I SERVICE MANUAL I

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I SERVICE MANUAL I
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.
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.
GENERAL INFORMA TION
PERIODIC MAINTENANCE
ENGINE
FI SYSTEM DIAGNOSIS
FUEL SYSTEM AND THROTTLE
BODY
COOLING AND LUBRICATION
SYSTEM
CHASSIS
ELECTRICAL SYSTEM
SERVICING INFORMATION
EMISSION CONTROL
INFORMATION
WIRING DIAGRAM
SUZUKl MOTOR CORPORATION
O COPYRIGHT SUZUKl MOTOR CORPORATION 2003
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
O I ~ u s t seal I
@ I Bearing I
@ ( Center spacer I
@ I Front wheel
@ I Brake disc bolt I
@
@
Tire valve
Front axle
SYMBOL
Listed in the table below are the symbols indicating instructions and other information necessary for servic-
ing. The meaning of each symbol is also included in the table.
SYMBOL
PI
DEFINITION
Torque control required.
Data beside it indicates specified
torque.
Apply oil. Use engine oil unless otherwise specified.
Apply molybdenum oil solution.
(Mixture of engine oil and SUZUKl
MOLY PASTE in a ratio of 1 :1)
Apply SUZUKl SUPER GREASE " A .
99000-25030 (USA)
99000-2501 0 (Others)
Apply SUZUKl MOLY PASTE.
99000-251 40
Apply SUZUKl SILICONE GREASE.
99000-251 00
Apply SUZUKl BOND "121 5"
99000-31 1 10 (Except USA)
Apply SUZUKl BOND "12078".
991 04-31 140 (USA)
99000-31 140 (Others)
Apply THREAD LOCK SUPER "1 303".
99000-32030
Apply THREAD LOCK SUPER "1 322.
99000-321 10 (Except USA)
Apply THREAD LOCK "1 342"
99000-32050
SYMBOL DEFINITION
Apply THREAD LOCK SUPER "1 360".
99000-32 130
Use engine coolant.
Use fork oil.
99000-99001 -SS8
Apply or use brake fluid.
Measure in voltage range.
Measure in current range.
Measure in resistance range.
Measure in diode test range.
Measure in continuity test range.
Use special tool.
Indication of service data.
ABBREVIATIONS USED IN THIS
MANUAL
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)
: Air Fuel Mixture
B
BBDC
BTDC
B+
: Before Bottom Dead Center
: Before Top Dead Center
: 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
(CM PS)
CO : Carbon Monoxide
CPU : Central Processing Unit
D
DC
DMC
DOHC
DRL
: Direct Current
: Dealer Mode Coupler
: Double Over Head Camshaft
: 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
F
FI
FP
FPR
FP Relay
G
GEN
GND
GP Switch
H
HC
I
IAP Sens
IAT Sensor
L
LCD
LED
Canister (Canister)
: Fuel Injection, Fuel Injector
: Fuel Pump
: Fuel Pressure Regulator
: Fuel Pump Relay
: Generator
: Ground
: Gear Position Switch
: Hydrocarbons
: Intake Air Pressure Senso r (IAPS)
: Intake Air Temperature Sensor
(I ATS)
: Ignition
: Liquid Crystal Display
: Light Emitting Diode
(Malfunction Indicator Lamp)
: Left Hand
Max
MIL
Min
N
NOx
0
OHC
OPS
P
PCV
R
RH
ROM
S
SAE
STC System
STP Sensor
ST Valve
: Malfunction Code
(Diagnostic Code)
: Maximum
: Malfunction Indicator Lamp
(LED)
: Minimum
: Nitrogen Oxides
: Over Head Camshaft
: Oil Pressure Switch
: Positive Crankcase
Ventilation (Crankcase Breather)
: Right Hand
: Read Only Memory
: Society of Automotive Engineers
: Secondary Throttle Control
System (STCS)
: Secondary Throttle Position
Sensor (STPS)
: 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 SUZUKl 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 SUZUKl names.
SAE TERM
FULL TERM
4
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 Ignition
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
ABBREVIATION
ACL
BAR0
B+
CMP Sensor
CKP Sensor
DLC
DTM
DTC
El ECM
ECL
ECT
RPM
EVAP
EVAP Canister
FC
FP
GEN
GND
FORMER SUZUKl TERM
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
FULL TERM
- -- - --
I
Idle Speed Control
Ignition Control
Ignition Control Module
lntake Air Temperature
M
Malfunction Indicator Lamp
Manifold Absolute Pressure
Mass Air Flow
0
On-Board Diagnostic
Open Loop
P
Programmable Read Only Memory
Pulsed Secondary Air lnjection
Purge Valve
R
Random Access Memory
Read Only Memory
S
Secondary Air lnjection
Secondary Throttle Control System
Secondary Throttle Valve
Secondary Throttle Valve Actuator
T
Throttle Body
Throttle Body Fuel lnjection
Throttle Position Sensor
v Voltage Regulator
Volume Air Flow
ABBREVIATION
ISC
I C
ICM
I AT
MIL
MAP
MAF
OBD
OL
PROM
PA1 R
Purge Valve
RAM
ROM
AIR
STCS
STV
STVA
TB
TBI
TP Sensor
VR
VAF
FORMER SUZUKl TERM
Electronic Spark Advance (ESA)
-
lntake Air Temperature (IAT), Air Temperature
LED Lamp
Malfunction Indicator Lamp (MIL)
lntake Air Pressure (IAP), lntake 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 lnjection (TBI)
TP Sensor (TPS)
Voltage Regulator
Air Flow
WIRE COLOR
B : Black
BI : Blue
Br : Brown
Dg : Dark green
G : Green
Gr :Gray
Lbl : Light blue
Lg : Light green
0 : Orange
P :Pink
: Black with Blue tracer
: Black with Green tracer
: Black with Red tracer
: Black with Yellow tracer
: Blue with Green tracer
: Blue with White tracer
: Brown with Black tracer
: Green with Black tracer
: Gray with Black tracer
: Gray with White tracer
: Orange with Blue tracer
: Orange with Red tracer
: Orange with Yellow tracer
: Red with Black tracer
: White with Black tracer
: White with Green tracer
: Yellow with Black tracer
: Yellow with Green tracer
: Yellow with White tracer
B/Br
B/O
BNV
BI/B
BI/R
BIN
BrNV
G N
Gr/R
O/B
O/G
ONV
PNV
RNV
W/BI
W/R
Y/BI
Y/R
R : Red
W : White
Y : Yellow
: Black with Brown tracer
: Black with Orange tracer
: Black with White tracer
: Blue with Black tracer
: Blue with Red tracer
: Blue with Yellow tracer
: Brown with White tracer
: Green with Yellow tracer
: Gray with Red tracer
: Orange with Black tracer
: Orange with Green tracer
: Orange with White tracer
: Pink with White tracer
: Red with White tracer
: White with Blue tracer
: White with Red tracer
: Yellow with Blue tracer
: Yellow with Red tracer
- . . .-
GENERAL INFORMATION 1-1
CONTENTS
WARNINGKA UTION/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-FREEZWENGINE COOLANT ...................................................... 1- 6
LIQUID AMOUNT OF WATEWENGINE 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 .................................................................... 1-1 1
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.
lndicates a potential hazard that could result in death or injury.
lndicates a potential hazard that could result in motorcycle damage.
NOTE:
lndicates 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
RIGHT SlDE LEFT SlDE
Difference between photographs and actual motorcycles depends on the markets.
SERIAL NUMBER LOCATION
The frame serial number or V.I.N. (Vehicle Identification Number) @ is stamped on the right side of the
steering head. The engine serial number 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.
2 -
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. -GENERAL INFORMATION 1-5
ENGINE OIL (FOR USA)
SUZUKl recommends the use of SUZUKl 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
- - - - --
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.
FRONT FORK OIL
Use fork oil SS8 or an equivalent fork oil.
ENGINE COOLANT
Use an anti-freezelengine 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.
1-6 GENERAL INFORMATION
ANTI-FREEZUENGINE COOLANT
The engine coolant perform as a corrosion and rust inhibitor as well as anti-freeze. Therefore, the engine
d 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 SUZUKl COOLANT anti-freezelengine coolant. If this is not available, use
an equivalent which is compatible with an aluminum radiator.
LIQUID AMOUNT OF WATEWENGINE COOLANT
Solution capacity (total): 1 900 ml(4.0113.34 USIlmp qt)
For engine coolant mixture information, refer to cooling system section, page 6-2
- - - - - - -
Mixing of anti-freezelengine coolant should be limited to 60 %. Mixing beyond it would
its efficiency. If the anti-freezelengine 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.
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 rlmin
Up to 1 600 km (1 000 miles): Below 7 500 rlmin
Over to 1 600 km (1 000 miles): Below 10 500 rlmin
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 rlmin at any time.
GENERAL INFORMATION 1-7
CYLINDER IDENTIFICATION
The two cylinders of this engine are identified as NO.l and N0.2 cylinder, as viewed from front to rear.
14 GENERAL INFORMATION
INFORMATION LABELS
@ Fuel caution label I A (For E-02,24) I I
L
@ Noise label
@ Information label
@ Vacuum hose routing label
DL650
A (For E-03,24,33)
A (For E-03,28,33)
A (For E-33)
@ Manual notice label
@ Frame caution plate
Screen warning label
0 Steerina warnina label
DL650UE
@ Tire information label
I Warning safetv label
A (For E-03, 33)
A
A
A
ICES Canada label
@ Rear carrier warnina label I A I A (For Enalish) I
A
A
A (For E-28)
@ ID plate
@ Safetv plate
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.
A
A
A
I
4.
A
A
A (Except for E-03,28,33)
A (For E-03. 28.33)
-
A
GENERAL INFORMATION 1-9
SPECIFICATIONS
DIMENSIONS AND DRY MASS
................................................................ Overall length
................................................................. Overall width
................................................................ Overall height
.................................................................... Wheelbase
Ground clearance ..........................................................
.................................................................... Seat height
....................................................................... Dry mass
ENGINE
.............................................................................. Type
Number of cylinders .....................................................
............................................................................. Bore..
.......................................................................... Stroke..
................................................................ Displacement
Compression ratio .........................................................
................................................................... Carburetion
..................................................................... Air cleaner
............................................................... Starter system
Lubrication system ........................................................
...................................................................... Idle speed
DRIVE TRAIN
............................................................................ Clutch
................................................................. Transmission
Gearshift pattern .........................................................
Primary reduction ratio ..................................................
Final reduction ratio .......................................................
Gear ratios, Low ...........................................................
............................................................ 2nd
........................................................... 3rd..
................................. 4th .... ........................
............................... 5th.. .... ........................
.......................................................... Top..
Drive chain ....................................................................
2 290 mm (90.2 in)
840 mm (33.1 in)
..... 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
1 540 mm (60.6 in)
165 mm ( 6.5 in)
820 mm (32.3 in)
190 kg (41 8 Ibs)
4-stroke, liquid-cooled, DOHC, 90 "-degree V-twin
2
81.0 mm (3.1 89 in)
62.6 mm (2.465 in)
645 cm3 (39.4 cu.in)
11.5: 1
Fuel injection
Non-woven fabric element
Electric
Wet sump
1 300 + 100 r/min
Wet multi-plate type
6-speed constant mesh
1 -down, 5-up
2.088 (71 134)
3.1 33 (4711 5)
2.461 (3211 3)
1.777 (3211 8)
1.380 (29/21)
1 .I 25 (27124)
0.961 (25126)
0.851 (23127)
DID 525 V8, 116 links
1-10 GENERAL INFORMATION
CHASSIS
Front suspension ..........................................................
Rear suspension ...........................................................
Front fork stroke ............................................................
Rear wheel travel ..........................................................
Caster ...........................................................................
Trail ...............................................................................
Steering angle ...............................................................
Turning radius ...............................................................
Front brake ....................................................................
Rear brake ....................................................................
Front tire size ....................... . .....................................
Rear tire size .................................................................
ELECTRICAL
Ignition type ...................................................................
Ignition timing ................................................................
..................................................................... Spark plug
Battery.. .........................................................................
Generator ......................................................................
Main fuse ......................................................................
Fuse ..............................................................................
Headlight .......................................................................
PositionlParking light ..................................................
Brake lightfraillight .......................................................
License plate light ........................................................
Turn signal light .............................................................
......................................................... Speedometer light
Turn signal indicator light ..............................................
Neutral indicator light ....................................................
High beam indicator light ..............................................
Oil pressureICoolant temperature1
Fuel injection warning light ............................................
Telescopic, coil spring, oil damped
Link type, coil spring, oil damped
150 mm (5.9 in)
150 mm (5.9 in)
26 "
11 0 mm (4.33 in)
40 " (right & left)
2.6 m (8.5 ft)
Disc brake, twin
Disc brake
1 10180 R19 MIC 59H, tubeless
150170 R17 MIC 69H, tubeless
Electronic ignition (Transistorized)
4 " B.T.D.C. at 1 300 rlmin
NGK CR8E, or DENS0 U24ESR-N
12V 36.0 k c (1 0 Ah)/l 0 HR
Three-phase A.C. generator
30 A
15115110110115115 A
12 V 60155 W x 2 (H4)
12 V 5 W x 2 ................. Except E-03, 24, 33
12v2115wx2
1 2 v 5 W
12v21 W
LED
LED
LED
LED
LED
CAPACITIES
Fuel tank, including reserve .......................................... 22 L (5.814.8 USllmp gal)
Engine oil, oil change ............................................... 2 300 ml (2.412.0 USllmp qt)
with filter change ........................................ 2 700 ml (2.912.4 USllmp qt)
overhaul ................................................... 3 100 ml (3.312.7 USllmp qt)
Coolant .......................................................................... 1.9 L (2.011.7 USllmp qt)
These specifications are subject to change without notice.
GENERAL INFORMATION 1-1 1
COUNTRY AND AREA CODES
The following codes stand for the applicable country (-ies) and area (-s).
COUNTRY or AREA
U.K.
U.S.A. (Except for california)
EU
Australia
Canada
California (U.S.A.)
EU
MODEL
DL650
DL650-UE
CODE
E-02
E-03
E-19
E-24
E-28
E-33
E-19
PERIODIC MAINTENANCE 2-1
CONTENTS
PERIODIC MAINTENANCE SCHEDULE ............................................... 2
PERIODIC MAINTENANCE CHART ................................................... 2
LUBRICATION POINTS ......................................................................... 4
MAINTENANCE AND TUNE-UP PROCEDURES ........................................ 5
AIR CLEANER ................................................................................... 5
SPARK PLUG ........................................................................................ 6
VALVE CLEARANCE ............................................................................ 2 8
FUEL LINE ............................................................................................. 2-13
ENGINE OIL AND OIL FILTER ........................................................... 2-13
ENGINE IDLE SPEED ............................................................................ 2-15
THROTTLE CABLE PLA Y ..................................................................... 2-15
THROTTLE VALVE SYNCHRONIZA TION ............................................ 2-16
EVAPORATIVE EMISSION CONTROL SYSTEM (E-33 ONLY) ........... 2-16
PAIR (AIR SUPPLY) SYSTEM ............................................................... 2-16
CLUTCH ................................................................................................. 2-17
COOLING SYSTEM ................................... ... .................................... 2-18
DRl VE 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
I Air cleaner element I - I I I I I R 1 1 1
Interval km
miles
months
1 000
600
2
Exhaust pipe bolts and muffler bolts
Valve clearance
Spark plugs
Fuel line
Engine oil
Enaine oil filter
6000
4 000
12
T
-
-
-
Idle speed
Throttle cable play
Throttle valve synchronization
I - - I Clutch - I I I I 1
R
R
Evaporative emission control system
(E-33 only)
PAIR (air supply) system
Engine coolant
Radiator hoses
12000
7 500
24
Replace every 4 years.
T
-
I
I
I
I
1
(E-33 onlv)
R
-
-
Drive chain
18000
11000
36
T
-
R
I
I
I
-
Brake hose
24000
14500
48
R
-
-
I
T
-
I
I
I
I
I
Replace vapor hose every 4 years.
-
-
T
1
R
I
R
R
I
-
I
R
-
1
I
-
Clean and lubricate every 1 000 km (600 miles).
Replace every 4 years.
I
I
I
I
-
-
I
I
I
Replace every 2 years.
I
I
-
I
1
I
I
-
Reolace everv 4 vears.
I
I
I
I I I
I
I
I
PERIODIC MAINTENANCE 2-3
Interval km
miles
-
1 Chassis bolts and nuts I T I T I T I T I T P I
1 000
600
2
Tires
Steering
Front forks
Rear sus~ension
NOTE:
/=Inspect and clean, adjust, replace or lubricate as necessary;
R=Replace; T=Tighten
Replace every 2 years.
I
6 000
4 000
12
-
I
-
-
I
12000
7 500
24
I
-
-
-
I
18000
11000
36
I
I
I
I
1
24000
14500
48
I
-
-
-
I
I
I
I
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.
@ / Clutch lever holder (
@ I Side-stand pivot I
1 and spring hook I
@ I Footrest pivot 1
Brake pedal pivot
and footrest pivot
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.
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
Inspect every 6 000 km (4 000 miles, 12 months) and
replace every 18 000 km (1 1 000 miles, 36 months).
Remove the seat. (W7-4)
Remove the fuel tank. (-5-7)
Remove the air cleaner box cap 0.
Remove the air cleaner element @.
Carefully use air hose to blow the dust from the cleaner element.
Always use air pressure on the throttle body side of
the air cleaner element. If air pressure i s 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.
Install the O-ring @ properly.
Reinstall the cleaned or new air cleaner element in the
reverse order of removal.
CAUTION I
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!
26 PERIODIC MAINTENANCE
NOTE:
When cleaning the air cleaner element, drain water from the air
cleaner by removing the drain plug.
SPARK PLUG
Inspect every 6 000 km (4 000 miles, 12 months) and
replace every 12 000 km (7 500 miles, 24 months).
NO.l (FRONT) SPARK PLUG REMOVAL
Remove the cowling. (-7-5).
Remove the radiator mounting bolt a.
Move the radiator lower side to forward.
Remove the spark plug cap Q.
NOTE:
Be careful not to damage the radiator fins.
The hot radiator and the hot engine can burn you. Wait
until the radiator and the engine are cool enough to
touch.
Remove the spark plug with the special tool.
m09930-10121: Spark plug socket wrench set
PERIODIC MAINTENANCE 2-7
N0.2 (REAR) SPARK PLUG REMOVAL
Remove the seat. (-7-4)
Lift and support the fuel tank. ( W 5 - 7 )
Remove the spark plug cap.
Remove the spark plug with the special tool.
a09930-10121: Spark plug socket wrench set
HEAT RANGE
Check to see the heat range of the plug.
I Standard I Cold t v ~ e 1 Hot t v ~ e
I I - . I * . 1 NGK 1 CR8E CR9E CR7E I
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 @
Standard: 0.7 - 0.8 mm (0.028 - 0.031 in)
a 09900-20803: Thickness gauge
--
ELECTRODES CONDITION
Check to see the worn or burnt condition of the electrodes. If it
is extremely worn or burnt, replace the plug. And also replace
the plug if it has a broken insulator, damaged thread.
-1
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
I CAUTION I
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.
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 Ib-ft)
NOTE:
When fitting the spark plug caps, front and rear, face the triangle
mark @ on the water-proof cover to each cylinder exhaust side.
VALVE CLEARANCE
I Inspect every 24 000 krn (15 000 miles, 48 months). I
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
exhaust valves.
different for intake and
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 @ show
the front cylinder at TDC of compression stroke.
* The cams (IN & EX) on the rear cylinder at position @$ show
the rear cylinder at TLIC 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.
PERIODIC MAINTENANCE 2-9
Remove the generator cover plug @ and timing inspection
plug 0.
Turn the crankshaft to set the No.1 (Front) cylinder at TDC of
compression stroke. (Align the "F I 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 (314 turns) to set the No.2
(Rear) cylinder at TDC of compression stroke. (Align the
"R I 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
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. (W3-21,23)
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 2-1 1 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.
piiimiq
Reinstall the camshafts as the specified manner.
(W3-99)
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 @.
Install the following items.
* Cylinder head cover (-3-106)
* Spark plug and plug cap (-2-8)
* Valve timing inspection plug (-3-1 08)
* Generator cover plug (W3-108)
TAPPET SHlM SELECTION TABLE [INTAKE]
TAPPET SHlM NO. (1 2892-05C00-XXX)
I TAPPET SHlM SET (1 2800-05830) I
HOW TO USE THIS CHART:
I. Measure tappet clearance. "ENGINE IS COLD"
It. Measure present shim size.
Ill. Match clearance in vertical column with present shim size in horizontal
column.
EXAMPLE
Tappet clearance is 0.23 mm
Present shim size 1.65 mm
Shim size to be used 1.75 mm
TAPPET SHlM SELECTION TABLE [EXHAUST]
TAPPET SHl M NO. (1 2892-05C00-XXX)
TAPPET SHlM SET (1 2800-05830)
SUFFIX 120 125 130 135 !40 145 150 155 160 ?55 170 175 180 185 190 195 200 205 210 215 220
1.20 1.25 1.30 1.35 1.40 1.45 1.50 1.55 1.60 1.65 1.70 1.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20
0.05-0.09 1.20 1.25 1.30 1.35 1.40 1.45 1.50 1.55 1.60 1.65 1.70 1.75 1.80 1.85 1.90 1.95 2.00 2.05
HOW TO USE THIS CHART:
I. Measure tappet clearance. "ENGINE IS COLD"
II. Measure present shim size.
Ill. Match clearance in vertical column with present shim size in horizontal
column.
EXAMPLE
Tappet clearance is 0.33 mm
Present shim size 1.65 mm
Shim size to be used 1.75 mm
PERIODIC MAINTENANCE 2-13
FUEL LINE
lnspect every 6 000 km (4 000 miles, 12 months).
Replace every 4 years.
Lift and support the fuel tank. (-5-7)
Inspect the fuel feed hose @ for damage and fuel leakage. If
any defects are found, the fuel hoses must be replaced.
ENGINE OIL AND OIL FILTER
(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 (1 1 000 miles, 36 months) thereafter.
Oil should be changed while the engine is warm. Oil filter
replacement at the above intervals, should be done together
with the engine oil change.
ENGINE OIL REPLACEMENT
Keep the motorcycle upright.
Place an oil pan below the engine, and drain oil by removing
the drain plug @ and filler cap 0.
- Tighten the drain plug @ to the specified torque, and pour
fresh oil through the oil filler. The engine will hold about 2.7 L
(2.912.4 USIlmp qt) of oil. Use an API classification of SF or
SG oil with SAE 1 OW-40 viscosity.
Oil drain plug: 21 N-m (2.1 kgf-m, 15.0 Ib-ft)
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 @. 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 @ with the special tool.
-09915-40610: Oil filter wrench
Apply engine oil lightly to the gasket of the new filter a 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.
* Afler 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 (2.412.0 USIlmp qt)
Filter change: 2.7 L (2.912.4 USllmp qt)
Engine overhaul: 3.1 L (3.312.7 USllmp qt)
ONLY USE A GENUINE SUZUKl 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
lnspect initially at 1 000 km (600 miles, 2 month) and
every 6 000 km (4 000 miles, 12 months) thereafter.
NOTE:
Make this adjustment when the engine is hot.
Start up the engine and set its idle speed to the specified
range by turning the throttle stop screw a.
Engine idle speed: 1 300 * 100 rlmin
THROTTLE CABLE PLAY
lnspect initially at 1 000 km (600 miles, 2 month) and
every 6 000 km (4 000 miles, 12 months) thereafter.
Adjust the throttle cable play @ with the following three steps.
MINOR ADJUSTMENT
First step:
Remove the cable adjuster covers a.
Loosen the lock-nut @ of the throttle returning cable @ and
turn in the adjuster @ fully into the threads.
Second step:
Loosen the lock-nut @ of the throttle pulling cable @.
Turn the adjuster in or out until the throttle cable play @
should be 2.0 - 4.0 mm (0.08 - 0.16 in) at the throttle grip.
Tighten the lock-nut @ while holding the adjuster O.
Third step:
While holding the throttle grip at the fully closed position,
slowly turn out the adjuster @ of the throttle returning cable @
to feel resistance.
Tighten the lock-nut @ while holding the adjuster @.
Throttle cable play @: 2.0 - 4.0 mm (0.08 - 0.16 in)
After the adjustment is completed, check that handlebar movement does not raise the engine idle speed
and that the throttle grip returns smoothly and autoNOTE:
Major adjustment can be made by the throttle body side
adjuster.
2-16 PERIODIC MAINTENANCE
MAJOR ADJUSTMENT
Remove the fuel tank. (-5-7)
Remove the air cleaner box. (-5-1 5)
Loosen the lock-nut @ of the throttle returning cable.
Turn the returning cable adjuster to obtain proper cable
play.
Loosen the lock-nut @ of the throttle pulling cable.
Turn the pulling cable adjuster @ in or out until the throttle
cable play @ should be 2.0 - 4.0 mm (0.08 - 0.16 in) at the
throttle grip.
Tighten the lock-nut @ securely while holding the adjuster @.
Throttle cable play @I: 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 @ to obtain a slack of
1.0 mm (0.04 in).
Tighten the lock-nut @ securely.
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.
THROTTLE VALVE SYNCHRONIZATION
lnspect initially at 1 000 km (600 miles, 2 months) (E-33
only) and every 12 000 km (7 500 miles, 24 months).
lnspect the throttle valve synchronization periodically.
(-5-32)
EVAPORATIVE EMISSION CONTROL SYS-
TEM (E-33 ONLY)
lnspect every 12 000 km (7 500 miles, 24 months).
Replace vapor hose every 4 years.
lnspect the evaporative emission control system periodically.
PAlR (AIR SUPPLY) SYSTEM
I lnspect every 12 000 krn (7 500 miles, 24 months). (
lnspect the PAIR (air supply) system periodically. (-10-6)
PERIODIC MAINTENANCE 2-17
CLUTCH
Inspect every 6 000 km (4 000 miles, 12 months).
Loosen the lock-nut @ and turn the adjuster @ all the way
into the clutch lever assembly.
Remove the engine sprocket cover.
Loosen the lock-nut @ and turn out the adjusting screw @ =T- *?%a r- two or three rotations.
From that position, slowly turn the adjuster screw @ in until it
stops.
Turn the adjuster screw @ out 114 rotation, and tighten the
lock-nut @. C
I
Loosen the lock-nuts 0, turn the cable adjuster
10 - 15 mm (0.4 - 0.6 in) of free play @ at the
end.
Tighten the lock-nuts 0.
Clutch cable play @: 10 - 15 mm (0.4 - 0.6
-. Clutch release screw: 114 turns back.
@ to obtain
clutch lever
in)
2-18 PERIODIC MAINTENANCE
COOLING SYSTEM
Inspect every 6 000 km (4 000 miles, 12 months).
Replace engine coolant every 2 years.
Replace radiator hoses every 4 years.
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.
@ Full line @ 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 0.
Drain the engine coolant by removing the drain bolt @.
* 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!
Flush the radiator with fresh water if necessary.
Tighten the water drain bolt @ to the specified torque.
Water drain bolt: 13 N-m (1.3 kgf-m, 9.5 Ib-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.
PERIODIC MAINTENANCE 2-19
v - 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 @ and slowly swing the motor- "
cycle, right and left, to bleed the air trapped in the thermostat
case O.
P Add engine coolant up to the radiator inlet.
Repeat the above procedure until bleed no air from the radiator inlet. l
Close the radiator cap @ 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. ( W 7 - 8 )
I Repeat the above procedure several times and make I
sure that the radiator is filled with engine coolant up to
the reserve tank full level.
a Engine coolant capacity
Reverse tank side: 250 ml(0.5310.44 USnmp qt)
Engine side: 1 650 ml (3.4912.90 USllmp qt)
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
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).
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
O O-ring
O 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 0.
Tense the drive chain fully by turning both chain adjusters @.
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 rnrn (12.57 in)
ADJUSTING
Loosen or tighten both chain adjusters @ until the chain has
20 - 30 mm (0.8 - 1.2 in) of slack @ in the middle between
engine and rear sprockets. The ends of left and right spacers
must be at the same position on the scales (g) 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 @ to the
specified torque.
Recheck the drive chain slack after tightening the axle nut 0.
Rear axle nut: 100 N-rn (10.0 kgf-rn, 72.5 Ib-ft)
2-22 PERIODIC MAINTENANCE
CLEANING AND LUBRICATING
Wash the chain with kerosene. If the chain tends to rust
quickly, the intervals must be shortened.
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 "0"-rings (or seals) confining the grease in the
bush to pin clearance. Remember, high durability
comes from the presence of grease in that clearance.
After washing and drying the chain, oil it with a heavy-weight
motor oil.
-1
- -
Do not use any oil sold commercially as "drive chain
oil". Such oil can damage the "On-rings (or seals).
* The standard drive chain is DID525V8. SUZUKl recommends that this standard drive chain should be
used for the replacement.
BRAKE
(BRAKE)
lnspect 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. I
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
PERIODIC MAINTENANCE 2-23
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.
BRAKE PADS
Remove the brake caliper. (Front)
The extent of brake pad wear can be checked by observing
the grooved limit @ on the pad. When the wear exceeds the
grooved limit, replace the pads with the new ones. ( W 7 - 5 9
and - 69)
-1
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 @ and rotate the push rod a to locate
brake pedal 20 - 30 mm (0.59 - 0.98 in) @ below the top face
of the footrest.
Retighten the lock-nut @ to secure the push rod a in the
proper position.
Brake pedal height @: 20 - 30 mm (0.79 - 1 . I8 in)
Rear brake master cylinder rod lock-nut 0:
17 N-rn (1.7 kgf-m, 12.5 Ib-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.
e E : xitan tan
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.
fl Air bleeder valve (Front): 7.5 N-m (0.75 kgf-m, 5.5 Ib-ft)
Air bleeder valve (Rear): 6 N-m (0.6 kgf-m, 4.3 Ib-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.
Handle brake fluid with care: the fluid reacts chemically with paint, plastics, rubber materials and so on.
The only difference between bleeding the front and rear
brakes is that the rear master cylinder is actuated by a pedal.
2-26 PERIODIC MAINTENANCE
TlRE
I Inspect every 6 000 km (4 000 miles, 12 months). I
TlRE 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)
TlRE 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.
I COLD INFLATION I SOLO RlNDlNG 1 DUAL RIDING I
I FRONT 1 225 1 2.25 1 33 1 225 1 2.25 1 33 1
- --- . - -
TlRE PRESSURE
I L I
I REAR 1250 1 2.50 1 36 1 280 1 2.80 1 41
The standard tire fitted on this motorcycle is 110180
R19MlC (59H) for front and 150170 R17MlC (69H) for
I
kPa I kgf/cmz I psi I kPa I kgf/cm2 I psi
rear. The use of tires other than those specified may
cause instability. It is highly recommended to use a
SUZUKl Genuine Tire.
TlRE TYPE
BRIDGESTONE (Front : TW101F Rear : TW152F)
STEERING
lnspect initially at 1 000 km (600 miles, 2 month) and
every 12 000 km (7 500 miles, 24 months) thereafter.
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.
PERIODIC MAINTENANCE 2-27
FRONT FORK
lnspect every 12 000 km (7 500 miles, 12 months).
lnspect the front forks for oil leakage, scoring or scratches on
the outer surface of the inner tubes. Replace any defective
parts, if necessary. (W7-17)
REAR SUSPENSION
I lnspect every 12 000 km (7 500 miles, 12 months). I
lnspect 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. (W7-45)
EXHAUST PIPE BOLT
Tighten initially at 1 000 km (600 miles, 2 month) and
every 6 000 km (4 000 miles, 12 months) thereafter.
Tighten the exhaust pipe bolts and muffler mounting bolts to
- the specified torque.
Muffler mounting bolt h u t @: 23 N-m (2.3 kgf-m, 16.5 Ib-ft)
Exhaust pipe bolt @loo: 23 N-m (2.3 kgf-m, 16.5 Ib-ft)
a 99000-32050: THREAD LOCK "1 342"
EXHAUST GAS SEALER: PERMATEX 1372
2-28 PERIODIC MAINTENANCE
CHASSIS BOLT AND NUT
- - -- -
Tighten initially at 1 000 km (600 miles, 2 month) and
miles, 12 months) thereafter.
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.)
ITEM I ~ . m I kgf-m I I b-ft 1
@ Steering stem head nut I 90 1 9.0 1 65.0 I
@ Front axle I 65 I 6.5 I 47.0 I
a Steering stem lock-nut
0 Front fork upper clamp bolt
@ Front fork lower clamp bolt
I @ Front axle pinch bolt I 23 I 2.3 1 16.5 I
80
23
23
I Air bleeder valve (Rear) 1 6 I 0.6 1 4.3 I
Handlebar clamp bolt
@ Front brake master cylinder mounting bolt
@ Front brake caliper mounting bolt
0 Brake hose union bolt
@ Air bleeder valve (Front)
8.0
2.3
2.3
10 Front footrest bracket mountinq bolt I 25 1 2.5 I 18.0 I
58.0
16.5
16.5
23
10
39
23
7.5
@ Brake disc bolt (Front & Rear)
@ Rear brake caliper mounting bolt
@ Rear brake master cylinder mounting bolt
@ Rear brake master cvlinder rod lock-nut
1 @ Swingarm pivot nut I 100 I 10.0 I 72.5 I
I Swingarm pivot lock-nut 90 9.0 65.0
2.3
1 .O
3.9
2.3
0.75
23
22
10
18
(a Rear shock absorber mounting nut
IUmer & Lower)
16.5
7.0
28.0
16.5
5.5
2.3
2.2
1 .O
1.8
-
7 I @seat rail mounting bolt 1 50 5.0 1 36.0 I
16.5
16.0
7.0
13.0
, - I I- -
@I Cusion lever nut
Cusion rod nut
I Rear axle nut
78
78
100
7.8
7.8
10.0
56.5
56.5
72.5
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 (1 1 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
(1 1 kgfIcm2, 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. ( W 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.
a 0991 5-6451 2: Compression gauge
0991 3-1 0750: Adaptor
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
Above 100 kPa (1.0 kgf/cm2, 14 psi) I Below 400 kPa (4.0 kgflcm2, 57 poi) at 3 000 rlmin., Oil temp. at 60 OC (140 OF)
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 @.
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 rlmin.
Winter 20 min. at 2 000 rlmin.
After warming up, increase the engine speed to 3 000 rlmin.
(with the engine tachometer), and read the oil pressure
gauge.
0991 5-74521 : Oil pressure gauge hose
09915-74532: Oil pressure gauge attachment
09915-77331 : Meter (for high pressure)
[rJ Main oil gallery plug [M 81: 18 N m (1.8 kgf-m, 13.0 Ib-ft)
ENGINE 3-1
CONTENTS
ENGINE COMPONENTS REMOVABLE WITH THE ENGINE IN PLACE .... 3 - 2
ENGINE REMOVAL AND INSTALLATION ................................................... 3
ENGINE REMOVAL .............................................................................. 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
..................................................... CAMSHAFTKAMSHAFT 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 SHAFTIGEARSHIFT 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 394
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
1 PARTS I REMOVAL 1 INSTALLATION I
I Clutch release I 3-5 I 3-1 7 I
Engine sprocket
Generator
Gear position switch
I Starter idle gear 3-26 3-93 I
3-6
3-26, 3-32
3-33
3-1 6
3-86, 3-93
3-85
ENGINE RIGHT SIDE -
I Primary drive gear I 3-31 I 3-87 I
1 Priman, driven gear 1 I
INSTALLATION
3-90
PARTS
Clutch
3-29, 3-70
ENGINE CENTER
1 PARTS REMOVAL INSTALLATION I
REMOVAL
3-27
3-70, 3-90
Oil pump
Gearshift shaft
Water pump
3-29
3-30
6-1 4
I Throttle body 5-1 5 5-23
I 3-22, 3-25 I 3-97 I 1 Cylinder heads
-
3-89
3-89
6-1 7
-
Cylinder head covers
Camshafts
1 Cylinders I 3-23, 3-25 1 3-96 I
1 Pistons 1 3-23, 3-26 1 3-94 I
3-20
3-2 1. 3-23
1 Cam chain tension adjusters 3-22, 3-24 3-1 01, 3-104 I
3-1 06
3-99
1 o i l pressure switch I I 3-58 3-58 I
Thermostat
Oil filter
1 starter motor 3-26 3-94 I 6-1 2
2-1 4
6-1 3
2-14
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. (W2-13)
Drain the engine coolant. (-2-18)
Remove the seat. (-7-4)
Disconnect the battery @ lead wire a.
Remove the fuel tank 0. (-5-7)
Disconnect the cooling fan motor and thermo-switch lead wire
coupler. (W6-5)
Remove the radiator and water hoses. (W6-5)
Remove the air cleaner box 0. (-5-1 5)
3-4 ENGINE
Remove the throttle body. (W5-16)
-
d Disconnect the spark plug caps.
Remove the left side frame cover. (-7-5)
Disconnect the gear position switch lead wire coupler a.
Disconnect the generator lead wire coupler @ and CKP sensor lead wire coupler @.
Remove the ECT sensor lead wire coupler @.
ENGINE 3-5
Remove the gearshift lever @.
Remove the engine sprocket cover @.
Remove the clutch release assembly 0, its support plate @
and spring @.
Remove the clutch push rod @.
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 @ of the clutch release
lever.
Flatten the lock washer.
Remove the engine sprocket
depressing the brake pedal.
nut @I and lock washer while
36 ENGINE
Remove the cotter pin. (For E-03,28,33)
Loosen the rear axle nut 0.
Loosen the chain adjusters @.
Remove the engine sprocket @.
Disconnect the engine ground lead wire @.
Disconnect the H02 sensor lead wire coupler @ and release
the H02 sensor lead wire from the clamp @.
Remove the muffler mounting bolts.
ENGINE 3-7
Remove the muffler mounting bolt @.
Loosen the front exhaust pipe mounting bolts Q.
Remove the front exhaust pipe @.
Loosen the rear exhaust pipe mounting bolts.
Remove the muffler.
Remove the right footrest bracket mounting bolts.
Remove the oil cooler @.
3-8 ENGINE
Disconnect the starter motor lead wire @ and oil pressure
switch lead wire @.
Support the engine with an engine jack.
Remove the engine mounting nut @ and bolt 0.
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 @.
Disconnect the ignition coil lead wires a.
Disconnect the water hose clamp @.
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 @.
Gradually lower the engine assembly by removing the bolt @,
0.
I CAUTION (
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.
3-12 ENGINE
Before installing the engine assembly, install the spacer @,
collar @ and engine thrust adjuster 0.
Install the collar onto the crankcase properly as shown.
Install the left engine mounting bracket @.
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 Ib-ft)
a 99000-32050: THREAD LOCK "1 342"
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.
rn Engine mounting thrust adjuster:
12 N-m (1.2 kgf-m, 8.5 Ib-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
rn Engine mounting thrust adjuster lock-nut:
45 N-m (4.5 kgf-m, 32.5 Ib-ft)
After tightening the
bolt @.
rn Engine mounting
Engine mounting
engine mounting bolt, tighten the pinch
bolt: 55 N-m (5.5 kgf-m, 40.0 Ib-ft)
pinch bolt @:
25 N-m (2.5 kgf-m, 18.0 lb-ft)
- Tighten the engine mounting nuts to the specified torque. rn Engine mounting nut @: 93 N-m (9.3 kgf-m, 67.5 Ib-ft)
Engine mounting nut: 55 N-m (5.5 kgf-m, 40.0 Ib-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 Ib-ft)
w4 Cr Install the new gaskets.
Apply THREAD LOCK to the muffler mounting bolt.
a 99000-32050: THREAD LOCK "1 342"
ENGINE 3-15
Adjust the brake pedal height.
C1
rn Brake pedal height @
Standard: 20 - 30 mm (0.79 - 1 .18 in)
ITEM
80300
Install the gearshift arm as shown.
rn Gearshift arm angle @: Approx. 63.6 "
N-m
23
kgf-m
2.3
Ib-ft
16.5
3-16 ENGINE
Adjust the gearshift lever as shown.
Gearshift lever height @)
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.
a 99000-32050: THREAD LOCK "1 342"
Tighten the engine sprocket nut @ to the specified torque.
rn Engine sprocket nut: 145 N-m (14.5 kgf-m, 105 Ib-ft)
Bend the lock washer.
Adjust the drive chain slack. ( W 2 - 2 1 )
Tighten the rear axle nut to the specified torque.
rn Rear axle nut: 100 N-m (10.0 kgf-m, 72.5 Ib-ft)
Install the cotter pin. (For E-03, 28, 33)
-
Apply SUZUKl SUPER GREASE to the clutch push rod and install it.
99000-25030: SUZUKl SUPER GREASE "A" (USA)
99000-25010: SUZUKl SUPER GREASE "A" (Others)
-
ENGINE 3-17
Install the clutch cable to the generator cover temporarily. E l m Oh- /Re Apply SUZUKl MOLY PASTE to the clutch release.
& 99000-251 40: SUZUKl MOLY PASTE
Assemble the clutch release so that the lever arm @ will be
angle of 80 degree with axle @.
Adjust the clutch cable play. (W2-17)
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. (-9-1 6)
Adjust the following items.
Engine oil (-2-1 4)
Engine coolant (-2-1 9)
Engine idle speed (-2-1 5)
Throttle cable play (-2-1 5)
Clutch cable play (-2-17)
Throttle body synchronization (-5-32)
ENGINE 3-19
ENGINE DISASSEMBLY
- ENGINE TOP SIDE
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.
-- Remove the spark plugs. ( W 2 - 6 )
Disconnect the crankcase breather hoses @I.
Disconnect the PAIR hoses @.
Remove the thermostat case @ along with the hoses @I.
NOTE:
- Refer to the section 6 for their servicing.
Remove the water unions @ and intake pipes 0.
3-20 ENGINE
Remove the oil cooler bracket a.
Remove the rear exhaust pipe @ and gasket.
Remove the valve timing inspection plug @
cover plug OD.
CYLINDER HEAD COVER
Remove the front cylinder head cover a.
and generator
Remove the dowel pin @ and O-ring @.
ENGINE 3-21
Remove the rear cylinder head cover @.
Remove the dowel pin @ and O-ring @.
FRONT CAMSHAFTS
Turn the crankshaft to bring the " 1 F line @ on generator rotor
to the index mark @ 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.
(W 2-8)
Remove the cam chain guide @.
3-22 ENGINE
Remove the spring holder bolt @, spring and gasket.
Remove the cam chain tension adjuster @.
Remove the intake camshaft journal holder @.
Remove the exhaust camshaft journal holder @.
NOTE:
Mark the cylinder location as "F" to the camshaft journal holders.
Remove the dowel pins 0.
Remove the intake camshaft O.
Remove the exhaust camshaft @.
NOTE:
Do not drop the dowel pins into the crankcase.
FRONT CYLINDER HEAD
Remove the cylinder head bolt (M6) 0.
Remove the cylinder head bolts (M6) @.
Remove the cylinder head bolts @ and washers.
NOTE:
When loosening the cylinder head bolts, loosen each bolt little
by little diagonally.
Remove the cylinder head @.
ENGINE 3-23
Remove the cylinder head gasket a, dowel pins @ and cam
chain guide a.
FRONT CYLINDER
Remove the cylinder nuts @I.
Remove the cylinder @.
Remove the cylinder base gasket 8 and dowel pins @.
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 O.
Remove the piston @ 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 " I F" line @ on the generator rotor with the index
mark @ of the valve timing inspection hole.
3-24 ENGINE
NOTE:
* At the above condition, the rear cylinder is at A TDC 90 " on
expansion stroke.
* Before removing the camshafts, inspect the valve clearance.
(W 2-8)
Remove the cam chain guide a.
Remove the cam chain tension adjuster cap bolt @, spring
and gasket.
Remove the cam chain tension adjuster @.
Remove the intake camshaft journal holder @.
Remove the exhaust camshaft journal holder @.
NOTE:
Mark the cylinder location as "I?" to the camshaft journal holders.
Remove the dowel pins @.
Remove the intake camshaft a.
Remove the exhaust camshaft @.
ENGINE 3-25
REAR CYLINDER HEAD
Remove the cylinder head bolt (M6) 0.
Remove the cylinder bolts (M6) 0.
Remove the cylinder head bolts @ and washers.
NOTE:
When loosening the cylinder head bolts, loosen each bolt little
by little diagonally.
Remove the cylinder head @.
I .
Remove the cylinder head gasket @, dowel pins @ and cam
chain guide a.
REAR CYLINDER
Remove the cylinder nuts @ and clamp.
Remove the cylinder @.
Remove the cylinder base gasket @ and dowel pins @. - C
NOTE:
Make sure that the oil jet @ 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 0.
Remove the piston (3 by driving out the piston pin.
NOTE:
Scribe the cylinder number on the head of the piston.
STARTER MOTOR Wv
Remove the starter motor mounting bolts and the clamp 0. . -, Remove the starter motor (3.
ENGINE BOTTOM SIDE
OIL FILTER
Remove the oil filter @ with the special tool.
09915-40610: Oil filter wrench
GENERATOR COVER
Remove the generator cover @.
Remove the gasket and dowel pins @.
Remove the starter idle gear @ and its shaft 6).
ENGINE 3-27
CLUTCH COVER
Remove the clutch cover @.
Remove the dowel pins @ and gasket @I.
CLUTCH
Hold the generator rotor with the special tool.
a 09930-44530: Rotor holder
Remove the clutch springs.
NOTE:
Loosen the clutch spring set bolts little by little and diagonally.
Remove the pressure plate @.
Remove the clutch push piece 0, the bearing @ and thrust
washer @.
3-28 ENGINE
Remove the clutch push rod @.
NOTE:
If it is difficult to pull out the push rod 0, use a magnetic hand or
a wire.
Remove the clutch drive plates and driven plates.
Remove the spring washer and spring washer seat @.
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 thrust washer a.
Remove the primary driven gear assembly @.
Remove the spacer Q.
OIL PUMP
Remove the snap ring a.
Remove the oil pump driven gear a.
NOTE:
Do not drop the snap ring @ into the crankcase.
.-
Remove the pin @ and the washer @I. I
NOTE: ;
Do not drop the pin @ and washer @ into the crankcase.
3-30 ENGINE
- -A - -- -
Remove the oil pump @.
GEARSHIFT SYSTEM
Remove the snap ring @I and washer @I.
Remove the gearshift shaft assembly @ and washer @.
Remove the gearshift cam plate bolt @.
Remove the gearshift cam plate @.
Remove the gearshift cam stopper a.
ENGINE 3-31
Remove the following parts.
@ Gearshift cam stopper bolt
@ Gearshift cam stopper spring
@J Washer
OIL PIPE
Remove the oil pipe stopper 6).
Remove the oil pipe @.
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 @ and primary drive gear
'
0. ,3- .t $Yd-7 . REAR CAM CHAIN
Remove the cam chain tensioner @.
4b.
-
NOTE:
Do not drop the washer @ into the crankcase. i
r -- - 7 - m a Remove the rear cam chain @ and cam chain drive sprocket
8. a
GENERATOR ROTOR
Hold the generator rotor with the special tool.
m09930-44530: Rotor holder
Remove the generator rotor bolt.
Remove the generator rotor @ with the special tools.
-09930-30450: Rotor remover
09930-44530: Rotor holder
ENGINE 3-33
Remove the key 0.
Remove the starter driven gear @.
FRONT CAM CHAIN
Remove the cam chain tensioner @.
NOTE:
Do not drop the washer into the crankcase.
Remove the front cam chain @.
GEAR POSITION SWITCH
Remove the driveshaft oil seal retainer @.
Remove the gear position switch @.
3-34 ENGINE
Remove the O-ring @.
Remove the switch contacts @ and springs @.
CRANKCASE
Remove the oil plate a.
Remove the crankcase bolts and clamp @.
NOTE:
Loosen the crankcase bolts diagonally and smaller sizes first.
Separate the crankcase into 2 parts, right and left with the
special tool.
09920-1 31 20: 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 @ and dowel pins @.
CRANKSHAFT
Remove the crankshaft a.
Remove the driveshaft assembly @ and countershaft assembly @.
TRANSMISSION
Remove the gearshift fork shafts @.
Remove the gearshift cam 0.
Remove the gear shift forks @.
Remove the engine sprocket spacer @ and O-ring a.
3-36 ENGINE
ENGINE COMPONENTS INSPECTION
AND SERVICING
CYLINDER HEAD COVER
DISASSEMBLY
Be sure to identify each removed part as to its location, and lay the parts out in groups designated as
NO.^", "No.2" "Exhaust", "Intake", so that each will
be restored to the original location during assembly.
Remove the PAIR reed valve cover a.
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.
ENGINE 3-37
Apply THREAD LOCK to the bolts and then install the PAIR
reed valve cover. p - * - rr
a 99000-32050: THREAD LOCK "1 342" I
NOTE:
The inlet pipe of the PAlR reed valve cover must face left side of
the engine.
CAMSHAFTKAMSHAFT JOURNAL
-1
tion, and lay the parts out in groups designated as
"No.l", NO.^", "Exhaust", "Intake", so that each will
be restored to the original location during assembly.
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 @
and cords a stamped on the camshaft ends.
1 I Letter Cil I Cord (23 1
1 No.1 (Front) intake camshaft I INF I K I
I No.1 (Front) exhaust camshaft EXF I 6
No.2 (Rear) intake camshaft
No.2 (Rear) exhaust camshaft
INR
EXR
M
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 0, which is to be measured with a
micrometer. Replace camshaft if it wears worn down to the limit.
rn Cam height 0
Service Limit: (Intake): 35.18 mm (1.385 in)
(Exhaust): 33.18 mm (1.306 in)
a 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:
rn Camshaft journal oil clearance
Service Limit (IN & EX): 0.150 mm (0.0059 in)
a 09900-22301 : Plastigauge
09900-22302: Plastigauge
NOTE:
* Install camshaft journal holder to their original positions.
(W 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 .O kgf-m, 7.0 Ib-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 339
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.
rn Journal holder I.D.
Standard (IN & EX): 22.01 2 - 22.025 mm
(0.8666 - 0.8671 in)
a 09900-20602: Dial gauge (1/1000,1 mm)
09900-22403: Small bore gauge (18 - 35 mm)
rn Camshaft journal O.D.
Standard (IN & EX): 21.959 - 21.980 mm
(0.8645 - 0.8654 in)
a 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)
a 09900-20607: Dial gauge (1M00 mm)
09900-20701 : Magnetic stand
09900-21304: V-block set (100 mm)
CAM CHAIN TENSION ADJUSTER
Check that the push rod @ can slide smoothly with the lock @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 e -----vli
VALVE AND VALVE SPRING DISASSEMBLY
a% - -- - *-a
4
Remove the tappets @ and shims @ by fingers or magnetic
hand.
-1 -.
Identify the position of each removed part. - - -3 . f
a- a. .
Using special tools, compress the valve springs and remove
the two cotter halves @ from valve stem.
-0991 6-1 451 0: Valve lifter
0991 6-1 4521 : Valve lifter attachment
0991 6-8451 1 : Tweezers
Remove the valve spring retainer @ and valve springs @. piimiq
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 @ and spring seats E.
picmii-1
Do not reuse the removed oil seals.
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)
a 09900-20607: Dial gauge ( I l l00 mm)
09900-20701 : Magnetic stand
09900-21304: V-block set (100 mm)
342 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.
rn Valve head radial runout
Service Limit: 0.03 mm (0.001 in)
09900-20607: Dial gauge (111 00 mm)
09900-20701 : Magnetic stand
09900-21 304: 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 @. If it is
out of specification, replace the valve with a new one.
rn Valve head thickness @
Service Limit: 0.5 mm (0.02 in)
a 09900-201 02: 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.
rn Valve stem deflection (IN & EX)
Service Limit: 0.35 mm (0.014 in)
@ 09900-20607: Dial gauge (111 00 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)
a 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.
rn 0991 6-4321 0: Valve guide removerlinstaller
NOTE:
* Discard the removed valve guide subassemblies.
* Only oversized valve guides are available as replacement
parts. (Part No. 1 1 115-18072)
Re-finish the valve guide holes in cylinder head with the
reamer and handle.
0991 6-34580: Valve guide reamer
0991 6-34542: Reamer handle
I CAUTION 1
When refinishing or removing the reamer from the
valve guide hole, always turn it clockwise.
Apply engine oil to the valve guide hole, and valve guide.
Drive the valve guide into the hole with the special tools.
rn 0991 6-4321 0: Valve guide installer/remover
0991 6-53330: Attachment
NOTE:
Install the valve guide until the attachment @ contacts with the
cylinder head @.
[CAUTION I
Failure to oil the valve guide hole before driving the
new guide into place may result in a damaged guide or
head.
After installing the valve guides, re-finish their guiding bores
using the reamer.
Clean and oil the guides after reaming.
a 0991 6-3321 0: Valve guide reamer
0991 6-34542: Valve guide reamer handle
NOTE:
Insert the reamer from the combustion chamber and always turn
the reamer handle clockwise.
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.
0991 6-1 091 1 : Valve lapper set
If the seat width @ measured exceeds the standard value, or
seat width is not uniform reface the seat using the seat cutter.
Valve seat width @
Standard: 0.9 - 1.1 mm (0.035 - 0.043 in)
VALVE SEAT SERVICING
The valve seats @ for both the intake valve @ and exhaust
valve @ are machined to four different angles. The seat contact
surface is cut at 45 ".
EXHAUST
N-121
0991 6-21 1 1 1 : Valve seat cutter set
0991 6-22430: Valve seat cutter (N-128)
0991 6-20640: 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 (0991 6-27 11 1).
* Use the solid pilot (N- 100-4.5) along with the valve seat cutter.
The valve seal contact area must be inspected after
each cut.
When installing the solid pilot @, rotate it slightly. Seat the
pilot snugly. Install the 45 " cutter, attachment and T-handle.
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 @ 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
cams haft.
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 @ is too high on the valve, or if it is too
wide, use the 15 " (for the exhaust side 0) and the 30 " (for
the intake side @) to lower and narrow the contact area.
NOTE:
Contact area too hight and too wide on face of valve.
BOlTOM NARROWING CUT
If the contact area @I is too wide or too low, use the 60 " cutter
to narrow and raise the contact area.
3-46 ENGINE
FINAL SEAT CUT
If the contact area @I is too low or too narrow, use the 45 "
cutter to raise and widen the contact area.
NOTE:
* After cutting the 15 O, 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.
CAUTlONI
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
I valve which will occur during the first few seconds of I
engine operation.
Clean and assemble the head and valve components. Fill the
intake and exhaust ports with gasoline to check for leaks.
If any leaks occur, inspect the valve seat and face for burrs or
other things that could prevent the valve from sealing.
Always use extreme caution when handling gasoline.
NOTE:
After servicing the valve seats, be sure to check the tappet
clearance after the cylinder head has been reinstalled. (-2-8)
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 rnrn (1.45 in)
OUTER: 39.8 rnrn (1.57 in)
Valve spring tension
Standard: (IN & EX) INNER : 4.2 - 4.8 kgfl29.9 rnrn
(9.26 - 10.58 lbs11.18 in)
OUTER: 17.0 - 19.6 kgf133.4 rnrn
(37.48 - 43.21 lbs11.31 in)
09900-201 02: Vernier calipers
3-48 ENGINE
VALVE AND VALVE SPRING INSTALLATION
Install the valve spring seats @.
Apply engine oil to each oil seal Q.
Install the oil seal.
/m.mq
Do not reuse the removed oil seals. I
Insert the valves, with their stems coated with MOLYBDENUM OIL SOLUTION all around and along the full stem
length without any break.
When inserting each valve, take care not to damage
the lip of the oil seal.
3 MOLYBDENUM OIL SOLUTION
Install the valve springs with the small-pitch portion @ facing
cylinder head.
@ Large-pitch portion
0 UPWARD
0 Paint
Put on the valve spring retainer 0, 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 @ to wedge in
between retainer and stem. Be sure that the rounded lip @ of
the cotter fits snugly into the groove @ in the stem end.
a 0991 6-1 451 0: Valve lifter
09916-14521 : Valve lifter attachment
0991 6-8451 1 : Tweezers
/ Be sure to restore each spring and valve to their origi- I
nal 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 a.
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.
O Oil jet (#8) (For cam chain tension adjuster)
OIL JET INSTALLATION
Fit the new O-rings to each oil jets.
pimiq
Use the new O-rings to prevent oil leakage.
NOTE:
* Apply grease to the O-rings when installing the oil jets.
* Apply engine oil to the oil jet hole on the cylinder head.
3-50 ENGINE
CYLINDER
CYLINDER DISTORTION T r f l d Check the gasketed surface of the cylinder for distortion with a
straightedge and thickness gauge, taking a clearance reading at
several places as indicated.
led b L 'Y94 If the largest reading at any position of the straightedge exceeds . -1 ...
the limit, replace the cylinder.
-C
rn Cylinder distortion
Service Limit: 0.05 mrn (0.002 in) rn 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.
rn Cylinder bore
Standard: 81.000 - 81 .015 rnm (3.1 890 - 3.1 896 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) @ from the piston skirt end.
If the measurement is less than the limit, replace the piston.
rn 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.
rn 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.
- rn Piston-ring-to-groove clearance
Service Limit (1st) : 0.18 mm (0.0071 in)
(2nd): 0.15 mm (0.0059 in)
3-52 ENGINE
rn Piston ring groove width
Standard (1st) : 1.21 - 1.23 mm (0.0476 - 0.0484 in)
(2nd): 1 .O1 - 1.03 mm (0.0398 - 0.0406 in)
(Oil) : 2.01 - 2.03 mm (0.0791 - 0.0799 in)
rn Piston ring thickness
Standard (1st) : 1.17 - 1 .I9 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 RlNG FREE END GAP AND PISTON RlNG 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.
rn Piston ring free end gap
Service Limit (1st) : 7.6 mm (0.30 in)
(2nd): 8.8 mm (0.35 in)
09900-201 02: Vernier calipers
rn 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 RlNG
The following two types of oversize piston rings are used.
They bear the following identification numbers.
STD
0.5 mm O.S.
NIL
50
NIL
50
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.
SIZE
Measure the outside diameter to identify the size.
@ Oil ring spacer
@ Paint
STD
0.5 mm O.S.
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 (111 000 mm)
09900-22403: Small bore gauge (1 8 - 35 mm)
COLOR
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)
SIDE RAIL
NIL
BLUE
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 (111 000 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.
SPACER
RED
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 .OO mm (0.825 - 0.827 in)
a 09900-20205: Micrometer (0 - 25 mm)
CRANK PIN WIDTH
Check the crank pin width @.
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. ( W 3 - 5 7 )
piEEq
Never rotate the crankshaft or conrod when a piece of
plastigauge is installed.
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 (0.001 3 - 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 ) @.
Check the corresponding crank pin O.D. code numbers ("I",
" 2 or "3))) @.
Bearing selection table
I Crank pin O.D. 0 I Code I
I
1 2 3 --*-. L -7
Conrod
I.D. @
1
2
Green
Black
Black
Brown
Brown
Yellow
3-56 ENGINE
rn Conrod I.D.
41.000 - 41.008 mm 1 (1.6142 - 1.6145 in)
Code I.D. s~ecification
I Code I O.D. specification I
2
37.992 - 38.000 mm 1 (1.4957 - 1.4961 in)
41.008 - 41 .016 mm
(1.61 45 - 1.61 48 in)
37.984 - 37.992 mm 1 (1.4954 - 1.4957 in)
rn Crank pin O.D.
37.976 - 37.984 mm / (1.4951 - 1.4954 in)
09900-20202: Micrometer (25 - 50 mm)
rn Bearing thickness
Color (Part No.)
Green
(1 21 64 - 46E01-OAO)
Black
(1 21 64 - 46E01-OBO)
Brown
(1 21 64 - 46E01-OCO)
I CAUTION I
The bearings must be replaced as a set.
Thickness
1.480 - 1.484 mm
(0.0583 - 0.0584 in)
1.484 - 1.488 mm
(0.0584 - 0.0586 in)
1.488 - 1.492 mm
(0.0586 - 0.0587 in)
Yellow
(1 21 64 - 46E01-ODO)
@ Color code
CONROD AND BEARING REASSEMBLY
When fitting the bearings to the bearing cap and conrod, be
sure to fix the stopper part @ first and press in the other end.
1.492 - 1.496 mm
(0.0587 - 0.0589 in)
I CAUTION I
Be sure to clean the conrod big end.
Apply MOLYBDENUM OIL SOLUTION to the crank pin and
bearing surface.
3 MOLYBDENUM OIL SOLUTION
ENGINE 3-57
When fitting the conrods on the crankshaft, make sure that
I.D. codes @ 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 Ib-ft)
(Final) : After tightening the bolts to the above torque,
tighten them 114 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 @.
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 Ib-ft)
3-58 ENGINE
OIL PRESSURE SWITCH
Remove the oil pressure switch a.
Inspect the oil pressure switch. ( P 8 - 3 4 )
Apply SUZUKl BOND to the thread part of the oil pressure
switch @ and tighten it to the specified torque.
a 991 04-31 140: SUZUKl BOND "1 2078'' (USA)
99000-31 140: SUZUKl BOND "1 2078" (Others)
Oil pressure switch: 13 N m (1.3 kgf-rn, 9.5 Ib-ft)
NOTE:
Be careful not to apply SUZUKI BOND to the hole of the thread
end.
OIL STRAINER
Remove the oil strainer plate a.
Remove the oil strainer a.
Clean the oil strainer with a compressed air.
ENGINE 3-59
Install the oil strainer @.
NOTE:
Fit the projection
of the crankcase.
r X c-4
@ of the oil strainer @ in the concave portion ,- -.
Install the oil strainer plate and tighten the oil starainer
plate screw to the specified torque.
- m
- 7
OIL JET
Removal
Remove the oil jets a, @ from the left and right crankcase
halves.
Remove the oil seal @ and oil gallery plug @.
Remove the oil jet @ 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.
@ Piston cooling oil jet (#13)
@ Oil jet (#14) (For transmission)
@ Oil jet (#14) (For each cylinder head)
Installation
Fit the new O-rings to each oil jets.
pEi5q
Use the new O-rings to prevent oil leakage.
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 @ to the left and right crankcase halves.
Apply a small quantity of THREAD LOCK to the bolts and
tighten them to the specified torque.
a 99000-32050: THREAD LOCK "1 342"
[ZJ Piston cooling oil jet bolt: 10 N.m (1.0 kgf-m, 7.0 Ib-ft)
Push the oil jet into the left crankcase half until it stops.
Tighten the oil gallery plug @ to the specified torque.
[2) Oil gallery plug (M8): 18 N-m (1.8 kgf-m, 13.0 Ib-ft)
GEARSHIFT ARM STOPPER
When installing the gearshift arm stopper bolt @, apply a
small quantity of THREAD LOCK to its thread and tighten it to
the specified torque.
a 99000-32030: THREAD LOCK SUPER "1303"
[ZJ Gearshift arm stopper bolt: 19 N-m (1.9 kgf-m, 13.5 Ib-ft)
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 @ "A", " B or "C", is
stamped on the inside of each crankcase half.
Bearing selection table
Crankcase I.D. @
Bearing color 1 Green I Black I Brown I
Crank shaft journal I.D.
I.D. code @ I.D. s~ecification 1
rR
(1.8110- 1.8113 in)
46.006 - 46.01 2 mm
Y
P
(1.8113- 1.8115 in)
46.01 2 - 46.01 8 mm
3-62 ENGINE
Bearing thickness
I Color (Part No.) I Thickness I
Green 1.996 - 1.999 mm 1 (1 2229 - 27G00-OAO) 1 (0.0786 - 0.0787 in)
Black I 1.999 - 2.002 mm
(1 2229 - 27G00-OBO)
Brown
Bearing must be replaced as a set.
@ Color code
(0.0787 - 0.0788 in)
2.002 - 2.005 mm
(1 2229 - 27G00-OCO)
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.
(0.0788 - 0.0789 in)
m09913-60221: Journal bearing remover/installer
NOTE:
Remove the crankshaft journal bearings in only one direction,
from inside to outside of each crankcase half.
ENGINE 3-63
Gradually press out the bearing with the special tool by using
the hand-press.
The removed bearings must be replaced with new
ones.
@ Hand-press
@ Crankcase
@ 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.
a 09924-84510: Bearing installer set
0991 0-201 16: Conrod holder
0991 3-60221 : Journal bearing remover/installer
Set the specified crankshaft journal bearings to the special
tool.
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 @ and also the bearing end with
the mating surface of the special tool.
NOTE:
The upper and lower bearings are same.
3-64 ENGINE
Tighten the special tool bolts to the specified torque.
Special tool bolt: 23 N-rn (2.3 kgf-m, 16.5 Ib-ft)
pmi6q
Before installing the bearings, lightly shave off the
sharp edge part @ of the crankcase chamfer by using
an oilstone and wash the crankcase bore with enough
engine oil.
Set the bearings installed in the special tool to the crankcase
half as shown.
pmi6q
crankcase bore.
* Align the bearinglspecial tool mating surface with
NOTE:
Install the bearing from inside to outside of each crankcase
halves.
ENGINE 3-65
Apply enough engine oil to the special tool and the bearings -_ .
and then set the special tool carefully.
Gradually press @ in the bearing @ into the main journal bore
by using the hand-press until the special tool @ contacts the
special tool @.
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
0991 0-201 16: Conrod holder
0991 3-60221 : 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 @, 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 s eals with the special tool or a suitable bar
~O9913-SOl21: Oil seal remover
Remove the bearing retainers @.
ENGINE 3-67
Remove the crankcase bearings by with the special tool.
09921 -20240: Bearing remover set
' pr-.n'- NOTE: -- -a .. ; re . 1 - -,
Select the suitable size attachment as following illustration.
/ 4
Bearing remover attachment
@ Q25 mm @ 617 mm @ $20 mm @ Left crankcase @ Right crankcase
3-68 ENGINE
INSTALLATION
Install the crankcase bearings and oil seals with the special
ef -: v???,,
tool. m--a 0991 3-7021 0: Bearing installer set 7 .
NOTE:
Select the suitable size attachment as following illustration.
Bearing installer attachment
I Bearing I Oil seal I @ Left crankcase 0 Right crankcase
Apply SUZUKl SUPER GREASE to the oil seal lip.
99000-25030: SUZUKl SUPER GREASE "A" (USA)
99000-2501 0: SUZUKl SUPER GREASE "A" (Others)
B
,'
. LA:-
p. :- .'*
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.
rn Drive plate thickness
Standard: 2.92 - 3.08 mm (0.1 15 - 0.1 21 in)
@ 09900-201 02: 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.
rn Drive plate claw width
Service Limit: 11.5 mm (0.453 in)
rn 09900-201 02: 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.
rn Driven plate distortion
Service Limit: 0.10 mm (0.004 in)
rn 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.
rn Clutch spring free length
Service Limit: 50.5 mm (1.99 in)
@ 09900-201 02: Vernier calipers
3-70 ENGINE
CLUTCH BEARING INSPECTION
Smooth engagement and disengagement of the clutch depends
on the condition of this bearing.
lnspect the clutch release bearing for any abnormality, particularly cracks, to decide whether it can be reused or should be
replaced.
CLUTCH SLEEVE HUBIPRIMARY DRIVEN GEAR ASSEM-
BLY
lnspect 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 @.
Remove the oil pump drive gear @ and pin.
INSPECTION
lnspect the primary driven gear bushing for any damage.
lnspect the spring of primary driven gear for any damages.
If necessary, replace it with a new one.
REASSEMBLY
Install the pin 0.
Align the oil pump drive gear slot @ with the pin 0.
ENGINE 3-71
Install the snap ring @.
GEARSHIFT SHAFTIGEARSHIFT ARM
DISASSEMBLY
Remove the following parts from the gearshift shawgearshift
arm.
@I Washer @ Washer
@ Snap ring @ Plate return spring
@ Gearshift shaft return spring a Gearshift cam drive plate
@ Snap ring
,
INSPECTION
Check the gearshift shawgearshift arm for wear or bend.
Check the return springs for damage or fatigue.
REASSEMBLY
Install the following parts to the gearshift shawgearshift arm
as shown in the right illustration.
@I Washer @ Washer
@ Snap ring @ Plate return spring
@ Gearshift shaft return spring a Gearshift cam drive plate
@ Snap ring
NOTE:
When installing the gearshift shaft return spring @, position the
stopper @ of the gearshift arm between the shaft return spring
ends @.
3-72 ENGINE
TRANSMISSION
COUNTERSHAFT DISASSEMBLY
)I
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.
Remove the 6th drive gear snap ring @ from its groove and
slide it towards the 3rdl4th drive gears @I.
Remove the concaved washer @ and O-ring @.
Slide the 6th @ and 2nd drive gears @ toward the 3rdl4th
drive gears a, then remove the 2nd drive gear circlip @.
Remove the 2nd drive gear @, 6th drive gear @, bushing and
washer.
Remove the snap ring @ and 3rdI4th drive gears @.
Remove the snap ring a, washer @I and 5th drive gear @.
ENGINE 3-73
Remove the 5th drive gear bushing @.
DRIVESHAFT DISASSEMBLY
Remove the washer @ and 1 st driven gear @.
Remove the 1st driven gear bushing @,
driven gear @.
washer @ and 5th
3-74 ENGINE
Remove the 3rd driven gear bushing @ and washer 0.
-
-
Remove the snap ring @ and 6th driven gear @.
Remove the snap ring @ and 2nd driven gear bushing @.
Remove the 2nd driven gear @.
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: SUZUKl MOLY PASTE
Before installing the O-ring, apply SUZUKl SUPER GREASE
to it.
99000-25030: SUZUKl SUPER GREASE "A" (USA)
99000-25010: SUZUKl SUPER GREASE "A" (Others)
NOTE:
Rotate the bushings by hand to inspect for smooth rotation.
Replace the bushings if there is anything unusual.
* 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.
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 I
the snap ring. Fit it to the side where the thrust is as shown in
the illustration.
@I Thrust
@l Sharp edge
3-76 ENGINE
When installing the 6th drive gear, 3rd driven gear and 4th driven gear bushings onto the shaft, align the
shaft oil hole @ with the bushing oil hole @I.
@ 6th drive gear bushing
@ 3rd driven gear bushing
@ 4th driven gear bushing
After installing the 3rd driven gear @ onto the driveshaft,
install lock washer No.2 @ onto the driveshaft, and position it
so it fits into the groove.
Then, fit lock washer No.1 0 into lock washer No.2 0.
ENGINE 3-77
I @ 13rdI4th drive gear 1 13rd driven gear I
@
@
1st (Low) drive gearlcountershaft
5th drive aear
@
@
@
(8)
6th (Top) drive gear
2nd drive gear
1st (Low) driven gear
5th driven gear
4th driven aear
@
@
6th (Top) driven gear
2nd driven gear
145 N.m (14.5 kgf-m, 105 Ib-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.
rn Shift fork to groove clearance
Service Limit: 0.50 mm (0.020 in)
rn 09900-20803: Thickness gauge
09900-201 02: 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.
rn Shift fork groove width
Standard: 5.5 - 5.6 mm (0.217 - 0.220 in)
rn 09900-20102: Vernier calipers
GEARSHIFT FORK THICKNESS
Measure the gearshift fork thickness using the vernier calipers.
rn Shift fork thickness
Standard: 5.3 - 5.4 mm (0.209 - 0.213 in)
rn 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 @ from the guide @.
REASSEMBLY
When inserting the one-way clutch @ into the guide 0, fit the
flange @ in the step of the guide @.
3-80 ENGINE
Be sure to seat the flange @ of the one way clutch @ to the
guide @.
Install the guide @ to the generator rotor with the arrow mark
faced upward.
Apply THREAD LOCK SUPER to the bolts and tighten them
to the specified torque.
4 99000-32030: THREAD LOCK SUPER "1 303"
Starter clutch bolt: 25 N.m (2.5 kgf-m, 18.0 Ib-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 @ and the CKP
sensor set bolts @ tighten them to the specified torque.
Generator stator set bolt: 11 N-m (1.1 kgf-m, 8.0 Ib-ft)
CKP sensor set bolt: 6.5 N.m (0.65 kgf-m, 4.7 Ib-ft)
NOTE:
Be sure to install the grommet @ 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.
-1
Do not
bl y .
The oil
attempt to disassemble the oil pump assempump is available only as an assembly.
CLUTCH RELEASE
--
INSPECTION
Check the teeth of clutch release for any damage and wear.
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 @ and the driveshaft
assembly 0 to the left crankcase half.
Install the washer @ onto the driveshaft assembly a.
GEARSHIFT
Install the gearshift forks @/@I@, gearshift cam @I and gearshift fork shafts @.
NOTE:
Identify the gearshift forks as follows.
For 5th driven gear
For 6th driven gear
@ For 3rdl4th drive gear
@ For 5th driven gear For 6th driven gear @ For 3rdl4th drive gear
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.
pmmq
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.
- CRANKCASE
Clean the mating surfaces of the left and right crankcase
halves.
Install the O-rings @, @ and dowel pins @.
Apply SUZUKl SUPER GREASE to the O-rings a, 0.
99000-25030: SUZUKI SUPER GREASE "A" (USA)
99000-25010: SUZUKI SUPER GREASE "A" (Others)
Apply SUZUKl BOND to the mating surface of the left crankcase.
a 991 04-31 140: SUZUKI BOND "1 2O7B" (USA)
a 99000-31 110: 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 SUZUKl BOND to the oil
hole, oil groove and bearing.
Apply to distorted surfaces as it forms a comparatively thick
.- film.
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.
rn Crankcase bolt: (M8) 26 N-rn (2.6 kgf-rn, 19.0 Ib-ft)
(M6) 11 N-rn (1.1 kgf-rn, 8.0 Ib-ft)
/ CAUTION I
Do not drop the O-ring into the crankcase when
assembling the right and left crankcase halves.
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 0 as shown.
OIL PLATE
Install the oil plate @I and the oil plate bolts tighten to the
specified torque.
rn Oil plate bolt: 10 N-rn (1.0 kgf-rn, 7.0 Ib-ft)
ENGINE SPROCKET SPACER
lnstall the new O-ring into the engine sprocket spacer @.
pii%%
I Use the new O-ring to prevent oil leakage. 1
Install the engine sprocket spacer @
NOTE:
* The grooved @ side of the engine sprocket spacer @I must
face crankcase side.
* Apply SUZUKl SUPER GREASE to the oil seal lip and O-ring.
99000-25030: SUZUKl SUPER GREASE "A" (USA)
99000-25010: SUZUKl SUPER GREASE "A" (Others)
ENGINE 3-85
GEAR POSITION SWITCH
lnstall the gear position switch contacts and springs.
-
Apply SUZUKl SUPER GREASE to the O-ring Q and then
install it onto the gear position switch.
99000-25030: SUZUKl SUPER GREASE "A" (USA)
99000-25010: SUZUKl SUPER GREASE "A" (Others)
lnstall the gear position switch @ as shown.
Tighten the gear position switch bolt to the specified torque.
rn Gear position switch bolt: 6.5 N*m (0.65 kgf-m, 4.7 Ib-ft)
lnstall the drive shaft oil seal retainer @.
NOTE:
Pass through the gear position switch lead wire under the drive- shaft oil seal retainer.
FRONT CAM CHAIN
lnstall the front cam chain 6).
lnstall the cam chain tensioner a, washer @ and cam chain
tensioner bolt @.
Tighten the cam chain tensioner bolt @I to the specified
torque.
rn Cam chain tensioner bolt: 10 N-m (1.0 kgf-m, 7.0 Ib-f)
NOTE:
The front and rear cam chain tensioners are the same.
3-86 ENGINE
GENERATOR ROTOR
Install the starter driven gear a.
Apply engine oil to the bushing of the starter driven gear.
Degrease the tapered portions @ of the generator rotor
assembly and the crankshaft. Use nonflammable cleaning e4
solvent to wipe off oily or greasy matter and make these surfaces completely dry.
Fit the key in the key slot on the crankshaft completely.
Install the generator rotor assembly onto the crankshaft.
I
- .-
a While holding the generator rotor with the special tool, tighten
its bolt to the specified torque.
a 09930-44530: Rotor holder
Generator rotor bolt: 120 N-m (12.0 kgf-m, 87 Ib-ft)
CAM CHAIN DRIVE SPROCKET
Install the cam chain drive sprocket 0 onto the crankshaft.
NOTE:
* Align the punched mark @ on the cam chain drive sprocket
with the punched mark @9 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 @.
lnstall the cam chain tensioner 0, washer @ and cam chain
tensioner bolt @.
-- Tighten the cam chain tensioner bolt @ to the specified
torque.
rn Cam chain tensioner bolt: 10 N-m (1.0 kgf-m, 7.0 Ib-ft)
NOTE:
The front and rear cam chain tensioners are the same.
PRIMARY DRIVE GEAR
Install the primary drive gear @ and water pump drive gear
0.
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 Ib-ft)
NOTE:
This bolt has left-hand thread.
3-88 ENGINE
OIL PIPE
Install the oil pipe @.
Tighten the oil pipe stopper screw @ to the specified torque.
[L1 Oil pipe stopper screw: 8 N-m (0.8 kgf-m, 6.0 Ib-ft)
NOTE:
Align the projection @ of the oil pipe with the groove @ of its
stopper.
GEARSHIFT SYSTEM
Install the gearshift cam stopper 0, its bolt @, washer @ and
return spring @.
[11 Gearshift cam stopper bolt: 10 N-m (1.0 kgf-m, 7.0 Ib-ft)
Confirm the gearshift cam stopper movement.
Check the neutral position.
NOTE:
Hook the return spring end @ to the stopper.
Install the gearshift cam stopper plate @ with the gearshift
cam pins @ inserted into the gearshift cam stopper plate
holes @I.
ENGINE 3-89
Apply a small quantity of THREAD LOCK to the gearshift cam
stopper plate bolt and tighten it to the specified torque.
a 99000-32050: THREAD LOCK "1342"
Gearshift cam stopper plate bolt: 13 N-m
(1.3 kgf-m, 9.5 Ib-ft)
Install the gearshift shawgearshift arm with the washer @
as shown.
-
Locate the gearshift arm stopper @ between return spring
ends 0.
Install the washer @I and snap ring @I.
OIL PUMP
Install the oil pump with the three screws.
3-90 ENGINE
lnstall the washer @ and pin 0.
lnstall the oil pump driven gear @.
lnstall the snap ring (a.
CLUTCH
lnstall the spacer @ and apply ENGINE OIL to it.
lnstall the primary driven gear assembly @ onto the countershaft.
NOTE:
Be sure to engage the oil pump drive and driven gears, primaly
drive and driven gears.
lnstall the thrust washer @.
lnstall the clutch sleeve hub @ and lock washer @.
Replace the lock washer @ with a new one.
lnstall the clutch sleeve hub nut @.
NOTE:
The chamfer side @ of the clutch sleeve hub nut faces outward.
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 Ib-ft)
Bend the lock washer to lock the nut securely.
Install the spring washer seat and spring washer @ onto
the clutch sleeve hub correctly.
Insert the clutch drive plates @, @ and driven plates @ one
by one into the clutch sleeve hub in the prescribed order, No.2
drive plate @ being inserted first.
NOTE:
Apply the ENGINE OIL to the clutch driven and drive plates
before installing them.
@ No.2 Drive plate @I No.1 Drive plate @ Direction of inside.
3-92 ENGINE
Install the clutch push rod @ into the countershaft.
Install the clutch push piece @, the bearing @ and thrust
washer @ to the countershaft.
NOTE:
Thrust washer @ is located between the pressure plate and
bearing @.
Hold the generator rotor (crankshaft) with the special tool.
a 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-rn, 7.0 Ib-ft)
NOTE:
Tighten the clutch spring set bolts diagonally.
CLUTCH COVER
Install the gasket and dowel pins a.
I Use the new gasket to prevent oil leakage. I
ENGINE 3-93
lnstall the clutch cover
GENERATOR COVER
Apply MOLYBDENUM OIL SOLUTION to both ends of the
- shaft a.
MOLYBDENUM OIL SOLUTION
lnstall the starter idle gear and shaft a.
lnstall the dowel pins @ and gasket @.
-1
Use the new gasket to prevent oil leakage.
lnstall the generator cover.
Generator cover bolt: 10 Nem (1.0 kgf-m, 7.0 Ib-ft)
NOTE:
Fit the gasket washers to the generator cover bolts @ correctly
as shown.
I CAUTION I
I Use the new gasket washers to prevent oil leakage. I
OIL FILTER
lnstall the oil filter with the special tool. (-2-1 3)
0991 5-4061 0: Oil filter wrench
3-94 ENGINE
STARTER MOTOR
Install the new O-ring to the starter motor.
Use the new O-ring to prevent oil leakage.
Apply SUZUKl SUPER GREASE to the O-ring.
99000-25030: SUZUKl SUPER GREASE "A" (USA)
99000-25010: SUZUKl SUPER GREASE "A" (Others)
Install the starter motor a.
Tighten the starter motor mounting bolts with the clamp
securely.
NOTE:
First tighten the starter motor mounting bolt @.
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 a.
After placing the spacer, fit the two side rails a.
NOTE:
Side designations, top and bottom, are not applied to the spacer
and side rails: you can position each either way.
( CAUTION I
When installing the spacer, be careful not to allow its
two ends to overlap in the groove.
@ INCORRECT
@ CORRECT
Install the 2nd ring (3 and 1 st ring @.
NOTE:
1 st ring and 2nd ring differ in shape.
ENGINE 3-95
1st ring @ and 2nd ring @ 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.
@ 2nd ring and Lower side rail
Upper side rail
0 1 st 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 0 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 a, front and rear.
Install the piston pin circlips @.
pmzq
Use new piston pin circlips to prevent circlip failure
which will occur with a bend one.
NOTE:
End gap of the circlip should not be aligned with the cutaway in
the piston pin bore.
/-mEmq
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 SUZUKl SUPER GREASE to the new O-rings.
99000-25030: SUZUKl SUPER GREASE "A" (USA)
99000-25010: SUZUKl 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.
CAUTlONI
Use the new O-rings to prevent oil leakage.
CYLINDER
Coat SUZUKl BOND lightly to the mating surfaces at the parting line between the right and left crankcases as shown.
a 99104-31 140: SUZUKI BOND "1207B" (USA)
a 99000-31 11 0: SUZUKI BOND "1 21 5" (Others)
Apply engine oil to the sliding surface of the pistons.
Fit the dowel pins @, and new gaskets @, @ to the crankcase.
pimiq
1 Use the new gaskets to prevent oil leakage. I
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 @.
"FRON 7: 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 @.
" F : Front cylinder head
"R": Rear cylinder head
Pull the cam chain out of the cylinder and install the cam
chain guide @.
I There is the guide holder for the bottom end of the (
cam chain guide @ cast in the crankcase. Be sure that
the cam chain guide @ is inserted properly.
NOTE:
The front and rear cam chain guides are the same.
3-98 ENGINE
Fit the dowel pins @ and new cylinder head gasket @ to the
cylinder.
I CAUTION I
I Use the new gasket to prevent gas leakage. 1
Install the washers @ to the cylinder head bolts (M10) @ 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 Ib-ft)
Final 42 N-m (4.2 kgf-m, 30.5 Ib-ft)
After firmly tightening the cylinder head bolts (MlO), install the
cylinder head bolts (M6) @, 0.
Tighten the cylinder head bolts @, 0, and cylinder nuts @.
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 @
EXF : No.1 (Front) exhaust camshaft
INR : No.2 (Rear) intake camshaft @
EXR: No.2 (Rear) exhaust camshaft @
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 " 1 F" line @ on the generator rotor with the index
mark @I of the valve timing inspection hole while keeping the
cam chains pulled upward.
I CAUTION I
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 " I F" line @I with the index mark @ and hold
this position when installing the camshafts.
Pull the cam chain lightly.
The No.1 exhaust camshaft sprocket has an arrow mark "1 F'
0. Install the exhaust camshaft so that the arrow 0 is aligned
with the mating surface of the cylinder head. (W3-100)
Engage the cam chain with the exhaust camshaft sprocket.
NOTE:
Before installing the camshaft, check that the tappets are
installed correctly.
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 0 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
---
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 @ of the camshafts with the groove 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
0.
ENGINE 3-101
Tighten the camshaft journal holder bolts to the specified
torque.
rn Camshaft journal holder bolt: 10 N-m (1.0 kgf-m, 7.0 Ib-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.
- 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 @I and push the push rod @ all the way in.
Install the gasket and oil jet.
Install the cam chain tension adjuster @I with "UP mark faced
to the top of cylinder head.
Tighten the cam chain tension adjuster mounting bolts to the
specified torque.
p i E q
I Use the new gasket to prevent oil leakage. I
Cam chain tension adjuster mounting bolt:
10 N.m (1.0 kgf-m 7.0 Ib-ft)
Install the spring @, gasket @ and spring holder bolt @.
-1
Use the new gasket to prevent oil leakage.
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 Ib-ft)
ICAUTlONI
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 a.
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 " 1 F line @ on the generator rotor
with the index mark @ of the valve timing inspection hole.
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 " IF" line @ with the index mark @$ and hold this
position when installing the camshafts.
Pull the cam chain lightly.
The No.2 intake camshaft sprocket has an arrow mark "1 R"
0. Install the intake camshaft so that the arrow 0 is aligned
with the mating surface of the cylinder head. ( W 3 - 1 0 3 )
Engage the cam chain with the intake camshaft sprocket.
NOTE:
Before installing the camshaft, check that the tappets are
installed correctly.
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 0 on the cam
chain with the arrow mark "3" on the exhaust sprocket.
(W3-103)
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 @I. 3-104 ENGINE
Apply engine oil to the camshaft journal holders. P
Install the camshaft journal holders, intake and exhaust. ? @ 0
Fasten the camshaft journal holders evenly by tightening the
camshaft journal holder bolts sequentially and diagonally.
NOTE: i
* Align the flange @ of the camshafts with the groove 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
0.
Tighten the camshaft journal holder bolts to the specified
torque.
Camshaft journal holder bolt: 10 N-m
(1 .O kgf-m, 7.0 Ib-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.
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 a.
After installing the rear camshafts, rotate the generator rotor
(same turns), and recheck the positions of the camshafts.
ENGINE 3-105
No.1 (Front) cylinde TDC of compression stroke
@ Cam chain guide @ Cam chain guide Forward
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. ( W 2 - 8 )
lnstall the dowel pins @ and O-rings @.
Install the new gaskets to each cylinder head cover.
Apply SUZUKI BOND to the cam end caps of the gaskets.
a 991 04-31 140: SUZUKI BOND "1 2078" (USA)
a 99000-31 110: SUZUKI BOND "1 215" (Others)
pmim
Use the new gaskets to prevent oil leakage.
The cylinder head covers can be distinguished by the
embossed letters @.
"F": Front cylinder head cover
"R": Rear cylinder head cover
Install the cylinder head covers on each cylinder head.
Fit the gaskets @, @ to each head cover bolt.
piEim
Use the new gaskets to prevent oil leakage. I
NOTE:
The metal side of the gasket @ 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 Ib-ft)
ENGINE 3-107
EXHAUST PlPE
Tighten the exhaust pipe bolts @ to the specified torque.
Exhaust pipe bolt: 23 N m (2.3 kgf-m, 16.5 Ib-ft)
pmEq
Use the new gasket to prevent exhaust gas leakage.
WATER UNION
Install the O-ring to the water union.
I Replace the O-ring with a new one. I
When installing the water union, apply engine coolant to the
O-ring.
ENGINE COOLANT
INTAKE PlPE
Apply SUZUKl SUPER GREASE to the O-ring.
99000-25030: SUZUKl SUPER GREASE "A" (USA)
99000-25010: SUZUKI SUPER GREASE "A" (Others)
pE6i-1
Use the new O-ring to prevent air from sucking
through the joint.
Make sure that the "UP mark @ faces upward.
Install the intake pipes.
NOTE:
The intake pipe can be identified by the mark @.
F: Front cylinder head intake pipe
R: Rear cylinder head intake pipe
3-108 ENGINE
GENERATOR COVER PLUG
Apply engine oil to the O-ring of the generator cover plug.
Tighten the valve timing inspection plug @ and generator
cover plug @ to the specified torque.
Valve timing inspection plug: 23 N.m
(2.3 kgf-my 16.3 Ib-ft)
Generator cover plug: 11 N-m (1.1 kgf-my 8.0 Ib-ft)
1 Use the new O-ring to prevent oil leakage. I
THERMOSTAT CASE AND WATER HOSE
Install the thermostat case along with the water hoses @
and tighten the clamp screws securely. (-9-24)
SPARK PLUG AND HOSES
Connect the PAIR hoses @.
Connect the crankcase breather hoses @.
Install the spark plugs. (-2-8)
CONTENTS
PRECAUTIONS IN SERVICING .................................................................... 2
ELECTRICAL PARTS ......................................................................... 2
FUSE ....................................................................................................... 4 - 3
ECMNARIOUS 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 ANAL YSlS ................................................. 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" H02 SENSOR (H02S) CIRCUIT MALFUNCTION (E.02. 19) ..... 4-47
FI SYSTEM DIAGNOSIS 4-1
...................................................................................................... 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
.................................................................... /AT 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
H02 SENSOR INSPECTION (E.02. 19) ................................................. 4-50
H02 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
CONNECTOFUCOUPLER
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.
lnspect each terminal on the connector/coupler for looseness
or bending.
lnspect each terminal for corrosion and contamination.
The terminals must be clean and free of any foreign material
which could impede proper terminal contact.
lnspect 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.
O Coupler
@ Probe
Fl 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.
- O Coupler
@ 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.
ECMNARIOUS 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.
4-4 FI SYSTEM DIAGNOSIS
When disconnecting and connecting the ECM, make sure to
turn OFF the ignition switch @, 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
Fl 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.
@ Sensor
@ ECM
@ 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.
@ Check contact tension by
inserting and removing.
@ 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.
@ Looseness of crimping
Q Open
@ Thin wire (a few strands left)
4-6 FI SYSTEM DIAGNOSIS
Continuity check
Measure resistance across coupler @ (between @ and 0 in
the figure).
If no continuity is indicated (infinity or over limit), the circuit is
open between terminals @ and 0.
@ ECM
Disconnect the coupler @ and measure resistance between
couplers @ and @.
If no continuity is indicated, the circuit is open between couplers @ and 0. If continuity is indicated, there is an open circuit between couplers @' and 0 or an abnormality in coupler
@' or coupler 0.
@ 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 @ and 0.
Voltage Between:
0 and body ground: Approx. 5 V
(@ and body ground: Approx. 5 V
@ 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 @ and @.
Voltage Between:
0 and body ground: Approx. 5 V
@ and body ground: Approx. 5 V 2 V voltage drop
0 and body ground: 3 V
Fl 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 (@
terminal in figure) and body ground. If continuity is indicated,
there is a short circuit to ground between terminals @ and 0.
@ To other parts.
@ Other parts
Disconnect the connector/coupler included in circuit (coupler
@) and measure resistance between terminal @ and body
ground.
If continuity is indicated, the circuit is shorted to the ground
between terminals @ and @.
@ To other parts.
@ ECM
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 @I, - will be shown as 10.00 M i 2 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.
e09900-25009: Needle Dointed Drobe set
Fl 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.
I
Intake Air Pressure Intake air pressure
Sensor (IAP Sensor) signal
I Basic
Crankshaft Position Engine speed
Sensor (CKP Sensor) signal injection
time
Throttle Position Throttle opening
Sensor (TP Sensor) signal
Various
Sensors
Various signals
I =-I Compensation h I
Ultimate
Injection signal
Injectors
injection
I time
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).
SIGNAL
ENGINE COOLANT TEMPERATURE SEN-
SOR SIGNAL
INTAKE AIR TEMPERATURE SENSOR
SIGNAL
BATTERY VOLTAGE SIGNAL
DECELERATION SIGNAL
INJECTION STOP CONTROL
DESCRIPTION I
When engine coolant temperature is low, injection time (volume) is increased.
When intake air temperature is low, injection time (volume)
is increased.
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.
At high speed, the injection time (volume) is increased.
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 1 DESCRIPTION I
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 supI I rev. limit rpm. I
OVER-REV. LIMITER SIGNAL
plied to the fuel pump, fuel injector and ignition coil.
The fuel injectors stop operation when engine rpm reaches
Fl SYSTEM DIAGNOSIS 4-1 1
FI SYSTEM PARTS LOCATION
@ Speedometer
@I CKP sensor
0 TP sensor
0 Gear position sensor
O STP sensor
@ Fuel injector, No.1
Fuel injector, No.2
@ Ignition coil, No.1
@ STVA
@ TO sensor
4-12 FI SYSTEM DIAGNOSIS
@ IAP sensor
Q IAT sensor
G$ ECT sensor
0 Fuel pump relay
0 Ignition coil, No.2
@ PAIR control valve
ECM
@ FP
@ DON
0 AT
Q +B
@ CLT
O IGi
@ IG2
@ THW
(D SOL
cD, FI R 1
(6> FI 112
@ MO+
QD MO-
THA
am vcc
0 TPS
QD €2
@ STPS
0 H02 (OXH)
'24 H02(OX)
@I TACO
EJTECH
B M I ; I
WR &
U
MODE SELECTION SWITCH
G/B I
ILI
4-1 4 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
MALFUNCTION
I I
- -
Engine can not I "FI" letters I FI light turns ON
LCD (DISPLAY)
INDICATION
"NO" 1 Clock
"YES"
Enaine can start
start 1 *2 1 and blinks.
FI LIGHT
INDICATION
-
INDICATION MODE I
Clock and "FI" letters
*1
Each 2 sec. Clock or "FI" FI light turns ON.
"FI" is indicated
continuously.
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-standfignition 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.
Fl 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
EGiEq
* 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.
I "YES
INDICATION I INDICATION I INUILH
LCD (DISPLAY)
TlON MODE
FI LIGHT
I
. . - - . - . . . . - . - I
.. a - a - .
COO
C**code is indicated from
-
small numeral to large one. I
"FI" letter turns OFF.
indicated.
For each 2 sec., code is
4-16 FI SYSTEM DIAGNOSIS
-
CODE
COO
C12
C13
C14
C15
C21
C23
C24
C25
C28
C29
C31
C32
C33
C41
C42
C44
C49
MALFUNCTION PART
None
Crankshaft position sensor (CKPS)
lntake air pressure sensor (IAPS)
Throttle position sensor (TPS)
Engine coolant temperature sensor (ECTS)
Intake air temperature sensor (IATS)
Tip over sensor (TOS)
lgnition signal #I (IG coil # I )
lgnition 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 (H02S)
PAIR control solenoid valve
REMARKS
No defective part
Pick-up coil signal, signal generator
For #I cylinder
For #2 cylinder
For # I cylinder
For #2 cylinder
Fuel pump, Fuel pump relay
Anti-theft
For E-02, 19
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 f 100 rpm. (-2-1 5)
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 Ib-ft)
@ Incorrect
@ Correct position
09930-1 1950: Torx wrench
09930-82720: Mode select switch
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.
ITEM
lntake air pressure sensor
Throttle position sensor
I lgnition timing is also fixed. I
FAIL-SAFE MODE
full open position, and STV is fixed
at 112 open position.
lntake air pressure and atmospheric
pressure are fixed to 760 mmHg.
The throttle opening signal is fixed to
"NO" I
STARTI NG
ABILITY
I
Engine coolant temperature
sensor
Intake air temperature
sensor
Ignition signal
#1
Injection signal
RUNNING
ABILITY -
"YES"
#2
-
"YES"
Engine coolant temperature value is
fixed to 80 "C (176 OF).
Intake air temperature value is fixed
to 40 "C (104 OF).
#1 Fuel cut
#2 Fuel cut
"YES"
"YES"
"YES"
"YES"
"YES"
#2
( "YES" 1 YES" I
"YES"
"YES"
"YES"
"YES"
#2 cvlinder can run.
I Secondary throttle valve actuator
#2 cylinder can run.
"YES"
#2 Fuel-cut
ECM stops controlling STV.
I "YES" I "YES" I
# I cylinder can run.
I Secondary throttle position sensor
"YES"
ECM stops controlling STV.
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.
"YES
Gear position signal
Heated oxygen sensor
(E-02, 19)
PAIR control solenoid valve
I
# I cvlinder can run.
Gear position signal is fixed to 4th
gear.
Fuel-air compensation ratio is fixed
to normal condition.
ECM stops controlling PAIR control
solenoid valve.
"YES"
"YES"
"YES"
"Y ES"
"YES"
"YES"
4-1 8 Fl 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
4
I user name: I Model: I VIN: I
I Date of issue: I Date Reg. I Date of problem: 1 Mileage: I
Malfunction indicator
lam^ condition (LED)
I Always ON El Sometimes ON Always OFF Good condition I
PROBLEM SYMPTOMS
Malfunction displaytcode
(LCD)
Difficult Starting Poor Driveability
1
User mode: No display Malfunction display ( 1
Dealer mode: No code El Malfunction code (
0 No cranking
No initial combustion
Hesitation on acceleration
0 Back fire10 After fire
0 No combustion 0 Lack of power
0 Poor starting at 0 Surging
( 0 cold warm 0 always) 0 Abnormal knocking
ig Other Engine rpm jumps briefly
0 Other
Poor Idling Engine Stall when
Poor fast Idle Immediately after start
Abnormal idling speed 0 Throttle valve is opened
( 0 High Low) ( rlmin) Throttle valve is closed
0 Unstable 0 Load is applied
0 Hunting ( rtmin. to rtmin) 0 Other
0 Other
OTHERS:
F1 SYSTEM DIAGNOSIS 4-19
I MOTORCYCLEIENVIRONMENTAL CONDITION WHEN PROBLEM OCCURS 1
Motorcycle con- +
Environmental condition
dition
Weather
Temperature
Frequency
Road
1
NOTE:
0 Fair 0 Cloudy 0 Rain 0 Snow 0 Always Other
0 Hot Warm Cool Cold ( OF1 OC) Always
0 Always 0 Sometimes ( times/ day, month) Only once
0 Under certain condition
Urban Suburb 0 Highway 0 Mountainous (U Uphill Downhill)
0 Tarmacadam 0 Gravel Other
Motorcycle condition
Cold Warming up phase 0 Warmed up Always Other at starting
Immediately after start Racing without load Engine speed ( rimin)
During driving: q Constant speed Accelerating q Decelerating
0 Right hand corner Left hand corner 0 At stop
Motorcycle speed when problem occurs ( km/h, Milelh) I
0 Other
* The above form is a standard sample. It should be modified according to conditions characteristic of each
market.
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 (W4-14 ,
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"
( W 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: 0 -
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 COO is indicates, the malfunction codes are cleared.
Disconnect the special tool from the dealer mode coupler.
FI SYSTEM DIAGNOSIS 4-21
MALFUNCTION CODE AND DEFECTIVE CONDITION
MALFUNCTION
CODE
COO
DETECTED ITEM
DETECTED FAILURE CONDITION
CHECK FOR
I
NO FAULT
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 wirelcoupler connection)
lntake air pressure I The sensor should produce following voltage.
sor
sensor
Throttle position sen0.1 V 2 sensor voltage < 4.8 V
Without the above ranae for 4 sec. and more. C14 is indicated.
0.1 V 5 sensor voltage 5 4.8 V
Without the above range for 4 sec. and more, C13 is indicated.
lntake air pressure sensor, lead wire/coupler connection.
The sensor should produce following voltage.
Engine coolant terns Throttle position sensor, lead wire/coupler connection.
The sensor voltage should be the following.
perature sensor
sensor 10.1 V S sensor voltage < 4.6 V
0.1 V $ sensor voltage < 4.6 V
Without the above ranae for 4 sec. and more, C15 is indicated.
lntake air temperature
I Without the above ranae for 4 sec. and more. C21 is indicated.
Engine coolant temperature sensor, lead wire/coupler connection.
The sensor voltage should be the following.
I after ignition switch turns ON.
Tip over sensor
lgnition signal #11#2
lntake air temperature sensor, lead wirelcoupler connection.
The sensor voltage should be the following for 2 sec. and more
0.2 V 2 sensor voltage 2 4.6 V
Without the above value for 2 sec. and more, C23 is indicated.
Tip over sensor, lead wire/coupler connection.
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 Fl SYSTEM DIAGNOSIS
MALFUNCTION
CODE
DETECTED ITEM
Secondary throttle
valve actuator
Secondary throttle
position sensor
Gear position signal
Fuel injector #11#2
Fuel pump relay
Ignition switch
Heated oxygen sensor
(H02S)
[E-02, 191
PAlR control solenoid
valve
DETECTED FAILURE CONDITION
CHECK FOR
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 wirelcoupler.
The sensor should produce following voltage.
0.1 V 5 sensor voltage $ 4.8 V
Without the above ranae for 4 sec. and more. C29 is indicated. w
Secondary throttle position sensor, lead wire/coupler connection.
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.
When fuel injector voltage gets 1.3 V and less, C32 or C33 is
indicated.
-
Injector, wiringlcoupler connection, power supply to the injector.
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 #11#2, when the contact of fuel
pump is OFF.
Fuel pump relay, connecting lead wire, power source to fuel
Dumw relay. fuel iniectors.
lgnition switch signal is not input in ECM.
lgnition switch, lead wirelcoupler.
The sensor voltage should be the following and less after warming up condition.
(Sensor voltage 5 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.
H02S lead wirelcoupler connection.
Batterv voltaae SUDDIY to the H02S.
PAlR control solenoid valve voltage is not input in ECM.
PAlR control solenoid valve, lead wirelcoupler.
FI SYSTEM DIAGNOSIS 4-23
"C12" CKP SENSOR CIRCUIT MALFUNCTION
The signal does not reach ECM for 3 sec. and more,
after receiving the IAP signal.
POSSIBLE CAUSE
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.
INSPECTION
Step1
1) Turn the ignition switch OFF.
- 2) Check the CKP sensor coupler @ 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 R
(White - Green)
4) If OK, then check the continuity between each terminal and
ground.
CKP sensor continuity: R (Infinity)
(White - Ground)
(Green - Ground)
09900-25008: Multi circuit tester set
i) Tester knob indication: Resistance (R)
Are the resistance and continuity OK?
I YES I GO to step 2. I
I 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. (@ - @)
09900-25008: Multi circuit tester set
g ! Tester knob indication: voltage (--)
Is the voltage OK?
YES
NO
BIW or White wire open or shorted to ground, or
poor @I or OD connection.
If wire and connection are OK, intermittent trouble or faulty ECM.
Recheck each terminal and wire harness for
open circuit and poor connection.
Loose or poor contacts on the CKP sensor coupler or ECM coupler.
Re~lace the CKP sensor with a new one.
Fl SYSTEM DIAGNOSIS 4-25
"C13" IAP SENSOR CIRCUIT MALFUNCTION
DETECTED CONDITION
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.
POSSIBLE CAUSE
IAP sensor voltage is out of the specified range.
0.1 V 5 Sensor voltage 5 4.8 V
NOTE:
Note that atmospheric pressure varies depending on
weather conditions as well as altitude.
Take that into consideration when inspecting voltaae.
4) Disconnect the IAP sensor coupler.
5) Turn the ignition switch ON.
6) Measure the voltage at the Red wire @I and ground.
If OK, then measure the voltage at the Red wire @ and BIBr
wire 0.
IAP sensor input voltage: 4.5 - 5.5 V
(@ Red - @ Ground)
(@ Red - @ B/Br)
09900-25008: Multi circuit tester set
9) Tester knob indication: Voltage (I)
Is the voltage OK?
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.
-.
NO
Loose or poor contacts on the ECM coupler.
Open or short circuit in the Red wire or BIBr
wire.
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
(@ GIB - @ BIBr)
09900-25008: Multi circuit tester set
09900-25009: Needle pointed probe set
j) Tester knob indication: Voltage (=)
throttle body vacuum for crack or damage. 1 No I Open or short circuit in the G/B wire.
YES -
I I Replace the IAP sensor with a new one.
Go to Step 3
Check the vacuum hose and the passage of
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 @ (check that total
voltage is 4.5 - 5.0 V) and connect @ terminal to the ground
terminal and @ terminal to the Vcc terminal.
Check the voltage between Vout @ and ground. Also, check
if voltage reduces when vacuum is applied up to 400 mmHg
by using vacuum pump gauge. (-4-27)
0991 7-4701 1 : Vacuum pump gauge
09900-25008: Multi circuit tester set
iB Tester knob indication: Voltage (=)
Is the voltage OK?
YES
Red, G/B or B/Br wire open or shorted to
ground, or poor 0, @ or @ connection.
If wire and connection are OK, intermittent trouble or faulty ECM.
Recheck each terminal and wire harness for
open circuit and poor connection.
If check result is not satisfactory, replace IAP sensor with a new one.
Fl SYSTEM DIAGNOSIS 4-27
Output voltage (Vcc voltage 4.5 V, ambient temp. 25 OC,
77 OF)
ALTITUDE ATMOSPHERIC I (Reference) I PRESSURE I ,","z:E I
0
I
2 000
2 001
I
5 000
0
I
61 0
5 001
I
8 000
61 1
I
1 524
8 001
1
10 000
760
I
707
1 525
I
2 438
707
I
634
2 439
I
3 048
loo
I
94
634
1
567
Approx.
3.3 - 3.6
94
I
85
567
I
526
Approx.
3.0 - 3.3
85
1
76
Approx.
2.7 - 3.0
76
I
70
Approx.
2.5 - 2.7
4-28 FI SYSTEM DIAGNOSIS
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.
"C14" TP SENSOR CIRCUIT MALFUNCTION
If OK, then measure the TP sensor input voltage.
Disconnect the TP sensor coupler.
DETECTED CONDITION
Output voltage is out of the specified range.
0.1 V 5 Sensor voltage c 4.8 V
Turn the ignition switch ON.
Measure the voltage at the Red wire and ground.
If OK, then measure the voltage at the Red wire and B/Br
wire.
POSSIBLE CAUSE
TP sensor maladjusted.
TP sensor circuit open or short.
TP sensor malfunction.
ECM malfunction.
TP sensor input voltage: 4.5 - 5.5 V
(@ Red - @ Ground)
(@ Red - @ BIBr)
09900-25008: Multi circuit tester set
i) Tester knob indication: Voltage (=)
Is the voltage OK?
Loose or poor contacts on the ECM coupler.
Open or short circuit in the Red wire or B/Br
wire.
FI SYSTEM DIAGNOSIS 4-29
Step 2
1) Remove the air cleaner box. (-5-1 5)
2) Turn the ignition switch OFF.
3) Disconnect the TP sensor coupler.
4) Check the continuity between @ and ground.
TP sensor continuity: - SZ (Infinity)
(@ - Ground)
5) If OK, then measure the TP sensor resistance (between @
and @).
-
6) Turn the throttle grip and measure the resistance.
TP sensor resistance
Throttle valve is closed : Approx. 1.12 kSZ
Throttle valve is opened: Approx. 4.26 kSZ
09900-25008: Multi circuit tester set
kB Tester knob indication: Resistance (SZ)
Are the resistance and continuity OK?
NO
Reset the TP sensor position correctly.
Replace the TP sensor with a new one.
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 @ PNV 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?
YES
''a
ECM coupler
Red, PNV or B/Br wire open or shorted to
ground, or poor @, @ or @I 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.
Fl SYSTEM DIAGNOSIS 4-31
"C15" ECT SENSOR CIRCUIT MALFUNCTION
DETECTED CONDITION POSSIBLE CAUSE I
1 Output voltage is out of the specified range. I ECT sensor circuit open or short. I
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.
0.1 V S Sensor voltage c 4.6 V
4) Measure the voltage between BIB1 wire terminal @ and
ground.
5) If OK, then measure the voltage between BIB1 wire terminal
@ and B/Br wire terminal a.
ETC sensor voltage: 4.5 - 5.5 V
(@ BIB1 - @ Ground)
(@ BIB1 - @ BIB r)
09900-25008: Multi circuit tester set
?m Tester knob indication: Voltage (-)
ECT sensor malfunction.
ECM malfunction.
Is the voltage OK?
YES
NO
Go to Step 2
Loose or poor contacts on the ECM coupler.
Open or short circuit in the BIB1 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 k B at 20 "C (68 O F ) (Terminal - Terminal)
09900-25008: Multi circuit tester set
cB Tester knob indication: Resistance (8)
NO I Replace the ECT sensor with a new one.
Is the resistance OK?
I Engine Coolant Temp 1 Resistance I
YES
I 20 "C (68 OF) I Approx. 2.45 k B I
BIBr or BIB1 wire open or shorted to ground, or
poor @ or @ connection.
If wire and connection are OK, intermittent trouble or faulty ECM.
Recheck each terminal and wire harness for
open circuit and poor connection.
ECM coupler
60 OC (140 OF)
80 "C (1 76 OF)
Approx. 0.587 k B
Approx. 0.322 kQ
Fl SYSTEM DIAGNOSIS 4-33
"C21" IAT SENSOR CIRCUIT MALFUNCTION
I DETECTED CONDITION POSSIBLE CAUSE
I Output voltage is out of the specified range. 1 rn IAT sensor circuit open or short. 1
0.1 V $ Sensor voltage c 4.6 V IAT sensor malfunction.
ECM 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 @ and
ground.
6) If OK, then measure the voltage between Dg wire terminal @
and B/Br wire terminal @.
IAT sensor voltage: 4.5 - 5.5 V
(@ Dg - @ Ground)
(@ Dg - @ WBr)
a 09900-25008: Multi circuit tester set
@ Tester knob indication: Voltage (=)
Is the voltage OK?
I YES IGO to Step 2
No Loose or poor contacts on the ECM coupler.
Open or short circuit in the Dg wire or BIBr 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 kQ at 20 OC (68 OF) (Terminal - Terminal)
09900-25008: Multi circuit tester set
lm Tester knob indication: Resistance (Q)
Is the resistance OK?
Dg or B/Br wire open or shorted to ground, or
poor @ or @ connection.
If wire and connection are OK, intermittent trouYES I ble or faulty ECM.
Intake Air Temp Resistance I
NO
Recheck each terminal and wire harness for
open circuit and poor connection.
Replace the IAT sensor with a new one.
20 "C (68 OF) Approx. 2.45 W2
I
NOTE:
40 "C (1 04 OF)
-
/AT sensor resistance measurement method is the same way as
Approx. 1.1 48 W2
60 "C (1 40 OF)
80 "C (176 OF)
that of the ECT sensor. Refer to page 6-10 for details.
I
Approx. 0.587 W2
Approx. 0.322 kC2
Fl SYSTEM DIAGNOSIS 4-35
INSPECTION
Step 1
1) Remove the seat. (W7-4)
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.
"C23" TO SENSOR CIRCUIT MALFUNCTION
4) Remove the TO sensor.
5) Measure the resistance between @ and @ terminals.
DETECTED CONDITION
The sensor voltage should be the following for 2 sec.
and more after ignition switch turns ON.
0.2 V 5 Sensor voltage 5 4.6 V
TO sensor resistance:
19.1 - 19.7 kQ (@ - @ terminals)
POSSIBLE CAUSE
TO sensor circuit open or short.
TO sensor malfunction.
ECM malfunction.
09900-25008: Multi circuit tester set
fim Tester knob indication: Resistance (Q)
Is the resistance OK?
YES
NO
Go to Step 2
Replace the TO sensor with a new one.
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 BrNV
and BIBr wires of the TO sensor at horizontal.
TO sensor voltage: 0.4 - 1.4 V
(@ BrMI - @ BIBr)
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
(@ BrMI - @ BIBr)
a 09900-25008: Multi circuit tester set
09900-25009: Needle pointed probe set
i) Tester knob indication: Voltage (=)
Is the voltage OK?
YES
Red, BrNV or BIBr wire open or shorted to
ground, or poor @I, @ or a) connection.
If wire and connection are OK, intermittent trouble or faulty ECM.
Recheck each terminal and wire harness for
open circuit and poor connection.
Loose or poor contacts on the ECM coupler.
Open or short circuit in the BrNV wire or BIBr
wire.
Replace the TO sensor with a new one.
"C24" or "C25" IGNITION SYSTEM MALFUNCTION
*Refer to the IGNITION SYSTEM for details. (-8-23)
F1 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. S ~ V operating order: Full open @ + Open
(Approx. 1 seconds later)
Is the operation OK?
DETECTED CONDITION
The operation voltage does not reach the STVA.
ECM does not receive communication signal from
the STVA.
1 YES )Go to Step 2
POSSIBLE CAUSE
STVA malfunction.
STVA circuit open or short.
STVA motor malfunction.
I No I Loose or poor contacts on the STVA coupler. Open or short circuit in the B/R and RIB wires.
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 and ground.
STVA continuity: = R (Infinity)
I NO I Replace the STVA with a new one. I
5) If OK, then measure the STVA resistance.
STVA resistance: Approx. 7 - 14 S2
09900-25008: Multi circuit tester set
@ Tester knob indication: Resistance (Q)
Is the resistance OK?
YES
Loose or poor contacts on the STVA coupler, or
poor @ or (23 connection.
If wire and connection are OK, intermittent trouble or faulty ECM. Recheck each terminal and
wire harness for open circuit and poor connection.
4-38 FI SYSTEM DIAGNOSIS
"C29" STP SENSOR CIRCUIT MALFUNCTION
I DETECTED CONDITION
- -
voltage is out of the specified range.
Difference between actual throttle opening and
opening calculated by ECM in larger than specified
I value.
10.1 V 5 Sensor voltage 5 4.8 V
INSPECTION
Step 1
1) Remove the air cleaner box. (-5-1 5)
2) Turn the ignition switch OFF.
POSSIBLE CAUSE
STP sensor maladjusted.
STP sensor circuit open or short.
STP sensor malfunction.
ECM malfunction.
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 BIBr
wire.
STP sensor input voltage: 4.5 - 5.5 V
(@ Red - @ Ground)
(@ Red - @ BIBr)
@ 09900-25008: Multi circuit tester set
lu Tester knob indication: Voltage (=)
Is the voltage OK?
Loose or poor contacts on the ECM coupler.
Open or short circuit in the Red wire or B/Br
wire.
Fl 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: m Q (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 0, and measure the STP sensor resistance with both STV positions.
STP sensor resistance
Secondary throttle valve is closed: Approx. 0.58 kQ
Secondary throttle valve is opened: Approx. 4.38 kQ
m09900-25008: Multi circuit tester set
im Tester knob indication: Resistance (Q)
pimq
Do not use the tool for turning the STVA shaft to prevent breakdown.
Is the resistance OK?
YES
NO
Go to Step 3
Reset the STP sensor position correctly.
(W5-29)
Replace the STP sensor with a new one.
4-40 Fl 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 @ BIBr 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 0.
STP sensor output voltage
Secondary throttle valve is closed: Approx. 0.58 V
Secondary throttle valve is opened: Approx. 4.40 V
e09900-25008: Multi circuit tester set
09900-25009: Needle pointed probe set
im Tester knob indication: Voltage (=)
Do not use the tool for turning the STVA shaft to prevent breakdown.
Is the voltage OK?
YES
Red, Yellow or BIBr wire open or shorted to
ground, or poor @, @ or @ connection.
If wire and connection are OK, intermittent trouble or faulty ECM.
Recheck each terminal and wire harness for
open circuit and poor connection.
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
I DETECTED CONDITION POSSIBLE CAUSE 1
Switch Voltage g 0.2 V I ECM malfunction.
No Gear Position switch voltage
Switch voltage is out of the specified range.
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.
Gear Position switch circuit open or short.
Gear Position switch malfunction.
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
ga Tester knob indication: Voltage (==)
Is the voltage OK?
YES
NO
Inspect the GP switch voltage. (-8-20)
Pink wire open or shorted to ground, or poor @I
connection.
If wire and connection are OK, intermittent trouble or faulty ECM.
Recheck each terminal and wire harness for
open circuit and poor connection.
O ~ e n or short circuit in the Pink wire.
4-42 Fl SYSTEM DIAGNOSIS
"C32" or "C33" FUEL INJECTOR CIRCUIT MALFUNCTION
lnjector malfunction.
ECM malfunction.
DETECTED CONDITION
Fuel injector voltage is 1.3 V and less.
INSPECTION
Step 1
1) Remove the air cleaner box. (W5-15)
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.
lnjector resistance: 11 - 13 Q at 20 "C (68 O F )
(No.1: O - 0)
(N0.2: @I - @)
5) If OK, then check the continuity between injector terminals
and ground.
lnjector continuity: 00 Q (Infinity)
(No.1: @ - Ground)
(No.2: @I - Ground)
09900-25008: Multi circuit tester set
i m ~ e s t e r knob indication: Resistance (Q)
POSSIBLE CAUSE
Injector circuit open or short.
Is the resistance OK?
-
I
I NO / Replace the lnjector with a new one. (-5-18)
Fl 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.
lnjector voltage: Battery voltage
NOTE:
lnjector voltage can
(@ YIR -
detected
@ Ground)
only 2 seconds after ignition
switch is turned ON.
a 09900-25008: Multi circuit tester set
- im Tester knob indication: Voltage (-)
Is the voltage OK?
YES
NO
GrNV or Gr/B wire open or shorted to ground, or
poor @ or @ 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 pump relay. (-5-10) 4-44 FI SYSTEM DIAGNOSIS
"C41" FP RELAY CIRCUIT MALFUNCTION
I DETECTED CONDITION
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.
INSPECTION
Step 1
1) Remove the seat. ( W 7 - 4 )
2) Turn the ignition switch OFF.
POSSIBLE CAUSE 1
Fuel pump relay circuit open or short.
Fuel pump relay malfunction.
ECM malfunction.
3) Check the FP relay coupler for loose or poor contacts.
If OK, then check the insulation and continuity. Refer to page
5-1 0 for details.
Is the FP relay OK?
NO I Replace the FP relay with a new one.
YES
NOTE:
When the both fuel injectors break down at a time, "C4 1" is indiY/B or O/G (OIW: For E-03,24,28 and 33) wire
open or shorted to ground, or poor @ or @ 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. (W4-42 )
cated.
"C42" IG SWITCH CIRCUIT MALFUNCTION
DETECTED CONDITION
Ignition switch signal is not input in the ECM.
INSPECTION
*Refer to the IGNITION SWITCH INSPECTION for details. (-8-39)
POSSIBLE CAUSE
Ignition system circuit open or short.
I ECM malfunction. Fl SYSTEM DIAGNOSIS 4-45
"C49" PAlR CONTROL SOLENOID VALVE CIRCUIT MALFUNCTION
INSPECTION
Step 1
1) Remove the fuel tank. (-5-7)
2) Turn the ignition switch OFF.
3) Check the PAlR control solenoid valve coupler for loose or
poor contacts. If OK, then measure the PAlR control solenoid valve resistance.
DETECTED CONDITION
PAlR control solenoid valve voltage is not input in
ECM.
4) Remove the air cleaner box. (-5-1 5)
5) Disconnect the PAIR control solenoid valve coupler and measure the resistance between terminals.
PAlR control solenoid valve resistance:
20 - 24 Q at 20 OCI68 OF
09900-25008: Multi circuit tester set
Tester knob indication: Resistance (Q)
Is the resistance OK?
POSSIBLE CAUSE
PAlR control solenoid valve circuit open or short.
PAIR control solenoid valve malfunction.
ECM malfunction.
YES
NO
Go to Step 2
Loose or poor contacts on the ECM coupler.
Replace the PAlR control solenoid valve with a
new one.
4-46 Fl SYSTEM DIAGNOSIS
Step 2
1) Connect the PAlR control solenoid valve coupler.
4
2) Turn the ignition switch ON.
3) Insert the needle pointed probes to the PAlR control solenoid
valve coupler.
4) Measure the voltage at the wire side coupler between Brown
wire and ground. 11
PAlR control solenoid valve voltage: Battery voltage
(@ Brown - @ Ground)
09900-25008: Multi circuit tester set
09900-25009: Needle pointed probe set
~u Tester knob indication: Voltage (=)
Is the voltage OK? 0
Brown wire open or shorted to ground, or
connection.
If wire and connection are OK, intermittent trouble or faulty ECM.
Recheck each terminal and wire harness for
open circuit and poor connection.
O ~ e n or short circuit in the Brown wire.
FI SYSTEM DIAGNOSIS 4-47
"C44" H02 SENSOR (H02S) 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 H02 sensor coupler for loose or poor contacts.
--
DETECTED CONDITION
The sensor voltage should be the following and less
after warming up condition.
(Sensor Voltage 5 0.4 V)
4) Insert the needle pointed probes to the H02 sensor coupler.
5) Turn the ignition switch ON and measure the heater voltage
between ONV wire (ECM side) and ground.
6) If the tester voltage indicates the battery voltage for few seconds, it is good condition.
POSSIBLE CAUSE
H02 sensor or its circuit open or short.
Fuel system malfunction.
ECM malfunction.
Heater voltage: Battery voltage ( O M - 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
I&# Tester knob indication: Voltage (--)
Is the voltage OK?
1 YES / GO to Step 2 I
I NO 1 Replace the H02 sensor with a new one. 1
4-48 FI SYSTEM DIAGNOSIS
Step 2
1) Warm up the engine enough.
2) Insert the needle pointed probes to the H02 sensor coupler.
3) Measure the H02 sensor output voltage at the coupler
(between WIG and BIBr wires) when idling condition.
4) Also, measure the H02 sensor output voltage while holding
the engine speed at 5 000 rlmin.
rn H02 sensor output voltage at idle speed:
0.4 V and less (@ WIG - @ BIBr)
H02 sensor output voltage at 5 000 rlmin:
0.6 V and more (@ WIG - @ BIBr)
rn 09900-25008: Multi circuit tester set
09900-25009: Needle pointed probe set
ru Tester knob indication: Voltage (--)
Is the voltage OK?
1 YES ]GO to Step 3 I
NO I Replace the H02 sensor with a new one. I
Step 3
1) Turn the ignition switch OFF.
2) Disconnect the H02 sensor coupler.
3) Check the resistance between the terminals (White - White)
of the H02 sensor.
rn H02 heater resistance: 4 - 5 52 (at 23 "CR3.4 O F )
(White - White)
NOTE:
* Temperature of the sensor affects resistance value largely.
* Make sure that the sensor heater is at correct temperature.
rn 09900-25008: Multi circuit tester set
IU Tester knob indication: Resistance (52)
Is the resistance OK?
YES
WIB, OIG, WIG or BIBr wire open or shorted to
ground, or poor @, @, @ or @ 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 1 Replace the H02 sensor with a new one.
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. (W4-25 )
IAP SENSOR REMOVAL AND INSTALLA-
TION
Lift and support the fuel tank. ( W 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. (-5-1 5)
Remove the TP sensor. (-5-1 9)
Install the TP sensor in the reverse order of removal.
rn TP sensor mounting screw: 3.5 N-m (0.35 kgf-m, 2.5 Ib-ft)
TPS ADJUSTMENT
Adjust the TP sensor. (W4-16)
ECT SENSOR INSPECTION
The ECT sensor is installed on the thermostat case. (W4-31 )
ECT SENSOR REMOVAL AND INSTALLA-
TION
Remove the ECT sensor. (W6-10)
Install the ECT sensor in the reverse order of removal.
ECT sensor: 19 N-m (1.9 kgf-m, 13.5 Ib-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 Ib-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 " U P mark @ 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. (-5-1 5)
Remove the STP sensor. (-5-1 9)
Install the STP sensor in the reverse order of removal.
rn STP sensor mounting screw: 2.0 N.m (0.2 kgf-m, 1.5 Ib-ft)
STP SENSOR ADJUSTMENT
Adjust the STP sensor. (-5-28)
H02 SENSOR INSPECTION (E-02,19)
H02 SENSOR REMOVAL AND INSTALLA-
TION
The H02 sensor is installed at the exhaust pipe.
Remove the seat. (-7-4)
Disconnect the H02 sensor lead wire coupler and remove the
H02 sensor.
Install the H02 sensor in the reverse order of removal.
rn H02 sensor: 47.5 N-m (4.75 kgf-m, 34.3 Ib-ft)
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 kgflcm2, 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.
@ I Fuel filter (For hiah pressure) I @ I BEFORE-PRESSURIZED F U E L I
1 @ I Fuel pressure regulator 1 @ I PRESSURIZED FUEL I
-
@ I Fuel pump I
@
@
(3
Fuel injector
Fuel feed hose
Fuel mesh filter (For low ~ressure)
0 I RELIEVED FUEL
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 ONIOFF 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).
@
@
@
Relief valve
Brush
Magnet
Impeller
@
@
a @
Outlet port
Checkvalve
Armature
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 @ I Flow clearance I @ I Turning direction I
(3
@
(3
Outlet
Blade groove
Inlet
@
@
(7)
Impeller
Motor shaft
Vortex flow
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.
I
@ Spring a Valve @ Fuel from fuel pump @ 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).
I
@ Needle valve @ Plunger @ solenoid coil @ 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.
@ I Neutral lamp IOIECM I
@2
Q
@
I Fuel pump I @ I Clutch switch I
Battery
Ignition coil
Main switch
@
$3
@ I Fuel pump relay I
@
@
@
Side-stand relay
Enaine s t o ~ switch
Tip over sensor
Starter button
Starter relay
@
44
Side-stand switch
Gear position switch
FUEL SYSTEM AND THROTTLE BODY 5-7
FUEL SYSTEM
7' -rrT
FUEL TANK LIFT-UP
Remove the seat. (W7-4)
Remove the cowring. (-7-5)
Remove the fuel tank mounting bolt and fuel tank mount stay
0.
Lift and support the fuel tank with the fuel tank mount stay.
FUEL TANK REMOVAL
Lift and support the fuel tank. (-5-7)
Disconnect the fuel pump lead wire coupler @.
I Gasoline is highly flammable and explosive. I
Place a rag under the fuel feed hose and disconnect the fuel
feed hose @ from the fuel tank.
Disconnect the fuel tank drain hose @.
pEiGq ,'$I r - ?-*
Keep heat, spark and flame away.
When removing the fuel tank, do not leave the fuel
feed hose on the fuel tank side.
-
a Remove the fuel tank mounting bolt and nut. /, 1 , /
-
Remove the fuel tank.
FUEL TANK INSTALLATION
Installation is in the reverse order of removal.
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.
09940-4021 1 : Fuel pressure gauge adaptor
09940-40220: Fuel pressure gauge hose attachment
0991 5-7451 1 : 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
Before removing the special tools, turn the ignition
switch to OFF position and release the fuel pressure
slowly.
Gasoline i s highly flammable and explosive. Keep
heat, sparks and flame away.
@ To fuel delivery pipe. @ To fuel feed hose.
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
I Gasoline is highly flammable and explosive. I
I Keep heat, spark and flame away. I
-
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 @J to pull out the power source lead wire (Yellow with black tracer @).
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
(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
(5.715.9 USllmp oz)llO sec.
NOTE:
The battery must be in fully charged condition.
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 @ and a terminals with
pocket tester. Then apply 12 volts to @ and @ terminals, @ to
@ and @ to @, and check the continuity between @ and @.
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.
Gasoline is highly flammable and explosive.
Keep heat, spark and flame away.
Remove the screws.
Remove the nuts @ and screw a.
Disconnect the clamp @.
Remove the fuel level gauge.
FUEL SYSTEM AND THROTTLE BODY 5-1 1
Remove the screws.
Remove the fuel pump assy @ from the fuel pump plate a.
Remove the fuel pump holder @.
Remove the fuel mesh filter a.
Remove the fuel pressure regulator holder @ and the fuel
pressure regulator @.
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
f removal. Pay attention to the following points: d
a Install the new O-rings to the fuel pressure regulator and fuel
pipe.
Apply thin coat of the engine oil to the O-rings.
I Use the new O-rings to prevent fuel leakage. I
Tighten the screw together with the lead wire terminal.
Tighten the nuts together with the lead wire terminals.
@ ...... @I terminal for fuel pump
03 ...... @I terminal for fuel level gauge
0 ...... ($3 terminal for fuel level gauge
Connect the clamp @.
Install the fuel level gauge.
FUEL SYSTEM AND THROTTLE BODY 5-13
P - -- Install the new O-ring and apply SUZUKI SUPER GREASE to
it.
c5 I 1
The O-ring must be replaced with a new one to prevent
fuel leakage.
99000-25030: SUZUKl SUPER GREASE "A" (USA)
99000-25010: SUZUKl 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 Ib-ft)
NOTE:
Apply a small quantity of the THREAD LOCK to the thread portion of the fuel pump mounting bolt.
a 99000-32050: THREAD LOCK "1 342"
0
@
@
Fuel pressure regulator
Fuel pump caselfuel filter cartridge
(For high pressure)
Fuel pump
@
Fuel mesh filter (For low pressure)
0
@
Fuel level gauge
Fuel pump mounting bolt
5-14 FUEL SYSTEM AND THROTTLE BODY
THROTTLE BODY AND STV ACTUATOR
CONSTRUCTION
I @ I TP sensor 1 @ I STP sensor mounting screw I
I @ I Fuel delivery pipe I *I ( Do not turn the screw.
9
I @ I Injector I
STP sensor PI @ ' ITEM 8
TP sensor mounting screw
Fuel delivery pipe mounting
screw
N-m
2.0
kgf-m
0.2
Ib-ft
1.5
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 a.
Remove the IAP sensor vacuum hose @.
Disconnect the IAP sensor coupler @.
Loosen the throttle body clamp screws.
Disconnect the PAIR hose.
Disconnect the PAIR lead wire coupler @.
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. ( D 5 - 1 5 )
Disconnect the various lead wire couplers.
@ TP sensor
@ STP sensor
@ 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
piimic
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.
Remove the IAP sensor vacuum damper and its hose.
Disconnect the fuel feed hose a.
Remove the throttle link rod and secondary throttle link rod
0.
NOTE:
The throttle link rod is longer than the secondary throttle link
rod 0.
Remove the fuel delivery pipe @.
Remove the fuel injectors.
FUEL SYSTEM AND THROTTLE BODY 5-19
Remove the TPS @ and STPS @I with the special tool.
09930-1 1950: Torx wrench (TH 25)
09930-1 1960: 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 a.
I Do not turn the screws 0. I
I Never remove the STVA. I
5-20 FUEL SYSTEM AND THROTTLE BODY
Remove the throttle stop screw @.
NOTE:
Measure the length @I for accurate reinstallation.
/CAUTION1
Never loosen the throttle stop screw @I on the No.2 throttle body.
Never remove the throttle valve and secondary throttle
valve.
FUEL SYSTEM AND THROTTLE BODY 5-21
I Never remove the throttle body link plates. I
Remove the fast idle link lever 0.
Remove the spring @.
Remove the spring @, bushing @ and plastic washer @.
5-22 FUEL SYSTEM AND THROTTLE BODY
THROTTLE BODY CLEANING
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.
Clean all passageways with a spray type carburetor cleaner
and blow dry with compressed air.
EmiGq
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.
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.
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 SUZUKl SUPER GREASE to the throttle stop screw tip
and the both ends of a spring.
99000-25030: SUZUKl SUPER GREASE "A" (USA)
99000-25010: SUZUKl SUPER GREASE "A" (Others)
Install the plastic washer @ and bushing 0.
NOTE:
The concave of a bushing is faced outside.
Install the spring.
Apply SUZUKl MOLY PASTE to the fast idle link lever.
& 99000-251 40: SUZUKl MOLY PASTE
----- -
Install the spring @.
5-24 FUEL SYSTEM AND THROTTLE BODY
Install the spring @ and fast idle link lever @.
NOTE:
Make sure that the spring ends are hooked correctly.
Install the washers @, @, spring washer and nut @.
NOTE:
The washer @ 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 @.
Apply a small quantity of SUZUKI SUPER GREASE to the
shaft ends and seal lips.
99000-25030: SUZUKl SUPER GREASE "A" (USA)
99000-25010: SUZUKI SUPER GREASE "A" (Others)
a Turn the TP sensor counterclockwise and install the mounting
screws.
Tighten the TP sensor mounting screws.
09930-1 1950: Torx wrench
TP sensor mounting screw: 3.5 N.m (0.35 kgf-m, 2.5 Ib-ft)
FUEL SYSTEM AND THROTTLE BODY 5-25
NOTE:
Make sure the throttle valve open or close smoothly.
Align the boss @ of the STP sensor with the groove @ of the
ST valve shaft.
Install the STP sensor.
Tighten the STP sensor mounting screws.
a 09930-1 1960: Torx wrench
STP sensor mounting screw:
2.0 N-m (0.2 kgf-m, 1.5 Ib-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 @, and install it to the fuel injector.
I Replace the cushion seal and O-ring with a new one. 1
Install the O-ring 03 to the fuel injector.
Apply thin coat of the engine oil to the new O-ring @I.
5-26 FUEL SYSTEM AND THROTTLE BODY
Install the fuel injectors by pushing them straight to each throttle body.
CAUTlONI
Never turn the injector while pushing it.
Install the fuel delivery pipe assembly to the throttle body
assembly.
Never turn the fuel injectors while installing them.
Tighten the fuel delivery pipe mounting screws.
Fuel delivery pipe mounting screw:
5.0 N.m (0.5 kgf-m, 3.7 Ib-ft)
Install the throttle link rod @ and secondary throttle link rod
8.
NOTE:
The throttle link rod @ is longer than the secondary throttle link
rod 0.
lnstall the IAP sensor vacuum damper and hose.
I CAUTION I
I The stamp 0 of the IAP sensor vacuum damper faces 1
into the throttle body side.
FUEL SYSTEM AND THROTTLE BODY 5-27
STV SYNCHRONIZATION
Install the throttle body. ( U S - 2 7 )
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 @ will be same as @.
I Do not use the tool for turning the STVA shaft to pre- /
vent breakdown.
NOTE:
Measure the throttle valve height @, @I from top of the throttle
body @ to the throttle valve @.
While holding above No.1 STV position, turn the adjust screw
@ so that the throttle valve height 0 will be same as 0.
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.
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 @.
* 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:
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)
rn 09900-25008: Multi circuit tester set
09900-25009: Needle pointed probe set
3) Tester knob indication: Voltage (--)
Do not use the tool for turning the STVA shaft to prevent breakdown.
Loosen the STP sensor mounting screws.
Adjust the STP sensor until voltage is within specification and
tighten the STP sensor mounting screws.
rn 09930-1 1960: Torx wrench STP sensor mounting screw:
2.0 N-m (0.2 kgf-m, 1.5 Ib-ft)
I
AIR CLEANER BOX INSTALLATION
Installation is in the reveres order of removal.
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. (W5-20)
& 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.
09930-1 1950: Torx wrench
TP sensor mounting screw: 3.5 N.m (0.35 kgf-m, 2.5 Ib-ft)
@ Incorrect
@ 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.
Fast idle link lever
@ Fast idle cam
@ STVA
NOTE:
The fast idle link lever opens throttle valve a little to increase the
engine speed.
Fast idle cancelling Water
Fast idle rpm I Temp.
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.
1 500 - 2 000 rpm
40 - 50 OC
(1 04 - 122 OF)
FUEL SYSTEM AND THROTTLE BODY 5-31
FAST IDLE ADJUSTMENT - -
Remove the fuel tank. ( W 5 - 7 )
Remove the air cleaner box. (-5-15) P
Disconnect the STVA lead wire coupler and turn the ignition
switch ON. 1 .
r .ti.
* xw Open the STV fully with a finger. Measure the output voltage
- of the TP sensor.
pimq
Do not use the tool for turning the STVA shaft to prevent breakdown.
If the TP sensor output voltage is out of specification, turn the
fast idle adjusting screw @ and adjust the output voltage to
specification.
TP sensor output voltage: 1.21 V
(Red - BIBr)
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 @.
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. ( W 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 @I 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.
09913-131 21 : Vacuum balancer gauge
Start up the engine and keep it running at 1 300 rpm by turn- ing throttle stop screw a. 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. (3: $- I FUEL SYSTEM AND THROTTLE BODY 5-33
Turn the air screw @ of the gauge so that the vacuum acting
on the tube of that hose will bring the steel ball @ in the tube
to the center line @.
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 (3 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 @
from each vacuum nipples on No.1 and No.2 throttle body.
Connect the vacuum balancer gauge hoses to the vacuum
nipples respectively.
& 0991 3-1 31 21 : Vacuum balancer gauge
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 @ 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.
ICAUTION I
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.
NOTE:
Make sure that the throttle lever should have a gap @ (between
the throttle lever and throttle lever stopper screw) during synchronization.
Throttle lever gap @: 0.17 mm (0.007 in)
CONTENTS
....................................................................................... ENGINE COOLANT 6 - 2
COOLING CIRCUIT ....................................................................................... 6 - 3
COOLING CIRCUIT INSPECTION ......................................................... 6 - 3
RA DlA TOR ................................................................................................ 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-S WITCH .............................................................. 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
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 LUBRICA TION 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 5050 mixture of distilled water and ethylene glycol anti-freeze. This 5050 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 O F ) .
If the motorcycle is to be exposed to temperatures below -31 "C (-24 OF), this mixing ratio should be
increased up to 55 O/O or 60 % according to the figure.
I Anti-freeze density 1 Freezing point I
1 CAUTION I
* 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.
50 '10 Engine coolant including reserve tank capacity
I Water 1 950 ml (2.0111.67 US1lmp.pt) I
20 40 60 80 100 0 10 20 30 40 50 60
Density (%) Density (%)
Fig.1 Engine coolant density-freezing Fig.2 Engine coolant density-boiling
point curve. point curve.
* 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
@ Thermostat Q Reserve tank @ Radiator @ No.1 cylinder head @ No.1 cylinder
@ No.2 cylinder No.2 cylinder head @ Water pump
COOLING CIRCUIT INSPECTION
Before removing the radiator and draining the engine coolant,
inspect the cooling circuit for tightness.
Remove the cowling. ( W 7 - 5 )
Remove the radiator cap @I and connect the radiator tester @
to the filler.
- -
Do not remove the radiator cap when the engine is
hot.
Give a pressure of about 120 kPa (1.2 kgflcm2, 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.
When removing the radiator cap tester, put a rag on
the filler to prevent spouting of engine coolant.
I DO not allow the pressure to exceed specified pres- I
sure, or the radiator can be damaged. I
6-4 COOLING AND LUBRICATION SYSTEM
RADIATOR
REMOVAL
Remove the cowling. (-7-5)
Drain the engine coolant. (-2-1 8)
Disconnect the right and left radiator hoses from the radiator.
Disconnect the siphon hose @ from the radiator.
Disconnect the horn lead wire coupler @.
COOLING AND LUBRICATION SYSTEM 6-5
Remove the radiator lower mounting bolt.
Disconnect the cooling fan motor and thermo-switch lead wire
coupler @.
Remove the radiator upper mounting bolt.
Disconnect the speed sensor lead wire from the clamp @.
With the hooks @ unlocked, remove the radiator from the
radiator shroud @.
Remove the cooling fan and
@ from the radiator shroud.
thermo-switch lead wire coupler
Remove the cooling fan 0.
Disconnect the cooling fan thermo-switch lead wire coupler
and remove the cooling fan thermo-switch.
Remove the horn @.
-
I CAUTION I
When removing the horn @, 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.
4
-
. -'
INSTALLATION
Install the radiator in the reverse order of removal.
Pay attention to the following points :
Install the cooling fan and horn 0.
Cooling fanthorn mounting bolt:
8 N-m (0.8 kgf-m, 6.0 Ib-ft)
lnstall 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. (W2-18)
Bleed air from the cooling circuit. (-2-1 9)
Install the cowling. ( W 7 - 8 )
COOLING AND LUBRICATION SYSTEM 6-7
RADIATOR CAP
INSPECTION
Remove the radiator cap. (-6-3)
Fit the cap @ to the radiator cap tester @.
Build up pressure slowly by operating the tester. Make sure
that the pressure build-up stops at 95 - 125 kPa (0.95 - 1.25
kgflcmz, 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 FAY
INSPECTION
Remove the cowling. ( W 7 - 5 )
Disconnect the cooling fan motor and thermo-switch lead wire
coupler O.
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 applies 12
volts to the fan motor (3. With the fan motor with electric motor
fan running at full speed, the ammeter @ 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. ( W 7 - 5 )
Drain the engine coolant. (-2-1 8)
Remove the radiator. ( W 6 - 4 )
Disconnect the cooling fan thermo-switch coupler a.
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 Ib-ft)
Connect the cooling fan thermo-switch coupler a.
Install the radiator.
Route the radiator hoses properly. (-9-24)
Pour engine coolant. (-2-1 8)
Bleed the air from the cooling circuit. (-2-1 9)
Install the cowling. ( W 7 - 8 )
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 therrno-switch lead wire coupler
0.
Remove the cooling fan thermo-switch 0.
INSPECTION
Check the thermo-switch closing or opening temperatures b! Y
testing it at the bench as shown in the figure. Connect the
thermo-switch @ 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 @ when the switch closes or opens.
09900-25008: Multi circuit tester set
Tester knob indication: Continuity test (4))
Cooling fan thermo-switch operating temperature
Standard (OFF+ON): Approx. 98 OC (208 OF)
(ON+OFF): Approx. 92 OC (198 OF)
p5mm-l
--- -- -
* 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 @ and
the column thermometer @ with a pan.
INSTALLATION
Install a new O-ring @ 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 Ib-ft)
Pour engine coolant. (W2-18)
Bleed air from the cooling circuit. (-2-1 9)
Install the cowling. (-7-8)
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 @.
INSPECTION
Check the ECT sensor by testing it at the bench as shown in
the figure. Connect the ECT sensor @ 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 a 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
Temperature Standard resistance I
I
If the resistance noted to show infinity or too much different
20 "C (68 OF)
40 "C (104 OF)
60 "C (140 OF)
80 "C (176 OF)
resistance value, replace the ECT sensor with a new one.
Approx. 2.45 kR
Approx. 1.148 kQ
Approx. 0.587 kR
Approx. 0.322 kR
CAUTION I
Take special care when handling the ECT sensor. It
may cause damage if it gets a sharp impact.
Do not contact the ECT sensor @ and the column
thermometer with a pan.
I
COOLING AND LUBRICATION SYSTEM 6-11
INSTALLATION
Install a new sealing washer a.
Tighten the ECT sensor to the specified torque.
ECT sensor: 19 N-m (1.9 kgf-m, 13.5 Ib-ft)
piimiq
Take special care when handling the ECT sensor. It
may cause damage if it gets a sharp impact.
Pour engine coolant. ( W 2 - 1 8 )
Bleed air from the cooling circuit. (-2-19)
6-12 COOLING AND LUBRICATION SYSTEM
THERMOSTAT CASE ASSEMBLY
REMOVAL
Drain the engine coolant. (W2-18)
Place a rag under the thermostat case.
Remove the thermostat case cap 0.
Remove the thermostat a.
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 @I and observe the rising temperature on a thermometer a.
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 OC (190 OF)
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 OC (Over 0.31 in at 212 OF)
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 @ of the thermostat faces upside.
Install the thermostat case cap 0.
NOTE:
The rib @ 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 Ib-ft)
Pour engine coolant. (-2-18)
Bleed air from the cooling circuit. (-2-1 9)
6-14 COOLING AND LUBRICATION SYSTEM
WATER PUMP
REMOVAL AND DISASSEMBLY
Drain the engine coolant. (W2-18)
Drain the engine oil. (W2-13)
Disconnect the water hoses @, a.
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. (117 6- 16)
Remove the snap ring and water pump driven gear @.
Remove the pin @I and washer @.
COOLING AND LUBRICATION SYSTEM 6-15
Remove the water pump @ from the clutch cover.
Remove the screws and separate the water pump.
Remove the O-rings D.
Remove the E-ring from the impeller shaft.
Remove the impeller from the other side.
Remove the mechanical seal ring @ and rubber seal @ 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 neces='Y.
pimiGq
- - 1 The removed bearings must be replaced with the new I
ones.
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.
The removed mechanical seal and oil seal must be
replaced with a new one.
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.
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 m
Install the oil seal with the special tool.
a 09913-70210: Bearing installer set (0 22 mm) w
NOTE:
The stamped mark on the oil seal faces impeller side. m,
Apply a small quantity of the SUZUKl SUPER GREASE to the
oil seal lip.
99000-25030: SUZUKl SUPER GREASE "A" (USA)
99000-2501 0: SUZUKl 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)
lnstall the new bearings with the special tool.
09913-70210: Bearing installer set (4 25 mm)
NOTE:
The stamped mark on the bearing faces to the crankcase side.
Install the rubber seal @ 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 @ of the mechanical seal ring faces to
the impeller.
Apply SUZUKl SUPER GREASE to the impeller shaft.
99000-25030: SUZUKI SUPER GREASE "A" (USA)
99000-25010: SUZUKl SUPER GREASE " A (Others)
lnstall the impeller to the water pump body.
Fix the impeller shaft with the E-ring a.
Apply SUZUKI SUPER GREASE to the O-rings.
99000-25030: SUZUKI SUPER GREASE "A" (USA)
99000-25010: SUZUKl SUPER GREASE "A" (Others)
lnstall new O-rings @.
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 @.
Install a new O-ring.
pmq
Use a new O-ring to prevent engine coolant leakage.
Connect the water hoses.
Pour engine coolant. (-2-1 8)
Pour engine oil. (-2-1 4) -'@
(0.45 kgf-m, 3.3 Ib-ft)
6-20 COOLING AND LUBRICATION SYSTEM
LUBRICATION SYSTEM
OIL PRESSURE
W 2 - 3 1
OIL FILTER
W 2 - 1 4
OIL PRESSURE REGULATOR
-3-57
OIL STRAINER
W 3 - 5 8
OIL JET
W3-49, -59, -60 and -96
OIL PUMP
W 3 - 8 1 and -89
OIL PRESSURE SWITCH
W 3 - 5 8 and 8-34
COOLING AND LUBRICATION SYSTEM 6-21
OIL COOLER
REMOVAL
Drain the engine oil. (W2-13)
Disconnect the oil cooler hoses.
- Remove the oil cooler.
Remove the oil cooler fin guard net 0.
Remove the oil hoses a.
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 @.
Use the new gasket washers to prevent engine oil
leakage.
Connect the oil hoses.
Install the oil cooler.
rn Oil cooler mounting bolt: 10 N-m (1.0 kgf-m, 7.0 Ib-ft)
Tighten the oil cooler hose union bolts to the specified torque.
rn Oil cooler hose union bolt: 23 N-m (2.3 kgf-m, 16.5 Ib-ft)
p i i E q
The oil cooler hoses should be contacted with the
stoppers @.
COOLING AND LUBRICATION SYSTEM 6-23
ENGINE LUBRICATION FLOW CHART
( EXHAUST I STARTER CLUTCH I I EXHAUST
1 CAMSHAFT JOURN, 1 TMSHAF; JOURNAL 1
1 EXHAUST (
SHAFT 1 , -.ZM CHAIN I '.
CAMSHAFT
CAM CHAIN
TENSION
t t t '
' :
CRANK PIN 9
INTAKE 1 CAMSHAFT I FRONT AND REAR CONROD BIG END BEARINGS
1 1
1 b b b
I 1 0 I b b b
I FRONT PISTON AND I I REAR PISTON AND 1
[CYLINDER WALL I I CYLINDER WALL I
t t ' ? O'? 1 / REAR CYLINDER I
I OIL JET (# l4) I OIL JET (#14)
OIL GALLERY
I 4
OIL JET (#14) --
DRIVEN GEAR AND
BUSHING
t( DRIVE SHAFT 14-
+
CLUTCH PUSH PEACE
A 1
1 i r i
4 1 0 I 4 bb
I CLUTCH PLATES I
OIL PRESSURE
I 1 bb
t--- OfL PAN *
6-24 COOLING AND LUBRICATION SYSTEM
ENGINE LUBRICATION CIRCUIT
FRONT CYLINDER
COOLING AND LUBRICATION SYSTEM 6-25
REAR CYLINDER
CONTENTS
EXTERIOR PARTS ................................................................................... 7 2
CONSTRUCTION ................................................................................... 2
REMOVAL ............................................................................................ 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 S WINGARM ................................................................................ 7 - 4 9
CONSTRUCTION ................................................................................... 7-49
REMOVAL .............................................................................................. 7-50
INSPECTION AND DISASSEMBLY ...................................................... 7-51
REASSEMBLY ....................................................................................... 7-54
CHASSIS 7-1
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
E
X
TE
R
IO
R
P
A
R
T
S
C
O
N
S
T
R
U
C
T
IO
N
I @
I
I W
ind screen brace
I @
1 C
ow ling inner cover
I
m @
@
I
C
ow ling brace
@
Left cow
ling
@
R
ight cow
ling
@
C
ow ling brace m
ounting bolt
W
ind screen cover
W
ind screen
@
(3
C
ow ling body
C
om bination m
eter w
anel
CHASSIS
7-3
@
@
@
S
eat rail
R
ear fender N
o .1
R
ear fender N
o .2
@
@
@
M
u d guard
F
ram
e cover
S
eat rail m
ountina bolt
P
I
IT
E
M
@
N
-m 50
kgf-m
5.0
Ib -ft
36.0
7-4 CHASSIS
REMOVAL
SEAT
Remove the seat with the ignition key 0.
CARRIER
Remove the seat. (-7-4)
Remove the carrier a.
FUEL TANK SIDE COVER
Remove the seat. (-7-4)
Remove the fuel tank side covers a
NOTE:
''b " indicates hook location.
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 @.
NOTE:
I , 11 ts indicates hook location.
REAR FENDER T
Remove the seat. (-7-4)
Remove the carrier. (U7-4)
Remove the bolts a.
Disconnect the brake light/taillight lead wire coupler @ and
seat lock cable @I.
Remove the rear fender.
COWLING AND COWLING BRACE
Remove the seat. (-7-4)
Disconnect the battery @ lead wire.
Remove the wind screen covers 0.
7-6 CHASSIS
Remove the wind screen @.
Remove the fuel tank top cover @.
Remove the combination meter panel mounting screws @.
Remove the combination meter panel 0.
NOTE:
I h 19 b indicates hook location.
Disconnect the speedometer lead wire coupler 0.
Remove the cowling inner cover a by removing two screws
and seven fasteners.
CHASSIS 7-7
Remove the left cowling @.
Remove the right cowling @.
w-Remove the wind screen brace @.
Disconnect the turn signal light lead wire couplers @.
Remove the screws @.
Remove the cowling body @.
NOTE:
'$2 " indicates hook location.
7-8 CHASSIS
Disconnect the coupler @.
Remove the cowling blace 0.
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 @ as shown in the photograph.
NOTE:
lnstall the larger diameter bolts on the wind screen brace attaching section @.
NOTE:
The wind screen height can be adjusted by changing the wind
screen brace installed position.
CHASSIS 7-9
FRONT WHEEL
CONSTRUCTION
I o I Brake disc I @ 1 Front wheel I m
1 - 1
I @ I Tire valve
Y
1 ITEM I N.m I ksf-m 1 Ib-ft I
( @ ( Bearing I @ I Front axle I
I @ I Center spacer I @ I Brake disc bolt
7-10 CHASSIS
REMOVAL
Remove the right and left brake calipers. ( W 7 - 5 9 )
Loosen the axle pinch bolt @ on the right front fork leg.
I Do not operate the brake lever while r e i o v i n g T h z I
i pers.
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 @ 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 ( W 7 - 6 5 )
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.
CHASSIS 7-11
Remove the dust seal with the special tool.
0991 3-501 21 : Oil seal remover
piEi5q
Do not reuse the removed dust seals.
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 (11100)
09900-20701 : Magnetic stand
09900-21304: V-block set (100 mm)
rn 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)
rn 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 any- thing unusual.
Remove the wheel bearings with the special tool.
@ 09921 -20240: Bearing remover set ( Q 17)
p E 6 q
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:
@ Left @ Right
CHASSIS 7-13
WHEEL BEARING
Apply SUZUKl SUPER GREASE to the wheel bearings.
99000-25030: SUZUKl SUPER GREASE "A" (USA)
99000-25010: SUZUKl 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 -3451 3: BearingJSteering race installer set
0991 3-7021 0: Bearing installer set (i 40)
I The sealed cover of the bearing must face outside.
@ Spacer @ Old bearing @ Left @ Right 0 Clearance
DUST SEAL
Install the dust seal with the special tool.
@ 0991 3-7021 0: Bearing installer set ( Q 40)
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 @ on the brake disc should face to the outside.
Brake disc bolt: 23 N-m (2.3 kgf-m, 16.5 Ib-ft)
a 99000-32130: THREAD LOCK SUPER "1 360"
WHEEL
Install the front wheel with the front axle and tighten the front
axle temporarily.
The directional arrow @ on the wheel must point to
the wheel rotation, when remounting the wheel.
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 Ib-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.
@J 09900-1 871 0: Hexagon bit 12 mm
Front axle: 65 N-m (6.5 kgf-m, 47.0 Ib-ft)
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 @ on the right front fork leg to the
specified torque.
Front axle pinch bolt: 23 N.m (2.3 kgf-m, 16.5 Ib-ft)
7-16 CHASSIS
FRONT FORK
CONSTRUCTION
@ I Washer I @ 1 Guide metal I
O
O
(3) I Spacer 143 I Oil lock piece I
@ I Spring I @ [Outer tube I
Spring adjuster
0-rina
0 I Oil seal
@ 1 Oil seal retainer
@ Slide metal @ Front fork cap bolt
@ Gasket @ Front axle pinch bolt
@ Dust seal '32 Cylinder bolt
Oil seal stopper ring
@
(73
Rebound spring
Inner tube
@
63
Cylinder
Washer m
CHASSIS 7-17
REMOVAL AND DISASSEMBLY
Remove the front wheel. (W7-10)
Remove the speedometer lead wire mounting bolts a.
Remove the front fender bolts and brake hose bolts.
Remove the front fender @.
Loosen the front fork upper clamp bolts @.
NOTE:
slightly loosen the front fork cap bolts @ 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 @.
Remove the spacer @, washer a and spring @.
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 dust seal.
Remove the rebound spring and cylinder @.
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.
I CAUTION]
The slide metals, oil seal and dust seal must be
replaced with the new ones when reassembling the
front fork.
Remove the following parts.
0 Oil seal
@ Oil seal retainer
Q Guide metal
@ Slide metal
O Oil lock piece
Remove the pin @.
Remove the washer @.
Remove the spring adjuster @ from front fork cap bolt.
7-20 CHASSIS
INSPECTION -
INNER AND OUTER TUBES
Inspect the inner tube outer surface and the outer tube inner sur- 4
face 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
lnspect the cylinder and cylinder ring @ 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.
* 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.
Assemble the following parts as shown.
0 Oil seal
0 Oil seal retainer
@ Guide metal
@ Slide metal
NOTE:
- Stamped mark on the oil seal must face upward.
Install the oil lock piece @ 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.
7-22 CHASSIS
Install the oil seal stopper ring @ and the dust seal m.
@ Dust seal
@ Oil seal stopper ring
0 Oil seal
(D Oil seal retainer
(0 Guide metal
CYLINDER
Install the rebound spring @ to the cylinder a.
Apply fork oil to the cylinder ring.
Install the cylinder into the front fork.
Apply THREAD LOCK to the cylinder bolt.
jCAUTlON
Use a new gasket @ to prevent oil leakage.
a 99000-32050: THREAD LOCK "1 342"
Tighten the cylinder bolt to the specified torque with the special tools.
09940-34520: "T" Handle
09940-34531 : Attachment A
(II Cylinder bolt: 20 N-m (2.0 kgf-m, 14.5 Ib-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.
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.
a 99000-99001-SS8: SUZUKl FORK OIL SS-08
Front fork o i l capacity (each leg):
524 m1 (17.7118.5 USAmp 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.
09943-741 11 : Front fork oil level gauge
Fork oil level: 143 mm (5.63 in)
a 99000-99001-SS8: SUZUKl FORK OIL SS-08
7-24 CHASSIS
FORK SPRING
Install the fork spring @ into the front fork.
Install the washer and spacer @.
NOTE:
The smaller spring pitch end @ must face downward.
Apply fork oil lightly to the O-ring.
pm5K
I Use a new O-ring to prevent oil leakage. I
Install the spring adjuster to the front fork cap bolt.
Apply fork oil lightly to the O-ring.
1 Use a new O-ring to prevent oil leakage. I
Tighten the front fork cap bolt temporarily.
Set the front fork to the front fork lower bracket temporarily by
tightening the lower clamp bolts.
CHASSIS 7-25
Tighten the front fork cap bolt @ to the specified torque.
Front fork cap bolt: 23 N-m (2.3 kgf-m, 16.5 Ib-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.
rn Front fork upper clamp bolt: 23 N-m (2.3 kgf-m, 16.5 Ib-ft)
Front fork lower clamp bolt: 23 N-m (2.3 kgf-m, 16.5 Ib-ft)
Install the front wheel. (-7-10)
Install the front brake calipers. (W7-59)
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.
7-26 CHASSIS
STEERING AND HANDLEBAR
CONSTRUCTION
- " , , -
@ I ~ u s t seal I @ I Expander I
@
@ I Bearing upper 1 @ I Handlebar clamp bolt I
@ ( Bearing lower I @ 1 Steering stem head nut I
Handlebars
Steerina stem uooer bracket
@ I Handlebar balancer (03 I Front fork lower clamp bolt I
O
@
O
@ i) Expander
Spacer
Washer
U
[ ITEM I N-m I kgf-m 1 Ib-ft I
Steering stem lower bracket
Steerina stem nut
0
0
Front fork upper clamp bolt
Steerina stem lock-nut
CHASSIS 7-27
REMOVAL
HANDLEBARS
Remove the handlebar balancers @.
Remove the rear view mirrors @.
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 @I.
Remove the right handlebar switch box @ and throttle case
Remove the left handlebar switch box 0.
Remove the grip rubber @.
Loosen the clutch lever holder bolt @.
Disconnect the clamps @.
Remove the clamp bolt caps @.
7-28 CHASSIS
Remove the handlebars by removing the handlebar clamp
bolts.
m Remove the clutch lever holder ($3.
STEERING STEM
Remove the front forks. (-7-17)
Remove the handlebars. (-7-27)
Remove the guides @I.
Remove the brake hose guide 13.
Remove the ignition switch 1 3 with the special tools.
~ O 9 9 3 O - i i 9 2 O : Tom bit JT40H
09930-1 1940: Bit holder
Remove the steering stem upper bracket by removing the
steering stem head nut.
Remove the steering stem lock-nut with the special tools.
a 09940-1491 1 : Steering stem nut wrench
09940-14960: Steering stem nut wrench socket
Remove the washer @I.
Remove the steering stem nut with the special tools.
a 09940-1 491 1 : 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 Q and bearing inner race @.
730 CHASSIS
Remove the steering stem upper bearing a.
Remove the steering stem lower bearing @.
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.
I The removed bearing inner race and dust seal must be I
/ replaced with the new ones. I
Drive out the steering stem upper and lower bearing races
with the special tools.
09941 -5491 1 : Bearing outer race remover
09925-1 801 1 : Steering bearing installer
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.
a 09941-34513: Steering outer race installer
09913-70210: Bearing installer set (Q 55)
BEARINGS
Press in the dust seal and lower bearing with the special tool.
-
09925-1801 1 : Steering bearing installer
Apply SUZUKI SUPER GREASE to the bearings and dust
seal.
Install the lower bearing to the steering stem lower bracket.
lnstall the upper bearing, bearing inner race, dust seal onto
the frame.
99000-25030: SUZUKl SUPER GREASE "A" (USA)
99000-2501 0: SUZUKl SUPER GREASE "A" (Others)
STEERING STEM
Tighten the steering stem nut to the specified torque with the
special tools.
09940-1 491 1 : Steering stem nut wrench
09940-14960: Steering stem nut wrench socket
Steering stem nut: 45 N-m (4.5 kgf-m, 32.5 Ib-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 114 - 112 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.
09940-1491 1 : Steering stem nut wrench
09940-14960: Steering stem nut wrench socket
rn Steering stem lock-nut: 80 N.m (8.0 kgf-m, 58.0 Ib-ft)
Install the steering stem upper bracket and tighten the steering stem nut lightly.
Install the ignition switch @ and harness guide a. (-8-38)
Install the front fork to the steering stem and tighten the lower 7- k+h.
clamp bolts temporarily.
Tighten the steering stem head nut to the specified torque.
rn Steering stem head nut: 90 N.m (9.0 kgf-m, 65.0 Ib-ft)
Remount the front forks and the front fender. (-7-21)
HANDLEBARS -
Install the handlebars with the punch mark @ aligned with the
mating surface (@ of the handlebar holder.
CHASSIS 7-33
Set the punch mark 0 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 Ib-ft)
NOTE:
When tightening the handlebar clamp bolts, first tighten the
@ and then tighten the bolt @.
bolt
HANDLEBAR SWITCH BOX
Install the throttle cable case.
Apply SUZUKI SUPER GREASE to the throttle cables and
their holes.
99000-25030: SUZUKl SUPER GREASE "A" (USA)
99000-2501 0: SUZUKl SUPER GREASE "A" (Others)
Align the mating surface @I of the throttle case with the punch
mark @ on the handlebars.
a Install the right handlebar switch box to the handlebars by
engaging the stopper @ with the handlebar's hole a.
Install the front brake master cylinder. (W7-67)
I
Install the handlebars with the punch mark 0 aligned with the
mating surface 0 of the clutch lever holder. I
i Install the left handlebar switch box to the handlebars by
engaging the stopper with the handlebars hole @.
Install the clutch master cylinder with the proper clutch hose
routing.
Install the handlebar balancers and the rear view mirrors.
(Handlebar balancer installation: W 9 - 3 5 )
Install the front wheel. ( W 7 - 1 2 )
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 @ I Rear axle 1 I Retainer 1
1 @ I ~ u s t seal I @I I Sprocket mounting drum 1
I @ 1 Bearing 1 @ 1 ~ u s t seal I
@
0
-
@ I Rear wheel I @ I collar 1 .PI
O Tire valve @ Brake disc bolt
@ Damper @I Rear sprocket nut
@ Spacer 0 Rear axle nut 43.5
Brake disc
Collar
I @ I Bearing I
@
@
Rear sprocket
Bearina
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.
I Do not operate the brake pedal while removing the I
rear wheel.
Remove the collars a, @.
Remove the rear sprocket mounting drum assembly @ from
the wheel hub.
NOTE:
Before removing the rear sprocket mounting drum, slightly
loosen the rear sprocket nuts @ to facilitate later disassembly.
Remove the rear sprocket mounting drum retainer @.
CHASSIS 7-37
Remove the rear sprocket @ from the rear sprocket mounting
drum.
Remove the brake disc a.
-
INSPECTION AND DISASSEMBLY
TIRE: (-7-79)
WHEEL: (-7-1 1 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)
a 09900-20607: Dial gauge (111 00 mm)
09900-20701 : Magnetic stand
09900-21 304: V-block set (1 00 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.
@ Normal wear
@ Excessive wear
DUST SEAL
lnspect 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.
@ 0991 3-501 21 : Oil seal remover
I CAUTION I
I DO not reuse the removed dust seal. I
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 bear- -- < - ings with the special tool.
09921-20240: Bearing remover set (a 0 30)
(8 0 20)
-1
The removed bearings must be replaced with the new
ones.
4
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:
@ Left @ Right
CHASSIS 7-41
BEARING
Apply SUZUKl SUPER GREASE to the bearings before
installing.
99000-25030: SUZUKl SUPER GREASE "A" (USA)
99000-25010: SUZUKl SUPER GREASE "A" (Others)
Install the new bearing to the sprocket mounting drum with the
special tool.
-
09913-70210: Bearing installer set ( Q 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: BearingISteering race installer set
0991 3-7021 0: Bearing installer set (@ 47)
p G i q
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 (@ Q 62)
(O Q 47)
NOTE:
When installing the dust seals, the stamped mark of dust seal
must face the special tool.
Apply SUZUKl SUPER GREASE to the dust seal lips before
assembling rear wheel.
99000-25030: SUZUKI SUPER GREASE "A" (USA)
99000-2501 0: 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 @ on the brake disc should face to the outside.
Apply THREAD LOCK to the disc bolts and tighten them to
the specified torque.
a 99000-321 30: THREAD LOCK SUPER "1 360"
P] Brake disc bolt: 23 Nmm (2.3 kgf-m, 16.5 Ib-ft)
REAR SPROCKET
Install the rear sprocket to the rear sprocket mounting drum.
NOTE:
Stamped mark @ on the sprocket must face outside.
Apply SUZUKl SUPER GREASE to the rear sprocket mounting retainer.
Install the rear sprocket mounting drum retainer @ as shown.
Apply SUZUKl 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.
tT) Rear sprocket nut: 60 N-m (6.0 kgf-m, 43.5 Ib-ft)
lnstall 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.
tT) Rear axle nut: 100 N-m (1 0.0 kgf-m, 72.5 Ib-ft)
lnstall the new cotter pin. (For E-03,28, 33)
7-44 CHASSIS
REAR SHOCK ABSORBER
CONSTRUCTION
Rear shock absorber lower
mounting nut
U
ITEM 1 N-m I kaf-m 1 Ib-ft I
@
Rear shock absorber upper mounting nut
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 @.
-- - .
Remove the cushion lever rod boltslnuts and the cushion rods
0.
Disconnect the pre-load adjuster hose from the clamp @. /
Remove the rear shock absorber upper mounting bolt @.
-
Remove the rear shock absorber lower mounting bolt @.
-
Remove the rear shock absorber @.
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.
-1
Do not attempt to disassemble the rear shock
absorber unit. It is unserviceable.
REAR SHOCK ABSORBER DISPOSAL
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.
GAS PRESSURE RELEASE
Mark the drill hole at @, shown in the illustration, with a center
punch.
Cover the rear shock absorber with a transparent vinyl bag @.
Hold the rear shock absorber Q with a vice.
Make a hole with a 3 mm drill.
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 uppertlower mounting nuts.
rn Rear shock absorber lower mounting nut:
50 N-m (5.0 kgf-m, 36.0 Ib-ft)
Rear shock absorber upper mounting nut:
50 N-rn (5.0 kgf-rn, 36.0 Ib-ft)
NOTE:
When installing the rear shock absorber, the outlet hose of the
prel-load adjuster faces backward.
Clamp the pre-load adjuster hose a.
Install the cushion rod 0.
Tighten the cushion rod nuts to the specified torque.
rn Cushion rod nut: 78 N m (7.8 kgf-m, 56.5 Ib-ft)
748 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"
@ STD position
@I Stiffest position
O Softest position
DAMPING FORCE ADJUSTMENT
The rebound damping force is adjusted by turning the adjuster.
Fully turn the damping adjuster @I 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)
1 112 turns back from stiffest position
(E-03,28,33)
I Do not turn the adjuster more than the given position I
or the adjuster may be damaged.
CHASSIS 7-49
REAR SWINGARM
CONSTRUCTION
10 1 Rear shock absorber 10 I Swingarm 1
I - I I 1 mounting nut " I
@
@
U
1 ITEM 1 N-m 1 knf-m 1 Ib-ft I
Rear cushion rod
Rear cushion lever
10 I Pivot spacer I I Swingarm pivot lock-nut I
@
@
$3
I @I I Chain cover I O 1 Swingarrn pivot nut I
@
-
I @ 1 Chain buffer
Spacer
Bearing
Washer
Rear shock absorber lower
mounting nut I
Center spacer
Rear shock absorber umer m
@
0
0
Cushion lever nut
Cushion rod nut
Swinaarm pivot shaft
7-50 CHASSIS
REMOVAL
Remove the exhaust pipe and exhaust muffler. ( W 3 - 6 )
Raise the rear wheel off the ground and support the motorcycle with a jack or wooden block.
Remove the rear wheel. ( W 7 - 3 6 )
Remove the rear brake hose guides @.
Remove the cushion rods a.
Remove the shock absorber lower mounting bolt @.
Remove the cushion lever @.
Remove the swingarm pivot shaft lock-nut with the special
tool.
a 09940-14940: Swingarm pivot thrust adjuster socket
wrench
Hold the swingarm pivot shaft @ and remove the swingarm
pivot nut @.
Remove the swingarm pivot shaft with the special tool.
a 09944-28320: Hexagon bit 19 mm
Remove the chain cover a.
CHASSIS 7-51
Remove the mud guard @.
Remove the chain buffer @.
INSPECTION AND DISASSEMBLY
SPACER
Remove the spacers @ 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
lnspect 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.
a 09921-20240: Bearing remover set (25 mm)
I DO not reuse the removed bearings. I
Remove the cushion rod bearings with the special tool.
rn 09921 -20240: Bearing remover set (1 7 mm)
I CAUTION I
/ DO not reuse the removed bearings. I
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 (11100 mm, 10 mm)
09900-20701 : Magnetic stand
09900-21 304: V-block (1 00 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.
CHASSIS 7.53
Remove the cushion lever bearings with the special tool.
a 09921-20240: Bearing remover set (20 mm and 17 mm)
pmKq
1 The removed bearings must be replaced with the new I
ones.
CUSHION ROD
Inspect the cushion rods for damage and distortion.
7-54 CHASSIS
REASSEMBLY
Reassemble the swingarm in the reverse order of disassembly and removal.
Pay attention to the following points:
Frame @ Rear shock absorber
Swingarm @ Left 0 Right
@ Washer @ Cushion lever @ Cushion rod
CHASSIS 7-55
SWINGARM BEARING
Install the bearings and spacer into the swingarm pivot all
together with the special tools.
a 09941 -3451 3: Steering race installer
09913-70210: Bearing installer set ( Q 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.
- a 09941 -3451 3: 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 SUZUKl SUPER GREASE to the bearings and spacers.
99000-25030: SUZUKl SUPER GREASE "A" (USA)
99000-25010: SUZUKl 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.
rn Swingarm pivot shaft: 15 N-m (1.5 kgf-m, 11 .O Ib-ft)
a 09944-28320: Hexagon bit 19 mm
Hold the swingarm pivot shaft @I with the special tool and
tighten the swingarm pivot nut a to the specified torque.
@ 09944-28320: Hexagon bit 19 mm
rn Swingarm pivot nut: 100 N-m (10.0 kgf-m, 72.5 Ib-ft)
Tighten the swingarm pivot lock-nut to the specified torque
with the special tool.
@ 09940-14940: Swingarm pivot thrust adjuster socket
wrench
rn Swingarm pivot lock-nut: 90 N-m (9.0 kgf-m, 65.0 Ib-ft)
CHASSIS 7-57
CUSHION LEVER AND CUSHION ROD
Install the washers @I and cushion lever @.
NOTE:
lnsert the cushion lever mounting bolt from the left side.
(rz7 7-54)
Install the cushion rod and rear shock absorber. B '- ----. NOTE:
lnsert the cushion rod mounting bolts and rear shock absorber
mounting bolts from the left side. (W 7-54)
Tighten the cushion lever nut @, cushion rod nut @ and rear
shock absorber lower mounting nut @ to the specified torque.
Cushion lever nut: 78 N-m (7.8 kgf-m, 56.5 Ib-ft)
Cushion rod nut: 78 N-m (7.8 kgf-m, 56.5 Ib-ft)
Rear shock absorber lower mounting nut:
50 N-m (5.0 kgf-m, 36.0 Ib-ft)
Install the rear wheel. (W7-40)
Install the exhaust pipe and muffler. (W3-14)
FINAL INSPECTION AND ADJUSTMENT
After installing the rear suspension and wheel, the following
adjustments are required before driving.
* Drive chain: ( W 2 - 2 1 )
* Tire pressure: (-7-82)
* Chassis bolts and nuts: (W2-28)
7-58 CHASSIS
FRONT BRAKE
CONSTRUCTION
I @ 1 Dia~hraam 10 1 ~ u s t seal
I I ~ u s t boot I @I I piston I
- -
@ I Pin m I Front brake master cylinder I
@
@I
Pistonlcup set
Brake hose
@
a @
@
@I
03
Pad mounting pin
Brake pad spring
Brake pad
Piston seal
Caliper holder
Caber
'e'
@
0
0
mounting bolt
Brake hose union bolt
Air bleeder valve
Brake caliper mounting bolt
39
ITEM
@
@
0
3.9
N-m
10
23
7.5
28.0
kgf-m
1.0
2.3
0.75
Ib-fl
7.0
16.5
5.5
-
CHASSIS 7-59
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. 1
BRAKE PAD REPLACEMENT
Remove the caliper.
piiEm-1
Do not operate the brake lever while removing the caliper.
Remove the pin 0.
Remove the brake pads by removing the pad mounting pin 0.
Clean up the caliper especially around the caliper pistons.
Install the outer pad with the detent @ of pad fitted to the
detent 03 on the caliper holder.
T i K E q
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 0.
Install the pad mounting pin 0.
Install the pin @ 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 Ib-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.
fi 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 Ib-ft)
CHASSIS 7-61
CAUTlONI
servicing and which has been stored for long periods of time.
Bleed air from the brake system. (-2-25)
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.
1 CAUTION]
Do not reuse the brake fluid left over from previous
servicing and stored for long periods of time.
- -- I Brake fluid, if it leaks, will interfere with safe running I
and discolor painted surfaces. Check the brake hose
and hose joints for cracks and fluid leakage.
Remove the caliper holder @.
Remove the pad spring a.
7-62 CHASSIS
Place a rag over the pistons to prevent them from popping out
and then force out the pistons using compressed air.
- I Do not use high pressure air to prevent piston dam- I
age.
Remove the dust seals @ and piston seals @.
Do not reuse the removed dust seals and piston seals
to prevent fluid leakage.
CALIPER INSPECTION
BRAKE CALIPER
lnspect 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
lnspect the caliper holder for damage. If any damage is found,
replace it with a new one.
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.
a Specification and Classification: DOT 4
pimq
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.
PISTON SEAL
Install the piston seals as shown in the illustration.
Install the piston to the caliper.
O Dust seal
@I Piston seal
O Caliper
7-64 CHASSIS
CALIPER HOLDER
Apply SUZUKl SILICONE GREASE to the caliper holder pin.
& 99000-25100: SUZUKl SILICONE GREASE
Install the caliper holder to the caliper.
Install the pad spring @.
NOTE: -
When installing the pad spring, seated on the lug of pad spring
to concaved part of brake caliper.
R
--- - 7. . - --
a Install the brake pads. (-7-59)
NOTE:
Before remounting the caliper, push the piston all the way into
the caliper. lnstall the brake caliper to the front fork.
Tighten each bolt to the specified torque.
Front brake caliper mounting bolt a:
39 N-m (3.9 kgf-m, 28.0 Ib-ft)
Front brake hose union bolt @I:
23 N-m (2.3 kgf-m, 16.5 Ib-ft)
pi.Kq
1 * The seal washers should be replaced with the new 1
( ones to prevent fluid leakage. I
* 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)
m09900-20205: Micrometer (0 - 25 mm)
Measure the runout with a dial gauge.
Replace the disc if the runout exceeds the service limit.
' ~ r o n t disc runout: Service Limit: 0.30 mm (0.012 in)
m09900-20607: Dial gauge (111 00 mm)
09900-20701 : Magnetic stand
* Brake disc removal (W7-10)
* 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 @.
I chemically with paint, plastics and rubber materials, (
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.
pmGq
etc. and will damage them severely.
--
Remove the master cylinder a.
Immediately and completely wipe off any brake fluid
contacting any part of the motorcycle. The fluid reacts
7-66 CHASSIS
Remove the brake lever @ and brake switch @.
Pull out the dust boot @ and remove the snap ring 0.
Remove the piston and return spring.
Piston
@ Secondary cup
@ Primary cup
@ Return spring
MASTER CYLINDER INSPECTION
lnspect the master cylinder bore for any scratches or other damage.
lnspect the piston surface for any scratches or other damage.
lnspect 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:
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.
a Specification and Classification: DOT 4
Apply brake fluid to the piston and cups.
Install the following parts to the master cylinder.
@ Dust boot
@ Snap ring
O Secondary cup
@ Piston
@ Primary cup
@ Return spring
When remounting the brake master cylinder O onto the handlebars, align the master cylinder holder's mating surface @
with punch mark @ on the handlebars @ as shown.
Tighten the front brake master cylinder mounting bolt to the
specified torque and first tighten the upper mounting bolt.
rn Front brake master cylinder mounting bolt:
10 N-m (1.0 kgf-m, 7.0 Ib-ft)
@ Master cylinder holder
@ "UP mark
Tighten the union bolt to the specified torque. (Brake hose
routing: -9-26)
rn Brake hose union bolt: 23 N-m (2.3 kgf-m, 16.5 Ib-ft)
The seal washers should be replaced with the new
ones to prevent fluid leakage.
7-68 CHASSIS
REAR BRAKE
CONSTRUCTION
@ 1 Brake hose I @ 1 Brake pad spring
@ I Pistonlcup set I @ I Brake hose union bolt
a @
I Piston seal 1 0 I Air bleeder valve
Diaphragm
Reservoir tank hose
8
63
@ I Pad shim 1 I Brake caliper sliding pin
@
@
Push rod
Dust boot
@
@
Caliper bracket
Caliper
C1
1 ITEM 1 N-m I kaf-m 1 Ib-ft 1 @
'
Dust seal
Piston
@
@I
Rear brake master cylinder
mounting bolt
Rear brake master cylinder
rod lock-nut
0
Pad insulator
Brake pad
Brake caliper mounting bolt
Pad mountina pin
Q3 I Plug
CHASSIS 7-69
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.
I CAUTION 1 -~ - - -
~ a n d l e brake fluid with care: the fluid reacts chemically with paint, plastics, rubber materials
etc. and will damage them severly.
BRAKE PAD REPLACEMENT
Remove the plug 6).
Loosen the pad mounting pin 0.
Remove the caliper bracket bolt @I.
1-
the pads.
Replace the brake pads as a set, otherwise braking
performance will be adversely affected.
Remove the pad mounting pin and brake pads with the rear
caliper pivoted up.
Clean up the caliper especially around the caliper pistons.
7-70 CHASSIS
Assemble the insulator @ and shim @ to the new brake pad
8.
-1
Replace the brake pads as a set, otherwise braking
performance will be adversely affected.
lnstall 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 a and pad mounting pin @
to the specified torque.
Rear brake caliper mounting bolt:
22 N-m (2.2 kgf-m, 16.0 Ib-ft)
Rear brake pad mounting pin:
17 N-m (1.7 kgf-m, 12.5 Ib-ft)
Install the plug @ to the specified torque.
Pad pin plug: 2.5 N-m (0.25 kgf-m, 1.8 Ib-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.
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
I Bleed air from the brake system. (-2-25) I
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 @.
I CAUTION I
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 @.
4
'. - --- r
.d C
Remove the pad spring @.
Remove the spacer and boot @ from the caliper.
Remove the brake caliper sliding pin @
Place a rag over the piston to prevent it from popping out and
then force out the piston using compressed air.
-1
I DO not use high pressure air to prevent piston dam- I
age.
CHASSIS 7-73
Remove the dust seal and piston seal @.
Do not reuse the dust seal and piston seal to prevent
fluid leakage.
CALIPER INSPECTION
BRAKE CALIPER
lnspect 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
lnspect 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
lnspect 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.
lnspect the boot and spacer for damage and wear. If any damage is found, replace boot and spacer with the new ones.
7-74 CHASSIS
BRAKE DISC INSPECTION
Inspect the rear brake disc in the same manner as the front
brake disc. ( W 7 - 6 5 )
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:
mm5i-j
* 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.
fi Specification and Classification: DOT 4
PISTON SEAL
Install the piston seals as shown in the illustration.
Install the piston to the caliper.
@ Dust seal
@ Piston seal
@ Caliper
BRAKE CALIPER SLIDING PIN
Install the boot 0.
Apply SUZUKl SILICONE GREASE to the inside of the boot.
99000-251 00: SUZUKl SILICONE GREASE
Install the spacer @.
CHASSIS 7-75
Tighten the brake caliper sliding pin @ to the specified torque.
Brake caliper sliding pin: 27 N-m (2.7 kgf-m, 19.5 Ib-ft)
Apply SUZUKl SILICONE GREASE to the brake caliper sliding pin.
& 99000-25100: SUZUKl SILICONE GREASE
Install the caliper to the caliper bracket @.
Set the boot onto the brake caliper sliding pin @ 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 Ib-ft)
pmmq
The seal washers should be replaced with the new
ones to prevent fluid leakage.
Bleed air from the system after reassembling the caliper. (W2-25 )
MASTER CYLINDER REMOVAL AND DISAS-
SEMBLY
Drain the brake fluid. (-7-71)
- Remove the brake fluid reservoir tank mounting bolt @.
7-76 CHASSIS
Loosen the lock-nut @.
Remove the master cylinder mounting bolts @.
Place a rag underneath the union bolt on the master cylinder
to catch spilled drops of brake fluid. Remove the union bolt @
and disconnect the brake hose.
CAUTlONj
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.
Remove
rod 0.
the master cylinder by turning the master cylinder
Disconnect the reservoir hose @.
Remove the connector by removing the snap ring @.
Remove the O-ring @.
Replace the O-ring with a new one. I
--
Pull out the dust boot @, then remove the snap ring @.
Remove the push rod, piston/primary cup and spring.
CHASSIS 7-77
MASTER CYLINDER INSPECTION
- CYLINDER, PISTON AND CUP SET
lnspect 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:
pmEq
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.
a Specification and Classification: DOT 4
Apply brake fluid to the pistonlcup set.
Install the following parts.
@ Spring
@ Pistonlprimaty cup
@ Push rod
@ Snap ring
@ Dust boot
Apply the SUZUKI MOLY PASTE to the push rod.
99000-25140: SUZUKl MOLY PASTE
Install the O-ring 0, connector and snap ring @ to the
master cylinder.
I CAUTION 1
Replace the removed O-ring with a new one.
7-78 CHASSIS
lnstall the master cylinder.
Tighten the lock-nut 3.
[I] Rear brake master cylinder rod lock-nut:
18 N-m (1.8 kgf-m, 13.0 Ib-ft)
Install the reservoir tank. (Rear brake hose routing: W 9 - 2 7 )
Temporarily install the master cylinder to the frame.
Connect the brake hose to the master cylinder. (Rear brake
hose routing: W 9 - 2 7 )
Tighten the brake hose union bolt @D to the specified torque.
[I] Brake hose union bolt: 23 N-m (2.3 kgf-m, 16.5 Ib-ft)
pmiq
The seal washers should be replaced with the new
ones to prevent fluid leakage.
Bleed air from the system after reassembling the
master cylinder. ( W 2 - 2 5 )
Adjust the brake pedal height. ( W 2 - 2 4 )
lnstall the master cylinder.
Tighten the master cylinder mounting bolts to the specified
torque.
[I] Rear master cylinder mounting bolt:
10 N-m (1.0 kgf-m, 7.0 Ib-ft)
CHASSIS 7-79
TlRE AND WHEEL
TlRE 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 (-7-1 1)
TlRE
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 @ has abnormal deformation, replace the valve with a new one.
VALVE INSTALLATION
Any dust or rust around the valve hole @ 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.
Be careful not to damage the lip of valve.
@ Wheel
@ Valve lip
$3 Valve
CHASSIS 7-81
TIRE INSTALLATION
Apply tire lubricant to the tire bead.
When installing the tire onto the wheel, observe the following
points.
* Do not reuse the valve which has been once
removed.
* Do not use oil, grease or gasoline on the tire bead in
place of tire lubricant.
When installing the tire, the arrow @I 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 inflate the tire to more than 400 kPa (4.0kgfl
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" @ cast on the tire side
walls. The line must be equidistant from the wheel rim all
around. If the distance between the rim line @ and wheel rim
varies, this indicates that the bead is not properly seated. If
this is the case, deflate the tire completely and unseat the
bead for both sides. 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.
1 DO not run with a repaired tire at a high speed. I
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)
CHASSIS 7-83
DRIVE CHAIN
Use the special tool in the following procedures, to cut and rejoin
the drive chain.
@ 09922-2271 1: 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.
@ Tool body
@ Grip handle
@ Pressure bolt " A
@ Pressure bolt "B"
@ Bar
@ Adjuster bolt (with through hole)
Pin remover
@ Chain holder (engraved mark 500)
with reamer bolt M5 x 10
NOTE:
The tip of pin remover should be positioned inside @ approximately 5 mm (0.2 in) from the end face of pressure bolt "A" @I
as shown in the illustration.
7.84 CHASSIS
Place the drive chain link being disjointed on the holder part
@ of the tool.
Turn in both the adjuster bolt @ and pressure bolt " A @ so
that each of their end hole fits over the chain joint pin properly.
Tighten the pressure bolt " A @ with the bar.
Turn in the pressure bolt " B @ with the bar @ and force out
the drive chain joint pin @.
Continue turning in the pressure bolt "B" @ until the
joint pin has been completely pushed out of the chain.
NOTE:
After the joint pin is removed, loosen the pressure bolt "5" @
and then pressure bolt "A"@.
Remove the joint pin @ of the other side of joint plate.
I CAUTION I
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.
DRIVE CHAIN CONNECTING
JOINT PLATE INSTALLATION
Set up the special tool as shown in the illustration.
@ Tool body @ Adjuster bolt
(3 Grip handle (without hole)
(3 Joint plate holder @ Pressure bolt "A"
(engraved mark "F520) Bar
@ Wedge holder & wedge pin
Connect both ends of the drive chain with the joint pin (8)
inserted from the wheel side @ as installed on the motorcycle.
@ O-ring . .. 4 pcs
@ Joint plate
Joint set part number
DID: 27620-32C10
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.
Apply grease on the recessed portion of the joint plate holder
@ and set the joint plate @.
NOTE:
When positioning the joint plate @ on the tool, its stamp mark
must face the joint plate holder @ side.
Set the drive chain on the tool as illustrated and turn in the
adjuster bolt @ to secure the wedge holder & wedge pin @.
Turn in the pressure bolt " A @ and align two joint pins @
properly with the respective holes of the joint plate @
Turn in the pressure bolt " A @ further using the bar O 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 @
DID 18.70 - 18.90 mrn (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.
JOINT PIN STAKING
Set up the special tool as shown in the illustration.
@ Tool body
@ Grip handle
@ Pressure bolt " A
@ Adjuster bolt (without hole)
a Staking pin (stowed inside grip handle behind rubber cap)
@ Bar
NOTE:
Before staking the joint pin, apply a small quantity of grease to
the staking pin 0.
7-86 CHASSIS
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.
Stake the joint pin by turning (approximately 718 turn) the
pressure bolt " A @ with the bar until the pin end diameter
becomes the specified dimension.
Pin end diameter specification 0
Adjust the drive chain, after connecting it. (-2-21)
DID 5.5 - 5.8 mm (0.21 7 - 0.228 in)
ELECTRICAL SYSTEM 8-1
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 ...................................... 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 RELA Y 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 LlGHTflAlLLlGHT AND TURN
SIGNAL LIGHT ....................................................................................... 8-36
RELA YS .................... ..... .......................................................................... 8-37
TURN SIGNAUSIDE-STAND RELAY ................................................... 8-37
STARTER RELAY ................................................................................ 8-37
FUEL PUMP RELA Y .............................................................................. 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.
lnspect 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.
lnspect each terminal on the coupler for being loose or bent.
lnspect each terminal for corrosion and contamination.
CLAMP
Clamp the wire harness at such positions as indicated in
"WIRE HARNESS ROUTING". ( W 9 - 1 6 to 9-1 8)
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.
CORRECT INCORRECT
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 9-1 8)
INCORRECT /
8-4 ELECTRICAL SYSTEM
USING THE MULTl 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.
I CAUTION I
Before using the multi circuit tester, read its instruction
manual.
ELECTRICAL SYSTEM 8-5
LOCATION OF ELECTRICAL COMPONENTS
@ Horn
@ Fuel injector (W4-42)
@ STP sensor (W4-38)
@ TP sensor (-4-28)
@ STV actuator (-4-37)
@ Fuel pump (-5-9)
Speed sensor (W8-35)
@ Ignition coil (No.1)
@ CKP sensor (-4-23)
@ Generator (-8-1 0)
@ Gear position switch (W8-20)
@ Side-stand switch (W8-20)
8-6 ELECTRICAL SYSTEM
@ TO sensor ( W 4 - 3 5 )
@ Fuel pump relay ( W 5 - 1 0 )
@ ECM (Engine Control Module)
@ Fuse box
@ Turn signallside-stand relay ( W 8 - 3 7 )
@ Starter relay ( W 8 - 1 9 )
O Battery
@ IAP sensor ( W 4 - 2 5 )
@ IAT sensor ( W 4 - 3 3 )
@ PAIR control valve (-10-7)
@ Regulatorlrectifier (-8-1 1)
@ Cooling fan thermo-switch ( W 6 - 9 )
Q H02 sensor ( W 4 - 4 7 )
@ ECT sensor ( W 4 - 3 1 )
@ Ignition coil (No.2)
@ Oil pressure switch
0 Starter motor
ELECTRICAL SYSTEM 8-7
CHARGING SYSTEM
@ Generator @ Regulator/rectifier @ Ignition switch @ Main fuse @ Battery @ Load
-
TROUBLE SHOOTING
Battery runs down quickly
Step1
1) Check accessories which use excessive amounts of electricity.
Are accessories being installed?
YES
NO
Remove accessories.
Go to Step2.
Step2
1) Check the battery for current leaks. (-8-9)
Is the battery for current leaks OK?
YES
NO
Go to Step3.
Short circuit of wire harness.
Faulty electrical equipment.
Step3
1) Measure the charging voltage between the battery terminals. (-8-9)
Is the battery charging of voltage OK?
YES
NO
Faulty battery.
Abnormal driving condition.
Go to Step4.
8-8 ELECTRICAL SYSTEM
Step4
1) Measure the continuity of the generator coil. (W8-10)
Is the resistance of generator coil OK?
Faulty generator coil.
Disconnected lead wires.
Step5
1) Measure the generator no-load voltage. (-8-10)
Is generator no-load performance OK?
Step6
1 ) Inspect the regulatorJrectifier. (-8-1 1 )
Is the regulatorlrectifier OK?
YES
NO
Go to Step6.
Faultv aenerator.
Step7
1) Inspect the wire harness.
Is the wire harness OK?
YES
NO
YES I Faultv batterv I
Go to Step7.
Faultv reaulatorlrectifier.
Battery overcharges
Faulty regulatorlrectifier.
Faulty battery.
Poor contact of generator lead wire coupler.
NO
Short circuit of wire harness.
Poor contact of coupler.
ELECTRICAL SYSTEM 8-9
INSPECTION
- BAlTERY 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
rn Battery current (leak): 3 mA and less
aD Tester knob indication: Current (=, 20 mA)
- -1
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.
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 rlmin. 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 regulatorlrectifier.
(-8-1 0 and 8-1 1)
NOTE:
When making this test, be sure that the battery is in fullycharged condition.
09900-25008: Multi circuit tester set
b@ Tester knob indication: Voltage (=)
rn Charging output (Regulated voltage):
14.0 - 15.5 V at 5 000 rlmin.
8-10 ELECTRICAL SYSTEM
GENERATOR COIL RESISTANCE
Remove the right cowling. (-7-5)
Disconnect the generator coupler a.
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.
a 09900-25008: Multi circuit tester set
r) Tester knob indication: Resistance (Q)
rn Generator coil resistance: 0.2 - 0.7 Q (Black - Black)
= Q (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 rlrnin.
Using the rnulti circuit tester, measure the voltage between three
lead wires.
If the tester reads under the specified value, replace the generator with a new one.
a 09900-25008: Multi circuit tester set
ju Tester knob indication: Voltage (-)
rn Generator no-load performance:
60 V and more at 5 000 rimin (When engine is cold)
ELECTRICAL SYSTEM 8-1 I
REGULATOR/RECTIFIER
Remove the right cowling. (-7-5)
Disconnect the regulatorlrectifier couplers 0.
Remove the regulatorlrectifier 0.
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 regulatorlrectifier with a
new one.
09900-25008: Multi circuit tester set
fij) Tester knob indication: Diode test (fe)
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.
8-12 ELECTRICAL SYSTEM
STARTER SYSTEM AND SIDE-STANDIIGNITION INTERLOCK
SYSTEM
@ Starter motor @ Starter relay @ Clutch switch @ Starter button @ Engine stop switch
@ Turn signallside-stand relay a Ignition switch @ Fuse @ Side-stand switch
0 Gear position switch @ Battery @ 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?
l YES I GO to ~ t e ~ 2 . I
I NO I Go to Step3
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?
I Faulty starter relay. I
!YES I Loose or disconnected starter motor lead wire. I
NO
Loose or disconnected between starter relay and @ battery terminal.
Faultv starter motor.
ELECTRICAL SYSTEM 8-13
Step3
1) Measure the starter relay voltage at the starter relay connectors (between B N and YIG) when the starter
button is pushed.
Is a voltage OK?
Faulty gear position switch.
Faulty starter button.
Faulty engine stop switch.
Faulty turn signallside-stand relay.
Faulty ignition switch.
Faulty clutch switch.
Faulty side-stand switch.
I I Improper connector contact.
I I Open circuit in wire harness.
Step4
1) Inspect the starter relay. (W8-19 )
Is the starter relay OK?
1 YES I Poor starter relav connection.
I NO / Faulty starter relay. I
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.
I) Inspect the side-stand switch. (-8-20)
Is the side-stand switch OK?
YES Open circuit in wire harness.
Poor contact of connector.
NO I Faulty side-stand switch. I
Engine does not turn though the starter motor runs.
Faulty starter clutch. (W3-79 )
8-1 4 ELECTRICAL SYSTEM
STARTER MOTOR REMOVAL AND
DISASSEMBLY
Remove the starter motor and disconnect the starter motor
lead wire a.
Disassemble the starter motor as shown in the illustration.
@ Housing end (rear bracket) @ Armature @I Thrust stopper
@ Brush spring (2 pcs) a Starter motor case @ O-ring (2 pcs)
O Brush holder @ Seal ring (2 pcs) 0 O-ring
@ Terminal
(3 Washer
@ Washer
@J Slip washer
@ Housing end (front bracket)
ELECTRICAL SYSTEM 8-15
STARTER MOTOR INSPECTION
CARBONBRUSH
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 @.
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.
Insulator
Q 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 (4))
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:
Replace the O-rings with the new ones to prevent oil
leakage and moisture.
--
a Apply SUZUKl 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 SUZUKl MOLY PASTE to the armature shaft.
& 99000-251 40: SUZUKl MOLY PASTE
Install the spacer @ to brush terminal.
When installing the brush holder on the rear bracket, set the
projection @ of the brush holder into the groove 8 of the rear
bracket.
ELECTRICAL SYSTEM 8-17
r I-.-- - -
lnstall the washers (12 x 6.5 x 2), washer @ (16 x 6.5 x I),
washer @ (14 x 6.5 x 1) and nut 0.
I Replace the O-rings with the new ones to prevent oil I
leakage and moisture.
lnstall the washers @.
NOTE:
The number of washer @ varies according to individual.
-
Install the seal rings @ to starter motor case a.
/
When install the rear bracket to starter motor case, align the
marks @ on the rear bracket with cut point @$ at the starter
motor case.
Replace the seal rings with the new ones to prevent oil
leakage and moisture.
Install the washers @ slip washer @ and thrust stopper @.
NOTE: I
The number of washer @ varies according to individual. ' A 1 , 181 ,
Install the front bracket. b
Align the marks 0 on the front bracket with the marks @ on
the starter motor case. 1 I
I
1
8-18 ELECTRICAL SYSTEM
Apply SUZUKl SUPER GREASE to the starter motor O-rings.
99000-25030: SUZUKl SUPER GREASE "A" (USA)
99000-25010: SUZUKl SUPER GREASE "A" (Others)
/ Use new O-rings to prevent oil leakage. 1
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 @ as shown. First tighten the starter motor lower mounting bolt @, then
tighten the starter motor upper mounting bolt @I.
Connect the starter motor read wire as shown.
Tighten the nut @ and fit the cap @.
ELECTRICAL SYSTEM 8-19
STARTER RELAY INSPECTION
- Remove the seat. (W7-4)
Disconnect the battery @ lead wire from the battery.
Remove the starter relay cover 6).
Disconnect the starter relay coupler @.
Disconnect the starter motor lead wire @ and battery lead , 1
wire 8.
Remove the starter relay @.
Apply 12 V to @ and @ terminals and check for continuity dl......l+between the positive and negative terminals using the multi circuit tester. If the starter relay clicks and continuity is found, the
relay is ok.
rn 09900-25008: Multi circuit tester set
Tester knob indication: Continuity test (4))
/-mmGq
Do not apply a battery voltage to the starter relay for
five seconds and more, since the relay coil may overheat and get damaged.
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
1) Tester knob indication: Resistance (Q)
Starter relay resistance: 3 - 6 C2
8-20 ELECTRICAL SYSTEM
SIDE-STANDIIGNITION 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 @ and measure the
voltage between BlacldWhite and Green lead wires.
rn 09900-25008: Multi circuit tester set
;m Tester knob indication: Diode test (fe)
Side-stand up @
- --
NOTE:
If the tester reads under 1.4 V when the tester probes are not
connected, replace its battery.
Side-stand down @I
GEAR POSITION SWITCH
Remove the left frame cover. (-7-5)
Disconnect the gear position switch coupler and check the
continuity between Blue and BlacWhite with the transmission in "NEUTRAL".
rn 09900-25008: Multi circuit tester set
rm Tester knob indication: Continuity test (4))
BlacWhite
(@ probe)
1.4 V and more
(Tester's battery voltage)
Green
(@ probe)
I ON (Neutral) 1 - I
0.4 - 0.6 V
Blue BlacWhite
When disconnecting and connecting the gear position
switch coupler, make sure to turn OFF the ignition
switch, or electronic parts may get damaged.
OFF (Expect neutral) I
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 BNV 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
Gear
position
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.
Voltage
- -.-- -- - --
TURN SIGNAUSIDE-STAND RELAY REMOVAL AND
INSTALLATION
The turn signallside-stand relay is composed of the turn signal
relay, side-stand relay and diode.
Remove the seat. (-7-4)
Remove the turn signallside-stand relay 0.
Install the turn signallside-stand relay in the reverse order of
removal.
1 st
Approx.
1.36 V
2nd
Approx.
1.77 V
3rd
Approx.
2.49 V
4th
Approx.
3.23 V
5th 6th
Approx.
4.10 V
Approx.
4.55 V
8-22 ELECTRICAL SYSTEM
SIDE-STAND RELAY INSPECTION
First check the insulation between 0 and terminals with the
tester. Then apply 12 V to terminals 0 and 0 (@ to 0 and O to
0) and check the continuity between 0 and a. If there is no
continuity, replace the turn signallside-stand relay with a new
one.
a 09900-25008: Multi circuit tester set
im Tester knob indication: Continuity test (4))
@ Diode
@ Side-stand relay
@ Turn signal relay
DIODE INSPECTION
Measure the voltage between the terminals using the multi circuit tester. Refer to the following table.
Unit: V
@ Probe of tester to:
1.4 V and more
0.4 - 0.6
a 09900-25008: Multi circuit tester set
Lm Tester knob indication: Diode test (U)
NOTE:
If the multi circuit tester reads 1.4 V and below when the tester
probes are not connected, replace its battery.
ELECTRICAL SYSTEM 8-23
IGNITION SYSTEM
@ CKP sensor @ ECM @ Wave form arrangement circuit @ Power source circuit @ CPU
@ TP sensor ECT sensor @ Gear position switch @ Engine stop switch @I lgnition coil #1
Spark plug #I @ lgnition coil #2 @ Spark plug #2 @ Side-stand relay @ Fuse
@ lgnition switch @ 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 (OIG and BIW) at the ECM with the ignition switch
in the "ON" position.
Is the voltage OK?
YES
NO
l YES I GO to ~ t e ~ 3 . I
Go to Step2.
lmoro~er cou~ler connection.
I
1 - Faulty ignition switch.
Faulty turn signallside-stand relay.
Faulty engine stop switch.
I I Broken wire harness or poor connection of related circuit couplers. I
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) lnspect the spark plug. (-2-6)
Is the spark plug OK?
Step5
1) lnspect the ignition coil. (-8-26)
Is the ignition coil OK?
YES
NO
1 YES I Go to Step6. 1
lmproper spark plug connection.
Go to Step5.
Faulty spark plug.
I NO I Faulty ignition coil. I
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?
Faulty ECM.
Faulty wire harness.
NO
lmproper ignition coupler connection.
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: WhiteIBlue terminal
@ Probe: Ground
No.2 ignition coil: @ Probe: Black terminal
@ Probe: Ground
@ Peak volt adaptor
Q Ignition coil (No.1 or No.2)
@ New spark plug
@ ECM
@ Battery
NOTE:
Do not disconnect the ignition coil primary wire coupler.
09900-25008: Multi circuit tester set
Before using the multi circuit tester and peak volt
adaptor, be sure to refer to the appropriate instruction
manual.
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.
8-26 ELECTRICAL SYSTEM
Repeat the above procedure a few times and measure the
highest ignition coil primary peak voltage.
ga Tester knob indication: Voltage (=)
rn Ignition coil primary peak voltage: 150 V and more
While testing, do not touch the tester probes and
spark plugs to prevent receiving an electric shock.
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
;u Tester knob indication: Resistance (Q)
rn lgnition coil resistance
Primary : 2 - 5 Q (@ terminal - @ terminal)
Secondary : 24 - 37 kQ (Plug cap - @ terminal)
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: BlacWhite lead wire
09900-25008: Multi circuit tester set
zzmiiq
Before using the multi circuit tester and peak volt
adaptor, be sure to refer to the appropriate instruction
manual.
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.
@I CKP sensor
O CKP sensor coupler
O ECM coupler
@ Peak volt adaptor
4) Tester knob indication: Voltage (=)
rn 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 (=)
rn CKP sensor peak voltage: 3.7 V and more
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.
@ CKP sensor
@ CKP sensor coupler
a 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.
@ CKP sensor
CKP sensor coupler
09900-25008: Multi circuit tester set
Tester knob indication: Resistance (R)
CKP sensor resistance: 130 - 240 SZ (White - Green)
00 SZ (White - Ground)
ELECTRICAL SYSTEM 8-29
COMBINATION METER
REMOVAL AND DISASSEMBLY
Disconnect the battery @ lead wire.
Remove the combination meter panel. (W7-6).
Remove the combination meter @.
When disconnecting and connecting the combination
meter coupler, make sure to turn OFF the ignition
switch, or electronic parts may get damaged.
- ~
Disassemble the combination meter as follows.
Do not attempt to disassemble the combination meter
unit.
I @ ( Combination meter cover I @ I Combination meter unit I
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 harnesslcoupler.
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 harNOTE:
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 @ pressed, turn the ignition switch on.
2) Keep pushing the ADJ switch @ for 3 to 5 seconds.
3) Push the ADJ switch @ twice (within 1 second). + Reset
* Complete the operation within 10 seconds after the ignition switch has been turned on.
I Time ADJ switch @
Push
1 @ ADJ SWITCH
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.
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 @.
3. Push the ADJ switch @ for 2 seconds.
8-32 ELECTRICAL SYSTEM
INDICATORS
ENGINE COOLANT TEMPERATURE METER INSPECTION
Disconnect the ECT sensor coupler a.
I CAUTION I
When connecting and disconnecting the ECT sensor
lead wire coupler, make sure to turn OFF the ignition
switch, or electronic parts may get damaged.
Connect the variable resistor @ 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.
@ Variable resister
@I ECT sensor
Water tem~erateurel 39 "C and below I 40 - 59 "C 60 - 79 'C 80-111 "C
Resistance
and more
I Water temperateurel 1 12 - 11 9 "C 1 120 "C and over 1 122 "C and over I
Engine coolant
temperature meter
G
0
I 3 n n
I Resistance 1 0.140 - 0.1 16 kR
0
0
a [7
El U u m m
'iI.!
m m m m m
0.1 16 k!2 0.111 kR
and less I and less
Engine coolant
temperature meter
n m m m m
m m m m m
m m m
d:m m
ELECTRICAL SYSTEM 8-33
FUEL LEVEL GAUGE INSPECTION
Remove the fuel tank. (-5-7)
Remove the fuel pump. (-5-1 0)
Measure the resistance at each fuel level gauge float position. If
the resistance is incorrect, replace the fuel level gauge with a =----.k new one.
I Float position Resistance I
09900-25008: Multi circuit tester set
um~ester knob indication: Resistance (GI)
8 " F (Full)
@ “E" (Empty)
-
Install the fuel pump. (-5-12)
Approx. 4 R
Approx. 182 R
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
BlacWhite 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 , 67.0 I More than
Fuel level
meter
OIL PRESSURE INDICATOR INSPECTION
NOTE:
Before inspecting the oil pressure switch, check the engine oil
level. 0 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 0.
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 @I.
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. (-7-1 0)
Disconnect the speed sensor coupler. (W8-35)
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 kQ resistance and the
tester to the speed sensor lead wire coupler as shown.
09900-25008: Multi-circuit tester set
Q) 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.
8-36 ELECTRICAL SYSTEM
LAMPS
HEADLIGHT, BRAKE LIGHTnAILLIGHT AND TURN SIGNAL LIGHT
HEADLIGHT
12V60155 W
1 2 V 6 0 / 5 5 W + 5 W
@ ONLY E-02, 19
BRAKE LlGHTrrAlL LIGHT
12 V 2115 W
TURN SIGNAL LIGHT
1 2 v 2 1 W
HEADLIGHT BEAM ADJUSTMENT
Adjust the headlight beam, both vc
0: Vertical adjuster
0: Horizontal adjuster
NOTE:
To adjust the headlight beam, adjust
then adjust the vertically.
!rtical and horizontal.
' the beam horizontally first,
ELECTRICAL SYSTEM 8-37
RELAYS
TURN SIGNAUSIDE-STAND RELAY
The turn signallside-stand relay is composed of the turn signal
relay, side-stand relay and diode.
INSPECTION
Before removing the turn signallside-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 signal1
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.
@ Diode
@ Side-stand relay
@ Turn signal relay
STARTER RELAY
(-8-1 9)
FUEL PUMP RELAY
(-5-1 0)
8-38 ELECTRICAL SYSTEM
SWITCHES
IGNITION SWITCH REMOVAL
Remove the fuel tank. ( W 5 - 7 )
Remove the air cleaner box. ( W 5 - 1 5 )
Disconnect the ignition switch coupler a.
Remove the ignition switch mounting bolts with the special
tools.
09930-1 1920: Torx bit JT40H
09930-1 1940: Bit holder
When reusing the ignition switch bolt, clean thread and
apply the THREAD LOCK SUPER "1322" or THREAD
LOCK "1342".
a 99000-32050: THREAD LOCK "1 342" (USA)
a 99000-321 10: THREAD LOCK SUPER "1 322" (Others)
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.
REAR BRAKE SWITCH IGNITION SWITCH
R
ON 0
CLUTCH SWITCH
OFF
ON
0
A
V
0 I 0
DIMMER SWITCH B N
OFF Color
O N
n B N
OIL PRESSURE SWITCH .
Br 0
TURN SIGNAL LIGHT SWITCH
k G N
I ON (engine 1
IS &0~Ded)
Ground
I , I I
OFF (engine
is running)
Lg I R I 0 I 0
PASSING LIGHT SWITCH
Lbl
L
NOTE:
B
Before inspecting the oil pressure switch, check the
engine oil level. p 2 - 13)
PUSH I
0
I I
PUSH I 0 I 0
0
WIRE COLOR BIB1 : Black with Blue tracer
ENGINE STOP SWITCH B : Black BMI : Black with White tracer
Br : Brown B N : Black with Yellow tracer
Lbl : Light blue BIR : Black with Red tracer
Lg : Light green GN : Green with Yellow tracer
0 : Orange OIB : Orange with Black tracer
R : Red OIR : Orange with Red tracer
Y : Yellow OMI : Orange with White tracer
W : White O N : Orange with Yellow tracer
WIB : White with Black tracer
I RUN (0) I 0 I 0
STARTER BUTTON
O/B
I I PUSH / 0 I 0 I
OMI
YIG : Yellow with Green tracer
YMI : Yellow with White tracer
HORN BUTTON
HAZARD
I OFF (
FRONT BRAKE SWITCH
LS
ON 0
Lbl
n B
0
8-40 ELECTRICAL SYSTEM
BATTERY
SPECIFICATIONS
@ Upper cover breather @ Terminal
@ Cathode plates @ Safety valve
@ Stopper Anode plates
@ Filter @ Separator (Fiberglass plate)
Type designation
Capacity
INITIAL CHARGING
Filling electrolyte
Remove the aluminum tape @ sealing the battery electrolyte
filler holes @.
YTX12 - BS
12 V, 36.0 k c (1 0 Ah)/lO HR
NOTE:
When filling electrolyte, the battery must be removed from the
vehicle and must be put on the level ground.
Remove the caps @.
NOTE:
* After filling the electrolyte completely, use the removed cap @
as the sealed caps of battery-filler holes.
* Do not remove or pierce the sealed areas of the electrolyte
container.
Insert the nozzles of the electrolyte container @ 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 @ are coming up each electrolyte container, and leave in this position for about more than 20 minutes.
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 baftery.
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 @ 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.
1 CAUTION 1
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.
For initial charging, use the charger specially designed for MF battery.
pEEi6iq
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.
@ Charging period
0 Stop charging
(CAUTlONI
When recharging the battery, remove the battery
from the motorcycle.
Do not remove the caps on the battery top while
recharging.
Recharging time: 1.4 A for 5 to 10 hours or 6 A for one hour
Be careful not to permit the charging current to
exceed 6 A at any time.
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.
0 10 20 30 40 50 60
Time (Minutes)
100 75 50 25 0 ('10)
Battety charged condition
SERVICING INFORMATION 9-1
CONTENTS
TROUBLESHOOTING ................................................................................... 2
MALFUNCTION CODE AND DEFECTIVE CONDITION ........................ 9 - 2
................................................................................................... ENGINE 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 (H02S) WlRE ROUTING
(FOR E.02, 19) ........................................................................................ 9-18
ENGINE ELECTRICAL PARTS SET4P ................................................ 9-19
SPEED SENSOR LEAD WIRE ROUTING .............................................. 9-20
THROTTLE CABLE ROUTING ............................................................... 9-21
CLUTCH CABLE ROUTING ................................................................... 9-22
THROTTLE BODY INSTALLATIONIHOSE 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-STA ND SE T-UP ............................................................................. 9-33
BRAKE PEDAUFOOTREST 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
COO
DETECTED ITEM
sensor I receiving the IAP signal. I
DETECTED FAILURE CONDITION
CHECK FOR
NO FAULT
Crankshaft position
I The crankshaft position sensor wiring and mechanical parts. I
The signal does not reach ECM for 3 sec. and more, after
sensor
lntake air pressure
0.1 V 5 sensor voltage 5 4.8 V
Without the above ranae for 4 sec. and more. C13 is indicated.
(Crankshaft position sensor, lead wirelcoupler connection)
The sensor should produce following voltage.
Throttle position senSO r
lntake air pressure sensor, lead wirelcoupler connection.
The sensor should produce following voltage.
0.1 V 4 sensor voltage < 4.8 V
Without the above range for 4 sec. and more, C14 is indicated.
Tip over sensor
Engine coolant temperature sensor
lntake air temperature
sensor
Ignition signal #1/#2
-
Throttle position sensor, lead wirelcoupler connection.
The sensor voltage should be the following.
0.1 V S sensor voltage < 4.6 V
Without the above range for 4 sec. and more, C15 is indicated.
Engine coolant temperature sensor, lead wirelcoupler connection.
The sensor voltage should be the following.
0.1 V 5 sensor voltage < 4.6 V
Without the above range for 4 sec. and more, C21 is indicated.
lntake air temperature sensor, lead wirelcoupler connection.
The sensor voltage should be the following for 2 sec. and more
after ignition switch turns ON.
0.2 V S sensor voltage 5 4.6 V
Without the above value for 2 sec. and more, C23 is indicated.
Tip over sensor, lead wirelcoupler connection.
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, wiringlcoupler connection, power supply from the
battery.
-
SERVICING INFORMATION 9-3
IALFUNCTION
CODE
DETECTED ITEM
Secondary throttle
valve actuator
Secondary throttle
position sensor
Gear position signal
Fuel injector #11#2
Fuel pump relay
Ignition switch
Heated oxygen sensor
(H02S)
[E-02, 191
PAlR control solenoid
valve
DETECTED FAILURE CONDITION
CHECK FOR
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 wirelcoupler.
The sensor should produce following voltage.
0.1 V S sensor voltage $ 4.8 V
Without the above range for 4 sec. and more, C29 is indicated.
Secondary throttle position sensor, lead wirelcoupler connection.
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, wiringlcoupler connection. Gearshift cam
etc.
When fuel injector voltage gets 1.3 V and less, C32 or C33 is
indicated.
-
Injector, wiing/coupler connection, power supply to the injector.
No voltage is applied to the both injectors #11#2 for 3 sec. after
the contact of fuel pump relay is turned ON. Or voltage is
applied to the both injectors #11#2, when the contact of fuel
pump is OFF.
Fuel pump relay, connecting lead wire, power source to fuel
pump relav, fuel iniectors.
- - --
Ignition switch signal is not input in ECM.
Ignition switch, lead wirelcoupler. The sensor voltage should be the following and less after warming up condition.
(Sensor voltage I 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.
H02S lead wirelcoupler connection.
Battew voltaqe supply to the H02S.
PAlR control solenoid valve voltaae is not i n ~ u t in ECM.
- -- -
PAlR control solenoid valve, lead wirelcoupler.
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 fuellair 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
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.
ENGINE STALLS OFTEN
Symptom, possible causes and remedy
1) Incorrect fuellair 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.
Adjust.
Replace or repair.
Replace.
Replace.
Adjust or replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Adjust.
Replace.
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 internaVelectrical 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.
lmbalanced 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
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 fuellair mixture
Short-circuited IAP sensorllead wire.
short-circuited IAT sensorllead 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.
DIRTY OR HEAVY EXHAUST SMOKE
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.
SLIPPING CLUTCH
Symptom, possible causes and remedy
Weakened clutch springs.
Worn or distorted pressure plates.
Distorted clutch plates or pressure plates.
DRAGGING CLUTCH
Symptom, possible causes and remedy
Some clutch springs weakened while others are
not.
Distorted pressure plates or clutch plates.
TRANSMISSION WILL NOT SHIFT
Symptom, possible causes and remedy
Broken gearshift cam.
Distorted gearshift forks.
Worn gearshift pawl.
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.
Check with inspection window. Drain excess oil.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
9-10 SERVICING INFORMATION
TRANSMISSION WILL NOT SHIFT BACK
Symptom, possible causes and remedy
Broken return spring on shift shaft.
Rubbing or sticky shift shaft.
Distorted or worn gearshift forks.
TRANSMISSION JUMPS OUT OF GEAR
Symptom, possible causes and remedy
Worn shifting gears on driveshaft or countershaft.
Distorted or worn gearshift forks.
Weakened stopper spring on gearshift stopper.
RADIATOR (COOLING SYSTEM)
ENGINE OVERHEATS
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.
ENGINE OVERCOOLS
Symptom, possible causes and remedy
Defective cooling fan thermo-switch.
Extremely cold weather.
Defective thermostat.
Replace.
Repair or replace.
Replace.
Replace.
Replace.
Replace.
Add coolant.
Clean.
Repair or replace.
Replace.
Clean.
Bleed out air.
Replace.
Replace.
Replace.
Replace.
Put on the radiator cover.
Replace.
SERVICING INFORMATION 9-11
CHASSIS
HEAVY STEERING
Symptom, possible causes and remedy
Overtightened steering stem nut.
Broken bearing in steering stem.
Distorted steering stem.
Not enough pressure in tires.
WOBBLY HANDLEBARS
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 bearinglrace in steering stem.
WOBBLY FRONT WHEEL
Symptom, possible causes and remedy
Distorted wheel rim.
Worn front wheel bearings.
Defective or incorrect tire.
Loose axle or axle pinch bolt.
lncorrect front fork oil level.
lncorrect front wheel weight balance.
FRONT SUSPENSION TOO SOFT
Symptom, possible causes and remedy
Weakened springs.
Not enough fork oil.
Wrong viscous fork oil.
Improperly set front fork spring adjuster.
FRONT SUSPENSION TOO STIFF
Symptom, possible causes and remedy
Too viscous fork oil.
Too much fork oil.
Improperly set front fork spring adjuster.
Bent front axle.
NOISY FRONT SUSPENSION
Symptom, possible causes and remedy
Not enough fork oil.
Loose bolts on suspension.
WOBBLY REAR WHEEL
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.
Adjust.
Replace.
Replace.
Adjust.
Adjust.
Repair or replace.
Replace.
Adjust.
Adjust or replace.
Replace.
Replace.
Replace.
Replace.
Retighten.
Adjust.
Adjust.
Replace.
Replenish.
Replace.
Adjust.
Replace.
Drain excess oil.
Adjust.
Replace.
Replenish.
Retighten.
Replace.
Replace.
Replace.
Replace.
Retighten.
9-12 SERVICING INFORMATION
REAR SUSPENSION TOO SOFT
Symptom, possible causes and remedy
Weakened spring of shock absorber.
Leakage of oil from shock absorber.
Improperly set rear spring unit adjuster.
REAR SUSPENSION TOO STIFF
Symptom, possible causes and remedy
Bent shock absorber shaft.
Bent swingarm pivot shaft.
Worn swingarm and suspension bearings.
Improperly set rear spring unit adjuster.
NOISY REAR SUSPENSION
Symptom, possible causes and remedy
Loose nuts or bolts on rear suspension.
Worn swingarm and suspension bearings.
BRAKES
INSUFFICIENT BRAKE POWER
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.
BRAKE SQUEAKING
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.
EXCESSIVE BRAKE LEVER STROKE
Symptom, possible causes and remedy
Air in hydraulic system.
Insufficient brake fluid.
Improper quality of brake fluid.
LEAKAGE OF BRAKE FLUID
Symptom, possible causes and remedy
lnsufficient tightening of connection joints.
Cracked hose.
Worn piston and/or cup.
Replace.
Replace.
Adjust.
Replace.
Replace.
Replace.
Adjust.
Retighten.
Replace.
Repair or replace.
Replace.
Clean disc and pads.
Replace.
Bleed air.
Replenish.
Repair surface with sandpaper.
Correct pad fitting or replace.
Replace.
Tighten to specified torque.
Replace.
Replace brake fluid.
Disassemble and clean master cylinder.
Bleed air.
Replenish fluid to specified level; bleed air
Replace with correct fluid.
Tighten to specified torque.
Replace.
Replace piston and/or cup.
SERVICING INFORMATION 9-13
BRAKE DRAGS
Symptom, possible causes and remedy
Rusty part.
Insufficient brake lever or brake pedal pivot
lubrication.
Clean and lubricate.
Lubricate.
ELECTRICAL
NO SPARKING OR POOR SPARKING
Symptom, possible causes and remedy
Defective ignition coils or spark plug caps. Replace.
Defective spark plugs. Replace.
Defective CKP sensor. Replace.
Defective ECM. Replace.
Defective TO sensor. Replace.
Open-circuited wiring connections. Check and repair.
SPARK PLUG SOON BECOME FOULED WITH CARBON
Symptom, possible causes and remedy
Mixture too rich. Inspect FI system.
Idling speed set too high. Adjust fast idle or throttle stop screw.
Incorrect gasoline. Change.
Dirty air cleaner element. Clean or replace.
Too cold spark plugs. Replace with hot type plugs.
SPARK PLUG BECOME FOULED TOO SOON
Symptom, possible causes and remedy
Worn piston rings. Replace.
Worn piston or cylinders. Replace.
Excessive clearance of valve stems in valve Replace.
guides.
Worn stem oil seal. Replace.
SPARK PLUG ELECTRODES OVERHEAT OR BURN
Symptom, possible causes and remedy
Too hot spark plugs.
Overheated the engine.
Loose spark plugs.
Too lean mixture.
GENERATORDOESNOTCHARGE
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 regulatorlrectifier.
Replace with cold type plugs.
Tune up.
Retighten.
Consult FI system.
Repair or replace or retighten.
Replace.
Replace.
9-14 SERVICING INFORMATION
GENERATOR DOES CHARGE, BUT CHARGING RATE IS BELOW THE SPECIFICATION
Symptom, possible causes and remedy
Lead wires tend to get short- or open-circuited or Repair or retighten.
loosely connected at terminals.
Grounded or open-circuited generator coil. Replace.
Defective regulatorlrectifier. Replace.
Defective cell plates in the battery. Replace the battery.
GENERATOROVERCHARGES
Symptom, possible causes and remedy
Internal short-circuit in the battery. Replace the battery.
Damaged or defective resistor element in the Replace.
regulatorlrectifier.
Poorly grounded regulatorlrectifier. Clean and tighten ground connection.
UNSTABLE CHARGING
Symptom, possible causes and remedy
Lead wire insulation frayed due to vibration, Repair or replace.
resulting in intermittent short-circuiting.
Internally short-circuited generator. Replace.
Defective regulatorlrectifier. Replace.
STARTER BUTTON IS NOT EFFECTIVE
Symptom, possible causes and remedy
Run down battery. Repair or replace.
Defective switch contacts. Replace.
Brushes not seating properly on starter motor Repair or replace.
commutator.
Defective starter relaylstarter interlock switch. Replace.
Defective main fuse. Replace.
SERVICING INFORMATION 9-15
BATTERY
"SULFATION", ACIDIC WHITE POWDERY SUBSTANCE OR SPOTS ON SURFACE OF CELL PLATES
Symptom, possible causes and remedy
Cracked battery case. Replace the battery.
Battery has been left in a run-down condition for a Replace the battery.
long time.
BATTERY RUNS DOWN QUICKLY
Symptom, possible causes and remedy
Trouble in charging system. Check the generator, regulatorlrectifier and circuit
connections and make necessary adjustments to
obtain specified charging operation.
Cell plates have lost much of their active material Replace and correct the charging system.
as a result of overcharging.
Internal short-circuit in the battery. Replace.
Too low battery voltage. Recharge fully.
Too old battery. Replace.
BATTERY "SULFATION"
Symptom, possible causes and remedy
Incorrect charging rate. Replace.
(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 Replace if badly sulfated.
long.
9-16 SERVICING INFORMATION
WlRE HARNESS, CABLE AND HOSE ROUTING
WlRE HARNESS ROUTING
@
@
@
@
@
a @I
@)
IAT sensor lead wire
H02 sensor lead wire
Wiring harness
Throttle cable
Clutch cable
Handlebar switch left
Water hose
High-tension cord
Side-stand switch
* j
*2
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.
Route the wiring harness under the cowling fastener fitted section.
SERVICING INFORMATION 9-17
I 1 Wiring harness No.2 *Q I Triangle mark of each spark plug cap must be 1 u I brought to the exhaust side. I
@
@
*1
*3
Magneto lead wire
Ignition coil No.2
tz I seat lock cable.
Clamp the turn signal light read wire.
Pass through the license light read wire over the
I valve.
*4
*5
I
Cut the clamp end.
Do not slack the lead wire.
"6
Pass through the PAIR reed valve lead wire
between the frame and PAIR control solenoid
9-18 SERVICING INFORMATION
HEATED OXYGEN SENSOR (H02S) WIRE ROUTING (FOR E-02,19)
m I H02 sensor (For E-02, 19) *I / Route the H02 sensor lead wire along the fuel
\.!J
,, w
@
H02 sensor lead wire
Wiring harness
I
*,
L 1 the swingarm.
tank drain hose.
Pass through the H02 sensor lead wire forward
SERVICING INFORMATION 9-19
ENGINE ELECTRICAL PARTS SET-UP
n Generator lead wire vl
. cover
Starter motor lead wire mounting
*1
45 " and less
@ nut
I I CKP sensor set bolt First tighten the starter motor lower mount in^ bolt.
U
1 ITEM 1 N.m I knf-m 1 Ib-ft I
9-20 SERVICING INFORMATION
SPEED SENSOR LEAD WIRE ROUTING
10 I Speed sensor lead wire I '1 I Cut the clamp end. 1
Route speed sensor lead wire to come outside
the brake hose guide. I I Brake hose Route speed sensor lead wire on inside of front
fork outer tube boss. I
I ~m I S ~ e e d sensor I
SERVICING INFORMATION 9-21
THROTTLE CABLE ROUTING
I @ I Throttle cable No.1 I @ 1 Wiring harness
@
*
Throttle cable No.2
Front brake hose
*1 I Fit the cable boots securely.
9-22 SERVICING INFORMATION
CLUTCH CABLE ROUTING
B - B C - C D - D E - E
Throttle cable (Pull)
Throttle cable (Return)
0
* A
Handle switch wiring harness
Reserve tank bracket
Route left handle switch wiring harness in the
I
*2
Clutch cable
Throttle cable auide
groove of radiator shroud.
Route left handle switch wiring harness to come
*3
*4
outside throttle and clutch cables.
Route clutch cable inside the guide.
Route clutch cable inside the auide.
@ I Radiator shroud I
SERVICING INFORMATION 9-23
THROTTLE BODY INSTALLATIONIHOSE ROUTING
I a / Throttle body assembly @ Pass through the vacuum hose inside the PAIR 1 *2 1 hose.
I @ I Air cleaner box 1 *3 1 E-33 Only
IAT sensor
Vacuum damper
I@ I Outlet tube clamp I
@
*1
@
Intake pipe clamp
To canister (For E-33)
Fuel pump assembly
ECT sensor
TP sensor
*4
*5
*6
H02 sensor clamp (For E-02, 19)
Matching mark (Yellow)
Matching mark (White)
9-24 SERVICING INFORMATION
COOLING SYSTEM HOSE ROUTING
m Clamp
Wiring harness
Oil pressure switch
*3
*4
*5
1 *2 1 Matching mark (White) I
Matching mark (Yellow)
Clamp the water drain hose and oil pressure
switch lead wire.
Fill the bearing with engine oil until engine oil
comes out from the hole of the be bearing housing.
@
*I
Oil filter
Clamp end must face downward.
*6
*7
Clamp bolt head must face upward.
Clamp bolt head must face downward.
SERVICING INFORMATION 9-25
Installation point
I I Union 1 *4 1 Clamp bolt head must face downward. I
@
@
I ' I
V I clamp.
*2
*3
Clamp
Jiaale valve
@
* I
Matching mark (White)
Marking (Yellow)
Radiator hose
Marking
*5
*c;
Clamp bolt head must face left side.
Leave clearance between bulge of union and
9-26 SERVICING INFORMATION
FRONT BRAKE HOSE ROUTING
Throttle cables
* 1
*2
*3
After the brake hose union has contacted the
stopper, tighten the union bolt.
After positioning the brake hose junction with the
stopper, tighten the bolt.
After positioning the clamp with the stopper,
tighten the damp bolt.
*4
*5
Assemble the brake hose firmly.
Clamp the brake hose firmly.
SERVICING INFORMATION 9-27
REAR BRAKE HOSE ROUTING
A - A
@ I Frame
@ I stopper
@
@
*1
*2
Clamp ends should face forward.
White paint faces outside.
Brake hose
Brake hose guide
*3
*4
After the brake hose union has contacted the
stopper, tighten the union bolt.
Pass through the brake hose outside the seat
rail.
9-28 SERVICING INFORMATION
FUEL TANK DRAIN HOSE ROUTING
SERVICING INFORMATION 9-29
FUEL TANK INSTALLATION
I
I Fuel tank side cushion
-'--
*.I I Align the front end of fuel tank center shield with
I 1 this position. 0
Fuel tank center shield
9-30 SERVICING INFORMATION
PAIR (AIR SUPPLY) SYSTEM HOSE ROUTING
1, / Matching mark (White) * .I 1 Pass the PAIR hose between the cylinder head I
1" 1 I I 1 cover and intake ~ i ~ e . I
I I I , , I a I Matchina mark (Yellow) I
SERVICING INFORMATION 9-31
SEAT LOCK CABLE ROUTING
VlEW OF TOP
\
VlEW OF LEFT
I @ 1 Seat lock cable I
HEAD LAMP SET-UP
I I Adhere cushion along the ridge line of lens. I ., I Right and left cushions shall be attached sym- I
I
*2 Start to adhere cushion from the corner of lens.
J I metrically. I
9-32 SERVICING INFORMATION
ABSORBER HOSE ROUTING
BATTERY CUSHION INSTALLATION
@I
@I
VIEW OF LEFT
108 1 Battery protector I '1 (Adhere battery protector at the upper end. 1'
Absorber hose
Clamp
@ ( Rear fender (Front)
SERVICING INFORMATION 9-33
SIDE-STAND SET-UP
U
ITEM I N-m I kgf-m I Ib-ft
1 0 1 100 I 10.0 1 72.5 1
BRAKE PEDAUFOOTREST SET-UP
Footrest
Brake light switch
@ Pin
E-rina
@
@
9-34 SERVICING INFORMATION
ENGINE CAP INSTALLATION
VlEW OF LEFT
u VlEW OF RIGHT
. 1 remove looseness. I
0 "1 Engine cap Push the center of cap so as to thoroughly
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.
9-36 SERVICING INFORMATION
SPECIAL TOOLS
19900-18710
iexagon bit 12 mm
19900-20508
Zylinder gauge set
'ire depth gauge
j9900-25009
Jeedle pointed
,robe set
19900-201 01
19900-201 02
rlernier calipers
19900-20602
3ial gauge
:1/1000 mm, 1 mm)
19900-21 304
rl-block set (1 00 rnm)
1991 0-201 16
Zonrod holder
19900-20202
Micrometer
:25 - 50 mm)
19900-20607
Dial gauge
:1/l00 mm, 10 mm]
Plastigauge
19900-20204
Micrometer
175 - 100 mm)
19900-20701
Magnetic stand
19900-22403
Small bore gauge
1 8 - 35 mm)
1991 3-1 31 21
Vacuum balancer
3auge
19900-20205
Ulicrometer
0 - 25 mm)
19900-20803
19900-20806
rhickness gauge
19900-25008
blulti circuit tester se
19913-501 21
3il seal remover
SERVICING INFORMATION 9-37
0991 3-60221
Journal bearing
removerlinstaller
0991 5-74521
Oil pressure gauge
hose
0991 6-1 4521
Valve lifter
attachment
0991 6-3321 0
Valve guide reamer
(4.5 mm)
Bearing installer set
3991 5-74532
Dil pressure gauge
attachment
3991 6-21 1 11
rlalve seat cutter set
3991 6-34580
Valve guide
reamer (1 0.8 mm)
1991 5-4061 0
3il filter wrench
1991 5-77331
Meter
:for high pressure)
1991 6-20640
Solid pilot
:N-100-4.5)
1991 6-4321 0
rlalve guide
nstallerlremover
0991 5-6451 2
Compression
gauge
0991 6-1 091 1
Valve lapper set
0991 6-22430
Valve seat cutter heac
(N-128)
0991 6-53330
Attachment
0991 5-7451 1
Oil pressure gauge
set
0991 6-1 451 0
Valve lifter
0991 6-34542
Reamer handle
0991 6-8451 1
Tweezers
9-38 SERVICING INFORMATION
0991 7-4701 1
Vacuum pump
Steering bearing
installer
09930-1 1960
Torx wrench
09940-1 4940
Swingarm pivot thrust
adjuster socket wrenct
09920-13120
Crankcase
separating tool
09930-1 01 21
Spark plug socket
wrench set
09930-30450
Rotor remover
09940-1 4960
Steering stem nut
wrench socket
09920-53740
Clutch sleeve hub
holder
09930-1 1920
Torx bit JT40H
09930-44530
Rotor holder
09940-1 4990
Engine mounting thrust
adjuster socket wrench
3earing remover set
19930-1 1940
3it holder
19930-82720
Mode select switch
19940-34520
'T" Handle
09924-8451 0
Bearing installer
set
09930-1 1950
Torx wrench
09940-1 491 1
Steering stem nut
wrench
09940-34531
Attachment A
SERVICING INFORMATION 9-39
19940-4021 1
%el pressure
yauge adaptor
I9941 -5491 1
3earing outer race
'emover
D9940-40220
Fuel pressure gauge
hose attachment
D9943-74111
Front fork oil level
gauge
19940-52861
'ront fork oil seal
nstaller
19944-28320
iexagon bit 19 mm
Spring scale
19941 -3451 3
3earinglsteering
.ace installer set
When order the special tool, please confirm whether it is available or not.
9-40 SERVICING INFORMATION
TIGHTENING TORQUE
ENGINE
I b-ft I ITEM
Cylinder head cover bolt
S ~ a r k ~ l u g
Camshaft journal holder bolt
Cylinder head bolt [M: 101
N m
14
11
Cam chain tension adjuster cap bolt
Cam chain tension adjuster mounting bolt
knf-rn
10
1.4
1.1
8
10
Initial
Final
10.0
8.0
1 .O
Water drain bolt
Clutch sleeve hub nut
Oil pressure regulator I 27 1 2.7 1 19.5
7.0
0.8
1 .O
25
42
Clutch spring set bolt
Oil date bolt
5.7
7.0
13
50
2.5
4.2
10
10
-
Oil strainer plate bolt
Primaw drive gear bolt
18.0
30.5
1.3
5 .O
Generator cover plug
Valve timing ins~ection ~ l u q
9.5
36 -0
1 .O
1 .O
10
70
Generator rotor bolt
I Starter clutch bolt
I ear shift cam stopper bolt I 10 1 1.0 1 7 . 0
7.0
7.0
10
23
Generator stator set bolt
CKP sensor set bolt
1 .O
7.0
120
25
7.0
50.5
1 .O
2.3
11
6.5
Gearshift cam stopper plate bolt
Gearshift arm stopper bolt
1 Generator cover bolt [M:61 1 10 1 1 . 0 1 7 . 0
7.0
16.3
12.0
1 Oil gallery plug [M: 81 1 18 ( 1.8 1 13.0
87
1.1
0.65
13
19
Oil pressure switch
8.0
4.7
13
11
26
Crankcase bolt
I
2.5
1.3
1.9
[M: 61
IM: 81
Oil drain plug
Piston cooling oil iet bolt
18.0
9.5
13.5
1.3
1.1
2.6
Conrod bearing cap bolt
9.5
8.0
19.0
15.0
7.0
2 1
10
Initial
Final
2.1
1 .O
21
After tightenig the bolts to the above torque,
tighten them 114 of a turn (90 O).
2.1 15.0
SERVICING INFORMATION 9-41
I N.m I knf-m I Ib-ft
1 Exhaust pipe bolthut
. . . .
I Enaine sprocket nut 145 14.5 105
Muffler mounting bolthut
Oil pipe stopper screw
Engine mounting bolthut
23
8
I Engine mounting thrust adjuster lock-nut
Engine mounting nut
2.3
0.8
16.5
6.0
[Center]
Engine mounting bracket bolt
Enaine mounting pinch bolt
Enaine mountina thrust adiuster
Cooling fan thermo-switch
ECT sensor
93
35
25
Fuel pump mounting bolt
Fuel delivery pipe mounting screw
17
19
Cooling fanlhorn mounting bolt
Thermostat case bolt
I Oil cooler hose union bolt 23 2.3 16.5
8.5
9.3
12
3.5
2.5
10
5.0
I oil cooler mounting bolt 1 I I
FI SYSTEM PARTS
67.5
1.2
25.5
18.0
1.7
1.9
8
10
ITEM Nmm kgf-m Ib-ft I
12.5
13.5
1 .O
0.5
7.0 10
7.0
3.7
0.8
1.0
1 .O
6.0
7.0
TP sensor mounting screw
STP sensor mounting screw
ECT sensor
IAT sensor
3.5
2.0
19
18
0.35
0.2
2.5
1.5
1.9
1.8
13.5
13.0
9-42 SERVICING INFORMATION
CHASSIS
ITEM
Steering stem head nut
Steering stem lock-nut
Front fork upper clamp bolt
I Front fork cap bolt 1 23 1 2.3 1 16.5
N-rn
. .
I Front fork lower clamp bolt I 1 I
I Front fork cylinder bolt 1 20 1 2.0 1 14.5
90
80
23
23
( Front axle 1 65 1 6.5 1 47.0
kgf-rn I b-ft
9.0
8.0
2.3
2.3
1 Front brake master cylinder mounting bolt I 10 1 1.0 1 7.0
65.0
58.0
16.5
16.5
Front axle pinch bolt
Handlebar clamp bolt
I Front brake caliper mounting bolt 1 39 1 3.9 1 28.0
I Brake hose union bolt 1 23 1 2.3 1 16.5 1
23
23
I Front caliper air bleeder valve 1 7.5 1 0.75 1 5.5 1
2.3
2.3
I Rear brake caliper sliding pin 1 27 / 2.7 1 19.5 1
16.5
16.5
Rear caliper air bleeder valve
Brake disc bolt (Front and Rear)
Rear brake caliper mountina bolt
I Rear brake master cvlinder rod lock-nut 1 18 I 1.8 1 13.0 1
6
23
22
Rear brake pad mounting pin
Rear brake pad mounting pin plug
Rear brake master cvlinder mountina bolt
1 Front footrest bracket mounting bolt 1 25 1 2.5 1 18.0 1
I Swingarm pivot shaft I 15 1 1.5 1 11.0 I
0.6
2.3
2.2
17
2.5
10
4.3
16.5
16.0
I Rear shock absorber mounting nut (Upper & Lower) 1 50 1 5.0 1 36.0 1
1.7
0.25
1 .O
Swingarm pivot nut
Swinaarm pivot lock-nut
I Cushion lever nut I 78 1 7.8 1 56.5 1
12.5
1.8
7.0
I Cushion rod nut 1 78 1 7.8 1 56.5 1
100
90
I Rear axle nut 100 10.0 72.5
10.0
9.0
72.5
65.0
Rear sprocket nut
Seat rail mounting bolt
Side stand bracket mountina bolt
Side stand bolt
60
50
100
Side stand nut
I 50
6.0
5.0
10.0
40
43.5
36.0
72.5
5.0 36.0
4.0 29.0
SERVICING INFORMATION 9-43
Conventional bolt
TIGHTENING TORQUE CHART
For other nuts and bolts not listed in the preceding page, refer to this chart:
"4" marked bolt
Bolt Diameter
@ (mm)
4
5
6
8
10
12
14
'1 6
18
"7" marked bolt
Conventional or "4" marked bolt "7" marked bolt
I b-ft
1 .O
2.0
4.0
9.5
21 .O
32.5
47.0
76.0
1 15.5
N-m
1.5
3
5.5
13
29
45
65
105
160
kgf-m
0.15
0.3
0.55
1.3
2.9
4.5
6.5
10.5
16.0
I b-ft
1.5
3.0
7.0
16.5
36.0
61.5
97.5
152.0
173.5
N-m
2.3
4.5
10
23
50
85
135
21 0
240
kgf-m
0.23
0.45
1 .O
2.3
5.0
8.5
13.5
21 .O
24.0
9-44 SERVICING INFORMATION
SERVICE DATA
VALVE + GUIDE
ITEM
Valve diam.
Valve clearance (when cold)
Valve guide to valve stem
clearance
I Valve guide I.D.
Valve stem O.D.
Valve stem deflection
Valve stem runout
I Valve head thickness
Valve seat width
I Valve head radial runout
Valve spring free length
(IN. & EX.)
Valve spring tension
(IN. & EX.)
EX. I
Unit: mm (ir
STANDARD
IN. I
LIMIT
IN.
EX.
EX. I
IN. & EX. I
0.10 - 0.20
(0.004 - 0.008)
0.20 - 0.30
(0.008 - 0.012)
IN. I
-
-
EX. I
IN. &EX. I
IN. & EX.
IN.& EX. I
-
IN. & EX.
IN. & EX. 1
0.35
(0.01 4)
INNER I
-
OUTER I
0.5
(0.02)
INNER
OUTER
at length 29.9 mm (1 . I8 in)
17.0 - 19.6 kgf
(37.48 -43.21 Ibs)
at length 33.4 mm (1 -31 in)
-
SERVICING INFORMATION 9-45
CAMSHAFT + CYLINDER HEAD Unit: mm (in
ITEM
Cam height
Camshaft journal oil clearance
Camshaft journal holder I.D.
Camshaft journal O.D.
Camshaft runout
LIMIT
35.18
(1.3850)
STANDARD
IN. & EX.
IN. & EX.
I I 1 %
IN.
IN. & EX.
IN. & EX.
Cam chain in (at arrow "3) . . I I
35.48 - 35.53
(1.3968 - 1.3988)
0.032 - 0.066
(0.001 3 - 0.0026)
22.01 2 - 22.025
(0.8666 - 0.8671 )
16th in 1 Cylinder head distortion
0.1 50
(0.0059)
-
21.959 - 21.980
(0.8645 - 0.8654)
-
1 0.05
-
0.10
(0.004)
9-46 SERVICING INFORMATION
CYLINDER + PISTON + PISTON RING Unit: mm (in
Compression pressure
difference
ITEM
Compression pressure
Piston to cylinder clearance
Cylinder bore
STANDARD
1 300 - 1 700 kPa
Nicks or I Scratches
LIMIT
1 100 kPa
Piston diam.
1 3 - 17 kgflcmz
185 - 242 psi
Cvlinder distortion
Measure at 20 mm (0.79 in) from the skirt end.
Piston ring free end gap
Piston ring end gap
2 nd
Piston ring to groove clearance I lSt I
I st
Approx. 1 1 (0.43)
Piston ring groove width
Approx. 9.5 (0.37)
Oil
2.01 - 2.03
(0.0791 - 0.0799)
Piston ring thickness
Piston pin bore
Piston pin O.D.
1 st
2nd
1.17- 1.19
(0.0461 - 0.0469)
0.97 - 0.99
(0.0382 - 0.0390)
20.002 - 20.008
(0.7875 - 0.7877)
19.992 - 20.000
(0.7871 - 0.7874)
SERVICING INFORMATION 9-47
CONROD + CRANKSHAFT Unit: mm (itConrod small end I.D. I 20.010 - 20.01 8 1 20.040
ITEM STANDARD
Conrod big end side clearance
Conrod big end width
Crank pin width
Conrod big end oil clearance
Crankshaft journal oil clearance
LIMIT
Crank in O.D.
Crankshaft journal O.D.
(0.7878 - 0.7881)
0.170 - 0.320
(0.0067 - 0.01 26)
20.95 - 21 .OO
(0.825 - 0.827)
42.17 - 42.22
(1.660 - 1.662)
0.032 - 0.056
Crankshaft runout
(0.7890)
0.5
(0.02)
-
-
0.080
(0.001 3 - 0.0022)
37.976 - 38.000
(0.0031)
I I Below 400 kPa (4.0 kgf/cm2, 57 psi) 1 - 1
ITEM
Oil pressure (at 60 "C, 140 O F )
CLUTCH Unit: mm (in)
STANDARD
Above 100 kPa (1.0 kgf/cm2, 14 psi)
. ,
I ITEM 1 STANDARD LIMIT 1
LIMIT
Clutch cable play
Clutch release screw
Drive plate thickness
Drive plate claw width
I Clutch spring free length
10- 15
(0.4 - 0.6)
114 turns back
Driven plate distortion
-
-
No.1 & No.2
No.1 & No.2
-
2.92 - 3.08
(0.1 15 - 0.121)
13.7 - 13.8
(0.539 - 0.543)
0.10
(0.004)
2.62
(0.1 03)
12.9
(0.507)
9-48 SERVICING INFORMATION
TRANSMISSION + DRIVE CHAIN Unit: mm (in) Except ratio
Primary reduction ratio I 2.088 (71134) I . .
Final reduction ratio I 3.1 33 (4711 5) 1 ITEM
Gear ratios
STANDARD LIMIT
Low
Shift fork groove width
5th
TOP
Shift fork to groove clearance
Shift fork thickness
2.46 1 (3211 3)
Drive chain
-
0.961 (25126)
0.851 (23127)
0.1 - 0.3
(0.004 - 0.012)
-
-
0.50
(0.020)
Type
Links
Drive chain slack (on side-stand)
Dl D525V8
116 links
Gearshift lever height
-
-
-
20-pitch
length
25
(0.98)
-
-
31 9.4
(1 2.57)
20 - 30
(0.79 - 1.18)
-
SERVICING INFORMATION 9-49
THERMOSTAT + RADIATOR + FAN + COOLANT
Thermostat valve opening
temperature
ECT sensor resistance
Radiator cap valve opening
pressure
Cooling fan thermo-switch
1 operating temperature
Engine coolant type
Engine coolant including reserve r
STANDARD 1 NOTE I
Approx. 88 "C (190 OF)
I
Over 8.0 mm (0.31 in) at 100 "C (212 OF) - I
Approx. 0.587 kR
20 "C
Approx. 2.45 kR
(68 OF)
40 OC
Approx. 1.148 kR
(1 04 OF)
Approx. 0.322 kR
-
-
I
95 - 125 kPa
(0.95 - 1.25 kgf/cm2, 13.5 - 17.8 psi)
OFF+ON Approx. 98 "C (208 OF)
ON+OFF Approx. 92 OC (198 OF)
-
-
-
Jse an antifreeze/coolant compatible with aluminum
*adiator, mixed with distilled water only, at the ratio
)f 50:50.
Reserve Approx. 250 ml
tank side (0.5310.44 US/lmp qt)
Engine Approx. 1650 ml
side (3.4912.90 US/lmp qt)
for 10 sec. at 300 kPa (3.0 kgf/cm2, 43 psi)
-
-
-
INJECTOR + FUEL PUMP + FUEL PRESSURE REGULATOR
ITEM
Injector resistance
Fuel pump discharge amount
Fuel pressure regulator operating
set pressure
SPECIFICATION
11 -13Rat20°C(68"F)
MIN. 168 ml (5.715.9 US/lmp oz)
Approx. 300 kPa (3.0 kgf/cm2, 43 psi)
NOTE
9-50 SERVICING INFORMATION
FI SENSORS+ SECONDARY THROTTLE VALVE ACTUATOR
I ITEM I SPECIFICATION I NOTE 1
1 CKP sensor resistance I 130-240R I W - G 1
I CKP sensor peak voltage I 3.7 V (When cranking) and more I I
IAP sensor input voltage
IAP sensor output voltage
I Opened I Approx. 4.26 kn 1 I
TP sensor input voltage
TP sensor resistance
TP sensor output voltage
4.5 - 5.5 V
Approx. 2.7 V at idle speed
4.5 - 5.5 V
Closed 1 Approx. 1.1 2 ki2
@ GIB - @
BIB r
I ECT sensor input voltage 4.5 - 5.5 V I
Closed
Opened
I IAT sensor resistance I Approx. 2.45 kR at 20 "C (68 OF) I I
Approx. 1.12 V
Approx. 4.26 V
ECT sensor resistance
I TO sensor resistance I 19.1 - 19.7 kR I I
@ P / W - 0
BIBr
Approx. 2.45 kR at 20 "C (68 O F )
I STP sensor input voltage I 4.5 - 5.5 V 1 I
IAT sensor input voltaae
TO sensor voltage
GP switch voltage
lniector voltaae
4.5 - 5.5 V
I STV actuator resistance I 7-14R 1 I
Normal
Leaning 65 "
STP sensor resistance
STP sensor output voltage
I PAIR solenoid valve resistance I 20 - 24 kQ at 20 "C (68 OF) I I
THROTTLE BODY
1.0 V and more (From 1 st to Top)
Batterv voltaae
0.4 - 1.4 V
3.7 - 4.4 V
Closed
Opened
Closed
Opened
@ BrNV-0
BIB r
1 Idle rlmin. I 1 300 100 rlminIWarmed engine I
Approx. 0.58 kQ
Approx. 4.38 kR
Approx. 0.58 V
Approx. 4.40 V
ITEM
I.D. No.
Bore size
Fast idle rlmin.
1 Throttle cable play
Y - B
@ Y - 0
BIBr
SPECIFICATION
27 GO (Others), 27 G I (For E-33)
39 mm
1 800 - 2 400 rlmin at 25 "C (77 "F)
2.0 - 4.0 mm
(0.08 - 0.16 in)
SERVICING INFORMATION 9-51
I Firina order
ELECTRICAL Unit: mm (ir
ITEM
u Spark plug
I Spark performance I I I Over 8 mm (0.3 in) at 1 atm.
SPECIFICATION
Gap
NOTE
Type
0.7 - 0.8 mm
(0.028 - 0.031 in)
NGK: CR8E
DENSO: U24ESR-N
CKP sensor resistance
lgnition coil resistance
1 CKP sensor peak voltage
Secondary
3.7 V and more
When I crankina
W - G
O tap O tap
130 - 240 R
24 - 37 kR
I Ignition coil primary peak voltage I 150 V and more I
Primary
O tap Plug cap
I Generator coil resistance 0.2 - 0.7 R
2 - 5 R
I Generator Max. output Approx. 375 W at 5 000 rtrnin
I Generator no-load voltage (When cold) 60 V (AC) and more at 5 000 rtmin.
Fuse size
Headlight
14.0 - 15.5 V at 5 000 rtmin.
3 - 6 R
YTX12-BS
Regulated voltage
Starter relay resistance
Battery Type designation
Capacity
1
Fuel
Ignition
Fan motor
Signal
Main
12 V 36.0 k c (1 0 Ah)/lO HR
10 A
10 A
15 A
15 A
30 A
9-52 SERVICING INFORMATION
WATTAGE Unit: W
I , . , 1 Headliaht I 1 12 V 60155 W x 2 (H4) 1 t
ITEM
[Speedometer light LED t
SPECIFICATION
l ~ u r n signal indicator light LED t I
E-03.24.28.33
1 2 V 5 W x 2
t t t - . ,
PositionJParking light
I High beam indicator light I LED I t I
Others
Brake lightrraillight
Turn signal light
License liaht
12 V 2115 W x 2
1 2 V 2 1 W
1 2 V 5 W
Neutral indicator light
Oil pressure1Coolant temp./Fuel injection warning
LED
LED
t t SERVICING INFORMATION 9-53
BRAKE + WHEEL Unit: mm ( i ~
ITEM
3ear brake ~eda l heiaht
3rake disc thickness
Brake disc runout
1 Rear I
STANDARD
15 - 25 (0.59 - 0.98)
Master cylinder bore
LIMIT
-
Front
Rear
Master cylinder piston diam.
Brake caliper cylinder bore
5
(0.20)
5
(0.20)
- Front
Rear
I Front I
4.5
(0.1 8)
4.5
(0.1 8)
-
15.870 - 15.91 3
(0.6248 - 0.6265)
Front
1 Rear I
0.3
(0.01 2)
13.957 - 13.984
(0.5495 - 0.5506)
Brake caliper piston diam.
1 5.827 - 15.854
(0.6231 - 0.6242)
-
1 Front I
-
Brake fluid type I DOT 4 I
Rear
Wheel rim runout I Axial I
38.098 - 38.148
(1.4999 - 1.501 9)
-
Wheel rim size
Wheel axle runout
Rear
I Front 1 Radial
Front
17 M/C x MT4.00
-
19 M/C x MT2.50
-
2.0
(0.08)
-
9-54 SERVICING INFORMATION
ITEM
Cold inflation tire pressure
(Solo riding)
Cold inflation tire pressure
(Dual riding)
Tire size
Tire type
Tire tread depth
SUSPENSION
STDISPEC. LIMIT
Front
225 kPa
Front 1 (2.25 kgf/cm2, 33 psi) I Rear
225 kPa
(2.25 kgf/cm2, 33 psi)
Front I 1 10180 R19 M/C (59 H) I -
250 kPa
(2.50 kgf/cm2, 36 psi)
Rear
-
Rear I BRIDGESTONE: TW152 F I -
280 kPa
(2.80 kgf/cm2, 41 psi)
Rear
Front
Front I
-
150RO R17 M/C (69 H)
BRIDGESTONE: TWIO1 F
Unit: mm (ir
-
-
Rear ITEM
Front fork stroke
Front fork spring free length
Front fork spring adjuster 1 3 groove from TopISpring adjuster height 9 mm I 2.0
(0.08)
Front fork oil level (without spring,
outer tube fully compressed)
(0.35 in)
STDISPEC.
150
(5.9)
444.1 (1 7.5)
Front fork oil type
LIMIT
-
435 (17.1)
143 (5.63)
SUZUKI FORK OIL SS-08
or eauivalent fork oil
-
Front fork oil capacity (each leg) 524 ml
(1 7.711 8.5 US/lmp oz)
Rear shock absorber spring
adiuster
2 groove from bottom
Rear shock absorber damping
force adjuster
Rear wheel travel
Swingarm pivot shaft runout
Rebound
1 turn back from stiffest position
1 112 turns back from stiffest position
E-02, 19, 24
E-03, 28, 33
150 mm
(5.9 in)
-
-
0.3
(0.01)
SERVICING INFORMATION 9-55
FUEL + OIL
ITEM
%el type
Fuel tank capacity
Enaine oil tvDe
Engine oil capacity
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.
Gasoline used should be graded 91 octane or
higher. An unleaded gasoline is recommended.
22 L (5.814.8 USIlrnp gal)
SAE 10 W - 40, API SF or SG
Change I 2 300 ml
(2.412.0 U S A ~ D at)
Filter change I 2 700 ml
(2.912.4 USllmr, at)
NOTE
Overhaul
Others
3 100ml
(3.312.7 USIlrnp qt)
EMISSION CONTROL INFORMATION 10-1
CONTENTS
EMISSION CONTROL SYSTEMS .............................................................. 1 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 ....................................... 1 0 . 6
HOSES ................................................................................................. 1 6
PAIR REED VALVE ............................................................................. 10- 6
.................................................. PAIR CONTROL SOLENOID VALVE 1 7
PAIR (AIR SUPPLY) SYSTEM HOSE ROUTING ................................ 10- 8
HEATED OXYGEN SENSOR (H02S) WIRE ROUTING (E.02. 19) .... 10- 8
EVAPORATIVE EMlSSlON CONTROL SYSTEM INSPECTION
(Only for E-33) ........................................................................................... 1 0 - 10
HOSES ........................................................................................... 10-10
EVAP CANISTER ............................................................................... 10-10
FUEL-SHUT OFF VALVE .................................................................... 10-10
EVAP CANISTER HOSE ROUTING (Only for E-33) ................................. 10-1 1
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.
I @ I Fuel injector 10 I RELIEVED FUEL I
(2)
Fuel filter (For high pressure)
Fuel pressure reaulator
@
@?
BEFORE-PRESSURIZED FUEL
PRESSURIZED FUEL
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.
-
I @ 1 Air cleaner box 1 - 1 I 0 I BLOW-BY GAS 1
@ ( PAIR reed valve
@ 1 Breather hose
I @ I PAIR control solenoid valve I
8
@I
FRESH AIR
FUEUAIR MIXTURE
10-4 EMISSION CONTROL INFORMATION
EXHAUST EMISSION CONTROL SYSTEM (PAIR SYSTEM)
The exhaust emission control system is composed of the PAlR system and THREE-WAY CATALYST system. (Except for E-03, -24 and-28) The fresh air is drawn into the exhaust port with the PAlR solenoid valve
and PAlR reed valve. The PAlR solenoid valve is operated by the ECM, and the fresh air flow is controlled
according to the TPS, ECTS, IATS and IAPS.
@
@
@
@
@
ECM
Air cleaner box
Injector
PAIR reed valve
PAIR control solenoid valve
PAIR reed valve
8
@
FRESH AIR
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)
I @ 1 IAP sensor I O I Surge hose I
No.2 Throttle body
1 - 1
18 1 HC VAPOR 1
a O
I @ I No.1 Throttle body 10 I FRESH AIR I
I @ I Purge hose lo 1 VACUUM I
Vacuum damper
Vacuum hose
@
@
Fuel shut-off valve
EVAP canister
10-6 EMISSION CONTROL INFORMATION
PAlR (AIR SUPPLY) SYSTEM INSPECTION
HOSES
lnspect the hoses for wear or damage.
lnspect that the hoses are securely connected.
PAlR REED VALVE
Remove the PAlR reed valve cover. (-3-36)
lnspect the reed valve for the carbon deposit.
If the carbon deposit is found in the reed valve, replace the
PAlR reed valve with a new one
Installation is in the reverse order of removal.
EMISSION CONTROL INFORMATION 10-7
PAlR CONTROL SOLENOID VALVE
Remove the air cleaner box. (-5-1 5)
Remove the PAIR control solenoid valve @I.
Check that air flows through the air inlet port to the air outlet
port.
If air does not flow out, replace the PAlR 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 PAlR control solenoid valve.
Resistance: 20 - 24 (at 20 OW68 O F )
a 09900-25008: Multi circuit tester set
-
;m Tester knob indication: Resistance (a)
If the resistance is not within the standard range, replace the
PAlR control solenoid valve with a new one.
Connect the PAlR control solenoid valve lead wire coupler
securely.
Installation is in the reverse order of removal.
10-8 EMISSION CONTROL INFORMATION
PAIR (AIR SUPPLY) SYSTEM HOSE ROUTING
-9-30
HEATED OXYGEN SENSOR (H02S) WIRE ROUTING (E-02,19)
-9-18
EMISSION CONTROL INFORMATION 10-9
HEATED OXYGEN SENSOR (H02S)
INSPECTION (E-02, 19)
Remove the seat. ( W 7 - 4 )
Disconnect the H02 sensor coupler.
Remove the H02 sensor unit.
I Do not remove the H02 sensor while it is hot. I
Be careful not to expose it to excessive shock.
Do not use an impact wrench while removing or
installing the H02 sensor unit.
Inspect the H02 sensor and its circuit referring to flow table of
the malfunction code (C44).
Disconnect the H02 sensor coupler.
Check the resistance between the terminals (white - white) of
the H02 sensor.
Resistance: 4 - 5 R (at 23 "Cn3.4 OF)
09900-25008: Multi circuit tester set
L
g) Tester knob indication: Resistance (R)
If the resistance is not within the standard range, replace the
H02 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 H02 sensor coupler securely.
Installation is in the reverse order of removal.
I CAUTION I
Do not apply oil or other materials to the sensor air
hole.
Tighten the sensor unit to the specified torque.
H02 SENSOR: 47.5 N m (4.75 kgf-m, 34.3 Ib-ft)
Route the H02 sensor lead wire into the frame.
Connect the H02 sensor coupler.
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
lnspect the hoses for wear or damage.
Make sure that the hoses are securely connected.
EVAP CANISTER
lnspect the canister for damage to the body.
FUEL-SHUT OFF VALVE
lnspect the fuel-shut off valve body for damage.
lnspect 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 @
positioned upward, the air can pass through to the canister
side.
When air is blown into the fuel-shut off valve with its side @
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)
(1 clamp ends should face inside. 1 *6 1 Clamp ends should face down side. I
@
0
@I
Purge hose
Wiring harness
EVAP canister
Frame
*2
*3
*4
*5
Clamp ends should face outside.
White paint mark should face top side.
Pass through the purge hose between the frame
and wiring harness.
To throttle bodv.

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