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Suzuki Boulevard M50 Service Manual

Summary of Boulevard M50

  • Page 1

    Vz800 printed in japan k5 vz800 no.5230 99500-38050-01e vz800k5 service manual 2004. 11. 29 cover_14 for ps printing (16 mm) top bottom k5 9 9 5 0 0 - 3 8 0 5 0 - 0 1 e dic75.

  • Page 2: Group Index

    Group index general information 1 periodic maintenance 2 engine 3 shaft drive 4 fi system 5 fuel system and throttle body 6 cooling and lubrication system 7 chassis 8 electrical system 9 servicing information 10 emission control information 11 wiring diagram 12 © copyright suzuki motor corporation 2...

  • Page 3: How to Use This Manual

    How to use this manual to locate what you are looking for: 1. The text of this manual is divided into sections. 2. The section titles are listed in the group index. 3. Holding the manual as shown at the right will allow you to find the first page of the section easily. 4. The contents are listed on ...

  • Page 4

    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 definition symbol definition torque control required. Data beside it indicates specified torque. Apply thread loc...

  • Page 5: Abbreviations Used In This

    Abbreviations used in this manual a abdc : after bottom dead center ac : alternating current acl : air cleaner, air cleaner box api : american petroleum institute atdc : after top dead center atm pressure: atmospheric pressure atmospheric pressure sensor (aps) a/f : air fuel mixture b bbdc : before ...

  • Page 6

    M mal-code : malfunction code (diagnostic code) max : maximum mil : malfunction indicator lamp (led) min : minimum n nox : nitrogen oxides o ohc : over head camshaft ops : oil pressure switch p pcv : positive crankcase ventilation (crankcase breather) r rh : right hand rom : read only memory s sae :...

  • Page 7

    Wire color b : black gr : gray r : red bl : blue lbl : light blue w : white br : brown lg : light green y : yellow dg : dark green o : orange g : green p : pink b/bl : black with blue tracer b/br : black with brown tracer b/g : black with green tracer b/lg : black with light green tracer b/r : black...

  • Page 8: General Information

    1 general information 1-1 contents general information warning/caution/note .........................................................................1- 2 general precautions ...........................................................................1- 2 suzuki vz800k5 (’05-model) ......................

  • Page 9: Warning/caution/note

    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 mes- sages highlighted by these signal words. Indicates...

  • Page 10

    General information 1-3 * if parts replacement is necessary, replace the parts with suzuki genuine parts or their equiva- lent. * when removing parts that are to be reused, keep them arranged in an orderly manner so that they may be reinstalled in the proper order and orientation. * be sure to use s...

  • Page 11: Suzuki Vz800K5 (’05-Model)

    1-4 general information suzuki vz800k5 (’05-model) right side left side * difference between illustration and actual motorcycle may exist depending on the markets. Serial number location the frame serial number or v.I.N. (vehicle identification number) 1 is stamped on the right side of the steering ...

  • Page 12

    General information 1-5 engine oil oil quality is a major contributor to your engine’s performance and life. Always select good quality engine oil. Use of api sf/ sg or sh/sj with jaso ma. Suzuki recommends the use of sae 10w-40 engine oil. If sae 10w-40 engine oil is not available, select an altern...

  • Page 13: Break-In Procedures

    1-6 general information break-in procedures during manufacturing only the best possible materials are used and all machined parts are finished to a very high standard. It is still necessary to allow the moving parts to “break-in” before subjecting the engine to maximum stresses. The future performan...

  • Page 14: Information Labels

    General information 1-7 information labels a: attached vz800 1 noise label a for e-03, 24, 33 2 information label a for e-03, 28, 33 3 vacuum hose routing label a for e-33 4 manual notice label a for e-03, 33 5 fuel caution label a for e-02, 24 6 tire information label a 7 general warning label a 8 ...

  • Page 15: Specifications

    1-8 general information specifications dimensions and dry mass overall length.......................................................2 370 mm (93.3 in) overall width ........................................................ 920 mm (36.2 in) overall height..................................................

  • Page 16

    General information 1-9 chassis front suspension................................................. Inverted telescopic, coil spring, oil damped rear suspension ................................................. Swingarm type, coil spring, oil damped front suspension stroke................................

  • Page 17: Periodic Maintenance

    2 6 6 periodic maintenance 2-1 contents periodic maintenance periodic maintenance schedule .......................................................2- 2 periodic maintenance chart .....................................................2- 2 lubrication points ................................................

  • Page 18

    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 kilome- ters, miles and time for your conve...

  • Page 19

    Periodic maintenance 2-3 lubrication points proper lubrication is important for smooth operation and long life of each working part of the motorcycle. Major lubrication points are indicated below. Note: * before lubricating each part, clean off any rusty spots and wipe off any grease, oil, dirt or g...

  • Page 20

    2-4 periodic maintenance maintenance and tune-up procedures this section describes the servicing procedures for each item of the periodic maintenance requirements. Air cleaner • remove the air cleaner cover 1. • remove the air cleaner element 2. • carefully use air hose to blow the dust from the cle...

  • Page 21

    Periodic maintenance 2-5 note: when cleaning the air cleaner element, drain water from the air cleaner by removing the drain plug. Spark plug no. 1 (front) spark plug removal • remove the rear and front seats. ( 8-3) • remove the fuel tank. ( 6-3) • remove the right frame cover 1. : hooked part •...

  • Page 22

    2-6 periodic maintenance no. 2 (rear) spark plug removal • remove the rear and front seats. ( 8-3) • remove the fuel tank. ( 6-3) • remove the spark plug cap. • remove the spark plug with a spark plug wrench. Heat range • check to see the heat range of the plug. Carbon deposit • check to see if th...

  • Page 23

    Periodic maintenance 2-7 spark plug and plug cap installation • install the spark plugs to the cylinder heads by finger tight, and then tighten them to the specified torque.  spark plug: 11 n·m (1.1 kgf-m, 8.0 lb-ft) • install the spark plug caps. Valve clearance valve clearance must be checked and...

  • Page 24

    2-8 periodic maintenance • remove the cylinder head cover caps (1, 2). • remove the pair pipe. • remove the gasket 3. Do not reuse the removed gasket. Sa mp le.

  • Page 25

    Periodic maintenance 2-9 • remove all the inspection caps. • remove all the spark plugs. • remove the generator cover plug 4. • remove the cap 5 and the timing inspection plug 6. • rotate the generator rotor to set the no. 1 engine’s piston at tdc of the compression stroke. (rotate the rotor until t...

  • Page 26

    2-10 periodic maintenance • rotate the generator rotor 450 degrees (1 and 1/4 turns) and align the “f i t” line on the rotor with the center of hole on the generator cover. Inspect the no. 2 engine’s valve clearance as the same manner above. Note: use the thickness gauge from the arrow marks as show...

  • Page 27

    Periodic maintenance 2-11 engine oil and oil filter oil should be changed while the engine is warm. Oil filter replacement at the above intervals, should be done together with the engine oil change. Engine oil replacement • keep the motorcycle upright. • place an oil pan below the engine, and drain ...

  • Page 28

    2-12 periodic maintenance oil filter replacement • drain engine oil in the same manner of engine oil replacement procedure. • remove the oil filter 1 by using the oil filter wrench. (special tool) • apply engine oil lightly to the o-ring of the new filter before installation. • install the new filte...

  • Page 29

    Periodic maintenance 2-13 engine idle speed note: warm up the engine before adjusting the engine idle speed. • connect the multi-circuit tester to the high-tension cord. • start up the engine and set its idle speed to the specified range by turning the throttle stop screw 1.  engine idle speed: 1 1...

  • Page 30

    2-14 periodic maintenance throttle cable play adjust the throttle cable play a with the following three steps. Minor adjustment first step: • loosen the lock nut 1 of the throttle returning cable 2 and turn in the adjuster 3 fully into the threads. Second step: • loosen the lock nut 4 of the throttl...

  • Page 31

    Periodic maintenance 2-15 major adjustment • remove the rear and front seats. ( 8-3) • remove the fuel tank. ( 6-3) • loosen the lock nut 1 of the throttle returning cable. • turn the returning cable adjuster 2 to obtain proper cable play. • loosen the lock nut 3 of the throttle pulling cable. • t...

  • Page 32

    2-16 periodic maintenance clutch • loosen the lock nut 1. • turn in the adjuster 2 all the way into the clutch lever assem- bly. • remove the left frame cover. ( 8-3) • remove the secondary gear case cover 3. • remove the clutch release cover 4. • loosen the lock nut 3 and turn out the adjusting sc...

  • Page 33

    Periodic maintenance 2-17 cooling system engine coolant level check • keep the motorcycle upright. • check the engine coolant level by observing the full and lower lines on the engine coolant reserve tank. A full line b lower line • if the level is below the lower line, add engine coolant to the ful...

  • Page 34

    2-18 periodic maintenance 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 en...

  • Page 35

    Periodic maintenance 2-19 final gear oil • keep the motorcycle upright. • place an oil pan under the final gear case. • remove the filler cap 1 and drain plug 2 to drain oil. • refit the drain plug 2. Pour the specified oil (sae 90 hypoid gear oil with gl-5 under api classification) through the fill...

  • Page 36

    2-20 periodic maintenance front brake pads the extent of brake pad wear can be checked by observing the grooved limit a on the pad. When the wear exceeds the grooved limit, replace the pads with new ones. ( 8-52) rear brake pedal height • loosen the lock nut 1. • adjust the brake pedal height a by ...

  • Page 37

    Periodic maintenance 2-21 rear brake adjusting • adjust the free travel a to 20 – 30 mm by turning the adjust- ing nut 1.  rear brake pedal free travel a: 20 – 30 mm (0.8 – 1.2 in) rear brake shoe wear this motorcycle is equipped with brake lining wear limit indicator on the rear brake. To check br...

  • Page 38

    2-22 periodic maintenance air bleeding from 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 cylin- der and thus interferes with the full braking performance of the brake caliper. The presence of air is ...

  • Page 39

    Periodic maintenance 2-23 tire tire tread condition operating the motorcycle with excessively worn tires will decrease riding stability and consequently invite a dangerous situation. It is highly recommended to replace a tire when the remaining depth of tire tread reaches the following specification...

  • Page 40

    2-24 periodic maintenance front fork inspect the front forks for oil leakage, scoring or scratches on the outer surface of the inner tubes. Replace any defective parts, if necessary. ( 8-13) rear suspension inspect the damper for oil leakage and the spring unit for dam- age. Check that there is no ...

  • Page 41

    Periodic maintenance 2-25 chassis bolt and nut check that all chassis bolts and nuts are tightened to their specified torque. (refer to page 2-26 for the loca- tions of the following nuts and bolts on the motorcycle.) tighten initially at 1 000 km (600 miles, 2 months) and every 6 000 km (4 000 mile...

  • Page 42

    2-26 periodic maintenance sa mp le.

  • Page 43: Compression Pressure Check

    Periodic maintenance 2-27 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 mainte- nance records kept at your dealership should include compressi...

  • Page 44: Oil Pressure Check

    2-28 periodic maintenance oil pressure check check periodically the oil pressure in the engine to judge roughly the condition of the moving parts. Oil pressure specification if the oil pressure is lower or higher than the specification, the following causes may be considered. Low oil pressure * clog...

  • Page 45: Sds Check

    Periodic maintenance 2-29 sds check using sds, take the sample of data from the new motorcycle and at the time of periodic maintenance at your dealership. Save the data in the computer or by printing and filing the hard copies. The saved or filed data are useful for troubleshooting as they can be co...

  • Page 46

    2-30 periodic maintenance data at 3 000 r/min under no load data at the time of racing check the manifold absolute pressure. Xxx mmhg check the manifold absolute pressure. Xxx mmhg secondary valve moves approx. Xx degree. Secondary valve moves approx. Xx degree. Xxxx r/min xxxx r/min throttle : thro...

  • Page 47: Engine

    3 6 6 engine 3-1 contents engine engine components removable with engine in place ..............3- 2 engine removal and installation ....................................................3- 3 engine removal ...............................................................................3- 3 engine inst...

  • Page 48

    3-2 engine engine components removable with engine in place the parts listed below can be removed and reinstalled without removing the engine from the frame. Refer to the page listed in this section for removal and reinstallation instructions. Engine center engine left side engine right side parts r...

  • Page 49

    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 engine oil. ( 2-11) • drain e...

  • Page 50

    3-4 engine • remove the engine coolant reservoir tank. • disconnect the water hoses 3. • disconnect the side-stand switch lead wire coupler 4. • disconnect the neutral switch lead wire coupler 5. • disconnect the generator lead wire coupler 6 and the signal generator lead wire coupler 7. • remove th...

  • Page 51

    Engine 3-5 • remove the pair (air supply) cover. • remove the pair mounting bolts. • disconnect the pair hoses b and lead wire coupler c. • remove the air cleaner box d and air intake pipe e. ( 5-47) • remove the air cleaner box bracket. • remove the throttle body f. ( 6-14) sa mp le.

  • Page 52

    3-6 engine • disconnect the ect sensor lead wire coupler g. • disconnect the spark plug caps. • remove the right frame cover. ( 8-4) • disconnect the ho2 sensor lead wire coupler h. (for e-02, 19, 24) • remove the no. 1 muffler i. • remove the exhaust pipes and the no. 2 muffler. Sa mp le.

  • Page 53

    Engine 3-7 • remove the rear clutch cover j. • remove the rear brake link k. • disconnect the horn lead wire coupler l and rear brake switch lead wire coupler m. • remove the cooling fan n. ( 7-8) • remove the engine frame mounting bolt o. • remove the ground lead wire p. • support the engine with ...

  • Page 54

    3-8 engine engine installation install the engine in the reverse order of engine removal. Pay attention to the following points: • install the universal joint. Note: be sure to face the short portion a backward when installing it. • install the boot. Note: make sure that the “up” mark b faces up. • ...

  • Page 55

    Engine 3-9 note: * the engine mounting nuts are self-locking. Once the nut has been removed, they are no longer of any use. * be sure to use new nuts and tighten them to the specified torque. • install the gearshift lever and the footrest in the correct posi- tion.  gearshift lever height a standar...

  • Page 56

    3-10 engine • apply grease to the push rod and install it.  99000-25030: suzuki super grease “a” (usa) 99000-25010: suzuki super grease “a” (others) • apply grease to the clutch release mechanism and install it.  99000-25030: suzuki super grease “a” (usa) 99000-25010: suzuki super grease “a” (othe...

  • Page 57

    Engine 3-11 engine disassembly • remove the pair pipes. • remove the spark plugs.  09930-10121: spark plug wrench set • remove the gaskets. • remove the cylinder head cover caps (1, 2). • remove the water outlet union 3. • remove the breather cover 4 and gasket 5. Sa mp le.

  • Page 58

    3-12 engine • remove the valve inspection caps. (f & r) • remove the intake pipes 6. (f & r) cylinder head cover • remove the valve timing inspection plug 1 and the generator cover cap 2. • position “r i t” line on the generator with the center of the valve timing inspection hole. • remove the cylin...

  • Page 59

    Engine 3-13 • remove the dowel pins and camshaft end cap 3. • rotate the generator rotor 450 degrees (1 and 1/4 turns) and align the “f i t” line on the generator with the center of the valve timing inspection hole. • remove the cylinder head cover. (front) • remove the dowel pins and camshaft end c...

  • Page 60

    3-14 engine cylinder head/cylinder • loosen the water hose clamp screws. • remove the cylinder head bolts. (front cylinder) • after unlocking the ratchet, push the cam chain tension adjuster rod fully. • insert the special tool between the ratchet and the adjuster body.  09918-53810: chain tensione...

  • Page 61

    Engine 3-15 • separate the cylinder head/cylinder assembly. (front cylin- der) • remove the cam chain guide 4. • remove the dowel pins and gasket 5. • remove the cylinder head bolts. (rear cylinder) • push the cam chain tension adjuster rod and insert the spe- cial tool.  09918-53810: chain tension...

  • Page 62

    3-16 engine • remove the dowel pins and gasket 7. • remove the cam chain guide 8. • remove the water hose and pipe. • remove the cylinder 9. (rear cylinder) • remove the dowel pins and gasket 0. Piston • place a clean rag under the piston to prevent any parts from falling into the crankcase. • remov...

  • Page 63

    Engine 3-17 • draw out each piston pin 2 and remove the pistons 3. (f & r) note: scribe the cylinder position on the head. Starter motor • remove the starter motor cover 1. • remove the starter motor 2. Clutch • remove the clutch cover. • remove the dowel pins and gasket 1. Sa mp le.

  • Page 64

    3-18 engine • remove the clutch spring mounting bolts and springs diago- nally. • remove the pressure plate 2. • remove the thrust washer 3, bearing 4, push piece 5 and push rod 6. • remove the clutch drive and driven plates 7. • remove the spring washer 8 and spring washer seat 9. Sa mp le.

  • Page 65

    Engine 3-19 • remove the clutch sleeve hub nut with the special tool.  09920-53740: clutch sleeve hub holder • remove the washer 0 and the clutch sleeve hub a. • remove the thrust washer b, spacer c, and needle roller bearing d. • remove the primary driven gear assembly e and the oil pump drive cha...

  • Page 66

    3-20 engine oil pump • remove the oil pump by removing the snap ring.  09900-06107: snap ring pliers • remove the pin 1 and washer 2. • remove the oil pump 3. Gearshift • draw out the gearshift shaft 1. • remove the cam guide and the pawl lifter. • remove the cam driven gear assembly 2 by removing ...

  • Page 67

    Engine 3-21 primary drive gear • remove the primary drive gear by removing the primary drive gear bolt with the special tool.  09930-40113: rotor holder • remove the cam chain tensioner 1, washers, spacer 2 and the chain 3. • remove the cam chain drive sprocket 4 and the thrust washer 5. Oil filter...

  • Page 68

    3-22 engine neutral switch • remove the oil pressure switch lead wire. • remove the neutral switch assembly. • remove the neutral switch contacts 1 and spring 2. Generator • remove the generator cover. • remove the dowel pins and gasket 1. • remove the starter motor driven gear and the idle gear. Sa...

  • Page 69

    Engine 3-23 • loosen the generator rotor bolt. Note: when loosen the rotor bolt, do not remove it. The rotor bolt is used in conjunction with the rotor remover when removing the rotor. • remove the generator rotor assembly with the special tool.  09930-33730: rotor remover • remove the starter gear...

  • Page 70

    3-24 engine • remove the water pump assembly and gasket 1. Secondary driven gear • remove the secondary driven gear housing bolts. • remove the secondary driven gear case. • remove the secondary driven gear assembly 1 and shims 2. • remove the bearing 3, pin 4, oil jet 5, and dowel pins. Sa mp le.

  • Page 71

    Engine 3-25 oil jet • remove the oil jets. Crankcase • remove the crankcase bolts. • separate the crankcase into two parts with the special tool.  09920-13120: crankcase separator • remove the dowel pins and o-ring. Sa mp le.

  • Page 72

    3-26 engine • remove the thrust shim 1 and crankshaft 2. • remove the gearshift fork shafts 3 gearshift forks 4 and gearshift cam 5. • remove the transmission. • remove the washer. Secondary drive bevel gear • remove the over driving gear 1 and bush 2. • remove the secondary drive bevel gear assembl...

  • Page 73: Engine Components Inspection

    Engine 3-27 engine components inspection and servicing cylinder head cover disassembly • loosen the rocker arm shafts and pull out the rocker arm shafts. Cylinder head cover distortion after removing sealant from the fitting surface of the cylinder head cover, place the cylinder head cover on a surf...

  • Page 74

    3-28 engine reassembly • apply suzuki moly paste to the rocker arms and their shafts.  99000-25140: suzuki moly paste  rocker arm shaft: 27 n·m (2.7 kgf-m, 19.5 lb-ft) camshaft the camshafts should be checked for wear and also for runout of cams and journals if the engine has been noted to produce...

  • Page 75

    Engine 3-29 camshaft journal wear determine whether each journal is worn down to the limit or not by measuring camshaft journal oil clearance with the camshaft installed. Use plastigauge to read the clearance, which is speci- fied as follows:  camshaft journal oil clearance service limit: 0.150 mm ...

  • Page 76

    3-30 engine cam chain tensioner and guide cam chain tensioner for driving the camshafts, two cam chain tensioners are used on the respective cam drive chains. Unlock the ratchet mecha- nism, and move the push rod in place to see if it slides smoothly. If any stickiness is noted or ratchet mechanism ...

  • Page 77

    Engine 3-31 • pull out the valve 5 from the other side. • remove the valve stem seal 6 and valve spring seat 7. Note: removal of valves completes ordinary disassembling work. If valve guides have to be removed for replacement after inspect- ing related parts, carry out the steps shown in valve guide...

  • Page 78

    3-32 engine valve head radial runout place the dial gauge at right angles to the valve head face, and measure the valve head radial runout. If it measures more than limit, replace the valve.  valve head radial runout service limit: 0.03 mm (0.001 in)  09900-20701: magnetic stand 09900-20607: dial ...

  • Page 79

    Engine 3-33 • re-finish the valve guide holes in cylinder head with a 10.8 mm reamer and handle.  09916-34580: valve guide hole reamer 09916-34542: reamer handle • cool down the new valve guides in a freezer for about one hour and heat the cylinder head to 100 – 150 °c (212 – 302 °f) with a hot pla...

  • Page 80

    3-34 engine • the ring-like dye impression left on the valve face must be continuous – without any break. In addition, the width of the dye ring, which is the visualized seat “width”, must be within the following specification:  valve seat width w standard: 0.9 – 1.1 mm (0.035 – 0.043 in)  09916-1...

  • Page 81

    Engine 3-35 • insert the solid pilot 1 (09916-24450: n-100-5.52) with a slight rotation. Seat the pilot snugly. Install the 45° cutter, attachment and t-handle. 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 ...

  • Page 82

    3-36 engine bottom narrowing cut • if the contact area w is too wide or too low, use the 60° (intake side only) to narrow and raise the contact area. Final seat cut • if the contact area w is too low or too narrow, use the 45° cut- ter to raise and widen the contact area. Note: after cutting the 15°...

  • Page 83

    Engine 3-37 • 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. Valve stem end condition inspect the valve st...

  • Page 84

    3-38 engine valve and valve spring reassembly • fit the valve spring lower seats 1. • oil each oil seal, and press-fit the oil seal 2 into position with the valve guide installer.  09916-44910: valve guide remover/installer • insert the valves, with their stems coated with high quality molybdenum d...

  • Page 85

    Engine 3-39 note: when installing the water union to the cylinder head, apply grease to the new o-rings.  99000-25030: suzuki super grease “a” (usa) 99000-25010: suzuki super grease “a” (others) sa mp le.

  • Page 86

    3-40 engine cylinder cylinder distortion check the gasketed surface of the cylinder for distortion with a straightedge and thickness gauge, taking a clearance reading at several places as indicated. If the largest reading at any position of the straightedge exceeds the limit, replace the cylinder. ...

  • Page 87

    Engine 3-41 piston piston diameter using a micrometer, measure the piston outside diameter at the place shown in fig. If the measurement is less than the limit, replace the piston.  piston diameter service limit: 82.880 mm (3.2630 in)  09900-20204: micrometer (75 – 100 mm) piston-to-cylinder clear...

  • Page 88

    3-42 engine piston ring free end gap and end gap before installing piston rings, measure the free end gap of each ring using vernier calipers. Next, fit the ring in the cylinder, and measure each ring end gap using a thickness gauge. If any ring has an excess end gap, replace the ring.  piston ring...

  • Page 89

    Engine 3-43 piston pin and pin bore using a small bore gauge, measure the piston pin bore inside diameter, and using a micrometer, measure the piston pin out- side diameter. If the reading exceeds following limit, replace both piston and piston pin.  piston pin bore i.D. Service limit: 20.030 mm (0...

  • Page 90

    3-44 engine • 1st ring and 2nd ring have letter “r” 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. Conrod/crankshaft ...

  • Page 91

    Engine 3-45  conrod big end width standard: 21.95 – 22.00 mm (0.864 – 0.866 in) crank pin width standard: 22.10 – 22.15 mm (0.870 – 0.872 in)  09900-20205: micrometer (0 – 25 mm) 09900-20605: dial calipers (10 – 34 mm) conrod-crank pin bearing selection • loosen the bearing cap nuts and tap the bo...

  • Page 92

    3-46 engine • remove the caps and measure the width of compressed plas- tigauge with envelope scale. This measurement should be taken at the widest part.  conrod big end oil clearance standard: 0.024 – 0.042 mm (0.0009 – 0.0017 in) service limit: 0.080 mm (0.0031 in) • if oil clearance exceeds the ...

  • Page 93

    Engine 3-47 bearing thickness specification conrod/crank pin bearing assembly • when fitting the bearing to the bearing cap and conrod, be sure to fix the stopper part 1 first and press in the other end. • apply molybdenum oil solution to the crank pin and bearing surface.  molybdenum oil solution ...

  • Page 94

    3-48 engine crankcase/crankshaft bearing inspection • inspect the crankshaft and crankshaft journal bearings for any damage. If any, replace them with a specified set of bearings. • measure the crankshaft journal o.D. 1 by using the special tool.  crankshaft journal o.D. 1 standard: 47.965 – 47.980...

  • Page 95

    Engine 3-49 bearing thickness crankshaft journal bearing replacement use the special tool to replace the crankshaft journal bearings. The replacement procedure is as follows:  09913-60230: journal bearing remover/installer • set the special tool as shown to remove the crankshaft journal bearings. N...

  • Page 96

    3-50 engine note: using the hand-press is recommended to remove the crankshaft journal bearings. However, the crankshaft journal bearings can be removed by using with the following special tools.  09924-84510: bearing installer set 09924-74570: final drive gear bearing remover/installer • set the s...

  • Page 97

    Engine 3-51 • set the bearings installed in the special tool to the crankcase half as shown. Note: the upper and lower bearings are same. • insert the thickness gauge 1 between the crankcase and special tool 3 for 1 mm (0.04 in) clearance. • apply enough engine oil to the special tool and the bearin...

  • Page 98

    3-52 engine 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 09924-74570: final drive gear bearing remover/installer • after insta...

  • Page 99

    Engine 3-53 • if the thrust clearance exceeds the standard range, adjust the thrust clearance by the following procedures: • remove the thrust shim, and measure its thickness with a micrometer. • change the thrust shim with the other shim if the thrust clear- ance is incorrect. • perform the thrust ...

  • Page 100

    3-54 engine measure each driven plate for distortion with a thickness gauge and surface plate. Replace driven plates which exceed the limit.  clutch driven plate distortion service limit: 0.10 mm (0.004 in)  09900-20803: thickness gauge clutch spring free length measure the free length of each coi...

  • Page 101

    Engine 3-55 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 one direction only. If a large resistance is felt to rotation, inspect the starter clutch for dam...

  • Page 102

    3-56 engine • when installing the starter clutch guide 2, make sure that the flange b side faces out. • apply thread lock super “1303” to the securing bolts and tighten them to the specified torque while holding the rotor with off-set wrench.  99000-32030: thread lock super “1303”  starter clutch ...

  • Page 103

    Engine 3-57 transmission disassembly • disassemble the transmission gears as shown in the illustration. 1 driveshaft bolt 8 2nd driven gear 2 over driving gear 9 countershaft/1st drive gear 3 1st driven gear 0 4th drive gear 4 4th driven gear a 3rd drive gear 5 3rd driven gear b 5th drive gear 6 dri...

  • Page 104

    3-58 engine reassembly assemble the countershaft and driveshaft in the reverse order of disassembly. Pay attention to following points: note: always use new circlips. Note: before installing the gears, coat lightly moly paste or engine oil to the driveshaft and countershaft.  99000-25140: suzuki mo...

  • Page 105

    Engine 3-59 transmission gears and related parts when installing the 1st and 3rd driven gear bushings, align the bushing oil hole c with the driveshaft oil hole d. Sa mp le.

  • Page 106

    3-60 engine gearshift fork gearshift fork to groove clearance using a thickness gauge, check the shifting fork clearance in the groove of its gear. The clearance for each of the three shifting forks plays an impor- tant role in the smoothness and positiveness of shifting action. If the clearance che...

  • Page 107

    Engine 3-61 crankcase oil sump filter • remove the oil sump filter cover. • remove the oil sump filter. • clean the oil sump filter using compressed air. • when installing the new o-ring, apply grease to it.  99000-25030: suzuki super grease “a” (usa) 99000-25010: suzuki super grease “a” (others) o...

  • Page 108

    3-62 engine • when installing the oil pipe, use the new o-rings. • apply grease to the o-rings.  99000-25030: suzuki super grease “a” (usa) 99000-25010: suzuki super grease “a” (others) • apply a small quantity of the thread lock “1342” to the oil pipe retainer bolts and tighten them securely.  99...

  • Page 109

    Engine 3-63 bearing disassembly • remove the bearing retainers. • remove the bearing with the special tools.  09913-70210: bearing installer set 09921-20240: bearing remover set note: if abnormal noise does not occur, it is not necessary to remove the bearing. Bearing reassembly • install the beari...

  • Page 110

    3-64 engine • when installing the switch, apply suzuki bond “1207b”.  oil pressure switch: 14 n·m (1.4 kgf-m, 10.0 lb-ft)  99000-31140: suzuki bond ‘‘1207b” oil seal • remove the oil seal with the special tool.  09913-70210: bearing installer set • install the oil seal with the special tool. • ap...

  • Page 111: Engine Reassembly

    Engine 3-65 engine reassembly reassemble the engine in the reverse order of disassembly. The following steps require special attention or precautionary measures should be taken. Note: apply engine oil to each running and sliding part before reas- sembling. Secondary drive bevel gear • install the se...

  • Page 112

    3-66 engine • install the gearshift forks 3 4, gearshift fork shafts and gear- shift cam. 3 no. 1 shift forks (for 4th and 5th driven gears) 4 no. 2 shift fork (for 3rd drive gear) crankshaft • install the thrust shim 1 on the crankshaft. Note: * the grooved face a of thrust shim 1 faces to cranksha...

  • Page 113

    Engine 3-67 • install the dowel pins and o-ring on the left crankcase half. Note: apply grease to the o-ring.  99000-25030: suzuki super grease “a” (usa) 99000-25010: suzuki super grease “a” (others) • clean the mating surfaces of the left and right crankcase halves. • apply suzuki bond “1207b” to ...

  • Page 114

    3-68 engine secondary driven bevel gear • install the secondary driven bevel gear bearing and the pin 1. Note: * align the hole a of the secondary driven bevel gear bearing with the pin 1. * the stamped mark side of the bearing face rearward. • install the secondary driven bevel gear assembly, shim(...

  • Page 115

    Engine 3-69 • tighten the secondary driven bevel gear bolt to the specified torque. Note: * hollow portion e of the secondary driven gear assembly faces inside. * apply a small quantity of thread lock super “1303” to the bolt.  99000-32030: thread lock super “1303”  secondary driven bevel gear bol...

  • Page 116

    3-70 engine • install the new o-ring. • install the water pump cover. Note: * fit the clamp to the bolt a. * apply grease to the o-ring.  99000-25030: suzuki super grease “a” (usa) 99000-25010: suzuki super grease “a” (others) cam chain/cam chain tensioner • install the cam chain tensioner 1, washe...

  • Page 117

    Engine 3-71 • install the starter driven gear to the rotor. • install the generator rotor assembly and tighten its bolt to the specified torque.  generator rotor bolt: 160 n·m (16.0 kgf-m, 115.5 lb-ft) • install the starter driven gear and the idle gear. • install the new gasket 3 and dowel pins. •...

  • Page 118

    3-72 engine • install the neutral switch. • install the oil pressure switch lead wire. Oil filter • apply engine oil lightly to the gasket of the oil filter before installation. • install the oil filter turning it by hand until feeling that the filter gasket contacts the mounting surface. Then tight...

  • Page 119

    Engine 3-73 • install the primary drive gear and tighten the primary drive gear bolt to the specified torque with the special tool.  primary drive gear bolt: 95 n·m (9.5 kgf-m, 68.5 lb-ft)  09930-40113: rotor holder note: this bolt has left-hand thread. Gearshift • install the washer 1. • install ...

  • Page 120

    3-74 engine • install the gearshift return spring properly. • install the gearshift shaft with the center of shift gear on the shaft aligned the center of gearshift cam driven gear. Oil pump • install the oil pump.  oil pump mounting bolt: 11 n·m (1.1 kgf-m, 8 lb-ft) note: set the oil pump shaft en...

  • Page 121

    Engine 3-75 • install the primary driven gear assembly and engage the chain with the oil pump driven gear. • apply engine oil to the primary driven gear bearing 3 and install it. • install the spacer 4 and thrust washer 5. • install the clutch sleeve hub 6 and washer 7. Note: the convex side of the ...

  • Page 122

    3-76 engine a no. 2 drive plate thickness: 3.5 mm (0.14 in) .......... 1 pc. B no. 1 drive plate thickness: 3.0 mm (0.12 in) .......... 6 pcs. A driven plate ......................................6 pcs. • install the wave washer seat 8 and the wave washer 9. 95 n.M (9.5 kgf-m, 68.5 lb-ft) 60 n.M (6....

  • Page 123

    Engine 3-77 • install the clutch drive plate no. 2 a first. • install the drive and driven plate one by one into the clutch sleeve hub. • install the push rod. • install the clutch push piece 0, bearing a and thrust washer b. • apply engine oil to the bearing. • install the springs and tighten the c...

  • Page 124

    3-78 engine starter motor • install the starter motor. Note: apply grease to the new o-ring.  99000-25030: suzuki super grease “a” (usa) 99000-25010: suzuki super grease “a” (others) • install the starter motor cover. Oil jet • apply engine oil to the new o-ring and install the oil jets. Piston • a...

  • Page 125

    Engine 3-79 cylinder • install the cam chain tension adjuster to the cylinder. • after unlocking the ratchet, push the cam chain tension adjuster rod. • insert the special tool between the ratchet and the adjuster body.  09918-53810: chain tensioner lock tool  cam chain tension adjuster mounting b...

  • Page 126

    3-80 engine cylinder head • install the cam chain guide. 1 for front cylinder 2 for rear cylinder • fit the dowel pins and the new gasket 3. • install the cylinder head and tighten the cylinder head bolts diagonally to the specified torque. (rear cylinder)  cylinder head bolt (m10): initial: 25 n·m...

  • Page 127

    Engine 3-81 • fit the dowel pins and the new gasket 2. • install the front cylinder assembly to the crankcase. • connect the water hoses. • tighten the cylinder head bolts diagonally to the specified torque.  cylinder head bolt (m10): initial: 25 n·m (2.5 kgf-m, 18.0 lb-ft) final : 38 n·m (3.8 kgf-...

  • Page 128

    3-82 engine • align the arrow marks on the front and rear camshafts so it is parallel with the surface of the cylinder heads. Note: arrow marks are located to forward. • engage the chains on the cam sprockets with the locating pin holes a as shown in the photograph. Note: do not rotate the generator...

  • Page 129

    Engine 3-83 • apply suzuki bond “1216b” to the mating surface of the cylinder head cover. • fit the camshaft end caps 1. • apply grease to the new o-ring 2 and install it. (front cylin- der only) 99000-31230: suzuki bond “1216b”  99000-25030: suzuki super grease “a” (usa) 99000-25010: suzuki super ...

  • Page 130

    3-84 engine location of cylinder head cover bolt note: * before installing the bolt 1, apply suzuki bond “1207b” to the thread of the bolt. * allen bolt: 2 * fit the gasket to the bolt 3. • remove the tensioner lock tools. Note: click sound is heard when the cam chain tension adjuster is released. F...

  • Page 131

    Engine 3-85 • install the intake pipe. • apply grease to the new o-ring and install the water outlet union.  99000-25030: suzuki super grease “a” (usa) 99000-25010: suzuki super grease “a” (others) • install the gasket and the breather cover. • apply grease to the new o-rings and install the valve ...

  • Page 132

    3-86 engine • install the new gaskets. • install the pair pipes. • install the spark plugs.  09930-10121: spark plug wrench set sa mp le.

  • Page 133: Shaft Drive

    4 6 6 shaft drive 4-1 contents shaft drive secondary bevel gears .......................................................................4- 2 construction ...................................................................................4- 2 removal .....................................................

  • Page 134: Secondary Bevel Gears

    4-2 shaft drive secondary bevel gears construction * a: do not disassemble the secondary driven gear. 1 bush 7 shims (5 kinds) c oil seal 2 overdriving driven gear 8 driven bevel gear bearing d bearing stopper 3 circlip 9 o-ring e universal joint 4 output cam dog 0 shims (5 kinds) a secondary drive ...

  • Page 135

    Shaft drive 4-3 standard clearance a: 1.00 mm (0.039 in) b: 1.00 mm (0.039 in) adjust backlash by selecting shims. (use two pieces of shims.) shim 1 size table the shims 1 are available as a set (24945-05810). Shim 2 size table the shims 2 are available as a set (24935-38810). Part number thickness ...

  • Page 136

    4-4 shaft drive removal secondary drive bevel gear the crankcase must be separated to service the secondary drive bevel gear. The secondary drive bevel gear service requires engine removal and disassembly. Refer to the engine removal and the engine disassembly sections for secondary drive bevel gear...

  • Page 137

    Shaft drive 4-5 secondary driven bevel gear • remove the bearing stopper with the special tool.  09921-21820: bearing retainer wrench • remove the oil seal 1 and o-ring 2. Inspection inspect the removed parts for the following abnormalities. * drive and driven bevel gears damage or wear * improper ...

  • Page 138

    4-6 shaft drive secondary gear shims adjustment backlash • install the secondary drive bevel gear assembly with the removed shims and tighten the bolts to the specified torque.  secondary drive bevel gear bearing retainer bolt: 23 n·m (2.3 kgf-m, 16.5 lb-ft) note: when replacing the secondary drive...

  • Page 139

    Shaft drive 4-7 • measure the backlash as follows. • set-up a dial gauge as shown in photo.  09900-20606: dial gauge (1/100 mm, 10 mm) 09900-20701: magnetic stand • adjust the dial gauge so that it touches the secondary drive bevel gear cam dog; hold the driven bevel gear securely, and turn the dri...

  • Page 140

    4-8 shaft drive driven bevel gear side note: the shims (driven bevel gear side) are available as a set (24945-05810). Tooth contact after bringing the backlash within specification by changing the secondary driven bevel gear shims, it will be necessary to check tooth contact. • remove the drive beve...

  • Page 141

    Shaft drive 4-9 shim specifications drive bevel gear side note: the shims (drive bevel gear side) are available as a set (24935-38810). Driven bevel gear side note: the shims (driven bevel gear side) are available as a set (24945-35810). Part no. Shim thickness 24935-38a01-030 0.30 mm (0.012 in) 249...

  • Page 142

    4-10 shaft drive reassembly secondary driven bevel gear • apply grease to the lip of oil seal.  99000-25030: suzuki super grease “a” (usa) 99000-25010: suzuki super grease “a” (others) • tighten the bearing stopper to the specified torque with the special tool.  bearing stopper: 105 n·m (10.5 kgf-...

  • Page 143: Final Bevel Gears

    Shaft drive 4-11 final bevel gears construction 1 oil seal a oil seal k final drive coupling 2 final gear bearing case b final gear case l snap ring 3 o-ring c shims (5 kinds) m oil seal 4 plate d stopper plate (2 kinds) n spring 5 final driven gear bearing e final drive gear bearing o propeller sha...

  • Page 144

    4-12 shaft drive standard clearance b: 2.3 mm (0.091 in) shim 2 size table the shims 2 are available as a set {27326-34810 (1.40 – 1.50), 27326-34820 (1.05 – 1.35)}. Standard clearance a: 1.00 mm (0.039 in) shim 1 size table standard clearance c: 1.00 mm (0.039 in) shim 3 size table part number thic...

  • Page 145

    Shaft drive 4-13 final gear case removal after draining final gear oil, the following components must be removed in the described order before removing the final gear case. Note: refer to the following pages for the details of each step. • drain final gear oil. ( 2-19) • remove the rear wheel. ( 8...

  • Page 146

    4-14 shaft drive 4 spring 5 propeller shaft 6 snap ring • using a chisel, unlock the nut. • remove the final drive bevel gear coupling nut with the spe- cial tool.  09924-62430: 22 mm long socket 09924-64510: final drive gear coupling holder • remove the washer 7 and the final drive coupling 8. • r...

  • Page 147

    Shaft drive 4-15 • remove the bearing from the final drive bevel gear with the special tool.  09913-50121: bearing puller note: if no abnormal noise, the bearing removal is not necessary. • remove the final gear bearing case bolts. • remove the final gear bearing case from the final gear case, by u...

  • Page 148

    4-16 shaft drive • remove the bearing retainer screws, using an impact driver set.  09900-09004: impact driver set • remove the final driven gear bearing c and oil seal d with the special tools.  09941-64511: bearing remover 09930-30104: sliding shaft note: if no abnormal noise, the bearing remova...

  • Page 149

    Shaft drive 4-17 final gear shims adjustment final gear bearing case shim clearance • install the final driven gear, shims (1 and 2) and final gear bearing case to the final gear case. • tighten the final gear case bolts to the specified torque.  final gear case bolt: 23 n·m (2.3 kgf-m, 16.5 lb-ft)...

  • Page 150

    4-18 shaft drive backlash after assembling the final gear case, measure the final bevel gear backlash as follows. • install the backlash measuring tool on the drive bevel gear coupling, and set-up a dial gauge as shown in photo.  09924-34510: backlash measuring tool (27 – 50 mm) 09900-20607: dial g...

  • Page 151

    Shaft drive 4-19 shims 2 specifications the shims 1 are available as a set (27327-34810). Example: final gear to case shims 1; 1.45 mm + 1.40 mm = 2.85 mm final gear bearing to bearing case shims 2, 0.35 mm + 0.60 mm = 0.95 mm original total measurement = 3.80 mm backlash too large: final gear to ca...

  • Page 152

    4-20 shaft drive • remove the final gear bearing case and final driven bevel gear, and inspect the coated teeth of the driven bevel gear. The contact patch should be as shown at right: • if the tooth contact pattern is incorrect, as shown in 1, a thin- ner shim 4 is needed between the final drive be...

  • Page 153

    Shaft drive 4-21 final gear case reassembly reassemble the final gear case in the reverse order of disas- sembly. Pay attention to the following points. • install a new oil seal 1 and o-ring 2 to the bearing stopper. • install the bearing to the final drive bevel gear with the special tool.  09913-...

  • Page 154

    4-22 shaft drive • install the needle roller bearing for the final driven bevel gear into the final gear case with the special tool.  09913-76010: bearing installer note: the boss on the bearing end should face to the driven bevel gear side. • install the bearing retainer. Apply a small quantity of...

  • Page 155

    Shaft drive 4-23 • install the correct shims 2 to the final drive bevel gear and install the bevel gear to the final gear case. Shim adjustment ( 4-18) • apply grease to the o-ring and the oil seal. • install the bearing stopper 3.  99000-25030: suzuki super grease “a” (usa) 99000-25010: suzuki su...

  • Page 156

    4-24 shaft drive • apply lithium base molybdenum grease (nlgi #2) to the pro- peller shaft splines and final drive bevel gear coupling. • install the spring 6 and propeller shaft 7.  99000-25140: suzuki moly paste • install the snap ring 8. • after installing the propeller shaft with a new snap rin...

  • Page 157

    Shaft drive 4-25 final gear case installation installation is in the reverse order of removal. Note: refer to the following pages for the details of each step. • install the final gear case. • tighten the final gear case bolts to the specified torque.  final gear case nut: 40 n·m (4.0 kgf-m, 29.0 l...

  • Page 158: Fi System

    Fi system 5-1 5 fi system contents precautions in servicing ....................................................................5- 3 connector/coupler .......................................................................5- 3 fuse .......................................................................

  • Page 159: Fi System

    Fi system contents 5-2 fi system “c32” (p0201) or “c33” (p0202) fuel injector circuit malfunction ...................................................................................... 5-66 “c41” (p0230) fp relay circuit malfunction ........................... 5-68 “c42” (p01650) ig switch circuit m...

  • Page 160: Precautions In Servicing

    Fi system 5-3 precautions in servicing when handling the fi component parts or servicing the fi sys- tem, observe the following points for the safety of the system. Connector/coupler • when connecting a connector, be sure to push it in until a click is felt. • with a lock type coupler, be sure to re...

  • Page 161

    5-4 fi system • when connecting meter probe from the terminal side of the coupler where (connection from harness side not being possi- ble), use extra care not to force and cause the male terminal to bend or the female terminal to open. Connect the probe as shown to avoid opening of female ter- mina...

  • Page 162

    Fi system 5-5 • when disconnecting and connecting the ecm couplers, 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 reve...

  • Page 163

    5-6 fi system electrical circuit inspection procedure while there are various methods for electrical circuit inspection, described here is a general method to check for open and short circuit using an ohmmeter and a voltmeter. Open circuit check possible causes for the open circuit are as follows. A...

  • Page 164

    Fi system 5-7 continuity check • measure resistance across coupler b (between a and c in the figure). If no continuity is indicated (infinity or over limit), the circuit is open between terminals a and c. • disconnect the coupler b and measure resistance between couplers a and b. If no continuity is...

  • Page 165

    5-8 fi system 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 thos...

  • Page 166

    Fi system 5-9 using the multi-circuit tester • use the suzuki multi-circuit tester (09900-25008). • use well-charged batteries in the tester. • be sure to set the tester to the correct testing range. Using the tester • incorrectly connecting the + and - probes may cause the inside of the tester to b...

  • Page 167: Fi System Technical Features

    5-10 fi system 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 the intake air pressure, engine speed and throttle opening angle, and various compensations. These compe...

  • Page 168

    Fi system 5-11 compensation of injection time (volume) the following different signals are output from the respective sensors for compensation of the fuel injection time (volume). Injection stop control signal description engine coolant temperature sen- sor signal when engine coolant temperature is ...

  • Page 169: Fi System Parts Location

    5-12 fi system fi system parts location ecm #2 #1 #1 a speedometer h gear position switch b starter relay i crankshaft position sensor (ckps) c starter motor j fuel injector #2 (fi) d intake air pressure sensor #1 (iaps) k fuel injector #1 (fi) e fuel pump relay (fp relay) l ignition coil #1 (ig coi...

  • Page 170

    Fi system 5-13 ecm n intake air pressure sensor #2 (iaps) r intake air temperature sensor (iats) o secondary throttle position sensor (stps) s ignition coil #2 (ig coil) p throttle position sensor (tps) t engine coolant temperature sensor (ects) q secondary throttle valve actuator (stva) u ho2 senso...

  • Page 171

    5-14 fi system fi system wiring diagram intak e air pressure sensor (iaps) f ront intak e air pressure sensor (iaps) rear engine coolant temper ature sensor (ects) intak e air temper ature sensor (ia ts) tip-o v er sensor (t os) ecm heated o xygen sensor (ho2s) fuel pump fuel injector (fi) #1 #2 ign...

  • Page 172: Ecm Terminal

    Fi system 5-15 ecm terminal terminal no. Circuit terminal no. Circuit 1 gp switch signal (gp) h ignition switch signal (at) 2 iat sensor signal (iat) i ect sensor signal (ect) 3 rear cylinder iap sensor signal (iap. R) j to sensor signal (tos) 4 stp sensor signal (stp) k tp sensor signal (tp) 5 blan...

  • Page 173: Self-Diagnosis Function

    5-16 fi system 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...

  • Page 174

    Fi system 5-17 dealer mode the defective function is memorized in the computer. Use the special tool’s coupler to connect to the dealer mode coupler. The memorized malfunction code is displayed on the lcd (display) panel. Malfunction means that the ecm does not receive signal from the devices. These...

  • Page 175

    5-18 fi system in the lcd (display) panel, the malfunction code is indicated from small code to large code. *1 to get the proper signal from the throttle position sensor, the sensor basic position is indicated in the lcd (display) panel. The malfunction code is indicated in three digits. In front of...

  • Page 176

    Fi system 5-19 tps adjustment 1. Warm up the engine and adjust the engine idle speed to 1 100 ± 100 r/min. ( 2-13) 2. Connect the special tool (mode select switch) and select the dealer mode. 3. Remove the fuel tank. ( 6-3) 4. Loosen the inlet pipe screws. ( 5-47) 5. Move the inlet pipe 1. 6. Loo...

  • Page 177: Fail-Safe Function

    5-20 fi system fail-safe function fi system is provided with fail-safe function to allow the engine to start and the motorcycle to run in a mini- mum performance necessary even under malfunction condition. The engine can start and can run even if the above signal is not received from each sensor. Bu...

  • Page 178: Fi System Troubleshooting

    Fi system 5-21 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 an inspection form such as below will facilitate collecting information required for proper analysis and ...

  • Page 179

    5-22 fi system note: the above form is a standard sample. The form should be modified according to conditions and characteris- tics of each market. Visual inspection • prior to diagnosis using the mode select switch or sds, perform the following visual inspections. The rea- son for visual inspection...

  • Page 180

    Fi system 5-23 self-diagnostic procedures note: * don’t disconnect couplers from the ecm, the battery cable from the battery, ecm ground wire harness from the engine or main fuse before confirming the malfunction code (self-diag- nostic trouble code) stored in memory. Such disconnection will erase t...

  • Page 181

    5-24 fi system use of sds diagnostic procedures * don’t disconnect couplers from ecm, the battery cable from the battery, ecm ground wire harness from the engine or main fuse before confirming the malfunction code (self-diagnostic trouble code) stored in memory. Such disconnection will erase the mem...

  • Page 182

    Fi system 5-25 use of sds diagnosis reset proce- dure • after repairing the trouble, turn off the ignition switch and turn on again. • click the dtc inspection button 1. • check the dtc. • the previous malfunction history code (past dtc) still remains stored in the ecm. Therefore, erase the history ...

  • Page 183

    5-26 fi system show data when trouble (displaing data at the time of dtc) ecm stores the engine and driving conditions (in the form of data as shown in the figure) at the moment of the detection of a malfunction in its memory. This data is called “show data when trouble”. Therefore, it is possible t...

  • Page 184

    Fi system 5-27 malfunction code and defective condition dtc no. Detected item detected failure condition check for c00 no fault ––––––––––– ––––––––––– c12 ckp sensor the signal does not reach ecm for 3 sec. Or more, after receiving the starter signal. Ckp sensor wiring and mechan- ical parts ckp se...

  • Page 185

    5-28 fi system dtc no. Detected item detected failure condition check for c21 iat sensor the sensor voltage should be the fol- lowing. 0.1 v sensor voltage in other than the above range, c21 (p0110) is indicated. Iat sensor, lead wire/coupler connection p0110 h sensor voltage is higher than specifie...

  • Page 186

    Fi system 5-29 note: ho2 sensor voltage measuring condition 1. 10 minutes after the engine start (idling) or 100 sec. After the engine start (engine revolution is over 2 000 r/min). 2. Coolant temperature is upper 45 ºc (113 ºf). Dtc no. Detected item detected failure condition check for c31 gear po...

  • Page 187

    5-30 fi system “c12” (p0335) ckp sensor circuit malfunction inspection step 1 1) remove the left frame cover ( 8-3) 2) remove the left frame lower cover 1. : hooked part 3) remove the tool box cover 2. Detected condition possible cause the signal does not reach ecm for 3 sec. Or more, after receiv...

  • Page 188

    Fi system 5-31 4) remove the tool box 3. 5) turn the ignition switch off. 6) check the ckp sensor coupler for loose or poor contacts. If ok, then measure the ckp sensor resistance. 7) disconnect the ckp sensor coupler and measure the resis- tance.  ckp sensor resistance: 184 – 276 Ω (green – blue) ...

  • Page 189

    5-32 fi system step 2 1) crank the engine a few seconds with the starter motor, and measure the ckp sensor peak voltage at the coupler. 2) repeat the above test procedure a few times and measure the highest peak voltage.  ckp sensor peak voltage: 4.0 v and more (+ green – - blue) 1 peak volt adapto...

  • Page 190

    Fi system 5-33 “c13” (p1750) or “c17” (p0105) iap sensor circuit malfunction inspection step 1 (when indicating c13/p1750 for iap sensor #2) 1) for the other inspection procedures are the same as c17/ p0105. (when indicating c17/p0105 for iap sensor #1) 1) remove the fuel tank. ( 6-3) 2) turn the i...

  • Page 191

    5-34 fi system is the voltage ok? 8) after repairing the trouble, clear the dtc using sds tool. ( 5-25) step 2 1) connect the iap sensor coupler. 2) reinstall the fuel tank and lift up the fuel tank. 3) insert the needle pointed probes to the lead wire coupler. 4) start the engine at idle speed and...

  • Page 192

    Fi system 5-35 step 3 1) turn the ignition switch off. 2) remove the iap sensor. ( 5-75) 3) connect the vacuum pump gauge to the vacuum port of the iap sensor. 4) arrange 3 new 1.5 v batteries in series 1 (check that total - voltage is 4.5 – 5.0 v) and connect - terminal to the ground - terminal 2 ...

  • Page 193

    5-36 fi system output voltage (vcc voltage 4.5 – 5.0 v, ambient temp. 20 – 30 °c, 68 – 86 °f) altitude (reference) atmospheric pressure output voltage (ft) (m) (mmhg) kpa (v) 0 2 000 0 610 760 707 100 94 3.4 – 4.0 2 001 5 000 611 1 524 707 634 94 85 2.8 – 3.7 5 001 8 000 1 525 2 438 634 567 85 76 2....

  • Page 194

    Fi system 5-37 “c14” (p0120-h/l) tp sensor circuit malfunction inspection step 1 (when indicating c14:) 1) remove the fuel tank. ( 6-3) 2) turn the ignition switch off. 3) check the tp sensor coupler for loose or poor contacts. If ok, then measure the tp sensor input voltage. 4) disconnect the tp s...

  • Page 195

    5-38 fi system step 1 (when indicating p0120-h:) 1) remove the fuel tank. ( 6-3) 2) turn the ignition switch off. 3) check the tp sensor coupler for loose or poor contacts. If ok, then check the tp sensor lead wire continuity. 4) disconnect the tp sensor coupler. 5) check the continuity between bi/...

  • Page 196

    Fi system 5-39 step 1 (when indicating p0120-l:) 1) remove the fuel tank. ( 6-3) 2) turn the ignition switch off. 3) check the tp sensor coupler for loose or poor contacts. If ok, then measure the tp sensor lead wire continuity. 4) disconnect the tp sensor coupler. 5) check the continuity between b...

  • Page 197

    5-40 fi system step 2 1) turn the ignition switch off. 2) disconnect the tp sensor coupler. 3) check the continuity between yellow wire and ground.  tp sensor continuity: ∞ Ω (infinity) (yellow – ground) 4) if ok, then measure the tp sensor resistance at the termi- nals (between yellow wire and bla...

  • Page 198

    Fi system 5-41 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. 4) measure the tp sensor output voltage at the coupler (between bl/b wire a and b/br wire b) by turning the throttle grip.  tp sensor output voltage ...

  • Page 199

    5-42 fi system “c15” (p0115-h/l) ect sensor circuit malfunction inspection step 1 (when indicating c15:) 1) remove the fuel tank. ( 6-3) 2) turn the ignition switch off. 3) check the ect sensor coupler for loose or poor contacts. If ok, then measure the ect sensor voltage at the wire side coupler. ...

  • Page 200

    Fi system 5-43 step 1 (when indicating p0115-h:) 1) remove the fuel tank. ( 6-3) 2) turn the ignition switch off. 3) check the ect sensor coupler for loose or poor contacts. If ok, then check the ect sensor lead wire continuity. 4) remove the right frame cover. ( 8-4) 5) disconnect the ect sensor ...

  • Page 201

    5-44 fi system step 1 (when indicating p0115-l:) 1) remove the fuel tank. ( 6-3) 2) turn the ignition switch off. 3) check the ect sensor coupler for loose or poor contacts. If ok, then check the ect sensor lead wire continuity. 4) disconnect the ect sensor coupler. 5) check the continuity between ...

  • Page 202

    Fi system 5-45 step 2 1) turn the ignition switch off. 2) loosen the inlet pipe screw. 3) lift up the inlet pipe 1. 4) disconnect the ect sensor coupler. 5) measure the ect sensor resistance.  ect sensor resistance: approx. 2.3 – 2.6 k Ω at 20 °c (68 °f) (terminal – terminal)  09900-25008: multi-c...

  • Page 203

    5-46 fi system ect sensor inspection • remove the ect sensor. ( 5-77) • check the ect sensor by testing it at the bench as shown in the figure. Connect the ect sensor 1 to a circuit tester and place it in the oil 2 contained in a pan, which is placed on a stove. • heat the oil to raise its temperat...

  • Page 204

    Fi system 5-47 “c21” (p0110-h/l) iat sensor circuit malfunction inspection step 1 (when indicating c21:) 1) loosen the inlet pipe screw 1. 2) remove the air cleaner box 2. 3) turn the ignition switch off. 4) check the iat sensor coupler for loose or poor contacts. If ok, then measure the iat sensor ...

  • Page 205

    5-48 fi system 6) measure the voltage between dg wire terminal 3 and ground. 7) also, measure the voltage between dg wire terminal 3 and b/br wire terminal 4.  iat sensor input voltage: 4.5 – 5.5 v (+ dg – - ground) (+ dg – - b/br)  09900-25008: multi-circuit tester set  tester knob indication: v...

  • Page 206

    Fi system 5-49 step 1 (when indicating p0110-h:) 1) loosen the inlet pipe screw. ( 5-47) 2) remove the air cleaner box. ( 6-13) 3) turn the ignition switch off. 4) check the iat sensor coupler for loose or poor contacts. If ok, then check the iat sensor lead wire continuity. 5) remove the right fr...

  • Page 207

    5-50 fi system step 1 (when indicating p0110-l:) 1) loosen the inlet pipe screw. ( 5-47) 2) remove the air cleaner box. ( 6-13) 3) turn the ignition switch off. 4) check the iat sensor coupler for loose or poor contacts. If ok, then check the iat sensor lead wire continuity. 5) disconnect the iat ...

  • Page 208

    Fi system 5-51 step 2 1) turn the ignition switch off. 2) disconnect the iat sensor coupler. 3) measure the iat sensor resistance.  iat sensor resistance: approx. 2.6 kΩ at 20 °c (68 °f) (terminal – terminal)  09900-25008: multi-circuit tester set  tester knob indication: resistance (Ω) is the re...

  • Page 209

    5-52 fi system “c23” (p1651-h/l) to sensor circuit malfunction inspection step 1 (when indicating c23:) 1) remove the right frame cover. ( 8-4) 2) turn the ignition switch off. 3) check the to sensor coupler for loose or poor contacts. If ok, then measure the to sensor resistance. 4) disconnect the...

  • Page 210

    Fi system 5-53 step 1 (when indicating p1651-h:) 1) remove the right frame cover. ( 8-4) 2) turn the ignition switch off. 3) check the to sensor coupler for loose or poor contacts. If ok, then check the to sensor lead wire continuity. 4) disconnect the to sensor coupler. 5) check the continuity bet...

  • Page 211

    5-54 fi system step 1 (when indicating p1651-l:) 1) remove the right frame cover. ( 8-4) 2) turn the ignition switch off. 3) check the to sensor coupler for loose or poor contacts. If ok, then check the to sensor lead wire continuity. 4) disconnect the to sensor coupler. 5) check the continuity bet...

  • Page 212

    Fi system 5-55 step 2 1) connect the to sensor coupler. 2) insert the needle pointed probes to the lead wire coupler. 3) turn the ignition switch on. 4) measure the voltage at the wire side coupler between br/w 1 and b/br 2 wires. Also, measure the voltage when leaning the motorcycle.  to sensor vo...

  • Page 213

    5-56 fi system “c28” (p1655) stv actuator circuit malfunction inspection step 1 1) remove the fuel tank. ( 6-3) 2) turn the ignition switch off. 3) check the stva lead wire coupler for loose or poor contacts. 4) loosen the inlet pipe screw. ( 2-7) lift up the inlet pipe. ( 5-45) 5) turn the ignit...

  • Page 214

    Fi system 5-57 step 2 1) turn the ignition switch off. 2) disconnect the stva lead wire coupler. 3) check the continuity between each terminal and ground.  stva continuity: ∞Ω (infinity) (terminal – ground) 4) if ok, then measure the stva resistance (between black wire a and pink wire b) and (betwe...

  • Page 215

    5-58 fi system active control inspection 1) set up the sds tool. (refer to the sds operation manual for further details) 2) turn the ignition switch on. 3) click “secondary throttle operating control” 1. 4) click each button 2. At this time, if an operation sound is heard from the stva, the function...

  • Page 216

    Fi system 5-59 “c29” (p1654-h/l) stp sensor circuit malfunction inspection step 1 (when indicating c29:) 1) remove the fuel tank. ( 6-3) 2) turn the ignition switch off. 3) check the stp sensor coupler for loose or poor contacts. If ok, then measure the stp sensor input voltage. 4) disconnect the s...

  • Page 217

    5-60 fi system step 1 (when indicating p1654-h:) 1) remove the fuel tank. ( 6-3) 2) turn the ignition switch off. 3) check the stp sensor coupler for loose or poor contacts. If ok, then check the stp sensor lead wire continuity. 4) disconnect the stp sensor coupler. 5) check the continuity between ...

  • Page 218

    Fi system 5-61 step 1 (when indicating p1654-l:) 1) remove the fuel tank. ( 6-3) 2) turn the ignition switch off. 3) check the stp sensor coupler for loose or poor contacts. If ok, then check the stp sensor lead wire continuity. 4) disconnect the to sensor coupler. 5) check the continuity between y...

  • Page 219

    5-62 fi system step 2 1) turn the ignition switch off. 2) disconnect the stp sensor coupler. 3) check the continuity between each terminal and ground.  stp sensor continuity: ∞Ω (infinity) (terminal – ground) 4) if ok, then measure the stp sensor resistance at the wire terminals (between yellow wir...

  • Page 220

    Fi system 5-63 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 lead wire coupler. 5) loosen the inlet pipe screw. ( 2-7) lift the inlet pipe. ( 5-45) 6) turn the ignition switch on. 7) ...

  • Page 221

    5-64 fi system “c31” (p0705) gp switch circuit malfunction inspection step 1 1) remove the secondary gear case cover. ( 2-16) 2) turn the ignition switch off. 3) check the gp switch coupler for loose or poor contacts. If ok, then measure the gp switch voltage. 4) support the motorcycle with a jack....

  • Page 222

    Fi system 5-65 is the voltage ok? 10)after repairing the trouble, clear the dtc using sds tool. ( 5-25) yes • pink wire open or shorted to ground • if wire and connection are ok, intermittent trou- ble or faulty ecm. • recheck each terminal and wire harness for open circuit and poor connection. • r...

  • Page 223

    5-66 fi system “c32” (p0201) or “c33” (p0202) fuel injector circuit malfunction inspection (when indicating c32/p0201 for fuel injector #1) (when indicating c33/p0202 for fuel injector #2) step 1 1) remove the fuel tank. ( 6-3) 2) loosen the inlet pipe screw. ( 2-7) lift up the inlet pipe. ( 5-45...

  • Page 224

    Fi system 5-67 6) if ok, then check the continuity between each terminal and ground.  stp sensor continuity: ∞Ω (infinity)  09900-25008: multi-circuit tester set  tester knob indication: resistance (Ω) are the resistance and continuity ok? 7) after repairing the trouble, clear the dtc using sds t...

  • Page 225

    5-68 fi system “c41” (p0230) fp relay circuit malfunction inspection step 1 1) remove the secondary gear case cover. ( 2-16) 2) turn the ignition switch off. 3) check the fp relay coupler for loose or poor contacts. If ok, then check the fp relay. (refer to page 6-6 for details.) is the fp relay ok...

  • Page 226

    Fi system 5-69 “c44” (p0130/p0135) ho2 sensor (ho2s) circuit malfunction (for e-02, 19, 24) inspection step 1 (when indicating c44/p0130:) 1) remove the right frame cover. ( 8-4) 2) turn the ignition switch off. 3) check the ho2 sensor for loose or poor contacts. If ok, then check the ho2 sensor le...

  • Page 227

    5-70 fi system 7) remove the right frame cover. ( 8-4) 8) remove the ecm bracket ( 5-38) and disconnect the ecm coupler. 9) check the continuity between w/bl wire a and terminal 7. 10)also, check the continuity between b/br wire b and terminal d.  ho2s lead wire continuity: continuity ()  09900...

  • Page 228

    Fi system 5-71 is the voltage ok? 3) after repairing the trouble, clear the dtc using sds tool. ( 5-25) step 1 (when indicating c44/p0135:) 1) remove the right frame cover. ( 8-4) 2) turn the ignition switch off. 3) check the ho2 sensor for loose or poor contacts. If ok, then measure the ho2 senso...

  • Page 229

    5-72 fi system step 2 (when indicating c44/p0135:) 1) connect the ho2 sensor coupler. 2) insert the needle pointed probes to the ho2 sensor coupler. 3) turn the ignition switch on and measure the heater voltage between w/b wire a and ground. 4) if the tester voltage indicates the battery voltage, it...

  • Page 230

    Fi system 5-73 “c49” (p1656) pair control solenoid valve circuit malfunction inspection step 1 1) turn the ignition switch off. 2) check the pair control solenoid valve coupler for loose or poor contacts. If ok, then measure the pair control solenoid valve resis- tance. 3) disconnect the pair contro...

  • Page 231

    5-74 fi system step 2 1) turn the ignition switch on. 2) measure the voltage between o/w wire a and ground.  pair valve voltage: battery voltage (+ o/w a – - ground)  09900-25008: multi-circuit tester set  tester knob indication: voltage () is the voltage ok? 3) after repairing the trouble, clea...

  • Page 232: Sensors

    Fi system 5-75 sensors iap sensor inspection the intake air pressure sensor is located on the air inlet pipe. ( 5-33) iap sensor removal/installation • remove the fuel tank. ( 6-3) • remove the iap sensors 1 and disconnect the couplers 2 and vacuum hoses 3. • installation is in the reverse order o...

  • Page 233

    5-76 fi system stp sensor inspection the secondary throttle position sensor is installed on the no. 2 throttle body. ( 5-59) stp sensor removal/installation • remove the fuel tank. ( 6-3) • disconnect the coupler 1. • remove the screw with a torx wrench (t25) and stp sensor 2. • install the stp se...

  • Page 234

    Fi system 5-77 iat sensor inspection the intake air temperature sensor is installed at the back side of the air cleaner box. ( 5-47) iat sensor removal/installation • remove the air cleaner box. ( 5-47) • disconnect the iat sensor coupler 1 and remove the iat sensor 2. • installation is in the rev...

  • Page 235

    5-78 fi system ho2 sensor inspection (for e-02, 19, 24) the heated oxygen sensor is installed on the pre-muffler. ( 5-69) ho2 sensor removal/installation • remove the right frame cover. ( 8-4) • disconnect the coupler 1 and remove the ho2 sensor unit. • installation is in the reverse order of remo...

  • Page 236: Fuel System and Throtle Body

    Fuel system and throttle body 6-1 6 fuel system and throtle body contents fuel delivery system ...........................................................................6- 2 fuel system ..............................................................................................6- 3 fuel tank remo...

  • Page 237: Fuel Delivery System

    6-2 fuel system and throttle body fuel delivery system the fuel delivery system consists of the fuel tank, fuel pump, fuel filters, fuel feed hose, fuel delivery pipe (including fuel injectors) and fuel pressure regulator. There is no fuel return hose. The fuel in the fuel tank is pumped up by the f...

  • Page 238: Fuel System

    Fuel system and throttle body 6-3 fuel system fuel tank removal • remove the seats. ( 8-3) • remove the fuel tank mounting bolt. • lift and support the fuel tank about 10 cm (3.94 in) with the proper stay. Note: be careful not to lift the fuel more than about 10 cm (3.94 in), or hoses will be twist...

  • Page 239

    6-4 fuel system and throttle body fuel pressure inspection • lift and support the fuel tank. ( 6-3) • place a rag under the fuel feed hose. • remove the fuel feed hose 1. • install the special tools between the fuel tank and fuel delivery pipe.  09940-40211: fuel pressure gauge adaptor 09940-40220...

  • Page 240

    Fuel system and throttle body 6-5 fuel pump inspection turn the ignition switch on and check that the fuel pump operates for few seconds. If the fuel pump motor does not make operating sound, inspect the fuel pump circuit connections or inspect the fuel pump relay and tip-over sensor. If the fuel pu...

  • Page 241

    6-6 fuel system and throttle body fuel pump relay inspection fuel pump relay is located inside the secondary gear case cover. • remove the secondary gear case cover. ( 2-16) • remove the fuel pump relay. First, check the insulation between a and b terminals with pocket tester. Then apply 12 volts t...

  • Page 242

    Fuel system and throttle body 6-7 fuel pump removal and disassembly construction 1 thermistor 6 o-ring 2 fuel pump 7 cover 3 vessel 8 fuel mesh filter item n·m kgf-m lb-ft 4 rubber cushion a fuel pump mounting bolt a 10 1.0 7.0 5 fuel pump holder sa mp le.

  • Page 243

    6-8 fuel system and throttle body • remove the fuel tank. ( 6-3) • remove the fuel pump assembly mounting bolts diagonally. • lift the fuel pump assembly 1 as shown in the photograph. • with the recessed section a of the delivery pipe positioned at the edge of the tank opening as shown in the photo...

  • Page 244

    Fuel system and throttle body 6-9 • with the fuel pump assembly 1 being turned approximately 30° counterclockwise as shown in the photograph, pull the fuel pump wiring coupler 3 out of the tank opening while taking care not to cause it to interfere with the tank opening. • remove the thermistor 4 fr...

  • Page 245

    6-10 fuel system and throttle body • remove the thermistor 7. • disconnect fuel pump coupler 8. • remove the fuel pump 9. • remove the rubber cushion 0 and vessel a. • remove the fuel pump holder b. • remove the cover c and fuel mesh filter d. Sa mp le.

  • Page 246

    Fuel system and throttle body 6-11 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 sed...

  • Page 247: Throttle Body

    6-12 fuel system and throttle body throttle body construction 1 stp sensor 9 three way joint (for e-33) 2 tp sensor 0 hose (for e-33) 3 iap sensor a vacuum hoses 4 stva b throttle stop screw 5 fuel delivery pipe c idle adjusting screw 6 o-ring a stp sensor mounting screw item n·m kgf-m lb-ft 7 fuel ...

  • Page 248

    Fuel system and throttle body 6-13 air cleaner box removal • remove the fuel tank. ( 6-3) • remove the bolts. : hooked part • loosen the clamp screw 1. • disconnect the iap sensor lead wire coupler 2. • disconnect the pair hose 3. • remove the air cleaner box. Air cleaner box installation installa...

  • Page 249

    6-14 fuel system and throttle body • disconnect the fuel injector lead wire couplers 9. • disconnect the vacuum hoses 0. • loosen the throttle body clamp screw at the intake pipe side. • disconnect the throttle cables from their drum. Throttle body disassembly • remove the vacuum hose 1 and fuel fee...

  • Page 250

    Fuel system and throttle body 6-15 • remove the fuel delivery hose 4. • remove the fuel delivery pipes 5. • remove the fuel injectors 6. • remove the tp sensor 7 and stp sensor 8 with the special tool.  09930-11950: torx wrench note: prior to disassembly, mark each sensor’s original position with a...

  • Page 251

    6-16 fuel system and throttle body • remove the fuel delivery pipes e. * do not loosen the nut 0. * the fast idle screw a is factory-adjusted at the time of delivery and therefore avoid removing or turning it unless otherwise necessary. * do not turn the screw b. Never remove the secondary throttle ...

  • Page 252

    Fuel system and throttle body 6-17 throttle body cleaning • clean all passageways with a spray-type carburetor cleaner and blow dry with compressed air. Inspection • check following items for any damage or clogging. * o-ring * throttle valve * secondary throttle valve * vacuum hose * delivery hose *...

  • Page 253

    6-18 fuel system and throttle body • with the stv fully opened, install the stp sensor 1 and tighten the stp sensor mounting screw to the specified torque. Stp sensor: green color coupler note: * apply thin coat of the engine oil to the new o-ring. * align the secondary throttle shaft end a with the...

  • Page 254

    Fuel system and throttle body 6-19 • install the o-rings and dust seals to each fuel injector. • apply thin coat of the engine oil to the new o-rings and dust seal. • install the fuel injector 3 by pushing it straight to the delivery pipe 4. Note: align the boss e of the injector with the groove f o...

  • Page 255

    6-20 fuel system and throttle body • install the fuel delivery pipe joint hose 6 to the delivery pipes. • tighten the fuel delivery pipe hose mounting screws to the specified torque.  fuel delivery pipe joint hose mounting screw: 3.5 n·m (0.35 kgf-m, 2.5 lb-ft) throttle body installation installati...

  • Page 256

    Fuel system and throttle body 6-21 stp sensor adjustment if the stp sensor adjustment is necessary, measure the sensor out put voltage and adjust the stp sensor position as follows: • remove the air cleaner box. ( 6-13) • disconnect the stva coupler. ( 6-13) • insert the needle pointed probes to t...

  • Page 257

    6-22 fuel system and throttle body fuel injector installation • apply thin coat of the engine oil to new injector dust seals and o-rings. ( 6-19) • install the injector by pushing it straight to the throttle body. Never turn the injector while pushing it. ( 6-19) fast idle the fast idle system is ...

  • Page 258

    Fuel system and throttle body 6-23 • turn the ignition switch off. • disconnect the stva coupler. • turn the ignition switch on. • open the secondary throttle valve fully by moving the fast idle link with your finger. • with the secondary throttle valve held at this position, mea- sure the output vo...

  • Page 259

    6-24 fuel system and throttle body throttle valve synchronization check and adjust the throttle valve synchronization among two cylinders. Use of vacuum balancer gauge calibrating each vacuum gauge • start up the engine and run it in idling condition for warming up. • stop the warmed-up engine. • di...

  • Page 260

    Fuel system and throttle body 6-25 • after making sure that the steel ball stays steady at the center line, disconnect the hose from the no. 1 throttle body vacuum nipple and connect the next hose to this vacuum nipple. • turn air screw to bring the other steel ball 6 to the center line. The balance...

  • Page 261

    Cooling and lubrication system 7-1 7 cooling and lubrication system contents engine coolant .......................................................................................7- 2 cooling circuit .......................................................................................7- 3 cooling ...

  • Page 262: Engine Coolant

    7-2 cooling and lubrication system engine coolant at the time of manufacture, the cooling system is filled with a 50:50 mixture of distilled water and ethylene glycol anti-freeze. This 50:50 mixture will provide the optimum corrosion protection and excellent heat protection, and will protect the coo...

  • Page 263: Cooling Circuit

    Cooling and lubrication system 7-3 cooling circuit cooling circuit inspection before removing the radiator and draining the engine coolant, inspect the cooling circuit for tightness. • remove the fuel tank. ( 6-3) • remove the radiator cap 1 and connect the tester 2 to the filler. • give a pressure...

  • Page 264: Radiator and Water Hoses

    7-4 cooling and lubrication system radiator and water hoses radiator removal • remove the fuel tank. ( 6-3) • remove the frame head covers. ( 3-3) • drain the engine coolant. ( 2-17) • remove the radiator cover 1. • remove the radiator mounting bolts. • disconnect the ect sensor coupler 2 and wat...

  • Page 265

    Cooling and lubrication system 7-5 radiator cap inspection • fit the cap 1 to the radiator cap tester 2. • build up pressure slowly by operating the tester. Make sure that the pressure build-up stops at 95 – 125 kpa (0.95 – 12.5 kgf/cm², 13.5 – 17.8 psi) and that, with the tester held stand- still, ...

  • Page 266

    7-6 cooling and lubrication system water hose and reservoir tank inspection • remove the fuel tank. ( 6-3) • remove the secondary gear case cover. ( 8-40) • remove the frame head covers. ( 3-3) • any water hose and reservoir tank 1 found in a cracked con- dition or flattened must be replaced. • a...

  • Page 267: Cooling Fan

    Cooling and lubrication system 7-7 cooling fan inspection • disconnect the cooling fan lead wire coupler 1. • test the cooling fan motor for load current with an ammeter connected as shown in the illustration. • the voltmeter is for making sure that the battery applies 12 volts to the motor. With th...

  • Page 268

    7-8 cooling and lubrication system • remove the cooling fan 1 by disconnecting the cooling fan lead wire coupler. Installation install the cooling fan in the reverse order of removal. Pay atten- tion to the following points: • put the cooling fan 1 between the down tube and the engine. • temporary t...

  • Page 269: Cooling Fan Thermo-Switch

    Cooling and lubrication system 7-9 cooling fan thermo-switch removal • drain the engine coolant. ( 2-17) • disconnect the cooling fan thermo-switch coupler 1. • remove the cooling fan thermo-switch 2. Inspection • check the thermo-switch closing or opening temperatures by testing it at the bench as...

  • Page 270

    7-10 cooling and lubrication system engine coolant temperature sensor removal • lift and support the fuel tank. ( 6-3) • remove the frame head covers. ( 3-3) • disconnect the engine coolant temperature sensor coupler 1. • keep the motorcycle upright. • place a rag under the sensor and remove the e...

  • Page 271

    Cooling and lubrication system 7-11 installation install the engine coolant temperature sensor order of removal. Pay attention to the following points: • tighten the engine coolant temperature sensor to the speci- fied torque.  engine coolant temperature sensor: 18 n·m (1.8 kgf-m, 13.0 lb-ft) take ...

  • Page 272: Thermostat

    7-12 cooling and lubrication system thermostat removal • drain engine coolant. ( 2-17) • remove the reservoir tank. ( 3-4) • remove the water hoses 1 and water pump case 2. • remove the thermostat case 3. • remove the thermostat 4. Inspection inspect the thermostat pellet for signs of cracking. Te...

  • Page 273

    Cooling and lubrication system 7-13 • 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 6.0 mm (0.24 in).  thermostat valve lift a standard: 6.0 mm and over at 90 °c (0.24 in and over at...

  • Page 274: Water Pump

    7-14 cooling and lubrication system water pump removal and disassembly • drain the engine oil. ( 2-11) • drain engine coolant. ( 2-17) • remove the water pump case. ( 7-12) note: before draining engine oil and engine coolant, inspect engine oil and coolant leakage between the water pump and crank...

  • Page 275

    Cooling and lubrication system 7-15 • remove the bearings with the special tool.  09921-20240: bearing remover set note: if there is no abnormal noise condition, bearing removal is not necessary. • remove the mechanical seal with the special tool.  09921-20240: bearing remover set note: if there i...

  • Page 276

    7-16 cooling and lubrication system oil seal • visually inspect the oil seal for damage, with particular atten- tion given to the lip. • replace the oil seal that shows indications of leakage. Bearing case • visually inspect the bearing case for damage. • replace the water pump body if necessary. Re...

  • Page 277

    Cooling and lubrication system 7-17 • install the new mechanical seal using a suitable size socket wrench. Note: on the new mechanical seal, the sealer a has been applied. • install the new bearings with the special tool.  09913-70210: bearing installer set note: the stamped mark on the bearing fac...

  • Page 278

    7-18 cooling and lubrication system • apply grease to the new o-ring. • install the impeller 2 and impeller shaft 3 to the water pump body. • install the pin 4 and e-ring 5.  99000-25030: suzuki super grease “a” (usa) 99000-25010: suzuki super grease “a” (others) • install the new gasket 6. • apply...

  • Page 279: Lubrication System

    Cooling and lubrication system 7-19 lubrication system oil pressure 2-28 oil filter 2-12 oil pressure regulator 3-62 oil strainer 3-61 oil jet 3-60 oil pump 3-56 oil pressure switch 3-63 sa mp le.

  • Page 280: Oil Pan

    7-20 cooling and lubrication system engine lubrication system chart pressure regulator oil pan oil pump driven chain driveshaft gears driveshaft driveshaft left bearing clutch plates clutch sleeve hub countershaft gears countershaft countershaft left bearing oil jet secondary bevel gear and bearings...

  • Page 281: Chassis

    Chassis 8-1 8 chassis contents exterior parts ........................................................................................8- 3 removal ...............................................................................................8- 3 remounting .............................................

  • Page 282: Chassis

    Chassis contents 8-2 chassis brake pad replacement............................................................... 8-52 brake fluid replacement............................................................ 8-53 brake caliper removal and disassembly..........................................................

  • Page 283: Exterior Parts

    Chassis 8-3 exterior parts removal seat • remove the rear seat by removing the bolt. • remove the rear seat grip band by removing the bolts. • remove the seat. Frame cover • remove the left frame cover 1 with the ignition key. : hooked part be careful not to scratch the rear fender. Be careful not ...

  • Page 284

    8-4 chassis • remove the right frame covers 2 by removing the bolts. : hooked part rear fender • remove the seat. ( 8-3) • disconnect the coupler 1. • remove the left and right side frame handle grip. • remove the rear fender 2. Note: when installing the frame handle grip bolts, apply a small quan...

  • Page 285: Front Wheel

    Chassis 8-5 front wheel construction 1 bearing (r) 5 brake disc 2 front wheel 6 spacer item n·m kgf-m lb-ft 3 spacer a front axle a 65 6.5 47.0 4 bearing (l) b brake disc mounting bolt b 23 2.3 16.5 sa mp le.

  • Page 286

    8-6 chassis a front axle b brake disc bolt item n·m kgf-m lb-ft a 65 6.5 47.0 b 23 2.3 16.5 left right sa mp le.

  • Page 287

    Chassis 8-7 removal and disassembly • loosen the front axle pinch bolt 1. • loosen the front axle with the special tool.  09900-18710: hexagon socket (12 mm) • raise the front wheel off the ground with a jack or a wooden block. • remove the front axle 2, spacer 3 and front wheel. • remove the brake...

  • Page 288

    8-8 chassis inspection wheel bearings inspect the play of the wheel bearings by finger while they are in the wheel. Rotate the inner race by finger to inspect for abnor- mal noise and smooth rotation. Replace the bearing in the following procedure if there is any- thing unusual. Wheel bearings remov...

  • Page 289

    Chassis 8-9 front axle measure the front axle runout using the dial gauge. If the runout exceeds the service limit, replace the front axle with a new one.  09900-20607: dial gauge (1/100 mm) 09900-20701: magnetic stand 09900-21304: v-block set (100 mm)  wheel axle runout service limit: 0.25 mm (0....

  • Page 290

    8-10 chassis brake disc • make sure that the brake disc is clean and free of any grease. Apply thread lock super to the brake disc bolts and tighten them to the specified torque.  99000-32130: thread lock super “1360”  brake disc bolt: 23 n·m (2.3 kgf-m, 16.5 lb-ft) speed sensor • apply suzuki sup...

  • Page 291

    Chassis 8-11 • tighten the front axle to the specified torque. • tighten the front axle pinch bolt 3 on the specified torque.  front axle: 65 n·m (6.5 kgf-m, 47.0 lb-ft) front axle pinch bolt: 23 n·m (2.3 kgf-m, 16.5 lb-ft)  09900-18710: hexagon socket (12 mm) note: before tightening the front axl...

  • Page 292: Front Fork

    8-12 chassis front fork construction 1 o-ring 6 oil seal a front fork cap bolt 2 spacer 7 oil seal stopper ring b inner rod lock-nut 3 spring 8 dust seal c front axle pinch bolt 4 outer tube 9 inner rod/damper rod (cartridge) d caliper rod bolt 5 oil seal retainer 0 inner tube item n·m kgf-m lb-ft i...

  • Page 293

    Chassis 8-13 removal and disassembly • remove the front wheel. ( 8-7) • remove the front brake caliper. ( 8-52) • remove the front fender. • loosen the front fork upper clamp bolts 1. Note: slightly loosen the front fork cap bolts 2 before loosening the lower clamp bolts to facilitate later disass...

  • Page 294

    8-14 chassis • remove the front fork cap bolt from the inner rod by loosening the lock nut. • compress the fork spring with the special tool and remove the special tool. • remove the spacer 3 and spring 4. • invert the front fork and stroke the inner rod several times to let out fork oil. • under th...

  • Page 295

    Chassis 8-15 • extract the outer tube from the inner tube. Note: be careful not to damage the “anti-friction” metals. • remove the dust seal 6. • remove the oil seal stopper ring 7. • remove the oil seal 8 with the special tool.  09913-50121: oil seal remover • remove the oil seal retainer 9. The r...

  • Page 296

    8-16 chassis inspection inner and outer tubes • inspect the inner tube outer surface and outer tube inner sur- face for scratches. • inspect the “anti-friction” metal surfaces for scratches. • if any defects are found, replace them with a new one. Fork spring measure the fork spring free length. If ...

  • Page 297

    Chassis 8-17 reassembly and remounting reassemble and remount the front fork in the reverse order of removal and disassembly. Pay attention to the following points: oil seal and dust seal • install the dust seal, oil seal stopper ring, oil seal and oil seal retainer onto the inner tube. 1 dust seal ...

  • Page 298

    8-18 chassis • tighten the damper rod bolt to the specified torque, using the special tool.  09940-30221: front fork assembling tool  caliper rod bolt: 39 n·m (3.9 kgf-m, 28.0 lb-ft) fork oil • place the front fork vertically without spring. • compress it fully. • pour specified front fork oil up ...

  • Page 299

    Chassis 8-19 fork spring • install the fork spring as shown in the illustration. • install the spring 1 and spacer 2. Front fork cap bolt • pull up the inner rod with the special tool a. • compress the spring with the special tool b and then insert the special tool c between the lock-nut and the spa...

  • Page 300

    8-20 chassis • install the front fork to the steering stem, turn signal clamps ( 10-22 and -23) and steering stem upper bracket. • align the upper surface of the outer tube with the upper sur- face of the steering stem upper bracket. • after loosening the front fork upper clamp bolts 4 slightly, ti...

  • Page 301: Handlebar

    Chassis 8-21 handlebar construction fwd fwd 1 handlebars 3 left handle grip 5 right handle grip 2 handlebar balancer 4 left handle switch 6 right handle switch sa mp le.

  • Page 302

    8-22 chassis removal and disassembly • remove the brake master cylinder 1. ( 8-57) • remove the right handle switch 2. • remove the handle balancer 3. • remove the throttle grip 4. • remove the left rear view mirror 5. • disconnect the clutch lever position switch lead wires 6. • loosen the clutch ...

  • Page 303

    Chassis 8-23 • install the handlebars with the punch mark a aligned with the handlebar clamp as shown. • first, tighten the handlebar clamp bolts 1 to the half of speci- fied torque, and then tighten the handlebar clamp bolts 1 and 2 to the specified torque.  handlebar set bolt: 23 n·m (2.3 kgf-m, ...

  • Page 304: Steering

    8-24 chassis steering construction 1 handlebar set bolt cap 6 steering stem upper bearing c front fork upper clamp bolt 2 handlebar clamp/holder 7 steering stem lower bearing d handlebar holder nut 3 steering stem upper bracket 8 steering stem e front fork lower clamp bolt 4 steering stem nut a hand...

  • Page 305

    Chassis 8-25 removal and disassembly • remove the front forks. ( 8-13) • remove the brake hose union bolt 1. ( 8-57) • disconnect the clamps. • remove the handlebar. ( 8-22) • remove the steering stem head nut 2 and washer. • remove the steering stem upper bracket 3. • remove the speed sensor lea...

  • Page 306

    8-26 chassis • remove the steering stem nut with the special tool.  09940-14911: steering stem nut wrench • remove the steering stem lower bracket. Note: hold the steering stem lower bracket to prevent it from falling. • remove the dust seal 5, steering stem upper bearing inner race 6 and bearing 7...

  • Page 307

    Chassis 8-27 inspection and disassembly inspect the removed parts for the following abnormalities. * handlebars distortion * race wear and brinelling * bearing wear or damage * abnormal noise of bearing if any abnormal points are found, replace defective parts with the new ones. • remove the steerin...

  • Page 308

    8-28 chassis bearing • apply suzuki super grease “a” to the bearings and bearing races.  99000-25030: suzuki super grease “a” (usa) 99000-25010: suzuki super grease “a” (others) • install the lower bearing to the steering stem lower bracket. • install the upper bearing and bearing inner race. Steer...

  • Page 309

    Chassis 8-29 handlebar holder • install the handlebar holders and related parts to the steering stem head. • tighten the handlebar holder nuts to the specified torque.  handlebar holder nut: 54 n·m (5.4 kgf-m, 39.0 lb-ft) front fork and steering stem upper bracket • install the steering stem upper ...

  • Page 310

    8-30 chassis 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. • wit...

  • Page 311: Rear Wheel

    Chassis 8-31 rear wheel construction 1 rear axle 8 bearing (lh) e brake cam lever 2 spacer (lh) 9 spacer (rh) f cotter pin (for e-03, 28, 33) 3 lock washer 0 bearing (rh) a driven joint stopper bolt 4 driven joint stopper a rear wheel b rear brake cam lever bolt 5 driven joint b brake shoe c rear ax...

  • Page 312

    8-32 chassis a rear axle nut b brake cam lever nut item n·m kgf-m lb-ft item n·m kgf-m lb-ft c rear torque link nut (f) a 65 6.5 47.0 c 35 3.5 25.5 d rear torque link nut (r) b 10 1.0 7.0 d 25 2.5 18.0 right left for e-03, 28, 33 sa mp le.

  • Page 313

    Chassis 8-33 removal • raise the rear wheel off the ground and support the motorcy- cle with a jack or wooden block. • remove the rear brake rod 1. • remove the torque link rod 2. • remove the left frame cover. ( 8-3) • remove the left frame lower cover 3. : hooked part • remove the rear swingarm ...

  • Page 314

    8-34 chassis • remove the cotter pin 4. (for e-03, 28, 33) • remove the axle nut 5 and draw out the rear axle. Note: the rear fender removal is not necessary when the rear part of motorcycle can be lifted high enough to take the rear wheel out smoothly. Disassembly • flatten the lock washers. • remo...

  • Page 315

    Chassis 8-35 inspection and disassembly wheel ( 8-66) tire ( 2-23 and 8-66) wheel bearings inspect the play of the wheel bearings by finger while they are in the wheel. Rotate the inner race by finger to inspect for abnor- mal noise and smooth rotation. Replace the bearing in the following procedu...

  • Page 316

    8-36 chassis reassembly and remounting reassemble and remount the rear wheel in the reverse order of removal and disassembly. Pay attention to the following points: wheel bearing • apply grease to the bearings before installation.  99000-25030: suzuki super grease “a” (usa) 99000-25010: suzuki supe...

  • Page 317

    Chassis 8-37 driven joint • install the driven joint 1. Note: apply grease to the o-ring and the final gear spline before installing the driven joint.  99000-25030: suzuki super grease “a” (usa) 99000-25010: suzuki super grease “a” (others) • apply thread lock super to the thread of driven joint st...

  • Page 318: Rear Suspension

    8-38 chassis rear suspension construction 1 rear shock absorber 6 swingarm pivot bearing b rear cushion rod mounting nut 2 rear cushion rod 7 swingarm bearing c rear cushion lever mounting nut 3 spacer 8 swingarm d rear swingarm pivot bolt lock nut 4 rear cushion lever bearing 9 boot e rear swingarm...

  • Page 319

    Chassis 8-39 left right ( ) 50 n.M 5.0 kgf-m 43.5 lb-ft ( ) 78 n.M 7.8 kgf-m 56.5 lb-ft ( ) 100 n.M 10.0 kgf-m 72.5 lb-ft ( ) 100 n.M 10.0 kgf-m 72.5 lb-ft 1 mm 1 mm 1 mm 1 mm ( ) 9.5 n.M 0.95 kgf-m 7.0 lb-ft sa mp le.

  • Page 320

    8-40 chassis removal • remove the rear wheel. ( 8-33) • remove the final gear case with propeller shaft. • remove the fuel tank. ( 6-3) • remove the battery 1 and disconnect the coupler 2. • remove the set mounting bracket 3. • disconnect the starter motor lead wire 4 and starter relay coupler 5. ...

  • Page 321

    Chassis 8-41 • remove the right frame lower cover 8, clutch rear cover 9. : hooked part • remove the tool box cover 0. • remove the tool box. • remove the fuse box and relay stay. • remove the cushion lever mounting bolt and nut and cushion rods a (l & r). Sa mp le.

  • Page 322

    8-42 chassis • remove the shock absorber b. • remove the right side swingarm pivot bolt lock nut c. • remove the left and right side swingarm pivot bolts d. Note: slightly loosen the cushion rod mounting nuts and the shock absorber lower mounting nut before removing the swingarm to facilitate later ...

  • Page 323

    Chassis 8-43 inspection and disassembly spacer • remove spacer from swingarm. • remove the spacers from the cushion lever. • inspect the spacers for any flaws or other damage. If any defects are found, replace the spacers with new ones. Swingarm bearing insert the spacer into swingarm cushion rod up...

  • Page 324

    8-44 chassis cushion lever bearing insert the spacer into bearing and check the play to move the spacer up and down. If an excessive play is noted, replace the bearing with a new ones. • remove the cushion rod lower side bearings by with the spe- cial tool.  09921-20240: bearing remover set (17 mm)...

  • Page 325

    Chassis 8-45 reassembly reassemble the swingarm and shock absorber in the reverse order of disassembly and removal, and pay attention to the fol- lowing points: swingarm bearing • install the swingarm pivot bearing races by with the special tool.  09913-70210: bearing installer set (40 mm) note: th...

  • Page 326

    8-46 chassis • tighten the cushion lever to the specified torque.  shock absorber mounting nut: 50 n·m (5.0 kgf-m, 36.0 lb-ft) remounting remount the swingarm and shock absorber in the reverse order of disassembly and removal, and pay attention to the following points. Swingarm • before installing ...

  • Page 327

    Chassis 8-47 • tighten the right side swingarm pivot bolt 2 to the specified torque.  swingarm pivot bolt (right side): 9.5 n·m (0.95 kgf-m, 7.0 lb-ft) • tighten the swingarm pivot lock nut 3 to the specified torque.  swingarm pivot lock nut: 100 n·m (10.0 kgf-m, 72.5 lb-ft) note: after tightening...

  • Page 328

    8-48 chassis • apply lithium base molybdenum grease (nlgi #2) to the pro- peller shaft spline. Note: to install the final gear case easily, move the dust boot front and the universal joint back. Engage the universal joint to the propel- ler shaft first and then engage it to the secondary driven beve...

  • Page 329

    Chassis 8-49 rear shock absorber disposal gas pressure release • mark the drill hole with a center punch. • cover the rear shock absorber with a transparent plastic bag 1. • hold the rear shock absorber 2 with a vice. • mark a hole with a 3 mm drill. Suspension setting after installing the rear susp...

  • Page 330: Front Brake

    8-50 chassis front brake construction 1 cap 6 caliper holder a insulator 2 diaphragm 7 caliper a master cylinder mounting bolt 3 master cylinder 8 pad set b brake hose union bolt 4 piston set 9 piston c brake caliper mounting bolt 5 brake hose 0 piston and dust seal item n·m kgf-m lb-ft a 10 1.0 7.0...

  • Page 331

    Chassis 8-51 * the brake system is filled with an glycol-based brake fluid, which is classified dot 4. Do not use or mix other types of brake fluid, such as silicone-based and petroleum-based brake flu- ids when refilling the brake system, otherwise serious damage to the brake system will result. * ...

  • Page 332

    8-52 chassis brake pad replacement • remove the reflex reflector 1. (for e-03, 28, 33) • remove the brake caliper by removing the brake caliper mounting bolts. • remove the pin 2. • remove the pad pin 3. • remove the brake pads 4. • install the new brake pads. • tighten the brake caliper mounting bo...

  • Page 333

    Chassis 8-53 brake fluid replacement • place the motorcycle on a level surface and keep the handle- bar straight. • remove the master cylinder reservoir cap and diaphragm. • remove as much old brake fluid as possible. • fill the reservoir with new brake fluid.  specification and classification: dot...

  • Page 334

    8-54 chassis • remove the brake pads. ( 8-52) • remove the insulator 3. • remove the brake caliper holder 4. • remove the spring 5. • place a rag over the brake caliper pistons to prevent them from popping out, and then force out the pistons using com- pressed air. • remove the dust seals 6 and pis...

  • Page 335

    Chassis 8-55 rubber parts replace the removed rubber parts with new ones. Brake caliper reassembly and remounting reassemble and remount the brake caliper in the reverse order of removal and disassembly. Pay special attention to the follow- ing points: • wash the caliper bores and pistons with the s...

  • Page 336

    8-56 chassis insulators • apply suzuki silicon e grease to the insulators.  99000-25100: suzuki silicone grease brake caliper holder • apply suzuki silicon e grease to the brake caliper holder.  99000-25100: suzuki silicone grease • tighten the brake caliper mounting bolts 1, and brake hose union ...

  • Page 337

    Chassis 8-57 measure the runout using the dial gauge. If the runout exceeds the service limit, replace the brake disc with a new one.  09900-20607: dial gauge (1/100 mm) 09900-20701: magnetic stand  brake disc runout service limit: 0.3 mm (0.012 in) • if either measurement exceeds the service limi...

  • Page 338

    8-58 chassis • pull the dust boot 6 out and remove the snap ring 7. • remove the piston assembly. Master cylinder inspection master cylinder inspect the master cylinder bore for any scratches or damage. If any damages are found, replace the master cylinder with a new one. Piston and rubber parts ins...

  • Page 339

    Chassis 8-59 master cylinder reassembly and remounting reassemble and remount the master cylinder in the reverse order of removal and disassembly. Pay special attention to the following points:  specification and classification: dot 4 • when installing the brake light switch, align the projection o...

  • Page 340

    8-60 chassis • when remounting the master cylinder onto the handlebars, align the master cylinder holder’s mating surface 1 with the punch mark 2 on the handlebars and tighten the upper clamp bolt first.  master cylinder mount bolt: 10 n·m (1.0 kgf-m, 7.0 lb-ft) • tighten the brake hose union bolt ...

  • Page 341: Rear Brake

    Chassis 8-61 rear brake construction 1 brake shoe 2 brake camshaft item n·m kgf-m lb-ft 3 brake panel a 65 6.5 47.0 4 brake cam lever b 10 1.0 7.0 5 cotter pin (for e-03, 28, 33) a rear axle nut b rear brake cam lever bolt sa mp le.

  • Page 342

    8-62 chassis removal and disassembly • remove the rear wheel. ( 8-33) • remove the rear brake panel 1. • remove the brake shoes 2. • remove the rear brake cam lever 3 by removing bolt. • remove the washer 4, spring 5 and o-ring 6. • remove the rear brake cam 7. Inspection brake drum inspect the bra...

  • Page 343

    Chassis 8-63 brake shoes check the brake shoe wear ( 2-21) and decide whether it should be replaced or not. Reassembly and remounting brake camshaft • when installing the brake camshaft, apply suzuki super grease “a” to the camshaft and cam face.  99000-25030: suzuki super grease “a” (usa) 99000-2...

  • Page 344

    8-64 chassis rear brake rod removal and disassembly • remove the exhaust pipes and mufflers assembly. ( 3-6) • remove the right frame lower cover 1, clutch rear cover 2. : hooked part • remove the rear brake switch spring 3. • remove the rear brake pedal 4. • remove the cotter pin 5. • remove the ...

  • Page 345

    Chassis 8-65 • remove the cotter pins. Reassembly remounting reassemble and remount the rear brake rod in the reverse order of removal and disassembly. Pay attention to the following points. • apply grease to the rear brake link pivot bolt and tighten it to the specified torque.  99000-25030: suzuk...

  • Page 346: Tire and Wheel

    8-66 chassis tire and wheel tire removal the most critical factor of tubeless tire is the seal between the wheel rim and the tire bead. For this reason, it is recommended to use a tire changer that can satisfy this sealing requirement and can make the operation efficient as well as functional. For o...

  • Page 347

    Chassis 8-67 valve inspection inspect the valve after the tire is removed from the rim. Replace the valve with a new one if the seal a rubber is peeling or has damage. Note: if the external appearance of the valve shows no abnormal con- dition, removing of the valve is not necessary. If the seal has...

  • Page 348

    8-68 chassis tire installation • apply tire lubricant to the tire bead. • when installing the tire onto the wheel, observe the following points. • when installing the tire, the arrow a on the side wall should point to the direction of wheel rotation. • align the chalk mark put on the tire at the tim...

  • Page 349

    Chassis 8-69 • in this condition, check the “rim line” b cast on the tire side walls. The line must be equidistant from the wheel rim all around. If the distance between the rim line and wheel rim varies, this indicates that the bead is not properly seated. If this is the case, deflate the tire comp...

  • Page 350: Electrical System

    Electrical system 9-1 9 contents electrical system cautions in servicing ..........................................................................9- 3 connector..........................................................................................9- 3 coupler .......................................

  • Page 351: Electrical System

    Electrical system contents 9-2 electrical system switches ................................................................................................... 9-35 battery ..................................................................................................... 9-37 specifications ..........

  • Page 352: Cautions In Servicing

    Electrical system 9-3 cautions in servicing connector • when connecting a connector, be sure to push it in until a click is felt. • inspect the connector for corrosion, contamination and break- age in its cover. Coupler • with a lock type coupler, be sure to release the lock before disconnecting and...

  • Page 353

    9-4 electrical system 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 mot...

  • Page 354

    Electrical system 9-5 using the multi-circuit tester • properly use the multi-circuit tester + and - probes. Improper use can cause damage to the motorcycle and tester. • if the voltage and current values are not known, begin mea- suring in the highest range. • when measuring the resistance, make su...

  • Page 355

    9-6 electrical system location of electrical components 1 iap sensor (#2) ( 5-33) 0 tp sensor ( 5-37) 2 iap sensor (#1) ( 5-33) a to sensor ( 5-52) 3 fuel injector (#1) ( 5-66) b starter motor 4 ecm (engine control module) c ignition switch 5 speed sensor d horn 6 ignition coil (#2) e cooling f...

  • Page 356

    Electrical system 9-7 1 fuel level switch 9 starter relay/main fuse 2 fuel pump ( 6-5) 0 turn signal/side-stand relay 3 battery a regulator/rectifier 4 ect sensor ( 5-42) b oil pressure switch 5 fuse box c generator 6 ignition coil (#1) d ckp sensor ( 5-30) 7 fuel pump relay ( 6-6) e gp switch (...

  • Page 357: Charging System

    9-8 electrical system charging system troubleshooting battery runs down quickly step 1 1) check accessories which use excessive amounts of electricity. Are accessories being installed? Step 2 1) check the battery for current leaks. ( 9-9) is the battery for current leaks ok? Step 3 1) measure the r...

  • Page 358

    Electrical system 9-9 step 5 1) measure the generator no-load voltage. ( 9-11) is the generator no-load voltage ok? Step 6 1) inspect the regulator/rectifier. ( 9-11) is the regulator/rectifier ok? Step 7 1) inspect wirings. Is the wirings ok? Battery overcharges • faulty regulator/rectifier • fau...

  • Page 359

    9-10 electrical system regulated voltage • remove the seat. ( 8-3) • start the engine and keep it running at 5 000 r/min. With light- ing switch turned on and dimmer switch turned hi position. Measure the dc voltage between the + and - battery termi- nals using the multi circuit tester. If the volt...

  • Page 360

    Electrical system 9-11 generator no-load performance • disconnect the generator coupler. ( 9-10) • start the engine and keep it running at 5 000 r/min. Using the multi circuit tester, measure the voltage between three lead wires. If the tester reads under the specified value, replace the genera- to...

  • Page 361

    9-12 electrical system starter system and side-stand/ignition interlock system troubleshooting starter motor will not run step 1 1) shift the transmission to neutral. 2) pull the clutch lever, turn on the ignition switch with the engine stop switch in the “run” position and listen for a click from t...

  • Page 362

    Electrical system 9-13 step 3 1) measure the starter relay voltage at the starter relay connectors (between y/g + and y/b -) when the starter button is pushed. Is a voltage ok? Step 4 1) check the starter relay. ( 9-16 to -17) is the starter relay ok? Starter motor runs but does not crank the engin...

  • Page 363

    9-14 electrical system starter motor removal and disas- sembly • disconnect the battery - lead wire. • drain engine coolant. ( 2-17) • remove the mufflers and exhaust pipe. ( 3-6) • remove the engine coolant pipe 1. • remove the starter motor cover 2. • remove the water union 3. • remove the start...

  • Page 364

    Electrical system 9-15 starter motor inspection carbon brush inspect the brushes for abnormal wear, cracks, or smoothness in the brush holder. If any damages are found, replace the brush assembly with a new one. Commutator inspect the commutator for discoloration, abnormal wear or undercut a. If abn...

  • Page 365

    9-16 electrical system • apply a small quantity of suzuki moly paste to the arma- ture shaft.  99000-25140: suzuki moly paste • align the torque 1 on the brush holder with the groove 2 on the housing end. • align the torque 3 on the brush holder with the mark 4 on the starter motor case. • align th...

  • Page 366

    Electrical system 9-17 apply 12 v to a and b terminals and check for continuity between the positive and negative terminals using the multi cir- cuit tester. If the starter relay clicks and continuity is found, the relay is ok.  09900-25008: multi circuit tester set  tester knob indication: contin...

  • Page 367

    9-18 electrical system gear position switch • remove the secondary gear case cover. ( 8-40) • disconnect the gear position switch coupler and check the continuity between blue and black/white with the transmis- sion in “neutral”.  09900-25008: multi circuit tester set  tester knob indication: con...

  • Page 368

    Electrical system 9-19 turn signal/side-stand relay the turn signal/side-stand relay is composed of the turn signal relay, side-stand relay and diode. • remove the secondary gear case cover. ( 8-40) • remove the turn signal/side-stand relay. Side-stand relay inspection first check the insulation be...

  • Page 369: Ignition System

    9-20 electrical system ignition system note: the fuel cut-off circuit is incorporated in this ecm in order to prevent over-running of engine. When engine speed reaches 8 000 r/min during running, this circuit cuts off fuel at the fuel injector. Troubleshooting no spark or poor spark note: check that...

  • Page 370

    Electrical system 9-21 step 2 1) measure the battery voltage between input lead wires at the ecm with the ignition switch in the “on” position. (e-02, 19, 24: o/g and b/w, e-03, 28, 33: o/w and b/w) is the voltage ok? Step 3 1) measure the ignition coil primary peak voltage. ( 9-22) note: this insp...

  • Page 371

    9-22 electrical system inspection ignition coil primary peak voltage • remove the fuel tank. ( 6-3) • remove the frame head covers. ( 3-3) • disconnect the spark plug caps. • connect new spark plugs to each spark plug cap and ground them to the cylinder head. Note: make sure that all couplers and ...

  • Page 372

    Electrical system 9-23 ignition coil resistance • remove the fuel tank. ( 6-3) • remove the frame head covers. ( 3-3) • disconnect the spark plug caps. • measure the ignition coil resistance in both the primary and secondary windings. If the resistance is not within the stan- dard range, replace t...

  • Page 373

    9-24 electrical system • shift the transmission into the neutral and turn ignition switch “on”. • crank the engine a few seconds with the starter motor by depressing starter button and check the ckp sensor peak voltage. • repeat the above test procedure a few times and measure the highest peak volta...

  • Page 374

    Electrical system 9-25 speedometer and pilot lamp box description this speedometer mainly consists of the stepping motor, lcd (liquid crystal display) and led (light emit- ting diode). This speedometer is light, thin and of high response compared to those currently in use because of this composition...

  • Page 375

    9-26 electrical system speedometer removal and disassembly • remove the headlight. • disconnect the speedometer lead wire couplers. • remove the speedometer cover 1. : hooked part • remove the speedometer. When disconnecting and reconnecting the speedome- ter coupler, make sure to turn off the igni...

  • Page 376

    Electrical system 9-27 • disassemble the speedometer as follows. Do not attempt to disassemble the speedometer unit. 1 speedometer cover 2 speedometer unit 3 speedometer case sa mp le.

  • Page 377

    9-28 electrical system pilot lamp box removal and disassembly • lift and support the fuel tank. ( 6-3) • remove the coupler 1. • remove the fuel tank upper cover 2. • remove the pilot lamp box. When disconnecting and reconnecting the pilot lamp box coupler, make sure to turn off the ignition switch...

  • Page 378

    Electrical system 9-29 inspection led (light emitting diode) check that the led lights (fi light, oil pressure indicator light, engine coolant indicator light and fuel level indicator light) immediately after turning the ignition switch on. Also, other led lights (neutral indicator light, high-beam ...

  • Page 379

    9-30 electrical system engine coolant temperature meter and indicator ect sensor inspection. ( !7-10) • remove the fuel tank. ( !6-3) • remove the frame head covers. ( !3-3) • disconnect the ect sensor coupler 1. " • connect the variable resistor a between the terminals. • turn the ignition switch o...

  • Page 380

    Electrical system 9-31 • when the switch is immersed in kerosene under the above condition, the bulb should go out. If the bulb remains lit, replace the unit with a new one. Fuel level indicator light inspection if the fuel level indicator light does not function properly, check the fuel level indic...

  • Page 381

    9-32 electrical system • connect 12 v battery (between o/r and b/w), 10 k Ω resistor (between o/r and p) and the multi circuit tester (+ probe of tester to o/r and - to p) as shown right illustration. O/r : orange with red tracer b/w : black with white tracer p : pink  09900-25008: multi circuit te...

  • Page 382: Lamps

    Electrical system 9-33 lamps headlight, brake light/taillight, license plate light and turn signal light headlight 12 v 60/55 w position light 12 v 5 w (e-02, 19) brake light/taillight led licence plate light 4 12 v 5 w turn signal light 5 front 12 v 21/5 w ...................... (e-03, 28, 33) 12 v...

  • Page 383

    9-34 electrical system headlight beam adjustment • adjust the headlight beam. A: vertical adjuster b: horizontal adjuster note: to adjust the headlight beam, adjust the beam horizontally first, then adjust vertically. Sa mp le.

  • Page 384: Relays

    Electrical system 9-35 relays turn signal/side-stand relay the turn signal/side-stand relay is composed of the turn signal relay, side-stand relay and diode. Inspection before removing the turn signal/side-stand relay, check the operation of the turn signal light. If the turn signal light does not i...

  • Page 385

    9-36 electrical system color position ignition switch hazard switch inspect each switch for continuity with a tester. If any abnormality is found, replace the respective switch assemblies with new ones. Note: before inspecting the oil pressure switch, check if the engine oil level is correct. ( :2-1...

  • Page 386: Battery

    Electrical system 9-37 battery specifications initial charging filling electrolyte • remove the aluminum tape 1 sealing the battery electrolyte filler holes. • remove the caps 2. Note: * after filling the electrolyte completely, use the removed cap 2 as sealing caps of battery-filler holes. * do not...

  • Page 387

    9-38 electrical system note: if no air bubbles are coming up from a filler port, tap the bottom of the electrolyte container two or three times. Never remove the container from the battery. • after confirming that the electrolyte has entered the battery completely, remove the electrolyte containers ...

  • Page 388

    Electrical system 9-39 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 powder...

  • Page 389: Servicing Information

    Servicing information 10-1 10 servicing information contents troubleshooting .................................................................................10- 2 fi system malfunction code and defective condition ..10- 2 engine .........................................................................

  • Page 390: Troubleshooting

    10-2 servicing information troubleshooting fi system malfunction code and defective condition dtc no. Detected item detected failure condition check for c00 no fault ––––––––––– ––––––––––– c12 ckp sensor the signal does not reach ecm for 3 sec. Or more, after receiving the starter signal. Ckp senso...

  • Page 391

    Servicing information 10-3 dtc no. Detected item detected failure condition check for c21 iat sensor the sensor voltage should be the fol- lowing. 0.1 v sensor voltage in other than the above range, c21 (p0110) is indicated. Iat sensor, lead wire/coupler connection p0110 h sensor voltage is higher t...

  • Page 392

    10-4 servicing information dtc no. Detected item detected failure condition check for c31 gear posi- tion signal gear position signal voltage should be higher than the following for 3 seconds and more. Gear position sensor voltage > 0.6 v if lower than the above value, c31 (p0705) is indicated. Gp s...

  • Page 393

    Servicing information 10-5 engine complaint symptom and possible causes remedy engine will not start or is hard to start. Compression too low 1. Out of adjustment valve clearance 2. Worn valve guides or poor seating of valves 3. Mistiming valves 4. Excessively worn piston rings 5. Worn-down cylinder...

  • Page 394

    10-6 servicing information complaint symptom and possible causes remedy engine idles poorly. 1. Out of adjustment valve clearance 2. Poor seating of valves 3. Defective valve guides 4. Worn down camshafts 5. Too wide spark plug gaps 6. Defective ignition coil 7. Defective ckp sensor 8. Defective ecm...

  • Page 395

    Servicing information 10-7 complaint symptom and possible causes remedy noisy engine excessive valve chatter 1. Too large valve clearance 2. Weakened or broken valve springs 3. Worn tappet or cam surface 4. Worn and burnt camshaft journal noise seems to come from piston 1. Worn down pistons or cylin...

  • Page 396

    10-8 servicing information complaint symptom and possible causes remedy engine runs poorly in high speed range. Defective engine internal/electrical parts 1. Weakened valve springs 2. Worn camshafts 3. Valve timing out of adjustment 4. Too narrow spark plug gaps 5. Ignition not advanced sufficiently...

  • Page 397

    Servicing information 10-9 complaint symptom and possible causes remedy engine lacks power. Defective engine internal/electrical parts 1. Loss of valve clearance 2. Weakened valve springs 3. Out of adjustment valve timing 4. Worn piston rings or cylinders 5. Poor seating of valves 6. Fouled spark pl...

  • Page 398

    10-10 servicing information radiator (cooling system) complaint symptom and possible causes remedy dirty or heavy exhaust smoke 1. Too much engine oil in the engine 2. Worn piston rings or cylinders 3. Worn valve guides 4. Scored or scuffed cylinder walls 5. Worn valves stems 6. Defective stem seal ...

  • Page 399

    Servicing information 10-11 chassis complaint symptom and possible causes remedy heavy steering 1. Overtightened steering stem nut 2. Broken bearing in steering stem 3. Distorted steering stem 4. Not enough pressure in tires adjust. Replace. Replace. Adjust. Wobbly handlebars 1. Loss of balance betw...

  • Page 400

    10-12 servicing information shaft drive brakes complaint symptom and possible causes remedy noisy shaft drive noise seems to come from secondary bevel gear and final bevel gear assemblies. 1. Oil level too low 2. Drive and driven bevel gears damaged or worn 3. Excessive backlash 4. Improper tooth co...

  • Page 401

    Servicing information 10-13 electrical complaint symptom and possible causes remedy no sparking or poor sparking 1. Defective ignition coils or ckp sensor 2. Defective spark plugs 3. Defective ecm 4. Defective tip over sensor 5. Open-circuited wiring connections replace. Replace. Replace. Replace. C...

  • Page 402

    10-14 servicing information battery complaint symptom and possible causes remedy “sulfation”, acidic white powdery sub- stance or spots on surface of cell plates. 1. Cracked battery case 2. Battery has been left in a run-down condition for a long time. Replace the battery. Replace the battery. Batte...

  • Page 403

    Servicing information 10-15 wiring harness, cable and hose routing wiring harness routing regulator/rectifier electrical parts holder fuse wiring harness generator leadwire clamp clamp clamp wiring harness front turn signal light (l & r) handlebar switch (l & r) speed sensor starter motor leadwire *...

  • Page 404

    10-16 servicing information to brake switch, etc. To horn to horn resorvoir hose indicator lamp harness breaser hose match mark set inside of the frame. Tapping clamp frame harness tapping clamp iat sensor battery harness horn frame wiring harness radiator fwd shuroud tapping clamp turn down. Set un...

  • Page 405

    Servicing information 10-17 star ter motor oil pressure s witch star ter motor lead wire 80˚ – 110˚ 30˚ – 60˚ 90˚ cr ankcase (r) clamp clamp clamp gener ator lead wire 20˚ – 45˚ sa mp le.

  • Page 406

    10-18 servicing information cable routing *1 set the clutch cable dented part and clamp the clutch cable at white tape of cable. *4 clamp the back side of cushion. *2 clamp with this direction. *5 do not hang the clamp on the bar. *3 clamp the clutch cable attach to the cushion. *6 clamp inside the ...

  • Page 407

    Servicing information 10-19 throttle body installation 1 iap sensor (front cylinder) 7 iat sensor 2 iap sensor (rear cylinder) 8 purge hose (e-33 only) item n·m kgf-m lb-ft 3 pcv (breather) hose *1 match mark 5 18 1.8 13.0 4 fuel feed hose *2 pass through the pcv (breather) hose upper the fuel hose....

  • Page 408

    10-20 servicing information cooling system hose routing *1 pass through the reservoir hose between frame and throttle valve actuator. *4 set the hose with dent of engine case. *2 clamp the hose with frame and harness. A the end of the clamp should face... *3 be careful not to dent hose with frame co...

  • Page 409

    Servicing information 10-21 front brake routing *1 after the brake hose union touching to the stop- per, tighten the union bolt. *3 clamp the sleeve firmly. *2 pass through the brake hose firmly. *4 set the clamp with stopper before tightening. 28 ˚ *3 *1 *2 *1 *4 sa mp le.

  • Page 410

    10-22 servicing information speed sensor harness routing front turn signal installation 1 pass through the speed sensor harness in front of the brake hose and guide. 5 clamp 2 pass through the speed sensor harness in front of the brake hose. 6 clip 3 do not catch the speed sensor harness to the cali...

  • Page 411

    Servicing information 10-23 front turn signal lead wire routing muffler & exhaust pipe installation *1 cut after clamping. Clamp *1 left handle switch harness brake hose guide right front turn signal clamp right front turn signal speed sensor wiring harness left front turn signal apply permatex 1372...

  • Page 412

    10-24 servicing information handlebar balancer battery protector 1 handlebar 4 handle balancer expander 2 nut 5 handlebar balancer 3 throttle grip 6 screw 1 stick protectors to upper end of this surface. 4 60 mm (2.36 in) 2 90 mm (3.54 in) 5 65 mm (2.56 in) 3 30 mm (1.18 in) 5.5 n·m (0.5 kgf-m, 4.0 ...

  • Page 413

    Servicing information 10-25 lubrication points 5.3 mm (2.1 in) sa mp le.

  • Page 414

    10-26 servicing information fuel tank installation 1 cut after clamping. 2 frame inside sa mp le.

  • Page 415

    Servicing information 10-27 rear combination lamp installation 1 pass through the left turn signal harness. 4 reflex reflector 2 reflex reflector 5 right reflex reflector (for e-03, 28, 33) 3 license plate bracket (for e-02, 19, 24) 6 left reflex reflector (for e-03, 28, 33) 1.8 n.M (0.18 kgf-m, 1.3...

  • Page 416

    10-28 servicing information frame head cover cushion installation left side cover cushion installation 1 cushion 4 5 mm (0.20 in) 7 10 mm (0.39 in) 2 3 mm (0.12 in) 5 15 mm (0.59 in) 3 12 mm (0.47 in) 6 20 mm (0.79 in) 1 cushion 2 27 mm (1.06 in) 3 35 mm (1.38 in) sa mp le.

  • Page 417

    Servicing information 10-29 rear fender cushion installation 7 mm (0.28 in) 13.5 mm (0.53 in) sa mp le.

  • Page 418

    10-30 servicing information left side cover installation sa mp le.

  • Page 419

    Servicing information 10-31 lid cushion instsallation 1 cushion 2 10 mm (0.39 in) 3 45 mm (1.77 in) sa mp le.

  • Page 420

    10-32 servicing information tail lamp installation *1 *2 *3 *4 grommet clamp *1 pass through the tail lamp harness and left turn signal harness over the right side mounting boss. *3 pass through the wiring harness outside of cushions. *2 assemble to the rear fender. *4 pass through the wiring harnes...

  • Page 421

    Servicing information 10-33 pair (air supply) system diagram *3 *1 *2 1 pair control solenoid valve *1 from air cleaner 2 pair reed valve *2 to #1 cylinders a fresh air *3 to #2 cylinders sa mp le.

  • Page 422

    10-34 servicing information pair (air supply) system hose routing *2 *2 *1 *3 *5 *4 1 pair control solenoid valve *2 matching mark 2 throttle body *3 do not contact the hose and throttle cable drum. 3 bolt *4 the sealant side should face pair pipe side. *1 to air cleaner box *5 with the bolt lightly...

  • Page 423: Special Tools

    Servicing information 10-35 special tools 09900-06107 snap ring pliers 09900-06108 snap ring pliers 09900-09004 impact driver set 09900-18710 hexagon socket (12 mm) 09900-20101 09900-20102 vernier calipers 09900-20202 micrometer (25 – 50 mm) 09900-20203 micrometer (50 – 75 mm) 09900-20204 micrometer...

  • Page 424

    10-36 servicing information 09913-60230 journal bearing remover/installer 09913-60241 journal bearing remover/installer 09913-60910 bearing puller 09913-70210 bearing installer set 09913-75821 bearing installer 09913-76010 bearing installer 09913-84510 bearing installer 09915-40610 oil filter wrench...

  • Page 425

    Servicing information 10-37 09917-47011 vacuum pump gauge 09918-03810 compression gauge adaptor 09918-53810 chain tensioner lock tool 09920-13120 crankcase & shaft remover 09920-53740 clutch sleeve hub holder 09921-21820 bearing retainer wrench 09921-20240 bearing remover set 09923-73210 bearing rem...

  • Page 426

    10-38 servicing information note: when order the special tool, please confirm whether it is available or not. 09940-14911 steering stem nut wrench 09940-30221 front fork assem- bling tool 09940-40211 fuel pressure gauge adaptor 09940-40220 fuel pressure gauge hose attachment 09940-50120 front fork i...

  • Page 427: Tightening Torque

    Servicing information 10-39 tightening torque engine item n·m kgf-m lb-ft rocker arm shaft 27 2.7 19.5 cylinder head cover bolt 6 mm 10 1.0 7.0 8 mm 25 2.5 18.0 cylinder head bolt and nut 8 mm initial 10 1.0 7.0 final 25 2.5 18.0 10 mm initial 25 2.5 18.0 final 38 3.8 27.5 cam sprocket bolt 15 1.5 1...

  • Page 428

    10-40 servicing information secondary and final fi system and intake air system cooling system item n·m kgf-m lb-ft secondary drive bevel gear bearing retainer bolt 23 2.3 16.5 secondary driven bevel gear bolt 23 2.3 16.5 secondary driven bevel gear bearing stopper 105 10.5 76.0 secondary drive gear...

  • Page 429

    Servicing information 10-41 chassis item n·m kgf-m lb-ft front axle 65 6.5 47.0 front axle pinch bolt 23 2.3 16.5 brake disc bolt 23 2.3 16.5 front fork cap bolt 23 2.3 16.5 front fork spring stopper nut 35 3.5 25.5 front fork damper rod bolt 40 4.0 29.0 front fork upper clamp bolt 23 2.3 16.5 front...

  • Page 430

    10-42 servicing information tightening torque chart for other nuts and bolts not listed in the preceding page, refer to this chart: bolt diameter a (mm) conventional or “4” marked bolt “7” marked bolt n·m kgf-m lb-ft n·m kgf-m lb-ft 4 1.5 0.15 1.0 2.3 0.23 1.5 5 3 0.3 2.0 4.5 0.45 3.0 6 5.5 0.55 4.0...

  • Page 431: Service Data

    Servicing information 10-43 service data valve + guide unit: mm (in) item standard limit valve diam. In. 30 (1.18) — ex. 26 (1.02) — valve clearance (when cold) in. 0.08 – 0.13 (0.003 – 0.005) — ex. 0.17 – 0.22 (0.007 – 0.009) — valve guide to valve stem clearance in. 0.010 – 0.037 (0.0004 – 0.0015)...

  • Page 432

    10-44 servicing information camshaft + cylinder head unit: mm (in) cylinder + piston + piston ring unit: mm (in) item standard limit cam height in. 35.50 – 35.54 (1.398 – 1.399) 35.20 (1.386) ex. 36.58 – 36.62 (1.440 – 1.442) 36.28 (1.428) camshaft journal oil clearance 0.032 – 0.066 (0.0013 – 0.002...

  • Page 433

    Servicing information 10-45 conrod + crankshaft unit: mm (in) oil pump piston ring groove width 1st 1.01 – 1.03 (0.0398 – 0.0406) — 2nd 1.21 – 1.23 (0.0476 – 0.0484) — oil 2.51 – 2.53 (0.0988 – 0.0996) — piston ring thickness 1st 0.970 – 0.990 (0.0382 – 0.0390) — 2nd 1.170 – 1.190 (0.0461 – 0.0469) ...

  • Page 434

    10-46 servicing information clutch unit: mm (in) transmission unit: mm (in) except ratio shaft drive unit: mm (in) item standard limit clutch lever play 10 – 15 (0.4 – 0.6) — clutch release screw 1/4 turn back — drive plate thickness no. 1 2.92 – 3.08 (0.115 – 0.121) 2.62 (0.103) no. 2 3.42 – 3.58 (...

  • Page 435

    Servicing information 10-47 thermostat + radiator + fan + engine coolant injector + fuel pump + fuel pressure regulator item standard/specification note thermostat valve opening temperature approx. 75 °c (167 °f) — thermostat valve lift over 6 mm (0.24 in) at 90 °c (194 °f) — ect sensor resistance 2...

  • Page 436

    10-48 servicing information fi sensors+ secondary throttle valve actuator throttle body item specification note ckp sensor resistance 184 – 276 Ω ckp sensor peak voltage 4.0 v and more when cranking iap sensor input voltage 4.5 – 5.5 v iap sensor output voltage approx. 2.6 v at idle speed tp sensor ...

  • Page 437

    Servicing information 10-49 electrical unit: mm (in) item specification note firing order 1·2 spark plug type ngk: dpr7ea-9 denso: x22epr-u9 gap 0.8 – 0.9 (0.031 – 0.035) spark performance over 8 (0.3) at 1 atm. Ckp sensor resistance 184 – 276 Ω ckp sensor peak voltage 4.0 v and more ignition coil r...

  • Page 438

    10-50 servicing information wattage unit: w brake + wheel unit: mm (in) item specification e-03, 28, 33 e-24 others headlight hi 60 ← ← lo 55 ← ← position/parking light 5 brake light/taillight led ← ← turn signal light 21/5 (front), 21 (rear) 21 ← licence plate light 5 ← ← speedometer light led ← ← ...

  • Page 439

    Servicing information 10-51 tire suspension unit: mm (in) item standard limit cold inflation tire pressure (solo riding) front 200 kpa (2.00 kgf/cm², 29 psi) ---- rear 250 kpa (2.50 kgf/cm², 36 psi) ---- cold inflation tire pressure (dual riding) front 200 kpa (2.00 kgf/cm², 29 psi) ---- rear 250 kp...

  • Page 440

    10-52 servicing information fuel + oil item specification note fuel type use only unleaded gasoline of at least 87 pump octane (r/2 + m/2) or 91 octane or higher rated by the research method. Gasoline containing mtbe (methyl tertiary butyl ether), less than 10% ethanol, or less than 5% methanol with...

  • Page 441: Emission Control Information

    Emission control information 11-1 11 emission control information contents emission control systems ...............................................................11- 2 fuel injection system..................................................................11- 2 exhaust emission control system (pair ...

  • Page 442: Emission Control Systems

    11-2 emission control information emission control systems fuel injection system vz800 motorcycles are equipped with a fuel injection system for emission level control. This fuel injection system is precision designed, manufactured and adjusted to comply with the applicable emission limits. 1 fuel t...

  • Page 443

    Emission control information 11-3 exhaust emission control system (pair system) the exhaust emission control system is composed of the pair system and three-way catalyst sys- tem (for e-02, 19, 24, 33). The fresh air is drawn into the exhaust port with the pair control solenoid valve and pair reed v...

  • Page 444

    11-4 emission control information noise emission control system tampering with the noise control system prohibited: local law prohibits the following acts or the causing thereof: 1. The removal or rendering inoperative by any person, other than for purposes of maintenance, repair or replacement, of ...

  • Page 445

    Emission control information 11-5 pair (air supply) system inspection hoses • remove the pair cover. ( 3-5) • inspect the hoses for wear or damage. • inspect that the hoses for secure connection. Pair reed valve • remove the pair control solenoid valve. ( 3-5) • remove the reed valve case 1 and pa...

  • Page 446

    11-6 emission control information pair control solenoid valve • remove the pair control solenoid valve. ( 3-5) • check that air flows through the air inlet port to the air outlet port. • if air does not flow out, replace the pair control solenoid valve with a new one. A air flow • connect the 12 v ...

  • Page 447

    Emission control information 11-7 pair (air supply) system hose routing *2 *2 *1 *3 *5 *4 1 pair control solenoid valve *2 matching mark 2 throttle body *3 do not contact the hose and throttle cable drum. 3 bolt *4 the sealant side should face pair pipe side. *1 to air cleaner box. *5 with the bolt ...

  • Page 448

    11-8 emission control information heated oxgen sensor (ho2s) inspection (for e-02, 19, 24) • disconnect the ho2 sensor lead wire coupler. ( 5-69) • inspect the ho2 sensor and its circuit referring to flow table of the malfunction code c44 (p0130/p0135). • check the resistance between the terminals ...

  • Page 449: (Only For E-33)

    Emission control information 11-9 evaporative emission control system inspection (only for e-33) • remove the seats 1. ( 8-3) • remove the fuel tank 2. ( 6-3) • remove the right frame cover 3. ( 8-4) hoses (evap hose) inspect the hoses for wear or damage. Make sure that the hoses are securely con...

  • Page 450

    11-10 emission control information evap canister hose routing (only for e-33) *3 *1 *2 *4 *6 *5 1 three way joint *2 white paint mark should face upside. 2 wiring harness *3 to three way joint. 3 fuel shut-off valve *4 face the clamp end right side. 4 evap canister *5 face the clamp end right side. ...

  • Page 451

    12 wiring diagram e-02, 19, 24 wiring diagrams wire color, refer to section “wire color”. O/ro/r p b/wb/w o/r p b/w w b/wb/w br/bbr/b b y g b/yb/y gr/wgr/w gr/bgr/b b/wb/w p/wp/w w/bw/b b/lgb/lg bl/rbl/r bl/ybl/y gr/rgr/r b/gb/g w/rw/r g/yg/y blbl y/gy/g b/brb/br b/brb/br g/bg/b bl/bbl/b br/wbr/w b/...

  • Page 452

    E-03, 28, 33 o/ro/r p b/wb/w o/r p b/w w b/wb/w br/bbr/b b y g b/yb/y gr/wgr/w gr/bgr/b b/wb/w p/wp/w b/lgb/lg bl/rbl/r bl/ybl/y gr/rgr/r b/gb/g w/rw/r g/yg/y blbl y/gy/g b/brb/br g/bg/b bl/bbl/b br/wbr/w b/blb/bl o/yo/y bl/wbl/w bl/bbl/b bl/gbl/g b/brb/br b/wb/w r/blr/bl o/wo/w y/ry/r brbr y/by/b r...

  • Page 453

    Prepared by december, 2004 part no. 99500-38050-01e printed in japan 456 sa mp le.

  • Page 454: Vz800

    Vz800 printed in japan k5 vz800 no.5230 99500-38050-01e vz800k5 service manual 2004. 11. 29 cover_14 for ps printing (16 mm) top bottom k5 9 9 5 0 0 - 3 8 0 5 0 - 0 1 e dic75.