Suzuki E-24 2002 Manuals

Manuals and User Guides for Suzuki E-24 2002. We have 1 Suzuki E-24 2002 manual available for free PDF download: Service Manual

Suzuki E-24 2002 Service Manual

Suzuki E-24 2002 Service Manual (463 pages)

Brand: Suzuki | Category: Motorcycle | Size: 32.89 MB

Table of Contents

General Information 1

8
- Table of Contents
  8
- Warning/ Caution/ Note
  9
- General Precautions
  9
- Suzuki An650K3 ('03-Model)
  11
- Serial Number Location
  11
- Fuel, Oil and Engine Coolant Recommendation
  11
- Fuel (for Usa and Canada)
  11
- Fuel (for Other Countries)
  11
- Anti-Freeze/Engine Coolant
  12
- Water for Mixing
  12
- Engine Coolant
  12
- Brake Fluid
  12
- Front Fork Oil
  12
- Final Gear Oil
  12
- Engine Oil and Transmission Oil (for Other Countries)
  12
- Engine Oil and Transmission Oil (for Usa)
  12
- Liquid Amount of Water/Engine Coolant
  13
- BREAK-Ln PROCEDURES
  14
- Cylinder Identification
  14
- Information Labels
  15
- Specifications
  16
Electrical

17
- Country and Area Codes
  18
- Periodic Maintenance Chart
  20
- Periodic Maintenance Schedule
  20
- Lubrication Points
  21
- Air Cleaner
  22
- Maintenance and Tune-Up Procedures
  22
- Spark Plug
  24
- Tappet Clearance
  25
- Engine Oil and Oil Filter
  31
- Fuel Hose
  31
- Final Gear Oil
  33
- Transmission Oil
  33
- Cvt Filter
  34
- Engine Idle Speed
  36
- Throttle Cable Play
  36
- Pair (Air Supply) System
  37
- Throttle Valve Synchronization
  37
- Cooling System
  38
- Brake
  40
- Tire
  43
- Front Fork
  44
- Steering
  44
- Exhaust Pipe Bolt and Muffler Mounting Bolt
  45
- Rear Suspension
  45
- Chassis Bolt and Nut
  46
- Compression Pressure Check
  48
- Compression Test Procedure
  48
- Oil Pressure Check
  49
- Oil Pressure Test Procedure
  49
- Automatic Clutch Inspection
  50
- Clutch "Lock-Up" Inspection
  50
- Initial Engagement Inspection
  50
- Brake-Lock Inspection
  51
Engine

52
- Engine Components Removable with the Engine in Place
  53
- Engine Removal
  54
- Engine Removal and Remounting
  54
- Engine Remounting
  61
- Engine Disassembly
  63
- Cylinder Head Cover
  73
- Engine Component Inspection and Service
  73
- Camshaft
  74
- Cam Chain Guide
  76
- Cam Chain Tension Adjuster
  76
- Cam Chain Tensioner
  76
- Cylinder Head
  77
- Cylinder
  85
- Piston and Piston Ring
  87
- Clutch
  89
- Starter Clutch
  94
- Oil Pressure Regulator/Oil Sump Filter
  95
- Oil Pump
  95
- Starter Torque Limiter
  95
- Crank Balancer
  96
- Driveshaft
  96
- Conrod/Crankshaft
  98
- Oil Jet
  106
- Crankcase
  107
- Engine Reassembly
  110
Drive Train

127
- Construction
  128
- Drive Train
  128
- Removal and Disassembly
  129
- Inspection and Replacement
  130
- Reassembly and Remounting
  133
Cvt Assembly Removal and Installation/Cvt Disassembly and Reassembly

135
- Cvt Assembly Removal
  136
- Cvt Assembly Removal and Installation
  136
- Cvt Assembly Installation
  138
- Cvt Disassembly and Reassembly
  139
- Cvt Disassembly
  140
- Cvt Inspection
  145
- Cvt Primary Pulley Shims Adjustment
  150
- Cvt Reassembly
  153
Fi System/ Cvt System

162
- Electrical Parts
  163
- Precautions in Servicing
  163
- Electrical Circuit Inspection Procedure
  166
- Using Testers
  169
- Fi System Technical Features
  170
- Injection Time (Injection Volume)
  170
- Compensation of Injection Time (Volume)
  171
- Injection Stop Control
  171
- Fi System Parts Location
  172
- Fi System Wiring Diagram
  174
- Cvt System Technical Features
  175
- Cvt System Parts Location
  176
- Self-Diagnosis Function
  179
- User Mode
  179
- Dealer Mode
  180
- Tps Adjustment
  181
- Fail-Safe Function
  182
- Customer Complaint Analysis
  183
- Fi System/ Cvt System Troubleshooting
  183
- Self-Diagnosis Reset Procedure
  185
- Self-Diagnostic Procedures
  185
- Battery
  186
- Malfunction Code and Defective Condition
  186
- C11" Cmp Sensor Circuit Malfunction
  188
- C12" Ckp Sensor Circuit Malfunction
  189
- C13" Iap Sensor Circuit Malfunction
  190
- C14" Tp Sensor Circuit Malfunction
  192
- C15" Ect Sensor Circuit Malfunction
  194
- C16" Speed Sensor Circuit Malfunction
  195
- C21" Iat Sensor Circuit Malfunction
  197
- C22" Ap Sensor Circuit Malfunction
  198
- C23" to Sensor Circuit Malfunction
  200
- C24" or "C25" IGNITION SYSTEM MALFUNCTION
  201
- C32" or "C33" FUEL INJECTOR CIRCUIT MALFUNCTION
  201
- C40" Iac Valve Circuit Malfunction
  202
- C41" Fp Relay Circuit Malfunction
  202
- C42" Ig Switch Circuit Malfunction
  202
- C44" Ho2 Sensor (Ho2S) Circuit Malfunction (E-02, 19)
  203
- C50" Cvt Serial Communication Circuit Malfunction
  205
- C51" Cvt Motor Circuit Malfunction
  206
- C52" Cvt Pulley Position Sensor (Pps) Circuit Malfunction
  208
- C53" Cvt Speed Sensor Circuit Malfunction
  210
- C54" Cvt Secondary Pulley Revolution Sensor Circuit Malfunction
  212
- C55" Cvt Engine Revolution Signal Circuit Malfunction
  214
- C56" Cvt Throttle Position Signal Circuit Malfunction
  215
- C58" Cvt Reduction Ratio Disagreement
  216
- Sensors
  217
Fuel System and Throttle Body

220
- Fuel System
  221
- Fuel Tank Components
  221
- Fuel Tank Removal
  222
- Fuel Tank Installation
  223
- Fuel Tank Pressure Control (Ftpc) Valve Inspection
  223
- Fuel Pressure Inspection
  224
- Fuel Pump Inspection
  225
- Fuel Pump Relay Inspection
  225
- Fuel Pump Components
  226
- Fuel Pump/Fuel Level Gauge Removal and Disassembly
  226
- Fuel Level Gauge Inspection
  229
- Fuel Mesh Filter Inspection and Cleaning
  229
- Fuel Pump/Fuel Level Gauge Reassembly and Installation
  230
- Throttle Body
  233
- Throttle Body Components
  233
- Throttle Body Removal
  234
- Throttle Body Disassembly
  236
- Throttle Body Cleaning and Inspection
  238
- Iac Valve Inspection
  239
- Throttle Body Reassembly
  239
- Throttle Body Installation
  241
- Fuel Injector Inspection
  242
- Fuel Injector Installation
  242
- Fuel Injector Removal
  242
- Throttle Cable Adjustment
  242
- Tp Sensor Adjustment
  242
- Throttle Valve Synchronization
  243
Cooling and Lubrication System

244
- Cooling Circuit
  245
- Cooling System
  245
- Description
  245
- Oil Cooler
  245
- Engine Coolant
  246
- Cooling Circuit Inspection
  247
- Radiator and Hoses
  247
- Radiator Cap Inspection
  247
- Radiator Inspection
  247
- Radiator Hose Inspection
  248
- Radiator Removal
  249
- Radiator Remounting
  250
- Radiator Reservoir Tank
  250
- Cooling Fan
  251
- Inspection
  251
- Removal
  251
- Remounting
  252
- Cooling Fan Thermo-Switch
  253
- Main Fuse
  253
- Removal
  253
- Inspection
  254
- Installation
  254
- Engine Coolant Temperature Sensor
  255
- Removal
  255
- Inspection
  256
- Instalation
  256
- Inspection
  257
- Removal
  257
- Thermostat
  257
- Installation
  258
- Construction
  259
- Water Pump
  259
- Removal and Disassembly
  260
- Inspection
  262
- Reassembly and Installation
  264
- Lubrication System
  268
- Oil Cooler
  268
- Oil Filter
  268
- Oil Level Switch
  268
- Oil Pressure
  268
- Oil Pressure Regulator
  268
- Oil Pressure Switch
  268
- Oil Pump
  268
- Oil Return Pump
  268
- Oil Sump Filter
  268
- Engine Lubrication System Chart
  269
- Engine Lubrication System
  270
Chassis

272
- Construction
  274
- Exterior Parts
  274
- Removal
  278
- Remounting
  295
- Construction
  297
- Front Wheel
  297
- Removal
  298
- Inspection and Disassembly
  299
- Reassembly and Remounting
  301
- Construction
  304
- Front Fork
  304
- Removal and Disassembly
  305
- Inspection
  307
- Reassembly and Remounting
  308
- Construction
  312
- Steering and Handlebars
  312
- Removal
  313
- Inspection and Disassembly
  315
- Reassembly and Remounting
  315
- Steering Tension Adjustment
  318
- Construction
  319
- Rear Wheel
  319
- Removal
  320
- Inspection and Disassembly
  322
- Reassembly and Remounting
  324
- Construction
  329
- Rear Shock Absorber
  329
- Removal
  329
- Inspection
  330
- Remounting
  330
- Suspension Setting
  330
- Construction
  331
- Rear Swingarm
  331
- Removal
  331
- Inspection
  332
- Remounting
  333
- Construction
  335
- Front Brake
  335
- Brake Pad Replacement
  336
- Brake Fluid Replacement
  337
- Caliper Removal and Disassembly
  338
- Caliper Inspection
  339
- Caliper Reassembly and Remounting
  340
- Brake Disc Inspection
  342
- Master Cylinder Removal and Disassembly
  342
- Master Cylinder Inspection
  343
- Master Cylinder Reassembly and Remounting
  343
- Construction
  345
- Rear Brake
  345
- Brake Pad Replacement
  346
- Brake Fluid Replacement
  348
- Caliper Removal and Disassembly
  348
- Caliper Inspection
  350
- Caliper Reassembly and Remounting
  351
- Brake Disc Inspection
  355
- Master Cylinder Inspection
  355
- Master Cylinder Reassembly and Remounting
  355
- Master Cylinder Removal and Disassembly
  355
- Brake-Lock Adjustment
  356
- Brake-Lock Cable Replacement
  357
- Brake-Lock System
  359
- Inspection
  363
- Tire and Wheel
  363
- Tire Removal
  363
- Tire Installation
  364
- Valve Installation
  364
- Balancer Weight Installation
  365
Electrical System

366
- Cautions in Servicing
  367
- Clamps
  367
- Connectors
  367
- Couplers
  367
- Fuses
  367
- Semi-Conductor Equipped Parts
  367
- Battery
  368
- Connecting the Battery
  368
- Using the Multi Circuit Tester
  368
- Wiring Procedure
  368
- Location of Electrical Components
  369
- Charging System
  371
- Troubleshooting
  371
- Inspection
  373
- Starter System
  376
- Troubleshooting
  376
- Starter Motor Removal and Disassembly
  377
- Starter Motor Inspection
  378
- Starter Motor Reassembly
  379
- Starter Relay Inspection
  380
- Side-Stand/Ignition Interlock System Parts Inspection
  381
- Ignition System
  383
- Troubleshooting
  383
- Inspection
  385
- Combination Meter
  388
- Parts Names
  388
- Removal and Disassembly
  388
- Operating Procedure
  389
- Inspection
  391
- Headlight
  396
- Lamp
  396
- Brake Light/ Taillight, Turn Signal Light and License Light
  397
- Cooling Fan Motor Relay
  399
- Fuel Pump Relay
  399
- Ignition Switch Removal
  399
- Relays
  399
- Side-Stand Relay
  399
- Starter Relay
  399
- Switches
  399
- Turn Signal Light
  399
- Turn Signal Relay
  399
- Battery
  402
- Initial Charging
  402
- Specifications
  402
- Recharging Operation
  404
- Servicing
  404
Servicing Information

405
- Fi System/ Cvt System Malfunction Code and Defective Condition
  406
- Troubleshooting
  406
- Engine
  408
- Cvt
  413
- Radiator (Cooling System)
  413
- Chassis
  414
- Brakes
  415
- Electrical
  416
- Battery
  417
- Wiring Harness Routing
  418
- Wiring Harness, Cable and Hose Routing
  418
- Cable Routing
  422
- Throttle Body Installation/Hose Routing
  424
- Fuel Tank Mounting
  425
- Fuel Tank Hose Routing
  427
- Radiator Hose Routing
  429
- Front Brake Hose Routing
  430
- Rear Brake Hose Routing
  431
- Center Stand Set-Up
  432
- Side-Stand Set-Up
  432
- Special Tools
  433
- Engine
  437
- Tightening Torque
  437
- Chassis
  438
- Cvt
  438
- Tightening Torque Chart
  439
- Service Data
  440
- Brake Light/Taillight
  446
- Brake Lock Indicator Light
  446
- Drive Indicator Light
  446
- Gear Position Indicator Light
  446
- High Beam Indicator Light
  446
- License Light
  446
- Oil Pressure Indicator Light
  446
- Power Mode Indicator Light
  446
- Turn Signal Indicator Light
  446
- Emission Control Systems
  450
- Fuel Injection System
  450
- Crankcase Emission Control System
  451
- Exhaust Emission Control System (Pair System)
  452
- Noise Emission Control System
  453
- Hose
  454
- Pair (Air Supply) System Inspection
  454
- Pair Control Solenoid Valve
  454
- Pair Reed Valve
  454
- Pair (Air Supply) System Hose Routing
  456
- Heated Oxgen Sensor (Ho2S) Inspection
  457

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