Мануал для сузуки бандит 1200

Suzuki GSF1200 Bandit

Warning / Caution / Note

B649G10000001

Please read this manual and follow its instructions carefully. Toemphasize special information, the symbol and the words WARNING, CAUTION and NOTE have special meanings. Pay special attention to the messages highlighted by these signal words.

! WARNING

Indicates a potential hazard that could result in death or injury.

! CAUTION

Indicates a potential hazard that could result in motorcycle damage.

NOTE

Indicates special information to make maintenance easier or instructions clearer.

Please note, however, that the warnings and cautions contained in this manual cannot possibly cover all potential hazards relating to the servicing, or lack of servicing, of the motorcycle. In addition to the WARNINGS and CAUTIONS stated, you must use good judgement and basic mechanical safety principles. If you are unsure about how to perform a particular service operation, ask a more experienced mechanic for advice.

General Precautions

B649G10000002

!WARNING

•Proper service and repair proceduresare important for the safety of the service mechanic and the safety and reliabilityof the motorcycle.

•When 2 or more persons work together, pay attention to the safety of eachother.

•When it is necessary to run the engine indoors, make sure that exhaust gasis forced outdoors.

•When working with toxic or flammable materials, make sure that the area you work in is well-ventilated and that you follow all of the materialmanufacturer’s instructions.

•Never use gasoline as a cleaning solvent.

•Toavoid getting burned, do not touch the engine, engine oil, oil cooler and exhaust system until they have cooled.

•After servicing the fuel, oil, exhaust or brake systems, check all lines andfittings related to the system for leaks.

!CAUTION

•If parts replacement is necessary,replace the parts with Suzuki Genuine Parts or their equivalent.

•When removing partsthat are to be reused, keep them arranged in an orderly manner so that they may be reinstalled in the proper order and orientation.

•Be sure to use special toolswhen instructed.

•Make sure that all parts used in reassembly are clean. Lubricatethem when specified.

•Use the specified lubricant, bond,or sealant.

•When removing the battery, disconnect the negative (–) cable first and then the positive cable.

•When reconnecting the battery, connect the positive cable first and then the negative (–) cable, and replace the terminal cover on the positive terminal.

•When performing service to electrical parts, if the service procedures not require use of battery power, disconnect the negative (–) cable the battery.

•When tightening the cylinder head and case bolts and nuts, tighten the larger sizes first. Always tighten the bolts and nuts diagonally from the inside working out and to the specified tighteningtorque.

•Whenever you remove oil seals, gaskets, packing, O-rings, locking washers, selflocking nuts, cotter pins, circlips and certain other parts as specified, be sureto replace them with new ones. Also, before installing these new parts, be sure to remove any left over material from the mating surfaces.

•Never reuse a circlip. When installing a new circlip, take care not to expand the end gap larger than required to slip the circlip over the shaft. After installing a circlip, always ensure that it iscompletely seated in its groove and securely fitted.

•Use a torque wrench to tightenfasteners to the specified torque. Wipe off grease and oil if a thread is smeared withthem.

•After reassembling, check partsfor tightness and proper operation.

•Toprotect the environment, do not unlawfully dispose of used motor oil, engine coolant and other fluids:batteries, and tires.

•Toprotect Earth’s natural resources, properly dispose of used motorcycleand parts.

Precautions for Electrical Circuit Service

B649G10000003

When handling the electrical parts or servicing the ABS system, observe the following points for the safety of the system.

Electrical Parts

Connector / Coupler

•When connecting a connector, be sure to push it in until a click is felt.

I310G1000001-01

•With a lock type coupler, be sure to release the lock when disconnecting, and push it in fully till the lock works when connecting it.

•When disconnecting the coupler, be sure to hold the coupler body and do not pull the lead wires.

•Inspect each terminal on the connector/couplerfor looseness or bending.

•Inspect each terminal for corrosion and contamination. The terminals must be clean andfree of any foreign material which could impede proper terminal contact.

I310G1000002-01

•Inspect each lead wire circuit for poor connection by shaking it by hand lightly. If any abnormal condition is found, repair or replace.

I310G1000003-01

•When taking measurements at electrical connectors using a tester probe, be sure to insert the probefrom the wire harness side (backside) of the connector/ coupler.

2

1

I649G1000013-01

•When connecting meter probe from the terminal side of the coupler (connection from harness side not being possible), use extra care not to force and cause the male terminal to bend or the female terminal to open. Connect the probe as shown to avoid opening of female terminal. Never push in the probe where male terminal is supposed to fit.

•The ABS control unit/HU cannot bedisassembled. Replace the whole unit with a new one.

I649G1000005-01

•Battery connection in reverse polarity is strictly prohibited. Such a wrong connection will damage the components of the ABS control unit/HU instantly when reverse power is applied.

I649G1000006-01

•Removing any battery terminal of a running engine is strictly prohibited. The moment such removal is made, damaging counter electromotive force will be applied to the Ignition unit and ABS control unit/HU which may result in serious damage.

I310G1000011-01

•Before measuring voltage at each terminal, check to make sure that battery voltage is 11 V or higher. Terminal voltage check at low battery voltage will lead to erroneous diagnosis.

I310G1000012-01

•Never connect any tester (voltmeter, ohmmeter, or whatever) to the Ignition and ABS control unit/HU when its coupler is disconnected. Otherwise, damage to Ignitor and ABS control unit/HU may result.

•Never connect an ohmmeter to the Ignitor and ABS control unit/HU with its coupler connected. If attempted, damage to Ignitor and ABS control unit/HU or sensors may result.

•Be sure to use a specifiedvoltmeter/ohmmeter. Otherwise, accurate measurements may notbe obtained and personal injury may result.

Electrical Circuit Inspection Procedure

While there are various methods for electrical circuit inspection, described here is a general method to check for open and short circuit using an ohmmeter and a voltmeter.

Open circuit check

Possible causes for the open circuit are as follows. As the cause can exist in the connector/coupler or terminal, they need to be checked carefully.

•Loose connection of connector/coupler

•Poor contact of terminal (due to dirt, corrosion or rust, poor contact tension, entry of foreign object etc.)

•Wire harness being open.

•Poor terminal-to-wire connection.

When checking system circuits including an electronic control unit such as ignitor, ABS control unit/HU, etc., it is important to perform careful check, starting with items which are easier to check.

1)Disconnect the negative (–) cable from the battery.

2)Check each connector/coupler at both ends of the circuit being checked for loose connection. Also check for condition of the coupler lock ifequipped.

“A”

“A”

Ignitor

1

I649G1000026-01

3)Using a test male terminal, check the female terminals of the circuit being checked for contact tension.

Check each terminal visually for poor contact (possibly caused by dirt, corrosion, rust, entry of foreign object, etc.). At the same time, check to make sure that each terminal is fully inserted in the coupler and locked.

If contact tension is not enough, rectify the contact to increase tension or replace. The terminals must be clean and free of any foreign material which could impede proper terminal contact.

“B”

“C”

I649G1000027-01

“B”: Check contact tension by inserting and removing.

“C”: Check each terminal for bend and proper alignment.

4)Using continuity inspect or voltage check procedure as described below, inspect the wire harness terminals for open circuit and poor connection. Locate abnormality, if any.

“D” “F”

“E”

I649G1000028-01

”D”: Looseness of crimping

“E”: Open

“F”: Thin wire (A few strands left)

Continuity check

1)Measure resistance across coupler “B” (between “A” and “C” in figure).

If no continuity is indicated (infinity or over limit), the circuit is open between terminals “A” and “C”.

“A”

“B” Ignitor

“C”

I649G1000019-03

2)Disconnect the coupler “B” and measureresistance between couplers “A” and “B-1”.

If no continuity is indicated, the circuit is open between couplers “A” and “B-1”. If continuity is indicated, there is an open circuit between couplers “B-2” and “C” or an abnormality in coupler “B-2” or coupler “C”.

“A”

“B-2”

Ignitor

“B” “C”

“B-1”

I649G1000029-02

Voltage check

If voltage is supplied to the circuit being checked, voltage check can be used as circuit check.

1)With all connectors/couplers connected andvoltage applied to the circuit being checked, measure voltage between each terminal and bodyground.

2)If measurements were taken as shown in figureat the right and results are as listed below, it means that the circuit is open between terminals “A” and “B”.

Voltage between

“A” and body ground: Approx. 5V “B” and body ground: Approx. 5V “C” and body ground: 0 V

3)Also, if measured values are as listed below, a resistance (abnormality) exists which causes the voltage drop in the circuit between terminals “A” and “B”.

Voltage between

“A” and body ground: Approx. 5 V

“B” and body ground: Approx. 5 V – 2 V voltage drop

“C” and body ground: 3 V – 2 V voltage drop

“A”

Ignitor

“B”

“C”

5V

I649G1000021-02

Short circuit check (Wire harness to ground)

1)Disconnect the negative (–) cable from thebattery.

2)Disconnect the connectors/couplers at both endsof the circuit to be checked.

NOTE

If the circuit to be checked branches to other parts as shown, disconnect all connectors/ couplers of those parts. Otherwise, diagnosis will be misled.

3)Measure resistance between terminal at one endof circuit (“A” terminal in figure) and body ground. If continuity is indicated, there is a short circuit to ground between terminals “A” and “C”.

“A”

“D”

“B” Ignitor

“C”

“E”

5V

“A” “C”

I649G1000022-02

4)Disconnect the connector/coupler included incircuit (coupler “B”) and measure resistance between terminal “A” and body ground. If continuity is indicated, the circuit is shorted to the ground between terminals “A” and “B”.

“A”

“D”

Ignitor

“B” “C”

I649G1000023-02

“D”: To other parts

Vehicle Side View

B649G10101003

NOTE

Difference between photographs and actual motorcycles may exist depending on the markets.

SUZUKI GSF1200 (2006-model)

Right Side

I649G1010008-01

Left Side

I649G1010009-01

SUZUKI GSF1200S (2006-model)

Right Side

I649G1010005-06

Left Side

I649G1010006-05

Vehicle Identification Number

B649G10101004

The frame serial number or V.I.N. (Vehicle Identification Number) “A” is stamped on the right side of the steering head pipe. The engine serial number “B” is located on the right side of the crankcase. These numbers are required especially for registering the machine and ordering spare parts.

“A”

I649G1010001-02

“B”

I649G1010002-03

Fuel and OilRecommendation

B649G10101005

Fuel (For USA)

Use only unleaded gasoline of at least 87 pump octane (R/2 + M/2) or 91 octane or higher rated by the research method.

Gasoline containing MTBE (Methyl Tertiary Butyl Ether), less than 10% ethanol, or less than 5% methanol with appropriate cosolvents and corrosion inhibitor is permissible.

Fuel (For Other Countries)

Gasoline used should be graded 91 octane (Research Method) or higher. Unleaded gasoline is recommended.

Engine Oil

Oil quality is a major contributor to your engine’s performance and life. Always select good quality 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 an alternative according to the chart.

I310G1010005-01

Brake Fluid

Specification and classification: DOT4

! WARNING

Since the brake system of this motorcycle is filled with a glycol-based brake fluid by the manufacturer, do not use or mix different types of fluid such as silicone-based and petroleum-based fluid for refilling the system, otherwise serious damage will result.

Do not use any brake fluid taken from old or used or unsealed containers.

Never reuse brake fluid left over from a previous servicing, which has been stored for a long period.

Front Fork Oil

Use fork oil SS8 or an equivalent fork oil.

BREAK-IN Procedures

B649G10101007

During manufacture only the best possible materials are used and all machined parts are finished to a very high standard but it is still necessary to allow the moving parts to “BREAK-IN” before subjecting the engine to maximum stresses. The future performance and reliability of the engine depends on the care and restraint exercised during its early life. The general rules are asfollows.

1)Keep to these break-in engine speed limits:

Speed limits

Initial 800 km: Below 5 500 r/min Up to 1 600 km: Below 8 000 r/min Over 1 600 km: Below 11 000 r/min

2)Upon reaching an odometer reading of 1 600 km (1 000 miles) you can subject the motorcycle to full throttle operation. However, do not exceed 11 000r/ min at any time.

Cylinder Identification

B649G10101008

The four cylinders of this engine are identified as No.1, 2, 3 and No.4 cylinder, as counted from left to right (as viewed by the rider on the seat).

I649G1010010-01

Country and Area Codes

B649G10101009

The following codes stand for the applicable country(- ies) and area(-s).

Air Cleaner Element Removal and Installation

B649G10206001

Inspect air cleaner element

Every 6 000 km (4 000 miles, 12 months)

Replace air cleaner element

Every 18 000 km (11 000 miles, 36 months) Removal

1)Remove the fuel tank. Refer to “Carburetor Assembly Removal and Installation: in Section1G”.

2)Remove the two screws and slide the aircleaner cover backward.

I649G1020002-02

3) Remove the air cleaner element(1).

1

I649G1020003-02

Installation

Reinstall the cleaned or new air cleaner element in the reverse order of removal. Pay attention to thefollowing points:

•When installing the air cleaner element into the air cleaner box, make sure that the mark points “A”up.

•After cleaning or installing the air cleaner element, drain water from the air cleaner by removing the drain plug.

I649G1020005-01

Air Cleaner Element Inspection and Cleaning

B649G10206002

Refer to “Air Cleaner Element Removal and Installation: ”.

Inspect air cleaner element

Every 6 000 km (4 000 miles, 12 months)

Replace air cleaner element

Every 18 000 km (11 000 miles, 36 months)

Inspection

Inspect the air cleaner element for clogging.

! CAUTION

If driving under dusty conditions, clean the air cleaner element more frequently. The surest way to accelerate engine wear is to operate the engine without the element or to use a torn element. Make sure that the air cleaner is in good condition at all times. Life of the engine depends largely on this component.

Cleaning

Carefully use compressed air to clean the aircleaner element.

! CAUTION

Always apply compressed air to the inside of the air cleaner element. If compressed air is applied to the outside, dirt will be forced into the pores of the air cleaner element, restricting air flow through the air cleaner element.

I649G1020007-01

Spark Plug Removal and Installation

B649G10206003

Inspect spark plug

Every 6 000 km (4 000 miles, 12 months)

Replace spark plug

Every 12 000 km (7 500 miles, 24months)

Removal

! WARNING

The hot engine can burn you.

Wait until the engine is cool enough to touch.

!

Confirm the thread size and reach when replacing the plug. If the reach is too short, carbon will be deposited on the screw portion of the plug hole and enginedamage may result.

1) Remove the spark plug caps.

I649G1020008-02

2)Remove the spark plugs with the spark plug wrench.

Special tool

(A): 09930–10121 (Spark plug wrench set)

(A)

I649G1020009-02

Installation

Install the spark plugs in the reverse order of removal. Pay attention to the following points:

! CAUTION

Before tightening the spark plug to the specified torque,carefully turnthespark plug by finger into the threads of the cylinder head to prevent damage the aluminum threads.

•Install the spark plugs to the cylinder heads byfinger tight, and then tighten them to the specifiedtorque.

Tightening torque

Spark plug: 11 N·m (1.1 kgf-m, 8.0 lb-ft)

•Install the spark plug caps onto the spark plugs. Make sure that each spark plug cap is installed in the correct location and direction.

Spark Plug Inspection and Cleaning

B649G10206004

Refer to “Spark Plug Removal and Installation: ”.

Inspect spark plug

Every 6 000 km (4 000 miles, 12 months)

Replace spark plug

Every 12 000 km (7 500 miles, 24 months)

Heat Range

Check spark plug heat range by observing electrode color.

If it is white or glazed appearing, replace the spark plug with colder type one.

Carbon Deposits

Check to see if there are carbon deposits on the spark plug.

If carbon is deposited, remove it using a spark plug cleaner machine or carefully use a tool with a pointed end.

I649G1020010-01

Spark Plug Gap

Measure the spark plug gap using a thickness gauge. Adjust the spark plug gap if necessary.

Spark plug gap

0.6 – 0.7 mm (0.024 – 0.028 in)

Special tool

(A): 09900–20803 (Thickness gauge)

Electrodes Condition

Check to see the worn or burnt condition of the electrodes.

If it is extremely worn or burnt, replace the plug. And also replace the plug if it has a broken insulator, damaged thread.

Exhaust Pipe Bolt and Muffler Mounting Bolt Inspection

B649G10206021

Tighten exhaust pipe bolt and muffler mounting bolt Initially at 1 000 km (600 miles, 2 month) and every 12 000 km (7 500 miles, 24 months) thereafter.

Check the exhaust pipe bolts, muffler mounting bolts and nut to the specified torque.

Tightening torque

Exhaust pipe bolt (a): 23 N·m (2.3 kgf-m, 16.5 lb-ft) Muffler mounting bolt (b): 23 N·m (2.3 kgf-m, 16.5 lb-ft)

Muffler connecting bolt (c): 23 N·m (2.3 kgf-m, 16.5 lb-ft)

(a)

(a)

(a)

I649G1020054-03

(b)

(b)

Valve Clearance Inspection and Adjustment

B649G10206005

Inspect valve clearance

Initially at 1 000 km (600 miles, 2 month) and every 12 000 km (7 500 miles, 24 months) thereafter.

Valve clearance adjustment must be checked and adjusted, a) at the time of periodic inspection, b) when the valve mechanism is serviced, and c) when the camshafts are removed for servicing.

1)Remove the fuel tank. Refer to “Fuel TankRemoval and Installation: in Section 1G”.

2)Remove the frame head covers. (GSF1200) Refer to “Exterior Parts Removal and Installation: in Section 9D”.

3)Remove the PAIR valve. Refer to “PAIRSystem Removal and Installation: in Section 1B”.

4)Remove all the spark plugs. Refer to “SparkPlug Removal and Installation: ”.

5)Remove the breather cover (1).

1

I649G1020066-01

6)Remove the cylinder head cover. Refer to “Engine Top Side Disassembly: in Section 1D”.

NOTE

The valve clearance specification is different for both intake and exhaust valves.

Valve clearance (When cold)

IN.: 0.10 – 0.15 mm (0.004 – 0.006 in) EX.: 0.18 – 0.23 mm (0.007 – 0.009 in)

NOTE

•The camshafts must be at positions “A” or

“B”, in order to check or adjust the valve clearance. Clearance readings should not be taken with the camshafts in any other position than the ones shown.

•The valve clearance should onlybe checked when the engine is cold.

I649G1020012-01

7)Remove the CKP sensor cover. Refer to “CKP Sensor Removal and Installation: in Section1H”.

Turn the crankshaft clockwise and align the “T” mark on the rotor with the center of the CKP sensor. Also, position the notches “C” on the right end of each camshaft as shown. Then, measure the following valve clearances “D”.

•Cylinder #1: Intake and exhaust valve clearances

•Cylinder #2: Exhaust valve clearance

•Cylinder #3: Intake valve clearance

I649G1020013-02

“C” “C”

I649G1020014-02

“D” “D”

Engine Oil and Filter Replacement

B649G10206007

Replace engine oil

Initially at 1 000 km (600 miles, 2 month) and every 6 000 km (4 000 miles, 12 months) thereafter.

Replace oil filter

Initially at 1 000 km (600 miles, 2 month) and every 18 000 km (11 000 miles, 36 months) thereafter.

Oil should be changed while the engine is warm. Oil filter replacement at the above intervals, should be done together with the engine oil change.

Engine Oil Replacement

1)Keep the motorcycle upright.

2)Place an oil pan below the engine, and drainengine oil by removing the oil drain plug (1) and filler cap

(2).

1

I649G1020019-01

2

I649G1020020-01

3)Tighten the oil drain plug (1) to the specified torque, and pour new oil through the oil filler. When performing an oil change (without oil filter replacement), the engine will hold about 3.3 L of oil. Use of SF/SG or SH/SJ in API with MA in JASO.

Tightening torque

Oil drain plug (a): 23 N·m (2.3 kgf-m, 16.5 lb-ft)

1, (a)

I649G1020021-03

4)Start up the engine and allow it to run forseveral minutes at idling speed.

5)Turn off the engine and wait about three minutes, then check the oil level through the inspection window (3). If the level is below the “L” mark, addoil to the “F” mark. If the level is above the “F” mark, drain the oil until the level reaches the “F” mark.

3

I649G1020022-01

Oil Filter Replacement

1)Drain engine oil as described in the engineoil replacement procedure.

2)Remove the oil filter (1) using the special tool.

Special tool

(A): 09915–40610 (Oil filter wrench)

(A)

1

I649G1020023-02

Engine Idle Speed Inspection and Adjustment

B649G10206011

Inspect engine idle speed

Initially at 1 000 km (600 miles, 2 month) and every 6 000 km (4 000 miles, 12 months) thereafter.

NOTE

Make this adjustment when the engine is hot.

Start the engine, turn the throttle stop screw (1) and set the engine idle speed “a”.

Engine idle speed “a”

1300 100 r/min (E-28)

1200 100 r/min (Others)

1

I649G1020025-02

Throttle Valve Synchronization

B649G10206013

Inspect throttle valve synchronization Every 12 000 km (7 500 miles, 24months)

Inspect the throttle valve synchronization periodically. Refer to “Carburetor Synchronization: in Section 1G”.

PAIR System Inspection

B649G10206014

Inspect PAIR system

Every 12 000 km (7 500 miles, 24months)

Inspect the PAIR (air supply) system periodically.Refer to “PAIR System Inspection: ”.

Clutch SystemInspection

B649G10206026

Inspect clutch hose and clutch fluid Every 6 000 km (4 000 miles, 12 months)

Replace clutch hose Every 4 years

Replace clutch fluid Every 2 years

! WARNING

The clutch system of this motorcycle is filled with a glycol-based brake fluid. Do not use or mix different types of fluid such as siliconebased or petroleum-based. Do not use any brake fluid taken from old, used or unsealed containers. Never reuse brake fluid left over from the last servicing or stored for a long period of mine. Check the clutch hose and hose joints for cracks and fluid leakage.

Clutch Fluid Level Check

1)Keep the motorcycle upright and placethe handlebars straight.

2)Check the clutch fluid level by observing thelower limit line on the clutch fluid reservoir.

When the clutch fluid level is below the lowerlimit line, replenish with clutch fluid that meets the following specification.

BF: Brake fluid (DOT 4)

I649G1020028-01

Clutch Hose Inspection

1)Remove the left frame cover. Refer to “Exterior Parts Removal and Installation: in Section 9D”.

2)Remove the fuel tank. Refer to “Fuel TankRemoval and Installation: in Section 1G”.

3)Inspect the clutch hose for crack, damage or clutch fluid leakage. If it is defected, replace the clutch hose with a new one.

I649G1020031-01

4)After finishing the clutch hose inspection,reinstall the removed parts.

Clutch Hose Replacement

B649G10206031

Refer to “Clutch Hose Removal and Installation: in Section 5C”.

Air Bleeding from Clutch Fluid Circuit

B649G10206032

Refer to “Air Bleeding from Clutch Fluid Circuit: ”.

Clutch Fluid Replacement

B649G10206033

Refer to “Clutch Fluid Replacement: in Section 5C”.

Drive Chain Inspection and Adjustment

B649G10206028

Inspect drive chain

Initially at 1 000 km (600 miles, 2 month) and every 6 000 km (4 000 miles, 12 months) thereafter.

Drive Chain Visual Check

1)With the transmission in neutral, support the motorcycle using the center-stand and turn therear wheel slowly by hand.

2)Visually check the drive chain for the possible defects listed as follows. If any defects are found, the drive chain must be replaced. Refer to “Drive Chain Replacement: in Section 3A”.

•Loose pins

•Damaged rollers

•Dry or rusted links

•Kinked or binding links

•Excessive wear

•Improper chain adjustment

•Missing O-ring seals

NOTE

When replacing the drive chain, replace the drive chain and sprockets as a set.

2

1

I649G1020032-01

Drive Chain Length Inspection

1)Remove the cotter pin. (For E-28)

2)Loosen the axle nut (1).

3)Loosen the chain adjuster lock-nuts (2).

4)Give tension to the drive chain fully by turningboth chain adjuster bolts (3).

I649G1020033-01

5)Count out 21 pins (20 pitches) on the chain and measure the distance between the two points. If the distance exceeds the service limit, the chain must be replaced.

Drive chain 20-pitch length Service limit: 319.4 mm (12.57 in)

I649G1020034-01

6)After finishing the drive chain lengthinspection, adjust the drive chain slack.

Drive Chain Slack Adjustment

1)Place the motorcycle on its side-stand foraccurate adjustment.

2)Loosen the axle nut (1).

3)Loosen the chain adjuster lock-nuts (2).

4)Loosen or tighten both chain adjuster bolts (3) until there is 20 – 30 mm (0.8 – 1.2 in) “a” of slack atthe middle of the chain between the engine and rear sprockets as shown.

! CAUTION

The reference marks “A” on both sides of the swingarm and the edge of each chain adjuster must be aligned to ensure that the front and rear wheels are correctly aligned.

Drive chain slack “a”

Standard 20 – 30 mm (0.8 – 1.2 in)

“A” “A” 1

I649G1020035-02

“a”

I649G1020036-01

5)After adjusting the drive chain, tighten the axle nut

(1) to the specified torque.

6)Tighten both chain adjuster lock-nuts (2) securely.

Tightening torque

Rear axle nut: 100 N·m (10.0 kgf-m, 72.5 lb-ft)

7)Install a new cotter pin. (For E-28)

Recheck the drive chain slack after tighteningthe axle nut.

Drive Chain Cleaning and Lubricating

B649G10206029

Clean and lubricate drive chain Every 1 000 km (600 miles)

Clean and lubricate the drive chain in the following procedures:

1)Clean the drive chain with kerosine. If the drive chain tends to rust quickly, the intervals must be shortened.

! CAUTION

Do not use trichloroethylene, gasoline or any similar solvent.

These fluids have too great a dissolving power for this chain and they can damage the O-rings. Use only kerosine to clean the drive chain.

2)After cleaning and drying the chain, oil it witha heavyweight motor oil.

!CAUTION

•Do not use any oil sold commercially as “drive chain oil”. Such oil can damagethe O-rings.

•The standard drive chain is a RK GB50GSVZ3. SUZUKI recommends to use this standard drive chain as a replacement.

I649G1020037-01

Brake System Inspection

B649G10206030

Inspect brake system

Initially at 1 000 km (600 miles, 2 month) and every 6

000 km (4 000 miles, 12 months) thereafter.

Inspect brake hose and brake fluid Every 6 000 km (4 000 miles, 12 months)

Replace brake hose Every 4 years

Replace brake fluid Every 2 years

!WARNING

•The brake system of this motorcycle is filled with a glycol-based brake fluid. Do not use or mix different types of fluid such as silicone-based and petroleum-based fluids. Do not use any brake fluid taken from old, used or unsealed containers. Never reuse brake fluid left over from the last servicing or stored for a long period of time.

•Brake fluid, if it leaks, will interfere with safe running and immediately discolor painted surfaces. Check the brake hoses and hose joints for cracks and oilleakage before riding.

Brake Fluid Level Check

1)Keep the motorcycle upright and placethe handlebars straight.

2)Check the brake fluid level by observing the lower limit lines on the front and rear brake fluid reservoirs. When the brake fluid level is below the lower limit line, replenish with brake fluid that meets the following specification.

BF: Brake fluid (DOT 4)

I649G1020038-01

I649G1020039-01

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” and “Rear Brake Pad Replacement: in Section 4C”.

! CAUTION

Replace the brake pad as a set, otherwise braking performance will be adversely affected.

“A”

I649G1020040-02

“A”

I649G1020041-02

Front Brake Hose Inspection

Inspect the brake hoses and hose joints for crack, damage or oil leakage. If any defects are found, replace the brake hose with a new one.

I649G1020047-01

Rear Brake Hose Inspection

Inspect the brake hose for crack, damage or brakeoil leakage. If any defects are found, replace the brake hose with a new one.

I649G1020048-01

Brake Pedal Height Inspection and Adjustment

1)Inspect the brake pedal height “a” between the pedal top face and footrest.

Adjust the brake pedal height if necessary.

Brake pedal height “a” Standard: 60 mm (2.4 in)

2)Loosen the lock-nut (1).

3)Turn the push rod (2) until the brake pedal is 60mm (2.4 in) below the top of the footrest.

4)Tighten the lock-nut (1) securely.

Tightening torque

Rear master cylinder rod lock-nut (a): 18 N·m ( 1.8 kgf-m, 13.0 lb-ft)

I649G1020042-04

Rear Brake Light Switch Adjustment

B649G10206036

Refer to “Rear Brake Light Switch Inspection and Adjustment: in Section 4A”.

Brake Hose Replacement

B649G10206037

Refer to “Front Brake Hose Removal and Installation: in Section 4A” and “Rear Brake Hose Removal and Installation: in Section 4A”.

Air Bleeding from Brake Fluid Circuit

B649G10206034

Refer to “Air Bleeding from Brake Fluid Circuit: in Section 4A”.

Brake Fluid Replacement

B649G10206035

Refer to “Brake Fluid Replacement: in Section 4A”.

Tire Inspection

B649G10206017

Inspect tire

Every 6 000 km (4 000 miles, 12months)

Tire Tread Condition

Operating the motorcycle with excessively worn tires will decrease riding stability and consequently invite a dangerous situation. It is highly recommended to replace a tire when the remaining depth of tire tread reaches the following specification.

Special tool

: 09900–20805 (Tire depth gauge)

Tire tread depth (Service limit) Front: 1.6 mm (0.06 in)

Rear: 2.0 mm (0.08 in)

I310G1020068-01

Tire Pressure

If the tire pressure is too high or too low, steering will be adversely affected and tire wear increased. Therefore, maintain the correct tire pressure for good roadability or shorter tire life will result. Cold inflation tire pressure is as follows.

I310G1020069-01

Chassis Bolt and Nut Inspection

B649G10206022

Tighten chassis bolt and nut

Initially at 1 000 km (600 miles, 2 month) and every 6 000 km (4 000 miles, 12 months) thereafter.

Check that all chassis bolts and nuts are tightened to their specified torque.

5, (c)

8, (b) 7, (b)

10, (f)

14, (b)

I649G1020060-03

14. Front fork lower clamp bolt

: 23 N m (2.3 kgf-m, 16.5 lb-ft)

21, (o) 17, (h)

16, (b)

Refer to “Compression Pressure Check: in Section1D”.

Oil Pressure Check

B649G10206024

Refer to “Oil Pressure Check: in Section 1E”.