specifications

    Ignition System: 1H-10 3) Remove the ignition switch mounting bolts (3) with Installation the special tools and remove the ignition switch (4). Install the ignition switch in the reverse order of removal. Pay attention to the following point: Special tool •...

  • Page 338: Special Tools And Equipment

    1H-11 Ignition System: Special Tools and Equipment Recommended Service Material B944H11808001 Material SUZUKI recommended product or Specification Note Thread lock cement THREAD LOCK CEMENT SUPER P/No.: 99000–32110 (Page 1H-10) 1322 or equivalent Special Tool B944H11808002 09900–25008 09900–25009 Multi circuit tester set...

  • Page 339: Starting System

    Starting System: 1I-1 Starting System Engine Schematic and Routing Diagram Starting System Diagram B944H11902001 Refer to “Wire Color Symbols in Section 0A (Page 0A-5)”. Ignition Engine stop switch switch Fuse (30 A) Fuse Gear (10 A) position Starter Starter switch button motor Starter relay...

  • Page 340: Starter Motor Will Not Run

    1I-2 Starting System: Starter Motor will not Run B944H11904002 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 341: Repair Instructions

    Starting System: 1I-3 Repair Instructions Starter Motor Components B944H11906001 I944H1190002-02 1. O-ring 7. Brush holder : 10 N⋅m (1.0 kgf-m, 7.0 lbf-ft) 2. Housing end (Inside) 8. Housing end assembly (Outside) : Apply grease to sliding surface. 3. O-ring 9. O-ring : Apply moly past to sliding surface.

  • Page 342: Starter Motor Removal And Installation

    Starter motor lead wire mounting nut (b): 6 N·m ( 0.6 kgf-m, 4.5 lbf-ft) I944H1190004-02 Installation 1) Apply grease to the starter motor O-ring. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) CAUTION Replace the O-ring with a new one. I944H1190007-01...
  • Page 343 • Apply a small quantity of moly paste to the armature Reassemble the starter motor in the reverse order of shaft. removal. Pay attention to the following points: : Moly paste 99000–25140 (SUZUKI MOLY PASTE or equivalent) CAUTION Replace the O-ring and square-ring with new ones to prevent oil leakage and moisture.

  • Page 344: Starter Motor Related Parts Inspection

    1I-6 Starting System: Starter Motor Related Parts Inspection B944H11906004 Refer to “Starter Motor Disassembly and Assembly (Page 1I-4)”. Carbon Brush Inspect the carbon brushes for abnormal wear, cracks or smoothness in the brush holder. If either carbon brush is defective, replace the brush holder set with a new one.

  • Page 345: Starter Relay Inspection

    Starting System: 1I-7 5) Disconnect the starter motor lead wire (3) and battery (+) lead wire (4). + To battery To starter motor NOTE Be sure to disconnect the starter motor lead wire (3) first, then disconnect the battery (+) lead wire (4).

  • Page 346: Turn Signal / Side-Stand Relay Removal And Installation

    1I-8 Starting System: Turn Signal / Side-stand Relay Removal and 4) Measure the voltage between Green and Black/ White lead wires. Installation B944H11906007 Special tool Refer to “Electrical Components Location in Section 0A : 09900–25008 (Multi-circuit tester set) (Page 0A-7)”. Tester knob indication Removal Diode test (...
  • Page 347 Starting System: 1I-9 Side-stand relay 1) Remove the turn signal/side-stand relay. Refer to “Turn Signal / Side-stand Relay Removal and “A” Installation (Page 1I-8)”. “B” 2) Check the insulation between “D” and “E” terminals using the multi-circuit tester. “C” 3) Apply 12 V to terminals “D” and “C” ((+) to “D” and (– “C”...

  • Page 348: Starter Clutch Removal And Installation

    1I-10 Starting System: 3) Check the continuity between Blue and Black/White Starter Clutch Removal and Installation B944H11906009 lead wires with the transmission in “NEUTRAL”. Removal Special tool 1) Drain engine oil. : 09900–25008 (Multi-circuit tester set) 2) Remove the generator rotor (1). Refer to “Generator Tester knob indication Removal and Installation in Section 1J (Page 1J-4)”.
  • Page 349 Starting System: 1I-11 6) Remove the one way clutch (7) from the guide (8). • Install the guide (3) to the generator rotor with the arrow mark “B” faced upward. “B” I944H1190027-02 I944H1190030-03 Installation • Apply THREAD LOCK to the bolts (4), and then Install the starter clutch in the reverse order of removal.

  • Page 350: Starter Clutch Inspection

    1I-12 Starting System: • Apply engine oil to the bushing of the starter driven Starter Driven Gear Bushing gear. Inspect the starter driven gear bushing for wear or damage. If necessary, replace it with a new one. I944H1190033-02 • Fit the key (5) in the key slot on the crankshaft. I944H1190036-01 Starter Idle Gear Inspect the starter idle gear for wear or damage.

  • Page 351: Specifications

    Starting System: 1I-13 3) Inspect the starter button for continuity with a tester. 4) After finishing the starter button inspection, reinstall If any abnormality is found, replace the right handle the right frame body cover. Refer to “Exterior Parts switch assembly with a new one. Refer to Removal and Installation in Section 9D (Page 9D- “Handlebars Removal and Installation in Section 6B 4)”.

  • Page 352: Special Tools And Equipment

    Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010 (Page 1I-4) / (Page 1I-5) equivalent Moly paste SUZUKI MOLY PASTE or equivalent P/No.: 99000–25140 (Page 1I-5) Thread lock cement THREAD LOCK CEMENT SUPER P/No.: 99000–32030 (Page 1I-11) 1303 or equivalent NOTE Required service material is also described in the following.

  • Page 353: Charging System

    Charging System: 1J-1 Charging System Engine Schematic and Routing Diagram Charging System Diagram B944H11A02001 Regulator/Rectifier Ignition switch Generator I944H11A0001-01 Component Location Charging System Components Location B944H11A03001 Refer to “Electrical Components Location in Section 0A (Page 0A-7)”. Diagnostic Information and Procedures Charging System Symptom Diagnosis B944H11A04001 Condition...

  • Page 354: Battery Runs Down Quickly

    1J-2 Charging System: Condition Possible cause Correction / Reference Item Battery overcharges Faulty regulator/rectifier. Replace. Faulty battery. Replace. Poor contact of generator lead wire Repair. coupler. “Sulfation”, acidic white Cracked battery case. Replace the battery. powdery substance or Battery has been left in a run-down Replace the battery.

  • Page 355: Repair Instructions

    Charging System: 1J-3 Repair Instructions Battery Current Leakage Inspection Regulated Voltage Inspection B944H11A06001 B944H11A06002 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-4)”.

  • Page 356: Generator Inspection

    1J-4 Charging System: Generator Inspection No-load Performance B944H11A06003 1) Disconnect the generator coupler (1). Generator Coil Resistance 1) Disconnect the generator coupler (1). I944H11A0003-01 2) Start the engine and keep it running at 5 000 r/min. I944H11A0002-01 3) Using the multi-circuit tester, measure the voltage 2) Measure the resistance between the three lead between three lead wires.
  • Page 357 Charging System: 1J-5 2) Remove the engine sprocket cover (1). Refer to 6) Remove the speed sensor (8) and generator cover “Engine Sprocket Removal and Installation in (9). Section 3A (Page 3A-2)”. I944H11A0007-02 7) Remove the gasket (10) and dowel pins (11). I944H11A0004-01 3) Remove the clutch release arm (2), spring (3) and washer (4).
  • Page 358 1J-6 Charging System: 9) Remove the generator rotor (12) with the special tool. NOTE Remove the starter clutch if necessary. Refer to “Starter Clutch Removal and Installation in Section 1I (Page 1I-10)”. Special tool (A): 09930–44530 (Rotor holder) (B): 09930–30450 (Rotor remover bolt) I944H11A0012-02 •...
  • Page 359 I944H11A0016-02 • Apply a small quantity of grease to the clutch push rod cap and clutch push rod. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I944H11A0019-03 • Route the wiring harness. Refer to “Wiring Harness Routing Diagram in Section 9A (Page 9A-5)”.

  • Page 360: Regulator / Rectifier Construction

    1J-8 Charging System: • Tighten the clutch release arm bolt (11) to the specified torque. Tightening torque “D” Clutch release arm bolt (e): 9 N·m (0.9 kgf-m, 6.5 lbf-ft) “C” I944H11A0020-03 • Check the clutch cable play. Refer to “Clutch System Inspection in Section 0B (Page 0B-14)”.

  • Page 361: Regulator / Rectifier Removal And Installation

    Charging System: 1J-9 3) Measure the voltage between the terminals using the multi-circuit tester as indicated in the following table. If the voltage is not within the specified value, replace the regulator/rectifier with a new one. NOTE If the tester reads 1.4 V and below when the tester probes are not connected, replace its battery. Special tool : 09900–25008 (Multi-circuit tester set) Tester knob indication...

  • Page 362: Battery Components

    1J-10 Charging System: Battery Components 2) Remove the caps (2) from the electrolyte container. B944H11A06007 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 363 Charging System: 1J-11 NOTE Correct If no air bubbles are coming up from a filler port, tap the bottom of the electrolyte container two or three times. Never remove the container from the battery. Incorrect I310G11A0024-01 6) After confirming that the electrolyte has entered the battery completely, remove the electrolyte containers from the battery.

  • Page 364: Battery Removal And Installation

    1J-12 Charging System: 2) Measure the battery voltage using the multi-circuit Battery Removal and Installation B944H11A06009 tester. Refer to “Electrical Components Location in Section 0A If the voltage reading is less than the 12 V (DC), (Page 0A-7)”. recharge the battery with a battery charger. Recharging time Removal 1.2 A for 5 to 10 hours or 5 A for 1 hour...

  • Page 365: Battery Visual Inspection

    Charging System: 1J-13 Battery Visual Inspection If any signs of cracking or electrolyte leakage from B944H11A06010 the sides of the battery have occurred, replace the Inspect the battery in the following procedures: battery with a new one. 1) Remove the seat. Refer to “Exterior Parts Removal If the battery terminals are found to be coated with and Installation in Section 9D (Page 9D-4)”.

  • Page 366: Special Tools And Equipment

    1J-14 Charging System: Special Tools and Equipment Recommended Service Material B944H11A08001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010 (Page 1J-7) equivalent Molybdenum oil MOLYBDENUM OIL SOLUTION — (Page 1J-7) Special Tool B944H11A08002 09900–25008...

  • Page 367: Exhaust System

    Exhaust System: 1K-1 Exhaust System Engine Precautions Precautions for Exhaust System B944H11B00001 WARNING To avoid the danger 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 pipe and muffler have enough clearance from the rubber parts and plastic parts to avoid melting.

  • Page 368: Repair Instructions

    1K-2 Exhaust System: Repair Instructions Exhaust System Construction B944H11B06003 I944H11B0030-05 1. Front exhaust pipe 6. Gasket : 5.5 N⋅m (0.55 kgf-m, 4.0 lbf-ft) 2. Rear exhaust pipe 7. HO2 sensor : Apply muffler seal. 3. Muffler 8. Chamber support bracket : Do not reuse.

  • Page 369: Exhaust Pipe / Muffler Removal And Installation

    Exhaust System: 1K-3 Exhaust Pipe / Muffler Removal and Installation 5) Disconnect the HO2 sensor coupler (4) and clamps B944H11B06004 (5). Removal 1) Loosen the muffler connecting bolt (1). 2) Remove the muffler (2) by removing the mounting bolt and nut (3). NOTE Support the muffler to prevent it from falling.
  • Page 370 1K-4 Exhaust System: 8) Remove the front exhaust pipe (8) with the exhaust 11) Remove the rear exhaust pipe (12). assembly (9) by removing the bolts (10). NOTE Support the exhaust assembly to prevent it from falling. I944H11B0010-02 12) Remove the gasket (13). I944H11B0008-03 I944H11B0011-02 13) Remove the front exhaust pipe (14).
  • Page 371 Exhaust System: 1K-5 14) Remove the HO2 sensor (15). • Tighten the muffler cover bolts (1) to the specified torque. CAUTION Tightening torque • Be careful not to expose the HO2 sensor to Muffler cover bolt (a): 5.5 N·m (0.55 kgf-m, 4.0 lbf- an excessive shock.
  • Page 372 1K-6 Exhaust System: • Install the new exhaust connectors (3). • Tighten the exhaust mounting bolts (7) and front exhaust pipe bolts (8) to the specified torque. NOTE Tightening torque When installing new exhaust connectors, Exhaust pipe bolt (c): 23 N·m (2.3 kgf-m, 16.5 lbf- remove the old sealer from the exhaust pipe and exhaust.

  • Page 373: Exhaust System Inspection

    Exhaust System: 1K-7 • Tighten the muffler mounting nut (12) and muffler connecting bolt (13) to the specified torque. Tightening torque Muffler mounting nut (g): 25 N·m (2.5 kgf-m, 18.0 lbf-ft) Muffler connecting bolt (h): 23 N·m (2.3 kgf-m, 16.5 lbf-ft) I944H11B0026-03 •...

  • Page 374: Specifications

    For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List in Section 0C (Page 0C-7)”. Special Tools and Equipment Recommended Service Material B944H11B08001 Material SUZUKI recommended product or Specification Note Muffler seal MUFFLER SEAL LOCTITE 5920 — (Page 1K-6) /...
  • Page 375 Table of Contents 2- i Section 2 Suspension CONTENTS Precautions ..........2-1 Swingarm Related Parts Inspection ....2C-9 Swingarm Bearing Removal and Installation ..2C-10 Precautions............. 2-1 Specifications .............2C-12 Precautions for Suspension ........2-1 Service Data............2C-12 Suspension General Diagnosis....2A-1 Tightening Torque Specifications......2C-12 Special Tools and Equipment ......2C-13 Diagnostic Information and Procedures....2A-1 Recommended Service Material .......2C-13...

  • Page 376: Precautions

    2-1 Precautions: Precautions Suspension Precautions Precautions for Suspension B944H12000001 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 377: Suspension General Diagnosis

    Suspension General Diagnosis: 2A-1 Suspension General Diagnosis Suspension Diagnostic Information and Procedures Suspension and Wheel Symptom Diagnosis B944H12104001 Condition Possible cause Correction / Reference Item Wobbly front wheel Distorted wheel rim. Replace. Worn front wheel bearings. Replace. Defective or incorrect tire. Replace.

  • Page 378: Front Suspension

    2B-1 Front Suspension: Front Suspension Suspension Repair Instructions Front Fork Components B944H12206001 I944H1220031-01 1. Dust seal 11. Ring 21. Spring 2. Oil seal stopper ring 12. Cylinder 22. Front axle pinch bolt 3. Oil seal 13. Rebound spring 23. Outer tube (right) 4.

  • Page 379: Front Fork Removal And Installation

    Front Suspension: 2B-2 Front Fork Removal and Installation 7) Loosen the front fork lower clamp bolts (7) and B944H12206002 remove the front fork. NOTE NOTE The right and left front forks are installed symmetrically and therefore the removal Hold the front fork by the hand to prevent procedure for one side is the same as that for sliding out of the steering stem.

  • Page 380: Front Fork Inspection

    2B-3 Front Suspension: 5) Tighten the front fork lower clamp bolts (1). WARNING Tightening torque After remounting the brake caliper, pump the Front fork lower clamp bolt (b): 23 N·m (2.3 kgf- brake lever until the pistons push the pads m, 16.5 lbf-ft) correctly.

  • Page 381: Front Fork Disassembly And Assembly

    Front Suspension: 2B-4 Front Fork Disassembly and Assembly 6) Remove the dust seal (6). B944H12206003 Refer to “Front Fork Removal and Installation (Page 2B- 2)”. Disassembly 1) Remove the front fork protector (1). I944H1220009-01 7) Remove the oil seal stopper ring (7). I944H1220007-01 2) Remove the front fork cap bolt (2).
  • Page 382 Do not damage the Teflon coated surface of the inner tube’s slide metal when mounting it. • Apply fork oil to the inner tube slide metal. I717H1220017-01 : Fork Oil 99000–99001–SS8 (SUZUKI FORK 12) Remove the following parts. OIL SS-08 or equivalent) • Oil lock piece (12) •...
  • Page 383 2B-6 • Apply fork oil to the outer slide metal and oil seal lip. • Install the oil seal stopper ring (5). : Fork Oil 99000–99001–SS8 (SUZUKI FORK CAUTION OIL SS-08 or equivalent) Make sure that the oil seal stopper ring is fitted securely.
  • Page 384 • Pour specified front fork oil up to the top level of the CAUTION inner tube. Use a new cylinder bolt gasket (5) to prevent oil leakage. : Fork Oil 99000–99001–SS8 (SUZUKI FORK OIL SS-08 or equivalent) NOTE Capacity (Each leg) 517 ml (17.5/18.2 US/lmp oz) Check the front fork for smoothness by stroking it after installing the cylinder.
  • Page 385 When adjusting the fork oil level, remove the Use a new O-ring (1) to prevent oil leakage. fork spring and compress the inner tube fully. : Fork Oil 99000–99044–10G (SUZUKI FORK Special tool OIL G-10 or equivalent) (A): 09943–74111 (Fork oil level gauge) •...

  • Page 386: Front Fork Parts Inspection

    — outer tube fully compressed) Front fork spring adjuster 3th groove from top — Item Specification Note Front fork oil type SUZUKI TORK OIL SS-08 or equivalent fork oil Front fork oil capacity (Each leg) 517 ml (17.5/18.2 US/lmp oz)

  • Page 387: Tightening Torque Specifications

    For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List in Section 0C (Page 0C-7)”. Special Tools and Equipment Recommended Service Material B944H12208001 Material SUZUKI recommended product or Specification Note Fork Oil SUZUKI FORK OIL SS-08 or P/No.: 99000–99001– (Page 2B-5) /...

  • Page 388: Rear Suspension

    2C-1 Rear Suspension: Rear Suspension Suspension Repair Instructions Rear Suspension Components B944H12306001 I944H1230046-01 1. Rear shock absorber 7. Cushion rod mounting nut : 50 N⋅m (5.0 kgf-m, 36.0 lbf-ft) 2. Rear shock absorber mounting nut 8. Spacer : 78 N⋅m (7.8 kgf-m, 56.5 lbf-ft) 3.

  • Page 389: Rear Suspension Assembly Construction

    Rear Suspension: 2C-2 Rear Suspension Assembly Construction B944H12306002 Left Right “ a ” “ b ” “a ” “ c ” I944H1230001-01 1. Rear shock absorber mounting nut (Upper) 6. Swingarm pivot nut “a”: 1.0 mm (0.04 in) 2. Rear shock absorber mounting bolt (Lower) : 50 N⋅m (5.0 kgf-m 36.0 lbf-ft) “b”: 0.25 mm (0.01 in) 3.

  • Page 390: Rear Shock Absorber Removal And Installation

    2C-3 Rear Suspension: Rear Shock Absorber Removal and Installation Installation B944H12306003 Install the rear shock absorber in the reverse order of removal. Pay attention to the following points: Removal • Temporary install the rear shock absorber and 1) Support the motorcycle with a jack to be no load for cushion rod.

  • Page 391: Rear Suspension Adjustment

    Rear Suspension: 2C-4 2) Inspect the rear shock absorber for damage and oil leakage, and absorber bushing for wear and damage. If any defect is found, replace the rear shock absorber with a new one. CAUTION Do not attempt to disassemble the rear shock absorber.

  • Page 392: Cushion Lever / Cushion Rod Removal And Installation

    2C-5 Rear Suspension: 2) Wrap rear shock absorber (1) with a vinyl bag (2) 3) Remove the front footrest bracket mounting bolts (2). and fix it on a vise as shown. 3) Drill a 2 – 3 mm (0.08 – 0.12 in) hole at the marked drill center using a drilling machine and let out gas while taking care not to get the vinyl bag entangled with the drill bit.

  • Page 393: Cushion Lever Inspection

    Rear Suspension: 2C-6 Installation • Tighten the gearshift link arm mounting bolt. Install the cushion lever in the reverse order of removal. Pay attention to the following point: • Temporarily the cushion rod mounting nut. NOTE The stamped marks “A” on the cushion rod should be face out side.

  • Page 394: Cushion Lever Bearing Removal And Installation

    2C-7 Rear Suspension: Cushion Lever Inspect the cushion lever for damage. If any defect is found, replace the cushion lever with a new one. I944H1230022-01 Installation I944H1230019-01 CAUTION Cushion Rod The removed bearings must be replaced with Inspect the cushion rods for damage and bend. If any new ones.

  • Page 395: Swingarm Removal And Installation

    Rear Suspension: 2C-8 2) Apply grease to the bearings. 5) Remove the rear shock absorber (4). Refer to “Rear Shock Absorber Removal and Installation (Page 2C- : Grease 99000–25010 (SUZUKI SUPER 3)”. GREASE A or equivalent) I944H1230028-01 I944H1230025-01 6) Remove the swingarm by removing the swingarm 3) Install the cushion lever.

  • Page 396: Swingarm Related Parts Inspection

    2C-9 Rear Suspension: Installation Swingarm Related Parts Inspection B944H12306012 Install the swingarm in the reverse order of removal. Pay Refer to “Swingarm Removal and Installation (Page 2C- attention to the following points: 8)”. • Install the washer and swingarm pivot nut (1). •...

  • Page 397: Swingarm Bearing Removal And Installation

    Rear Suspension: 2C-10 Swingarm 3) Draw out the swingarm pivot bearings (1) using the Inspect the swingarm for damage. If any defect is found, special tool. replace the swingarm with a new one. Special tool (A): 09921–20240 (Bearing remover set) I944H1230038-01 I944H1230039-01 Swingarm Pivot Shaft...
  • Page 398 (A): 09924–84510 (Bearing installer set) (B): 09941–34513 (Steering race installer) “A” I944H1230043-01 4) Apply grease to the bearings. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I944H1230042-01 2) Install the bearing and center spacer. I944H1230044-01 5) Install the swingarm. Refer to “Swingarm Removal and Installation (Page 2C-8)”.

  • Page 399: Specifications

    Rear Suspension: 2C-12 Specifications Service Data B944H12307001 Suspension Unit: mm (in) Item Standard Limit Rear shock absorber spring 3rd position — adjuster Rear wheel travel 130 (5.1) — Swingarm pivot shaft runout — 0.3 (0.01) Tightening Torque Specifications B944H12307002 Tightening torque Fastening part Note N⋅m...

  • Page 400: Special Tools And Equipment

    2C-13 Rear Suspension: Special Tools and Equipment Recommended Service Material B944H12308001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010 (Page 2C-8) / (Page 2C- equivalent NOTE Required service material is also described in the following.

  • Page 401: Wheels And Tires

    Wheels and Tires: 2D-1 Wheels and Tires Suspension Precautions Precautions for Wheel and Tire B944H12400001 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 402: Repair Instructions

    2D-2 Wheels and Tires: Repair Instructions Front Wheel Components B944H12406001 I944H1240052-02 1. Front axle 6. Dust seal : 65 N⋅m (6.5 kgf-m, 47.0 lbf-ft) 2. Brake disc bolt 7. Collar : 23 N⋅m (2.3 kgf-m, 16.5 lbf-ft) 3. Brake disc 8.

  • Page 403: Front Wheel Assembly Construction

    Wheels and Tires: 2D-3 Front Wheel Assembly Construction B944H12406002 Left Right “a ” I944H1240042-03 1. Brake disc bolt “a”: Clearance : Apply grease. 2. Brake caliper mounting bolt : 23 N⋅m (2.3 kgf-m, 16.5 lbf-ft) : Apply thread lock to thread part. 3.

  • Page 404: Front Wheel Assembly Removal And Installation

    2D-4 Wheels and Tires: Front Wheel Assembly Removal and Installation 6) Remove the collar (3). B944H12406003 Removal 1) Remove the brake calipers. Refer to “Front Brake Caliper Removal and Installation in Section 4B (Page 4B-3)”. 2) Loosen axle pinch bolt (1) on the right front fork leg. 3) Loosen the front axle (2) by using the special tool.
  • Page 405 Wheels and Tires: 2D-5 3) Tighten the brake caliper mounting bolts (2) to the 5) Tighten axle pinch bolt (4) to the specified torque. specified torque. NOTE WARNING Before toughening the front axle pinch bolt, move the front fork up and down four or five After remounting the brake calipers, pump times.

  • Page 406: Front Wheel Related Parts Inspection

    2D-6 Wheels and Tires: Front Wheel Related Parts Inspection Wheel B944H12406004 Inspect the wheel in the following procedures: Refer to “Front Wheel Assembly Removal and 1) Remove the brake pads. Refer to “Front Brake Pad Installation (Page 2D-4)” Replacement in Section 4B (Page 4B-2)”. 2) Make sure that the wheel rim runout checked as Tire shown does not exceed the service limit.

  • Page 407: Front Wheel Dust Seal / Bearing Removal And Installation

    CAUTION The removed dust seals and bearings must be replaced with new ones. 1) Apply grease to the wheel bearings. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I944H1240017-01 3) Remove the bearings (2) on both sides using the special tool.
  • Page 408 (B): 09941–34513 (Steering race installer) CAUTION The sealed cover of the bearing must face outside. I944H1240022-01 4) Apply grease to the lip of dust seals. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I944H1240020-01 Left Right I944H1240023-01 5) Install the front wheel assembly. Refer to “Front Wheel Assembly Removal and Installation (Page 2D-4)”.

  • Page 409: Rear Wheel Components

    Wheels and Tires: 2D-9 Rear Wheel Components B944H12406006 I944H1240054-01 1. Rear axle 9. Bearing 17. Rear axle nut 2. Brake disc 10. Sprocket 18. Brake disc bolt 3. Spacer 11. Collar : 23 N⋅m (2.3 kgf-m, 16.5 lbf-ft) 4. Dust seal 12.

  • Page 410: Rear Wheel Assembly Construction

    2D-10 Wheels and Tires: Rear Wheel Assembly Construction B944H12406007 Left Right “ a ” I944H1240046-03 1. Rear sprocket nut “a”: Clearance : Apply grease. 2. Rear axle nut : 60 N⋅m (0.6 kgf-m, 16.5 lbf-ft) : Apply thread lock to thread part. 3.

  • Page 411: Rear Wheel Assembly Removal And Installation

    Wheels and Tires: 2D-11 Rear Wheel Assembly Removal and Installation 6) Remove the spacer (3) and collar (4). B944H12406008 Removal 1) Loosen the rear 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 412: Rear Wheel Related Parts Inspection

    2D-12 Wheels and Tires: Rear Wheel Related Parts Inspection Wheel Axle B944H12406009 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 413: Rear Wheel Dust Seal / Bearing Removal And Installation

    The removed dust seals and bearings must be replaced with new ones. 1) Apply grease to the wheel bearings. I944H1240032-02 3) Remove the dust seal (2). : Grease 99000–25010 (SUZUKI SUPER Special tool GREASE A or equivalent) (A): 09913–50121 (Oil seal remover) I649G1240019-02...
  • Page 414 (B): 09913–70210 (Bearing installer set) CAUTION The sealed cover of the bearing must face outside. I944H1240038-01 4) Apply grease to the dust seal lip. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I944H1240036-01 Left Right I944H1240039-01 5) Install the rear sprocket mounting drum assembly (2).

  • Page 415: Tire Removal And Installation

    Wheels and Tires: 2D-15 Tire Removal and Installation B944H12406011 Removal The most critical factor of a tubeless tire is the seal between the wheel rim and the tire bead. For this reason, it is recommended to use a tire changer that can satisfy this sealing requirement and can make the operation efficient as well as functional.

  • Page 416: Wheel / Tire / Air Valve Inspection And Cleaning

    2D-16 Wheels and Tires: 6) If the distance between the rim line and wheel rim Tire varies, this indicates that the bead is not properly Tire must be checked for the following points: seated. If this is the case, deflate the tire completely •...

  • Page 417: Air Valve Removal And Installation

    Wheels and Tires: 2D-17 Air Valve Removal and Installation B944H12406013 Removal 1) Remove the wheel assembly. Refer to “Front Wheel Assembly Removal and Installation (Page 2D-4)” and “Rear Wheel Assembly Removal and Installation (Page 2D-11)”. 2) Remove the tire. Refer to “Tire Removal and Installation (Page 2D-15)”.

  • Page 418: Specifications

    2D-18 Wheels and Tires: Specifications Service Data B944H12407001 Wheel Unit: mm (in) Item Standard Limit Axial — 2.0 (0.08) Wheel rim runout Radial — 2.0 (0.08) Front — 0.25 (0.010) Wheel axle runout Rear — 0.25 (0.010) Front 17 M/C x MT3.50 —...

  • Page 419: Special Tools And Equipment

    Wheels and Tires: 2D-19 Special Tools and Equipment Recommended Service Material B944H12408001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010 (Page 2D-7) / (Page 2D- equivalent 8) / (Page 2D-13) / (Page 2D-14) NOTE Required service material is also described in the following.
  • Page 420 2D-20 Wheels and Tires:...
  • Page 421 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 422: 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 DID520VM2. Suzuki recommends to use this standard drive chain as a replacement.

  • Page 423: 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 B944H13104001 Condition Possible cause Correction / Reference Item Noisy Drive Chain Worn sprocket.

  • Page 424: Engine Sprocket Removal And Installation

    3A-2 Drive Chain / Drive Train / Drive Shaft: Engine Sprocket Removal and Installation 6) Remove the speed sensor rotor (9) by removing its B944H13106002 bolt (10) while depressing the rear brake pedal. Removal 1) Remove the gearshift link arm (1) by removing its bolt (2).
  • Page 425 Drive Chain / Drive Train / Drive Shaft: 3A-3 13) Remove the washer (15) and engine sprocket (16). • Bend the lock washer (3). I944H1310006-02 I944H1310031-01 • Tighten the speed sensor rotor bolt (5) to the specified Installation torque. Install the engine sprocket in the reverse order of Tightening torque removal.

  • Page 426: Rear Sprocket / Rear Sprocket Mounting Drum Removal And Installation

    • Adjust the drive chain slack. Refer to “Drive Chain the following points: Inspection and Adjustment in Section 0B (Page 0B- • Apply grease to the retainer (1). 15)”. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) Rear Sprocket / Rear Sprocket Mounting Drum Removal and Installation B944H13106003...

  • Page 427: Drive Chain Related Parts Inspection

    I944H1310016-03 • Apply grease to the contacting surface between the rear wheel hub and the mounting drum. I944H1310018-02 : Grease 99000–25010 (SUZUKI SUPER Bearing GREASE A or equivalent) Inspect the play of the sprocket mounting drum bearings by hand while they are in the wheel and drum. Rotate the inner race by hand to inspect for abnormal noise and smooth rotation.

  • Page 428: Sprocket Mounting Drum Dust Seal / Bearing Removal And Installation

    (Page 2D-13)”. 3) Remove the retainer (1). I944H1310022-01 Installation CAUTION The removed dust seal and bearing must be replaced with new ones. 1) Apply grease to the bearing before installing. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I944H1310020-01 I649G1310020-02...

  • Page 429: Drive Chain Replacement

    : 09922–22711 (Drive chain cutting and joining tool) I944H1310023-02 3) Apply grease to the dust seal lip. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I649G1310023-02 Drive Chain Cutting 1) Set up the special tool as shown in the illustration.
  • Page 430 3A-8 Drive Chain / Drive Train / Drive Shaft: NOTE 6) Remove the joint pin (9) of the other side of joint plate. The tip of pin remover (7) should be positioned inside “a” approximately 5 mm CAUTION (0.2 in) from the end face of pressure bolt [A] Never reuse joint pins, O-rings and plates.
  • Page 431 Drive Chain / Drive Train / Drive Shaft: 3A-9 2) Apply grease to the joint pins (8), O-rings (9) and 7) Turn in the pressure bolt [A] (6) further using the bar plates (10). (7) to press the joint plate over the joint pins. CAUTION Replace the joint pins (8), O-rings (9) and plates (10) with new ones.

  • Page 432: Specifications

    3A-10 Drive Chain / Drive Train / Drive Shaft: 2) Stake the joint pin by turning (approximately 7/8 turn) the pressure bolt [A] (3) with the bar (6) until the pin end diameter becomes the specified dimension. CAUTION • After joining of the chain has been completed, check to make sure that the link is smooth and no abnormal condition is found.

  • Page 433: Special Tools And Equipment

    Drive Chain / Drive Train / Drive Shaft: 3A-11 Special Tools and Equipment Recommended Service Material B944H13108001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010 (Page 3A-4) / (Page 3A- equivalent 5) /...
  • Page 434 3A-12 Drive Chain / Drive Train / Drive Shaft:...
  • Page 435 Table of Contents 4- i Section 4 Brake CONTENTS Precautions ..........4-1 Special Tools and Equipment ......4A-17 Recommended Service Material .......4A-17 Precautions............. 4-1 Special Tool ............4A-17 Precautions for Brake System ......4-1 Brake Fluid Information ......... 4-1 Front Brakes ..........4B-1 Brake Control System and Diagnosis ...

  • Page 436: Precautions

    4-1 Precautions: Precautions Brake Precautions Precautions for Brake System B944H14000001 Refer to “General Precautions in Section 00 (Page 00-1)”. Brake Fluid Information B944H14000002 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 437: 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 B944H14102001 “A” “ b ” “ a ” “ c ” “ a ” “ a ” “d” “ b ” “...

  • Page 438: Rear Brake Hose Routing Diagram

    4A-2 Brake Control System and Diagnosis: Rear Brake Hose Routing Diagram B944H14102003 “ a ” “C” “A” “ b ” “B” “C” “ c ” I944H1410042-01 1. Stopper “C”: Insert the reservoir hose firmly. : After the brake hose union has contacted the stopper, tighten the union bolt. 2.

  • Page 439: Diagnostic Information And Procedures

    Brake Control System and Diagnosis: 4A-3 Diagnostic Information and Procedures Brake Symptom Diagnosis B944H14104001 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 440: Repair Instructions

    4A-4 Brake Control System and Diagnosis: Repair Instructions Brake Pedal Height Inspection and Adjustment 2) Disconnect the rear brake light switch lead coupler B944H14106001 (1). Refer to “Brake System Inspection in Section 0B (Page 0B-16)”. Front Brake Light Switch Inspection B944H14106002 Inspect the front brake light switch in the following procedures:...

  • Page 441: Brake Fluid Level Check

    Brake Control System and Diagnosis: 4A-5 Brake Fluid Level Check 3) Squeeze and release the brake lever several times B944H14106005 in rapid succession and squeeze the lever fully Refer to “Brake System Inspection in Section 0B without releasing it. (Page 0B-16)”. Brake Hose Inspection B944H14106006 Refer to “Brake System Inspection in Section 0B...

  • Page 442: Brake Fluid Replacement

    4A-6 Brake Control System and Diagnosis: 8) Fill the reservoir with brake fluid to the upper line of • Fill the reservoir with brake fluid to the upper mark of the reservoir. the reservoir. I944H1410006-01 I944H1410009-01 9) Install the reservoir cap. •...
  • Page 443 Brake Control System and Diagnosis: 4A-7 5) Connect a clear hose to the air bleeder valve and 8) Fill the reservoir with brake fluid to the upper line insert the other end of the hose into a receptacle. reservoir. I944H1410011-01 I944H1410014-01 6) Loosen the air bleeder valve and pump the brake 9) Install the reservoir cap.

  • Page 444: Brake Hose Removal And Installation

    4A-8 Brake Control System and Diagnosis: 7) Loosen the air bleeder valve and pump the brake 9) Fill the reservoir with brake fluid to the upper mark pedal until the old brake fluid flows out of the brake reservoir. system. I944H1410019-01 10) Install the reservoir cap.

  • Page 445: Front Brake Master Cylinder Components

    Brake Control System and Diagnosis: 4A-9 Front Brake Master Cylinder Components B944H14106010 I944H1410043-02 1. Reservoir cap 7. Brake lever : 10 N⋅m (1.0 kgf-m, 7.0 lbf-ft) 2. Plate 8. Brake lever pivot bolt : 6 N⋅m (0.6 kgf-m, 4.5 lbf-ft) 3.

  • Page 446: Front Brake Master Cylinder Assembly Removal And Installation

    4A-10 Brake Control System and Diagnosis: Front Brake Master Cylinder Assembly Removal Tightening torque Master cylinder holder bolt (Upper and Lower) and Installation (a): 10 N·m (1.0 kgf-m, 7.0 lbf-ft) B944H14106011 Removal 1) Remove the right rear view mirror (1). 2) Drain brake fluid.

  • Page 447: Front Brake Master Cylinder / Brake Lever Disassembly And Assembly

    Brake Control System and Diagnosis: 4A-11 Front Brake Master Cylinder / Brake Lever 4) Remove the following parts from the master cylinder. Disassembly and Assembly • Piston (8) B944H14106020 • Secondary cup (9) Refer to “Front Brake Master Cylinder Assembly Removal and Installation (Page 4A-10)”.

  • Page 448: Front Brake Master Cylinder Parts Inspection

    • Apply grease to the brake lever pivot bolt. • Apply grease to the contact point between piston and brake lever. I649G1410027-02 : Grease 99000–25100 (SUZUKI Silicone Piston Grease or equivalent) Inspect the piston surface for any scratches or other damage.

  • Page 449: Rear Brake Master Cylinder Components

    Brake Control System and Diagnosis: 4A-13 Rear Brake Master Cylinder Components B944H14106014 I944H1410045-01 1. Reservoir tank 5. Brake hose connector 9. Rear brake master cylinder Apply silicone grease. mounting bolt 2. Diaphragm 6. Piston/Cup set : 23 N⋅m (2.3 kgf-m, 16.5 lbf-ft) : Apply brake fluid.

  • Page 450: 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 of removal. Pay attention to the following points: B944H14106019 Removal CAUTION 1) Remove the right rear frame cover. Refer to “Exterior The seal washers should be replaced with the Parts Removal and Installation in Section 9D new ones to prevent fluid leakage.

  • Page 451: Rear Brake Master Cylinder Disassembly And Assembly

    Brake Control System and Diagnosis: 4A-15 Rear Brake Master Cylinder Disassembly and Assembly B944H14106016 Disassembly 1) Disconnect the reservoir hose (1). I944H1410032-02 6) Remove the push rod (8), piston/cup set (9) and spring (10). I944H1410041-01 2) Remove the lock-nut (2). 3) Remove the snap ring (3).

  • Page 452: Rear Brake Master Cylinder Parts Inspection

    Rear Brake Master Cylinder Parts Inspection • Apply grease to the push rod end. B944H14106017 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 453: Tightening Torque Specifications

    For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List in Section 0C (Page 0C-7)”. Special Tools and Equipment Recommended Service Material B944H14108001 Material SUZUKI recommended product or Specification Note Brake fluid DOT 4 — (Page 4A-6) /...

  • Page 454: Front Brakes

    4B-1 Front Brakes: Front Brakes Brake Repair Instructions Front Brake Components B944H14206001 I944H1420027-02 1. Caliper holder 8. Pad mounting pin : 23 N⋅m (2.3 kgf-m, 16.5 lbf-ft) 2. Front brake caliper mounting bolt 9. Air bleeder bolt : Apply silicone grease to sliding surface. 3.

  • Page 455: Front Brake Pad Inspection

    Front Brakes: 4B-2 Front Brake Pad Inspection 3) Remove the brake pads (4) by removing the pad B944H14206002 mounting pin (5). The extent of brake pads wear can be checked by observing the grooved limit line “A” on the pads. When the wear exceeds the grooved limit line, replace the pads with new ones.

  • Page 456: Front Brake Caliper Removal And Installation

    4B-3 Front Brakes: 8) Install the clip (7) securely. 3) Remove the brake caliper by removing the caliper mounting bolts (2). I944H1420005-03 9) Remount the caliper. I944H1420008-01 10) Tighten the caliper mounting bolts (8) to the specified Installation torque. Install the brake caliper in the reverse order of removal. Tightening torque Pay attention to the following points: Front brake caliper mounting bolt (a): 39 N·m (...

  • Page 457: Front Brake Caliper Disassembly And Assembly

    Front Brakes: 4B-4 Front Brake Caliper Disassembly and Assembly 5) Remove the pad guide (5). B944H14206005 Refer to “Front Brake Caliper Removal and Installation (Page 4B-3)”. NOTE The right and left calipers are installed symmetrically and therefore the disassembly procedure for one side is the same as that for the other side.
  • Page 458 I944H1420016-01 • Apply grease to the caliper holder sliding pins. : Grease 99000–25100 (SUZUKI SILICONE GREASE or equivalent) I649G1420012-02 • Apply the brake fluid to piston seals (1) and dust seals (2).

  • Page 459: Front Brake Caliper Parts Inspection

    Front Brakes: 4B-6 Front Brake Caliper Parts Inspection Brake Pad Spring and Pad Guide B944H14206006 Inspect the brake pad spring and pad guide for damage Refer to “Front Brake Caliper Disassembly and and excessive bend. If any defects are found, replace Assembly (Page 4B-4)”.

  • Page 460: Front Brake Disc Inspection

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

  • Page 461: Specifications

    Front Brakes: 4B-8 Specifications Service Data B944H14207001 Brake Unit: mm (in) Item Standard Limit Brake disc thickness Front 4.3 – 4.7 (0.17 – 0.19) 4.0 (0.16) Brake disc runout — 0.30 (0.012) Brake caliper cylinder bore Front 27.000 – 27.076 (1.0630 – 1.0660) —...

  • Page 462: Special Tools And Equipment

    4B-9 Front Brakes: Special Tools and Equipment Recommended Service Material B944H14208001 Material SUZUKI recommended product or Specification Note Brake fluid DOT 4 — (Page 4B-5) / (Page 4B- Grease SUZUKI SILICONE GREASE or P/No.: 99000–25100 (Page 4B-5) equivalent Thread lock cement Thread Lock Cement Super 1360 or P/No.: 99000–32130...

  • Page 463: Rear Brakes

    Rear Brakes: 4C-1 Rear Brakes Brake Repair Instructions Rear Brake Components B944H14306001 I944H1430026-01 1. Rear caliper bracket 6. Rear brake disc : 23 N⋅m (2.3 kgf-m, 16.5 lbf-ft) 2. Piston : 6 N⋅m (0.6 kgf-m, 4.5 lbf-ft) : Apply silicone grease to sliding surface. 3.

  • Page 464: Rear Brake Pad Replacement

    4C-2 Rear Brakes: Rear Brake Pad Replacement 5) Clean up the caliper especially around the caliper B944H14306003 piston. 1) Remove the plug (1). 6) Install the new brake pads. CAUTION Replace the brake pads as a set, otherwise braking performance will be adversely affected.

  • Page 465: Rear Brake Caliper Removal And Installation

    Rear Brakes: 4C-3 8) Install the plug (6) to the specified torque. 3) Remove the brake pads. Refer to “Rear Brake Pad Replacement (Page 4C-2)”. Tightening torque 4) Pivot the caliper up and remove the caliper from the Pad pin plug (c): 2.5 N·m (0.25 kgf-m, 1.8 lbf-ft) caliper bracket.

  • Page 466: Rear Brake Caliper Disassembly And Assembly

    4C-4 Rear Brakes: • After setting the brake hose union to the stopper, 2) Remove the pad spring (3). tighten the union bolt (4) to the specified torque. CAUTION The seal washers should be replaced with the new ones to prevent fluid leakage. Tightening torque Brake hose union bolt (b): 23 N·m (2.3 kgf-m, 16.5 lbf-ft)

  • Page 467: Rear Brake Caliper Parts Inspection

    I944H1430017-01 I649G1420013-02 • Apply grease to the inside of the boot. Assembly : Grease 99000–25100 (SUZUKI Silicone Assemble the caliper in the reverse order of Grease or equivalent) disassembly. Pay attention to the following points: • Wash the caliper bore and piston with specified brake •...

  • Page 468: Rear Brake Disc Removal And Installation

    4C-6 Rear Brakes: Brake Caliper Piston Brake Pad Spring Inspect the brake caliper piston surface for any Inspect the brake pad springs for damage and excessive scratches or other damage. If any damage is found, bend. If any defects are found, replace them with new replace the piston with a new one.

  • Page 469: Rear Brake Disc Inspection

    Rear Brakes: 4C-7 Installation Brake Disc Runout Install the rear brake disc in the reverse order of 1) Remove the rear brake caliper. Refer to “Rear Brake removal. Pay attention to the following points: Caliper Removal and Installation (Page 4C-3)”. •...

  • Page 470: Specifications

    4C-8 Rear Brakes: Specifications Service Data B944H14307001 Brake Unit: mm (in) Item Standard Limit Brake disc thickness Rear 4.8 – 5.2 (0.19 – 0.20) 4.5 (0.18) Brake disc runout — 0.30 (0.012) Brake caliper cylinder bore Rear 38.180 – 38.230 (1.5031 – 1.5051) —...

  • Page 471: Special Tools And Equipment

    Rear Brakes: 4C-9 Special Tools and Equipment Recommended Service Material B944H14308001 Material SUZUKI recommended product or Specification Note Brake fluid DOT 4 — (Page 4C-5) / (Page 4C- Grease SUZUKI Silicone Grease or P/No.: 99000–25100 (Page 4C-5) / (Page 4C-...
  • Page 472 4C-10 Rear Brakes:...
  • Page 473 Table of Contents 5- i Section 5 Transmission / Transaxle CONTENTS Precautions ..........5-1 Tightening Torque Specifications......5B-18 Special Tools and Equipment ......5B-19 Precautions............. 5-1 Recommended Service Material .......5B-19 Precautions for Transmission / Transaxle..... 5-1 Special Tool ............5B-19 Manual Transmission......5B-1 Clutch ............5C-1 Diagnostic Information and Procedures....5B-1 Precautions............5C-1 Manual Transmission Symptom Diagnosis ..

  • Page 474: Precautions

    5-1 Precautions: Precautions Transmission / Transaxle Precautions Precautions for Transmission / Transaxle B944H15000001 Refer to “General Precautions in Section 00 (Page 00-1)”.

  • Page 475: Manual Transmission

    Manual Transmission: 5B-1 Manual Transmission Transmission / Transaxle Diagnostic Information and Procedures Manual Transmission Symptom Diagnosis B944H15204001 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 476: Repair Instructions

    5B-2 Manual Transmission: Repair Instructions Transmission Components B944H15206001 I944H1520071-03 1. 1st driven gear 10. 3rd/4th drive gear 19. Gear position switch 2. 5th driven gear 11. 6th drive gear 20. Gearshift cam stopper plate 3. 4th driven gear 12. 2nd drive gear : Apply oil.

  • Page 477: Transmission Removal And Installation

    Manual Transmission: 5B-3 Transmission Removal and Installation Driveshaft Assembly / Countershaft Assembly B944H15206002 1) Remove the driveshaft assembly (1) and Removal countershaft assembly (2). 1) Remove the engine assembly from the frame. Refer to “Engine Assembly Removal in Section 1D (Page 1D-18)”.
  • Page 478 5B-4 Manual Transmission: Gearshift cam / Gearshift fork • Install the crankshaft (6). • Install the gearshift forks into the gearshifting grooves NOTE in the correct position and direction. • Be sure to set the crankshaft in the proper direction. •...

  • Page 479: Transmission Construction

    Manual Transmission: 5B-5 Transmission Construction B944H15206004 I944H1520011-04 1. Counter shaft 2. Drive shaft 3. Snap ring : Assemble snap ring with sharp edge side out.

  • Page 480: Countershaft Gear / Driveshaft Gear Disassembly And Assembly

    5B-6 Manual Transmission: Countershaft Gear / Driveshaft Gear • Remove the snap ring (6) and 3rd/4th drive gears (7). Disassembly and Assembly B944H15206005 Refer to “Transmission Removal and Installation (Page 5B-3)”. Disassembly CAUTION Identify the position of each removed part. Organize the parts in their respective groups (i.e., drive or driven) so that they can be reinstalled in their original positions.
  • Page 481 Manual Transmission: 5B-7 • Remove the snap ring (6), washer (7) and 4th driven CAUTION gear (8). • Never reuse a snap rings. After a snap • Remove the 4th driven gear bushing (9), lock washers rings has been removed from a shaft, it (10) and 3rd driven gear (11).

  • Page 482: Transmission Related Parts Inspection

    5B-8 Manual Transmission: • After installing the 3rd driven gear (2) onto the Countershaft driveshaft, install lock washer No. 2 (3) onto the • When installing the 6th drive gear bushing (1) onto the driveshaft, and position it so it fits into the groove. countershaft, align the shaft oil hole “A”...

  • Page 483: Transmission Oil Seal / Bearing Inspection

    Manual Transmission: 5B-9 Gearshift Fork Groove Width Measure the gearshift fork groove width using the vernier calipers. Special tool (A): 09900–20102 (Vernier calipers (1/20 mm, 200 mm)) Gearshift fork groove width Standard (No. 1, No. 2 & No. 3): 5.5 – 5.6 mm (0.217 – 0.220 in) I944H1520026-01 Gearshift Cam...

  • Page 484: Transmission Oil Seal / Bearing Removal And Installation

    5B-10 Manual Transmission: Bearing 4) Remove the bearings from the left crankcase with Rotate the bearing inner race by finger to inspect for the special tool. abnormal play, noise and smooth rotation while the Special tool bearings are in the crankcase. (B): 09921–20240 (Bearing remover set) Replace the bearing if there is anything unusual.
  • Page 485 Manual Transmission: 5B-11 6) Remove the bearings from right crankcase with the special tool. Special tool “A” (B): 09921–20240 (Bearing remover set) (C): 09913–70210 (Bearing installer set) “A” I944H1520038-01 I944H1520036-01 “B” “B” I944H1520039-01 I944H1520037-01 Installation CAUTION “A” The removed oil seals and bearings must be replaced with new ones.

  • Page 486: Gear Position Switch Inspection

    5) Remove the oil seal retainer mounting bolts (2). 4) Apply grease to the oil seal lips. 6) Remove the gear position switch mounting bolts (3). : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I944H1520028-02 7) Move the oil seal retainer (4) as shown.

  • Page 487: Gearshift Lever Construction

    Replace the O-ring with a new one. NOTE Align the gear position switch pin “A” with the gearshift cam hole “B”. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I944H1520069-01 1. Gearshift link arm “a”: 45 – 55 mm (1.8 – 2.2 in) 2.

  • Page 488: Gearshift Shaft / Gearshift Cam Plate Components

    5B-14 Manual Transmission: 2) Loosen the lock-nuts (1). Gearshift Construction B944H15206013 3) Turn the gearshift link rod (2) until the gearshift lever is 45 – 55 mm (1.8 – 2.2 in) below the top of the footrest. 4) Tighten the lock-nuts securely. I944H1520070-02 I944H1520047-01 1.
  • Page 489 Manual Transmission: 5B-15 4) Remove the snap ring (2) and washer (3) from the 7) Remove the gearshift cam plate bolt (12) and gearshift shaft. gearshift cam plate (13). 8) Remove the gearshift cam stopper (14). Special tool : 09900–06107 (Snap ring pliers) NOTE Do not drop the each parts into the crankcase.
  • Page 490 5B-16 Manual Transmission: • Check the gearshift cam stopper moves smoothly. • Apply a small quantity of thread lock to the gearshift arm stopper (1) and tighten it to the specified torque. • Locate the gearshift cam in the neutral position. •...

  • Page 491: Gearshift Linkage Inspection

    Manual Transmission: 5B-17 • Install the gearshift shaft assembly (8) and washer (9) Gearshift Linkage Inspection B944H15206015 as shown. Refer to “Gearshift Shaft / Gearshift Cam Plate Removal and Installation (Page 5B-14)”. NOTE Pinch the gearshift arm stopper (10) with Gearshift Shaft return spring ends “F”.

  • Page 492: Specifications

    5B-18 Manual Transmission: Installation • Apply grease to the oil seal lip. Install the oil seal in the reverse order of removal. Pay : Grease 99000–25010 (SUZUKI SUPER attention to the following points: GREASE A or equivalent) CAUTION The removed oil seal must be replaced with new ones.

  • Page 493: Special Tools And Equipment

    Manual Transmission: 5B-19 Special Tools and Equipment Recommended Service Material B944H15208001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010 (Page 5B-12) / equivalent (Page 5B-13) / (Page 5B-18) Thread lock cement THREAD LOCK CEMENT SUPER P/No.: 99000–32030...

  • Page 494: Clutch

    5C-1 Clutch: Clutch Transmission / Transaxle Precautions Precautions for Clutch System B944H15300001 Refer to “General Precautions in Section 00 (Page 00-1)”. Diagnostic Information and Procedures Clutch System Symptom Diagnosis B944H15304001 Condition Possible cause Correction / Reference Item Engine is noisy (Noise Worn countershaft spline.

  • Page 495: Repair Instructions

    Clutch: 5C-2 Repair Instructions Clutch Lever Position Switch Inspection 3) Loosen the cable lock-nut (3) and adjuster (4). B944H15306001 Inspect the clutch lever position switch in the following NOTE procedures: Align the clutch lever, cable lock-nut (3) and 1) Disconnect the clutch lever switch coupler (1). adjuster (4) with the cutaway.

  • Page 496: Clutch Lever Components

    5C-3 Clutch: Clutch Lever Components B944H15306025 I944H1530067-04 1. Adjuster 5. Oil seal 9. Clutch push rod (left) 2. Lock-nut 6. Bearing : 5 N⋅m (0.5 kgf-m, 3.8 lbf-ft) 3. Clutch lever 7. Clutch release camshaft : Apply grease. 4. Clutch lever position switch 8.

  • Page 497: Clutch Lever Removal And Installation

    Pay attention to the following points: Removal • Apply grease to the clutch lever pivot bolt. 1) Disconnect the clutch cable (1) (Clutch lever side). : Grease 99000–25100 (SUZUKI SILICONE Refer to “Clutch Cable Removal and Installation GREASE or equivalent) (Page 5C-2)”.

  • Page 498: Clutch Push Rod (Left) Inspection

    I944H1530014-01 • Apply a small quantity of grease to the clutch push rod. I944H1530011-01 5) Remove the bearing (6) and oil seal (7). : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I944H1530012-01 I944H1530015-01 Installation • Install the generator cover. Refer to “Generator Install the clutch push rod (left) / clutch release camshaft Removal and Installation in Section 1J (Page 1J-4)”.

  • Page 499: Clutch Components

    Clutch: 5C-6 Clutch Components B944H15306028 I944H1530069-03 1. Clutch pressure plate 8. Spring washer 15. Clutch push rod (right) 2. Thrust washer 9. Spring washer seat 16. Oil seal 3. Bearing 10. Clutch sleeve hub nut lock washer : 10 N⋅m (1.0 kgf-m, 7.0 lbf-ft) 4.

  • Page 500: Clutch Removal

    5C-7 Clutch: Clutch Removal 6) Remove the clutch springs and clutch pressure plate B944H15306029 (8). 1) Drain engine oil and coolant. Refer to “Engine Oil NOTE and Filter Replacement in Section 0B (Page 0B-10)” and “Cooling System Inspection in Section 0B Loosen the clutch spring set bolts little by (Page 0B-12)”.
  • Page 501 Clutch: 5C-8 9) Remove the thrust washer (13), bearing (14) and 12) Hold the clutch sleeve hub with the special tool and clutch push piece (15). remove the clutch sleeve hub nut. Special tool (A): 09920–53740 (Clutch sleeve hub holder) I944H1530023-02 10) Remove the clutch push rod (16).

  • Page 502: Clutch Installation

    5C-9 Clutch: 15) Remove the spacer (21). 3) Install the snap ring (3). CAUTION The removed snap ring (3) must be replaced with a new one. Special tool : 09900–06107 (Snap ring pliers) I944H1530029-02 16) Remove the snap ring (22), oil pump drive gear (23) and pin (24).
  • Page 503 Clutch: 5C-10 6) Install the thrust washer (9). I944H1530037-02 10) Bend the lock washer to lock nut securely. I944H1530035-02 7) Install the clutch sleeve hub (10) and new lock washer (11). NOTE The removed lock washer (11) must be replaced with a new one. 8) Install the clutch sleeve hub nut (12).
  • Page 504 5C-11 Clutch: 13) Install the spring washer seat (18) and spring washer (19) onto the clutch sleeve hub correctly. “B” “B” I944H1530044-02 Drive plate I.D. “B” No. 1 (21) 116 mm (4.5 in) No. 2 (20) 122.5 mm (4.82 in) I944H1530041-03 14) Apply engine oil to the clutch drive plates and driven plates.
  • Page 505 Clutch: 5C-12 20) Install the gasket (26) and the dowel pins (27). CAUTION Use the new gasket to prevent oil leakage. 21) Remove the bolt (28). 22) Install the clutch cover (29). NOTE When installing the clutch cover (29), align “E”...

  • Page 506: Clutch Parts Inspection

    5C-13 Clutch: Clutch Parts Inspection B944H15306018 Refer to “Clutch Removal (Page 5C-7)” and “Clutch Installation (Page 5C-9)”. Clutch Drive and Driven Plate NOTE Wipe off the engine oil from the drive and driven plates with a clean rag. I649G1530058-03 Measure the thickness of drive plates with a vernier Clutch Spring calipers.

  • Page 507: Primary Drive Gear Removal And Installation

    Clutch: 5C-14 Push Rod (Right) Primary Drive Gear Removal and Installation B944H15306021 Inspect the push rod for bend and damage. Removal If any defects are found, replace the push rod with a new 1) Remove the clutch cover. Refer to “Clutch Removal one.

  • Page 508: Primary Drive Gear Inspection

    5C-15 Clutch: Installation CAUTION This primary drive gear bolt has left-hand thread. 1) Install the primary drive gear assembly (1) and water pump drive gear (2). 2) Temporarily tighten the primary drive gear bolt (3). I944H1530059-01 3) Install the primary drive gear assembly. Refer to “Primary Drive Gear Removal and Installation (Page 5C-14)”.

  • Page 509: Specifications

    Clutch: 5C-16 Reassembly 4) Install the new snap ring (4). 1) Set the springs (1) into the grooves. Special tool 2) Install the scissors gear (2). : 09900–06107 (Snap ring pliers) NOTE CAUTION Align the hole of the primary drive gear with The removed snap ring (4) must be replaced the hole of the scissors gear.

  • Page 510: Tightening Torque Specifications

    For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List in Section 0C (Page 0C-7)”. Special Tools and Equipment Recommended Service Material B944H15308001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010 (Page 5C-5) /...
  • Page 511 Table of Contents 6- i Section 6 Steering CONTENTS Precautions ..........6-1 Handlebars Inspection ........6B-4 Steering Components .........6B-5 Precautions............. 6-1 Steering Removal and Installation ......6B-5 Precautions for Steering ........6-1 Steering Related Parts Inspection.......6B-8 Steering General Diagnosis....6A-1 Steering System Inspection ........6B-8 Steering Stem Bearing Removal and Diagnostic Information and Procedures....6A-1 Installation ............6B-8...

  • Page 512: Precautions

    6-1 Precautions: Precautions Steering Precautions Precautions for Steering B944H16000001 Refer to “General Precautions in Section 00 (Page 00-1)”.

  • Page 513: Steering General Diagnosis

    Steering General Diagnosis: 6A-1 Steering General Diagnosis Steering Diagnostic Information and Procedures Steering Symptom Diagnosis B944H16104001 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 514: Steering / Handlebar

    6B-1 Steering / Handlebar: Steering / Handlebar Steering Repair Instructions Handlebars Components B944H16206001 “A” “ a ” I944H1620023-02 1. Throttle grip 5. Handle balancer expander “A”: Apply handle grip bond. 2. Handlebars 6. Handle balancer screw “a”: 0.5 – 1.5 mm (0.02 – 0.06 in) (Throttle grip) 3.

  • Page 515: Handlebar Construction

    Steering / Handlebar: 6B-2 Handlebar Construction B944H16206002 “A” “A” “ a ” “ a ” “B” “A” “A” “ a ” I944H1620001-03 1. Front brake master cylinder “A”: Punch mark : 10 N⋅m (1.0 kgf-m, 7.0 lbf-ft) 2. Handlebar holder “B”: UP mark : 23 N⋅m (2.3 kgf-m, 16.5 lbf-ft) 3.

  • Page 516: Handlebars Removal And Installation

    6B-3 Steering / Handlebar: Handlebars Removal and Installation 3) Remove the caps and handlebar holder bolts. B944H16206003 Removal 1) Remove the following parts from the left handlebar. a) Rear view mirror (1) b) Left handlebar switch box (2) c) Handlebar balancer (3) d) Grip rubber (4) e) Disconnect the clutch cable (5) Clutch lever (6)

  • Page 517: Handlebars Inspection

    • Apply grease to the end of the throttle cables and cable pulley. – Throttle cable play (Refer to “Throttle Cable Play Inspection and Adjustment in Section 0B (Page 0B- : Grease 99000–25010 (SUZUKI SUPER 12)”) GREASE A or equivalent) • Insert the projection “C” of the right handlebar switch Handlebars Inspection box into the hole of the handlebars.

  • Page 518: Steering Components

    6B-5 Steering / Handlebar: Steering Components B944H16206006 I944H1620024-01 1. Steering stem head nut 6. Dust seal : 23 N⋅m (2.3 kgf-m, 16.5 lbf-ft) 2. Handlebar holder bolt 7. Steering stem upper bearing : 90 N⋅m (9.0 kgf-m, 65.0 lbf-ft) 3. Handlebar holder 8.
  • Page 519 Steering / Handlebar: 6B-6 7) Remove the combination meter bracket (4) by 11) Remove the steering stem head nut (8) and washer removing the bracket mounting bolts (5). (9). Remove the steering stem upper bracket (10). I944H1620011-02 8) Remove the brake hose clamp (6). I944H1620014-02 12) Remove the steering stem nut (11) with the special tool.
  • Page 520 This adjustment will vary from motorcycle to Bearing motorcycle. • Apply grease to the bearings, races and dust seals before remounting the steering stem. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) “a ” I649G1620026-02 Steering stem upper bracket...

  • Page 521: Steering Related Parts Inspection

    Steering / Handlebar: 6B-8 Steering Related Parts Inspection 2) Remove the steering stem lower bearing and inner B944H16206008 race using a chisel. Refer to “Steering Removal and Installation (Page 6B- 5)”. Inspect the removed parts for the following abnormalities. • Distortion of the steering stem •...

  • Page 522: Steering Tension Adjustment

    6B-9 Steering / Handlebar: Inner race 4) Do the same on the other grip end. • Press in the lower inner race and bearing using the 5) If the initial force read on the scale when the special tool. handlebar starts turning is either to heavy or too light, adjust it till it satisfies the specification.

  • Page 523: Specifications

    For the tightening torque of fastener not specified in this section, refer to “Tightening Torque Specifications in Section 0B (Page 0B-21)”. Special Tools and Equipment Recommended Service Material B944H16208001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010 (Page 6B-4) /...

  • Page 524: Special Tool

    6B-11 Steering / Handlebar: Special Tool B944H16208002 09910–60611 09930–11920 Universal clamp wrench Torx bit (JT40H) (Page 6B-9) (Page 6B-6) 09930–11940 09940–14911 Torx bit holder Steering stem nut socket wrench (Page 6B-6) (Page 6B-6) / (Page 6B- 09940–92720 09941–34513 Spring scale Bearing installer (Page 6B-9) (Page 6B-8)
  • Page 525 Table of Contents 9- i Section 9 Body and Accessories CONTENTS Precautions ..........9-1 Service Data............9B-15 Tightening Torque Specifications......9B-15 Precautions............. 9-1 Special Tools and Equipment ......9B-16 Precautions for Electrical System ......9-1 Special Tool ............9B-16 Component Location ..........9-1 Electrical Components Location ......9-1 Combination Meter / Fuel Meter / Horn..
  • Page 526 9-ii Table of Contents Recommended Service Material ......9D-7 Side-stand Construction........9E-3 Specifications ............9E-3 Body Structure .........9E-1 Tightening Torque Specifications......9E-3 Repair Instructions ..........9E-1 Special Tools and Equipment ......9E-3 Body Frame Construction ........9E-1 Recommended Service Material ......9E-3 Front Footrest Construction ........ 9E-2...

  • Page 527: Precautions

    Precautions: Precautions Body and Accessories Precautions Precautions for Electrical System B944H19000001 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 B944H19003001 Refer to “Electrical Components Location in Section 0A (Page 0A-7)”.

  • Page 528: Wiring Systems

    9A-1 Wiring Systems: Wiring Systems Body and Accessories Schematic and Routing Diagram Wiring Diagram B944H19102001 Refer to “Wire Color Symbols in Section 0A (Page 0A-5)”. For E-02, 19, 24 : TURN SIGNAL INDICATOR LIGHT (R) : TURN SIGNAL INDICATOR LIGHT (L) : HI-BEAM INDICATOR LIGHT HANDLEBAR SWITCH (R) : NEUTRAL INDICATOR LIGHT...
  • Page 529 Wiring Systems: 9A-2 LICENSE LIGHT REAR TURN SIGNAL LIGHT (R) REAR COMBINATION LIGHT REAR TURN SIGNAL LIGHT (L) SENSOR FAN RELAY SENSOR SENSOR SENSOR BATTERY SPEED GENERATOR REGULATOR/ 1:MAIN FUSE(30A) SENSOR RECTIFIER STARTER STARTER MOTOR RELAY FREE PUSH SIDE STAND SWITCH I944H1910902-06...
  • Page 530 9A-3 Wiring Systems: For E-28 : TURN SIGNAL INDICATOR LIGHT (R) : TURN SIGNAL INDICATOR LIGHT (L) : HI-BEAM INDICATOR LIGHT HANDLEBAR SWITCH (R) : NEUTRAL INDICATOR LIGHT : FUEL INDICATOR LIGHT : OIL TEMP. FI INDICATOR LIGHT ENGINESTOP STARTER FRONT BRAKE SWITCH BUTTON...
  • Page 531 Wiring Systems: 9A-4 LICENSE LIGHT REAR TURN SIGNAL LIGHT (R) REAR COMBINATION LIGHT REAR TURN SIGNAL LIGHT (L) SENSOR FAN RELAY SENSOR SENSOR SENSOR SPEED REGULATOR/ BATTERY GENERATOR 1:MAIN FUSE(30A) SENSOR RECTIFIER STARTER STARTER MOTOR RELAY FREE PUSH SIDE STAND SWITCH I944H1910904-07...

  • Page 532: Wiring Harness Routing Diagram

    9A-5 Wiring Systems: Wiring Harness Routing Diagram B944H19102005 “ a ” “A” “B” “C” “ a ” “E” “D” I944H1910910-02 1. Clamp 13. Clutch cable : Bind the wiring harness, rear brake light switch lead wire and starter motor lead wire with the clamp. 2.
  • Page 533 Wiring Systems: 9A-6 “ a ” “ a ” “B” “A” “ b ” “ a ” “c” “c” “C” I944H1910907-07 1. Clamp 9. Fuel hose : Bind the battery (–) lead wire. 2. Clamp “A”: Pass the wiring harness under the fuel hose. : Bind the right handlebar switch harnesses speedometer and ignition switch lead wire with the clamp.
  • Page 534 9A-7 Wiring Systems: “B” VIEW b VIEW a “A” “C” “D” “D” 1, 2 3, 4 I944H1910908-04 1. Rear combination light lead wire coupler 8. Rear frame cover 2. Right rear turn signal light lead wire coupler 9. Frange 3. Left rear turn signal light lead wire coupler “A”: Pass the wiring harness through the hole provided on the upper part of rear fender.
  • Page 535 Wiring Systems: 9A-8 “ a ” “ b ” “ a ” “c ” “ d ” “e ” “ g ” “ f ” “ f ” I944H1910905-03 1. Starter motor lead wire : 11 N⋅m (1.1 kgf-m, 8.0 lbf-ft) 2.

  • Page 536: Specifications

    9A-9 Wiring Systems: Specifications Service Data B944H1910S002 Electrical Item Specification Note 10 A Headlight 10 A Ignition 15 A Fuse size Signal 10 A 15 A Fuel 10 A Main 30 A Tightening Torque Specifications B944H1910S003 NOTE The specified tightening torque is described in the following. “Wiring Harness Routing Diagram (Page 9A-5)”...

  • Page 537: Lighting Systems

    Lighting Systems: 9B-1 Lighting Systems Body and Accessories Repair Instructions Headlight Construction B944H19206029 I944H1920001-02 1. Headlight 3. Headlight side cover 2. Headlight cover 4. Headlight brace...

  • Page 538: Headlight Cover Construction

    9B-2 Lighting Systems: Headlight Cover Construction B944H19206030 I944H1920002-02 1. Headlight cover 2. Headlight side cover 3. Headlight brace...
  • Page 539 Lighting Systems: 9B-3 Headlight Components I944H1920044-02 1. Headlight bulb (12 V 60/55 W, H4) 3. Bulb socket rubber cap 2. Position light bulb (12 V 5 W)

  • Page 540: Headlight Removal And Installation

    9B-4 Lighting Systems: Headlight Removal and Installation Installation B944H19206003 Installation is in the reverse order of removal. Pay attention to the following point: Removal • After installing, be sure to inspect the headlight beam. 1) Removal the headlight side covers (1) by removing Refer to “Headlight Beam Adjustment (Page 9B-5)”.

  • Page 541: Headlight Beam Adjustment

    Lighting Systems: 9B-5 4) Reinstall the removed parts. Headlight Beam Adjustment B944H19206005 Adjust the headlight beam in the following procedures: NOTE Insert a plus screw driver along the guide as shown and Properly fit the bulb socket rubber cap (1). adjust the headlight beam horizontally.

  • Page 542: Rear Lighting System Construction

    9B-6 Lighting Systems: Rear Lighting System Construction B944H19206007 I944H1920003-02 1. Rear combination light 5. Reflex refractor (For E-03, 28, 33) 2. License plate light : 1.8 N⋅m (0.18 kgf-m, 1.5 lbf-ft) 3. Rear turn signal light (For E-03, 28, 33) : 1.3 N⋅m (0.13 kgf-m, 1.0 lbf-ft) 4.

  • Page 543: Rear Combination Light Components

    Lighting Systems: 9B-7 Rear Combination Light Components B944H19206006 I944H1920045-02 1. Brake light/Taillight bulb (12 V 21/5 W) : 1.8 N⋅m (0.18 kgf-m, 1.5 lbf-ft) 2. Rear combination light mounting bolt Rear Combination Light Removal and 3) Remove the rear fender bracket (2) by removing the rear turn signal light mounting nuts (3).

  • Page 544: Rear Combination Light Bulb Replacement

    9B-8 Lighting Systems: 5) Remove the rear combination light (5) by removing Rear Combination Light Bulb Replacement B944H19206009 the rear combination light bolts (6). CAUTION • When you touch the bulb with your bare hands, clean the bulb with a cloth moistened with alcohol or soapy water to prevent premature bulb failure.

  • Page 545: License Plate Light Components

    Lighting Systems: 9B-9 License Plate Light Components B944H19206010 I944H1920046-02 1. License plate light bulb (12 V 5 W) 2. Lens License Plate Light Removal and Installation 3) Remove the license plate light assembly (1) by B944H19206011 removing the nuts (2). Removal 1) Remove the rear fender assembly.

  • Page 546: License Plate Light Bulb Replacement

    9B-10 Lighting Systems: License Plate Light Bulb Replacement B944H19206012 Replace the license plate light bulb in the following procedures: CAUTION • When you touch the bulb with your bare hands, clean the bulb with a cloth moistened with alcohol or soapy water to prevent premature bulb failure.

  • Page 547: Turn Signal Light Components

    Lighting Systems: 9B-11 Turn Signal Light Components B944H19206032 I944H1920047-05 1. Turn signal light bulb (12 V 10 W x 4) 3. Turn signal light mounting nut 2. Lens : 1.3 N⋅m (0.13 kgf-m, 1.0 lbf-ft) Front Turn Signal Light Removal and Installation Install the front turn signal light in the reverse order of Installation...

  • Page 548: Rear Turn Signal Light Removal And Installation

    9B-12 Lighting Systems: Rear Turn Signal Light Removal and Installation 3) Remove the rear fender cover (5) by removing the B944H19206015 screw (6). Removal 1) Remove the pillion rider handles (1) and rear frame cover (2). Refer to “Exterior Parts Removal and Installation in Section 9D (Page 9D-4)”.

  • Page 549: Turn Signal Light Bulb Replacement

    Lighting Systems: 9B-13 Turn Signal Light Bulb Replacement Turn Signal / Side-stand Relay Inspection B944H19206016 B944H19206018 Refer to “Electrical Components Location in Section 0A CAUTION (Page 0A-7)”. • When you touch the bulb with your bare NOTE hands, clean the bulb with a cloth moistened with alcohol or soapy water to Make sure that the battery is fully charged.

  • Page 550: Turn Signal Switch Inspection

    9B-14 Lighting Systems: 4) After finishing the hazard switch inspection, reinstall Passing Light Switch Inspection B944H19206022 the removed parts. Inspect the passing light switch in the following procedures: Turn Signal Switch Inspection 1) Remove the left frame body cover. Refer to “Exterior B944H19206021 Inspect the turn signal switch in the following Parts Removal and Installation in Section 9D...

  • Page 551: Dimmer Switch Inspection

    Lighting Systems: 9B-15 Dimmer Switch Inspection 3) Inspect the dimmer switch for continuity with a tester. B944H19206023 If any abnormality is found, replace the left Inspect the dimmer switch in the following procedures: handlebar switch assembly with a new one. 1) Remove the left frame body cover.
  • Page 552 9B-16 Lighting Systems: Special Tools and Equipment Special Tool B944H19208001 09900–25008 Multi circuit tester set (Page 9B-13) / (Page 9B-14) / (Page 9B-14) / (Page 9B-15)

  • Page 553: 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 B944H19301001 This combination meter mainly consists of the stepping motor, LCD (Liquid Crystal Display) and LED (Light Emitting Diode).

  • Page 554: Repair Instructions

    9C-2 Combination Meter / Fuel Meter / Horn: Repair Instructions Combination Meter Components B944H19306001 I944H1930025-03 1. Combination meter upper case 3. Combination meter lower case 2. Combination meter unit 4. Combination meter cover Combination Meter Removal and Installation 2) Remove the screws (3) and disconnect the B944H19306002 combination meter coupler (4).

  • Page 555: Combination Meter Disassembly And Assembly

    Combination Meter / Fuel Meter / Horn: 9C-3 4) Remove the combination meter assembly (6). Combination Meter Inspection B944H19306004 LED Inspection Check that the LEDs (FI indicator light, oil pressure/ Engine coolant temperature indicator light, Fuel level indicator light and Meter panel illumination) immediately light up when the ignition switch is turned to ON.

  • Page 556: Engine Coolant Temperature Indicator Light Inspection

    9C-4 Combination Meter / Fuel Meter / Horn: 3) Keep pushing the adjuster switch (1) for more than 4 3) Connect the variable resistor (2) between the sec. terminals. → Reset I944H1930008-01 I718H1930009-05 4) Turn the ignition switch ON. Time Ignition switch Adjuster switch (1) 5) Check the LED (3) and LCD (4) operations when the...

  • Page 557: Fuel Level Indicator Light Inspection

    Combination Meter / Fuel Meter / Horn: 9C-5 Fuel Level Indicator Light Inspection Speedometer Inspection B944H19306008 B944H19306010 If the fuel level indicator light (1) does not function If the speedometer, odometer or tripmeter does not properly, check the fuel level gauge and its lead wire/ function properly, inspect the speed sensor and the coupler.

  • Page 558: Speed Sensor Inspection

    9C-6 Combination Meter / Fuel Meter / Horn: Installation 3) Move a screwdriver back and forth across the pick- Install the speed sensor in the reverse order of removal. up surface of the speed sensor. The voltage readings should cycle as follows (0 V → 12 V or 12 V Pay attention to the following points: →...

  • Page 559: Oil Pressure Switch Removal And Installation

    Combination Meter / Fuel Meter / Horn: 9C-7 3) Check if the oil pressure indicator (LED) “A” and 3) Inspect the ignition switch for continuity with a tester. (LCD) “B” will light up when grounding the lead wire If any abnormality is found, replace the ignition (1).

  • Page 560: Horn Removal And Installation

    9C-8 Combination Meter / Fuel Meter / Horn: 3) Inspect the horn button for continuity with a tester. Horn Removal and Installation B944H19306026 If any abnormality is found, replace the left Removal handlebar switch assembly with a new one. 1) Remove the left frame body cover. Refer to “Exterior Refer to “Handlebars Removal and Installation in Parts Removal and Installation in Section 9D Section 6B (Page 6B-3)”.

  • Page 561: Specifications

    Combination Meter / Fuel Meter / Horn: 9C-9 Specifications Service Data B944H19307001 Wattage Unit: W Specification Item E-03, 28, 33 E-02, 19, 24 ← Headlight ← ← Position/Parking light ← Brake light/Taillight 21/5 Turn signal light 21 x 4 10 x 4 ←...

  • Page 562: Exterior Parts

    9D-1 Exterior Parts: Exterior Parts Body and Accessories Schematic and Routing Diagram Seat Lock Cable Routing Diagram B944H19402001 I944H1940021-01 1. Seat lock cable 2. Seat lock...

  • Page 563: Repair Instructions

    Exterior Parts: 9D-2 Repair Instructions Frame Cover Construction B944H19406001 I944H1940001-03 1. Frame lower cover 4. Rear frame cover 2. Frame cover 5. Cap 3. Pillion rider handle : Apply thread lock to thread part.

  • Page 564: Rear Fender Construction

    9D-3 Exterior Parts: Rear Fender Construction B944H19406003 I944H1940003-02 1. Rear front fender 4. Rear fender cover 2. Rear fender 5. Rear fender guard (For E-24) 3. Rear fender bracket : Apply thread lock to the thread part.

  • Page 565: Fastener Removal And Installation

    Exterior Parts: 9D-4 Fastener Removal and Installation Exterior Parts Removal and Installation B944H19406006 B944H19406007 Removal Seat Removal 1) Depress the head of fastener center piece (1). 1) Unlock the seat with the ignition key (1). 2) Pull out the fastener (2). 2) Remove the seat.
  • Page 566 9D-5 Exterior Parts: 4) Remove the rear frame cover (3). “A” I944H1940006-03 I944H1940009-03 “A”: Hooked point 5) Disconnect the clamps (4). Installation 6) Disconnect the rear turn signal light lead wire Install the frame covers in the reverse order of removal. couplers (5), rear combination lead wire coupler (6) and license plate light lead wire coupler (7).
  • Page 567 Exterior Parts: 9D-6 8) Remove the rear fender cover (9) by removing the screw (10). “A” “A” I944H1940016-01 • Rout the wiring harness. Refer to “Wiring Harness Routing Diagram in Section 9A (Page 9A-5)”. I944H1940013-04 • Apply thread lock to the pillion rider handle mounting “A”: Hooked point bolts (2).

  • Page 568: Special Tools And Equipment

    9D-7 Exterior Parts: Special Tools and Equipment Recommended Service Material B944H19408001 Material SUZUKI recommended product or Specification Note Thread lock cement THREAD LOCK CEMENT SUPER P/No.: 99000–32110 (Page 9D-6) / (Page 9D- 1322 or equivalent NOTE Required service material is also described in the following.

  • Page 569: Body Structure

    Body Structure: 9E-1 Body Structure Body and Accessories Repair Instructions Body Frame Construction B944H19506001 I944H1950003-01 1. Frame...

  • Page 570: Front Footrest Construction

    9E-2 Body Structure: Front Footrest Construction B944H19506004 I944H1950001-01 : 18 N⋅m (1.8 kgf-m, 13.0 lbf-ft) : Apply thread lock to thread part.

  • Page 571: Side-Stand Construction

    Body Structure: 9E-3 Side-stand Construction B944H19506005 I944H1950002-01 : 40 N⋅m (4.0 kgf-m, 29.0 lbf-ft) : Apply grease to sliding surface. : 10 N⋅m (1.0 kgf-m, 7.0 lbf-ft) Specifications Tightening Torque Specifications B944H19507001 NOTE The specified tightening torque is described in the following. “Front Footrest Construction (Page 9E-2)”...
  • Page 572 Prepared by December, 2008 Part No. 99500-36190-01E Printed in Japan...
  • Page 573 Printed in Japan...

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