The Manual - V

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GROUP INDEX
GENERAL INFORMATION 1
PERIODIC MAINTENANCE 2
ENGINE 3
FI SYSTEM DIAGNOSIS 4
FUEL SYSTEM AND THROTTLE
BODY 5
COOLING AND LUBRICATION
SYSTEM 6
CHASSIS 7
ELECTRICAL SYSTEM 8
SERVICING INFORMATION 9
10
FOREWORD
This manual contains an introductory description on
the SUZUKI DL650 and procedures for its inspection/service and overhaul of its main components.
Other information considered as generally known is
not included.
Read the GENERAL INFORMATION section to
familiarize yourself with the motorcycle and its maintenance. Use this section as well as other sections
to use as a guide for proper inspection and service.
This manual will help you know the motorcycle better so that you can assure your customers of fast
and reliable service.
© COPYRIGHT SUZUKI MOTOR CORPORATION 2003
* This manual has been prepared on the basis
of the latest specifications at the time of publication. If modifications have been made since
then, differences may exist between the content of this manual and the actual motorcycle.
* Illustrations in this manual are used to show
the basic principles of operation and work
procedures. They may not represent the
actual motorcycle exactly in detail.
* This manual is written for persons who have
enough knowledge, skills and tools, including
special tools, for servicing SUZUKI motorcycles. If you do not have the proper knowledge
and tools, ask your authorized SUZUKI
motorcycle dealer to help you.
Inexperienced mechanics or mechanics
without the proper tools and equipment
may not be able to properly perform the
services described in this manual.
Improper repair may result in injury to the
mechanic and may render the motorcycle
unsafe for the rider and passenger.
EMISSION CONTROL
INFORMATION
99500-36135-03E
03 ENGINE.book Page 105 Tuesday, February 28, 2006 3:03 PM
11
12
13
SUPPLEMENTS
DL650K5 ('05- MODEL)
DL650K6 ('06- MODEL)
DL650/AK7 ('07- MODEL)
14
15DL650/AK9 (’09-MODEL)
DL650/AK8 ('08- MODEL)
16WIRING DIAGRAM
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.
4. The contents are listed on the first page of each section to
help you find the item and page you need.
COMPONENT PARTS AND WORK TO BE DONE
Under the name of each system or unit, is its exploded view. Work instructions and other service information
such as the tightening torque, lubricating points and locking agent points, are provided.
Example: Front wheel
1 Brake disc
2 Dust seal
3 Bearing
4 Center spacer
5 Front wheel
6 Tire valve
A Front axle
B Brake disc bolt
"
ITEM N·m kgf-m lb-ft
A 65 6.5 47.0
B 23 2.3 16.5
SYMBOL
Listed in the table below are the symbols indicating instructions and other information necessary for servicing. The meaning of each symbol is also included in the table.
SYMBOL DEFINITION SYMBOL DEFINITION
Torque control required.
Data beside it indicates specified
torque.
Apply THREAD LOCK SUPER “1360”.
99000-32130
Apply oil. Use engine oil unless otherwise specified.
Use engine coolant.
Apply molybdenum oil solution.
(Mixture of engine oil and SUZUKI
MOLY PASTE in a ratio of 1:1)
Use fork oil.
99000-99001-SS8
Apply SUZUKI SUPER GREASE “A”.
99000-25030 (USA)
99000-25010 (Others)
Apply or use brake fluid.
Apply SUZUKI MOLY PASTE.
99000-25140
Measure in voltage range.
Apply SUZUKI SILICONE GREASE.
99000-25100
Measure in current range.
Apply SUZUKI BOND “1215”.
99000-31110 (Except USA)
Measure in resistance range.
Apply SUZUKI BOND “1207B”.
99104-31140 (USA)
99000-31140 (Others)
Measure in diode test range.
Apply THREAD LOCK SUPER “1303”.
99000-32030
Measure in continuity test range.
Apply THREAD LOCK SUPER “1322”.
99000-32110 (Except USA)
Use special tool.
Apply THREAD LOCK “1342”.
99000-32050
Indication of service data.
ABBREVIATIONS USED IN THIS
MANUAL
A
ABDC : After Bottom Dead Center
AC : Alternating Current
ACL : Air Cleaner, Air Cleaner Box
API : American Petroleum Institute
ATDC : After Top Dead Center
ATM Pressure: Atmospheric Pressure
Atmospheric Pressure Sensor
(APS)
A/F : Air Fuel Mixture
B
BBDC : Before Bottom Dead Center
BTDC : Before Top Dead Center
B+ : Battery Positive Voltage
C
CKP Sensor : Crankshaft Position Sensor
(CKPS)
CKT : Circuit
CLP Switch : Clutch Lever Position Switch
(Clutch Switch)
CMP Sensor : Camshaft Position Sensor
(CMPS)
CO : Carbon Monoxide
CPU : Central Processing Unit
D
DC : Direct Current
DMC : Dealer Mode Coupler
DOHC : Double Over Head Camshaft
DRL : Daytime Running Light
E
ECM : Engine Control Module
Engine Control Unit (ECU)
(FI Control Unit)
ECT Sensor : Engine Coolant Temperature
Sensor (ECTS), Water Temp.
Sensor (WTS)
EVAP : Evaporative Emission
EVAP Canister : Evaporative Emission
Canister (Canister)
F
FI : Fuel Injection, Fuel Injector
FP : Fuel Pump
FPR : Fuel Pressure Regulator
FP Relay : Fuel Pump Relay
G
GEN : Generator
GND : Ground
GP Switch : Gear Position Switch
H
HC : Hydrocarbons
I
IAP Sensor : Intake Air Pressure Sensor (IAPS)
IAT Sensor : Intake Air Temperature Sensor
(IATS)
IG : Ignition
L
LCD : Liquid Crystal Display
LED : Light Emitting Diode
(Malfunction Indicator Lamp)
LH : Left Hand
M
MAL-Code : Malfunction Code
(Diagnostic Code)
Max : Maximum
MIL : Malfunction Indicator Lamp
(LED)
Min : Minimum
N
NOx : Nitrogen Oxides
O
OHC : Over Head Camshaft
OPS : Oil Pressure Switch
P
PCV : Positive Crankcase
Ventilation (Crankcase Breather)
R
RH : Right Hand
ROM : Read Only Memory
S
SAE : Society of Automotive Engineers
STC System : Secondary Throttle Control
System (STCS)
STP Sensor : Secondary Throttle Position
Sensor (STPS)
ST Valve : Secondary Throttle Valve (STV)
STV Actuator : Secondary Throttle Valve Actuator
(STVA)
T
TO Sensor : Tip Over Sensor (TOS)
TP Sensor : Throttle Position Sensor (TPS)
V
VD : Vacuum Damper
SAE-TO-FORMER SUZUKI TERM
This table lists SAE (Society of Automotive Engineers) J1930 terms and abbreviations which may be used in
this manual in compliance with SAE recommendations, as well as their former SUZUKI names.
SAE TERM
FORMER SUZUKI TERM
FULL TERM ABBREVIATION
A
Air Cleaner
B
Barometric Pressure
Battery Positive Voltage
C
Camshaft Position Sensor
Crankshaft Position Sensor
D
Data Link Connector
Diagnostic Test Mode
Diagnostic Trouble Code
E
Electronic lgnition
Engine Control Module
Engine Coolant Level
Engine Coolant Temperature
Engine Speed
Evaporative Emission
Evaporative Emission Canister
F
Fan Control
Fuel Level Sensor
Fuel Pump
G
Generator
Ground
ACL
BARO
B+
CMP Sensor
CKP Sensor
DLC
DTM
DTC
EI
ECM
ECL
ECT
RPM
EVAP
EVAP Canister
FC
-------
FP
GEN
GND
Air Cleaner, Air Cleaner Box
Barometric Pressure, Atmospheric
Pressure (APS, AP Sensor)
Battery Voltage, +B
Camshaft Position Sensor (CMPS)
Crankshaft Position Sensor (CKPS),
Crank Angle
Dealer Mode Coupler
-------
Diagnostic Code, Malfunction Code
-------
Engine Control Module (ECM)
FI Control Unit, Engine Control Unit (ECU)
Coolant Level
Coolant Temperature, Engine Coolant Temperature
Water Temperature
Engine Speed (RPM)
Evaporative Emission
------- (Canister)
-------
Fuel Level Sensor, Fuel Level Gauge
Fuel Pump (FP)
Generator
Ground (GND, GRD)
SAE TERM
FORMER SUZUKI TERM
FULL TERM ABBREVIATION
I
Idle Speed Control
Ignition Control
Ignition Control Module
Intake Air Temperature
M
Malfunction Indicator Lamp
Manifold Absolute Pressure
Mass Air Flow
O
On-Board Diagnostic
Open Loop
P
Programmable Read Only Memory
Pulsed Secondary Air Injection
Purge Valve
R
Random Access Memory
Read Only Memory
S
Secondary Air Injection
Secondary Throttle Control System
Secondary Throttle Valve
Secondary Throttle Valve Actuator
T
Throttle Body
Throttle Body Fuel Injection
Throttle Position Sensor
V
Voltage Regulator
Volume Air Flow
ISC
IC
ICM
IAT
MIL
MAP
MAF
OBD
OL
PROM
PAIR
Purge Valve
RAM
ROM
AIR
STCS
STV
STVA
TB
TBI
TP Sensor
VR
VAF
-------
Electronic Spark Advance (ESA)
-------
Intake Air Temperature (IAT), Air Temperature
LED Lamp
Malfunction Indicator Lamp (MIL)
Intake Air Pressure (IAP), Intake Vacuum
Air Flow
Self-Diagnosis Function
Diagnostic
-------
-------
Pulse Air Control (PAIR)
Purge Valve (SP Valve)
-------
ROM
-------
STC System (STCS)
ST Valve (STV)
STV Actuator (STVA)
Throttle Body (TB)
Throttle Body Fuel Injection (TBI)
TP Sensor (TPS)
Voltage Regulator
Air Flow
WIRE COLOR
B : Black Gr : Gray R : Red
Bl : Blue Lbl : Light blue W : White
Br : Brown Lg : Light green Y : Yellow
Dg : Dark green O : Orange
G : Green P : Pink
B/Bl : Black with Blue tracer B/Br : Black with Brown tracer
B/G : Black with Green tracer B/O : Black with Orange tracer
B/R : Black with Red tracer B/W : Black with White tracer
B/Y : Black with Yellow tracer Bl/B : Blue with Black tracer
Bl/G : Blue with Green tracer Bl/R : Blue with Red tracer
Bl/W : Blue with White tracer Bl/Y : Blue with Yellow tracer
Br/B : Brown with Black tracer Br/W : Brown with White tracer
G/B : Green with Black tracer G/Y : Green with Yellow tracer
Gr/B : Gray with Black tracer Gr/R : Gray with Red tracer
Gr/W : Gray with White tracer O/B : Orange with Black tracer
O/Bl : Orange with Blue tracer O/G : Orange with Green tracer
O/R : Orange with Red tracer O/W : Orange with White tracer
O/Y : Orange with Yellow tracer P/W : Pink with White tracer
R/B : Red with Black tracer R/W : Red with White tracer
W/B : White with Black tracer W/Bl : White with Blue tracer
W/G : White with Green tracer W/R : White with Red tracer
Y/B : Yellow with Black tracer Y/Bl : Yellow with Blue tracer
Y/G : Yellow with Green tracer Y/R : Yellow with Red tracer
Y/W : Yellow with White tracer
GENERAL INFORMATION 1-1
1
GENERAL INFORMATION
CONTENTS
WARNING/CAUTION/NOTE .........................................................................1- 2
GENERAL PRECAUTIONS...........................................................................1- 2
SUZUKI DL650K4 (’04-MODEL) ...................................................................1- 4
SERIAL NUMBER LOCATION......................................................................1- 4
FUEL, OIL AND ENGINE COOLANT RECOMMENDATION........................1- 4
FUEL (FOR USA AND CANADA)...........................................................1- 4
FUEL (FOR OTHER COUNTRIES).........................................................1- 4
ENGINE OIL (FOR USA)........................................................................1- 5
ENGINE OIL (FOR OTHER COUNTRIES) ............................................1- 5
BRAKE FLUID.........................................................................................1- 5
FRONT FORK OIL ..................................................................................1- 5
ENGINE COOLANT ................................................................................1- 5
WATER FOR MIXING .............................................................................1- 5
ANTI-FREEZE/ENGINE COOLANT........................................................1- 6
LIQUID AMOUNT OF WATER/ENGINE COOLANT ..............................1- 6
BREAK-IN PROCEDURES ...........................................................................1- 6
CYLINDER IDENTIFICATION .......................................................................1- 7
INFORMATION LABELS...............................................................................1- 8
SPECIFICATIONS .........................................................................................1- 9
DIMENSIONS AND DRY MASS .............................................................1- 9
ENGINE ...................................................................................................1- 9
DRIVE TRAIN ..........................................................................................1- 9
CHASSIS .................................................................................................1-10
ELECTRICAL ..........................................................................................1-10
CAPACITIES ...........................................................................................1-10
COUNTRY AND AREA CODES....................................................................1-11
1-2 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 messages highlighted by these signal words.
!
Indicates a potential hazard that could result in death or injury.
"
Indicates a potential hazard that could result in motorcycle damage.
NOTE:
Indicates special information to make maintenance easier or instructions clearer.
Please note, however, that the warnings and cautions contained in this manual cannot possibly cover all
potential hazards relating to the servicing, or lack of servicing, of the motorcycle. In addition to the WARNINGS and CAUTIONS stated, you must use good judgement and basic mechanical safety principles. If you
are unsure about how to perform a particular service operation, ask a more experienced mechanic for
advice.
GENERAL PRECAUTIONS
!
* Proper service and repair procedures are important for the safety of the service mechanic and
the safety and reliability of the motorcycle.
* When 2 or more persons work together, pay attention to the safety of each other.
* When it is necessary to run the engine indoors, make sure that exhaust gas in forced outdoors.
* When working with toxic or flammable materials, make sure that the area you work in is wellventilated and that you follow all of the material manufacturer’s instructions.
* Never use gasoline as a cleaning solvent.
* To avoid getting burned, do not touch the engine, engine oil, radiator and exhaust system
until they have cooled.
* After servicing the fuel, oil, water, exhaust or brake systems, check all lines and fittings
related to the system for leaks.
GENERAL INFORMATION 1-3
"
* If parts replacement is necessary, replace the parts with Suzuki Genuine Parts or their equivalent.
* 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.
* Be sure to use special tools when instructed.
* Make sure that all parts used in reassembly are clean. Lubricate them when specified.
* Use the specified lubricant, bond, or sealant.
* When removing the battery, disconnect the negative cable first and then the positive cable.
* When reconnecting the battery, connect the positive cable first and then the negative cable,
and replace the terminal cover on the positive terminal.
* When performing service to electrical parts, if the service procedures not require use of battery power, disconnect the negative cable the battery.
* When tightening the cylinder head and case bolts and nuts, tighten the larger sizes first.
Always tighten the bolts and nuts diagonally from the inside toward outside and to the specified tightening torque.
* Whenever you remove oil seals, gaskets, packing, O-rings, locking washers, self-locking
nuts, cotter pins, circlips and certain other parts as specified, be sure to replace them with
new ones. Also, before installing these new parts, be sure to remove any left over material
from the mating surfaces.
* Never reuse a circlip. When installing a new circlip, take care not to expand the end gap larger
than required to slip the circlip over the shaft. After installing a circlip, always ensure that it is
completely seated in its groove and securely fitted.
* Use a torque wrench to tighten fasteners to the specified torque. Wipe off grease and oil if a
thread is smeared with them.
* After reassembling, check parts for tightness and proper operation.
* To protect the environment, do not unlawfully dispose of used motor oil, engine coolant and
other fluids: batteries, and tires.
* To protect Earth’s natural resources, properly dispose of used motorcycle and parts.
1-4 GENERAL INFORMATION
SUZUKI DL650K4 (’04-MODEL)
• Difference between photographs and actual motorcycles depends 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. The engine serial number 2 is located on the left side of the crankcase. These numbers are
required especially for registering the machine and ordering spare parts.
FUEL, OIL AND ENGINE COOLANT RECOMMENDATION
FUEL (FOR USA AND CANADA)
Use only unleaded gasoline of at least 87 pump octane ( ) or 91 octane or higher rated by the
research method.
Gasoline containing MTBE (Methyl Tertiary Butyl Ether), less than 10 % ethanol, or less than 5 % methanol
with appropriate cosolvents and corrosion inhibitor is permissible.
FUEL (FOR OTHER COUNTRIES)
Gasoline used should be graded 91 octane (Research Method) or higher. Unleaded gasoline is recommended.
RIGHT SIDE LEFT SIDE
2
R + M
GENERAL INFORMATION 1-5
ENGINE OIL (FOR USA)
SUZUKI recommends the use of SUZUKI PERFORMANCE 4 MOTOR OIL or an oil which is rated SF or SG
under the API (American Petroleum Institute) service classification. The recommended viscosity is SAE
10W-40. If an SAE 10W-40 oil is not available, select and alternative according to the following chart.
ENGINE OIL (FOR OTHER COUNTRIES)
Use a premium quality 4-stroke motor oil to ensure longer service life of your motorcycle. Use only oils which are rated SF or
SG under the API service classification. The recommended viscosity is SAE 10W-40. If an SAE 10W-40 motor oil is not available, select an alternative according to the right chart.
BRAKE FLUID
Specification and classification: DOT 4
!
FRONT FORK OIL
Use fork oil SS8 or an equivalent fork oil.
ENGINE COOLANT
Use an anti-freeze/engine coolant compatible with an aluminum radiator, mixed with distilled water only.
WATER FOR MIXING
Use distilled water only. Water other than distilled water can corrode and clog the aluminum radiator.
Since the brake system of this motorcycle is filled with a glycol-based brake fluid by the manufacturer, do not use or mix different types of fluid such as silicone-based and petroleum-based
fluid for refilling the system, otherwise serious damage will result.
Do not use any brake fluid taken from old or used or unsealed containers.
Never re-use brake fluid left over from a previous servicing, which has been stored for a long
period.
1-6 GENERAL INFORMATION
ANTI-FREEZE/ENGINE COOLANT
The engine coolant perform as a corrosion and rust inhibitor as well as anti-freeze. Therefore, the engine
coolant should be used at all times even though the atmospheric temperature in your area does not go down
to freezing point.
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.
LIQUID AMOUNT OF WATER/ENGINE COOLANT
Solution capacity (total): 1 900 ml (4.01/3.34 US/lmp qt)
For engine coolant mixture information, refer to cooling system section, page 6-2
"
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. The future performance and reliability of the engine depends on the care and restraint
exercised during its early life. The general rules are as follows.
• Keep to these break-in engine speed limits:
Initial 800 km ( 500 miles): Below 5 000 r/min
Up to 1 600 km (1 000 miles): Below 7 500 r/min
Over to 1 600 km (1 000 miles): Below 10 500 r/min
• Upon reaching an odometer reading of 1 600 km (1 000 miles) you can subject the motorcycle to full throttle operation. However, do not exceed 10 500 r/min at any time.
Mixing of anti-freeze/engine coolant should be limited to 60 %. Mixing beyond it would reduce
its efficiency. If the anti-freeze/engine coolant mixing ratio is below 50 %, rust inhabiting performance is greatly reduced. Be sure to mix it above 50 % even though the atmospheric temperature does not go down to the freezing point.
GENERAL INFORMATION 1-7
CYLINDER IDENTIFICATION
The two cylinders of this engine are identified as NO.1 and NO.2 cylinder, as viewed from front to rear .
*5
*4
NO.2
NO.1
1-8 GENERAL INFORMATION
INFORMATION LABELS
A: Attached
*1: For E-28 (French) *2: Except for E-28 *3: For E-28 *4: These labels are attached on the right frame.
*5: This label is attached on the up side of chain cover.
DL650 DL650UE
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 Manual notice label A (For E-03, 33)
6 Frame caution plate A A
7 Screen warning label A A
8 Steering warning label A A
9 Tire information label A A
0 Warning safety label A A
A ICES Canada label A (For E-28)
B ID plate A (Except for E-03, 28, 33) A
C Safety plate A (For E-03, 28, 33)
D Rear carrier warning label A A (For English)
*5
*4
*1
*2 *3
GENERAL INFORMATION 1-9
SPECIFICATIONS
DIMENSIONS AND DRY MASS
Overall length ................................................................ 2 290 mm (90.2 in)
Overall width ................................................................. 840 mm (33.1 in)
Overall height ................................................................ 1 390 mm (54.7 in) ..... Low windshield position (STD)
1 420 mm (55.9 in) ..... Middle windshield position
1 450 mm (57.1 in) ..... High windshield position
Wheelbase .................................................................... 1 540 mm (60.6 in)
Ground clearance.......................................................... 165 mm ( 6.5 in)
Seat height .................................................................... 820 mm (32.3 in)
Dry mass ....................................................................... 190 kg (418 lbs)
ENGINE
Type .............................................................................. 4-stroke, liquid-cooled, DOHC, 90 °-degree V-twin
Number of cylinders ...................................................... 2
Bore............................................................................... 81.0 mm (3.189 in)
Stroke............................................................................ 62.6 mm (2.465 in)
Displacement ................................................................ 645 cm³ (39.4 cu.in)
Compression ratio ......................................................... 11.5 : 1
Carburetion ................................................................... Fuel injection
Air cleaner ..................................................................... Non-woven fabric element
Starter system ............................................................... Electric
Lubrication system ........................................................ Wet sump
Idle speed...................................................................... 1 300 ± 100 r/min
DRIVE TRAIN
Clutch ............................................................................ Wet multi-plate type
Transmission................................................................. 6-speed constant mesh
Gearshift pattern ........................................................... 1-down, 5-up
Primary reduction ratio .................................................. 2.088 (71/34)
Final reduction ratio....................................................... 3.133 (47/15)
Gear ratios, Low ........................................................... 2.461 (32/13)
2nd............................................................ 1.777 (32/18)
3rd............................................................. 1.380 (29/21)
4th............................................................. 1.125 (27/24)
5th............................................................. 0.961 (25/26)
Top............................................................ 0.851 (23/27)
Drive chain .................................................................... DID 525 V8, 116 links
1-10 GENERAL INFORMATION
CHASSIS
Front suspension .......................................................... Telescopic, coil spring, oil damped
Rear suspension ........................................................... Link type, coil spring, oil damped
Front fork stroke............................................................ 150 mm (5.9 in)
Rear wheel travel .......................................................... 150 mm (5.9 in)
Caster ........................................................................... 26 °
Trail ............................................................................... 110 mm (4.33 in)
Steering angle............................................................... 40 ° (right & left)
Turning radius ............................................................... 2.6 m (8.5 ft)
Front brake.................................................................... Disc brake, twin
Rear brake .................................................................... Disc brake
Front tire size ................................................................ 110/80 R19 M/C 59H, tubeless
Rear tire size................................................................. 150/70 R17 M/C 69H, tubeless
ELECTRICAL
Ignition type................................................................... Electronic ignition (Transistorized)
Ignition timing................................................................ 4 ° B.T.D.C. at 1 300 r/min
Spark plug..................................................................... NGK CR8E, or DENSO U24ESR-N
Battery........................................................................... 12V 36.0 kC (10 Ah)/10 HR
Generator...................................................................... Three-phase A.C. generator
Main fuse ...................................................................... 30 A
Fuse.............................................................................. 15/15/10/10/15/15 A
Headlight....................................................................... 12 V 60/55 W × 2 (H4)
Position/Parking light .................................................... 12 V 5 W × 2................. Except E-03, 24, 33
Brake light/Taillight........................................................ 12 V 21/5 W × 2
License plate light ......................................................... 12 V 5 W
Turn signal light............................................................. 12 V 21 W
Speedometer light......................................................... LED
Turn signal indicator light .............................................. LED
Neutral indicator light .................................................... LED
High beam indicator light .............................................. LED
Oil pressure/Coolant temperature/
Fuel injection warning light............................................ LED
CAPACITIES
Fuel tank, including reserve .......................................... 22 L (5.8/4.8 US/lmp gal)
Engine oil, oil change................................................... 2 300 ml (2.4/2.0 US/lmp qt)
with filter change ........................................ 2 700 ml (2.9/2.4 US/lmp qt)
overhaul ..................................................... 3 100 ml (3.3/2.7 US/lmp qt)
Coolant.......................................................................... 1.9 L (2.0/1.7 US/lmp qt)
These specifications are subject to change without notice.
GENERAL INFORMATION 1-11
COUNTRY AND AREA CODES
The following codes stand for the applicable country (-ies) and area (-s).
MODEL CODE COUNTRY or AREA
DL650
E-02
E-03
E-19
E-24
E-28
E-33
U.K.
U.S.A. (Except for california)
EU
Australia
Canada
California (U.S.A.)
DL650-UE E-19 EU
2
6
PERIODIC MAINTENANCE 2-1
CONTENTS
PERIODIC MAINTENANCE
PERIODIC MAINTENANCE SCHEDULE .....................................................2- 2
PERIODIC MAINTENANCE CHART .....................................................2- 2
LUBRICATION POINTS .........................................................................2- 4
MAINTENANCE AND TUNE-UP PROCEDURES ........................................2- 5
AIR CLEANER .......................................................................................2- 5
SPARK PLUG ........................................................................................2- 6
VALVE CLEARANCE ............................................................................2- 8
FUEL LINE .............................................................................................2-13
ENGINE OIL AND OIL FILTER ..............................................................2-13
ENGINE IDLE SPEED ............................................................................2-15
THROTTLE CABLE PLAY .....................................................................2-15
THROTTLE VALVE SYNCHRONIZATION ............................................2-16
EVAPORATIVE EMISSION CONTROL SYSTEM (E-33 ONLY) ...........2-16
PAIR (AIR SUPPLY) SYSTEM ...............................................................2-16
CLUTCH .................................................................................................2-17
COOLING SYSTEM ...............................................................................2-18
DRIVE CHAIN .........................................................................................2-20
BRAKE ...................................................................................................2-22
TIRE ........................................................................................................2-26
STEERING ..............................................................................................2-26
FRONT FORK ........................................................................................2-27
REAR SUSPENSION .............................................................................2-27
EXHAUST PIPE BOLT ...........................................................................2-27
CHASSIS BOLT AND NUT ....................................................................2-28
COMPRESSION PRESSURE CHECK .........................................................2-30
COMPRESSION TEST PROCEDURE ...................................................2-30
OIL PRESSURE CHECK ..............................................................................2-31
2-2 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 kilometers, miles and time for your convenience.
IMPORTANT: The periodic maintenance intervals and service requirements have been established in
accordance with EPA regulations. Following these instructions will ensure that the motorcycle will not
exceed emission standards and it will also ensure the reliability and performance of the motorcycle.
NOTE:
More frequent servicing may be performed on motorcycles that are used under severe conditions.
PERIODIC MAINTENANCE CHART
Interval
Item
km 1 000 6 000 12 000 18 000 24 000
miles 600 4 000 7 500 11 000 14 500
months 2 12 24 36 48
Air cleaner element — I I R I
Exhaust pipe bolts and muffler bolts T T T T T
Valve clearance — — — — I
Spark plugs — I R I R
Fuel line — I I I I
Replace every 4 years.
Engine oil R R R R R
Engine oil filter R — — R —
Idle speed I I I I I
Throttle cable play I I I I I
Throttle valve synchronization I — I — I
(E-33 only)
Evaporative emission control system
(E-33 only)
— — I — I
Replace vapor hose every 4 years.
PAIR (air supply) system — — I — I
Engine coolant Replace every 2 years.
Radiator hoses — I I I I
Replace every 4 years.
Clutch — I I I I
Drive chain I I I I I
Clean and lubricate every 1 000 km (600 miles).
Brakes I I I I I
Brake hose — I I I I
Replace every 4 years.
PERIODIC MAINTENANCE 2-3
NOTE:
I=Inspect and clean, adjust, replace or lubricate as necessary;
R=Replace; T=Tighten
Interval
Item
km 1 000 6 000 12 000 18 000 24 000
miles 600 4 000 7 500 11 000 14 500
months 2 12 24 36 48
Brake fluid — I I I I
Replace every 2 years.
Tires — I I I I
Steering I — I — I
Front forks — — I — I
Rear suspension — — I — I
Chassis bolts and nuts T T T T T
2-4 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.
NOTE:
* Before lubricating each part, clean off any rusty spots and wipe off any grease, oil, dirt or grime.
* Lubricate exposed parts which are subject to rust, with a rust preventative spray whenever the motorcycle
has been operated under wet or rainy conditions.
1 Clutch lever holder
2 Side-stand pivot
and spring hook
3 Footrest pivot
4 Drive chain
5 Brake lever holder
and throttle cables
6 Brake pedal pivot
and footrest pivot
PERIODIC MAINTENANCE 2-5
MAINTENANCE AND TUNE-UP PRO-
CEDURES
This section describes the servicing procedures for each item of
the Periodic Maintenance requirements.
AIR CLEANER
• Remove the seat. (!7-4)
• Remove the fuel tank. (!5-7)
• Remove the air cleaner box cap
1.
• Remove the air cleaner element 2.
• Carefully use air hose to blow the dust from the cleaner element.
"
• Install the O-ring 3 properly.
• Reinstall the cleaned or new air cleaner element in the
reverse order of removal.
"
Inspect every 6 000 km (4 000 miles, 12 months) and
replace every 18 000 km (11 000 miles, 36 months).
Always use air pressure on the throttle body 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.
If driving under dusty condition, clean the air cleaner
element more frequently. The surest way to accelerate
engine wear is to use the engine without the element
or to use a ruptured element. Make sure that the air
cleaner is in good condition at all times. Life of the
engine depends largely on this component!
2-6 PERIODIC MAINTENANCE
NOTE:
When cleaning the air cleaner element, drain water from the air
cleaner by removing the drain plug.
SPARK PLUG
NO.1 (FRONT) SPARK PLUG REMOVAL
• Remove the cowling. (!7-5).
• Remove the radiator mounting bolt
1.
• Move the radiator lower side to forward.
• Remove the spark plug cap 2.
NOTE:
Be careful not to damage the radiator fins.
#
• Remove the spark plug with the special tool.
$09930-10121: Spark plug socket wrench set
Inspect every 6 000 km (4 000 miles, 12 months) and
replace every 12 000 km (7 500 miles, 24 months).
The hot radiator and the hot engine can burn you. Wait
until the radiator and the engine are cool enough to
touch.
PERIODIC MAINTENANCE 2-7
NO.2 (REAR) SPARK PLUG REMOVAL
• Remove the seat. (!7-4)
• Lift and support the fuel tank. (!5-7)
• Remove the spark plug cap.
• Remove the spark plug with the special tool.
$09930-10121: Spark plug socket wrench set
HEAT RANGE
• Check to see the heat range of the plug.
CARBON DEPOSIT
• Check to see if there are carbons deposit on the plugs. If carbon is deposited, remove it with a spark plug cleaner machine
or carefully using a tool with a pointed end.
SPARK PLUG GAP
• Measure the plug gap with a thickness gauge. If out of specification, adjust it to the following gap.
% Spark plug gap
A
Standard: 0.7 – 0.8 mm (0.028 – 0.031 in)
$ 09900-20803: Thickness gauge
ELECTRODES CONDITION
• Check to see the worn or burnt condition of the electrodes. If it
is extremely worn or burnt, replace the plug. And also replace
the plug if it has a broken insulator, damaged thread.
"
Standard Cold type Hot type
NGK CR8E CR9E CR7E
DENSO U24ESR-N U27ESR-N U22ESR-N
Confirm the thread size and reach when replacing the
plug. If the reach is too short, carbon will be deposited
on the screw portion of the plug hole and engine damage may result.
2-8 PERIODIC MAINTENANCE
SPARK PLUG AND PLUG CAP INSTALLATION
"
• Install the spark plugs to the cylinder heads by finger tight,
and then tighten them to the specified torque.
& Spark plug: 11 N·m (1.1 kgf-m, 8.0 lb-ft)
NOTE:
When fitting the spark plug caps, front and rear, face the triangle
mark
A on the water-proof cover to each cylinder exhaust side.
VALVE CLEARANCE
• Remove the seat. (!7-4)
• Lift and support the fuel tank. (!5-7)
• Remove the spark plugs. (!2-6)
• Remove the cylinder head covers.
The valve clearance specification is different for intake and
exhaust valves.
Valve clearance must be checked and adjusted, 1) at the time of
periodic inspection, 2) when the valve mechanism is serviced,
and 3) when the camshafts are disturbed by removing them for
servicing.
% Valve clearance (when cold)
IN. : 0.10 – 0.20 mm (0.004 – 0.008 in)
EX. : 0.20 – 0.30 mm (0.008 – 0.012 in)
NOTE:
* The valve clearance should be taken when each cylinder is at
Top Dead Center (TDC) of compression stroke.
* The cams (IN & EX) on the front cylinder at position A show
the front cylinder at TDC of compression stroke.
* The cams (IN & EX) on the rear cylinder at position B show
the rear cylinder at TDC of compression stroke.
* The clearance specification is for COLD state.
* To turn the crankshaft for clearance checking, be sure to use a
17-mm wrench, and rotate in the normal running direction. All
spark plugs should be removed.
Before using a spark plug wrench, carefully turn the
spark plug by finger into the threads of the cylinder
head to prevent damage the aluminum threads.
Inspect every 24 000 km (15 000 miles, 48 months).
PERIODIC MAINTENANCE 2-9
• Remove the generator cover plug
1 and timing inspection
plug 2.
• Turn the crankshaft to set the No.1 (Front) cylinder at TDC of
compression stroke. (Align the “F | T” line on the generator
rotor to the index mark of valve timing inspection hole and
also bring the camshafts to the position as shown in page
2-8.)
• To inspect the No.1 (Front) cylinder valve clearance, use a
thickness gauge between the tappet and the cam. If the clearance is out of specification, adjust it into the specified range.
$ 09900-20803: Thickness gauge
• Turn the crankshaft 270 degrees (3/4 turns) to set the No.2
(Rear) cylinder at TDC of compression stroke. (Align the
“R | T” line on the generator rotor to the index mark of valve
timing inspection hole and also bring the camshafts to the
position as shown in page 2-8.)
• Inspect the No.2 (Rear) cylinder valve clearance as the same
manner of No.1 (Front) cylinder and adjust the clearance if
necessary.
$ 09900-20803: Thickness gauge
F
R
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. (!3-21, 23)
• Remove the tappet and shim by fingers or magnetic hand.
• Check the figures printed on the shim. These figures indicate
the thickness of the shim, as illustrated.
• Select a replacement shim that will provide a clearance within
the specified range. For the purpose of this adjustment, a total
of 21 sizes of tappet shim are available ranging from 1.20 to
2.20 mm in steps of 0.05 mm. Fit the selected shim to the
valve stem end, with numbers toward tappet. Be sure to
check shim size with micrometer to ensure its size.
Refer to the tappet shim selection table (Pages 2-11 and - 12)
for details.
NOTE:
* Be sure to apply engine oil to tappet shim top and bottom
faces.
* When seating the tappet shim, be sure to face figure printed
surface to the tappet.
"
• After replacing the tappet shim and camshafts, rotate the
engine so that the tappet is depressed fully. This will squeeze
out oil trapped between the shim and the tappet that could
cause an incorrect measurement, then check the clearance
again to confirm that it is within the specified range.
• After finishing the valve clearance adjustment, reinstall the following items.
• When installing the cylinder head cover, do not forget the gasket
A.
• Install the following items.
* Cylinder head cover (!3-106)
* Spark plug and plug cap (!2-8)
* Valve timing inspection plug (!3-108)
* Generator cover plug (!3-108)
Reinstall the camshafts as the specified manner.
(!3-99)
165
1.65 mm
PERIODIC MAINTENANCE 2-11
(INTAKE SIDE)
M
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m m 2-12 PERIODIC MAINTENANCE
(EXHAUST SIDE)
M
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m m PERIODIC MAINTENANCE 2-13
FUEL LINE
• Lift and support the fuel tank. (!5-7)
• Inspect the fuel feed hose
A for damage and fuel leakage. If
any defects are found, the fuel hoses must be replaced.
ENGINE OIL AND OIL FILTER
Oil should be changed while the engine is warm. Oil filter
replacement at the above intervals, should be done together
with the engine oil change.
ENGINE OIL REPLACEMENT
• Keep the motorcycle upright.
• Place an oil pan below the engine, and drain oil by removing
the drain plug 1 and filler cap 2.
• Tighten the drain plug 3 to the specified torque, and pour
fresh oil through the oil filler. The engine will hold about 2.7 L
(2.9/2.4 US/Imp qt) of oil. Use an API classification of SF or
SG oil with SAE 10W-40 viscosity.
& Oil drain plug: 21 N·m (2.1 kgf-m, 15.0 lb-ft)
Inspect every 6 000 km (4 000 miles, 12 months).
Replace every 4 years.
(ENGINE OIL)
Replace initially at 1 000 km (600 miles, 2 month) and
every 6 000 km (4 000 miles, 12 months) thereafter.
(OIL FILTER)
Replace initially at 1 000 km (600 miles, 2 month) and
every 18 000 km (11 000 miles, 36 months) thereafter.
2-14 PERIODIC MAINTENANCE
• Start up the engine and allow it to run for several minutes at
idling speed.
• Turn off the engine and wait about one minute, then check the
oil level through the inspection window
A. If the level is below
mark “L”, add oil to “F” level. If the level is above mark “F”,
drain oil to “F” level.
OIL FILTER REPLACEMENT
• Drain engine oil in the same manner of engine oil replacement
procedure.
• Remove the oil filter 1 with the special tool.
$09915-40610: Oil filter wrench
• Apply engine oil lightly to the gasket of the new filter 2 before
installation.
• Install the new filter turning it by hand until you feel that the filter gasket contacts the mounting surface. Then tighten it 2
turns with the special tool.
$ 09915-40610: Oil filter wrench
NOTE:
* To properly tighten the filter, use the special tool. Never
tighten the filter by hand.
* After contcting the gasket, tighten 2 turns.
• Pour fresh engine oil and check the oil level in the same manner of engine oil replacement procedure.
% Engine oil capacity
Oil change: 2.3 L (2.4/2.0 US/Imp qt)
Filter change: 2.7 L (2.9/2.4 US/Imp qt)
Engine overhaul: 3.1 L (3.3/2.7 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), filtering performance and durability which may lead to
engine damage or oil leaks. Also, do not use a genuine
Suzuki automobile oil filter on this motorcycle.
PERIODIC MAINTENANCE 2-15
ENGINE IDLE SPEED
NOTE:
Make this adjustment when the engine is hot.
• Start up the engine and set its idle speed to the specified
range by turning the throttle stop screw
1.
% Engine idle speed: 1 300 ± 100 r/min
THROTTLE CABLE PLAY
Adjust the throttle cable play A with the following three steps.
MINOR ADJUSTMENT
First step:
• Remove the cable adjuster covers 1.
• Loosen the lock-nut 2 of the throttle returning cable 3 and
turn in the adjuster 4 fully into the threads.
Second step:
• Loosen the lock-nut 5 of the throttle pulling cable 6.
• Turn the adjuster 7 in or out until the throttle cable play A
should be 2.0 – 4.0 mm (0.08 – 0.16 in) at the throttle grip.
• Tighten the lock-nut 5 while holding the adjuster 7.
Third step:
• While holding the throttle grip at the fully closed position,
slowly turn out the adjuster 4 of the throttle returning cable 1
to feel resistance.
• Tighten the lock-nut 3 while holding the adjuster 4.
% Throttle cable play A: 2.0 – 4.0 mm (0.08 – 0.16 in)
#
NOTE:
Major adjustment can be made by the throttle body side
adjuster.
Inspect initially at 1 000 km (600 miles, 2 month) and
every 6 000 km (4 000 miles, 12 months) thereafter.
Inspect initially at 1 000 km (600 miles, 2 month) and
every 6 000 km (4 000 miles, 12 months) thereafter.
After the adjustment is completed, check that handlebar movement does not raise the engine idle speed
and that the throttle grip returns smoothly and automatically.
2-16 PERIODIC MAINTENANCE
MAJOR ADJUSTMENT
• Remove the fuel tank. (!5-7)
• Remove the air cleaner box. (!5-15)
• Loosen the lock-nut
1 of the throttle returning cable.
• Turn the returning cable adjuster 2 to obtain proper cable
play.
• Loosen the lock-nut 3 of the throttle pulling cable.
• Turn the pulling cable adjuster 4 in or out until the throttle
cable play A should be 2.0 – 4.0 mm (0.08 – 0.16 in) at the
throttle grip.
• Tighten the lock-nut 3 securely while holding the adjuster 4.
%'Throttle cable play A: 2.0 – 4.0 mm (0.08 – 0.16 in)
• While holding the throttle grip at the fully closed position,
slowly turn the returning cable adjuster 2 to obtain a slack of
1.0 mm (0.04 in).
• Tighten the lock-nut 1 securely.
#
THROTTLE VALVE SYNCHRONIZATION
Inspect the throttle valve synchronization periodically.
(!5-32)
EVAPORATIVE EMISSION CONTROL SYS-
TEM (E-33 ONLY)
Inspect the evaporative emission control system periodically.
PAIR (AIR SUPPLY) SYSTEM
Inspect the PAIR (air supply) system periodically. (!10-6)
After the adjustment is completed, check that handlebar movement does not raise the engine idle speed
and that the throttle grip returns smoothly and automatically.
Inspect initially at 1 000 km (600 miles, 2 months) (E-33
only) and every 12 000 km (7 500 miles, 24 months).
Inspect every 12 000 km (7 500 miles, 24 months).
Replace vapor hose every 4 years.
Inspect every 12 000 km (7 500 miles, 24 months).
PERIODIC MAINTENANCE 2-17
CLUTCH
• Loosen the lock-nut
1 and turn the adjuster 2 all the way
into the clutch lever assembly.
• Remove the engine sprocket cover.
• Loosen the lock-nut 3 and turn out the adjusting screw 4
two or three rotations.
• From that position, slowly turn the adjuster screw 3 in until it
stops.
• Turn the adjuster screw 3 out 1/4 rotation, and tighten the
lock-nut 4.
• Loosen the lock-nuts 5, turn the cable adjuster 6 to obtain
10 – 15 mm (0.4 – 0.6 in) of free play A at the clutch lever
end.
• Tighten the lock-nuts 5.
% Clutch cable play A: 10 – 15 mm (0.4 – 0.6 in)
Clutch release screw: 1/4 turns back.
Inspect every 6 000 km (4 000 miles, 12 months).
2-18 PERIODIC MAINTENANCE
COOLING SYSTEM
ENGINE COOLANT LEVEL CHECK
• Keep the motorcycle upright.
• Check the engine coolant level by observing the full and lower
lines on the engine coolant reserve tank.
A Full line B Lower line
• If the level is below the lower line, add engine coolant to the
full line from the engine coolant reserve tank filler. To remove
the filler cap, remove the left fuel tank side cover. (!7-4)
ENGINE COOLANT CHANGE
• Remove the left cowling. (!7-5)
• Remove the radiator cap 1.
• Drain the engine coolant by removing the drain bolt A.
#
• Flush the radiator with fresh water if necessary.
• Tighten the water drain bolt A to the specified torque.
& Water drain bolt: 13 N·m (1.3 kgf-m, 9.5 lb-ft)
• Pour the specified engine coolant up to the radiator inlet.
• Bleed the air from the engine coolant circuit as following procedure.
NOTE:
For engine coolant information, refer to page 6-2.
Inspect every 6 000 km (4 000 miles, 12 months).
Replace engine coolant every 2 years.
Replace radiator hoses every 4 years.
* 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. If engine coolant
gets into the eyes or in contact with the skin, flush
thoroughly with plenty of water. If swallowed, induce
vomiting and call physician immediately!
PERIODIC MAINTENANCE 2-19
AIR BLEEDING THE COOLING CIRCUIT
• Add engine coolant up to the radiator inlet.
• Support the motorcycle upright.
• Slowly swing the motorcycle, right and left, to bleed the air
trapped in the cooling circuit.
• Add engine coolant up to the radiator inlet.
• Start up the engine and bleed air from the radiator inlet completely.
• Lightly tap the thermostat case
1 and slowly swing the motorcycle, right and left, to bleed the air trapped in the thermostat
case 1.
• Add engine coolant up to the radiator inlet.
• Repeat the above procedure until bleed no air from the radiator inlet.
• Close the radiator cap 2 securely.
• After warming up and cooling down the engine several times,
add the engine coolant up to the full level of the reserve tank.
• Install the cowling. (!7-8)
"
( Engine coolant capacity
Reverse tank side: 250 ml (0.53/0.44 US/Imp qt)
Engine side: 1 650 ml (3.49/2.90 US/Imp qt)
Repeat the above procedure several times and make
sure that the radiator is filled with engine coolant up to
the reserve tank full level.
2-20 PERIODIC MAINTENANCE
RADIATOR HOSES
• Remove the cowling. (!7-5)
• 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.
DRIVE CHAIN
Visually check the drive chain for the possible defects listed
below. (Support the motorcycle by a jack and a wooden block,
turn the rear wheel slowly by hand with the transmission shifted
to Neutral.)
* Loose pins * Excessive wear
* Damaged rollers * Improper chain adjustment
* Dry or rusted links * Missing O-ring seals
* Kinked or binding links
1 O-ring
2 Grease
If any defects are found, the drive chain must be replaced.
NOTE:
When replacing the drive chain, replace the drive chain and
sprockets as a set.
CHECKING
• Remove the cotter pin. (For E-03, 28, 33)
• Loosen the axle nut 1.
• Tense the drive chain fully by turning both chain adjusters 2.
Inspect initially at 1 000 km (600 miles, 2 month) and
every 6 000 km (4 000 miles, 12 months) thereafter.
Clean and Lubricate every 1 000 km (600 miles).
PERIODIC MAINTENANCE 2-21
• Count out 21 pins (20 pitches) on the chain and measure the
distance between the two points. If the distance exceeds the
service limit, the chain must be replaced.
% Drive chain 20-pitch length
Service Limit: 319.4 mm (12.57 in)
ADJUSTING
• Loosen or tighten both chain adjusters
1 until the chain has
20 – 30 mm (0.8 – 1.2 in) of slack A in the middle between
engine and rear sprockets. The ends of left and right spacers
must be at the same position on the scales B to ensure that
the front and rear wheels are correctly aligned.
• Place the motorcycle on its side-stand for accurate adjustment.
• After adjusting the drive chain, tighten the axle nut 2 to the
specified torque.
• Recheck the drive chain slack after tightening the axle nut 1.
& Rear axle nut: 100 N·m (10.0 kgf-m, 72.5 lb-ft)
1 2 3 19 20 21
2-22 PERIODIC MAINTENANCE
CLEANING AND LUBRICATING
• Wash the chain with kerosene. If the chain tends to rust
quickly, the intervals must be shortened.
"
• After washing and drying the chain, oil it with a heavy-weight
motor oil.
"
BRAKE
BRAKE FLUID LEVEL CHECK
• Keep the motorcycle upright and place the handlebars
straight.
• Check the brake fluid level by observing 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.
) Specification and Classification: DOT 4
Do not use trichlene, gasoline or any similar fluids:
These fluids have too great a dissolving power for this
chain and, what is more important, they can damage
the “O”-rings (or seals) confining the grease in the
bush to pin clearance. Remember, high durability
comes from the presence of grease in that clearance.
* Do not use any oil sold commercially as “drive chain
oil”. Such oil can damage the “O”-rings (or seals).
* The standard drive chain is DID525V8. SUZUKI recommends that this standard drive chain should be
used for the replacement.
(BRAKE)
Inspect initially at 1 000 km (600 miles, 2 month) 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. Replace fluid every 2
years.
PERIODIC MAINTENANCE 2-23
#
#
BRAKE PADS
• Remove the brake caliper. (Front)
• The extent of brake pad wear can be checked by observing
the grooved limit
A on the pad. When the wear exceeds the
grooved limit, replace the pads with the new ones. (!7-59
and - 69)
"
The brake system of this motorcycle is filled with a
glycol-based brake fluid. Do not use or mix different
types of fluid such as silicone-based or petroleum-based. Do not use any brake fluid taken from
old, used or unsealed containers. Never re-use brake
fluid left over from the last servicing or stored for a
long period.
Brake fluid, if it leaks, will interfere with safe running
and immediately discolor painted surfaces. Check the
brake hoses and hose joints for cracks and oil leakage
before riding.
UPPER
LOWER
Replace the brake pad as a set, otherwise braking performance will be adversely affected.
2-24 PERIODIC MAINTENANCE
BRAKE PEDAL HEIGHT
• Loosen the lock-nut
1 and rotate the push rod 2 to locate
brake pedal 20 – 30 mm (0.59 – 0.98 in) A below the top face
of the footrest.
• Retighten the lock-nut 1 to secure the push rod 2 in the
proper position.
% Brake pedal height A: 20 – 30 mm (0.79 – 1.18 in)
& Rear brake master cylinder rod lock-nut 1:
17 N·m (1.7 kgf-m, 12.5 lb-ft)
REAR BRAKE SWITCH
Adjust the rear brake switch so that the brake light will come on
just before pressure is felt when the brake pedal is depressed.
PERIODIC MAINTENANCE 2-25
AIR BLEEDING THE BRAKE FLUID CIRCUIT
Air trapped in the fluid circuit acts like a cushion to absorb a
large proportion of the pressure developed by the master cylinder and thus interferes with the full braking performance of the
brake caliper. The presence of air is indicated by “sponginess”
of the brake lever and also by lack of braking force. Considering
the danger to which such trapped air exposes the machine and
rider, it is essential that, after remounting the brake and restoring the brake system to the normal condition, the brake fluid circuit be purged of air in the following manner:
• Fill up the master cylinder reservoir to the “UPPER” line.
Place the reservoir cap to prevent entry of dirt.
• Attach a pipe to the air bleeder valve, and insert the free end
of the pipe into a receptacle.
& Air bleeder valve (Front): 7.5 N·m (0.75 kgf-m, 5.5 lb-ft)
Air bleeder valve (Rear): 6 N·m (0.6 kgf-m, 4.3 lb-ft)
• Front brake: Bleed the air from the air bleeder valve.
• Squeeze and release the brake lever several times in rapid
succession and squeeze the lever fully without releasing it.
Loosen the bleeder valve by turning it a quarter of a turn so
that the brake fluid runs into the receptacle; this will remove
the tension of the brake lever causing it to touch the handlebar grip. Then, close the valve, pump and squeeze the lever,
and open the valve. Repeat this process until the fluid flowing
into the receptacle no longer contains air bubbles.
NOTE:
Replenish the brake fluid in the reservoir as necessary while
bleeding the brake system. Make sure that there is always some
fluid visible in the reservoir.
• Close the bleeder valve, and disconnect the pipe. Fill the reservoir with brake fluid to the “UPPER” line.
"
• The only difference between bleeding the front and rear
brakes is that the rear master cylinder is actuated by a pedal.
Handle brake fluid with care: the fluid reacts chemically with paint, plastics, rubber materials and so on.
2-26 PERIODIC MAINTENANCE
TIRE
TIRE TREAD CONDITION
Operating the motorcycle with excessively worn tires will
decrease riding stability and consequently invite a dangerous
situation. It is highly recommended to replace a tire when the
remaining depth of tire tread reaches the following specification.
$ 09900-20805: Tire depth gauge
% Tire tread depth
Service Limit (FRONT) : 1.6 mm (0.06 in)
(REAR) : 2.0 mm (0.08 in)
TIRE PRESSURE
If the tire pressure is too high or too low, steering will be
adversely affected and tire wear increased. Therefore, maintain
the correct tire pressure for good roadability or shorter tire life
will result. Cold inflation tire pressure is as follows.
"
TIRE TYPE
BRIDGESTONE (Front : TW101F Rear : TW152F)
STEERING
Steering should be adjusted properly for smooth turning of handlebars and safe running. Overtight steering prevents smooth
turning of the handlebars and too loose steering will cause poor
stability. Check that there is no play in the steering stem while
grasping the lower fork tubes by supporting the machine so that
the front wheel is off the ground, with the wheel straight ahead,
and pull forward. If play is found, perform steering bearing
adjustment as described in page 7-31 of this manual.
Inspect every 6 000 km (4 000 miles, 12 months).
COLD INFLATION
TIRE PRESSURE
SOLO RINDING DUAL RIDING
kPa kgf/cm² psi kPa kgf/cm² psi
FRONT 225 2.25 33 225 2.25 33
REAR 250 2.50 36 280 2.80 41
The standard tire fitted on this motorcycle is 110/80
R19M/C (59H) for front and 150/70 R17M/C (69H) for
rear. The use of tires other than those specified may
cause instability. It is highly recommended to use a
SUZUKI Genuine Tire.
Inspect initially at 1 000 km (600 miles, 2 month) and
every 12 000 km (7 500 miles, 24 months) thereafter.
PERIODIC MAINTENANCE 2-27
FRONT FORK
Inspect the front forks for oil leakage, scoring or scratches on
the outer surface of the inner tubes. Replace any defective
parts, if necessary. (!7-17)
REAR SUSPENSION
Inspect the damper for oil leakage and the spring unit for damage. Check that there is no play in the swingarm assembly.
Replace any defective parts, if necessary. (!7-45)
EXHAUST PIPE BOLT
• Tighten the exhaust pipe bolts and muffler mounting bolts to
the specified torque.
& Muffler mounting bolt /nut
A: 23 N·m (2.3 kgf-m, 16.5 lb-ft)
Exhaust pipe bolt BCD: 23 N·m (2.3 kgf-m, 16.5 lb-ft)
* 99000-32050: THREAD LOCK ‘‘1342’’
EXHAUST GAS SEALER: PERMATEX 1372
Inspect every 12 000 km (7 500 miles, 12 months).
Inspect every 12 000 km (7 500 miles, 12 months).
Tighten initially at 1 000 km (600 miles, 2 month) and
every 6 000 km (4 000 miles, 12 months) thereafter.
Apply
PERMATEX 1372
Apply
PERMATEX 1372
2-28 PERIODIC MAINTENANCE
CHASSIS BOLT AND NUT
Check that all chassis bolts and nuts are tightened to their specified torque. (Refer to page 2-29 for the locations of the following nuts and bolts on the motorcycle.)
Tighten initially at 1 000 km (600 miles, 2 month) and
every 6 000 km (4 000 miles, 12 months) thereafter.
ITEM N·m kgf-m lb-ft
1 Steering stem head nut 90 9.0 65.0
2 Steering stem lock-nut 80 8.0 58.0
3 Front fork upper clamp bolt 23 2.3 16.5
4 Front fork lower clamp bolt 23 2.3 16.5
5 Front axle 65 6.5 47.0
6 Front axle pinch bolt 23 2.3 16.5
7 Handlebar clamp bolt 23 2.3 16.5
8 Front brake master cylinder mounting bolt 10 1.0 7.0
9 Front brake caliper mounting bolt 39 3.9 28.0
0 Brake hose union bolt 23 2.3 16.5
A Air bleeder valve (Front) 7.5 0.75 5.5
B Air bleeder valve (Rear) 6 0.6 4.3
C Brake disc bolt (Front & Rear) 23 2.3 16.5
D Rear brake caliper mounting bolt 22 2.2 16.0
E Rear brake master cylinder mounting bolt 10 1.0 7.0
F Rear brake master cylinder rod lock-nut 18 1.8 13.0
G Front footrest bracket mounting bolt 25 2.5 18.0
H Swingarm pivot nut 100 10.0 72.5
I Swingarm pivot lock-nut 90 9.0 65.0
J Rear shock absorber mounting nut
(Upper & Lower)
50 5.0 36.0
K Cusion lever nut 78 7.8 56.5
L Cusion rod nut 78 7.8 56.5
M Rear axle nut 100 10.0 72.5
N Seat rail mounting bolt 50 5.0 36.0
PERIODIC MAINTENANCE 2-29
2-30 PERIODIC MAINTENANCE
COMPRESSION PRESSURE CHECK
The compression 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 maintenance records kept at your dealership should include compression readings for each maintenance service.
COMPRESSION PRESSURE SPECIFICATION (Automatic de-comp. actuated)
Low compression pressure can indicate any of the following conditions:
* Worn-down piston or piston rings
* Piston rings stuck in grooves
* Poor seating of valves
* Ruptured or otherwise defective cylinder head gasket
Overhaul the engine in the following cases:
* Compression pressure in one of the cylinders is 1 100 kPa (11 kgf/cm², 156 psi) and less.
* Difference in compression pressure between two cylinders is 200 kPa (2 kgf/cm², 28 psi) and more.
* All compression pressure are below 1 300 kPa (13 kgf/cm², 185 psi) even when they measure 1 100 kPa
(11 kgf/cm², 156 psi) and more.
COMPRESSION TEST PROCEDURE
NOTE:
* Before testing the engine for compression pressure, make
sure that the cylinder head bolts are tightened to the specified
torque values and valves are properly adjusted.
* Have the engine warmed up by idling before testing.
* Be sure that the battery used is in fully-charged condition.
Remove the parts concerned and test the compression pressure
in the following manner.
• Lift and support the fuel tank. (!5-7)
• Remove all the spark plugs. (!2-6)
• Fit the compression gauge in one of the plug holes, while taking care of the tight connection.
• Keep the throttle grip in full-open position.
• While cranking the engine a few seconds with the starter, and
record the maximum gauge reading as the compression of
that cylinder.
• Repeat this procedure with an other cylinder.
$ 09915-64512: Compression gauge
09913-10750: Adaptor
Standard Limit Difference
1 300 – 1 700 kPa
13 – 17 kgf/cm²
185 – 242 psi( )
1 100 kPa
11 kgf/cm²
156 psi( )
200 kPa
2 kgf/cm²
28 psi( )
PERIODIC MAINTENANCE 2-31
OIL PRESSURE CHECK
Check periodically the oil pressure in the engine to judge roughly the condition of the moving parts.
OIL PRESSURE SPECIFICATION
If the oil pressure is lower or higher than the specification, the following causes may be considered.
LOW OIL PRESSURE
* Clogged oil filter
* Oil leakage from the oil passage way
* Damaged O-ring
* Defective oil pump
* Combination of the above items
HIGH OIL PRESSURE
* Used of high viscosity engine oil
* Clogged oil passage way
* Combination of the above items
OIL PRESSURE TEST PROCEDURE
Start the engine and check if the oil pressure indicator light is
turned on. If it keeps on lighting, check the oil pressure indicator
light circuit. If it is in good condition, check the oil pressure in the
following manner.
• Remove the main oil gallery plug
1.
• Install the oil pressure gauge with attachment in the position
shown in the figure.
• Warm up the engine as follows:
Summer 10 min. at 2 000 r/min.
Winter 20 min. at 2 000 r/min.
• After warming up, increase the engine speed to 3 000 r/min.
(with the engine tachometer), and read the oil pressure
gauge.
$ 09915-74521: Oil pressure gauge hose
09915-74532: Oil pressure gauge attachment
09915-77331: Meter (for high pressure)
& Main oil gallery plug [M 8]: 18 N·m (1.8 kgf-m, 13.0 lb-ft)
Above 100 kPa (1.0 kgf/cm², 14 psi)
Below 400 kPa (4.0 kgf/cm², 57 psi)
at 3 000 r/min., Oil temp. at 60 °C (140 °F)
ENGINE 3-1
ENGINE
CONTENTS
3
ENGINE COMPONENTS REMOVABLE WITH THE ENGINE IN PLACE....3- 2
ENGINE REMOVAL AND INSTALLATION...................................................3- 3
ENGINE REMOVAL ................................................................................3- 3
ENGINE INSTALLATION........................................................................3-11
ENGINE DISASSEMBLY...............................................................................3-19
ENGINE TOP SIDE .................................................................................3-19
ENGINE BOTTOM SIDE .........................................................................3-26
ENGINE COMPONENTS INSPECTION AND SERVICING ..........................3-36
CYLINDER HEAD COVER......................................................................3-36
CAMSHAFT/CAMSHAFT JOURNAL .....................................................3-37
CYLINDER HEAD ...................................................................................3-40
CYLINDER...............................................................................................3-50
PISTON AND PISTON RING ..................................................................3-51
CONROD AND CRANKSHAFT ..............................................................3-53
CRANKCASE ..........................................................................................3-57
CRANKSHAFT JOURNAL BEARING ....................................................3-61
CRANKCASE BEARING AND OIL SEAL ..............................................3-66
CLUTCH ..................................................................................................3-69
PRIMARY DRIVEN GEAR ASSEMBLY .................................................3-70
GEARSHIFT SHAFT/GEARSHIFT ARM ................................................3-71
TRANSMISSION .....................................................................................3-72
STARTER CLUTCH ................................................................................3-79
GENERATOR AND SIGNAL GENERATOR...........................................3-80
OIL PUMP................................................................................................3-81
CLUTCH RELEASE ................................................................................3-81
ENGINE REASSEMBLY................................................................................3-82
ENGINE BOTTOM SIDE .........................................................................3-82
ENGINE TOP SIDE .................................................................................3-94
3-2 ENGINE
ENGINE COMPONENTS REMOVABLE WITH THE ENGINE IN PLACE
Engine components which can be removed while the engine is installed on the chassis are listed below. For
the installing and removing procedures, refer to respective paragraphs describing each component.
ENGINE LEFT SIDE
ENGINE RIGHT SIDE
ENGINE CENTER
PARTS REMOVAL INSTALLATION
Engine sprocket 3-6 3-16
Generator 3-26, 3-32 3-86, 3-93
Gear position switch 3-33 3-85
Clutch release 3-5 3-17
Starter idle gear 3-26 3-93
PARTS REMOVAL INSTALLATION
Clutch 3-27 3-90
Primary driven gear 3-29, 3-70 3-70, 3-90
Primary drive gear 3-31 3-87
Oil pump 3-29 3-89
Gearshift shaft 3-30 3-89
Water pump 6-14 6-17
PARTS REMOVAL INSTALLATION
Throttle body 5-15 5-23
Cylinder head covers 3-20 3-106
Camshafts 3-21, 3-23 3-99
Cylinder heads 3-22, 3-25 3-97
Cylinders 3-23, 3-25 3-96
Pistons 3-23, 3-26 3-94
Cam chain tension adjusters 3-22, 3-24 3-101, 3-104
Thermostat 6-12 6-13
Oil filter 2-14 2-14
Oil pressure switch 3-58 3-58
Starter motor 3-26 3-94
ENGINE 3-3
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 the engine oil. (!2-13)
• Drain the engine coolant. (!2-18)
• Remove the seat. (!7-4)
• Disconnect the battery
- lead wire 1.
• Remove the fuel tank 2. (!5-7)
• Disconnect the cooling fan motor and thermo-switch lead wire
coupler. (!6-5)
• Remove the radiator and water hoses. (!6-5)
• Remove the air cleaner box 3. (!5-15)
3-4 ENGINE
• Remove the throttle body. (!5-16)
• Disconnect the spark plug caps.
• Remove the left side frame cover. (!7-5)
• Disconnect the gear position switch lead wire coupler
1.
• Disconnect the generator lead wire coupler 2 and CKP sensor lead wire coupler 3.
• Remove the ECT sensor lead wire coupler 4.
ENGINE 3-5
• Remove the gearshift lever
1.
• Remove the engine sprocket cover 2.
• Remove the clutch release assembly 3, its support plate 4
and spring 5.
• Remove the clutch push rod 6.
• Remove the clutch cable from the generator cover.
NOTE:
If it is necessary to replace the clutch cable or clutch release
lever, pry up and bend down the stopper A of the clutch release
lever.
• Flatten the lock washer.
• Remove the engine sprocket nut 7 and lock washer while
depressing the brake pedal.
3-6 ENGINE
• Remove the cotter pin. (For E-03, 28, 33)
• Loosen the rear axle nut
1.
• Loosen the chain adjusters 2.
• Remove the engine sprocket 3.
• Disconnect the engine ground lead wire 4.
• Disconnect the HO2 sensor lead wire coupler 5 and release
the HO2 sensor lead wire from the clamp 6.
• Remove the muffler mounting bolts.
ENGINE 3-7
• Remove the muffler mounting bolt
1.
• Loosen the front exhaust pipe mounting bolts 2.
• Remove the front exhaust pipe 3.
• Loosen the rear exhaust pipe mounting bolts.
• Remove the muffler.
• Remove the right footrest bracket mounting bolts.
• Remove the oil cooler 4.
3-8 ENGINE
• Disconnect the starter motor lead wire
1 and oil pressure
switch lead wire 2.
• Support the engine with an engine jack.
• Remove the engine mounting nut 3 and bolt 4.
• Loosen the engine mounting thrust adjuster lock-nut with the
special tool.
" 09940-14990: Engine mounting thrust adjuster socket
wrench
• Loosen the engine mounting thrust adjuster.
ENGINE 3-9
• Remove the left engine mounting bracket
1.
• Disconnect the ignition coil lead wires 2.
• Disconnect the water hose clamp 3.
• Remove the engine mounting nut.
• Loosen the engine mounting thrust adjuster lock-nut.
" 09940-14990: Engine mounting thrust adjuster socket
wrench
• Loosen the engine mounting thrust adjuster.
3-10 ENGINE
• Loosen the pinch bolt
1.
• Gradually lower the engine assembly by removing the bolt 2,
3.
#
Be careful not to damage the frame and engine when
removing the engine from the frame.
ENGINE 3-11
ENGINE INSTALLATION
Remount the engine in the reverse order of engine removal.
Pay attention to the following points:
NOTE:
* The engine mounting nuts are self-locking.
* Once the nut has been removed, it is no longer of any use. Be sure to use new nuts, and then tighten them
to the specified torque.
FW
D
RHLH
RHLH
ITEM N·m kgf-m lb-ft
AF 45 4.5 32.5
BG 12 1.2 8.5
C 93 9.3 67.5
D 25 2.5 18.0
EH 55 5.5 40.0
I 35 3.5 25.5
3-12 ENGINE
• Before installing the engine assembly, install the spacer
A,
collar B and engine thrust adjuster C.
• Install the collar 1 onto the crankcase properly as shown.
• Install the left engine mounting bracket 2.
• Apply THREAD LOCK to the engine mounting bracket bolts.
• Tighten the engine mounting bracket bolts to the specified
torque.
$ Engine mounting bracket bolt:
35 N·m (3.5 kgf-m, 25.5 lb-ft)
% 99000-32050: THREAD LOCK “1342”
FW
D
ENGINE 3-13
• Put the drive chain on the driveshaft.
• Gradually raise the engine assembly and align all the bolt
holes.
• Install the engine mounting bolts and tighten them temporarily.
• Tighten the engine mounting thrust adjusters to the specified
torque.
$ Engine mounting thrust adjuster:
12 N·m (1.2 kgf-m, 8.5 lb-ft)
• Tighten the engine mounting thrust adjuster lock-nuts to the
specified torque with the special tool.
" 09940-14990: Engine mounting thrust adjuster socket
wrench
$ Engine mounting thrust adjuster lock-nut:
45 N·m (4.5 kgf-m, 32.5 lb-ft)
• After tightening the engine mounting bolt, tighten the pinch
bolt
A.
$ Engine mounting bolt: 55 N·m (5.5 kgf-m, 40.0 lb-ft)
Engine mounting pinch bolt A:
25 N·m (2.5 kgf-m, 18.0 lb-ft)
• Tighten the engine mounting nuts to the specified torque.
$ Engine mounting nut A: 93 N·m (9.3 kgf-m, 67.5 lb-ft)
Engine mounting nut: 55 N·m (5.5 kgf-m, 40.0 lb-ft)
3-14 ENGINE
• Install the washers and tighten the union bolt to the specified
torque.
$ Oil cooler union bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft)
• Install the new gaskets.
• Apply THREAD LOCK to the muffler mounting bolt.
% 99000-32050: THREAD LOCK “1342”
ENGINE 3-15
$
• Adjust the brake pedal height.
& Brake pedal height
A
Standard: 20 – 30 mm (0.79 – 1.18 in)
• Install the gearshift arm as shown.
& Gearshift arm angle A: Approx. 63.6 °
Apply PARMATEX 1372
Apply PARMATEX 1372
ITEM N·m kgf-m lb-ft
ABCD 23 2.3 16.5
63.6 ˚
3-16 ENGINE
• Adjust the gearshift lever as shown.
& Gearshift lever height
A
Standard: 20 – 30 mm (0.79 – 1.18 in)
• Install the engine sprocket.
• Install the engine sprocket and the washer.
• Apply a small quantity of THREAD LOCK to the drive shaft
thread portion.
% 99000-32050: THREAD LOCK “1342”
• Tighten the engine sprocket nut 1 to the specified torque.
$ Engine sprocket nut: 145 N·m (14.5 kgf-m, 105 lb-ft)
• Bend the lock washer.
• Adjust the drive chain slack. (!2-21)
• Tighten the rear axle nut 2 to the specified torque.
$ Rear axle nut: 100 N·m (10.0 kgf-m, 72.5 lb-ft)
• Install the cotter pin. (For E-03, 28, 33)
• Apply SUZUKI SUPER GREASE to the clutch push rod and
install it.
' 99000-25030: SUZUKI SUPER GREASE “A” (USA)
99000-25010: SUZUKI SUPER GREASE “A” (Others)
ENGINE 3-17
• Install the clutch cable to the generator cover temporarily.
• Apply SUZUKI MOLY PASTE to the clutch release.
( 99000-25140: SUZUKI MOLY PASTE
\
• Assemble the clutch release so that the lever arm
A will be
angle of 80 degree with axle B.
• Adjust the clutch cable play. (!2-17)
NOTE:
After installing the clutch release, make sure that there is clearance between the clutch cable end and the driveshaft end.
3-18 ENGINE
• After installing the engine, route the wire harness, cables and
hoses properly. (!9-16)
• Adjust the following items.
* Engine oil (!2-14)
* Engine coolant (!2-19)
* Engine idle speed (!2-15)
* Throttle cable play (!2-15)
* Clutch cable play (!2-17)
* Throttle body synchronization (!5-32)
ENGINE 3-19
ENGINE DISASSEMBLY
ENGINE TOP SIDE
#
• Remove the spark plugs. (!2-6)
• Disconnect the crankcase breather hoses
1.
• Disconnect the PAIR hoses 2.
• Remove the thermostat case 3 along with the hoses 4.
NOTE:
Refer to the section 6 for their servicing.
• Remove the water unions 5 and intake pipes 6.
Identify the position of each removed part. Organize
the parts in their respective groups (e.g., intake,
exhaust) so that they can be reinstalled in their original positions.
3-20 ENGINE
• Remove the oil cooler bracket
7.
• Remove the rear exhaust pipe 8 and gasket.
• Remove the valve timing inspection plug 9 and generator
cover plug 0.
CYLINDER HEAD COVER
• Remove the front cylinder head cover 1.
• Remove the dowel pin 2 and O-ring 3.
ENGINE 3-21
• Remove the rear cylinder head cover
4.
• Remove the dowel pin 5 and O-ring 6.
FRONT CAMSHAFTS
• Turn the crankshaft to bring the “F” line A on generator rotor
to the index mark B of the valve inspection hole and also to
bring the cams to the position as shown in illustration.
NOTE:
* At the above condition, the front cylinder is at TDC of compression stroke.
* Before removing the camshafts, inspect the valve clearance.
(!2-8)
• Remove the cam chain guide 1.
3-22 ENGINE
• Remove the spring holder bolt
2, spring and gasket.
• Remove the cam chain tension adjuster 3.
• Remove the intake camshaft journal holder 4.
• Remove the exhaust camshaft journal holder 5.
NOTE:
Mark the cylinder location as “F” to the camshaft journal holders.
• Remove the dowel pins 6.
• Remove the intake camshaft 7.
• Remove the exhaust camshaft 8.
NOTE:
Do not drop the dowel pins into the crankcase.
FRONT CYLINDER HEAD
• Remove the cylinder head bolt (M6) 1.
• Remove the cylinder head bolts (M6) 2.
• Remove the cylinder head bolts 3 and washers.
NOTE:
When loosening the cylinder head bolts, loosen each bolt little
by little diagonally.
• Remove the cylinder head 4.
ENGINE 3-23
• Remove the cylinder head gasket
5, dowel pins 6 and cam
chain guide 7.
FRONT CYLINDER
• Remove the cylinder nuts 1.
• Remove the cylinder 2.
• Remove the cylinder base gasket 3 and dowel pins 4.
NOTE:
Make sure that the oil jet is inserted in the crankcase.
FRONT PISTON
• Place a clean rag over the cylinder base so as not to drop the
piston pin circlip into the crankcase.
• Remove the piston pin circlip 1.
• Remove the piston 2 by driving out the piston pin.
NOTE:
Scribe the cylinder number on the head of the piston.
REAR CAMSHAFTS
• Rotate the generator 360 degrees (1 turn) counterclockwise
and align the “F” line A on the generator rotor with the index
mark B of the valve timing inspection hole.
3-24 ENGINE
NOTE:
* At the above condition, the rear cylinder is at ATDC 90 ° on
expansion stroke.
* Before removing the camshafts, inspect the valve clearance.
(!2-8)
• Remove the cam chain guide
1.
• Remove the cam chain tension adjuster cap bolt 2, spring
and gasket.
• Remove the cam chain tension adjuster 3.
• Remove the intake camshaft journal holder 4.
• Remove the exhaust camshaft journal holder 5.
NOTE:
Mark the cylinder location as “R” to the camshaft journal holders.
• Remove the dowel pins 6.
• Remove the intake camshaft 7.
• Remove the exhaust camshaft 8.
ENGINE 3-25
REAR CYLINDER HEAD
• Remove the cylinder head bolt (M6)
1.
• Remove the cylinder bolts (M6) 2.
• Remove the cylinder head bolts 3 and washers.
NOTE:
When loosening the cylinder head bolts, loosen each bolt little
by little diagonally.
• Remove the cylinder head 4.
• Remove the cylinder head gasket 5, dowel pins 6 and cam
chain guide 7.
REAR CYLINDER
• Remove the cylinder nuts 1 and clamp.
• Remove the cylinder 2.
• Remove the cylinder base gasket 3 and dowel pins 4.
NOTE:
Make sure that the oil jet 5 is inserted in the crankcase.
3-26 ENGINE
REAR PISTON
• Place a clean rag over the cylinder base so as not to drop the
piston pin circlip into the crankcase.
• Remove the piston pin circlip
1.
• Remove the piston 2 by driving out the piston pin.
NOTE:
Scribe the cylinder number on the head of the piston.
STARTER MOTOR
• Remove the starter motor mounting bolts and the clamp 1.
• Remove the starter motor 2.
ENGINE BOTTOM SIDE
OIL FILTER
• Remove the oil filter 1 with the special tool.
" 09915-40610: Oil filter wrench
GENERATOR COVER
• Remove the generator cover 1.
• Remove the gasket 2 and dowel pins 3.
• Remove the starter idle gear 4 and its shaft 5.
ENGINE 3-27
CLUTCH COVER
• Remove the clutch cover
1.
• Remove the dowel pins 2 and gasket 3.
CLUTCH
• Hold the generator rotor 1 with the special tool.
" 09930-44530: Rotor holder
• Remove the clutch springs.
NOTE:
Loosen the clutch spring set bolts little by little and diagonally.
• Remove the pressure plate 2.
• Remove the clutch push piece 3, the bearing 4 and thrust
washer 5.
3-28 ENGINE
• Remove the clutch push rod
6.
NOTE:
If it is difficult to pull out the push rod 6, use a magnetic hand or
a wire.
• Remove the clutch drive plates and driven plates.
• Remove the spring washer 7 and spring washer seat 8.
• Flatten the clutch sleeve hub nut lock washer.
• Hold the clutch sleeve hub with the special tool.
" 09920-53740: Clutch sleeve hub holder
• Remove the clutch sleeve hub nut.
ENGINE 3-29
• Remove the lock washer
9.
• Remove the clutch sleeve hub 0.
• Remove the thrust washer A.
• Remove the primary driven gear assembly B.
• Remove the spacer C.
OIL PUMP
• Remove the snap ring 1.
• Remove the oil pump driven gear 2.
NOTE:
Do not drop the snap ring 1 into the crankcase.
• Remove the pin 3 and the washer 4.
NOTE:
Do not drop the pin 3 and washer 4 into the crankcase.
3-30 ENGINE
• Remove the oil pump
5.
GEARSHIFT SYSTEM
• Remove the snap ring 1 and washer 2.
• Remove the gearshift shaft assembly 3 and washer 4.
• Remove the gearshift cam plate bolt 5.
• Remove the gearshift cam plate 6.
• Remove the gearshift cam stopper 7.
ENGINE 3-31
• Remove the following parts.
8 Gearshift cam stopper bolt
9 Gearshift cam stopper spring
0 Washer
OIL PIPE
• Remove the oil pipe stopper 1.
• Remove the oil pipe 2.
PRIMARY DRIVE GEAR
• Hold the generator rotor with the special tool.
" 09930-44530: Rotor holder
• Remove the primary drive gear bolt.
#
This bolt has left-hand thread. Turning it counterclockwise may cause damage.
3-32 ENGINE
• Remove the water pump drive gear
1 and primary drive gear
2.
REAR CAM CHAIN
• Remove the cam chain tensioner 1.
NOTE:
Do not drop the washer 2 into the crankcase.
• Remove the rear cam chain 3 and cam chain drive sprocket
4.
GENERATOR ROTOR
• Hold the generator rotor with the special tool.
" 09930-44530: Rotor holder
• Remove the generator rotor bolt.
• Remove the generator rotor 1 with the special tools.
" 09930-30450: Rotor remover
09930-44530: Rotor holder
ENGINE 3-33
• Remove the key
2.
• Remove the starter driven gear 3.
FRONT CAM CHAIN
• Remove the cam chain tensioner 1.
NOTE:
Do not drop the washer 2 into the crankcase.
• Remove the front cam chain 3.
GEAR POSITION SWITCH
• Remove the driveshaft oil seal retainer 1.
• Remove the gear position switch 2.
3-34 ENGINE
• Remove the O-ring
3.
• Remove the switch contacts 4 and springs 5.
CRANKCASE
• Remove the oil plate 1.
• Remove the crankcase bolts and clamp 2.
NOTE:
Loosen the crankcase bolts diagonally and smaller sizes first.
• Separate the crankcase into 2 parts, right and left with the
special tool.
" 09920-13120: Crankcase separating tool
NOTE:
* Fit the crankcase separating tool, so that the tool arms are in
parallel with the side of crankcase.
* The crankshaft and transmission components should remain
in the left crankcase half.
ENGINE 3-35
• Remove the O-rings
3 and dowel pins 4.
CRANKSHAFT
• Remove the crankshaft 1.
TRANSMISSION
• Remove the gearshift fork shafts 1.
• Remove the gearshift cam 2.
• Remove the gear shift forks 3.
• Remove the driveshaft assembly 4 and countershaft assembly 5.
• Remove the engine sprocket spacer 6 and O-ring 7.
3-36 ENGINE
ENGINE COMPONENTS INSPECTION
AND SERVICING
CYLINDER HEAD COVER
DISASSEMBLY
#
• Remove the PAIR reed valve cover
1.
INSPECTION
Inspect the PAIR reed valve for damage and the carbon deposit.
If any damage or the carbon deposit is found in the reed valve,
replace it with a new one.
REASSEMBLY
• Install the PAIR reed valve as shown.
Be sure to identify each removed part as to its location, and lay the parts out in groups designated as
“No.1”, “No.2” “Exhaust”, “Intake”, so that each will
be restored to the original location during assembly.
ENGINE 3-37
• Apply THREAD LOCK to the bolts and then install the PAIR
reed valve cover.
% 99000-32050: THREAD LOCK “1342”
NOTE:
The inlet pipe of the PAIR reed valve cover must face left side of
the engine.
CAMSHAFT/CAMSHAFT JOURNAL
#
CAMSHAFT
• All camshafts should be checked for runout and also for wear
of cams and journals if the engine has been noted as giving
abnormal noise, vibration or lack power output. Any of these
conditions may be caused by camshafts worn down or distorted to the service limit.
• The camshafts can be identified by the embossed letters
1
and cords 2 stamped on the camshaft ends.
Be sure to identify each removed part as to its location, and lay the parts out in groups designated as
“No.1”, “No.2”, “Exhaust”, “Intake”, so that each will
be restored to the original location during assembly.
Letter 1 Cord 2
No.1 (Front) intake camshaft INF K
No.1 (Front) exhaust camshaft EXF B
No.2 (Rear) intake camshaft INR M
No.2 (Rear) exhaust camshaft EXR D
3-38 ENGINE
CAM WEAR
Worn-down cams are often the cause of mistimed valve operation resulting in reduced power output.
The limit of cam wear is specified for both intake and exhaust
cams in terms of cam height
H, which is to be measured with a
micrometer. Replace camshaft if it wears worn down to the limit.
& Cam height H
Service Limit: (Intake): 35.18 mm (1.385 in)
(Exhaust): 33.18 mm (1.306 in)
" 09900-20202: Micrometer (25 – 50 mm)
CAMSHAFT JOURNAL WEAR
Determine whether or not each journal is worn down to the limit
by measuring the oil clearance with the camshaft installed in
place.
• Use the plastigauge to read the clearance at the widest portion, which is specified as follows:
& Camshaft journal oil clearance
Service Limit (IN & EX): 0.150 mm (0.0059 in)
" 09900-22301: Plastigauge
09900-22302: Plastigauge
NOTE:
* Install camshaft journal holder to their original positions.
(!3-99, 3-102)
* Do not rotate the camshaft with the plastigauge in place.
• Tighten the camshaft journal holder bolts evenly and diagonally to the specified torque.
$ Camshaft journal holder bolt: 10 N·m
(1.0 kgf-m, 7.0 lb-ft)
• Remove the camshaft holders, and read the width of the compressed plastigauge with envelope scale. This measurement
should be taken at the widest part.
ENGINE 3-39
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.
& Journal holder I.D.
Standard (IN & EX): 22.012 – 22.025 mm
(0.8666 – 0.8671 in)
" 09900-20602: Dial gauge (1/1000, 1 mm)
09900-22403: Small bore gauge (18 – 35 mm)
& Camshaft journal O.D.
Standard (IN & EX): 21.959 – 21.980 mm
(0.8645 – 0.8654 in)
" 09900-20205: Micrometer (0 – 25 mm)
CAMSHAFT RUNOUT
Measure the runout using the dial gauge. Replace the camshaft
if the runout exceeds the limit.
& Camshaft runout
Service Limit (IN & EX): 0.1 mm (0.004 in)
" 09900-20607: Dial gauge (1/100 mm)
09900-20701: Magnetic stand
09900-21304: V-block set (100 mm)
CAM CHAIN TENSION ADJUSTER
Check that the push rod
1 can slide smoothly with the lock 2 of
the ratchet mechanism released. If it does not slide smoothly or
the ratchet mechanism is worn or damaged, replace the cam
chain tension adjuster with a new one.
CAM CHAIN TENSIONER
Check the contacting surface of the cam chain tensioner.
If it is worn or damaged, replace it with a new one.
3-40 ENGINE
CAM CHAIN GUIDE
Check the contacting surface of the cam chain guide.
If it is worn or damaged, replace it with a new one.
CYLINDER HEAD
VALVE AND VALVE SPRING DISASSEMBLY
• Remove the tappets
1 and shims 2 by fingers or magnetic
hand.
#
• Using special tools, compress the valve springs and remove
the two cotter halves 3 from valve stem.
" 09916-14510: Valve lifter
09916-14521: Valve lifter attachment
09916-84511: Tweezers
• Remove the valve spring retainer 4 and valve springs 5.
#
Identify the position of each removed part.
Be careful not to damage the tappet sliding surface
with the special tool.
ENGINE 3-41
• Pull out the valve from the other side.
• Remove the oil seals
6 and spring seats 7.
#
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.
& Cylinder head distortion
Standard: 0.05 mm (0.002 in)
" 09900-20803: Thickness gauge
VALVE STEM RUNOUT
Support the valve using V-blocks and check its runout using the
dial gauge as shown.
If the runout exceeds the service limit, replace the valve.
& Valve stem runout
Service Limit: 0.05 mm (0.002 in)
" 09900-20607: Dial gauge (1/100 mm)
09900-20701: Magnetic stand
09900-21304: V-block set (100 mm)
Do not reuse the removed oil seals.
3-42 ENGINE
VALVE HEAD RADIAL RUNOUT
Place the dial gauge at a right angle to the valve head face and
measure the valve head radial runout.
If it measures more than the service limit, replace the valve.
& Valve head radial runout
Service Limit: 0.03 mm (0.001 in)
" 09900-20607: Dial gauge (1/100 mm)
09900-20701: Magnetic stand
09900-21304: V-block set (100 mm)
VALVE FACE WEAR
Visually inspect each valve face for wear. Replace any valve
with an abnormally worn face. The thickness of the valve face
decreases as the face wears. Measure the valve face
T. If it is
out of specification, replace the valve with a new one.
& Valve head thickness T
Service Limit: 0.5 mm (0.02 in)
" 09900-20102: Vernier calipers
VALVE STEM DEFLECTION
Lift the valve about 10 mm (0.39 in) from the valve seat.
Measure the valve stem deflection in two directions, “X” and “Y”
perpendicular to each other, by positioning the dial gauge as
shown.
If the deflection measured exceeds the limit, then determine
whether the valve or the guide should be replaced with a new
one.
& Valve stem deflection (IN & EX)
Service Limit: 0.35 mm (0.014 in)
" 09900-20607: Dial gauge (1/100 mm)
09900-20701: Magnetic stand
VALVE STEM WEAR
If the valve stem is worn down to the limit, as measured with a
micrometer, where the clearance is found to be in excess of the
limit indicated, replace the valve.
If the stem is within the limit, then replace the guide.
• After replacing valve or guide, be sure to recheck the clearance.
& Valve stem O.D.
Standard (IN): 4.465 – 4.480 mm (0.1758 – 0.1764 in)
(EX): 4.455 – 4.470 mm (0.1754 – 0.1760 in)
" 09900-20205: Micrometer (0 – 25 mm)
NOTE:
If valve guides have to be removed for replacement after
inspecting related parts, carry out the steps shown in valve
guide servicing.
ENGINE 3-43
VALVE GUIDE SERVICING
• Using the valve guide remover, drive the valve guide out
toward the intake or exhaust camshaft side.
" 09916-43210: Valve guide remover/installer
NOTE:
* Discard the removed valve guide subassemblies.
* Only oversized valve guides are available as replacement
parts. (Part No. 11115-18D72)
• Re-finish the valve guide holes in cylinder head with the
reamer and handle.
" 09916-34580: Valve guide reamer
09916-34542: Reamer handle
#
• Apply engine oil to the valve guide hole, and valve guide.
• Drive the valve guide into the hole with the special tools.
" 09916-43210: Valve guide installer/remover
09916-53330: Attachment
NOTE:
Install the valve guide until the attachment
1 contacts with the
cylinder head 2.
#
• After installing the valve guides, re-finish their guiding bores
using the reamer.
• Clean and oil the guides after reaming.
" 09916-33210: Valve guide reamer
09916-34542: Valve guide reamer handle
NOTE:
Insert the reamer from the combustion chamber and always turn
the reamer handle clockwise.
When refinishing or removing the reamer from the
valve guide hole, always turn it clockwise.
Failure to oil the valve guide hole before driving the
new guide into place may result in a damaged guide or
head.
3-44 ENGINE
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 Prussian Blue and set the valve in
place.Rotate the valve with light pressure.
• Check that the transferred blue on the valve face is uniform all
around and in center of the valve face.
" 09916-10911: Valve lapper set
If the seat width
W measured exceeds the standard value, or
seat width is not uniform reface the seat using the seat cutter.
& Valve seat width W
Standard: 0.9 – 1.1 mm (0.035 – 0.043 in)
VALVE SEAT SERVICING
The valve seats 1 for both the intake valve 2 and exhaust
valve 3 are machined to four different angles. The seat contact
surface is cut at 45 °.
" 09916-21111: Valve seat cutter set
09916-22430: Valve seat cutter (N-128)
09916-20640: Solid pilot (N-100-4.5)
NOTE:
* The valve seat cutters (N-121), (N-122) and (N-111) are
included in the valve seat cutter set (09916-21111).
* Use the solid pilot (N-100-4.5) along with the valve seat cutter.
#
• When installing the solid pilot 1, rotate it slightly. Seat the
pilot snugly. Install the 45 ° cutter, attachment and T-handle.
INTAKE EXHAUST
15 ° N-121
30 ° N-128
45 ° N-128 N-122
60 ° N-111 N-111
15 ˚
45 ˚
60 ˚
30 ˚
45 ˚
60 ˚
The valve seal contact area must be inspected after
each cut.
ENGINE 3-45
INITIAL SEAT CUT
• Using the 45 ° cutter, descale and clean up the seat. Rotate
the cutter one or two turns.
• Measure the valve seat width
W after every cut.
NOTE:
Cut only the minimum amount necessary from the seat to prevent the possibility of the valve stem becoming too close to the
camshaft.
• If the valve seat is pitted or burned, use the 45 ° cutter to condition the seat some more.
TOP NARROWING CUT
• If the contact area W is too high on the valve, or if it is too
wide, use the 15 ° (for the exhaust side A) and the 30 ° (for
the intake side B) to lower and narrow the contact area.
NOTE:
Contact area too hight and too wide on face of valve.
BOTTOM NARROWING CUT
• If the contact area W is too wide or too low, use the 60 ° cutter
to narrow and raise the contact area.
45 ˚
15 ˚
30 ˚
60 ˚
3-46 ENGINE
FINAL SEAT CUT
• If the contact area
W is too low or too narrow, use the 45 °
cutter to raise and widen the contact area.
NOTE:
* After cutting the 15 °, 30 ° and 60 ° angles, it is possible that
the valve seat (45 °) is too narrow. If so, re-cut the valve seat
to the correct width.
* Contact area too low and too narrow on face of valve.
• After the desired seat position and width is achieved, use the
45 ° cutter very lightly to clean up any burrs caused by the
previous cutting operations.
#
• 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.
)
NOTE:
After servicing the valve seats, be sure to check the tappet
clearance after the cylinder head has been reinstalled. (!2-8)
45 ˚
Do not use lapping compound after the final cut is
made.
The finished valve seat should have a velvety smooth
finish but not a highly polished or shiny finish. This
will provide a soft surface for the final seating of the
valve which will occur during the first few seconds of
engine operation.
Always use extreme caution when handling gasoline.
ENGINE 3-47
VALVE STEM END CONDITION
• Check the valve stem end face for pitting and wear.
VALVE SPRING
The force of the coil springs keeps the valve seat tight. Weakened springs result in reduced engine power output, and often
account for the chattering noise coming from the valve mechanism.
• Check the valve springs for proper strength by measuring
their free length and also by the force required to compress
them. If the spring length is less than the service limit, or if the
force required to compress the spring does not fall within the
range specified, replace both the inner and outer springs as a
set.
& Valve spring free length (IN & EX)
Service limit: INNER : 36.8 mm (1.45 in)
OUTER: 39.8 mm (1.57 in)
& Valve spring tension
Standard: (IN & EX) INNER : 4.2 – 4.8 kgf/29.9 mm
(9.26 – 10.58 lbs/1.18 in)
OUTER: 17.0 – 19.6 kgf/33.4 mm
(37.48 – 43.21 lbs/1.31 in)
" 09900-20102: Vernier calipers
3-48 ENGINE
VALVE AND VALVE SPRING INSTALLATION
• Install the valve spring seats
1.
• Apply engine oil to each oil seal 2.
• Install the oil seal.
#
• Insert the valves, with their stems coated with MOLYBDENUM OIL SOLUTION all around and along the full stem
length without any break.
#
* MOLYBDENUM OIL SOLUTION
• Install the valve springs with the small-pitch portion A facing
cylinder head.
B Large-pitch portion
C UPWARD
D Paint
• Put on the valve spring retainer 1, and using the valve lifter,
press down the springs, fit the cotter halves to the stem end,
and release the lifter to allow the cotter 2 to wedge in
between retainer and stem. Be sure that the rounded lip A of
the cotter fits snugly into the groove B in the stem end.
" 09916-14510: Valve lifter
09916-14521: Valve lifter attachment
09916-84511: Tweezers
#
Do not reuse the removed oil seals.
When inserting each valve, take care not to damage
the lip of the oil seal.
Be sure to restore each spring and valve to their original positions.
ENGINE 3-49
• Install the tappet shim and the tappet to their original position.
NOTE:
* Before installing them, apply engine oil to the shims and tappets all over, also to the tappet chambers on the cylinder
head.
* When seating the tappet shim, be sure the figure printed surface faces the tappet.
OIL JET REMOVAL
• Remove the oil jets
1.
OIL JET INSPECTION AND CLEANING
• Check the oil jets for clogging.
• If they are clogged, clean their oil passage with a proper wire
and compressed air.
1 Oil jet (#8) (For cam chain tension adjuster)
OIL JET INSTALLATION
• Fit the new O-rings to each oil jets.
#
NOTE:
* Apply grease to the O-rings when installing the oil jets.
* Apply engine oil to the oil jet hole on the cylinder head.
Use the new O-rings to prevent oil leakage.
3-50 ENGINE
CYLINDER
CYLINDER DISTORTION
Check the gasketed surface of the cylinder for distortion with a
straightedge and thickness gauge, taking a clearance reading at
several places as indicated.
If the largest reading at any position of the straightedge exceeds
the limit, replace the cylinder.
& Cylinder distortion
Service Limit: 0.05 mm (0.002 in)
" 09900-20803: Thickness gauge
CYLINDER BORE
Inspect the cylinder wall for any scratches, nicks or other damage. Measure the cylinder bore diameter at six places.
& Cylinder bore
Standard: 81.000 – 81.015 mm (3.1890 – 3.1896 in)
" 09900-20508: Cylinder gauge set
ENGINE 3-51
PISTON AND PISTON RING
PISTON DIAMETER
• Using a micrometer, measure the piston outside diameter at
20 mm (0.79 in)
A from the piston skirt end.
If the measurement is less than the limit, replace the piston.
& Piston diameter
Service Limit: 80.88 mm (3.184 in)
at 20 mm (0.79 in) from the skirt end
" 09900-20204: Micrometer (75 – 100 mm)
PISTON-TO CYLINDER CLEARANCE
As a result of the previous measurement, if the piston-to-cylinder
clearance exceeds the service limit, rebore the cylinder and use
an oversize piston or replace both the cylinder and piston.
& Piston-to-cylinder clearance
Standard: 0.055 – 0.065 mm (0.0022 – 0.0026 in)
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 exceed the limit, replace both the piston
and piston rings.
& Piston-ring-to-groove clearance
Service Limit (1st) : 0.18 mm (0.0071 in)
(2nd): 0.15 mm (0.0059 in)
3-52 ENGINE
& Piston ring groove width
Standard (1st) : 1.21 – 1.23 mm (0.0476 – 0.0484 in)
(2nd): 1.01 – 1.03 mm (0.0398 – 0.0406 in)
(Oil) : 2.01 – 2.03 mm (0.0791 – 0.0799 in)
& Piston ring thickness
Standard (1st) : 1.17 – 1.19 mm (0.0461 – 0.0469 in)
(2nd): 0.97 – 0.99 mm (0.0382 – 0.0390 in)
" 09900-20803: Thickness gauge
09900-20205: Micrometer (0 – 25 mm)
PISTON RING FREE END GAP AND PISTON RING END GAP
• Measure the piston ring free end gap using vernier calipers.
• Next, fit the piston ring squarely into the cylinder and measure
the piston ring end gap using the thickness gauge.
If any of the measurements exceed the service limit, replace the
piston ring with a new one.
& Piston ring free end gap
Service Limit (1st) : 7.6 mm (0.30 in)
(2nd): 8.8 mm (0.35 in)
" 09900-20102: Vernier calipers
& Piston ring end gap
Service Limit (1st) : 0.70 mm (0.028 in)
(2nd): 0.70 mm (0.028 in)
" 09900-20803: Thickness gauge
OVERSIZE PISTON RING
The following two types of oversize piston rings are used.
They bear the following identification numbers.
SIZE 1st 2nd
STD NIL NIL
0.5 mm O.S. 50 50
0.5 mm
O.S.
ENGINE 3-53
OVERSIZE OIL RING
The following two types of oversize oil rings are available as
optional parts.
They bear the following identification marks.
• Measure the outside diameter to identify the size.
1 Oil ring spacer
A Paint
PISTON PINS AND PIN BORE
Measure the piston pin bore inside diameter using the small
bore gauge.
If the measurement is out of specifications replace the piston.
& Piston pin bore I.D.
Service Limit: 20.030 mm (0.7886 in)
" 09900-20602: Dial gauge (1/1000 mm)
09900-22403: Small bore gauge (18 – 35 mm)
Measure the piston pin outside diameter at three positions using
the micrometer.
If any of the measurements are out of specification, replace the
piston pin.
& Piston pin O.D.
Service Limit: 19.98 mm (0.7866 in)
" 09900-20205: Micrometer (0 – 25 mm)
CONROD AND CRANKSHAFT
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: 20.040 mm (0.7890 in)
" 09900-20602: Dial gauge (1/1 000 mm, 1 mm)
09900-22403: Small bore gauge (18 – 35 mm)
If the inside diameter of the conrod small end exceeds the limit,
replace the conrod.
SIZE
COLOR
SIDE RAIL SPACER
STD NIL RED
0.5 mm O.S. BLUE BLUE
3-54 ENGINE
CONROD BIG END SIDE CLEARANCE
Check the conrod side clearance by using a thickness gauge.
If the clearance exceeds the limit, replace conrod or crankshaft.
& Conrod big end side clearance
Service Limit: 0.50 mm (0.020 in)
" 09900-20803: Thickness gauge
CONROD BIG END WIDTH
Check the conrod big end width.
& Conrod big end width
Standard: 20.95 – 21.00 mm (0.825 – 0.827 in)
" 09900-20205: Micrometer (0 – 25 mm)
CRANK PIN WIDTH
Check the crank pin width
A.
& Crank pin width
Standard: 42.17 – 42.22 mm (1.660 – 1.662 in)
CONROD REMOVAL AND BEARING INSPECTION
• Loosen the bearing cap bolts, and tap the bearing cap bolt
lightly with plastic hammer to remove the bearing cap.
• 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.
ENGINE 3-55
CONROD-CRANK PIN BEARING SELECTION
• Place the plastigauge axially along the crank pin, avoiding the
oil hole, at TDC or BDC side as shown.
" 09900-22301: Plastigauge
09900-22302: Plastigauge
• Tighten the conrod cap bolts to the specified torque, in two
stages. (!3-57)
#
• Remove the bearing caps and measure the width of the compressed plastigauge using the envelope scale. This measurement should be taken at the widest part of the compressed
plastigauge.
& Conrod big end oil clearance
Standard: 0.032 – 0.056 mm (0.0013 – 0.0022 in)
Service Limit: 0.080 mm (0.0031 in)
• If the oil clearance exceeds the service limit, select the specified bearings from the bearing selection table.
• Check the corresponding conrod I.D. code numbers (“1” or
“2”)
A.
• Check the corresponding crank pin O.D. code numbers (“1”,
“2” or “3”) B.
Bearing selection table
Never rotate the crankshaft or conrod when a piece of
plastigauge is installed.
Crank pin O.D. B
Code 1 2 3
Conrod
I.D. A
1 Green Black Brown
2 Black Brown Yellow
3-56 ENGINE
& Conrod I.D.
& Crank pin O.D.
" 09900-20202: Micrometer (25 – 50 mm)
& Bearing thickness
#
A Color code
CONROD AND BEARING REASSEMBLY
• When fitting the bearings to the bearing cap and conrod, be
sure to fix the stopper part A first and press in the other end.
#
• Apply MOLYBDENUM OIL SOLUTION to the crank pin and
bearing surface.
* MOLYBDENUM OIL SOLUTION
Code I.D. specification
1
41.000 – 41.008 mm
(1.6142 – 1.6145 in)
2
41.008 – 41.016 mm
(1.6145 – 1.6148 in)
Code O.D. specification
1
37.992 – 38.000 mm
(1.4957 – 1.4961 in)
2
37.984 – 37.992 mm
(1.4954 – 1.4957 in)
3
37.976 – 37.984 mm
(1.4951 – 1.4954 in)
Color (Part No.) Thickness
Green
(12164 – 46E01-0A0)
1.480 – 1.484 mm
(0.0583 – 0.0584 in)
Black
(12164 – 46E01-0B0)
1.484 – 1.488 mm
(0.0584 – 0.0586 in)
Brown
(12164 – 46E01-0C0)
1.488 – 1.492 mm
(0.0586 – 0.0587 in)
Yellow
(12164 – 46E01-0D0)
1.492 – 1.496 mm
(0.0587 – 0.0589 in)
The bearings must be replaced as a set.
Be sure to clean the conrod big end.
ENGINE 3-57
• When fitting the conrods on the crankshaft, make sure that
I.D. codes
A of the conrods face each cylinder intake valve
sides.
• Apply engine oil to the thread and flange of the bearing cap
bolts.
• Tighten the bearing cap bolt as following two steps.
$ Conrod bearing cap bolt
(Initial): 21 N·m (2.1 kgf-m, 15.0 lb-ft)
(Final) : After tightening the bolts to the above torque,
tighten them 1/4 of a turn (90 °).
• Apply engine oil to the conrod big end side surfaces.
• Check the conrod movement for smooth turning.
CRANKCASE
OIL PRESSURE REGULATOR
• Remove the oil pressure regulator 1.
• Check 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 regulator with a new one.
• Tighten the oil pressure regulator to the specified torque.
$ Oil pressure regulator: 27 N·m (2.7 kgf-m, 19.5 lb-ft)
90 ˚
90 ˚
3-58 ENGINE
OIL PRESSURE SWITCH
• Remove the oil pressure switch
1.
• Inspect the oil pressure switch. (!8-34)
• Apply SUZUKI BOND to the thread part of the oil pressure
switch 1 and tighten it to the specified torque.
+ 99104-31140: SUZUKI BOND “1207B” (USA)
99000-31140: SUZUKI BOND “1207B” (Others)
$ Oil pressure switch: 13 N·m (1.3 kgf-m, 9.5 lb-ft)
NOTE:
Be careful not to apply SUZUKI BOND to the hole of the thread
end.
OIL STRAINER
• Remove the oil strainer plate 1.
• Remove the oil strainer 2.
• Clean the oil strainer with a compressed air.
ENGINE 3-59
• Install the oil strainer
3.
NOTE:
Fit the projection A of the oil strainer 3 in the concave portion
of the crankcase.
• Install the oil strainer plate 2 and tighten the oil starainer
plate screw to the specified torque.
$ Oil strainer plate screw: 10 N·m (1.0 kgf-m, 7.0 lb-ft)
OIL JET
Removal
• Remove the oil jets 1, 2 from the left and right crankcase
halves.
• Remove the oil seal 3 and oil gallery plug 4.
• Remove the oil jet 5 from left crankcase half.
NOTE:
If it is difficult to remove the oil jet, use a sting.
3-60 ENGINE
Inspection and cleaning
• Check the oil jets for clogging.
• If they are clogged, clean their oil passage with a proper wire
and compressed air.
1 Piston cooling oil jet (#13)
2 Oil jet (#14) (For transmission)
3 Oil jet (#14) (For each cylinder head)
Installation
• Fit the new O-rings to each oil jets.
#
NOTE:
* Apply grease to the O-rings when installing the oil jets.
* Apply engine oil to the oil jet holes on the crankcase.
• Install the piston cooling oil jets 1 to the left and right crankcase halves.
• Apply a small quantity of THREAD LOCK to the bolts and
tighten them to the specified torque.
% 99000-32050: THREAD LOCK “1342”
$ Piston cooling oil jet bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft)
• Push the oil jet into the left crankcase half until it stops.
• Tighten the oil gallery plug 2 to the specified torque.
$ Oil gallery plug (M8): 18 N·m (1.8 kgf-m, 13.0 lb-ft)
GEARSHIFT ARM STOPPER
• When installing the gearshift arm stopper bolt 1, apply a
small quantity of THREAD LOCK to its thread and tighten it to
the specified torque.
, 99000-32030: THREAD LOCK SUPER “1303”
$ Gearshift arm stopper bolt: 19 N·m (1.9 kgf-m, 13.5 lb-ft)
Use the new O-rings to prevent oil leakage.
ENGINE 3-61
CRANKSHAFT JOURNAL BEARING
INSPECTION
• Inspect the crankshaft journal bearings for any damage.
• If any, replace them with a specified set of bearings.
SELECTION
• Inspect the crankshaft journal for any damage.
• Measure the crankshaft journal O.D. with the special tool.
& Crankshaft journal O.D.
Standard: 41.985 – 42.000 mm
(1.6529 – 1.6535 in)
" 09900-20202: Micrometer (25 – 50 mm)
• Select the specified bearings from the crankcase bore I.D.
code. The crankcase bore I.D. code
1 “A”, “B” or “C”, is
stamped on the inside of each crankcase half.
Bearing selection table
& Crank shaft journal I.D.
Crankcase I.D. 1
A B C
Bearing color Green Black Brown
I.D. code 1 I.D. specification
A
46.000 – 46.006 mm
(1.8110 – 1.8113 in)
B
46.006 – 46.012 mm
(1.8113 – 1.8115 in)
C
46.012 – 46.018 mm
(1.8115 – 1.8117 in)
3-62 ENGINE
& Bearing thickness
#
A Color code
REPLACEMENT
Use the special tool to replace the crankshaft journal bearings.
The replacement procedure is as follows.
• Set the special tool as shown to remove the crankshaft journal
bearings with the special tool.
" 09913-60221: Journal bearing remover/installer
NOTE:
Remove the crankshaft journal bearings in only one direction,
from inside to outside of each crankcase half.
Color (Part No.) Thickness
Green
(12229 – 27G00-0A0)
1.996 – 1.999 mm
(0.0786 – 0.0787 in)
Black
(12229 – 27G00-0B0)
1.999 – 2.002 mm
(0.0787 – 0.0788 in)
Brown
(12229 – 27G00-0C0)
2.002 – 2.005 mm
(0.0788 – 0.0789 in)
Bearing must be replaced as a set.
ENGINE 3-63
• Gradually press out the bearing with the special tool by using
the hand-press.
#
1 Hand-press
2 Crankcase
3 Bearing
NOTE:
Using the hand-press is recommended to remove the crankshaft
journal bearings. However, the crankshaft journal bearings can
be removed by using with the following special tools.
" 09924-84510: Bearing installer set
09910-20116: Conrod holder
09913-60221: Journal bearing remover/installer
• Set the specified crankshaft journal bearings to the special
tool.
#
NOTE:
The upper and lower bearings are same.
The removed bearings must be replaced with new
ones.
* Before setting the bearing, apply enough engine oil
to the special tool and bearings.
* When setting the bearing, align the bearing side with
the engraved line A and also the bearing end with
the mating surface of the special tool.
3-64 ENGINE
• Tighten the special tool bolts to the specified torque.
$ Special tool bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft)
#
• Set the bearings installed in the special tool to the crankcase
half as shown.
#
NOTE:
Install the bearing from inside to outside of each crankcase
halves.
Before installing the bearings, lightly shave off the
sharp edge part
A of the crankcase chamfer by using
an oilstone and wash the crankcase bore with enough
engine oil.
* Be sure the bearing protruded side B faces the
crankcase bore.
* Align the bearing/special tool mating surface with
the line C on the crankcase.
ENGINE 3-65
• Apply enough engine oil to the special tool and the bearings
and then set the special tool carefully.
• Gradually press
1 in the bearing 2 into the main journal bore
by using the hand-press until the special tool 3 contacts the
special tool 4.
NOTE:
Using the hand-press is recommended to install the crankshaft
journal bearings. However, the crankshaft journal bearings can
be installed by using the following special tools.
" 09924-84510: Bearing installer set
09910-20116: Conrod holder
09913-60221: Journal bearing remover/installer
• After installing the bearings, check the bearing surface for any
scratch or damage.
3-66 ENGINE
CRANKCASE BEARING AND OIL SEAL
INSPECTION
Rotate the bearing inner race by finger to inspect for abnormal
play
A, noise and smooth rotation while the bearings are in the
crankcase.
Replace the bearing with new ones, if there is anything unusual.
Inspect the oil seals for any damage.
REMOVAL
• Remove the oil seals with the special tool or a suitable bar.
" 09913-50121: Oil seal remover
• Remove the bearing retainers 1.
ENGINE 3-67
• Remove the crankcase bearings by with the special tool.
" 09921-20240: Bearing remover set
NOTE:
Select the suitable size attachment as following illustration.
Bearing remover attachment
1 -25 mm 2 -17 mm 3 -20 mm A Left crankcase B Right crankcase
3-68 ENGINE
INSTALLATION
• Install the crankcase bearings and oil seals with the special
tool.
" 09913-70210: Bearing installer set
NOTE:
Select the suitable size attachment as following illustration.
Bearing installer attachment
• Apply SUZUKI SUPER GREASE to the oil seal lip.
' 99000-25030: SUZUKI SUPER GREASE “A” (USA)
99000-25010: SUZUKI SUPER GREASE “A” (Others)
Bearing Oil seal
A Left crankcase B Right crankcase
1 - 62 mm - 52 mm
2 - 40 mm - 35 mm
3 - 32 mm ---------4 ---------- - 22 mm
5 - 52 mm ---------6 - 40 mm ---------7 - 47 mm ---------ENGINE 3-69
CLUTCH
CLUTCH DRIVE PLATES
NOTE:
Wipe off engine oil from the clutch drive plates with a clean rag.
• Measure the thickness of drive plates with a vernier calipers.
• If each drive plate is not within the standard range, replace it
with a new one.
& Drive plate thickness
Standard: 2.92 – 3.08 mm (0.115 – 0.121 in)
" 09900-20102: Vernier calipers
• Measure the claw width of drive plates with a vernier calipers.
• Replace the drive plates found to have worn down to the limit.
& Drive plate claw width
Service Limit: 11.5 mm (0.453 in)
" 09900-20102: Vernier calipers
CLUTCH DRIVEN PLATES
NOTE:
Wipe off engine oil from the clutch driven plates with a clean rag.
• Measure each driven plate for distortion with a thickness
gauge and surface plate.
• Replace driven plates which exceed the limit.
& Driven plate distortion
Service Limit: 0.10 mm (0.004 in)
" 09900-20803: Thickness gauge
CLUTCH SPRING
• Measure the free length of each coil spring with a vernier calipers, and compare the length with the specified limit.
• Replace all the springs if any spring is not within the limit.
& Clutch spring free length
Service Limit: 50.5 mm (1.99 in)
" 09900-20102: Vernier calipers
3-70 ENGINE
CLUTCH BEARING INSPECTION
Smooth engagement and disengagement of the clutch depends
on the condition of this bearing.
Inspect the clutch release bearing for any abnormality, particularly cracks, to decide whether it can be reused or should be
replaced.
CLUTCH SLEEVE HUB/PRIMARY DRIVEN GEAR ASSEM-
BLY
Inspect the slot of the clutch sleeve hub and primary driven gear
assembly for damage or wear caused by the clutch plates.
If necessary, replace it with a new one.
PRIMARY DRIVEN GEAR ASSEMBLY
DISASSEMBLY
• Remove the snap ring
1.
• Remove the oil pump drive gear 2 and pin.
INSPECTION
Inspect the primary driven gear bushing for any damage.
Inspect the spring of primary driven gear for any damages.
If necessary, replace it with a new one.
REASSEMBLY
• Install the pin 1.
• Align the oil pump drive gear slot A with the pin 1.
ENGINE 3-71
• Install the snap ring
2.
GEARSHIFT SHAFT/GEARSHIFT ARM
DISASSEMBLY
• Remove the following parts from the gearshift shaft/gearshift
arm.
1 Washer 5 Washer
2 Snap ring 6 Plate return spring
3 Gearshift shaft return spring 7 Gearshift cam drive plate
4 Snap ring
INSPECTION
Check the gearshift shaft/gearshift arm for wear or bend.
Check the return springs for damage or fatigue.
REASSEMBLY
• Install the following parts to the gearshift shaft/gearshift arm
as shown in the right illustration.
1 Washer 5 Washer
2 Snap ring 6 Plate return spring
3 Gearshift shaft return spring 7 Gearshift cam drive plate
4 Snap ring
NOTE:
When installing the gearshift shaft return spring 3, position the
stopper B of the gearshift arm between the shaft return spring
ends A.
3-72 ENGINE
TRANSMISSION
COUNTERSHAFT DISASSEMBLY
#
• Remove the 6th drive gear snap ring
1 from its groove and
slide it towards the 3rd/4th drive gears 2.
• Remove the concaved washer 3 and O-ring 4.
• Slide the 6th 5 and 2nd drive gears 6 toward the 3rd/4th
drive gears 7, then remove the 2nd drive gear circlip 8.
• Remove the 2nd drive gear 6, 6th drive gear 5, bushing and
washer.
• Remove the snap ring 9 and 3rd/4th drive gears 0.
• Remove the snap ring A, washer B and 5th drive gear C.
Be sure to identify each removed part as to its location, and lay the parts out in groups designated as
“Drive” and “Driven”, so that each will be restored to
the original location during assembly.
ENGINE 3-73
• Remove the 5th drive gear bushing
D.
DRIVESHAFT DISASSEMBLY
• Remove the washer 1 and 1st driven gear 2.
• Remove the 1st driven gear bushing 3, washer 4 and 5th
driven gear 5.
• Remove the snap ring 6, washer 7 and 4th driven gear 8.
• Remove the 4th driven gear bushing 9, lock washers 0 and
3rd driven gear A.
3-74 ENGINE
• Remove the 3rd driven gear bushing
B and washer C.
• Remove the snap ring D and 6th driven gear E.
• Remove the snap ring F and 2nd driven gear bushing G.
• Remove the 2nd driven gear H.
INSPECTION
Inspect the each gear and bushing for wear and damage.
If they are found to be damaged, replace them with new ones.
ENGINE 3-75
REASSEMBLY
Assemble the countershaft and driveshaft in the reverse order of
disassembly. Pay attention to the following points:
• Before installing the gears, lightly coat MOLY PASTE or
engine oil to the driveshaft and countershaft.
( 99000-25140: SUZUKI MOLY PASTE
• Before installing the O-ring, apply SUZUKI SUPER GREASE
to it.
' 99000-25030: SUZUKI SUPER GREASE “A” (USA)
99000-25010: SUZUKI SUPER GREASE “A” (Others)
NOTE:
* Rotate the bushings by hand to inspect for smooth rotation.
Replace the bushings if there is anything unusual.
#
NOTE:
When reassembling the transmission, attention must be given to
the locations and positions of washers and snap rings. The
cross sectional view shows the correct position of the gears,
bushings, washers and snap rings. (!3-77)
When installing a new snap ring, pay attention to the direction of
the snap ring. Fit it to the side where the thrust is as shown in
the illustration.
A Thrust
B Sharp edge
* Never reuse a snap ring. After a snap ring has been
removed from a shaft, it should be discarded and a
new snap ring must be installed.
* When installing a new snap ring, do not expand the
end gap larger than required to slip the snap ring
over the shaft.
* After installing a snap ring, make sure that it is completely seated in its groove and securely fitted.
3-76 ENGINE
\
#
1 6th drive gear bushing
2 3rd driven gear bushing
3 4th driven gear bushing
• After installing the 3rd driven gear 4 onto the driveshaft,
install lock washer No.2 5 onto the driveshaft, and position it
so it fits into the groove.
• Then, fit lock washer No.1 6 into lock washer No.2 5.
When installing the 6th drive gear, 3rd driven gear and
4th driven gear bushings onto the shaft, align the
shaft oil hole A with the bushing oil hole B.
ENGINE 3-77
1 1st (Low) drive gear/countershaft 7 5th driven gear
2 5th drive gear 8 4th driven gear
3 3rd/4th drive gear 9 3rd driven gear
4 6th (Top) drive gear 0 6th (Top) driven gear
5 2nd drive gear A 2nd driven gear
6 1st (Low) driven gear A 145 N·m (14.5 kgf·m, 105 lb-ft)
3-78 ENGINE
GEARSHIFT FORK TO GROOVE CLEARANCE
Using a thickness gauge, check the gearshift fork clearance in
the groove of its gear.
The clearance for each gearshift fork plays an important role in
the smoothness and positiveness of the shifting action.
& Shift fork to groove clearance
Service Limit: 0.50 mm (0.020 in)
" 09900-20803: Thickness gauge
09900-20102: Vernier calipers
If the clearance checked is noted to exceed the limit specified,
replace the fork or its gear, or both.
GEARSHIFT FORK GROOVE WIDTH
• Measure the gearshift fork groove width using the vernier calipers.
& Shift fork groove width
Standard: 5.5 – 5.6 mm (0.217 – 0.220 in)
" 09900-20102: Vernier calipers
GEARSHIFT FORK THICKNESS
• Measure the gearshift fork thickness using the vernier calipers.
& Shift fork thickness
Standard: 5.3 – 5.4 mm (0.209 – 0.213 in)
" 09900-20102: Vernier calipers
ENGINE 3-79
STARTER CLUTCH
INSPECTION
Install the starter driven gear onto the starter clutch and turn the
starter driven gear by hand to inspect the starter clutch for a
smooth movement. The gear turns in one direction only. If a
large resistance is felt for rotation, inspect the starter clutch or
the starter clutch contacting surface on the starter driven gear
for wear and damage.
If they are found to be damaged, replace them with new ones.
Inspect the starter driven gear bearing for any damage.
DISASSEMBLY
• Hold the generator rotor with the special tool and remove the
starter clutch bolts.
" 09930-44530: Rotor holder
• Remove the one way clutch
1 from the guide 2.
REASSEMBLY
• When inserting the one-way clutch 1 into the guide 2, fit the
flange A in the step of the guide 2.
3-80 ENGINE
• Be sure to seat the flange
A of the one way clutch 3 to the
guide 4.
• Install the guide 5 to the generator rotor with the arrow mark
B faced upward.
• Apply THREAD LOCK SUPER to the bolts and tighten them
to the specified torque.
, 99000-32030: THREAD LOCK SUPER “1303”
$ Starter clutch bolt: 25 N·m (2.5 kgf-m, 18.0 lb-ft)
• Apply engine oil to the one way clutch.
GENERATOR AND SIGNAL GENERATOR
INSPECTION
Refer to pages 8-10, 27 for generator and CKP sensor inspection.
REASSEMBLY
• When installing the generator starter set bolts 1 and the CKP
sensor set bolts 2 tighten them to the specified torque.
$ Generator stator set bolt: 11 N·m (1.1 kgf-m, 8.0 lb-ft)
CKP sensor set bolt: 6.5 N·m (0.65 kgf-m, 4.7 lb-ft)
NOTE:
Be sure to install the grommet A to the generator cover.
ENGINE 3-81
OIL PUMP
INSPECTION
Rotate the oil pump by hand and check that it moves smoothly.
If it does not move smoothly, replace the oil pump assembly.
#
CLUTCH RELEASE
INSPECTION
• Check the teeth of clutch release for any damage and wear.
* Do not attempt to disassemble the oil pump assembly.
* The oil pump is available only as an assembly.
3-82 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 reassembling.
ENGINE BOTTOM SIDE
TRANSMISSION
• Install the countershaft assembly
1 and the driveshaft
assembly 2 to the left crankcase half.
• Install the washer 3 onto the driveshaft assembly 2.
GEARSHIFT
• Install the gearshift forks 1/2/3, gearshift cam 4 and gearshift fork shafts 5.
NOTE:
Identify the gearshift forks as follows.
1 For 5th driven gear
2 For 6th driven gear
3 For 3rd/4th drive gear
1 For 5th driven gear 2 For 6th driven gear 3 For 3rd/4th drive gear
35
15
10 10
35 31
ENGINE 3-83
CRANKSHAFT
• Coat lightly MOLYBDENUM OIL SOLUTION to the crankshaft
journal bearings.
* MOLYBDENUM OIL SOLUTION
• Install the crankshaft into the left crankcase half.
#
CRANKCASE
• Clean the mating surfaces of the left and right crankcase
halves.
• Install the O-rings
1, 2 and dowel pins 3.
• Apply SUZUKI SUPER GREASE to the O-rings 1, 2.
' 99000-25030: SUZUKI SUPER GREASE “A” (USA)
99000-25010: SUZUKI SUPER GREASE “A” (Others)
• Apply SUZUKI BOND to the mating surface of the left crankcase.
+ 99104-31140: SUZUKI BOND “1207B” (USA)
. 99000-31110: SUZUKI BOND “1215” (Others)
NOTE:
Use of SUZUKI BOND is as follows:
* Make surfaces free from moisture, oil, dust and other foreign
materials.
* Spread on surfaces thinly to form an even layer, and assemble
the crankcases within few minutes.
* Take extreme care not to apply any SUZUKI BOND to the oil
hole, oil groove and bearing.
* Apply to distorted surfaces as it forms a comparatively thick
film.
Never strike the crankshaft with a plastic hammer
when inserting it into the crankcase. It will be easy to
install the crankshaft to left crankcase.
3-84 ENGINE
• When securing the right and left crankcase halves, tighten
each bolt a little at a time to equalize the pressure. Tighten all
the securing bolts to the specified torque values.
$ Crankcase bolt: (M8) 26 N·m (2.6 kgf-m, 19.0 lb-ft)
(M6) 11 N·m (1.1 kgf-m, 8.0 lb-ft)
#
NOTE:
* After the crankcase bolts have been tightened, check if the
crankshaft, the driveshaft and the countershaft rotate
smoothly.
* Fit the clamp to the bolt
C as shown.
OIL PLATE
• Install the oil plate 1 and the oil plate bolts tighten to the
specified torque.
$ Oil plate bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft)
ENGINE SPROCKET SPACER
• Install the new O-ring 1 into the engine sprocket spacer 2.
#
• Install the engine sprocket spacer 2.
NOTE:
* The grooved A side of the engine sprocket spacer 1 must
face crankcase side.
* Apply SUZUKI SUPER GREASE to the oil seal lip and O-ring.
' 99000-25030: SUZUKI SUPER GREASE “A” (USA)
99000-25010: SUZUKI SUPER GREASE “A” (Others)
Do not drop the O-ring into the crankcase when
assembling the right and left crankcase halves.
Use the new O-ring to prevent oil leakage.
ENGINE 3-85
GEAR POSITION SWITCH
• Install the gear position switch contacts
1 and springs.
• Apply SUZUKI SUPER GREASE to the O-ring 2 and then
install it onto the gear position switch.
' 99000-25030: SUZUKI SUPER GREASE “A” (USA)
99000-25010: SUZUKI SUPER GREASE “A” (Others)
• Install the gear position switch 3 as shown.
• Tighten the gear position switch bolt to the specified torque.
$ Gear position switch bolt: 6.5 N·m (0.65 kgf-m, 4.7 lb-ft)
• Install the drive shaft oil seal retainer 4.
NOTE:
Pass through the gear position switch lead wire under the driveshaft oil seal retainer.
FRONT CAM CHAIN
• Install the front cam chain 1.
• Install the cam chain tensioner 2, washer 3 and cam chain
tensioner bolt 4.
• Tighten the cam chain tensioner bolt 4 to the specified
torque.
$ Cam chain tensioner bolt: 10 N·m (1.0 kgf-m, 7.0 lb-f)
NOTE:
The front and rear cam chain tensioners are the same.
3-86 ENGINE
GENERATOR ROTOR
• Install the starter driven gear
1.
• Apply engine oil to the bushing of the starter driven gear.
• Degrease the tapered portions A of the generator rotor
assembly and the crankshaft. Use nonflammable cleaning
solvent to wipe off oily or greasy matter and make these surfaces completely dry.
• Fit the key 2 in the key slot on the crankshaft completely.
• Install the generator rotor assembly onto the crankshaft.
• While holding the generator rotor with the special tool, tighten
its bolt to the specified torque.
" 09930-44530: Rotor holder
$ Generator rotor bolt: 120 N·m (12.0 kgf-m, 87 lb-ft)
CAM CHAIN DRIVE SPROCKET
• Install the cam chain drive sprocket 1 onto the crankshaft.
NOTE:
* Align the punched mark A on the cam chain drive sprocket
with the punched mark B on the crankshaft.
* Apply MOLYBDENUM OIL SOLUTION to the cam chain drive
sprocket.
* MOLYBDENUM OIL SOLUTION
{
{
ENGINE 3-87
REAR CAM CHAIN
• Install the rear cam chain
1.
• Install the cam chain tensioner 2, washer 3 and cam chain
tensioner bolt 4.
• Tighten the cam chain tensioner bolt 4 to the specified
torque.
$ Cam chain tensioner bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft)
NOTE:
The front and rear cam chain tensioners are the same.
PRIMARY DRIVE GEAR
• Install the primary drive gear 1 and water pump drive gear
2.
• Hold the generator rotor (crankshaft) with the special tool.
" 09930-44530: Rotor holder
• Tighten the primary drive gear bolt to the specified torque.
$ Primary drive gear bolt: 70 N·m (7.0 kgf-m, 50.5 lb-ft)
NOTE:
This bolt has left-hand thread.
3-88 ENGINE
OIL PIPE
• Install the oil pipe
1.
• Tighten the oil pipe stopper screw 2 to the specified torque.
$ Oil pipe stopper screw: 8 N·m (0.8 kgf-m, 6.0 lb-ft)
NOTE:
Align the projection A of the oil pipe with the groove B of its
stopper.
GEARSHIFT SYSTEM
• Install the gearshift cam stopper 1, its bolt 2, washer 3 and
return spring 4.
$ Gearshift cam stopper bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft)
• Confirm the gearshift cam stopper movement.
• Check the neutral position.
NOTE:
Hook the return spring end 5 to the stopper.
• Install the gearshift cam stopper plate 6 with the gearshift
cam pins A inserted into the gearshift cam stopper plate
holes B.
ENGINE 3-89
• Apply a small quantity of THREAD LOCK to the gearshift cam
stopper plate bolt and tighten it to the specified torque.
% 99000-32050: THREAD LOCK “1342”
$ Gearshift cam stopper plate bolt: 13 N·m
(1.3 kgf-m, 9.5 lb-ft)
• Install the gearshift shaft/gearshift arm
7 with the washer 8
as shown.
• Locate the gearshift arm stopper 9 between return spring
ends C.
• Install the washer 0 and snap ring A.
OIL PUMP
• Install the oil pump with the three screws.
3-90 ENGINE
• Install the washer
1 and pin 2.
• Install the oil pump driven gear 3.
• Install the snap ring 4.
CLUTCH
• Install the spacer 1 and apply ENGINE OIL to it.
• Install the primary driven gear assembly 2 onto the countershaft.
NOTE:
Be sure to engage the oil pump drive and driven gears, primary
drive and driven gears.
• Install the thrust washer 3.
• Install the clutch sleeve hub 4 and lock washer 5.
#
• Install the clutch sleeve hub nut 6.
NOTE:
The chamfer side A of the clutch sleeve hub nut faces outward.
Replace the lock washer 5 with a new one.
ENGINE 3-91
• Hold the clutch sleeve hub with the special tool.
" 09920-53740: Clutch sleeve hub holder
• Tighten the clutch sleeve hub nut to the specified torque.
$ Clutch sleeve hub nut: 50 N·m (5.0 kgf-m, 36.0 lb-ft)
• Bend the lock washer to lock the nut securely.
• Install the spring washer seat
7 and spring washer 8 onto
the clutch sleeve hub correctly.
• Insert the clutch drive plates 9, 0 and driven plates A one
by one into the clutch sleeve hub in the prescribed order, No.2
drive plate 9 being inserted first.
NOTE:
Apply the ENGINE OIL to the clutch driven and drive plates
before installing them.
9 No.2 Drive plate 0 No.1 Drive plate A Direction of inside.
8.3 mm
(0.33 in)
11.3 mm
(0.44 in)
3-92 ENGINE
• Install the clutch push rod
B into the countershaft.
• Install the clutch push piece C, the bearing D and thrust
washer E to the countershaft.
NOTE:
Thrust washer E is located between the pressure plate and
bearing D.
• Hold the generator rotor (crankshaft) with the special tool.
" 09930-44530: Rotor holder
• Install the clutch pressure plate.
• Tighten the clutch spring set bolts to the specified torque.
$ Clutch spring set bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft)
NOTE:
Tighten the clutch spring set bolts diagonally.
CLUTCH COVER
• Install the gasket 1 and dowel pins 2.
#
Use the new gasket to prevent oil leakage.
ENGINE 3-93
• Install the clutch cover.
GENERATOR COVER
• Apply MOLYBDENUM OIL SOLUTION to both ends of the
shaft
1.
* MOLYBDENUM OIL SOLUTION
• Install the starter idle gear 2 and shaft 1.
• Install the dowel pins 3 and gasket 4.
#
• Install the generator cover.
$ Generator cover bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft)
NOTE:
Fit the gasket washers to the generator cover bolts A correctly
as shown.
#
OIL FILTER
• Install the oil filter with the special tool. (!2-13)
" 09915-40610: Oil filter wrench
Use the new gasket to prevent oil leakage.
Use the new gasket washers to prevent oil leakage.
3-94 ENGINE
STARTER MOTOR
• Install the new O-ring to the starter motor.
#
• Apply SUZUKI SUPER GREASE to the O-ring.
' 99000-25030: SUZUKI SUPER GREASE “A” (USA)
99000-25010: SUZUKI SUPER GREASE “A” (Others)
• Install the starter motor
1.
• Tighten the starter motor mounting bolts with the clamp 2
securely.
NOTE:
First tighten the starter motor mounting bolt A.
ENGINE TOP SIDE
PISTON
• Install the piston rings in the order of oil ring, 2nd ring and 1st
ring.
• The first member to go into the oil ring groove is a spacer 1.
After placing the spacer, fit the two side rails 2.
NOTE:
Side designations, top and bottom, are not applied to the spacer
and side rails: you can position each either way.
#
A INCORRECT
B CORRECT
• Install the 2nd ring 3 and 1st ring 4.
NOTE:
1st ring and 2nd ring differ in shape.
Use the new O-ring to prevent oil leakage.
When installing the spacer, be careful not to allow its
two ends to overlap in the groove.
ENGINE 3-95
• 1st ring
5 and 2nd ring 6 have letters “T” marked on the
side. Be sure to bring the marked side to the top when fitting
them to the piston.
• Position the gaps of the three rings as shown. Before inserting
each piston into the cylinder, check that the gaps are so
located.
A 2nd ring and Lower side rail
B Upper side rail
C 1st ring and spacer
• Apply a small quantity of MOLYBDENUM OIL SOLUTION
onto each piston pin.
* MOLYBDENUM OIL SOLUTION
NOTE:
When installing the pistons, front and rear, the indents D on the
piston heads must be located to each exhaust side.
• Place a clean rag over the cylinder base so as not to drop the
piston pin circlips into the crankcase.
• Install the pistons 7, front and rear.
• Install the piston pin circlips 8.
#
NOTE:
End gap of the circlip should not be aligned with the cutaway in
the piston pin bore.
#
120 ˚ 120 ˚
IN
EX
120 ˚
Use new piston pin circlips to prevent circlip failure
which will occur with a bend one.
When turning the crankshaft, pull the cam chains
upward, or the chains will be caught between the
crankcase and the cam drive sprocket.
3-96 ENGINE
OIL JET
• Apply SUZUKI SUPER GREASE to the new O-rings.
' 99000-25030: SUZUKI SUPER GREASE “A” (USA)
99000-25010: SUZUKI SUPER GREASE “A” (Others)
• Apply engine oil to the oil jet holes on the crankcase.
• Install each of the oil jet (#14) to the left and right crankcase,
as shown in the illustration.
#
CYLINDER
• Coat SUZUKI BOND lightly to the mating surfaces at the parting line between the right and left crankcases as shown.
+ 99104-31140: SUZUKI BOND “1207B” (USA)
. 99000-31110: SUZUKI BOND “1215” (Others)
• Apply engine oil to the sliding surface of the pistons.
• Fit the dowel pins
1, 2 and new gaskets 3, 4 to the crankcase.
#
Use the new O-rings to prevent oil leakage.
Use the new gaskets to prevent oil leakage.
ENGINE 3-97
• Apply engine oil to the sliding surface of the cylinders.
NOTE:
The front and rear cylinders can be distinguished by the
embossed-letters
A.
“FRONT” : Front cylinder
“REAR” : Rear cylinder
• Hold the piston rings in proper position, and insert each of the
piston into the respective cylinders.
NOTE:
When installing the cylinders, keep the cam chains taut. The
cam chain must not be caught between cam drive sprocket and
crankcase when turning the crankshaft.
• Tighten the cylinder nuts (M6) temporarily.
CYLINDER HEAD
• The cylinder heads can be distinguished by the embossed-letters A.
“F” : Front cylinder head
“R”: Rear cylinder head
• Pull the cam chain out of the cylinder and install the cam
chain guide 1.
#
NOTE:
The front and rear cam chain guides are the same.
There is the guide holder for the bottom end of the
cam chain guide 1 cast in the crankcase. Be sure that
the cam chain guide 1 is inserted properly.
3-98 ENGINE
• Fit the dowel pins
2 and new cylinder head gasket 3 to the
cylinder.
#
• Install the washers 4 to the cylinder head bolts (M10) 5 as
shown.
• Apply engine oil to the washers and thread portion of the bolts
before installing the cylinder head bolts.
• Place the rear cylinder head on the cylinder.
NOTE:
When installing the cylinder head, keep the cam chain taut.
• Tighten the cylinder head bolts (M10) to the specified
two-step torque with a torque wrench sequentially and diagonally.
$ Cylinder head bolt (M10):
Initial 25 N·m (2.5 kgf-m, 18.0 lb-ft)
Final 42 N·m (4.2 kgf-m, 30.5 lb-ft)
• After firmly tightening the cylinder head bolts (M10), install the
cylinder head bolts (M6) 6, 7.
• Tighten the cylinder head bolts 6, 7, and cylinder nuts 8.
Use the new gasket to prevent gas leakage.
ENGINE 3-99
• Install the front cylinder head in same manner as the rear cylinder head installation.
CAM SHAFT
• The cam shafts are identified by the embossed letters.
INF : No.1 (Front) intake camshaft
1
EXF : No.1 (Front) exhaust camshaft 2
INR : No.2 (Rear) intake camshaft 3
EXR: No.2 (Rear) exhaust camshaft 4
• Before installing the camshafts to the cylinder head, apply
MOLYBDENUM OIL SOLUTION to their journals.
* MOLYBDENUM OIL SOLUTION
No.1 (Front) Camshafts
• Turn the crankshaft counterclockwise with the box wrench
and align “F” line A on the generator rotor with the index
mark B of the valve timing inspection hole while keeping the
cam chains pulled upward.
#
• Pull the cam chain lightly.
• The No.1 exhaust camshaft sprocket has an arrow mark “1F”
C. Install the exhaust camshaft so that the arrow C is aligned
with the mating surface of the cylinder head. (!3-100)
• Engage the cam chain with the exhaust camshaft sprocket.
NOTE:
Before installing the camshaft, check that the tappets are
installed correctly.
* Pull the cam chains upward, or the chain will be
caught between crankcase and cam drive sprocket.
* To adjust the camshaft timing correctly, be sure to
align “F” line A with the index mark B and hold
this position when installing the camshafts.
“2”
3-100 ENGINE
• The other arrow mark “2” on the exhaust camshaft sprocket
should now be pointing straight up. Starting from the roller pin
that is directly above the arrow mark “2” count out 16 roller
pins (from the exhaust camshaft side going towards the intake
camshaft side). Engage the 16 roller pin
D on the cam chain
with the arrow mark “3” on the intake sprocket. (!3-100)
NOTE:
The cam chain should now be on all three sprockets. Be careful
not to move the crankshaft until the camshaft journal holders
and cam chain tension adjuster is secured.
No.1 (FRONT) CYLINDER HEAD
• Install the dowel pins 1.
• Apply engine oil to the camshaft journal holders.
• Install the camshaft journal holders, intake and exhaust.
• Fasten the camshaft journal holders evenly by tightening the
crankshaft journal holder bolts sequentially and diagonally.
NOTE:
* Align the flange E of the camshafts with the groove F of the
camshaft journal holders.
* Damage to head or camshaft journal holder thrust surfaces
may result if the camshaft journal holders are not drawn down
evenly.
* Each camshaft journal holder is identified with a cast-on letters
G.
“3”
1 2 3 4 5 6 7 8 9 10 1112 13 14 15 16
ENGINE 3-101
• Tighten the camshaft journal holder bolts to the specified
torque.
$ Camshaft journal holder bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft)
#
• Recheck the front camshaft positions, intake and exhaust.
Cam chain tension adjuster
• With the spring holder bolt and spring removed from the cam
chain tension adjuster, release locking of the ratchet mechanism
1 and push the push rod 2 all the way in.
• Install the gasket and oil jet.
• Install the cam chain tension adjuster 3 with “UP” mark faced
to the top of cylinder head.
• Tighten the cam chain tension adjuster mounting bolts to the
specified torque.
#
$ Cam chain tension adjuster mounting bolt:
10 N·m (1.0 kgf-m 7.0 lb-ft)
• Install the spring 4, gasket 5 and spring holder bolt 6.
#
• Tighten the cam chain tension adjuster cap bolt to the specified torque.
$ Cam chain tension adjuster cap bolt:
23 N·m (2.3 kgf-m, 16.5 lb-ft)
#
The camshaft journal holder bolts are made of a special material and much superior in strength, compared
with other types of high strength bolts.
Take special care not to use other types of bolts
instead of these special bolts. To identify these bolts,
each of them has a figure “9” on its head.
Use the new gasket to prevent oil leakage.
Use the new gasket to prevent oil leakage.
After installing the cam chain tension adjuster, check
to be sure that the adjuster work properly by checking
the slack of cam chain.
3-102 ENGINE
• Install the cam chain guide
7.
No.2 (Rear) Camshafts
• From the position where the front camshafts have now been
installed, rotate the generator rotor 360 degrees (1 turn) counterclockwise and align the “F” line A on the generator rotor
with the index mark B of the valve timing inspection hole.
#
#
• Pull the cam chain lightly.
• The No.2 intake camshaft sprocket has an arrow mark “1R”
C. Install the intake camshaft so that the arrow C is aligned
with the mating surface of the cylinder head. (!3-103)
• Engage the cam chain with the intake camshaft sprocket.
NOTE:
Before installing the camshaft, check that the tappets are
installed correctly.
Pull the cam chain upward, or the chain will be caught
between crankcase and cam drive sprocket.
To adjust the camshaft timing correctly, be sure to
align “F” line A with the index mark B and hold this
position when installing the camshafts.
“2”
ENGINE 3-103
• The other arrow mark “2” on the intake camshaft sprocket
should now be pointing straight up. Starting from the roller pin
that is directly above the arrow mark “2” count out 16 roller
pins (from the intake camshaft side going towards the exhaust
camshaft side). Engage the 16th roller pin
D on the cam
chain with the arrow mark “3” on the exhaust sprocket.
(!3-103)
NOTE:
The cam chain should now be on all three sprockets. Be careful
not to move the crankshaft until the camshaft journal holders
and cam chain tension adjuster is secured.
No.2 (REAR) CYLINDER HEAD
• Install the dowel pins 1.
“3”
12345678910111213141516
3-104 ENGINE
• Apply engine oil to the camshaft journal holders.
• Install the camshaft journal holders, intake and exhaust.
• Fasten the camshaft journal holders evenly by tightening the
camshaft journal holder bolts sequentially and diagonally.
NOTE:
* Align the flange
E of the camshafts with the groove F of the
camshaft journal holders.
* Damage to head or camshaft journal holder thrust surfaces
may result if the camshaft journal holders are not drawn down
evenly.
* Each camshaft journal holder is identified with a cast-on letter
G.
• Tighten the camshaft journal holder bolts to the specified
torque.
$ Camshaft journal holder bolt: 10 N·m
(1.0 kgf-m, 7.0 lb-ft)
#
• Recheck the rear camshaft positions, intake and exhaust.
Cam chain tension adjuster
• Install the cam chain tension adjuster. (!3-101)
• Install the cam chain guide 1.
• After installing the rear camshafts, rotate the generator rotor
(same turns), and recheck the positions of the camshafts.
The camshaft journal holder bolts are made of a special material and much superior in strength, compared
with other types of high strength bolts.
Take special care not to use other types of bolts
instead of these special bolts. To identify these bolts,
each of them has a figure “9” on its head.
ENGINE 3-105
No.1 (Front) cylinde TDC of compression stroke
1 Cam chain guide 2 Cam chain guide A Forward
21
R
3
1F
2
1R
3
1F
2
1R3
1F
2
1R
3
1F
3-106 ENGINE
CYLINDER HEAD COVER
• Pour engine oil in each oil pocket in the front and rear cylinder
heads.
NOTE:
Be sure to check the valve clearance. (!2-8)
• Install the dowel pins
1 and O-rings 2.
• Install the new gaskets to each cylinder head cover.
• Apply SUZUKI BOND to the cam end caps of the gaskets.
+ 99104-31140: SUZUKI BOND “1207B” (USA)
. 99000-31110: SUZUKI BOND “1215” (Others)
#
• The cylinder head covers can be distinguished by the
embossed letters A.
“F”: Front cylinder head cover
“R”: Rear cylinder head cover
• Install the cylinder head covers on each cylinder head.
• Fit the gaskets 3, 4 to each head cover bolt.
#
NOTE:
The metal side of the gasket 3 must face to the bolt flange.
• After applying engine oil to the gaskets tighten the head cover
bolts to the specified torque.
$ Head cover bolt: 14 N·m (1.4 kgf-m, 10.0 lb-ft)
Use the new gaskets to prevent oil leakage.
Use the new gaskets to prevent oil leakage.
ENGINE 3-107
EXHAUST PIPE
• Tighten the exhaust pipe bolts
1 to the specified torque.
$ Exhaust pipe bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft)
#
WATER UNION
• Install the O-ring to the water union.
#
• When installing the water union, apply engine coolant to the
O-ring.
/ ENGINE COOLANT
INTAKE PIPE
• Apply SUZUKI SUPER GREASE to the O-ring.
' 99000-25030: SUZUKI SUPER GREASE “A” (USA)
99000-25010: SUZUKI SUPER GREASE “A” (Others)
#
• Make sure that the “UP” mark A faces upward.
• Install the intake pipes.
NOTE:
The intake pipe can be identified by the mark B.
F: Front cylinder head intake pipe
R: Rear cylinder head intake pipe
Use the new gasket to prevent exhaust gas leakage.
Replace the O-ring with a new one.
Use the new O-ring to prevent air from sucking
through the joint.
3-108 ENGINE
GENERATOR COVER PLUG
• Apply engine oil to the O-ring of the generator cover plug.
• Tighten the valve timing inspection plug
1 and generator
cover plug 2 to the specified torque.
$ Valve timing inspection plug: 23 N·m
(2.3 kgf-m, 16.3 lb-ft)
Generator cover plug: 11 N·m (1.1 kgf-m, 8.0 lb-ft)
#
THERMOSTAT CASE AND WATER HOSE
• Install the thermostat case 1 along with the water hoses 2
and tighten the clamp screws securely. (!9-24)
SPARK PLUG AND HOSES
• Connect the PAIR hoses 1.
• Connect the crankcase breather hoses 2.
• Install the spark plugs. (!2-8)
Use the new O-ring to prevent oil leakage.
03 ENGINE.book Page 105 Tuesday, February 28, 2006 3:03 PM
FI SYSTEM DIAGNOSIS
CONTENTS
PRECAUTIONS IN SERVICING....................................................................4- 2
ELECTRICAL PARTS.............................................................................4- 2
FUSE .......................................................................................................4- 3
ECM/VARIOUS SENSORS.....................................................................4- 3
ELECTRICAL CIRCUIT INSPECTION PROCEDURE ...........................4- 5
USING TESTERS....................................................................................4- 8
FI SYSTEM TECHNICAL FEATURES..........................................................4- 9
INJECTION TIME (INJECTION VOLUME).............................................4- 9
COMPENSATION OF INJECTION TIME (VOLUME).............................4-10
INJECTION STOP CONTROL................................................................4-10
FI SYSTEM PARTS LOCATION.............................................................4-11
FI SYSTEM WIRING DIAGRAM .............................................................4-13
SELF-DIAGNOSIS FUNCTION.....................................................................4-14
USER MODE...........................................................................................4-14
DEALER MODE ......................................................................................4-15
TPS ADJUSTMENT ................................................................................4-16
FAIL-SAFE FUNCTION.................................................................................4-17
FI SYSTEM TROUBLESHOOTING...............................................................4-18
CUSTOMER COMPLAINT ANALYSIS ..................................................4-18
SELF-DIAGNOSTIC PROCEDURES .....................................................4-20
SELF-DIAGNOSIS RESET PROCEDURE .............................................4-20
MALFUNCTION CODE AND DEFECTIVE CONDITION........................4-21
“C12” CKP SENSOR CIRCUIT MALFUNCTION...................................4-23
“C13” IAP SENSOR CIRCUIT MALFUNCTION ....................................4-25
“C14” TP SENSOR CIRCUIT MALFUNCTION......................................4-28
“C15” ECT SENSOR CIRCUIT MALFUNCTION ...................................4-31
“C21” IAT SENSOR CIRCUIT MALFUNCTION ....................................4-33
“C23” TO SENSOR CIRCUIT MALFUNCTION .....................................4-35
“C24” or “C25” IGNITION SYSTEM MALFUNCTION ..........................4-36
“C28” STV ACTUATOR CIRCUIT MALFUNCTION ..............................4-37
“C29” STP SENSOR CIRCUIT MALFUNCTION ...................................4-38
“C31” GEAR POSITION (GP) SWITCH CIRCUIT MALFUNCTION ......4-41
“C32” or “C33” FUEL INJECTOR CIRCUIT MALFUNCTION ..............4-42
“C41” FP RELAY CIRCUIT MALFUNCTION.........................................4-44
“C42” IG SWITCH CIRCUIT MALFUNCTION .......................................4-44
“C49” PAIR CONTROL SOLENOID VALVE CIRCUIT
MALFUNCTION ......................................................................................4-45
“C44” HO2 SENSOR (HO2S) CIRCUIT MALFUNCTION (E-02, 19).....4-47
FI SYSTEM DIAGNOSIS 4-1
4
SENSORS......................................................................................................4-49
CKP SENSOR INSPECTION ..................................................................4-49
CKP SENSOR REMOVAL AND INSTALLATION ..................................4-49
IAP SENSOR INSPECTION....................................................................4-49
IAP SENSOR REMOVAL AND INSTALLATION....................................4-49
TP SENSOR INSPECTION .....................................................................4-49
TP SENSOR REMOVAL AND INSTALLATION .....................................4-49
TPS ADJUSTMENT ................................................................................4-49
ECT SENSOR INSPECTION...................................................................4-49
ECT SENSOR REMOVAL AND INSTALLATION ..................................4-49
IAT SENSOR INSPECTION ....................................................................4-50
IAT SENSOR REMOVAL AND INSTALLATION....................................4-50
TO SENSOR INSPECTION.....................................................................4-50
TO SENSOR REMOVAL AND INSTALLATION.....................................4-50
STP SENSOR INSPECTION...................................................................4-50
STP SENSOR REMOVAL AND INSTALLATION...................................4-50
STP SENSOR ADJUSTMENT ................................................................4-50
HO2 SENSOR INSPECTION (E-02, 19) .................................................4-50
HO2 SENSOR REMOVAL AND INSTALLATION ..................................4-50
4-2 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 is felt.
• With a lock type coupler, be sure to release the lock when disconnecting, and push it in fully till the works when connecting
it.
• When disconnecting the coupler, be sure to hold the coupler
body and do not pull the lead wires.
• Inspect each terminal on the connector/coupler for looseness
or bending.
• Inspect each terminal for corrosion and contamination.
The terminals must be clean and free of any foreign material
which could impede proper terminal contact.
• Inspect each lead wire circuit for poor connection by shaking it
by hand lightly. If any abnormal condition is found, repair or
replace.
When taking measurements at electrical connectors using a
tester probe, be sure to insert the probe from the wire harness
side (backside) of the connector/coupler.
1 Coupler
2 Probe
Click
Click
FI SYSTEM DIAGNOSIS 4-3
• When connecting meter probe from the terminal side of the
coupler (connection from harness side not being possible),
use extra care not to force and cause the male terminal to
bend or the female terminal to open.
Connect the probe as shown to avoid opening of female terminal.
Never push in the probe where male terminal is supposed to
fit.
• Check the male connector for bend and female connector for
excessive opening. Also check the coupler for locking (looseness), corrosion, dust, etc.
1 Coupler
2 Probe
3 Where male
terminal fits.
FUSE
• When a fuse blows, always investigate the cause correct it
and then replace the fuse.
• Do not use a fuse of a different capacity.
• Do not use wire or any other substitute for the fuse.
ECM/VARIOUS SENSORS
• Since each component is a high-precision part, great care
should be taken not to apply any sharp impacts during
removal and installation.
• Be careful not to touch the electrical terminals of the ECM.
The static electricity from your body may damage this part.
INCORRECT
4-4 FI SYSTEM DIAGNOSIS
• When disconnecting and connecting the ECM, make sure to
turn OFF the ignition switch
1, or electronic parts may get
damaged.
• 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.
• Removing any battery terminal of a running engine is strictly
prohibited.
The moment such removal is made, damaging counter electromotive force will be applied to the ECM which may result in
serious damage.
• Before measuring voltage at each terminal, check to make
sure that battery voltage is 11 V or higher. Terminal voltage
check at low battery voltage will lead to erroneous diagnosis.
• Never connect any tester (voltmeter, ohmmeter, or whatever)
to the ECM when its coupler is disconnected.
Otherwise, damage to ECM may result.
• Never connect an ohmmeter to the ECM with its coupler connected. If attempted, damage to ECM or sensors may result.
• Be sure to use a specified voltmeter/ohmmeter. Otherwise,
accurate measurements may not be obtained and personal
injury may result.
INCORRECT
FI SYSTEM DIAGNOSIS 4-5
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.
• Loose connection of connector/coupler.
• Poor contact of terminal (due to dirt, corrosion or rust, poor
contact tension, entry of foreign object etc.).
• Wire harness being open.
• Poor terminal-to-wire connection.
• Disconnect the negative cable from the battery.
• Check each connector/coupler at both ends of the circuit
being checked for loose connection. Also check for condition
of the coupler lock if equipped.
1 Sensor
2 ECM
A Check for loose
connection.
• Using a test male terminal, check the female terminals of the
circuit being checked for contact tension.
Check each terminal visually for poor contact (possibly
caused by dirt, corrosion, rust, entry of foreign object, etc.). At
the same time, check to make sure that each terminal is fully
inserted in the coupler and locked.
If contact tension is not enough, rectify the contact to increase
tension or replace.
The terminals must be clean and free of any foreign material
which could impede proper terminal contact.
A Check contact tension by
inserting and removing.
B Check each terminal for
bend and proper alignment.
• Using continuity inspect or voltage check procedure as
described below, inspect the wire harness terminals for open
circuit and poor connection. Locate abnormality, if any.
1 Looseness of crimping
2 Open
3 Thin wire (a few strands left)
4-6 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.
If no continuity is indicated, the circuit is open between couplers A and B. If continuity is indicated, there is an open circuit between couplers B’ and C or an abnormality in coupler
B’ or coupler C.
1 ECM
VOLTAGE CHECK
If voltage is supplied to the circuit being checked, voltage check
can be used as circuit check.
• With all connectors/couplers connected and voltage applied
to the circuit being checked, measure voltage between each
terminal and body ground.
If measurements were taken as shown in the figure at the right
and results are as listed below, it means that the circuit is open
between terminals A and B.
Voltage Between:
C and body ground: Approx. 5 V
B and body ground: Approx. 5 V
A and body ground: 0 V
Also, if measured values are as listed below, a resistance
(abnormality) exists which causes the voltage drop in the circuit
between terminals A and B.
Voltage Between:
C and body ground: Approx. 5 V
B and body ground: Approx. 5 V 2 V voltage drop
A and body ground: 3 V
5 V
0 V
5 V
5 V
FI SYSTEM DIAGNOSIS 4-7
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. Otherwise,
diagnosis will be misled.
• Measure resistance between terminal at one end of circuit (
A
terminal in figure) and body ground. If continuity is indicated,
there is a short circuit to ground between terminals A and C.
1 To other parts.
2 Other parts
• Disconnect the connector/coupler included in circuit (coupler
B) and measure resistance between terminal A and body
ground.
If continuity is indicated, the circuit is shorted to the ground
between terminals A and B.
1 To other parts.
2 ECM
5 V
4-8 FI SYSTEM DIAGNOSIS
USING TESTERS
• Use the Suzuki multi-circuit tester set (09990-25008).
• 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.
• If the voltage and current are not known, make measurements using the highest range.
• When measuring the resistance with the multi-circuit tester 1,
∞ will be shown as 10.00 MΩ and “1” flashes in the display.
• Check that no voltage is applied before making the measurement. If voltage is applied the tester may be damaged.
• After using the tester, turn the power off.
! 09900-25008: Multi-circuit tester set
NOTE:
* When connecting the multi-circuit tester, use the needle
pointed probe to the back side of the lead wire coupler and
connect the probes of tester to them.
* Use the needle pointed probe to prevent the rubber of the
water proof coupler from damage.
! 09900-25009: Needle pointed probe set
FI SYSTEM DIAGNOSIS 4-9
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.
Intake Air Pressure
Sensor (IAP Sensor)
Intake air pressure
signal
Engine speed
signal
Throttle opening
signal
Crankshaft Position
Sensor (CKP Sensor)
Throttle Position
Sensor (TP Sensor)
Various
Sensors
Various signals
Injection signal
Injectors
ECM
Basic
fuel
injection
time
Ultimate
fuel
injection
time
Compensation
4-10 FI SYSTEM DIAGNOSIS
COMPENSATION OF INJECTION TIME (VOLUME)
The following different signals are output from the respective sensors for compensation of the fuel injection
time (volume).
INJECTION STOP CONTROL
SIGNAL DESCRIPTION
ENGINE COOLANT TEMPERATURE SEN-
SOR SIGNAL
When engine coolant temperature is low, injection time (volume) is increased.
INTAKE AIR TEMPERATURE SENSOR
SIGNAL
When intake air temperature is low, injection time (volume)
is increased.
BATTERY VOLTAGE SIGNAL ECM operates on the battery voltage and at the same time,
it monitors the voltage signal for compensation of the fuel
injection time (volume). A longer injection time is needed to
adjust injection volume in the case of low voltage.
ENGINE RPM SIGNAL At high speed, the injection time (volume) is increased.
ACCELERATION SIGNAL/
DECELERATION SIGNAL
During acceleration, the fuel injection time (volume) is
increased in accordance with the throttle opening speed and
engine rpm. During deceleration, the fuel injection time (volume) is decreased.
SIGNAL DESCRIPTION
TIP OVER SENSOR SIGNAL
(FUEL SHUT-OFF)
When the motorcycle tips over, the tip over sensor sends a
signal to the ECM. Then, this signal cuts OFF current supplied to the fuel pump, fuel injector and ignition coil.
OVER-REV. LIMITER SIGNAL The fuel injectors stop operation when engine rpm reaches
rev. limit rpm.
FI SYSTEM DIAGNOSIS 4-11
FI SYSTEM PARTS LOCATION
A Speedometer F Fuel injector, No.1
B CKP sensor G Fuel injector, No.2
C TP sensor H Ignition coil, No.1
D Gear position sensor I STVA
E STP sensor J TO sensor
ECM
A
I
F G C
E
J
H
B
D
4-12 FI SYSTEM DIAGNOSIS
K IAP sensor N Fuel pump relay
L IAT sensor O Ignition coil, No.2
M ECT sensor P PAIR control valve
K L
M
N
O
P
ECM
FI SYSTEM DIAGNOSIS 4-13
FI SYSTEM WIRING DIAGRAM
IG
2
IG
1
O
/G
B
/Y
W
/B
l B
B
/B
l B
r G
r/ W
G
r/ B
B
/R
R
/B D
g R
P
/W
B
/B
r W
/B
W
/GY P W B
/W
W
/R
G
/B
B
r/ B
B
/G
B
/W
B
/WY
/B
B
r/ W
O
/R
M
O
D
E
S
E
LE
C
T
IO
N
S
W
IT
C
H
S
P
E
E
D
O
M
E
T
E
R
IN
TA
K
E
A
IR
P
R
E
S
S
U
R
E
S
E
N
S
O
R
PA
IR
S
O
LE
N
O
ID
C
O
N
T
R
O
L
V
A
LV
E
S
ID
E
-
S
TA
N
D
S
W
IT
C
H
G
E
A
R
P
O
S
IT
IO
N
S
W
IT
C
H
C
LU
T
C
H
S
W
IT
C
H
F
P
D
O
N AT +
B
C
LT IG
1
T
H
W
T
H
A
V
C
C
T
P
S E
2
S
T
P
S
H
O
2
(O
X
H
)
H
O
2
(O
X
)
G
P
N
+
E
1
T
S
P
M
TA
C
O
E
01
E
02
T
E
C
H
S
O
L
F
l #
1
F
l #
2
M
O
+
M
O

IG
2
IG
N
IT
IO
N
C
O
IL
30
A
10
A
10
A
10
A
N
E
U
T
R
A
L
LA
M
P
S
ID
E
-S
TA
N
D
R
E
LA
Y
E
N
G
IN
E
S
TO
P
S
W
IT
C
H
F
U
E
L
P
U
M
P
R
E
LA
Y
T
IP
O
V
E
R
S
E
N
S
O
R
M
A
IN
S
W
IT
C
H
B
AT
T
E
R
Y
E
C
M
F
U
E
L
P
U
M
P
S
TA
R
T
E
R
B
U
T
TO
N
S
TA
R
T
E
R
R
E
LA
Y
S
T
P
S
IA
T
S
S
T
V
A
T
P
S
E
C
T
S
C
K
P
S
F
l 8
H
O
2
4-14 FI SYSTEM DIAGNOSIS
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 light). To check
the function of the individual FI system devices, the dealer mode is prepared. In this check, the special tool
is necessary to read the code of the malfunction items.
USER MODE
*1
When one of the signals is not received by ECM, the fail-safe circuit works and injection is not stopped. In
this case, “FI” and clock are indicated in the LCD panel and motorcycle can run.
*2
The injection signal is stopped, when the crankshaft position sensor signal, tip over sensor signal, #1/#2
ignition signals, #1/#2 injector signals, fuel pump relay signal or ignition switch signal is not sent to ECM. In
this case, “FI” is indicated in the LCD panel. Motorcycle does not run.
“CHEC”: The LCD panel indicates “CHEC” when no communication signal from the ECM is received for 3
seconds.
For Example, The ignition switch is turned ON, and the engine stop switch is turned OFF. In this case, the
speed-meter does not receive any signal from ECM, and the panel indicates “CHEC”.
If CHEC is indicated, the LCD does not indicate the trouble code. It is necessary to check the
wiring harness between ECM and speedometer couplers.
The possible cause of this indication is as follows;
Engine stop switch is in OFF position. Side-stand/ignition inter-lock system is not working Ignition fuse is
burnt.
NOTE:
Until starting the engine, the FI light turns ON.
The FI light is also turned ON when engine temperature is high or oil pressure is low.
MALFUNCTION
LCD (DISPLAY)
INDICATION
FI LIGHT
INDICATION
INDICATION MODE
“NO” Clock ---- ---“YES”
Engine can start
Clock and “FI” letters
*1
FI light turns ON. Each 2 sec. Clock or “FI”
is indicated.
Engine can not
start
“FI” letters
*2
FI light turns ON
and blinks.
“FI” is indicated
continuously.
FI SYSTEM DIAGNOSIS 4-15
DEALER MODE
The defective function is memorized in the computer. Use the special tool’s coupler to connect to the dealer
mode coupler. ("4-20) 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.
! 09930-82720: Mode select switch
#
* Do not disconnect the ECM lead wire couplers, before checking the malfunction code, or the
malfunction code memory is erased and the malfunction code can not be checked.
* Confirm the malfunction code after ignition ON or cranking the engine for few seconds.
MALFUNCTION
LCD (DISPLAY)
INDICATION
FI LIGHT
INDICATION
INDICATION MODE
“NO” C00
“FI” letter turns OFF.
----
“YES”
C**code is indicated from
small numeral to large one.
For each 2 sec., code is
indicated.
4-16 FI SYSTEM DIAGNOSIS
In the LCD (DISPLAY) panel, the malfunction code is indicated from small code to large code.
TPS ADJUSTMENT
1. Warm up the engine and adjust the engine idle speed to
1 300 ± 100 rpm. ("2-15)
2. Stop the engine.
3. Connect the special tool (Mode select switch) and select the
dealer mode.
4. If the throttle position sensor adjustment is necessary, loosen
the screws and turn the throttle position sensor and bring the
line to middle.
5. Then, tighten the screw to fix the throttle position sensor.
$ TP sensor mounting screw: 3.5 N·m (0.35 kgf-m, 2.5 lb-ft)
A Incorrect
B Correct position
! 09930-11950: Torx wrench
09930-82720: Mode select switch
CODE MALFUNCTION PART REMARKS
C00
C12
C13
C14
C15
C21
C23
C24
C25
C28
C29
C31
C32
C33
C41
C42
C44
C49
None
Crankshaft position sensor (CKPS)
Intake air pressure sensor (IAPS)
Throttle position sensor (TPS)
Engine coolant temperature sensor (ECTS)
Intake air temperature sensor (IATS)
Tip over sensor (TOS)
Ignition signal #1 (IG coil #1)
Ignition signal #2 (IG coil #2)
Secondary throttle valve actuator (STVA)
Secondary throttle position sensor (STPS)
Gear position signal (GP switch)
Fuel injector signal #1
Fuel injector signal #2
Fuel pump control system (FP control system)
Ignition switch signal (IG switch signal)
Heated oxygen sensor (HO2S)
PAIR control solenoid valve
No defective part
Pick-up coil signal, signal generator
For #1 cylinder
For #2 cylinder
For #1 cylinder
For #2 cylinder
Fuel pump, Fuel pump relay
Anti-theft
For E-02, 19
FI SYSTEM DIAGNOSIS 4-17
FAIL-SAFE FUNCTION
FI system is provided with fail-safe function to allow the engine to start and the motorcycle to run in a minimum performance necessary even under malfunction condition.
The engine can start and can run even if the above signal is not received from each sensor. But, the engine
running condition is not complete, providing only emergency help (by fail-safe circuit). In this case, it is necessary to bring the motorcycle to the workshop for complete repair.
ITEM FAIL-SAFE MODE
STARTING
ABILITY
RUNNING
ABILITY
Intake air pressure sensor Intake air pressure and atmospheric
pressure are fixed to 760 mmHg.
“YES” “YES”
Throttle position sensor The throttle opening signal is fixed to
full open position, and STV is fixed
at 1/2 open position.
Ignition timing is also fixed.
“NO” “YES”
Engine coolant temperature
sensor
Engine coolant temperature value is
fixed to 80 °C (176 °F).
“YES” “YES”
Intake air temperature
sensor
Intake air temperature value is fixed
to 40 °C (104 °F).
“YES” “YES”
Ignition signal
#1 #1 Fuel cut
“YES” “YES”
#2 cylinder can run.
#2 #2 Fuel cut
“YES” “YES”
#1 cylinder can run.
Injection signal
#1 #1 Fuel-cut
“YES” “YES”
#2 cylinder can run.
#2 #2 Fuel-cut
“YES” “YES”
#1 cylinder can run.
Secondary throttle valve
actuator
ECM stops controlling STV.
“YES” “YES”
Secondary throttle position
sensor
ECM stops controlling STV.
“YES” “YES”
Gear position signal Gear position signal is fixed to 4th
gear.
“YES” “YES”
Heated oxygen sensor
(E-02, 19)
Fuel-air compensation ratio is fixed
to normal condition.
“YES” “YES”
PAIR control solenoid valve ECM stops controlling PAIR control
solenoid valve.
“YES” “YES”
4-18 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 will facilitate collecting information to the point required for proper
analysis and diagnosis.
EXAMPLE: CUSTOMER PROBLEM INSPECTION FORM
User name: Model: VIN:
Date of issue: Date Reg. Date of problem: Mileage:
Malfunction indicator
lamp condition (LED)
Always ON Sometimes ON Always OFF Good condition
Malfunction display/code
(LCD)
User mode: No display Malfunction display ( )
Dealer mode: No code Malfunction code ( )
PROBLEM SYMPTOMS
Difficult Starting Poor Driveability
No cranking Hesitation on acceleration
No initial combustion Back fire/ After fire
No combustion Lack of power
Poor starting at
( cold warm always)
Surging
Abnormal knocking
Other Engine rpm jumps briefly
Other
Poor Idling Engine Stall when
Poor fast Idle Immediately after start
Abnormal idling speed
( High Low) ( r/min)
Throttle valve is opened
Throttle valve is closed
Unstable Load is applied
Hunting ( r/min. to r/min) Other
Other
OTHERS:
FI SYSTEM DIAGNOSIS 4-19
NOTE:
* The above form is a standard sample. It should be modified according to conditions characteristic of each
market.
MOTORCYCLE/ENVIRONMENTAL CONDITION WHEN PROBLEM OCCURS
Environmental condition
Weather
Temperature
Frequency
Fair Cloudy Rain Snow Always Other
Hot Warm Cool Cold ( °F/ °C) Always
Always Sometimes ( times/ day, month) Only once
Under certain condition
Road Urban Suburb Highway Mountainous ( Uphill Downhill)
Tarmacadam Gravel Other
Motorcycle condition
Engine condition Cold Warming up phase Warmed up Always Other at starting
Immediately after start Racing without load Engine speed ( r/min)
Motorcycle condition
During driving: Constant speed Accelerating Decelerating
Right hand corner Left hand corner At stop
Motorcycle speed when problem occurs ( km/h, Mile/h)
Other
4-20 FI SYSTEM DIAGNOSIS
SELF-DIAGNOSTIC PROCEDURES
Don’t disconnect couplers from ECM, battery cable from battery,
ECM ground wire harness from engine or main fuse before confirming malfunction code (self-diagnostic trouble code) stored in
memory. Such disconnection will erase memorized information
in ECM memory.
Malfunction code stored in ECM memory can be checked by the
special tool.
Before checking malfunction code, read SELF-DIAGNOSIS
FUNCTION “USER MODE and DEALER MODE” ("4-14,
15) carefully to have good understanding as to what functions
are available and how to use it.
Be sure to read “PRECAUTIONS for Electrical Circuit Service”
("4-2) before inspection and observe what is written there.
• Remove the seat. ("7-4)
• Connect the special tool to the dealer mode coupler at the wiring harness, and start the engine or crank the engine for 4
seconds and more.
• Turn the special tool’s switch ON and check the malfunction
code to determine the malfunction part.
! 09930-82720: Mode select switch
NOTE:
The dealer mode coupler is located inside of the left frame
cover.
SELF-DIAGNOSIS RESET PROCEDURE
• After repairing the trouble, turn OFF the ignition switch and
turn ON again.
• If C00 is indicates, the malfunction codes are cleared.
• Disconnect the special tool from the dealer mode coupler.
ON OFF
FI SYSTEM DIAGNOSIS 4-21
MALFUNCTION CODE AND DEFECTIVE CONDITION
MALFUNCTION
CODE
DETECTED ITEM
DETECTED FAILURE CONDITION
CHECK FOR
C00 NO FAULT –––––––––––
C12
Crankshaft position
sensor
The signal does not reach ECM for 3 sec. and more, after
receiving the IAP signal.
The crankshaft position sensor wiring and mechanical parts.
(Crankshaft position sensor, lead wire/coupler connection)
C13
Intake air pressure
sensor
The sensor should produce following voltage.
0.1 V sensor voltage 4.8 V
Without the above range for 4 sec. and more, C13 is indicated.
Intake air pressure sensor, lead wire/coupler connection.
C14
Throttle position sensor
The sensor should produce following voltage.
0.1 V sensor voltage < 4.8 V
Without the above range for 4 sec. and more, C14 is indicated.
Throttle position sensor, lead wire/coupler connection.
C15
Engine coolant temperature sensor
The sensor voltage should be the following.
0.1 V sensor voltage < 4.6 V
Without the above range for 4 sec. and more, C15 is indicated.
Engine coolant temperature sensor, lead wire/coupler connection.
C21
Intake air temperature
sensor
The sensor voltage should be the following.
0.1 V sensor voltage < 4.6 V
Without the above range for 4 sec. and more, C21 is indicated.
Intake air temperature sensor, lead wire/coupler connection.
C23
Tip over sensor The sensor voltage should be the following for 2 sec. and more
after ignition switch turns ON.
0.2 V sensor voltage 4.6 V
Without the above value for 2 sec. and more, C23 is indicated.
Tip over sensor, lead wire/coupler connection.
C24/C25
Ignition signal #1/#2 Crankshaft position sensor (pick-up coil) signal is produced, but
signal from ignition coil is interrupted continuous by 8 times or
more. In this case, the code C24 or C25 is indicated.
Ignition coil, wiring/coupler connection, power supply from the
battery.
4-22 FI SYSTEM DIAGNOSIS
MALFUNCTION
CODE
DETECTED ITEM
DETECTED FAILURE CONDITION
CHECK FOR
C28
Secondary throttle
valve actuator
When no actuator control signal is supplied from the ECM or
communication signal does not reach ECM or operation voltage
does not reach STVA motor, C28 is indicated. STVA can not
operate.
STVA lead wire/coupler.
C29
Secondary throttle
position sensor
The sensor should produce following voltage.
0.1 V sensor voltage 4.8 V
Without the above range for 4 sec. and more, C29 is indicated.
Secondary throttle position sensor, lead wire/coupler connection.
C31
Gear position signal It judges from gear position voltage, engine speed and throttle
position by ECM, when the gear position voltage is 0.2 V and
less.
Gear position sensor, wiring/coupler connection. Gearshift cam
etc.
C32/C33
Fuel injector #1/#2 When fuel injector voltage gets 1.3 V and less, C32 or C33 is
indicated.
Injector, wiring/coupler connection, power supply to the injector.
C41
Fuel pump relay No voltage is applied to the both injectors #1/#2 for 3 sec. after
the contact of fuel pump relay is turned ON. Or voltage is
applied to the both injectors #1/#2, when the contact of fuel
pump is OFF.
Fuel pump relay, connecting lead wire, power source to fuel
pump relay, fuel injectors.
C42
Ignition switch Ignition switch signal is not input in ECM.
Ignition switch, lead wire/coupler.
C44
Heated oxygen sensor
(HO2S)
[E-02, 19]
The sensor voltage should be the following and less after warming up condition.
(Sensor voltage 0.4 V)
Without the above value, C44 is indicated.
Heater operation voltage does not reach in the oxygen heater
circuit, C44 in indicated.
The Heater can not operate.
HO2S lead wire/coupler connection.
Battery voltage supply to the HO2S.
C49
PAIR control solenoid
valve
PAIR control solenoid valve voltage is not input in ECM.
PAIR control solenoid valve, lead wire/coupler.
FI SYSTEM DIAGNOSIS 4-23
“C12” CKP SENSOR CIRCUIT MALFUNCTION
INSPECTION
Step1
1) Turn the ignition switch OFF.
2) Check the CKP sensor coupler
1 for loose or poor contacts.
If OK, then measure the CKP sensor resistance.
3) Disconnect the CKP sensor coupler and measure the resistance.
% CKP sensor resistance: 130 – 240 Ω
(White – Green)
4) If OK, then check the continuity between each terminal and
ground.
% CKP sensor continuity: ∞ Ω (Infinity)
(White – Ground)
(Green – Ground)
! 09900-25008: Multi circuit tester set
& Tester knob indication: Resistance (Ω)
Are the resistance and continuity OK?
DETECTED CONDITION POSSIBLE CAUSE
The signal does not reach ECM for 3 sec. and more,
after receiving the IAP signal.
• Metal particles or foreign materiel being attached
on the CKP sensor and rotor tip.
• CKP sensor circuit open or short.
• CKP sensor malfunction.
• ECM malfunction.
1
1
YES Go to Step 2.
NO Replace the CKP sensor with a new one.
1
4-24 FI SYSTEM DIAGNOSIS
Step2
1) Disconnect the CKP sensor coupler.
2) Crank the engine a few seconds with the starter motor, and
measure the CKP sensor peak voltage at the coupler.
% CKP sensor peak voltage: 3.7 V and more
(
+ White – - Green)
3) Repeat the above test procedure a few times and measure
the highest peak voltage.
If OK, then measure the CKP sensor peak voltage at the
ECM terminals. (P – T)
! 09900-25008: Multi circuit tester set
' Tester knob indication: voltage ( )
Is the voltage OK?
2
2
V
YES
• B/W or White wire open or shorted to ground, or
poor P or T connection.
• If wire and connection are OK, intermittent trouble or faulty ECM.
• Recheck each terminal and wire harness for
open circuit and poor connection.
NO
• Loose or poor contacts on the CKP sensor coupler or ECM coupler.
• Replace the CKP sensor with a new one.
FI SYSTEM DIAGNOSIS 4-25
“C13” IAP SENSOR CIRCUIT MALFUNCTION
INSPECTION
Step 1
1) Lift and support the fuel tank. ("5-7)
2) Turn the ignition switch OFF.
3) Check the IAP sensor coupler for loose or poor contacts.
If OK, then measure the IAP sensor input voltage.
4) Disconnect the IAP sensor coupler.
5) Turn the ignition switch ON.
6) Measure the voltage at the Red wire
1 and ground.
If OK, then measure the voltage at the Red wire 1 and B/Br
wire 2.
% IAP sensor input voltage: 4.5 – 5.5 V
(+ Red – - Ground)
(+ Red – - B/Br)
! 09900-25008: Multi circuit tester set
' Tester knob indication: Voltage ( )
Is the voltage OK?
DETECTED CONDITION POSSIBLE CAUSE
IAP sensor voltage is out of the specified range.
0.1 V Sensor voltage 4.8 V
NOTE:
Note that atmospheric pressure varies depending on
weather conditions as well as altitude.
Take that into consideration when inspecting voltage.
• Clogged vacuum passage between throttle body
and IAP sensor.
• Air being drawn from vacuum passage between
throttle body and IAP sensor.
• IAP sensor circuit open or shorted to ground.
• IAP sensor malfunction.
• ECM malfunction.
1
YES Go to Step 2
NO
• Loose or poor contacts on the ECM coupler.
• Open or short circuit in the Red wire or B/Br
wire.
1
V
4-26 FI SYSTEM DIAGNOSIS
Step 2
1) Connect the IAP sensor coupler.
2) Insert the needle pointed probes to the lead wire coupler.
3) Start the engine at idle speed.
4) Measure the IAP sensor output voltage at the wire side coupler (between G/B and B/Br wires).
% IAP sensor output voltage: Approx. 2.7 V at idle speed
(
+ G/B – - B/Br)
! 09900-25008: Multi circuit tester set
09900-25009: Needle pointed probe set
' Tester knob indication: Voltage ( )
Step 3
1) Remove the IAP sensor. ("4-49)
2) Connect the vacuum pump gauge to the vacuum port of the
IAP sensor.
Arrange 3 new 1.5 V batteries in series 1 (check that total
voltage is 4.5 – 5.0 V) and connect - terminal to the ground
terminal and + terminal to the Vcc 2 terminal.
Check the voltage between Vout 3 and ground. Also, check
if voltage reduces when vacuum is applied up to 400 mmHg
by using vacuum pump gauge. ("4-27)
! 09917-47011: Vacuum pump gauge
09900-25008: Multi circuit tester set
' Tester knob indication: Voltage ( )
Is the voltage OK?
YES Go to Step 3
NO
• Check the vacuum hose and the passage of
throttle body vacuum for crack or damage.
• Open or short circuit in the G/B wire.
• Replace the IAP sensor with a new one.
2
V
3
YES
• Red, G/B or B/Br wire open or shorted to
ground, or poor 0, F or X connection.
• If wire and connection are OK, intermittent trouble or faulty ECM.
• Recheck each terminal and wire harness for
open circuit and poor connection.
NO
If check result is not satisfactory, replace IAP sensor with a new one.
FI SYSTEM DIAGNOSIS 4-27
Output voltage (Vcc voltage 4.5 V, ambient temp. 25 °C,
77 °F)
ALTITUDE
(Reference)
ATMOSPHERIC
PRESSURE
OUTPUT
VOLTAGE
(ft) (m) (mmHg) kPa (V)
0

2 000
0

610
760

707
100

94
Approx.
3.3 – 3.6
2 001

5 000
611

1 524
707

634
94

85
Approx.
3.0 – 3.3
5 001

8 000
1 525

2 438
634

567
85

76
Approx.
2.7 – 3.0
8 001

10 000
2 439

3 048
567

526
76

70
Approx.
2.5 – 2.7
4-28 FI SYSTEM DIAGNOSIS
“C14” TP SENSOR CIRCUIT MALFUNCTION
INSPECTION
Step 1
1) Remove the fuel tank ("5-7).
2) Turn the ignition switch OFF.
3) Check the TP sensor coupler for loose or poor contacts.
If OK, then measure the TP sensor input voltage.
4) Disconnect the TP sensor coupler.
5) Turn the ignition switch ON.
6) Measure the voltage at the Red wire and ground.
7) If OK, then measure the voltage at the Red wire and B/Br
wire.
% TP sensor input voltage: 4.5 – 5.5 V
(
+ Red – - Ground)
(+ Red – - B/Br)
! 09900-25008: Multi circuit tester set
' Tester knob indication: Voltage ( )
Is the voltage OK?
DETECTED CONDITION POSSIBLE CAUSE
Output voltage is out of the specified range.
0.1 V Sensor voltage < 4.8 V
• TP sensor maladjusted.
• TP sensor circuit open or short.
• TP sensor malfunction.
• ECM malfunction.
1
YES Go to Step 2
NO
• Loose or poor contacts on the ECM coupler.
• Open or short circuit in the Red wire or B/Br
wire.
1
V
1
V
FI SYSTEM DIAGNOSIS 4-29
Step 2
1) Remove the air cleaner box. ("5-15)
2) Turn the ignition switch OFF.
3) Disconnect the TP sensor coupler.
4) Check the continuity between
A and ground.
% TP sensor continuity: ∞ Ω (Infinity)
(A – Ground)
5) If OK, then measure the TP sensor resistance (between A
and B).
6) Turn the throttle grip and measure the resistance.
% TP sensor resistance
Throttle valve is closed : Approx. 1.12 kΩ
Throttle valve is opened: Approx. 4.26 kΩ
! 09900-25008: Multi circuit tester set
& Tester knob indication: Resistance (Ω)
Are the resistance and continuity OK?
2
YES Go to Step 3
NO
• Reset the TP sensor position correctly.
• Replace the TP sensor with a new one.
2
4-30 FI SYSTEM DIAGNOSIS
Step 3
1) Connect the TP sensor coupler.
2) Insert the needle pointed probes to the lead wire coupler.
3) Turn the ignition switch ON.
Measure the TP sensor output voltage at the coupler
(between
+ P/W and - B/Br) by turning the throttle grip.
% TP sensor output voltage
Throttle valve is closed : Approx. 1.12 V
Throttle valve is opened: Approx. 4.26 V
! 09900-25008: Multi circuit tester set
09900-25009: Needle pointed probe set
' Tester knob indication: Voltage ( )
Is the voltage OK?
3
V
YES
• Red, P/W or B/Br wire open or shorted to
ground, or poor 0, I or X connection.
• If wire and connection are OK, intermittent trouble or faulty ECM.
• Recheck each terminal and wire harness for
open circuit and poor connection.
NO
If check result is not satisfactory, replace TP sensor with a new one.
ECM coupler
FI SYSTEM DIAGNOSIS 4-31
“C15” ECT SENSOR CIRCUIT MALFUNCTION
INSPECTION
Step 1
1) Turn the ignition switch OFF.
2) Check the ECT sensor coupler for loose or poor contacts.
If OK, then measure the ECT sensor voltage at the wire side
coupler.
3) Disconnect the coupler and turn the ignition switch ON.
4) Measure the voltage between B/BI wire terminal
1 and
ground.
5) If OK, then measure the voltage between B/BI wire terminal
1 and B/Br wire terminal 2.
% ETC sensor voltage: 4.5 – 5.5 V
(+ B/BI – - Ground)
(+ B/BI – - B/Br)
! 09900-25008: Multi circuit tester set
' Tester knob indication: Voltage ( )
Is the voltage OK?
DETECTED CONDITION POSSIBLE CAUSE
Output voltage is out of the specified range.
0.1 V Sensor voltage < 4.6 V
• ECT sensor circuit open or short.
• ECT sensor malfunction.
• ECM malfunction.
1
1
YES Go to Step 2
NO
• Loose or poor contacts on the ECM coupler.
• Open or short circuit in the B/BI wire or B/Br
wire.
4-32 FI SYSTEM DIAGNOSIS
Step 2
1) Turn the ignition switch OFF.
2) Measure the ECT sensor resistance. (Refer to page 6-10 for
details.)
% 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)
Is the resistance OK?
2
YES
• B/Br or B/Bl wire open or shorted to ground, or
poor
X or Z connection.
• If wire and connection are OK, intermittent trouble or faulty ECM.
• Recheck each terminal and wire harness for
open circuit and poor connection.
NO Replace the ECT sensor with a new one.
Engine Coolant Temp Resistance
20 °C (68 °F) Approx. 2.45 kΩ
40 °C (104 °F) Approx. 1.148 kΩ
60 °C (140 °F) Approx. 0.587 kΩ
80 °C (176 °F) Approx. 0.322 kΩ
ECM coupler
FI SYSTEM DIAGNOSIS 4-33
“C21” IAT SENSOR CIRCUIT MALFUNCTION
INSPECTION
Step 1
1) Lift and support the fuel tank. ("5-7)
2) Turn the ignition switch OFF.
3) Check the IAT sensor coupler for loose or poor contacts.
If OK, then measure the IAT sensor voltage at the wire side
coupler.
4) Disconnect the coupler and turn the ignition switch ON.
5) Measure the voltage between Dg wire terminal
1 and
ground.
6) If OK, then measure the voltage between Dg wire terminal 1
and B/Br wire terminal 2.
% IAT sensor voltage: 4.5 – 5.5 V
(+ Dg – - Ground)
(+ Dg – - B/Br)
! 09900-25008: Multi circuit tester set
' Tester knob indication: Voltage ( )
Is the voltage OK?
DETECTED CONDITION POSSIBLE CAUSE
Output voltage is out of the specified range.
0.1 V Sensor voltage < 4.6 V
• IAT sensor circuit open or short.
• IAT sensor malfunction.
• ECM malfunction.
1
V
1
YES Go to Step 2
NO
• Loose or poor contacts on the ECM coupler.
• Open or short circuit in the Dg wire or B/Br wire.
4-34 FI SYSTEM DIAGNOSIS
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?
NOTE:
IAT sensor resistance measurement method is the same way as
that of the ECT sensor. Refer to page 6-10 for details.
2
YES
• Dg or B/Br wire open or shorted to ground, or
poor
D or X connection.
• If wire and connection are OK, intermittent trouble or faulty ECM.
• Recheck each terminal and wire harness for
open circuit and poor connection.
NO Replace the IAT sensor with a new one.
Intake Air Temp Resistance
20 °C (68 °F) Approx. 2.45 kΩ
40 °C (104 °F) Approx. 1.148 kΩ
60 °C (140 °F) Approx. 0.587 kΩ
80 °C (176 °F) Approx. 0.322 kΩ
FI SYSTEM DIAGNOSIS 4-35
“C23” TO SENSOR CIRCUIT MALFUNCTION
INSPECTION
Step 1
1) Remove the seat. ("7-4)
2) Turn the ignition switch OFF.
3) Check the TO sensor coupler for loose or poor contacts.
If OK, then measure the TO sensor resistance.
4) Remove the TO sensor.
5) Measure the resistance between
A and B terminals.
% TO sensor resistance:
19.1 – 19.7 kΩ (A – B terminals)
! 09900-25008: Multi circuit tester set
& Tester knob indication: Resistance (Ω)
Is the resistance OK?
DETECTED CONDITION POSSIBLE CAUSE
The sensor voltage should be the following for 2 sec.
and more after ignition switch turns ON.
0.2 V Sensor voltage 4.6 V
• TO sensor circuit open or short.
• TO sensor malfunction.
• ECM malfunction.
1
YES Go to Step 2
NO Replace the TO sensor with a new one.
1
4-36 FI SYSTEM DIAGNOSIS
Step 2
1) Connect the TO sensor coupler.
2) Insert the needle pointed probe to the lead wire coupler.
3) Turn the ignition switch ON.
4) Measure the voltage at the wire side coupler between Br/W
and B/Br wires of the TO sensor at horizontal.
% TO sensor voltage: 0.4 – 1.4 V
(
+ Br/W – - B/Br)
Also, measure the voltage when leaning of the motorcycle.
5) Measure the voltage when it is leaned more than 65 °, left
and right, from the horizontal level.
% TO sensor voltage: 3.7 – 4.4 V
(+ Br/W – - B/Br)
! 09900-25008: Multi circuit tester set
09900-25009: Needle pointed probe set
' Tester knob indication: Voltage ( )
Is the voltage OK?
“C24” or “C25” IGNITION SYSTEM MALFUNCTION
*Refer to the IGNITION SYSTEM for details. ("8-23)
2
V
2
V
65 ˚
YES
• Red, Br/W or B/Br wire open or shorted to
ground, or poor 0, a or X connection.
• If wire and connection are OK, intermittent trouble or faulty ECM.
• Recheck each terminal and wire harness for
open circuit and poor connection.
NO
• Loose or poor contacts on the ECM coupler.
• Open or short circuit in the Br/W wire or B/Br
wire.
• Replace the TO sensor with a new one.
FI SYSTEM DIAGNOSIS 4-37
“C28” STV ACTUATOR CIRCUIT MALFUNCTION
INSPECTION
Step 1
1) Remove the fuel tank and air cleaner box. ("5-15)
2) Turn the ignition switch OFF.
3) Check the STVA coupler for loose or poor contacts.
4) Turn the ignition switch ON to check the STV operation.
STV operating order: Full open
A → Open B
(Approx. 1 seconds later)
Is the operation OK?
Step 2
1) Turn the ignition switch OFF.
2) Check the STVA coupler for loose or poor contacts.
3) Disconnect the STVA coupler.
4) Check the continuity between terminal 1 and ground.
% STVA continuity: ∞ Ω (Infinity)
5) If OK, then measure the STVA resistance.
% STVA resistance: Approx. 7 – 14 Ω
! 09900-25008: Multi circuit tester set
' Tester knob indication: Resistance (Ω)
Is the resistance OK?
DETECTED CONDITION POSSIBLE CAUSE
The operation voltage does not reach the STVA.
ECM does not receive communication signal from
the STVA.
• STVA malfunction.
• STVA circuit open or short.
• STVA motor malfunction.
YES Go to Step 2
NO
• Loose or poor contacts on the STVA coupler.
• Open or short circuit in the B/R and R/B wires.
1
2
YES
• Loose or poor contacts on the STVA coupler, or
poor J or L connection.
• If wire and connection are OK, intermittent trouble or faulty ECM. Recheck each terminal and
wire harness for open circuit and poor connection.
NO Replace the STVA with a new one.
2
4-38 FI SYSTEM DIAGNOSIS
“C29” STP SENSOR CIRCUIT MALFUNCTION
INSPECTION
Step 1
1) Remove the air cleaner box. ("5-15)
2) Turn the ignition switch OFF.
3) Check the STP sensor coupler for loose or poor contacts.
If OK, then measure the STP sensor input voltage.
4) Disconnect the STP sensor coupler.
5) Turn the ignition switch ON.
6) Measure the voltage at the Red wire and ground.
7) If OK, then measure the voltage at the Red wire and B/Br
wire.
% STP sensor input voltage: 4.5 – 5.5 V
(
+ Red – - Ground)
(+ Red – - B/Br)
! 09900-25008: Multi circuit tester set
' Tester knob indication: Voltage ( )
Is the voltage OK?
DETECTED CONDITION POSSIBLE CAUSE
Signal voltage is out of the specified range.
Difference between actual throttle opening and
opening calculated by ECM in larger than specified
value.
0.1 V Sensor voltage 4.8 V
• STP sensor maladjusted.
• STP sensor circuit open or short.
• STP sensor malfunction.
• ECM malfunction.
1
1
V
1
V
YES Go to Step 2
NO
• Loose or poor contacts on the ECM coupler.
• Open or short circuit in the Red wire or B/Br
wire.
FI SYSTEM DIAGNOSIS 4-39
Step 2
1) Turn the ignition switch OFF.
2) Disconnect the STP sensor coupler.
3) Check the continuity between Yellow wire and ground.
% STP sensor continuity: ∞ Ω (Infinity)
(Yellow – Ground)
4) If OK, then measure the STP sensor resistance at the coupler
(between Yellow and Black wires).
5) Close and open the secondary throttle valve fully by turning
the actuator shaft end
1, and measure the STP sensor resistance with both STV positions.
% STP sensor resistance
Secondary throttle valve is closed: Approx. 0.58 kΩ
Secondary throttle valve is opened: Approx. 4.38 kΩ
! 09900-25008: Multi circuit tester set
& Tester knob indication: Resistance (Ω)
#
Is the resistance OK?
2
2
Do not use the tool for turning the STVA shaft to prevent breakdown.
2
YES Go to Step 3
NO
• Reset the STP sensor position correctly.
("5-29)
• Replace the STP sensor with a new one.
4-40 FI SYSTEM DIAGNOSIS
Step 3
1) Turn the ignition switch OFF.
2) Connect the STP sensor coupler.
3) Insert the needle pointed probes to the STP sensor coupler.
4) Disconnect the STVA coupler.
5) Turn the ignition switch ON.
6) Measure the STP sensor output voltage at the coupler
(between
+ Yellow and - B/Br wires) when the secondary
throttle valve is full closed and opened.
NOTE:
The secondary throttle valve can be turned by rotating the actuator shaft end 1.
% STP sensor output voltage
Secondary throttle valve is closed: Approx. 0.58 V
Secondary throttle valve is opened: Approx. 4.40 V
! 09900-25008: Multi circuit tester set
09900-25009: Needle pointed probe set
' Tester knob indication: Voltage ( )
#
Is the voltage OK?
Do not use the tool for turning the STVA shaft to prevent breakdown.
3
V
3
YES
• Red, Yellow or B/Br wire open or shorted to
ground, or poor 0, d or X connection.
• If wire and connection are OK, intermittent trouble or faulty ECM.
• Recheck each terminal and wire harness for
open circuit and poor connection.
NO
If check result is not satisfactory, replace STP
sensor with a new one.
FI SYSTEM DIAGNOSIS 4-41
“C31” GEAR POSITION (GP) SWITCH CIRCUIT MALFUNCTION
INSPECTION
Step 1
1) Remove the left frame cover. ("7-5)
2) Turn the ignition switch OFF.
3) Check the GP switch coupler for loose or poor contacts.
If OK, then measure the GP switch voltage.
4) Support the motorcycle with a jack.
5) Turn the side-stand to up-right position.
6) Make sure the engine stop switch is in the “RUN” position.
7) Insert the needle pointed probes to the GP switch coupler.
8) Turn the ignition switch ON.
9) Measure the voltage at the wire side coupler between Pink
wire and ground, when shifting the gearshift lever from 1st to
Top.
% GP switch voltage: 1.0 V and more
(Pink – Ground)
! 09900-25008: Multi circuit tester set
09900-25009: Needle pointed probe set
' Tester knob indication: Voltage ( )
Is the voltage OK?
DETECTED CONDITION POSSIBLE CAUSE
No Gear Position switch voltage
Switch voltage is out of the specified range.
Switch Voltage 0.2 V
• Gear Position switch circuit open or short.
• Gear Position switch malfunction.
• ECM malfunction.
1
1
V
YES
• Inspect the GP switch voltage. ("8-20)
• Pink wire open or shorted to ground, or poor
U
connection.
• If wire and connection are OK, intermittent trouble or faulty ECM.
• Recheck each terminal and wire harness for
open circuit and poor connection.
NO Open or short circuit in the Pink wire.
4-42 FI SYSTEM DIAGNOSIS
“C32” or “C33” FUEL INJECTOR CIRCUIT MALFUNCTION
INSPECTION
Step 1
1) Remove the air cleaner box. ("5-15)
2) Turn the ignition switch OFF.
3) Check the injector couplers for loose or poor contacts.
If OK, then measure the injector resistance.
4) Disconnect the injector couplers and measure the resistance
between terminals.
% Injector resistance: 11 – 13 Ω at 20 °C (68 °F)
(No.1:
1 – 2)
(No.2: 3 – 4)
5) If OK, then check the continuity between injector terminals
and ground.
% Injector continuity: ∞ Ω (Infinity)
(No.1: 1 – Ground)
(No.2: 3 – Ground)
! 09900-25008: Multi circuit tester set
&Tester knob indication: Resistance (Ω)
Is the resistance OK?
DETECTED CONDITION POSSIBLE CAUSE
Fuel injector voltage is 1.3 V and less. • Injector circuit open or short.
• Injector malfunction.
• ECM malfunction.
1
1
1
YES Go to Step 2
NO Replace the Injector with a new one. ("5-18)
FI SYSTEM DIAGNOSIS 4-43
Step 2
1) Disconnect the injector couplers.
2) Turn the ignition switch ON.
3) Measure the injector voltage between Y/R wire (No.1 injector
coupler and No.2 injector coupler) and ground.
% Injector voltage: Battery voltage
(
+ Y/R – - Ground)
NOTE:
Injector voltage can be detected only 2 seconds after ignition
switch is turned ON.
! 09900-25008: Multi circuit tester set
' Tester knob indication: Voltage ( )
Is the voltage OK?
VV
2
YES
• Gr/W or Gr/B wire open or shorted to ground, or
poor 5 or 6 connection.
• If wire and connection are OK, intermittent trouble or faulty ECM.
• Recheck each terminal and wire harness for
open circuit and poor connection.
NO • Inspect the fuel pump relay. ("5-10)
4-44 FI SYSTEM DIAGNOSIS
“C41” FP RELAY CIRCUIT MALFUNCTION
INSPECTION
Step 1
1) Remove the seat. ("7-4)
2) Turn the ignition switch OFF.
3) Check the FP relay coupler for loose or poor contacts.
If OK, then check the insulation and continuity. Refer to page
5-10 for details.
Is the FP relay OK?
NOTE:
When the both fuel injectors break down at a time, “C41” is indicated.
“C42” IG SWITCH CIRCUIT MALFUNCTION
INSPECTION
*Refer to the IGNITION SWITCH INSPECTION for details. ("8-39)
DETECTED CONDITION POSSIBLE CAUSE
No voltage is applied to the both injectors for 3 sec.
after the contact of fuel pump relay is turned ON.
Or voltage is applied to the both injectors, when the
contact of fuel pump is OFF.
• Fuel pump relay circuit open or short.
• Fuel pump relay malfunction.
• ECM malfunction.
1
YES
• Y/B or O/G (O/W: For E-03, 24, 28 and 33) wire
open or shorted to ground, or poor
V or 9 connection.
• If wire and connection are OK, intermittent trouble or faulty ECM.
• Recheck each terminal and wire harness for
open circuit and poor connection.
• Inspect the fuel injectors. ("4-42)
NO Replace the FP relay with a new one.
DETECTED CONDITION POSSIBLE CAUSE
Ignition switch signal is not input in the ECM. • Ignition system circuit open or short.
• ECM malfunction.
FI SYSTEM DIAGNOSIS 4-45
“C49” PAIR CONTROL SOLENOID VALVE CIRCUIT MALFUNCTION
INSPECTION
Step 1
1) Remove the fuel tank. ("5-7)
2) Turn the ignition switch OFF.
3) Check the PAIR control solenoid valve coupler for loose or
poor contacts.
If OK, then measure the PAIR control solenoid valve resistance.
4) Remove the air cleaner box. ("5-15)
5) Disconnect the PAIR control solenoid valve coupler and measure the resistance between terminals.
% PAIR control solenoid valve resistance:
20 – 24 Ω at 20 °C/68 °F
! 09900-25008: Multi circuit tester set
& Tester knob indication: Resistance (Ω)
Is the resistance OK?
DETECTED CONDITION POSSIBLE CAUSE
PAIR control solenoid valve voltage is not input in
ECM.
• PAIR control solenoid valve circuit open or short.
• PAIR control solenoid valve malfunction.
• ECM malfunction.
1
YES Go to Step 2
NO
• Loose or poor contacts on the ECM coupler.
• Replace the PAIR control solenoid valve with a
new one.
1
4-46 FI SYSTEM DIAGNOSIS
Step 2
1) Connect the PAIR control solenoid valve coupler.
2) Turn the ignition switch ON.
3) Insert the needle pointed probes to the PAIR control solenoid
valve coupler.
4) Measure the voltage at the wire side coupler between Brown
wire and ground.
% PAIR control solenoid valve voltage: Battery voltage
(
+ Brown – - Ground)
! 09900-25008: Multi circuit tester set
09900-25009: Needle pointed probe set
' Tester knob indication: Voltage ( )
Is the voltage OK?
2
V
YES
• Brown wire open or shorted to ground, or 7
connection.
• If wire and connection are OK, intermittent trouble or faulty ECM.
• Recheck each terminal and wire harness for
open circuit and poor connection.
NO Open or short circuit in the Brown wire.
FI SYSTEM DIAGNOSIS 4-47
“C44” HO2 SENSOR (HO2S) CIRCUIT MALFUNCTION (E-02, 19)
INSPECTION
Step 1
1) Lift and support the fuel tank. ("5-7)
2) Turn the ignition switch OFF.
3) Check the HO2 sensor coupler for loose or poor contacts.
4) Insert the needle pointed probes to the HO2 sensor coupler.
5) Turn the ignition switch ON and measure the heater voltage
between O/W wire (ECM side) and ground.
6) If the tester voltage indicates the battery voltage for few seconds, it is good condition.
% Heater voltage: Battery voltage (O/W – Ground)
NOTE:
Battery voltage can be detected only during few seconds after
ignition switch is turned ON.
! 09900-25008: Multi circuit tester set
09900-25009: Needle pointed probe set
' Tester knob indication: Voltage ( )
Is the voltage OK?
DETECTED CONDITION POSSIBLE CAUSE
The sensor voltage should be the following and less
after warming up condition.
(Sensor Voltage 0.4 V)
• HO2 sensor or its circuit open or short.
• Fuel system malfunction.
• ECM malfunction.
1
YES Go to Step 2
NO Replace the HO2 sensor with a new one.
1
V
4-48 FI SYSTEM DIAGNOSIS
Step 2
1) Warm up the engine enough.
2) Insert the needle pointed probes to the HO2 sensor coupler.
3) Measure the HO2 sensor output voltage at the coupler
(between W/G and B/Br wires) when idling condition.
4) Also, measure the HO2 sensor output voltage while holding
the engine speed at 5 000 r/min.
% HO2 sensor output voltage at idle speed:
0.4 V and less (
+ W/G – - B/Br)
HO2 sensor output voltage at 5 000 r/min:
0.6 V and more (+ W/G – - B/Br)
! 09900-25008: Multi circuit tester set
09900-25009: Needle pointed probe set
' Tester knob indication: Voltage ( )
Is the voltage OK?
Step 3
1) Turn the ignition switch OFF.
2) Disconnect the HO2 sensor coupler.
3) Check the resistance between the terminals (White – White)
of the HO2 sensor.
% HO2 heater resistance: 4 – 5 Ω (at 23 °C/73.4 °F)
(White – White)
NOTE:
* Temperature of the sensor affects resistance value largely.
* Make sure that the sensor heater is at correct temperature.
! 09900-25008: Multi circuit tester set
& Tester knob indication: Resistance (Ω)
Is the resistance OK?
YES Go to Step 3
NO Replace the HO2 sensor with a new one.
YES
• W/B, O/G, W/G or B/Br wire open or shorted to
ground, or poor 8, 9, N or X connection.
• If wire and connection are OK, intermittent trouble or faulty ECM.
• Recheck each terminal and wire harness for
open circuit and poor connection.
NO Replace the HO2 sensor with a new one.
2
V
3
FI SYSTEM DIAGNOSIS 4-49
SENSORS
CKP SENSOR INSPECTION
The crankshaft position sensor is installed in the generator
cover. ("4-23)
CKP SENSOR REMOVAL AND INSTALLA-
TION
• Remove the generator cover. ("3-26)
• Install the generator cover in the reverse order of removal.
IAP SENSOR INSPECTION
The intake air pressure sensor is installed at the rear side of the
air cleaner box. ("4-25)
IAP SENSOR REMOVAL AND INSTALLA-
TION
• Lift and support the fuel tank. ("5-7)
• Remove the IAP sensor from the air cleaner box.
• Install the IAP sensor in the reverse order of removal.
TP SENSOR INSPECTION
The throttle position sensor is installed at the left side of the
No.2 throttle body. ("4-28)
TP SENSOR REMOVAL AND INSTALLATION
• Remove the air cleaner box. ("5-15)
• Remove the TP sensor. ("5-19)
• Install the TP sensor in the reverse order of removal.
$ TP sensor mounting screw: 3.5 N·m (0.35 kgf-m, 2.5 lb-ft)
TPS ADJUSTMENT
• Adjust the TP sensor. ("4-16)
ECT SENSOR INSPECTION
The ECT sensor is installed on the thermostat case. ("4-31)
ECT SENSOR REMOVAL AND INSTALLA-
TION
• Remove the ECT sensor. ("6-10)
• Install the ECT sensor in the reverse order of removal.
$ ECT sensor: 19 N·m (1.9 kgf-m, 13.5 lb-ft)
4-50 FI SYSTEM DIAGNOSIS
IAT SENSOR INSPECTION
The intake air temperature sensor is installed on the right side of
the air cleaner box. ("4-33)
IAT SENSOR REMOVAL AND INSTALLA-
TION
• Lift and support the fuel tank. ("5-7)
• Remove the IAT sensor from the air cleaner box.
• Install the IAT sensor in the reverse order of removal.
$ IAT sensor: 18 N·m (1.8 kgf-m, 13.0 lb-ft)
TO SENSOR INSPECTION
TO SENSOR REMOVAL AND INSTALLATION
The tip over sensor is located in under the seat. ("4-35)
• Remove the right frame cover. ("7-5)
• Remove the TO sensor from the rear fender.
• Install the TO sensor in the reverse order of removal.
NOTE:
When installing the TO sensor, the “UP” mark
A must be
pointed upward.
STP SENSOR INSPECTION
STP SENSOR REMOVAL AND INSTALLA-
TION
The secondary throttle position sensor is installed at the left side
of the No.2 throttle body.
• Remove the air cleaner box. ("5-15)
• Remove the STP sensor. ("5-19)
• Install the STP sensor in the reverse order of removal.
$ STP sensor mounting screw: 2.0 N·m (0.2 kgf-m, 1.5 lb-ft)
STP SENSOR ADJUSTMENT
• Adjust the STP sensor. ("5-28)
HO2 SENSOR INSPECTION (E-02, 19)
HO2 SENSOR REMOVAL AND INSTALLA-
TION
The HO2 sensor is installed at the exhaust pipe.
• Remove the seat. ("7-4)
• Disconnect the HO2 sensor lead wire coupler and remove the
HO2 sensor.
• Install the HO2 sensor in the reverse order of removal.
$ HO2 sensor: 47.5 N·m (4.75 kgf-m, 34.3 lb-ft)
FUEL SYSTEM AND THROTTLE BODY 5-1
5
FUEL SYSTEM AND THROTTLE BODY
CONTENTS
FUEL SYSTEM ..............................................................................................5- 2
FUEL DELIVERY SYSTEM.....................................................................5- 2
FUEL PUMP ............................................................................................5- 3
FUEL PRESSURE REGULATOR ...........................................................5- 5
FUEL INJECTOR ....................................................................................5- 5
FUEL PUMP CONTROL SYSTEM..........................................................5- 6
FUEL SYSTEM ..............................................................................................5- 7
FUEL TANK LIFT-UP..............................................................................5- 7
FUEL TANK REMOVAL..........................................................................5- 7
FUEL TANK INSTALLATION .................................................................5- 7
FUEL PRESSURE INSPECTION............................................................5- 8
FUEL PUMP INSPECTION .....................................................................5- 9
FUEL PUMP RELAY INSPECTION ........................................................5-10
FUEL PUMP AND FUEL FILTER REMOVAL ........................................5-10
FUEL MESH FILTER INSPECTION AND CLEANING ...........................5-12
FUEL PUMP AND FUEL MESH FILTER INSTALLATION.....................5-12
THROTTLE BODY AND STV ACTUATOR...................................................5-14
CONSTRUCTION ....................................................................................5-14
AIR CLEANER AND THROTTLE BODY REMOVAL .............................5-15
THROTTLE BODY DISASSEMBLY .......................................................5-18
THROTTLE BODY CLEANING...............................................................5-22
THROTTLE BODY INSPECTION ...........................................................5-22
THROTTLE BODY REASSEMBLY ........................................................5-23
STV SYNCHRONIZATION ......................................................................5-27
THROTTLE BODY INSTALLATION .......................................................5-27
STP SENSOR ADJUSTMENT ................................................................5-28
AIR CLEANER BOX INSTALLATION ....................................................5-28
TP SENSOR ADJUSTMENT...................................................................5-29
FAST IDLE INSPECTION .......................................................................5-30
FAST IDLE ADJUSTMENT.....................................................................5-31
THROTTLE VALVE SYNCHRONIZATION.............................................5-32
5-2 FUEL SYSTEM AND THROTTLE BODY
FUEL SYSTEM
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.
Fuel pressure is regulated by the fuel pressure regulator. As the fuel pressure applied to the fuel injector (the
fuel pressure in the fuel delivery pipe) is always kept at absolute fuel pressure of 300 kPa (3.0 kgf/cm2,
43 psi), the fuel is injected into the throttle body in conic dispersion when the injector opens according to the
injection signal from the ECM.
The fuel relieved by the fuel pressure regulator flows back to the fuel tank.
1 Fuel filter (For high pressure) A BEFORE-PRESSURIZED FUEL
2 Fuel pressure regulator B PRESSURIZED FUEL
3 Fuel injector C RELIEVED FUEL
4 Fuel feed hose
5 Fuel mesh filter (For low pressure)
6 Fuel pump
FUEL SYSTEM AND THROTTLE BODY 5-3
FUEL PUMP
The electric fuel pump is mounted at the bottom of the fuel tank, which consists of the armature, magnet,
impeller, brush, check valve and relief valve. The ECM controls its ON/OFF operation as controlled under
the FUEL PUMP CONTROL SYSTEM.
When electrical energy is supplied to the fuel pump, the motor in the pump runs and together with the impeller. This causes a pressure difference to occur on both sides of the impeller as there are many grooves
around it. Then the fuel is drawn through the inlet port, and with its pressure increased, it is discharged
through the outlet port. The fuel pump has a check valve to keep some pressure in the fuel feed hose even
when the fuel pump is stopped. Also, the relief valve is equipped in the fuel pump, which releases pressurized fuel to the fuel tank when the outlet of the fuel pressure has increased up to 450 – 600 kPa (4.5 – 6.0
kgf/cm2, 64 – 85 psi).
1 Relief valve 5 Outlet port
2 Brush 6 Check valve
3 Magnet 7 Armature
4 Impeller 8 Inlet port
5-4 FUEL SYSTEM AND THROTTLE BODY
When the impeller is driven by the motor, pressure differential occurs between the front part and the rear
part of the blade groove as viewed in angular direction due to fluid friction. This process continuously takes
place causing fuel pressure to be built up. The pressurized fuel is then let out from the pump chamber and
discharged through the motor section and the check valve.
1 Outlet 5 Impeller
2 Blade groove 6 Motor shaft
3 Inlet 7 Vortex flow
4 Flow clearance A Turning direction
FUEL SYSTEM AND THROTTLE BODY 5-5
FUEL PRESSURE REGULATOR
The fuel pressure regulator consists of the spring and valve. It keeps absolute fuel pressure of 300 kPa
(3.0 kgf/cm2, 43 psi) to be applied to the injector at all times.
When the fuel pressure rises more than 300 kPa (3.0 kgf/cm2, 43 psi), the fuel pushes the valve in the regulator open and excess fuel returns to the fuel tank.
1 Spring 2 Valve A Fuel from fuel pump B Fuel returns to the fuel tank
FUEL INJECTOR
The fuel injector consists of the solenoid coil, plunger, needle valve and filter.
It is an electromagnetic type injection nozzle which injects fuel in the throttle body according to the signal
from the ECM.
When the solenoid coil of the injector is energized by the ECM, it becomes an electromagnet and attracts
the plunger. At the same time, the needle valve incorporated with the plunger opens and the injector which
is under the fuel pressure injects fuel in conic dispersion. As the lift stroke of the needle valve of the injector
is set constant, the volume of the fuel injected at one time is determined by the length of time during which
the solenoid coil is energized (injection time).
1 Needle valve 2 Plunger 3 solenoid coil 4 Filter
5-6 FUEL SYSTEM AND THROTTLE BODY
FUEL PUMP CONTROL SYSTEM
When the ignition switch is turned on, current from the battery flows to the fuel pump motor through the sidestand relay and the fuel pump relay causing the motor to turn.
Since the ECM has a timer function, the fuel pump motor stops turning in three seconds after the switch has
been turned on.
Thereafter, when the crankshaft is turned by the starter motor or the engine has been started, the engine
revolving signal is input to the ECM. Then, current flows to the fuel pump motor from the battery through the
side-stand relay and the fuel pump relay so that the pump continues to function.
A tip over sensor is provided in the fuel pump control circuit. By this provision, anytime the motorcycle tips
over, the tip over sensor sends a signal to the ECM to turn off power to the fuel pump relay, causing the fuel
pump motor to stop. At the same time, current to the fuel injectors as well as the ignition coil is interrupted,
which then stops the engine.
IG2 IG1
CKPS
Fl 30 A 10 A
10 A
10 A
1 Battery 9 Tip over sensor
2 Ignition coil 0 Starter button
3 Main switch A Starter relay
4 Neutral lamp B ECM
5 Side-stand relay C Side-stand switch
6 Engine stop switch D Gear position switch
7 Fuel pump E Clutch switch
8 Fuel pump relay
FUEL SYSTEM AND THROTTLE BODY 5-7
FUEL SYSTEM
FUEL TANK LIFT-UP
• Remove the seat. (!7-4)
• Remove the cowring. (!7-5)
• Remove the fuel tank mounting bolt and fuel tank mount stay
1.
• Lift and support the fuel tank with the fuel tank mount stay.
FUEL TANK REMOVAL
• Lift and support the fuel tank. (!5-7)
• Disconnect the fuel pump lead wire coupler 1.
• Place a rag under the fuel feed hose and disconnect the fuel
feed hose 2 from the fuel tank.
• Disconnect the fuel tank drain hose 3.
"
#
• Remove the fuel tank mounting bolt and nut.
• Remove the fuel tank.
FUEL TANK INSTALLATION
• Installation is in the reverse order of removal.
When removing the fuel tank, do not leave the fuel
feed hose 2 on the fuel tank side.
Gasoline is highly flammable and explosive.
Keep heat, spark and flame away.
5-8 FUEL SYSTEM AND THROTTLE BODY
FUEL PRESSURE INSPECTION
• Lift and support the fuel tank. (!5-7)
• Place a rag under the fuel feed hose.
• Remove the fuel feed hose and install the special tools
between the fuel tank and fuel delivery pipe.
$ 09940-40211: Fuel pressure gauge adaptor
09940-40220: Fuel pressure gauge hose attachment
09915-74511: Oil pressure gauge set
Turn the ignition switch ON and check the fuel pressure.
% Fuel pressure: Approx. 300 kPa (3.0 kgf/cm², 43 psi)
If the fuel pressure is lower than the specification, inspect the
following items:
* Fuel hose leakage
* Clogged fuel filter
* Pressure regulator
* Fuel pump
If the fuel pressure is higher than the specification, inspect the
following items:
* Fuel pump check valve
* Pressure regulator
#
A To fuel delivery pipe. B To fuel feed hose.
* Before removing the special tools, turn the ignition
switch to OFF position and release the fuel pressure
slowly.
* Gasoline is highly flammable and explosive. Keep
heat, sparks and flame away.
FUEL SYSTEM AND THROTTLE BODY 5-9
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, replace
the fuel pump assembly or inspect the fuel pump relay and tip
over sensor.
FUEL DISCHARGE AMOUNT INSPECTION
#
• Lift and support the fuel tank. (!5-7)
• Disconnect the fuel feed hose from the fuel tank.
• Connect a proper fuel hose to the fuel pump.
• Place the measuring cylinder and insert the fuel hose end into
the measuring cylinder.
• Disconnect the ECM lead wire coupler from the ECM.
• Push the lock
A to pull out the power source lead wire (Yellow with black tracer V).
• Connect the ECM to the ECM lead wire coupler.
• Apply 12 volts to the fuel pump for 10 seconds and measure
the amount of fuel discharged.
Battery + terminal –––– Power source lead wire 1
(Yellow with black tracer)
If the pump does not discharge the amount specified, it means
that the fuel pump is defective or that the fuel filter is clogged.
% Fuel discharge amount: MIN. 168 ml
(5.7/5.9 US/Imp oz)/10 sec.
NOTE:
The battery must be in fully charged condition.
Gasoline is highly flammable and explosive.
Keep heat, spark and flame away.
5-10 FUEL SYSTEM AND THROTTLE BODY
FUEL PUMP RELAY INSPECTION
Fuel pump relay is located behind the ECM.
• Remove the seat. (!7-4)
• Remove the fuel pump relay.
First, check the insulation between
1 and 2 terminals with
pocket tester. Then apply 12 volts to 3 and 4 terminals, + to
3 and - to 4, and check the continuity between 1 and 2.
If there is no continuity, replace it with a new one.
FUEL PUMP AND FUEL FILTER REMOVAL
• Remove the fuel tank. (!5-7)
• Remove the fuel pump assembly by removing its mounting
bolts diagonally.
#
• Remove the screws.
• Remove the nuts 1 and screw 2.
• Disconnect the clamp 3.
• Remove the fuel level gauge.
Gasoline is highly flammable and explosive.
Keep heat, spark and flame away.
FUEL SYSTEM AND THROTTLE BODY 5-11
• Remove the screws.
• Remove the fuel pump assy
4 from the fuel pump plate 5.
• Remove the fuel pump holder 6.
• Remove the fuel mesh filter 7.
• Remove the fuel pressure regulator holder 8 and the fuel
pressure regulator 9.
5-12 FUEL SYSTEM AND THROTTLE BODY
FUEL MESH FILTER INSPECTION AND
CLEANING
If the fuel mesh filter is clogged with sediment or rust, fuel will
not flow smoothly and loss in engine power may result.
Blow the fuel mesh filter with compressed air.
NOTE:
If the fuel mesh filter is clogged with many sediment or rust,
replace the fuel filter cartridge with a new one.
FUEL PUMP AND FUEL MESH FILTER
INSTALLATION
Install the fuel pump and fuel mesh filter in the reverse order of
removal. Pay attention to the following points:
• Install the new O-rings to the fuel pressure regulator and fuel
pipe.
• Apply thin coat of the engine oil to the O-rings.
"
• Tighten the screw together with the lead wire terminal.
• Tighten the nuts together with the lead wire terminals.
A ......+ terminal for fuel pump
B ......+ terminal for fuel level gauge
C ......- terminal for fuel level gauge
• Connect the clamp 1.
• Install the fuel level gauge.
Use the new O-rings to prevent fuel leakage.
FUEL SYSTEM AND THROTTLE BODY 5-13
• Install the new O-ring and apply SUZUKI SUPER GREASE to
it.
#
& 99000-25030: SUZUKI SUPER GREASE “A” (USA)
99000-25010: SUZUKI SUPER GREASE “A” (Others)
• When installing the fuel pump assembly, first tighten all the
fuel pump assembly mounting bolts lightly in the ascending
order of numbers, and then tighten them to the specified
torque in the above tightening order
.
' Fuel pump mounting bolt: 10 N·m (1.0 kgf-m, 7.3 lb-ft)
NOTE:
Apply a small quantity of the THREAD LOCK to the thread portion of the fuel pump mounting bolt.
( 99000-32050: THREAD LOCK “1342”
The O-ring must be replaced with a new one to prevent
fuel leakage.
1 6
3
52
4
1
Fuel pressure regulator
4
Fuel mesh filter (For low pressure)
2
Fuel pump case/Fuel filter cartridge
(For high pressure)
5
Fuel level gauge '
ITEM N·m kgf-m lb-ft
3 Fuel pump A Fuel pump mounting bolt A 10 1.0 7.3
5-14 FUEL SYSTEM AND THROTTLE BODY
THROTTLE BODY AND STV ACTUATOR
CONSTRUCTION
*1
1 TP sensor A STP sensor mounting screw
2 STP sensor B TP sensor mounting screw '
3
STVA
C
Fuel delivery pipe mounting
screw
ITEM N·m kgf-m lb-ft
A 2.0 0.2 1.5
4 Fuel delivery pipe *1 Do not turn the screw. B 3.5 0.35 2.5
5 Injector C 5.0 0.5 3.7
FUEL SYSTEM AND THROTTLE BODY 5-15
AIR CLEANER AND THROTTLE BODY
REMOVAL
AIR CLEANER BOX
• Remove the fuel tank. (!5-7)
• Disconnect the IAT sensor coupler
1.
• Remove the IAP sensor vacuum hose 2.
• Disconnect the IAP sensor coupler 3.
• Loosen the throttle body clamp screws.
• Disconnect the PAIR hose.
• Disconnect the PAIR lead wire coupler 4.
• Disconnect the crankcase breather hoses.
• Remove the air cleaner box.
5-16 FUEL SYSTEM AND THROTTLE BODY
THROTTLE BODY
• Remove the fuel tank. (!5-7)
• Remove the air cleaner box. (!5-15)
• Disconnect the various lead wire couplers.
1 TP sensor
2 STP sensor
3 STVA motor
• Remove the injector lead wire coupler.
• Disconnect the idle stop screw.
• Loosen the throttle body clamp screws.
FUEL SYSTEM AND THROTTLE BODY 5-17
• Disconnect the throttle cables from their drum.
• Dismount the throttle body assembly.
"
* Be careful not to damage the throttle cable bracket
and fast idle lever when dismounting or remounting
the throttle body assembly.
* After disconnecting the throttle cables, do not snap
the throttle valve from full open to full close. It may
cause damage to the throttle valve and throttle body.
5-18 FUEL SYSTEM AND THROTTLE BODY
THROTTLE BODY DISASSEMBLY
"
• Remove the IAP sensor vacuum damper and its hose.
• Disconnect the fuel feed hose
1.
• Remove the throttle link rod 2 and secondary throttle link rod
3.
NOTE:
The throttle link rod 2 is longer than the secondary throttle link
rod 3.
• Remove the fuel delivery pipe 4.
• Remove the fuel injectors.
* Be careful not to damage the throttle lever when disassembling the throttle body.
* The throttle body is assembled precisely in factory.
Do not disassemble it other than shown in this manual.
FUEL SYSTEM AND THROTTLE BODY 5-19
• Remove the TPS
5 and STPS 6 with the special tool.
$ 09930-11950: Torx wrench (TH 25)
09930-11960: Torx wrench (TH 20)
NOTE:
Prior to disassembly, mark each sensor’s original position with a
paint or scribe for accurate reinstallation.
• Remove the oil seals 7.
"
"
Do not turn the screws 8.
Never remove the STVA.
5-20 FUEL SYSTEM AND THROTTLE BODY
• Remove the throttle stop screw
9.
NOTE:
Measure the length A for accurate reinstallation.
"
"
Never loosen the throttle stop screw B on the No.2 throttle body.
Never remove the throttle valve and secondary throttle
valve.
FUEL SYSTEM AND THROTTLE BODY 5-21
"
• Remove the fast idle link lever
0.
• Remove the spring A.
• Remove the spring B, bushing C and plastic washer D.
Never remove the throttle body link plates.
5-22 FUEL SYSTEM AND THROTTLE BODY
THROTTLE BODY CLEANING
#
• Clean all passageways with a spray type carburetor cleaner
and blow dry with compressed air.
"
THROTTLE BODY INSPECTION
• Check following items for any damage or clogging.
* O-ring * Secondary throttle valve
* Throttle shaft bushing and seal * Injector cushion seal
* Throttle valve * Vacuum hose
Check the fuel injector filter for evidence of dirt and contamination. If present, clean and check for presence of dirt in the fuel
lines and fuel tank.
Some carburetor cleaning chemicals, especially diptype soaking solutions, are very corrosive and must
be handled carefully. Always follow the chemical manufacturer’s instructions on proper use, handling and
storage.
Do not use wire to clean passageways. Wire can damage passageways. If the components cannot be
cleaned with a spray cleaner it may be necessary to
use a dip-type cleaning solution and allow them to
soak. Always follow the chemical manufacturer’s
instructions for proper use and cleaning of the throttle
body components. Do not apply carburetor cleaning
chemicals to the rubber and plastic materials.
FUEL SYSTEM AND THROTTLE BODY 5-23
THROTTLE BODY REASSEMBLY
Reassemble the throttle body in the reverse order of disassembly.
Pay attention to the following points:
• Apply SUZUKI SUPER GREASE to the throttle stop screw tip
and the both ends of a spring.
& 99000-25030: SUZUKI SUPER GREASE “A” (USA)
99000-25010: SUZUKI SUPER GREASE “A” (Others)
• Install the plastic washer
1 and bushing 2.
NOTE:
The concave of a bushing is faced outside.
• Install the spring.
• Apply SUZUKI MOLY PASTE to the fast idle link lever.
) 99000-25140: SUZUKI MOLY PASTE
• Install the spring 3.
5-24 FUEL SYSTEM AND THROTTLE BODY
• Install the spring
4 and fast idle link lever 5.
NOTE:
Make sure that the spring ends are hooked correctly.
• Install the washers 5, 6, spring washer 7 and nut 8.
NOTE:
The washer 5 is inserting in the axis certainly.
• Apply SUZUKI SUPER GREASE to the seal lips.
& 99000-25030: SUZUKI SUPER GREASE “A” (USA)
99000-25010: SUZUKI SUPER GREASE “A” (Others)
• Install the seal 9.
• Apply a small quantity of SUZUKI SUPER GREASE to the
shaft ends and seal lips.
& 99000-25030: SUZUKI SUPER GREASE “A” (USA)
99000-25010: SUZUKI SUPER GREASE “A” (Others)
• Turn the TP sensor counterclockwise and install the mounting
screws.
• Tighten the TP sensor mounting screws.
$ 09930-11950: Torx wrench
' TP sensor mounting screw: 3.5 N·m (0.35 kgf-m, 2.5 lb-ft)
FUEL SYSTEM AND THROTTLE BODY 5-25
NOTE:
Make sure the throttle valve open or close smoothly.
• Align the boss
A of the STP sensor with the groove B of the
ST valve shaft.
• Install the STP sensor.
• Tighten the STP sensor mounting screws.
$ 09930-11960: Torx wrench
' STP sensor mounting screw:
2.0 N·m (0.2 kgf-m, 1.5 lb-ft)
NOTE:
Make sure the ST valve open or close smoothly.
• Apply thin coat of the engine oil to the new fuel injector cushion seal 0, and install it to the fuel injector.
"
• Install the O-ring A to the fuel injector.
• Apply thin coat of the engine oil to the new O-ring A.
Replace the cushion seal and O-ring with a new one.
5-26 FUEL SYSTEM AND THROTTLE BODY
• Install the fuel injectors by pushing them straight to each throttle body.
"
• Install the fuel delivery pipe assembly to the throttle body
assembly.
"
• Tighten the fuel delivery pipe mounting screws.
' Fuel delivery pipe mounting screw:
5.0 N·m (0.5 kgf-m, 3.7 lb-ft)
• Install the throttle link rod
B and secondary throttle link rod
C.
NOTE:
The throttle link rod B is longer than the secondary throttle link
rod C.
• Install the IAP sensor vacuum damper and hose.
"
Never turn the injector while pushing it.
Never turn the fuel injectors while installing them.
The stamp C of the IAP sensor vacuum damper faces
into the throttle body side.
FUEL SYSTEM AND THROTTLE BODY 5-27
STV SYNCHRONIZATION
• Install the throttle body. (!5-27)
• Turn the ignition switch OFF, if STV synchronization is performed on the vehicle.
• Turn the STVA shaft with a finger so that the throttle valve
height
A will be same as B.
"
NOTE:
Measure the throttle valve height A, B from top of the throttle
body 1 to the throttle valve 2.
• While holding above No.1 STV position, turn the adjust screw
3 so that the throttle valve height C will be same as D.
THROTTLE BODY INSTALLATION
Installation is in the reverse order of removal. Pay attention to
the following points:
• Connect the throttle pulling cable and throttle returning cable
to the throttle cable drum.
Do not use the tool for turning the STVA shaft to prevent breakdown.
5-28 FUEL SYSTEM AND THROTTLE BODY
• Connect the fuel injector couplers to the fuel injectors.
NOTE:
* The fuel injector coupler No.1 (FRONT) can be distinguished
from that of the No.2 (REAR) by the “F” mark
A.
* Adjust the throttle cable play with the cable adjusters.
Refer to page 2-15 for details.
STP SENSOR ADJUSTMENT
If the STP sensor adjustment is necessary, measure the sensor
resistance and adjust the STP sensor positioning as follows:
• Disconnect the STVA coupler 1 and turn the ignition switch
ON.
• To set the ST valve to fully open position.
• Measure the STP sensor voltage at fully open position.
% STP sensor voltage
ST valve is fully opened: Approx. 4.38 V and more
(Yellow – Black)
$ 09900-25008: Multi circuit tester set
09900-25009: Needle pointed probe set
* Tester knob indication: Voltage (+)
"
• Loosen the STP sensor mounting screws.
• Adjust the STP sensor until voltage is within specification and
tighten the STP sensor mounting screws.
$ 09930-11960: Torx wrench
' STP sensor mounting screw:
2.0 N·m (0.2 kgf-m, 1.5 lb-ft)
AIR CLEANER BOX INSTALLATION
Installation is in the reveres order of removal.
Do not use the tool for turning the STVA shaft to prevent breakdown.
V
FUEL SYSTEM AND THROTTLE BODY 5-29
TP SENSOR ADJUSTMENT
After checking or adjusting the throttle valve synchronization,
adjust the TP sensor positioning as follows:
• After warming up engine, adjust the idling speed to 1 300 rpm.
• Stop the warmed-up engine and connect the special tool to
the dealer mode coupler. (!5-20)
$ 09930-82720: Mode select switch
• If the TP sensor adjustment is necessary, loosen the TP sensor mounting screws.
• Turn the TP sensor and bring the line to middle.
• Tighten the TP sensor mounting screws.
$ 09930-11950: Torx wrench
' TP sensor mounting screw: 3.5 N·m (0.35 kgf-m, 2.5 lb-ft)
A Incorrect
B Correct position
5-30 FUEL SYSTEM AND THROTTLE BODY
FAST IDLE INSPECTION
The fast idle system is automatic type.
When the fast idle cam is turned by the secondary throttle valve
actuator, the cam pushes the lever on the throttle valve shaft
causing the throttle valve to open and raise the engine speed.
When the engine has warmed up, depending on the water temperature and ambient temperature as shown in the following
table, the fast idle is cancelled allowing the engine to resume
idle speed.
1 Fast idle link lever
2 Fast idle cam
3 STVA
NOTE:
The fast idle link lever opens throttle valve a little to increase the
engine speed.
%
If, under the above conditions, the fast idle cannot be cancelled,
the cause may possibly be short-circuit in the ECT sensor or wiring connections or maladjusted fast idle.
Fast idle rpm
Fast idle cancelling Water
Temp.
1 500 – 2 000 rpm
40 – 50 °C
(104 – 122 °F)
FUEL SYSTEM AND THROTTLE BODY 5-31
FAST IDLE ADJUSTMENT
• Remove the fuel tank. (!5-7)
• Remove the air cleaner box. (!5-15)
• Disconnect the STVA lead wire coupler and turn the ignition
switch ON.
• Open the STV fully with a finger. Measure the output voltage
of the TP sensor.
"
• If the TP sensor output voltage is out of specification, turn the
fast idle adjusting screw
1 and adjust the output voltage to
specification.
% TP sensor output voltage: 1.21 V
(Red – B/Br)
$ 09900-25008: Multi circuit tester set
09900-25009: Needle pointed probe set
, Tester knob indication: Voltage (+)
• After adjusting the fast idle speed, set the idle speed to 1 300
rpm by turning the throttle stop screw 2.
Do not use the tool for turning the STVA shaft to prevent breakdown.
V
5-32 FUEL SYSTEM AND THROTTLE BODY
THROTTLE VALVE SYNCHRONIZATION
Check and adjust the throttle valve synchronization between two
cylinders.
CALIBRATING EACH GAUGE (For vacuum balancer gauge)
• Start up the engine and run it in idling condition for warming
up.
• Stop the warmed-up engine.
• Remove the fuel tank. (!5-7)
• Remove the air cleaner box. (!5-15)
• Install the fuel tank.
• Connect the IAT and PAIR control valve sensor couplers.
• Connect the IAP sensor coupler and vacuum hose.
• Connect the PAIR hose.
• Remove the rubber cap
1 from the No.1 throttle body.
• Connect one of the four rubber hoses of the vacuum balancer
gauge to the nipple on the No.1 throttle body.
$ 09913-13121: Vacuum balancer gauge
• Start up the engine and keep it running at 1 300 rpm by turning throttle stop screw 3.
"
Avoid drawing dirt into the throttle body while running
the engine without air cleaner box. Dirt drawn into the
engine will damage the internal engine parts.
FUEL SYSTEM AND THROTTLE BODY 5-33
• Turn the air screw
4 of the gauge so that the vacuum acting
on the tube of that hose will bring the steel ball 5 in the tube
to the center line 6.
NOTE:
The vacuum gauge is positioned approx. 30 ° from the horizontal level.
• After making sure that the steel ball stays steady at the center
line, disconnect the hose from the No.1 throttle body nipple
and connect the next hose of the gauge to this nipple.
• Turn air screw to bring the other steel ball 7 to the center
line.
The balancer gauge is now ready for use in balancing the throttle valves.
THROTTLE VALVE SYNCHRONIZATION
• To synchronize throttle valves, remove the rubber caps 1
from each vacuum nipples on No.1 and No.2 throttle body.
• Connect the vacuum balancer gauge hoses to the vacuum
nipples respectively.
$ 09913-13121: Vacuum balancer gauge
30 ˚
5-34 FUEL SYSTEM AND THROTTLE BODY
• Connect a tachometer and start up the engine.
• Bring the engine rpm to 1 300 rpm by the throttle step screw.
• Check the vacuum of the two cylinders and balance the two
throttle valves with the synchronizing screw
2 on the No.2
throttle body.
NOTE:
* During balancing the throttle valves, always set the engine
rpm at 1 300 rpm, using throttle stop screw.
* After balancing the two valves, set the idle rpm to 1 300 rpm.
"
NOTE:
Make sure that the throttle lever should have a gap A (between
the throttle lever and throttle lever stopper screw) during synchronization.
% Throttle lever gap A: 0.17 mm (0.007 in)
Avoid drawing dirt into the throttle body while running
the engine without the air cleaner box. Dirt drawn into
the engine will damage the internal engine parts.
COOLING AND LUBRICATION SYSTEM
CONTENTS
COOLING AND LUBRICATION SYSTEM
ENGINE COOLANT.......................................................................................6- 2
COOLING CIRCUIT.......................................................................................6- 3
COOLING CIRCUIT INSPECTION .........................................................6- 3
RADIATOR ....................................................................................................6- 4
REMOVAL...............................................................................................6- 4
INSPECTION AND CLEANING ..............................................................6- 6
INSTALLATION ......................................................................................6- 6
RADIATOR CAP............................................................................................6- 7
INSPECTION...........................................................................................6- 7
WATER HOSE...............................................................................................6- 7
INSPECTION...........................................................................................6- 7
COOLING FAN..............................................................................................6- 8
INSPECTION...........................................................................................6- 8
REMOVAL...............................................................................................6- 8
INSTALLATION ......................................................................................6- 8
COOLING FAN THERMO-SWITCH..............................................................6- 9
REMOVAL...............................................................................................6- 9
INSPECTION...........................................................................................6- 9
INSTALLATION ......................................................................................6- 9
ECT SENSOR................................................................................................6-10
REMOVAL...............................................................................................6-10
INSPECTION...........................................................................................6-10
INSTALLATION ......................................................................................6-11
THERMOSTAT CASE ASSEMBLY ..............................................................6-12
REMOVAL...............................................................................................6-12
INSPECTION...........................................................................................6-12
INSTALLATION ......................................................................................6-13
WATER PUMP...............................................................................................6-14
REMOVAL AND DISASSEMBLY...........................................................6-14
INSPECTION...........................................................................................6-16
REASSEMBLY AND INSTALLATION ...................................................6-17
LUBRICATION SYSTEM...............................................................................6-20
OIL PRESSURE......................................................................................6-20
OIL FILTER .............................................................................................6-20
OIL PRESSURE REGULATOR ..............................................................6-20
OIL STRAINER .......................................................................................6-20
OIL JET ...................................................................................................6-20
COOLING AND LUBRICATION SYSTEM 6-1
6
OIL PUMP................................................................................................6-20
OIL PRESSURE SWITCH .......................................................................6-20
OIL COOLER .................................................................................................6-21
REMOVAL ...............................................................................................6-21
INSPECTION AND CLEANING ..............................................................6-21
INSTALLATION.......................................................................................6-22
ENGINE LUBRICATION FLOW CHART.......................................................6-23
ENGINE LUBRICATION CIRCUIT ................................................................6-24
6-2 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 protection, and will protect the cooling system from freezing at temperatures above –31 °C (–24 °F).
If the motorcycle is to be exposed to temperatures below –31 °C (–24 °F), this mixing ratio should be
increased up to 55 % or 60 % according to the figure.
!
50 % Engine coolant including reserve tank capacity
"
Anti-freeze density Freezing point
50 % –31 °C (–24 °F)
55 % –40 °C (–40 °F)
60 % –55 °C (–67 °F)
* Use a high quality ethylene glycol base anti-freeze, mixed with distilled water. Do not mix an
alcohol base anti-freeze and different brands of anti-freeze.
* Do not rut in 60 % and more anti-freeze or 50 % and less. (Refer to below figure.)
* Do not use a radiator anti-leak additive.
Anti-freeze 950 ml (2.01/1.67 US/lmp.pt)
Water 950 ml (2.01/1.67 US/lmp.pt)
20 40 60 80 100
Density (%)
0
–10
–20
–30
–40
–50
–60
–70
32
14
–4
–22
–40
–58
–76
–94
Fr ee zi ng p oi nt Fig.1 Engine coolant density-freezing
point curve.
(˚C)(˚F)
0 10 20 30 40 50 60
Density (%)
150
140
130
120
110
100
B
ili
ng p oi nt (˚C)(˚F)
302
284
266
248
230
212
Engine coolant density-boiling
point curve.
Fig.2
(kgf/cm²)
1.5
0.9
0.5
0
G
au ge p re ss ur e * You can be injured by scalding fluid or steam if you open the radiator cap when the engine is
hot. After the engine cools, wrap a thick cloth around cap and carefully remove the cap by
turning it a quarter turn to allow pressure to escape and then turn the cap all the way off.
* The engine must be cool before servicing the cooling system.
* Coolant is harmful;
• If it comes in contact with skin or eyes, flush with water.
• If swallowed accidentally, induce vomiting and call physician immediately.
• Keep it away from children.
COOLING AND LUBRICATION SYSTEM 6-3
COOLING CIRCUIT
1 Thermostat 2 Reserve tank 3 Radiator 4 No.1 cylinder head 5 No.1 cylinder
6 No.2 cylinder 7 No.2 cylinder head 8 Water pump
COOLING CIRCUIT INSPECTION
Before removing the radiator and draining the engine coolant,
inspect the cooling circuit for tightness.
• Remove the cowling. (#7-5)
• Remove the radiator cap 1 and connect the radiator tester 2
to the filler.
"
• Give a pressure of about 120 kPa (1.2 kgf/cm², 17.0 psi) and
see if the system holds this pressure for 10 seconds.
• If the pressure should fall during this 10-second interval, it
means that there is a leaking point in the system. In such a
case, inspect the entire system and replace the leaking component or part.
"
!
Do not remove the radiator cap when the engine is
hot.
When removing the radiator cap tester, put a rag on
the filler to prevent spouting of engine coolant.
Do not allow the pressure to exceed specified pressure, or the radiator can be damaged.
6-4 COOLING AND LUBRICATION SYSTEM
RADIATOR
REMOVAL
• Remove the cowling. (#7-5)
• Drain the engine coolant. (#2-18)
• Disconnect the right and left radiator hoses from the radiator.
• Disconnect the siphon hose
1 from the radiator.
• Disconnect the horn lead wire coupler 2.
COOLING AND LUBRICATION SYSTEM 6-5
• Remove the radiator lower mounting bolt.
• Disconnect the cooling fan motor and thermo-switch lead wire
coupler
3.
• Remove the radiator upper mounting bolt.
• Disconnect the speed sensor lead wire from the clamp 4.
• With the hooks A unlocked, remove the radiator from the
radiator shroud 5.
• Remove the cooling fan and thermo-switch lead wire coupler
6 from the radiator shroud.
• Remove the cooling fan 7.
• Disconnect the cooling fan thermo-switch lead wire coupler
and remove the cooling fan thermo-switch.
• Remove the horn 8.
!
When removing the horn 8, hold the nut by spanner
to prevent the horn bracket distortion.
6-6 COOLING AND LUBRICATION SYSTEM
INSPECTION AND CLEANING
Road dirt or trash stuck to 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.
INSTALLATION
• Install the radiator in the reverse order of removal.
Pay attention to the following points :
• Install the cooling fan and horn
1.
$ Cooling fan/horn mounting bolt:
8 N·m (0.8 kgf-m, 6.0 lb-ft)
• Install the cooling fan thermo-switch. (#6-8)
• Route the radiator hoses properly. (#9-24)
• Install the drain plug with a new sealing washer and pour
engine coolant. (#2-18)
• Bleed air from the cooling circuit. (#2-19)
• Install the cowling. (#7-8)
COOLING AND LUBRICATION SYSTEM 6-7
RADIATOR CAP
INSPECTION
• Remove the radiator cap. (#6-3)
• Fit the cap
1 to the radiator cap tester 2.
• Build up pressure slowly by operating the tester. Make sure
that the pressure build-up stops at 95 – 125 kPa (0.95 – 1.25
kgf/cm², 13.5 – 17.8 psi) and that, with the tester held standstill, the cap is capable of holding that pressure for at least 10
seconds.
• Replace the cap if it is found not to satisfy above requirements.
% Radiator cap valve opening pressure
Standard: 95 – 125 kPa
(0.95 – 1.25 kgf/cm², 13.5 – 17.8 psi)
WATER HOSE
INSPECTION
• Remove the cowling. (#7-5)
Any water hose found in a cracked condition or flattened or
water leaked must be replaced.
Any leakage from the connecting section should be corrected by
proper tightening.
6-8 COOLING AND LUBRICATION SYSTEM
COOLING FAN
INSPECTION
• Remove the cowling. (#7-5)
• Disconnect the cooling fan motor and thermo-switch lead wire
coupler
1.
Test the cooling fan motor for load current with an ammeter connected as shown in the illustration.
The voltmeter is for making sure that the battery 2 applies 12
volts to the fan motor 3. With the fan motor with electric motor
fan running at full speed, the ammeter 4 should be indicating
not 5 amperes and more.
If the fan motor does not turn, replace the fan motor assembly
with a new one.
NOTE:
When making above test, it is not necessary to remove the cooling fan.
REMOVAL
• Remove the cowling. (#7-5)
• Drain the engine coolant. (#2-18)
• Remove the radiator. (#6-4)
• Disconnect the cooling fan thermo-switch coupler 1.
• Remove the cooling fan.
INSTALLATION
• Install the cooling fan to the radiator.
$ Cooling fan motor mounting bolt:
8 N·m (0.8 kgf-m, 6.0 lb-ft)
• Connect the cooling fan thermo-switch coupler 1.
• Install the radiator.
• Route the radiator hoses properly. (#9-24)
• Pour engine coolant. (#2-18)
• Bleed the air from the cooling circuit. (#2-19)
• Install the cowling. (#7-8)
Bl B/R
COOLING AND LUBRICATION SYSTEM 6-9
COOLING FAN THERMO-SWITCH
REMOVAL
• Remove the cowling. (#7-5)
• Drain the engine coolant. (#2-18)
• Disconnect the cooling fan thermo-switch lead wire coupler
1.
• Remove the cooling fan thermo-switch 2.
INSPECTION
• Check the thermo-switch closing or opening temperatures by
testing it at the bench as shown in the figure. Connect the
thermo-switch 1 to a circuit tester and place it in the OIL contained in a pan, which is placed on a stove.
• Heat the oil to raise its temperature slowly and read the column thermometer 2 when the switch closes or opens.
& 09900-25008: Multi circuit tester set
' Tester knob indication: Continuity test ( )
% Cooling fan thermo-switch operating temperature
Standard (OFF→ON): Approx. 98 °C (208 °F)
(ON→OFF): Approx. 92 °C (198 °F)
!
INSTALLATION
• Install a new O-ring 1 and apply engine coolant to the O-ring.
• Tighten the cooling fan thermo-switch to the specified torque.
$ Cooling fan thermo-switch: 17 N·m (1.7 kgf-m, 12.5 lb-ft)
• Pour engine coolant. (#2-18)
• Bleed air from the cooling circuit. (#2-19)
• Install the cowling. (#7-8)
* Take special care when handling the thermo-switch.
It may cause damage if it gets a sharp impact.
* Do not contact the cooling fan thermo-switch 1 and
the column thermometer 2 with a pan.

6-10 COOLING AND LUBRICATION SYSTEM
ECT SENSOR
REMOVAL
• Drain the engine coolant. (#2-18)
• Disconnect the ECT sensor lead wire coupler.
• Place a rag under the ECT sensor and remove the ECT sensor
1.
INSPECTION
• Check the ECT sensor by testing it at the bench as shown in
the figure. Connect the ECT sensor 1 to a circuit tester and
place it in the WATER contained in a pan, which is placed on
a stove.
• Heat the water to raise its temperature slowly and read the
column thermometer 2 and the ohmmeter.
• If the ECT sensor ohmic valve does not change in the proportion indicated, replace it with a new one.
% Temperature sensor specification
If the resistance noted to show infinity or too much different
resistance value, replace the ECT sensor with a new one.
!
Temperature Standard resistance
20 °C (68 °F) Approx. 2.45 kΩ
40 °C (104 °F) Approx. 1.148 kΩ
60 °C (140 °F) Approx. 0.587 kΩ
80 °C (176 °F) Approx. 0.322 kΩ
* Take special care when handling the ECT sensor. It
may cause damage if it gets a sharp impact.
* Do not contact the ECT sensor 1 and the column
thermometer 2 with a pan.
COOLING AND LUBRICATION SYSTEM 6-11
INSTALLATION
• Install a new sealing washer
1.
• Tighten the ECT sensor to the specified torque.
$ ECT sensor: 19 N·m (1.9 kgf-m, 13.5 lb-ft)
!
• Pour engine coolant. (#2-18)
• Bleed air from the cooling circuit. (#2-19)
Take special care when handling the ECT sensor. It
may cause damage if it gets a sharp impact.
6-12 COOLING AND LUBRICATION SYSTEM
THERMOSTAT CASE ASSEMBLY
REMOVAL
• Drain the engine coolant. (#2-18)
• Place a rag under the thermostat case.
• Remove the thermostat case cap
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 following manner.
• Pass a string between flange, as shown in the photograph.
• Immerse the thermostat in the WATER contained in a beaker,
as shown in the illustration. Note that the immersed thermostat is in suspension. Heat the water by placing the beaker on
a stove 1 and observe the rising temperature on a thermometer 2.
• Read the thermometer just when opening the thermostat. This
reading, which is the temperature level at which the thermostat valve begins to open, should be within the standard
value.
% Thermostat valve opening temperature
Standard: Approx. 88 °C (190 °F)
COOLING AND LUBRICATION SYSTEM 6-13
• 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 8.0 mm
(0.31 in).
% Thermostat valve lift
Standard: Over 8.0 mm at 100 °C (Over 0.31 in at 212 °F)
• A thermostat failing to satisfy either of the two requirements,
start-to-open temperature and valve lift, must be replaced.
INSTALLATION
• Apply engine coolant to the rubber seal on the thermostat.
• Install the thermostat.
NOTE:
The jiggle valve
A of the thermostat faces upside.
• Install the thermostat case cap 1.
NOTE:
The rib A of the thermostat case cap should be faced upward.
• Tighten the thermostat case bolts to the specified torque.
$ Thermostat case bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft)
• Pour engine coolant. (#2-18)
• Bleed air from the cooling circuit. (#2-19)
6-14 COOLING AND LUBRICATION SYSTEM
WATER PUMP
REMOVAL AND DISASSEMBLY
• Drain the engine coolant. (#2-18)
• Drain the engine oil. (#2-13)
• Disconnect the water hoses
1, 2.
• Remove the water pump case and clutch cover. (#3-27)
NOTE:
Before draining engine oil and engine coolant, inspect engine oil
and coolant leakage between the water pump and clutch cover.
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 ring. (#6-16)
• Remove the snap ring and water pump driven gear 3.
• Remove the pin 4 and washer 5.
COOLING AND LUBRICATION SYSTEM 6-15
• Remove the water pump
6 from the clutch cover.
• Remove the screws and separate the water pump.
• Remove the O-rings 7.
• Remove the E-ring from the impeller shaft.
• Remove the impeller from the other side.
• Remove the mechanical seal ring 5 and rubber seal 6 from
the impeller.
6-16 COOLING AND LUBRICATION SYSTEM
• Remove the bearings with the special tool.
& 09921-20240: Bearing remover set (10 mm)
NOTE:
If there is no abnormal noise, bearings removal is not necessary.
!
• Remove the mechanical seal and oil seal with the special tool.
& 09913-70210: Bearing installer set () 20 mm)
NOTE:
If there is no abnormal condition, the mechanical seal and the oil
seal removal is not necessary.
!
INSPECTION
BEARING
Inspect the play of the bearing by hand while it is in the water
pump case.
Rotate the inner race by hand to inspect for abnormal noise and
smooth rotation.
Replace the bearing if there is anything unusual.
MECHANICAL SEAL
Visually inspect the mechanical seal for damage, with particular
attention given to the sealing face.
Replace the mechanical seal that shows indications of leakage.
Also replace the seal ring if necessary.
The removed bearings must be replaced with the new
ones.
The removed mechanical seal and oil seal must be
replaced with a new one.
COOLING AND LUBRICATION SYSTEM 6-17
OIL SEAL
Visually inspect the oil seal for damage, with particular attention
given to the lip.
Replace the oil seal that shows indications of oil leakage.
BEARING CASE
Visually inspect the bearing case for damage.
Replace the water pump body if necessary.
REASSEMBLY AND INSTALLATION
• Install the oil seal with the special tool.
& 09913-70210: Bearing installer set () 22 mm)
NOTE:
The stamped mark on the oil seal faces impeller side.
• Apply a small quantity of the SUZUKI SUPER GREASE to the
oil seal lip.
* 99000-25030: SUZUKI SUPER GREASE “A” (USA)
99000-25010: SUZUKI SUPER GREASE “A” (Others)
6-18 COOLING AND LUBRICATION SYSTEM
• Install the new mechanical seal with the special tool.
& 09913-70210: Bearing installer set () 25 mm)
• Install the new bearings with the special tool.
& 09913-70210: Bearing installer set () 25 mm)
NOTE:
The stamped mark on the bearing faces to the crankcase side.
• Install the rubber seal
1 into the impeller.
• After wiping off the oily or greasy matter from the mechanical
seal ring, install it into the impeller.
NOTE:
The paint marked side A of the mechanical seal ring faces to
the impeller.
• Apply SUZUKI SUPER GREASE to the impeller shaft.
* 99000-25030: SUZUKI SUPER GREASE “A” (USA)
99000-25010: SUZUKI SUPER GREASE “A” (Others)
• Install the impeller to the water pump body.
• Fix the impeller shaft with the E-ring 2.
• Apply SUZUKI SUPER GREASE to the O-rings.
* 99000-25030: SUZUKI SUPER GREASE “A” (USA)
99000-25010: SUZUKI SUPER GREASE “A” (Others)
• Install new O-rings 3.
• Fill the bearing with engine oil until engine oil comes out from
the hole of the be bearing housing.
COOLING AND LUBRICATION SYSTEM 6-19
• Apply engine coolant to the O-ring
4.
• Install a new O-ring.
!
• Connect the water hoses.
• Pour engine coolant. (#2-18)
• Pour engine oil. (#2-14)
Use a new O-ring to prevent engine coolant leakage.
4.5 N·m
(0.45 kgf-m, 3.3 lb-ft)
6-20 COOLING AND LUBRICATION SYSTEM
LUBRICATION SYSTEM
OIL PRESSURE
#2-31
OIL FILTER
#2-14
OIL PRESSURE REGULATOR
#3-57
OIL STRAINER
#3-58
OIL JET
#3-49, -59, -60 and -96
OIL PUMP
#3-81 and -89
OIL PRESSURE SWITCH
#3-58 and 8-34
COOLING AND LUBRICATION SYSTEM 6-21
OIL COOLER
REMOVAL
• Drain the engine oil. (#2-13)
• Disconnect the oil cooler hoses.
• Remove the oil cooler.
• Remove the oil cooler fin guard net
1.
• Remove the oil hoses 2.
INSPECTION AND CLEANING
Inspect the oil cooler and hose joints for oil leakage. If any
defect are found, replace the oil cooler and oil hoses with the
new ones.
Road dirt or trash stuck to the fins must be removed.
Use of compressed air is recommended for this cleaning.
6-22 COOLING AND LUBRICATION SYSTEM
Fins bent down or dented can be repaired by straightening them
with the blade of a small screwdriver.
INSTALLATION
• Install the new gasket washers
1.
!
• Connect the oil hoses.
• Install the oil cooler.
$ Oil cooler mounting bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft)
• Tighten the oil cooler hose union bolts to the specified torque.
$ Oil cooler hose union bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft)
!
Use the new gasket washers to prevent engine oil
leakage.
The oil cooler hoses should be contacted with the
stoppers A.
COOLING AND LUBRICATION SYSTEM 6-23
ENGINE LUBRICATION FLOW CHART
OIL PAN
OIL STRAINER
CLUTCH PLATES
CLUTCH PUSH PEACE
OIL PRESSURE
REGULATOR
OIL PUMP
OIL FILTER
OIL GALLERY
RIGHT SIDE CRANKSHAFT JOURNAL BEARINGLEFT SIDE CRANKSHAFT JOURNAL BEARING
OIL PRESSURE
SWITCH
DRIVEN GEAR AND
BUSHING
DRIVEN GEAR AND
BUSHINGS
PRIMARY DRIVEN
GEAR BUSHING
OIL JET
OIL JET (#14)
OIL JET (#14)
REAR CYLINDER
REAR CYLINDER HEAD
FRONT CYLINDER
FRONT CYLINDER HEAD
INTAKE
CAMSHAFT
CAM FACES
CRANK PIN
FRONT AND REAR CONROD
BIG END BEARINGS
STARTER CLUTCH
CAM FACES
CAM CHAINEXHAUST
CAMSHAFT
FRONT PISTON AND
CYLINDER WALL
REAR PISTON AND
CYLINDER WALL
PISTON COOLING
OIL JET (#13)
EXHAUST
CAMSHAFT JOURNAL
EXHAUST
CAMSHAFT JOURNAL
STARTER
DRIVEN GEAR BUSHING
LEFT SIDE
CRANKSHAFT
JOURNAL
RIGHT SIDE
CRANKSHAFT
JOURNAL
INTAKE
CAMSHAFT
JOURNALS
OIL JET (#8)
CAM CHAIN
TENSION
ADJUSTER
INTAKE
CAMSHAFT
JOURNALS
CAM CHAIN
TENSION
ADJUSTER
OIL JET (#8)
DRIVE SHAFT
OIL PIPE
COUNTER SHAFT OIL COOLER
CAM FACES
CAM FACES
CAM CHAIN
PISTON COOLING
OIL JET (#13)
OIL JET (#14)
6-24 COOLING AND LUBRICATION SYSTEM
ENGINE LUBRICATION CIRCUIT
FRONT CYLINDER
/
COOLING AND LUBRICATION SYSTEM 6-25
REAR CYLINDER
CHASSIS
CONTENTS
EXTERIOR PARTS .......................................................................................7- 2
CONSTRUCTION ...................................................................................7- 2
REMOVAL ..............................................................................................7- 4
INSTALLATION .....................................................................................7- 8
FRONT WHEEL ............................................................................................7- 9
CONSTRUCTION ...................................................................................7- 9
REMOVAL ..............................................................................................7-10
INSPECTION AND DISASSEMBLY ......................................................7-10
REASSEMBLY AND REMOUNTING .....................................................7-12
FRONT FORK ...............................................................................................7-16
CONSTRUCTION ...................................................................................7-16
REMOVAL AND DISASSEMBLY ..........................................................7-17
INSPECTION ..........................................................................................7-20
REASSEMBLY AND REMOUNTING .....................................................7-21
SUSPENSION SETTING ........................................................................7-25
STEERING AND HANDLEBAR ...................................................................7-26
CONSTRUCTION ...................................................................................7-26
REMOVAL ..............................................................................................7-27
INSPECTION AND DISASSEMBLY ......................................................7-30
REASSEMBLY AND REMOUNTING .....................................................7-31
STEERING TENSION ADJUSTMENT ...................................................7-34
REAR WHEEL ..............................................................................................7-35
CONSTRUCTION ...................................................................................7-35
REMOVAL ..............................................................................................7-36
INSPECTION AND DISASSEMBLY ......................................................7-37
REASSEMBLY AND REMOUNTING .....................................................7-40
REAR SHOCK ABSORBER .........................................................................7-44
CONSTRUCTION ...................................................................................7-44
REMOVAL ..............................................................................................7-45
INSPECTION ..........................................................................................7-46
REAR SHOCK ABSORBER DISPOSAL ...............................................7-46
REMOUNTING .......................................................................................7-47
SUSPENSION SETTING ........................................................................7-48
REAR SWINGARM .......................................................................................7-49
CONSTRUCTION ...................................................................................7-49
REMOVAL ..............................................................................................7-50
INSPECTION AND DISASSEMBLY ......................................................7-51
REASSEMBLY .......................................................................................7-54
CHASSIS 7-1
7
REMOUNTING ....................................................................................... 7-56
FINAL INSPECTION AND ADJUSTMENT ............................................ 7-57
FRONT BRAKE ............................................................................................ 7-58
CONSTRUCTION .................................................................................. 7-58
BRAKE PAD REPLACEMENT .............................................................. 7-59
BRAKE FLUID REPLACEMENT ........................................................... 7-60
CALIPER REMOVAL AND DISASSEMBLY ......................................... 7-61
CALIPER INSPECTION ......................................................................... 7-62
CALIPER REASSEMBLY AND REMOUNTING ................................... 7-63
BRAKE DISC INSPECTION .................................................................. 7-65
MASTER CYLINDER REMOVAL AND DISASSEMBLY ...................... 7-65
MASTER CYLINDER INSPECTION ...................................................... 7-66
MASTER CYLINDER REASSEMBLY AND REMOUNTING ................. 7-67
REAR BRAKE .............................................................................................. 7-68
CONSTRUCTION .................................................................................. 7-68
BRAKE PAD REPLACEMENT .............................................................. 7-69
BRAKE FLUID REPLACEMENT ........................................................... 7-71
CALIPER REMOVAL AND DISASSEMBLY ......................................... 7-71
CALIPER INSPECTION ......................................................................... 7-73
BRAKE DISC INSPECTION .................................................................. 7-74
CALIPER REASSEMBLY AND REMOUNTING ................................... 7-74
MASTER CYLINDER REMOVAL AND DISASSEMBLY ...................... 7-75
MASTER CYLINDER INSPECTION ...................................................... 7-77
MASTER CYLINDER REASSEMBLY AND REMOUNTING ................. 7-77
TIRE AND WHEEL ....................................................................................... 7-79
TIRE REMOVAL .................................................................................... 7-79
INSPECTION ......................................................................................... 7-79
VALVE INSTALLATION ........................................................................ 7-80
TIRE INSTALLATION ............................................................................ 7-81
DRIVE CHAIN ............................................................................................... 7-83
DRIVE CHAIN CUTTING ....................................................................... 7-83
DRIVE CHAIN CONNECTING ............................................................... 7-84
7-2 CHASSIS
EXTERIOR PARTS
CONSTRUCTION
1 Wind screen cover 6 Cowling body
2 Wind screen 7 Combination meter panel
3 Wind screen brace 8 Cowling inner cover !
4 Cowling brace 9 Left cowling ITEM N·m kgf-m lb-ft
5 Right cowling A Cowling brace mounting bolt A 35 3.5 25.5
CHASSIS 7-3
1 Seat rail 4 Mud guard !
2 Rear fender No.1 5 Frame cover ITEM N·m kgf-m lb-ft
3 Rear fender No.2 A Seat rail mounting bolt A 50 5.0 36.0
7-4 CHASSIS
REMOVAL
SEAT
• Remove the seat with the ignition key
1.
FUEL TANK SIDE COVER
• Remove the seat. ("7-4)
• Remove the fuel tank side covers 1.
NOTE:
“✩” indicates hook location.
CARRIER
• Remove the seat. ("7-4)
• Remove the carrier 1.
CHASSIS 7-5
FRAME COVER
• Remove the seat. ("7-4)
• Remove the carrier. ("7-4)
• Remove the fuel tank side cover. ("7-4)
• Remove the frame covers
1.
NOTE:
“✩” indicates hook location.
REAR FENDER
• Remove the seat. ("7-4)
• Remove the carrier. ("7-4)
• Remove the bolts 1.
• Disconnect the brake light/taillight lead wire coupler 2 and
seat lock cable 3.
• Remove the rear fender.
COWLING AND COWLING BRACE
• Remove the seat. ("7-4)
• Disconnect the battery - lead wire.
• Remove the wind screen covers 1.
7-6 CHASSIS
• Remove the wind screen
2.
• Remove the fuel tank top cover 3.
• Remove the combination meter panel mounting screws 4.
• Remove the combination meter panel 5.
NOTE:
“✩” indicates hook location.
• Disconnect the speedometer lead wire coupler 6.
• Remove the cowling inner cover 7 by removing two screws
and seven fasteners.
CHASSIS 7-7
• Remove the left cowling
8.
• Remove the right cowling 9.
• Remove the wind screen brace 0.
• Disconnect the turn signal light lead wire couplers A.
• Remove the screws B.
• Remove the cowling body C.
NOTE:
“✩” indicates hook location.
7-8 CHASSIS
• Disconnect the coupler
D.
• Remove the cowling blace E.
• Remove the combination meter. ("8-29)
INSTALLATION
Install the exterior parts in the reverse order of removal. Pay
attention to the following points:
• Install the wind screen brace 1 as shown in the photograph.
NOTE:
Install the larger diameter bolts on the wind screen brace attaching section A.
NOTE:
The wind screen height can be adjusted by changing the wind
screen brace installed position.
CHASSIS 7-9
FRONT WHEEL
CONSTRUCTION
1 Brake disc 5 Front wheel !
2 Dust seal 6 Tire valve ITEM N·m kgf-m lb-ft
3 Bearing A Front axle A 65 6.5 47.0
4 Center spacer B Brake disc bolt B 23 2.3 16.5
7-10 CHASSIS
REMOVAL
• Remove the right and left brake calipers. ("7-59)
• Loosen the axle pinch bolt
1 on the right front fork leg.
#
• Slightly loosen the front axle with the special tool.
$ 09900-18710: Hexagon bit 12 mm
• Raise the front wheel off the ground and support the motorcycle with a jack or a wooden block.
• Remove the front axle 2 and the front wheel.
NOTE:
After removing the front wheel, fit the calipers temporarily to the
original positions.
INSPECTION AND DISASSEMBLY
TIRE ("7-79)
BRAKE DISC ("7-65)
• Remove the brake discs.
DUST SEAL
• Inspect the dust seal lip for wear or damage. If any damages
are found, replace the dust seal with a new one.
Do not operate the brake lever while removing the calipers.
CHASSIS 7-11
• Remove the dust seal with the special tool.
$ 09913-50121: Oil seal remover
!
#
FRONT AXLE
Using a dial gauge, check the front axle for runout and replace it
if the runout exceeds the limit.
$ 09900-20607: Dial gauge (1/100)
09900-20701: Magnetic stand
09900-21304: V-block set (100 mm)
% Axle shaft runout
Service Limit: 0.25 mm (0.010 in)
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. (Wheel inspection: "7-79)
% Wheel runout
Service Limit (Axial and Radial): 2.0 mm (0.08 in)
WHEEL BEARING
Inspect the play of the wheel bearings by finger while they are in
the wheel. Rotate the inner race by finger to inspect for abnormal noise and smooth rotation.
Replace the bearing in the following procedure if there is anything unusual.
• Remove the wheel bearings with the special tool.
$ 09921-20240: Bearing remover set (& 17)
#
Do not reuse the removed dust seals.
Do not reuse the removed bearings.
7-12 CHASSIS
REASSEMBLY AND REMOUNTING
Reassemble and remount the front wheel in the reverse order of removal and disassembly. Pay attention to
the following points:
A Left B Right
39 N·m
3.9 kgf-m
28.0 lb-ft ( )
23 N·m
2.3 kgf-m
16.5 lb-ft ( )
39 N·m
3.9 kgf-m
28.0 lb-ft ( )
23 N·m
2.3 kgf-m
16.5 lb-ft ( )
65 N·m
6.5 kgf-m
47.0 lb-ft ( )
23 N·m
2.3 kgf-m
16.5 lb-ft ( )
CHASSIS 7-13
WHEEL BEARING
• Apply SUZUKI SUPER GREASE to the wheel bearings.
' 99000-25030: SUZUKI SUPER GREASE “A” (USA)
99000-25010: SUZUKI SUPER GREASE “A” (Others)
• First install the left wheel bearing, then install the right wheel
bearing and spacer with the special tools and used bearing.
$ 09941-34513: Bearing/Steering race installer set
09913-70210: Bearing installer set (& 40)
#
1 Spacer 2 Old bearing A Left B Right C Clearance
DUST SEAL
• Install the dust seal with the special tool.
$ 09913-70210: Bearing installer set (& 40)
The sealed cover of the bearing must face outside.
7-14 CHASSIS
BRAKE DISC
Make sure that the brake disc is clean and free of any greasy
matter.
• Apply THREAD LOCK to the disc mounting bolts and tighten
them to the specified torque.
NOTE:
The stamped mark
A on the brake disc should face to the outside.
! Brake disc bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft)
( 99000-32130: THREAD LOCK SUPER “1360”
WHEEL
Install the front wheel with the front axle and tighten the front
axle temporarily.
)
BRAKE CALIPER
• Tighten the brake caliper mounting bolts to the specified
torque.
! Front brake caliper mounting bolt:
39 N·m (3.9 kgf-m, 28.0 lb-ft)
NOTE:
Push the pistons all the way into the caliper and remount the calipers.
FRONT AXLE
• Tighten the front axle to the specified torque with the special
tool.
$ 09900-18710: Hexagon bit 12 mm
! Front axle: 65 N·m (6.5 kgf-m, 47.0 lb-ft)
The directional arrow A on the wheel must point to
the wheel rotation, when remounting the wheel.
CHASSIS 7-15
NOTE:
Before tightening the axle pinch bolt on the right front fork leg,
move the front fork up and down 4 or 5 times without applying
front brake.
• Tighten the axle pinch bolt
1 on the right front fork leg to the
specified torque.
! Front axle pinch bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft)
7-16 CHASSIS
FRONT FORK
CONSTRUCTION
1 Spring adjuster B Oil seal
2 O-ring C Oil seal retainer
3 Washer D Guide metal
4 Spacer E Oil lock piece
5 Spring F Outer tube
6 Rebound spring G Cylinder
7 Inner tube H Washer !
8 Slide metal A Front fork cap bolt ITEM N·m kgf-m lb-ft
9 Gasket B Front axle pinch bolt A 23 2.3 16.5
0 Dust seal C Cylinder bolt B 23 2.3 16.5
A Oil seal stopper ring C 20 2.0 14.5
CHASSIS 7-17
REMOVAL AND DISASSEMBLY
• Remove the front wheel. ("7-10)
• Remove the speedometer lead wire mounting bolts
1.
• Remove the front fender bolts and brake hose bolts.
• Remove the front fender 2.
• Loosen the front fork upper clamp bolts 3.
NOTE:
Slightly loosen the front fork cap bolts 4 before loosening the
lower clamp bolts to facilitate later disassembly.
• Loosen the front fork lower clamp bolts.
NOTE:
Hold the front fork by the hand to prevent sliding out of the steering stem.
• Remove the front fork.
• Remove the front fork cap bolt 5.
• Remove the spacer 6, washer 7 and spring 8.
7-18 CHASSIS
• Invert the fork and drain the fork oil out of the fork by stroking.
• Hold the fork inverted for a few minutes to drain the fork oil.
• Remove the front axle pinch bolt. (For right front fork reg)
• Remove the damper rod bolt with the special tools.
• Remove the damper rod.
$ 09940-34520: “T” Handle
09940-34531: Attachment A
NOTE:
If the damper rod turns together with the damper rod bolt, temporarily install the fork spring, spacer, washer and cap bolt to
prevent the damper rod from turning.
• Remove the rebound spring
9 and cylinder 0.
• Remove the dust seal.
CHASSIS 7-19
• Remove the oil seal stopper ring.
• Pull the inner tube out of the outer tube.
NOTE:
Be careful not to damage the inner tube.
#
• Remove the following parts.
A Oil seal
B Oil seal retainer
C Guide metal
D Slide metal
E Oil lock piece
• Remove the pin F.
• Remove the washer G.
• Remove the spring adjuster H from front fork cap bolt.
The slide metals, oil seal and dust seal must be
replaced with the new ones when reassembling the
front fork.
7-20 CHASSIS
INSPECTION
INNER AND OUTER TUBES
Inspect the inner tube outer surface and the outer tube inner surface for scratches. If any defects are found, replace them with
the new ones.
FORK SPRING
Measure the fork spring free length. If it is shorter than the service limit, replace it with a new one.
% Front fork spring free length
Service limit: 435 mm (17.1 in)
CYLINDER
Inspect the cylinder and cylinder ring
1 for damage. If any
defect is found, replace them with a new one.
CHASSIS 7-21
REASSEMBLY AND REMOUNTING
Reassemble and remount the front fork in the reverse order of
removal and disassembly. Pay attention to the following points:
METALS AND SEALS
• Hold the inner tube vertically and clean the metal groove and
install the guide metal by hand as shown.
#
• Assemble the following parts as shown.
1 Oil seal
2 Oil seal retainer
3 Guide metal
4 Slide metal
NOTE:
Stamped mark on the oil seal must face upward.
• Install the oil lock piece 5 into the inner tube.
• Install the inner tube into the outer tube with care not to drop
the oil lock piece out.
NOTE:
After installing the inner tube into the outer tube, keep the oil
lock piece into the inner tube by compressing the front fork fully.
• Insert the inner tube into the outer tube and fit the oil seal and
dust seal with the special tool.
$ 09940-52861: Front fork oil seal installer
NOTE:
Stamped mark on the oil seal should face outside.
* Use special care to prevent damage to the “Teflon”
coated surface of the guide metal when mounting it.
* When installing the oil seal to inner tube, be careful
not to damage the oil seal lip.
* Replace the removed metals and seals with new
ones.
* Apply fork oil to the Anti-friction metals and lip of the
oil seal.
7-22 CHASSIS
• Install the oil seal stopper ring
6 and the dust seal 7.
A Dust seal
B Oil seal stopper ring
C Oil seal
D Oil seal retainer
E Guide metal
CYLINDER
• Install the rebound spring 1 to the cylinder 2.
• Apply fork oil to the cylinder ring.
• Install the cylinder into the front fork.
• Apply THREAD LOCK to the cylinder bolt.
#
* 99000-32050: THREAD LOCK “1342”
• Tighten the cylinder bolt to the specified torque with the special tools.
$ 09940-34520: “T” Handle
09940-34531: Attachment A
! Cylinder bolt: 20 N·m (2.0 kgf-m, 14.5 lb-ft)
NOTE:
* If the cylinder turns together with the cylinder bolt, temporarily
install the fork spring, spacer, washer and cap bolt to prevent
the cylinder from turning.
* Check the front fork for smoothness by stroking it after installing the cylinder.
Use a new gasket 3 to prevent oil leakage.
CHASSIS 7-23
FORK OIL
• Place the front fork vertically without spring.
• Compress the front fork fully.
• Pour the specified front fork oil into the front fork.
+ 99000-99001-SS8: SUZUKI FORK OIL SS-08
% Front fork oil capacity (each leg):
524 ml (17.7/18.5 US/Imp oz)
• Move the inner tube up and down several strokes until no
more bubbles come out from the oil.
• Keep the front fork vertically and leave it during 5 – 6 minutes.
NOTE:
Take extreme attention to pump out air completely.
• Hold the front fork vertically and adjust the fork oil level with
the special tool.
NOTE:
When adjusting the fork oil level, remove the fork spring and
compress the inner tube fully.
$ 09943-74111: Front fork oil level gauge
% Fork oil level: 143 mm (5.63 in)
+ 99000-99001-SS8: SUZUKI FORK OIL SS-08
7-24 CHASSIS
FORK SPRING
• Install the fork spring
1 into the front fork.
• Install the washer 2 and spacer 3.
NOTE:
The smaller spring pitch end A must face downward.
• Apply fork oil lightly to the O-ring.
#
• Install the spring adjuster to the front fork cap bolt.
• Apply fork oil lightly to the O-ring.
#
• Tighten the front fork cap bolt temporarily.
• Set the front fork to the front fork lower bracket temporarily by
tightening the lower clamp bolts.
Use a new O-ring to prevent oil leakage.
Use a new O-ring to prevent oil leakage.
CHASSIS 7-25
• Tighten the front fork cap bolt
4 to the specified torque.
! Front fork cap bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft)
• Loosen the front fork lower clamp bolt.
• Align the top of the inner tube to the upper surface of the
steering stem upper bracket.
• Tighten the front fork upper and lower clamp bolts.
! Front fork upper clamp bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft)
Front fork lower clamp bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft)
• Install the front wheel. ("7-10)
• Install the front brake calipers. ("7-59)
NOTE:
After install the brake calipers, front brake should be efficient by
pumping the front brake lever.
SUSPENSION SETTING
After installing the front fork, adjust the spring per-load as follows.
SPRING PRE-LOAD ADJUSTMENT
There are four grooved lines on the side of the spring adjuster.
Position 0 provides the maximum spring pre-load and position 5
provides the minimum spring pre-load.
STD POSITION: 3
)
Be sure to adjust the spring pre-load on both front
fork legs equally.
0
1
2
3
4
5
0
7-26 CHASSIS
STEERING AND HANDLEBAR
CONSTRUCTION
1 Handlebars 0 Spacer
2 Steering stem upper bracket A Washer
3 Dust seal B Expander !
4 Bearing upper A Handlebar clamp bolt ITEM N·m kgf-m lb-ft
5 Bearing lower B Steering stem head nut A 23 2.3 16.5
6 Steering stem lower bracket C Front fork upper clamp bolt B 90 9.0 65.0
7 Steering stem nut D Steering stem lock-nut C 23 2.3 16.5
8 Handlebar balancer E Front fork lower clamp bolt D 80 8.0 58.0
9 Expander E 23 2.3 16.5
CHASSIS 7-27
REMOVAL
HANDLEBARS
• Remove the handlebar balancers
1.
• Remove the rear view mirrors 2.
NOTE:
Do not remove the handlebar balancer mounting screw before
removing the handlebar balancer. Slightly loosen the mounting
screw, and then pull the balancer assembly out of handlebars.
• Remove the front brake master cylinder 3.
• Remove the right handlebar switch box 4 and throttle case
5.
• Disconnect the clutch switch lead wire coupler 6.
• Remove the left handlebar switch box 7.
• Remove the grip rubber 8.
• Loosen the clutch lever holder bolt 9.
• Disconnect the clamps 0.
• Remove the clamp bolt caps A.
7-28 CHASSIS
• Remove the handlebars by removing the handlebar clamp
bolts.
• Remove the clutch lever holder
B.
STEERING STEM
• Remove the front forks. ("7-17)
• Remove the handlebars. ("7-27)
• Remove the guides 1.
• Remove the brake hose guide 2.
• Remove the ignition switch 3 with the special tools.
$ 09930-11920: Torx bit JT40H
09930-11940: Bit holder
CHASSIS 7-29
• Remove the steering stem upper bracket by removing the
steering stem head nut.
• Remove the steering stem lock-nut with the special tools.
$ 09940-14911: Steering stem nut wrench
09940-14960: Steering stem nut wrench socket
• Remove the washer
4.
• Remove the steering stem nut with the special tools.
$ 09940-14911: Steering stem nut wrench
09940-14960: Steering stem nut wrench
NOTE:
When loosing the steering stem nut, hold the steering stem
lower bracket to prevent it from falling.
• Remove the steering stem lower bracket.
• Remove the dust seal 5 and bearing inner race 6.
7-30 CHASSIS
• Remove the steering stem upper bearing
7.
• Remove the steering stem lower bearing 8.
INSPECTION AND DISASSEMBLY
Inspect the removed parts for the following abnormalities.
* Distortion of the steering stem
* Bearing wear or damage
* Abnormal bearing noise
* Handlebars distriction
* Race wear and brinelling
If any abnormal points are found, replace defective parts with
the new ones.
• Remove the steering stem lower bearing inner race using a
chisel.
#
• Drive out the steering stem upper and lower bearing races
with the special tools.
$ 09941-54911: Bearing outer race remover
09925-18011: Steering bearing installer
The removed bearing inner race and dust seal must be
replaced with the new ones.
CHASSIS 7-31
REASSEMBLY AND REMOUNTING
Reassemble and remount the steering stem in the reverse order
of removal and disassembly. Pay attention to the following
points:
OUTER RACES
• Press in the upper and lower outer races with the special tool.
$ 09941-34513: Steering outer race installer
09913-70210: Bearing installer set (& 55)
BEARINGS
• Press in the dust seal and lower bearing with the special tool.
$ 09925-18011: Steering bearing installer
• Apply SUZUKI SUPER GREASE to the bearings and dust
seal.
• Install the lower bearing to the steering stem lower bracket.
• Install the upper bearing, bearing inner race, dust seal onto
the frame.
' 99000-25030: SUZUKI SUPER GREASE “A” (USA)
99000-25010: SUZUKI SUPER GREASE “A” (Others)
STEERING STEM
• Tighten the steering stem nut to the specified torque with the
special tools.
$ 09940-14911: Steering stem nut wrench
09940-14960: Steering stem nut wrench socket
! Steering stem nut: 45 N·m (4.5 kgf-m, 32.5 lb-ft)
• Turn the steering stem about five or six times to the left and
right so that the angular ball bearing will be seated properly.
• Loosen the steering stem nut by 1/4 – 1/2 turn.
NOTE:
This adjustment will vary from motorcycle to motorcycle.
7-32 CHASSIS
• Install the washer.
NOTE:
When installing the washer, align the stopper lug to the groove
of the steering stem.
• Install the steering stem lock-nut and tighten it to the specified
torque with the special tools.
$ 09940-14911: Steering stem nut wrench
09940-14960: Steering stem nut wrench socket
! Steering stem lock-nut: 80 N·m (8.0 kgf-m, 58.0 lb-ft)
• Install the steering stem upper bracket and tighten the steering stem nut lightly.
• Install the ignition switch
1 and harness guide 2. ("8-38)
• Install the front fork to the steering stem and tighten the lower
clamp bolts temporarily.
• Tighten the steering stem head nut to the specified torque.
! Steering stem head nut: 90 N·m (9.0 kgf-m, 65.0 lb-ft)
• Remount the front forks and the front fender. ("7-21)
HANDLEBARS
• Install the handlebars with the punch mark A aligned with the
mating surface B of the handlebar holder.
CHASSIS 7-33
• Set the punch mark
C on the handlebar clamp forward.
• Tighten the handlebar clamp bolts to the specified torque.
! Handlebar clamp bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft)
NOTE:
When tightening the handlebar clamp bolts, first tighten the bolt
1 and then tighten the bolt 2.
HANDLEBAR SWITCH BOX
• Install the throttle cable case.
• Apply SUZUKI SUPER GREASE to the throttle cables and
their holes.
' 99000-25030: SUZUKI SUPER GREASE “A” (USA)
99000-25010: SUZUKI SUPER GREASE “A” (Others)
• Align the mating surface B of the throttle case with the punch
mark A on the handlebars.
• Install the right handlebar switch box to the handlebars by
engaging the stopper 1 with the handlebar’s hole 2.
• Install the front brake master cylinder. ("7-67)
• Install the handlebars with the punch mark C aligned with the
mating surface D of the clutch lever holder.
7-34 CHASSIS
• Install the left handlebar switch box to the handlebars by
engaging the stopper
3 with the handlebars hole 4.
• Install the clutch master cylinder with the proper clutch hose
routing.
• Install the handlebar balancers and the rear view mirrors.
(Handlebar balancer installation: "9-35)
• Install the front wheel. ("7-12)
STEERING TENSION ADJUSTMENT
Check the steering movement in the following procedure.
• By supporting the motorcycle with a jack, lift the front wheel
until it is off the floor by 20 – 30 mm (0.8 – 1.2 in).
• Check to make sure that the cables and wire harnesses are
properly routed.
• With the front wheel in the straight ahead state, hitch the
spring scale (special tool) on one handlebar grip end as
shown in the figure and read the graduation when the handlebar starts moving. Do the same on the other grip end.
% Initial force: 200 – 500 grams
$ 09940-92720: Spring scale
• If the initial force read on the scale when the handlebar starts
turning is either too heavy or too light, adjust it till it satisfies
the specification.
1) First, loosen the front fork upper clamp bolts, steering stem
head nut and steering stem lock-nut, and then adjust the
steering stem nut by loosening or tightening it.
2) Tighten the steering stem lock-nut, stem head nut and front
fork upper clamp bolts to the specified torque and re-check
the initial force with the spring scale according to the previously described procedure.
3) If the initial force is found within the specified range, adjustment has been completed.
NOTE:
Hold the front fork legs, move them back and forth and make
sure that the steering is not loose.
CHASSIS 7-35
REAR WHEEL
CONSTRUCTION
1 Rear axle A Retainer
2 Dust seal B Sprocket mounting drum
3 Brake disc C Rear sprocket
4 Collar D Bearing
5 Bearing E Dust seal
6 Rear wheel F Collar !
7 Tire valve A Brake disc bolt ITEM N·m kgf-m lb-ft
8 Damper B Rear sprocket nut A 23 2.3 16.5
9 Spacer C Rear axle nut B 60 6.0 43.5
0 Bearing C 100 10.0 72.5
7-36 CHASSIS
REMOVAL
• Remove the cotter pin. (For E-03, 28, 33)
• Loosen the rear axle nut.
• Raise the rear wheel off the ground and support the motorcycle with a jack or wooden block.
• Remove the axle nut and draw out the rear axle.
#
• Remove the collars
1, 2.
• Remove the rear sprocket mounting drum assembly 3 from
the wheel hub.
NOTE:
Before removing the rear sprocket mounting drum, slightly
loosen the rear sprocket nuts 4 to facilitate later disassembly.
• Remove the rear sprocket mounting drum retainer 5.
Do not operate the brake pedal while removing the
rear wheel.
CHASSIS 7-37
• Remove the rear sprocket
6 from the rear sprocket mounting
drum.
• Remove the brake disc 7.
INSPECTION AND DISASSEMBLY
TIRE: ("7-79)
WHEEL: ("7-11 and 7-79)
REAR AXLE
Using a dial gauge, check the rear axle for runout.
If the runout exceeds the limit, replace the rear axle.
% Axle shaft runout: Service Limit: 0.25 mm (0.010 in)
$ 09900-20607: Dial gauge (1/100 mm)
09900-20701: Magnetic stand
09900-21304: V-block set (100 mm)
WHEEL DAMPER
Inspect the dampers for wear and damage.
Replace the damper if there is anything unusual.
7-38 CHASSIS
SPROCKET
Inspect the rear sprocket teeth for wear. If they are worn as
shown, replace the engine sprocket, rear sprocket and drive
chain as a set.
A Normal wear
B Excessive wear
DUST SEAL
• Inspect the wheel dust seal lip and sprocket mounting drum
dust seal lips for wear or damage. If any damages are found,
replace the dust seal with a new one.
• Remove the dust seal with the special tool.
$ 09913-50121: Oil seal remover
#
Do not reuse the removed dust seal.
CHASSIS 7-39
BEARING
Inspect the play of the wheel and sprocket mounting drum bearings by hand while they are in the wheel and drum. Rotate the
inner race by hand to inspect for abnormal noise and smooth
rotation. Replace the bearing if there is anything unusual.
• Remove the sprocket mounting drum bearing and wheel bearings with the special tool.
$ 09921-20240: Bearing remover set (
1 & 30)
(2 & 20)
#
The removed bearings must be replaced with the new
ones.
7-40 CHASSIS
REASSEMBLY AND REMOUNTING
Reassemble and remount the rear wheel in the reverse order of removal and disassembly. Pay attention to
the following points:
A Left B Right
60 N·m
6.0 kgf-m
43.5 lb-ft ( )
23 N·m
2.3 kgf-m
16.5 lb-ft ( )
100 N·m
10.0 kgf-m
72.5 lb-ft
E-03, 28, 33
( )
CHASSIS 7-41
BEARING
• Apply SUZUKI SUPER GREASE to the bearings before
installing.
' 99000-25030: SUZUKI SUPER GREASE “A” (USA)
99000-25010: SUZUKI SUPER GREASE “A” (Others)
• Install the new bearing to the sprocket mounting drum with the
special tool.
$ 09913-70210: Bearing installer set (& 62)
NOTE:
When installing the bearing, non-sealed side of bearing must
face the special tool.
• First install the right wheel bearing, then install the left wheel
bearing and spacer with the special tools.
$ 09941-34513: Bearing/Steering race installer set
09913-70210: Bearing installer set (& 47)
#
1 Spacer A Left B Right C Clearance
The sealed cover of the bearing must face outside.
7-42 CHASSIS
DUST SEAL
• Install the new dust seals with the special tool.
$ 09913-70210: Bearing installer set (
1 & 62)
(2 & 47)
NOTE:
When installing the dust seals, the stamped mark of dust seal
must face the special tool.
• Apply SUZUKI SUPER GREASE to the dust seal lips before
assembling rear wheel.
' 99000-25030: SUZUKI SUPER GREASE “A” (USA)
99000-25010: SUZUKI SUPER GREASE “A” (Others)
BRAKE DISC
Make sure that the brake disc is clean and free of any greasy
matter.
NOTE:
The stamped mark A on the brake disc should face to the outside.
• Apply THREAD LOCK to the disc bolts and tighten them to
the specified torque.
( 99000-32130: THREAD LOCK SUPER “1360”
! Brake disc bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft)
REAR SPROCKET
• Install the rear sprocket to the rear sprocket mounting drum.
NOTE:
Stamped mark A on the sprocket must face outside.
• Apply SUZUKI SUPER GREASE to the rear sprocket mounting retainer.
• Install the rear sprocket mounting drum retainer 1 as shown.
• Apply SUZUKI SUPER GREASE to the contacting surface
between the rear wheel and the sprocket drum.
' 99000-25030: SUZUKI SUPER GREASE “A” (USA)
99000-25010: SUZUKI SUPER GREASE “A” (Others)
CHASSIS 7-43
• Install the rear sprocket mounting drum assembly to the rear
wheel hub.
• Tighten the sprocket mounting nuts to the specified torque.
! Rear sprocket nut: 60 N·m (6.0 kgf-m, 43.5 lb-ft)
• Install the collar.
REAR AXLE
• Remount the rear wheel and rear axle, install the washer and
rear axle nut.
• Adjust the chain slack after rear wheel installation. ("2-21)
• Tighten the rear axle nut to the specified torque.
! Rear axle nut: 100 N·m (10.0 kgf-m, 72.5 lb-ft)
• Install the new cotter pin. (For E-03, 28, 33)
7-44 CHASSIS
REAR SHOCK ABSORBER
CONSTRUCTION
1
Rear shock absorber
B
Rear shock absorber lower
mounting nut
!
ITEM N·m kgf-m lb-ft
A
Rear shock absorber upper mounting nut
A 50 5.0 36.0
B 50 5.0 36.0
CHASSIS 7-45
REMOVAL
• Raise the rear wheel off the ground and support the motorcycle with a jack or wooden block.
• Remove the pre-load adjuster
1.
• Remove the cushion lever rod bolts/nuts and the cushion rods
2.
• Disconnect the pre-load adjuster hose from the clamp 3.
• Remove the rear shock absorber upper mounting bolt 4.
• Remove the rear shock absorber lower mounting bolt 5.
• Remove the rear shock absorber 6.
7-46 CHASSIS
INSPECTION
Inspect the shock absorber body and bushing for damage and
oil leakage.
If any defects are found, replace the shock absorber with a new
one.
#
REAR SHOCK ABSORBER DISPOSAL
)
GAS PRESSURE RELEASE
• Mark the drill hole at
A, shown in the illustration, with a center
punch.
• Cover the rear shock absorber with a transparent vinyl bag 1.
• Hold the rear shock absorber 2 with a vice.
• Make a hole with a 3 mm drill.
)
Do not attempt to disassemble the rear shock
absorber unit. It is unserviceable.
* The rear shock unit contains high-pressure nitrogen
gas. Mishandling can cause explosion.
* Keep away from fire and heat. High gas pressure
caused by heat can cause an explosion.
* Release gas pressure before disposing. 7 mm
(0.27 in)
* Be sure to wear protective glasses since drilling
chips and oil may fly off with blowing gas when the
drill bit has penetrated through the body.
* Make sure to drill at the specified position. Otherwise, pressurized oil may spout out forcefully.
CHASSIS 7-47
REMOUNTING
Remount the rear shock absorbers in the reverse order of
removal. Pay attention to the following points:
• Install the rear shock absorber and tighten the rear shock
absorber upper/lower mounting nuts.
! Rear shock absorber lower mounting nut:
50 N·m (5.0 kgf-m, 36.0 lb-ft)
Rear shock absorber upper mounting nut:
50 N·m (5.0 kgf-m, 36.0 lb-ft)
NOTE:
When installing the rear shock absorber, the outlet hose of the
prel-load adjuster faces backward.
• Clamp the pre-load adjuster hose
1.
• Install the cushion rod 2.
• Tighten the cushion rod nuts to the specified torque.
! Cushion rod nut: 78 N·m (7.8 kgf-m, 56.5 lb-ft)
7-48 CHASSIS
SUSPENSION SETTING
After installing the rear suspension, adjust the spring pre-load
and damping force as follows.
SPRING PRE-LOAD ADJUSTMENT
The pre-load is adjusted by turning the pre-load adjuster knob
without tool.
Position “0” provides the softest spring pre-load.
Position “5” provides the stiffest spring pre-load.
STD position: “2”
A STD position
B Stiffest position
C Softest position
DAMPING FORCE ADJUSTMENT
The rebound damping force is adjusted by turning the adjuster.
Fully turn the damping adjuster 1 clockwise. It is at stiffest position and turn it out to standard setting position.
STD position: 1 turn back from stiffest position
(E-02, 19, 24)
1 1/2 turns back from stiffest position
(E-03, 28, 33)
#
2
0
1
0
2
1
3
4
5
0
Do not turn the adjuster more than the given position
or the adjuster may be damaged.
CHASSIS 7-49
REAR SWINGARM
CONSTRUCTION
1 Rear shock absorber 0 Swingarm
2 Rear cushion rod A Center spacer
3 Rear cushion lever
A
Rear shock absorber upper
mounting nut
!
ITEM N·m kgf-m lb-ft
4 Spacer B Cushion lever nut A 50 5.0 36.0
5 Bearing C Cushion rod nut B 78 7.8 56.5
6 Washer D Swingarm pivot shaft C 78 7.8 56.5
7 Pivot spacer E Swingarm pivot lock-nut D 15 1.5 11.0
8 Chain cover F Swingarm pivot nut E 90 9.0 65.0
9 Chain buffer G
Rear shock absorber lower
mounting nut
F 100 10.0 72.5
G 50 5.0 36.0
7-50 CHASSIS
REMOVAL
• Remove the exhaust pipe and exhaust muffler. ("3-6)
• Raise the rear wheel off the ground and support the motorcycle with a jack or wooden block.
• Remove the rear wheel. ("7-36)
• Remove the rear brake hose guides
1.
• Remove the cushion rods 2.
• Remove the shock absorber lower mounting bolt 3.
• Remove the cushion lever 4.
• Remove the swingarm pivot shaft lock-nut with the special
tool.
$ 09940-14940: Swingarm pivot thrust adjuster socket
wrench
• Hold the swingarm pivot shaft 5 and remove the swingarm
pivot nut 6.
• Remove the swingarm pivot shaft with the special tool.
$ 09944-28320: Hexagon bit 19 mm
• Remove the chain cover 7.
CHASSIS 7-51
• Remove the mud guard
8.
• Remove the chain buffer 9.
INSPECTION AND DISASSEMBLY
SPACER
• Remove the spacers 1 from swingarm and cushion lever.
• Inspect the spacers for any flaws or other damage. If any
defect is found, replace the spacers with the new ones.
CHAIN BUFFER
Inspect the chain buffer for damage and excessive wear. If any
defect is found, replace the chain buffer with a new one.
7-52 CHASSIS
SWINGARM BEARING
Insert the spacer into bearing and check the play when moving
the spacer up and down.
If excessive play is noted, replace the bearing with a new one.
• Remove the swingarm pivot bearings and spacer with the
special tool.
$ 09921-20240: Bearing remover set (25 mm)
#
• Remove the cushion rod bearings with the special tool.
$ 09921-20240: Bearing remover set (17 mm)
#
SWINGARM PIVOT SHAFT
Using a dial gauge, check the pivot shaft runout and replace it if
the runout exceeds the limit.
$ 09900-20607: Dial gauge (1/100 mm, 10 mm)
09900-20701: Magnetic stand
09900-21304: V-block (100 mm)
% Swingarm pivot shaft runout:
Service limit: 0.3 mm (0.01 in)
CUSHION LEVER BEARING
Insert the spacer into bearing and check the play when moving
the spacer up and down.
If excessive play is noted, replace the bearing with a new one.
Do not reuse the removed bearings.
Do not reuse the removed bearings.
CHASSIS 7-53
• Remove the cushion lever bearings with the special tool.
$ 09921-20240: Bearing remover set (20 mm and 17 mm)
#
CUSHION ROD
Inspect the cushion rods for damage and distortion.
The removed bearings must be replaced with the new
ones.
7-54 CHASSIS
REASSEMBLY
Reassemble the swingarm in the reverse order of disassembly and removal.
Pay attention to the following points:
1 Frame 2 Rear shock absorber 3 Washer 4 Cushion lever 5 Cushion rod
6 Swingarm A Left B Right
50 N·m
5.0 kgf-m
36.0 lb-ft ( )
50 N·m
5.0 kgf-m
36.0 lb-ft ( )
90 N·m
9.0 kgf-m
65.0 lb-ft ( )
78 N·m
7.8 kgf-m
56.5 lb-ft ( )
78 N·m
7.8 kgf-m
56.5 lb-ft ( )
15 N·m
1.5 kgf-m
11.0 lb-ft ( )
100 N·m
10.0 kgf-m
72.5 lb-ft ( )
CHASSIS 7-55
SWINGARM BEARING
• Install the bearings and spacer into the swingarm pivot all
together with the special tools.
$ 09941-34513: Steering race installer
09913-70210: Bearing installer set (& 32)
NOTE:
When installing the bearing, the stamped mark on the bearing
must face the special tool.
• Install the cushion rod bearings with the special tool.
$ 09941-34513: Steering race installer
NOTE:
When installing the bearing, the dust seal that is embedded in
the bearing must face outside.
CUSHION LEVER BEARING
• Press the bearings into the cushion lever with the special tool.
$ 09941-34513: Steering race installer
NOTE:
When installing the bearing, the dust seal that is embedded in
the bearing must face outside.
• Apply SUZUKI SUPER GREASE to the bearings and spacers.
' 99000-25030: SUZUKI SUPER GREASE “A” (USA)
99000-25010: SUZUKI SUPER GREASE “A” (Others)
7-56 CHASSIS
REMOUNTING
Remount the swingarm in the reverse order of disassembly and
removal. Pay attention to the following points:
SWINGARM
• Insert the swingarm pivot shaft and tighten it to the specified
torque with the special tool.
! Swingarm pivot shaft: 15 N·m (1.5 kgf-m, 11.0 lb-ft)
$ 09944-28320: Hexagon bit 19 mm
• Hold the swingarm pivot shaft
1 with the special tool and
tighten the swingarm pivot nut 2 to the specified torque.
$ 09944-28320: Hexagon bit 19 mm
! Swingarm pivot nut: 100 N·m (10.0 kgf-m, 72.5 lb-ft)
• Tighten the swingarm pivot lock-nut to the specified torque
with the special tool.
$ 09940-14940: Swingarm pivot thrust adjuster socket
wrench
! Swingarm pivot lock-nut: 90 N·m (9.0 kgf-m, 65.0 lb-ft)
CHASSIS 7-57
CUSHION LEVER AND CUSHION ROD
• Install the washers
1 and cushion lever 2.
NOTE:
Insert the cushion lever mounting bolt from the left side.
("7-54)
• Install the cushion rod and rear shock absorber.
NOTE:
Insert the cushion rod mounting bolts and rear shock absorber
mounting bolts from the left side. ("7-54)
• Tighten the cushion lever nut 3, cushion rod nut 4 and rear
shock absorber lower mounting nut 5 to the specified torque.
! Cushion lever nut: 78 N·m (7.8 kgf-m, 56.5 lb-ft)
Cushion rod nut: 78 N·m (7.8 kgf-m, 56.5 lb-ft)
Rear shock absorber lower mounting nut:
50 N·m (5.0 kgf-m, 36.0 lb-ft)
• Install the rear wheel. ("7-40)
• Install the exhaust pipe and muffler. ("3-14)
FINAL INSPECTION AND ADJUSTMENT
After installing the rear suspension and wheel, the following
adjustments are required before driving.
* Drive chain: ("2-21)
* Tire pressure: ("7-82)
* Chassis bolts and nuts: ("2-28)
7-58 CHASSIS
FRONT BRAKE
CONSTRUCTION
1 Diaphragm 0 Dust seal
2 Dust boot A Piston
3 Piston/cup set B Caliper holder
4 Brake hose C Caliper
5 Pin
A
Front brake master cylinder
mounting bolt
!
ITEM N·m kgf-m lb-ft
6 Pad mounting pin B Brake hose union bolt A 10 1.0 7.0
7 Brake pad spring C Air bleeder valve B 23 2.3 16.5
8 Brake pad D Brake caliper mounting bolt C 7.5 0.75 5.5
9 Piston seal D 39 3.9 28.0
CHASSIS 7-59
)
#
BRAKE PAD REPLACEMENT
• Remove the caliper.
#
• Remove the pin
1.
• Remove the brake pads by removing the pad mounting pin 2.
• Clean up the caliper especially around the caliper pistons.
• Install the outer pad with the detent A of pad fitted to the
detent B on the caliper holder.
#
* 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.
* When storing the brake fluid, seal the container completely and keep away from children.
* When replenishing brake fluid, take care not to get dust into fluid.
* When washing brake components, use fresh brake fluid. Never use cleaning solvent.
* A contaminated brake disc or brake pad reduces braking performance. Discard contaminated
pads and clean the disc with high quality brake cleaner or neutral detergent.
Handle brake fluid with care: the fluid reacts chemically with paint, plastics, rubber materials
etc. and will damage then severly.
Do not operate the brake lever while removing the caliper.
Replace the brake pads as a set, otherwise braking
performance will be adversely affected.
7-60 CHASSIS
• Install the inner pad so that the inner pad will be seated on the
hatched part
C.
• Install the pad mounting pin 3.
• Install the pin 4 securely.
• Install the caliper.
• Tighten the caliper mounting bolts to the specified torque.
! Front brake caliper mounting bolt:
39 N·m (3.9 kgf-m, 28.0 lb-ft)
NOTE:
After replacing the brake pads, pump the brake lever several
times to check for proper brake operation and then check the
brake fluid level.
BRAKE FLUID REPLACEMENT
• Place the motorcycle on a level surface and keep the handlebars straight.
• Remove the brake fluid reservoir cap and diaphragm.
• Suck up the old brake fluid as much as possible.
• Fill the reservoir with the new brake fluid.
, Specification and Classification: DOT 4
• 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.
• Close the caliper air bleeder valve and disconnect a clear
hose. Fill the reservoir with the new fluid to the upper mark of
the reservoir.
! Brake air bleeder valve: 7.5 N·m (0.75 kgf-m, 5.5 lb-ft)
CHASSIS 7-61
#
CALIPER REMOVAL AND DISASSEMBLY
• Drain the brake fluid. ("7-60)
• Remove the brake pads. ("7-59)
• Disconnect the brake hoses by removing the brake hose
union bolts.
NOTE:
Place a rag underneath the union bolt on the brake caliper to
catch any spilt brake fluid.
• Remove the brake calipers by removing the caliper mounting
bolts.
#
)
• Remove the caliper holder
1.
• Remove the pad spring 2.
* Never reuse the brake fluid left over from previous
servicing and which has been stored for long periods of time.
* Bleed air from the brake system. ("2-25)
Do not reuse the brake fluid left over from previous
servicing and stored for long periods of time.
Brake fluid, if it leaks, will interfere with safe running
and discolor painted surfaces. Check the brake hose
and hose joints for cracks and fluid leakage.
7-62 CHASSIS
• Place a rag over the pistons to prevent them from popping out
and then force out the pistons using compressed air.
#
• Remove the dust seals
3 and piston seals 4.
#
CALIPER INSPECTION
BRAKE CALIPER
Inspect the brake caliper cylinder wall for nicks, scratches and
other damage. If any damage is found, replace the caliper with a
new one.
BRAKE CALIPER PISTON
Inspect the brake caliper piston surface for any scratches and
other damage. If any damage is found, replace the caliper pistons with the new ones.
CALIPER HOLDER
Inspect the caliper holder for damage. If any damage is found,
replace it with a new one.
Do not use high pressure air to prevent piston damage.
Do not reuse the removed dust seals and piston seals
to prevent fluid leakage.
CHASSIS 7-63
RUBBER PARTS
Inspect the rubber parts for damage. If any damage is found,
replace them with the new ones.
CALIPER REASSEMBLY AND REMOUNTING
Reassemble and remount the caliper in the reverse order of
removal and disassembly. Pay attention to the following points:
• Wash the caliper bores and pistons with specified brake fluid.
Particularly wash the dust seal grooves and piston seal
grooves.
, Specification and Classification: DOT 4
#
PISTON SEAL
• Install the piston seals as shown in the illustration.
• Install the piston to the caliper.
1 Dust seal
2 Piston seal
3 Caliper
* Wash the caliper components with fresh brake fluid
before reassembly. Never use cleaning solvent or
gasoline to wash them.
* Do not wipe the brake fluid off after washing the
components with a rag.
* When washing the components, use the specified
brake fluid. Never use different types of fluid or
cleaning solvent such as gasoline, kerosine or the
others.
* Replace the piston seals and dust seals with the new
ones when reassembly.
* Apply the brake fluid to both seals when installing
them.
7-64 CHASSIS
CALIPER HOLDER
• Apply SUZUKI SILICONE GREASE to the caliper holder pin.
- 99000-25100: SUZUKI SILICONE GREASE
• Install the caliper holder to the caliper.
• Install the pad spring
1.
NOTE:
When installing the pad spring, seated on the lug of pad spring
to concaved part of brake caliper.
• Install the brake pads. ("7-59)
NOTE:
Before remounting the caliper, push the piston all the way into
the caliper.
• Install the brake caliper to the front fork.
• Tighten each bolt to the specified torque.
! Front brake caliper mounting bolt 2:
39 N·m (3.9 kgf-m, 28.0 lb-ft)
Front brake hose union bolt 3:
23 N·m (2.3 kgf-m, 16.5 lb-ft)
#
* The seal washers should be replaced with the new
ones to prevent fluid leakage.
* Bleed air from the system after reassembling the caliper. ("2-25)
CHASSIS 7-65
BRAKE DISC INSPECTION
Visually check the brake disc for damage or cracks.
Measure the thickness with a micrometer.
Replace the disc if the thickness is less than the service limit or if
damage is found.
% Front disc thickness: Service Limit: 4.5 mm (0.18 in)
$ 09900-20205: Micrometer (0 – 25 mm)
Measure the runout with a dial gauge.
Replace the disc if the runout exceeds the service limit.
% Front disc runout: Service Limit: 0.30 mm (0.012 in)
$ 09900-20607: Dial gauge (1/100 mm)
09900-20701: Magnetic stand
* Brake disc removal ("7-10)
* Brake disc installation ("7-14)
MASTER CYLINDER REMOVAL AND DISAS-
SEMBLY
• Remove the rear view mirror and brake lever cover.
• Drain the brake fluid. ("7-60)
• Disconnect the front brake switch coupler
1.
• Place a rag underneath the union bolt on the master cylinder
to catch any spilt brake fluid. Remove the brake hose union
bolt and disconnect the brake hose.
#
• Remove the master cylinder 2.
Immediately and completely wipe off any brake fluid
contacting any part of the motorcycle. The fluid reacts
chemically with paint, plastics and rubber materials,
etc. and will damage them severely.
7-66 CHASSIS
• Remove the brake lever
3 and brake switch 4.
• Pull out the dust boot 5 and remove the snap ring 6.
• Remove the piston and return spring.
7 Piston
8 Secondary cup
9 Primary cup
0 Return spring
MASTER CYLINDER INSPECTION
Inspect the master cylinder bore for any scratches or other damage.
Inspect the piston surface for any scratches or other damage.
Inspect the primary cup, secondary cup and dust seal for wear
or damage.
CHASSIS 7-67
MASTER CYLINDER REASSEMBLY AND
REMOUNTING
Reassemble and remount the master cylinder in the reverse
order of removal and disassembly. Pay attention to the following
points:
#
, Specification and Classification: DOT 4
• Apply brake fluid to the piston and cups.
• Install the following parts to the master cylinder.
1 Dust boot
2 Snap ring
3 Secondary cup
4 Piston
5 Primary cup
6 Return spring
• When remounting the brake master cylinder 7 onto the handlebars, align the master cylinder holder’s mating surface A
with punch mark B on the handlebars 8 as shown.
• Tighten the front brake master cylinder mounting bolt to the
specified torque and first tighten the upper mounting bolt.
! Front brake master cylinder mounting bolt:
10 N·m (1.0 kgf-m, 7.0 lb-ft)
9 Master cylinder holder
C “UP” mark
• Tighten the union bolt to the specified torque. (Brake hose
routing: "9-26)
! Brake hose union bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft)
#
* Wash the master cylinder components with fresh
brake fluid before reassembly. Never use cleaning
solvent or gasoline to wash them.
* Do not wipe the components with a rag.
* Apply brake fluid to the cylinder bore and all the
component to be inserted into the bore.
* The seal washers should be replaced with the new
ones to prevent fluid leakage.
* Bleed air from the system after reassembling the
master cylinder. ("2-25)
7-68 CHASSIS
REAR BRAKE
CONSTRUCTION
1 Brake hose C Brake pad spring
2 Diaphragm D Caliper bracket
3 Reservoir tank hose E Caliper
4 Piston/cup set A Brake hose union bolt
5 Push rod
B
Rear brake master cylinder
mounting bolt
!
ITEM N·m kgf-m lb-ft
6 Dust boot
C
Rear brake master cylinder
rod lock-nut
A 23 2.3 16.5
B 10 1.0 7.0
7 Piston seal D Air bleeder valve C 18 1.8 13.0
8 Dust seal E Brake caliper mounting bolt D 6 0.6 4.3
9 Piston F Pad mounting pin E 22 2.2 16.0
0 Pad shim G Brake caliper sliding pin F 17 1.7 12.5
A Pad insulator H Plug G 27 2.7 19.5
B Brake pad H 2.5 0.25 1.8
CHASSIS 7-69
)
#
BRAKE PAD REPLACEMENT
• Remove the plug
1.
• Loosen the pad mounting pin 2.
• Remove the caliper bracket bolt 3.
#
• Remove the pad mounting pin and brake pads with the rear
caliper pivoted up.
• Clean up the caliper especially around the caliper pistons.
* This brake system is filled with an ethylene glycol-based DOT 4 brake fluid. Do not use or mix
different types of fluid such as silicone-based or petroleum-based.
* 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.
* When storing the brake fluid, seal the container completely and keep away from children.
* When replenishing brake fluid, take care not to get dust into fluid.
* When washing brake components, use fresh brake fluid. Never use cleaning solvent.
* A contaminated brake disc or brake pad reduces braking performance. Discard contaminated
pads and clean the disc with high quality brake cleaner or neutral detergent.
Handle brake fluid with care: the fluid reacts chemically with paint, plastics, rubber materials
etc. and will damage them severly.
* Do not operate the brake pedal while dismounting
the pads.
* Replace the brake pads as a set, otherwise braking
performance will be adversely affected.
7-70 CHASSIS
• Assemble the insulator
4 and shim 5 to the new brake pad
6.
#
• Install the new brake pads.
NOTE:
Make sure that the detent of the pad is seated onto the retainer
on the caliper bracket.
• Tighten the caliper mounting bolt 7 and pad mounting pin 8
to the specified torque.
! Rear brake caliper mounting bolt:
22 N·m (2.2 kgf-m, 16.0 lb-ft)
Rear brake pad mounting pin:
17 N·m (1.7 kgf-m, 12.5 lb-ft)
• Install the plug 9 to the specified torque.
! Pad pin plug: 2.5 N·m (0.25 kgf-m, 1.8 lb-ft)
NOTE:
After replacing the brake pads, pump the brake pedal several
times in order to operate the brake correctly and then check the
brake fluid level.
Replace the brake pads as a set, otherwise braking
performance will be adversely affected.
CHASSIS 7-71
BRAKE FLUID REPLACEMENT
• Remove the right frame cover. ("7-5)
• Remove the brake fluid reservoir cap.
• Replace the brake fluid in the same manner as the front
brake. ("7-60)
, Specification and Classification: DOT 4
#
CALIPER REMOVAL AND DISASSEMBLY
• Drain the brake fluid. ("7-71)
• Remove the brake pads. ("7-69)
• Place a rag underneath the union bolt to catch any spilt brake
fluid.
• Disconnect the brake hose by removing the brake hose union
bolt
1.
#
)
Bleed air from the brake system. ("2-25)
Do not reuse the brake fluid left over from previous
servicing and stored for long periods.
Brake fluid, if it leaks, will interfere with safe running
and discolor painted surfaces. Check the brake hose
and hose joints for cracks and fluid leakage.
7-72 CHASSIS
• Pivot the caliper up and remove the caliper from the caliper
bracket
2.
• Remove the pad spring 3.
• Remove the spacer 4 and boot 5 from the caliper.
• Remove the brake caliper sliding pin 6.
• Place a rag over the piston to prevent it from popping out and
then force out the piston using compressed air.
#
Do not use high pressure air to prevent piston damage.
CHASSIS 7-73
• Remove the dust seal
7 and piston seal 8.
#
CALIPER INSPECTION
BRAKE CALIPER
Inspect the brake caliper cylinder wall for nicks, scratches and
other damage. If any damage is found, replace the caliper with a
new one.
BRAKE CALIPER PISTON
Inspect the brake caliper piston surface for any scratches and
other damage. If any damage is found, replace the caliper piston
with a new one.
BRAKE CALIPER SLIDING PIN
Inspect the brake caliper sliding pin for wear and other damage.
If any damage is found, replace the brake caliper sliding pin with
a new one.
Inspect the boot and spacer for damage and wear. If any damage is found, replace boot and spacer with the new ones.
Do not reuse the dust seal and piston seal to prevent
fluid leakage.
7-74 CHASSIS
BRAKE DISC INSPECTION
Inspect the rear brake disc in the same manner as the front
brake disc. ("7-65)
% Service Limit
Rear disc thickness: 5 mm (0.20 in)
Rear disc runout: 0.30 mm (0.012 in)
* Brake disc removal ("7-37)
* Brake disc installation ("7-42)
CALIPER REASSEMBLY AND REMOUNTING
Reassemble and remount the caliper in the reverse order of
removal and disassembly. Pay attention to the following points:
#
, Specification and Classification: DOT 4
PISTON SEAL
• Install the piston seals as shown in the illustration.
• Install the piston to the caliper.
1 Dust seal
2 Piston seal
3 Caliper
BRAKE CALIPER SLIDING PIN
• Install the boot 1.
• Apply SUZUKI SILICONE GREASE to the inside of the boot.
- 99000-25100: SUZUKI SILICONE GREASE
• Install the spacer 2.
* Wash the caliper components with fresh brake fluid
before reassembly. Never use cleaning solvent or
gasoline to wash them.
* Apply brake fluid to the caliper bore and piston to be
inserted into the bore.
CHASSIS 7-75
• Tighten the brake caliper sliding pin
3 to the specified torque.
! Brake caliper sliding pin: 27 N·m (2.7 kgf-m, 19.5 lb-ft)
• Apply SUZUKI SILICONE GREASE to the brake caliper sliding pin.
- 99000-25100: SUZUKI SILICONE GREASE
• Install the caliper to the caliper bracket 4.
• Set the boot onto the brake caliper sliding pin 5 securely.
• Install the brake pad. ("7-69)
• Tighten the brake hose union bolt 6 with the brake hose
union pipe seated in the cutout on the caliper.
(Rear brake hose routing: "9-27)
! Brake hose union bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft)
#
MASTER CYLINDER REMOVAL AND DISAS-
SEMBLY
• Drain the brake fluid. ("7-71)
• Remove the brake fluid reservoir tank mounting bolt 1.
* The seal washers should be replaced with the new
ones to prevent fluid leakage.
* Bleed air from the system after reassembling the caliper. ("2-25)
7-76 CHASSIS
• Loosen the lock-nut
2.
• Remove the master cylinder mounting bolts 3.
• Place a rag underneath the union bolt on the master cylinder
to catch spilled drops of brake fluid. Remove the union bolt 4
and disconnect the brake hose.
#
• Remove the master cylinder by turning the master cylinder
rod 5.
• Disconnect the reservoir hose 6.
• Remove the connector 7 by removing the snap ring 8.
• Remove the O-ring 9.
#
• Pull out the dust boot 0, then remove the snap ring A.
• Remove the push rod, piston/primary cup and spring.
Immediately and completely wipe off any brake fluid
contacting any parts of the motorcycle. The fluid
reacts chemically with paint, plastic and rubber materials, etc. and will damage them severely.
Replace the O-ring with a new one.
CHASSIS 7-77
MASTER CYLINDER INSPECTION
CYLINDER, PISTON AND CUP SET
Inspect the cylinder bore wall for any scratches or other damage.
Inspect the cup set and each rubber part for damage.
MASTER CYLINDER REASSEMBLY AND
REMOUNTING
Reassemble and remount the master cylinder in the reverse
order of removal and disassembly. Pay attention to the following
points:
#
, Specification and Classification: DOT 4
• Apply brake fluid to the piston/cup set.
• Install the following parts.
1 Spring
2 Piston/primary cup
3 Push rod
4 Snap ring
5 Dust boot
• Apply the SUZUKI MOLY PASTE to the push rod.
. 99000-25140: SUZUKI MOLY PASTE
• Install the O-ring 6, connector 7 and snap ring 8 to the
master cylinder.
#
* Wash the master cylinder components with fresh
brake fluid before reassembly. Never use cleaning
solvent or gasoline to wash them.
* Do not wipe the components with a rag.
* Apply brake fluid to the cylinder bore and all the
component to be inserted into the bore.
Replace the removed O-ring with a new one.
7-78 CHASSIS
• Install the master cylinder.
• Tighten the lock-nut
9.
! Rear brake master cylinder rod lock-nut:
18 N·m (1.8 kgf-m, 13.0 lb-ft)
• Install the reservoir tank. (Rear brake hose routing: "9-27)
• Temporarily install the master cylinder to the frame.
• Connect the brake hose to the master cylinder. (Rear brake
hose routing: "9-27)
• Tighten the brake hose union bolt 0 to the specified torque.
! Brake hose union bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft)
#
• Adjust the brake pedal height. ("2-24)
• Install the master cylinder.
• Tighten the master cylinder mounting bolts A to the specified
torque.
! Rear master cylinder mounting bolt:
10 N·m (1.0 kgf-m, 7.0 lb-ft)
* The seal washers should be replaced with the new
ones to prevent fluid leakage.
* Bleed air from the system after reassembling the
master cylinder. ("2-25)
CHASSIS 7-79
TIRE AND WHEEL
TIRE REMOVAL
The most critical factor of a tubeless tire is the seal between the
wheel rim and the tire bead. For this reason, it is recommended
to use a tire changer that can satisfy this sealing requirement
and can make the operation efficient as well as functional.
For operating procedures, refer to the instructions supplied by
the tire changer manufacturer.
NOTE:
When removing the tire in the case of repair or inspection, mark
the tire with a chalk to indicate the tire position relative to the
valve position.
Even though the tire is refitted to the original position after
repairing puncture, the tire may have to be balanced again since
such a repair can cause imbalance.
INSPECTION
WHEEL
Wipe the wheel clean and check for the following:
* Distortion and crack
* Any flaws and scratches at the bead seating area
* Wheel rim runout ("7-11)
TIRE
Tire must be checked for the following points:
* Nick and rupture on side wall
* Tire tread depth ("2-26)
* Tread separation
* Abnormal, uneven wear on tread
* Surface damage on bead
* Localized tread wear due to skidding (Flat spot)
* Abnormal condition of inner liner
7-80 CHASSIS
VALVE
• Inspect the valve after the tire is removed from the rim.
Replace the valve with a new one if the seal rubber is peeling
or has damage.
• Inspect the valve core. If the seal
1 has abnormal deformation, replace the valve with a new one.
VALVE INSTALLATION
• Any dust or rust around the valve hole 1 must be cleaned off.
Then install the valve in the rim.
NOTE:
To properly install the valve into the valve hole, apply a special
tire lubricant or neutral soapy liquid to the valve.
#
A Wheel
B Valve lip
C Valve
Be careful not to damage the lip of valve.
CHASSIS 7-81
TIRE INSTALLATION
• Apply tire lubricant to the tire bead.
• When installing the tire onto the wheel, observe the following
points.
#
• When installing the tire, the arrow
1 on the side wall should
point to the direction of wheel rotation.
• Align the chalk mark put on the tire at the time of removal with
the valve position.
• For installation procedure of tire onto the wheel, follow the
instructions given by the tire changer manufacturer.
• Bounce the tire several times while rotating. This makes the
tire bead expand outward to contact the wheel, thereby facilitating air inflation.
• Inflate the tire.
)
* Do not reuse the valve which has been once
removed.
* Do not use oil, grease or gasoline on the tire bead in
place of tire lubricant.
* Do not inflate the tire to more than 400 kPa (4.0kgf/
cm²). If inflated beyond this limit, the tire can burst
and possibly cause injury. Do not stand directly over
the tire while inflating.
* In the case of preset pressure air inflator, pay special
care for the set pressure adjustment.
7-82 CHASSIS
• In this condition, check the “rim line”
A cast on the tire side
walls. The line must be equidistant from the wheel rim all
around. If the distance between the rim line A 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. Coat the bead with lubricant and fit the
tire again.
• When the bead has been fitted properly, adjust the pressure
to specification.
• As necessary, adjust the tire balance.
#
% Tire pressure
Solo riding: Front: 225 kPa (2.25 kgf/cm², 33 psi)
Rear : 250 kPa (2.50 kgf/cm², 36 psi)
Dual riding: Front: 225 kPa (2.25 kgf/cm², 33 psi)
Rear : 280 kPa (2.80 kgf/cm², 41 psi)
Do not run with a repaired tire at a high speed.
CHASSIS 7-83
DRIVE CHAIN
Use the special tool in the following procedures, to cut and rejoin
the drive chain.
$ 09922-22711: Drive chain cutting and joining tool set
NOTE:
When using the special tool, apply a small quantity of grease to
the threaded parts of the special tool.
DRIVE CHAIN CUTTING
• Set up the special tool as shown in the illustration.
1 Tool body
2 Grip handle
3 Pressure bolt “A”
4 Pressure bolt “B”
5 Bar
6 Adjuster bolt (with through hole)
7 Pin remover
8 Chain holder (engraved mark 500)
with reamer bolt M5 × 10
NOTE:
The tip of pin remover 7 should be positioned inside A approximately 5 mm (0.2 in) from the end face of pressure bolt “A” 3
as shown in the illustration.
7-84 CHASSIS
• Place the drive chain link being disjointed on the holder part
8 of the tool.
• Turn in both the adjuster bolt 6 and pressure bolt “A” 3 so
that each of their end hole fits over the chain joint pin properly.
• Tighten the pressure bolt “A” 3 with the bar.
• Turn in the pressure bolt “B” 4 with the bar 5 and force out
the drive chain joint pin 9.
#
NOTE:
After the joint pin 9 is removed, loosen the pressure bolt “B” 4
and then pressure bolt “A” 3.
• Remove the joint pin 9 of the other side of joint plate.
#
DRIVE CHAIN CONNECTING
JOINT PLATE INSTALLATION
• Set up the special tool as shown in the illustration.
1 Tool body 5 Adjuster bolt
2 Grip handle (without hole)
3 Joint plate holder 6 Pressure bolt “A”
(engraved mark “F520”) 7 Bar
4 Wedge holder & wedge pin
• Connect both ends of the drive chain with the joint pin 8
inserted from the wheel side A as installed on the motorcycle.
9 O-ring … 4 pcs
0 Joint plate
Joint set part number
DID: 27620-32C10
)
Continue turning in the pressure bolt “B” 4 until the
joint pin has been completely pushed out of the chain.
Never reuse joint pins, O-rings and plates. After joint
pins, O-rings and plates have been removed from the
drive chain, the removed joint pins, O-rings and plates
should be discarded and new joint plate, O-rings and
plate must be installed.
Do not use joint clip type of drive chain. The joint clip
may have a chance to drop which may cause severe
damage to motorcycle and severe injury.
(F520)
CHASSIS 7-85
• Apply grease on the recessed portion of the joint plate holder
3 and set the joint plate 0.
NOTE:
When positioning the joint plate 0 on the tool, its stamp mark
must face the joint plate holder 3 side.
• Set the drive chain on the tool as illustrated and turn in the
adjuster bolt 5 to secure the wedge holder & wedge pin 4.
• Turn in the pressure bolt “A” 6 and align two joint pins A
properly with the respective holes of the joint plate 0
• Turn in the pressure bolt “A” 6 further using the bar 7 to
press the joint plate over the joint pins.
• Continue pressing the joint plate until the distance between
the two joint plates come to the specification.
% Joint plate distance specification W
#
JOINT PIN STAKING
• Set up the special tool as shown in the illustration.
1 Tool body
2 Grip handle
3 Pressure bolt “A”
4 Adjuster bolt (without hole)
5 Staking pin (stowed inside grip handle behind rubber cap)
6 Bar
NOTE:
Before staking the joint pin, apply a small quantity of grease to
the staking pin 5.
DID 18.70 – 18.90 mm (0.736 – 0.744 in)
Should pressing of the joint plate be made excessively
beyond the specified dimension, the work should be
redone using the new joint parts.
7-86 CHASSIS
• Stake the joint pin by turning (approximately 7/8 turn) the
pressure bolt “A”
3 with the bar until the pin end diameter
becomes the specified dimension.
% Pin end diameter specification D
#
• Adjust the drive chain, after connecting it. ("2-21)
DID 5.5 – 5.8 mm (0.217 – 0.228 in)
* After joining of the chain has been completed, check
to make sure that the link is smooth and no abnormal
condition is found.
* Should any abnormal condition be found, reassemble the chain link using the new joint parts.
ELECTRICAL SYSTEM 8-1
8
ELECTRICAL SYSTEM
CONTENTS
CAUTIONS IN SERVICING ...........................................................................8- 2
CONNECTOR .........................................................................................8- 2
COUPLER ..............................................................................................8- 2
CLAMP ...................................................................................................8- 2
FUSE ......................................................................................................8- 2
SEMI-CONDUCTOR EQUIPPED PART ................................................8- 3
BATTERY ...............................................................................................8- 3
CONNECTING THE BATTERY ..............................................................8- 3
WIRING PROCEDURE ...........................................................................8- 3
USING THE MULTI CIRCUIT TESTER ..................................................8- 4
LOCATION OF ELECTRICAL COMPONENTS ............................................8- 5
CHARGING SYSTEM ....................................................................................8- 7
TROUBLE SHOOTING ..........................................................................8- 7
INSPECTION ..........................................................................................8- 9
STARTER SYSTEM AND SIDE-STAND/IGNITION INTERLOCK
SYSTEM .........................................................................................................8-12
TROUBLE SHOOTING ..........................................................................8-12
STARTER MOTOR REMOVAL AND DISASSEMBLY ..........................8-14
STARTER MOTOR INSPECTION ..........................................................8-15
STARTER MOTOR REASSEMBLY .......................................................8-16
STARTER RELAY INSPECTION ...........................................................8-19
SIDE-STAND/IGNITION INTERLOCK SYSTEM PARTS
INSPECTION ..........................................................................................8-20
IGNITION SYSTEM ........................................................................................8-23
TROUBLESHOOTING ...........................................................................8-23
INSPECTION ..........................................................................................8-25
COMBINATION METER ................................................................................8-29
REMOVAL AND DISASSEMBLY ..........................................................8-29
INSPECTION ..........................................................................................8-30
INDICATORS ..........................................................................................8-32
LAMPS ...........................................................................................................8-36
HEADLIGHT, BRAKE LIGHT/TAILLIGHT AND TURN
SIGNAL LIGHT .......................................................................................8-36
RELAYS .........................................................................................................8-37
TURN SIGNAL/SIDE-STAND RELAY ...................................................8-37
STARTER RELAY ..................................................................................8-37
FUEL PUMP RELAY ..............................................................................8-37
SWITCHES .............................................................................................8-38
INSPECTION ..........................................................................................8-39
BATTERY ......................................................................................................8-40
SPECIFICATIONS ..................................................................................8-40
INITIAL CHARGING ...............................................................................8-40
SERVICING ............................................................................................8-42
RECHARGING OPERATION .................................................................8-42
8-2 ELECTRICAL SYSTEM
CAUTIONS IN SERVICING
CONNECTOR
• When connecting a connector, be sure to push it in until a
click is felt.
• Inspect the connector for corrosion, contamination and breakage in its cover.
COUPLER
• With a lock type coupler, be sure to release the lock before
disconnecting it and push it in fully till the lock works when
connecting it.
• When disconnecting the coupler, be sure to hold the coupler
itself and do not pull the lead wires.
• Inspect each terminal on the coupler for being loose or bent.
• Inspect each terminal for corrosion and contamination.
CLAMP
• Clamp the wire harness at such positions as indicated in
“WIRE HARNESS ROUTING”. (!9-16 to 9-18)
• Bend the clamp properly so that the wire harness is clamped
securely.
• In clamping the wire harness, use care not to allow it to hang
down.
• Do not use wire or any other substitute for the band type
clamp.
FUSE
• When a fuse blows, always investigate the cause, correct it
and then replace the fuse.
• Do not use a fuse of a different capacity.
• Do not use wire or any other substitute for the fuse.
ELECTRICAL SYSTEM 8-3
SEMI-CONDUCTOR EQUIPPED PART
• Be careful not to drop the part with a semi-conductor built in
such as a ECM.
• When inspecting this part, follow inspection instruction strictly.
Neglecting proper procedure may cause damage to this part.
BATTERY
• The MF battery used in this motorcycle does not require maintenance (e.g., electrolyte level inspection, distilled water
replenishment).
• During normal charging, no hydrogen gas is produced. However, if the battery is overcharged, hydrogen gas may be produced. Therefore, be sure there are no fire or spark sources
(e.g., short circuit) nearby when charging the battery.
• Be sure to recharge the battery in a well-ventilated and open
area.
• Note that the charging system for the MF battery is different
from that of a conventional battery. Do not replace the MF
battery with a conventional battery.
CONNECTING THE BATTERY
• When disconnecting terminals from the battery for disassembly or servicing, be sure to disconnect the
- battery lead
wire, first.
• When connecting the battery lead wires, be sure to connect
the + battery lead wire, first.
• If the terminal is corroded, remove the battery, pour warm
water over it and clean it with a wire brush.
• After connecting the battery, apply a light coat of grease to the
battery terminals.
• Install the cover over the + battery terminal.
WIRING PROCEDURE
• Properly route the wire harness according to the “WIRE
ROUTING” section. (!9-16 to 9-18)
8-4 ELECTRICAL SYSTEM
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 measuring in the highest range.
• When measuring the resistance, make sure that no voltage is
applied. If voltage is applied, the tester will be damaged.
• After using the tester, be sure to turn the switch to the OFF
position.
"
Before using the multi circuit tester, read its instruction
manual.
ELECTRICAL SYSTEM 8-5
LOCATION OF ELECTRICAL COMPONENTS
1 Horn
2 Fuel injector (!4-42)
3 STP sensor (!4-38)
4 TP sensor (!4-28)
5 STV actuator (!4-37)
6 Fuel pump (!5-9)
7 Speed sensor (!8-35)
8 Ignition coil (No.1)
9 CKP sensor (!4-23)
0 Generator (!8-10)
A Gear position switch (!8-20)
B Side-stand switch (!8-20)
8-6 ELECTRICAL SYSTEM
1 TO sensor (!4-35)
2 Fuel pump relay (!5-10)
3 ECM (Engine Control Module)
4 Fuse box
5 Turn signal/side-stand relay (!8-37)
6 Starter relay (!8-19)
7 Battery
8 IAP sensor (!4-25)
9 IAT sensor (!4-33)
0 PAIR control valve (!10-7)
A Regulator/rectifier (!8-11)
B Cooling fan thermo-switch (!6-9)
C HO2 sensor (!4-47)
D ECT sensor (!4-31)
E Ignition coil (No.2)
F Oil pressure switch
G Starter motor
ELECTRICAL SYSTEM 8-7
CHARGING SYSTEM
1 Generator 2 Regulator/rectifier 3 Ignition switch 4 Main fuse 5 Battery 6 Load
TROUBLE SHOOTING
Battery runs down quickly
Step1
1) Check accessories which use excessive amounts of electricity.
Are accessories being installed?
Step2
1) Check the battery for current leaks. (!8-9)
Is the battery for current leaks OK?
Step3
1) Measure the charging voltage between the battery terminals. (!8-9)
Is the battery charging of voltage OK?
YES Remove accessories.
NO Go to Step2.
YES Go to Step3.
NO
• Short circuit of wire harness.
• Faulty electrical equipment.
YES
• Faulty battery.
• Abnormal driving condition.
NO Go to Step4.
8-8 ELECTRICAL SYSTEM
Step4
1) Measure the continuity of the generator coil. (!8-10)
Is the resistance of generator coil OK?
Step5
1) Measure the generator no-load voltage. (!8-10)
Is generator no-load performance OK?
Step6
1) Inspect the regulator/rectifier. (!8-11)
Is the regulator/rectifier OK?
Step7
1) Inspect the wire harness.
Is the wire harness OK?
Battery overcharges
Faulty regulator/rectifier.
Faulty battery.
Poor contact of generator lead wire coupler.
YES Go to Step5.
NO
• Faulty generator coil.
• Disconnected lead wires.
YES Go to Step6.
NO Faulty generator.
YES Go to Step7.
NO Faulty regulator/rectifier.
YES Faulty battery
NO
• Short circuit of wire harness.
• Poor contact of coupler.
ELECTRICAL SYSTEM 8-9
INSPECTION
BATTERY CURRENT LEAKAGE
• Remove the seat. (!7-4)
• Turn the ignition switch to the OFF position.
• Disconnect the battery
- lead wire.
Measure the current between - battery terminal and the - battery lead wire using the multi circuit tester. If the reading
exceeds the specified value, leakage is evident.
# 09900-25008: Multi circuit tester set
$ Battery current (leak): 3 mA and less
% Tester knob indication: Current (&, 20 mA)
"
When checking to find the excessive current leakage, remove
the couplers and connectors, one by one, checking each part.
REGULATED VOLTAGE
• Remove the seat. (!7-4).
• 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 terminals using the multi circuit tester. If the voltage is not within the
specified value, inspect the generator and regulator/rectifier.
(!8-10 and 8-11)
NOTE:
When making this test, be sure that the battery is in fullycharged condition.
# 09900-25008: Multi circuit tester set
' Tester knob indication: Voltage (&)
$ Charging output (Regulated voltage):
14.0 – 15.5 V at 5 000 r/min.
* Because the current leak might be large, turn the
tester to high range first to avoid tester damage.
* Do not turn the ignition switch to the “ON” position
when measuring current.
V
8-10 ELECTRICAL SYSTEM
GENERATOR COIL RESISTANCE
• Remove the right cowling. (!7-5)
• Disconnect the generator coupler
1.
Measure the resistance between the three lead wires.
If the resistance is out of the specified value, replace the stator
with a new one. Also, check that the generator core is insulated
properly.
# 09900-25008: Multi circuit tester set
( Tester knob indication: Resistance (Ω)
$ Generator coil resistance: 0.2 – 0.7 Ω (Black – Black)
∞ Ω (Black – Ground)
NOTE:
When making above test, it is not necessary to remove the generator.
GENERATOR NO-LOAD PERFORMANCE
• Remove the right cowling. (!7-5)
• Disconnect the generator coupler.
• 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 generator with a new one.
# 09900-25008: Multi circuit tester set
' Tester knob indication: Voltage (∼)
$ Generator no-load performance:
60 V and more at 5 000 r/min (When engine is cold)
B
B
B
B
B
B
ELECTRICAL SYSTEM 8-11
REGULATOR/RECTIFIER
• Remove the right cowling. (!7-5)
• Disconnect the regulator/rectifier couplers
1.
• Remove the regulator/rectifier 2.
Measure the voltage between the terminals using the multi circuit tester as indicated in the table below. If the voltage is not
within the specified value, replace the regulator/rectifier with a
new one.
# 09900-25008: Multi circuit tester set
) Tester knob indication: Diode test (*)
Unit: V
✽ 1.4 V and more (tester’s battery voltage)
NOTE:
If the tester reads 1.4 V and below when the tester probes are not
connected, replace its battery.
+ Tester probe
-
T
es te r pr ob e B/R B1 B2 B3 B/W
B/R 0.4 – 0.7 0.4 – 0.7 0.4 – 0.7 0.5 – 1.2
B1 ✽ ✽ ✽ 0.4 – 0.7
B2 ✽ ✽ ✽ 0.4 – 0.7
B3 ✽ ✽ ✽ 0.4 – 0.7
B/W ✽ ✽ ✽ ✽
B/R B/R
B/W B/W
B2 B1
B3
8-12 ELECTRICAL SYSTEM
STARTER SYSTEM AND SIDE-STAND/IGNITION INTERLOCK
SYSTEM
1 Starter motor 2 Starter relay 3 Clutch switch 4 Starter button 5 Engine stop switch
6 Turn signal/side-stand relay 7 Ignition switch 8 Fuse 9 Side-stand switch
0 Gear position switch A Battery A To ECM and ignition coil.
TROUBLE SHOOTING
Make sure that the fuses are not blown and the battery is fully-charged before diagnosing.
Starter motor will not run.
Step1
1) Grasp the clutch lever, turn on the ignition switch with the engine stop switch in the “RUN” position and
side-stand switch in the “ON” position.
2) Listen for a click from the starter relay when the starter button is pushed.
Is a click sound heard?
Step2
1) Check if the starter motor runs when its terminal is connected to the + battery terminal (Do not use a thin
wire because a large amount of current flows.)
Does the starter motor run?
B/Y
O/W
Y/G
B/W
O/B
G
B/R
(30 A)
(10 A)
Bl O
O/Y
YES Go to Step2.
NO Go to Step3.
YES
• Faulty starter relay.
• Loose or disconnected starter motor lead wire.
• Loose or disconnected between starter relay and + battery terminal.
NO Faulty starter motor.
ELECTRICAL SYSTEM 8-13
Step3
1) Measure the starter relay voltage at the starter relay connectors (between B/Y and Y/G) when the starter
button is pushed.
Is a voltage OK?
Step4
1) Inspect the starter relay. (!8-19)
Is the starter relay OK?
Step5
The starter motor runs when the transmission is neutral with the side-stand up or down, but does not run
when the transmission is in any position other than neutral with the side-stand down.
1) Inspect the side-stand switch. (!8-20)
Is the side-stand switch OK?
Engine does not turn though the starter motor runs.
Faulty starter clutch. (!3-79)
YES Go to Step4.
NO
• Faulty gear position switch.
• Faulty starter button.
• Faulty engine stop switch.
• Faulty turn signal/side-stand relay.
• Faulty ignition switch.
• Faulty clutch switch.
• Faulty side-stand switch.
• Improper connector contact.
• Open circuit in wire harness.
YES Poor starter relay connection.
NO Faulty starter relay.
YES • Open circuit in wire harness.
• Poor contact of connector.
NO • Faulty side-stand switch.
8-14 ELECTRICAL SYSTEM
STARTER MOTOR REMOVAL AND
DISASSEMBLY
• Remove the starter motor and disconnect the starter motor
lead wire
1.
• Disassemble the starter motor as shown in the illustration.
1 Housing end (rear bracket) 6 Armature A Thrust stopper
2 Brush spring (2 pcs) 7 Starter motor case B O-ring (2 pcs)
3 Brush holder 8 Seal ring (2 pcs) C O-ring
4 Terminal 9 Washer D Housing end (front bracket)
5 Washer 0 Slip washer
3.5 N·m
(0.4 kgf-m, 2.45 lb-ft)
6 N·m
(0.6 kgf-m, 4.3 lb-ft)
ELECTRICAL SYSTEM 8-15
STARTER MOTOR INSPECTION
CARBON BRUSH
Inspect the brushes for abnormal wear, cracks, or smoothness
in the brush holder.
If any damage is found, replace the brush assembly with a new
one.
COMMUTATOR
Inspect the commutator for discoloration, abnormal wear or
undercut
A.
If abnormal wear is found, replace the armature with a new one.
If the commutator surface is discolored, polish it with #400 sand
paper and wipe it using a clean dry cloth.
If there is no undercut, scrape out the insulator with a saw blade.
1 Insulator
2 Segment
ARMATURE COIL INSPECTION
Check for continuity between each segment and between each
segment and the armature shaft using the multi circuit tester.
If there is no continuity between the segments or there is continuity between the segments and shaft, replace the armature
with a new one.
# 09900-25008: Multi circuit tester set
+ Tester knob indication: Continuity test (,)
OIL SEAL INSPECTION
Check the oil seal lip for damage or leakage.
If any damage is found, replace the housing end.
8-16 ELECTRICAL SYSTEM
STARTER MOTOR REASSEMBLY
Reassemble the starter motor in the reverse order of disassembly. Pay attention to the following points:
"
• Apply SUZUKI SUPER GREASE to the lip of the oil seal.
- 99000-25030: SUZUKI SUPER GREASE “A” (USA)
99000-25010: SUZUKI SUPER GREASE “A” (Others)
• Apply a small quantity of SUZUKI MOLY PASTE to the armature shaft.
. 99000-25140: SUZUKI MOLY PASTE
• Install the spacer
1 to brush terminal.
• When installing the brush holder on the rear bracket, set the
projection B of the brush holder into the groove A of the rear
bracket.
Replace the O-rings with the new ones to prevent oil
leakage and moisture.
ELECTRICAL SYSTEM 8-17
• Install the washers
2 (12 × 6.5 × 2), washer 3 (16 × 6.5 × 1),
washer 4 (14 × 6.5 × 1) and nut 5.
"
• Install the washers 6.
NOTE:
The number of washer 6 varies according to individual.
• Install the seal rings 8 to starter motor case 7.
• When install the rear bracket to starter motor case, align the
marks A on the rear bracket with cut point B at the starter
motor case.
"
• Install the washers 9 slip washer 0 and thrust stopper A.
NOTE:
The number of washer 9 varies according to individual.
• Install the front bracket.
• Align the marks C on the front bracket with the marks B on
the starter motor case.
Replace the O-rings with the new ones to prevent oil
leakage and moisture.
Replace the seal rings with the new ones to prevent oil
leakage and moisture.
8-18 ELECTRICAL SYSTEM
• Apply SUZUKI SUPER GREASE to the starter motor O-rings.
- 99000-25030: SUZUKI SUPER GREASE “A” (USA)
99000-25010: SUZUKI SUPER GREASE “A” (Others)
"
• Tighten the starter motor housing bolts to the specified
torque.
/ Starter motor housing bolt: 3.5 N·m (0.4 kgf-m 2.45 lb-ft)
• Install the starter motor.
• Install the clamp
B as shown.
• First tighten the starter motor lower mounting bolt C, then
tighten the starter motor upper mounting bolt D.
• Connect the starter motor read wire as shown.
• Tighten the nut E and fit the cap F.
Use new O-rings to prevent oil leakage.
90 ˚
45 ˚
ELECTRICAL SYSTEM 8-19
STARTER RELAY INSPECTION
• Remove the seat. (!7-4)
• Disconnect the battery
- lead wire from the battery.
• Remove the starter relay cover 1.
• Disconnect the starter relay coupler 2.
• Disconnect the starter motor lead wire 3 and battery lead
wire 4.
• Remove the starter relay 5.
Apply 12 V to A and B terminals and check for continuity
between the positive and negative terminals using the multi circuit tester. If the starter relay clicks and continuity is found, the
relay is ok.
# 09900-25008: Multi circuit tester set
+ Tester knob indication: Continuity test (,)
"
Measure the relay coil resistance between the terminals using
the multi circuit tester. If the resistance is not within the specified
value, replace the starter relay with a new one.
# 09900-25008: Multi circuit tester set
( Tester knob indication: Resistance (Ω)
$ Starter relay resistance: 3 – 6 Ω
Do not apply a battery voltage to the starter relay for
five seconds and more, since the relay coil may overheat and get damaged.
8-20 ELECTRICAL SYSTEM
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
• Remove the left frame cover. (!7-5)
• Disconnect the side-stand switch coupler
1 and measure the
voltage between Black/White and Green lead wires.
# 09900-25008: Multi circuit tester set
) Tester knob indication: Diode test (*)
NOTE:
If the tester reads under 1.4 V when the tester probes are not
connected, replace its battery.
GEAR POSITION SWITCH
• Remove the left frame cover. (!7-5)
• Disconnect the gear position switch coupler and check the
continuity between Blue and Black/White with the transmission in “NEUTRAL”.
# 09900-25008: Multi circuit tester set
+ Tester knob indication: Continuity test (,)
"
Black/White
(+ probe)
Green
(- probe)
Side-stand up A 0.4 – 0.6 V
Side-stand down B
1.4 V and more
(Tester’s battery voltage)
When disconnecting and connecting the gear position
switch coupler, make sure to turn OFF the ignition
switch, or electronic parts may get damaged.
ON (Neutral)
OFF (Expect neutral)
Blue Black/White
ELECTRICAL SYSTEM 8-21
• Connect the gear position switch coupler to the wiring harness.
• Turn the ignition switch to “ON” position and side-stand to
upright position.
• Insert the needle pointed probes to the gear position switch
coupler.
Measure the voltage between Pink and B/W lead wires using the
multi circuit tester when shifting the gearshift lever from low to
top.
# 09900-25008: Multi circuit tester set
09900-25009: Needle pointed probe set
' Tester knob indication: voltage (V)
$ Gear position switch voltage
NOTE:
* When connecting the multi circuit tester, use the needle
pointed probe to the back side of the lead wire coupler and
connect the probes of tester to them.
* Use a needle pointed probe outer diameter being below 0.5
mm to prevent the rubber of the water proof coupler from damage.
TURN SIGNAL/SIDE-STAND RELAY REMOVAL AND
INSTALLATION
The turn signal/side-stand relay is composed of the turn signal
relay, side-stand relay and diode.
• Remove the seat. (!7-4)
• Remove the turn signal/side-stand relay
1.
• Install the turn signal/side-stand relay in the reverse order of
removal.
Gear
position
1st 2nd 3rd 4th 5th 6th
Voltage Approx.
1.36 V
Approx.
1.77 V
Approx.
2.49 V
Approx.
3.23 V
Approx.
4.10 V
Approx.
4.55 V
V
8-22 ELECTRICAL SYSTEM
SIDE-STAND RELAY INSPECTION
First check the insulation between
D and E terminals with the
tester. Then apply 12 V to terminals D and C (+ to D and - to
C) and check the continuity between D and E. If there is no
continuity, replace the turn signal/side-stand relay with a new
one.
# 09900-25008: Multi circuit tester set
+ Tester knob indication: Continuity test (,)
1 Diode
2 Side-stand relay
3 Turn signal relay
DIODE INSPECTION
Measure the voltage between the terminals using the multi circuit tester. Refer to the following table.
Unit: V
# 09900-25008: Multi circuit tester set
) Tester knob indication: Diode test (*)
NOTE:
If the multi circuit tester reads 1.4 V and below when the tester
probes are not connected, replace its battery.
+ Probe of tester to:
-
P
ro be o f te st er to : C, B A
C, B 1.4 V and more
A 0.4 – 0.6
ELECTRICAL SYSTEM 8-23
IGNITION SYSTEM
1 CKP sensor 2 ECM 3 Wave form arrangement circuit 4 Power source circuit 5 CPU
6 TP sensor 7 ECT sensor 8 Gear position switch 9 Engine stop switch 0 Ignition coil #1
A Spark plug #1 B Ignition coil #2 C Spark plug #2 D Side-stand relay E Fuse
F Ignition switch G Battery
TROUBLESHOOTING
No spark or poor spark
Make sure the engine stop switch is in the “RUN” position and side-stand is in up-right position. Make sure
the fuse is not blown and the battery is fully-charged before diagnosing.
Step1
1) Check the ignition system couplers for poor connections.
Is there connection in the ignition switch couplers?
Step 2
1) Measure the battery voltage between input lead wire (O/G and B/W) at the ECM with the ignition switch
in the “ON” position.
Is the voltage OK?
(10 A)
(30 A)
O
B/R
O/Y
O/BO/WO/G
W/Bl
O/W
B/O
B
YES Go to Step2.
NO Improper coupler connection.
YES Go to Step3.
NO
• Faulty ignition switch.
• Faulty turn signal/side-stand relay.
• Faulty engine stop switch.
• Broken wire harness or poor connection of related circuit couplers.
8-24 ELECTRICAL SYSTEM
Step3
1) Measure the ignition coil primary peak voltage. (!8-25)
NOTE:
The ignition coil peak voltage inspection method is applicable only with the multi circuit tester and peak volt
adaptor.
Is the peak voltage OK?
Step4
1) Inspect the spark plug. (!2-6)
Is the spark plug OK?
Step5
1) Inspect the ignition coil. (!8-26)
Is the ignition coil OK?
Step6
1) Measure the CKP sensor peak voltage and its resistance.
NOTE:
The CKP sensor peak voltage inspection is applicable only with the multi circuit tester and peak volt adaptor.
Is the peak voltage and resistance OK?
YES Go to Step4.
NO Go to Step5.
YES
• Improper spark plug connection.
• Go to Step5.
NO Faulty spark plug.
YES Go to Step6.
NO Faulty ignition coil.
YES
• Faulty ECM.
• Faulty wire harness.
• Improper ignition coupler connection.
NO Faulty CKP sensor.
ELECTRICAL SYSTEM 8-25
INSPECTION
IGNITION COIL PRIMARY PEAK VOLTAGE
• Lift and support the fuel tank. (!5-7)
• Remove the radiator lower mounting bolt and move the radiator lower side to forward.
• Disconnect the two spark plug caps.
• Connect the new two spark plugs to each spark plug cap and
ground them.
NOTE:
Make sure that all couplers and spark plugs are connected properly and the battery used is in fully-charged condition.
Measure the No.1 and No.2 ignition coils primary peak voltage
in the following procedure.
• Connect the multi circuit tester with peak voltage adaptor as
follows.
No.1 ignition coil:
+ Probe: White/Blue terminal
- Probe: Ground
No.2 ignition coil: + Probe: Black terminal
- Probe: Ground
1 Peak volt adaptor
2 Ignition coil (No.1 or No.2)
3 New spark plug
4 ECM
5 Battery
NOTE:
Do not disconnect the ignition coil primary wire coupler.
# 09900-25008: Multi circuit tester set
"
• Shift the transmission into the neutral and then turn the ignition switch to the “ON” position.
• Pull the clutch lever.
• Push the starter button and allow the engine to crank for a few
seconds, and then measure the ignition coil primary peak voltage.
Before using the multi circuit tester and peak volt
adaptor, be sure to refer to the appropriate instruction
manual.
B or W/Bl
8-26 ELECTRICAL SYSTEM
• Repeat the above procedure a few times and measure the
highest ignition coil primary peak voltage.
' Tester knob indication: Voltage (&)
$ Ignition coil primary peak voltage: 150 V and more
0
• If the peak voltage is lower than the specified values, inspect
the ignition coil. (!8-26)
IGNITION COIL RESISTANCE
• Lift and support the fuel tank. (!5-7)
• Disconnect the spark plug caps and ignition coil lead wires.
Measure the ignition coil resistance in both the primary and secondary windings. If the resistance is not within the standard
range, replace the ignition coil with a new one.
# 09900-25008: Multi circuit tester set
( Tester knob indication: Resistance (Ω)
$ Ignition coil resistance
Primary : 2 – 5 Ω (
+ terminal – - terminal)
Secondary : 24 – 37 kΩ (Plug cap – + terminal)
While testing, do not touch the tester probes and
spark plugs to prevent receiving an electric shock.
kΩ
ELECTRICAL SYSTEM 8-27
CKP SENSOR PEAK VOLTAGE
• Remove the seat. (!7-4)
• Disconnect the ECM coupler.
NOTE:
Make sure that all of the couplers are connected properly and
the battery used is in fully-charged condition.
Measure the CKP sensor peak voltage in the following procedures.
• Connect the multi circuit tester with peak volt adaptor as follows.
+ Probe: White lead wire
- Probe: Black/White lead wire
# 09900-25008: Multi circuit tester set
"
• Shift the transmission into the neutral, and then turn the ignition switch to the “ON” position.
• Pull the clutch lever.
• Push the starter button and allow the engine to crank for a few
seconds, and then measure the CKP sensor peak voltage.
• Repeat the above procedure a few times and measure the
highest peak voltage.
1 CKP sensor
2 CKP sensor coupler
3 ECM coupler
4 Peak volt adaptor
' Tester knob indication: Voltage (&)
$ CKP sensor peak voltage: 3.7 V and more
If the peak voltage is less than the specified values, check the
peak voltage at the CKP sensor lead wire coupler.
• Remove the right cowling. (!7-5)
• Disconnect the CKP sensor lead wire coupler and connect the
multi circuit tester with the peak volt adaptor.
+ Probe: White lead wire
- Probe: Green lead wire
• Measure the CKP sensor peak voltage at the CKP sensor
lead wire coupler in the same manner as on the ECM coupler.
' Tester knob indication: Voltage (&)
$ CKP sensor peak voltage: 3.7 V and more
Before using the multi circuit tester and peak volt
adaptor, be sure to refer to the appropriate instruction
manual.
V
G/W
W
B
8-28 ELECTRICAL SYSTEM
If the peak voltage on the CKP sensor lead wire coupler is OK
but on the ECM coupler is out of specification, the wire harness
must be replaced. If both peak voltages are out of specification,
the CKP sensor must be replaced and re-checked.
5 CKP sensor
6 CKP sensor coupler
7 Peak volt adaptor
CKP SENSOR RESISTANCE
Measure the resistance between the lead wires and ground. If
the resistance is not specified value, the CKP sensor must be
replaced.
1 CKP sensor
2 CKP sensor coupler
# 09900-25008: Multi circuit tester set
( Tester knob indication: Resistance (Ω)
$ CKP sensor resistance: 130 – 240 Ω (White – Green)
∞ Ω (White – Ground)
G
BW
G
W
ELECTRICAL SYSTEM 8-29
COMBINATION METER
REMOVAL AND DISASSEMBLY
• Disconnect the battery
- lead wire.
• Remove the combination meter panel. (!7-6).
• Remove the combination meter 1.
"
• Disassemble the combination meter as follows.
"
When disconnecting and connecting the combination
meter coupler, make sure to turn OFF the ignition
switch, or electronic parts may get damaged.
Do not attempt to disassemble the combination meter
unit.
1 Combination meter cover 2 Combination meter unit
8-30 ELECTRICAL SYSTEM
INSPECTION
LED (LIGHT EMITTING DIODE)
Check that the LED lights immediately after turning the ignition switch on.
If the LED fails in operation, replace the combination meter unit with a new one after checking its wire harness/coupler.
STEPPING MOTOR
Check that the pointer calibrates itself immediately after turning the ignition switch on and stops at starting
point.
If abnormal condition is found, replace the combination meter unit with a new one after checking its wire harness/coupler.
NOTE:
The pointer may not return to the proper position even turning the ignition switch on under low temperature
condition. In that case, you can reset the pointer to the proper position by following the instruction below:
1) With the ADJ switch
A pressed, turn the ignition switch on.
2) Keep pushing the ADJ switch A for 3 to 5 seconds.
3) Push the ADJ switch A twice (within 1 second). → Reset
* Complete the operation within 10 seconds after the ignition switch has been turned on.
Pointer will return to the starting point right after the completion of the operation. In the case of the pointer
not returning to the proper position after doing above, replace the combination meter unit.
ADJ SWITCH
Time Ignition switch ADJ switch
OFF
ON0


3 sec
5 sec





10 sec
PUSH
Release
Push
Push → Reset
ELECTRICAL SYSTEM 8-31
ODOMETER
The odometer indicates “------” when the odometer is faulty.
Replace the combination meter unit with a new one.
TRIP METER
The trip meter indicates “----.-” when the trip meter is faulty.
In case the odometer works normaly, perform the trip meter
reset. If the trip meter isn’t restored after above reset, replace
the combination meter unit with a new one.
TRIP METER RESET PROCEDURE
1. Turn the ignition “ON”.
2. Select the trip meter by pushing the SEL switch
A.
3. Push the ADJ switch B for 2 seconds.
8-32 ELECTRICAL SYSTEM
INDICATORS
ENGINE COOLANT TEMPERATURE METER INSPECTION
• Disconnect the ECT sensor coupler
1.
"
• Connect the variable resistor A between the terminals.
• Turn the ignition switch “ON”.
• Check the display of engine coolant temperature meter as
shown below. If any abnormality is found, replace the combination meter with a new one.
A Variable resister
B ECT sensor
When connecting and disconnecting the ECT sensor
lead wire coupler, make sure to turn OFF the ignition
switch, or electronic parts may get damaged.
Resistance 1.148 kΩ
and more
1.148 – 0.587 kΩ 0.587 – 0.188 kΩ 0.188 – 0.140 kΩ
Engine coolant
temperature meter
Water temperateure 39 ˚C and below 40 – 59 ˚C 60 – 79 ˚C 80 – 111 ˚C
Resistance 0.140 – 0.116 kΩ
Engine coolant
temperature meter
Water temperateure 112 – 119 ˚C 120 ˚C and over 122 ˚C and over
0.116 kΩ
and less
0.111 kΩ
and less
ELECTRICAL SYSTEM 8-33
FUEL LEVEL GAUGE INSPECTION
• Remove the fuel tank. (!5-7)
• Remove the fuel pump. (!5-10)
Measure the resistance at each fuel level gauge float position. If
the resistance is incorrect, replace the fuel level gauge with a
new one.
# 09900-25008: Multi circuit tester set
(Tester knob indication: Resistance (Ω)
• Install the fuel pump. (!5-12)
Float position Resistance
A “F” (Full) Approx. 4 Ω
B “E” (Empty) Approx. 182 Ω
8-34 ELECTRICAL SYSTEM
FUEL LEVEL METER INSPECTION
• Remove the fuel tank left side cover. (!7-4)
• Disconnect the fuel pump lead wire coupler.
• Connect the each resistor between the Yellow/Black and
Black/White lead wires at the wire harness.
• Turn the ignition switch “ON” position and wait for approx. 40
seconds.
Check the display of fuel meter as shown below, If any abnormality is found, replace the combination meter with a new one.
OIL PRESSURE INDICATOR INSPECTION
NOTE:
Before inspecting the oil pressure switch, check the engine oil
level. (!2-13)
• Disconnect the oil pressure switch lead wire from the oil pressure switch.
• Turn the ignition switch “ON” position.
Check if the oil pressure indicator will light, when grounding the
oil pressure switch lead wire
1.
Resistance
More than
167.0 Ω
6.5 Ω
and less87.5 – 167.0 Ω 50.0 – 87.5 Ω 26.0 – 50.0 Ω 6.5 – 26.0 Ω
Fuel level
meter
ELECTRICAL SYSTEM 8-35
SPEEDOMETER AND SPEED SENSOR
If the speedometer, odometer or trip meter does not function
properly, inspect the speed sensor and connection of coupler
1.
If the speed sensor and connection are all right, replace the
meter with a new one.
SPEED SENSOR REMOVAL AND INSTALLATION
• Remove the front wheel. (!7-10)
• Disconnect the speed sensor coupler. (!8-35)
• Remove the speed sensor.
• Install the speed sensor in the reverse order of removal.
SPEED SENSOR INSPECTION
• Connect the four 1.5 V dry cells, 10 kΩ resistance and the
tester to the speed sensor lead wire coupler as shown.
# 09900-25008: Multi-circuit tester set
' Tester knob indication: Voltage (&)
Lift and turn the front wheel and check that voltage varies between 0 – 6 V.
If any abnormal condition is noted, replace the sensor.
10 kΩP
B/W
O/R
8-36 ELECTRICAL SYSTEM
LAMPS
HEADLIGHT, BRAKE LIGHT/TAILLIGHT AND TURN SIGNAL LIGHT
HEADLIGHT
12 V 60/55 W
12 V 60/55 W + 5 W
A ONLY E-02, 19
BRAKE LIGHT/TAIL LIGHT
12 V 21/5 W
TURN SIGNAL LIGHT
12 V 21 W
HEADLIGHT BEAM ADJUSTMENT
• Adjust the headlight beam, both vertical and horizontal.
A: Vertical adjuster
B: Horizontal adjuster
NOTE:
To adjust the headlight beam, adjust the beam horizontally first,
then adjust the vertically.
ELECTRICAL SYSTEM 8-37
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.
If the bulb, turn signal switch and circuit connection are OK, the
turn signal relay may be faulty; therefore, replace the turn signal/
side-stand relay with a new one.
NOTE:
* Make sure that the battery is fully charged.
* Refer to the page 8-22 for the side-stand relay and diode
inspection.
1 Diode
2 Side-stand relay
3 Turn signal relay
STARTER RELAY
(!8-19)
FUEL PUMP RELAY
(!5-10)
8-38 ELECTRICAL SYSTEM
SWITCHES
IGNITION SWITCH REMOVAL
• Remove the fuel tank. (!5-7)
• Remove the air cleaner box. (!5-15)
• Disconnect the ignition switch coupler
1.
• Remove the ignition switch mounting bolts with the special
tools.
# 09930-11920: Torx bit JT40H
09930-11940: Bit holder
"
1 99000-32050: THREAD LOCK “1342” (USA)
2 99000-32110: THREAD LOCK SUPER “1322” (Others)
When reusing the ignition switch bolt, clean thread and
apply the THREAD LOCK SUPER “1322” or THREAD
LOCK “1342”.
ELECTRICAL SYSTEM 8-39
INSPECTION
Inspect each switch for continuity with a tester. If any abnormality is found, replace the respective switch
assemblies with new ones.
G/Y Ground
ON (engine
is stopped)
OFF (engine
is running)
Color
Position
B/Y B/Y
OFF
ON
Color
Position
O W/B
OFF
ON
Color
Position
B/R B/Bl
OFF
ON
Color
Position
B/Bl B/W
PUSH
Color
Position
O/W Y/G
PUSH
Color
Position
O/R Y
PUSH
Color
Position
Lg Lbl B
L
PUSH
R
Color
Position
W Y Y/W
HI ()
LO ()
Color
Position
Lg Lbl B
ON
OFF
Color
Position
R O O/Y Br
ON
OFF
LOCK
P
Color
Position
O/B O/W
OFF ()
RUN ()
Color
Position
IGNITION SWITCH
HAZARD
OIL PRESSURE SWITCH
PASSING LIGHT SWITCH
DIMMER SWITCH
HORN BUTTON
FRONT BRAKE SWITCH
REAR BRAKE SWITCH
CLUTCH SWITCH
ENGINE STOP SWITCH
STARTER BUTTON
TURN SIGNAL LIGHT SWITCH
NOTE:
Before inspecting the oil pressure switch, check the
engine oil level. (2-13)
B : Black
Br : Brown
Lbl : Light blue
Lg : Light green
O : Orange
R : Red
Y : Yellow
W : White
B/Bl : Black with Blue tracer
B/W : Black with White tracer
B/Y : Black with Yellow tracer
B/R : Black with Red tracer
G/Y : Green with Yellow tracer
O/B : Orange with Black tracer
O/R : Orange with Red tracer
O/W : Orange with White tracer
O/Y : Orange with Yellow tracer
W/B : White with Black tracer
Y/G : Yellow with Green tracer
Y/W : Yellow with White tracer
WIRE COLOR
8-40 ELECTRICAL SYSTEM
BATTERY
SPECIFICATIONS
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
• Remove the aluminum tape 1 sealing the battery electrolyte
filler holes A.
NOTE:
When filling electrolyte, the battery must be removed from the
vehicle and must be put on the level ground.
• Remove the caps 2.
NOTE:
* After filling the electrolyte completely, use the removed cap 2
as the sealed caps of battery-filler holes.
* Do not remove or pierce the sealed areas 3 of the electrolyte
container.
• Insert the nozzles of the electrolyte container 4 into the battery’s electrolyte filler holes, holding the container firmly so
that it does not fall. Take precaution not to allow any of the
fluid to spill.
• Make sure air bubbles 5 are coming up each electrolyte container, and leave in this position for about more than 20 minutes.
Type designation YTX12 – BS
Capacity 12 V, 36.0 kC (10 Ah)/10 HR
ELECTRICAL SYSTEM 8-41
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 battery. Wait for about 20 minutes.
• Insert the caps
6 into the filler holes, pressing in firmly so that
the top of the caps do not protrude above the upper surface of
the battery’s top cover.
"
For initial charging, use the charger specially designed for MF battery.
"
* Never use anything except the specified battery.
* Once the caps have been installed to the battery, do
not remove the caps.
* Do not tap the caps with a tool such as hammer
when installing them.
CORRECT INCORRECT
* For charging the battery, make sure to use the charger specially designed for MF battery. Otherwise, the battery may be overcharged resulting in shortened service life.
* Do not remove the cap during charging.
* Position the battery with the cap facing upward during charging.
8-42 ELECTRICAL SYSTEM
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.
RECHARGING OPERATION
• Using the multi circuit tester, check the battery voltage. If the
voltage reading is less than the 12.0 V (DC), recharge the battery with a battery charger.
A Charging period
B Stop charging
"
Recharging time: 1.4 A for 5 to 10 hours or 6 A for one hour
"
• After recharging, wait for more than 30 minutes and check the
battery voltage with a multi circuit tester.
• If the battery voltage is less than the 12.5 V, recharge the battery again.
• If battery voltage is still less than 12.5 V, after recharging,
replace the battery with a new one.
• When the motorcycle is not used for a long period, check the
battery every 1 month to prevent the battery discharge.
* When recharging the battery, remove the battery
from the motorcycle.
* Do not remove the caps on the battery top while
recharging.
Be careful not to permit the charging current to
exceed 6 A at any time.
(V) (at 0 ˚– 40 ˚C)
14
13
12
11
10
100
Battety charged condition
75 50 25 0 (%)
SERVICING INFORMATION 9-1
9
SERVICING INFORMATION
CONTENTS
TROUBLESHOOTING...................................................................................9- 2
MALFUNCTION CODE AND DEFECTIVE CONDITION ........................9- 2
ENGINE ...................................................................................................9- 4
RADIATOR (COOLING SYSTEM) ..........................................................9-10
CHASSIS .................................................................................................9-11
BRAKES..................................................................................................9-12
ELECTRICAL ..........................................................................................9-13
BATTERY................................................................................................9-15
WIRE HARNESS, CABLE AND HOSE ROUTING........................................9-16
WIRE HARNESS ROUTING ...................................................................9-16
HEATED OXYGEN SENSOR (HO2S) WIRE ROUTING
(FOR E-02, 19) ........................................................................................9-18
ENGINE ELECTRICAL PARTS SET-UP ................................................9-19
SPEED SENSOR LEAD WIRE ROUTING..............................................9-20
THROTTLE CABLE ROUTING...............................................................9-21
CLUTCH CABLE ROUTING ...................................................................9-22
THROTTLE BODY INSTALLATION/HOSE ROUTING ..........................9-23
COOLING SYSTEM HOSE ROUTING....................................................9-24
FRONT BRAKE HOSE ROUTING ..........................................................9-26
REAR BRAKE HOSE ROUTING ............................................................9-27
FUEL TANK DRAIN HOSE ROUTING ...................................................9-28
FUEL TANK INSTALLATION .................................................................9-29
PAIR (AIR SUPPLY) SYSTEM HOSE ROUTING...................................9-30
SEAT LOCK CABLE ROUTING .............................................................9-31
HEAD LAMP SET-UP .............................................................................9-31
ABSORBER HOSE ROUTING................................................................9-32
BATTERY CUSHION INSTALLATION ...................................................9-32
SIDE-STAND SET-UP.............................................................................9-33
BRAKE PEDAL/FOOTREST SET-UP ....................................................9-33
ENGINE CAP INSTALLATION ...............................................................9-34
FOOTREST SET-UP ...............................................................................9-35
HANDLEBAR BALANCER INSTALLATION..........................................9-35
SPECIAL TOOLS ....................................................................................9-36
TIGHTENING TORQUE.................................................................................9-40
ENGINE ...................................................................................................9-40
FI SYSTEM PARTS.................................................................................9-41
CHASSIS .................................................................................................9-42
TIGHTENING TORQUE CHART.............................................................9-43
SERVICE DATA.............................................................................................9-44
9-2 SERVICING INFORMATION
TROUBLESHOOTING
MALFUNCTION CODE AND DEFECTIVE CONDITION
MALFUNCTION
CODE
DETECTED ITEM
DETECTED FAILURE CONDITION
CHECK FOR
C00 NO FAULT –––––––––––
C12
Crankshaft position
sensor
The signal does not reach ECM for 3 sec. and more, after
receiving the IAP signal.
The crankshaft position sensor wiring and mechanical parts.
(Crankshaft position sensor, lead wire/coupler connection)
C13
Intake air pressure
sensor
The sensor should produce following voltage.
0.1 V sensor voltage 4.8 V
Without the above range for 4 sec. and more, C13 is indicated.
Intake air pressure sensor, lead wire/coupler connection.
C14
Throttle position sensor
The sensor should produce following voltage.
0.1 V sensor voltage < 4.8 V
Without the above range for 4 sec. and more, C14 is indicated.
Throttle position sensor, lead wire/coupler connection.
C15
Engine coolant temperature sensor
The sensor voltage should be the following.
0.1 V sensor voltage < 4.6 V
Without the above range for 4 sec. and more, C15 is indicated.
Engine coolant temperature sensor, lead wire/coupler connection.
C21
Intake air temperature
sensor
The sensor voltage should be the following.
0.1 V sensor voltage < 4.6 V
Without the above range for 4 sec. and more, C21 is indicated.
Intake air temperature sensor, lead wire/coupler connection.
C23
Tip over sensor The sensor voltage should be the following for 2 sec. and more
after ignition switch turns ON.
0.2 V sensor voltage 4.6 V
Without the above value for 2 sec. and more, C23 is indicated.
Tip over sensor, lead wire/coupler connection.
C24/C25
Ignition signal #1/#2 Crankshaft position sensor (pick-up coil) signal is produced, but
signal from ignition coil is interrupted continuous by 8 times or
more. In this case, the code C24 or C25 is indicated.
Ignition coil, wiring/coupler connection, power supply from the
battery.
SERVICING INFORMATION 9-3
MALFUNCTION
CODE
DETECTED ITEM
DETECTED FAILURE CONDITION
CHECK FOR
C28
Secondary throttle
valve actuator
When no actuator control signal is supplied from the ECM or
communication signal does not reach ECM or operation voltage
does not reach STVA motor, C28 is indicated. STVA can not
operate.
STVA lead wire/coupler.
C29
Secondary throttle
position sensor
The sensor should produce following voltage.
0.1 V sensor voltage 4.8 V
Without the above range for 4 sec. and more, C29 is indicated.
Secondary throttle position sensor, lead wire/coupler connection.
C31
Gear position signal It judges from gear position voltage, engine speed and throttle
position by ECM, when the gear position voltage is 0.2 V and
less.
Gear position sensor, wiring/coupler connection. Gearshift cam
etc.
C32/C33
Fuel injector #1/#2 When fuel injector voltage gets 1.3 V and less, C32 or C33 is
indicated.
Injector, wiring/coupler connection, power supply to the injector.
C41
Fuel pump relay No voltage is applied to the both injectors #1/#2 for 3 sec. after
the contact of fuel pump relay is turned ON. Or voltage is
applied to the both injectors #1/#2, when the contact of fuel
pump is OFF.
Fuel pump relay, connecting lead wire, power source to fuel
pump relay, fuel injectors.
C42
Ignition switch Ignition switch signal is not input in ECM.
Ignition switch, lead wire/coupler.
C44
Heated oxygen sensor
(HO2S)
[E-02, 19]
The sensor voltage should be the following and less after warming up condition.
(Sensor voltage 0.4 V)
Without the above value, C44 is indicated.
Heater operation voltage does not reach in the oxygen heater
circuit, C44 in indicated.
The Heater can not operate.
HO2S lead wire/coupler connection.
Battery voltage supply to the HO2S.
C49
PAIR control solenoid
valve
PAIR control solenoid valve voltage is not input in ECM.
PAIR control solenoid valve, lead wire/coupler.
9-4 SERVICING INFORMATION
ENGINE
ENGINE WILL NOT START OR IS HARD TO START
Symptom, possible causes and remedy
1) Compression too low
• Valve clearance out of adjustment.
• Worn valve guides or poor seating of valves.
• Mistimed valves.
• Excessively worn piston rings.
• Worn-down cylinder bores.
• Starter motor cranks too slowly.
• Poor seating of spark plugs.
2) Plug not sparking
• Fouled spark plugs.
• Wet spark plugs.
• Defective ignition coils.
• Open or short in high-tension cord.
• Defective CKP sensor.
• Defective ECM.
• Open-circuited wiring connections.
3) No fuel reaching the intake manifold
• Clogged fuel filter or fuel hose.
• Defective fuel pump.
• Defective fuel pressure regulator.
• Defective fuel injector.
• Defective fuel pump relay.
• Defective ECM.
• Open-circuited wiring connections.
4) Incorrect fuel/air mixture
• TP sensor out of adjustment.
• Defective fuel pump.
• Defective fuel pressure regulator.
• Defective TP sensor.
• Defective CKP sensor.
• Defective IAP sensor.
• Defective ECM.
• Defective ECT sensor.
• Defective IAT sensor.
Adjust.
Repair or replace.
Adjust.
Replace.
Replace.
See electrical section.
Retighten.
Clean or replace.
Clean and dry.
Replace.
Replace.
Replace.
Replace.
Repair or replace.
Clean or replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Check and repair.
Adjust.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
SERVICING INFORMATION 9-5
ENGINE IDLES POORLY
ENGINE STALLS OFTEN
Symptom, possible causes and remedy
• Valve clearance out of adjustment.
• Poor seating of valves.
• Defective valve guides.
• Worn down camshafts.
• Too wide spark plug gaps.
• Defective ignition coils.
• Defective CKP sensor.
• Defective ECM.
• Defective TP sensor.
• Defective fuel pump.
• Imbalanced throttle valve or STV.
• Damaged or cracked vacuum hose.
Adjust.
Replace or repair.
Replace.
Replace.
Adjust or replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Adjust.
Replace.
Symptom, possible causes and remedy
1) Incorrect fuel/air mixture
• Defective IAP sensor or circuit.
• Clogged fuel filter.
• Defective fuel pump.
• Defective fuel pressure regulator.
• Defective ECT sensor.
• Defective thermostat.
• Defective IAT sensor.
• Damaged or cracked vacuum hose.
2) Fuel injector improperly operating
• Defective fuel injectors.
• No injection signal from ECM.
• Open or short circuited wiring connection.
• Defective battery or low battery voltage.
3) Control circuit or sensor improperly operating
• Defective ECM.
• Defective fuel pressure regulator.
• Defective TP sensor.
• Defective IAT sensor.
• Defective CKP sensor.
• Defective ECT sensor.
• Defective fuel pump relay.
4) Engine internal parts improperly operating
• Fouled spark plugs.
• Defective CKP sensor or ECM.
• Clogged fuel hose.
• Valve clearance out of adjustment.
Repair or replace.
Clean or replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Repair or replace.
Repair or replace.
Replace or recharge.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Clean.
Replace.
Clean.
Adjust.
9-6 SERVICING INFORMATION
NOISY ENGINE
Symptom, possible causes and remedy
1) Excessive valve chatter
• Too large valve clearance.
• Weakened or broken valve springs.
• Worn tappet or cam surface.
• Worn and burnt camshaft journal.
2) Noise seems to come from piston
• Worn down pistons or cylinders.
• Combustion chambers fouled with carbon.
• Worn piston pins or piston pin bore.
• Worn piston rings or ring grooves.
3) Noise seems to come from cam chain
• Stretched chain.
• Worn sprockets.
• Tension adjuster not working.
4) Noise seems to come from clutch
• Worn splines of countershaft or hub.
• Worn teeth of clutch plates.
• Distorted clutch plates, driven and drive.
• Worn clutch release bearing.
• Weakened clutch dampers.
5) Noise seems to come from crankshaft
• Rattling bearings due to wear.
• Worn and burnt big-end bearings.
• Worn and burnt journal bearings.
6) Noise seems to come from transmission
• Worn or rubbing gears.
• Worn splines.
• Worn or rubbing primary gears.
• Worn bearings.
7) Noise seems to come from water pump
• Too much play on pump shaft bearing.
• Worn or damaged impeller shaft.
• Worn or damaged mechanical seal.
• Contact between pump case and impeller.
Adjust.
Replace.
Replace.
Replace.
Replace.
Clean.
Replace.
Replace.
Replace.
Replace.
Repair or replace.
Replace.
Replace.
Replace.
Replace.
Replace the primary driven gear.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
SERVICING INFORMATION 9-7
ENGINE RUNS POORLY IN HIGH SPEED RANGE
Symptom, possible causes and remedy
1) Defective engine internal/electrical parts
• Weakened valve springs.
• Worn camshafts.
• Valve timing out of adjustment.
• Too narrow spark plug gaps.
• Ignition not advanced sufficiently due to poorly
working timing advance circuit.
• Defective ignition coils.
• Defective CKP sensor.
• Defective ECM.
• Clogged fuel hose, resulting in inadequate fuel
supply to injector.
• Defective fuel pump.
• Defective TP sensor.
• Defective STP sensor or STVA.
• Clogged air cleaner element.
2) Defective air flow system
• Clogged air cleaner element.
• Defective throttle valve.
• Defective secondary throttle valve.
• Sucking air from throttle body joint.
• Defective ECM.
• Imbalanced throttle valve synchronization.
3) Defective control circuit or sensor
• Low fuel pressure.
• Defective TP sensor.
• Defective IAT sensor.
• Defective CKP sensor.
• Defective GP switch.
• Defective IAP sensor.
• Defective ECM.
• TP sensor out of adjustment.
• Defective STP sensor and/or STVA.
Replace.
Replace.
Adjust.
Adjust.
Replace ECM.
Replace.
Replace.
Replace.
Clean and prime.
Replace.
Replace.
Replace.
Clean or replace.
Clean or replace.
Adjust or replace.
Adjust or replace.
Repair or replace.
Replace.
Adjust.
Repair or replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Adjust.
Replace.
9-8 SERVICING INFORMATION
ENGINE LACKS POWER
Symptom, possible causes and remedy
1) Defective engine internal/electrical parts
• Loss of valve clearance.
• Weakened valve springs.
• Valve timing out of adjustment.
• Worn piston rings or cylinders.
• Poor seating of valves.
• Fouled spark plugs.
• Incorrect spark plugs.
• Clogged injectors.
• TP sensor out of adjustment.
• Clogged air cleaner element.
• Imbalanced throttle valve synchronization.
• Sucking air from throttle valve or vacuum hose.
• Too much engine oil.
• Defective fuel pump or ECM.
• Defective CKP sensor and ignition coils.
Symptom, possible causes and remedy
2) Defective control circuit or sensor
• Low fuel pressure.
• Defective TP sensor.
• Defective IAT sensor.
• Defective CKP sensor.
• Defective GP switch.
• Defective IAP sensor.
• Defective ECM.
• Imbalanced throttle valve synchronization.
• TP sensor out of adjustment.
• Defective STP sensor and/or STVA.
Adjust.
Replace.
Adjust.
Replace.
Repair.
Clean or replace.
Adjust or replace.
Clean or replace.
Adjust.
Clean or replace.
Adjust.
Retighten or replace.
Drain out excess oil.
Replace.
Replace.
Repair or replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Adjust.
Adjust.
Replace.
SERVICING INFORMATION 9-9
ENGINE OVERHEATS
DIRTY OR HEAVY EXHAUST SMOKE
SLIPPING CLUTCH
DRAGGING CLUTCH
TRANSMISSION WILL NOT SHIFT
Symptom, possible causes and remedy
1) Defective engine internal parts
• Heavy carbon deposit on piston crowns.
• Not enough oil in the engine.
• Defective oil pump or clogged oil circuit.
• Sucking air from intake pipes.
• Use incorrect engine oil.
• Defective cooling system.
Symptom, possible causes and remedy
2) Lean fuel/air mixture
• Short-circuited IAP sensor/lead wire.
• Short-circuited IAT sensor/lead wire.
• Sucking air from intake pipe joint.
• Defective fuel injectors.
• Defective ECT sensor.
Symptom, possible causes and remedy
3) The other factors
• Ignition timing too advanced due to defective timing
advance system (ECT sensor, GP switch, CKP
sensor and ECM.)
• Drive chain is too tight.
Clean.
Add oil.
Replace or clean.
Retighten or replace.
Change.
See radiator section.
Repair or replace.
Repair or replace.
Repair or replace.
Replace.
Replace.
Replace.
Adjust.
Symptom, possible causes and remedy
• Too much engine oil in the engine.
• Worn piston rings or cylinders.
• Worn valve guides.
• Scored or scuffed cylinder walls.
• Worn valves stems.
• Defective stem seal.
• Worn oil ring side rails.
Check with inspection window. Drain excess oil.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Symptom, possible causes and remedy
• Weakened clutch springs.
• Worn or distorted pressure plates.
• Distorted clutch plates or pressure plates.
Replace.
Replace.
Replace.
Symptom, possible causes and remedy
• Some clutch springs weakened while others are
not.
• Distorted pressure plates or clutch plates.
Replace.
Replace.
Symptom, possible causes and remedy
• Broken gearshift cam.
• Distorted gearshift forks.
• Worn gearshift pawl.
Replace.
Replace.
Replace.
9-10 SERVICING INFORMATION
TRANSMISSION WILL NOT SHIFT BACK
TRANSMISSION JUMPS OUT OF GEAR
RADIATOR (COOLING SYSTEM)
ENGINE OVERHEATS
ENGINE OVERCOOLS
Symptom, possible causes and remedy
• Broken return spring on shift shaft.
• Rubbing or sticky shift shaft.
• Distorted or worn gearshift forks.
Replace.
Repair or replace.
Replace.
Symptom, possible causes and remedy
• Worn shifting gears on driveshaft or countershaft.
• Distorted or worn gearshift forks.
• Weakened stopper spring on gearshift stopper.
Replace.
Replace.
Replace.
Symptom, possible causes and remedy
• Not enough engine coolant.
• Radiator core and oil cooler core clogged with dirt
or scale.
• Faulty cooling fan.
• Defective cooling fan thermo-switch.
• Clogged water passage.
• Air trapped in the cooling circuit.
• Defective water pump.
• Use of incorrect engine coolant.
• Defective thermostat.
Add coolant.
Clean.
Repair or replace.
Replace.
Clean.
Bleed out air.
Replace.
Replace.
Replace.
Symptom, possible causes and remedy
• Defective cooling fan thermo-switch.
• Extremely cold weather.
• Defective thermostat.
Replace.
Put on the radiator cover.
Replace.
SERVICING INFORMATION 9-11
CHASSIS
HEAVY STEERING
WOBBLY HANDLEBARS
WOBBLY FRONT WHEEL
FRONT SUSPENSION TOO SOFT
FRONT SUSPENSION TOO STIFF
NOISY FRONT SUSPENSION
WOBBLY REAR WHEEL
Symptom, possible causes and remedy
• Overtightened steering stem nut.
• Broken bearing in steering stem.
• Distorted steering stem.
• Not enough pressure in tires.
Adjust.
Replace.
Replace.
Adjust.
Symptom, possible causes and remedy
• Loss of balance between right and left front forks.
• Distorted front fork.
• Distorted front axle or crooked tire.
• Loose steering stem nut.
• Worn or incorrect tire or wrong tire pressure.
• Worn bearing/race in steering stem.
Adjust.
Repair or replace.
Replace.
Adjust.
Adjust or replace.
Replace.
Symptom, possible causes and remedy
• Distorted wheel rim.
• Worn front wheel bearings.
• Defective or incorrect tire.
• Loose axle or axle pinch bolt.
• Incorrect front fork oil level.
• Incorrect front wheel weight balance.
Replace.
Replace.
Replace.
Retighten.
Adjust.
Adjust.
Symptom, possible causes and remedy
• Weakened springs.
• Not enough fork oil.
• Wrong viscous fork oil.
• Improperly set front fork spring adjuster.
Replace.
Replenish.
Replace.
Adjust.
Symptom, possible causes and remedy
• Too viscous fork oil.
• Too much fork oil.
• Improperly set front fork spring adjuster.
• Bent front axle.
Replace.
Drain excess oil.
Adjust.
Replace.
Symptom, possible causes and remedy
• Not enough fork oil.
• Loose bolts on suspension.
Replenish.
Retighten.
Symptom, possible causes and remedy
• Distorted wheel rim.
• Worn rear wheel bearing or swingarm bearings.
• Defective or incorrect tire.
• Worn swingarm and rear suspensions.
• Loose nuts or bolts on rear suspensions.
Replace.
Replace.
Replace.
Replace.
Retighten.
9-12 SERVICING INFORMATION
REAR SUSPENSION TOO SOFT
REAR SUSPENSION TOO STIFF
NOISY REAR SUSPENSION
BRAKES
INSUFFICIENT BRAKE POWER
BRAKE SQUEAKING
EXCESSIVE BRAKE LEVER STROKE
LEAKAGE OF BRAKE FLUID
Symptom, possible causes and remedy
• Weakened spring of shock absorber.
• Leakage of oil from shock absorber.
• Improperly set rear spring unit adjuster.
Replace.
Replace.
Adjust.
Symptom, possible causes and remedy
• Bent shock absorber shaft.
• Bent swingarm pivot shaft.
• Worn swingarm and suspension bearings.
• Improperly set rear spring unit adjuster.
Replace.
Replace.
Replace.
Adjust.
Symptom, possible causes and remedy
• Loose nuts or bolts on rear suspension.
• Worn swingarm and suspension bearings.
Retighten.
Replace.
Symptom, possible causes and remedy
• Leakage of brake fluid from hydraulic system.
• Worn pads.
• Oil adhesion on friction surface of pads.
• Worn disc.
• Air in hydraulic system.
• Not enough brake fluid in the reservoir.
Repair or replace.
Replace.
Clean disc and pads.
Replace.
Bleed air.
Replenish.
Symptom, possible causes and remedy
• Carbon adhesion on pad surface.
• Tilted pad.
• Damaged wheel bearing.
• Loose front wheel axle or rear wheel axle.
• Worn pads or disc.
• Foreign material in brake fluid.
• Clogged return port of master cylinder.
Repair surface with sandpaper.
Correct pad fitting or replace.
Replace.
Tighten to specified torque.
Replace.
Replace brake fluid.
Disassemble and clean master cylinder.
Symptom, possible causes and remedy
• Air in hydraulic system.
• Insufficient brake fluid.
• Improper quality of brake fluid.
Bleed air.
Replenish fluid to specified level; bleed air.
Replace with correct fluid.
Symptom, possible causes and remedy
• Insufficient tightening of connection joints.
• Cracked hose.
• Worn piston and/or cup.
Tighten to specified torque.
Replace.
Replace piston and/or cup.
SERVICING INFORMATION 9-13
BRAKE DRAGS
ELECTRICAL
NO SPARKING OR POOR SPARKING
SPARK PLUG SOON BECOME FOULED WITH CARBON
SPARK PLUG BECOME FOULED TOO SOON
SPARK PLUG ELECTRODES OVERHEAT OR BURN
GENERATOR DOES NOT CHARGE
Symptom, possible causes and remedy
• Rusty part.
• Insufficient brake lever or brake pedal pivot
lubrication.
Clean and lubricate.
Lubricate.
Symptom, possible causes and remedy
• Defective ignition coils or spark plug caps.
• Defective spark plugs.
• Defective CKP sensor.
• Defective ECM.
• Defective TO sensor.
• Open-circuited wiring connections.
Replace.
Replace.
Replace.
Replace.
Replace.
Check and repair.
Symptom, possible causes and remedy
• Mixture too rich.
• Idling speed set too high.
• Incorrect gasoline.
• Dirty air cleaner element.
• Too cold spark plugs.
Inspect FI system.
Adjust fast idle or throttle stop screw.
Change.
Clean or replace.
Replace with hot type plugs.
Symptom, possible causes and remedy
• Worn piston rings.
• Worn piston or cylinders.
• Excessive clearance of valve stems in valve
guides.
• Worn stem oil seal.
Replace.
Replace.
Replace.
Replace.
Symptom, possible causes and remedy
• Too hot spark plugs.
• Overheated the engine.
• Loose spark plugs.
• Too lean mixture.
Replace with cold type plugs.
Tune up.
Retighten.
Consult FI system.
Symptom, possible causes and remedy
• Open- or short-circuited lead wires, or loose lead
connections.
• Short-circuited, grounded or open generator coil.
• Short-circuited or punctured regulator/rectifier.
Repair or replace or retighten.
Replace.
Replace.
9-14 SERVICING INFORMATION
GENERATOR DOES CHARGE, BUT CHARGING RATE IS BELOW THE SPECIFICATION
GENERATOR OVERCHARGES
UNSTABLE CHARGING
STARTER BUTTON IS NOT EFFECTIVE
Symptom, possible causes and remedy
• Lead wires tend to get short- or open-circuited or
loosely connected at terminals.
• Grounded or open-circuited generator coil.
• Defective regulator/rectifier.
• Defective cell plates in the battery.
Repair or retighten.
Replace.
Replace.
Replace the battery.
Symptom, possible causes and remedy
• Internal short-circuit in the battery.
• Damaged or defective resistor element in the
regulator/rectifier.
• Poorly grounded regulator/rectifier.
Replace the battery.
Replace.
Clean and tighten ground connection.
Symptom, possible causes and remedy
• Lead wire insulation frayed due to vibration,
resulting in intermittent short-circuiting.
• Internally short-circuited generator.
• Defective regulator/rectifier.
Repair or replace.
Replace.
Replace.
Symptom, possible causes and remedy
• Run down battery.
• Defective switch contacts.
• Brushes not seating properly on starter motor
commutator.
• Defective starter relay/starter interlock switch.
• Defective main fuse.
Repair or replace.
Replace.
Repair or replace.
Replace.
Replace.
SERVICING INFORMATION 9-15
BATTERY
“SULFATION”, ACIDIC WHITE POWDERY SUBSTANCE OR SPOTS ON SURFACE OF CELL PLATES
BATTERY RUNS DOWN QUICKLY
BATTERY “SULFATION”
Symptom, possible causes and remedy
• Cracked battery case.
• Battery has been left in a run-down condition for a
long time.
Replace the battery.
Replace the battery.
Symptom, possible causes and remedy
• Trouble in charging system.
• Cell plates have lost much of their active material
as a result of overcharging.
• Internal short-circuit in the battery.
• Too low battery voltage.
• Too old battery.
Check the generator, regulator/rectifier and circuit
connections and make necessary adjustments to
obtain specified charging operation.
Replace and correct the charging system.
Replace.
Recharge fully.
Replace.
Symptom, possible causes and remedy
• Incorrect charging rate.
(When not in use battery should be checked at
least once a month to avoid sulfation.)
• The battery was left unused in a cold climate for too
long.
Replace.
Replace if badly sulfated.
9-16 SERVICING INFORMATION
WIRE HARNESS, CABLE AND HOSE ROUTING
WIRE HARNESS ROUTING
*1
*2
Clamp
Wiring harness Clamp
Starter motor
Wiring harness
Clamp
Gear position switch
Wiring harness
Side-stand switch
Generator
1 IAT sensor lead wire
*1
Insert the protruded section each on the handlebar switch lead wire coupler, ignition switch lead
wire coupler and cooling fan motor lead wire coupler into the respective holes provided on the
frame.
2 HO2 sensor lead wire
3 Wiring harness
4 Throttle cable
5 Clutch cable
6 Handlebar switch left
*2
Route the wiring harness under the cowling fastener fitted section.7 Water hose
8 High-tension cord
9 Side-stand switch
SERVICING INFORMATION 9-17
*1
*3 *4
*5
*6
*2
1
Wiring harness No.2
*3
Triangle mark of each spark plug cap must be
brought to the exhaust side.
2 Magneto lead wire *4 Cut the clamp end.
3 Ignition coil No.2 *5 Do not slack the lead wire.
*1 Clamp the turn signal light read wire.
*6
Pass through the PAIR reed valve lead wire
between the frame and PAIR control solenoid
valve.*2
Pass through the license light read wire over the
seat lock cable.
9-18 SERVICING INFORMATION
HEATED OXYGEN SENSOR (HO2S) WIRE ROUTING (FOR E-02, 19)
*1
*2
1
HO2 sensor (For E-02, 19)
*1
Route the HO2 sensor lead wire along the fuel
tank drain hose.
2
HO2 sensor lead wire
*2
Pass through the HO2 sensor lead wire forward
the swingarm.
3 Wiring harness
SERVICING INFORMATION 9-19
ENGINE ELECTRICAL PARTS SET-UP
90 ˚
90 ˚
*1
*2
Bolt
Gear position
switch lead wire
Generator lead wire
Clamp
Starter motor lead wire
*1
Battery ground lead wire
Generator cover
A
Starter motor lead wire mounting
nut
*1
45 ° and less !
ITEM N·m kgf-m lb-ft
B
CKP sensor set bolt
*2
First tighten the starter motor
lower mounting bolt.
A 6.0 0.6 4.3
B 6.5 0.65 4.7
9-20 SERVICING INFORMATION
SPEED SENSOR LEAD WIRE ROUTING
20 mm
(0.79 in)
*1
*2
*3
20 mm
(0.79 in)
1 Speed sensor lead wire *1 Cut the clamp end.
2
Clamp
*2
Route speed sensor lead wire to come outside
the brake hose guide.
3
Brake hose
*3
Route speed sensor lead wire on inside of front
fork outer tube boss.
4 Speed sensor
SERVICING INFORMATION 9-21
THROTTLE CABLE ROUTING
1 Throttle cable No.1 4 Wiring harness
2 Throttle cable No.2 *1 Fit the cable boots securely.
3 Front brake hose
0 mm (0 in)
0 mm (0 in)
*1
9-22 SERVICING INFORMATION
CLUTCH CABLE ROUTING
\
B – B
*2
*1
*3 *4
C – C D – D E – E
B
B
C
C
E
E
D
D
1 Throttle cable (Pull) 7 Reserve tank bracket
2
Throttle cable (Return)
*1
Route left handle switch wiring harness in the
groove of radiator shroud.
3
Handle switch wiring harness
*2
Route left handle switch wiring harness to come
outside throttle and clutch cables.
4 Clutch cable *3 Route clutch cable inside the guide.
5 Throttle cable guide *4 Route clutch cable inside the guide.
6 Radiator shroud
SERVICING INFORMATION 9-23
THROTTLE BODY INSTALLATION/HOSE ROUTING
\
15 ˚ ~ 25 ˚
*4
*1
*2
*3
*5
*6
*6
VIEW A
*6
40 ˚ ~ 50 ˚
2 ~ 5 mm (0.08 ~ 0.20 in)
15 ˚ ~ 25 ˚
A
1 IAT sensor 9 Intake pipe clamp
2 Vacuum damper *1 To canister (For E-33)
3
Throttle body assembly
*2
Pass through the vacuum hose inside the PAIR
hose.
4 Air cleaner box *3 E-33 Only
5 Fuel pump assembly *4 HO2 sensor clamp (For E-02, 19)
6 ECT sensor *5 Matching mark (Yellow)
7 TP sensor *6 Matching mark (White)
8 Outlet tube clamp
9-24 SERVICING INFORMATION
COOLING SYSTEM HOSE ROUTING
\
*1
*6
*6
*3
*2
*7
*7
*4
*5
1 Clamp *3 Matching mark (Yellow)
2
Wiring harness
*4
Clamp the water drain hose and oil pressure
switch lead wire.
3
Oil pressure switch
*5
Fill the bearing with engine oil until engine oil
comes out from the hole of the be bearing housing.
4 Oil filter *6 Clamp bolt head must face upward.
*1 Clamp end must face downward. *7 Clamp bolt head must face downward.
*2 Matching mark (White)
SERVICING INFORMATION 9-25
\
*1
*2
*3
*4
*5
*1*6
*1
0 ~ 90 ˚
90 ˚
Marking position
Installation point
90 ˚90 ˚
1 Clamp *2 Matching mark (White)
2 Jiggle valve *3 Marking (Yellow)
3 Union *4 Clamp bolt head must face downward.
4 Radiator hose *5 Clamp bolt head must face left side.
*1
Marking
*6
Leave clearance between bulge of union and
clamp.
9-26 SERVICING INFORMATION
FRONT BRAKE HOSE ROUTING
\
Throttle cables
Stopper
21 ˚
21 ˚
Stopper
Brake hose guide
*4
*2
*1
*5
*3
*5
*1
Brake hose
clamp
Stopper
Stopper
*1
Stopper
21 ˚
Brake hose
42 ˚
*1
After the brake hose union has contacted the
stopper, tighten the union bolt.
*4
Assemble the brake hose firmly.
*2
After positioning the brake hose junction with the
stopper, tighten the bolt.
*5
Clamp the brake hose firmly.
*3
After positioning the clamp with the stopper,
tighten the clamp bolt.
SERVICING INFORMATION 9-27
REAR BRAKE HOSE ROUTING
\
UPPER
LOWER
35 ˚*1
*1
*3
*3
*2
*4
42 ˚
A – A
35 ˚
A
A
1 Frame *1 Clamp ends should face forward.
2 Stopper *2 White paint faces outside.
3
Brake hose
*3
After the brake hose union has contacted the
stopper, tighten the union bolt.
4
Brake hose guide
*4
Pass through the brake hose outside the seat
rail.
9-28 SERVICING INFORMATION
FUEL TANK DRAIN HOSE ROUTING
*1
*3
*2
*1
Route fuel tank drain hose so that its curve faces
forward.
*3
Make sure to position the clamp in the specified
direction.
*2
Route fuel tank drain hose to come inside (left
side) gear position sensor wiring harness.
SERVICING INFORMATION 9-29
FUEL TANK INSTALLATION
1 ~ 2 mm
(0.04 ~ 0.08 in)
27 mm
(1.06 in)
*1
1
Fuel tank center shield
*1
Align the front end of fuel tank center shield with
this position.
2 Fuel tank side cushion
9-30 SERVICING INFORMATION
PAIR (AIR SUPPLY) SYSTEM HOSE ROUTING
*1
1
Matching mark (White)
*1
Pass the PAIR hose between the cylinder head
cover and intake pipe.
2 Matching mark (Yellow)
SERVICING INFORMATION 9-31
SEAT LOCK CABLE ROUTING
HEAD LAMP SET-UP
1 Seat lock cable
VIEW OF LEFT
VIEW OF TOP
*1 *2
*3
*1
Adhere cushion along the ridge line of lens.
*3
Right and left cushions shall be attached symmetrically.
*2 Start to adhere cushion from the corner of lens.
9-32 SERVICING INFORMATION
ABSORBER HOSE ROUTING
BATTERY CUSHION INSTALLATION
1 Absorber hose 3 Rear fender (Front)
2 Clamp
*1
*1
FRONT
VIEW OF LEFT
12 Battery protector *1 Adhere battery protector at the upper end.
SERVICING INFORMATION 9-33
SIDE-STAND SET-UP
BRAKE PEDAL/FOOTREST SET-UP
!
ITEM N·m kgf-m lb-ft
A 40 4.0 29.0
B 50 5.0 36.0
C 100 10.0 72.5
1 Pin 3 Footrest
2 E-ring 4 Brake light switch
A – A
A
A
9-34 SERVICING INFORMATION
ENGINE CAP INSTALLATION
*1
VIEW OF RIGHT
VIEW OF LEFT
1
Engine cap
*1
Push the center of cap so as to thoroughly
remove looseness.
SERVICING INFORMATION 9-35
FOOTREST SET-UP
HANDLEBAR BALANCER INSTALLATION
NOTE:
After installing the RH balancer weight, check that throttle grip rotate smoothly by turning it.
!
ITEM N·m kgf-m lb-ft
A 5.5 0.55 4
9-36 SERVICING INFORMATION
SPECIAL TOOLS
09900-18710
Hexagon bit 12 mm
09900-20101
09900-20102
Vernier calipers
09900-20202
Micrometer
(25 – 50 mm)
09900-20204
Micrometer
(75 – 100 mm)
09900-20205
Micrometer
(0 – 25 mm)
09900-20508
Cylinder gauge set
09900-20602
Dial gauge
(1/1000 mm, 1 mm)
09900-20607
Dial gauge
(1/100 mm, 10 mm)
09900-20701
Magnetic stand
09900-20803
09900-20806
Thickness gauge
09900-20805
Tire depth gauge
09900-21304
V-block set (100 mm)
09900-22301
09900-22302
Plastigauge
09900-22403
Small bore gauge
(18 – 35 mm)
09900-25008
Multi circuit tester set
09900-25009
Needle pointed
probe set
09910-20116
Conrod holder
09913-10750
Adaptor
09913-13121
Vacuum balancer
gauge
09913-50121
Oil seal remover
SERVICING INFORMATION 9-37
09913-60221
Journal bearing
remover/installer
09913-70210
Bearing installer set
09915-40610
Oil filter wrench
09915-64512
Compression
gauge
09915-74511
Oil pressure gauge
set
09915-74521
Oil pressure gauge
hose
09915-74532
Oil pressure gauge
attachment
09915-77331
Meter
(for high pressure)
09916-10911
Valve lapper set
09916-14510
Valve lifter
09916-14521
Valve lifter
attachment
09916-21111
Valve seat cutter set
09916-20640
Solid pilot
(N-100-4.5)
09916-22430
Valve seat cutter head
(N-128)
09916-34542
Reamer handle
09916-33210
Valve guide reamer
(4.5 mm)
09916-34580
Valve guide
reamer (10.8 mm)
09916-43210
Valve guide
installer/remover
09916-53330
Attachment
09916-84511
Tweezers
9-38 SERVICING INFORMATION
09917-47011
Vacuum pump
gauge
09920-13120
Crankcase
separating tool
09920-53740
Clutch sleeve hub
holder
09921-20240
Bearing remover set
09924-84510
Bearing installer
set
09925-18011
Steering bearing
installer
09930-10121
Spark plug socket
wrench set
09930-11920
Torx bit JT40H
09930-11940
Bit holder
09930-11950
Torx wrench
09930-11960
Torx wrench
09930-30450
Rotor remover
09930-44530
Rotor holder
09930-82720
Mode select switch
09940-14911
Steering stem nut
wrench
09940-14940
Swingarm pivot thrust
adjuster socket wrench
09940-14960
Steering stem nut
wrench socket
09940-14990
Engine mounting thrust
adjuster socket wrench
09940-34520
“T” Handle
09940-34531
Attachment A
SERVICING INFORMATION 9-39
NOTE:
When order the special tool, please confirm whether it is available or not.
09940-40211
Fuel pressure
gauge adaptor
09940-40220
Fuel pressure gauge
hose attachment
09940-52861
Front fork oil seal
installer
09940-92720
Spring scale
09941-34513
Bearing/steering
race installer set
09941-54911
Bearing outer race
remover
09943-74111
Front fork oil level
gauge
09944-28320
Hexagon bit 19 mm
9-40 SERVICING INFORMATION
TIGHTENING TORQUE
ENGINE
ITEM N·m kgf-m lb-ft
Cylinder head cover bolt 14 1.4 10.0
Spark plug 11 1.1 8.0
Camshaft journal holder bolt 10 1.0 7.0
Cam chain tension adjuster cap bolt 8 0.8 5.7
Cam chain tension adjuster mounting bolt 10 1.0 7.0
Cylinder head bolt [M: 10] Initial 25 2.5 18.0
Final 42 4.2 30.5
Water drain bolt 13 1.3 9.5
Clutch sleeve hub nut 50 5.0 36.0
Clutch spring set bolt 10 1.0 7.0
Oil plate bolt 10 1.0 7.0
Oil pressure regulator 27 2.7 19.5
Oil strainer plate bolt 10 1.0 7.0
Primary drive gear bolt 70 7.0 50.5
Generator cover plug 10 1.0 7.0
Valve timing inspection plug 23 2.3 16.3
Generator rotor bolt 120 12.0 87
Starter clutch bolt 25 2.5 18.0
Generator stator set bolt 11 1.1 8.0
CKP sensor set bolt 6.5 0.65 4.7
Gearshift cam stopper bolt 10 1.0 7.0
Gearshift cam stopper plate bolt 13 1.3 9.5
Gearshift arm stopper bolt 19 1.9 13.5
Oil pressure switch 13 1.3 9.5
Crankcase bolt [M: 6] 11 1.1 8.0
[M: 8] 26 2.6 19.0
Generator cover bolt [M: 6] 10 1.0 7.0
Oil gallery plug [M: 8] 18 1.8 13.0
Oil drain plug 21 2.1 15.0
Piston cooling oil jet bolt 10 1.0 7.0
Conrod bearing cap bolt Initial 21 2.1 15.0
Final
After tightenig the bolts to the above torque,
tighten them 1/4 of a turn (90 °).
SERVICING INFORMATION 9-41
FI SYSTEM PARTS
ITEM N·m kgf-m lb-ft
Exhaust pipe bolt/nut 23 2.3 16.5
Muffler mounting bolt/nut 23 2.3 16.5
Oil pipe stopper screw 8 0.8 6.0
Engine sprocket nut 145 14.5 105
Engine mounting bolt/nut 55 5.5 40.0
Engine mounting nut [Center] 93 9.3 67.5
Engine mounting thrust adjuster 12 1.2 8.5
Engine mounting thrust adjuster lock-nut 45 4.5 32.5
Engine mounting bracket bolt 35 3.5 25.5
Engine mounting pinch bolt 25 2.5 18.0
Cooling fan thermo-switch 17 1.7 12.5
ECT sensor 19 1.9 13.5
Fuel pump mounting bolt 10 1.0 7.0
Fuel delivery pipe mounting screw 5.0 0.5 3.7
Cooling fan/horn mounting bolt 8 0.8 6.0
Thermostat case bolt 10 1.0 7.0
Oil cooler mounting bolt 10 1.0 7.0
Oil cooler hose union bolt 23 2.3 16.5
ITEM N·m kgf-m lb-ft
TP sensor mounting screw 3.5 0.35 2.5
STP sensor mounting screw 2.0 0.2 1.5
ECT sensor 19 1.9 13.5
IAT sensor 18 1.8 13.0
9-42 SERVICING INFORMATION
CHASSIS
ITEM N·m kgf-m lb-ft
Steering stem head nut 90 9.0 65.0
Steering stem lock-nut 80 8.0 58.0
Front fork upper clamp bolt 23 2.3 16.5
Front fork lower clamp bolt 23 2.3 16.5
Front fork cap bolt 23 2.3 16.5
Front fork cylinder bolt 20 2.0 14.5
Front axle 65 6.5 47.0
Front axle pinch bolt 23 2.3 16.5
Handlebar clamp bolt 23 2.3 16.5
Front brake master cylinder mounting bolt 10 1.0 7.0
Front brake caliper mounting bolt 39 3.9 28.0
Brake hose union bolt 23 2.3 16.5
Front caliper air bleeder valve 7.5 0.75 5.5
Rear caliper air bleeder valve 6 0.6 4.3
Brake disc bolt (Front and Rear) 23 2.3 16.5
Rear brake caliper mounting bolt 22 2.2 16.0
Rear brake caliper sliding pin 27 2.7 19.5
Rear brake pad mounting pin 17 1.7 12.5
Rear brake pad mounting pin plug 2.5 0.25 1.8
Rear brake master cylinder mounting bolt 10 1.0 7.0
Rear brake master cylinder rod lock-nut 18 1.8 13.0
Front footrest bracket mounting bolt 25 2.5 18.0
Swingarm pivot shaft 15 1.5 11.0
Swingarm pivot nut 100 10.0 72.5
Swingarm pivot lock-nut 90 9.0 65.0
Rear shock absorber mounting nut (Upper & Lower) 50 5.0 36.0
Cushion lever nut 78 7.8 56.5
Cushion rod nut 78 7.8 56.5
Rear axle nut 100 10.0 72.5
Rear sprocket nut 60 6.0 43.5
Seat rail mounting bolt 50 5.0 36.0
Side stand bracket mounting bolt 100 10.0 72.5
Side stand bolt 50 5.0 36.0
Side stand nut 40 4.0 29.0
SERVICING INFORMATION 9-43
TIGHTENING TORQUE CHART
For other nuts and bolts not listed in the preceding page, refer to this chart:
Bolt Diameter
A (mm)
Conventional or “4” marked bolt “7” marked bolt
N·m kgf-m lb-ft N·m kgf-m lb-ft
4 1.5 0.15 1.0 2.3 0.23 1.5
5 3 0.3 2.0 4.5 0.45 3.0
6 5.5 0.55 4.0 10 1.0 7.0
8 13 1.3 9.5 23 2.3 16.5
10 29 2.9 21.0 50 5.0 36.0
12 45 4.5 32.5 85 8.5 61.5
14 65 6.5 47.0 135 13.5 97.5
16 105 10.5 76.0 210 21.0 152.0
18 160 16.0 115.5 240 24.0 173.5
Conventional bolt “4” marked bolt “7” marked bolt
9-44 SERVICING INFORMATION
SERVICE DATA
VALVE + GUIDE Unit: mm (in)
ITEM STANDARD LIMIT
Valve diam.
IN.
31
(1.2)
----
EX.
25.5
(1.0)
----
Valve clearance (when cold)
IN.
0.10 – 0.20
(0.004 – 0.008)
----
EX.
0.20 – 0.30
(0.008 – 0.012)
----
Valve guide to valve stem
clearance
IN.
0.020 – 0.047
(0.0008 – 0.0019)
----
EX.
0.030 – 0.057
(0.0012 – 0.0022)
----
Valve guide I.D.
IN. & EX.
4.500 – 4.512
(0.1772 – 0.1776)
----
Valve stem O.D.
IN.
4.465 – 4.480
(0.1758 – 0.1764)
----
EX.
4.455 – 4.470
(0.1754 – 0.1760)
----
Valve stem deflection
IN. & EX. ----
0.35
(0.014)
Valve stem runout
IN. & EX. ----
0.05
(0.002)
Valve head thickness
IN. & EX. ----
0.5
(0.02)
Valve seat width
IN. & EX.
0.9 – 1.1
(0.035 – 0.043)
----
Valve head radial runout
IN. & EX. ----
0.03
(0.001)
Valve spring free length
(IN. & EX.)
INNER ----
36.8
(1.45)
OUTER ----
39.8
(1.57)
Valve spring tension
(IN. & EX.) INNER
4.2 – 4.8 kgf
(9.26 – 10.58 lbs)
at length 29.9 mm (1.18 in)
----
OUTER
17.0 – 19.6 kgf
(37.48 – 43.21 lbs)
at length 33.4 mm (1.31 in)
----
SERVICING INFORMATION 9-45
CAMSHAFT + CYLINDER HEAD Unit: mm (in)
ITEM STANDARD LIMIT
Cam height
IN.
35.48 – 35.53
(1.3968 – 1.3988)
35.18
(1.3850)
EX.
33.48 – 33.53
(1.3181 – 1.3201)
33.18
(1.3063)
Camshaft journal oil clearance
IN. & EX.
0.032 – 0.066
(0.0013 – 0.0026)
0.150
(0.0059)
Camshaft journal holder I.D.
IN. & EX.
22.012 – 22.025
(0.8666 – 0.8671)
----
Camshaft journal O.D.
IN. & EX.
21.959 – 21.980
(0.8645 – 0.8654)
----
Camshaft runout
IN. & EX. ----
0.10
(0.004)
Cam chain pin (at arrow “3”) 16th pin ---Cylinder head distortion
----
0.05
(0.002)
9-46 SERVICING INFORMATION
CYLINDER + PISTON + PISTON RING Unit: mm (in)
ITEM STANDARD LIMIT
Compression pressure
Compression pressure
difference ---Piston to cylinder clearance 0.055 – 0.065
(0.0022 – 0.0026)
0.120
(0.0047)
Cylinder bore 81.000 – 81.015
(3.1890 – 3.1896)
Nicks or
Scratches
Piston diam. 80.950 – 80.955
(3.1870 – 3.1872)
Measure at 20 mm (0.79 in) from the skirt end.
80.88
(3.184)
Cylinder distortion
----
0.05
(0.002)
Piston ring free end gap
1st Approx. 9.5 (0.37)
7.6
(0.30)
2nd Approx. 11 (0.43)
8.8
(0.35)
Piston ring end gap
1st
0.20 – 0.35
(0.008 – 0.014)
0.70
(0.028)
2nd
0.20 – 0.35
(0.008 – 0.0014)
0.70
(0.028)
Piston ring to groove clearance
1st ---0.180
(0.0071)
2nd ---0.150
(0.0059)
Piston ring groove width
1st
1.21 – 1.23
(0.0476 – 0.0484)
----
2nd
1.01 – 1.03
(0.0398 – 0.0406)
----
Oil
2.01 – 2.03
(0.0791 – 0.0799)
----
Piston ring thickness
1st
1.17 – 1.19
(0.0461 – 0.0469)
----
2nd
0.97 – 0.99
(0.0382 – 0.0390)
----
Piston pin bore 20.002 – 20.008
(0.7875 – 0.7877)
20.030
(0.7886)
Piston pin O.D. 19.992 – 20.000
(0.7871 – 0.7874)
19.98
(0.7866)
)(
1 300 – 1 700 kPa
13 – 17 kgf/cm²
185 – 242 psi )(
1 100 kPa
11 kgf/cm²
156 psi
)(
200 kPa
2 kgf/cm²
28 psi
SERVICING INFORMATION 9-47
CONROD + CRANKSHAFT Unit: mm (in)
OIL PUMP
CLUTCH Unit: mm (in)
ITEM STANDARD LIMIT
Conrod small end I.D. 20.010 – 20.018
(0.7878 – 0.7881)
20.040
(0.7890)
Conrod big end side clearance 0.170 – 0.320
(0.0067 – 0.0126)
0.5
(0.02)
Conrod big end width 20.95 – 21.00
(0.825 – 0.827)
----
Crank pin width 42.17 – 42.22
(1.660 – 1.662)
----
Conrod big end oil clearance 0.032 – 0.056
(0.0013 – 0.0022)
0.080
(0.0031)
Crank pin O.D. 37.976 – 38.000
(1.4951 – 1.4960)
----
Crankshaft journal oil clearance 0.002 – 0.029
(0.0001 – 0.0011)
0.080
(0.0031)
Crankshaft journal O.D. 41.985 – 42.000
(1.6529 – 1.6535)
----
Crankshaft runout
----
0.05
(0.002)
ITEM STANDARD LIMIT
Oil pressure (at 60 °C, 140 °F) Above 100 kPa (1.0 kgf/cm², 14 psi)
Below 400 kPa (4.0 kgf/cm², 57 psi)
at 3 000 r/min.
----
ITEM STANDARD LIMIT
Clutch cable play 10 – 15
(0.4 – 0.6)
----
Clutch release screw 1/4 turns back ---Drive plate thickness
No.1 & No.2
2.92 – 3.08
(0.115 – 0.121)
2.62
(0.103)
Drive plate claw width
No.1 & No.2
13.7 – 13.8
(0.539 – 0.543)
12.9
(0.507)
Driven plate distortion
----
0.10
(0.004)
Clutch spring free length 53.1
(2.09)
50.5
(1.99)
9-48 SERVICING INFORMATION
TRANSMISSION + DRIVE CHAIN Unit: mm (in) Except ratio
ITEM STANDARD LIMIT
Primary reduction ratio 2.088 (71/34) ---Final reduction ratio 3.133 (47/15) ---Gear ratios Low 2.461 (32/13) ---2nd 1.777 (32/18) ----
3rd 1.380 (29/21) ----
4th 1.125 (27/24) ----
5th 0.961 (25/26) ----
Top 0.851 (23/27) ----
Shift fork to groove clearance 0.1 – 0.3
(0.004 – 0.012)
0.50
(0.020)
Shift fork groove width 5.5 – 5.6
(0.217 – 0.220)
----
Shift fork thickness 5.3 – 5.4
(0.209 – 0.213)
----
Drive chain
Type DID525V8
----
----
Links 116 links ---20-pitch
length
----
319.4
(12.57)
Drive chain slack (on side-stand) 20 – 30
(0.79 – 1.18)
----
Gearshift lever height 25
(0.98)
----
SERVICING INFORMATION 9-49
THERMOSTAT + RADIATOR + FAN + COOLANT
INJECTOR + FUEL PUMP + FUEL PRESSURE REGULATOR
ITEM STANDARD NOTE
Thermostat valve opening
temperature
Approx. 88 °C (190 °F) ---Thermostat valve lift Over 8.0 mm (0.31 in) at 100 °C (212 °F) ---ECT sensor resistance 20 °C
(68 °F)
Approx. 2.45 kΩ ---40 °C
(104 °F)
Approx. 1.148 kΩ ---60 °C
(140 °F)
Approx. 0.587 kΩ ---80 °C
(176 °F)
Approx. 0.322 kΩ ---Radiator cap valve opening
pressure
95 – 125 kPa
(0.95 – 1.25 kgf/cm², 13.5 – 17.8 psi)
----
Cooling fan thermo-switch
operating temperature
OFF→ON Approx. 98 °C (208 °F) ---ON→OFF Approx. 92 °C (198 °F) ---Engine coolant type Use an antifreeze/coolant compatible with aluminum
radiator, mixed with distilled water only, at the ratio
of 50:50.
----
Engine coolant including reserve Reserve
tank side
Approx. 250 ml
(0.53/0.44 US/lmp qt)
----
Engine
side
Approx. 1650 ml
(3.49/2.90 US/lmp qt)
----
ITEM SPECIFICATION NOTE
Injector resistance 11 – 13 Ω at 20 °C (68 °F)
Fuel pump discharge amount MIN. 168 ml (5.7/5.9 US/lmp oz)
for 10 sec. at 300 kPa (3.0 kgf/cm², 43 psi)
Fuel pressure regulator operating
set pressure
Approx. 300 kPa (3.0 kgf/cm², 43 psi)
9-50 SERVICING INFORMATION
FI SENSORS+ SECONDARY THROTTLE VALVE ACTUATOR
THROTTLE BODY
ITEM SPECIFICATION NOTE
CKP sensor resistance 130 – 240 Ω W – G
CKP sensor peak voltage 3.7 V (When cranking) and more
IAP sensor input voltage 4.5 – 5.5 V
IAP sensor output voltage
Approx. 2.7 V at idle speed
+ G/B – -
B/Br
TP sensor input voltage 4.5 – 5.5 V
TP sensor resistance Closed Approx. 1.12 kΩ
Opened Approx. 4.26 kΩ
TP sensor output voltage Closed Approx. 1.12 V + P/W – B/BrOpened Approx. 4.26 V
ECT sensor input voltage 4.5 – 5.5 V
ECT sensor resistance Approx. 2.45 kΩ at 20 °C (68 °F)
IAT sensor input voltage 4.5 – 5.5 V
IAT sensor resistance Approx. 2.45 kΩ at 20 °C (68 °F)
TO sensor resistance 19.1 – 19.7 kΩ
TO sensor voltage Normal 0.4 – 1.4 V + Br/W – B/BrLeaning 65 ° 3.7 – 4.4 V
GP switch voltage 1.0 V and more (From 1st to Top)
Injector voltage Battery voltage
STP sensor input voltage 4.5 – 5.5 V
STP sensor resistance Closed Approx. 0.58 kΩ
Y – B
Opened Approx. 4.38 kΩ
STP sensor output voltage Closed Approx. 0.58 V + Y – B/BrOpened Approx. 4.40 V
STV actuator resistance 7 – 14 Ω
PAIR solenoid valve resistance 20 – 24 kΩ at 20 °C (68 °F)
ITEM SPECIFICATION
I.D. No. 27 G0 (Others), 27 G1 (For E-33)
Bore size 39 mm
Fast idle r/min. 1 800 – 2 400 r/min at 25 °C (77 °F)
Idle r/min. 1 300 ± 100 r/min/Warmed engine
Throttle cable play 2.0 – 4.0 mm
(0.08 – 0.16 in)
SERVICING INFORMATION 9-51
ELECTRICAL Unit: mm (in)
ITEM SPECIFICATION NOTE
Firing order 1.2
Spark plug
Type
NGK: CR8E
DENSO: U24ESR-N
Gap
0.7 – 0.8 mm
(0.028 – 0.031 in)
Spark performance Over 8 mm (0.3 in) at 1 atm.
CKP sensor resistance 130 – 240 Ω W – G
Ignition coil resistance
Primary 2 – 5 Ω
+ tap –
- tap
Secondary 24 – 37 kΩ
+ tap –
Plug cap
CKP sensor peak voltage
3.7 V and more
When
cranking
Ignition coil primary peak voltage 150 V and more
Generator coil resistance 0.2 – 0.7 Ω
Generator Max. output Approx. 375 W at 5 000 r/min
Generator no-load voltage
(When cold)
60 V (AC) and more at 5 000 r/min.
Regulated voltage 14.0 – 15.5 V at 5 000 r/min.
Starter relay resistance 3 – 6 Ω
Battery Type designation YTX12-BS
Capacity 12 V 36.0 kC (10 Ah)/10 HR
Fuse size
Headlight
HI 15 A
LO 15 A
Fuel 10 A
Ignition 10 A
Fan motor 15 A
Signal 15 A
Main 30 A
9-52 SERVICING INFORMATION
WATTAGE Unit: W
ITEM
SPECIFICATION
E-03, 24, 28, 33 Others
Headlight 12 V 60/55 W × 2 (H4) ←
Position/Parking light 12 V 5 W × 2
Brake light/Taillight 12 V 21/5 W × 2 ←
Turn signal light 12 V 21 W ←
License light 12 V 5 W ←
Speedometer light LED ←
Turn signal indicator light LED ←
High beam indicator light LED ←
Neutral indicator light LED ←
Oil pressure/Coolant temp./Fuel injection warning LED ←
SERVICING INFORMATION 9-53
BRAKE + WHEEL Unit: mm (in)
ITEM STANDARD LIMIT
Rear brake pedal height 15 – 25 (0.59 – 0.98) ---Brake disc thickness
Front
5
(0.20)
4.5
(0.18)
Rear
5
(0.20)
4.5
(0.18)
Brake disc runout
----
0.3
(0.012)
Master cylinder bore
Front
15.870 – 15.913
(0.6248 – 0.6265)
----
Rear
14.000 – 14.043
(0.5512 – 0.5529)
----
Master cylinder piston diam.
Front
15.827 – 15.854
(0.6231 – 0.6242)
----
Rear
13.957 – 13.984
(0.5495 – 0.5506)
----
Brake caliper cylinder bore
Front
30.230 – 30.306
(1.1902 – 1.1931)
----
Rear
38.180 – 38.256
(1.5031 – 1.5061)
----
Brake caliper piston diam.
Front
30.150 – 30.200
(1.1870 – 1.1890)
----
Rear
38.098 – 38.148
(1.4999 – 1.5019)
----
Brake fluid type DOT 4
Wheel rim runout
Axial ---2.0
(0.08)
Radial ---2.0
(0.08)
Wheel rim size Front 19 M/C × MT2.50 ---Rear 17 M/C × MT4.00 ---Wheel axle runout
Front ---0.25
(0.010)
Rear ---0.25
(0.010)
9-54 SERVICING INFORMATION
TIRE
SUSPENSION Unit: mm (in)
ITEM STD/SPEC. LIMIT
Cold inflation tire pressure
(Solo riding)
Front
225 kPa
(2.25 kgf/cm², 33 psi)
----
Rear
250 kPa
(2.50 kgf/cm², 36 psi)
----
Cold inflation tire pressure
(Dual riding)
Front
225 kPa
(2.25 kgf/cm², 33 psi)
----
Rear
280 kPa
(2.80 kgf/cm², 41 psi)
----
Tire size Front 110/80 R19 M/C (59 H) ---Rear 150/70 R17 M/C (69 H) ----
Tire type Front BRIDGESTONE: TW101 F ---Rear BRIDGESTONE: TW152 F ---Tire tread depth
Front ---1.6
(0.06)
Rear ---2.0
(0.08)
ITEM STD/SPEC. LIMIT
Front fork stroke 150
(5.9)
----
Front fork spring free length 444.1 (17.5) 435 (17.1)
Front fork oil level (without spring,
outer tube fully compressed)
143 (5.63) ----
Front fork spring adjuster 3 groove from Top/Spring adjuster height 9 mm
(0.35 in)
----
Front fork oil type SUZUKI FORK OIL SS-08
or equivalent fork oil
----
Front fork oil capacity (each leg) 524 ml
(17.7/18.5 US/Imp oz)
----
Rear shock absorber spring
adjuster
2 groove from bottom ---Rear shock absorber damping
force adjuster
Rebound
1 turn back from stiffest position E-02, 19, 24
1 1/2 turns back from stiffest position E-03, 28, 33
Rear wheel travel 150 mm
(5.9 in)
----
Swingarm pivot shaft runout
----
0.3
(0.01)
SERVICING INFORMATION 9-55
FUEL + OIL
ITEM STD/SPEC. NOTE
Fuel type Use only unleaded gasoline of at least 87 pump
octane ( ) or 91 octane or higher rated by the
research method.
Gasoline containing MTBE (Methyl Tertiary Butyl
Ether), less than 10 % ethanol, or less than 5 %
methanol with appropriate cosolvents and corrosion
inhibitor is permissible.
E-03, 28, 33
Gasoline used should be graded 91 octane or
higher. An unleaded gasoline is recommended.
Others
Fuel tank capacity 22 L (5.8/4.8 US/lmp gal)
Engine oil type SAE 10 W – 40, API SF or SG
Engine oil capacity
Change
2 300 ml
(2.4/2.0 US/lmp qt)
Filter change
2 700 ml
(2.9/2.4 US/lmp qt)
Overhaul
3 100 ml
(3.3/2.7 US/lmp qt)
2
R + M
10
EMISSION CONTROL INFORMATION 10-1
CONTENTS
EMISSION CONTROL INFORMATION
EMISSION CONTROL SYSTEMS ..............................................................10- 2
FUEL INJECTION SYSTEM .................................................................10- 2
CRANKCASE EMISSION CONTROL SYSTEM ..................................10- 3
EXHAUST EMISSION CONTROL SYSTEM (PAIR SYSTEM) ............10- 4
NOISE EMISSION CONTROL SYSTEM ..............................................10- 5
EVAPORATIVE EMISSION CONTROL SYSTEM (Only for E-33) .....10- 5
PAIR (AIR SUPPLY) SYSTEM INSPECTION ............................................10- 6
HOSES .................................................................................................10- 6
PAIR REED VALVE .............................................................................10- 6
PAIR CONTROL SOLENOID VALVE ..................................................10- 7
PAIR (AIR SUPPLY) SYSTEM HOSE ROUTING ................................10- 8
HEATED OXYGEN SENSOR (HO2S) WIRE ROUTING (E-02, 19) ....10- 8
EVAPORATIVE EMISSION CONTROL SYSTEM INSPECTION
(Only for E-33) ............................................................................................10-10
HOSES .................................................................................................10-10
EVAP CANISTER .................................................................................10-10
FUEL-SHUT OFF VALVE ....................................................................10-10
EVAP CANISTER HOSE ROUTING (Only for E-33) .................................10-11
10-2 EMISSION CONTROL INFORMATION
EMISSION CONTROL SYSTEMS
FUEL INJECTION SYSTEM
DL650 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.
1 Fuel filter (For high pressure) A BEFORE-PRESSURIZED FUEL
2 Fuel pressure regulator B PRESSURIZED FUEL
3 Fuel injector C RELIEVED FUEL
4 Fuel feed hose
5 Fuel mesh filter (For low pressure)
6 Fuel pump
EMISSION CONTROL INFORMATION 10-3
CRANKCASE EMISSION CONTROL SYSTEM
The engine is equipped with a PCV system. Blow-by gas in the engine is constantly drawn into the crankcase, which is returned to the combustion chamber through the breather hose, air cleaner and throttle body.
1 PAIR reed valve A FRESH AIR
2 Breather hose B FUEL/AIR MIXTURE
3 Air cleaner box C BLOW-BY GAS
4 PAIR control solenoid valve
10-4 EMISSION CONTROL INFORMATION
EXHAUST EMISSION CONTROL SYSTEM (PAIR SYSTEM)
The exhaust emission control system is composed of the PAIR system and THREE-WAY CATALYST system. (Except for E-03, -24 and-28) The fresh air is drawn into the exhaust port with the PAIR solenoid valve
and PAIR reed valve. The PAIR solenoid valve is operated by the ECM, and the fresh air flow is controlled
according to the TPS, ECTS, IATS and IAPS.
1 ECM 5 Injector
2 Air cleaner box 6 PAIR reed valve
3 PAIR control solenoid valve A FRESH AIR
4 PAIR reed valve B EXHAUST GAS
EMISSION CONTROL INFORMATION 10-5
NOISE EMISSION CONTROL SYSTEM
TAMPERING WITH THE NOISE CONTROL SYSTEM PROHIBITED: Federal 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. The use of the vehicle after such device or element of design has been removed or rendered inoperative
by any person.
AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW:
• Removing or puncturing the muffler, baffles, header pipes, screen type spark arrester (if equipped) or any
other component which conducts exhaust gases.
• Removing or puncturing the air cleaner case, air cleaner cover, baffles or any other component which
conducts intake air.
• Replacing the exhaust system or muffler with a system or muffler not marked with the same model specific code as the code listed on the Motorcycle Noise Emission Control Information label.
EVAPORATIVE EMISSION CONTROL SYSTEM (Only for E-33: K4, K5, K6)
1 IAP sensor 7 Surge hose
2 Vacuum damper 8 Fuel shut-off valve
3 Vacuum hose 9 EVAP canister
4 No.2 Throttle body A HC VAPOR
5 No.1 Throttle body B FRESH AIR
6 Purge hose C VACUUM
10-6 EMISSION CONTROL INFORMATION
(FOR E-33: K7)
PAIR (AIR SUPPLY) SYSTEM INSPECTION
HOSES
• Inspect the hoses for wear or damage.
• Inspect that the hoses are securely connected.
PAIR REED VALVE
• Remove the PAIR reed valve cover. ( 3-36)
• Inspect the reed valve for the carbon deposit.
• If the carbon deposit is found in the reed valve, replace the
PAIR reed valve with a new one
• Installation is in the reverse order of removal.
1 IAP sensor 7 Fuel shut-off valve
2 Vacuum hose 8 EVAP canister
3 No.2 Throttle body A HC VAPOR
4 No.1 Throttle body B FRESH AIR
5 Purge hose C VACUUM
6 Surge hose
EMISSION CONTROL INFORMATION 10-7
PAIR CONTROL SOLENOID VALVE
• Remove the air cleaner box. (!5-15)
• Remove the PAIR control solenoid valve
1.
• Check that air flows through the air inlet port to the air outlet
port.
• If air does not flow out, replace the PAIR control solenoid
valve with a new one.
• Connect the 12 V battery to the PAIR control solenoid valve
terminals and check the air flow.
• If air does not flow out, the solenoid valve is in normal condition.
• Check the resistance between the terminals of the PAIR control solenoid valve.
" Resistance: 20 – 24 Ω (at 20 °C/68 °F)
# 09900-25008: Multi circuit tester set
$ Tester knob indication: Resistance (Ω)
If the resistance is not within the standard range, replace the
PAIR control solenoid valve with a new one.
• Connect the PAIR control solenoid valve lead wire coupler
securely.
• Installation is in the reverse order of removal.
12 V
10-8 EMISSION CONTROL INFORMATION
PAIR (AIR SUPPLY) SYSTEM HOSE ROUTING
!9-30
HEATED OXYGEN SENSOR (HO2S) WIRE ROUTING (E-02, 19)
!9-18
EMISSION CONTROL INFORMATION 10-9
HEATED OXYGEN SENSOR (HO2S)
INSPECTION (E-02, 19)
• Remove the seat. (!7-4)
• Disconnect the HO2 sensor coupler.
• Remove the HO2 sensor unit.
%
&
• Inspect the HO2 sensor and its circuit referring to flow table of
the malfunction code (C44).
• Disconnect the HO2 sensor coupler.
• Check the resistance between the terminals (white – white) of
the HO2 sensor.
" Resistance: 4 – 5 Ω (at 23 °C/73.4 °F)
# 09900-25008: Multi circuit tester set
$ Tester knob indication: Resistance (Ω)
If the resistance is not within the standard range, replace the
HO2 sensor with a new one.
NOTE:
* Temperature of the sensor affects resistance value largely.
* Make sure that the sensor heater is at correct temperature.
• Connect the HO2 sensor coupler securely.
• Installation is in the reverse order of removal.
&
• Tighten the sensor unit to the specified torque.
' HO2 SENSOR: 47.5 N·m (4.75 kgf-m, 34.3 lb-ft)
• Route the HO2 sensor lead wire into the frame.
• Connect the HO2 sensor coupler.
Do not remove the HO2 sensor while it is hot.
Be careful not to expose it to excessive shock.
Do not use an impact wrench while removing or
installing the HO2 sensor unit.
Be careful not to twist or damage the sensor lead wire.
Do not apply oil or other materials to the sensor air
hole.
10-10 EMISSION CONTROL INFORMATION
EVAPORATIVE EMISSION CONTROL SYSTEM INSPECTION
(Only for E-33)
• Remove the frame cover. (!7-5)
• Lift and support the fuel tank with its prop stay. (!5-7)
HOSES
Inspect the hoses for wear or damage.
Make sure that the hoses are securely connected.
EVAP CANISTER
Inspect the canister for damage to the body.
FUEL-SHUT OFF VALVE
Inspect the fuel-shut off valve body for damage.
Inspect the fuel-shut off valve operation in the following procedure.
• Remove the fuel-shut off valve.
• When air is blown into the fuel-shut off valve with its side
A
positioned upward, the air can pass through to the canister
side.
• When air is blown into the fuel-shut off valve with its side A
positioned sideways, the air cannot pass through to the canister side.
• If the fuel-shut off valve operates otherwise, it must be
replaced.
%
Gasoline and gasoline vapor is toxic. A small amount
of fuel remains in the fuel-shut off valve when checking it.
Do not swallow the fuel when blowing the fuel-shut off
valve.
EMISSION CONTROL INFORMATION 10-11
EVAP CANISTER HOSE ROUTING (Only for E-33)
*6
*5
*3
*2
*4
*1
1 Purge hose *2 Clamp ends should face outside.
2 Wiring harness *3 White paint mark should face top side.
3
EVAP canister
*4
Pass through the purge hose between the frame
and wiring harness.
4 Frame *5 To throttle body.
*1 Clamp ends should face inside. *6 Clamp ends should face down side.
NOTE:
The specifications and service data are the same as K4-MODEL.
CONTENTS
DL650K5 ('05- MODEL)
DL650K5 ('05 MODEL)
11
11- 1
SERVICE DATA.......................................................................................11- 3
SPECIFICATIONS....................................................................................11- 2
EXHAUST PIPE/MUFFLER INSTALLATON...........................................11-15
STARTER BUTTON INSPECTION INFORMATION...............................11-15
DL650_K5_SB.fm Page 2 Wednesday, October 20, 2004 4:30 PMSPECIFICATIONS
DIMENSIONS AND DRY MASS
Overall length ...................................................................................... 2 290 mm (90.2 in)
Overall width........................................................................................ 840 mm (33.1 in)
Overall height ...................................................................................... 1 390 mm (54.7 in) ........... Low windshield position (STD)
1 420 mm (55.9 in) ........... Middle windshield position
1 450 mm (57.1 in) ........... High windshield position
Wheelbase .......................................................................................... 1 540 mm (60.6 in)
Ground clearance................................................................................ 165 mm (6.5 in)
Seat height. ......................................................................................... 820 mm (32.3 in)
Dry mass............................................................................................. 190 kg (418 lbs)
ENGINE
Type..................................................................................................... 4-stroke, liquid-cooled, DOHC, 90 ° -degree V-twin
Number of cylinders ............................................................................ 2
Bore..................................................................................................... 81.0 mm (3.189 in)
Stroke .................................................................................................. 62.6 mm (2.465 in)
Displacement ...................................................................................... 645 cm3 (39.4 cu. in)
Compression ratio ............................................................................... 11.5 : 1
Carburetion.......................................................................................... Fuel injection
Air cleaner ........................................................................................... Non-woven fabric element
Starter system..................................................................................... Electric
Lubrication system .............................................................................. Wet sump
Idle speed............................................................................................ 1 300 ± 100 r/min
DRIVE TRAIN
Clutch .................................................................................................. Wet multi-plate type
Transmission ....................................................................................... 6-speed constant mesh
Gearshift pattern ................................................................................. 1-down, 5-up
Primary reduction ratio ........................................................................ 2.088 (71/34)
Final reduction ratio............................................................................. 3.133 (47/15)
Gear ratios, Low .................................................................................. 2.461 (32/13)
2nd................................................................................... 1.777 (32/18)
3rd ................................................................................... 1.380 (29/21)
4th.................................................................................... 1.125 (27/24)
5th.................................................................................... 0.961 (25/26)
Top................................................................................... 0.851 (23/27)
Drive chain .......................................................................................... DID525V8, 116 links
CHASSIS
Front suspension................................................................................. Telescopic, coil spring, oil damped
Rear suspension ................................................................................. Link type, coil spring, oil damped
Front fork stroke .................................................................................. 150 mm (5.9 in)
Rear wheel travel................................................................................. 150 mm (5.9 in)
Caster.................................................................................................. 26 °
Trail...................................................................................................... 110 mm (4.33 in)
Steering angle ..................................................................................... 40 ° (right & left)
Turning radius...................................................................................... 2.6 m (8.5 ft)
Front brake .......................................................................................... Disc brake, twin
Rear brake........................................................................................... Disc brake
Front tire size....................................................................................... 110/80 R19 M/C 59H, tubeless
Rear tire size ....................................................................................... 150/70 R17 M/C 69H, tubeless
ELECTRICAL
Ignition type......................................................................................... Electronic ignition (Transistorized)
Ignition timing. ..................................................................................... 4 ° B.T.D.C. at 1 300 r/min
Spark plug ........................................................................................... NGK CR8E or DENSO U24ESR-N
Battery................................................................................................. 12 V 36.0 kC (10 Ah) /10 HR
Generator ............................................................................................ Three-phase A.C. generator
Main fuse............................................................................................. 30 A
Fuse .................................................................................................... 15/15/10/10/15/15 A
Headlight ............................................................................................. 12 V 60/55 W x 2 (H4)
Position/parking light ........................................................................... 12 V 5 W x 2 ......Except E-03, 24, 28, 33
Brake light/Taillight............................................................................... 12 V 21/5 W x 2
License plate light ............................................................................... 12 V 5 W
Turn signal light ................................................................................... 12 V 21 W
Speedometer light ............................................................................... LED
Turn signal indicator light..................................................................... LED
Neutral indicator light........................................................................... LED
High beam indicator light..................................................................... LED
Oil pressure/Coolant temperature/Fuel injection warning light............ LED
CAPACITIES
Fuel tank, including reserve ............................................................... 22 L (5.8/4.8 US/Imp gal)
Engine oil, oil change ......................................................................... 2 300 ml (2.4/2.0 US/Imp qt)
with filter change............................................................... 2 700 ml (2.9/2.4 US/Imp qt)
overhaul. ........................................................................... 3 100 ml (3.3/2.7 US/Imp qt)
Coolant................................................................................................ 1.9 L (2.0/1.7 US/Imp qt)
DL650K5 ('05 MODEL)11- 2– 2 –
DL650_K5_SB.fm Page 3 Wednesday, October 20, 2004 4:30 PMSERVICE DATA
4 STROKE
VALVE + GUIDE Unit: mm (in)
ITEM STANDARD LIMIT
Valve diam.
IN.
31
(1.2)
----
EX.
25.5
(1.0)
----
Valve clearance (when cold)
IN.
0.10 – 0.20
(0.004 – 0.008)
----
EX.
0.20 – 0.30
(0.008 – 0.012)
----
Valve guide to valve stem
clearance
IN.
0.020 – 0.047
(0.0008 – 0.0019)
----
EX.
0.030 – 0.057
(0.0012 – 0.0022)
----
Valve guide I.D.
IN. & EX.
4.500 – 4.512
(0.1772 – 0.1776)
----
Valve stem O.D.
IN.
4.465 – 4.480
(0.1758 – 0.1764)
----
EX.
4.455 – 4.470
(0.1754 – 0.1760)
----
Valve stem deflection
IN. & EX. ----
0.35
(0.014)
Valve stem runout
IN. & EX. ----
0.05
(0.002)
Valve head thickness
IN. & EX. ----
0.5
(0.02)
Valve seat width
IN. & EX.
0.9 – 1.1
(0.035 – 0.043)
----
Valve head radial runout
IN. & EX. ----
0.03
(0.001)
Valve spring free length
(IN. & EX.)
INNER ----
36.8
(1.45)
OUTER ----
39.8
(1.57)
Valve spring tension
(IN. & EX.) INNER
41 – 47 N (4.2 – 4.8 kgf)
(9.26 – 10.58 lbs)
at length 29.9 mm (1.18 in)
----
OUTER
166 – 192 N (17.0 – 19.6 kgf)
(37.48 – 43.21 lbs)
at length 33.4 mm (1.31 in)
----
DL650K5 ('05 MODEL) 11- 3– 3 –
DL650_K5_SB.fm Page 4 Wednesday, October 20, 2004 4:30 PMCAMSHAFT + CYLINDER HEAD Unit: mm (in)
ITEM STANDARD LIMIT
Cam height
IN.
35.48 – 35.53
(1.3968 – 1.3988)
35.18
(1.3850)
EX.
33.48 – 33.53
(1.3181 – 1.3201)
33.18
(1.3063)
Camshaft journal oil clearance
IN. & EX.
0.032 – 0.066
(0.0013 – 0.0026)
0.150
(0.0059)
Camshaft journal holder I.D.
IN. & EX.
22.012 – 22.025
(0.8666 – 0.8671)
----
Camshaft journal O.D.
IN. & EX.
21.959 – 21.980
(0.8645 – 0.8654)
----
Camshaft runout
IN. & EX. ----
0.10
(0.004)
Cam chain pin (at arrow “3”) 16th pin ---Cylinder head distortion
----
0.05
(0.002)
DL650K5 ('05 MODEL)11- 4– 4 –
DL650_K5_SB.fm Page 5 Wednesday, October 20, 2004 4:30 PMCYLINDER + PISTON + PISTON RING Unit: mm (in)
ITEM STANDARD LIMIT
Compression pressure
1 300 – 1 700 kPa
(13 – 17 kgf/cm², 185 – 242 psi)
1 100 kPa
(11 kgf/cm²,
156 psi)
Compression pressure
difference ---200 kPa
(2 kgf/cm²,
28 psi)
Piston to cylinder clearance 0.055 – 0.065
(0.0022 – 0.0026)
0.120
(0.0047)
Cylinder bore 81.000 – 81.015
(3.1890 – 3.1896)
Nicks or
Scratches
Piston diam. 80.950 – 80.955
(3.1870 – 3.1872)
Measure at 20 mm (0.79 in) from the skirt end.
80.88
(3.184)
Cylinder distortion
----
0.05
(0.002)
Piston ring free end gap
1st Approx. 9.5 (0.37)
7.6
(0.30)
2nd Approx. 11 (0.43)
8.8
(0.35)
Piston ring end gap
1st
0.20 – 0.35
(0.008 – 0.014)
0.70
(0.028)
2nd
0.20 – 0.35
(0.008 – 0.0014)
0.70
(0.028)
Piston ring to groove clearance
1st ---0.180
(0.0071)
2nd ---0.150
(0.0059)
Piston ring groove width
1st
1.21 – 1.23
(0.0476 – 0.0484)
----
2nd
1.01 – 1.03
(0.0398 – 0.0406)
----
Oil
2.01 – 2.03
(0.0791 – 0.0799)
----
Piston ring thickness
1st
1.17 – 1.19
(0.0461 – 0.0469)
----
2nd
0.97 – 0.99
(0.0382 – 0.0390)
----
Piston pin bore 20.002 – 20.008
(0.7875 – 0.7877)
20.030
(0.7886)
Piston pin O.D. 19.992 – 20.000
(0.7871 – 0.7874)
19.98
(0.7866)
DL650K5 ('05 MODEL) 11- 5– 5 –
DL650_K5_SB.fm Page 6 Wednesday, October 20, 2004 4:30 PMCONROD + CRANKSHAFT Unit: mm (in)
OIL PUMP
CLUTCH Unit: mm (in)
ITEM STANDARD LIMIT
Conrod small end I.D. 20.010 – 20.018
(0.7878 – 0.7881)
20.040
(0.7890)
Conrod big end side clearance 0.170 – 0.320
(0.0067 – 0.0126)
0.5
(0.02)
Conrod big end width 20.95 – 21.00
(0.825 – 0.827)
----
Crank pin width 42.17 – 42.22
(1.660 – 1.662)
----
Conrod big end oil clearance 0.032 – 0.056
(0.0013 – 0.0022)
0.080
(0.0031)
Crank pin O.D. 37.976 – 38.000
(1.4951 – 1.4960)
----
Crankshaft journal oil clearance 0.002 – 0.029
(0.0001 – 0.0011)
0.080
(0.0031)
Crankshaft journal O.D. 41.985 – 42.000
(1.6529 – 1.6535)
----
Crankshaft runout
----
0.05
(0.002)
ITEM STANDARD LIMIT
Oil pressure (at 60 °C, 140 °F) Above 100 kPa (1.0 kgf/cm², 14 psi)
Below 400 kPa (4.0 kgf/cm², 57 psi)
at 3 000 r/min.
----
ITEM STANDARD LIMIT
Clutch cable play 10 – 15
(0.4 – 0.6)
----
Clutch release screw 1/4 turns back ---Drive plate thickness
No.1 & No.2
2.92 – 3.08
(0.115 – 0.121)
2.62
(0.103)
Drive plate claw width
No.1 & No.2
13.7 – 13.8
(0.539 – 0.543)
12.9
(0.507)
Driven plate distortion
----
0.10
(0.004)
Clutch spring free length 53.1
(2.09)
50.5
(1.99)
DL650K5 ('05 MODEL)11- 6– 6 –
DL650_K5_SB.fm Page 7 Wednesday, October 20, 2004 4:30 PMTRANSMISSION + DRIVE CHAIN Unit: mm (in) Except ratio
ITEM STANDARD LIMIT
Primary reduction ratio 2.088 (71/34) ---Final reduction ratio 3.133 (47/15) ---Gear ratios Low 2.461 (32/13) ---2nd 1.777 (32/18) ----
3rd 1.380 (29/21) ----
4th 1.125 (27/24) ----
5th 0.961 (25/26) ----
Top 0.851 (23/27) ----
Shift fork to groove clearance 0.1 – 0.3
(0.004 – 0.012)
0.50
(0.020)
Shift fork groove width 5.5 – 5.6
(0.217 – 0.220)
----
Shift fork thickness 5.3 – 5.4
(0.209 – 0.213)
----
Drive chain
Type DID525V8
----
----
Links 116 links ---20-pitch
length
----
319.4
(12.57)
Drive chain slack (on side-stand) 20 – 30
(0.79 – 1.18)
----
Gearshift lever height 25
(0.98)
----
DL650K5 ('05 MODEL) 11- 7– 7 –
DL650_K5_SB.fm Page 8 Wednesday, October 20, 2004 4:30 PMTHERMOSTAT + RADIATOR + FAN + COOLANT
INJECTOR + FUEL PUMP + FUEL PRESSURE REGULATOR
ITEM STANDARD NOTE
Thermostat valve opening
temperature
Approx. 88 °C (190 °F) ---Thermostat valve lift Over 8.0 mm (0.31 in) at 100 °C (212 °F) ---ECT sensor resistance 20 °C
(68 °F)
Approx. 2.45 kΩ ---40 °C
(104 °F)
Approx. 1.148 kΩ ---60 °C
(140 °F)
Approx. 0.587 kΩ ---80 °C
(176 °F)
Approx. 0.322 kΩ ---Radiator cap valve opening
pressure
95 – 125 kPa
(0.95 – 1.25 kgf/cm², 13.5 – 17.8 psi)
----
Cooling fan thermo-switch
operating temperature
OFF→ON Approx. 98 °C (208 °F) ---ON→OFF Approx. 92 °C (198 °F) ---Engine coolant type Use an antifreeze/coolant compatible with aluminum
radiator, mixed with distilled water only, at the ratio
of 50:50.
----
Engine coolant including reserve Reserve
tank side
Approx. 250 ml
(0.53/0.44 US/lmp qt)
----
Engine
side
Approx. 1650 ml
(3.49/2.90 US/lmp qt)
----
ITEM SPECIFICATION NOTE
Injector resistance 11 – 13 Ω at 20 °C (68 °F)
Fuel pump discharge amount MIN. 168 ml (5.7/5.9 US/lmp oz)
for 10 sec. at 300 kPa (3.0 kgf/cm², 43 psi)
Fuel pressure regulator operating
set pressure
Approx. 300 kPa (3.0 kgf/cm², 43 psi)
DL650K5 ('05 MODEL)11- 8– 8 –
DL650_K5_SB.fm Page 9 Wednesday, October 20, 2004 4:30 PMFI SENSORS+ SECONDARY THROTTLE VALVE ACTUATOR
THROTTLE BODY
ITEM SPECIFICATION NOTE
CKP sensor resistance 130 – 240 Ω W – G
CKP sensor peak voltage 3.7 V (When cranking) and more
IAP sensor input voltage 4.5 – 5.5 V
IAP sensor output voltage
Approx. 2.7 V at idle speed
+ G/B – -
B/Br
TP sensor input voltage 4.5 – 5.5 V
TP sensor resistance Closed Approx. 1.12 kΩ
Opened Approx. 4.26 kΩ
TP sensor output voltage Closed Approx. 1.12 V + P/W – B/BrOpened Approx. 4.26 V
ECT sensor input voltage 4.5 – 5.5 V
ECT sensor resistance Approx. 2.45 kΩ at 20 °C (68 °F)
IAT sensor input voltage 4.5 – 5.5 V
IAT sensor resistance Approx. 2.45 kΩ at 20 °C (68 °F)
TO sensor resistance 19.1 – 19.7 kΩ
TO sensor voltage Normal 0.4 – 1.4 V + Br/W – B/BrLeaning 65 ° 3.7 – 4.4 V
GP switch voltage 1.0 V and more (From 1st to Top)
Injector voltage Battery voltage
STP sensor input voltage 4.5 – 5.5 V
STP sensor resistance Closed Approx. 0.58 kΩ
Y – B
Opened Approx. 4.38 kΩ
STP sensor output voltage Closed Approx. 0.58 V + Y – B/BrOpened Approx. 4.40 V
STV actuator resistance 7 – 14 Ω
PAIR solenoid valve resistance 20 – 24 kΩ at 20 °C (68 °F)
ITEM SPECIFICATION
I.D. No. 27 G0 (Others), 27 G1 (For E-33)
Bore size 39 mm
Fast idle r/min. 1 800 – 2 400 r/min at 25 °C (77 °F)
Idle r/min. 1 300 ± 100 r/min/Warmed engine
Throttle cable play 2.0 – 4.0 mm
(0.08 – 0.16 in)
DL650K5 ('05 MODEL) 11- 9– 9 –
DL650_K5_SB.fm Page 10 Wednesday, October 20, 2004 4:30 PMELECTRICAL Unit: mm (in)
ITEM SPECIFICATION NOTE
Firing order 1.2
Spark plug
Type
NGK: CR8E
DENSO: U24ESR-N
Gap
0.7 – 0.8 mm
(0.028 – 0.031 in)
Spark performance Over 8 mm (0.3 in) at 1 atm.
CKP sensor resistance 130 – 240 Ω W – G
Ignition coil resistance
Primary 2 – 5 Ω
+ tap –
- tap
Secondary 24 – 37 kΩ
+ tap –
Plug cap
CKP sensor peak voltage
3.7 V and more
When
cranking
Ignition coil primary peak voltage 150 V and more
Generator coil resistance 0.2 – 0.7 Ω
Generator Max. output Approx. 375 W at 5 000 r/min
Generator no-load voltage
(When cold)
60 V (AC) and more at 5 000 r/min.
Regulated voltage 14.0 – 15.5 V at 5 000 r/min.
Starter relay resistance 3 – 6 Ω
Battery Type designation YTX12-BS
Capacity 12 V 36.0 kC (10 Ah)/10 HR
Fuse size
Headlight
HI 15 A
LO 15 A
Fuel 10 A
Ignition 10 A
Fan motor 15 A
Signal 15 A
Main 30 A
DL650K5 ('05 MODEL)11-10– 10 –
DL650_K5_SB.fm Page 11 Wednesday, October 20, 2004 4:30 PMWATTAGE Unit: W
ITEM
SPECIFICATION
E-03, 24, 28, 33 Others
Headlight 12 V 60/55 W × 2 (H4) ←
Position/Parking light 12 V 5 W × 2
Brake light/Taillight 12 V 21/5 W × 2 ←
Turn signal light 12 V 21 W ←
License light 12 V 5 W ←
Speedometer light LED ←
Turn signal indicator light LED ←
High beam indicator light LED ←
Neutral indicator light LED ←
Oil pressure/Coolant temp./Fuel injection warning LED ←
DL650K5 ('05 MODEL) 11-11– 11 –
DL650_K5_SB.fm Page 12 Wednesday, October 20, 2004 4:30 PMBRAKE + WHEEL Unit: mm (in)
ITEM STANDARD LIMIT
Rear brake pedal height 15 – 25 (0.59 – 0.98) ---Brake disc thickness
Front
5
(0.20)
4.5
(0.18)
Rear
5
(0.20)
4.5
(0.18)
Brake disc runout
----
0.3
(0.012)
Master cylinder bore
Front
15.870 – 15.913
(0.6248 – 0.6265)
----
Rear
14.000 – 14.043
(0.5512 – 0.5529)
----
Master cylinder piston diam.
Front
15.827 – 15.854
(0.6231 – 0.6242)
----
Rear
13.957 – 13.984
(0.5495 – 0.5506)
----
Brake caliper cylinder bore
Front
30.230 – 30.306
(1.1902 – 1.1931)
----
Rear
38.180 – 38.256
(1.5031 – 1.5061)
----
Brake caliper piston diam.
Front
30.150 – 30.200
(1.1870 – 1.1890)
----
Rear
38.098 – 38.148
(1.4999 – 1.5019)
----
Brake fluid type DOT 4
Wheel rim runout
Axial ---2.0
(0.08)
Radial ---2.0
(0.08)
Wheel rim size Front 19 M/C × MT2.50 ---Rear 17 M/C × MT4.00 ---Wheel axle runout
Front ---0.25
(0.010)
Rear ---0.25
(0.010)
DL650K5 ('05 MODEL)11-12– 12 –
DL650_K5_SB.fm Page 13 Wednesday, October 20, 2004 4:30 PMTIRE
SUSPENSION Unit: mm (in)
ITEM STD/SPEC. LIMIT
Cold inflation tire pressure
(Solo riding)
Front
225 kPa
(2.25 kgf/cm², 33 psi)
----
Rear
250 kPa
(2.50 kgf/cm², 36 psi)
----
Cold inflation tire pressure
(Dual riding)
Front
225 kPa
(2.25 kgf/cm², 33 psi)
----
Rear
280 kPa
(2.80 kgf/cm², 41 psi)
----
Tire size Front 110/80 R19 M/C (59 H) ---Rear 150/70 R17 M/C (69 H) ----
Tire type Front BRIDGESTONE: TW101 F ---Rear BRIDGESTONE: TW152 F ---Tire tread depth
Front ---1.6
(0.06)
Rear ---2.0
(0.08)
ITEM STD/SPEC. LIMIT
Front fork stroke 150
(5.9)
----
Front fork spring free length 444.1 (17.5) 435 (17.1)
Front fork oil level (without spring,
outer tube fully compressed)
143 (5.63) ----
Front fork spring adjuster 3 groove from Top/Spring adjuster height 9 mm
(0.35 in)
----
Front fork oil type SUZUKI FORK OIL SS-08
or equivalent fork oil
----
Front fork oil capacity (each leg) 524 ml
(17.7/18.5 US/Imp oz)
----
Rear shock absorber spring
adjuster
2 groove from bottom ---Rear shock absorber damping
force adjuster
Rebound
1 turn back from stiffest position E-02, 19, 24
1 1/2 turns back from stiffest position E-03, 28, 33
Rear wheel travel 150 mm
(5.9 in)
----
Swingarm pivot shaft runout
----
0.3
(0.01)
DL650K5 ('05 MODEL) 11-13– 13 –
DL650_K5_SB.fm Page 14 Wednesday, October 20, 2004 4:30 PMFUEL + OIL
ITEM STD/SPEC. NOTE
Fuel type Use only unleaded gasoline of at least 87 pump
octane (R/2 + M/2) or 91 octane or higher rated by
the research method.
Gasoline containing MTBE (Methyl Tertiary Butyl
Ether), less than 10 % ethanol, or less than 5 %
methanol with appropriate cosolvents and corrosion
inhibitor is permissible.
E-03, 28, 33
Gasoline used should be graded 91 octane or
higher. An unleaded gasoline is recommended.
Others
Fuel tank capacity 22 L (5.8/4.8 US/lmp gal)
Engine oil type SAE 10 W – 40, API SF or SG
Engine oil capacity
Change
2 300 ml
(2.4/2.0 US/lmp qt)
Filter change
2 700 ml
(2.9/2.4 US/lmp qt)
Overhaul
3 100 ml
(3.3/2.7 US/lmp qt)
DL650K5 ('05 MODEL)11-14– 14 –
DL650_K5_SB.fm Page 15 Wednesday, October 20, 2004 4:30 PMEXHAUST PIPE/MUFFLER INSTALLATION
!
STARTER BUTTON INSPECTION INFORMATION
Inspect switch for continuity with a tester.
If any abnormality is found, replace the respective switch
assembies with new ones.
WIRE COLOR
O/R: Orange with Red tracer
O/W: Orange with White tracer
Y/G: Yellow with Black tracer
Y/W: Yellow with White tracer
Apply PARMATEX 1372
Apply PARMATEX 1372
ITEM N·m kgf-m lb-ft
ABCD 23 2.3 16.5
PUSH
Position
Color
FREE
O/W Y/G O/R Y/W
DL650K5 ('05 MODEL) 11-15– 15 –
03 ENGINE.book Page 105 Tuesday, February 28, 2006 3:03 PM
NOTE:
Asterisk mark (*) indicates the new K6-model service data..
K5 ('05 MODEL).
NOTE:
Ø Any differences between DL650K5 ('05 MODEL) and DL650K6 ('06 MODEL) in
specifications and service data are clearly indicated with the asterisk marks (*).
Ø
CONTENTS
DL650K6 ('06- MODEL)
DL650K6 ('06 MODEL)
12
12- 1
EMISSION CONTROL SYSTEM..............................................................12-15
SPECIFICATIONS....................................................................................12 - 2
SERVICE DATA.......................................................................................12 - 3
This chapter describes service data , servicing procedures which differ from those of the DL650Please refer to chapter 1 trough 11 for details which are not given in this chapter.
SPECIFICATIONS
DIMENSIONS AND DRY MASS
Overall length ...................................................................................... 2 290 mm (90.2 in)
Overall width ....................................................................................... 840 mm (33.1 in)
Overall height ...................................................................................... 1 390 mm (54.7 in) ........... Low windshield position (STD)
1 420 mm (55.9 in) ........... Middle windshield position
1 450 mm (57.1 in) ........... High windshield position
Wheelbase .......................................................................................... 1 540 mm (60.6 in)
Ground clearance................................................................................ 165 mm (6.5 in)
Seat height. ......................................................................................... 820 mm (32.3 in)
Dry mass ............................................................................................. 190 kg (418 lbs)
ENGINE
Type .................................................................................................... 4-stroke, liquid-cooled, DOHC, 90 ° -degree V-twin
Number of cylinders ............................................................................ 2
Bore..................................................................................................... 81.0 mm (3.189 in)
Stroke.................................................................................................. 62.6 mm (2.465 in)
Displacement ...................................................................................... 645 cm3 (39.4 cu. in)
Compression ratio ............................................................................... 11.5 : 1
Carburetion. ........................................................................................ Fuel injection
Air cleaner ........................................................................................... Non-woven fabric element
Starter system ..................................................................................... Electric
Lubrication system .............................................................................. Wet sump
Idle speed............................................................................................ 1 300 ± 100 r/min
DRIVE TRAIN
Clutch .................................................................................................. Wet multi-plate type
Transmission....................................................................................... 6-speed constant mesh
Gearshift pattern ................................................................................. 1-down, 5-up
Primary reduction ratio ........................................................................ 2.088 (71/34)
Final reduction ratio............................................................................. 3.133 (47/15)
Gear ratios, Low.................................................................................. 2.461 (32/13)
2nd................................................................................... 1.777 (32/18)
3rd ................................................................................... 1.380 (29/21)
4th.................................................................................... 1.125 (27/24)
5th.................................................................................... 0.961 (25/26)
Top .................................................................................. 0.851 (23/27)
Drive chain .......................................................................................... DID525V8, 116 links
CHASSIS
Front suspension................................................................................. Telescopic, coil spring, oil damped
Rear suspension ................................................................................. Link type, coil spring, oil damped
Front fork stroke .................................................................................. 150 mm (5.9 in)
Rear wheel travel. ............................................................................... 150 mm (5.9 in)
Caster.................................................................................................. 26 °
Trail ..................................................................................................... 110 mm (4.33 in)
Steering angle ..................................................................................... 40 ° (right & left)
Turning radius ..................................................................................... 2.6 m (8.5 ft)
Front brake.......................................................................................... Disc brake, twin
Rear brake .......................................................................................... Disc brake
Front tire size ...................................................................................... 110/80 R19 M/C 59H, tubeless
Rear tire size ....................................................................................... 150/70 R17 M/C 69H, tubeless
ELECTRICAL
Ignition type......................................................................................... Electronic ignition (Transistorized)
Ignition timing. ..................................................................................... 4 ° B.T.D.C. at 1 300 r/min
Spark plug ........................................................................................... NGK CR8E or DENSO U24ESR-N
Battery................................................................................................. 12 V 36.0 kC (10 Ah) /10 HR
Generator ............................................................................................ Three-phase A.C. generator
Main fuse............................................................................................. 30 A
Fuse .................................................................................................... 15/15/10/10/15/15 A
Headlight ............................................................................................. 12 V 60/55 W x 2 (H4)
Position/parking light ........................................................................... 12 V 5 W x 2 ......Except E-03, 24, 28, 33
Brake light/Taillight .............................................................................. 12 V 21/5 W x 2
License plate light ............................................................................... 12 V 5 W
Turn signal light................................................................................... 12 V 21 W
Speedometer light ............................................................................... LED
Tachometer light ................................................................................. LED
Turn signal indicator light .................................................................... LED
Neutral indicator light .......................................................................... LED
High beam indicator light..................................................................... LED
Oil pressure/Coolant temperature/Fuel injection warning light............ LED
CAPACITIES
Fuel tank, including reserve ............................................................... 22 L (5.8/4.8 US/Imp gal)
Engine oil, oil change ......................................................................... 2 300 ml (2.4/2.0 US/Imp qt)
with filter change............................................................... 2 700 ml (2.9/2.4 US/Imp qt)
overhaul. ........................................................................... 3 100 ml (3.3/2.7 US/Imp qt)
Coolant................................................................................................ 1.9 L (2.0/1.7 US/Imp qt)
DL650K6 ('06 MODEL)12- 2– 2 –
SERVICE DATA
4 STROKE
VALVE + GUIDE Unit: mm (in)
ITEM STANDARD LIMIT
Valve diam.
IN.
31
(1.2)
----
EX.
25.5
(1.0)
----
Valve clearance (when cold)
IN.
0.10 – 0.20
(0.004 – 0.008)
----
EX.
0.20 – 0.30
(0.008 – 0.012)
----
Valve guide to valve stem
clearance
IN.
0.020 – 0.047
(0.0008 – 0.0019)
----
EX.
0.030 – 0.057
(0.0012 – 0.0022)
----
Valve guide I.D.
IN. & EX.
4.500 – 4.512
(0.1772 – 0.1776)
----
Valve stem O.D.
IN.
4.465 – 4.480
(0.1758 – 0.1764)
----
EX.
4.455 – 4.470
(0.1754 – 0.1760)
----
Valve stem deflection
IN. & EX. ----
0.35
(0.014)
Valve stem runout
IN. & EX. ----
0.05
(0.002)
Valve head thickness
IN. & EX. ----
0.5
(0.02)
Valve seat width
IN. & EX.
0.9 – 1.1
(0.035 – 0.043)
----
Valve head radial runout
IN. & EX. ----
0.03
(0.001)
Valve spring free length
(IN. & EX.)
INNER ----
36.8
(1.45)
OUTER ----
39.8
(1.57)
Valve spring tension
(IN. & EX.) INNER
41 – 47 N (4.2 – 4.8 kgf)
(9.26 – 10.58 lbs)
at length 29.9 mm (1.18 in)
----
OUTER
166 – 192 N (17.0 – 19.6 kgf)
(37.48 – 43.21 lbs)
at length 33.4 mm (1.31 in)
----
DL650K6 ('06 MODEL) 12- 3– 3 –
CAMSHAFT + CYLINDER HEAD Unit: mm (in)
ITEM STANDARD LIMIT
Cam height
IN.
35.48 – 35.53
(1.3968 – 1.3988)
35.18
(1.3850)
EX.
33.48 – 33.53
(1.3181 – 1.3201)
33.18
(1.3063)
Camshaft journal oil clearance
IN. & EX.
0.032 – 0.066
(0.0013 – 0.0026)
0.150
(0.0059)
Camshaft journal holder I.D.
IN. & EX.
22.012 – 22.025
(0.8666 – 0.8671)
----
Camshaft journal O.D.
IN. & EX.
21.959 – 21.980
(0.8645 – 0.8654)
----
Camshaft runout
IN. & EX. ----
0.10
(0.004)
Cam chain pin (at arrow “3”) 16th pin ---Cylinder head distortion
----
0.05
(0.002)
DL650K6 ('06 MODEL)12- 4– 4 –
CYLINDER + PISTON + PISTON RING Unit: mm (in)
ITEM STANDARD LIMIT
Compression pressure
1 300 – 1 700 kPa
(13 – 17 kgf/cm², 185 – 242 psi)
1 100 kPa
(11 kgf/cm²,
156 psi)
Compression pressure
difference ---200 kPa
(2 kgf/cm²,
28 psi)
Piston to cylinder clearance 0.055 – 0.065
(0.0022 – 0.0026)
0.120
(0.0047)
Cylinder bore 81.000 – 81.015
(3.1890 – 3.1896)
Nicks or
Scratches
Piston diam. 80.950 – 80.955
(3.1870 – 3.1872)
Measure at 20 mm (0.79 in) from the skirt end.
80.88
(3.184)
Cylinder distortion
----
0.05
(0.002)
Piston ring free end gap
1st Approx. 9.5 (0.37)
7.6
(0.30)
2nd Approx. 11 (0.43)
8.8
(0.35)
Piston ring end gap
1st
0.20 – 0.35
(0.008 – 0.014)
0.70
(0.028)
2nd
0.20 – 0.35
(0.008 – 0.0014)
0.70
(0.028)
Piston ring to groove clearance
1st ---0.180
(0.0071)
2nd ---0.150
(0.0059)
Piston ring groove width
1st
1.21 – 1.23
(0.0476 – 0.0484)
----
2nd
1.01 – 1.03
(0.0398 – 0.0406)
----
Oil
2.01 – 2.03
(0.0791 – 0.0799)
----
Piston ring thickness
1st
1.17 – 1.19
(0.0461 – 0.0469)
----
2nd
0.97 – 0.99
(0.0382 – 0.0390)
----
Piston pin bore 20.002 – 20.008
(0.7875 – 0.7877)
20.030
(0.7886)
Piston pin O.D. 19.992 – 20.000
(0.7871 – 0.7874)
19.98
(0.7866)
DL650K6 ('06 MODEL) 12- 5– 5 –
CONROD + CRANKSHAFT Unit: mm (in)
OIL PUMP
CLUTCH Unit: mm (in)
ITEM STANDARD LIMIT
Conrod small end I.D. 20.010 – 20.018
(0.7878 – 0.7881)
20.040
(0.7890)
Conrod big end side clearance 0.170 – 0.320
(0.0067 – 0.0126)
0.5
(0.02)
Conrod big end width 20.95 – 21.00
(0.825 – 0.827)
----
Crank pin width 42.17 – 42.22
(1.660 – 1.662)
----
Conrod big end oil clearance 0.032 – 0.056
(0.0013 – 0.0022)
0.080
(0.0031)
Crank pin O.D. 37.976 – 38.000
(1.4951 – 1.4960)
----
Crankshaft journal oil clearance 0.002 – 0.029
(0.0001 – 0.0011)
0.080
(0.0031)
Crankshaft journal O.D. 41.985 – 42.000
(1.6529 – 1.6535)
----
Crankshaft runout
----
0.05
(0.002)
ITEM STANDARD LIMIT
Oil pressure (at 60 °C, 140 °F) Above 100 kPa (1.0 kgf/cm², 14 psi)
Below 400 kPa (4.0 kgf/cm², 57 psi)
at 3 000 r/min.
----
ITEM STANDARD LIMIT
Clutch cable play 10 – 15
(0.4 – 0.6)
----
Clutch release screw 1/4 turns back ---Drive plate thickness
No.1 & No.2
2.92 – 3.08
(0.115 – 0.121)
2.62
(0.103)
Drive plate claw width
No.1 & No.2
13.7 – 13.8
(0.539 – 0.543)
12.9
(0.507)
Driven plate distortion
----
0.10
(0.004)
Clutch spring free length 53.1
(2.09)
50.5
(1.99)
DL650K6 ('06 MODEL)12- 6– 6 –
TRANSMISSION + DRIVE CHAIN Unit: mm (in) Except ratio
ITEM STANDARD LIMIT
Primary reduction ratio 2.088 (71/34) ---Final reduction ratio 3.133 (47/15) ---Gear ratios Low 2.461 (32/13) ---2nd 1.777 (32/18) ----
3rd 1.380 (29/21) ----
4th 1.125 (27/24) ----
5th 0.961 (25/26) ----
Top 0.851 (23/27) ----
Shift fork to groove clearance 0.1 – 0.3
(0.004 – 0.012)
0.50
(0.020)
Shift fork groove width 5.5 – 5.6
(0.217 – 0.220)
----
Shift fork thickness 5.3 – 5.4
(0.209 – 0.213)
----
Drive chain
Type DID525V8
----
----
Links 116 links ---20-pitch
length
----
319.4
(12.57)
Drive chain slack (on side-stand) 20 – 30
(0.79 – 1.18)
----
Gearshift lever height 25
(0.98)
----
DL650K6 ('06 MODEL) 12- 7– 7 –
THERMOSTAT + RADIATOR + FAN + COOLANT
INJECTOR + FUEL PUMP + FUEL PRESSURE REGULATOR
ITEM STANDARD NOTE
Thermostat valve opening
temperature
Approx. 88 °C (190 °F) ---Thermostat valve lift Over 8.0 mm (0.31 in) at 100 °C (212 °F) ---ECT sensor resistance 20 °C
(68 °F)
Approx. 2.45 kΩ ---40 °C
(104 °F)
Approx. 1.148 kΩ ---60 °C
(140 °F)
Approx. 0.587 kΩ ---80 °C
(176 °F)
Approx. 0.322 kΩ ---Radiator cap valve opening
pressure
95 – 125 kPa
(0.95 – 1.25 kgf/cm², 13.5 – 17.8 psi)
----
Cooling fan thermo-switch
operating temperature
OFF→ON Approx. 98 °C (208 °F) ---ON→OFF Approx. 92 °C (198 °F) ---Engine coolant type Use an antifreeze/coolant compatible with aluminum
radiator, mixed with distilled water only, at the ratio
of 50:50.
----
Engine coolant including reserve Reserve
tank side
Approx. 250 ml
(0.53/0.44 US/lmp qt)
----
Engine
side
Approx. 1650 ml
(3.49/2.90 US/lmp qt)
----
ITEM SPECIFICATION NOTE
Injector resistance 11 – 13 Ω at 20 °C (68 °F)
Fuel pump discharge amount MIN. 168 ml (5.7/5.9 US/lmp oz)
for 10 sec. at 300 kPa (3.0 kgf/cm², 43 psi)
Fuel pressure regulator operating
set pressure
Approx. 300 kPa (3.0 kgf/cm², 43 psi)
DL650K6 ('06 MODEL)12- 8– 8 –
FI SENSORS+ SECONDARY THROTTLE VALVE ACTUATOR
THROTTLE BODY
ITEM SPECIFICATION NOTE
CKP sensor resistance 130 – 240 Ω W – G
CKP sensor peak voltage 3.7 V (When cranking) and more
IAP sensor input voltage 4.5 – 5.5 V
IAP sensor output voltage
Approx. 2.7 V at idle speed
+ G/B – -
B/Br
TP sensor input voltage 4.5 – 5.5 V
TP sensor resistance Closed Approx. 1.12 kΩ
Opened Approx. 4.26 kΩ
TP sensor output voltage Closed Approx. 1.12 V + P/W – B/BrOpened Approx. 4.26 V
ECT sensor input voltage 4.5 – 5.5 V
ECT sensor resistance Approx. 2.45 kΩ at 20 °C (68 °F)
IAT sensor input voltage 4.5 – 5.5 V
IAT sensor resistance Approx. 2.45 kΩ at 20 °C (68 °F)
TO sensor resistance 19.1 – 19.7 kΩ
TO sensor voltage Normal 0.4 – 1.4 V + Br/W – B/BrLeaning 65 ° 3.7 – 4.4 V
GP switch voltage 1.0 V and more (From 1st to Top)
Injector voltage Battery voltage
STP sensor input voltage 4.5 – 5.5 V
STP sensor resistance Closed Approx. 0.58 kΩ
Y – B
Opened Approx. 4.38 kΩ
STP sensor output voltage Closed Approx. 0.58 V + Y – B/BrOpened Approx. 4.40 V
STV actuator resistance 7 – 14 Ω
PAIR solenoid valve resistance 20 – 24 kΩ at 20 °C (68 °F)
ITEM SPECIFICATION
I.D. No. 27 G0 (Others), 27 G1 (For E-33)
Bore size 39 mm
Fast idle r/min. 1 800 – 2 400 r/min at 25 °C (77 °F)
Idle r/min. 1 300 ± 100 r/min/Warmed engine
Throttle cable play 2.0 – 4.0 mm
(0.08 – 0.16 in)
DL650K6 ('06 MODEL) 12- 9– 9 –
ELECTRICAL Unit: mm (in)
ITEM SPECIFICATION NOTE
Firing order 1.2
Spark plug
Type
NGK: CR8E
DENSO: U24ESR-N
Gap
0.7 – 0.8 mm
(0.028 – 0.031 in)
Spark performance Over 8 mm (0.3 in) at 1 atm.
CKP sensor resistance 130 – 240 Ω W – G
Ignition coil resistance
Primary 2 – 5 Ω
+ tap –
- tap
Secondary 24 – 37 kΩ
+ tap –
Plug cap
CKP sensor peak voltage
3.7 V and more
When
cranking
Ignition coil primary peak voltage 150 V and more
Generator coil resistance 0.2 – 0.7 Ω
Generator Max. output Approx. 375 W at 5 000 r/min
Generator no-load voltage
(When cold)
60 V (AC) and more at 5 000 r/min.
Regulated voltage 14.0 – 15.5 V at 5 000 r/min.
Starter relay resistance 3 – 6 Ω
Battery Type designation YTX12-BS
Capacity 12 V 36.0 kC (10 Ah)/10 HR
Fuse size
Headlight
HI 15 A
LO 15 A
Fuel 10 A
Ignition 10 A
Fan motor 15 A
Signal 15 A
Main 30 A
DL650K6 ('06 MODEL)12-10– 10 –
WATTAGE Unit: W
ITEM
SPECIFICATION
E-03, 24, 28, 33 Others
Headlight 12 V 60/55 W × 2 (H4) ←
Position/Parking light 12 V 5 W × 2
Brake light/Taillight 12 V 21/5 W × 2 ←
Turn signal light 12 V 21 W ←
License light 12 V 5 W ←
Speedometer light LED ←
Turn signal indicator light LED ←
High beam indicator light LED ←
Neutral indicator light LED ←
Oil pressure/Coolant temp./Fuel injection warning LED ←
DL650K6 ('06 MODEL) 11-11– 11 –
BRAKE + WHEEL Unit: mm (in)
ITEM STANDARD LIMIT
Rear brake pedal height 15 – 25 (0.59 – 0.98) ---Brake disc thickness
Front
5
(0.20)
4.5
(0.18)
Rear
5
(0.20)
4.5
(0.18)
Brake disc runout
----
0.3
(0.012)
Master cylinder bore
Front
15.870 – 15.913
(0.6248 – 0.6265)
----
Rear
14.000 – 14.043
(0.5512 – 0.5529)
----
Master cylinder piston diam.
Front
15.827 – 15.854
(0.6231 – 0.6242)
----
Rear
13.957 – 13.984
(0.5495 – 0.5506)
----
Brake caliper cylinder bore
Front
30.230 – 30.306
(1.1902 – 1.1931)
----
Rear
38.180 – 38.256
(1.5031 – 1.5061)
----
Brake caliper piston diam.
Front
30.150 – 30.200
(1.1870 – 1.1890)
----
Rear
38.098 – 38.148
(1.4999 – 1.5019)
----
Brake fluid type DOT 4
Wheel rim runout
Axial ---2.0
(0.08)
Radial ---2.0
(0.08)
Wheel rim size Front 19 M/C × MT2.50 ---Rear 17 M/C × MT4.00 ---Wheel axle runout
Front ---0.25
(0.010)
Rear ---0.25
(0.010)
DL650K6 ('06 MODEL)12-12– 12 –
TIRE
SUSPENSION Unit: mm (in)
ITEM STD/SPEC. LIMIT
Cold inflation tire pressure
(Solo riding)
Front
225 kPa
(2.25 kgf/cm², 33 psi)
----
Rear
250 kPa
(2.50 kgf/cm², 36 psi)
----
Cold inflation tire pressure
(Dual riding)
Front
225 kPa
(2.25 kgf/cm², 33 psi)
----
Rear
280 kPa
(2.80 kgf/cm², 41 psi)
----
Tire size Front 110/80 R19 M/C (59 H) ---Rear 150/70 R17 M/C (69 H) ----
Tire type Front BRIDGESTONE: TW101 F ---Rear BRIDGESTONE: TW152 F ---Tire tread depth
Front ---1.6
(0.06)
Rear ---2.0
(0.08)
ITEM STD/SPEC. LIMIT
Front fork stroke 150
(5.9)
----
Front fork spring free length 444.1 (17.5) 435 (17.1)
Front fork oil level (without spring,
outer tube fully compressed)
143 (5.63) ----
Front fork spring adjuster 3 groove from Top/Spring adjuster height 9 mm
(0.35 in)
----
Front fork oil type SUZUKI FORK OIL SS-08
or equivalent fork oil
----
Front fork oil capacity (each leg) 524 ml
(17.7/18.5 US/Imp oz)
----
Rear shock absorber spring
adjuster
2 groove from bottom ---Rear shock absorber damping
force adjuster
Rebound
1 turn back from stiffest position E-02, 19, 24
1 1/2 turns back from stiffest position E-03, 28, 33
Rear wheel travel 150 mm
(5.9 in)
----
Swingarm pivot shaft runout
----
0.3
(0.01)
DL650K6 ('06 MODEL) 12-13– 13 –
FUEL + OIL
ITEM STD/SPEC. NOTE
Fuel type Use only unleaded gasoline of at least 87 pump
octane (R/2 + M/2) or 91 octane or higher rated by
the research method.
Gasoline containing MTBE (Methyl Tertiary Butyl
Ether), less than 10 % ethanol, or less than 5 %
methanol with appropriate cosolvents and corrosion
inhibitor is permissible.
E-03, 28, 33
Gasoline used should be graded 91 octane or
higher. An unleaded gasoline is recommended.
Others
Fuel tank capacity 22 L (5.8/4.8 US/lmp gal)
Engine oil type *SAE 10 W – 40, API SF/SG or SH/SJ with JASO MA
Engine oil capacity
Change
2 300 ml
(2.4/2.0 US/lmp qt)
Filter change
2 700 ml
(2.9/2.4 US/lmp qt)
Overhaul
3 100 ml
(3.3/2.7 US/lmp qt)
DL650K6 ('06 MODEL)12-14– 14 –
EMISSION CONTROL SYSTEM
EXHAUST EMISSION CONTROL SYSTEM (PAIR SYSTEM)
The exhaust emission control system is composed of the PAIR system and THREE-WAY CATALYST system. The fresh air is drawn into the exhaust port with the PAIR solenoid valve and PAIR reed valve. The
PAIR solenoid valve is operated by the ECM, and the fresh air flow is controlled according to the TPS,
ECTS, IATS and IAPS.
1 ECM 6 HO2 sensor (E-02, 19)
2
Air cleaner box
7
Three-way catalyst (E-02, 19, 33)
* Addition to (E-03, 28)
3 PAIR control solenoid valve A FRESH AIR
4 PAIR reed valve B EXHAUST GAS
5 Fiel injector
DL650K6 ('06 MODEL) 12-15– 15 –
CONTENTS
DL650K7/AK7 (’07-MODEL)
This manual describes service data, service specifications, servicing procedures ABS and servicing procedures which differ from those of the DL650K6 (’06-model).
NOTE:
• Any differences between the DL650K6 (’06-model) and DL650K7 (’07-model) in specifications and service data are indicated with an asterisk mark (*).
• Any differences between the DL650K7 (’07-model) and DL650AK7 (’07-model) in specifications and service data are indicated with an asterisk mark (**).
13
DL650K7/AK7 (’07-MODEL) 13- 1
ABBREVIATIONS USED IN THIS MANUAL .....................................................13- 3
SAE-TO-FORMER SUZUKI TERM ....................................................................13- 5
SPECIFICATIONS (DL650K7) ...........................................................................13- 7
SPECIFICATIONS (DL650AK7).........................................................................13- 9
PERIODIC MAINTENANCE SCHEDULE ..........................................................13-11
PERIODIC MAINTENANCE CHART ........................................................13-11
MAINTENANCE AND TUNE-UP PROCEDURES .............................................13-12
SPARK PLUG ...........................................................................................13-12
THROTTLE CABLE PLAY........................................................................13-14
THROTTLE VALVE SYNCHRONIZATION...............................................13-14
FI SYSTEM DIAGNOSIS ....................................................................................13-15
ECM TERMINAL .......................................................................................13-15
FAIL-SAFE FUNCTION.............................................................................13-16
DTC TABLE AND DEFECTIVE CONDITION ...........................................13-17
DTC TROUBLESHOOTING ......................................................................13-20
FUEL PUMP .......................................................................................................13-44
THROTTLE BODY..............................................................................................13-50
THROTTLE VALVE SYNCHRONIZATION...............................................13-61
ISC VALVE................................................................................................13-63
ISC VALVE PRE-SET ...............................................................................13-64
IGNITION SYSTEM ............................................................................................13-65
INSPECTION .............................................................................................13-65
COMBINATION METER.....................................................................................13-67
FUEL LEVEL GAUGE INSPECTION........................................................13-67
FUEL LEVEL METER INSPECTION ........................................................13-67
INTRODUCTION OF ABS (For DL650A) ..........................................................13-68
CAUTIONS IN SERVICING ................................................................................13-72
ABS COMPONENTS..........................................................................................13-75
ABS COMPONENTS LOCATION.............................................................13-75
ABS COUPLER CONNECTION DIAGRAM .............................................13-76
ABS WIRING DIAGRAM...........................................................................13-77
• Please refer to chapters 1 through 12 for details which are not given in this chapter.
DL650K7/AK7 (’07-MODEL)
CONTENTS
COUNTRY AND AREA CODES
The following codes stand for the applicable country(-ies) and area(-s).
MODEL CODE COUNTRY or AREA EFFECTIVE FRAME NO.
DL650
E-02
E-03
E-19
E-24
E-28
E-33
U.K.
U.S.A. (Except for california)
E.U.
Australia
Canada
California (U.S.A.)
JS1B1111200100001 –
JS1VP54A 72100001 –
JS1B1111100100001 –
JS1B1111300100001 –
JS1VP54A 72100001 –
JS1VP54A 72100001 –
DL650A
E-02
E-03
E-19
E-24
E-28
E-33
U.K.
U.S.A. (Except for california)
E.U.
Australia
Canada
California (U.S.A.)
JS1B1112200100001 –
JS1VP54B 72100001 –
JS1B1112100100001 –
JS1B1112300100001 –
JS1VP54B 72100001 –
JS1VP54B 72100001 –
DL650P E-41 Greece JS1B1111100100001 –
DL650AP E-41 Greece JS1B1112100100001 –
DL650UE E-19 E.U. JS1B1211100100001 –
DL650AUE E-19 E.U. JS1B1212100100001 –
13- 2 DL650K7/AK7 (’07-MODEL)
ABS UNIT SYSTEM DIAGRAM ............................................................... 13-78
ABS TROUBLESHOOTING .............................................................................. 13-79
TROUBLESHOOTING PROCEDURE...................................................... 13-80
DTC (Diagnostic Trouble Code) OUTPUT ............................................. 13-89
DTC DELETING AND ABS OPERATION CHECK .................................. 13-91
USE OF SDS DIAGNOSTIC PROCEDURES........................................... 13-94
USE OF SDS DIAGNOSIS RESET PROCEDURE .................................. 13-95
DTC TABLE OF ABS ............................................................................... 13-101
DTC TROUBLESHOOTING ..................................................................... 13-102
ABS COMPONENT REMOVAL, INSPECTION AND INSTALLATION ............ 13-119
WIRE HARNESS, HOSE ROUTING AND SENSOR INSTALLATION ............. 13-128
SPECIAL TOOLS............................................................................................... 13-141
TIGHTENING TORQUE ..................................................................................... 13-141
SERVICE DATA (DL650K7) .............................................................................. 13-142
SERVICE DATA (DL650AK7) ........................................................................... 13-154
WIRING DIAGRAM ............................................................................................ 13-167
ABBREVIATIONS USED IN THIS
MANUAL
A
ABDC : After Bottom Dead Center
ABS : Anti-lock brake system
AC : Alternating Current
ACL : Air Cleaner, Air Cleaner Box
API : American Petroleum Institute
ATDC : After Top Dead Center
A/F : Air Fuel Mixture
B
BBDC : Before Bottom Dead Center
BTDC : Before Top Dead Center
B+ : Battery Positive Voltage
C
CKP Sensor : Crankshaft Position Sensor
(CKPS)
CKT : Circuit
CLP Switch : Clutch Lever Position Switch
(Clutch Switch)
CO : Carbon Monoxide
CPU : Central Processing Unit
D
DC : Direct Current
DMC : Dealer Mode Coupler
DOHC : Double Over Head Camshaft
DRL : Daytime Running Light
DTC : Diagnostic Trouble Code
E
ECM : Engine Control Module
Engine Control Unit (ECU)
(FI Control Unit)
ECT Sensor : Engine Coolant Temperature
Sensor (ECTS), Water Temp.
Sensor (WTS)
EVAP : Evaporative Emission
EVAP Canister : Evaporative Emission
Canister (Canister)
F
FI : Fuel Injection, Fuel Injector
FP : Fuel Pump
FPR : Fuel Pressure Regulator
FP Relay : Fuel Pump Relay
G
GEN : Generator
GND : Ground
GP Switch : Gear Position Switch
H
HC : Hydrocarbons
HO2 Sensor : Heated Oxygen Sensor (HO2S)
I
IAP Sensor : Intake Air Pressure Sensor (IAPS)
IAT Sensor : Intake Air Temperature Sensor
(IATS)
IG : Ignition
ISC Valve : Idle Speed control valve (ISCV)
L
LCD : Liquid Crystal Display
LED : Light Emitting Diode
(Malfunction Indicator Lamp)
LH : Left Hand
M
MAL-Code : Malfunction Code
(Diagnostic Code)
Max : Maximum
MIL : Malfunction Indicator Lamp
(LED)
Min : Minimum
DL650K7/AK7 (’07-MODEL) 13- 3
N
NOx : Nitrogen Oxides
O
OHC : Over Head Camshaft
OPS : Oil Pressure Switch
P
PAIR : Pulsed Secondary Air Injection
PCV : Positive Crankcase
Ventilation (Crankcase Breather)
R
RH : Right Hand
ROM : Read Only Memory
S
SAE : Society of Automotive Engineers
SDS : Suzuki Diagnosis System
STC System : Secondary Throttle Control
System (STCS)
STP Sensor : Secondary Throttle Position
Sensor (STPS)
ST Valve : Secondary Throttle Valve (STV)
STV Actuator : Secondary Throttle Valve Actuator
(STVA)
T
TO Sensor : Tip Over Sensor (TOS)
TP Sensor : Throttle Position Sensor (TPS)
13- 4 DL650K7/AK7 (’07-MODEL)
SAE-TO-FORMER SUZUKI TERM
This table lists SAE (Society of Automotive Engineers) J1930 terms and abbreviations which may be used in
this manual in compliance with SAE recommendations, as well as their former SUZUKI names.
SAE TERM
FORMER SUZUKI TERM
FULL TERM ABBREVIATION
A
Anti-lock brake system ABS Anti-lock brake system
Air Cleaner ACL Air Cleaner, Air Cleaner Box
B
Barometric Pressure BARO Barometric Pressure, Atmospheric
Pressure (APS, AP Sensor)
Battery Positive Voltage B+ Battery Voltage, +B
C
Crankshaft Position Sensor CKP Sensor Crankshaft Position Sensor (CKPS),
Crank Angle
D
Data Link Connector DLC Dealer Mode Coupler
Diagnostic Test Mode DTM ––––
Diagnostic Trouble Code DTC Diagnostic Code, Malfunction Code
E
Electronic Ignition El ––––
Engine Control Module ECM Engine Control Module (ECM)
Fl Control Unit, Engine Control Unit (ECU)
Engine Coolant Level ECL Coolant Level
Engine Coolant Temperature ECT Coolant Temperature, Engine Coolant Temperature, Water Temperature
Engine Speed RPM Engine Speed (RPM)
Evaporative Emission EVAP Evaporative Emission
Evaporative Emission Canister EVAP Canister –––– (Canister)
F
Fan Control FC ––––
Fuel Level Sensor –––– Fuel Level Sensor, Fuel Level Gauge
Fuel Pump FP Fuel Pump (FP)
G
Generator GEN Generator
Ground GND Ground (GND, GRD)
H
Heated Oxygen Sensor HO2S Heated Oxygen Sensor (HO2S), O2 Sensor
DL650K7/AK7 (’07-MODEL) 13- 5
SAE TERM
FORMER SUZUKI TERM
FULL TERM ABBREVIATION
I
Idle Speed Control ISC ––––
Idle Speed Control Valve –––– ISC Valve
Ignition Control IC Electronic Spark Advance (ESA)
Ignition Control Module ICM ––––
Intake Air Temperature IAT Intake Air Temperature (IAT), Air Temperature
M
Malfunction Indicator Lamp MIL LED Lamp
Malfunction Indicator Lamp (MIL)
Manifold Absolute Pressure MAP Intake Air Pressure, Intake Vacuum
Mass Air Flow MAF Air Flow
O
On-Board Diagnostic OBD Self-Diagnosis Function
Diagnostic
Open Loop OL ––––
P
Programmable Read Only Memory PROM ––––
Pulsed Secondary Air lnjection PAIR Pulse Air Control (PAIR)
Purge Valve Purge Valve Purge Valve (SP Valve)
R
Random Access Memory RAM ––––
Read Only Memory ROM ROM
S
Secondary Air Injection AIR ––––
Secondary Throttle Control System STCS STC System (STCS)
Secondary Throttle Valve STV ST Valve (STV)
Secondary Throttle Valve Actuator STVA STV Actuator (STVA)
T
Throttle Body TB Throttle Body (TB)
Throttle Body Fuel Injection TBI Throttle Body Fuel Injection (TBI)
Throttle Position Sensor TP Sensor TP Sensor (TPS)
V
Voltage Regulator VR Voltage Regulator
Volume Air Flow VAF Air Flow
13- 6 DL650K7/AK7 (’07-MODEL)
SPECIFICATIONS (DL650K7)
DIMENSIONS AND DRY MASS
Overall length ...................................................... 2 290 mm (90.2 in)
Overall width ....................................................... 840 mm (33.1 in)
Overall height ...................................................... 1 390 mm (54.7 in) .... Low windshield position (STD)
1 420 mm (55.9 in) .... Middle windshield position
1 450 mm (57.1 in) .... High windshield position
Wheelbase .......................................................... * 1 555 mm (61.2 in)
Ground clearance................................................ 165 mm (6.5 in)
Seat height .......................................................... 820 mm (32.3 in)
Dry mass ............................................................. * 194 kg (427 lbs)
ENGINE
Type .................................................................... 4-stroke, liquid-cooled, DOHC,
90°-degree V-twin
Number of cylinders ............................................ 2
Bore..................................................................... 81.0 mm (3.189 in)
Stroke.................................................................. 62.6 mm (2.465 in)
Displacement ...................................................... 645 cm3 (39.4 cu. in)
Compression ratio ............................................... 11.5 : 1
Fuel system......................................................... Fuel injection
Air cleaner ........................................................... Non-woven fabric element
Starter system ..................................................... Electric
Lubrication system .............................................. Wet sump
Idle speed............................................................ 1 300 ± 100 r/min
DRIVE TRAIN
Clutch .................................................................. Wet multi-plate type
Transmission....................................................... 6-speed constant mesh
Gearshift pattern ................................................. 1-down, 5-up
Primary reduction ratio ........................................ 2.088 (71/34)
Gear ratios, Low ............................................... 2.461 (32/13)
2nd................................................ 1.777 (32/18)
3rd................................................. 1.380 (29/21)
4th ................................................. 1.125 (27/24)
5th ................................................. 0.961 (25/26)
Top................................................ 0.851 (23/27)
Final reduction ratio............................................. 3.133 (47/15)
Drive chain .......................................................... * DID 525V8, 118 links
DL650K7/AK7 (’07-MODEL) 13- 7
CHASSIS
Front suspension ................................................. Telescopic, coil spring, oil damped
Rear suspension .................................................. Link type, coil spring, oil damped
Front fork stroke................................................... 150 mm (5.9 in)
Rear wheel travel ................................................. 150 mm (5.9 in)
Caster .................................................................. 26°
Trail ...................................................................... 110 mm (4.33 in)
Steering angle...................................................... 40° (right & left)
Turning radius ...................................................... 2.6 m (8.5 ft)
Front brake........................................................... Disc brake, twin
Rear brake ........................................................... Disc brake
Front tire size ....................................................... 110/80 R19 M/C 59H, tubeless
Rear tire size........................................................ 150/70 R17 M/C 69H, tubeless
ELECTRICAL
Ignition type.......................................................... Electronic ignition (Transistorized)
Ignition timing....................................................... 4° B.T.D.C. at 1 300 r/min
Spark plug............................................................ NGK CR8E or DENSO U24ESR-N
Battery.................................................................. 12 V 36.0 kC (10 Ah)/10 HR
Generator............................................................. Three-phase A.C. generator
Main fuse ............................................................. 30 A
Fuse ..................................................................... 15/15/10/10/15/15 A
Headlight.............................................................. 12 V 60/55 W × 2 (H4)
Position/Parking light ........................................... 12 V 5 W × 2 ..............Except for E-03, 24, 28,33
Brake light/Taillight............................................... 12 V 21/5 W × 2
Licence plate light ................................................ 12 V 5 W
Turn signal light.................................................... 12 V 21 W
Speedometer light................................................ LED
Tachometer light .................................................. LED
Turn signal indicator light ..................................... LED
Neutral indicator light ........................................... LED
High beam indicator light ..................................... LED
Oil pressure/Coolant temperature/
Fuel injection indicator light.................................. LED
CAPACITIES
Fuel tank, including reserve ................................. 22.0 L (5.8/4.8 US/lmp gal)
Engine oil, oil change ......................................... 2 300 ml (2.4/2.0 US/lmp qt)
with filter change............................... 2 700 ml (2.9/2.4 US/lmp qt)
overhaul............................................ 3 100 ml (3.3/2.7 US/lmp qt)
Engine coolant ..................................................... 1.9 L (2.0/1.7 US/lmp qt)
These specifications are subject to change without notice.
13- 8 DL650K7/AK7 (’07-MODEL)
SPECIFICATIONS (DL650AK7)
DIMENSIONS AND DRY MASS
Overall length ...................................................... 2 290 mm (90.2 in)
Overall width ....................................................... 840 mm (33.1 in)
Overall height ...................................................... 1 390 mm (54.7 in) .... Low windshield position (STD)
1 420 mm (55.9 in) .... Middle windshield position
1 450 mm (57.1 in) .... High windshield position
Wheelbase .......................................................... 1 555 mm (61.2 in)
Ground clearance................................................ 165 mm (6.5 in)
Seat height .......................................................... 820 mm (32.3 in)
Dry mass ............................................................. ** 197 kg (434 lbs)
ENGINE
Type .................................................................... 4-stroke, liquid-cooled, DOHC,
90°-degree V-twin
Number of cylinders ............................................ 2
Bore..................................................................... 81.0 mm (3.189 in)
Stroke.................................................................. 62.6 mm (2.465 in)
Displacement ...................................................... 645 cm3 (39.4 cu. in)
Compression ratio ............................................... 11.5 : 1
Fuel system......................................................... Fuel injection
Air cleaner ........................................................... Non-woven fabric element
Starter system ..................................................... Electric
Lubrication system .............................................. Wet sump
Idle speed............................................................ 1 300 ± 100 r/min
DRIVE TRAIN
Clutch .................................................................. Wet multi-plate type
Transmission....................................................... 6-speed constant mesh
Gearshift pattern ................................................. 1-down, 5-up
Primary reduction ratio ........................................ 2.088 (71/34)
Gear ratios, Low ............................................... 2.461 (32/13)
2nd................................................ 1.777 (32/18)
3rd................................................. 1.380 (29/21)
4th ................................................. 1.125 (27/24)
5th ................................................. 0.961 (25/26)
Top................................................ 0.851 (23/27)
Final reduction ratio............................................. 3.133 (47/15)
Drive chain .......................................................... DID 525V8, 118 links
DL650K7/AK7 (’07-MODEL) 13- 9
CHASSIS
Front suspension ................................................. Telescopic, coil spring, oil damped
Rear suspension .................................................. Link type, coil spring, oil damped
Front fork stroke................................................... 150 mm (5.9 in)
Rear wheel travel ................................................. 150 mm (5.9 in)
Caster .................................................................. 26°
Trail ...................................................................... 110 mm (4.33 in)
Steering angle...................................................... 40° (right & left)
Turning radius ...................................................... 2.6 m (8.5 ft)
Front brake........................................................... Disc brake, twin
Rear brake ........................................................... Disc brake
Front tire size ....................................................... 110/80 R19 M/C 59H, tubeless
Rear tire size........................................................ 150/70 R17 M/C 69H, tubeless
ELECTRICAL
Ignition type.......................................................... Electronic ignition (Transistorized)
Ignition timing....................................................... 4° B.T.D.C. at 1 300 r/min
Spark plug............................................................ NGK CR8E or DENSO U24ESR-N
Battery.................................................................. 12 V 36.0 kC (10 Ah)/10 HR
Generator............................................................. Three-phase A.C. generator
Main fuse ............................................................. 30 A
Fuse ..................................................................... 15/15/10/10/15/15 A
ABS fuse .............................................................. 40/25 A
Headlight.............................................................. 12 V 60/55 W × 2 (H4)
Position/Parking light ........................................... 12 V 5 W × 2 ..............Except for E-03, 24, 28,33
Brake light/Taillight............................................... 12 V 21/5 W × 2
Licence plate light ................................................ 12 V 5 W
Turn signal light.................................................... 12 V 21 W
Speedometer light................................................ LED
Tachometer light .................................................. LED
Turn signal indicator light ..................................... LED
Neutral indicator light ........................................... LED
High beam indicator light ..................................... LED
Oil pressure/Coolant temperature/
Fuel injection indicator light.................................. LED
ABS indicator light................................................**LED
CAPACITIES
Fuel tank, including reserve ................................. 22.0 L (5.8/4.8 US/lmp gal)
Engine oil, oil change ......................................... 2 300 ml (2.4/2.0 US/lmp qt)
with filter change............................... 2 700 ml (2.9/2.4 US/lmp qt)
overhaul............................................ 3 100 ml (3.3/2.7 US/lmp qt)
Engine coolant ..................................................... 1.9 L (2.0/1.7 US/lmp qt)
These specifications are subject to change without notice.
13-10 DL650K7/AK7 (’07-MODEL)
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 kilometers, miles and time for your convenience.
IMPORTANT: The periodic maintenance intervals and service requirements have been established in
accordance with EPA regulations. Following these instructions will ensure that the motorcycle will not
exceed emission standards and it will also ensure the reliability and performance of the motorcycle.
NOTE:
More frequent servicing may be performed on motorcycles that are used under severe conditions.
PERIODIC MAINTENANCE CHART
NOTE:
I = Inspect and clean, adjust, replace or lubricate as necessary; R = Replace; T = Tighten
Interval
Item
km 1 000 6 000 12 000 18 000 24 000
miles 600 4 000 7 500 11 000 14 500
months 2 12 24 36 48
Air cleaner element — I I R I
Exhaust pipe bolts and muffler bolts T T T T T
Valve clearance — — — — I
Spark plugs — I R I R
Fuel hose — I I I I
Replace every 4 years.
Engine oil R R R R R
Engine oil filter R — — R —
Throttle cable play I I I I I
Throttle valve synchronization I — I — I
(E-33 only)
Evaporative emission control system
(E-33 only)
— — I — I
Replace vapor hose every 4 years.
PAIR (air supply) system — — I — I
Engine coolant Replace every 2 years.
Radiator hose — I I I I
Replace every 4 years.
Clutch — I I I I
Drive chain I I I I I
Clean and lubricate every 1 000 km (600 miles).
Brakes I I I I I
Brake hose — I I I I
Replace every 4 years.
Brake fluid — I I I I
Replace every 2 years.
Tires — I I I I
Steering I — I — I
Front forks — — I — I
Rear suspension — — I — I
Chassis bolts and nuts T T T T T
DL650K7/AK7 (’07-MODEL) 13- 11
MAINTENANCE AND TUNE-UP
PROCEDURES
This section describes the servicing procedures for each Periodic Maintenance item which differ from those of the DL650K6
(’06-MODEL).
For details other than the following items, refer to the DL650
Service Manual.
SPARK PLUG
NO.1 (FRONT) SPARK PLUG REMOVAL
• Remove the cowling. (!DL650K4 7-5)
• Remove the radiator mounting bolt.
• Move the radiator lower side to forward.
• Remove the spark plug caps (1, 2).
NOTE:
Be careful not to damage the radiator fins.
"
• Remove the spark plugs with the special tool.
# 09930-10121: Spark plug socket wrench set
Inspect every 6 000 km (4 000 miles, 12 months) and
replace every 12 000 km (7 500 miles, 24 months).
The hot radiator and the hot engine can burn you. Wait
until the radiator and the engine are cool enough to
touch.
13-12 DL650K7/AK7 (’07-MODEL)
NO.2 (REAR) SPARK PLUG REMOVAL
• Lift and support the fuel tank. (!DL650K4 5-7)
• Remove the spark plug caps.
• Remove the spark plugs with the special tool.
# 09930-10121: Spark plug socket wrench set
HEAT RANGE
• Check to see the heat range of the plug.
CARBON DEPOSIT
• Check to see if there are carbons deposit on the plugs. If carbon is deposited, remove it with a spark plug cleaner machine
or carefully using a tool with a pointed end.
SPARK PLUG GAP
• Measure the plug gap with a thickness gauge. If out of specification, adjust it to the following gap.
$ Spark plug gap A
Standard: 0.7 – 0.8 mm (0.028 – 0.031 in)
# 09900-20803: Thickness gauge
ELECTRODES CONDITION
• Check to see the worn or burnt condition of the electrodes. If it
is extremely worn or burnt, replace the plug. And also replace
the plug if it has a broken insulator, damaged thread.
%
Standard Cold type Hot type
NGK CR8E CR9E CR7E
DENSO U24ESR-N U27ESR-N U22ESR-N
Confirm the thread size and reach when replacing the
plug. If the reach is too short, carbon will be deposited
on the screw portion of the plug hole and engine damage may result.
DL650K7/AK7 (’07-MODEL) 13-13
SPARK PLUG AND PLUG CAP INSTALLATION
%
• Install the spark plugs to the cylinder heads by finger tight,
and then tighten them to the specified torque.
& Spark plug: 11 N·m (1.1 kgf-m, 8.0 lb-ft)
NOTE:
When fitting the spark plug caps, front and rear of cylinder head
cover side, face the triangle mark A on the water-proof cover to
each cylinder exhaust side.
THROTTLE CABLE PLAY
Adjust the throttle cable play A with the following three steps.
First step:
• Loosen the lock-nut 2 of the throttle returning cable 1.
• Turn in the adjuster 3 fully.
Second step:
• Loosen the lock-nut 5 of the throttle pulling cable 4.
• Turn the adjuster 6 in or out until the throttle cable play A
should be 2.0 – 4.0 mm (0.08 – 0.16 in) at the throttle grip.
• Tighten the lock-nut 5 while holding the adjuster 6.
Third step:
• While holding the throttle grip at the fully closed position,
slowly turn out the adjuster 3 of the throttle returning cable 1
to feel resistance.
• Tighten the lock-nut 2 while holding the adjuster 3.
$ Throttle cable play A: 2.0 – 4.0 mm (0.08 – 0.16 in)
"
THROTTLE VALVE SYNCHRONIZATION
Inspect the throttle valve synchronization periodically. (!Page 61)
Before using a spark plug wrench, carefully turn the
spark plug by finger into the threads of the cylinder
head to prevent damage the aluminum threads.
Inspect initially at 1 000 km (600 miles, 2 month) and
every 6 000 km (4 000 miles, 12 months) thereafter.
After the adjustment is completed, check that handlebar movement does not raise the engine idle speed
and that the throttle grip returns smoothly and automatically.
Inspect initially at 1 000 km (600 miles, 2 months) (E-33
only) and every 12 000 km (7 500 miles, 24 months).
13-14 DL650K7/AK7 (’07-MODEL)
FI SYSTEM DIAGNOSIS
ECM TERMINAL
TERMINAL
NO.
CIRCUIT
TERMINAL
NO.
CIRCUIT
1 GP switch signal (GP) H —
2 IAT sensor signal (IAT) I ECT sensor signal (ECT)
3 IAP sensor signal #1 (IAP. F) J TO sensor signal (TOS)
4 STP sensor signal (STP) K TP sensor signal (TP)
5 Power source for sensors (VCC) L IAP sensor signal #2 (IAP. R)
6 HO2 sensor signal M —
7 Clutch lever position switch (CLT) N Mode select switch
8 CKP sensor signal (CKP–) O Starter switch
9 Power source for fuel injector (VM) P Neutral switch
0 Power source for back-up Q CKP sensor signal (CKP+)
A Power source R —
B Sensor ground (E2) S Blank
C ECM ground (E1) T Blank
D — U Serial data for speedometer (TECH)
E — V Serial data for self-diagnosis
F — W —
G HO2 sensor heater (HO2. H) X Fuel pump relay (FP Relay)
TERMINAL
NO.
CIRCUIT
TERMINAL
NO.
CIRCUIT
Y STVA signal (STVA. 1B) d STVA signal (STVA. 2B)
Z Tachometer e PAIR control solenoid valve (PAIR)
[ STVA signal (STVA. 1A) f STVA signal (STVA. 2A)
ISC signal (ISC. 2B) g ISC signal (ISC. 1A)
] Blank h —
^ ISC signal (ISC. 2A) i ISC signal (ISC. 1B)
a Ground j Ground
b Fuel injector #2 (#21) k Fuel injector #1 (#11)
c Ignition coil #2 l Ignition coil #1
DL650K7/AK7 (’07-MODEL) 13-15
FAIL-SAFE FUNCTION
FI system is provided with fail-safe function to allow the engine to start and the motorcycle to run in a minimum performance necessary even under malfunction condition.
The engine can start and can run even if the above signal is not received from each sensor. But, the engine
running condition is not complete, providing only emergency help (by fail-safe circuit). In this case, it is necessary to bring the motorcycle to the workshop for complete repair.
When two ignition signals or two injector signals are not received by ECM, the fail-safe circuit can not work
and ignition or injection is stopped.
ITEM FAIL-SAFE MODE
STARTING
ABILITY
RUNNING
ABILITY
Intake air pressure sensor
(Front & Rear)
Intake air pressure is fixed to
760 mmHg.
“YES” “YES”
Throttle position sensor TPS opening value is fixed to full
open position.
“YES” “YES”
Engine coolant temp. sensor Engine coolant temperature value is
fixed to 80 °C.
“YES” “YES”
Intake air temperature sensor Intake air temperature value is fixed
to 40 °C.
“YES” “YES”
Ignition signal #1 (IG coil #1) #1 Ignition-off and #1 Fuel-cut “YES” “YES”
#2 cylinder can run.
Ignition signal #2 (IG coil #2) #2 Ignition-off and #2 Fuel-cut “YES” “YES”
#1 cylinder can run.
Injection signal #1 #1 Fuel-cut “YES” “YES”
#2 cylinder can run.
Injection signal #2 #2 Fuel-cut “YES” “YES”
#1 cylinder can run.
HO2 sensor
(For E-02, 19, 24, 41)
Feedback compensation is inhibited.
(Air/fuel ratio is fixed to normal.)
“YES” “YES”
Secondary throttle valve
actuator
Secondary throttle valve is fixed in
any position.
“YES” “YES”
Secondary throttle position
sensor
Secondary throttle valve is fixed in
full close position.
“YES” “YES”
Gear position signal Gear position signal is fixed to 6th
gear.
“YES” “YES”
PAIR control solenoid valve O2 feedback control is stopped and
PAIR valve is fixed to open position.
“YES” “YES”
ISC valve When motor disconnection or lock
occurs, power from ECM is shut off.
“YES” “YES”
13-16 DL650K7/AK7 (’07-MODEL)
DTC TABLE AND DEFECTIVE CONDITION
DTC No.
DETECTED
ITEM
DETECTED FAILURE CONDITION CHECK FOR
C00 NO FAULT ––––––––––– –––––––––––
C12 (P0335)
CKP sensor The signal does not reach ECM for 2
sec. or more, after receiving the starter
signal.
CKP sensor wiring and mechanical parts
CKP sensor, lead wire/coupler
connection
C13 (P1750)/
C17 (P0105)
IAP sensor The sensor should produce following
voltage.
0.1 V sensor voltage < 4.8 V
In other than the above range, C13
(P1750) or C17 (P0105) is indicated.
IAP sensor, lead wire/coupler
connection
C14 (P0120)
TP sensor The sensor should produce following
voltage.
0.1 V < sensor voltage < 4.8 V
In other than the above range, C14
(P0120) is indicated.
TP sensor, lead wire/coupler
connection
P0120
H
Sensor voltage is higher than specified
value.
TP sensor circuit shorted to
VCC or ground circuit open
L
Sensor voltage is lower than specified
value.
TP sensor circuit open or
shorted to ground or VCC circuit
open
C15 (P0115)
ECT sensor The sensor voltage should be the following.
0.1 V sensor voltage 4.6 V
In other than the above range, C15
(P0115) is indicated.
ECT sensor, lead wire/coupler
connection
P0115
H
Sensor voltage is higher than specified
value.
ECT sensor circuit open or
ground circuit open
L
Sensor voltage is lower than specified
value.
ECT sensor circuit shorted to
ground
C21 (P0110)
IAT sensor The sensor voltage should be the following.
0.1 V sensor voltage 4.6 V
In other than the above range, C21
(P0110) is indicated.
IAT sensor, lead wire/coupler
connection
P0110
H
Sensor voltage is higher than specified
value.
IAT sensor circuit open or
ground circuit open
L
Sensor voltage is lower than specified
value.
IAT sensor circuit shorted to
ground
DL650K7/AK7 (’07-MODEL) 13-17
DTC No.
DETECTED
ITEM
DETECTED FAILURE CONDITION CHECK FOR
C23 (P1651)
TO sensor The sensor voltage should be the following for 2 sec. and more, after ignition switch is turned ON.
0.2 V < sensor voltage < 4.6 V
In other than the above value, C23
(P1651) is indicated.
TO sensor, lead wire/coupler
connection
P1651
H
Sensor voltage is higher than specified
value.
TO sensor circuit shorted to
VCC or ground circuit open
L
Sensor voltage is lower than specified
value.
TO sensor circuit open or
shorted to ground or VCC circuit
open
C24 (P0351)/
C25 (P0352)
Ignition signal
CKP sensor (pick-up coil) signal is produced, but signal from ignition coil is
interrupted 8 times or more continuously. In this case, the code C24
(P0351) or C25 (P0352) is indicated.
Ignition coil, wiring/coupler connection, power supply from the
battery
C28 (P1655)
Secondary
throttle valve
actuator
When no actuator control signal is
supplied from the ECM, communication signal does not reach ECM or
operation voltage does not reach
STVA motor, C28 (P1655) is indicated.
STVA can not operate.
STVA motor, STVA lead wire/
coupler
C29 (P1654)
STP sensor The sensor should produce following
voltage.
0.1 V < sensor voltage < 4.88 V
In other than the above range, C29
(P1654) is indicated.
STP sensor, lead wire/coupler
connection
P1654
H
Sensor voltage is higher than specified
value.
STP sensor circuit shorted to
VCC or ground circuit open
L
Sensor voltage is lower than specified
value.
STP sensor circuit open or
shorted to ground or VCC circuit
open
C31(P0705)
Gear position signal
When gear position switch voltage is
as follows.
GP switch voltage > 0.2 V for 4 sec.
and more
When gear position switch voltage is
neutral and switch voltage is as follows.
GP switch voltage 4.77 V for 4 sec.
and more
If lower than the above value, C31
(P0705) is indicated
GP switch, wiring/coupler connection, gearshift cam, etc.
13-18 DL650K7/AK7 (’07-MODEL)
DTC No.
DETECTED
ITEM
DETECTED FAILURE CONDITION CHECK FOR
C32 (P0201)/
C33 (P0202)
Fuel injector CKP sensor (pickup coil) signal is produced, but fuel injector signal is interrupted several times (Front 50 times,
Rear 25 times) or more continuously.
In this case, the code C32 (P0201) or
C33 (P0202) is indicated.
Fuel injector, wiring/coupler connection, power supply to the
injector
C40 (P0505)
ISC valve The circuit voltage of motor drive is
unusual.
Idle speed is higher than the normal
condition.
ISC valve circuit open or shorted
to ground
Power source circuit open
ISC valve is fixed to full open
Disconnected ISC valve hose
C40 (P0506)
Idle speed is lower than the desired
idle speed.
Air passage clogged
ISC valve is fixed
ISC valve PRE-SET position is
incorrect
C40 (P0507)
Idle speed is higher than the desired
idle speed.
ISC valve hose connection
ISC valve is fixed
ISC valve PRE-SET position is
incorrect
C41 (P0230)
Fuel pump
relay
No voltage is applied to the fuel pump,
although fuel pump relay is turned ON,
or voltage is applied to fuel pump
although fuel pump relay is turned
OFF.
Fuel pump relay, lead wire/coupler connection, power source to
fuel pump relay and fuel injectors
C42 (P1650)
Ignition
switch
Ignition switch signal is not input to
ECM.
Ignition switch, lead wire/coupler
C44 (P0130)
HO2 sensor
(E-02, 19, 24,
41)
HO2 sensor output voltage is not input
to ECM during engine operation and
running condition.
(Sensor voltage < 0.45 V)
In other than the above value, C44
(P0130) is indicated.
HO2 sensor circuit open or
shorted to ground
C44 (P0135)
The Heater can not operate so that
heater operation voltage is not supply
to the oxygen heater circuit, C44
(P0135) is indicated.
HO2 sensor lead wire/coupler
connection
Battery voltage supply to the
HO2 sensor
C49 (P1656)
PAIR control
solenoid
valve
PAIR control solenoid valve voltage is
not input to ECM.
PAIR control solenoid valve, lead
wire/coupler
DL650K7/AK7 (’07-MODEL) 13-19
DTC TROUBLESHOOTING
“C12” (P0335) CKP SENSOR CIRCUIT MALFUNCTION
On model K7, the connector terminals to be used for checking
sensors for voltage, resistance or continuity at the ECM terminal
are located as shown in the illustration.
* Refer to the DL650 service manual 4-23 for details.
“C13” (P1750) or “C17” (P0105) IAP SENSOR CIRCUIT MALFUNCTION
INSPECTION
NOTE:
After repairing the trouble, clear the DTC using SDS tool.
Step 1
(When indicating C13/P1750 for rear cylinder IAP sensor)
(When indicating C17/P0105 for front cylinder IAP sensor)
1) Turn the ignition switch OFF.
2) Lift and support the fuel tank. (!DL650K4 5-7)
ECM coupler (Harness side)
DETECTED CONDITION POSSIBLE CAUSE
IAP sensor voltage low or high
(0.1 V Sensor voltage < 4.8V)
NOTE:
Note that atmospheric pressure varies depending on
weather conditions as well as altitude.
Take that into consideration when inspecting voltage.
• Clogged vacuum passage between throttle body
and IAP sensor.
• Air being drawn from vacuum passage between
throttle body and IAP sensor.
• IAP sensor circuit open or shorted to ground.
• IAP sensor malfunction.
• ECM malfunction.
ECM
R
G/B
B/Br
VCC
IAP. F
E2
IAP sensor (F)
IAP sensor (R)
R
G/Y
B/Br
IAP. R
1 1
13-20 DL650K7/AK7 (’07-MODEL)
3) Check the IAP sensor coupler (Front cylinder side 1 or Rear
cylinder side 2) for loose or poor contacts.
If OK, then measure the IAP sensor input voltage.
4) Disconnect the IAP sensor coupler.
5) Turn the ignition switch ON.
6) Measure the voltage at the Red wire 3 and ground.
7) Also, measure the voltage at the Red wire 3 and B/Br wire 4.
$ IAP sensor input voltage: 4.5 – 5.5 V
(+ Red – - Ground)
(+ Red – - B/Br)
# 09900-25008: Multi-circuit tester set
' Tester knob indication: Voltage ( )
Is the voltage OK?
Step 2
1) Connect the IAP sensor coupler.
2) Insert the needle pointed probes to the lead wire coupler.
3) Start the engine at idle speed and measure the IAP sensor
output voltage at the wire side coupler.
(Front cylinder side: between G/B and B/Br wires)
(Rear cylinder side: between G/Y and B/Br wires)
$ IAP sensor output voltage: Approx. 1.6 V at idle speed
(Front cylinder side: + G/B – - B/Br)
(Rear cylinder side: + G/Y – - B/Br)
# 09900-25008: Multi-circuit tester set
09900-25009: Needle pointed probe set
' Tester knob indication: Voltage ( )
Is the voltage OK?
YES Go to Step 2.
NO
• Loose or poor contacts on the ECM coupler
(terminal 5 or B).
• Open or short circuit in the Red wire or B/Br
wire.
YES Go to Step 3.
NO
• Check the vacuum hose for crack or damage.
• Open or short circuit in the G/B wire.
(Front cylinder side)
• Open or short circuit in the G/Y wire.
(Rear cylinder side)
• If vacuum hose and wire are OK, replace the
IAP sensor with a new one.
1
V
2
V
DL650K7/AK7 (’07-MODEL) 13-21
Step 3
1) Turn the ignition switch OFF.
2) Remove the IAP sensor.
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 – 5.0 V) and connect - terminal to the ground terminal 2 and + terminal to the Vcc terminal 3.
5) Check the voltage between Vout 4 and ground. Also, check if
voltage reduces when vacuum is applied up to 400 mmHg by
using vacuum pump gauge. (!below)
# 09917-47011: Vacuum pump gauge
09900-25008: Multi-circuit tester set
' Tester knob indication: Voltage ( )
Is the voltage OK?
Output voltage (Vcc voltage 4.5 – 5.0 V, ambient temp. 20 –
30 °C, 68 – 86 °F)
YES
• G/B, R or B/Br wire open or shorted to ground,
or poor 3, 5 or B connection.
(Front cylinder side)
• R, B/Br or G/Y wire open or shorted to ground,
or poor 5, B or L connection.
(Rear cylinder side)
• If wire and connection are OK, intermittent trouble or faulty ECM.
• Recheck each terminal and wire harness for
open circuit and poor connection.
• Replace the ECM with a known good one, and
inspect it again.
NO
If check result is not satisfactory, replace the IAP
sensor with a new one.
ALTITUDE
(Reference)
ATMOSPHERIC
PRESSURE
OUTPUT
VOLTAGE
(ft) (m) (mmHg) kPa (V)
0

2 000
0

610
760

707
100

94
3.4 – 4.0
2 001

5 000
611

1 524
707

634
94

85
3.0 – 3.7
5 001

8 000
1 525

2 438
634

567
85

76
2.6 – 3.4
8 001

10 000
2 439

3 048
567

526
76

70
2.4 – 3.1
3
ECM coupler (Harness side)
3
13-22 DL650K7/AK7 (’07-MODEL)
“C14” (P0120-H/L) TP SENSOR CIRCUIT MALFUNCTION
INSPECTION
NOTE:
After repairing the trouble, clear the DTC using SDS tool.
Step 1
1) Turn the ignition switch OFF.
2) Lift and support the fuel tank. (!DL650K4 5-7)
3) Check the TP sensor coupler for loose or poor contacts.
If OK, then measure the TP sensor input voltage.
4) Disconnect the TP sensor coupler.
5) Turn the ignition switch ON.
DETECTED CONDITION POSSIBLE CAUSE
C14
(P0120)
Output voltage is not within the following
range.
Difference between actual throttle opening and opening calculated by ECM is
larger than specified value.
0.1 V < Sensor voltage < 4.8 V
• TP sensor maladjusted
• TP sensor circuit open or short
• TP sensor malfunction
• ECM malfunction
P0120
H
Sensor voltage is higher than specified
value.
• TP sensor circuit shorted to VCC or ground circuit
open
• TP sensor circuit open or shorted to ground or
VCC circuit open
L
Sensor voltage is lower than specified
value.
ECM
R
B/Br
VCC
TP
E2
P/W
TP sensor
1
DL650K7/AK7 (’07-MODEL) 13-23
6) Measure the voltage at the Red wire B and ground.
7) Also, measure the voltage at the Red wire B and B/Br wire C.
$ TP sensor input voltage: 4.5 – 5.5 V
(+ Red – - Ground)
(+ Red – - B/Br)
# 09900-25008: Multi-circuit tester set
' Tester knob indication: Voltage ( )
Is the voltage OK?
Step 2
1) Turn the ignition switch ON.
2) Connect the test harness 1 between TP sensor and wire harness.
3) Measure the TP sensor output voltage at the coupler
(between + P/W and - B/Br) by turning the throttle grip.
$ TP sensor output voltage
Throttle valve is closed: Approx. 1.1 V
Throttle valve is opened: Approx. 4.3 V
# 09900-25008: Multi-circuit tester set
09900-28630: TPS test wire harness
' Tester knob indication: Voltage ( )
Is the voltage OK?
YES Go to Step 2.
NO
• Loose or poor contacts on the ECM coupler
(terminal 5 or B).
• Open or short circuit in the Red wire or B/Br
wire.
1
V
2
V
ECMTPS
P/W
R
B/Br
2
YES
• R, B/Br or P/W wire open or shorted to ground,
or poor 5, B or K connection.
• If wire and connection are OK, intermittent trouble or faulty ECM.
• Recheck each terminal and wire harness for
open circuit and poor connection.
• Replace the ECM with a known good one, and
inspect it again.
NO
• Reset the TP sensor position correctly.
• Replace the TP sensor with a new one.
ECM coupler (Harness side)
2
13-24 DL650K7/AK7 (’07-MODEL)
“C15” (P0115-H/L) ECT SENSOR CIRCUIT MALFUNCTION
On model K7, the connector terminals to be used for checking
sensors for voltage, resistance or continuity at the ECM terminal
are located as shown in the illustration.
* Refer to the DL650 service manual 4-31 for details.
“C21” (P0110-H/L) IAT SENSOR CIRCUIT MALFUNCTION
INSPECTION
NOTE:
After repairing the trouble, clear the DTC using SDS tool.
Step 1
1) Turn the ignition switch OFF.
2) Lift and support the fuel tank. (!DL650K4 5-7)
3) Check the IAT sensor coupler for loose or poor contacts.
If OK, then measure the IAT sensor voltage at the wire side
coupler.
4) Disconnect the IAT sensor coupler and turn the ignition switch
ON.
ECM coupler (Harness side)
DETECTED CONDITION POSSIBLE CAUSE
C21
(P0110)
Output voltage is not within the following
range.
0.1 Sensor voltage 4.6 V
• IAT sensor circuit open or short.
• IAT sensor malfunction.
• ECM malfunction.
P0110
H
Sensor voltage is higher than specified
value.
• IAT sensor circuit open or ground circuit open.
• IAT sensor circuit shorted to ground.
L
Sensor voltage is lower than specified
value.
ECM
B/Br E2
IATDg
IAT sensor
1
DL650K7/AK7 (’07-MODEL) 13-25
5) Measure the voltage between Dg wire terminal and ground.
6) Also, measure the voltage between Dg wire terminal and B/Br
wire terminal.
$ IAT sensor input voltage: 4.5 – 5.5 V
(+ Dg – - Ground)
(+ Dg – - B/Br)
# 09900-25008: Multi-circuit tester set
09900-25009: Needle pointed probe set
' Tester knob indication: Voltage ( )
Is the voltage OK?
Step 2
1) Turn the ignition switch OFF.
2) Remove the air cleaner box. (!Page 51)
3) Measure the IAT sensor resistance.
$ IAT sensor resistance: Approx. 2.6 kΩ at 20 °C (68 °F)
(Terminal – Terminal)
# 09900-25008: Multi-circuit tester set
) Tester knob indication: Resistance (Ω)
Is the resistance OK?
$ IAT sensor specification
NOTE:
IAT sensor resistance measurement method is the same way as that of the EOT sensor. Refer to DL650
service manual 6-10 for details.
YES Go to Step 2.
NO
• Loose or poor contacts on the ECM coupler
(Terminal 2 or B).
• Open or short circuit in the Dg wire or B/Br wire.
1
V
2
YES
• Dg or B/Br wire open or shorted to ground, or
poor 2 or B connection.
• If wire and connection are OK, intermittent trouble or faulty ECM.
• Recheck each terminal and wire harness for
open circuit and poor connection.
• Replace the ECM with a known good one, and
inspect it again.
NO Replace the IAT sensor with a new one.
Intake Air Temp Resistance
20 °C (68 °F) Approx. 2.56 kΩ
40 °C (104 °F) Approx. 1.20 kΩ
60 °C (140 °F) Approx. 0.61 kΩ
80 °C (176 °F) Approx. 0.33 kΩ
ECM coupler (Harness side)
2
13-26 DL650K7/AK7 (’07-MODEL)
“C23” (P1651-H/L) TO SENSOR CIRCUIT MALFUNCTION
On model K7, the connector terminals to be used for checking
sensors for voltage, resistance or continuity at the ECM terminal
are located as shown in the illustration.
* Refer to the DL650 service manual 4-35 for details.
“C24” (P0351) or “C25” (P0352) IGNITION SYSTEM MALFUNCTION
(When indicating C24/P0351 for IG coil #1)
(When indicating C25/P0352 for IG coil #2)
* Refer to the IGNITION SYSTEM for details. (!Page 65)
ECM coupler (Harness side)
DL650K7/AK7 (’07-MODEL) 13-27
“C28” (P1655) STV ACTUATOR CIRCUIT MALFUNCTION
INSPECTION
NOTE:
After repairing the trouble, clear the DTC using SDS tool.
Step 1
1) Turn the ignition switch OFF.
2) Lift and support the fuel tank. (!DL650K4 5-7)
3) Check the STVA coupler for loose or poor contacts.
4) Turn the ignition switch ON to check the STV operation.
(STV operating order: Full open → 10% open)
Is the operating OK?
DETECTED CONDITION POSSIBLE CAUSE
The operation voltage does not reach the STVA.
ECM does not receive communication signal from
the STVA.
• STVA malfunction.
• STVA circuit open or short.
• STVA motor malfunction.
ECM
STVA. 2B
STVA. 1A
STVA. 1B
STVA
B/Lg
P/W
G
W/B STVA. 2A
1
YES Go to Step 2.
NO
• Loose or poor contacts on the STVA coupler.
• Open or short circuit in the B/Lg, P/W, G or W/B
wires.
• If wire and connection are OK, go to Step 2.
1
13-28 DL650K7/AK7 (’07-MODEL)
Step 2
1) Turn the ignition switch OFF.
2) Disconnect the STVA coupler.
3) Remove the throttle body. (!Page 52)
4) Check the continuity between each terminal and ground.
$ STVA continuity: ∞ Ω (Infinity)
(Terminal – Ground)
5) If OK, then measure the STVA resistance (between terminal
A and terminal B) and (between terminal C and terminal D).
$ STVA resistance: Approx. 7 Ω
(Terminal A – Terminal B)
(Terminal C – Terminal D)
# 09900-25008: Multi-circuit tester set
) Tester knob indication: Resistance (Ω)
Is the resistance OK?
2
2
YES
• B/Lg, P/W, G and W/B wire open or shorted to
ground, or poor Y, [, d and f connection.
• If wire and connection are OK, intermittent trouble or faulty ECM.
• Recheck each terminal and wire harness for
open circuit and poor connection.
• Replace the ECM with a known good one, and
inspect it again.
NO
• Loose or poor contacts on the ECM coupler.
• Replace the STVA with a new one.
ECM coupler (Harness side)
2
DL650K7/AK7 (’07-MODEL) 13-29
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.
13-30 DL650K7/AK7 (’07-MODEL)
“C29” (P1654-H/L) STP SENSOR CIRCUIT MALFUNCTION
INSPECTION
NOTE:
After repairing the trouble, clear the DTC using SDS tool.
Step 1
1) Turn the ignition switch OFF.
2) Lift and support the fuel tank. (!DL650K4 5-7)
3) Check the STP sensor coupler for loose or poor contacts.
If OK, then measure the STP sensor input voltage.
4) Disconnect the STP sensor coupler.
5) Turn the ignition switch ON.
6) Measure the voltage at the Red wire A and ground.
7) Also, measure the voltage at the Red wire A and B/Br wire B.
$ STP sensor input voltage: 4.5 – 5.5 V
(+ Red – - Ground)
(+ Red – - B/Br)
# 09900-25008: Multi-circuit tester set
' Tester knob indication: Voltage ( )
Is the voltage OK?
DETECTED CONDITION POSSIBLE CAUSE
C29
(P1654)
Signal voltage is not within the following
range.
Difference between actual throttle opening and opening calculated by ECM is
larger than specified value.
0.1 V < Sensor voltage < 4.88 V
• STP sensor maladjusted.
• STP sensor circuit open or short.
• STP sensor malfunction.
• ECM malfunction.
P1654
H
Sensor voltage is higher than specified
value.
• STP sensor circuit shorted to VCC or ground circuit open.
• STP sensor circuit open or shorted to ground or
VCC circuit open.
L
Sensor voltage is lower than specified
value.
YES Go to Step 2.
NO
• Loose or poor contacts on the ECM coupler
(Terminal 5 or B).)
• Open or short circuit in the R wire or B/Br wire.
ECM
E2
VCCR
STP
STP sensor
B/Br
Y
1
1
V
DL650K7/AK7 (’07-MODEL) 13-31
Step 2
1) Turn the ignition switch OFF.
2) Remove the air cleaner box. (!Page 51)
3) Connect the STP sensor coupler.
4) Insert the needle pointed probes to the STP sensor coupler.
5) Disconnect the STVA lead wire coupler.
6) Turn the ignition switch ON.
7) Measure the STP sensor output voltage at the coupler
(between + Yellow wire and - B/Br wire) by turning the secondary throttle valve (close and open) with a finger.
$ STP sensor output voltage
Secondary throttle valve is closed: Approx. 0.6 V
Secondary throttle valve is opened: Approx. 4.5 V
# 09900-25008: Multi-circuit tester set
09900-25009: Needle pointed probe set
) Tester knob indication: Voltage ( )
Is the voltage OK?
“C31” (P0705) GP SWITCH CIRCUIT MALFUNCTION
On model K7, the connector terminals to be used for checking
sensors for voltage, resistance or continuity at the ECM terminal
are located as shown in the illustration.
* Refer to the DL650 service manual 4-41 for details.
2
V
22
YES
• Y, R, B/Br wire open or shorted to ground, or
poor 4, 5 or B connection.
• If wire and connection are OK, intermittent trouble or faulty ECM.
• Recheck each terminal and wire harness for
open circuit and poor connection.
• Replace the ECM with a known good one, and
inspect it again.
NO
• Reset the STP sensor position correctly.
• Replace the STP sensor with a new one.
ECM coupler (Harness side)
2
ECM coupler (Harness side)
13-32 DL650K7/AK7 (’07-MODEL)
“C32” (P0201) or “C33” (P0202) FUEL INJECTOR CIRCUIT MALFUNCTION
INSPECTION
NOTE:
After repairing the trouble, clear the DTC using SDS tool.
Step 1
(When indicating C32/P0201 for fuel injector #1)
(When indicating C33/P0202 for fuel injector #2)
1) Turn the ignition switch OFF.
2) Remove the air cleaner box. (!Page 51)
3) Check the injector coupler (Front cylinder side 1 or Rear cylinder side 2) for loose or poor contacts.
If OK, then measure the injector resistance.
4) Disconnect the injector coupler and measure the resistance
between terminals.
$ Injector resistance:11 – 13 Ω at 20 °C (68 °F)
(Terminal – Terminal)
DETECTED CONDITION POSSIBLE CAUSE
CKP signals produced but fuel injector signal is
interrupted continuous by several times (Front 50
times, Rear 25 times) or more.
• Injector circuit open or short.
• Injector malfunction.
• ECM malfunction.
ECM Fuel pump relay
Fuel injector
(Front cylinder) (Rear cylinder)
Y/R
Gr/W
Gr/B#1
#2
To engine
stop switch
1
1
DL650K7/AK7 (’07-MODEL) 13-33
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?
Step 2
1) Turn the ignition switch ON.
2) Measure the injector voltage between Y/R wire and ground.
NOTE:
Injector voltage can be detected only 3 seconds after ignition
switch is turned ON.
$ Injector voltage: Battery voltage
(+ Y/R – - Ground)
# 09900-25008: Multi-circuit tester set
' Tester knob indication: Voltage ( )
Is the voltage OK?
YES Go to Step 2.
NO
Replace the injector with a new one.
(!Page 54)
YES
• Gr/B wire open or shorted to ground, or poor k
connection.
(Front cylinder side)
• Gr/W wire open or shorted to ground, or poor b
connection.
(Rear cylinder side)
• If wire and connection are OK, intermittent trouble or faulty ECM.
• Recheck each terminal and wire harness for
open circuit and poor connection.
• Replace the ECM with a known good one, and
inspect it again.
NO Open circuit in the Y/R wire.
1
2
V
ECM coupler (Harness side)
2
13-34 DL650K7/AK7 (’07-MODEL)
“C40” (P0505 or P0506 and P0507) ISC VALVE CIRCUIT MALFUNCTION
%
INSPECTION
NOTE:
After repairing the trouble, clear the DTC using SDS tool.
Step 1
1) Turn the ignition switch OFF.
2) Remove the air cleaner box. (!Page 51)
3) Check the ISC valve coupler for loose or poor contacts.
If OK, then check the ISC valve lead wire continuity.
DETECTED CONDITION POSSIBLE CAUSE
C40
(P0505)
The circuit voltage of motor drive is
unusual.
Idle speed is higher than the normal
condition.
• ISC valve circuit open or shorted to ground
• Power source circuit open
• ISC valve is fixed to full open
• Disconnected ISC valve hose
C40
(P0506)
Idle speed is lower than the desired idle
speed.
• Air passage clogged
• ISC valve is fixed
• ISC valve PRE-SET position is incorrect
C40
(P0507)
Idle speed is higher than the desired
idle speed.
• Disconnected ISC valve hose
• ISC valve is fixed
• ISC valve PRE-SET position is incorrect
ECM
ISC. 1A
ISC. 1B
ISC. 2A
ISC. 2B
BATT
ISC valve
Lbl
W/Y
Dbr
R/W
Lg 12 V
Be careful not to disconnect the ISC valve coupler at
least 5 seconds after ignition switch is turned to OFF.
If the ECM coupler or ISC valve coupler is disconnected within 5 seconds after ignition switch is turned
to OFF, there is a possibility of an usual valve being
written in ECM and causing an error of ISC valve operation.
1
DL650K7/AK7 (’07-MODEL) 13-35
4) Disconnect the ISC valve coupler and ECM coupler.
5) Check the continuity between terminals A and i, terminals
B and 0, terminals C and g, terminals D and \, terminals
E and 0, and terminals F and ^.
%
$ ISC valve wire continuity: Continuity (*)
# 09900-25008: Multi-circuit tester set
09900-25009: Needle pointed probe set
+ Tester knob indication: Continuity test (*)
Is the continuity OK?
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 – Terminal 4)
4) If OK, then measure the resistance between terminals 1 and
2, terminals 3 and 4.
$ ISC valve resistance: Approx. 30 ± 1.2 Ω at 20 °C (68 °F)
(Terminal 1 – Terminal 2)
(Terminal 3 – Terminal 4)
Is the resistance OK?
When using the multi-circuit tester, do not strongly
touch the terminal of the ECM coupler with a needle
pointed tester probe to prevent the terminal damage
or terminal bend.
YES Go to Step 2.
NO Lbl, W/Y, Dbr, R/W or Lg wire open.
1
ECM coupler (Harness side)
1
YES If wire is OK, intermittent trouble or faulty ECM.
NO Replace the ISC valve with a new one.
2
13-36 DL650K7/AK7 (’07-MODEL)
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” 2 is idle speed 1 300 ± 100 rpm.
6) Check that the “Desired idle speed” 3 is within the specified
idle rpm.
Check 2
1) Click the button 1 and decrease the “Spec” 2 to 1 200 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” 2 slowly.
4) Check that the “Desired idle speed” 3 is nearly equal to the
“Spec” 2. Also, check that the number of steps 5 in the ISC
valve position increases.
DL650K7/AK7 (’07-MODEL) 13-37
Check 3
1) Click the button 1 and increase the “Spec” 2 to 1 400 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.
Check 4
1) Increase the “Spec” 1 to 1 800 rpm.
2) Check that the “Desired idle speed” 2 is approx. 1 800 rpm.
3) Check that the “Engine speed” 3 is close to 1 800 rpm.
NOTE:
Be careful not to increase the “Spec” to more than 1 800 rpm, or
the “Engine speed” may reach the upper limit.
If the ISC valve does not function properly, replace the ISC valve or inspect the ISC valve. (!Page 63)
13-38 DL650K7/AK7 (’07-MODEL)
“C41” (P0230) FP RELAY CIRCUIT MALFUNCTION
On model K7, the connector terminals to be used for checking
sensors for voltage, resistance or continuity at the ECM terminal
are located as shown in the illustration.
* Refer to the DL650 service manual 4-44 for details.
“C42” (P01650) IG SWITCH CIRCUIT MALFUNCTION
* Refer to the DL650 service manual 8-39 for details.
ECM coupler (Harness side)
DL650K7/AK7 (’07-MODEL) 13-39
“C44” (P0130/P0135) HO2 SENSOR (HO2S) CIRCUIT MALFUNCTION
(FOR E-02, 19, 24, 41)
INSPECTION
NOTE:
After repairing the trouble, clear the DTC using SDS tool.
Step 1 (When indicating C44/P0130:)
1) Turn the ignition switch OFF.
2) Remove the seat. (!DL650K4 7-4)
3) Check the HO2 sensor for loose or poor contacts.
If OK, then check the HO2 sensor lead wire continuity.
4) Disconnect the HO2 sensor coupler.
5) Check the continuity between W/G wire A and ground.
6) Also, check the continuity between W/G wire A and B/Br wire
B. If the sound is not heard from the tester, the circuit condition is OK.
# 09900-25008: Multi-circuit tester set
+ Tester knob indication: Continuity test (*)
DETECTED CONDITION POSSIBLE CAUSE
C44
(P0130)
HO2 sensor output voltage is not input
to ECM during engine operation and
running condition.
(Sensor voltage < 0.45 V)
• HO2 sensor circuit open or shorted to ground.
• Fuel system malfunction.
• ECM malfunction.
C44
(P0135)
The heater can not operate so that
heater operation voltage is not supply to
the oxygen heater circuit.
• Battery voltage supply to the HO2 sensor.
ECM
Side-stand
relay
Ignition
switch
Engine stop
switch
O/W
WG
r BW
B/Br
W/G
W/B
HO2 sensor
HO2S
HO2. H
E2
To GP
switch
1
1
]
13-40 DL650K7/AK7 (’07-MODEL)
7) Disconnect the ECM coupler.
8) Check the continuity between W/G wire A and terminal 6.
9) Also, check the continuity between B/Br wire B and terminal B.
%
$ HO2 sensor lead wire continuity: Continuity (*)
# 09900-25008: Multi-circuit tester set
09900-25009: Needle pointed probe set
+ Tester knob indication: Continuity test (*)
Is the continuity OK?
Step 2 (When indicating C44/P0130:)
1) Connect the ECM coupler and HO2 sensor coupler.
2) Warm up the engine enough.
3) Measure the HO2 sensor output voltage between W/G wire
and B/Br wire, when idling condition.
$ HO2 sensor output voltage at idle speed:
0.4 V and less (+ W/G – - B/Br)
4) If OK, then pinch the PAIR hose 1 with a proper hose clamp.
5) Measure the HO2 sensor output voltage while holding the
engine speed at 5 000 r/min.
$ HO2 sensor output voltage at 5 000 r/min:
0.6 V and more (+ W/G – - B/Br)
# 09900-25008: Multi-circuit tester set
09900-25009: Needle pointed probe set
' Tester knob indication: Voltage ( )
When using the multi-circuit tester, do not strongly
touch the terminal of the ECM coupler with a needle
pointed tester probe to prevent the terminal damage
or terminal bend.
YES Go to Step 2. (When indicating C44/P0130:)
NO
W/G wire shorted to ground, or W/G or B/Br wire
open.
1
]
ECM coupler (Harness side)
2
V
2
DL650K7/AK7 (’07-MODEL) 13-41
Is the voltage OK?
Step 1 (When indicating C44/P0135:)
1) Turn the ignition switch OFF.
2) Remove the seat. (!DL650K4 7-4)
3) Check the HO2 sensor for loose or poor contacts.
If OK, then measure the HO2 sensor resistance.
4) Disconnect the HO2 sensor coupler and measure the resistance between terminals.
NOTE:
* Temperature of the sensor affects resistance value largely.
* Make sure that the sensor heater is at correct temperature.
$ HO2 heater resistance: 11 – 15 Ω at 23 °C (73.4 °F)
(White – White)
# 09900-25008: Multi-circuit tester set
) Tester knob indication: Resistance (Ω)
Is the voltage OK?
YES
• W/G wire or B/Br wire open or shorted to
ground, or poor 6 or B connection.
• If wire and connection are OK, intermittent trouble or faulty ECM.
• Recheck each terminal and wire harness for
open circuit and poor connection.
• Replace the ECM with a known good one, and
inspect it again.
NO Replace the HO2 sensor with a new one.
ECM coupler (Harness side)
2
1
YES Go to Step 2.
NO Replace the HO2 sensor with a new one.
1
13-42 DL650K7/AK7 (’07-MODEL)
Step 2 (When indicating C44/P0135:)
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.
$ Heater voltage: Battery voltage
(+ W/B – - Ground)
NOTE:
Battery voltage can be detected only before starting the engine.
# 09900-25008: Multi-circuit tester set
09900-25009: Needle pointed probe set
' Tester knob indication: Voltage ( )
Is the voltage OK?
“C49” (P1656) PAIR CONTROL SOLENOID VALVE CIRCUIT MALFUNCTION
On model K7, the connector terminals to be used for checking
sensors for voltage, resistance or continuity at the ECM terminal
are located as shown in the illustration.
* Refer to the DL650 service manual 4-45 for details.
YES
• O/W or W/B wire open or shorted to ground, or
poor G connection.
• Recheck each terminal and wire harness for
open circuit and poor connection.
• If wire and connection are OK, intermittent trouble or faulty ECM.
• Replace the ECM with a known good one, and
inspect it again.
NO
• Open or short circuit in the W/B wire or O/W
wire.
• Loose or poor contacts on the ECM coupler
(terminal G) or HO2 sensor coupler.
2
V
ECM coupler (Harness side)
2
ECM coupler (Harness side)
DL650K7/AK7 (’07-MODEL) 13-43
FUEL PUMP
FUEL DISCHARGE AMOUNT INSPECTION
"
• Lift and support the fuel tank. (!DL650K4 5-7)
• Disconnect the fuel feed hose 1 from the fuel tank.
• Connect a proper fuel hose 2 to the fuel pump.
• Place the measuring cylinder and insert the fuel hose end into
the measuring cylinder.
• Disconnect the fuel pump lead wire coupler 3.
• Connect a proper lead wire into the fuel pump lead wire coupler (fuel pump side) and apply 12 volts to the fuel pump
(between Y/R wire and B/W wire) for 6 seconds and measure
the amount of fuel discharged.
Battery + terminal (Yellow with red tracer)
Battery - terminal (Black with white tracer)
If the pump does not discharge the amount specified, it means
that the fuel pump is defective or that the fuel filter is clogged.
$ Fuel discharge amount: 75 ml and more/6 sec.
(2.5/2.6 US/Imp oz)/6 sec.
NOTE:
The battery must be in fully charged condition.
Gasoline is highly flammable and explosive.
Keep heat, spark and flame away.
13-44 DL650K7/AK7 (’07-MODEL)
FUEL PUMP CONSTRUCTION
1 Fuel level gauge 5 Fuel pump
2 O-ring 6 Fuel mesh filter &
3 Fuel pressure regulator 7 O-ring ITEM N·m kgf-m lb-ft
4 O-ring A Fuel pump mounting bolt A 10 1.0 7.0
DL650K7/AK7 (’07-MODEL) 13-45
FUEL PUMP REMOVAL AND DISASSEMBLY
REMOVAL
• Remove the fuel tank. (!DL650K4 5-7)
• Remove the fuel pump assembly by removing its mounting
bolts diagonally.
"
DISASSEMBLY
• Remove the screws.
• Disconnect the terminals and
• Remove the fuel level gauge 1.
• Remove the fuel pressure regulator holder 2.
Gasoline is highly flammable and explosive.
Keep heat, spark and flame away.
13-46 DL650K7/AK7 (’07-MODEL)
• Remove the fuel pressure regulator 3.
• Remove the O-ring 4 and fuel pump holder 5.
• Remove the fuel mesh filter 6.
• Remove the fuel pump 7.
• Remove the fuel joint pipe 8.
DL650K7/AK7 (’07-MODEL) 13-47
FUEL MESH FILTER INSPECTION AND
CLEANING
If the fuel mesh filter is clogged with sediment or rust, fuel will
not flow smoothly and loss in engine power may result.
Blow the fuel mesh filter with compressed air.
NOTE:
If the fuel mesh filter is clogged with many sediment or rust,
replace the fuel filter cartridge with a new one.
FUEL PUMP REASSEMBLY AND
INSTALLATION
Reassemble and Install the fuel pump in the reverse order of
removal. Pay attention to the following points:
• Install the new O-rings.
• Apply thin coat of the engine oil to the O-rings.
%
• Connect the lead wire terminals.
A ......+ terminal for fuel pump
B ......+ terminal for fuel level gauge
• Install the fuel level gauge.
Use the new O-rings to prevent fuel leakage.
13-48 DL650K7/AK7 (’07-MODEL)
• Install a new O-ring and apply SUZUKI SUPER GREASE to it.
"
, 99000-25010: SUZUKI SUPER GREASE “A”
(or equivalent grease)
• When installing the fuel pump assembly, first tighten all the
fuel pump assembly mounting bolts lightly in the ascending
order of numbers, and then tighten them to the specified
torque in the above tightening order
.
& Fuel pump mounting bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft)
NOTE:
Apply a small quantity of the THREAD LOCK to the thread portion of the fuel pump mounting bolt.
- 99000-32050: THREAD LOCK “1342”
The O-ring must be replaced with a new one to prevent
fuel leakage.
1
2
3
4
5
6
DL650K7/AK7 (’07-MODEL) 13-49
THROTTLE BODY
CONSTRUCTION
Only for E-33
1 STP sensor 8 Secondary throttle link rod
2 TP sensor 9 Throttle link rod
3 O-ring 0 STVA &
4 Fuel delivery pipe/hose A STP sensor mounting screw ITEM N·m kgf-m lb-ft
5 Fuel injector B TP sensor mounting screw A 3.5 0.35 2.5
6 O-ring
C
Fuel delivery pipe mounting
screw
B 3.5 0.35 2.5
7 Cushion seal C 5 0.5 3.5
13-50 DL650K7/AK7 (’07-MODEL)
AIR CLEANER AND THROTTLE BODY
REMOVAL
AIR CLEANER BOX
• Remove the fuel tank. (!DL650K4.5-7)
• Remove the IAP sensor vacuum hoses (1, 2).
• Disconnect the IAP sensor (R) coupler 3.
• Remove the clamp and disconnect the IAP sensor (F) coupler
4.
• Loosen the throttle body clamp screws.
• Disconnect the PAIR hose and ISC valve hose.
• Disconnect the PAIR lead wire coupler 5.
• Disconnect the crankcase breather hoses.
• Disconnect the IAT sensor coupler 6.
• Remove the air cleaner box.
DL650K7/AK7 (’07-MODEL) 13-51
THROTTLE BODY
• Disconnect the various lead wire couplers.
1 TP sensor
2 STP sensor
3 STVA
• Remove the injector lead wire couplers.
• Disconnect the ISC valve hoses.
• Loosen the throttle body clamp screws.
13-52 DL650K7/AK7 (’07-MODEL)
• Disconnect the throttle cables from their drum.
• Dismount the throttle body assembly.
%
THROTTLE BODY DISASSEMBLY
%
• Remove the vacuum hoses (1, 2).
• Disconnect the fuel feed hose 3.
• Remove the throttle link rod 4 and secondary throttle link rod
5.
NOTE:
The throttle link rod 4 is longer than the secondary throttle link
rod 5.
• Remove the fuel delivery pipe/hose 6.
* Be careful not to damage the throttle cable bracket
and fast idle lever when dismounting or remounting
the throttle body assembly.
* After disconnecting the throttle cables, do not snap
the throttle valve from full open to full close. It may
cause damage to the throttle valve and throttle body.
* Be careful not to damage the throttle lever when disassembling the throttle body.
* The throttle body is assembled precisely in factory.
Do not disassemble it other than shown in this manual.
DL650K7/AK7 (’07-MODEL) 13-53
• Remove the fuel injectors.
• Remove the TP sensor 7 and STP sensor 8 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.
%
%
Never remove the STVA 9 and throttle body link
plates 0.
These adjusting screws (A, B, C) are factoryadjusted at the time of delivery and therefore avoid
removing or turning them unless otherwise necessary.
13-54 DL650K7/AK7 (’07-MODEL)
%
THROTTLE BODY CLEANING
"
• Clean all passageways with a spray-type carburetor cleaner
and blow dry with compressed air.
%
INSPECTION
Check following items for any damage or clogging.
* O-ring
* Throttle valve
* Secondary throttle valve
* Vacuum hose
* Delivery pipe/hose
* Injector cushion seal
Never remove the throttle valve D and secondary
throttle valve E.
Some carburetor cleaning chemicals, especially diptype soaking solutions, are very corrosive and must
be handled carefully. Always follow the chemical manufacturer’s instructions for proper use, handling and
storage.
Do not use wire to clean passageways. Wire can damage passageways. If the components cannot be
cleaned with a spray cleaner it may be necessary to
use a dip-type cleaning solution and allow them to
soak. Always follow the chemical manufacturer’s
instructions for proper use and cleaning of the throttle
body components. Do not apply carburetor cleaning
chemicals to the rubber and plastic materials.
DL650K7/AK7 (’07-MODEL) 13-55
THROTTLE BODY REASSEMBLY
Reassemble the throttle body in the reverse order of disassembly. Pay attention to the following points:
• With the STV fully closed, install the STP sensor 1 and
tighten the STP sensor mounting screw to the specified
torque.
NOTE:
* Apply thin coat of the engine oil to the O-ring.
* Align the secondary throttle shaft end A with the groove B of
STP sensor.
* Apply SUZUKI SUPER GREASE “A” to the secondary throttle
shaft end A if necessary.
, 99000-25010: SUZUKI SUPER GREASE “A”
(or equivalent)
# 09930-11950: Torx wrench
& STP sensor mounting screw: 3.5 N·m (0.35 kgf-m, 2.5 lb-ft)
NOTE:
* Make sure the STP valve open or close smoothly.
* If the STP sensor adjustment is necessary, refer to page 59 for
STP sensor setting procedure.
• With the throttle valve fully closed, install the TP sensor 2
and tighten the TP sensor mounting screw to the specified
torque.
NOTE:
* 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”
(or equivalent)
# 09930-11950: Torx wrench
& TP sensor mounting screw: 3.5 N·m (0.35 kgf-m, 2.5 lb-ft)
NOTE:
* Make sure the throttle valve open or close smoothly.
* TP sensor setting procedure. (!Page 60)
13-56 DL650K7/AK7 (’07-MODEL)
• Apply thin coat of the engine oil to the new cushion seal 3,
and the O-ring 4.
%
• Install the fuel injector 5 by pushing it straight to the delivery
pipe 6.
NOTE:
Align the coupler E of injector with boss F of the delivery pipe.
%
• Install the fuel delivery pipe/hose 7 to the throttle body
assembly.
%
• Tighten the fuel delivery pipe mounting screws to the specified torque.
& Fuel delivery pipe mounting screw:
5 N·m (0.5 kgf-m, 3.5 lb-ft)
• Install the throttle link rod 8 and secondary throttle link rod
9.
NOTE:
The throttle link rod 8 is longer than the secondary throttle link
rod 9.
Replace the cushion seal and O-ring with the new
ones.
Never turn the injector while pushing it.
Never turn the fuel injectors while installing them.
DL650K7/AK7 (’07-MODEL) 13-57
AIR CLEANER BOX AND THROTTLE BODY
INSTALLATION
Installation is in the reverse order of removal. Pay attention to
the following points:
• Connect the throttle pulling cable 1 and throttle returning
cable 2 to the throttle cable drum.
• Loosen each throttle cable lock-nut.
• Turn in each throttle cable adjuster fully and locate each outer
cable so that the clearance is 0 mm (0 in).
• Tighten each lock-nut.
• Adjust the throttle cable play.
Refer to page 14 for details.
• 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 coupler refers to the appropriate fuel
injector.
Front injector lead wire coupler 3: Brown
Rear injector lead wire coupler 4: Gray
• Connect the TP sensor lead wire coupler 5 and STP sensor
lead wire coupler 6.
%
TPS lead wire coupler 5: Gray
STPS lead wire coupler 6: Black
• Install the air cleaner box and tighten the throttle body clamp
screws as shown in the illustration. (!Page 136)
0 mm (0 in)
0 mm (0 in)
TP sensor lead wire coupler and STP sensor lead wire
coupler resemble each other very closely in external
appearance.
Make sure to check the color of coupler before installing.
13-58 DL650K7/AK7 (’07-MODEL)
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 box. (!Page 51)
• Disconnect the STVA coupler. (!Page 28)
• Insert the needle pointed probes to the STP sensor lead wire
coupler.
• Turn the ignition switch ON.
• Close the secondary throttle valve by finger, and measure the
STP sensor out put voltage.
$ STP sensor output voltage
ST valve is full closed: Approx. 0.6 V
(+ Yellow – - B/Br)
# 09900-25008: Multi-circuit tester set
09900-25009: Needle pointed probe set
' Tester knob indication: Voltage ( )
• If the STP sensor voltage is out of specification, loosen the
STP sensor mounting screw and adjust the STP sensor voltage to specification.
• Tighten the STP sensor mounting screw.
# 09930-11950: Torx wrench
& STP sensor mounting screw:
3.5 N·m (0.35 kgf-m, 2.5 lb-ft)
V
DL650K7/AK7 (’07-MODEL) 13-59
TP SENSOR ADJUSTMENT
After all adjustments are completed, check or adjust the TPS
setting condition.
1. Warm up the engine and check the engine idle r/min.
2. Remove the seat. (!DL650K4 7-4)
3. Connect the special tool (Mode select switch) to the dealer
mode coupler at the wiring harness. (!Page 64)
4. Lift and support the fuel tank. (!DL650K4 5-7)
5. If the throttle position sensor adjustment is necessary, loosen
the screw and turn the throttle position sensor and bring the
line to the middle.
6. Then, tighten the screw to fix the throttle position sensor.
# 09930-11950: Torx wrench
09930-82720: Mode select switch
The LCD displays the line for 0.4 sec. at a time, and when such
a display repeats two times, it indicates the current position
where the sensor is fixed.
A Incorrect
B Correct position
13-60 DL650K7/AK7 (’07-MODEL)
THROTTLE VALVE SYNCHRONIZATION
USE OF SDS TOOL
Check and adjust the throttle valve synchronization between two
cylinders.
Step 1
• Lift and support the fuel tank. (!DL650K4 5-7)
• Remove the rubber caps 1 from each vacuum nipple on the
throttle body.
• Connect the vacuum tester hoses 2 to each vacuum nipple.
Step 2
• Connect a tachometer.
• Set up the SDS tool.
• Click “Data monitor”.
• Warm up the engine (Water temp. more than 80 °C (176 °F)).
DL650K7/AK7 (’07-MODEL) 13-61
• Click “Active control”.
• Click “ISC air volume control” 3.
• Click “ON” bottom 4 to fix the ISC air volume between two
cylinders.
NOTE:
When making this synchronization, be sure that the water temperature is within 80 – 100 °C (176 – 212 °F).
A Engine speed: Approx. 1 300 rpm
B ISC valve position: Approx. 58 step
• Check for the synchronization of vacuum between #1 and #2
cylinders.
• Equalize the #1 and #2 vacuum by turning each air screw 5
and keep it running at idling speed.
NOTE:
Always set the engine rpm at idle rpm.
# 09913-10130: Carburetor adjuster driver
• If the adjustment is not yet correct, remove each air screw
and clean them with a spray-type carburetor cleaner and blow
dry with a compressed air.
• Also, clean the air screw passageways.
NOTE:
* Slowly turn the air screw in clockwise and count the number of
turns until the screw is lightly seated.
* Make a note of how many turns were made so the screw can
be reset correctly after cleaning.
Step 3
Repeat the procedures of Step 2.
#1 #2
13-62 DL650K7/AK7 (’07-MODEL)
ISC VALVE
REMOVAL
• Remove the air cleaner box. (!Page 51)
• Disconnect the ISC valve coupler 1.
%
• Disconnect the hoses and remove the ISC valve 2.
INSTALLATION
Install the ISC valve in the reverse order of removal.
NOTE:
When removing or replacing the ISC valve, must be set the ISC
valve to the PRE-SET position. (!Page 64)
INSPECTION
The ISC valve can be checked without removing it.
NOTE:
The ISC valve can be checked without removing it.
(!Page 37)
If the resistance is not within the standard range, replace the
ISC valve motor assembly with a new one.
Visual inspection
• Remove the screws.
• Check the ISC valve for wear, damage or carbon deposited,
replace it with a new one.
%
Be careful not to disconnect the ISC valve coupler at
least 5 seconds after ignition switch is turned to OFF.
If the ECM coupler or ISC valve coupler is disconnected within 5 seconds after ignition switch is turned
to OFF, there is a possibility of an usual valve position being written in the ECM and causing an error of the
ISC valve operation.
Normally, the removed O-ring must be replaced with a
new one. However, this O-ring is not available for the
spare parts. If it is found to be damaged, replace the
ISC valve with new one.
DL650K7/AK7 (’07-MODEL) 13-63
13-64 DL650K7/AK7 (’07-MODEL)
ISC VALVE PRE-SET
When removing or replacing the ISC valve, set the ISC valve
using the following procedure:
PROCEDURE
1) Turn the ignition switch to the OFF position.
2) Remove the seat. ( 7-4)
3) Connect the special tool to the dealer mode coupler and turn
its switch to ON position.
09930-82720: Mode select switch
4) Turn the ignition switch to the ON position.
5) Turn the ignition switch to the OFF position.
6) Then, wait more than 5 seconds.
NOTE:
The ISC valve automatically is set at the PRE-SET position.
7) Turn the special tool to the OFF position and remove it from
the dealer mode coupler.
DL650
DL650A
IGNITION SYSTEM
INSPECTION
IGNITION COIL PRIMARY PEAK VOLTAGE
• Disconnect all the spark plug caps. (!Page 12)
• Connect new spark plugs to each spark plug cap and ground
them on the cylinder.
NOTE:
Be sure that all the spark plugs are connected properly and the
battery used is in fully-charged condition.
Measure ignition coil primary peak voltage (for #1 cylinder) in
the following procedure.
• Insert the needle pointed probe A to the lead wire coupler (for
B/W wire).
%
# 09900-25009: Needle pointed probe set
• Connect the multi-circuit tester with the peak voltage adaptor
as follows.
Ignition coil (for #1cylinder):
B/W wire (+ Probe) – Ground (- Probe)
NOTE:
Do not disconnect the ignition coil primary lead wire.
# 09900-25008: Multi-circuit tester set
%
Use the special tool, to prevent the rubber of the water
proof coupler from damage.
Before using the multi-circuit tester and peak voltage
adaptor, refer to the appropriate instruction manual.
Peak volt adaptor
Ignition coil
ECM
Battery
New spark plugs
B/WW/Bl
DL650K7/AK7 (’07-MODEL) 13-65
• Shift the transmission into neutral, turn the ignition switch to
the “ON” position and grasp the clutch lever.
• Press the starter button and allow the engine to crank for a
few seconds, and then measure the ignition coil primary peak
voltage.
• Repeat the above procedure a few times and measure the
highest ignition coil primary peak voltage.
$ Ignition coil primary peak voltage: 150 V and more
' Tester knob indication: Voltage ( )
"
Measure ignition coil primary peak voltage (for #2 cylinder) in
the same manner as for cylinder #1.
Ignition coil (for #2 cylinder):
B wire (+ Probe) – Ground (- Probe)
NOTE:
Do not disconnect the ignition coil primary lead wire.
A Needle pointed probe
$ Ignition coil primary peak voltage: 150 V and more
' Tester knob indication: Voltage ( )
"
If the voltages are lower than the standard values, inspect the
ignition coil. (!below)
IGNITION COIL RESISTANCE
• Measure the ignition coil resistance in both the primary and
secondary windings. If the windings are in sound condition,
their resistance should be close to the specified values.
$ Ignition coil resistance
Primary: 1 – 5 Ω (Terminal – Terminal)
Secondary: 25 – 40 kΩ
(Spark plug cap – Spark plug cap)
) Tester knob indication: Resistance (Ω)
Do not touch the tester probes and spark plugs to prevent an electric shock while testing.
Do not touch the tester probes and spark plugs to prevent an electric shock while testing.
B/W
Peak volt adaptor
Ignition coil
ECM
Battery
New spark plugs
B
13-66 DL650K7/AK7 (’07-MODEL)
COMBINATION METER
FUEL LEVEL GAUGE INSPECTION
!DL650K4 8-33
FUEL LEVEL METER INSPECTION
• Remove the fuel tank left side cover. (!DL650K4 7-4)
• Disconnect the fuel pump lead wire coupler.
• Connect the each resistor between the Yellow/Black and
Black/White lead wires at the wire harness.
• Turn the ignition switch “ON” position and wait for approx. 40
seconds.
Check the display of fuel meter as shown below, If any abnormality is found, replace the combination meter with a new one.
Resistance
More than
167.0 Ω
9.0 Ω
and less87.5 – 167.0 Ω 50.0 – 87.5 Ω 26.0 – 50.0 Ω 9.0 – 26.0 Ω
Fuel level
meter
DL650K7/AK7 (’07-MODEL) 13-67
INTRODUCTION OF ABS (For DL650A)
FRONT AND REAR WHEEL SPEED
SENSORS
Wheel speed sensor consists of wheel speed sensor 1 and
sensor rotor 2.
ABS CONTROL UNIT
ABS control unit calculates signals input from each one of front
and rear wheel speed sensors, monitors the slipping conditions
of the wheels and, at the same time, sends control signal to
Hydraulic Unit (HU).
This ABS control unit/HU can not be disassembled.
ABS control unit
HU
13-68 DL650K7/AK7 (’07-MODEL)
ABS CONTROL UNIT CALCULATING PROCESS
The ABS controls and its calculations, in addition to the self-diagnosing and the fail-safe processes, occur
during the ABS control unit calculating process. In addition, if a malfunction is detected by the self-diagnosis
function, the brake stops being controlled by the ABS and a diagnostic trouble code is stored.
Normal calculating process Calculating process when a malfunction occurs
Ignition switch turned to ON
ABS control unit Initialization
Self-diagnosis
(during start up)
Self-diagnosis (while riding)
Wheel speed sensor signal
enters
ABS control calculation
Hydraulic unit control signal
output
ABS indicator light
lights up
Is ABS under control ?
Diagnostic trouble code
memorized
Malfunction
indicated
Malfunction
indicated
No malfunction
Correct
Interim ABS control
YES
NO
Prohibition of ABS control
DL650K7/AK7 (’07-MODEL) 13-69
HYDRAULIC UNIT (HU)
The hydraulic unit operates the solenoid valves based upon the signal which is output from the ABS control
unit. The brake fluid pressure is then adjusted accordingly. The hydraulic unit controls the front and rear
brake systems individually by operating separate components for the front and the rear, except for the pump
drive motor, which is shared by both systems.
Rear brake switch
Rear wheel
speed sensor
Front wheel
speed sensor
Rear systemFront system
ABS indicator light
Front brake switch
One-way
valve
Damper Damper
Solenoid
valve OUT
Solenoid
valve OUT
Solenoid
valve IN
Solenoid
valve IN
Motor
Rear brake
caliperFront brake
caliper
Front brake lever/
master cylinder
HU
Rear brake pedal/
master cylinder
ABS
control unit
13-70 DL650K7/AK7 (’07-MODEL)
DL650K7/AK7 (’07-MODEL) 13-71
FAIL-SAFE FUNCTION
If malfunction occurs in the ABS electric system, this sets valve relay OFF. Consequently, motor relay will be
set OFF and the indicator light ON, and no current will be applied to motor solenoid valve inactivating ABS
and turning ABS indicator light ON. In this case, it functions as the normal brake. However, if a malfunction
occurs while ABS is being activated, when ABS control unit diagnoses that the operation can continue, it will
effectuate ABS provisional control (turning the ABS indicator light ON). Upon the moment when ABS provisional control is over, the valve relay will be set OFF.
SELF-DIAGNOSIS FUNCTION AND ABS INDICATOR LIGHT
The ABS control unit performs the self-diagnosis and can store any electronically detected malfunctions as
diagnostic trouble codes. If a malfunction has occurred, the indicator light lights up to inform the rider of the
malfunction. The special tool, when connected to the mode select coupler, enables the ABS indicator light to
display the diagnostic trouble codes.
ABS INDICATOR LIGHT
The ABS indicator light informs the rider of any ABS malfunctions. If a malfunction occurred, the ABS indicator light flashes,
during the self-diagnosis, to indicate the diagnostic trouble code
so that the correct part can be repaired.
• When the ignition switch is turned to ON, the ABS indicator
light lights up even if no malfunction has occurred, to indicate
that the bulb is not burnt out. It will go off after the motorcycle
is ridden at more than 5 km/h (3.1 mile/h).
• If an ABS malfunction has occurred, the ABS indicator light
keeps lighting up.
• When a malfunction has occurred in the ABS, connect the
special tool to the mode select coupler to display the diagnostic trouble code on the ABS indicator light. ( 13-89)
09930-82710: Mode select switch
ABS control unit
CPU
Ignition switchMotor relay
M
Motor
Valve relay
Solenoid valves
ABS indicator light
Indicator relay
O
B/W
CAUTIONS IN SERVICING
ABS WIRING
• The ABS parts are connected to various lead wires. The coupler and lead wire connections, as well as the lead wire and
wire harness routing must be done correctly. Make sure that
the proper clamps are used and positioned correctly.
NOTE:
If all of the connections are not properly connected, the ABS
may not operate correctly. For connector and coupler precautions. (!DL650K4 4-2 and 8-2)
• When connecting meter probe from the terminal side of the
coupler (where connection from harness side not being possible), use extra care not to force and cause the male terminal
to bend or the female terminal to open.
• Check the male connector for bend and female connector for
excessive opening. Also check the coupler for locking (looseness), corrosion, dust, etc.
FUSES
• If a fuse is blown, find the cause of the problem and correct it
before replacing the fuse.
• Only use a fuse of the specified rating.
• Never improvise when replacing a fuse.
Click
Click
13-72 DL650K7/AK7 (’07-MODEL)
BATTERY
• Only use a fully charged battery.
• In order to prevent damage to the ABS control unit etc., be
sure to connect the battery properly.
• Never disconnect the battery or any other lead wires while the
engine is running.
NOTE:
For battery and battery connection precautions.
(!DL650K4 4-4 and 8-3)
ABS CONTROL UNIT/HU
• Never allow dust or water to contact the ABS control unit/HU.
• Never subject the ABS control unit/HU to strong impacts or
allow them to be dropped.
• The ABS control unit/HU cannot be disassembled. Replace
the whole unit with a new one.
Incorrect
Incorrect
Incorrect
DL650K7/AK7 (’07-MODEL) 13-73
ABS INFORMATION
"
• Be sure to route the brake hoses correctly.
• The ABS does not shorten the motorcycle’s braking distance. When riding down slopes or on wet or
bumpy roads the braking distance is lengthened as compared to a motorcycle without ABS. In addition,
braking distance increases the more slippery the road is.
• The ABS does not control slides which may occur when braking while turning. As with a motorcycle that
does not have ABS, it is best not apply the brakes while turning.
• The brake levers may move by themselves when they are applied. This is not a malfunction.
• Only use the specified tires.
TESTER
• Use the Suzuki multi-circuit tester (09900-25008).
• Use well-charged batteries in the tester.
• Be sure to set the tester to the correct testing range.
• Since the resistance may differ depending on the tester used
and the temperature, the resistance should be set to the specification.
USING THE TESTER
• Incorrectly connecting the + and - probes may cause the
inside of the tester to burnout.
• If the voltage and current are not known, make measurements using the highest range.
• When measuring the resistance with the multi-circuit tester, ∞
will be shown as 10.00 MΩ and “1” flashes in the display.
• Check that no voltage is applied before making the measurement. If voltage is applied the tester may be damaged.
• After using the tester, turn the power off.
# 09900-25008: Multi-circuit tester set
NOTE:
* When connecting the multi-circuit tester, use a needle pointed
probe set to the back side of the lead wire coupler and connect
the probes of tester to them.
* Use a needle pointed probe set to prevent the rubber of the
water proof coupler from damage.
# 09900-25009: Needle pointed probe set
* Be sure to bleed air from the brake fluid circuit when the brake feel is spongy or when a brake
relating part is replaced.
* Never ride the motorcycle before bleeding the air.
MULTI-CIRCUIT TESTER
NEEDLE POINTED PROBE SET
13-74 DL650K7/AK7 (’07-MODEL)
ABS COMPONENTS
ABS COMPONENTS LOCATION
1 ABS indicator light 4 ABS control unit/HU
2 Front wheel speed sensor rotor 5 Rear wheel speed sensor rotor
3 Front wheel speed sensor 6 Rear wheel speed sensor
DL650K7/AK7 (’07-MODEL) 13-75
13-76 DL650K7/AK7 (’07-MODEL)
ABS COUPLER CONNECTION DIAGRAM
S
P
E
E
D
O
M
E
T
E
R
F
U
S
E
B
O
X
A
B
S
M
O
TO
R
F
U
S
E
F
R
O
N
T
W
H
E
E
L
S
P
E
E
D
S
E
N
S
O
R
IG
N
IT
IO
N
S
W
IT
C
H
M
O
D
E
SE
LE
C
T
SW
IT
C
H
R
E
A
R
W
H
E
E
L
S
P
E
E
D
S
E
N
S
O
R
A
B
S
C
O
N
T
R
O
L
U
N
ITA
B
S
V
A
LV
E
F
U
S
E
W
IR
E
H
A
R
N
E
S
S
(W
ire
h ar ne ss N
o. 2)
(W
ire
h ar ne ss N
o. 1)
(H
ar ne ss s id e) 1
0
A
1
5
A
1
5
A
1
0
A
1
5
A
1
5
A
1
0
A
1
5
A
O
B/W
O/R
O
O
Gr O/G
BrR
O/Y
BrB/R
Y
/B
BLg R
/W
B
/W B
l B
/G
Y
B
l/B
O
/G
B
r/ B
P
/W
G
/Y
O
/R
Bl/B B
Br/B
Lg P/W
B/W
R/W
Y
Y/B
Br Bl G/Y
O/R
B/Bl
B/G
O/G
Bl/B
Br/B
Lg P/W
B/W
R/W
Y
Y/B
Br B
Bl G/Y
O/R
W
B/G
O/G
W
B
W
B
B
/R
W
/R
B
/Y
W
/Y
25
A
40
A
S
PA
R
E
4
0A
S
PA
R
E
2
5A
B
O
RR
/B
B
/W
B
/R
W
/Y
G
r/ R
B
l W
/R
O
/Y
B
/Y
H
E
A
D
-H
I
IG
N
IT
IO
N
S
IG
N
A
L
H
E
A
D
-L
O
F
U
E
L
FA
N
S
PA
R
E
S
PA
R
E
W
IR
E
C
O
L
O
R
S
B
B
l B
r O
/G
O
/R
O
/Y
P
/W
R
/B
R
/W
W
/R
W
/Y
Y
/B
: B
la ck : B
lu e : B
ro w n : O
ra n g e w it h G
re en t ra ce r : O
ra n g e w it h R
ed t ra ce r : O
ra n g e w it h Y
el lo w t ra ce r : P
in k w it h W
h it e tr ac er : R
ed w it h B
la ck t ra ce r : R
ed w it h W
h it e tr ac er : W
h it e w it h R
ed t ra ce r : W
h it e w it h Y
el lo w t ra ce r : Y
el lo w w it h B
la ck t ra ce r G
r L
g O R W Y
: G
ra y : L
ig h t g re en : O
ra n g e : R
ed : W
h it e : Y
el lo w B
/B
l B
/G
B
/R
B
/W
B
/Y
B
l/B
B
r/ B
G
/Y
G
r/ R
: B
la ck w it h B
lu e tr ac er : B
la ck w it h G
re en t ra ce r : B
la ck w it h R
ed t ra ce r : B
la ck w it h W
h it e tr ac er : B
la ck w it h Y
el lo w t ra ce r : B
lu e w it h B
la ck t ra ce r : B
ro w n w it h B
la ck t ra ce r : G
re en w it h Y
el lo w t ra ce r : G
ra y w it h R
ed t ra ce r S
D
S
O/G
Gr/R
W/R B/W
ABS WIRING DIAGRAM
R O
B
/R O
O B
/Y
O
/Y
W
/R B
l G
r/ R
W
/Y
B
/R
B
/W
R
/B R B
O
/Y O O
/G B
/R
B
/W
B B
/Y
W
/Y
B
/R
W
/R
B W B W
O B
/WR RRR
R
R R
/B
B
I
O/G
Bl O/G
Bl O
/G
ON
OFF
LOCK
P
IGNITION SWITCH
BATTERY1: MAIN 30 A
STARTER
RELAY
1
FUSE BOX
1. HEAD HI
2. HEAD LO
3. FUEL
4. IGNITION
5. SIGNAL
6. FAN
15 A
15 A
10 A
10 A
15 A
15 A
1 2 3
4 5 6
ABS
FWS RWS
ABS
VALVE
FUSE
(25 A)
ABS
MOTOR
FUSE
(40 A)
ABS CONTROL UNIT
MODE
SELECT
COUPLER
SDS
COUPLERSPEEDOMETERABS INDICATOR LIGHT
DL650K7/AK7 (’07-MODEL) 13-77
ABS UNIT SYSTEM DIAGRAM
P
um p m ot or M
ot or re la y V
al ve re la y R
ea r w he el sp ee d se ns or Fr on t w
he el sp ee d se ns or A
B
S
in di ca to r lig
ht 25
11
16
5
7
19
4
1
3
2
12
18
4
3
2
1
15
14
13
12
11
10
9
8
7
6
5
26
25
24
23
22
21
20
19
18
17
16
1
Fr on t i
nl et v al ve 2
Fr on t o
ut le t v
al ve 3
R
ea r in le t v
al ve 4
R
ea r ou tle
t v
al ve F
us e 40
A
F
us e 25
A
F
us e 10
A
S
D
S
M
od e se le ct co up le r Ig ni tio
n B
at te ry 13-78 DL650K7/AK7 (’07-MODEL)
ABS TROUBLESHOOTING
ABS TROUBLESHOOTING DESCRIPTION
Many of the ABS malfunction diagnosing operations are performed by checking the wiring continuity. Quick
and accurate detection of malfunctions within the complex circuitry assures the proper operation of the ABS.
Before beginning any repairs, thoroughly read and understand this Supplementary Service Manual.
The ABS is equipped with a self-diagnosis function. The detected malfunction is stored as a diagnostic trouble code which causes the ABS indicator light to light up or flash in set patterns to indicate the malfunction.
Diagnostic trouble codes are stored even when the ignition switch is turned to OFF and they can only be
erased manually. In order to repair the ABS correctly, ask the customer for the exact circumstances under
which the malfunction occurred, then check the ABS indicator light and the output diagnostic trouble codes.
Explain to the customer that depending on how the motorcycle is operated (e.g., if the front wheel is off the
ground), the ABS indicator light may light up even though the ABS is operating correctly.
ABS OPERATION AND ABS INDICATOR LIGHT
The ABS indicator light shows the ABS operating condition. During normal operation, the ABS indicator light lights up when the
ignition switch is turned to ON and goes off after the motorcycle
is ridden at more than 5 km/h (3.1 mile/h). If a malfunction has
occurred, the ABS indicator light keeps lighting up.
STORED DTCs (Diagnostic Trouble Codes)
The maximum of six DTCs can be recorded. In these records, duplication of the same DTC will not occur. If
the system detects the 7th DTC, it overwrites the record of the oldest DTC.
Check and see if any diagnostic trouble code remains, by actually running the machine to activate ABS and
by carrying out the self-diagnosis after deleting the diagnostic trouble code once the malfunctioned part is
repaired.
The ABS indicator light goes off when the motorcycle is ridden at more than 5 km/h (3.1 mile/h).
The ABS is normally activated.
The ABS indicator light keeps lighting up even
though the motorcycle is ridden at more than 5 km/h
(3.1 mile/h).
One or more malfunction has been found and ABS
activation been hanged up.
The ABS indicator light does not light up when turning the ignition switch to ON.
Check the wire harness and combination meter.
(!Page 86)
DL650K7/AK7 (’07-MODEL) 13-79
TROUBLESHOOTING PROCEDURE
Troubleshooting should be proceed as follows. If the order is performed incorrectly or any part is omitted, a
misdiagnosis may result.
1. Gather information from the customer. (!Page 82)
2. Perform the pre-diagnosis inspection. (!Page 83)
3. Inspect the ABS indicator light. (!Page 86)
4. Output the DTCs stored in the ABS control unit. (!Page 89)
5. Perform appropriate troubleshooting procedures according to the DTCs output. (!Page 90)
If troubleshooting procedures cannot be performed, try to determine the cause of the malfunction according
to the information gathered in 1 through 4 and inspect the wiring. (!Page 77 and 78)
%
6. Inspect the ABS components. (!Page 119)
7. Delete the DTCs and check the brake operation. (!Page 91)
* When disconnecting couplers and turning the ignition switch to ON, disconnect the ABS control unit coupler in order to prevent a DTC from being stored.
* Each time a resistance is measured, the ignition switch should be set to OFF.
13-80 DL650K7/AK7 (’07-MODEL)
BASIC TROUBLESHOOTING DIAGRAM
1. Gather information from the customer. (:Page 82)
2. Perform the pre-diagnosis inspection. (:Page 83)
3. Inspect the ABS indicator light. (:Page 86)
6. Inspect the ABS components. (:Page 119)
4. Output the DTCs stored in the ABS control unit. (:Page 89)
7. Delete the DTCs and check the brake operation. (:Page 91)
5. Perform appropriate troubleshooting procedures according to the DTCs output.
(:Page 90)
If troubleshooting procedures cannot be performed, try to determine the cause of the malfunction according to the information gathered in 1 through 4 and inspect the wiring.
(:Page 77 and 78)
DL650K7/AK7 (’07-MODEL) 13-81
INFORMATION GATHERING
To properly diagnose a malfunction, one must not make guesses or assumptions about the circumstances
that caused it. Proper diagnosis and repair require duplicating the situation in which the malfunction
occurred. If a diagnosis is made without duplicating the malfunction, even an experienced service technician
may make a misdiagnosis and not perform the servicing procedure correctly, resulting in the malfunction not
being repaired. For example, a malfunction that occurs only while braking on slippery surfaces will not occur
if the motorcycle is ridden on a non-slippery surface. Therefore, in order to properly diagnose and repair the
motorcycle, the customer must be questioned about the conditions at the time that the malfunction occurred
making “Information gathering” very important. In order for the information obtained from the customer to be
used as a reference during troubleshooting, it is necessary to ask certain important questions concerning
the malfunction. Therefore, a questionnaire has been created to improve the information-gathering procedure.
Questionnaire Example
NOTE:
The above form is a standard sample. It should be modified according to characteristic of each market.
Customer’s name License plate No. Frame serial No. Mileage
First registered year Date malfunction occurred Frequency of occurrence Weather of date of occurrence
PROBLEM SYMPTOMS
ABS operation Past malfunctions and repairs
ABS does not work
ABS works so often
Too long stopping distance
Others
CONDITIONS WHEN MALFUNCTION OCCURED
ABS indicator light Riding conditions
Does not light up While stopping
Lights up
Goes off after running over 5 km/h
Yes No
Over 10 km/h
When turning
Others
Flashes Brake operating conditions
Tires Usual braking
Abnormal air pressure Quick/hard braking
Less thread depth Interface
No specified tires installed Too big pulsations at brake levers
Road surface Too large brake lever strokes
Paved road Others
Dry Wet Others Others
Unpaved road Abnormal noise from the ABS control unit/HU
Gravel Muddy Uneven Skid noise from the calipers
Others Vibration at the brake levers
Note:
13-82 DL650K7/AK7 (’07-MODEL)
PRE-DIAGNOSIS INSPECTION
The mechanical and hydraulic components of the brake system should be inspected prior to performing any
electrical checks. These inspections may find problems that the ABS could not detect; thus, shortening
repair time.
BRAKE
Brake fluid level check (!DL650K4 2-22)
Brake pad inspection (!DL650K4 2-23)
Brake fluid circuit air bleeding (!DL650K4 2-25)
Tire type
BRIDGESTONE (Front: TW101 J Rear: TW152 F)
%
Tire pressure (!DL650K4 2-26)
Wheel (!DL650K4 7-11 and -79)
BATTERY
Battery voltage
• Turn the ignition switch to OFF.
• Remove the seat. (!DL650K4 7-4)
• Measure the voltage between the + and - battery terminals
using the multi-circuit tester.
$ Battery voltage: 12.0 V and more
# 09900-25008: Multi-circuit tester set
' Tester knob indication: Voltage ( )
If the voltage is less than 12.0 V, charge or replace the battery
and inspect the charging system. (!DL650K4 8-7)
* The standard tire fitted on this motorcycle is 110/
80R19M/C 59H for front and 150/70R17M/C 69H for
rear. The use of tires other than those specified may
cause instability. It is highly recommended to use a
SUZUKI Genuine Tire.
* Replace the tire as a set, otherwise the DTC “25”
(C1625) may be stored.
DL650K7/AK7 (’07-MODEL) 13-83
ABS COMPONENT
Wheel speed sensor – sensor rotor clearance
• Inspect the clearance between the wheel speed sensor and
sensor rotor for each wheel using the thickness gauge.
$ Wheel speed sensor – sensor rotor clearance:
0.3 – 1.5 mm (0.012 – 0.059 in)
# 09900-20803: Thickness gauge
09900-20806: Thickness gauge
ABS control unit/HU ground wire inspection
• Turn the ignition switch to OFF.
• Remove the seat. (!DL650K4 7-4)
• Disconnect the battery - lead wire.
• Remove the ABS control unit/HU cover 1.
• Disconnect the ABS control unit coupler 2.
13-84 DL650K7/AK7 (’07-MODEL)
• Check for continuity between 1 terminal of coupler and battery - terminal, also 4 terminal of coupler and battery - terminal.
# 09900-25008: Multi-circuit tester set
+ Tester knob indication: Continuity (*)
If there are no continuity, repair the coupler or wire harness.
ABS control unit coupler (Harness end)
Battery - terminal
DL650K7/AK7 (’07-MODEL) 13-85
ABS INDICATOR LIGHT INSPECTION
Step 1
1) Check if the ABS indicator light lights up when turning the
ignition switch to ON.
NOTE:
If the ABS indicator light flashes, there may be a short-circuit
existing in the mode select switch wire.
Does the ABS indicator light up?
The ABS indicator light lights up
Step 2
1) Ride the motorcycle at more than 5 km/h (3.1 mile/h).
Does the ABS indicator light go off?
The ABS indicator light does not light up
Step 3
1) Remove the seat. (!DL650K4 7-4)
2) Open the fuse box and inspect the signal fuse 1.
Signal fuse: 15 A
Is the signal fuse OK?
%
YES Go to step 2.
NO Go to step 3.
YES Normal (No DTC exists)
NO
DTC OUTPUT (!Page 89)
If DTC can not be output (the ABS indicator light
does not flash), go to step 6.
YES Go to step 4.
NO Replace the signal fuse.
If a fuse is blown, find the cause of the problem and
correct it before replacing the fuse.
13-86 DL650K7/AK7 (’07-MODEL)
Step 4
1) Turn the ignition switch to OFF.
2) Disconnect the ABS control unit coupler. (!Page 84)
3) Turn the ignition switch to ON with the ABS control unit coupler disconnected, measure the voltage between B terminal
and 4 terminal at the coupler.
$ Normal value: 7.5 – 9.5 V and more
# 09900-25008: Multi-circuit tester set
09900-25009: Needle pointed probe set
' Tester knob indication: Voltage ( )
Is the voltage between B and 4 normal?
Step 5
1) Turn the ignition switch to OFF.
2) Check for continuity between 4 terminal of coupler and body
ground.
+ Tester knob indication: Continuity (*)
Are there continuity between 4 and body ground?
Step 6
The ABS indicator light does not go off
1) Turn the ignition switch to OFF.
2) Remove the seat. (!DL650K 7-4)
3) Open the fuse box and inspect the ignition fuse 1.
Ignition fuse: 10 A
Is the ignition fuse OK?
%
YES Go to step 5.
NO
Inspect the wire harness. (Faulty indicator light
wire or ground wire)
Faulty ABS indicator light.
ABS control unit coupler (Harness end)
YES Replace the ABS control unit/HU.
NO Inspect the wire harness. (Faulty ground wire)
YES Go to step 7.
NO Replace the ignition fuse.
If a fuse is blown, find the cause of the problem and
correct it before replacing the fuse.
ABS control unit coupler
(Harness end)
DL650K7/AK7 (’07-MODEL) 13-87
Step 7
1) Turn the ignition switch to OFF and disconnect the ABS control unit coupler. (!Page 84)
2) Turn the ignition switch to ON with the ABS control unit coupler disconnected, measure the voltage between H terminal
and 4 terminal at the coupler.
$ Normal value: Battery voltage (12.0 V and more)
# 09900-25008: Multi-circuit tester set
09900-25009: Needle pointed probe set
' Tester knob indication: Voltage ( )
Is the voltage between H and 4 normal?
Step 8
1) Turn the ignition switch to ON with the ABS control unit coupler disconnected, measure the voltage between B terminal
and 4 terminal at the coupler.
$ Normal value: 7.5 – 9.5 V and more
' Tester knob indication: Voltage ( )
Is the voltage between B and 4 normal?
YES Go to step 8.
NO
Inspect the wire harness. (Faulty ignition wire or
ground wire)
ABS control unit coupler (Harness end)
YES Replace the ABS control unit/HU.
NO
Inspect the wire harness. (Faulty indicator light
wire or ground wire)
ABS control unit coupler (Harness end)
13-88 DL650K7/AK7 (’07-MODEL)
DL650K7/AK7 (’07-MODEL) 13-89
DTC (Diagnostic Trouble Code) OUTPUT
Connect the special tool to the mode select coupler to output the
memorized DTCs on the ABS indicator light.
• Turn the ignition switch to OFF.
• Remove the seat. ( 7-4)
• Connect the special tool to the mode select coupler
1
(Orange – B/W).
09930-82710: Mode select switch
• Switch the special tool to ON.
• Turn the ignition switch to ON.
The ABS indicator light starts flashing to indicate the DTC.
NOTE:
* If there is a DTC recorded, the ABS indicator light repeatedly
flashes in a cyclic manner. (However, when five minutes have
elapsed from the start of self-diagnosis mode, the output of the
DTC will be interrupted.)
* If no DTC is recorded, the light repeats flashing for 3.6 seconds in a cyclic manner.
* In the case that the mode select switch is turned off or the
vehicle speed (both wheels) exceeds 10 km/h (6.2 mile/h), the
output of DTC will be interrupted.
UNDERSTANDING THE DTC (Diagnostic Trouble Code)
A two-digit DTC is shown through the flashing pattern of the ABS indicator light. A number between 1 and 9
is represented by the number of times that the ABS indicator light lights up in interval of 0.4 seconds and the
separation between the tens and ones are indicated by the light staying off for 1.6 seconds. In addition, the
separation between the start code and the DTC is indicated by the light being off for 3.6 seconds. After the
start code is displayed, DTCs appear from the smallest number code.
If no DTC is recorded, the light repeats flashing for 3.6 seconds in a cyclic manner.
1 About 2 seconds (Initial minimum light ON time)
2 3.6 seconds
3 0.4 seconds (Main code light ON time)
4 0.4 seconds (Main code light OFF time)
5 1.6 seconds (Main-sub code interval)
6 0.4 seconds (Sub code light ON time)
7 0.4 seconds (Sub code light OFF time)
8 3.6 seconds
ON
OFF
ON
OFF
ON
OFF
ON
OFF
Output finish
Output start
Code 25
Code 41
ABS indicator light
(Malfunction exist)
ABS indicator light
(No malfunction exist)
Mode select switch
Ignition switch
13-90 DL650K7/AK7 (’07-MODEL)
DL650K7/AK7 (’07-MODEL) 13-91
DTC DELETING AND ABS OPERATION
CHECK
DTC DELETING
• Connect the special tool to the mode select coupler (O – B/W)
and output the DTCs.
09930-82710: Mode select switch
• While the DTCs are being output, set the special tool to OFF.
• In the DTC deletion mode, switch the ABS test switch from
OFF to ON 3 times, each time leaving it at ON for more than 1
second.
NOTE:
After deleting DTC with the mode select switch in ON position,
the system resumes the self-diagnosis mode again and outputs
the DTC.
The DTC deletion mode starts 12.5 seconds after the
switch is set to OFF.
ABS OPERATION CHECK
After deleting the DTCs, repeat the code output procedure and
make sure that no DTCs remain (the ABS indicator light no
longer flashes). If any DTCs remain, perform the appropriate
procedures, then delete the codes. If DTCs are left stored, confusion may occur and unnecessary repairs may be made.
Afterwards, ride the motorcycle at more than 30 km/h (18.6 mile/
h) and quickly apply the brakes to check that the ABS activates
correctly.
ON
OFF
ON
ON
OFF
OFFABS indicator light
(Malfunction exist)
Mode select switch
Ignition switch
DTC indication 1 sec. 1 sec. 1 sec.
Cleaning start
Max. 12.5 seconds
1 2 3
13-92 DL650K7/AK7 (’07-MODEL)
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.
For example, when a motorcycle is brought in for service but the troubleshooting is difficult, comparison with
the normal data that have been saved or filed can allow the specific ABS failure to be determined.
• Remove the seat. (!DL650K4 7-4)
• Set up the SDS tool. (!Page 94)
# 09904-41010: SDS set tool
99565-01010-008: CD-ROM Ver. 8
NOTE:
* Before taking the sample of data, check and clear the Past DTC. (!Page 95)
* A number of different data under a fixed condition as shown below should be saved or filed as sample.
DATA SAMPLED FROM ABS HU SYSTEM
Check the rear wheel speed.
XX km/h
Check the battery voltage.
XX V
Check the front wheel speed.
XX km/h
DL650K7/AK7 (’07-MODEL) 13-93
USE OF SDS DIAGNOSTIC PROCEDURES
* Don’t disconnect couplers from ABS HU, the battery cable
from the battery, ABS HU 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 ABS HU memory.
* DTC stored in ABS HU memory can be checked by the SDS.
* Be sure to read “CAUTIONS IN SERVICING” (!Page 72)
before inspection and observe what is written there.
• Remove the seat. (!DL650K4 7-4)
• Set up the SDS tool. (Refer to the SDS operation manual for
further details)
• Read the DTC (Diagnostic Trouble Code) and show data
when trouble (displaying data at the time of DTC) according to
instructions displayed on SDS.
• Not only is SDS used for detecting Diagnostic Trouble Codes
but also for reproducing and checking on screen the failure
condition as described by customers using the trigger.
• How to use trigger. (Refer to the SDS operation manual for
further details.)
# 09904-41010: SDS set tool
99565-01010-008: CD-ROM Ver. 8
13-94 DL650K7/AK7 (’07-MODEL)
USE OF SDS DIAGNOSIS RESET
PROCEDURE
• After repairing the trouble, turn OFF the ignition switch and
turn ON again.
• Click the ABS button 1.
• Click the “DTC inspection” button 2.
• Check the DTC.
• The previous malfunction history code (Past DTC) still
remains stored in the ABS HU. Therefore, erase the history
code memorized in the ABS HU using SDS tool.
NOTE:
The DTC is memorized in the ABS HU also when the wire coupler of any sensor is disconnected. Therefore, when a wire coupler has been disconnected at the time of diagnosis, erase the
stored malfunction history code using SDS.
• Click “Clear” 3 to delete history code (Past DTC).
DL650K7/AK7 (’07-MODEL) 13-95
• Follow the displayed instructions.
• Check that both “Current DTC” 4 and “Past DTC” 5 are
deleted (NIL).
13-96 DL650K7/AK7 (’07-MODEL)
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 “ABS” 1.
4) Click “Active control” 2.
5) Click “ABS HU operating” 3.
DL650K7/AK7 (’07-MODEL) 13-97
6) It progresses to the next according to the following indication of screens.
Return Next Cancel Help
Return Next Cancel Help
13-98 DL650K7/AK7 (’07-MODEL)
NOTE:
* If the front wheel is selected, lift the front wheel off the ground using a jack.
* Two operators are needed in this work; One should apply a rotational force to the front wheel.
Return Next Cancel Help
Return Next Cancel Help
DL650K7/AK7 (’07-MODEL) 13-99
NOTE:
* In normal cases, the front brake lever feels a reaction force and the front wheel turns discontinuously. At
the same time, the ABS HU operating sound will be heard.
* The ABS HU motor operates for 6 seconds and then stops automatically.
NOTE:
* Inspect the rear brake as the same manner of front brake.
* If the ABS does not function, the cause may lie in the ABS control unit/HU.
Return Next Cancel Help
Return Finish Cancel Help
13-100 DL650K7/AK7 (’07-MODEL)
DTC TABLE OF ABS
*1 It goes off after running at more than 5 km/h (3.1 mile/h).
*2 The wheel speed sensor lead wire is connected to the ABS control unit, but a short-circuit or faulty continuity inside the ABS control unit caused this DTC to appear, therefore, the ABS control unit/HU assembly
must be replaced. An insufficient wheel speed sensor output voltage is the cause of a malfunction in
which the ABS is activated even if the brakes are not suddenly applied. If this occurs frequently even
though the wheel speed sensor is operating correctly, the ABS control unit/HU assembly should be
replaced.
*3 When the voltage resumes the normal level, the ABS indicator light will go off.
*4 There are times that the ABS indicator light does not light up.
%
DTC No.
DTC parameter Indicator
status
Page
Possible cause
None Normal ON *1 —
25
(C1625)
Wheel speed sensor related malfunction ON
!
Page 102
Incorrect tire size, poor tire pressure, deformed wheel, wheel spinning,
incorrect tooth count, interference at one or more wheels, permanent
bad signal, etc.
ON
35
(C1635)
ABS motor malfunction
ON
!
Page 104
Motor relay circuit open or short, broken fuse for motor relay, pump
motor circuit open or short, faulty motor relay, faulty ABS motor, faulty
ABS control unit, etc.
41
(C1641)
Wheel speed sensor signal malfunction (F) *2
ON
!
Page 105
Too great air gap, worn or missing teeth, noise, interference between
lines, loose contact in wheel speed sensor connector, wheel speed sensor not securely fastened, input amplifier in ABS control unit failure, etc.
42
(C1642)
Wheel speed sensor circuit open (F) *2
ON
!
Page 106Wheel speed sensor circuit open or short, loosen contact in wheel
speed sensor connector, input amplifier in ABS control unit failure, etc.
44
(C1644)
Wheel speed sensor signal malfunction (R) *2
ON
!
Page 109
Too great air gap, worn or missing teeth, noise, interference between
lines, loose contact in wheel speed sensor connector, wheel speed sensor not securely fastened, input amplifier in ABS control unit failure, etc.
45
(C1645)
Wheel speed sensor circuit open (R) *2
ON
!
Page 110Wheel speed sensor circuit open or short, loosen contact in wheel
speed sensor connector, input amplifier in ABS control unit failure, etc.
47
(C1647)
Supply voltage (Increased)
ON *3
!
Page 113Faulty regulator/rectifier, faulty battery, faulty wire harness, etc.
48
(C1648)
Supply voltage (Decreased)
ON *3
!
Page 115Faulty generator, faulty regulator/rectifier, faulty battery, faulty wire harness, etc.
55
(C1655)
ABS control unit malfunction
(ON) *4
!
Page 117Faulty ABS control unit
61
(C1661)
ABS solenoid malfunction
ON
!
Page 118Valve relay circuit open or short, broken fuse for valve relay, faulty valve
relay, interruption of valve, failure output from ABS control unit, etc.
When disconnecting couplers and turning the ignition switch to ON, disconnect the ABS control unit coupler in order to prevent a DTC from being stored. Each time a resistance is measured, the ignition switch should be set to OFF.
DL650K7/AK7 (’07-MODEL) 13-101
DTC TROUBLESHOOTING
DTC “25” (C1625): WHEEL SPEED SENSOR RELATED MALFUNCTION
Step 1
1) Check that the specified tires are installed.
TIRE TYPE:
Front: BRIDGESTONE TW101 J 110/80R19M/C 59H
Rear: BRIDGESTONE TW152 F 150/70R17M/C 69H
Are the tires OK?
Step 2
1) Make sure the tire pressure for each tire.
(!DL650K4 2-26)
Is the tire pressure for each tire correct?
Step 3
1) Inspect both wheel speed sensor rotors for damage and
check that no foreign objects are caught in the rotor openings.
Are the rotors OK?
POSSIBLE CAUSE
Incorrect tire size, poor tire pressure, deformed wheel, wheel
spinning, incorrect tooth count, interference at one or more
wheels, permanent bad signal, etc.
YES Go to step 2.
NO Use the specified tires.
COLD INFLATION
TIRE PRESSURE
SOLO RIDING DUAL RIDING
kPa kgf/cm² psi kPa kgf/cm² psi
FRONT 225 2.25 33 225 2.25 33
REAR 250 2.50 36 280 2.80 41
YES Go to step 3.
NO Adjust the tire pressure.
YES Go to step 4.
NO Clean or replace the rotor.
13-102 DL650K7/AK7 (’07-MODEL)
Step 4
1) Inspect the clearances of the front and rear wheel speed sensor – sensor rotor using the thickness gauge.
$ Wheel speed sensor – sensor rotor clearance:
0.3 – 1.5 mm (0.012 – 0.059 in)
# 09900-20803: Thickness gauge
09900-20806: Thickness gauge
Are the clearances OK?
YES Replace the ABS control unit/HU.
NO Adjust the clearance.
DL650K7/AK7 (’07-MODEL) 13-103
DTC “35” (C1635): ABS MOTOR MALFUNCTION
Step 1
1) Inspect if the pump motor makes turning noise by setting the
ignition switch to ON from OFF when the vehicle stands still.
Does the pump motor make any turning noise?
Step 2
1) Remove the seat. (!DL650K4 7-4)
2) Inspect the ABS motor fuse.
ABS motor fuse: 40 A
Is the ABS motor fuse OK?
%
Step 3
1) Turn the ignition switch to OFF.
2) Remove the ABS control unit/HU cover. (!Page 84)
3) Check the ABS control unit coupler for loose or poor contacts. If OK, then disconnect the ABS control unit coupler.
4) Measure the voltage between 2 terminal and 1 terminal at
the coupler.
$ Normal value: Battery voltage (12.0 V and more)
# 09900-25008: Multi-circuit tester set
' Tester knob indication: Voltage ( )
Is the voltage between 2 and 1 normal?
POSSIBLE CAUSE
Motor relay circuit open or short, broken fuse for motor relay,
pump motor circuit open or short, faulty motor relay, faulty ABS
motor, faulty ABS control unit, etc.
YES
Faulty HU motor
Replace the ABS control unit/HU.
NO Go to step 2.
YES Go to step 3.
NO Replace the ABS motor fuse.
If a fuse is blown, find the cause of the problem and
correct it before replacing the fuse.
YES Replace the ABS control unit/HU.
NO
Inspect the wire harness. (Faulty motor power
supply or ground wire)
ABS control unit coupler (Harness end)
13-104 DL650K7/AK7 (’07-MODEL)
DTC “41” (C1641): WHEEL SPEED SENSOR SIGNAL MALFUNCTION (F)
Step 1
1) Inspect the clearance between the front wheel speed sensor
and sensor rotor using the thickness gauge.
$ Wheel speed sensor – sensor rotor clearance:
0.3 – 1.5 mm (0.012 – 0.059 in)
# 09900-20803: Thickness gauge
09900-20806: Thickness gauge
Is the clearance OK?
Step 2
1) Inspect the front wheel speed sensor rotor for damage and
check that no foreign objects are caught in the rotor openings.
Is the sensor rotor OK?
Step 3
1) Check that the front wheel speed sensor is mounted steadily.
Is the sensor mounted steadily?
POSSIBLE CAUSE
Too great air gap, worn or missing teeth, noise, interference
between lines, loose contact in wheel speed sensor connector,
wheel speed sensor not securely fastened, input amplifier in
ABS control unit failure, etc.
YES Go to step 2.
NO Adjust the clearance.
YES Go to step 3.
NO Clean or replace the sensor rotor.
YES Go to DTC “42” (C1642). (!Page 106)
NO
Tighten the mounting bolts or replace the bracket
if necessary.
DL650K7/AK7 (’07-MODEL) 13-105
DTC “42” (C1642): WHEEL SPEED SENSOR CIRCUIT OPEN (F)
Step 1
1) Turn the ignition switch to OFF.
2) Remove the air cleaner box cap. (!DL650K4 2-5)
3) Remove the ABS control unit/HU cover. (!Page 84)
4) Check the ABS control unit coupler and front wheel speed
sensor coupler for loose or poor contacts. If OK, then disconnect the ABS control unit coupler.
5) Check for continuity between F terminal and 5 terminal at
the ABS control unit coupler.
# 09900-25008: Multi-circuit tester set
09900-25009: Needle pointed probe set
+ Tester knob indication: Continuity (*)
Is there continuity between F and 5?
Step 2
1) Measure the resistance between F terminal and ground at
the ABS control unit coupler.
$ Normal value: ∞ Ω (Infinity)
) Tester knob indication: Resistance (Ω)
Is the resistance between F and ground OK?
Step 3
1) Disconnect the front wheel speed sensor coupler.
2) Measure the resistance between 2 terminal and ground at
the front wheel speed sensor coupler.
$ Normal value: ∞ Ω (Infinity)
) Tester knob indication: Resistance (Ω)
Is the resistance between 2 and ground OK?
POSSIBLE CAUSE
Wheel speed sensor circuit open or short, loosen contact in
wheel speed sensor connector, input amplifier in ABS control
unit failure, etc.
YES
Inspect the wire harness. (Faulty sensor wire)
Faulty front wheel speed sensor
NO Go to step 2.
YES Go to step 4.
NO Go to step 3.
YES Inspect the wire harness. (Faulty W/R wire)
NO Faulty front wheel speed sensor
ABS control unit coupler (Harness end)
ABS control unit coupler
(Harness end)
Sensor side
13-106 DL650K7/AK7 (’07-MODEL)
Step 4
1) Measure the resistance between 5 terminal and ground at
the ABS control unit coupler.
$ Normal value: ∞ Ω (Infinity)
) Tester knob indication: Resistance (Ω)
Is the resistance between 5 and ground OK?
Step 5
1) Measure the resistance between 1 terminal and ground at
the front wheel speed sensor coupler.
$ Normal value: ∞ Ω (Infinity)
) Tester knob indication: Resistance (Ω)
Is the resistance between 1 and ground OK?
Step 6
1) Check for continuity between F terminal on the ABS control
unit coupler and 2 terminal on the front wheel speed sensor
coupler.
$ Normal value: Continuity (*)
+ Tester knob indication: Continuity test (*)
Is there continuity between F and 2?
Step 7
1) Check for continuity between 5 terminal on the ABS control
unit coupler and 1 terminal on the front wheel speed sensor
coupler.
$ Normal value: Continuity (*)
+ Tester knob indication: Continuity test (*)
Is there continuity between 5 and 1?
YES Go to step 6.
NO Go to step 5.
YES Inspect the wire harness. (Faulty B/R wire)
NO Faulty front wheel speed sensor
YES Go to step 7.
NO Inspect the wire harness. (Faulty W/R wire)
YES Go to step 8.
NO Inspect the wire harness. (Faulty B/R wire)
ABS control unit coupler
(Harness end)
Sensor side
ABS control unit coupler (Harness end)
Harness side
ABS control unit coupler (Harness end)
Harness side
DL650K7/AK7 (’07-MODEL) 13-107
Step 8
1) Connect the front wheel speed sensor coupler.
2) Connect three 1.5 V dry cells A in series as shown and make
sure that their total voltage is more than 4.5 V.
Measure the current between + dry cell terminal and F terminal on the ABS control unit coupler.
$ Normal value: 5.9 – 16.8 mA
/ Tester knob indication: Current ( , 20 mA)
Is the current OK?
YES Replace the ABS control unit/HU.
NO Faulty front wheel speed sensor.
DCmA
ABS control unit coupler (Harness end)
13-108 DL650K7/AK7 (’07-MODEL)
DTC “44” (C1644): WHEEL SPEED SENSOR SIGNAL MALFUNCTION (R)
Step 1
1) Inspect the clearance between the rear wheel speed sensor
and sensor rotor using the thickness gauge.
$ Wheel speed sensor – sensor rotor clearance:
0.3 – 1.5 mm (0.012 – 0.059 in)
# 09900-20803: Thickness gauge
09900-20806: Thickness gauge
Is the clearance OK?
Step 2
1) Inspect the rear wheel speed sensor rotor for damage and
check that no foreign objects are caught in the rotor openings.
Is the sensor rotor OK?
Step 3
1) Check that the rear wheel speed sensor is mounted steadily.
Is the sensor mounted steadily?
POSSIBLE CAUSE
Too great air gap, worn or missing teeth, noise, interference
between lines, loose contact in wheel speed sensor connector,
wheel speed sensor not securely fastened, input amplifier in
ABS control unit failure, etc.
YES Go to step 2.
NO Adjust the clearance.
YES Go to step 3.
NO Clean or replace the sensor rotor.
YES Go to DTC “45” (C1645). (!Page 110)
NO
Tighten the mounting bolts or replace the bracket
if necessary.
DL650K7/AK7 (’07-MODEL) 13-109
DTC “45” (C1645): WHEEL SPEED SENSOR CIRCUIT OPEN (R)
Step 1
1) Turn the ignition switch to OFF.
2) Remove the seat. (!DL650K4 7-4)
3) Remove the ABS control unit/HU cover. (!Page 84)
4) Check the ABS control unit coupler and rear wheel speed
sensor coupler for loose or poor contacts. If OK, then disconnect the ABS control unit coupler.
5) Check for continuity between 7 terminal and I terminal at
the ABS control unit coupler.
# 09900-25008: Multi-circuit tester set
09900-25009: Needle pointed probe set
+ Tester knob indication: Continuity (*)
Is there continuity between 7 and I?
Step 2
1) Measure the resistance between 7 terminal and ground at
the ABS control unit coupler.
$ Normal value: ∞ Ω (Infinity)
) Tester knob indication: Resistance (Ω)
Is the resistance between 7 and ground OK?
Step 3
1) Disconnect the rear wheel speed sensor coupler.
2) Measure the resistance between 2 terminal and ground at
the rear wheel speed sensor coupler.
$ Normal value: ∞ Ω (Infinity)
) Tester knob indication: Resistance (Ω)
Is the resistance between 2 and ground OK?
POSSIBLE CAUSE
Wheel speed sensor circuit open or short, loosen contact in
wheel speed sensor connector, input amplifier in ABS control
unit failure, etc.
YES
Inspect the wire harness. (Faulty sensor wire)
Faulty rear wheel speed sensor.
NO Go to step 2.
YES Go to step 4.
NO Go to step 3.
YES Inspect the wire harness. (Faulty W/Y wire)
NO Replace the rear wheel speed sensor.
ABS control unit coupler (Harness end)
ABS control unit coupler
(Harness end)
Sensor side
13-110 DL650K7/AK7 (’07-MODEL)
Step 4
1) Measure the resistance between I terminal and ground at
the ABS control unit coupler.
$ Normal value: ∞ Ω (Infinity)
) Tester knob indication: Resistance (Ω)
Is the resistance between I and ground OK?
Step 5
1) Measure the resistance between 1 terminal and ground at
the rear wheel speed sensor coupler.
$ Normal value: ∞ Ω (Infinity)
Is the resistance between 1 and ground OK?
Step 6
1) Check for continuity between 7 terminal on the ABS control
unit coupler and 2 terminal on the rear wheel speed sensor
coupler.
$ Normal value: Continuity (*)
+ Tester knob indication: Continuity test (*)
Is there continuity between 7 and 2?
Step 7
1) Check the continuity between I terminal on the ABS control
unit coupler and 1 terminal on the rear wheel speed sensor
coupler.
$ Normal value: Continuity (*)
+ Tester knob indication: Continuity test (*)
Is there continuity between I and 1?
YES Go to step 6.
NO Go to step 5.
YES Inspect the wire harness. (Faulty B/Y wire)
NO Replace the rear wheel speed sensor.
ABS control unit coupler
(Harness end)
Sensor side
YES Go to step 7.
NO Inspect the wire harness. (Faulty W/Y wire)
YES Go to step 8.
NO Inspect the wire harness. (Faulty B/Y wire)
]
ABS control unit coupler (Harness end)
Harness side
ABS control unit coupler (Harness end)
Harness side
DL650K7/AK7 (’07-MODEL) 13-111
Step 8
1) Connect the rear wheel speed sensor coupler.
2) Connect three 1.5 V dry cells A in series as shown and make
sure that their total voltage is more than 4.5 V.
Measure the current between + dry cell terminal and 7 terminal on the ABS control unit coupler.
$ Normal value: 5.9 – 16.8 mA
# 09900-25008: Multi-circuit tester set
09900-25009: Needle pointed probe set
/ Tester knob indication: Current ( , 20 mA)
Is the current OK?
YES Replace the ABS control unit/HU.
NO Replace the rear wheel speed sensor.
DCmA
ABS control unit coupler (Harness end)
13-112 DL650K7/AK7 (’07-MODEL)
DTC “47” (C1647): SUPPLY VOLTAGE (INCREASED)
NOTE:
When the voltage resumes the normal level, the ABS indicator
light will go off.
Step 1
1) Turn the ignition switch to OFF.
2) Remove the seat. (!DL650K4 7-4)
3) Measure the voltage between the + and - battery terminals
using the multi-circuit tester.
$ Battery voltage: 12.0 V and more
# 09900-25008: Multi-circuit tester set
' Tester knob indication: Voltage ( )
Is the voltage over 12 V?
Step 2
1) Run the engine at 5 000 r/min with the dimmer switch set to
HI.
2) Measure the voltage between the + and - battery terminals.
$ Regulated voltage: 14.0 – 15.5 V at 5 000 r/min
# 09900-25008: Multi-circuit tester set
' Tester knob indication: Voltage ( )
Is the voltage 14.0 – 15.5 V?
POSSIBLE CAUSE
Faulty regulator/rectifier, faulty battery, faulty wire harness, etc.
YES Go to step 2.
NO Charge or replace the battery.
YES Go to step 3.
NO
Inspect the regulator/rectifier.
(!DL650K4 8-11)
DL650K7/AK7 (’07-MODEL) 13-113
Step 3
1) Turn the ignition switch to OFF.
2) Remove the ABS control unit/HU cover. (!Page 84)
3) Check the ABS control unit coupler for loose or poor contacts. If OK, then disconnect the ABS control unit coupler.
4) Run the engine at 5 000 r/min with the dimmer switch set to
HI.
5) Measure the voltage between H terminal and 4 terminal at
the coupler.
# 09900-25009: Needle pointed probe set
' Tester knob indication: Voltage ( )
Is the voltage same as step 2 above?
YES Replace the ABS control unit/HU.
NO
Inspect the wire harness. (Faulty ignition or
ground wire)
ABS control unit coupler (Harness end)
13-114 DL650K7/AK7 (’07-MODEL)
DTC “48” (C1648): SUPPLY VOLTAGE (DECREASED)
NOTE:
When the voltage resumes the normal level, the ABS indicator
light will go off.
Step 1
1) Turn the ignition switch to OFF.
2) Remove the seat. (!DL650K4 7-4)
3) Measure the voltage between the + and - battery terminals
using the multi-circuit tester.
$ Battery voltage: 12.0 V and more
# 09900-25008: Multi-circuit tester set
' Tester knob indication: Voltage ( )
Is the voltage over 12 V?
Step 2
1) Run the engine at 5 000 r/min with the dimmer switch set to
HI.
2) Measure the voltage between the + and - battery terminals.
$ Regulated voltage: 14.0 – 15.5 V at 5 000 r/min
' Tester knob indication: Voltage ( )
Is the voltage 14.0 – 15.5 V?
POSSIBLE CAUSE
Faulty generator, faulty regulator/rectifier, faulty battery, faulty
wire harness, etc.
YES Go to step 2.
NO Charge or replace the battery.
YES Go to step 3.
NO
Inspect the generator and regulator/rectifier.
(!DL650K4 8-10)
DL650K7/AK7 (’07-MODEL) 13-115
Step 3
1) Turn the ignition switch to OFF.
2) Remove the ABS control unit/HU cover. (!Page 84)
3) Check the ABS control unit coupler for loose or poor contacts. If OK, then disconnect the ABS control unit coupler.
4) Run the engine at 5 000 r/min with the dimmer switch set to
HI.
5) Measure the voltage between H terminal and 4 terminal at
the coupler.
# 09900-25009: Needle pointed probe set
' Tester knob indication: Voltage ( )
Is the voltage same as step 2 above?
YES Replace the ABS control unit/HU.
NO
Inspect the wire harness. (Faulty ignition or
ground wire)
ABS control unit coupler (Harness end)
13-116 DL650K7/AK7 (’07-MODEL)
DTC “55” (C1655): ABS CONTROL UNIT MALFUNCTION
Step 1
1) Inspect the clearances of the front and rear wheel speed sensor – sensor rotor using the thickness gauge.
$ Wheel speed sensor – sensor rotor clearance:
0.3 – 1.5 mm (0.012 – 0.059 in)
# 09900-20803: Thickness gauge
09900-20806: Thickness gauge
Are the clearances OK?
Step 2
1) Inspect both of the wheel speed sensor rotors for damage
and check that no foreign objects are caught in the rotor
openings.
Are the rotors OK?
Step 3
1) Check that the front and rear wheel speed sensors are
mounted steadily.
Are the sensors mounted steadily?
Step 4
1) Delete DTCs (!Page 91) and repeat the code output procedure.
If the DTC “55” (C1655) is output again, the ABS control unit/
HU should be replaced.
POSSIBLE CAUSE
Faulty ABS control unit
YES Go to step 2.
NO Adjust the clearance.
YES Go to step 3.
NO Clean or replace the rotor.
YES Go to step 4.
NO
Tighten the mounting bolts or replace the bracket
if necessary.
DL650K7/AK7 (’07-MODEL) 13-117
DTC “61” (C1661): ABS SOLENOID MALFUNCTION
Step 1
1) Turn the ignition switch to OFF.
2) Remove the seat. (!DL650K4 7-4)
3) Open the fuse box and inspect the ABS valve fuse 1.
ABS valve fuse: 25 A
Is the ABS valve fuse OK?
%
Step 2
1) Remove the ABS control unit/HU cover. (!Page 84)
2) Check the ABS control unit coupler for loose or poor contacts. If OK, then disconnect the ABS control unit coupler.
3) Measure the voltage between 3 terminal and 4 terminal at
the coupler.
$ Normal value: Battery voltage (12.0 V and more)
# 09900-25008: Multi-circuit tester set
' Tester knob indication: Voltage ( )
Is the voltage between 3 and 4 normal?
IRREPARABLE MALFUNCTIONS
Even though the ABS is operating correctly, a DTC is memorized in any of the following conditions.
• After carrying out DTC deleting and ABS operation check
(!Page 91), explain to the customer that the ABS is operating correctly.
POSSIBLE CAUSE
Valve relay circuit open or short, broken fuse for valve relay,
faulty valve relay, interruption of valve, failure output from ABS
control unit, etc.
YES Go to step 2.
NO Replace the ABS valve fuse.
If a fuse is blown, find the cause of the problem and
correct it before replacing the fuse.
YES Replace the ABS control unit/HU.
NO
Inspect the wire harness. (Faulty valve relay
power supply or ground wire)
Conditions
• Spinning wheel is detected.
• Previous malfunctions were repaired, but the DTCs were
not deleted.
ABS control unit coupler (Harness end)
13-118 DL650K7/AK7 (’07-MODEL)
ABS COMPONENT REMOVAL, INSPECTION AND INSTALLATION
FRONT WHEEL SPEED SENSOR/SENSOR ROTOR
REMOVAL
%
• Raise the front wheel off the ground and support the motorcycle with a jack or wooden block.
• Remove the front wheel speed sensor by removing the
mounting bolt.
• Remove the front wheel assembly. (!DL650K4 7-10)
"
• Remove the front wheel speed sensor bracket 1.
• Remove the front wheel speed sensor rotor 2.
%
* The ABS is made up of many precision parts; never
subject it to strong impacts or allow it to become
dirty or dusty.
* Do not hit the sensor rotor when dismounting the
wheel.
* The wheel speed sensor cannot be disassembled.
Make sure that the motorcycle is supported securely.
When replacing the tire, make sure not to damage the
sensor rotor.
DL650K7/AK7 (’07-MODEL) 13-119
• Remove the fuel tank. (!DL650K4 5-7)
• Remove the air cleaner box cap. (!DL650K4 2-5)
• Disconnect the sensor coupler and remove the front wheel
speed sensor. (!Page 133)
INSPECTION
• Inspect the wheel speed sensor for damage.
• Clean the sensor if any metal particle or foreign material stuck
on it.
• Check that no wheel speed sensor rotor teeth are broken and
that no foreign objects are caught in the wheel speed sensor.
INSTALLATION
Installation is in the reverse order of removal. Pay attention to
the following points:
• Install the wheel speed sensor rotor as the letters “50T” face
outside.
13-120 DL650K7/AK7 (’07-MODEL)
• Align the recess A on the speed sensor bracket with the stopper B on the right front fork.
• Check the clearance between the front wheel speed sensor
and sensor rotor using the thickness gauge.
$ Wheel speed sensor – sensor rotor clearance:
0.3 – 1.5 mm (0.012 – 0.059 in)
# 09900-20803: Thickness gauge
09900-20806: Thickness gauge
DL650K7/AK7 (’07-MODEL) 13-121
FRONT WHEEL SPEED SENSOR INSTALLATION
Front wheel
speed sensor
RightLeft
0.3 – 1.5 mm (0.012 – 0.059 in)
13-122 DL650K7/AK7 (’07-MODEL)
REAR WHEEL SPEED SENSOR/SENSOR ROTOR
REMOVAL
%
• Raise the front wheel off the ground and support the motorcycle with a jack or wooden block.
• Remove the rear wheel speed sensor by removing the mounting bolt.
• Remove the rear wheel assembly. (!DL650K4 7-36)
"
• Remove the rear wheel speed sensor rotor 1.
%
• Remove the seat. (!DL650K4 7-4)
• Disconnect the sensor coupler and remove the rear wheel
speed sensor. (!Page 134)
* The ABS is made up of many precision parts; never
subject it to strong impacts or allow it to become
dirty or dusty.
* Do not hit the sensor rotor when dismounting the
wheel.
* The wheel speed sensor cannot be disassembled.
Make sure that the motorcycle is supported securely.
When replacing the tire, make sure not to damage the
sensor rotor.
DL650K7/AK7 (’07-MODEL) 13-123
INSPECTION
• Inspect the wheel speed sensor for damage.
• Clean the sensor if any metal particle or foreign material stuck
on it.
• Check that no wheel speed sensor rotor teeth are broken and
that no foreign objects are caught in the wheel speed sensor.
INSTALLATION
Installation is in the reverse order of removal. Pay attention to
the following points:
• Install the wheel speed sensor rotor as the letters “50T” face
outside.
• Check the clearance between the rear wheel speed sensor
and sensor rotor using the thickness gauge.
$ Wheel speed sensor – sensor rotor clearance:
0.3 – 1.5 mm (0.012 – 0.059 in)
# 09900-20803: Thickness gauge
09900-20806: Thickness gauge
13-124 DL650K7/AK7 (’07-MODEL)
REAR WHEEL SPEED SENSOR INSTALLATION
For E-03, 28, 33
RightLeft
0.3 – 1.5 mm (0.012 – 0.059 in)
Rear wheel
speed sensor
DL650K7/AK7 (’07-MODEL) 13-125
ABS CONTROL UNIT/HU
REMOVAL
"
%
• Remove the seat. (!DL650K4 7-4)
• Remove the battery.
• Drain the brake fluid. (!DL650K4 7-71)
• Disconnect the following parts from the battery case 1.
2 Fuse box and turn signal/side-stand relay
3 Starter relay
4 Fuel pump relay
5 ABS valve relay fuse
6 ABS motor relay fuse
7 TO sensor
• Remove the ABS control unit/HU cover 8.
• Remove the battery case 1.
When storing the brake fluid, seal the container completely and keep away from children.
* This brake system is filled with an ethylene glycol-based DOT 4 brake fluid. Do not 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.
* Handle brake fluid with care: the fluid reacts chemically with paint, plastics, rubber materials
etc. and will damage then severely.
* The ABS is made up of many precision parts; never subject it to strong impacts or allow it to
become dirty or dusty.
* The ABS control unit/HU cannot be disassembled.
13-126 DL650K7/AK7 (’07-MODEL)
• Loosen the flare nuts 9 and disconnect the brake pipes.
• Disconnect the ABS control unit coupler 0.
• Remove the ABS control unit/HU by removing the mounting
bolts.
INSTALLATION
Installation is in the reverse order of removal. Pay attention to
the following points.
• Tighten the brake pipe flare nuts to the specified torque.
& Brake pipe flare nut: 16 N·m (1.6 kgf-m, 11.5 lb-ft)
%
• Bleed air from the brake fluid circuit.
(!DL650K4 2-25)
"
* Route the brake hoses and pipes correctly.
(!Page 131 and 132)
* Make sure to hold the brake pipe when tightening the
flare nut, or it may be misaligned.
Never ride the motorcycle before bleeding the air.
DL650K7/AK7 (’07-MODEL) 13-127
WIRE HARNESS, HOSE ROUTING AND SENSOR INSTALLATION
WIRE HARNESS ROUTING
*1 Clamp end should face upward. *3 Pass through the harness under the cowling boss.
*2 Cut the tip of clamp after clamp. *4
Triangle mark of each spark plug cap must be brought
to the exhaust side.
Wiring harness
IG coil coupler
Clamp
Starter motor
Wire harness
Stop lamp switch
ABS sensor (DL650A)
Fuel pump coupler
Taping clamp
Clamp
Rectifier
(Breather hose)
IAP sensor
*1
Solenoid
Clamp
ISC valve coupler
Speed sensor
*2
Wire harness
Handle switch L & R
*3
Clutch cable Handle
switch (L)
Throttle cable
Taping clamp
Fuse
DL650A
only
Joint coupler
#1 Ignition
coil
Hightension
cord
Water hose
Inside Clamp
Clamp
Clamp
Side-stand switch
Wire harness
Side-stand switch
GP switch
Side-stand switch
GP switch
*4
12-128 DL650K7/AK7 (’07-MODEL)
*1
Triangle mark of each spark plug cap
must be brought to the exhaust side.
*4 Do not slack the lead wire.
*2 Cut the tip of clamp after clamping. *5
Pass through the PAIR reed valve wire between the
frame and PAIR control solenoid valve.
*3 Clamp the high-tension cord. *6
Pass through the licence lamp wire in front of the seat
lock cable.
Clamp
*1 Clamp
*2
#1
Ignition
coil
ABS brake hose
(DL650A only)
Reserver
inlet
hose
Frame
*6
Taping clamp
Clamp
EX IN
*4
*5
*3
*2
ICES label
(E-28 only)
#2 Ignition coil
Magneto
lead wire
DL650K7/AK7 (’07-MODEL) 13-129
FRONT BRAKE HOSE ROUTING (For DL650)
1 Brake hose *2 After positioning the brake hose junction with the stopper, tighten the bolt.
2 Brake hose guide *3
After positioning the clamp with the stopper,
tighten the clamp bolt.
3 Brake hose clamp *4 Assemble the brake hose firmly.
4 Throttle cables *5 Clamp the brake hose firmly.
*1 After the brake hose union has contacted the stopper, tighten the union bolt. *6
Don’t contact the brake hose with the boss of
front fork outer tube.
21 ˚
21 ˚
*4
*2
*1
*5
*3
*5
*1
*1
21 ˚
42 ˚
*6
13-130 DL650K7/AK7 (’07-MODEL)
FRONT BRAKE HOSE ROUTING (For DL650A)
1 Brake hose 7 ABS control unit/HU
2 Throttle cable (Return) *1 After the brake hose union has contacted the stopper, tighten the union bolt.
3 Throttle cable (Pull) *2 Clamp the brake hose firmly.
4 Clutch cable *3 Set the white painted marking side of the hose to the joint.
5 Harness *4 Clamp pipes on line painted.
6 Front brake joint *5 Set the rubber properly.
*1
*2
21˚
*5
*4
*2
*3
*1*1
*1
*1
42˚
42˚42˚
35˚
42˚
21˚
14˚ 14˚
49˚
21˚
DL650K7/AK7 (’07-MODEL) 13-131
REAR BRAKE HOSE ROUTING (For DL650A)
1 ABS control unit *3 White paint outside.
2 Guide *4 Insert the reservoir hose into union to the root.
3 Wheel speed sensor lead wire *5 Pass through the reservoir hose outside of the seat rail.
4 Brake hose *6 Clamp ends should face forward.
*1 After the brake hose union has contacted the stopper, tighten the union bolt. *7 Clamp ends should face backward.
*2 Position the brake hose with stopper before tightening.
42˚
*6
*2
*3
*4, *5
*1*7
*1
42˚
13-132 DL650K7/AK7 (’07-MODEL)
FRONT WHEEL SPEED SENSOR INSTALLATION (For DL650A)
NOTE: Cut the tip of clamp after clamping.
*1 Hold the wheel speed sensor lead wire with clamp on the top of the radiator. *8
Pass through the wheel speed sensor lead wire
in front of the brake hose. Make clearance
between the wheel speed sensor lead wire and
the front fender.
*2 Align the protector with the edge of radiator shield. *9 Letters should face outside.
*3
Clamp the speed sensor lead wire to brake
hose with wheel speed sensor at white marking.
*10 Pass through the wheel speed sensor lead wire forward of the brake hose.
*4 Set the wheel speed sensor lead wire to the part of the brake hose union with a clamp. *11
Clamp the wheel speed sensor lead wire forward of the brake hose.
*5 Hold the wheel speed sensor lead wire with guide at white marking position. *12
Pass through the speed sensor lead wire inside
the boss of front fork outer tube.
*6 Pass through the wheel speed sensor lead wire inside the boss of front fork outer tube. *13
Clamp the wheel speed sensor lead wire to
brake hose with speed sensor lead wire at yellow marking.
*7 Clamp the wheel speed sensor lead wire to brake hose at sleeve.
*4*3
*9
*11
*2
*7
*8
21˚
*12
*1
*5
21˚
*6
Sensor
clamp
*10
*13
DL650K7/AK7 (’07-MODEL) 13-133
REAR WHEEL SPEED SENSOR INSTALLATION (For DL650A)
1 Guide *1 Clamp the sensor lead wire to the brake hose at white painted marking.
2
Wheel speed sensor
lead wire
*2 Pass through the sensor lead wire inside of brake hose guide.
3 Brake hose *3 Letters should face outside.
*3
*2
*1
13-134 DL650K7/AK7 (’07-MODEL)
FUEL TANK DRAIN HOSE ROUTING
1 Fuel tank water drain hose 6 Brake pipe (For ABS model)
2 Reservoir tank overflow hose *1 Pass through the hoses under the brake pipe. (For ABS model)
3 Reservoir tank inlet hose *2
Pass through the hoses outside of brake pipe and reservoir tank
hose.
4 HO2 sensor
(For E-02, 19, 24, 41)
*3
Make sure to position the clamp in the specified direction.
*1
*2
48 N.m
4.8 kgf-m
34.5 lb-ft
*3
90 m
m (3.54 in)
90˚
DL650K7/AK7 (’07-MODEL) 13-135
THROTTLE BODY INSTALLATION
1 ISC valve *4 Matching mark (Yellow)
*1 Clamp ends should face back side. *5 Matching mark (White)
*2 Clamp ends should face lower side. *6 Align the marking with the rib of pipe.
*3 Clamp ends should face left side.
10 N.m
(1.0 kgf-m, 7.0 lb-ft)
*5, *6
*1
*1
*5
To canister
(Purge hose E-33 only)
25˚
FR
RH
LH
RH
LH
Air cleaner side
Engine side
FR
RR
RR
15 – 25˚
19 N.m (1.9 kgf-m, 13.5 lb-ft)
*2
*2
*3
*4 *4
*1
*1
*5
FW
D
48 N.m (4.8 kgf-m, 34.5 lb-ft)
13-136 DL650K7/AK7 (’07-MODEL)
COOLING SYSTEM HOSE ROUTING
1 Clamp *4 Clamp the water drain hose and oil pressure switch lead wire.
2 Wiring harness *5 Fill the bearing with engine oil until engine oil comes out from the hole of the be bearing housing.
3 Oil pressure switch *6 Clamp bolt head upward.
4 Oil filter *7 Clamp bolt head downward.
*1 Clamp end downward. *8 Pass through the reservoir overflow hose between the brake pipe and reservoir inlet hose.
*2 Matching mark (White) *9 Pass through the reservoir inlet hose left side of high tension cord and right side of harness (for IAP sensor).
*3 Matching mark (Blue)
*6
*1
*6
*8
*7
*7
*9
*2
*3
*4
*5
DL650K7/AK7 (’07-MODEL) 13-137
1 Clamp *3 Marking (Yellow)
2 Jiggle valve *4 Clamp bolt head downward.
3 Union *5 Clamp bolt head left side.
4 Radiator hose *6 Make clearance between bulge of union and clamp.
*1 Marking *7 Clamp face left side.
*2 Matching mark (White)
0 – 90˚
90˚ 90˚
90˚
*1
*2
*5
*7
*4
*5
*3
Marking position
*6
*1
*1
Installation point
13-138 DL650K7/AK7 (’07-MODEL)
PAIR (AIR SUPPLY) SYSTEM HOSE ROUTING
*1
Approx. 20˚
1 Matching mark (White) 4 PAIR control solenoid valve
2
Matching mark (Yellow)
*1
Pass through the PAIR hose between the cylinder head cover and intake pipe.
3 Hose
DL650K7/AK7 (’07-MODEL) 13-139
BATTERY PROTECTOR INSTALLATION
*1
Align the top of protector with the upper surface
of the battery holder.
FWD 45 mm (1.77 in)
3.12 mm (0.12 in)
6.2 mm (0.24 in)
20 mm (0.79 in)
*1
*1
13-140 DL650K7/AK7 (’07-MODEL)
SPECIAL TOOLS
NOTE:
When order the special tool, please confirm whether it is available or not.
TIGHTENING TORQUE
09900-20803
09900-20806
Thickness gauge
09900-25008
Multi-circuit tester
set
09900-25009
Needle pointed
probe set
09900-28630
TPS test wire harness
09904-41010
SDS set tool
09913-10130
Carburetor adjuster
driver
09917-47011
Vacuum pump
gauge
09930-10121
Spark plug socket
wrench set
09930-11950
Torx wrench
09930-82710
Mode select switch
09930-82720
Mode select switch
99565-01010-008
CD-ROM Ver. 8
ITEM N·m kgf-m lb-ft
Brake pipe flare nut 16 1.6 11.5
Fuel delivery pipe mounting screw 5 0.5 3.5
Fuel pump mounting bolt 10 1.0 7.0
HO2 sensor 48 4.8 34.5
Spark plug 11 1.1 8.0
STP sensor mounting screw 3.5 0.35 2.5
TP sensor mounting screw 3.5 0.35 2.5
DL650K7/AK7 (’07-MODEL) 13-141
SERVICE DATA (DL650K7)
VALVE + GUIDE Unit: mm (in)
ITEM STANDARD LIMIT
Valve diam.
IN.
31
(1.2)
----
EX.
25.5
(1.0)
----
Valve clearance (when cold)
IN.
0.10 – 0.20
(0.004 – 0.008)
----
EX.
0.20 – 0.30
(0.008 – 0.012)
----
Valve guide to valve stem
clearance
IN.
0.020 – 0.047
(0.0008 – 0.0019)
----
EX.
0.030 – 0.057
(0.0012 – 0.0022)
----
Valve guide I.D.
IN. & EX.
4.500 – 4.512
(0.1772 – 0.1776)
----
Valve stem O.D.
IN.
4.465 – 4.480
(0.1758 – 0.1764)
----
EX.
4.455 – 4.470
(0.1754 – 0.1760)
----
Valve stem deflection
IN. & EX. ----
0.35
(0.014)
Valve stem runout
IN. & EX. ----
0.05
(0.002)
Valve head thickness
IN. & EX. ----
0.5
(0.02)
Valve seat width
IN. & EX.
0.9 – 1.1
(0.035 – 0.043)
----
Valve head radial runout
IN. & EX. ----
0.03
(0.001)
Valve spring free length
(IN. & EX.)
INNER ----
36.8
(1.45)
OUTER ----
39.8
(1.57)
Valve spring tension
(IN. & EX.) INNER
41 – 47 N (4.2 – 4.8 kgf)
(9.26 – 10.58 lbs)
at length 29.9 mm (1.18 in)
----
OUTER
166 – 192 N (17.0 – 19.6 kgf)
(37.48 – 43.21 lbs)
at length 33.4 mm (1.31 in)
----
13-142 DL650K7/AK7 (’07-MODEL)
CAMSHAFT + CYLINDER HEAD Unit: mm (in)
ITEM STANDARD LIMIT
Cam height
IN.
35.48 – 35.53
(1.3968 – 1.3988)
35.18
(1.3850)
EX.
33.48 – 33.53
(1.3181 – 1.3201)
33.18
(1.3063)
Camshaft journal oil clearance
IN. & EX.
0.032 – 0.066
(0.0013 – 0.0026)
0.150
(0.0059)
Camshaft journal holder I.D.
IN. & EX.
22.012 – 22.025
(0.8666 – 0.8671)
----
Camshaft journal O.D.
IN. & EX.
21.959 – 21.980
(0.8645 – 0.8654)
----
Camshaft runout
IN. & EX. ----
0.10
(0.004)
Cam chain pin (at arrow “3”) 16th pin ---Cylinder head distortion
----
0.05
(0.002)
DL650K7/AK7 (’07-MODEL) 13-143
CYLINDER + PISTON + PISTON RING Unit: mm (in)
ITEM STANDARD LIMIT
Compression pressure 1 300 – 1 700 kPa
(13 – 17 kgf/cm2, 185 – 242 psi)
1 100 kPa
(11 kgf/cm2, 156 psi)
Compression pressure
difference
----
200 kPa
(2 kgf/cm2, 28 psi)
Piston to cylinder clearance 0.055 – 0.065
(0.0022 – 0.0026)
0.120
(0.0047)
Cylinder bore 81.000 – 81.015
(3.1890 – 3.1896)
Nicks or
Scratches
Piston diam. * 80.940 – 80.955
(3.1866 – 3.1872)
Measure at 20 mm (0.79 in) from the skirt end.
80.88
(3.184)
Cylinder distortion
----
0.05
(0.002)
Piston ring free end gap
1st * Approx. 7 (0.28)
* 5.6
(0.22)
2nd Approx. 11 (0.43)
8.8
(0.35)
Piston ring end gap
1st
0.20 – 0.35
(0.008 – 0.014)
0.70
(0.028)
2nd
0.20 – 0.35
(0.008 – 0.0014)
0.70
(0.028)
Piston ring to groove clearance
1st ---0.180
(0.0071)
2nd ---0.150
(0.0059)
Piston ring groove width
1st
* 0.83 – 0.85
(0.0327 – 0.0335)
----
2nd
1.01 – 1.03
(0.0398 – 0.0406)
----
Oil
2.01 – 2.03
(0.0791 – 0.0799)
----
Piston ring thickness
1st
* 0.76 – 0.81
(0.0299 – 0.0319)
----
2nd
0.97 – 0.99
(0.0382 – 0.0390)
----
Piston pin bore 20.002 – 20.008
(0.7875 – 0.7877)
20.030
(0.7886)
Piston pin O.D. 19.992 – 20.000
(0.7871 – 0.7874)
19.98
(0.7866)
13-144 DL650K7/AK7 (’07-MODEL)
CONROD + CRANKSHAFT Unit: mm (in)
OIL PUMP
CLUTCH Unit: mm (in)
ITEM STANDARD LIMIT
Conrod small end I.D. 20.010 – 20.018
(0.7878 – 0.7881)
20.040
(0.7890)
Conrod big end side clearance 0.170 – 0.320
(0.0067 – 0.0126)
0.5
(0.02)
Conrod big end width 20.95 – 21.00
(0.825 – 0.827)
----
Crank pin width 42.17 – 42.22
(1.660 – 1.662)
----
Conrod big end oil clearance 0.032 – 0.056
(0.0013 – 0.0022)
0.080
(0.0031)
Crank pin O.D. 37.976 – 38.000
(1.4951 – 1.4960)
----
Crankshaft journal oil clearance 0.002 – 0.029
(0.0001 – 0.0011)
0.080
(0.0031)
Crankshaft journal O.D. 41.985 – 42.000
(1.6529 – 1.6535)
----
Crankshaft runout
----
0.05
(0.002)
ITEM STANDARD LIMIT
Oil pressure (at 60 °C, 140 °F) Above 100 kPa (1.0 kgf/cm², 14 psi)
Below 400 kPa (4.0 kgf/cm², 57 psi)
at 3 000 r/min.
----
ITEM STANDARD LIMIT
Clutch cable play 10 – 15
(0.4 – 0.6)
----
Clutch release screw 1/4 turn back ---Drive plate thickness
No.1 & No.2
2.92 – 3.08
(0.115 – 0.121)
2.62
(0.103)
Drive plate claw width
No.1 & No.2
13.7 – 13.8
(0.539 – 0.543)
12.9
(0.507)
Driven plate distortion
----
0.10
(0.004)
Clutch spring free length 53.1
(2.09)
50.5
(1.99)
DL650K7/AK7 (’07-MODEL) 13-145
TRANSMISSION + DRIVE CHAIN Unit: mm (in) Except ratio
ITEM STANDARD LIMIT
Primary reduction ratio 2.088 (71/34) ---Final reduction ratio 3.133 (47/15) ---Gear ratios Low 2.461 (32/13) ---2nd 1.777 (32/18) ----
3rd 1.380 (29/21) ----
4th 1.125 (27/24) ----
5th 0.961 (25/26) ----
Top 0.851 (23/27) ----
Shift fork to groove clearance 0.1 – 0.3
(0.004 – 0.012)
0.50
(0.020)
Shift fork groove width 5.5 – 5.6
(0.217 – 0.220)
----
Shift fork thickness 5.3 – 5.4
(0.209 – 0.213)
----
Drive chain
Type DID525V8
----
----
Links * 118 links ---20-pitch
length
----
319.4
(12.57)
Drive chain slack (on side-stand) 20 – 30
(0.79 – 1.18)
----
Gearshift lever height 25
(0.98)
----
13-146 DL650K7/AK7 (’07-MODEL)
THERMOSTAT + RADIATOR + FAN + COOLANT
INJECTOR + FUEL PUMP + FUEL PRESSURE REGULATOR
ITEM STANDARD NOTE
Thermostat valve opening
temperature
Approx. 88 °C (190 °F) ---Thermostat valve lift Over 8.0 mm (0.31 in) at 100 °C (212 °F) ---ECT sensor resistance 20 °C
(68 °F)
Approx. 2.45 kΩ ---40 °C
(104 °F)
Approx. 1.148 kΩ ---60 °C
(140 °F)
Approx. 0.587 kΩ ---80 °C
(176 °F)
Approx. 0.322 kΩ ---Radiator cap valve opening
pressure
95 – 125 kPa
(0.95 – 1.25 kgf/cm², 13.5 – 17.8 psi)
----
Cooling fan thermo-switch
operating temperature
OFF→ON Approx. 98 °C (208 °F) ---ON→OFF Approx. 92 °C (198 °F) ---Engine coolant type Use an antifreeze/coolant compatible with aluminum radiator, mixed with distilled water only, at the
ratio of 50:50.
----
Engine coolant including reserve Reserve
tank side
Approx. 250 ml
(0.53/0.44 US/lmp qt)
----
Engine
side
Approx. 1 650 ml
(3.49/2.90 US/lmp qt)
----
ITEM SPECIFICATION NOTE
Injector resistance 11 – 13 Ω at 20 °C (68 °F)
Fuel pump discharge amount * More than 75 ml (2.5/2.6 US/lmp oz)
for 6 sec. at 300 kPa (3.0 kgf/cm², 43 psi)
Fuel pressure regulator operating
set pressure
Approx. 300 kPa (3.0 kgf/cm², 43 psi)
DL650K7/AK7 (’07-MODEL) 13-147
FI SENSORS + STVA + ISC VALVE
THROTTLE BODY
ITEM SPECIFICATION NOTE
CKP sensor resistance 130 – 240 Ω W – G
CKP sensor peak voltage 3.7 V (When cranking) and more
IAP sensor input voltage (F & R) 4.5 – 5.5 V
IAP sensor output voltage (F & R) * Approx. 1.6 V at idle speed
TP sensor input voltage 4.5 – 5.5 V
TP sensor output voltage Closed * Approx. 1.1 V + P/W –
- B/BrOpened * Approx. 4.3 V
ECT sensor input voltage 4.5 – 5.5 V
ECT sensor resistance Approx. 2.45 kΩ at 20 °C (68 °F)
IAT sensor input voltage 4.5 – 5.5 V
IAT sensor resistance Approx. 2.45 kΩ at 20 °C (68 °F)
TO sensor resistance * 16.5 – 22.3 kΩ
TO sensor voltage Normal 0.4 – 1.4 V + Br/W –
- B/BrLeaning 65° 3.7 – 4.4 V
GP switch voltage 1.0 V and more (From 1st to Top)
Injector voltage Battery voltage
STP sensor input voltage 4.5 – 5.5 V
STP sensor output voltage Closed * Approx. 0.6 V + Y –
- B/BrOpened * Approx. 4.5 V
STV actuator resistance * Approx. 7 Ω
Heated oxygen sensor output voltage
0.4 V and less at idle speed
E-02, 19, 24, 41
0.6 V and more at 5 000 r/min
Heated oxygen sensor resistance * 11 – 15 Ω at 23 °C (73.4 °F) E-02, 19, 24, 41
PAIR solenoid valve resistance 20 – 24 kΩ at 20 °C (68 °F)
ISC valve resistance * Approx. 30 ± 1.2 Ω at 20 °C (68 °F)
ITEM SPECIFICATION
I.D. No. * 27 G2 (Others), 27 G3 (For E-33)
Bore size 39 mm
Fast idle r/min. * 1 800 – 2 200 r/min at 25 °C (77 °F)
Idle r/min. 1 300 ± 100 r/min/Warmed engine
Throttle cable play 2.0 – 4.0 mm
(0.08 – 0.16 in)
13-148 DL650K7/AK7 (’07-MODEL)
ELECTRICAL Unit: mm (in)
ITEM SPECIFICATION NOTE
Firing order 1.2
Spark plug
Type
NGK: CR8E
DENSO: U24ESR-N
Gap
0.7 – 0.8 mm
(0.028 – 0.031 in)
Spark performance Over 8 mm (0.3 in) at 1 atm.
CKP sensor resistance 130 – 240 Ω W – G
Ignition coil resistance
Primary * 1 – 5 Ω
Terminal –
Terminal
Secondary * 25 – 40 kΩ
Plug cap – Plug
cap
CKP sensor peak voltage 3.7 V and more When cranking
Ignition coil primary peak voltage 150 V and more
Generator coil resistance 0.2 – 0.7 Ω
Generator Max. output Approx. 375 W at 5 000 r/min
Generator no-load voltage
(When cold)
60 V (AC) and more at 5 000 r/min.
Regulated voltage 14.0 – 15.5 V at 5 000 r/min.
Starter relay resistance 3 – 6 Ω
Battery Type designation
YTX12-BS
Capacity 12 V 36.0 kC (10 Ah)/10 HR
Fuse size
Headlight
HI 15 A
LO 15 A
Fuel 10 A
Ignition 10 A
Fan motor 15 A
Signal 15 A
Main 30 A
DL650K7/AK7 (’07-MODEL) 13-149
WATTAGE Unit: W
ITEM
SPECIFICATION
E-03, 24, 28, 33 Others
Headlight 12 V 60/55 W × 2 (H4) ←
Position/Parking light 12 V 5 W × 2
Brake light/Taillight 12 V 21/5 W × 2 ←
Turn signal light 12 V 21 W ←
License light 12 V 5 W ←
Speedometer light LED ←
Turn signal indicator light LED ←
High beam indicator light LED ←
Neutral indicator light LED ←
Oil pressure/Coolant temp./
FI indicator light
LED ←
13-150 DL650K7/AK7 (’07-MODEL)
BRAKE + WHEEL Unit: mm (in)
ITEM STANDARD LIMIT
Rear brake pedal height 15 – 25 (0.59 – 0.98) ---Brake disc thickness
Front
5
(0.20)
4.5
(0.18)
Rear
5
(0.20)
4.5
(0.18)
Brake disc runout
----
0.3
(0.012)
Master cylinder bore
Front
* 14.000 – 14.043
(0.5512 – 0.5529)
----
Rear
14.000 – 14.043
(0.5512 – 0.5529)
----
Master cylinder piston diam.
Front
* 13.957 – 13.984
(0.5495 – 0.5506)
----
Rear
13.957 – 13.984
(0.5495 – 0.5506)
----
Brake caliper cylinder bore
Front
* 27.000 – 27.076
(1.0630 – 1.0660)
----
Rear
38.180 – 38.230
(1.5031 – 1.5051)
----
Brake caliper piston diam.
Front
* 26.920 – 26.970
(1.0598 – 1.0618)
----
Rear
38.080 – 38.130
(1.4992 – 1.5012)
----
Brake fluid type DOT 4
Wheel rim runout
Axial ---2.0
(0.08)
Radial ---2.0
(0.08)
Wheel rim size Front 19 M/C × MT2.50 ---Rear 17 M/C × MT4.00 ---Wheel axle runout
Front ---0.25
(0.010)
Rear ---0.25
(0.010)
DL650K7/AK7 (’07-MODEL) 13-151
TIRE
SUSPENSION Unit: mm (in)
ITEM STD/SPEC. LIMIT
Cold inflation tire pressure
(Solo riding)
Front
225 kPa
(2.25 kgf/cm², 33 psi)
----
Rear
250 kPa
(2.50 kgf/cm², 36 psi)
----
Cold inflation tire pressure
(Dual riding)
Front
225 kPa
(2.25 kgf/cm², 33 psi)
----
Rear
280 kPa
(2.80 kgf/cm², 41 psi)
----
Tire size Front 110/80 R19 M/C 59H ---Rear 150/70 R17 M/C 69H ---Tire type Front BRIDGESTONE: TW101 F ---Rear BRIDGESTONE: TW152 F ---Tire tread depth
Front ---1.6
(0.06)
Rear ---2.0
(0.08)
ITEM STD/SPEC. LIMIT
Front fork stroke 150
(5.9)
----
Front fork spring free length 444.1 (17.5) 435 (17.1)
Front fork oil level (without spring,
outer tube fully compressed)
* 139 (5.47) ----
Front fork spring adjuster 3 grooves from Top/Spring adjuster height 9 mm
(0.35 in)
----
Front fork oil type SUZUKI FORK OIL SS-08
or equivalent fork oil
----
Front fork oil capacity (each leg) * 528 ml
(17.8/18.6 US/Imp oz)
----
Rear shock absorber spring
adjuster
2 grooves from bottom ---Rear shock absorber damping
force adjuster
Rebound 1 turn back from stiffest position ---Rear wheel travel 150 mm
(5.9 in)
----
Swingarm pivot shaft runout
----
0.3
(0.01)
13-152 DL650K7/AK7 (’07-MODEL)
FUEL + OIL
ITEM STD/SPEC. NOTE
Fuel type Use only unleaded gasoline of at least 87 pump
octane (R/2 + M/2) or 91 octane or higher rated by
the research method.
Gasoline containing MTBE (Methyl Tertiary Butyl
Ether), less than 10 % ethanol, or less than 5 %
methanol with appropriate cosolvents and corrosion inhibitor is permissible.
E-03, 28, 33
Gasoline used should be graded 91 octane or
higher. An unleaded gasoline is recommended.
Others
Fuel tank capacity 22 L (5.8/4.8 US/lmp gal)
Engine oil type SAE 10W-40, API SF/SG or SH/SJ with JASO MA
Engine oil capacity
Change
2 300 ml
(2.4/2.0 US/lmp qt)
Filter change
2 700 ml
(2.9/2.4 US/lmp qt)
Overhaul
3 100 ml
(3.3/2.7 US/lmp qt)
DL650K7/AK7 (’07-MODEL) 13-153
SERVICE DATA (DL650AK7)
VALVE + GUIDE Unit: mm (in)
ITEM STANDARD LIMIT
Valve diam.
IN.
31
(1.2)
----
EX.
25.5
(1.0)
----
Valve clearance (when cold)
IN.
0.10 – 0.20
(0.004 – 0.008)
----
EX.
0.20 – 0.30
(0.008 – 0.012)
----
Valve guide to valve stem
clearance
IN.
0.020 – 0.047
(0.0008 – 0.0019)
----
EX.
0.030 – 0.057
(0.0012 – 0.0022)
----
Valve guide I.D.
IN. & EX.
4.500 – 4.512
(0.1772 – 0.1776)
----
Valve stem O.D.
IN.
4.465 – 4.480
(0.1758 – 0.1764)
----
EX.
4.455 – 4.470
(0.1754 – 0.1760)
----
Valve stem deflection
IN. & EX. ----
0.35
(0.014)
Valve stem runout
IN. & EX. ----
0.05
(0.002)
Valve head thickness
IN. & EX. ----
0.5
(0.02)
Valve seat width
IN. & EX.
0.9 – 1.1
(0.035 – 0.043)
----
Valve head radial runout
IN. & EX. ----
0.03
(0.001)
Valve spring free length
(IN. & EX.)
INNER ----
36.8
(1.45)
OUTER ----
39.8
(1.57)
Valve spring tension
(IN. & EX.) INNER
41 – 47 N (4.2 – 4.8 kgf)
(9.26 – 10.58 lbs)
at length 29.9 mm (1.18 in)
----
OUTER
166 – 192 N (17.0 – 19.6 kgf)
(37.48 – 43.21 lbs)
at length 33.4 mm (1.31 in)
----
13-154 DL650K7/AK7 (’07-MODEL)
CAMSHAFT + CYLINDER HEAD Unit: mm (in)
ITEM STANDARD LIMIT
Cam height
IN.
35.48 – 35.53
(1.3968 – 1.3988)
35.18
(1.3850)
EX.
33.48 – 33.53
(1.3181 – 1.3201)
33.18
(1.3063)
Camshaft journal oil clearance
IN. & EX.
0.032 – 0.066
(0.0013 – 0.0026)
0.150
(0.0059)
Camshaft journal holder I.D.
IN. & EX.
22.012 – 22.025
(0.8666 – 0.8671)
----
Camshaft journal O.D.
IN. & EX.
21.959 – 21.980
(0.8645 – 0.8654)
----
Camshaft runout
IN. & EX. ----
0.10
(0.004)
Cam chain pin (at arrow “3”) 16th pin ---Cylinder head distortion
----
0.05
(0.002)
DL650K7/AK7 (’07-MODEL) 13-155
CYLINDER + PISTON + PISTON RING Unit: mm (in)
ITEM STANDARD LIMIT
Compression pressure 1 300 – 1 700 kPa
(13 – 17 kgf/cm2, 185 – 242 psi)
1 100 kPa
(11 kgf/cm2, 156 psi)
Compression pressure
difference
----
200 kPa
(2 kgf/cm2, 28 psi)
Piston to cylinder clearance 0.055 – 0.065
(0.0022 – 0.0026)
0.120
(0.0047)
Cylinder bore 81.000 – 81.015
(3.1890 – 3.1896)
Nicks or
Scratches
Piston diam. 80.940 – 80.955
(3.1866 – 3.1872)
Measure at 20 mm (0.79 in) from the skirt end.
80.88
(3.184)
Cylinder distortion
----
0.05
(0.002)
Piston ring free end gap
1st Approx. 7 (0.28)
5.6
(0.22)
2nd Approx. 11 (0.43)
8.8
(0.35)
Piston ring end gap
1st
0.20 – 0.35
(0.008 – 0.014)
0.70
(0.028)
2nd
0.20 – 0.35
(0.008 – 0.0014)
0.70
(0.028)
Piston ring to groove clearance
1st ---0.180
(0.0071)
2nd ---0.150
(0.0059)
Piston ring groove width
1st
0.83 – 0.85
(0.0327 – 0.0335)
----
2nd
1.01 – 1.03
(0.0398 – 0.0406)
----
Oil
2.01 – 2.03
(0.0791 – 0.0799)
----
Piston ring thickness
1st
0.76 – 0.81
(0.0299 – 0.0319)
----
2nd
0.97 – 0.99
(0.0382 – 0.0390)
----
Piston pin bore 20.002 – 20.008
(0.7875 – 0.7877)
20.030
(0.7886)
Piston pin O.D. 19.992 – 20.000
(0.7871 – 0.7874)
19.98
(0.7866)
13-156 DL650K7/AK7 (’07-MODEL)
CONROD + CRANKSHAFT Unit: mm (in)
OIL PUMP
CLUTCH Unit: mm (in)
ITEM STANDARD LIMIT
Conrod small end I.D. 20.010 – 20.018
(0.7878 – 0.7881)
20.040
(0.7890)
Conrod big end side clearance 0.170 – 0.320
(0.0067 – 0.0126)
0.5
(0.02)
Conrod big end width 20.95 – 21.00
(0.825 – 0.827)
----
Crank pin width 42.17 – 42.22
(1.660 – 1.662)
----
Conrod big end oil clearance 0.032 – 0.056
(0.0013 – 0.0022)
0.080
(0.0031)
Crank pin O.D. 37.976 – 38.000
(1.4951 – 1.4960)
----
Crankshaft journal oil clearance 0.002 – 0.029
(0.0001 – 0.0011)
0.080
(0.0031)
Crankshaft journal O.D. 41.985 – 42.000
(1.6529 – 1.6535)
----
Crankshaft runout
----
0.05
(0.002)
ITEM STANDARD LIMIT
Oil pressure (at 60 °C, 140 °F) Above 100 kPa (1.0 kgf/cm², 14 psi)
Below 400 kPa (4.0 kgf/cm², 57 psi)
at 3 000 r/min.
----
ITEM STANDARD LIMIT
Clutch cable play 10 – 15
(0.4 – 0.6)
----
Clutch release screw 1/4 turn back ---Drive plate thickness
No.1 & No.2
2.92 – 3.08
(0.115 – 0.121)
2.62
(0.103)
Drive plate claw width
No.1 & No.2
13.7 – 13.8
(0.539 – 0.543)
12.9
(0.507)
Driven plate distortion
----
0.10
(0.004)
Clutch spring free length 53.1
(2.09)
50.5
(1.99)
DL650K7/AK7 (’07-MODEL) 13-157
TRANSMISSION + DRIVE CHAIN Unit: mm (in) Except ratio
ITEM STANDARD LIMIT
Primary reduction ratio 2.088 (71/34) ---Final reduction ratio 3.133 (47/15) ---Gear ratios Low 2.461 (32/13) ---2nd 1.777 (32/18) ----
3rd 1.380 (29/21) ----
4th 1.125 (27/24) ----
5th 0.961 (25/26) ----
Top 0.851 (23/27) ----
Shift fork to groove clearance 0.1 – 0.3
(0.004 – 0.012)
0.50
(0.020)
Shift fork groove width 5.5 – 5.6
(0.217 – 0.220)
----
Shift fork thickness 5.3 – 5.4
(0.209 – 0.213)
----
Drive chain
Type DID525V8
----
----
Links 118 links ---20-pitch
length
----
319.4
(12.57)
Drive chain slack (on side-stand) 20 – 30
(0.79 – 1.18)
----
Gearshift lever height 25
(0.98)
----
13-158 DL650K7/AK7 (’07-MODEL)
THERMOSTAT + RADIATOR + FAN + COOLANT
INJECTOR + FUEL PUMP + FUEL PRESSURE REGULATOR
ITEM STANDARD NOTE
Thermostat valve opening
temperature
Approx. 88 °C (190 °F) ---Thermostat valve lift Over 8.0 mm (0.31 in) at 100 °C (212 °F) ---ECT sensor resistance 20 °C
(68 °F)
Approx. 2.45 kΩ ---40 °C
(104 °F)
Approx. 1.148 kΩ ---60 °C
(140 °F)
Approx. 0.587 kΩ ---80 °C
(176 °F)
Approx. 0.322 kΩ ---Radiator cap valve opening
pressure
95 – 125 kPa
(0.95 – 1.25 kgf/cm², 13.5 – 17.8 psi)
----
Cooling fan thermo-switch
operating temperature
OFF→ON Approx. 98 °C (208 °F) ---ON→OFF Approx. 92 °C (198 °F) ---Engine coolant type Use an antifreeze/coolant compatible with aluminum radiator, mixed with distilled water only, at the
ratio of 50:50.
----
Engine coolant including reserve Reserve tank
side
Approx. 250 ml
(0.53/0.44 US/lmp qt)
----
Engine side
Approx. 1650 ml
(3.49/2.90 US/lmp qt)
----
ITEM SPECIFICATION NOTE
Injector resistance 11 – 13 Ω at 20 °C (68 °F)
Fuel pump discharge amount More than 75 ml (2.5/2.6 US/lmp oz)
for 6 sec. at 300 kPa (3.0 kgf/cm², 43 psi)
Fuel pressure regulator operating
set pressure
Approx. 300 kPa (3.0 kgf/cm², 43 psi)
DL650K7/AK7 (’07-MODEL) 13-159
FI SENSORS + STVA + ISC VALVE
THROTTLE BODY
ITEM SPECIFICATION NOTE
CKP sensor resistance 130 – 240 Ω W – G
CKP sensor peak voltage 3.7 V (When cranking) and more
IAP sensor input voltage (F & R) 4.5 – 5.5 V
IAP sensor output voltage (F & R) Approx. 1.6 V at idle speed
TP sensor input voltage 4.5 – 5.5 V
TP sensor output voltage Closed Approx. 1.1 V + P/W –
- B/BrOpened Approx. 4.3 V
ECT sensor input voltage 4.5 – 5.5 V
ECT sensor resistance Approx. 2.45 kΩ at 20 °C (68 °F)
IAT sensor input voltage 4.5 – 5.5 V
IAT sensor resistance Approx. 2.45 kΩ at 20 °C (68 °F)
TO sensor resistance 16.5 – 22.3 kΩ
TO sensor voltage Normal 0.4 – 1.4 V + Br/W –
- B/BrLeaning 65° 3.7 – 4.4 V
GP switch voltage 1.0 V and more (From 1st to Top)
Injector voltage Battery voltage
STP sensor input voltage 4.5 – 5.5 V
STP sensor output voltage Closed Approx. 0.6 V + Y –
- B/BrOpened Approx. 4.5 V
STV actuator resistance Approx. 7 Ω
Heated oxygen sensor output voltage
0.4 V and less at idle speed
E-02, 19, 24, 41
0.6 V and more at 5 000 r/min
Heated oxygen sensor resistance 11 – 15 Ω at 23 °C (73.4 °F) E-02, 19, 24, 41
PAIR solenoid valve resistance 20 – 24 kΩ at 20 °C (68 °F)
ISC valve resistance Approx. 30 ± 1.2 Ω at 20 °C (68 °F)
ITEM SPECIFICATION
I.D. No. 27 G2 (Others), 27 G3 (For E-33)
Bore size 39 mm
Fast idle r/min. 1 800 – 2 200 r/min at 25 °C (77 °F)
Idle r/min. 1 300 ± 100 r/min/Warmed engine
Throttle cable play 2.0 – 4.0 mm
(0.08 – 0.16 in)
13-160 DL650K7/AK7 (’07-MODEL)
ELECTRICAL Unit: mm (in)
ITEM SPECIFICATION NOTE
Firing order 1.2
Spark plug
Type
NGK: CR8E
DENSO: U24ESR-N
Gap
0.7 – 0.8 mm
(0.028 – 0.031 in)
Spark performance Over 8 mm (0.3 in) at 1 atm.
CKP sensor resistance 130 – 240 Ω W – G
Ignition coil resistance
Primary 1 – 5 Ω
Terminal –
Terminal
Secondary 25 – 40 kΩ
Plug cap – Plug
cap
CKP sensor peak voltage 3.7 V and more When cranking
Ignition coil primary peak voltage 150 V and more
Generator coil resistance 0.2 – 0.7 Ω
Generator Max. output Approx. 375 W at 5 000 r/min
Generator no-load voltage
(When cold)
60 V (AC) and more at 5 000 r/min.
Regulated voltage 14.0 – 15.5 V at 5 000 r/min.
Starter relay resistance 3 – 6 Ω
Battery Type designation
YTX12-BS
Capacity 12 V 36.0 kC (10 Ah)/10 HR
Fuse size
Headlight
HI 15 A
LO 15 A
Fuel 10 A
Ignition 10 A
Fan motor 15 A
Signal 15 A
Main 30 A
ABS motor ** 40 A
ABS valve ** 25 A
DL650K7/AK7 (’07-MODEL) 13-161
WATTAGE Unit: W
ITEM
SPECIFICATION
E-03, 24, 28, 33 Others
Headlight 12 V 60/55 W × 2 (H4) ←
Position/Parking light 12 V 5 W × 2
Brake light/Taillight 12 V 21/5 W × 2 ←
Turn signal light 12 V 21 W ←
License light 12 V 5 W ←
Speedometer light LED ←
Turn signal indicator light LED ←
High beam indicator light LED ←
Neutral indicator light LED ←
Oil pressure/Coolant temp./
FI indicator light
LED ←
ABS indicator light ** LED ←
13-162 DL650K7/AK7 (’07-MODEL)
BRAKE + WHEEL Unit: mm (in)
ITEM STANDARD LIMIT
Rear brake pedal height 15 – 25 (0.59 – 0.98) ---Brake disc thickness
Front
5
(0.20)
4.5
(0.18)
Rear
5
(0.20)
4.5
(0.18)
Brake disc runout
----
0.3
(0.012)
Master cylinder bore
Front
14.000 – 14.043
(0.5512 – 0.5529)
----
Rear
14.000 – 14.043
(0.5512 – 0.5529)
----
Master cylinder piston diam.
Front
13.957 – 13.984
(0.5495 – 0.5506)
----
Rear
13.957 – 13.984
(0.5495 – 0.5506)
----
Brake caliper cylinder bore
Front
27.000 – 27.076
(1.0630 – 1.0660)
----
Rear
38.180 – 38.230
(1.5031 – 1.5051)
----
Brake caliper piston diam.
Front
26.920 – 26.970
(1.0598 – 1.0618)
----
Rear
38.080 – 38.130
(1.4992 – 1.5012)
----
Brake fluid type DOT 4
Wheel rim runout
Axial ---2.0
(0.08)
Radial ---2.0
(0.08)
Wheel rim size Front 19 M/C × MT2.50 ---Rear 17 M/C × MT4.00 ---Wheel axle runout
Front ---0.25
(0.010)
Rear ---0.25
(0.010)
Wheel speed sensor to sensor
rotor clearance
Front & Rear
** 0.3 – 1.5
(0.012 – 0.059)
----
DL650K7/AK7 (’07-MODEL) 13-163
TIRE
SUSPENSION Unit: mm (in)
ITEM STD/SPEC. LIMIT
Cold inflation tire pressure
(Solo riding)
Front
225 kPa
(2.25 kgf/cm², 33 psi)
----
Rear
250 kPa
(2.50 kgf/cm², 36 psi)
----
Cold inflation tire pressure
(Dual riding)
Front
225 kPa
(2.25 kgf/cm², 33 psi)
----
Rear
280 kPa
(2.80 kgf/cm², 41 psi)
----
Tire size Front 110/80 R19 M/C 59H ---Rear 150/70 R17 M/C 69H ---Tire type Front BRIDGESTONE: TW101 F ---Rear BRIDGESTONE: TW152 F ---Tire tread depth
Front ---1.6
(0.06)
Rear ---2.0
(0.08)
ITEM STD/SPEC. LIMIT
Front fork stroke 150
(5.9)
----
Front fork spring free length 444.1 (17.5) 435 (17.1)
Front fork oil level (without spring,
outer tube fully compressed)
139 (5.47) ----
Front fork spring adjuster 3 grooves from Top/Spring adjuster height 9 mm
(0.35 in)
----
Front fork oil type SUZUKI FORK OIL SS-08
or equivalent fork oil
----
Front fork oil capacity (each leg) 528 ml
(17.8/18.6 US/Imp oz)
----
Rear shock absorber spring
adjuster
2 grooves from bottom ---Rear shock absorber damping
force adjuster
Rebound 1 turn back from stiffest position ---Rear wheel travel 150 mm
(5.9 in)
----
Swingarm pivot shaft runout
----
0.3
(0.01)
13-164 DL650K7/AK7 (’07-MODEL)
FUEL + OIL
ITEM STD/SPEC. NOTE
Fuel type Use only unleaded gasoline of at least 87 pump
octane (R/2 + M/2) or 91 octane or higher rated by
the research method.
Gasoline containing MTBE (Methyl Tertiary Butyl
Ether), less than 10 % ethanol, or less than 5 %
methanol with appropriate cosolvents and corrosion inhibitor is permissible.
E-03, 28, 33
Gasoline used should be graded 91 octane or
higher. An unleaded gasoline is recommended.
Others
Fuel tank capacity 22 L (5.8/4.8 US/lmp gal)
Engine oil type SAE 10W-40, API SF/SG or SH/SJ with JASO MA
Engine oil capacity
Change
2 300 ml
(2.4/2.0 US/lmp qt)
Filter change
2 700 ml
(2.9/2.4 US/lmp qt)
Overhaul
3 100 ml
(3.3/2.7 US/lmp qt)
DL650K7/AK7 (’07-MODEL) 13-165
03 ENGINE.book Page 105 Tuesday, February 28, 2006 3:03 PM
CONTENTS
PAGE
SERVICE DATA (DL650K8) ..................................................................... 14- 2
SERVICE DATA (DL650A/AUEK8) ........................................................... 14-14
NOTE:
Specifications are the same as the K7-MODEL.
DL650/AK (’0 -MODEL)
DL650/AK8 (’08-MODEL) 14- 1
8 8
14
– 2 –
SERVICE DATA (DL650K8)
VALVE + GUIDE Unit: mm (in)
ITEM STANDARD LIMIT
Valve diam.
IN.
31
(1.2)
----
EX.
25.5
(1.0)
----
Valve clearance (when cold)
IN.
0.10 – 0.20
(0.004 – 0.008)
----
EX.
0.20 – 0.30
(0.008 – 0.012)
----
Valve guide to valve stem
clearance
IN.
0.020 – 0.047
(0.0008 – 0.0019)
----
EX.
0.030 – 0.057
(0.0012 – 0.0022)
----
Valve guide I.D.
IN. & EX.
4.500 – 4.512
(0.1772 – 0.1776)
----
Valve stem O.D.
IN.
4.465 – 4.480
(0.1758 – 0.1764)
----
EX.
4.455 – 4.470
(0.1754 – 0.1760)
----
Valve stem deflection
IN. & EX. ----
0.35
(0.014)
Valve stem runout
IN. & EX. ----
0.05
(0.002)
Valve head thickness
IN. & EX. ----
0.5
(0.02)
Valve seat width
IN. & EX.
0.9 – 1.1
(0.035 – 0.043)
----
Valve head radial runout
IN. & EX. ----
0.03
(0.001)
Valve spring free length
(IN. & EX.)
INNER ----
36.8
(1.45)
OUTER ----
39.8
(1.57)
Valve spring tension
(IN. & EX.) INNER
41 – 47 N (4.2 – 4.8 kgf)
(9.26 – 10.58 lbs)
at length 29.9 mm (1.18 in)
----
OUTER
166 – 192 N (17.0 – 19.6 kgf)
(37.48 – 43.21 lbs)
at length 33.4 mm (1.31 in)
----
14-2 DL650/AK8 (’08-MODEL)
– 3 –
CAMSHAFT + CYLINDER HEAD Unit: mm (in)
ITEM STANDARD LIMIT
Cam height
IN.
35.48 – 35.53
(1.3968 – 1.3988)
35.18
(1.3850)
EX.
33.48 – 33.53
(1.3181 – 1.3201)
33.18
(1.3063)
Camshaft journal oil clearance
IN. & EX.
0.032 – 0.066
(0.0013 – 0.0026)
0.150
(0.0059)
Camshaft journal holder I.D.
IN. & EX.
22.012 – 22.025
(0.8666 – 0.8671)
----
Camshaft journal O.D.
IN. & EX.
21.959 – 21.980
(0.8645 – 0.8654)
----
Camshaft runout
IN. & EX. ----
0.10
(0.004)
Cam chain pin (at arrow “3”) 16th pin ---Cylinder head distortion
----
0.05
(0.002)
DL650/AK8 (’08-MODEL) 14- 3
– 4 –
CYLINDER + PISTON + PISTON RING Unit: mm (in)
ITEM STANDARD LIMIT
Compression pressure 1 300 – 1 700 kPa
(13 – 17 kgf/cm2, 185 – 242 psi)
1 100 kPa
(11 kgf/cm2, 156 psi)
Compression pressure
difference
----
200 kPa
(2 kgf/cm2, 28 psi)
Piston to cylinder clearance 0.055 – 0.065
(0.0022 – 0.0026)
0.120
(0.0047)
Cylinder bore 81.000 – 81.015
(3.1890 – 3.1896)
Nicks or
Scratches
Piston diam. 80.940 – 80.955
(3.1866 – 3.1872)
Measure at 20 mm (0.79 in) from the skirt end.
80.88
(3.184)
Cylinder distortion
----
0.05
(0.002)
Piston ring free end gap
1st Approx. 7 (0.28)
5.6
(0.22)
2nd * Approx. 11.5 (0.45)
8.8
(0.35)
Piston ring end gap
1st
* 0.20 – 0.30
(0.08 – 0.12)
0.70
(0.028)
2nd
* 0.30 – 0.45
(0.12 – 0.018)
0.70
(0.028)
Piston ring to groove clearance
1st ---0.180
(0.0071)
2nd ---0.150
(0.0059)
Piston ring groove width
1st
0.83 – 0.85
(0.0327 – 0.0335)
----
2nd
1.01 – 1.03
(0.0398 – 0.0406)
----
Oil
2.01 – 2.03
(0.0791 – 0.0799)
----
Piston ring thickness
1st
0.76 – 0.81
(0.0299 – 0.0319)
----
2nd
0.97 – 0.99
(0.0382 – 0.0390)
----
Piston pin bore 20.002 – 20.008
(0.7875 – 0.7877)
20.030
(0.7886)
Piston pin O.D. 19.992 – 20.000
(0.7871 – 0.7874)
19.98
(0.7866)
14-4 DL650/AK8 (’08-MODEL)
– 5 –
CONROD + CRANKSHAFT Unit: mm (in)
OIL PUMP
CLUTCH Unit: mm (in)
ITEM STANDARD LIMIT
Conrod small end I.D. 20.010 – 20.018
(0.7878 – 0.7881)
20.040
(0.7890)
Conrod big end side clearance 0.170 – 0.320
(0.0067 – 0.0126)
0.5
(0.02)
Conrod big end width 20.95 – 21.00
(0.825 – 0.827)
----
Crank pin width 42.17 – 42.22
(1.660 – 1.662)
----
Conrod big end oil clearance 0.032 – 0.056
(0.0013 – 0.0022)
0.080
(0.0031)
Crank pin O.D. 37.976 – 38.000
(1.4951 – 1.4960)
----
Crankshaft journal oil clearance 0.002 – 0.029
(0.0001 – 0.0011)
0.080
(0.0031)
Crankshaft journal O.D. 41.985 – 42.000
(1.6529 – 1.6535)
----
Crankshaft runout
----
0.05
(0.002)
ITEM STANDARD LIMIT
Oil pressure (at 60 °C, 140 °F) Above 100 kPa (1.0 kgf/cm², 14 psi)
Below 400 kPa (4.0 kgf/cm², 57 psi)
at 3 000 r/min.
----
ITEM STANDARD LIMIT
Clutch cable play 10 – 15
(0.4 – 0.6)
----
Clutch release screw 1/4 turn back ---Drive plate thickness
No.1 & No.2
2.92 – 3.08
(0.115 – 0.121)
2.62
(0.103)
Drive plate claw width
No.1 & No.2
13.7 – 13.8
(0.539 – 0.543)
12.9
(0.507)
Driven plate distortion
----
0.10
(0.004)
Clutch spring free length 53.1
(2.09)
50.5
(1.99)
DL650/AK8 (’08-MODEL) 14-5
– 6 –
TRANSMISSION + DRIVE CHAIN Unit: mm (in) Except ratio
ITEM STANDARD LIMIT
Primary reduction ratio 2.088 (71/34) ---Final reduction ratio 3.133 (47/15) ---Gear ratios Low 2.461 (32/13) ---2nd 1.777 (32/18) ----
3rd 1.380 (29/21) ----
4th 1.125 (27/24) ----
5th 0.961 (25/26) ----
Top 0.851 (23/27) ----
Shift fork to groove clearance 0.1 – 0.3
(0.004 – 0.012)
0.50
(0.020)
Shift fork groove width 5.5 – 5.6
(0.217 – 0.220)
----
Shift fork thickness 5.3 – 5.4
(0.209 – 0.213)
----
Drive chain
Type DID525V8
----
----
Links 118 links ---20-pitch
length
----
319.4
(12.57)
Drive chain slack (on side-stand) 20 – 30
(0.79 – 1.18)
----
Gearshift lever height 25
(0.98)
----
14- 6 DL650/AK8 (’08-MODEL)
– 7 –
THERMOSTAT + RADIATOR + FAN + COOLANT
INJECTOR + FUEL PUMP + FUEL PRESSURE REGULATOR
ITEM STANDARD NOTE
Thermostat valve opening
temperature
Approx. 88 °C (190 °F) ---Thermostat valve lift Over 8.0 mm (0.31 in) at 100 °C (212 °F) ---ECT sensor resistance 20 °C
(68 °F)
Approx. 2.45 kΩ ---40 °C
(104 °F)
Approx. 1.148 kΩ ---60 °C
(140 °F)
Approx. 0.587 kΩ ---80 °C
(176 °F)
Approx. 0.322 kΩ ---Radiator cap valve opening
pressure
95 – 125 kPa
(0.95 – 1.25 kgf/cm², 13.5 – 17.8 psi)
----
Cooling fan thermo-switch
operating temperature
OFF→ON Approx. 98 °C (208 °F) ---ON→OFF Approx. 92 °C (198 °F) ---Engine coolant type Use an antifreeze/coolant compatible with aluminum radiator, mixed with distilled water only, at the
ratio of 50:50.
----
Engine coolant including reserve Reserve
tank side
Approx. 250 ml
(0.53/0.44 US/lmp qt)
----
Engine
side
Approx. 1 650 ml
(3.49/2.90 US/lmp qt)
----
ITEM SPECIFICATION NOTE
Injector resistance 11 – 13 Ω at 20 °C (68 °F)
Fuel pump discharge amount More than 75 ml (2.5/2.6 US/lmp oz)
for 6 sec. at 300 kPa (3.0 kgf/cm², 43 psi)
Fuel pressure regulator operating
set pressure
Approx. 300 kPa (3.0 kgf/cm², 43 psi)
DL650/AK8 (’08-MODEL) 14- 7
– 8 –
FI SENSORS + STVA + ISC VALVE
THROTTLE BODY
ITEM SPECIFICATION NOTE
CKP sensor resistance 130 – 240 Ω W – G
CKP sensor peak voltage 3.7 V (When cranking) and more
IAP sensor input voltage (F & R) 4.5 – 5.5 V
IAP sensor output voltage (F & R) Approx. 1.6 V at idle speed
TP sensor input voltage 4.5 – 5.5 V
TP sensor output voltage Closed Approx. 1.1 V + P/W –
- B/BrOpened Approx. 4.3 V
ECT sensor input voltage 4.5 – 5.5 V
ECT sensor resistance Approx. 2.45 kΩ at 20 °C (68 °F)
IAT sensor input voltage 4.5 – 5.5 V
IAT sensor resistance Approx. 2.45 kΩ at 20 °C (68 °F)
TO sensor resistance 16.5 – 22.3 kΩ
TO sensor voltage Normal 0.4 – 1.4 V + Br/W –
- B/BrLeaning 65° 3.7 – 4.4 V
GP switch voltage 1.0 V and more (From 1st to Top)
Injector voltage Battery voltage
STP sensor input voltage 4.5 – 5.5 V
STP sensor output voltage Closed Approx. 0.6 V + Y –
- B/BrOpened Approx. 4.5 V
STV actuator resistance Approx. 7 Ω
Heated oxygen sensor output voltage
0.4 V and less at idle speed
E-02, 19, 24, 41
0.6 V and more at 5 000 r/min
Heated oxygen sensor resistance 11 – 15 Ω at 23 °C (73.4 °F) E-02, 19, 24, 41
PAIR solenoid valve resistance 20 – 24 kΩ at 20 °C (68 °F)
ISC valve resistance Approx. 30 ± 1.2 Ω at 20 °C (68 °F)
ITEM SPECIFICATION
I.D. No. 27 G2 (Others), 27 G3 (For E-33)
Bore size 39 mm
Fast idle r/min. 1 800 – 2 200 r/min at 25 °C (77 °F)
Idle r/min. 1 300 ± 100 r/min/Warmed engine
Throttle cable play 2.0 – 4.0 mm
(0.08 – 0.16 in)
14- 8 DL650/AK8 (’08-MODEL)
– 9 –
ELECTRICAL
ITEM SPECIFICATION NOTE
Firing order 1.2
Spark plug
Type
NGK: CR8E
DENSO: U24ESR-N
Gap
0.7 – 0.8 mm
(0.028 – 0.031 in)
Spark performance Over 8 mm (0.3 in) at 1 atm.
CKP sensor resistance 130 – 240 Ω W – G
Ignition coil resistance
Primary 1 – 5 Ω
Terminal –
Terminal
Secondary 25 – 40 kΩ
Plug cap – Plug
cap
CKP sensor peak voltage 3.7 V and more When cranking
Ignition coil primary peak voltage 150 V and more
Generator coil resistance * 0.2 – 0.8 Ω
Generator Max. output * Approx. 400 W at 5 000 r/min
Generator no-load voltage
(When cold)
* 65 V (AC) and more at 5 000 r/min.
Regulated voltage 14.0 – 15.5 V at 5 000 r/min.
Starter relay resistance 3 – 6 Ω
Battery Type designation
YTX12-BS
Capacity 12 V 36.0 kC (10 Ah)/10 HR
Fuse size
Headlight
HI 15 A
LO 15 A
Fuel 10 A
Ignition 10 A
Fan motor 15 A
Signal 15 A
Main 30 A
DL650/AK8 (’08-MODEL) 14- 9
– 10 –
WATTAGE Unit: W
ITEM
SPECIFICATION
E-03, 24, 28, 33 Others
Headlight 12 V 60/55 W × 2 (H4) ←
Position/Parking light 12 V 5 W × 2
Brake light/Taillight 12 V 21/5 W × 2 ←
Turn signal light 12 V 21 W ←
License light 12 V 5 W ←
Speedometer light LED ←
Turn signal indicator light LED ←
High beam indicator light LED ←
Neutral indicator light LED ←
Oil pressure/Coolant temp./
FI indicator light
LED ←
14- 10 DL650/AK8 (’08-MODEL)
– 11 –
BRAKE + WHEEL Unit: mm (in)
ITEM STANDARD LIMIT
Rear brake pedal height 15 – 25 (0.59 – 0.98) ---Brake disc thickness
Front
5
(0.20)
4.5
(0.18)
Rear
5
(0.20)
4.5
(0.18)
Brake disc runout
----
0.3
(0.012)
Master cylinder bore
Front
14.000 – 14.043
(0.5512 – 0.5529)
----
Rear
14.000 – 14.043
(0.5512 – 0.5529)
----
Master cylinder piston diam.
Front
13.957 – 13.984
(0.5495 – 0.5506)
----
Rear
13.957 – 13.984
(0.5495 – 0.5506)
----
Brake caliper cylinder bore
Front
27.000 – 27.076
(1.0630 – 1.0660)
----
Rear
38.180 – 38.230
(1.5031 – 1.5051)
----
Brake caliper piston diam.
Front
26.920 – 26.970
(1.0598 – 1.0618)
----
Rear
38.080 – 38.130
(1.4992 – 1.5012)
----
Brake fluid type DOT 4
Wheel rim runout
Axial ---2.0
(0.08)
Radial ---2.0
(0.08)
Wheel rim size Front 19 M/C × MT2.50 ---Rear 17 M/C × MT4.00 ---Wheel axle runout
Front ---0.25
(0.010)
Rear ---0.25
(0.010)
DL650/AK8 (’08-MODEL) 14- 11
– 12 –
TIRE
SUSPENSION Unit: mm (in)
ITEM STD/SPEC. LIMIT
Cold inflation tire pressure
(Solo riding)
Front
225 kPa
(2.25 kgf/cm², 33 psi)
----
Rear
250 kPa
(2.50 kgf/cm², 36 psi)
----
Cold inflation tire pressure
(Dual riding)
Front
225 kPa
(2.25 kgf/cm², 33 psi)
----
Rear
280 kPa
(2.80 kgf/cm², 41 psi)
----
Tire size Front 110/80 R19 M/C 59H ---Rear 150/70 R17 M/C 69H ---Tire type Front BRIDGESTONE: TW101 F ---Rear BRIDGESTONE: TW152 F ---Tire tread depth
Front ---1.6
(0.06)
Rear ---2.0
(0.08)
ITEM STD/SPEC. LIMIT
Front fork stroke 150
(5.9)
----
Front fork spring free length 444.1 (17.5) 435 (17.1)
Front fork oil level (without spring,
outer tube fully compressed)
139 (5.47) ----
Front fork spring adjuster 3 grooves from Top/Spring adjuster height 9 (0.35) ---Front fork oil type SUZUKI FORK OIL SS-08
or equivalent fork oil
----
Front fork oil capacity (each leg) 528 ml
(17.8/18.6 US/Imp oz)
----
Rear shock absorber spring
adjuster
2 grooves from bottom ---Rear shock absorber damping
force adjuster
Rebound 1 turn back from stiffest position ---Rear wheel travel 150
(5.9)
----
Swingarm pivot shaft runout
----
0.3
(0.01)
14- 1 DL650/AK8 (’08-MODEL)2
– 13 –
FUEL + OIL
ITEM STD/SPEC. NOTE
Fuel type Use only unleaded gasoline of at least 87 pump
octane (R/2 + M/2) or 91 octane or higher rated by
the research method.
Gasoline containing MTBE (Methyl Tertiary Butyl
Ether), less than 10 % ethanol, or less than 5 %
methanol with appropriate cosolvents and corrosion inhibitor is permissible.
E-03, 28, 33
Gasoline used should be graded 91 octane or
higher. An unleaded gasoline is recommended.
Others
Fuel tank capacity 22 L (5.8/4.8 US/lmp gal)
Engine oil type SAE 10W-40, API SF/SG or SH/SJ with JASO MA
Engine oil capacity
Change
2 300 ml
(2.4/2.0 US/lmp qt)
Filter change
2 700 ml
(2.9/2.4 US/lmp qt)
Overhaul
3 100 ml
(3.3/2.7 US/lmp qt)
DL650/AK8 (’08-MODEL) 14- 13
– 14 –
SERVICE DATA (DL650A/AUEK8)
VALVE + GUIDE Unit: mm (in)
ITEM STANDARD LIMIT
Valve diam.
IN.
31
(1.2)
----
EX.
25.5
(1.0)
----
Valve clearance (when cold)
IN.
0.10 – 0.20
(0.004 – 0.008)
----
EX.
0.20 – 0.30
(0.008 – 0.012)
----
Valve guide to valve stem
clearance
IN.
0.020 – 0.047
(0.0008 – 0.0019)
----
EX.
0.030 – 0.057
(0.0012 – 0.0022)
----
Valve guide I.D.
IN. & EX.
4.500 – 4.512
(0.1772 – 0.1776)
----
Valve stem O.D.
IN.
4.465 – 4.480
(0.1758 – 0.1764)
----
EX.
4.455 – 4.470
(0.1754 – 0.1760)
----
Valve stem deflection
IN. & EX. ----
0.35
(0.014)
Valve stem runout
IN. & EX. ----
0.05
(0.002)
Valve head thickness
IN. & EX. ----
0.5
(0.02)
Valve seat width
IN. & EX.
0.9 – 1.1
(0.035 – 0.043)
----
Valve head radial runout
IN. & EX. ----
0.03
(0.001)
Valve spring free length
(IN. & EX.)
INNER ----
36.8
(1.45)
OUTER ----
39.8
(1.57)
Valve spring tension
(IN. & EX.) INNER
41 – 47 N (4.2 – 4.8 kgf)
(9.26 – 10.58 lbs)
at length 29.9 mm (1.18 in)
----
OUTER
166 – 192 N (17.0 – 19.6 kgf)
(37.48 – 43.21 lbs)
at length 33.4 mm (1.31 in)
----
14- 1 DL650/AK8 (’08-MODEL)4
– 15 –
CAMSHAFT + CYLINDER HEAD Unit: mm (in)
ITEM STANDARD LIMIT
Cam height
IN.
35.48 – 35.53
(1.3968 – 1.3988)
35.18
(1.3850)
EX.
33.48 – 33.53
(1.3181 – 1.3201)
33.18
(1.3063)
Camshaft journal oil clearance
IN. & EX.
0.032 – 0.066
(0.0013 – 0.0026)
0.150
(0.0059)
Camshaft journal holder I.D.
IN. & EX.
22.012 – 22.025
(0.8666 – 0.8671)
----
Camshaft journal O.D.
IN. & EX.
21.959 – 21.980
(0.8645 – 0.8654)
----
Camshaft runout
IN. & EX. ----
0.10
(0.004)
Cam chain pin (at arrow “3”) 16th pin ---Cylinder head distortion
----
0.05
(0.002)
DL650/AK8 (’08-MODEL) 14- 15
– 16 –
CYLINDER + PISTON + PISTON RING Unit: mm (in)
ITEM STANDARD LIMIT
Compression pressure 1 300 – 1 700 kPa
(13 – 17 kgf/cm2, 185 – 242 psi)
1 100 kPa
(11 kgf/cm2, 156 psi)
Compression pressure
difference
----
200 kPa
(2 kgf/cm2, 28 psi)
Piston to cylinder clearance 0.055 – 0.065
(0.0022 – 0.0026)
0.120
(0.0047)
Cylinder bore 81.000 – 81.015
(3.1890 – 3.1896)
Nicks or
Scratches
Piston diam. 80.940 – 80.955
(3.1866 – 3.1872)
Measure at 20 mm (0.79 in) from the skirt end.
80.88
(3.184)
Cylinder distortion
----
0.05
(0.002)
Piston ring free end gap
1st Approx. 7 (0.28)
5.6
(0.22)
2nd * Approx. 11.5 (0.45)
8.8
(0.35)
Piston ring end gap
1st
* 0.20 – 0.30
(0.08 – 0.12)
0.70
(0.028)
2nd
* 0.30 – 0.45
(0.12 – 0.018)
0.70
(0.028)
Piston ring to groove clearance
1st ---0.180
(0.0071)
2nd ---0.150
(0.0059)
Piston ring groove width
1st
0.83 – 0.85
(0.0327 – 0.0335)
----
2nd
1.01 – 1.03
(0.0398 – 0.0406)
----
Oil
2.01 – 2.03
(0.0791 – 0.0799)
----
Piston ring thickness
1st
0.76 – 0.81
(0.0299 – 0.0319)
----
2nd
0.97 – 0.99
(0.0382 – 0.0390)
----
Piston pin bore 20.002 – 20.008
(0.7875 – 0.7877)
20.030
(0.7886)
Piston pin O.D. 19.992 – 20.000
(0.7871 – 0.7874)
19.98
(0.7866)
14- 1 DL650/AK8 (’08-MODEL)6
– 17 –
CONROD + CRANKSHAFT Unit: mm (in)
OIL PUMP
CLUTCH Unit: mm (in)
ITEM STANDARD LIMIT
Conrod small end I.D. 20.010 – 20.018
(0.7878 – 0.7881)
20.040
(0.7890)
Conrod big end side clearance 0.170 – 0.320
(0.0067 – 0.0126)
0.5
(0.02)
Conrod big end width 20.95 – 21.00
(0.825 – 0.827)
----
Crank pin width 42.17 – 42.22
(1.660 – 1.662)
----
Conrod big end oil clearance 0.032 – 0.056
(0.0013 – 0.0022)
0.080
(0.0031)
Crank pin O.D. 37.976 – 38.000
(1.4951 – 1.4960)
----
Crankshaft journal oil clearance 0.002 – 0.029
(0.0001 – 0.0011)
0.080
(0.0031)
Crankshaft journal O.D. 41.985 – 42.000
(1.6529 – 1.6535)
----
Crankshaft runout
----
0.05
(0.002)
ITEM STANDARD LIMIT
Oil pressure (at 60 °C, 140 °F) Above 100 kPa (1.0 kgf/cm², 14 psi)
Below 400 kPa (4.0 kgf/cm², 57 psi)
at 3 000 r/min.
----
ITEM STANDARD LIMIT
Clutch cable play 10 – 15
(0.4 – 0.6)
----
Clutch release screw 1/4 turn back ---Drive plate thickness
No.1 & No.2
2.92 – 3.08
(0.115 – 0.121)
2.62
(0.103)
Drive plate claw width
No.1 & No.2
13.7 – 13.8
(0.539 – 0.543)
12.9
(0.507)
Driven plate distortion
----
0.10
(0.004)
Clutch spring free length 53.1
(2.09)
50.5
(1.99)
DL650/AK8 (’08-MODEL) 14- 17
– 18 –
TRANSMISSION + DRIVE CHAIN Unit: mm (in) Except ratio
ITEM STANDARD LIMIT
Primary reduction ratio 2.088 (71/34) ---Final reduction ratio 3.133 (47/15) ---Gear ratios Low 2.461 (32/13) ---2nd 1.777 (32/18) ----
3rd 1.380 (29/21) ----
4th 1.125 (27/24) ----
5th 0.961 (25/26) ----
Top 0.851 (23/27) ----
Shift fork to groove clearance 0.1 – 0.3
(0.004 – 0.012)
0.50
(0.020)
Shift fork groove width 5.5 – 5.6
(0.217 – 0.220)
----
Shift fork thickness 5.3 – 5.4
(0.209 – 0.213)
----
Drive chain
Type DID525V8
----
----
Links 118 links ---20-pitch
length
----
319.4
(12.57)
Drive chain slack (on side-stand) 20 – 30
(0.79 – 1.18)
----
Gearshift lever height 25
(0.98)
----
14- 1 DL650/AK8 (’08-MODEL)8
– 19 –
THERMOSTAT + RADIATOR + FAN + COOLANT
INJECTOR + FUEL PUMP + FUEL PRESSURE REGULATOR
ITEM STANDARD NOTE
Thermostat valve opening
temperature
Approx. 88 °C (190 °F) ---Thermostat valve lift Over 8.0 mm (0.31 in) at 100 °C (212 °F) ---ECT sensor resistance 20 °C
(68 °F)
Approx. 2.45 kΩ ---40 °C
(104 °F)
Approx. 1.148 kΩ ---60 °C
(140 °F)
Approx. 0.587 kΩ ---80 °C
(176 °F)
Approx. 0.322 kΩ ---Radiator cap valve opening
pressure
95 – 125 kPa
(0.95 – 1.25 kgf/cm², 13.5 – 17.8 psi)
----
Cooling fan thermo-switch
operating temperature
OFF→ON Approx. 98 °C (208 °F) ---ON→OFF Approx. 92 °C (198 °F) ---Engine coolant type Use an antifreeze/coolant compatible with aluminum radiator, mixed with distilled water only, at the
ratio of 50:50.
----
Engine coolant including reserve Reserve tank
side
Approx. 250 ml
(0.53/0.44 US/lmp qt)
----
Engine side
Approx. 1650 ml
(3.49/2.90 US/lmp qt)
----
ITEM SPECIFICATION NOTE
Injector resistance 11 – 13 Ω at 20 °C (68 °F)
Fuel pump discharge amount More than 75 ml (2.5/2.6 US/lmp oz)
for 6 sec. at 300 kPa (3.0 kgf/cm², 43 psi)
Fuel pressure regulator operating
set pressure
Approx. 300 kPa (3.0 kgf/cm², 43 psi)
DL650/AK8 (’08-MODEL) 14- 19
– 20 –
FI SENSORS + STVA + ISC VALVE
THROTTLE BODY
ITEM SPECIFICATION NOTE
CKP sensor resistance 130 – 240 Ω W – G
CKP sensor peak voltage 3.7 V (When cranking) and more
IAP sensor input voltage (F & R) 4.5 – 5.5 V
IAP sensor output voltage (F & R) Approx. 1.6 V at idle speed
TP sensor input voltage 4.5 – 5.5 V
TP sensor output voltage Closed Approx. 1.1 V + P/W –
- B/BrOpened Approx. 4.3 V
ECT sensor input voltage 4.5 – 5.5 V
ECT sensor resistance Approx. 2.45 kΩ at 20 °C (68 °F)
IAT sensor input voltage 4.5 – 5.5 V
IAT sensor resistance Approx. 2.45 kΩ at 20 °C (68 °F)
TO sensor resistance 16.5 – 22.3 kΩ
TO sensor voltage Normal 0.4 – 1.4 V + Br/W –
- B/BrLeaning 65° 3.7 – 4.4 V
GP switch voltage 1.0 V and more (From 1st to Top)
Injector voltage Battery voltage
STP sensor input voltage 4.5 – 5.5 V
STP sensor output voltage Closed Approx. 0.6 V + Y –
- B/BrOpened Approx. 4.5 V
STV actuator resistance Approx. 7 Ω
Heated oxygen sensor output voltage
0.4 V and less at idle speed
E-02, 19, 24, 41
0.6 V and more at 5 000 r/min
Heated oxygen sensor resistance 11 – 15 Ω at 23 °C (73.4 °F) E-02, 19, 24, 41
PAIR solenoid valve resistance 20 – 24 kΩ at 20 °C (68 °F)
ISC valve resistance Approx. 30 ± 1.2 Ω at 20 °C (68 °F)
ITEM SPECIFICATION
I.D. No. 27 G2 (Others), 27 G3 (For E-33)
Bore size 39 mm
Fast idle r/min. 1 800 – 2 200 r/min at 25 °C (77 °F)
Idle r/min. 1 300 ± 100 r/min/Warmed engine
Throttle cable play 2.0 – 4.0 mm
(0.08 – 0.16 in)
14- DL650/AK8 (’08-MODEL)20
– 21 –
ELECTRICAL
ITEM SPECIFICATION NOTE
Firing order 1.2
Spark plug
Type
NGK: CR8E
DENSO: U24ESR-N
Gap
0.7 – 0.8 mm
(0.028 – 0.031 in)
Spark performance Over 8 mm (0.3 in) at 1 atm.
CKP sensor resistance 130 – 240 Ω W – G
Ignition coil resistance
Primary 1 – 5 Ω
Terminal –
Terminal
Secondary 25 – 40 kΩ
Plug cap – Plug
cap
CKP sensor peak voltage 3.7 V and more When cranking
Ignition coil primary peak voltage 150 V and more
Generator coil resistance * 0.2 – 0.8 Ω
Generator Max. output * Approx. 400 W at 5 000 r/min
Generator no-load voltage
(When cold)
* 65 V (AC) and more at 5 000 r/min.
Regulated voltage 14.0 – 15.5 V at 5 000 r/min.
Starter relay resistance 3 – 6 Ω
Battery Type designation
YTX12-BS
Capacity 12 V 36.0 kC (10 Ah)/10 HR
Fuse size
Headlight
HI 15 A
LO 15 A
Fuel 10 A
Ignition 10 A
Fan motor 15 A
Signal 15 A
Main 30 A
ABS motor 40 A
ABS valve 25 A
DL650/AK8 (’08-MODEL) 14- 21
– 22 –
WATTAGE Unit: W
ITEM
SPECIFICATION
E-03, 24, 28, 33 Others
Headlight 12 V 60/55 W × 2 (H4) ←
Position/Parking light 12 V 5 W × 2
Brake light/Taillight 12 V 21/5 W × 2 ←
Turn signal light 12 V 21 W ←
License light 12 V 5 W ←
Speedometer light LED ←
Turn signal indicator light LED ←
High beam indicator light LED ←
Neutral indicator light LED ←
Oil pressure/Coolant temp./
FI indicator light
LED ←
ABS indicator light LED ←
14- DL650/AK8 (’08-MODEL)22
– 23 –
BRAKE + WHEEL Unit: mm (in)
ITEM STANDARD LIMIT
Rear brake pedal height 15 – 25 (0.59 – 0.98) ---Brake disc thickness
Front
5
(0.20)
4.5
(0.18)
Rear
5
(0.20)
4.5
(0.18)
Brake disc runout
----
0.3
(0.012)
Master cylinder bore
Front
14.000 – 14.043
(0.5512 – 0.5529)
----
Rear
14.000 – 14.043
(0.5512 – 0.5529)
----
Master cylinder piston diam.
Front
13.957 – 13.984
(0.5495 – 0.5506)
----
Rear
13.957 – 13.984
(0.5495 – 0.5506)
----
Brake caliper cylinder bore
Front
27.000 – 27.076
(1.0630 – 1.0660)
----
Rear
38.180 – 38.230
(1.5031 – 1.5051)
----
Brake caliper piston diam.
Front
26.920 – 26.970
(1.0598 – 1.0618)
----
Rear
38.080 – 38.130
(1.4992 – 1.5012)
----
Brake fluid type DOT 4
Wheel rim runout
Axial ---2.0
(0.08)
Radial ---2.0
(0.08)
Wheel rim size Front 19 M/C × MT2.50 ---Rear 17 M/C × MT4.00 ---Wheel axle runout
Front ---0.25
(0.010)
Rear ---0.25
(0.010)
Wheel speed sensor to sensor
rotor clearance
Front & Rear
0.3 – 1.5
(0.012 – 0.059)
----
DL650/AK8 (’08-MODEL) 14- 23
– 24 –
TIRE
SUSPENSION Unit: mm (in)
ITEM STD/SPEC. LIMIT
Cold inflation tire pressure
(Solo riding)
Front
225 kPa
(2.25 kgf/cm², 33 psi)
----
Rear
250 kPa
(2.50 kgf/cm², 36 psi)
----
Cold inflation tire pressure
(Dual riding)
Front
225 kPa
(2.25 kgf/cm², 33 psi)
----
Rear
280 kPa
(2.80 kgf/cm², 41 psi)
----
Tire size Front 110/80 R19 M/C 59H ---Rear 150/70 R17 M/C 69H ---Tire type Front BRIDGESTONE: TW101 F ---Rear BRIDGESTONE: TW152 F ---Tire tread depth
Front ---1.6
(0.06)
Rear ---2.0
(0.08)
ITEM STD/SPEC. LIMIT
Front fork stroke 150
(5.9)
----
Front fork spring free length 444.1 (17.5) 435 (17.1)
Front fork oil level (without spring,
outer tube fully compressed)
139 (5.47) ----
Front fork spring adjuster 3 grooves from Top/Spring adjuster height 9 (0.35) ---Front fork oil type SUZUKI FORK OIL SS-08
or equivalent fork oil
----
Front fork oil capacity (each leg) 528 ml
(17.8/18.6 US/Imp oz)
----
Rear shock absorber spring
adjuster
2 grooves from bottom ---Rear shock absorber damping
force adjuster
Rebound 1 turn back from stiffest position ---Rear wheel travel 150
(5.9)
----
Swingarm pivot shaft runout
----
0.3
(0.01)
14- DL650/AK8 (’08-MODEL)24
– 25 –
FUEL + OIL
ITEM STD/SPEC. NOTE
Fuel type Use only unleaded gasoline of at least 87 pump
octane (R/2 + M/2) or 91 octane or higher rated by
the research method.
Gasoline containing MTBE (Methyl Tertiary Butyl
Ether), less than 10 % ethanol, or less than 5 %
methanol with appropriate cosolvents and corrosion inhibitor is permissible.
E-03, 28, 33
Gasoline used should be graded 91 octane or
higher. An unleaded gasoline is recommended.
Others
Fuel tank capacity 22 L (5.8/4.8 US/lmp gal)
Engine oil type SAE 10W-40, API SF/SG or SH/SJ with JASO MA
Engine oil capacity
Change
2 300 ml
(2.4/2.0 US/lmp qt)
Filter change
2 700 ml
(2.9/2.4 US/lmp qt)
Overhaul
3 100 ml
(3.3/2.7 US/lmp qt)
DL650/AK8 (’08-MODEL) 14- 25
03 ENGINE.book Page 105 Tuesday, February 28, 2006 3:03 PM
CONTENTS
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DL650/AK9 (’09-MODEL)
DL650/AK9 (’09-MODEL) 15- 1
15
SPECIFICATIONS
DIMENSIONS AND CURB MASS
Overall length ...................................................................................... 2 290 mm (90.2 in)
Overall width........................................................................................ 840 mm (33.1 in)
Overall height ...................................................................................... 1 390 mm (54.7 in) ........... Low windshield position (STD)
1 420 mm (55.9 in) ........... Middle windshield position
1 450 mm (57.1 in) ........... High windshield position
Wheelbase .......................................................................................... 1 555 mm (61.2 in)
Ground clearance................................................................................ 165 mm (6.5 in)
Seat height. ......................................................................................... 820 mm (32.3 in)
* Curb mass ........................................................................................ 217 kg (478 lbs) .......... DL650
220 kg (485 lbs) .......... DL650A
ENGINE
Type..................................................................................................... 4-stroke, liquid-cooled, DOHC, 90 ° V-twin
Number of cylinders ............................................................................ 2
Bore..................................................................................................... 81.0 mm (3.189 in)
Stroke .................................................................................................. 62.6 mm (2.465 in)
Displacement ...................................................................................... 645 cm3 (39.4 cu. in)
Compression ratio ............................................................................... 11.5 : 1
Fuel system......................................................................................... Fuel injection
Air cleaner ........................................................................................... Non-woven fabric element
Starter system..................................................................................... Electric
Lubrication system .............................................................................. Wet sump
Idle speed............................................................................................ 1 300 ± 100 r/min
DRIVE TRAIN
Clutch .................................................................................................. Wet multi-plate type
Transmission ....................................................................................... 6-speed constant mesh
Gearshift pattern ................................................................................. 1-down, 5-up
Primary reduction ratio ........................................................................ 2.088 (71/34)
Gear ratios, Low .................................................................................. 2.461 (32/13)
2nd................................................................................... 1.777 (32/18)
3rd ................................................................................... 1.380 (29/21)
4th.................................................................................... 1.125 (27/24)
5th.................................................................................... 0.961 (25/26)
Top................................................................................... 0.851 (23/27)
Final reduction ratio............................................................................. 3.133 (47/15)
Drive chain .......................................................................................... DID525V8, 118 links
CHASSIS
Front suspension................................................................................. Telescopic, coil spring, oil damped
Rear suspension ................................................................................. Link type, coil spring, oil damped
Front fork stroke .................................................................................. 150 mm (5.9 in)
Rear wheel travel. ............................................................................... 150 mm (5.9 in)
Caster.................................................................................................. 26 °
Trail...................................................................................................... 110 mm (4.33 in)
Steering angle ..................................................................................... 40 ° (right & left)
Turning radius...................................................................................... 2.6 m (8.5 ft)
Front brake .......................................................................................... Disc brake, twin
Rear brake........................................................................................... Disc brake
Front tire .............................................................................................. 110/80R19 M/C 59H, tubeless
Rear tire .............................................................................................. 150/70R17 M/C 69H, tubeless
ELECTRICAL
Ignition type......................................................................................... Electronic ignition (Transistorized)
Ignition timing. ..................................................................................... 8 ° B.T.D.C. at 1 300 r/min
Spark plug ........................................................................................... NGK CR8E or DENSO U24ESR-N
Battery................................................................................................. 12 V 36.0 kC (10 Ah) /10 HR
Generator ............................................................................................ Three-phase A.C. generator
Main fuse............................................................................................. 30 A
Fuse .................................................................................................... 15/15/10/10/15/15 A
Headlight ............................................................................................. 12 V 60/55 W (H4) × 2
Position/Parking light ........................................................................... 12 V 5 W × 2 ...................... E-02, 19
Brake/Tail light ..................................................................................... 12 V 21/5 W × 2
Turn signal light ................................................................................... 12 V 21 W
License plate light ............................................................................... 12 V 5 W
Speedometer light ............................................................................... LED
Tachometer light .................................................................................. LED
Neutral indicator light........................................................................... LED
High beam indicator light..................................................................... LED
Turn signal indicator light..................................................................... LED
Oil pressure/Coolant temperature/FI indicator light............................. LED
ABS indicator light ............................................................................... LED.................................... DL650A/AUE
CAPACITIES
Fuel tank ............................................................................................. 22.0 L (5.8/4.8 US/Imp gal)
Engine oil, oil change ......................................................................... 2 300 ml (2.4/2.0 US/Imp qt)
with filter change............................................................... 2 700 ml (2.9/2.4 US/Imp qt)
overhaul ............................................................................ 3 100 ml (3.3/2.7 US/Imp qt)
Coolant ................................................................................................ 1.9 L (2.0/1.7 US/Imp qt)
15-2 DL650/AK9 (’09-MODEL)
13
33 ,82 ,42 ,30E
R O O
/Y
O
/G B
r B
/R O O
/R
O
/G B
r B
/O B
O
/W
W
/B
l O
/G
W
/B
Y
/B
O
/W
R
/W Y
/R R
B
r/ W
B
/B
r W
/B
l B
B
/W
B
r/ B
G
r/ W
G
r/ B
B
r O
/W R
B
l/G
B
/W D
g R
/W
G
/B
B
/Y
P
/W B
/R
R
/B
B
/B
r B
/B
r B
/W
B
l/B
G
r/ R
W P Y
/B
O
/R
B
/B
r B
/B
l B
/G
B
l/W W
/R
B
r/ W
B
l/Y
B
l/R Y
B
/B
r B
l/W
B
l/B
B
l/G
B
l/R
B
l/Y R
O
/W
W
/R
G
r/ R
B
/W
O W
/B
Y
/R
B
/W
B
/L
g Y
/R
B
/W Y
/B
G
/Y
O
/B
l B
/W
O
/W B
r B
/B
l B
/B
rR Y
B
/B
r B
l Y B
B
l P
B
/W
B
/B
r G
/B R
O
/Y O O
/G
O
/B
l B
l/B B
l G O
/Y
O
/B B
r L
b l R P
/W
B
/B
r D
g B
/B
r O
/R
P
/W
B
/W
G B
/W
B
/W W B
/Y
Y
/G
B
/R
B
/R
B B B B
/R
B
/R
B
/W
B
/W
B B B B
/R
B
/R
B
/W
B
/W
B
/W
B
/W
O
/R P
B
/W
G B
/W G B
l B B B
B
l P
B
/W
B
/R B
l B
/R
B
/R
Lg Br B/W
B/W
B
B/W
B
Gr B/W
B/W
Gr B/W
B/W
Gr B/W
Lg B/W
Br B/W
Br B/W
Y
W/B
lB/B
Y
W/B
lB/B
Lg W/B
Lg W/B
B/rB
Y/G
W/P
R/O
W/R
G/B
B/Y
G/O
B/lB
Lg W/B
Y
B
W
B/rB
Y/G
W/P
R/O
W/R
G/B
B/Y
G/O
B/lB
Lg W/B
Y
B
lB/B
B
/R
W
/B
l Y
/B
l Y W R
/W
B
/G
R
/W
O
/R
P
/W G
/Y
B
r/ B
B
/W B L
g O
/G Y
B
l/B Y
/B
O
/B
O
/W
B
/R
B
/B
l Y
/G
Y
/W
O
/R
O
/B
O
/W
O
/G
W
/B
Y
/G
Y
/W O
B
/B
l B
/B
l O
/R
B
/W L
g L
b l B Y
/W Y W B
/Y
B
/Y
O B
/W L
g L
b l B Y
/W
Y
/B
l W
/B
l B
/W B
/Y
R
/B
B
/R
G
r/ W
Y
/R
G
r/ B
Y
/R
ON
OFF
KCOL
P
ON
OFF
M
EERF
HSUP
ON
OFF
EKARB RAER
HCTIWS
NOITINGI
1# LIOC
NOITINGI
2# LIOC
HCTIWS NOITINGI
MCE
LEUF
PMUP
OFF
ON
ERUSSERP LIO
HCTIWS
OT
ROSNES
PMUP LEUF
YALER
RAER
NOITANIBMOC
THGIL
NRUT RAER
)R( THGIL LANGIS
NRUT RAER
)L( THGIL LANGIS
ESNECIL
THGIL
YRETTAB A 03 NIAM :1
RETRATS
ROTOM
RETRATS
YALER
1
XOB ESUF IH DAEH .1
OL DAEH .2
LEUF .3
NOITINGI .4
LANGIS .5
NAF .6
15 A
15 A
10 A
10 A
15 A
15 A
/ROTALUGER
REIFITCER
ROTARENEG
DNATS-EDIS
HCTIWS
DEEPS
ROSNESIAT ROSNES
TP
ROSNES
321
654
ECT
ROSNES
IAP
ROSNES
RAEG
NOITISOP
HCTIWS
STP
ROSNES
GNILOOC
FAN
ROTOMGNILOOC
-OMREHT NAF
HCTIWS
RIAP
DIONELOS
B
/W
O
/G
)R( THGILDAEH
)L( THGILDAEH
TNORF
LANGIS NRUT
)R( THGIL
TNORF
LANGIS NRUT
)L( THGIL
THGIL ROTACIDNI LARTUEN :
THGIL ROTACIDNI MAEB-IH :
THGIL ROTACIDNI LIO :
)R( THGIL ROTACIDNI LANGIS NRUT :
)L( THGIL ROTACIDNI LANGIS NRUT :
N
H
O
R
L
LANOITPO(
)STRAP
RETAEH PIRG
PS AT
IL ILL
FI
OD
N
R
W
O
H
RETEMODEEPS OFF
NUR HSUP
FFO
ON
)R( HCTIWS RABELDNAH
ENIGNE
POTS
HCTIWS
EKARB TNORF
HCTIWS
RETRATS
NOTTUB
EERF
HSUPHSUP
L
HSUP
R
HI
LO
ON
OFF
HCTULC
HCTIWS
REMMID
HCTIWSLANGIS NRUT
HCTIWS THGIL
GNISSAP
THGIL
HCTIWS
NROH
NOTTUB
)L( HCTIWS RABELDNAH
DRAZAH
HCTIWS
NROH
ROTCEJNI
#2#1
STV
ROTAUTCA
16
DL650K7 (For E-03, 28, 33)
B
/B
l R O O
/Y G
r B
r B
/R O O
/R
O
/G B
r O
/B
O
/W
B
/R
B
/B
l Y
/G
Y
/W
O
/R
O
/B
O
/W
O
/G
W
/B
Y
/G
Y
/W OB
/W
O
/G
B
/O B
O
/W
W
/B
l O
/G
W
/B
Y
/B
O
/W
R
/W Y
/R R
B
r/ W
B
/B
r W
/B
l G
r/ W
B
/W
W
/Y
L
b l W
/B B
r G B
G
r/ B
B
/W
D
b r L
g P
/W
B
r/ B
B
/L
g Y
/B
B
l/Y
G
r/ R
B
/G
W
/R W B
l Y
/G
B
/W
G
/Y
P
/W
B
r/ W
B
/B
l O
/R
B
l/W
B
l/B
B
l/G
B
/W
B
/B
r O
/W
R
/W Y
/R
G
/B
l B
/Y R Y G
/B D
g P
L
b l R
/W
W
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D
b r R
/W L
g B
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r B
l/W
B
l/B
B
l/G
B
l/Y R
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W
/R
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r/ R
B
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/B
Y
/R
B
/W
R
/B
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/R
B
/W Y
/B
G
/Y
O
/B
l B
/W
B
/B
l B
/B
r B
/L
g P
/W G W
/B R Y
B
/B
r B
l P
B
/W
B
/B
r G
/B R
O
/Y O O
/G
O
/B
l B
l/B B
l G O
/Y
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/B B
r L
b l D
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/B
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P
/W
B
/W
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/G P
B
/W
G B
/W
G B
l B B B
B
/Y
Y
/G
B
/R
B
/R
B B B B
/R
B
/R
B
/W
B
/W
B
/R
B
/R
B
/W
B
/W
B
/W
B
/W
R P
/W
B
/B
r G B
/W
G
/B
l W
B
l P
B
/W
O
/W B
r B
/R B
l B/R
B
/B
l O
/R
B
/W L
g L
b l B Y
/W Y W B
/Y
B
/Y
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/W L
g L
b l B Y
/W
Y
/B
l W
/B
l B
/W B
/Y
Lg Br B/W
W/B
B
B/W
B
Gr B/W
W/B
Gr B/W
W/B
Gr B/W
Lg B/W
Br B/W
Br B/W
Y
B/W
B/Bl
Y
B/W
B/Bl
Lg B/W
Lg B/W
B
/G
R
/W
O
/R
P
/W G
/Y
B
r/ B
B
/W B L
g O
/G Y
B
l/B Y
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Br/B
G/Y
P/W
O/R
R/W
B/G
Y/B
O/G
Bl/B
Br/B
G/Y
P/W
O/R
R/W
B/G
Y/B
O/G
Bl/B
B
/R
W
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l Y
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l Y W R
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Lg B/W
Y
B
B/Bl
Lg B/W
Y
B
W
G
r/ W
Y
/R
G
r/ B
Y
/R
B
/B
r G
/Y R
ON
OFF
LOCK
P
OFF
RUN PUSH
OFF
ON
ON
OFF
M
FREE
PUSH
ON
OFF
FREE
PUSH
PUSH
L
PUSH
R
HI
LO
ON
OFF
HANDLEBAR SWITCH (R)
REAR BRAKE
SWITCH
IGNITION
COIL #1
IGNITION
COIL #2
IGNITION SWITCH
ENGINE
STOP
SWITCH
FRONT BRAKE
SWITCH
STARTER
BUTTON
ECMFUEL
PUMP
OFF
ON
OIL PRESSURE
SWITCH
TO
SENSOR
FUEL PUMP
RELAY
REAR
COMBINATION
LIGHT
REAR TURN
SIGNAL LIGHT (R)
REAR TURN
SIGNAL LIGHT (L)
LICENSE
LIGHT
BATTERY1: MAIN 30 A
STARTER
MOTOR
STARTER
RELAY
1
FUSE BOX
1. HEAD HI
2. HEAD LO
3. FUEL
4. IGNITION
5. SIGNAL
6. FAN
15 A
15 A
10 A
10 A
15 A
15 A
REGULATOR/
RECTIFIER
GENERATOR
SIDE-STAND
SWITCH
SPEED
SENSORIATSENSOR
TP
SENSOR
1 2 3
4 5 6
ECT
SENSORACTUATOR
INJECTOR
#2 #1
GEAR
POSITION
SWITCH
COOLING
FAN THERMO-
SWITCH
COOLING
FAN MOTOR
PAIR
SOLENOID
CLUTCH
SWITCH
DIMMER
SWITCHTURN SIGNAL
LIGHT SWITCH
PASSING
LIGHT
SWITCH
HORN
BUTTON
HANDLEBAR SWITCH (L)
HAZARD
SWITCH
HORN
GRIP HEATER
HEADLIGHT (R)
HEADLIGHT (L)
FRONT
TURN SIGNAL LIGHT (R)
FRONT
TURN SIGNAL LIGHT (L)
SP TA
IL ILL
FI
OD
N
R
W
O
H
: NEUTRAL INDICATOR LIGHT
: HI-BEAM INDICATOR LIGHT
: OIL INDICATOR LIGHT
: TURN SIGNAL INDICATOR LIGHT (R)
: TURN SIGNAL INDICATOR LIGHT (L)
N
H
O
R
L SPEEDOMETER
(OPTIONAL PARTS)
ISC VALVE
IAP
SENSOR
(R)
IAP
SENSOR
(F)
DL650AK7 (For E-03, 28, 33)
B
/B
l R O O
/Y G
r B
r B
/R O O
/R
O
/G B
r O
/B
O
/W
B
/R
B
/B
l Y
/G
Y
/W
O
/R
O
/B
O
/W
O
/G
W
/B
Y
/G
Y
/W OB
/W
O
/G
B
/O B
O
/W
W
/B
l O
/G
W
/B
Y
/B
O
/W
R
/W Y
/R R
B
r/ W
B
/B
r W
/B
l G
r/ W
B
/W
W
/Y
L
b l W
/B B
r G B
G
r/ B
B
/W
D
b r L
g P
/W
B
r/ B
B
/L
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/B
B
l/Y
G
r/ R
B
/G
W
/R W B
l Y
/G
B
/W
G
/Y
P
/W
B
r/ W
B
/B
l O
/R
B
l/W
B
l/B
B
l/G
B
/W
B
/B
r O
/W
R
/W Y
/R
G
/B
l B
/Y R Y G
/B D
g P
L
b l R
/W
W
/Y
D
b r R
/W L
g B
/B
r B
l/W
B
l/B
B
l/G
B
l/Y R
O
/W
W
/R
G
r/ R
B
/W O B
/Y
O
/Y
W
/R B
l G
r/ R
W
/Y
B
/R
B
/W
R
/B R B
O W
/B
Y
/R
B
/W
R
/B
Y
/R
B
/W Y
/B
G
/Y
B
/B
l B
/B
r B
l P
B
/W
B
/B
r G
/B R
O
/Y O O
/G
O
/B
l B
l/B B
l G O
/Y
O
/B B
r L
b l D
g B
/B
r O
/R
P
/W
B
/W
O
/G P
B
/W
G B
/W
G B
l B B B
B
/Y
Y
/G
B
/R
B
/R
B B B B
/R
B
/R
B
/W
B
/W
B
/R
B
/R
B
/W
B
/W
B
/W
B B
/B
r G
/Y RB
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W
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B
/R
W
/R
B W B W
O B
/WR RRR
R
R R
/B
R P
/W
B
/B
r G B
/W
G
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l W
B
l P
B
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O
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r B
/R B
l B/R
B
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l O
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B
/W L
g L
b l B Y
/W Y W B
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B
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/W L
g L
b l B Y
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l W
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l B
/W B
/Y
Lg Br B/W
W/B
B
B/W
B
Gr B/W
W/B
Gr B/W
W/B
Gr B/W
Lg B/W
Y
B/W
B/Bl
Y
B/W
B/Bl
Lg B/W
Lg B/W
B
/G
R
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O
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P
/W G
/Y
B
r/ B
B
/W B L
g O
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B
l/B B
l Y
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Br/B
G/Y
P/W
O/R
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B/G
Y/B
O/G
Bl/B
Bl Br/B
G/Y
P/W
O/R
R/W
B/G
Y/B
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Bl/B
Bl B
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W
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l Y
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l Y W R
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B
B/W
B
B/W
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B
B/Bl
Lg B/W
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B
W
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r/ W
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G
r/ B
Y
/RO
/B
l B
/W
B
/L
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/W G W
/B R Y
B
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r ON
OFF
LOCK
P
OFF
RUN PUSH
OFF
ON
ON
OFF
M
FREE
PUSH
ON
OFF
FREE
PUSH
PUSH
L
PUSH
R
HI
LO
ON
OFF
HANDLEBAR SWITCH (R)
REAR BRAKE
SWITCH
IGNITION
COIL #1
IGNITION
COIL #2
IGNITION SWITCH
ENGINE
STOP
SWITCH
FRONT BRAKE
SWITCH
STARTER
BUTTON
ECMFUELPUMP
OFF
ON
OIL PRESSURE
SWITCH
TO
SENSOR
FUEL PUMP
RELAY
REAR
COMBINATION
LIGHT
REAR TURN
SIGNAL LIGHT (R)
REAR TURN
SIGNAL LIGHT (L)
LICENSE
LIGHT
BATTERY1: MAIN 30 A
STARTER
MOTOR
STARTER
RELAY
1
FUSE BOX
1. HEAD HI
2. HEAD LO
3. FUEL
4. IGNITION
5. SIGNAL
6. FAN
15 A
15 A
10 A
10 A
15 A
15 A
REGULATOR/
RECTIFIER
GENERATOR
SIDE-STAND
SWITCH
SPEED
SENSORIATSENSOR
TP
SENSOR
1 2 3
4 5 6
ECT
SENSORACTUATOR
INJECTOR
#2 #1
GEAR
POSITION
SWITCH
COOLING
FAN THERMO-
SWITCH
COOLING
FAN MOTOR
PAIR
SOLENOID
CLUTCH
SWITCH
DIMMER
SWITCHTURN SIGNAL
LIGHT SWITCH
PASSING
LIGHT
SWITCH
HORN
BUTTON
HANDLEBAR SWITCH (L)
HAZARD
SWITCH
HORN
GRIP HEATER
HEADLIGHT (R)
HEADLIGHT (L)
FRONT
TURN SIGNAL LIGHT (R)
FRONT
TURN SIGNAL LIGHT (L)
SP TA
IL ILL
FI
OD
ABS
N
R
W
O
H
: NEUTRAL INDICATOR LIGHT
: HI-BEAM INDICATOR LIGHT
: OIL INDICATOR LIGHT
: TURN SIGNAL INDICATOR LIGHT (R)
: TURN SIGNAL INDICATOR LIGHT (L)
: ABS INDICATOR LIGHT
N
H
O
R
L
ABS
SPEEDOMETER
(OPTIONAL PARTS)
ISC VALVE
ABS CONTROL UNIT
IAP
SENSOR
(R)
RWSFWS
ABS
VALVE
FUSE
(25A)
ABS
MOTOR
FUSE
(40A)
IAP
SENSOR
(F)

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