Мануал suzuki intruder vzr1800

• Page 1
  VZR1800 9 9 5 0 0 — 3 9 2 9 0 — 0 1 E…

• Page 2: General Information

  FOREWORD GROUP INDEX This manual contains an introductory description on the SUZUKI VZR1800 and procedures for its inspection/service and overhaul of its main compo- GENERAL INFORMATION nents. Other information considered as generally known is not included. PERIODIC MAINTENANCE Read the GENERAL INFORMATION section to familiarize yourself with the motorcycle and its main- tenance.

• Page 3: How To Use This Manual

  HOW TO USE THIS MANUAL TO LOCATE WHAT YOU ARE LOOKING FOR: 1. The text of this manual is divided into sections. 2. The section titles are listed in the GROUP INDEX. 3. Holding the manual as shown at the right will allow you to find the first page of the section easily.

• Page 4
  Use engine oil unless otherwise speci- 99000-99032-11X fied. Apply molybdenum oil solution. Use fork oil or equivalent. (Mixture of engine oil and SUZUKI 99000-99044-L01 MOLY PASTE in a ratio of 1:1) Apply SUZUKI SUPER GREASE “A” or equivalent. Apply or use brake fluid.

• Page 5: Abbreviations Used In This Manual

  ABBREVIATIONS USED IN THIS MANUAL ABDC : After Bottom Dead Center : Fuel Injection, Fuel Injector : Alternating Current : Fuel Pump : Air Cleaner, Air Cleaner Box : Fuel Pressure Regulator : American Petroleum Institute FP Relay : Fuel Pump Relay ATDC : After Top Dead Center : Air Fuel Mixture…

• Page 6
  : Oil Pressure Switch : Positive Crankcase Ventilation (Crankcase Breather) : Right Hand : Read Only Memory : Society of Automotive Engineers : Suzuki Diagnosis System STC System : Secondary Throttle Control System (STCS) STP Sensor : Secondary Throttle Position Sensor…
• Page 7
  WIRE COLOR : Black : Green : Pink : Blue : Gray : Red : Brown : Light blue : White : Dark green : Light green : Yellow : Dark gray : Orange B/Bl : Black with Blue tracer B/Br : Black with Brown tracer : Black with Green tracer…

• Page 8: Table Of Contents

  GENERAL INFORMATION CONTENTS WARNING/CAUTION/NOTE…………….. 1- 2 GENERAL PRECAUTIONS …………….1- 2 SUZUKI VZR1800K6 (’06-MODEL) ………….. 1- 4 SERIAL NUMBER LOCATION …………..1- 4 FUEL, OIL AND ENGINE COOLANT RECOMMENDATION ……. 1- 5 FUEL (FOR USA AND CANADA)…………1- 5 FUEL (FOR OTHER COUNTRIES) …………1- 5 ENGINE OIL (FOR USA)…………….

• Page 9: Warning/Caution/Note

  GENERAL INFORMATION WARNING/CAUTION/NOTE Please read this manual and follow its instructions carefully. To emphasize special information, the symbol and the words WARNING, CAUTION and NOTE have special meanings. Pay special attention to the mes- sages highlighted by these signal words. Indicates a potential hazard that could result in death or injury.

• Page 10
  GENERAL INFORMATION » * If parts replacement is necessary, replace the parts with Suzuki Genuine Parts or their equiva- lent. * When removing parts that are to be reused, keep them arranged in an orderly manner so that they may be reinstalled in the proper order and orientation.

• Page 11: Suzuki Vzr1800K6 (’06-Model)

  GENERAL INFORMATION SUZUKI VZR1800K6 (’06-MODEL) RIGHT SIDE LEFT SIDE • Difference between illustration and actual motorcycle may exist depending on the markets. SERIAL NUMBER LOCATION The frame serial number or V.I.N. (Vehicle Identification Number) 1 is stamped on the right side of the steering head pipe.

• Page 12: Fuel, Oil And Engine Coolant Recommendation

  Suzuki recommends the use of SUZUKI PERFORMANCE 4 MOTOR OIL or equivalent engine oil. Use of API SF/SG or SH/SJ with JASO MA. 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 following chart.

• Page 13: Front Fork Oil

  Suzuki recommends the use of SUZUKI COOLANT anti-freeze/engine coolant. If this is not available, use an equivalent which is compatible with an aluminum radiator.

• Page 14: Break-In Procedures

  GENERAL INFORMATION BREAK-IN PROCEDURES 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.

• Page 15: Information Labels

  GENERAL INFORMATION INFORMATION LABELS VZR1800 VZR1800UF 1 Noise label A (For E-03, 24, 33) 2 Information label A (For E-03, 28, 33) 3 Vacuum hose routing label A (For E-33) 4 Fuel caution label A (For E-02, 24) 5 Fuel information label 6 Manual notice label A (For E-03, 33) 7 Tire information label…

• Page 16: Specifications

  GENERAL INFORMATION SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length …………2 450 mm (96.5 in) ..For E-03, 33 2 480 mm (97.6 in) ..For others Overall width …………875 mm (34.4 in) Overall height …………1 185 mm (46.7 in) Wheelbase …………

• Page 17: Chassis

  1-10 GENERAL INFORMATION CHASSIS Front suspension ……….Inverted telescopic, coil spring, oil damped Rear suspension ……….Link type, coil spring, oil damped Front fork stroke……….. 130 mm (5.1 in) Rear wheel travel ……….118 mm (4.6 in) Caster …………..31° 15’ Trail …………..

• Page 18: Periodic Maintenance

  PERIODIC MAINTENANCE PERIODIC MAINTENANCE CONTENTS PERIODIC MAINTENANCE SCHEDULE ………… 2- 2 PERIODIC MAINTENANCE CHART…………. 2- 2 LUBRICATION POINTS ……………. 2- 3 MAINTENANCE AND TUNE-UP PROCEDURES ……..2- 4 AIR CLEANER………………2- 4 EXHAUST PIPE BOLTS AND MUFFLER BOLTS ……. 2- 6 EXHAUST CONTROL VALVE …………..

• Page 19: Periodic Maintenance Schedule

  PERIODIC MAINTENANCE PERIODIC MAINTENANCE SCHEDULE The chart below lists the recommended intervals for all the required periodic service work necessary to keep the motorcycle operating at peak performance and economy. Mileages are expressed in terms of kilome- ters, miles and time for your convenience. NOTE: More frequent servicing may be required on motorcycles that are used under severe conditions.

• Page 20: Lubrication Points

  PERIODIC MAINTENANCE LUBRICATION POINTS Proper lubrication is important for smooth operation and long life of each working part of the motorcycle. Major lubrication points are indicated below. Brake lever holder Throttle cable Brake pedal pivot Clutch lever holder Side-stand pivot and Gearshift link pivot spring hook NOTE:…

• Page 21: Maintenance And Tune-Up Procedures

  PERIODIC MAINTENANCE MAINTENANCE AND TUNE-UP PROCEDURES This section describes the servicing procedures for each item of the Periodic Maintenance requirements. AIR CLEANER Inspect every 6 000 km (4 000 miles, 12 months) and replace every 18 000 km (11 000 miles, 36 months). •…

• Page 22
  PERIODIC MAINTENANCE • Carefully use air hose to blow the dust from the cleaner ele- ment. » Always use air pressure on the center air cleaner side of the air cleaner element. If air pressure is used on the other side, dirt will be forced into the pores of the air cleaner element thus restricting air flow through the air cleaner element.

• Page 23: Exhaust Pipe Bolts And Muffler Bolts

  PERIODIC MAINTENANCE EXHAUST PIPE BOLTS AND MUFFLER BOLTS Tighten initially at 1 000 km (600 miles, 2 months) and every 12 000 km (7 500 miles, 24 months) thereafter. • Tighten the exhaust pipe bolts, muffler mounting bolt and nut to the specified torque.

• Page 24: Exhaust Control Valve

  PERIODIC MAINTENANCE EXHAUST CONTROL VALVE Inspect initially at 1 000 km (600 miles, 2 months) and every 12 000 km (7 500 miles, 24 months) thereafter. • Remove the rubber cover 1. Check the exhaust control valve actuator 2 for its movement when the ignition switch is turned on.

• Page 25: Valve Clearance

  PERIODIC MAINTENANCE VALVE CLEARANCE Inspect every 24 000 km (14 500 miles, 48 months). • Remove the frame side covers. ($9-5) • Remove the fuel tank. ($6-3) • Remove the frame head covers and radiator covers. ($9-6) • Remove the air cleaner chamber. ($6-13) •…

• Page 26
  PERIODIC MAINTENANCE • Remove the secondary gear case cover. ($3-6) • Remove the generator cover cap 4, valve timing inspection plug 5 and generator cover plug 6. • Turn the crankshaft to set the #1 (Rear) cylinder at TDC of compression stroke.
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  2-10 PERIODIC MAINTENANCE VALVE CLEARANCE ADJUSTMENT The clearance is adjusted by replacing the existing tappet shim by a thicker or thinner shim. • Remove the intake or exhaust camshafts. ($3-14 to -15 and 3-17 to -18) • Remove the tappet and shim by fingers or magnetic hand. •…
• Page 28
  PERIODIC MAINTENANCE 2-11 (INTAKE SIDE)
• Page 29
  2-12 PERIODIC MAINTENANCE (EXHAUST SIDE)

• Page 30: Spark Plug

  PERIODIC MAINTENANCE 2-13 SPARK PLUG Inspect every 6 000 km (4 000 miles, 12 months). replace every 12 000 km (7 500 miles, 24 months). #2 (FRONT) SPARK PLUG REMOVAL • Remove the frame side covers. ($9-5) • Remove the fuel tank. ($6-3) •…

• Page 31
  2-14 PERIODIC MAINTENANCE #1 (REAR) SPARK PLUG REMOVAL • Remove the frame side covers. ($9-5) • Remove the fuel tank. ($6-3) • Disconnect lead wire coupler 1 from ignition coil/plug cap. » Disconnect the lead wire coupler before removing the ignition coil/plug cap to avoid lead wire coupler dam- age.
• Page 32
  PERIODIC MAINTENANCE 2-15 HEAT RANGE • Check spark plug heat range by observing electrode color. If the electrode of the spark plug is wet appearing or dark color, replace the spark plug with hotter type one. If it is white or glazed appearing, replace the spark plug with colder type one.

• Page 33: Fuel Line

  2-16 PERIODIC MAINTENANCE SPARK PLUG INSTALLATION • Screw the spark plugs into the cylinder head with fingers, and then tighten them to the specified torque. # Spark plug: 11 N·m (1.1 kgf-m, 8.0 Ib-ft) » Do not cross thread or over tighten the spark plug, or such an operation will damage the aluminum threads of the cylinder head.

• Page 34: Engine Oil And Oil Filter

  PERIODIC MAINTENANCE 2-17 ENGINE OIL AND OIL FILTER (ENGINE OIL) Replace initially at 1 000 km (600 miles, 2 months) and every 6 000 km (4 000 miles, 12 months) thereafter. (OIL FILTER) Replace initially at 1 000 km (600 miles, 2 months) and every 18 000 km (11 000 miles, 36 months) thereafter.

• Page 35
  Oil and filter change : 3.6 L (3.8/3.2 US/Imp qt) Engine overhaul : 4.7 L (5.0/4.1 US/Imp qt) » ONLY USE A GENUINE SUZUKI MOTORCYCLE OIL FILTER. Other manufacturer’s oil filters may differ in thread specifications (thread diameter and pitch), fil- tering performance and durability which may lead to engine damage or oil leaks.

• Page 36: Final Gear Oil

  PERIODIC MAINTENANCE 2-19 FINAL GEAR OIL Replace initially at 1 000 km (600 miles, 2 months) and inspect every 12 000 km (7 500 miles, 24 months) thereafter. • Keep the motorcycle upright. • Place an oil pan under the final gear case. •…

• Page 37: Throttle Valve Synchronization

  2-20 PERIODIC MAINTENANCE THROTTLE VALVE SYNCHRONIZATION Inspect initially at 1 000 km (600 miles, 2 months) (E-33 only) and every 12 000 km (7 500 miles, 24 moths). Inspect the throttle valve synchronization periodically. ($6-23) COOLING SYSTEM Inspect every 6 000 km (4 000 miles, 12 months). Replace engine coolant every 2 years.

• Page 38
  PERIODIC MAINTENANCE 2-21 • Drain engine coolant by disconnecting the radiator hose 2 from the radiator. * 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 39: Clutch Cable Play

  2-22 PERIODIC MAINTENANCE RADIATOR HOSES • Remove the fuel tank. ($6-3) • Remove the frame head covers, radiator covers and radiator bottom cover. ($9-6) • Check to see the radiator hoses for crack, damage or engine coolant leakage. • If any defects are found, replace the radiator hoses with new ones.

• Page 40: Brake

  PERIODIC MAINTENANCE 2-23 BRAKE (BRAKE) Inspect initially at 1 000 km (600 miles, 2 months) and every 6 000 km (4 000 miles, 12 months) thereafter. (BRAKE HOSE AND BRAKE FLUID) Inspect every 6 000 km (4 000 miles, 12 months). Replace hoses every 4 years.

• Page 41
  2-24 PERIODIC MAINTENANCE BRAKE PADS Front brake 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 the new ones. ($9-52) «…
• Page 42
  PERIODIC MAINTENANCE 2-25 BRAKE PEDAL HEIGHT • Loosen the lock nut 1. • Turn the push rod 2 until the brake pedal height becomes 25 – 35 mm (1.0 – 1.4 in) A below the top of the footrest. • Tighten the lock nut 1 securely. # Rear brake master cylinder rod lock nut: 18 N·m (1.8 kgf-m, 13.0 Ib-ft) % Brake pedal height A:…
• Page 43
  2-26 PERIODIC MAINTENANCE AIR BLEEDING FROM BRAKE FLUID CIRCUIT Air trapped in the brake fluid circuit acts like a cushion to absorb a large proportion of the pressure developed by the master cyl- inder and thus interferes with the full braking performance of the brake caliper.

• Page 44: Tires

  PERIODIC MAINTENANCE 2-27 REAR BRAKE • Bleed air from the rear brake system in the same manner as front brake. # Air bleeder valve: 7.5 N·m (0.75 kgf-m, 5.5 Ib-ft) NOTE: The only of between operation from bleeding the front brake is that the rear master cylinder is actuated by a pedal.

• Page 45: Steering

  2-28 PERIODIC MAINTENANCE TIRE PRESSURE If the tire pressure is too high or too low, steering will be adversely affected and tire wear will increase. Therefore, main- tain the correct tire pressure for good roadability and a longer tire life. Cold inflation tire pressure is as follows. % Cold inflation tire pressure Solo riding: Front: 250 kPa (2.50 kgf/cm , 36 psi)

• Page 46: Rear Suspension

  PERIODIC MAINTENANCE 2-29 REAR SUSPENSION Inspect every 12 000 km (7 500 miles, 24 months). • Remove the under cover. ($9-41) Inspect the rear shock absorber for oil leakage and check that there is no play in the swingarm. Replace any defective parts if necessary.

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  2-30 PERIODIC MAINTENANCE…

• Page 48: Compression Pressure Check

  PERIODIC MAINTENANCE 2-31 COMPRESSION PRESSURE CHECK The compression pressure reading of a cylinder is a good indicator of its internal condition. The decision to overhaul the cylinder is often based on the results of a compression test. Periodic mainte- nance records kept at your dealership should include compression readings for each maintenance service. COMPRESSION PRESSURE SPECIFICATION Standard Limit…

• Page 49: Oil Pressure Check

  2-32 PERIODIC MAINTENANCE OIL PRESSURE CHECK Check the engine oil pressure periodically. This will give a good indication of the condition of the moving parts. OIL PRESSURE SPECIFICATION 400 – 700 kPa (4.0 – 7.0 kgf/cm , 57 – 100 psi) at 3 000 r/min, Oil temp. at 60 °C (140 °F) If the oil pressure is lower or higher than the specification, the following causes may be considered.

• Page 50: Sds Check

  PERIODIC MAINTENANCE 2-33 SDS CHECK Using SDS, take the sample of data from the new motorcycle and at the time of periodic maintenance at your dealership. Save the data in the computer or by printing and filing the hard copies. The saved or filed data are useful for troubleshooting as they can be compared periodically with changes over time or failure conditions of the motorcycle.

• Page 51: Data At The Time Of Racing

  2-34 PERIODIC MAINTENANCE Data at 3 000 r/min under no load Approx. 3 000 r/min Check the water temperature. XX ˚C ˚ Check the manifold absolute pressure #1. XX mmHg Data at the time of racing ˚ Check the manifold absolute pressure #1 in according with the throttle valve opening.

• Page 52
  PERIODIC MAINTENANCE 2-35 Data of intake negative pressure during idling (100 °C) ˚ Check the water temperature. Approx. 100 ˚C Check the manifold absolute pressure #1. XX mmHg Data of manifold absolute pressure operation at the time of starting Check the manifold absolute pressure #1. XX mmHg Check the manifold absolute pressure #2.
• Page 53
  ENGINE ENGINE CONTENTS ENGINE COMPONENTS REMOVABLE WITH ENGINE IN PLACE ..3- 2 ENGINE REMOVAL AND INSTALLATION……….3- 3 ENGINE REMOVAL …………….3- 3 ENGINE INSTALLATION …………..3- 9 ENGINE DISASSEMBLY …………….3-13 ENGINE COMPONENTS INSPECTION AND SERVICE……3-29 CYLINDER HEAD COVER…………..3-29 CAMSHAFT ……………….

• Page 54: Engine Components Removable With Engine In Place

  ENGINE ENGINE COMPONENTS REMOVABLE WITH ENGINE IN PLACE The parts listed below can be removed and reinstalled without removing the engine from the frame. Refer to page listed in each section for removal and reinstallation instructions. ENGINE CENTER ITEM REMOVAL INSPECTION INSTALLATION !12-6…

• Page 55: Engine Removal And Installation

  ENGINE ENGINE REMOVAL AND INSTALLATION ENGINE REMOVAL Before taking the engine out of the frame, wash the engine using a steam cleaner. Engine removal is sequentially explained in the following steps. Reinstall the engine by reversing the removal procedure. • Drain engine oil. (!2-17) •…

• Page 56
  ENGINE • Disconnect the ECT sensor lead wire coupler 4. • Disconnect the ignition coil/plug cap lead wire couplers and remove the ignition coils/plug caps. (!2-13 and -14) » * Do not remove the ignition coil/plug cap before dis- connecting its coupler. * Do not pry up the ignition coil/plug cap with a screw driver or a bar to avoid its damage.
• Page 57
  ENGINE • Remove the right footrest 8. • Disconnect the starter motor lead wire 9. • Disconnect the oil cooler hose 0. • Remove the oil pressure switch lead wire A.
• Page 58
  ENGINE • Disconnect the cooling fan coupler B and horn lead wire cou- plers C. • Remove the left frame lower side cover D. • Remove the secondary gear case cover E. • Disconnect the generator lead wire coupler F. •…
• Page 59
  ENGINE • Remove the clutch cable K. • Support the engine with an engine jack. • Remove the left footrest L and gearshift lever M. • Remove the ground lead wire N. • Disconnect the GP switch lead wire coupler O. •…
• Page 60
  ENGINE • Slightly move the frame down tube by removing its bolts P, bolts and nuts Q. • Remove the caps. • Remove the engine mounting bracket bolts R. • Remove the engine mounting bolts and nuts S. • Remove the the engine assembly.

• Page 61: Engine Installation

  ENGINE ENGINE INSTALLATION Install the engine in the reverse order of engine removal. Pay attention to the following points: • Install the boot and universal joint. NOTE: Make sure that the “UP” mark A faces up. • Gradually raise the engine, and then engage the secondary driven gear shaft to the universal joint.

• Page 62
  3-10 ENGINE • Install the frame down tube and tighten the bolts 2, bolts and nuts 3 to the specified torque. NOTE: The frame down tube nuts are self-locking. Once the nuts have been removed, they are no longer of any use. # Frame down tube bolt: 50 N·m (5.0 kgf-m, 36.0 lb-ft) •…
• Page 63
  ENGINE 3-11 NOTE: The engine mounting nuts are self-locking. Once the nut has been removed, they are no longer of any use. Right Left 3 Bushing Engine mounting nut 4 Bushing Spacer ITEM N·m kgf-m lb-ft 40.0 • Install the gearshift lever and tighten the mounting bolts to the specified torque.
• Page 64
  3-12 ENGINE • Tighten the right front footrest mounting bolts to the specified torque. # Right front footrest bolt: 60 N·m (6.0 kgf-m, 43.5 lb-ft) • Install the rear brake master cylinder cover 4. (!9-72) • Install the throttle body. (!6-21) •…

• Page 65: Engine Disassembly

  ENGINE 3-13 ENGINE DISASSEMBLY » Identify the position of each removed part. Organize the parts in their respective groups (e.g., intake, exhaust) so that they can be reinstalled in their origi- nal positions. • Remove the front and rear spark plugs. STARTER MOTOR •…

• Page 66
  3-14 ENGINE REAR CYLINDER HEAD COVER • Remove the right and left head cover brackets 1. • Remove the rear cylinder head cover 2 and its gasket. REAR CAMSHAFT • Remove the generator cover cap 1. • Remove the valve timing inspection plug 2 and generator cover plug 3.
• Page 67
  ENGINE 3-15 • Turn the crankshaft to bring the “R I T” line on generator rotor to the index mark of the valve inspection hole and also to bring the cams to the position as shown. NOTE: At the above condition, the rear cylinder is at TDC of compres- sion stroke and also the engraved lines A on the camshafts are parallel with the mating surface of the cylinder head cover.
• Page 68
  3-16 ENGINE REAR CYLINDER HEAD • Remove the cylinder head bolts and washers. NOTE: Loosen the cylinder head bolts little by little diagonally with the smaller sizes first. • Remove the cylinder head 1. REAR CYLINDER • Remove the cylinder head gasket 1, dowel pins 2 and cam chain guide No.
• Page 69
  ENGINE 3-17 FRONT CYLINDER HEAD COVER • Remove the right and left head cover brackets 1. • Remove the front cylinder head cover 2 and its gasket. FRONT CAMSHAFT • Turn the crankshaft to bring the “F I T” line mark on generator rotor to the index mark of the valve inspection hole and also to bring the cams to the position as shown.
• Page 70
  3-18 ENGINE • Remove the cam chain guide No. 3 5. • Remove the camshaft journal holder 6. • Remove the dowel pins. » Be sure to loosen the camshaft journal holder bolts evenly by shifting the wrench in the descending order of numbers.
• Page 71
  ENGINE 3-19 • Remove the cylinder nuts. • Remove the cylinder 5. NOTE: Firmly grip the cylinder at both ends, and lift it straight up. If the cylinder does not come off, lightly tap on the finless portions of the cylinder with a plastic mallet to make the gasketed joint loose.
• Page 72
  3-20 ENGINE • Remove the clutch push rod 5 and clutch push rod release ball 6. NOTE: If it is difficult to pull out the push rod 5 and ball 6, use a long- bar. • Unlock the clutch sleeve hub nut. •…
• Page 73
  ENGINE 3-21 • Remove the thrust washer A. • Remove the primary driven gear assembly B. • Remove the needle roller bearing C and spacer D. REAR CAM CHAIN TENSION ADJUSTER • Unlock the ratchet 1 and insert the special tool. % 09917-62430: Chain tensioner lock tool •…
• Page 74
  3-22 ENGINE • Remove the cam chain No. 2 4, rear cam chain idler sprocket 5 and cam chain No. 1. REAR CAM CHAIN DRIVE SPROCKET • Hold the generator rotor and remove the rear cam chain drive sprocket bolt. «…
• Page 75
  ENGINE 3-23 NOTE: When loosen the rotor bolt, do not remove it. The rotor bolt is used in conjunction with the rotor remover when removing the rotor. • Remove the generator rotor assembly with the special tool. % 09930-30721: Rotor remover •…
• Page 76
  3-24 ENGINE • Remove the cam chain tensioner No. 1 6. • Remove the cam chain No. 2 7, front cam chain idler sprocket 8 and cam chain No. 1 9. • Remove the front cam chain tension adjuster No. 1 0. SECONDARY DRIVEN GEAR •…
• Page 77
  ENGINE 3-25 • Remove the gearshift cam plate 3. • Remove the gearshift cam stopper 4. SECONDARY DRIVE GEAR • Shift the gear position to 1st or 2nd. • Hold the primary driven gear with the special tool. % 09930-44541: Rotor holder •…
• Page 78
  3-26 ENGINE • Remove the oil pump drive gear 5 and pin 6. GEAR POSITION SWITCH • Remove the gear position switch 1. OIL FILTER • Remove the oil filter with the special tool. % 09915-40610: Oil filter wrench OIL COOLER/OIL PRESSURE SWITCH •…
• Page 79
  ENGINE 3-27 OIL PAN • Remove the oil pan 1 and stay 2. OIL PRESSURE REGULATOR • Remove the oil pressure regulator 1. OIL STRAINER • Remove the oil strainers 2 and O-rings 3. UPPER CRANKCASE • Remove the breather cover 1. •…
• Page 80
  3-28 ENGINE NOTE: * The crankshaft and transmission components should remain in the upper crankcase half. * If it is difficult to separate the crankcase halves, set the proper bolts and nuts to the crankcase by separating the upper and lower crankcase halves, as shown in the illustration.

• Page 81: Engine Components Inspection And Service

  ENGINE 3-29 ENGINE COMPONENTS INSPECTION AND SERVICE » Identify the position of each removed part. Organize the parts in their respective groups (i.e., intake, exhaust, No.1 or No.2) so that they can be installed in their original locations. CYLINDER HEAD COVER DISASSEMBLY •…

• Page 82
  3-30 ENGINE CAM WEAR • Check the camshaft for wear or damage. • Measure the cam height H with a micrometer. $ Cam height H: Service Limit: (IN. & EX.): 40.580 mm (1.5976 in) % 09900-20202: Micrometer (25 – 50 mm) CAMSHAFT JOURNAL WEAR •…

• Page 83: Camshaft Runout

  ENGINE 3-31 • If the camshaft journal oil clearance measured exceeds the limit, measure the inside diameter of the camshaft journal holder and outside diameter of the camshaft journal. • Replace the camshaft or the cylinder head depending upon which one exceeds the specification. $ Camshaft journal holder I.D.: Standard: (IN.

• Page 84: Cam Chain Tension Adjuster

  3-32 ENGINE CAM CHAIN TENSION ADJUSTER INSPECTION • The cam chain tension adjusters are maintained at the proper cam chain tension automatically. • Unlock the ratchet A, and move the push rod in place to see if it slides smoothly. If any stickiness is noted or ratchet mech- anism is faulty, replace the cam chain tension adjuster assembly with a new one.

• Page 85
  ENGINE 3-33 CYLINDER HEAD DISTORTION • Decarbonize the combustion chambers. • Check the gasketed surface of the cylinder head for distortion with a straightedge and thickness gauge, taking a clearance reading at several places indicated. • If the largest reading at any position of the straightedge exceeds the limit, replace the cylinder head.
• Page 86
  3-34 ENGINE • Remove the valve spring retainer 4 and valve spring 5. • Pull out the valve 6 from the combustion chamber side. • Remove the oil seal 7 and spring seat 8. » Do not reuse the removed oil seal. •…
• Page 87
  ENGINE 3-35 VALVE STEM AND VALVE FACE WEAR CONDITION • Visually inspect each valve stem and valve face for wear and pitting. If it is worn or damaged, replace the valve with a new one. VALVE STEM DEFLECTION • Lift the valve about 10 mm (0.39 in) from the valve seat. •…
• Page 88
  3-36 ENGINE VALVE GUIDE SERVICING • Using the valve guide remover, drive the valve guide out toward the intake or exhaust camshaft side. % 09916-46020: Valve guide remover/installer NOTE: * Discard the removed valve guide subassemblies. * Only oversized valve guides are available as replacement parts.
• Page 89
  ENGINE 3-37 VALVE SEAT WIDTH INSPECTION • Visually check for valve seat width on each valve face. • If the valve face has worn abnormally, replace the valve. • Coat the valve seat with a red lead (Prussian Blue) and set the valve in place.
• Page 90
  3-38 ENGINE • Clean and assemble the head and valve components. Fill the intake and exhaust ports with gasoline to check for leaks. • If any leaks occur, inspect the valve seat and face for burrs or other things that could prevent the valve from sealing. Always use extreme caution when handling gasoline.
• Page 91
  ENGINE 3-39 • Install the valve spring with the small-pitch portion A facing cylinder head. B Large-pitch portion C UPWARD D Paint • Put on the valve spring retainer 3, and using the valve lifter and protector 4, press down the spring, fit the cotter halves to the stem end, and release the lifter to allow the cotter 5 to wedge in between retainer and stem.
• Page 92
  3-40 ENGINE CAM CHAIN TENSIONER • Inspect the cam chain tensioner for damage. If any damage are found, replace the cam chain tensioner with a new one. • Install the cam chain tensioner 1, washers 2 and nuts 3. • Tighten the cam chain tensioner nuts to the specified torque. # Cam chain tensioner nut: 10 N·m (1.0 kgf-m, 7.0 lb-ft) WATER JACKET PLUG •…

• Page 93: Cylinder

  ENGINE 3-41 CYLINDER CYLINDER DISTORTION • Check the gasketed surface of the cylinder for distortion with a straightedge and thickness gauge, taking a clearance read- ing at several places as indicated. • If the largest reading at any position of the straightedge exceeds the limit, replace the cylinder.

• Page 94: Piston And Piston Ring

  3-42 ENGINE PISTON AND PISTON RING PISTON DIAMETER • Using a micrometer, measure the piston diameter at 10 mm (0.4 in) A from the piston skirt end. • If the measurement is less than the limit, replace the piston. $ Piston diameter: Service Limit: 111.880 mm (4.4047 in) at 10 mm (0.4 in) from the skirt end % 09900-20210: Micrometer (100 –…

• Page 95: Piston Ring Groove Width

  ENGINE 3-43 PISTON RING-TO-GROOVE CLEARANCE • Measure the side clearances of the 1st and 2nd piston rings using the thickness gauge. • If any of the clearances exceeds the limit, replace both the piston and piston rings. % 09900-20803: Thickness gauge 09900-20205: Micrometer (0 –…

• Page 96: Clutch

  3-44 ENGINE CLUTCH CLUTCH PLATE THICKNESS NOTE: Wipe off engine oil from the clutch plates with a clean rag. • Measure the thickness of drive and driven plates with a ver- nier calipers. If each plate is not within the service limit or standard range, replace it with a new one.

• Page 97
  ENGINE 3-45 CLUTCH RELEASE BEARING • Inspect the clutch release bearing for any abnormality, partic- ularly cracks, to decide whether it can be reused or should be replaced. • Smooth engagement and disengagement of the clutch depends on the condition of this bearing. CLUTCH PUSH ROD •…

• Page 98: Gearshift Cover

  REASSEMBLY • Install the bearing 1 and oil seal 2 with the special tool. % 09913-70210: Bearing installer set (22 mm) • Apply SUZUKI SUPER GREASE “A” to the oil seal lip. ) 99000-25010: SUZUKI SUPER GREASE “A” or equivalent «…

• Page 99: Starter Clutch

  ENGINE 3-47 STARTER CLUTCH STARTER DRIVEN GEAR INSPECTION • Turn the starter driven gear by hand. • Inspect the starter clutch for a smooth movement. • Check that the gear turns only in one direction. • Inspect the starter driven gear bushing for any damage. If necessary, replace it with a new one.

• Page 100: Oil Pump

  3-48 ENGINE • Apply THREAD LOCK SUPER to the bolts, and then tighten them to the specified torque. # Starter clutch bolt: 25 N·m (2.5 kgf-m, 18.0 lb-ft) * 99000-32030: THREAD LOCK SUPER “1303” or equivalent OIL PUMP REMOVAL • Remove the oil pump assembly 1 with oil return pump. DISASSEMBLY •…

• Page 101
  ENGINE 3-49 REASSEMBLY • Apply engine oil to the sliding surfaces of the oil pump inner rotor, outer rotor and shaft. • When installing the inner rotor 1, align the pin 2 with the groove 3. • When installing the inner rotor and outer rotor, face the punched marks A on the rotors to the outside.

• Page 102: Starter Torque Limiter

  3-50 ENGINE STARTER TORQUE LIMITER STARTER TORQUE LIMITER INSPECTION » * Do not attempt to disassemble the starter torque lim- iter. * The starter torque limiter is available only as an assembly. • Check the slip torque with the special tools. $ Slip torque Standard: 31 –…

• Page 103: Clutch Release Camshaft

  • Remove the clutch push rod cap 7 and oil seal 8. » The removed oil seal must be replaced with new one. REASSEMBLY • Apply SUZUKI SUPER GREASE “A” the release camshaft 1, new bearing 2 and oil seal 3 before installing. ) 99000-25010: SUZUKI SUPER GREASE “A” or equivalent •…

• Page 104: Water Pump

  3-52 ENGINE WATER PUMP !8-15 GEARSHIFT GEARSHIFT SHAFT/GEARSHIFT ARM DISASSEMBLY • Remove the following parts from the gearshift shaft/gearshift arm. 1 Washer 4 Gearshift cam drive plate 2 Snap ring 5 Plate return spring 3 Gearshift shaft return spring GEARSHIFT SHAFT/GEARSHIFT ARM INSPECTION •…

• Page 105: Oil Pressure Regulator

  ENGINE 3-53 OIL PRESSURE REGULATOR • Inspect the operation of the oil pressure regulator by pushing on the piston with a proper bar. • If the piston does not operate, replace the oil pressure regula- tor with a new one. OIL STRAINER •…

• Page 106: Transmission

  3-54 ENGINE TRANSMISSION CONSTRUCTION 1 Countershaft/1st drive gear 7 2nd driven gear 2 5th drive gear 8 3rd driven gear 3 4th drive gear 9 4th driven gear 4 3rd drive gear 0 5th driven gear 5 2nd drive gear A 1st driven gear 6 Driveshaft…

• Page 107
  ENGINE 3-55 DISASSEMBLY » Be sure to identify each removed part as to its loca- tion, and lay the parts out in groups designated as “Drive” and “Driven”, so that each will be restored to the original location during assembly. Countershaft •…
• Page 108
  3-56 ENGINE • Remove the snap ring D, washer E, 5th drive gear F and 5th drive gear bushing G. Driveshaft • Remove the bearing 1, washer 2 and 1st driven gear 3. • Remove the 1st driven gear bushing 4, washer 5 and 5th driven gear 6.
• Page 109
  Replace the bearings if there is anything unusual. * Before installing the gears, apply engine oil to the driveshaft and countershaft. * When installing the oil seal, apply SUZUKI SUPER GREASE “A” to it. ) 99000-25010: SUZUKI SUPER GREASE “A”…
• Page 110
  3-58 ENGINE • When installing a new snap ring, pay attention to its direction. Fit it to the side where the thrust is as shown in the illustration. A Thrust B Sharp edge » When installing the gear bushing onto the counter- shaft 1 and driveshaft 2, align the shaft oil hole 3 with the 3rd drive gear bushing oil hole 4 and 4th driven gear bushing oil hole 5.
• Page 111
  ENGINE 3-59 TRANSMISSION PARTS LOCATION 1 Countershaft 2 Driveshaft…

• Page 112: Crankcase

  3-60 ENGINE CRANKCASE GEARSHIFT FORK AND GEARSHIFT CAM Removal • Remove the gearshift cam bearing retainer screws 1 and gearshift fork shaft retainer plug 2 from the lower crankcase. • Remove the gearshift fork shafts 3 and gearshift forks 4 from the lower crankcase.

• Page 113
  ENGINE 3-61 GEARSHIFT FORK GROOVE WIDTH • Measure the gearshift fork groove width using the vernier cali- pers. $ Shift fork groove width: Standard: 5.0 – 5.1 mm (0.197 – 0.201 in) % 09900-20102: Vernier calipers GEARSHIFT FORK THICKNESS • Measure the gearshift fork thickness using the vernier cali- pers.
• Page 114
  3-62 ENGINE • Remove the gearshift cam bearing with the special tools. % 09923-74511: Bearing remover 09930-30104: Sliding shaft Installation • Install the bearings with the special tool. % 09913-70210: Bearing installer set (1 +20) (2 +32) NOTE: The stamped mark side of the gearshift shaft bearing 1 and gearshift cam bearing 2 faces outside.
• Page 115
  ENGINE 3-63 • Apply a small quantity of THREAD LOCK to the bearing retainer screws 8 and gearshift arm stopper bolt 9. • Tighten the bearing retainer screws 8, gearshift arm stopper bolt 9 and gearshift fork shaft retainer plug 0 to the specified torque.
• Page 116
  3-64 ENGINE Inspection and cleaning • Check the oil jets for clogging. • Inspect the operation of the oil jet by pushing on the piston with a proper bar • If they are clogged or piston does not opreat, clean their oil passage with a proper wire and compressed air or replace the oil jet with a new one.
• Page 117
  ENGINE 3-65 • Remove the oil gallery plugs 2 (for upper crankcase side). • Remove the oil gallery plugs 3 (for lower crankcase side). • Remove the oil gallery plugs 4 (for oil pan).
• Page 118
  3-66 ENGINE Installation • Apply THREAD LOCK to the water jaket plugoil gallery plugs 1 and oil gallery plugs (2, 3). & 99000-32050: THREAD LOCK “1342” or equivalent NOTE: It is not require to apply THREAD LOCK when installing the other removed oil gallery plugs.

• Page 119: Balancer Driven Gear

  ENGINE 3-67 BALANCER DRIVEN GEAR BALANCER DRIVEN GEAR INSPECTION Visually inspect the gear teeth for wear and damage. If they are worn, replace the gear with a new one. BALANCER DRIVEN GEAR DISASSEMBLY • Remove the balancer shaft with the special tool. % 09913-70210: Bearing installer set •…

• Page 120
  3-68 ENGINE • Hold the balancer driven gear No. 2 3 with the special tool. % 09920-53740: Clutch sleeve hub holder • Turn the balancer driven gear No. 1 4 and align the holes. • Apply THREAD LOCK SUPER to the bolts (5, 6). * 99000-32030: THREAD LOCK SUPER “1303”…

• Page 121: Crankshaft And Conrod

  ENGINE 3-69 CRANKSHAFT AND CONROD CONROD SMALL END I.D. • Using a small bore gauge, measure the inside diameter of the conrod small end. $ Conrod small end I.D.: Service Limit: 23.040 mm (0.9071 in) % 09900-20602: Dial gauge (1/1 000 mm, 1 mm) 09900-22403: Small bore gauge (18 –…

• Page 122
  3-70 ENGINE • Remove the conrods, and mark them to identify the cylinder position. • Inspect the bearing surfaces for any sign of fusion, pitting, burn, or flaws. If any, replace them with a specified set of bearings. CONROD-BIG END BEARING SELECTION •…
• Page 123
  ENGINE 3-71 • Check the corresponding conrod I.D. code number (“1” or “2”) • Check the corresponding crank pin O.D. code number (“1”, “L” “2” or “3”) B. $ Bearing selection table Crank pin O.D. B Code Green Black Brown Conrod “R”…
• Page 124
  3-72 ENGINE $ Crank pin O.D. Code O.D. specification 54.992 – 55.000 mm (2.1650 – 2.1654 in) 54.984 – 54.992 mm (2.1647 – 2.1650 in) 54.976 – 54.984 mm (2.1644 – 2.1647 in) % 09900-20202: Micrometer (25 – 50 mm) $ Bearing thickness Color code Color (Part No.)

• Page 125: Crankshaft Journal Bearing

  ENGINE 3-73 • Apply engine oil to the bearing cap bolts. • Tighten the bearing cap bolts as following two steps. # Conrod bearing cap bolt (Initial) : 35 N·m (3.5 kgf-m, 25.5 lb-ft) (Final) : After tightening the bolts to the above torque, tighten them 1/4 of a turn (90°).

• Page 126
  3-74 ENGINE • Remove the lower crankcase and measure the width of the compressed plastigauge using the envelope scale. This mea- surement should be taken at the widest part of the com- pressed plastigauge. $ Crankshaft journal oil clearance: Standard: 0.016 – 0.034 mm (0.0006 – 0.0013 in) Service Limit: 0.080 mm (0.0031 in) •…
• Page 127
  ENGINE 3-75 $ Crankshaft journal O.D. specification Code O.D. specification 54.994 – 55.000 mm (2.1651 – 2.1654 in) 54.988 – 54.994 mm (2.1649 – 2.1651 in) 54.982 – 54.988 mm (2.1646 – 2.1649 in) % 09900-20203: Micrometer (50 – 75 mm) $ Bearing thickness specification Color (Part No.) Thickness…

• Page 128: Crankshaft Thrust Bearing

  3-76 ENGINE CRANKSHAFT THRUST BEARING • With the crankshaft and thrust bearing 1 inserted in the upper crankcase, measure the thrust clearance by using the thickness gauge. $ Thrust clearance: Standard: 0.100 – 0.200 mm (0.0039 – 0.0078 in) % 09900-20803: Thickness gauge •…

• Page 129
  ENGINE 3-77 $ Thrust bearing selection table Clearance before Color Thrust bearing inserting left-side Thrust clearance (Part No.) thickness thrust bearing 2.400 – 2.450 mm 2.250 – 2.300 mm 0.100 – 0.200 mm (0.0944 – 0.0965 in) (12228-48G00-0A0) (0.0886 – 0.0906 in) (0.0039 –…

• Page 130: Engine Reassembly

  3-78 ENGINE ENGINE REASSEMBLY • Reassemble the engine in the reverse order of disassembly. • The following steps require special attention or precautionary measures should be taken. NOTE: Apply engine oil to each running and sliding part before reas- sembling. CRANKSHAFT •…

• Page 131
  ENGINE 3-79 • Turn the bearing to install the bearing dowel pin C in the posi- tion. • Install the oil seal 1. TRANSMISSION • Install the countershaft assembly on the upper crankcase. NOTE: Align the C-ring with the groove of bearing and the bearing pin with the indent on the bearing.
• Page 132
  3-80 ENGINE • Install the O-rings 1. • Apply SUZUKI SUPER GREASE “A” to the O-rings. ) 99000-25010: SUZUKI SUPER GREASE “A” or equivalent » Use a new O-ring to prevent oil leakage. • Install the dowel pins 2.
• Page 133
  ENGINE 3-81 • Apply SUZUKI BOND to the mating surface of the lower crankcase. , 99000-31110: SUZUKI BOND “1215” or equivalent NOTE: Use of SUZUKI BOND is as follows: * Make surfaces free from moisture, oil, dust and other foreign materials.
• Page 134
  3-82 ENGINE • Tighten the crankcase bolts a little at a time to equalize the pressure. NOTE: * Fit the new copper washers to the crankcase bolts B. * Fit the new gasket washers to the crankcase bolts C. # Crankcase bolt: (M6): 11 N·m (1.1 kgf-m, 8.0 lb-ft) (M8): 26 N·m (2.6 kgf-m, 19.0 lb-ft) (M10) Initial: 30 N·m (3.0 kgf-m, 21.5 lb-ft) Final: 50 N·m (5.0 kgf-m, 36.0 lb-ft)
• Page 135
  ENGINE 3-83 • Apply SUZUKI BOND to the mating surface of the breather cover. — 99000-31140: SUZUKI BOND “1207B” or equivalent NOTE: Use of SUZUKI BOND is as follows: * Make surfaces free from moisture, oil, dust and other foreign materials.
• Page 136
  Align the oil strainer C with the lower crankcase hole D. OIL PRESSURE REGULATOR • Apply SUZUKI SUPER GREASE “A” to the O-rings and press in the oil pressure regulator 1 to the lower crankcase. ) 99000-25010: SUZUKI SUPER GREASE “A”…
• Page 137
  ENGINE 3-85 OIL PAN • Apply SUZUKI BOND to the mating surface of the oil pan. , 99000-31110: SUZUKI BOND “1215” or equivalent NOTE: Use of SUZUKI BOND is as follows: * Make surfaces free from moisture, oil, dust and other foreign materials.
• Page 138
  , 99000-31110: SUZUKI BOND “1215” or equivalent # Oil pressure switch: 14 N·m (1.4 kgf-m, 10.0 lb-ft) NOTE: Be careful not to apply SUZUKI BOND to the hole of thread end. OIL COOLER • Apply engine oil to the O-ring.
• Page 139
  • Install the oil pump driven gear 3. • Install the snap ring 4. GEAR POSITION SWITCH • Apply SUZUKI SUPER GREASE “A” to the O-ring. NOTE: Align the gear position switch pin A with the gearshift cam hole ) 99000-25010: SUZUKI SUPER GREASE “A”…
• Page 140
  3-88 ENGINE GEARSHIFT • Install the gearshift cam stopper 1, its bolt 2, washer 3 and return spring 4. NOTE: Apply a small quantity of THREAD LOCK to the gearshift cam stopper bolt 2 and tighten its to the specified torque. &…
• Page 141
  • Install the dowel pins and gasket 1. » Use new gasket to prevent oil leakage. • Install the gearshift cover and tighten its bolts. NOTE: Apply grease to the oil seal lip before installing the gearshift cover. ) 99000-25010: SUZUKI SUPER GREASE “A” or equivalent…
• Page 142
  3-90 ENGINE SECONDARY DRIVEN GEAR • Install the shims 1 onto the secondary driven gear case. (!4-11) • Fit the O-ring 2 and apply engine oil. » Use the new O-ring to prevent oil pressure leak. • Install the secondary driven gear case 3 with the bolts and then tighten them to the specified torque.
• Page 143
  • Align the groove A on the cam idler sprocket with the embossed line B on the upper crankcase. (!3-94) • Apply SUZUKI MOLY PASTE to the idler shaft 2 and install the idler shaft. ( MOLYBDENUM OIL SOLUTION…
• Page 144
  3-92 ENGINE • Install the cam chain guide No. 1 3. • Apply a small quantity of THREAD LOCK SUPER to the bolts and tighten its to the specified torque. * 99000-32030: THREAD LOCK SUPER “1303” or equivalent # Cam chain guide No. 1 bolt: 18 N·m (1.8 kgf-m, 13.0 lb-ft) •…
• Page 145
  • Align the groove A on the cam idler sprocket with the embossed line B on the upper crankcase. (!3-94) • Apply SUZUKI MOLY PASTE to the idler shaft 1 and install the idler shaft. ( MOLYBDENUM OIL SOLUTION…
• Page 146
  3-94 ENGINE • After unlocking the ratchet, push the cam chain tension adjuster rod. • Insert the special tool between the ratchet and the adjuster body. % 09917-62430: Chain tensioner lock tool • Install the rear cam chain tension adjuster No. 1 with the bolts and tighten its bolts to the specified torque.
• Page 147
  ENGINE 3-95 CLUTCH • Install the needle bearing 1 and spacer 2 onto the counter- shaft. • Apply engine oil to them. • Install the primary driven gear assembly 3 onto the counter- shaft. • Install the thrust washer 4. •…
• Page 148
  3-96 ENGINE Outside DRIVE PLATE: A Drive plate No. 1 …5 pcs. B Drive plate No. 2 …1 pc. Wave plate C Wave washer D Wave washer seat DRIVEN PLATE: a Driven plate No. 1 …4 pcs. b Driven plate No. 2 …2 pcs. 3.6 mm (0.14 in) 2.6 mm (0.10 in) A Drive plate No.
• Page 149
  ENGINE 3-97 • Install the drive plate No. 2 7, spring washer 8 and spring washer seat 9 onto the clutch sleeve hub correctly. NOTE: The conical curve side of spring washer 8 faces outside. • Insert the clutch drive plates and driven plates one by one to the clutch sleeve hub after applying engine oil to the them.
• Page 150
  3-98 ENGINE • Tighten the clutch spring set bolts securely while holding the generator rotor. NOTE: Tighten the clutch spring bolts diagonally. PISTON RING • Install the piston rings in the order of oil ring, 2nd ring and 1st ring. •…
• Page 151
  ENGINE 3-99 • Position the gaps of the three ring as shown. Before inserting each piston into the cylinder, check that the gaps are so 120 ¡ located. 120 ¡ 120 ¡ C 2nd ring and lower side rail D Upper side rail E 1st ring and spacer •…
• Page 152
  3-100 ENGINE CYLINDER • Fit the dowel pins and new gaskets 1 to the crankcase front and rear. » Use the new gaskets to prevent oil leakage. • Apply a small quantity of MOLYBDENUM OIL SOLUTION to the sliding surface of the pistons and cylinder walls. “FR”…
• Page 153
  ENGINE 3-101 • Fit the dowel pins and new cylinder head gaskets 2 to the cylinders, front and rear. » Use the new gaskets to prevent gas leakage. Rear NOTE: “F” The cylinder heads can be distinguished by the embossed-let- ters, “F”…
• Page 154
  3-102 ENGINE • Tighten the front and rear cylinder nuts to the specified torque. # Cylinder nut: 13 N·m (1.3 kgf-m, 9.5 lb-ft) Front Rear FRONT CAMSHAFTS • Turn the crankshaft counterclockwise approx. 1-1/3 turns (486°) with the box wrench and align “F I T” line A on the crankshaft with the index marks B of the upper crankcase hole while keeping the camshaft drive chain pulled upward.
• Page 155
  ENGINE 3-103 • Pull the cam chain lightly. • The exhaust camshaft sprocket has an arrow marked “1” C. Turn the exhaust camshaft so that the arrow is aligned with the gasket surface of the cylinder head. • Engage the cam chain with the exhaust camshaft sprocket. •…
• Page 156
  3-104 ENGINE • Install the dowel pins. • Install the camshaft journal holders, intake and exhaust 1, and cam chain guide No. 3 2. • Have the camshaft journal holders seated evenly by tighten- ing the camshaft journal holder bolts lightly, in the ascending order of numbers.
• Page 157
  ENGINE 3-105 REAR CAMSHAFTS • From the position where the front camshafts have now been installed, rotate the generator rotor approx. 2/3 turn (234°) and align the “R I T” line A on the crankshaft with the index marks B of the upper crankcase hole. «…
• Page 158
  3-106 ENGINE • Pull the cam chain lightly. • The intake camshaft sprocket has an arrow marked “1” C. Turn the intake camshaft so that the arrow is aligned with the gasket surface of the cylinder head. • Engage the cam chain with the intake camshaft sprocket. •…
• Page 159
  ENGINE 3-107 • Install the dowel pins. • Install the camshaft journal holders, intake and exhaust 1, and cam chain guide No. 3 2. • Have the camshaft journal holders seated evenly by tighten- ing the camshaft journal holder bolts lightly, in the ascending order of numbers.
• Page 160
  3-108 ENGINE • Install the gasket 5 and cam chain tension adjuster cap bolt NOTE: Click sound is heard when the cam chain tension adjuster cap bolt is installed. • Tighten the cam chain tension adjuster cap bolt to the speci- fied torque.
• Page 161
  NOTE: Be sure to check the valve clearance. (!2-8) • Install the new gaskets to the cylinder head covers. • Apply SUZUKI BOND to the cam end caps of the gaskets as shown. — 99104-31140: SUZUKI BOND “1207B” or equivalent «…
• Page 162
  3-110 ENGINE • Tighten the head cover bolts in ascending order of numbers to the specified torque. # Head cover bolt (Front and Rear): 11 N·m (1.1 kgf-m, 8.0 lb-ft) GENERATOR COVER • Install the dowel pins and gasket 1. «…
• Page 163
  ENGINE 3-111 • Apply engine oil to the new O-ring and install the generator cover plug. » Use the new O-ring to prevent oil leakage. • Tighten the generator cover plug 2 and valve timing inspec- tion plug 3 to the specified torque. # Generator cover plug: 16 N·m (1.6 kgf-m, 11.5 lb-ft) Valve timing inspection plug: 23 N·m (2.3 kgf-m, 16.5 lb-ft)
• Page 164
  • Install the thermostat assembly 1 and connect the water hoses 2. • Tighten the thermostat assembly bolt. INTAKE PIPE • Apply SUZUKI SUPER GREASE “A” to the O-ring. ) 99000-25010: SUZUKI SUPER GREASE “A” or equivalent • Install the intake pipes.
• Page 165
  ENGINE 3-113 STARTER MOTOR • Apply SUZUKI SUPER GREASE “A” to the O-ring. ) 99000-25010: SUZUKI SUPER GREASE “A” or equivalent • Tighten the starter motor 1 bolts to the specified torque. # Starter motor bolt: 6 N·m (0.6 kgf-m, 4.5 lb-ft)
• Page 166
  DRIVELINE/AXLE DRIVELINE/AXLE CONTENTS SECONDARY BEVEL GEARS …………..4- 2 CONSTRUCTION ……………… 4- 2 REMOVAL ………………… 4- 4 DISASSEMBLY ………………4- 4 INSPECTION ………………4- 6 REASSEMBLY ………………4- 8 SECONDARY GEAR SHIMS ADJUSTMENT ……..4-10 FINAL BEVEL GEARS ………………. 4-13 CONSTRUCTION ………………

• Page 167: Secondary Bevel Gears

  DRIVELINE/AXLE SECONDARY BEVEL GEARS CONSTRUCTION 1 Driven bevel gear coupling 8 Shims E Driven bevel gear bearing 2 Oil seal 9 O-ring A Driven bevel gear coupling nut 3 Oil seal housing 0 Secondary gear case B Secondary driven bearing stopper 4 Bearing housing set A Output cam dog C Secondary driven bearing housing bolt…

• Page 168
  DRIVELINE/AXLE Backlash 0.03 – 0.15 mm (0.001 – 0.006 in) Adjust backlash by selecting shims. (Use two pieces of shims.) Shim 1 size table Part number Thickness 24945-26D00-030 0.30 mm (0.012 in) 24945-26D00-035 0.35 mm (0.014 in) 24945-26D00-040 0.40 mm (0.016 in) 24945-26D00-050 0.50 mm (0.020 in) 24945-26D00-060…

• Page 169: Removal

  DRIVELINE/AXLE REMOVAL The secondary bevel gear service requires engine removal and disassembly. Refer to the engine removal and the engine disas- sembly sections for secondary bevel gear assembly removal. Engine removal «3-3 DISASSEMBLY SECONDARY DRIVE BEVEL GEAR («3-28) SECONDARY DRIVEN BEVEL GEAR •…

• Page 170
  DRIVELINE/AXLE • Remove the shims 5. • Using a chisel, unlock the nut. • Remove the driven bevel gear coupling nut with the special tool. # 09924-64510: Final drive gear coupling holder • Remove the washer 6 and the driven bevel gear coupling 7. •…

• Page 171: Inspection

  DRIVELINE/AXLE • Remove the bearing housing 8, secondary driven gear 9, output cam dog 0, damper spring A, spring cam stopper B and shaft C. INSPECTION * Driven bevel gear damage or wear * Improper tooth contact * Output cam dog wear or damage * Shaft damage or wear.

• Page 172
  DRIVELINE/AXLE • Remove the oil seal with the special tool. # 09913-50121: Oil seal remover The removed oil seal must be replaced with a new one. • Remove the driven gear stopper with the special tool. # 09913-70210: Bearing installer set (30 mm) •…

• Page 173: Reassembly

  # 09913-70210: Bearing installer set (42 mm) NOTE: When installing the bearing, stamped mark on the bearing must face outside. • Apply SUZUKI BOND to the mating surface of the bearing housing and oil seal housing. & 99000-31140: SUZUKI BOND “1207B” or equivalent NOTE: * Make surfaces free from moisture, oil, dust and other foreign materials.

• Page 174
  DRIVELINE/AXLE • Install the oil seal with the special tool. # 09913-70210: Bearing installer set (62 mm) • Apply SUZUKI SUPER GREASE “A” to the oil seal lip. ‘ 99000-25010: SUZUKI SUPER GREASE “A” or equivalent SECONDARY DRIVEN BEVEL GEAR •…

• Page 175: Secondary Gear Shims Adjustment

  4-10 DRIVELINE/AXLE • Install the secondary driven gear assembly 3. • Apply a small quantity of the THREAD LOCK SUPER to the bearing housing bolts and tighten it to the specified torque. ( 99000-32030: THREAD LOCK SUPER “1303” or equivalnet ! Secondary driven bering housing bolt: 28 N·m (2.8 kgf-m, 20.0 lb-ft) •…

• Page 176
  DRIVELINE/AXLE 4-11 • If the backlash is not within specification, the shims (Driven bevel gear side) must be changed and the backlash should be re-checked until correct. Refer to the chart for appropriate changes. NOTE: When changing the shims (Driven bevel gear side), measure the thickness of old shims.
• Page 177
  4-12 DRIVELINE/AXLE 3 INCORRECT (Contact at tooth root) • If tooth contact is found to be incorrect, the shims of the sec- ondary drive bevel gear and secondary driven bevel gear must be changed, tooth contact should be re-checked until correct.

• Page 178: Final Bevel Gears

  DRIVELINE/AXLE 4-13 FINAL BEVEL GEARS CONSTRUCTION 1 Oil seal A Final drive bavel gear K Oil seal 2 Final gear bearing case B Shims L Propeller shaft 3 Shims C Washer M Universal joint 4 Final driven gear bearing D Final drive bevel gear bearing A Final gear case bolt (M8) 5 Final driven bevel gear E Oil seal…

• Page 179
  4-14 DRIVELINE/AXLE Standard clearance A: 1.00 mm (0.039 in) Shim 3 – Gear case cover clearance: 0.1 mm (0.004 in) Shim 1 size table Shim 3 size table Part number Thickness Part number Thickness 27445-24A01-030 0.30 mm (0.012 in) 27327-38B00-035 0.35 mm (0.014 in) 27445-24A01-035 0.35 mm (0.014 in)

• Page 180: Final Gear Case Removal

  DRIVELINE/AXLE 4-15 FINAL GEAR CASE REMOVAL After draining final gear oil, the following components must be removed in the described order before removing the final gear case. • Drain final gear oil. («2-19) • Remove the rear wheel. («9-34) • Remove the final gear case nut, spring washer and final gear case 1.

• Page 181
  4-16 DRIVELINE/AXLE • Remove the propeller shaft 4 and spring 5. • Using a chisel, unlock the nut. • Remove the final drive gear coupling nut with the special tool. # 09924-62430: 22 mm Long socket 09924-64510: Final drive gear coupling holder •…
• Page 182
  DRIVELINE/AXLE 4-17 • Remove the bearing with the inner race from the final drive bevel gear with the special tool. # 09913-60910: Bearing puller The removed bearing must be replaced with a new one. NOTE: If no abnormal noise, the bearing removal is not necessary. •…
• Page 183
  4-18 DRIVELINE/AXLE • Remove the shim A and final driven bevel gear B. • Remove the shims C. • Using two bolts or suitable bars, remove the final driven bevel gear bearing from the bevel gear. NOTE: If no abnormal noise the bearing removal is not necessary. The removed bearing must be replaced with a new one.
• Page 184
  DRIVELINE/AXLE 4-19 • Remove the final driven gear bearing D and oil seal E with the special tools. # 09941-64511: Bearing remover 09930-30104: Sliding shaft The removed bearing and oil seal must be replaced with new ones. • Remove the final drive gear bearing with the special tools. # 09923-74511: Bearing remover 09930-30104: Sliding shaft The removed bearing must be replaced with a new one.

• Page 185: Final Gear Shims Adjustment

  (M10): 50 N·m (5.0 kgf-m, 36.0 lb-ft) NOTE: (M10) It is not necessary to apply SUZUKI BOND “1207B” and THREAD LOCK to the matching surface and bolts at this stage. • Measure the clearance between the shims and bearing. If it is not within the specification, the shims must be changed.

• Page 186
  DRIVELINE/AXLE 4-21 BACKLASH After assembling the final gear case («4-24), measure the final bevel gear backlash as follows. • Install the backlash measuring tool on the drive bevel gear coupling, and set-up a dial gauge as shown in photo. # 09924-34510: Backlash measuring tool (27 – 50 mm) 09900-20607: Dial gauge (1/100 mm, 10 mm) 09900-20701: Magnetic stand •…
• Page 187
  4-22 DRIVELINE/AXLE Shims 2 specifications Part number Shim thickness 27327-38B00-035 0.35 mm (0.014 in) 27327-38B00-040 0.40 mm (0.016 in) 27327-38B00-050 0.50 mm (0.020 in) 27327-38B00-060 0.60 mm (0.024 in) The shims 2 are available as a set (27327-38810). EXAMPLE: Final gear to case shims 1; 1.45 mm + 1.40 mm = 2.85 mm Final gear bearing to bearing case shims 2, 0.35 mm + 0.60 mm = 0.95 mm Original total measurement = 3.80 mm…
• Page 188
  DRIVELINE/AXLE 4-23 • Remove the final gear bearing case and final driven bevel 3 INCORRECT (Contact at tooth root) gear, and inspect the coated teeth of the driven bevel gear. The contact patch should be as shown at right: • If the tooth contact pattern is incorrect, as shown in 1, a thin- ner shim 4 is needed between the final drive bevel gear bearing and final gear case.

• Page 189: Final Gear Case Reassembly

  * Use a new oil seal to prevent oil leakage. * The lip and spring of the oil seal A should face to the driven bevel gear side. • Apply SUZUKI SUPER GREASE “A” to the oil seal lip. ‘ 99000-25010: SUZUKI SUPER GREASE “A” or equivalent •…

• Page 190
  • Install a new oil seal to the final gear bearing case with the special tool. # 09951-16310: Final gear case oil seal installer • Apply SUZUKI SUPER GREASE “A” to the lip of the oil seal. ‘ 99000-25010: SUZUKI SUPER GREASE “A” or equivalent •…
• Page 191
  • Install the correct shims 9 to the final drive bevel gear and install the bevel gear to the final gear case. Shim adjustment («4-23) • Apply SUZUKI SUPER GREASE “A” to the O-ring and the lip of oil seal. • Install the bearing stopper 0.
• Page 192
  • Install the dust seal with the special tool. # 09940-51410: Steering bearing installer 09925-18011: Bearing installer • Apply SUZUKI SUPER GREASE “A” to the lip of the dust seal. Use a new dust seal to prevent oil leakage. ‘ 99000-25010: SUZUKI SUPER GREASE “A”…

• Page 193: Final Gear Case Installation

  4-28 DRIVELINE/AXLE • Apply SUZUKI BOND to the mating surface of final gear case. & 99000-31140: SUZUKI BOND “1207B” or equivalent • Install the stopper plate F to the final gear case. When installing the plate, fit the protrusion B of plate to the one of the bearing stopper grooves.

• Page 194
  DRIVELINE/AXLE 4-29 • Install the final gear case. • Tighten the final gear case bolts to the specified torque. ! Final gear case nut: 40 N·m (4.0 kgf-m, 29.0 lb-ft) • Install the rear wheel. («9-39) • Pour final gear oil. («2-19)

• Page 195: Fi System Diagnosis

  FI SYSTEM DIAGNOSIS FI SYSTEM DIAGNOSIS CONTENTS PRECAUTIONS IN SERVICING …………..5- 3 ELECTRICAL PARTS …………….5- 3 FUSE…………………. 5- 4 ECM/VARIOUS SENSORS …………..5- 4 ELECTRICAL CIRCUIT INSPECTION PROCEDURE……5- 6 USING THE MULTI-CIRCUIT TESTER……….5- 9 FI SYSTEM TECHNICAL FEATURES…………5-10 INJECTION TIME (INJECTION VOLUME) ………..

• Page 196
  FI SYSTEM DIAGNOSIS FI SYSTEM DIAGNOSIS CONTENTS “C32” (P0201) or “C33” (P0202) FUEL INJECTOR CIRCUIT MALFUNCTION………………5-68 “C40” (P0505-H/L or P0506 and P0507) ISC VALVE CIRCUIT MALFUNCTION………………5-70 “C41” (P0230-H/L) FP RELAY CIRCUIT MALFUNCTION ….5-76 “C42” (P01650) IG SWITCH CIRCUIT MALFUNCTION …… 5-78 “C44”…

• Page 197: Precautions In Servicing

  FI SYSTEM DIAGNOSIS PRECAUTIONS IN SERVICING When handling the component parts or servicing the FI system, observe the following points for the safety of the system. ELECTRICAL PARTS CONNECTOR/COUPLER • When connecting a connector, be sure to push it in until a Click click is felt.

• Page 198: Fuse

  FI SYSTEM DIAGNOSIS • When connecting meter probe from the terminal side of the coupler (where connection from harness side not being possi- ble), use extra care not to force and cause the male terminal to bend or the female terminal to open. Connect the probe as shown to avoid opening of female ter- minal.

• Page 199
  FI SYSTEM DIAGNOSIS • When disconnecting and connecting the ECM, make sure to turn OFF the ignition switch 1, or electronic parts may get damaged. INCORRECT • Battery connection in reverse polarity is strictly prohibited. Such a wrong connection will damage the components of the FI system instantly when reverse power is applied.

• Page 200: Electrical Circuit Inspection Procedure

  FI SYSTEM DIAGNOSIS ELECTRICAL CIRCUIT INSPECTION PROCEDURE While there are various methods for electrical circuit inspection, described here is a general method to check for open and short circuit using an ohmmeter and a voltmeter. OPEN CIRCUIT CHECK Possible causes for the open circuits are as follows. As the cause can exist in the connector/coupler or terminal, they need to be checked carefully.

• Page 201
  FI SYSTEM DIAGNOSIS Continuity check • Measure resistance across coupler B (between A and C in the figure). If no continuity is indicated (infinity or over limit), the circuit is open between terminals A and C. 1 ECM • Disconnect the coupler B and measure resistance between couplers A and B.
• Page 202
  FI SYSTEM DIAGNOSIS SHORT CIRCUIT CHECK (WIRE HARNESS TO GROUND) • Disconnect the negative cable from the battery. • Disconnect the connectors/couplers at both ends of the circuit to be checked. NOTE: If the circuit to be checked branches to other parts as shown, disconnect all connectors/couplers of those parts.

• Page 203: Using The Multi-Circuit Tester

  FI SYSTEM DIAGNOSIS USING THE MULTI-CIRCUIT TESTER • Use the Suzuki multi-circuit tester set (09900-25008). • Use well-charged batteries in the tester. • Be sure to set the tester to the correct testing range. USING THE TESTER • Incorrectly connecting the + and — probes may cause the inside of the tester to burnout.

• Page 204: Fi System Technical Features

  5-10 FI SYSTEM DIAGNOSIS FI SYSTEM TECHNICAL FEATURES INJECTION TIME (INJECTION VOLUME) The factors to determine the injection time include the basic fuel injection time, which is calculated on the basis of intake air pressure, engine speed and throttle opening angle, and various compensations. These compensations are determined according to the signals from various sensors that detect the engine and driving conditions.

• Page 205: Compensation Of Injection Time (Volume)

  FI SYSTEM DIAGNOSIS 5-11 COMPENSATION OF INJECTION TIME (VOLUME) The following different signals are output from the respective sensors for compensation of the fuel injection time (volume). SIGNAL DESCRIPTION ENGINE COOLANT TEMPERATURE SEN- When engine coolant temperature is low, injection time (vol- SOR SIGNAL ume) is increased.

• Page 206: Fi System Parts Location

  5-12 FI SYSTEM DIAGNOSIS FI SYSTEM PARTS LOCATION A Tachometer B ISC valve (ISCV) C Intake air pressure sensor #2 (IAPS) D Ignition coil #1 (IG COIL) E Secondary throttle position sensor (STPS) F Throttle position sensor (TPS) G Secondary throttle valve actuator (STVA) H PAIR control solenoid valve (For E-02, 19, 24) I Ignition coil/plug cap #2 J HO2 sensor #2 (HO2S) [For E-02, 19, 24]…

• Page 207
  FI SYSTEM DIAGNOSIS 5-13 A Speedometer B Intake air temperature sensor (IATS) C PAIR control solenoid valve D Fuel injector #1 E Fuel injector #2 F Intake air pressure sensor #1 (IAPS) G Fuel pump H Ignition coil/plug cap #1 I Tip-over sensor (TOS) J Fuel pump relay (FP RELAY) K Cooling fan relay…

• Page 208: Fi System Wiring Diagram

  5-14 FI SYSTEM DIAGNOSIS FI SYSTEM WIRING DIAGRAM…

• Page 209: Ecm Terminal

  FI SYSTEM DIAGNOSIS 5-15 ECM TERMINAL TERMINAL TERMINAL CIRCUIT CIRCUIT STVA signal (STVA. 2A) STVA signal (STVA. 2B) STVA signal (STVA. 1A) STVA signal (STVA. 1B) EXCVA power (MO–) STP sensor signal (STP) EXCVA power (MO+) Ignition switch signal EXCVA position sensor (MPS) TO sensor signal (TOS) Serial data for speedometer GP switch signal (GP)

• Page 210
  5-16 FI SYSTEM DIAGNOSIS TERMINAL TERMINAL CIRCUIT CIRCUIT ISC signal (ISC, 2A) ISC signal (ISC, 2B) ISC signal (ISC, 1A) ISC signal (ISC, 1B) — — — — Fuel pump relay (FP Relay) — — — HO2 sensor heater (HO2, H) Mode select switch Starter relay Neutral switch…

• Page 211: Self-Diagnosis Function

  FI SYSTEM DIAGNOSIS 5-17 SELF-DIAGNOSIS FUNCTION The self-diagnosis function is incorporated in the ECM. The function has two modes, “User mode” and “Dealer mode”. The user can only be notified by the LCD (DISPLAY) panel and LED (FI indicator light). To check the function of the individual FI system devices, the dealer mode is provided.

• Page 212: Dealer Mode

  5-18 FI SYSTEM DIAGNOSIS DEALER MODE The defective function is memorized in the computer. Use the special tool’s coupler to connect to the dealer mode coupler. The memorized malfunction code is displayed on LCD (DISPLAY) panel. Malfunction means that the ECM does not receive signal from the devices. These affected devices are indicated in the code form.

• Page 213
  FI SYSTEM DIAGNOSIS 5-19 CODE MALFUNCTION PART REMARKS None No defective part Crankshaft position sensor (CKPS) Pick-up coil signal, Generator Intake air pressure sensor #2 (IAPS #2) For Front cylinder Throttle position sensor (TPS) Engine coolant temp. sensor (ECTS) Intake air pressure sensor #1 (IAPS #1) For Rear cylinder Intake air temp.

• Page 214: Tps Adjustment

  5-20 FI SYSTEM DIAGNOSIS TPS ADJUSTMENT 1. Warm up the engine and check the engine idle r/min. Adjust the engine rpm to 900 r/min if necessary. (#6-22) 2. Connect the special tool (Mode select switch) to the dealer mode coupler at the wiring harness. 3.

• Page 215: Fail-Safe Function

  FI SYSTEM DIAGNOSIS 5-21 FAIL-SAFE FUNCTION FI system is provided with fail-safe function to allow the engine to start and the motorcycle to run in a mini- mum performance necessary even under malfunction condition. STARTING RUNNING ITEM FAIL-SAFE MODE ABILITY ABILITY IAP sensor Intake air pressure is fixed to 760…

• Page 216: Fi System Troubleshooting

  5-22 FI SYSTEM DIAGNOSIS FI SYSTEM TROUBLESHOOTING CUSTOMER COMPLAINT ANALYSIS Record details of the problem (failure, complaint) and how it occurred as described by the customer. For this purpose, use of such an inspection form such as below will facilitate collecting information required for proper analysis and diagnosis.

• Page 217: Visual Inspection

  FI SYSTEM DIAGNOSIS 5-23 MOTORCYCLE/ENVIRONMENTAL CONDITION WHEN PROBLEM OCCURS Environmental condition Weather Fair Cloudy Rain Snow Always Other Temperature Warm Cool Cold ( °C/ °F) Always Frequency Always Sometimes ( times/ day, month) Only once Under certain condition Road Urban Suburb Highway Mountainous (…

• Page 218: Self-Diagnostic Procedures

  5-24 FI SYSTEM DIAGNOSIS SELF-DIAGNOSTIC PROCEDURES NOTE: * Don’t disconnect couplers from the ECM, the battery cable from the battery, ECM ground wire harness from the engine or main fuse before confirming the malfunction code (self-diag- nostic trouble code) stored in memory. Such disconnection will erase the memorized information in ECM memory.

• Page 219: Use Of Sds Diagnostic Procedures

  FI SYSTEM DIAGNOSIS 5-25 USE OF SDS DIAGNOSTIC PROCEDURES * Don’t disconnect couplers from ECM, the battery cable from the battery, ECM ground wire harness from the engine or main fuse before confirming the malfunction code (self-diagnostic trouble code) stored in memory. Such disconnection will erase the memorized information in ECM memory.

• Page 220: Use Of Sds Diagnosis Reset Procedure

  5-26 FI SYSTEM DIAGNOSIS USE OF SDS DIAGNOSIS RESET PROCE- DURE • After repairing the trouble, turn OFF the ignition switch and turn ON again. • Click the DTC inspection button 1. • Check the DTC. • The previous malfunction history code (Past DTC) still remains stored in the ECM.

• Page 221: Show Data When Trouble (Displaing Data At The Time Of Dtc)

  FI SYSTEM DIAGNOSIS 5-27 SHOW DATA WHEN TROUBLE (DISPLAING DATA AT THE TIME OF DTC) ECM stores the engine and driving conditions (in the form of data as shown in the figure) at the moment of the detection of a malfunction in its memory. This data is called “Show data when trouble”. Therefore, it is possible to know engine and driving conditions (e.g., whether the engine was warm or not, where the motorcycle was running or stopped) when a malfunction was detected by checking the show data when trouble.

• Page 222: Malfunction Code And Defective Condition

  5-28 FI SYSTEM DIAGNOSIS MALFUNCTION CODE AND DEFECTIVE CONDITION DETECTED DTC No. DETECTED FAILURE CONDITION CHECK FOR ITEM NO FAULT ––––––––––– ––––––––––– CKP sensor The signal does not reach ECM for 3 CKP sensor wiring and mechan- sec. or more, after receiving the starter ical parts signal.

• Page 223
  FI SYSTEM DIAGNOSIS 5-29 DETECTED DTC No. DETECTED FAILURE CONDITION CHECK FOR ITEM TO sensor The sensor voltage should be the fol- TO sensor, lead wire/coupler lowing for 2 sec. and more, after igni- connection tion switch is turned ON. 0.2 V sensor voltage <…
• Page 224
  5-30 FI SYSTEM DIAGNOSIS DETECTED DTC No. DETECTED FAILURE CONDITION CHECK FOR ITEM ISC valve ISC valve motor current is higher than ISC valve circuit shorted to specified value. BATT or ground circuit open P0505 ISC valve motor circuit is open. ISC valve circuit open or BATT circuit open Idle speed is lower than the desired…
• Page 225
  FI SYSTEM DIAGNOSIS 5-31 DETECTED DTC No. DETECTED FAILURE CONDITION CHECK FOR ITEM Exhaust con- EXCVA position sensor produces fol- EXCVA, EXCVA lead wire/cou- trol valve lowing voltage. pler actuator 0.1 V sensor voltage < 4.9 V In other than the above range, C46 (P1657) is indicated.

• Page 226: C12″ (P0335) Ckp Sensor Circuit Malfunction

  5-32 FI SYSTEM DIAGNOSIS “C12” (P0335) CKP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE The signal does not reach ECM for 3 sec. or more, • Metal particles or foreign material being stuck on after receiving the starter signal. the CKP sensor and rotor tip. •…

• Page 227
  FI SYSTEM DIAGNOSIS 5-33 6) If OK, then check the continuity between each terminal and ground. $ CKP sensor continuity: ∞ Ω (Infinity) (Blue – Ground) (Green – Ground) ! 09900-25008: Multi-circuit tester set % Tester knob indication: Resistance (Ω) Are the resistance and continuity OK? Go to step 2.

• Page 228: C13″ (P1750-H/L) Or «C17» (P0105-H/L) Iap Sensor Circuit Malfunction

  5-34 FI SYSTEM DIAGNOSIS “C13” (P1750-H/L) or “C17” (P0105-H/L) IAP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE C13/C17 IAP sensor voltage is not within the fol- • Clogged vacuum passage between throttle body lowing range. and IAP sensor. 0.5 V Sensor voltage <…

• Page 229
  FI SYSTEM DIAGNOSIS 5-35 4) Disconnect the IAP sensor coupler. 5) Turn the ignition switch ON. 6) Measure the voltage at the Red wire 3 and ground. 7) If OK, then measure the voltage at the Red wire 3 and B/Br wire 4.
• Page 230
  5-36 FI SYSTEM DIAGNOSIS Step 3 1) Turn the ignition switch OFF. 2) Remove the IAP sensor. (#6-13) 3) Connect the vacuum pump gauge to the vacuum port of the IAP sensor. 4) Arrange 3 new 1.5 V batteries in series 1 (check that total — voltage is 4.5 –…
• Page 231
  FI SYSTEM DIAGNOSIS 5-37 Step 1 (When indicating P1750-H for IAP sensor #2) (When indicating P0105-H for IAP sensor #1) 1) Turn the ignition switch OFF. 2) Remove the fuel tank. (#6-3) 3) Check the IAP sensor coupler for loose or poor contacts. If OK, then check the IAP sensor lead wire continuity.
• Page 232
  5-38 FI SYSTEM DIAGNOSIS Check the continuity between P/B wire B and terminal 9 (#2), and G/B wire B and terminal P (#1). 9) If OK, then check the continuity between B/Br wire C (#1 and #2) and terminal S. «…
• Page 233
  FI SYSTEM DIAGNOSIS 5-39 7) Disconnect the ECM coupler. (#5-37) Check the continuity between Red wires A (#1 and #2) and terminal A. 9) Also, check the continuity between P/B wire B and terminal 9, and G/B wire B and terminal P. «…
• Page 234
  5-40 FI SYSTEM DIAGNOSIS Step 2 1) Connect the IAP sensor coupler and ECM coupler. 2) Reinstall the fuel tank and lift up the fuel tank. 3) Insert the needle pointed probes to the lead wire coupler. 4) Start the engine at idle speed and measure the IAP sensor output voltage at the wire side coupler.

• Page 235: C14″ (P0120-H/L) Tp Sensor Circuit Malfunction

  FI SYSTEM DIAGNOSIS 5-41 “C14” (P0120-H/L) TP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE Output voltage is not within the following • TP sensor maladjusted range. • TP sensor circuit open or short Difference between actual throttle open- • TP sensor malfunction ing and opening calculated by ECM is •…

• Page 236
  5-42 FI SYSTEM DIAGNOSIS Step 1 (When indicating P0120-H:) 1) Turn the ignition switch OFF. 2) Remove the fuel tank. (#6-3) 3) Check the TP sensor coupler for loose or poor contacts. If OK, then check the TP sensor lead wire continuity. 4) Disconnect the TP sensor coupler.
• Page 237
  FI SYSTEM DIAGNOSIS 5-43 Step 1 (When indicating P0120-L:) 1) Turn the ignition switch OFF. 2) Remove the fuel tank. (#6-3) 3) Check the TP sensor coupler for loose or poor contacts. If OK, then check the TP sensor lead wire continuity. 4) Disconnect the TP sensor coupler.
• Page 238
  5-44 FI SYSTEM DIAGNOSIS Step 2 1) Turn the ignition switch OFF. 2) Disconnect the TP sensor coupler and ECM coupler. 3) Install the test harness to the TP sensor. 4) Check the continuity between terminal A and ground. $ TP sensor continuity: ∞ Ω (Infinity) (Terminal A –…
• Page 239
  FI SYSTEM DIAGNOSIS 5-45 Step 3 1) Connect the TP sensor coupler 1 to the test harness. 2) Turn the ignition switch ON. 3) Measure the TP sensor output voltage at the coupler (between + P/B and — B/Br) by turning the throttle grip. $ TP sensor output voltage Throttle valve is closed: Approx.

• Page 240: C15″ (P0115-H/L) Ect Sensor Circuit Malfunction

  5-46 FI SYSTEM DIAGNOSIS “C15” (P0115-H/L) ECT SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE Output voltage is not within the following • ECT sensor circuit open or short range. • ECT sensor malfunction P0115 0.15 V Sensor voltage < 4.85 V •…

• Page 241
  FI SYSTEM DIAGNOSIS 5-47 Step 1 (When indicating P0115-H:) 1) Turn the ignition switch OFF. 2) Remove the right air cleaner box. (#6-13) 3) Check the ECT sensor coupler for loose or poor contacts. If OK, then check the ECT sensor lead wire continuity. 4) Disconnect the ECT sensor coupler and ECM coupler.
• Page 242
  5-48 FI SYSTEM DIAGNOSIS Step 1 (When indicating P0115-L:) 1) Turn the ignition switch OFF. 2) Remove the right air cleaner box. (#6-13) 3) Check the ECT sensor coupler for loose or poor contacts. If OK, then measure the output voltage. 4) Disconnect the ECT sensor coupler.
• Page 243
  FI SYSTEM DIAGNOSIS 5-49 Step 2 1) Turn the ignition switch OFF. 2) Disconnect the ECT sensor coupler. 3) Measure the ECT sensor resistance. $ ECT sensor resistance: Approx. 2.45 kΩ at 20 °C (68 °F) (Terminal – Terminal) ! 09900-25008: Multi-circuit tester set % Tester knob indication: Resistance (Ω) Refer to page 8-9 for details.

• Page 244: C21″ (P0110-H/L) Iat Sensor Circuit Malfunction

  5-50 FI SYSTEM DIAGNOSIS “C21” (P0110-H/L) IAT SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE Output voltage is not within the following • IAT sensor circuit open or short range. • IAT sensor malfunction P0110 0.15 V Sensor voltage < 4.85 V •…

• Page 245
  FI SYSTEM DIAGNOSIS 5-51 Step 1 (When indicating P0110-H:) 1) Turn the ignition switch OFF. 2) Remove the fuel tank. (#6-3) 3) Check the IAT sensor coupler for loose or poor contacts. If OK, then check the IAT sensor lead wire continuity. 4) Disconnect the IAT sensor coupler and ECM coupler.
• Page 246
  5-52 FI SYSTEM DIAGNOSIS Step 1 (When indicating P0110-L:) 1) Turn the ignition switch OFF. 2) Remove the fuel tank. (#6-3) 3) Check the IAT sensor coupler for loose or poor contacts. If OK, then check the IAT sensor lead wire continuity. 4) Disconnect the IAT sensor coupler.
• Page 247
  FI SYSTEM DIAGNOSIS 5-53 Step 2 1) Turn the ignition switch OFF. 2) Measure the IAT sensor resistance. $ IAT sensor resistance: Approx. 2.45 kΩ at 20 °C (68 °F) (Terminal – Terminal) ! 09900-25008: Multi-circuit tester set % Tester knob indication: Resistance (Ω) Is the resistance OK? ECM coupler (Harness side) •…

• Page 248: C23″ (P1651-H/L) To Sensor Circuit Malfunction

  5-54 FI SYSTEM DIAGNOSIS “C23” (P1651-H/L) TO SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE The sensor voltage should be the follow- • TO sensor circuit open or short ing for 2 sec. and more, after ignition • TO sensor malfunction switch is turned ON.

• Page 249
  FI SYSTEM DIAGNOSIS 5-55 Step 1 (When indicating P1651-H:) 1) Turn the ignition switch OFF. 2) Remove the fuel tank. (#6-3) 3) Check the TO sensor coupler for loose or poor contacts. If OK, then check the TO sensor lead wire continuity. 4) Disconnect the TO sensor coupler.
• Page 250
  5-56 FI SYSTEM DIAGNOSIS Step 1 (When indicating P1651-L:) 1) Turn the ignition switch OFF. 2) Remove the fuel tank. (#6-3) 3) Check the TO sensor coupler for loose or poor contacts. If OK, then check the TO sensor lead wire continuity. 4) Disconnect the TO sensor coupler.
• Page 251
  FI SYSTEM DIAGNOSIS 5-57 Step 2 1) Connect the TO sensor coupler and ECM coupler. 2) Insert the needle pointed probes to the lead wire coupler. 3) Turn the ignition switch ON. 4) Measure the voltage at the wire side coupler between Black and B/Br wires.

• Page 252: C28″ (P1655) Stv Actuator Circuit Malfunction

  5-58 FI SYSTEM DIAGNOSIS “C28” (P1655) STV ACTUATOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE The operation voltage does not reach the STVA. • STVA malfunction ECM does not receive communication signal from • STVA circuit open or short the STVA. •…

• Page 253
  FI SYSTEM DIAGNOSIS 5-59 Step 2 1) Turn the ignition switch OFF. 2) Disconnect the STVA lead wire coupler. 3) Check the continuity between each terminal and ground. $ STVA continuity: ∞ Ω (Infinity) (Terminal – Ground) 4) If OK, then measure the STVA resistance (between Black wire A and Pink wire B) and (between Green wire C and W/BI wire D).
• Page 254
  5-60 FI SYSTEM DIAGNOSIS ACTIVE CONTROL INSPECTION 1) Set up the SDS tool. (Refer to the SDS operation manual for further details.) 2) Turn the ignition switch ON. 3) Click “Secondary throttle operating control” 1. 4) Click each button 2. At this time, if an operation sound is heard from the STVA, the function is normal.

• Page 255: C29″ (P1654-H/L) Stp Sensor Circuit Malfunction

  FI SYSTEM DIAGNOSIS 5-61 “C29” (P1654-H/L) STP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE Signal voltage is not within the following • STP sensor maladjusted range. • STP sensor circuit open or short Difference between actual throttle open- • STP sensor malfunction ing and opening calculated by ECM is •…

• Page 256
  5-62 FI SYSTEM DIAGNOSIS Step 1 (When indicating P1654-H:) 1) Turn the ignition switch OFF. 2) Remove the right air cleaner box. (#6-13) 3) Check the STP sensor coupler for loose or poor contacts. If OK, then check the STP sensor lead wire continuity. STP sensor lead wire coupler: Black 4) Disconnect the STP sensor coupler.
• Page 257
  FI SYSTEM DIAGNOSIS 5-63 Step 1 (When indicating P1654-L:) 1) Turn the ignition switch OFF. 2) Remove the right air cleaner box. (#6-13) 3) Check the STP sensor coupler for loose or poor contacts. If OK, then check the STP sensor lead wire continuity. STP sensor lead wire coupler: Black 4) Disconnect the STP sensor coupler.
• Page 258
  5-64 FI SYSTEM DIAGNOSIS Step 2 1) Turn the ignition switch OFF. 2) Remove the air cleaner chamber. (#6-13) 3) Disconnect the STP sensor coupler. 4) Check the continuity between each terminal and ground. $ STP sensor continuity: ∞ Ω (Infinity) (Terminal –…
• Page 259
  FI SYSTEM DIAGNOSIS 5-65 Step 3 1) Turn the ignition switch OFF. 2) Disconnect the STP sensor coupler and install the test har- ness. 3) Disconnect the STVA lead wire coupler. 4) Turn the ignition switch ON. 5) Measure the STP sensor output voltage at the terminals (between + terminal A Y/W wire and — terminal C B/Br wire) by turning the secondary throttle valve (close and open) with a finger.

• Page 260: C31″ (P0705) Gp Switch Circuit Malfunction

  5-66 FI SYSTEM DIAGNOSIS “C31” (P0705) GP SWITCH CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE No Gear Position switch voltage • Gear Position switch circuit open or short Switch voltage is not within the following range. • Gear Position switch malfunction Switch voltage >…

• Page 261
  FI SYSTEM DIAGNOSIS 5-67 Is the voltage OK? ECM coupler (Harness side) • Pink wire open or shorted to ground (Black) (Gray) • If wire and connection are OK, intermittent trou- ble or faulty ECM. • Recheck each terminal and wire harness for open circuit and poor connection.

• Page 262: C32″ (P0201) Or «C33» (P0202) Fuel Injector Circuit Malfunction

  5-68 FI SYSTEM DIAGNOSIS “C32” (P0201) or “C33” (P0202) FUEL INJECTOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE CKP signals produced but fuel injector signal is • Injector circuit open or short. interrupted continuous by 4 times or more. • Injector malfunction. •…

• Page 263
  FI SYSTEM DIAGNOSIS 5-69 5) If OK, then check the continuity between each terminal and ground. $ STP sensor continuity: ∞ Ω (Infinity) ! 09900-25008: Multi-circuit tester set % Tester knob indication: Resistance (Ω) Are the resistance and continuity OK? Go to Step 2.

• Page 264: C40″ (P0505-H/L Or P0506 And P0507) Isc Valve Circuit Malfunction

  5-70 FI SYSTEM DIAGNOSIS “C40” (P0505-H/L or P0506 and P0507) ISC VALVE CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE ISC valve motor current is higher than • ISC valve circuit shorted to BATT or ground circuit P0505 the specified value. open •…

• Page 265
  FI SYSTEM DIAGNOSIS 5-71 INSPECTION Step 1 1) Remove the fuel tank. (#6-3) 2) Turn the ignition switch OFF. 3) Check the ISC valve coupler for loose or poor contacts. 4) If OK, then check the ISC valve lead wire continuity. 5) Disconnect the ISC valve coupler and ECM coupler.
• Page 266
  5-72 FI SYSTEM DIAGNOSIS Step 2 1) Turn the ignition switch OFF. 2) Disconnect the ISC valve coupler. 3) Check the continuity between terminals 1 and 3, terminals 2 and 4. $ ISC valve continuity: Approx. ∞ Ω (Infinity) (Terminal 1 – Terminal 3) (Terminal 2 –…
• Page 267
  FI SYSTEM DIAGNOSIS 5-73 ACTIVE CONTROL INSPECTION (ISC RPM CONTROL) Check 1 1) Set up the SDS tool. (Refer to the SDS operation manual for further details.) 2) Check that the engine is running. 3) Click the “Active control”. 4) Click the “ISC rpm control” 1. 5) Check that the “Spec”…
• Page 268
  5-74 FI SYSTEM DIAGNOSIS Check 2 1) Click the button 1 and decrease the “Spec” 2 to 800 rpm slowly. 2) Check that the “Desired idle speed” 3 is nearly equal to the “Spec” 2. At the same time, check that the number of steps in the ISC valve position decreases 3) Click the button 4 and increase the “Spec”…
• Page 269
  FI SYSTEM DIAGNOSIS 5-75 Check 3 1) Click the button 1 and increase the “Spec” 2 to 1 200 rpm slowly. 2) Check that the “Desired idle speed” 3 is nearly equal to the “Spec” 2. Also, check that the number of steps 4 in the ISC valve position increases «…

• Page 270: C41″ (P0230-H/L) Fp Relay Circuit Malfunction

  5-76 FI SYSTEM DIAGNOSIS “C41” (P0230-H/L) FP RELAY CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE No voltage is applied to fuel pump • Fuel pump relay circuit open or short although fuel pump relay is turned ON, • Fuel pump relay malfunction or voltage is applied to fuel pump, •…

• Page 271
  FI SYSTEM DIAGNOSIS 5-77 Step 1 (When indicating P0230-H:) 1) Turn the ignition switch OFF. 2) Remove the right frame side cover. (#9-5) 3) Check the FP relay coupler for loose or poor contacts. If OK, then check the FP relay. (#6-6) Is the FP relay OK? ECM coupler (Harness side) •…

• Page 272: C42″ (P01650) Ig Switch Circuit Malfunction

  5-78 FI SYSTEM DIAGNOSIS “C42” (P01650) IG SWITCH CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE Ignition switch signal is not input to the ECM. • Ignition system circuit open or short • ECM malfunction INSPECTION * Refer to the IGNITION SWITCH INSPECTION for details. (#10-42)

• Page 273: C44″ (P0156/P0161) Or «C64» (P0130/P0135) Ho2 Sensor (Ho2S) Circuit Malfunction (For E-02, 19, 24)

  FI SYSTEM DIAGNOSIS 5-79 “C44” (P0156/P0161) or “C64” (P0130/P0135) HO2 SENSOR (HO2S) CIRCUIT MALFUNCTION (FOR E-02, 19, 24) DETECTED CONDITION POSSIBLE CAUSE C44/C64 HO2 sensor output voltage is not input • HO2 sensor circuit open or shorted to ground. (P0156/ to ECM during engine operation and •…

• Page 274
  5-80 FI SYSTEM DIAGNOSIS 6) Disconnect the ECM coupler. (#5-37) 7) Check the continuity between W/G or W/Bl wire A and termi- nal B, E. Also, check the continuity between B/Br wire B and terminal » When using the multi-circuit tester, do not strongly (Gray) (Black) touch the terminal of the ECM coupler with a needle…
• Page 275
  FI SYSTEM DIAGNOSIS 5-81 Is the voltage OK? ECM coupler (Harness side) • W/G wire or B/Br wire open or shorted to (Black) (Gray) ground, or poor B, E or S connection. • If wire and connection are OK, intermittent trou- ble or faulty ECM.
• Page 276
  5-82 FI SYSTEM DIAGNOSIS Step 2 1) Connect the HO2 sensor coupler. 2) Insert the needle pointed probes to the HO2 sensor coupler. 3) Turn the ignition switch ON and measure the heater voltage between W/B wire and ground. 4) If the tester voltage indicates the battery voltage, it is good condition.

• Page 277: C46″ (P1657-H/L Or P1658) Excv Actuator Circuit Malfunction

  FI SYSTEM DIAGNOSIS 5-83 “C46” (P1657-H/L or P1658) EXCV ACTUATOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE The operation signal does not reach the • EXCVA maladjusted EXCV actuator. • EXCVA circuit open or short EXCVA position sensor voltage low or •…

• Page 278
  5-84 FI SYSTEM DIAGNOSIS Step 1 (When indicating P1657-H:) 1) Turn the ignition switch OFF. 2) Remove the lower frame cover. (#7-8) 3) Check the EXCVA position sensor coupler for loose or poor contacts. If OK, then check the EXCVA position sensor lead wire conti- nuity.
• Page 279
  FI SYSTEM DIAGNOSIS 5-85 Step 1 (When indicating P1657-L:) 1) Turn the ignition switch OFF. 2) Remove the lower frame cover. (#7-8) 3) Check the EXCVA position sensor coupler for loose or poor contacts. If OK, then check the EXCVA position sensor lead wire conti- nuity.
• Page 280
  5-86 FI SYSTEM DIAGNOSIS Step 1 (When indicating P1658:) 1) Turn the ignition switch OFF. 2) Remove the lower frame cover. (#7-8) 3) Check the EXCVA motor coupler for loose or poor contacts. Is the contacting OK? Go to Step 6. Loose or poor contacts on the EXCV motor cou- pler 4) After repairing the trouble, clear the DTC using SDS tool.
• Page 281
  FI SYSTEM DIAGNOSIS 5-87 Step 3 1) Turn the ignition switch OFF. 2) Check the continuity between Yellow wire and ground. $ Position sensor continuity: ∞ Ω (Infinity) 3) If OK, then measure the position sensor resistance. 4) Connect the position sensor coupler. 5) Set the EXCVA to adjustment position.
• Page 282
  5-88 FI SYSTEM DIAGNOSIS Step 4 1) Turn the ignition switch OFF. 2) Connect the position sensor coupler. 3) Measure the position sensor output voltage at fully close posi- tion and fully open position. 4) Insert the needle pointed probes to the back side of the posi- tion sensor lead wire coupler.
• Page 283
  FI SYSTEM DIAGNOSIS 5-89 Step 5 1) If the position sensor output voltage is 0.5 V and less at fully close position, adjust the output voltage to specified by turn- ing out the No. 1 cable adjuster 1. 2) Repeat the above procedure (Step 4) until the out put voltage becomes specified value.
• Page 284
  5-90 FI SYSTEM DIAGNOSIS Step 6 1) Turn the ignition switch OFF. 2) Disconnect the motor lead wire coupler of the EXCVA. 3) Apply 12 volts to the terminal and check the operation of EXCVA. 12 V 4) Then, swap the wires supplied 12 volts and check the opera- tion of EXCVA.
• Page 285
  FI SYSTEM DIAGNOSIS 5-91 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 “Exhaust valve operating control” 1. 4) Click each button 2. At this time, if an operation sound is heard from the EXCVA, the function is normal.

• Page 286: C49″ (P1768) Or «C61» (P1656) Pair Control Solenoid Valve Circuit Malfunction

  5-92 FI SYSTEM DIAGNOSIS “C49” (P1768) or “C61” (P1656) PAIR CONTROL SOLENOID VALVE CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE PAIR control solenoid valve voltage is not input to • PAIR control solenoid valve circuit open or short ECM. • PAIR control solenoid valve malfunction •…

• Page 287
  FI SYSTEM DIAGNOSIS 5-93 Step 2 1) Turn the ignition switch ON. 2) Measure the voltage between O/B wire and ground. $ PAIR valve voltage: Battery voltage (+ O/B – — Ground) ! 09900-25008: Multi-circuit tester set & Tester knob indication: Voltage (‘) Is the voltage OK? ECM coupler (Harness side) •…

• Page 288: C60″ (P0480) Cooling Fan Relay Circuit Malfunction

  5-94 FI SYSTEM DIAGNOSIS “C60” (P0480) COOLING FAN RELAY CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE Cooling fan relay signal is not input to ECM. • Cooling fan relay circuit open or short • ECM malfunction Side-stand Ignition Cooling fan relay switch relay To Side-stand…

• Page 289
  FI SYSTEM DIAGNOSIS 5-95 ACTIVE CONTROL INSPECTION 1) Set up the SDS tool. (Refer to the SDS operation manual for further details.) 2) Start the engine and run it idling condition. 3) Click “Cooling fan relay control” 1. 4) Click the operate button 2. At this time, if an operation sound is heard from the cooling fan relay and cooling fan motor is operated, the function is normal.
• Page 290
  5-96 FI SYSTEM DIAGNOSIS 6) Click the off button 4 to check the cooling fan relay and cooling fan motor operation. NOTE: This inspection should be begun from when the engine coolant temperature is below 50 °C (122 °F). Check that the cooling fan relay operates for a few seconds as the engine coolant temperature arrives each at 50 °C (122 °F), 70 °C (158 °F) and 90 °C (194 °F) / above 4 000 r/min.

• Page 291: Sensors

  FI SYSTEM DIAGNOSIS 5-97 SENSORS IAP SENSOR INSPECTION The intake air pressure sensor is located at the right and left side of the air cleaner box. (#6-13) IAP SENSOR REMOVAL AND INSTALLATION • Remove the fuel tank. (#6-3) • Remove the IAP sensors from the air cleaner chamber. •…

• Page 292: Stp Sensor Inspection

  5-98 FI SYSTEM DIAGNOSIS STP SENSOR INSPECTION The secondary throttle position sensor is installed on the No. 2 throttle body. (#5-61) STP SENSOR REMOVAL AND INSTALLATION • Remove the fuel tank. (#6-3) • Remove the right air cleaner box. (#6-13) •…

• Page 293: Iat Sensor Inspection

  FI SYSTEM DIAGNOSIS 5-99 IAT SENSOR INSPECTION The intake air temperature sensor is installed at the front left side of the air cleaner box. (#5-50) IAT SENSOR REMOVAL AND INSTALLATION • Remove the fuel tank. (#6-3) • Remove the IAT sensor from the air cleaner chamber. •…

• Page 294: Ho2 Sensor Inspection (For E-02, 19, 24)

  5-100 FI SYSTEM DIAGNOSIS HO2 SENSOR INSPECTION (FOR E-02, 19, 24) The heated oxygen sensor is installed on the pre-muffler. (#5-79) HO2 SENSOR REMOVAL AND INSTALLATION (FOR E-02, 19, 24) • Remove the HO2 sensor unit. Do not remove the HO2 sensor while it is hot. «…

• Page 295: Fuel System And Throttle Body

  FUEL SYSTEM AND THROTTLE BODY FUEL SYSTEM AND THROTTLE BODY CONTENTS FUEL DELIVERY SYSTEM…………….6- 2 FUEL SYSTEM………………… 6- 3 FUEL TANK REMOVAL……………. 6- 3 FUEL TANK INSTALLATION …………… 6- 3 FUEL PRESSURE INSPECTION …………6- 4 FUEL PUMP INSPECTION …………..6- 5 FUEL DISCHARGE AMOUNT INSPECTION ……..

• Page 296: Fuel Delivery System

  FUEL SYSTEM AND THROTTLE BODY FUEL DELIVERY SYSTEM The fuel delivery system consists of the fuel tank, fuel pump, fuel filters, fuel feed hose, fuel delivery pipe (including fuel injectors) and fuel pressure regulator. There is no fuel return hose. The fuel in the fuel tank is pumped up by the fuel pump and pressurized fuel flows into the injector installed in the fuel delivery pipe.

• Page 297: Fuel System

  FUEL SYSTEM AND THROTTLE BODY FUEL SYSTEM FUEL TANK REMOVAL • Remove the left and right frame side covers. («9-5) • Remove the fuel tank mounting bolt. • Lift and support the fuel tank about 10 cm (3.94 in) with the proper stay.

• Page 298: Fuel Pressure Inspection

  FUEL SYSTEM AND THROTTLE BODY FUEL PRESSURE INSPECTION • Lift and support the fuel tank. («6-3) • Place a rag under the fuel feed hose. • Disconnect the fuel feed hose 1. • Install the special tools between the fuel tank and fuel delivery pipe.

• Page 299: Fuel Pump Inspection

  FUEL SYSTEM AND THROTTLE BODY FUEL PUMP INSPECTION Turn the ignition switch ON and check that the fuel pump operates for few seconds. If the fuel pump motor does not make operating sound, inspect the fuel pump circuit connections or inspect the fuel pump relay and tip-over sensor.

• Page 300: Fuel Pump Relay Inspection

  FUEL SYSTEM AND THROTTLE BODY FUEL PUMP RELAY INSPECTION Cooling fan relay is located in front of the battery. • Remove the right side frame cover. («9-5) • Remove the fuel pump relay 1. First check the insulation between A and B terminals with tester.

• Page 301: Fuel Pump And Fuel Level Gauge Removal

  FUEL SYSTEM AND THROTTLE BODY FUEL PUMP AND FUEL LEVEL GAUGE REMOVAL CONSTRUCTION 1 Thermistor 5 O-ring 2 Fuel pump 6 Fuel level gauge ITEM N·m kgf-m lb-ft 3 Fuel mesh filter A Fuel pump mounting bolt 4 Filter cover…

• Page 302: Fuel Level Gauge Inspection

  FUEL SYSTEM AND THROTTLE BODY REMOVAL • Remove the fuel tank. («6-3) • Remove the fuel tank shield 1. A: Clamp • Remove the fuel pump assembly 2 mounting bolts diago- nally. Gasoline is highly flammable and explosive. Keep heat, spark and flame away. •…

• Page 303: Fuel Pump Disassembly

  FUEL SYSTEM AND THROTTLE BODY FUEL PUMP DISASSEMBLY • Disconnect the fuel pump coupler 1. • Remove the band 2 and clamp 3. • Remove the hose 4 and filter cover 5. • Remove the clamp 6 and thermistor 7. •…

• Page 304: Fuel Mesh Filter Inspection

  6-10 FUEL SYSTEM AND THROTTLE BODY FUEL MESH FILTER INSPECTION • Disconnect the clamp 1 and rubber boot 2. If the fuel mesh filter is clogged with sediment or rust, replace the fuel filter with a new one. FUEL PUMP AND FUEL LEVEL GAUGE REASSEMBLY AND INSTALLATION Install the fuel pump and fuel level gauge in the reverse order of removal and disassembly.

• Page 305
  FUEL SYSTEM AND THROTTLE BODY 6-11 • Apply thin coat of the engine oil to the bushing. • Install the fuel pump 1. • Install a new O-ring and apply SUZUKI SUPER GREASE “A” to it. ) 99000-25010: SUZUKI SUPER GREASE “A” or equivalent The O-ring must be replaced with a new one to prevent fuel leakage.

• Page 306: Throttle Body

  6-12 FUEL SYSTEM AND THROTTLE BODY THROTTLE BODY CONSTRUCTION Only for E-33 1 TP sensor 8 Cushion seal 2 STP sensor 9 Air screw 3 STVA 0 ISC valve 4 Fuel delivery pipe A Vacuum hose ITEM N·m kgf-m lb-ft 5 IAP sensor A Fuel delivery pipe mounting screw 6 O-ring…

• Page 307: Air Cleaner Box Removal

  FUEL SYSTEM AND THROTTLE BODY 6-13 AIR CLEANER BOX REMOVAL • Remove the fuel tank. («6-3) • Remove the bolts. *: Hooked part • Disconnect the drain hose 1. • Loosen the clamp screw 2. • Remove the right air cleaner box. •…

• Page 308
  6-14 FUEL SYSTEM AND THROTTLE BODY • Disconnect the PCV hose 8. • Loosen the throttle body clamp screws at the air cleaner chamber side. • Disconnect the PAIR lead wire couplers 9 and hoses 0. • Remove the air cleaner chamber. For E-03, 28, 33 For the others •…

• Page 309: Throttle Body Disassembly

  FUEL SYSTEM AND THROTTLE BODY 6-15 • Disconnect the clamp and fuel injector lead wire couplers D. • Loosen the throttle body clamp screws at the intake pipe side. • Disconnect the throttle cables from their drum. • Remove the throttle body assembly. Do not snap the throttle valve from full open to full close after disconnecting the throttle cables.

• Page 310
  6-16 FUEL SYSTEM AND THROTTLE BODY • Remove the fuel injectors 5. • Remove the TP sensor 6 and STP sensor 7 with the special tool. $ 09930-11950: Torx wrench NOTE: Prior to disassembly, mark each sensor’s original position with a paint or scribe for accurate reinstallation.

• Page 311: Throttle Body Cleaning

  FUEL SYSTEM AND THROTTLE BODY 6-17 THROTTLE BODY CLEANING Some carburetor cleaning chemicals, especially dip-type soaking solutions, are very corrosive and must be handled carefully. Always follow the chemical manufacturer’s instructions on proper use, handling and storage. • Clean passageways (except for main bore) with a spray-type carburetor cleaner and blow dry with compressed air.

• Page 312: Isc Valve Removal

  6-18 FUEL SYSTEM AND THROTTLE BODY ISC VALVE REMOVAL Disconnect the hoses and remove the ISC valve 1. INSPECTION Check the ISC valve for wear or damage, replace it with a new one if necessary. ISC VALVE INSTALLATION Install the ISC valve in the reverse order of removal.

• Page 313: Throttle Body Reassembly

  * Apply thin coat of the engine oil to the O-ring. * Align the throttle shaft end C with the groove D of TP sensor. * Apply SUZUKI SUPER GREASE “A” to the throttle shaft end C if necessary. ) 99000-25010: SUZUKI SUPER GREASE “A”…

• Page 314
  6-20 FUEL SYSTEM AND THROTTLE BODY • Apply thin coat of the engine oil to the new cushion seal 3, and the O-ring 4. Replace the cushion seal and O-ring with the new ones. • Install the fuel injector 5 by pushing it straight to the delivery pipe 6.

• Page 315: Air Cleaner Chamber And Throttle Body Installation

  FUEL SYSTEM AND THROTTLE BODY 6-21 AIR CLEANER CHAMBER AND THROTTLE BODY INSTALLATION Installation is in the reverse order of removal. Pay attention to the following points: • Connect the fuel injector couplers to the fuel injectors. Make sure that each coupler is installed in the correct position. The color on each lead wire refers to the appropriate fuel injector.

• Page 316: Stp Sensor Adjustment

  6-22 FUEL SYSTEM AND THROTTLE BODY STP SENSOR ADJUSTMENT If the STP sensor adjustment is necessary, measure the sensor out put voltage and adjust the STP sensor position as follows: • Remove the air cleaner chamber. («6-13) • Disconnect the STVA coupler. («6-14) •…

• Page 317: Fuel Injector Installation

  FUEL SYSTEM AND THROTTLE BODY 6-23 FUEL INJECTOR INSTALLATION • Apply thin coat of the engine oil to new injector cushion seals and O-rings. («6-20) • Install the injector by pushing it straight to the throttle body. Never turn the injector while pushing it. («6-20) THROTTLE VALVE SYNCHRONIZATION Check and adjust the throttle valve synchronization among two cylinders.

• Page 318: Throttle Position Sensor (Tps) Setting

  6-24 FUEL SYSTEM AND THROTTLE BODY Step 2 • Warm up the engine as follows: Summer: approx. 5 min at idle r/min Winter: approx. 8 min at idle r/min • Water temperature should be more than 80 °C (176 °F) and then wait 30 second.

• Page 319: Exhaust System

  EXHAUST SYSTEM EXHAUST SYSTEM CONTENTS EXCVA (EXHAUST CONTROL VALVE ACTUATOR) AND EXCV (EXHAUST CONTROL VALVE)……….7- 2 EXCVA AND EXCV REMOVAL …………. 7- 2 EXCVA INSPECTION…………….7- 3 EXCV INSPECTION …………….7- 3 CABLE INSPECTION …………….7- 3 EXCVA AND EXCV INSTALLATION…………. 7- 3 EXCVA ADJUSTMENT …………….

• Page 320: Excva (Exhaust Control Valve Actuator) And Excv (Exhaust Control Valve)

  EXHAUST SYSTEM EXCVA (EXHAUST CONTROL VALVE ACTUATOR) AND EXCV (EXHAUST CONTROL VALVE) EXCVA AND EXCV REMOVAL • Turn the ignition switch OFF. • Remove the left frame side cover. (!9-5) • Connect the special tool (Mode select switch) to the dealer mode coupler.

• Page 321: Excva Inspection

  EXHAUST SYSTEM • Disconnect the No. 2 cable 3 and then No. 1 cable 4 from the pulley. • Remove the EXCVA 5. • Remove the EXCV cover 6 from the EXCV pulley. • Disconnect the No. 1 7 and No. 2 8 cables. EXCVA INSPECTION !5-83 EXCV INSPECTION…

• Page 322: Excva And Excv Installation

  EXHAUST SYSTEM EXCVA AND EXCV INSTALLATION Install the EXCVA and EXCV in the reverse order of removal. Pay attention to the following points: • Connect the EXCV cables temporarily to the EXCV pulley. • Adjust the clearance A between the adjuster end and EXCV pulley to provide 4 mm (0.16 in) and more.

• Page 323
  EXHAUST SYSTEM • Check the EXCVA to adjustment position. (!7-2) Do not use the adjustable wrench to turn EXCVA pul- ley so as not to cause damage to the internal gear of EXCVA. • Install the pulley 8 to the shaft 9. NOTE: Make sure that the shaft’s line D and cable slots E facing upward as shown.

• Page 324: Excva Adjustment

  EXHAUST SYSTEM EXCVA ADJUSTMENT 1st step: • Set the EXCVA to adjustment position. (!7-2) • Make sure that the No. 2 cable and No. 1 cable are fixed into the clamp. 2nd step: • Turn the mode select switch OFF. •…

• Page 325
  EXHAUST SYSTEM • To set the EXCV to fully close position, apply 12 volts to A and B terminals. Positive wire –– A (Pink wire) terminal Negative wire –– B (Gray wire) terminal To prevent the motor damage, stop applying 12 V as soon as the EXCV reaches fully close position.

• Page 326: Exhaust Pipe And Muffler

  EXHAUST SYSTEM Measure the position sensor output voltage at fully open posi- tion. % Position sensor output voltage EXCV is fully open: 3.5 output voltage 4.5 V (+ Yellow – — B/Br) If the measured voltage is more than specification, adjust the No.2 cable adjuster as follows: •…

• Page 327
  EXHAUST SYSTEM • Disconnect the front and rear HO2 sensor lead wire couplers. (For E-02, 19, 24) • Remove the muffler cover 3. • Remove the No. 1 muffler 4. • Remove the right frame lower cover 5. NOTE: “ ( ” indicates hook location.

• Page 328: Installation

  7-10 EXHAUST SYSTEM • Remove the exhaust pipes 6 and the No. 2 muffler 7. INSTALLATION Install the exhaust pipe and muffler in the reverse order of removal. Play attention to the following points: • Install the exhaust pipes 1 with the No. 2 muffler 2. Replace the gaskets with new ones.

• Page 329
  EXHAUST SYSTEM 7-11 • Install the No. 1 muffler 3. • Tighten the No. 1 muffler bolts and muffler connecting bolts. $ Muffler mounting bolt : 23 N·m (2.3 kgf-m, 16.5 lb-ft)
• Page 330
  7-12 EXHAUST SYSTEM 23 N·m (2.3 kgf-m, 16.5 lb-ft) 23 N·m (2.3 kgf-m, 16.5 lb-ft) Muffler (#1) Muffler (#2) 23 N·m (2.3 kgf-m, 16.5 lb-ft) 23 N·m (2.3 kgf-m, 16.5 lb-ft) HO2 sensor (For E-02, 19, 24) 4.0 mm (0.16 in) and more 8.5 –…

• Page 331: Cooling And Lubrication System

  COOLING AND LUBRICATION SYSTEM COOLING AND LUBRICATION SYSTEM CONTENTS ENGINE COOLANT ………………8- 2 COOLING CIRCUIT ………………8- 3 COOLING CIRCUIT INSPECTION…………8- 3 RADIATOR AND WATER HOSE…………..8- 4 RADIATOR REMOVAL AND DISASSEMBLY ……..8- 4 RADIATOR DISASSEMBLY …………..8- 5 RADIATOR CAP INSPECTION………….

• Page 332: Engine Coolant

  COOLING AND LUBRICATION SYSTEM ENGINE COOLANT At the time of manufacture, the cooling system is filled with a 50:50 mixture of distilled water and ethylene glycol anti-freeze. This 50:50 mixture will provide the optimum corrosion protection and excellent heat pro- tection, and will protect the cooling system from freezing at temperatures above –31 °C (–24 °F).

• Page 333: Cooling Circuit

  COOLING AND LUBRICATION SYSTEM COOLING CIRCUIT RESERVOIR ENGINE COOLANT THERMOSTAT TEMPERATURE CYLINDER HEAD TANK SENSOR CYLINDER RADIATOR WATER PUMP COOLING CIRCUIT INSPECTION Before removing the radiator and draining the engine coolant, inspect the cooling circuit for tightness. • Remove the fuel tank. (#6-3) •…

• Page 334: Radiator And Water Hose

  COOLING AND LUBRICATION SYSTEM RADIATOR AND WATER HOSE RADIATOR REMOVAL AND DISASSEMBLY • Remove the fuel tank. (#6-3) • Remove the frame head covers and radiator covers. (#9-6) • Drain the engine coolant. (#2-20) • Disconnect the reservoir hose 1 and cooling fan lead wire coupler 2.

• Page 335: Radiator Disassembly

  COOLING AND LUBRICATION SYSTEM RADIATOR DISASSEMBLY • Remove the reservoir tank 1. • Remove the coolong fan 2 and shield 3. • Remove the radiator guard 4. RADIATOR CAP INSPECTION • Fit the cap 1 to the radiator cap tester 2. •…

• Page 336: Radiator Inspection And Cleaning

  COOLING AND LUBRICATION SYSTEM RADIATOR INSPECTION AND CLEANING • Road dirt or trash stuck on the fins must be removed. • Use of compressed air is recommended for this cleaning. • Fins bent down or dented can be repaired by straightening them with the blade of a small screwdriver.

• Page 337: Water Hose Inspection

  COOLING AND LUBRICATION SYSTEM WATER HOSE INSPECTION • Remove the fuel tank. (#6-3) • Remove the frame head covers and radiator covers. (#9-6) • Remove the left and right air cleaner boxs. (#6-13) • Remove the secondary gear case cover. (#3-6) •…

• Page 338: Cooling Fan

  COOLING AND LUBRICATION SYSTEM COOLING FAN INSPECTION • Remove the right frame head cover and right radiator cover. (#9-6) • Disconnect the cooling fan coupler 1. • Test the cooling fan motor for load current with an ammeter connected as shown in the illustration. •…

• Page 339: Ect Sensor

  COOLING AND LUBRICATION SYSTEM ECT SENSOR REMOVAL • Drain the engine coolant. (#2-20) • Remove the air cleaner chamber and throttle body. (#6-13) • Disconnect the ECT sensor coupler 1. • Remove the rear intake pipe and thermostat assembly. (#3-13) •…

• Page 340: Installation

  8-10 COOLING AND LUBRICATION SYSTEM If the resistance is noted to show infinity or too much different resistance value, replace the ECT sensor with a new one. * Take special care when handling the ECT sensor. It may cause damage if it gets a sharp impact. * Do not contact the ECT sensor and the column ther- mometer with a pan.

• Page 341: Thermostat

  COOLING AND LUBRICATION SYSTEM 8-11 THERMOSTAT REMOVAL • Remove the left air cleaner box. (#6-13) • Place a rag under the thermostat cover. • Remove the thermostat cover 1. • Remove the thermostat 2. INSPECTION Inspect the thermostat pellet for signs of cracking. Test the thermostat at the bench for control action, in the follow- ing manner.

• Page 342: Installation

  8-12 COOLING AND LUBRICATION SYSTEM • Keep on heating the water to raise its temperature. • Just when the water temperature reaches specified value, the thermostat valve should have lifted by at least 8 mm (0.31 in). $ Thermostat valve lift A Standard: 8.0 mm and over at 100 °C (0.31 in and over at 212 °F) •…

• Page 343: Water Pump

  COOLING AND LUBRICATION SYSTEM 8-13 WATER PUMP REMOVAL AND DISASSEMBLY NOTE: Before draining engine oil and engine coolant, inspect engine oil and coolant leakage between the water pump and crankcase. If engine oil is leaking, visually inspect the oil seal and O-ring. If engine coolant is leaking, visually inspect the mechanical seal and seal washer.

• Page 344
  8-14 COOLING AND LUBRICATION SYSTEM • Remove the water pump cover 3. • Remove the impeller securing bolt by holding the impeller with a water pump pliers. • Remove the mechanical seal ring 4 and rubber seal 5 from the impeller. •…

• Page 345: Inspection

  COOLING AND LUBRICATION SYSTEM 8-15 • Remove the oil seal 9. NOTE: If there is no abnormal condition, the oil seal removal is not nec- essary. The removed oil seal must be replaced with a new one. INSPECTION MECHANICAL SEAL •…

• Page 346: Reassembly And Installation

  % 09913-70210: Bearing installer set ()22) NOTE: The stamped mark on the oil seal faces mechanical seal side. • Apply a small quantity of the SUZUKI SUPER GREASE “A” to the oil seal lip. * 99000-25010: SUZUKI SUPER GREASE “A”…

• Page 347
  COOLING AND LUBRICATION SYSTEM 8-17 • Apply SUZUKI SUPER GREASE “A” to the impeller shaft and O-ring. Use the new O-ring to prevent engine oil leakage. * 99000-25010: SUZUKI SUPER GREASE “A” or equivalent • Install the impeller shaft 1, washer 2 and O-ring 3 to the water pump body.
• Page 348
  8-18 COOLING AND LUBRICATION SYSTEM • Install the new O-ring 9. Use the new O-ring to prevent engine coolant leakage. NOTE: Apply engine coolant to the O-ring. • Tighten the water pump cover screws. • Install the water pump. NOTE: Set the water pump shaft end E to the oil pump shaft F as shown.

• Page 349: Engine Lubrication System Chart

  COOLING AND LUBRICATION SYSTEM 8-19 ENGINE LUBRICATION SYSTEM CHART…

• Page 350
  CHASSIS CHASSIS CONTENTS EXTERIOR PARTS ………………9- 3 FASTENER REMOVAL AND INSTALLATION……..9- 3 FRONT AND REAR SEAT …………..9- 4 FRAME SIDE COVER …………….9- 5 REAR FRAME COVER …………….. 9- 5 FRAME HEAD COVER AND RADIATOR COVER ……. 9- 6 FRONT WHEEL ……………….
• Page 351
  CHASSIS CHASSIS CONTENTS REASSEMBLY ………………9-46 INSTALLATION………………9-49 SUSPENSION SETTING …………… 9-50 FRONT BRAKE……………….. 9-51 CONSTRUCTION ……………… 9-51 BRAKE PAD REPLACEMENT …………. 9-52 BRAKE FLUID REPLACEMENT …………9-53 CALIPER REMOVAL …………….9-54 CALIPER DISASSEMBLY …………..9-55 CALIPER INSPECTION ……………. 9-56 CALIPER REASSEMBLY …………..

• Page 352: Exterior Parts

  CHASSIS EXTERIOR PARTS FASTENER REMOVAL AND INSTALLATION FASTENER (Type A) Removal • Depress the head of fastener center piece 1. • Pull out the fastener a. Installation • Let the center piece stick out toward the head so that the pawls 2 close.

• Page 353: Front And Rear Seat

  CHASSIS Installation • Insert the fastener into the installation hole. NOTE: To prevent the pawl 2 from damage, insert the fastener all the way into the installation hole. • Push in the head of center piece. FRONT AND REAR SEAT REMOVAL •…

• Page 354: Frame Side Cover

  CHASSIS FRAME SIDE COVER REMOVAL • Remove the front seat. (!9-4) • Remove the left frame side cover 1. NOTE: “»” indicates hook location. • Disconnect the seat lock cable 2. • Remove the right frame side cover 3. NOTE: “»”…

• Page 355: Frame Head Cover And Radiator Cover

  CHASSIS FRAME HEAD COVER AND RADIATOR COVER REMOVAL • Remove the fuel tank. (!6-3) • Remove the right frame head cover 1 and left frame head cover 2. • Remove the right radiator cover 3 by removing the bolt 4 and fastener 5.

• Page 356
  CHASSIS INSTALLATION Install the frame head covers and radiator covers in the reverse order of removal. Pay attention to the following points: • Install the radiator bottom cover 1. NOTE: Pass the breather hose A in the hole B of a radiator bottom cover.

• Page 357: Front Wheel

  CHASSIS FRONT WHEEL CONSTRUCTION 1 Brake disc 5 Collar 2 Dust seal 6 Front wheel ITEM N·m kgf-m lb-ft 3 Bearing A Front axle 10.0 72.5 4 Spacer B Brake disc bolt 23.0 16.5…

• Page 358: Removal

  CHASSIS REMOVAL • Remove the brake calipers 1, left and right. Do not operate the brake lever while removing the cal- ipers. • Loosen the two axle pinch bolts 2 on the right front fork leg. • Loosen the front axle with the special tool. % 09900-18740: Hexagon socket (24 mm) •…

• Page 359
  9-10 CHASSIS WHEEL • Make sure that the wheel runout checked as shown does not exceed the service limit. An excessive runout is usually due to worn or loosened wheel bearings and can be reduced by replacing the bearings. If bearing replacement fails to reduce the runout, replace the wheel.

• Page 360: Reassembly And Installation

  Left Right 23 N·m (2.3 kgf-m, 16.5 lb-ft) 23 N·m (2.3 kgf-m, 16.5 lb-ft) 100 N·m (10.0 kgf-m, 72.5 lb-ft) WHEEL BEARING • Apply SUZUKI SUPER GREASE “A” to the wheel bearings. ‘ 99000-25010: SUZUKI SUPER GREASE “A” or equivalent…

• Page 361
  The sealed cover of the bearing must face outside. Clearance • Install the dust seal with the special tool. % 09913-70210: Bearing installer set (52 mm) • Apply SUZUKI SUPER GREASE “A” to the dust seal lip. ‘ 99000-25010: SUZUKI SUPER GREASE “A” or equivalent BRAKE DISC •…
• Page 362
  CHASSIS 9-13 WHEEL • Install the collar 1 in the left side. • Install the front wheel with the front axle and tighten the front axle with hand temporarily. The directional arrow on the tire should point to the wheel rotation, when remounting the wheel. FRONT AXLE •…

• Page 363: Front Fork

  9-14 CHASSIS FRONT FORK CONSTRUCTION 1 O-ring 6 Oil seal stopper ring A Front fork cap bolt 2 Spacer 7 Dust seal B Inner rod lock nut 3 Outer tube 8 Spring C Damper rod bolt 4 Oil seal retainer 9 Inner rod/Damper rod (cartridge) D Front axle pinch bolt 5 Oil seal…

• Page 364: Removal And Disassembly

  CHASSIS 9-15 REMOVAL AND DISASSEMBLY • Remove the front wheel. (!9-9) • Remove the bolts, left and right and front fender. • Remove the fasteners 1 and bolts 2. • Remove the head light assembly and disconnect the cou- plers. •…

• Page 365
  9-16 CHASSIS • Remove the front fork cap bolt 5 from the inner rod by loos- ening the lock nut. • Remove the special tools. After removing the front fork cap bolt 5, avoid hold- ing the outer tube vertically by hand to prevent the inner tube from falling and damaged.
• Page 366
  CHASSIS 9-17 • Remove the inner rod/damper rod (cartridge) 8. Do not disassemble the inner rod/damper rod (car- tridge). • Extract the outer tube from the inner tube. NOTE: Be careful not to damage the “ANTI-FRICTION” metals. • Remove the dust seal 9 and oil seal stopper ring 0. •…

• Page 367: Inspection

  9-18 CHASSIS INSPECTION INNER AND OUTER TUBES • Inspect the inner tube outer surface and outer tube inner sur- face for scratches. • Inspect the “ANTI-FRICTION” metal surfaces for scratches. • If any defects are found, replace them with a new one. Do not remove the “ANTI-FRICTION”…

• Page 368: Reassembly

  CHASSIS 9-19 REASSEMBLY Reassemble the front fork in the reverse order of disassembly. Pay attention to the following points: OIL SEAL AND DUST SEAL • Install the dust seal, oil seal stopper ring, oil seal and oil seal retainer onto the inner tube. 1 Dust seal 2 Oil seal stopper ring 3 Oil seal…

• Page 369
  • Compress it fully. • Pour specified front fork oil up to the top level of the outer tube. + 99000-99044-L01: SUZUKI FORK OIL L01 or an equivalent • Move the inner rod slowly with the special tool ten times and more until no more bubbles come out from the oil.
• Page 370
  CHASSIS 9-21 FRONT FORK INNER ROD LOCK NUT • Loosen the lock nut 1 to the bottom of inner rod threads. FORK SPRING • Install the fork spring as shown in the illustration. Upper side Lower side • Install the spring 1 and spacer 2. FRONT FORK CAP BOLT •…

• Page 371: Installation

  9-22 CHASSIS INSTALLATION Install the front fork in the reverse order of removal. Pay atten- tion to the following points: • Install the front fork to the steering stem and steering stem upper bracket. • Install the top of outer tube 5 mm (0.2 in) higher than the 5 mm upper surface of the steering stem upper bracket and tighten (0.2 in)

• Page 372: Steering

  CHASSIS 9-23 STEERING CONSTRUCTION 1 Handlebar clamp 6 Dust seal B Handlebar holder bracket bolt 2 Handlebar clamp holder 7 Steering stem upper bearing C Steering stem head nut 3 Handlebar holder bracket 8 Steering stem lower bearing D Front fork upper clamp bolt 4 Steering stem upper bracket 9 Steering stem E Handlebar holder bolt 5 Steering stem nut…

• Page 373: Removal

  9-24 CHASSIS REMOVAL • Remove the front forks. (!9-15) • Remove the handlebar. (!9-30) • Remove the tachometer. (!10-32) • Remove the turn signal mounting bolts 1, brake hose guide bolts 2 and brake hose mounting bolt 3. • Remove the steering stem head nut 4 and washer. •…

• Page 374: Inspection And Disassembly

  CHASSIS 9-25 • Remove the handlebar holder 9 from the steering stem upper bracket. • Remove the following parts. 0 Bolt A Rubber cushion B Rubber washer C Washer INSPECTION AND DISASSEMBLY Inspect the removed parts for the following abnormalities. * Handlebars distortion * Distortion of the steering stem.

• Page 375: Reassembly

  Install the steering stem in the reverse order of removal. Pay attention to the following points: BEARING • Apply SUZUKI SUPER GREASE “A” to the bearings. ‘ 99000-25010: SUZUKI SUPER GREASE “A” or equivalent • Install the upper bearing 1 to the steering stem.

• Page 376
  CHASSIS 9-27 • Tighten the steering stem nut to the specified torque with the special tool. % 09940-14911: Steering stem nut wrench # Steering stem nut: 45 N·m (4.5 kgf-m, 32.5 lb-ft) • Turn the steering stem lower bracket about five or six times to the left and right so that the bearing will be seated properly.

• Page 377: Steering Tension Adjustment

  9-28 CHASSIS Tighten the following points: • Tighten the handlebar bracket bolts to the specified torque. # Handlebar holder bracket bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft) • Install the tachometer. (!10-32) • Install the handlebar. (!9-31) # Handlebar clamp bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft) •…

• Page 378: Handlebars

  CHASSIS 9-29 HANDLEBARS CONSTRUCTION 1 Handlebars 3 Left handlebar grip 5 Right handlebar grip 2 Grip end cap 4 Left handlebar switch 6 Right handlebar switch…

• Page 379: Removal

  9-30 CHASSIS REMOVAL • Remove the right rear view mirror 1. • Remove the brake master cylinder 2. • Remove the throttle grip end cap 3. • Disconnect the front brake switch lead wire coupler 4 and remove the right handlebar switch 5. •…

• Page 380: Installation

  CHASSIS 9-31 INSTALLATION Install the handlebar in the reverse order of removal. Pay atten- tion to the following points: • When setting the handlebar clamp to the handlebar holder, face the punched mark A to the forward. • Align the punched mark B on handlebars with the handlebar clamp mating surface as shown.

• Page 381
  9-32 CHASSIS • Install the front brake master cylinder. (!9-61) • Apply the SUZUKI SUPER GREASE “A” to the throttle cables and their holder. ‘ 99000-25010: SUZUKI SUPER GREASE “A” or equivalent • When remounting the right and left handlebar switches, engage the stopper with the handlebar hole.

• Page 382: Rear Wheel

  CHASSIS 9-33 REAR WHEEL CONSTRUCTION 1 Rear axle 7 Damper C Collar 2 Spacer 8 O-ring D Brake disc 3 Bearing 9 Spacer E Cotter pin (For E-03, 28, 33) 4 Lock washer 0 Bearing A Rear brake disc bolt 5 Driven joint stopper A Rear wheel B Rear axle nut…

• Page 383: Removal

  9-34 CHASSIS REMOVAL • Remove the brake caliper bracket mounting bolt 1. • Remove the cotter pin 2. (For E-03, 28, 33) • Hold the rear axle with the special tool and remove the axle nut 3. % 09944-28320: Hexagon socket •…

• Page 384: Inspection And Disassembly

  CHASSIS 9-35 • Remove the O-ring 2. INSPECTION AND DISASSEMBLY WHEEL DAMPER • Inspect the damper for wear or damage. • Replace the damper if there is anything unusual. • Remove the dampers with a screw driver. WHEEL (!9-73) WHEEL AXLE (!9-9) TIRE (!2-27 and 9-73) BRAKE DISC (!9-69) •…

• Page 385: Reassembly And Installation

  9-36 CHASSIS • Remove the wheel bearings on both sides with the special tool. % 09921-20240: Bearing remover set (25 mm) The removed bearings should be replaced with new ones. REASSEMBLY AND INSTALLATION Reassemble and install the rear wheel in the reverse order of removal and disassembly.

• Page 386
  The sealed cover of the bearing must face outside. Clearance • Install the dust seal with the special tool. % 09913-70210: Bearing installer set (52 mm) • Apply SUZUKI SUPER GREASE “A” to the dust seal lip. ‘ 99000-25010: SUZUKI SUPER GREASE “A” or equivalent…
• Page 387
  • Install the new O-ring 1 and driven hub joint 2. NOTE: * Apply SUZUKI SUPER GREASE “A” to the O-ring and the final gear spline before installing the driven joint. * Align the driven joint flat surface A with the screw holes B of wheel.
• Page 388
  CHASSIS 9-39 REAR WHEEL • Install the spacer 1. • Apply SUZUKI SUPER GREASE “A” to the final gear spline before installing the rear wheel. ‘ 99000-25010: SUZUKI SUPER GREASE “A” or equivalent • Remount the rear wheel, rear axle and coller.

• Page 389: Rear Suspension

  9-40 CHASSIS REAR SUSPENSION CONSTRUCTION 1 Rear shock absorber 6 Dust seal B Rear cushion rod mounting nut 2 Rear cushion rod 7 Swingarm pivot bearing C Rear cushion lever mounting nut 3 Spacer 8 Swingarm D Swingarm pivot shaft 4 Rear cushion lever bearing 9 Boot 5 Rear cushion lever…

• Page 390: Removal

  CHASSIS 9-41 REMOVAL • Remove the exhaust pipe and muffler. (!7-8) • Remove the rear wheel. (!9-34) • Remove the final gear case. (!4-15) • Remove the under plate 1. • Remove the regulator/rectifier 2. • Remove the rear shock absorber front mounting bolt and nut. •…

• Page 391: Inspection And Disassembly

  9-42 CHASSIS • Loosen the swingarm pivot pinch bolt 5. • Loosen the swingarm pivot shaft with the special tool. % 09944-28320: Hexagon socket • Draw out the swingarm pivot shaft. • Remove the rear suspension assembly. • Remove the cushion rods 6 and cushion lever 7. •…

• Page 392
  CHASSIS 9-43 • Remove the swingarm pivot bearings 1 with the special tools. % 09923-74511: Bearing remover set 09930-30104: Sliding shaft The removed bearings must be replaced with new ones. CUSHION LEVER BEARING • Insert the spacer into bearings and check the play when mov- ing the spacer up and down.
• Page 393
  9-44 CHASSIS CUSHION ROD BEARING • Insert the spacer into bearings and check the play when mov- ing the spacer up and down. • If excessive play is noted, replace the bearings with a new one. • Remove the cushion lever bearings 1 with the special tool. % 09913-70210: Bearing installer set (25 mm) The removed bearings must be replaced with new ones.

• Page 394: Rear Shock Absorber Disposal

  CHASSIS 9-45 SWINGARM PIVOT SHAFT • Using a dial gauge, check the pivot shaft runout and replace it if the runout exceeds the limit. & Swingarm pivot shaft runout: Service limit: 0.3 mm (0.01 in) % 09900-20607: Dial gauge (1/100 mm, 10 mm) 09900-20701: Magnetic stand 09900-21304: V-block set (100 mm) REAR SHOCK ABSORBER DISPOSAL…

• Page 395: Reassembly

  9-46 CHASSIS REASSEMBLY Reassemble the rear suspension in the reverse order of disassembly and removal. Pay attention to the following points: NOTE: Tightening order are E to F . 1 1.0 mm (0.04 in) C Rear cushion lever lower nut 2 4.5 mm (0.17 in) D Rear cushion rod nut ITEM…

• Page 396
  • Install the dust seals into the cushion lever with the special tool. % 09913-70210: Bearing installer set (35 mm) NOTE: Apply SUZUKI SUPER GREASE “A” to the dust seals. ‘ 99000-25010: SUZUKI SUPER GREASE “A” or equivalent SWINGARM BEARING •…
• Page 397
  9-48 CHASSIS • Apply SUZUKI SUPER GREASE “A” to the spacers. ‘ 99000-25010: SUZUKI SUPER GREASE “A” or equivalent…

• Page 398: Installation

  CHASSIS 9-49 INSTALLATION Remount the swingarm and shock absorber in the reverse order of disassembly and removal, and pay attention to the following points. CUSHION ROD AND CUSHION LEVER • Install the cushion rods 1 and cushion lever 2 onto the swin- garm temporarily.

• Page 399: Suspension Setting

  9-50 CHASSIS • Tighten the swingarm pivot pinch bolt. CUSHION ROD, CUSHION LEVER AND REAR SHOCK ABSORBER • Assemble the cushion rod, cushion lever and rear shock absorber onto the swingarm. (!9-46) • Tighten the rear shock absorber front mounting nut to the specified torque.

• Page 400: Front Brake

  CHASSIS 9-51 FRONT BRAKE CONSTRUCTION 1 Dust boot 9 Brake pad 2 Piston set 0 Brake pad spring ITEM N·m kgf-m lb-ft 3 Cap A Master cylinder mounting bolt 4 Diaphrapm B Brake caliper mounting bolt 28.0 5 Master cylinder C Brake caliper air bleeder valve 0.75 6 Piston seal…

• Page 401: Brake Pad Replacement

  9-52 CHASSIS * This brake system is filled with an ethylene glycol-based DOT 4 brake fluid. Do not use mix different types of fluid such as silicone-based or petroleum-based. * Do not use any brake fluid taken from old, used or unsealed containers. Never reuse brake fluid left over from the last servicing or stored for long periods.

• Page 402: Brake Fluid Replacement

  CHASSIS 9-53 NOTE: * Install the brake pad shims 3 onto the new brake pad, as shown. * The arrow mark on the brake shim must face to the direction of brake disc rotation. • Install the new brake pads. •…

• Page 403: Caliper Removal

  9-54 CHASSIS • Connect a clear hose to the caliper air bleeder valve and insert the other end of hose into a receptacle. • Loosen the air bleeder valve and pump the brake lever until old brake fluid flows out of the bleeder system. •…

• Page 404: Caliper Disassembly

  CHASSIS 9-55 CALIPER DISASSEMBLY • Remove the pad spring 1. • Remove the caliper air bleeder valve 2. • Separate the caliper halves by removing the caliper housing bolts 3 with the special tools. % 09930-11920: Torx bit JT40H 09930-11940: Bit holder •…

• Page 405: Caliper Inspection

  9-56 CHASSIS CALIPER INSPECTION BRAKE CALIPER • Inspect the brake caliper cylinder wall for nicks, scratches or other damage. If any damage is found, replace it with a new one. BRAKE CALIPER PISTON • Inspect the brake caliper piston surface for any scratches or other damage.

• Page 406
  CHASSIS 9-57 PISTON SEAL • Install the piston seals as shown in the illustration. Dust seal Caliper body Piston seal O-RING • Install the new O-ring 1 and reassemble caliper halves. Replace the O-ring with a new one. • Temporarily tighten the air bleeder valve 2. •…

• Page 407: Caliper Installation

  9-58 CHASSIS CALIPER INSTALLATION Install the caliper in the reverse order of removal. Pay attention to the following points: • Install the brake pads and brake caliper. (!9-53) • to the specified torque. # Brake hose union bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft) * The seal washers should be replaced with the new ones to prevent brake fluid leakage.

• Page 408: Master Cylinder Removal And Disassembly

  CHASSIS 9-59 MASTER CYLINDER REMOVAL AND DISASSEMBLY • Drain the brake fluid. (!9-53) • Disconnect the front brake light switch lead wire coupler 1. • Place a rag underneath the union bolt 2 on the master cylin- der to catch any split brake fluid. Remove the union bolt and disconnect the brake hose.

• Page 409: Master Cylinder Inspection

  9-60 CHASSIS • Remove the following parts. 0 Piston A Secondary cup B Primary cup C Return spring MASTER CYLINDER INSPECTION MASTER CYLINDER • Inspect the master cylinder bore for any scratches or damage. If any defects are found, replace the master cylinder with a new one.

• Page 410: Master Cylinder Installation

  CHASSIS 9-61 • Apply SUZUKI SUPER GREASE “A” to the bolt and brake lever end. ‘ 99000-25010: SUZUKI SUPER GREASE “A” or equivalent • Tighten the pivot bolt and nut. • When installing the brake light switch, align the projection on the switch with the hole in the master cylinder.

• Page 411: Rear Brake

  9-62 CHASSIS REAR BRAKE CONSTRUCTION 1 Piston/Cup set 7 Dust seal 2 Reservoir hose 8 Brake pad spring ITEM N·m kgf-m lb-ft 3 Brake hose A Caliper air bleeder valve 0.75 4 Brake pad B Brake hose union bolt 16.5 5 Piston C Brake master cylinder rod lock nut 13.0…

• Page 412: Brake Pad Replacement

  CHASSIS 9-63 * This brake system is filled with an ethylene glycol-based DOT 4 brake fluid. Do not use mix different types of fluid such as silicone-based or petroleum-based. * Do not use any brake fluid taken from old, used or unsealed containers. Never reuse brake fluid left over from the last servicing or stored for long periods.

• Page 413: Brake Fluid Replacement

  9-64 CHASSIS • Inspect the pad mounting pin for bent or damage. If any defects are found, replace the pad mounting pins with the new ones. • Install the new brake pads. • Install the brake caliper. • Tighten the rear brake caliper mounting bolt to the specified torque.

• Page 414: Caliper Removal

  CHASSIS 9-65 • Connect a clear hose to the caliper air bleeder valve and insert the other end of hose into a receptacle. • Loosen the air bleeder valve and pump the brake pedal until old brake fluid flows out of the bleeder system. •…

• Page 415: Caliper Inspection

  9-66 CHASSIS • Remove the caliper air bleeder valves 3. • Remove the rubber boots 4. • Place a rag over the brake caliper pistons to prevent them from popping out, and then force out the pistons using com- pressed air. Do not use extremely high pressure to remove the brake caliper pistons, otherwise damage to the pis- tons will result.

• Page 416
  CHASSIS 9-67 BRAKE CALIPER HOLDER • Inspect the brake caliper holder for wear and other damage. If any defects are found, replace the holder with a new one. RUBBER BOOT • Inspect the rubber boot for damage and wear. If any defects are found, replace the boots with new ones.

• Page 417: Caliper Reassembly

  PISTON SEAL • Install the piston seals as shown in the illustration. Dust seal Caliper body Piston seal BRAKE CALIPER HOLDER • Apply SUZUKI SILICON GREASE to the brake caliper holder. . 99000-25100: SUZUKI SILICONE GREASE or equivalent…

• Page 418: Caliper Installation

  CHASSIS 9-69 RUBBER BOOT • Set the rubber boot onto the brake caliper. CALIPER INSTALLATION Install the caliper in the reverse order of removal. Pay attention to the following points: • Install the brake pads and brake caliper. (!9-64) • Tighten brake hose union bolt to the specified torque. (Rear brake hose routing:!11-40) # Brake hose union bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft) * The seal washers should be replaced with the new…

• Page 419: Master Cylinder Disassembly

  9-70 CHASSIS • Temporarily tighten the master cylinder mounting bolts 2. • Place a rag underneath the union bolt on the master cylinder to catch spilled drops of brake fluid. Remove the union bolt 3 and disconnect the brake hose. •…

• Page 420: Master Cylinder Inspection

  CHASSIS 9-71 • Remove the push rod 8, piston/primary cup 9 and spring 0. MASTER CYLINDER INSPECTION CYLINDER, PISTON • Inspect the cylinder bore wall for any scratches or other dam- age. CUP SET • Inspect the cup set. MASTER CYLINDER REASSEMBLY Reassemble the master cylinder in the reverse order of disas- sembly.

• Page 421: Master Cylinder Installation

  9-72 CHASSIS • Apply SUZUKI SILICONE GREASE to the push rod end. . 99000-25100: SUZUKI SILICONE GREASE or equivalent • Install the O-ring 1 and connector 2 to the master cylinder. MASTER CYLINDER INSTALLATION Install the master cylinder in the reverse order of removal. Pay attention to the following points: •…

• Page 422: Tire And Wheel

  CHASSIS 9-73 TIRE AND WHEEL TIRE REMOVAL The most critical factor of 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 423: Valve Inspection

  9-74 CHASSIS VALVE INSPECTION • Inspect the valve after the tire is removed from the rim. • Replace the valve with a new one if the seal A rubber is peel- ing or has damage. NOTE: If the external appearance of the valve shows no abnormal con- dition, removing of the valve is not necessary.

• Page 424: Tire Installation

  CHASSIS 9-75 TIRE INSTALLATION • Apply tire lubricant to the tire bead. • When installing the tire onto the wheel, observe the following points. * Do not reuse the valve which has been once removed. * Never use oil, grease or gasoline on the tire bead in place of tire lubricant.

• Page 425: Balancer Weight Installation

  9-76 CHASSIS • In this condition, check the “rim line” B cast on the tire side walls. The line must be equidistant from the wheel rim all around. If the distance between the rim line and wheel rim varies, this indicates that the bead is not properly seated. If this is the case, deflate the tire completely and unseat the bead for both sides.

• Page 426: Electrical System

  ELECTRICAL SYSTEM 10-1 ELECTRICAL SYSTEM CONTENTS CAUTIONS IN SERVICING …………… 10- 3 CONNECTOR ………………10- 3 COUPLER……………….. 10- 3 CLAMP ………………..10- 3 FUSE………………..10- 3 SEMI-CONDUCTOR EQUIPPED PART ……….10- 4 BATTERY ……………….. 10- 4 CONNECTING THE BATTERY…………10- 4 WIRING PROCEDURE…………….

• Page 427
  10-2 ELECTRICAL SYSTEM ELECTRICAL SYSTEM CONTENTS LAMPS …………………. 10-39 HEADLIGHT, BRAKE LIGHT/TAILLIGHT, LICENSE PLATE LIGHT AND TURN SIGNAL LIGHT ………… 10-39 HEADLIGHT RELAY INSPECTION ………… 10-40 RELAYS ………………..10-41 TURN SIGNAL/SIDE-STAND RELAY ……….10-41 STARTER RELAY …………….10-41 FUEL PUMP RELAY …………….10-41 COOLING FAN RELAY……………

• Page 428: Fuse

  ELECTRICAL SYSTEM 10-3 CAUTIONS IN SERVICING CONNECTOR • When connecting a connector, be sure to push it in until a click is felt. Click • Inspect the connector for corrosion, contamination and break- age in its cover. COUPLER Click • With a lock type coupler, be sure to release the lock when dis- connecting, and push in fully to engage the lock when con- necting.

• Page 429: Semi-Conductor Equipped Part

  10-4 ELECTRICAL SYSTEM SEMI-CONDUCTOR EQUIPPED PART • Be careful not to drop the part with a semi-conductor built in INCORRECT such as a ECM. • When inspecting this part, follow inspection instruction strictly. Neglecting proper procedure may cause damage to this part. BATTERY •…

• Page 430: Using The Multi-Circuit Tester

  ELECTRICAL SYSTEM 10-5 USING THE MULTI-CIRCUIT TESTER • Properly use the multi-circuit tester + and — probes. Improper use can cause damage to the motorcycle and tester. • If the voltage and current values are not known, begin mea- suring in the highest range. •…

• Page 431: Location Of Electrical Components

  10-6 ELECTRICAL SYSTEM LOCATION OF ELECTRICAL COMPONENTS 1 IAP sensor (#2) (!5-34) C Horn 2 IAP sensor (#1) (!5-34) D Turn signal/Side-stand relay 3 Fuel injector (#1) (!5-68) E Fuel pump relay (!6-6) 4 Fuel injector (#2) (!5-68) F Headlight relay 5 Ignition coil (#1) G Cooling fan relay (!8-8) 6 IAT sensor (!5-50)

• Page 432
  ELECTRICAL SYSTEM 10-7 1 Fuel level gauge 0 PAIR control solenoid valve (!12-6) 2 Fuel pump (!6-8) A Regulator/Rectifier 3 Battery B Oil pressure switch 4 ECM (Engine Control Module) C Generator 5 Fuse box D CKP sensor (!5-32) 6 Ignition coil (#2) E Speedometer sensor 7 Mode selection switch coupler (!5-24) F Side-stand switch…

• Page 433: Charging System

  10-8 ELECTRICAL SYSTEM CHARGING SYSTEM Regulator/Rectifier IG. switch Generator TROUBLESHOOTING Battery runs down quickly Step 1 1) Check accessories which use excessive amounts of electricity. Are accessories being installed? Remove accessories. Go to Step 2. Step 2 1) Check the battery for current leaks. (!10-9) Is the battery for current leaks OK? Go to Step 3.

• Page 434: Inspection

  ELECTRICAL SYSTEM 10-9 Step 5 1) Measure the generator no-load performance. (!10-11) Is the generator no-load performance OK? Go to Step 6. Faulty generator Step 6 1) Inspect the regulator/rectifier. (!10-11) Is the regulator/rectifier OK? Go to Step 7. Faulty regulator/rectifier Step 7 1) Inspect wirings.

• Page 435
  10-10 ELECTRICAL SYSTEM REGULATED VOLTAGE • Remove the front seat. (!9-4) • Start the engine and keep it running at 5 000 r/min with the dimmer switch turned HI position. • Measure the DC voltage between the + and — battery termi- nals using the multi-circuit tester.
• Page 436
  ELECTRICAL SYSTEM 10-11 GENERATOR NO-LOAD PERFORMANCE • Disconnect the generator coupler. (!10-10) • Start the engine and keep it running at 5 000 r/min. • Using the multi-circuit tester, measure the voltage between three lead wires. If the tester reads under the specified value, replace the gen- erator with a new one.

• Page 437: Starter System And Side-Stand/Ignition Interlock System

  10-12 ELECTRICAL SYSTEM STARTER SYSTEM AND SIDE-STAND/IGNITION INTERLOCK SYSTEM Engine stop Ignition switch switch Fuse (30 A) To Ignition coil Starter motor GP switch Fuse (15 A) (Neutral) Battery Starter relay Starter Turn signal/ button side-stand relay Clutch switch side-stand switch TROUBLESHOOTING Make sure that the fuses are not blown and the battery is fully-charged before diagnosing.

• Page 438
  ELECTRICAL SYSTEM 10-13 Step 3 1) Measure the starter relay voltage at the starter relay connectors (between Y/G + and B/Y -) when the starter button is pushed. Is a voltage OK? Go to Step 4. • Faulty engine stop switch •…

• Page 439: Starter Motor Removal

  10-14 ELECTRICAL SYSTEM STARTER MOTOR REMOVAL • Remove the right frame side cover. (!9-5) • Remove the exhaust pipe and muffler. (!7-8) • Remove the master cylinder cover 1. • Disconnect the battery — lead wire. • Disconnect the starter motor lead wire 2. •…

• Page 440: Starter Motor Disassembly

  ELECTRICAL SYSTEM 10-15 STARTER MOTOR DISASSEMBLY • Disassemble the starter motor as shown in the illustration. 1 O-ring 5 Brush holder 2 Housing end (inside) 6 Housing end (outside) ITEM N·m kgf-m lb-ft 3 Armature A Starter motor lead wire nut 4 Starter motor case B Starter motor mounting bolt…

• Page 441: Starter Motor Inspection

  10-16 ELECTRICAL SYSTEM STARTER MOTOR INSPECTION CARBON BRUSH Inspect the brushes for abnormal wear, cracks, or smoothness in the brush holder. If any damages are found, replace the brush assembly with a new one. Make sure that the length A is not less than 6.0 mm (0.24 in). If this length becomes less than 6.0 mm (0.24 in), replace the brush.

• Page 442: Starter Motor Reassembly

  STARTER MOTOR REASSEMBLY Reassemble the starter motor in the reverse order of disassem- bly. Pay attention to the following points: • Apply SUZUKI SUPER GREASE “A” to the lip of the oil seal and bearing. / 99000-25010: SUZUKI SUPER GREASE “A”…

• Page 443: Starter Relay Inspection

  10-18 ELECTRICAL SYSTEM • Tighten the starter motor mounting lead wire bolts 5 and nut 6 to the specified torque. , Starter motor mounting bolt: 6 N·m (0.6 kgf-m, 4.5 lb-ft) Starter motor lead wire nut: 6 N·m (0.6 kgf-m, 4.5 lb-ft) STARTER RELAY INSPECTION •…

• Page 444: Side Stand/Ignition Interlock System Parts Inspection

  ELECTRICAL SYSTEM 10-19 SIDE STAND/IGNITION INTERLOCK SYSTEM PARTS INSPECTION Check the interlock system for proper operation. If the interlock system does not operate properly, check each component for damage or abnormalities. If any abnormality is found, replace the component with a new one. SIDE-STAND SWITCH •…

• Page 445
  10-20 ELECTRICAL SYSTEM GEAR POSITION SWITCH • Remove the right frame side cover. (!9-5) • Disconnect the gear position switch coupler and check the continuity between Blue and Black/White with the transmis- sion in “NEUTRAL”. » 09900-25008: Multi-circuit tester set — Tester knob indication: Continuity test (.) Blue Black/White…
• Page 446
  ELECTRICAL SYSTEM 10-21 TURN SIGNAL/SIDE-STAND RELAY The turn signal/side-stand relay is composed of the turn signal relay, side-stand relay and diode. • Remove the left frame side cover. (!9-5) • Remove the turn signal/side-stand relay. SIDE-STAND RELAY INSPECTION First check the insulation between D and E terminals with the tester.

• Page 447: Ignition System

  10-22 ELECTRICAL SYSTEM IGNITION SYSTEM Engine stop switch Side- stand #1 (R) Power source relay circuit #1 (R) Fuse sensor Waveform arrangement Ignition circuit #2 (F) switch Fuse #2 (F) Battery sensor sensor switch NOTE: The fuel cut-off circuit is incorporated in this ECM in order to prevent over-running of engine. When engine speed reaches 7 200 r/min, this circuit cuts off fuel at the fuel injector.

• Page 448: Troubleshooting

  ELECTRICAL SYSTEM 10-23 TROUBLESHOOTING No spark or poor spark 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 1 1) Check the ignition system couplers for poor connections.

• Page 449
  10-24 ELECTRICAL SYSTEM Step 5 1) Inspect the ignition coil/plug caps and ignition coils. (!10-27 and -28) Is the ignition coil/plug cap and ignition coils OK? Go to Step 6. • Poor connection of the ignition coil/plug cap(-s) and ignition coils. •…

• Page 450: Inspection

  ELECTRICAL SYSTEM 10-25 INSPECTION IGNITION COIL PRIMARY PEAK VOLTAGE • Remove the left frame side covers. (!9-5) • Remove the fuel tank. (!6-3) • Remove the frame head covers and right radiator covers. (!9-6) • Remove the front cylinder right head cover cap and rear cylin- der left head cover cap.

• Page 451
  10-26 ELECTRICAL SYSTEM IGNITION COIL/PLUG CAP PRIMARY PEAK VOLTAGE Inspect each ignition coil primary peak voltage at the ignition coil/plug cap coupler. • Connect the multi-circuit tester with peak voltage adaptor as follows. #1 ignition coil/plug cap: W/Bl wire terminal (+ Probe) – Ground (- Probe) terminal #2 ignition coil/plug cap: Black wire terminal (+ Probe) –…
• Page 452
  ELECTRICAL SYSTEM 10-27 IGNITION COIL PRIMARY PEAK VOLTAGE Peak volt adaptor Inspect each ignition coil primary peak voltage in the following procedure. Ignition • Connect the multi-circuit tester with peak voltage adaptor as coil Y or G follows. #1 ignition coil: + Probe: Yellow lead wire terminal spark plug — Probe: Ground…
• Page 453
  10-28 ELECTRICAL SYSTEM IGNITION COIL RESISTANCE • Disconnect the spark plug caps. (!10-25) • Measure the ignition coil resistance in both the primary and secondary windings. If the resistance is not within the stan- Ω dard range, replace the ignition coil with a new one. kΩ…
• Page 454
  ELECTRICAL SYSTEM 10-29 CKP SENSOR RESISTANCE • Measure the resistance between the lead wires and ground. If the resistance is not within the standard range, replace the CKP sensor coupler CKP sensor with a new one. » 09900-25008: Multi-circuit tester set CKP sensor ( Tester knob indication: Resistance (Ω) $ CKP sensor resistance: 190 –…

• Page 455: Speedometer And Tachometer

  10-30 ELECTRICAL SYSTEM SPEEDOMETER AND TACHOMETER DESCRIPTION This speedometer and tachometer mainly consists of the stepping motor (except for tachometer), LCD (Liq- uid Crystal Display) and LED (Light Emitting Diode). The speedometer pointer is driven by the stepping motor. The LCDs indicate Tachometer, Engine coolant and Oil pressure temp mark, Odo/Trip1/Trip2/FI and Clock, Fuel level respectively.

• Page 456: Speedometer Removal And Disassembly

  ELECTRICAL SYSTEM 10-31 SPEEDOMETER REMOVAL AND DISASSEMBLY • Disconnect the speedometer lead wire coupler. (!6-3) • Remove the screw. • Remove the speedometer 1. NOTE: “2” indicates hook location. When disconnecting and reconnecting the speedome- ter coupler, make sure to turn OFF the ignition switch, or electronic parts may get damaged.

• Page 457: Tachometer Removal And Disassembly

  10-32 ELECTRICAL SYSTEM TACHOMETER REMOVAL AND DISASSEMBLY • Remove the handleber. (!9-30) • Remove the head light. (!9-15) • Remove the screws 1. • Disconnect the tachometer lead wire coupler and remove the tachometer 2. • Disassemble the tachometer as follows. Do not attempt to disassemble the tachometer unit 2.

• Page 458: Inspection

  ELECTRICAL SYSTEM 10-33 INSPECTION LED (LIGHT EMITTING DIODE) Check that the LED lights (FI indicator light, Fuel level indicator light) immediately after turning the ignition switch on. Also, other LED lights (Neutral indicator light, High-beam indicator light and Turn signal indicator light) can be checked by depending on each switch position.

• Page 459
  10-34 ELECTRICAL SYSTEM ENGINE COOLANT TEMPERATURE METER AND INDICATOR ECT sensor inspection (!8-9) • Remove the right frame side cover. (!9-5) • Remove the right air cleaner box. (!6-13) • Disconnect the ECT sensor coupler 1. When connecting and disconnecting the engine cool- ant temperature sensor lead wire coupler, make sure to turn OFF the ignition switch, or electronic parts may get damaged.
• Page 460
  ELECTRICAL SYSTEM 10-35 FUEL LEVEL INDICATOR SWITCH INSPECTION • Remove and disassemble the fuel pump assembly. (!6-8) • Connect 12 V battery and test bulb (12 V, 3.4 W) to the fuel Battery Test level indicator switch as shown in the right illustration. The bulb bulb should come on after one minutes if the switch is in good condition.
• Page 461
  10-36 ELECTRICAL SYSTEM FUEL LEVEL METER INSPECTION • Lift and support the fuel tank. (!6-3) • Disconnect the fuel pump lead wire coupler 1. • Connect variable resistor between the Light green and Black lead wires at the wire harness. •…
• Page 462
  The highest voltage reading in this test will be the same as that of battery (12 V). (Battery voltage) • Apply SUZUKI SUPER GREASE “A” to the speedometer sen- sor O-ring before installing it. / 99000-25010: SUZUKI SUPER GREASE “A”…
• Page 463
  10-38 ELECTRICAL SYSTEM OIL PRESSURE INDICATOR NOTE: Before inspecting the oil pressure switch, check if the engine oil level is correct. (!2-17) • Disconnect the oil pressure switch lead wire from the oil pres- sure switch. • Turn the ignition switch ON. •…

• Page 464: Position Light

  ELECTRICAL SYSTEM 10-39 LAMPS HEADLIGHT, BRAKE LIGHT/TAILLIGHT, LICENSE PLATE LIGHT AND TURN SIGNAL LIGHT HEADLIGHT 12 V 60/55 W 1 POSITION LIGHT ….. (E-02, 19, 24) 12 V 5 W BRAKE LIGHT/TAILLIGHT LICENCE PLATE LIGHT 12 V 5 W 2 TURN SIGNAL/POSITION LIGHT (E-03, 28, 33) 12 V 21 W/5 W ×…

• Page 465: Headlight Relay Inspection

  10-40 ELECTRICAL SYSTEM HEADLIGHT RELAY INSPECTION headlight relay is located in front of the battery. • Remove the right frame side cover. (!9-5) • Remove the headlight relay 1. First check the insulation between A and B terminals with tester. Then apply 12 volts to C and D terminals, + to C and — to D, and check the continuity between A and B.

• Page 466: Relays

  ELECTRICAL SYSTEM 10-41 RELAYS TURN SIGNAL/SIDE-STAND RELAY The turn signal/side-stand relay is composed of the turn signal relay, side-stand relay and diode. INSPECTION Before removing the turn signal/side-stand relay, check the operation of the turn signal light. If the turn signal light does not illuminate, inspect the bulb, turn signal switch and circuit connection.

• Page 467: Switches Inspection

  10-42 ELECTRICAL SYSTEM SWITCHES INSPECTION Inspect each switch for continuity with a tester. If any STARTER BUTTON abnormality is found, replace the respective switch Color Position assemblies with new ones. PUSH HAZARD SWITCH HORN BUTTON Color Position Color B/Bl (OFF) Position (ON) PUSH…

• Page 468: Battery

  ELECTRICAL SYSTEM 10-43 BATTERY SPECIFICATIONS Type designation FTZ16-BS Capacity 12 V, 64.8 kC (18 Ah)/10 HR 1 Upper cover breather 5 Terminal 2 Cathode plates 6 Safety valve 3 Stopper 7 Anode plates 4 Filter 8 Separator (Fiberglass plate) INITIAL CHARGING Filling electrolyte •…

• Page 469
  10-44 ELECTRICAL SYSTEM NOTE: If no air bubbles are coming up from a filler port, tap the bottom of the electrolyte container two or three times. Never remove the container from the battery. • After confirming that the electrolyte has entered the battery completely, remove the electrolyte containers from the bat- tery.

• Page 470: Servicing

  ELECTRICAL SYSTEM 10-45 SERVICING Visually inspect the surface of the battery container. If any signs of cracking or electrolyte leakage from the sides of the battery have occurred, replace the battery with a new one. If the battery terminals are found to be coated with rust or an acidic white powdery substance, clean the battery terminals with sandpaper.

• Page 471: Servicing Information

  SERVICING INFORMATION 11-1 SERVICING INFORMATION CONTENTS TROUBLESHOOTING …………….11- 3 FI SYSTEM MALFUNCTION CODE AND DEFECTIVE CONDITION…………..11- 3 ENGINE ………………..11- 7 RADIATOR (COOLING SYSTEM) …………11-13 CHASSIS ………………… 11-14 SHAFT DRIVE ………………11-15 BRAKES ………………..11-15 ELECTRICAL ………………11-16 BATTERY ………………..

• Page 472
  11-2 SERVICING INFORMATION SERVICING INFORMATION CONTENTS IGNITION COIL INSTALLATION …………11-51 SIDE-STAND INSTALLATION …………11-51 REAR TURN SIGNAL LIGHT, LICENSE LIGHT WIRE ROUTING ..11-52 SEAT LOCK CABLE ROUTING …………11-52 LICENSE LIGHT AND LICENSE PLATE INSTALLATION ….11-53 BRAKE LIGHT/TAILLIGHT INSTALLATION ……..11-53…

• Page 473: Troubleshooting

  SERVICING INFORMATION 11-3 TROUBLESHOOTING FI SYSTEM MALFUNCTION CODE AND DEFECTIVE CONDITION DETECTED DTC No. DETECTED FAILURE CONDITION CHECK FOR ITEM NO FAULT ––––––––––– ––––––––––– CKP sensor The signal does not reach ECM for 3 CKP sensor wiring and mechan- sec. or more, after receiving the starter ical parts signal.

• Page 474
  11-4 SERVICING INFORMATION DETECTED DTC No. DETECTED FAILURE CONDITION CHECK FOR ITEM TO sensor The sensor voltage should be the fol- TO sensor, lead wire/coupler lowing for 2 sec. and more, after igni- connection tion switch is turned ON. 0.2 V sensor voltage <…
• Page 475
  SERVICING INFORMATION 11-5 DETECTED DTC No. DETECTED FAILURE CONDITION CHECK FOR ITEM ISC valve ISC valve motor current is higher than ISC valve circuit shorted to specified value. BATT or ground circuit open P0505 ISC valve motor circuit is open. ISC valve circuit open or BATT circuit open Idle speed is lower than the desired…
• Page 476
  11-6 SERVICING INFORMATION DETECTED DTC No. DETECTED FAILURE CONDITION CHECK FOR ITEM Exhaust con- EXCVA position sensor produces fol- EXCVA, EXCVA lead wire/cou- trol valve lowing voltage. pler actuator 0.1 V sensor voltage < 4.9 V In other than the above range, C46 (P1675) is indicated.

• Page 477: Engine

  SERVICING INFORMATION 11-7 ENGINE Complaint Symptom and possible causes Remedy Engine will not start Compression too low or is hard to start. 1. Tappet clearance out of adjustment Adjust. 2. Worn valve guides or poor seating of valves Repair or replace. 3.

• Page 478
  11-8 SERVICING INFORMATION Complaint Symptom and possible causes Remedy Engine idles poorly. 1. Tappet clearance out of adjustment Adjust. 2. Poor seating of valves Replace or repair. 3. Defective valve guides Replace. 4. Worn down camshafts Replace. 5. Too wide spark plug gaps Adjust or replace.
• Page 479
  SERVICING INFORMATION 11-9 Complaint Symptom and possible causes Remedy Noisy engine Excessive valve chatter 1. Too large tappet clearance Adjust. 2. Weakened or broken valve springs Replace. 3. Worn tappet or cam surface Replace. 4. Worn and burnt camshaft journal Replace.
• Page 480
  11-10 SERVICING INFORMATION Complaint Symptom and possible causes Remedy Engine runs poorly Defective engine internal/electrical parts in high speed range. 1. Weakened valve springs Replace. 2. Worn camshafts Replace. 3. Valve timing out of adjustment Adjust. 4. Too narrow spark plug gaps Adjust.
• Page 481
  SERVICING INFORMATION 11-11 Complaint Symptom and possible causes Remedy Engine lacks power. Defective engine internal/electrical parts 1. Loss of tappet clearance Adjust. 2. Weakened valve springs Replace. 3. Valve timing out of adjustment Adjust. 4. Worn piston rings or cylinders Replace.
• Page 482
  11-12 SERVICING INFORMATION Complaint Symptom and possible causes Remedy Engine overheats Defective engine internal parts 1. Heavy carbon deposit on piston crowns Clean. 2. Not enough oil in the engine Add oil. 3. Defective oil pump or clogged oil circuit Replace or clean.

• Page 483: Radiator (Cooling System)

  SERVICING INFORMATION 11-13 RADIATOR (COOLING SYSTEM) Complaint Symptom and possible causes Remedy Engine overheats 1. Not enough engine coolant Add coolant. 2. Radiator core clogged with dirt or scale Clean. 3. Faulty cooling fan Repair or replace. 4. Defective cooling fan relay, or open- or short- Repair or replace.

• Page 484: Chassis

  11-14 SERVICING INFORMATION CHASSIS Complaint Symptom and possible causes Remedy Heavy steering 1. Overtightened steering stem nut Adjust. 2. Broken bearing in steering stem Replace. 3. Distorted steering stem Replace. 4. Not enough pressure in tires Adjust. Wobbly handlebars 1. Loss of balance between right and left front forks Adjust.

• Page 485: Shaft Drive

  SERVICING INFORMATION 11-15 SHAFT DRIVE Complaint Symptom and possible causes Remedy Noisy shaft drive Noise seems to come from secondary bevel gear and final bevel gear assemblies. 1. Oil level too low Refill. (Check oil jet./Replace oil seal.) 2. Drive and driven bevel gears damaged or worn Replace.

• Page 486: Electrical

  11-16 SERVICING INFORMATION ELECTRICAL Complaint Symptom and possible causes Remedy No sparking or poor 1. Defective ignition coils Replace. sparking 2. Defective ignition coil/plug caps Replace. 3. Defective spark plugs Replace. 4. Defective CKP sensor Replace. 5. Defective ECM Replace. 6.

• Page 487: Battery

  SERVICING INFORMATION 11-17 BATTERY Complaint Symptom and possible causes Remedy “Sulfation”, acidic 1. Cracked battery case Replace the battery. white powdery sub- 2. Battery has been left in a run-down condition for Replace the battery. stance or spots on a long time. surface of cell plates Battery runs down…

• Page 488: Special Tools

  11-18 SERVICING INFORMATION SPECIAL TOOLS 09900-18740 09900-20101 09900-20202 09900-20205 09900-06108 Hexagon socket 09900-20102 Micrometer Micrometer Snap ring pliers (24 mm) Vernier calipers (25 – 50 mm) (0 – 25 mm) 09900-20210 09900-20602 09900-20605 09900-20607 Micrometer Dial gauge Dial calipers Dial gauge 09900-20701 (100 –…

• Page 489
  SERVICING INFORMATION 11-19 09913-70210 09913-60910 09913-75821 09913-76010 09913-84510 Bearing installer set Bearing puller Bearing installer Bearing installer Bearing installer 09915-74511 09915-17410 09915-64512 09915-74521 09915-77331 Oil pressure gauge 09915-40610 Compression gauge Oil pressure gauge Meter attachment Oil filter wrench hose (for high pressure) 09916-14910 09916-37810 09916-10911…
• Page 490
  11-20 SERVICING INFORMATION 09920-53740 09918-53810 Clutch sleeve hub 09921-20210 09921-20240 Chain tensioner 09919-28610 holder Bearing remover Bearing remover set lock tool Sleeve protector 09924-62410 09924-34510 09924-41830 Final drive gear 09924-62430 09923-74511 Backlash measur- Bearing retainer bearing holder 22 mm Long Bearing remover ing tool (!27 –…
• Page 491
  SERVICING INFORMATION 11-21 09930-73170 09930-73180 09930-82720 09940-14911 09940-30221 Starter torque Starter torque Mode selection Steering stem nut Front fork assem- limiter holder limiter socket switch wrench bling tool 09940-40211 09940-40220 09940-52841 09940-52861 Fuel pressure Fuel pressure gauge Front fork inner Front fork oil seal 09940-51410 gauge adaptor…

• Page 492: Tightening Torque

  11-22 SERVICING INFORMATION TIGHTENING TORQUE ENGINE ITEM N·m kgf-m lb-ft Cylinder head cover bolt Cylinder head cover cap bracket bolt Cylinder head bolt M: 6 M: 8 19.0 Initial 18.0 M: 10 Final 30.5 Cylinder nut Cylinder head plug (Water jacket plug) 19.0 Camshaft housing bolt Sprocket cam chain drive bolt…

• Page 493: Fi System And Intake Air System

  SERVICING INFORMATION 11-23 ITEM N·m kgf-m lb-ft Gearshift cam stopper plate bolt Gearshift arm stopper bolt 13.5 Gearshift cam stopper bolt Gearshift lever shaft 36.0 Gearshift fork shaft retainer plug 25.5 Generator cover plug 11.5 Generator rotor bolt 16.0 115.5 Generator stator bolt Starter motor bolt Starter motor lead wire nut…

• Page 494: Chassis

  11-24 SERVICING INFORMATION CHASSIS N·m kgf-m lb-ft ITEM Handlebar clamp bolt 16.5 Handlebar holder bolt 61.5 Handlebar bracket bolt 16.5 Front fork upper and lower clamp bolt 16.5 Front fork cap bolt 16.5 Front fork damper rod bolt 29.0 Front fork inner rod lock nut 11.0 Steering stem head nut 65.0…

• Page 495: Tightening Torque Chart

  SERVICING INFORMATION 11-25 TIGHTENING TORQUE CHART For other nuts and bolts not listed in the preceding page, refer to this chart: Bolt Diameter Conventional or “4” marked bolt “7” marked bolt A (mm) N·m kgf-m lb-ft N·m kgf-m lb-ft 0.15 0.23 0.45 0.55…

• Page 496: Service Data

  11-26 SERVICING INFORMATION SERVICE DATA VALVE + GUIDE Unit: mm (in) ITEM STANDARD LIMIT Valve diam. — (1.65) — (1.50) Tappet clearance (when cold) 0.09 – 0.16 — (0.004 – 0.006) 0.20 – 0.30 — (0.008 – 0.012) Valve guide to valve stem 0.010 –…

• Page 497
  SERVICING INFORMATION 11-27 ITEM STANDARD LIMIT Camshaft runout 0.10 IN. & EX. — (0.004) Cam chain pin (at arrow “3”) 18th pin — Cylinder head distortion 0.05 — (0.002) CYLINDER + PISTON + PISTON RING Unit: mm (in) ITEM STANDARD LIMIT Compression pressure 1 100 –…
• Page 498
  11-28 SERVICING INFORMATION CONROD + CRANKSHAFT Unit: mm (in) ITEM STANDARD LIMIT Conrod small end I.D. 23.010 – 23.018 23.040 (0.9059 – 0.9062) (0.9071) Conrod big end side clearance 0.100 – 0.200 0.30 (0.0039 – 0.0078) (0.012) Conrod big end width 23.95 –…
• Page 499
  SERVICING INFORMATION 11-29 THERMOSTAT + RADIATOR + FAN + COOLANT ITEM STANDARD LIMIT Thermostat valve opening Approx. 88 °C (190 °F) — temperature Thermostat valve lift Over 8.0 mm (0.31 in) at 100 °C (212 °F) — Engine coolant temperature sensor 20 °C Approx.
• Page 500
  11-30 SERVICING INFORMATION DRIVELINE/AXLE Unit: mm (in) ITEM STANDARD/SPECIFICATION LIMIT Secondary bevel gear backlush 0.03 – 0.15 — (0.001 – 0.006) Final bevel gear backlush 0.08 – 0.16 — (0.003 – 0.006) Damper spring free length 64.6 — (2.54) Final gear oil type Hypoide gear oil SAE #90, API grade GL-5 —…
• Page 501
  SERVICING INFORMATION 11-31 ITEM SPECIFICATION NOTE STP sensor output voltage Closed Approx. 0.6 V Opened Approx. 4.2 V Approx. 7 Ω STV actuator resistance EXCVA position sensor input 4.5 – 5.5 V voltage EXCVA position sensor resistance At adjustment Approx. 3.1 kΩ position EXCVA position sensor output Closed…

• Page 502: Front Turn Signal/Position Light

  11-32 SERVICING INFORMATION ITEM SPECIFICATION NOTE Generator no-load voltage 70 V (AC) and more at 5 000 r/min (When engine is cold) Regulated voltage 14.0 – 15.5 V at 5 000 r/min 3 – 6 Ω Starter relay resistance Battery Type FTZ16-BS designation…

• Page 503
  SERVICING INFORMATION 11-33 BRAKE + WHEEL Unit: mm (in) ITEM STANDARD LIMIT Rear brake pedal height 25 – 35 — (1.0 – 1.4) Brake disc thickness 5.0 ± 0.2 Front (0.197 ± 0.008) (0.18) –0.4 Rear (0.276 (0.25) –0.016 Brake disc runout 0.30 —…

• Page 504: Fuel Tank Capacity

  Front fork oil level (without spring, inner tube fully — (5.2) compressed) Front fork oil type SUZUKI FORK OIL L01 or an equivalent fork oil — Front fork oil capacity (each leg) 684 ml — (23.1/24.1 US/lmp oz) Rear shock absorber spring —…

• Page 505: Wiring Harness, Cable And Hose Routing

  SERVICING INFORMATION 11-35 WIRING HARNESS, CABLE AND HOSE ROUTING WIRING HARNESS ROUTING Wiring harness Face the lead wire Clamp to the lower. Clamp ISC valve Set the speedometer Wiring harness harness to the right side. Clamp Keep the clearance between wiring harness and fuel tank and frame.

• Page 506
  11-36 SERVICING INFORMATION Pass the handlebar switch lead wire upper the brake switch coupler. Handlebar switch lead wire (R) To the Handlebar switch lead wire (L) tachometer Clamp Clamp Clamp Ignition coil high tension cord Pass the lead wire Wiring harness outside of the terminal.

• Page 507: Engine Electrical Parts Lead Wire Routing

  SERVICING INFORMATION 11-37 ENGINE ELECTRICAL PARTS LEAD WIRE ROUTING Clamp Starter motor Battery ground wire Starter motor lead wire Generator lead wire Grommet Gear position switch Speedometer sensor CKP sensor Oil pressure switch Oil pressure switch lead wire Clamp Clamp…

• Page 508: Cable Routing

  11-38 SERVICING INFORMATION CABLE ROUTING Pass the throttle cable between the handlebars and brake hose. Pass the throttle cables behind the right handlebar switch lead wire and brake switch coupler. VIEW A Front brake hose Throttle cable No.1 (pulling cable) Cable guide Throttle cable No.2 (returning cable) Throttle cable…

• Page 509: Front Brake Hose Routing

  SERVICING INFORMATION 11-39 FRONT BRAKE HOSE ROUTING 21˚ 14˚ 14˚ 1 Stopper 8 Bolt 2 Brake master cylinder 9 Brake caliper (R) 3 Throttle cable 0 Brake caliper (L) Tighten the brake hose union bolt to the specified torque after touching 4 Cable guide the brake hose union to the stopper.

• Page 510: Rear Brake Hose Routing

  11-40 SERVICING INFORMATION REAR BRAKE HOSE ROUTING 30˚ 14˚ 1 Stopper A Face the white paint on reservoir hose to forward. Tighten the hose guide bolt after positioning the stopper of 2 Reservoir hose guide to the swingarm. 3 Brake cylinder C Fix the grommet of brake hose to the hose guide.

• Page 511: Throttle Body Hose Routing

  SERVICING INFORMATION 11-41 THROTTLE BODY HOSE ROUTING Rear cylinder 15˚ Front cylinder Air cleaner outlet clamp 15˚ – 25˚ Front cylinder 25˚ – 35˚ Rear cylinder Intake pipe clamp 1 ISC valve hose (R) 0 Bolt 2 ISC valve hose (L) *1 Yellow mark 3 Throttle body *2 Face the tip of clip to upper.

• Page 512: Cooling System Hose Routing

  11-42 SERVICING INFORMATION COOLING SYSTEM HOSE ROUTING Rediator cap Keep clearance between clamp and hose. 90˚ 90˚ Mark 90˚ Rediator Face the tip of clip to the inside. White mark Face the tip of clip to the backward. Red mark Oil cooler Yellow mark Clamp…

• Page 513: Pair (Air Supply) System Hose Routing (For E-03, 28, 33)

  SERVICING INFORMATION 11-43 PAIR (AIR SUPPLY) SYSTEM HOSE ROUTING (FOR E-03, 28, 33) Set the PAIR hose to the concave of air cleaner tube. White mark Blue mark VIEW A Yellow mark White mark 1 PAIR control solenoid valve 2 PAIR reed valve…

• Page 514: Pair (Air Supply) System Hose Routing (For The Others)

  11-44 SERVICING INFORMATION PAIR (AIR SUPPLY) SYSTEM HOSE ROUTING (FOR THE OTHERS) Set the PAIR hose to the concave of air cleaner tube. White mark Yellow mark White mark 1 PAIR control solenoid valve 2 PAIR reed valve…

• Page 515: Fuel Tank Installation

  SERVICING INFORMATION 11-45 FUEL TANK INSTALLATION Forward Outside 1 Heat shield 6 Fuel tank cushion 2 Fuel pump 7 Rear fender cover cushion 3 Clamp 8 Apply instant adhesive to the shaded portion. 4 Face the tip of clamp to the backward. 9 Fuel tank rear bracket Face the arrow mark to the forward, when install- Attach the front of fuel tank cushion to the rein-…

• Page 516: Frame Head Cover And Radiator Cover Installation

  11-46 SERVICING INFORMATION FRAME HEAD COVER AND RADIATOR COVER INSTALLATION 1 Frame head cover (R) 6 Radiator lower cover (L) 2 Radiator cover (R) 7 Radiator bottom cover 3 Radiator lower cover (R) 8 Throttle cable No.1 (pulling cable) 4 Frame head cover (L) 9 Throttle cable No.2 (returning cable) 5 Radiator cover (L) 0 Clutch cable…

• Page 517: Frame Head Cover Cushion Installation

  SERVICING INFORMATION 11-47 FRAME HEAD COVER CUSHION INSTALLATION 1 Cushion 3 Frame head cover (L) 2 Frame head cover (R) RADIATOR UPPER COVER CUSHION INSTALLATION 3 mm (0.1 in) 2 mm (0.08 in) 18 mm (0.7 in) 16 mm (0.6 in) 1 Radiator upper cover 3 Cushion 2 Frame…

• Page 518: Left Frame Covers Installation

  11-48 SERVICING INFORMATION LEFT FRAME COVERS INSTALLATION 1 Rear fender 4 Side cover 2 Rear fender cover 5 Lower side cover 3 Rear side cover…

• Page 519: Right Frame Covers Installation

  SERVICING INFORMATION 11-49 RIGHT FRAME COVERS INSTALLATION 1 Rear fender 4 Side cover 2 Rear fender cover 5 Lower cover 3 Rear side cover…

• Page 520: Headlight Cover Installation

  11-50 SERVICING INFORMATION HEADLIGHT COVER INSTALLATION 1 Headlight lower cover 4 Headlight cover brace 2 Headlight cover 5 Steering stem upper bracket 3 Headlight back cover 6 Steering stem lower bracket…

• Page 521: Ignition Coil Installation

  SERVICING INFORMATION 11-51 IGNITION COIL INSTALLATION Forward 1 Ignition coil #1 3 Ignition coil bracket 2 Ignition coil #2 4 Spacer SIDE-STAND INSTALLATION…

• Page 522: Rear Turn Signal Light, License Light Wire Routing

  11-52 SERVICING INFORMATION REAR TURN SIGNAL LIGHT, LICENSE LIGHT WIRE ROUTING License light and right and left rear turn signal lead wirres installtion order. Fix the right and left rear turn signal light lead wires Connect the license light and left rear turn and license light lead wire with clamp.

• Page 523: License Light And License Plate Installation

  SERVICING INFORMATION 11-53 LICENSE LIGHT AND LICENSE PLATE INSTALLATION » 1 License light 4 Washer 2 License plate 5 Spacer ITEM N·m kgf-m lb-ft 3 Nut A License light nut BRAKE LIGHT/TAILLIGHT INSTALLATION 1 Rear frame cover 2 Brake light/Taillight…

• Page 524: Emission Control Information

  EMISSION CONTROL INFORMATION 12-1 EMISSION CONTROL INFORMATION CONTENTS EMISSION CONTROL SYSTEMS ………….. 12- 2 FUEL INJECTION SYSTEM…………..12- 2 CRANKCASE EMISSION CONTROL SYSTEM……..12- 3 EXHAUST EMISSION CONTROL SYSTEM (PAIR SYSTEM) …. 12- 4 NOISE EMISSION CONTROL SYSTEM……….12- 5 PAIR (AIR SUPPLY) SYSTEM AND EMISSION CONTROL SYSTEM INSPECTION ………………..

• Page 525: Emission Control Systems

  12-2 EMISSION CONTROL INFORMATION EMISSION CONTROL SYSTEMS FUEL INJECTION SYSTEM VZR1800 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 a view to reducing CO, NOX and HC, all of the fuel injection volumes are stringently controlled with the programmed injection maps in the ECM by varying engine conditions.

• Page 526: Crankcase Emission Control System

  EMISSION CONTROL INFORMATION 12-3 CRANKCASE EMISSION CONTROL SYSTEM The engine is equipped with a PCV system to prevent discharging crankcase emissions into the atomo- sphere. Blow-by gas in the engine is constantly drawn into the crankcase, which is returned to the combus- tion chamber through the PCV (breather) hose, air cleaner and throttle body.

• Page 527: Exhaust Emission Control System (Pair System)

  12-4 EMISSION CONTROL INFORMATION EXHAUST EMISSION CONTROL SYSTEM (PAIR SYSTEM) The exhaust emission control system is composed of the PAIR system, exhaust control system and three-way catalyst system. The fresh air is drawn into the exhaust port through the PAIR control solenoid valve and PAIR reed valve.

• Page 528: Noise Emission Control System

  EMISSION CONTROL INFORMATION 12-5 NOISE EMISSION CONTROL SYSTEM TAMPERING WITH THE NOISE CONTROL SYSTEM PROHIBITED: Local law prohibits the following acts or the causing thereof: 1. The removal or rendering inoperative by any person, other than for purposes of maintenance, repair or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use, or 2.

• Page 529: Pair (Air Supply) System And Emission Control System

  12-6 EMISSION CONTROL INFORMATION PAIR (AIR SUPPLY) SYSTEM AND EMISSION CONTROL SYSTEM INSPECTION PAIR HOSES • Remove the frame head covers. (!9-6) • Inspect the PAIR hoses for wear or damage. • Inspect the PAIR hoses for secure connection. PAIR REED VALVE •…

• Page 530
  EMISSION CONTROL INFORMATION 12-7 • Check the resistance between the terminals of the PAIR con- trol solenoid valve. » Resistance: 18 – 22 Ω at 20 – 30 °C (68 – 86 °F) # 09900-25008: Multi-circuit tester set $ Tester knob indication: Resistance (Ω) INSTALLATION If the resistance is not within the standard range, replace the PAIR control solenoid valve with a new one.

• Page 531: Pair (Air Supply) System Hose Routing (For E-03, 28, 33)

  12-8 EMISSION CONTROL INFORMATION PAIR (AIR SUPPLY) SYSTEM HOSE ROUTING (FOR E-03, 28, 33) Set the PAIR hose to the concave of air cleaner tube. White mark Blue mark VIEW A Yellow mark White mark 1 PAIR control solenoid valve 2 PAIR reed valve…

• Page 532: Pair (Air Supply) System Hose Routing (For The Others)

  EMISSION CONTROL INFORMATION 12-9 PAIR (AIR SUPPLY) SYSTEM HOSE ROUTING (FOR THE OTHERS) Set the PAIR hose to the concave of air cleaner tube. White mark Yellow mark White mark 1 PAIR control solenoid valve 2 PAIR reed valve…

• Page 533: Heated Oxgen Sensor (Ho2S) Inspection (For E-02, 19, 24)

  12-10 EMISSION CONTROL INFORMATION HEATED OXGEN SENSOR (HO2S) INSPECTION (FOR E-02, 19, 24) • Disconnect the HO2 sensor lead wire coupler. (!5-79) • Inspect the HO2 sensor and its circuit referring to flow table of malfunction code (P0156/P0161 P0130/P0135). • Check the resistance between the terminals of the HO2 sen- sor.

• Page 534: Wiring Diagram

  WIRING DIAGRAM E-02, 19, 24 Wiring diagrams wire color, refer to section “WIRE COLOR”. HANDLEBAR SWITCH (R) IGNITION IGNITION ENGINE STOP COIL/ COIL/ IGNITION IGNITION STARTER FRONT BRAKE SWITCH PLUG CAP #1 PLUG CAP #2 COIL #1 COIL #2 BUTTON SWITCH SIDE STAND SPEEDOMETER…

• Page 535
  E-03, 28, 33 HANDLEBAR SWITCH (R) IGNITION IGNITION COIL/ COIL/ IGNITION IGNITION ENGINE STOP STARTER FRONT BRAKE SWITCH PLUG CAP #1 PLUG CAP #2 COIL #1 COIL #2 BUTTON SWITCH SPEEDOMETER SIDE STAND TACHOMETER PUSH IGNITION SWITCH SWITCH FREE PUSH LOCK PAIR SOLENOID…
• Page 536
  Prepared by January, 2006 Part No. 99500-39290-01E Printed in Japan…
• Page 537
  Printed in Japan…
• Page 538
  The following departments in your dealership should be notified of this information: Warranty Sales Accessories ⌧ ⌧ ⌧ ⌧ Management ⌧ ⌧ ⌧ ⌧ Service ⌧ ⌧ ⌧ ⌧ Parts ⌧ ⌧ ⌧ American Suzuki Motor Corporation Technical Service Department Motorcycle / ATV / Scooter…
• Page 539
  FUEL SYSTEM AND THROTTLE BODY FUEL PUMP AND FUEL LEVEL GAUGE REMOVAL CONSTRUCTION 1 Regulator 5 O-ring 2 Fuel pump 6 Fuel level gauge ITEM N·m kgf-m lb-ft 3 Fuel mesh filter Thermistor 4 Filter cover Fuel pump mounting bolt…
• Page 540
  ELECTRICAL SYSTEM 10-35 FUEL LEVEL INDICATOR SWITCH (THERMISTOR) INSPECTION • Remove and disassemble the fuel pump assembly. (!6-8) • Connect 12 V battery and test bulb (12 V, 3.4 W) to the fuel Battery Test level indicator switch as shown in the right illustration. The bulb bulb should come on after one minutes if the switch is in good condition.
• Page 541
  MOTORCYCLE DIVISION 4-STROKE BULLETIN VS-VX-VZ-VL NO. 60 DATE: 1/4/2008 SUBJECT: SERVICE MANUAL CORRECTIONS — VALVE SPRING SPECIFICATIONS AND CLUTCH WASHER MODEL: VZR1800K6-K8 REFERENCE: VZR1800 SERVICE MANUAL (P/N 99500-39292-03E) Pages 3-38 and 11-26 VZR1800 SERVICE MANUAL (P/N 99500-39292-03E, prior to 08/07 revision) Pages 3-21 and 3-95 NOTICE: This bulletin contains service manual correction information for the VZR1800.

• Page 542: Bearing

  ENGINE 3-21 • Remove the thrust washer A. • Remove the primary driven gear assembly B. • Remove the needle roller bearing C, spacer D and washer REAR CAM CHAIN TENSION ADJUSTER • Unlock the ratchet 1 and insert the special tool. % 09917-62430: Chain tensioner lock tool •…

• Page 543: Spacer

  ENGINE 3-95 CLUTCH • Install the washer 1, spacer 2 and needle bearing 3 onto the countershaft. • Apply engine oil to them. • Install the primary driven gear assembly 3 onto the counter- shaft. • Install the thrust washer 4. •…

• Page 544
  The following departments in your dealership should be notified of this information: Warranty Sales Accessories ⌧ ⌧ ⌧ ⌧ Management ⌧ ⌧ ⌧ ⌧ Service ⌧ ⌧ ⌧ ⌧ Parts ⌧ ⌧ ⌧ American Suzuki Motor Corporation Technical Service Department Motorcycle / ATV / Scooter — 1/1 -…
• Page 545
  2-22 PERIODIC MAINTENANCE RADIATOR HOSES • Remove the fuel tank. (!6-3) • Remove the frame head covers, radiator covers and radiator bottom cover. (!9-6) • Check to see the radiator hoses for crack, damage or engine coolant leakage. • If any defects are found, replace the radiator hoses with new ones.
• Page 546
  PERIODIC MAINTENANCE 2-23 * Loosen the lock nut 3 and turn in the release screw 4 to feel resistance. * From that position, turn out the release screw 4 1 turn and tighten the lock nut 3 securely by holding the release screw «…
• Page 547
  2-24 PERIODIC MAINTENANCE BRAKE FLUID LEVEL CHECK • Keep the motorcycle upright and place the handlebars straight. • Check the brake fluid level relative to the lower limit lines on the front and rear brake fluid reservoirs. • When the level is below the lower limit line, replenish with brake fluid that meets the following specification.
• Page 548
  PERIODIC MAINTENANCE 2-25 Rear brake 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 the new ones. (!9-63) Replace the brake pads as a set, otherwise braking performance will be adversely affected.
• Page 549
  The following departments in your dealership should be notified of this information: ⌧ ⌧ Management ⌧ ⌧ Service Warranty Sales ⌧ ⌧ Parts Accessories ⌧ ⌧ ⌧ ⌧ ⌧ ⌧ ⌧ ⌧ ⌧ American Suzuki Motor Corporation Technical Service Department Motorcycle / ATV / Scooter — 1/24 -…
• Page 550
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• Page 580
  Federal law requires that ALL vehicles affected by a safety recall campaign be corrected prior to sale or lease to a customer. You must verify this on the Suzuki «Certificate of Vehicle Pre- Delivery» form (99923-09823-005), which is to be completed for all new and used vehicle sales.
• Page 581
  1) Check the repair status by checking the Vehicle History in the Suzuki Connect Service Menu. If the repair needs to be performed, you will see the message «CAMPAIGN NOT YET PERFORMED» displayed and the fuel delivery pipe assembly will need to be replaced.
• Page 582
  Enter date of repair MILEAGE: Enter mileage on unit CAMPAIGN NUMBER: 2096 LABOR HOURS: 1.0 hrs SUZUKI AUTH. NUMBER: As approved by TECH-LINE PARTS REPLACEMENT PART NUMBER: NO PARTS REQUIRED FAILURE DESCRIPTION DESCRIPTION OF FAILURE: Replace Fuel Delivery Pipe Assy per…
• Page 583
  FUEL DELIVERY PIPE ASSEMBLY REPLACEMENT PROCEDURE When working with the fuel system, work in a well ventilated area away from any flame or ignition sources. Store the motorcycle in an area away from any flame or ignition sources. NOTE: The fuel delivery pipe assembly can be removed from the throttle body without removing the throttle body assembly from the motorcycle.
• Page 584
  Only your conscientious action at the dealership level can lead to a successful campaign conclusion. Please extend Suzuki’s apologies for any inconvenience this recall campaign may cause them. Refer to page 7 for detailed information regarding Customer Reimbursement.
• Page 585
  Vehicle Safety Act. What is the reason for this notice? Suzuki Motor Corporation has decided that a defect that relates to motor vehicle safety exists in all 2006 and certain 2007 model year VZR1800/Z (M109R) motorcycles. According to our records, you are the owner of one of these affected VZR1800 (M109R) motorcycles.
• Page 586
  Vehicle Identification Number ready when calling. If you believe that (1) Suzuki or your Suzuki dealer has failed to or is unable to perform the recall service without charge, or (2) Suzuki has failed to or is unable to perform the recall…

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