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Suzuki Burgman AN400 Service Manual

Other manuals for Burgman AN400: Supplementary Service Manual

Summary of Burgman AN400

  • Page 1

    9 9 5 0 0 - 3 4 1 0 0 - 0 1 e an400

  • Page 2: Foreword

    Foreword this manual contains an introductory description on the suzuki an400 and procedures for its inspection/service and overhaul of its main components. Other information considered as generally known is not included. Read the general information section to familiarize yourself with the motorcyc...

  • Page 3: Table of Contents

    00 0 1 2 3 4 5 6 9 precautions............................................................... 00-i precautions ............................................................ 00-1 general information ................................................... 0-i general information ..............................

  • Page 5: Section 00

    Table of contents 00- i 00 section 00 contents precautions precautions ...............................................00-1 precautions........................................................... 00-1 warning / caution / note..................................... 00-1 general precautions .................

  • Page 6: Precautions

    00-1 precautions: precautions precautions warning / caution / note b705h10000001 please read this manual and follow its instructions carefully. To emphasize special information, the symbol and the words warning, caution and note have special meanings. Pay special attention to the messages highlighte...

  • Page 7

    Precautions: 00-2 caution ! • if parts replacement is necessary, replace the parts with suzuki genuine parts or their equivalent. • when removing parts that are to be reused, keep them arranged in an orderly manner so that they may be reinstalled in the proper order and orientation. • be sure to use...

  • Page 8

    00-3 precautions: • inspect each lead wire circuit for poor connection by shaking it by hand lightly. If any abnormal condition is found, repair or replace. • when taking measurements at electrical connectors using a tester probe, be sure to insert the probe from the wire harness side (backside) of ...

  • Page 9

    Precautions: 00-4 • when disconnecting and connecting the ecm couplers, make sure to turn off the ignition switch (1), or electronic parts may get damaged. Battery • battery connection in reverse polarity is strictly prohibited. Such a wrong connection will damage the components of the fi system ins...

  • Page 10

    00-5 precautions: when checking system circuits including an electronic control unit such as ecm, etc., it is important to perform careful check, starting with items which are easier to check. 1) disconnect the (–) cable from the battery. 2) check each connector/coupler at both ends of the circuit b...

  • Page 11

    Precautions: 00-6 voltage check if voltage is supplied to the circuit being checked, voltage check can be used as circuit check. 1) with all connectors/couplers connected and voltage applied to the circuit being checked, measure voltage between each terminal and body ground. 2) if measurements were ...

  • Page 12

    00-7 precautions: 4) disconnect the connector/coupler included in circuit (coupler “b”) and measure resistance between terminal “a” and body ground. If continuity is indicated, the circuit is shorted to the ground between terminals “a” and “b”. Using the multi-circuit tester • use the suzuki multi-c...

  • Page 13: Section 0

    Table of contents 0- i 0 section 0 contents general information general information ................................ 0a-1 general description .............................................0a-1 symbols .............................................................. 0a-1 abbreviations .....................

  • Page 14: General Information

    0a-1 general information: general information general description symbols b705h10101001 listed in the table below are the symbols indicating instructions and other information necessary for servicing. The meaning of each symbol is also included in the table. Symbol definition torque control required...

  • Page 15

    General information: 0a-2 abbreviations b705h10101002 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 a/f: air fuel mixture b: bbdc: before bottom dead center ...

  • Page 16

    0a-3 general information: vehicle side view b705h10101003 note difference between photographs and actual motorcycles depends on the markets. Right side left side vehicle identification number b705h10101004 the frame serial number or v.I.N. (vehicle identification number) (1) is stamped on the right ...

  • Page 17

    General information: 0a-4 engine oil and final gear oil (for usa) oil quality is a major contributor to your engine’s performance and life. Always select good quality engine oil. Suzuki recommends the use of suzuki performance 4 motor oil or an equivalent engine oil. Use of sf/sg or sh/sj in api wit...

  • Page 18

    0a-5 general information: country and area codes b705h10101009 the following codes stand for the applicable country(-ies) and area(-s). Wire color symbols b705h10101010 code country or area effective frame no. An400k7 (e-02) u.K. Js1cg111200100001 – an400k7 (e-03) u.S.A. Except for california js1ck4...

  • Page 19

    General information: 0a-6 warning, caution and information labels location b705h10101011 5 9 12, 13 14 15 1, 17 4 9 12 6 19 10 7 2, 18 3 11 [a] [b] [c] [d] i705h1010008-02 an400 1. Noise label for e-03, 24, 33 2. Information label for e-03, 28, 33 3. Vacuum hose routing label for e-33 4. Engine star...

  • Page 20

    0a-7 general information: component location electrical components location b705h10103001 2 1 3 5 6 7 8 9 11 10 12 13 14 15 16 17 18 19 4 i705h1010005-04 1. Fuel injector 6. Stva 11. Ambient air temperature sensor 16. Generator 2. Iap sensor 7. Front brake switch 12. Brake-lock relay 17. Ho2 sensor ...

  • Page 21

    General information: 0a-8 20 21 22 23 24 25 26 27 28 29 30 31 32 i705h1010007-04 20. To sensor 24. Left handlebar switch 28. Side-stand switch 32. Regulator/rectifier 21. Fuse box 25. Rear brake switch 29. Cooing fan thermo-switch 22. Turn signal/side-stand relay 26. Ignition coil 30. Cooing fan 23....

  • Page 22

    0a-9 general information: specifications specifications b705h10107001 note these specifications are subject to change without notice. Dimensions and dry mass engine drive train chassis item specification remark overall length 2 270 mm (89.4 in) overall width 760 mm (29.9 in) overall height 1 385 mm ...

  • Page 23

    General information: 0a-10 electrical capacities item specification remark lgnition type electronic ignition (transistorized) lgnition timing 7 ° b. T. D. C at 1 450 r/min spark plug ngk: cr7e or denso: u22esr-n battery 12 v 32.4 kc (9 ah)/10 hr generator three-phase a.C. Generator main fuse 30 a fu...

  • Page 24

    0a-11 general information: special tools and equipment special tool b705h10108001 09900-06108 09900-18710 09900-20101 09900-20102 snap ring pliers hexagon socket (12 mm) vernier calipers (1/15 mm, 150 mm) vernier calipers (1/20 mm, 200 mm) 09900-20202 09900-20203 09900-20205 09900-20508 micrometer (...

  • Page 25

    General information: 0a-12 09900-26006 09900-28630 09904-41010 09910-32812 engine tachometer (solar cell type) tps test wire harness sds set crankshaft installer 09910-32870 09910-60611 09913-10750 09913-50121 crankshaft installer attachment universal clamp wrench compression gauge adapter oil seal ...

  • Page 26

    0a-13 general information: 09916-34542 09916-34561 09916-43210 09916-53330 reamer handle valve guide reamer (11.3 mm) valve guide remover/ installer attachment 09916-84511 09917-47011 09919-28610 09920-13120 tweezers vacuum pump gauge sleeve protector crankcase separating tool 09920-31020 09920-5374...

  • Page 27

    General information: 0a-14 09940-14911 09940-30230 09940-34520 09940-34531 steering stem nut wrench socket hexagon (17 mm) t handle attachment a 09940-40211 09940-40230 09940-52861 09940-92720 fuel pressure gauge adapter fuel pressure gauge hose attachment front fork oil seal installer spring scale ...

  • Page 28: Maintenance and Lubrication

    0b-1 maintenance and lubrication: maintenance and lubrication precautions precautions for maintenance b705h10200001 the “periodic maintenance schedule chart” lists the recommended intervals for all the required periodic service work necessary to keep the motorcycle operating at peak performance and ...

  • Page 29

    Maintenance and lubrication: 0b-2 lubrication points b705h10205002 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 ...

  • Page 30

    0b-3 maintenance and lubrication: air cleaner element inspection b705h10206002 inspect air cleaner element every 6 000 km (4 000 miles, 12 months) replace air cleaner element every 18 000 km (11 000 miles, 36 months) remove the air duct (1) and inspect air cleaner element (2) for clogging. If it is ...

  • Page 31

    Maintenance and lubrication: 0b-4 spark plug inspection and cleaning b705h10206004 inspect spark plug every 6 000 km (4 000 miles, 12 months) replace spark plug every 12 000 km (7 500 miles, 24 months) carbon deposit check to see if there are carbon deposits on the plug. If carbon is deposited, remo...

  • Page 32

    0b-5 maintenance and lubrication: note • the clearance specification is for cold state. • to turn the crankshaft for clearance checking, be sure to use a wrench, and rotate in the normal running direction. Spark plug should be removed. 7) in this condition, read the valve clearance at each valve. If...

  • Page 33

    Maintenance and lubrication: 0b-6 (intake side) i310g1020024-02.

  • Page 34

    0b-7 maintenance and lubrication: (exhaust side) i310g1020025-02.

  • Page 35

    Maintenance and lubrication: 0b-8 note • be sure to apply engine oil to tappet shim top and bottom faces. • when seating the tappet shim, be sure the figure printed surface faces the tappet. 7) rotate the engine so that the tappet is depressed fully. This will squeeze out oil trapped between the shi...

  • Page 36

    0b-9 maintenance and lubrication: engine oil and filter change b705h10206007 replace engine oil initially at 1 000 km (600 miles, 2 month) and every 6 000 km (4 000 miles, 12 months) thereafter replace oil filter initially at 1 000 km (600 miles, 2 month) and every 18 000 km (11 000 miles, 36 months...

  • Page 37

    Maintenance and lubrication: 0b-10 6) install a new oil filter. 7) install the oil filter cap. 8) pour fresh engine oil and check the oil level in the same manner of engine oil replacement procedures. Oil: engine oil (sae 10w-40, api sf/sg or sh/ sj with jaso ma) necessary amount of engine oil oil c...

  • Page 38

    0b-11 maintenance and lubrication: drive v-belt removal and installation b705h10206029 inspect drive v-belt every 12 000 km (7 500 miles, 24 months) replace drive v-belt every 24 000 km (14 500 miles, 48 months) refer to “v-belt type continuously variable automatic transmission removal and installat...

  • Page 39

    Maintenance and lubrication: 0b-12 engine coolant change 1) remove the front panel. Refer to “front panel removal and installation in section 9d (page9d- 14)”. 2) remove the under cover. Refer to “under cover removal and installation in section 9d (page9d- 16)”. Warning ! Do not open the radiator ca...

  • Page 40

    0b-13 maintenance and lubrication: 11) close the air bleeding bolt securely. 12) close the radiator cap securely. 13) after warming up and cooling down the engine several times, add the engine coolant up to the full level of the reservoir. 14) install the removed parts. Caution ! Repeat the above pr...

  • Page 41

    Maintenance and lubrication: 0b-14 brake pad check the extent of brake pad wear can be checked by observing the grooved limit line “a” on the pad. When the wear exceeds the grooved limit line, replace the pads with the new ones. Refer to “front brake pad replacement in section 4b (page4b-2)” and “re...

  • Page 42

    0b-15 maintenance and lubrication: tire inspection b705h10206017 inspect tire every 6 000 km (4 000 miles, 6 months) 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 rep...

  • Page 43

    Maintenance and lubrication: 0b-16 front fork inspection b705h10206019 inspect front forks every 12 000 km (7 500 miles, 24 months) inspect the front forks for oil leakage, scoring or scratches on the outer surface of the inner tubes. Replace any defective parts, if necessary. Refer to “front fork d...

  • Page 44

    0b-17 maintenance and lubrication: chassis bolt and nut inspection b705h10206022 tighten chassis bolt and nut initially at 1 000 km (600 miles, 2 month) and every 6 000 km (4 000 miles, 12 months) thereafter check that all chassis bolts and nuts are tightened to their specified torque. 1. Handlebar ...

  • Page 45

    Maintenance and lubrication: 0b-18 12. Brake hose union bolt (front & rear) : 23 n ⋅m (2.3 kgf-m, 16.5 lb-ft) 14. Rear shock absorber mounting bolt/nut (upper & lower) : 50 n ⋅m (5.0 kgf-m, 36.0 lb-ft) 15. Cushion lever nut : 50 n ⋅m (5.0 kgf-m, 36.0 lb-ft) 16. Cushion rod nut : 50 n ⋅m (5.0 kgf-m, ...

  • Page 46

    0b-19 maintenance and lubrication: compression pressure check b705h10206023 refer to “compression pressure check in section 1d (page1d-3)”. Oil pressure check b705h10206024 refer to “oil pressure check in section 1e (page1e-3)”. Sds check b705h10206038 refer to “sds check in section 1a (page1a-17)”....

  • Page 47

    Maintenance and lubrication: 0b-20 4) briefly open the throttle fully and note the maximum engine rpms sustained during the test cycle. Caution ! Do not apply full power for more than 3 seconds or damage to the clutch or engine may occur. Lock-up r/min 4 000 – 5 000 r/min parking brake (brake-lock) ...

  • Page 48

    0b-21 maintenance and lubrication: specifications tightening torque specifications b705h10207001 note the specified tightening torque is also described in the following. “chassis bolt and nut inspection (page0b-17)” reference: for the tightening torque of fastener not specified in this section, refe...

  • Page 49: Service Data

    Service data: 0c-1 service data specifications service data b705h10307001 valve + valve guide unit: mm (in) camshaft + cylinder head unit: mm (in) item standard limit valve diam. In. 31.0 (1.22) — ex. 27.0 (1.06) — tappet clearance (when cold) in. 0.10 – 0.20 (0.003 – 0.008) — ex. 0.20 – 0.30 (0.008...

  • Page 50

    0c-2 service data: cylinder + piston + piston ring unit: mm (in) conrod + crankshaft unit: mm (in) oil pump clutch unit: mm (in) item standard limit compression pressure (automatic de-comp. Actuated) e-02, 19, 24, 54 1 060 – 1 140 kpa (10.6 – 11.4 kgf/cm 2 , 151 – 162 psi) 660 kpa (6.0 kgf/cm 2 , 94...

  • Page 51

    Service data: 0c-3 transmission unit: mm (in) except ratio injector + fuel pump + fuel pressure regulator fi sensors item specification note primary reduction ratio 1.000 — reduction ratio 2.200 – 0.839 secondary reduction ratio 2.214 — final reduction ratio 2.666 — drive v-belt width 25.1 (0.99) 24...

  • Page 52

    0c-4 service data: throttle body thermostat + radiator + fan + coolant electrical unit: mm (in) item specification e-02, 03, 19, 24, 28, 54 e-33 id no. 05h0 05h1 bore size 38 mm (1.5 in) ← fast idle r/min 1 500 – 2 000 r/min ← idle r/min 1 450 ± 100 r/min ← throttle cable play 2.0 – 4.0 mm (0.08 – 0...

  • Page 53

    Service data: 0c-5 wattage unit: w brake + wheel unit: mm (in) suspension unit: mm (in) item standard / specification e-02, 19, 24, 54 e-03, 28, 33 headlight hi 60/55 ← lo 55 ← parking/position light 5 x 2 ← brake light/taillight 21/5 x 2 ← turn signal light 21 x 2 (front), 21 x 2 (rear) 27/8 x 2 (f...

  • Page 54

    0c-6 service data: tire fuel + oil item standard limit cold inflation tire pressure solo riding front 175 kpa (1.75 kgf/cm 2 , 25 psi) — rear 200 kpa (2.00 kgf/cm 2 , 29 psi) — dual riding front 175 kpa (1.75 kgf/cm 2 , 25 psi) — rear 250 kpa (2.50 kgf/cm 2 , 36 psi) — tire size front 120/80-14m/c 5...

  • Page 55

    Service data: 0c-7 tightening torque specifications b705h10307002 engine cooling system item n ⋅m kgf-m lb-ft cam chain tensioner bolt 23 2.3 16.5 cam chain guide no.1 bolt 23 2.3 16.5 camshaft journal holder bolt 10 1.0 7.0 engine oil drain plug 23 2.3 16.5 final gear oil drain plug m8 12 1.2 8.5 f...

  • Page 56

    0c-8 service data: fi system and intake air system chassis item n ⋅m kgf-m lb-ft fuel cut valve bolt 3.5 0.35 2.5 fuel pump mounting bolt 4.5 0.45 3.3 fuel tank mounting bolt 10 1.0 7.0 fuel hose bolt 10 1.0 7.0 iat sensor mounting screw 3.5 0.35 2.5 speed sensor bolt 10 1.0 7.0 item n ⋅m kgf-m lb-f...

  • Page 57

    Service data: 0c-9 tightening torque chart for other bolts and nuts 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 5 0.5 3.5 6 5.5 0.55 4.0 10 1.0 ...

  • Page 58

    0c-10 service data:.

  • Page 59: Section 1

    Table of contents 1- i 1 section 1 contents engine precautions .................................................1-1 precautions............................................................. 1-1 precautions for engine.......................................... 1-1 engine general information and diagnos...

  • Page 60

    1-ii table of contents repair instructions ..............................................1c-1 ecm removal and installation............................1c-1 ckp sensor inspection .......................................1c-1 ckp sensor removal and installation ................1c-1 iap sensor inspection....

  • Page 61

    Table of contents 1-iii radiator hose routing diagram ......................... 1f-5 component location ........................................... 1f-5 engine cooling system components location ............................................................ 1f-5 diagnostic information and procedures.....

  • Page 62

    1-iv table of contents specifications...................................................... 1i-11 service data....................................................... 1i-11 tightening torque specifications....................... 1i-11 special tools and equipment ............................ 1i-12 rec...

  • Page 63: Precautions

    Precautions: 1-1 precautions precautions precautions for engine b705h11000001 refer to “general precautions in section 00 (page00-1)” and “precautions for electrical circuit service in section 00 (page00-2)”..

  • Page 64

    1a-1 engine general information and diagnosis: engine general information and diagnosis general description injection timing description b705h11101001 injection time (injection volume) the factors to determine the injection time include the basic fuel injection time which is calculated on the basis ...

  • Page 65

    Engine general information and diagnosis: 1a-2 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 self-diagnosis function b705h11101002 the self-diagnosis function...

  • Page 66

    1a-3 engine general information and diagnosis: the possible cause of this indication is as follows: engine stop switch is in off position. Side-stand/ignition inter-lock system is not working. Ignition fuse is burnt. Dealer mode caution ! Before checking the malfunction code, do not disconnect the e...

  • Page 67

    Engine general information and diagnosis: 1a-4 schematic and routing diagram fi system wiring diagram b705h11102001 30 a 10 a 15 a 10 a 3 9 14 7 21 5 16 17 13 12 36 15 34 35 8 44 43 37 30 33 22 1 19 11 20 23 6 24 25 29 2 ecm “a” “b” “c” “d” “e” “f” “g” “h” “i” “j” “v” “w” “x” “y” “k” “l” “m” “n” “z”...

  • Page 68

    1a-5 engine general information and diagnosis: terminal alignment of ecm coupler (harness side) b705h11102002 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 i705h1110115-01 terminal no. Circuit terminal no. Circuit (1) power...

  • Page 69

    Engine general information and diagnosis: 1a-6 component location fi system parts location b705h11103001 “a” “b” “c” “d” “e” “i” “j” “f” “g” “h” “k” i705h1110131-01 “a”: ecm “g”: intake air temperature (iats) “b”: fuel injector (fi) “h”: fuel pump (fp) “c”: idle speed control valve (isc valve) “i”: ...

  • Page 70

    1a-7 engine general information and diagnosis: diagnostic information and procedures engine symptom diagnosis b705h11104001 “a” “n” “q” “o” “p” “l” “m” i705h1110132-01 “l”: speedometer “o”: ignition coil (ig coil) “m”: tip-over sensor (tos) “p”: speed sensor “n”: intake air pressure sensor (iaps) “q...

  • Page 71

    Engine general information and diagnosis: 1a-8 engine will not start or is hard to start (no fuel reaching the intake manifold) clogged fuel filter or fuel hose. Clean or replace. Defective fuel pump. Replace. Defective fuel pressure regulator. Replace. Defective fuel injector. Replace. Defective fu...

  • Page 72

    1a-9 engine general information and diagnosis: engine noisy (noise seems to come from piston) worn down piston or cylinder. Replace. Combustion chambers fouled with carbon. Clean. Worn piston pin or piston pin bore. Replace. Worn piston rings or ring grooves. Replace. Engine noisy (noise seems to co...

  • Page 73

    Engine general information and diagnosis: 1a-10 engine lacks power (defective engine internal/ electrical parts) loss of valve clearance. Adjust. Weakened valve springs. Replace. Valve timing out of adjustment. Adjust. Worn piston rings or cylinder. Replace. Poor seating of valves. Repair. Fouled sp...

  • Page 74

    1a-11 engine general information and diagnosis: dtc table b705h11104009 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 m...

  • Page 75

    Engine general information and diagnosis: 1a-12 fi system troubleshooting b705h11104011 customer complaint analysis record details of the problem (failure, complaint) and how it occurred as described by the customer. For this purpose, use of such an inspection form will facilitate collecting informa...

  • Page 76

    1a-13 engine general information and diagnosis: visual inspection prior to diagnosis using the mode select switch or sds, perform the following visual inspections. The reason for visual inspection is that mechanical failures (such as oil leakage) cannot be displayed on the screen with the use of mod...

  • Page 77

    Engine general information and diagnosis: 1a-14 self-diagnosis reset procedures b705h11104013 1) after repairing the trouble, turn off the ignition switch and turn on again. If dtc is indicated (c00), the malfunction is cleared. 2) disconnect the special tool from the dealer mode coupler. Note • eve...

  • Page 78

    1a-15 engine general information and diagnosis: use of sds diagnosis reset procedures b705h11104031 clear the past dtc using sds in the following procedures: 1) set up the sds tools. 2) after repairing the trouble, turn off the ignition switch and turn on again. 3) click the dtc inspection button (1...

  • Page 79

    Engine general information and diagnosis: 1a-16 show data when trouble (displaying data at the time of dtc) b705h11104032 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...

  • Page 80

    1a-17 engine general information and diagnosis: sds check b705h11104036 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 of filed data are useful f...

  • Page 81

    Engine general information and diagnosis: 1a-18 data at 3 000 r/min under no load data at the time of racing check the manifold absolute pressure. Xx kpa 3 000 r/min i705h1110127-02 throttle: quick wide open throttle: slowly open secondary throttle valve opens closes in according with the engine r/m...

  • Page 82

    1a-19 engine general information and diagnosis: data of intake negative pressure during idling (100 °c) data of secondary throttle valve operation at the time of starting check the manifold absolute pressure. Approx. Xx kpa i705h1110129-03 closes fully in approx. Xx sec. I705h1110130-02.

  • Page 83

    Engine general information and diagnosis: 1a-20 malfunction code and defective condition table b705h11104014 malfunction code detected item detected failure condition check for c00 no fault — — c12 ckp sensor althaugh the intake pressure is fluctuated, the signal does not reach ecm for 3 sec. Or mor...

  • Page 84

    1a-21 engine general information and diagnosis: * : immobilizer system is equipped model only. C28 secondary throttle valve actuator when no actuator control signal is supplied from the ecm, communication signal does not reach ecm or operation voltage does not reach stva motor, c28 (p1655) is indica...

  • Page 85

    Engine general information and diagnosis: 1a-22 dtc “c12” (p0335): ckp sensor circuit malfunction b705h11104016 detected condition and possible cause wiring diagram detected condition possible cause although the intake pressure is fluctuated, the signal does not reach for 3 sec. Or more. Note if sds...

  • Page 86

    1a-23 engine general information and diagnosis: troubleshooting note after repairing the trouble, clear the dtc using sds tool. Refer to “use of sds diagnosis reset procedures (page1a-15)”. Step action yes no 1 1) turn the ignition switch off. 2) check the ckp sensor coupler (1) for loose or poor co...

  • Page 87

    Engine general information and diagnosis: 1a-24 2 1) crank the engine a few seconds with the starter motor, and measure the ckp sensor peak voltage at the coupler. Ckp sensor peak voltage 4.5 v and more (positive terminal: g – negative terminal: bl) special tool (a): 09900–25008 (multi-circuit teste...

  • Page 88

    1a-25 engine general information and diagnosis: dtc “c13” (p0105-h/l): iap sensor circuit malfunction b705h11104017 detected condition and possible cause wiring diagram detected condition possible cause iap sensor voltage is not within the following range. 0.24 v ≤ sensor voltage note • note that at...

  • Page 89

    Engine general information and diagnosis: 1a-26 troubleshooting caution ! When using the multi-circuit tester, do not strongly touch the terminal of the ecm coupler with a needle pointed tester probe to prevent the terminal damage or terminal bend. Note after repairing the trouble, clear the dtc usi...

  • Page 90

    1a-27 engine general information and diagnosis: 1 6) measure the voltage at the r wire and ground. If ok, then measure the voltage at the r wire and b/br wire. Iap sensor input voltage 4.5 – 5.5 v (positive terminal: r – negative terminal: ground, positive terminal: r – negative terminal: b/br) spec...

  • Page 91

    Engine general information and diagnosis: 1a-28 2 1) connect the iap sensor coupler. 2) insert the needle pointed probes to the lead wire coupler. 3) start the engine at idle speed. 4) measure the iap sensor output voltage at the wire side coupler (between g/b and b/br wires). Iap sensor output volt...

  • Page 92

    1a-29 engine general information and diagnosis: 3 1) remove the iap sensor. 2) connect the vacuum pump gauge to the vacuum port “a” of the iap sensor. 3) arrange 3 new 1.5 v batteries in series (check that total voltage is 4.5 – 5.0 v) and connect negative terminal to ground terminal and positive te...

  • Page 93

    Engine general information and diagnosis: 1a-30 dtc “c14” (p0120/h/l): tp sensor circuit malfunction b705h11104018 detected condition and possible cause wiring diagram troubleshooting caution ! When using the multi-circuit tester, do not strongly touch the terminal of the ecm coupler with a needle p...

  • Page 94

    1a-31 engine general information and diagnosis: step action yes no 1 1) turn the ignition switch off. 2) remove the helmet box front cover. (refer to “helmet box front cover removal and installation in section 9d (page9d-16)”.) 3) check the tp sensor (1) coupler for loose or poor contacts. If ok, th...

  • Page 95

    Engine general information and diagnosis: 1a-32 2 1) connect the tp sensor coupler. 2) insert the needle pointed probes to the coupler. 3) turn the ignition switch on. 4) measure the tp sensor output voltage (between positive terminal: y and negative terminal: b/br) by turning the throttle grip. Tp ...

  • Page 96

    1a-33 engine general information and diagnosis: dtc “c15” (p0115-h/l): ect sensor circuit malfunction b705h11104019 detected condition and possible cause wiring diagram detected condition possible cause output voltage is not with in the following range. 0.2 v ≤ sensor voltage note • if sds is used, ...

  • Page 97

    Engine general information and diagnosis: 1a-34 troubleshooting caution ! When using the multi-circuit tester, do not strongly touch the terminal of the ecm coupler with a needle pointed tester probe to prevent the terminal damage or terminal bend. Note • after repairing the trouble, clear the dtc u...

  • Page 98

    1a-35 engine general information and diagnosis: 1 7) if ok, then measure the voltage between dg wire terminal and b/bl wire terminal. Ect sensor voltage 4.5 – 5.5 v (positive terminal: dg – negative terminal: ground, positive terminal: dg – negative terminal: b/br) special tool (a): 09900–25008 (mul...

  • Page 99

    Engine general information and diagnosis: 1a-36 dtc “c16” (p0500): speed sensor b705h11104020 detected condition and possible cause wiring diagram troubleshooting caution ! When using the multi-circuit tester, do not strongly touch the terminal of the ecm coupler with a needle pointed tester probe t...

  • Page 100

    1a-37 engine general information and diagnosis: step action yes no 1 1) turn the ignition switch off. 2) remove the left foot board and clutch outer cover. (refer to “v-belt type continuously variable automatic transmission removal and installation in section 5a (page5a-3)”.) 3) check the speed sens...

  • Page 101

    Engine general information and diagnosis: 1a-38 2 1) insert the needle pointed probes to the lead wire coupler. (between positive terminal: p and negative terminal: b/ w) 2) turn the ignition switch on. 3) check that the speed sensor output voltage varies when a screwdriver is brought close to the p...

  • Page 102

    1a-39 engine general information and diagnosis: dtc “c21” (p0110-h/l): iat sensor circuit malfunction b705h11104021 detected condition and possible cause wiring diagram troubleshooting caution ! When using the multi-circuit tester, do not strongly touch the terminal of the ecm coupler with a needle ...

  • Page 103

    Engine general information and diagnosis: 1a-40 step action yes no 1 1) turn the ignition switch off. 2) remove the front frame cover. (refer to “front frame cover removal and installation in section 9d (page9d- 17)”.) 3) check the iat sensor coupler for loose or poor contacts. If ok, then measure t...

  • Page 104

    1a-41 engine general information and diagnosis: 2 1) turn the ignition switch off. 2) measure the iat sensor resistance. Iat sensor resistance approx. 2.58 k Ω at 20 °c (68 °f) (terminal – terminal) special tool (a): 09900–25008 (multi-circuit tester set) tester knob indication resistance ( Ω) is th...

  • Page 105

    Engine general information and diagnosis: 1a-42 dtc “c23” (p1651-h/l): to sensor circuit malfunction b705h11104023 detected condition and possible cause wiring diagram detected condition possible cause the sensor voltage should be the following for 2 sec. And more, after ignition switch is turned on...

  • Page 106

    1a-43 engine general information and diagnosis: troubleshooting caution ! When using the multi-circuit tester, do not strongly touch the terminal of the ecm coupler with a needle pointed tester probe to prevent the terminal damage or terminal bend. Note after repairing the trouble, clear the dtc usi...

  • Page 107

    Engine general information and diagnosis: 1a-44 2 1) connect the to sensor coupler. 2) remove the to sensor horizontally 3) insert the needle pointed probes to the lead wire coupler. 4) turn the ignition switch on. 5) measure the voltage at the wire side coupler between br/w and b/br wires when hold...

  • Page 108

    1a-45 engine general information and diagnosis: dtc “c24” (p0351): ignition system malfunction b705h11104024 refer to “no spark or poor spark in section 1h (page1h-4)” for details. Dtc “c28” (p1655): secondary throttle valve actuator (stva) malfunction b705h11104034 detected condition and possible c...

  • Page 109

    Engine general information and diagnosis: 1a-46 troubleshooting caution ! When using the multi-circuit tester, do not strongly touch the terminal of the ecm coupler with a needle pointed tester probe to prevent the terminal damage or terminal bend. Note after repairing the trouble, clear the dtc usi...

  • Page 110

    1a-47 engine general information and diagnosis: 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) special tool (a): 09900–25008 (multi-circuit tester set) tester kno...

  • Page 111

    Engine general information and diagnosis: 1a-48 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”. 4) click each button (1). At this time, if an operation sound is...

  • Page 112

    1a-49 engine general information and diagnosis: dtc “c29” (p1654-h/l): secondary throttle position sensor (stps) b705h11104035 detected condition and possible cause wiring diagram detected condition possible cause signal voltage is not within the following range. Difference between actual throttle o...

  • Page 113

    Engine general information and diagnosis: 1a-50 troubleshooting caution ! When using the multi-circuit tester, do not strongly touch the terminal of the ecm coupler with a needle pointed tester probe to prevent the terminal damage or terminal bend. Note after repairing the trouble, clear the dtc usi...

  • Page 114

    1a-51 engine general information and diagnosis: 2 1) turn the ignition switch to off. 2) disconnect the stva lead wire coupler. 3) connect the stp sensor coupler to the test harness. 4) turn the ignition switch to on. 5) measure the stp sensor output voltage at the wire terminal (between positive te...

  • Page 115

    Engine general information and diagnosis: 1a-52 dtc “c32” (p0201): fuel injector circuit malfunction b705h11104025 detected condition and possible cause wiring diagram detected condition possible cause no injector signal is detected for 0.8 sec. Note if sds is used, p0201 is indicated. • injector ci...

  • Page 116

    1a-53 engine general information and diagnosis: troubleshooting caution ! When using the multi-circuit tester, do not strongly touch the terminal of the ecm coupler with a needle pointed tester probe to prevent the terminal damage or terminal bend. Note • after repairing the trouble, clear the dtc u...

  • Page 117

    Engine general information and diagnosis: 1a-54 1 5) if ok, then check the continuity between each terminal and ground. Injector continuity ∞Ω (infinity) special tool (a): 09900–25008 (multi-circuit tester set) tester knob indication continuity ( ) are the resistance and continuity ok? Go to step 2....

  • Page 118

    1a-55 engine general information and diagnosis: dtc “c40” (p0505, p0506 or p0507): isc valve circuit malfunction b705h11104026 detected condition and possible cause wiring diagram detected condition possible cause isc valve motor current is higher than the specified value. Note if sds is used, p0505...

  • Page 119

    Engine general information and diagnosis: 1a-56 troubleshooting caution ! • be careful not to disconnect the isc valve coupler at least 3 seconds after ignition switch is turned to off. If the ecm coupler is disconnected within 3 seconds after ignition switch is turned to off, there is a possibility...

  • Page 120

    1a-57 engine general information and diagnosis: 1 6) check the continuity between terminals g and (34), terminals w/b and (36), terminals p/w and (15), terminals b/lg and (35). Isc valve wire continuity continuity ( ) special tool : 09900–25008 (multi-circuit tester set) : 09900–25009 (needle pointe...

  • Page 121

    Engine general information and diagnosis: 1a-58 active control inspection (isc rpm control) check 1 1) set up the sds tool. (refer to the sds operation manual for further details.) 2) check that the engine is running. 3) click the “active control”. 4) click the “isc rpm control”. 2 1) turn the ignit...

  • Page 122

    1a-59 engine general information and diagnosis: 5) check that the “spec” (1) is idle speed 1 450 ± 100 rpm. 6) check that the “desired idle speed” (2) is within the specified idle rpm. Check 2 1) click the button (3) and decrease the “spec” (1) to 1 200 rpm slowly. 2) check that the “desired idle sp...

  • Page 123

    Engine general information and diagnosis: 1a-60 check 3 1) click the button (5) and increase the “spec” (1) to 1 600 rpm slowly. 2) check that the “desired idle speed” (2) is nearly equal to the “spec” (1). Also, check that the number of steps (4) in the isc valve position increases. Check 4 1) incr...

  • Page 124

    1a-61 engine general information and diagnosis: dtc “c41” (p0230-h/l): fp relay circuit malfunction b705h11104027 detected condition and possible cause wiring diagram detected condition possible cause no voltage is applied to fuel pump although fuel pump relay is turned on, or voltage is applied to ...

  • Page 125

    Engine general information and diagnosis: 1a-62 troubleshooting caution ! When using the multi-circuit tester, do not strongly touch the terminal of the ecm coupler with a needle pointed tester probe to prevent the terminal damage or terminal bend. Note after repairing the trouble, clear the dtc usi...

  • Page 126

    1a-63 engine general information and diagnosis: dtc “42” (p1650): ig switch circuit malfunction b705h11104028 detected condition and possible cause troubleshooting refer to “ignition switch inspection in section 9b (page9b-11)” for details. Detected condition possible cause ignition switch signal is...

  • Page 127

    Engine general information and diagnosis: 1a-64 dtc “c44” (p0130, p0135): ho2 sensor (ho2s) circuit malfunction b705h11104029 detected condition and possible cause wiring diagram troubleshooting caution ! When using the multi-circuit tester, do not strongly touch the terminal of the ecm coupler with...

  • Page 128

    1a-65 engine general information and diagnosis: step action yes no 1 1) turn the ignition switch off. 2) check the ho2 sensor coupler (1) for loose or poor contacts. If ok, then measure the ho2 sensor output voltage. 3) insert the needle pointed probe to the ho2 sensor lead wire coupler. 4) warm up ...

  • Page 129

    Engine general information and diagnosis: 1a-66 2 1) turn the ignition switch off. 2) insert the needle pointed to the ho2 sensor coupler. 3) turn the ignition switch on and measure the heater voltage between o/w wire (ecm side) and ground. If the tester voltage indicates the battery voltage for few...

  • Page 130

    1a-67 engine general information and diagnosis: specifications service data b705h11107001 injector fi sensors item specification note injector resistance approx. 10.3 Ω at 20 °c (68 f°) — item specification note ckp sensor resistance 190 – 290 Ω ckp sensor peak voltage 4.5 v and more (when cranking)...

  • Page 131

    Engine general information and diagnosis: 1a-68 special tools and equipment special tool b705h11108001 09900–25008 09900–25009 multi-circuit tester set needle pointed probe set ) (page1a-23) / )(page1a- 23) / )(page1a-24) / ) (page1a-27) / )(page1a- 28) / )(page1a-29) / ) (page1a-31) / )(page1a- 32)...

  • Page 132: Emission Control Devices

    1b-1 emission control devices: emission control devices precautions precautions for emission control devices b705h11200001 refer to “general precautions in section 00 (page00-1)”. General description fuel injection system description b705h11201005 an400 motorcycles are equipped with a fuel injection...

  • Page 133

    Emission control devices: 1b-2 crankcase emission control system description b705h11201006 the engine is equipped with a pcv system. Blow-by gas in the engine is constantly drawn into the crankcase, which is returned to the combustion chamber through the pcv (breather) hose, air cleaner and throttle...

  • Page 134

    1b-3 emission control devices: exhaust emission control system description b705h11201007 the exhaust emission control system is composed of the three-way catalyst system. Noise emission control system description b705h11201001 tampering with the noise control system prohibited: local law or federal ...

  • Page 135

    Emission control devices: 1b-4 repair instructions heated oxygen sensor (ho2s) removal and installation b705h11206004 removal warning ! Do not remove the ho2 sensor while it is hot. Caution ! • be careful not to expose the ho2 sensor to excessive shock. • do not use an impact wrench when removing or...

  • Page 136

    1b-5 emission control devices: 3) check the resistance between the terminals (w – w) of the ho2 sensor. If the resistance is not within the standard range, replace the ho2 sensor with a new one. Resistance approx. 11.5 – 14.5 Ω (at 23 °c) special tool (a): 09900–25008 (multi-circuit tester set) test...

  • Page 137

    Emission control devices: 1b-6 specifications service data b705h11207002 fi sensors electrical unit: mm (in) tightening torque specifications b705h11207003 reference: for the tightening torque of fastener not specified in this section, refer to “tightening torque specifications in section 0c (page0c...

  • Page 138: Engine Electrical Devices

    1c-1 engine electrical devices: engine electrical devices precautions precautions for engine electrical device b705h11300001 refer to “general precautions in section 00 (page00-1)” and “precautions for electrical circuit service in section 00 (page00-2)”. Repair instructions ecm removal and installa...

  • Page 139

    Engine electrical devices: 1c-2 installation install the ckp sensor in the reverse order of removal. Pay attention to the following points: • install the ckp sensor to the generator cover. Refer to “generator removal and installation in section 1j (page1j-6)”. • install the muffler. Refer to “exhaus...

  • Page 140

    1c-3 engine electrical devices: tp sensor removal and installation b705h11306009 removal 1) remove the helmet box front cover. Refer to “helmet box front cover removal and installation in section 9d (page9d-16)”. 2) disconnect the coupler and remove the tp sensor (1). Installation install the tp sen...

  • Page 141

    Engine electrical devices: 1c-4 speed sensor removal and installation b705h11306013 removal 1) remove the outer clutch cover. Refer to “v-belt type continuously variable automatic transmission removal and installation in section 5a (page5a-3)”. 2) disconnect the coupler and remove the speed sensor (...

  • Page 142

    1c-5 engine electrical devices: to sensor removal and installation b705h11306019 removal 1) remove the meter panel. Refer to “meter panel removal and installation in section 9d (page9d- 14)”. 2) disconnect the coupler and remove the to sensor (1). Installation install the to sensor in the reverse or...

  • Page 143

    Engine electrical devices: 1c-6 6) close the stv by finger, and measure the stp sensor output voltage. If the output voltage is out of the value, loosen the stp sensor mounting screw. 7) adjust the stp sensor (3) until the output voltage comes within the specified value and tighten the stp sensor mo...

  • Page 144

    1c-7 engine electrical devices: 8) install the upper meter panel. Refer to “upper meter panel removal and installation in section 9d (page9d-13)”. Ho2 sensor inspection b705h11306020 inspect the ho2 sensor. Refer to “dtc “c44” (p0130, p0135): ho2 sensor (ho2s) circuit malfunction in section 1a (page...

  • Page 145: Engine Mechanical

    Engine mechanical: 1d-1 engine mechanical precautions precautions for engine mechanical b705h11400001 refer to “general precautions in section 00 (page00-1)”. Schematic and routing diagram camshaft and sprocket assembly diagram b705h11402001 (a) (b) i705h1140174-02 : 23 n ⋅m (2.3 kgf-m, 16.5 lb-ft) ...

  • Page 146

    1d-2 engine mechanical: throttle cable routing diagram b705h11402003 “ e ” 3 4 2 1 1 “ d ” “ c ” “ a ” “ b ” i705h1140175-02 1. Clamp “b”: pass the throttle cables through under and inside of the frame. Bind the brake-lock cable, starter motor lead wire and seat-lock cable together. 2. Wire harness ...

  • Page 147

    Engine mechanical: 1d-3 diagnostic information and procedures compression pressure check b705h11404002 the compression pressure reading of the 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 m...

  • Page 148

    1d-4 engine mechanical: repair instructions engine components removable with the engine in place b705h11406001 engine components which can be removed while the engine is installed on the frame are as follows. For the installing and removing procedures, refer to respective paragraphs describing each ...

  • Page 149

    Engine mechanical: 1d-5 engine right side clutch housing refer to “v-belt type continuously variable automatic transmission removal and installation in section 5a (page5a-3)”. Refer to “movable drive face parts inspection in section 5a (page5a-9)”. Refer to “v-belt type continuously variable automat...

  • Page 150

    1d-6 engine mechanical: engine assembly removal and installation b705h11406002 removal remove the engine from the frame in the following procedures: 1) drain engine oil. Refer to “engine oil and filter change in section 0b (page0b-9)”. 2) drain engine coolant. Refer to “cooling system inspection in ...

  • Page 151

    Engine mechanical: 1d-7 14) loosen the muffler connecting bolt (12) and remove the exhaust pipe bolts (13). 15) remove the exhaust pipe/muffler by removing the muffler mounting bolts. 16) remove the exhaust pipe gasket. 17) remove the brake hose clamps and rear brake caliper from the swingarm. 18) r...

  • Page 152

    1d-8 engine mechanical: installation install the engine in the reverse order of removal. Pay attention to the following points: • tighten the engine mounting nut (2) to the specified torque. Tightening torque engine mounting nut (a): 93 n·m (9.3 kgf-m, 67.0 lb-ft) • tighten the cushion rod nut (3) t...

  • Page 153

    Engine mechanical: 1d-9 crankcase bracket removal and installation b705h11406064 refer to “crankcase bracket removal and installation in section 2c (page2c-12)”. Crankcase bracket inspection b705h11406065 refer to “crankcase bracket related parts inspection in section 2c (page2c-12)”. Air cleaner bo...

  • Page 154

    1d-10 engine mechanical: 9) remove the air cleaner box. Installation install the air cleaner box in the reverse order of removal. Refer to “air cleaner element removal and installation in section 0b (page0b-2)”, “footboard removal and installation in section 9d (page9d-21)”, “front frame cover remov...

  • Page 155

    Engine mechanical: 1d-11 throttle body components b705h11406072 2 1 3 3 3 3 3 3 5 6 7 8 9 4 fwd fw d i705h1140207-05 1. Throttle body 4. Stp sensor 7. Insulator 2. Tp sensor 5. Isc valve 8. Fuel injector 3. O-ring 6. Iap sensor 9. Cushion seal.

  • Page 156

    1d-12 engine mechanical: throttle body construction b705h11406074 2 3 7 8 “a” “b” “c” 4 (a) 1 upside upside rh rh rh lh lh lh fwd 5 6 (b) (c) i705h1140237-03 1. Ect sensor 8. Iat sensor 2. Iap sensor “a”: triangle mark must point downward. 3. Isc valve “b”: tighten the bracket with the cylinder head...

  • Page 157

    Engine mechanical: 1d-13 throttle body removal and installation b705h11406070 removal 1) remove the air cleaner box. Refer to “air cleaner box removal and installation (page1d-9)”. 2) remove the throttle cables (1). 3) remove the fuel hose (2). 4) remove the throttle body assembly (3). 5) remove the...

  • Page 158

    1d-14 engine mechanical: 6) remove the tp sensor (8) and stv sensor (9). Note prior to disassembly, mark each sensors original position with a paint or scribe “a” for accurate reinstallation. Caution ! Never remove the stva (10) from the throttle body. Caution ! Never remove the throttle valve (11) ...

  • Page 159

    Engine mechanical: 1d-15 note make sure the tp valve open or close smoothly. If the tp sensor adjustment is necessary, refer to “tp sensor adjustment in section 1c (page1c-2)”. • install the isc valve. Refer to “isc valve removal and installation in section 1c (page1c-6)”. • apply thin coat of the e...

  • Page 160

    1d-16 engine mechanical: engine top side disassembly b705h11406004 it is unnecessary to remove the engine assembly from the frame when servicing the engine top side. Note before servicing the engine top side with engine inplace, remove the air cleaner box, throttle body, fuel tank, exhaust pipe, muf...

  • Page 161

    Engine mechanical: 1d-17 6) remove the intake camshaft (8) and exhaust camshaft (9). 7) remove the dowel pins. Cylinder head and cylinder 1) remove the water bypass hose (1). 2) remove the heat shield (2). 3) remove the cylinder head (3). Note be sure to loosen the cylinder head bolts evenly and in ...

  • Page 162

    1d-18 engine mechanical: piston 1) place a clean rag over the cylinder base so as not to drop the piston pin circlip into the crankcase. 2) remove the piston pin circlip (1). 3) remove the piston pin and piston. Engine top side assembly b705h11406037 assemble the engine top side in the reverse order...

  • Page 163

    Engine mechanical: 1d-19 cylinder head • place the dowel pins and a new gasket (1) on the cylinder. Caution ! Replace the gasket with a new one. • install the cylinder head. Note when installing the cylinder head, keep the cam chain taut. Cylinder head bolt tighten the cylinder head bolts “a” (l190)...

  • Page 164

    1d-20 engine mechanical: camshaft • turn the crankshaft to bring the piston to the tdc. (refer to “valve clearance inspection and adjustment in section 0b (page0b-4)”.) caution ! • keep the cam chain taut when turning the crankshaft, or the chain will be caught between crankcase and cam drive sprock...

  • Page 165

    Engine mechanical: 1d-21 • install the camshaft journal holder (1) and cam chain guide no. 2 (2). • tighten the camshaft journal holder bolts in the ascending order of numbers to the specified torque. Tightening torque camshaft journal holder bolt: 10 n·m (1.0 kgf-m, 0.7 lb-ft) cam chain tension adj...

  • Page 166

    1d-22 engine mechanical: • tighten the spring holder bolt to the specified torque. Tightening torque spring holder bolt: 23 n·m (2.3 kgf-m, 16.5 lb-ft) caution ! • when the cam chain tension adjuster has been installed, check for cam chain tension to determine if the tension adjuster is functioning ...

  • Page 167

    Engine mechanical: 1d-23 camshaft runout measure the runout using the dial gauge. Replace the camshaft if the runout exceeds the limit. Special tool (a): 09900–20606 (dial gauge (1/100 mm)) (b): 09900–20701 (magnetic stand) (c): 09900–21303 (v-block (75 mm)) camshaft runout (in & ex) service limit: ...

  • Page 168

    1d-24 engine mechanical: 5) if the camshaft journal oil clearance exceeds the limit, measure the inside diameter of the camshaft journal holder and the outside diameter of the camshaft journal. Replace the camshaft or the cylinder head depending upon which one exceeds the specification. Special tool...

  • Page 169

    Engine mechanical: 1d-25 cam chain guide inspection b705h11406049 inspect the cam chain guide in the following procedures: 1) remove the cam chain guides. Refer to “engine top side assembly (page1d-18)”. 2) check the contacting surface of the cam chain guide. If it is worn or damaged, replace it wit...

  • Page 170

    1d-26 engine mechanical: 6) remove the oil seal (7) and spring seat (8). Caution ! Do not reuse the removed oil seal. 7) remove the other valves in the same manner as described previously. 8) remove the thermostat case (9). 9) remove the thermostat (10). 10) remove the intake pipe (11). 11) remove t...

  • Page 171

    Engine mechanical: 1d-27 • apply engine oil to o-ring and install the oil jet. • apply engine coolant to o-ring and install the ect sensor. Caution ! Replace each o-ring with a new one. Tightening torque ect sensor: 12 n·m (1.2 kgf-m, 8.5 lb-ft) • make sure that the scooped part “a” faces downward. ...

  • Page 172

    1d-28 engine mechanical: • install the valve spring with the small-pitch portion “b” facing cylinder head. • put on the valve spring retainer (3), and using the special tools, press down the spring, fit the cotter halves to the stem end, and release the lifter to allow the cotter halves to wedge in ...

  • Page 173

    Engine mechanical: 1d-29 cylinder head and related parts inspection b705h11406014 cylinder head distortion 1) decarbonize the combustion chambers. 2) check the gasket surface of the cylinder head for distortion. Use a straightedge and thickness gauge. Take clearance readings at several places. If re...

  • Page 174

    1d-30 engine mechanical: valve stem deflection lift the valve about 10 mm (0.39 in) “a” from the valve seat. Measure the valve stem deflection in two directions, “x” and “y”, perpendicular to each other. Position the dial gauge as shown. If the deflection exceeds the service limit, then determine wh...

  • Page 175

    Engine mechanical: 1d-31 valve seat width 1) visually check for valve seat width on each valve face. If the valve face has worn abnormally, replace the valve. 2) coat the valve seat with a red lead (prussian blue) and set the valve in place. 3) rotate the valve with light pressure. Special tool (a):...

  • Page 176

    1d-32 engine mechanical: valve guide replacement b705h11406051 1) remove the cylinder head. Refer to “engine top side disassembly (page1d-16)”. 2) remove the valves. Refer to “cylinder head disassembly and reassembly (page1d-25)”. 3) using the valve guide remover, drive the valve guide out toward th...

  • Page 177

    Engine mechanical: 1d-33 note • be sure to cool down the cylinder head to ambient air temperature. • insert the reamer from the combustion chamber side and always turn the reamer handle clockwise. 9) reassemble the cylinder head. Refer to “cylinder head disassembly and reassembly (page1d-25)”. 10) i...

  • Page 178

    1d-34 engine mechanical: cylinder inspection b705h11406053 refer to “engine top side disassembly (page1d-16)”. Refer to “engine top side assembly (page1d-18)”. Cylinder distortion check the gasket surface of the cylinder for distortion. Use a straightedge and thickness gauge. Take clearance readings...

  • Page 179

    Engine mechanical: 1d-35 caution ! When installing the spacer, be careful so that the both edges are not overlapped. B) install the 2nd ring (3) and 1st ring (4) to piston. Note 1st ring (4) and 2nd ring (3) differ in shape. Note face the side with the stamped mark “a” upward when assembling. 2) pos...

  • Page 180

    1d-36 engine mechanical: piston-to-cylinder clearance subtract the piston diameter from the cylinder bore diameter. If the piston-to-cylinder clearance exceeds the service limit, replace both the cylinder and the piston. Piston-to-cylinder clearance service limit: 0.12 mm (0.0047 in) piston ring-to-...

  • Page 181

    Engine mechanical: 1d-37 piston pin and pin bore measure the piston pin bore inside diameter using the small bore gauge. If either is out of specification or the difference between these measurement is more than the limits, replace the piston. Special tool (a): 09900–20602 (dial gauge (1/1000 mm, 1 ...

  • Page 182

    1d-38 engine mechanical: ignition coil remove the ignition coil (1). Water pump remove the water pump assembly (1). Generator cover 1) remove the generator cover (1). 2) remove the dowel pins and gasket (2). Outer clutch cover remove the outer clutch cover (1). Oil filter 1) remove the oil filter ca...

  • Page 183

    Engine mechanical: 1d-39 speed sensor remove the speed sensor (1). Drivetrain 1) remove the inner clutch cover (1). 2) remove the dowel pins and gasket. 3) with the crankshaft held immovable, remove the fixed drive face nut and concaved washer. 4) remove the fixed drive face (2). 5) with the clutch ...

  • Page 184

    1d-40 engine mechanical: generator rotor 1) with the generator rotor held immovable, loosen the generator rotor nut. 2) remove the generator rotor (1) using the special tool. Special tool (a): 09930–31921 (rotor remover) starter drive gear remove the key (1) and starter driven gear (2). Cam chain an...

  • Page 185

    Engine mechanical: 1d-41 balancer driven gear 1) insert a proper steel rod “a” into the crankcase hole “b” and pass it through the crankshaft web holes in order to prevent the crankshaft from turning. 2) remove the balancer driven gear nut (1) and washer. 3) remove the balancer driven gear (2) along...

  • Page 186

    1d-42 engine mechanical: crankcase 1) remove the balancer drive gear nut. Special tool (a): 09922–21410 (long socket (46 mm)) 2) remove the steel rod. 3) remove the washer (1) and balancer drive gear (2). 4) remove the pin (3). 5) remove the crankcase bolts (m6 and m8). Caution ! Loosen the smaller ...

  • Page 187

    Engine mechanical: 1d-43 balancer shaft remove the balancer shaft (1). Oil sump filter 1) remove the oil sump filter cover (1). 2) remove the oil sump filter (2). Oil pump 1) remove the oil pump drive chain case (1). 2) remove the oil pump assembly (2). 3) remove the oil pump drive shaft (3) and cha...

  • Page 188

    1d-44 engine mechanical: engine bottom side assembly b705h11406058 assemble the engine bottom side in the reverse of disassembly. Pay attention to the following points: crankshaft • using the special tools, press in the crankshaft into the left crankcase. Note when pressing in the crankshaft into th...

  • Page 189

    Engine mechanical: 1d-45 oil sump filter refer to “oil sump filter removal and installation in section 1e (page1e-4)”. Balancer shaft • install the balancer shaft (1). Note bring the straightened part of the crank web toward the balancer shaft. Crankcase • install the o-rings (1) and (2). • install ...

  • Page 190

    1d-46 engine mechanical: • tighten the crankcase bolts to the specified torque. Tightening torque crankcase bolt (m6): 11 n·m (1.1 kgf-m, 8.0 lb-ft) crankcase bolt (m8): 22 n·m (2.2 kgf-m, 16.0 lb-ft) caution ! Tighten the larger diameter crankcase bolts first and then smaller ones diagonally and ev...

  • Page 191

    Engine mechanical: 1d-47 oil pump drive gear • install the spacer (1) and pin (2). • install the oil pump drive gear (3). Caution ! Make sure to align the slot of the oil pump drive gear with the pin. • with the crankshaft held immovable, tighten the oil pump drive gear nut (4) to the specified torq...

  • Page 192

    1d-48 engine mechanical: cam chain tensioner • install the cam chain tensioner (1) and tighten the cam chain tensioner bolt (2) to the specified torque. Tightening torque cam chain tensioner bolt: 23 n·m (2.3 kgf-m, 16.5 lb-ft) • tighten the cam chain guide bolt (3) to the specified torque. Tighteni...

  • Page 193

    Engine mechanical: 1d-49 generator cover • install the dowel pins (1) and gasket (2). Caution ! Replace the gasket with a new one. • install the generator cover (3). • tighten the generator cover bolts to the specified torque. Tightening torque generator cover bolt: 11 n·m (1.1 kgf-m, 8.0 lb-ft) • i...

  • Page 194

    1d-50 engine mechanical: oil filter • install the o-ring (1). Caution ! Replace the o-ring with a new one. • install the oil filter (2). Caution ! Position the oil filter so that the valve “a” comes outside. • install the o-ring (3). • install the spring (4). • tighten the oil filter cap bolts to th...

  • Page 195

    Engine mechanical: 1d-51 cam chain tensioner inspection b705h11406060 inspect the cam chain tensioner in the following procedures: 1) remove the cam chain tensioner. Refer to “engine bottom side disassembly (page1d-37)”. 2) inspect the contacting surface of the cam chain tensioner. If it is worn or ...

  • Page 196

    1d-52 engine mechanical: crankshaft runout • with the right and left crank journals supported with v- block, turn the crankshaft slowly. At this time, measure the crankshaft end runout using a dial gauge. If the runout exceeds the service limit, replace the crankshaft. Crankshaft runout service limi...

  • Page 197

    Engine mechanical: 1d-53 • remove the oil seal using the special tool. Special tool (a): 09913–50121 (oil seal remover) • remove the bearing (4) using the special tool. Special tool (b): 09913–70210 (bearing installer set) • remove the bearing (5) using the special tool. Special tool (c): 09921–2024...

  • Page 198

    1d-54 engine mechanical: • install the oil seal using the special tool. Special tool (e): 09913–70210 (bearing installer set) caution ! Replace the removed oil seal with a new one. Rear suspension mounting bushing removal and installation b705h11406063 removal 1) separate the crankcase. Refer to “en...

  • Page 199

    Engine mechanical: 1d-55 specifications service data b705h11407002 valve + valve guide unit: mm (in) camshaft + cylinder head unit: mm (in) item standard limit valve diam. In. 31.0 (1.22) — ex. 27.0 (1.06) — tappet clearance (when cold) in. 0.10 – 0.20 (0.003 – 0.008) — ex. 0.20 – 0.30 (0.008 – 0.00...

  • Page 200

    1d-56 engine mechanical: cylinder + piston + piston ring unit: mm (in) conrod + crankshaft unit: mm (in) throttle body item standard limit compression pressure (automatic de-comp. Actuated) e-02, 19, 24, 54 1 060 – 1 140 kpa (10.6 – 11.4 kgf/cm 2 , 151 – 162 psi) 660 kpa (6.0 kgf/cm 2 , 94 psi) e-03...

  • Page 201

    Engine mechanical: 1d-57 tightening torque specifications b705h11407003 note the specified tightening torque is also described in the following. “camshaft and sprocket assembly diagram (page1d-1)” “engine assembly removal and installation (page1d-6)” “throttle body construction (page1d-12)” referenc...

  • Page 202

    1d-58 engine mechanical: special tools and equipment recommended service material b705h11408001 note required service material is also described in the following. “engine assembly removal and installation (page1d-6)” special tool b705h11408002 material suzuki recommended product or specification not...

  • Page 203

    Engine mechanical: 1d-59 09900–20803 09900–21303 thickness gauge v-block (75 mm) ) (page1d-29) / )(page1d- 34) / )(page1d-36) / ) (page1d-36) / )(page1d- 51) ) (page1d-23) 09900–21304 09900–22301 v-block (100 mm) plastigauge (0.025 – 0.076 mm) ) (page1d-29) / )(page1d- 29) / )(page1d-51) / ) (page1d...

  • Page 204

    1d-60 engine mechanical: 09916–34561 09916–43210 valve guide reamer (11.3 mm) valve guide remover/ installer ) (page1d-32) ) (page1d-32) / )(page1d- 32) 09916–53330 09916–84511 attachment tweezers ) (page1d-32) ) (page1d-25) / )(page1d- 28) 09919–28610 09920–13120 sleeve protector crankcase separati...

  • Page 205: Engine Lubrication System

    Engine lubrication system: 1e-1 engine lubrication system precautions precautions for engine oil b705h11500001 refer to “fuel / oil / engine coolant recommendation in section 0a (page0a-3)”. Schematic and routing diagram engine lubrication system chart diagram b705h11502001 oil sump filter oil pump ...

  • Page 206

    1e-2 engine lubrication system: engine lubrication circuit diagram b705h11502002 2 1 3 “a” “b” i705h1150012-01 1. Oil sump filter 3. Oil filter “b”: returned oil 2. Oil pump “a”: lubrication oil.

  • Page 207

    Engine lubrication system: 1e-3 diagnostic information and procedures engine lubrication symptom diagnosis b705h11504001 oil pressure check b705h11504003 check the engine oil pressure periodically. This will give a good indication of the condition of the moving parts. Note before checking the oil pr...

  • Page 208

    1e-4 engine lubrication system: 5) stop the engine and remove the oil pressure gauge and attachment. 6) reinstall the main oil gallery plug and tighten it to the specified torque. Caution ! Use a new gasket to prevent oil leakage. Tightening torque main oil gallery plug: 16 n·m (1.6 kgf-m, 11.5 lb- ...

  • Page 209

    Engine lubrication system: 1e-5 oil pump removal and installation b705h11506015 removal 1) dismount the engine. Refer to “engine assembly removal and installation in section 1d (page1d-6)”. 2) separate the crankcase. Refer to “engine bottom side disassembly in section 1d (page1d-37)”. 3) remove the ...

  • Page 210

    1e-6 engine lubrication system: installation install the piston cooling nozzle in the reverse order of removal. Pay attention to the following point: note before installing, replace the o-ring (1) with a new one and coat the o-ring with engine oil. Piston cooling nozzle inspection b705h11506021 insp...

  • Page 211

    Engine lubrication system: 1e-7 special tools and equipment special tool b705h11508001 09915–74521 09915–74570 oil pressure gauge hose oil pressure gauge attachment ) (page1e-3) ) (page1e-3) 09915–77331 meter (for high pressure) ) (page1e-3).

  • Page 212: Engine Cooling System

    1f-1 engine cooling system: engine cooling system precautions engine cooling system warning b705h11600001 warning ! • you can be injured by scalding fluid or steam if you open the radiator cap when the engine is hot. After the engine cools, wrap a thick cloth around cap and carefully remove the cap ...

  • Page 213

    Engine cooling system: 1f-2 fig. 1: engine coolant density-freezing point curve fig. 2: engine coolant density-boiling point curve cooling fan thermo-switch description b705h11601003 the cooling fan is secured behind the radiator by three bolts and is automatically controlled by the thermo-switch. T...

  • Page 214

    1f-3 engine cooling system: engine coolant temperature sensor description b705h11601004 the following circuit diagram shows the electrical wiring for the thermometer. The major components are ect sensor in contact with coolant, and engine coolant temperature meter. Battery main fuse fuse fuse speedo...

  • Page 215

    Engine cooling system: 1f-4 schematic and routing diagram cooling circuit diagram b705h11602001 oil cooler (1) is located inside the crankcase. The engine oil is cooled by engine coolant, which is circulated through inside core of oil cooler. Oil cooler thermostat by-pass crankcase cylinder cylinder...

  • Page 216

    1f-5 engine cooling system: radiator hose routing diagram b705h11602002 component location engine cooling system components location b705h11603001 refer to “electrical components location in section 0a (page0a-7)”. 1 3 9 1 2 2 3 5 6 7 8 “a” “b” “b” “d” “g” 4 “c” “e” “f” i705h1160056-02 1. Reservoir ...

  • Page 217

    Engine cooling system: 1f-6 diagnostic information and procedures engine cooling symptom diagnosis b705h11604001 repair instructions cooling circuit inspection b705h11606001 warning ! • do not open the radiator cap when the engine is hot, as you may be injured by escaping hot liquid or vapor. • when...

  • Page 218

    1f-7 engine cooling system: radiator cap inspection b705h11606002 inspect the radiator cap in the following procedures: 1) remove the radiator cap. Refer to “cooling circuit inspection (page1f-6)”. 2) attach the radiator cap (1) to the radiator tester (2) as shown. 3) slowly apply pressure to the ra...

  • Page 219

    Engine cooling system: 1f-8 radiator cleaning b705h11606028 clean the radiator in the following procedures: 1) remove the radiator. Refer to “radiator removal and installation (page1f-7)”. 2) remove the cooling fan. Refer to “cooling fan removal and installation (page1f-10)”. 3) inspect the radiator...

  • Page 220

    1f-9 engine cooling system: radiator hose removal and installation b705h11606030 removal 1) drain engine coolant. Refer to “cooling system inspection in section 0b (page0b-11)”. 2) remove the left footboard. Refer to “footboard removal and installation in section 9d (page9d- 21)”. 3) remove the air ...

  • Page 221

    Engine cooling system: 1f-10 note the voltmeter is for making sure that the battery applies 12 v to the motor. With the motor with electric motor fan running at full speed, the ammeter should be indicating not more than 5 a. 5) if the fan motor does not turn, replace the cooling fan assembly with a ...

  • Page 222

    1f-11 engine cooling system: cooling fan thermo-switch inspection b705h11606012 inspect the cooling fan thermo-switch in the following procedures: caution ! • take special care when handling the cooling fan thermo-switch. Do not subject it to strong blows or allow it to be dropped. • do not contact ...

  • Page 223

    Engine cooling system: 1f-12 installation install the thermostat in the reverse order of removal. Pay attention to the following points: • apply engine coolant to the rubber seal around the thermostat. • position the thermostat with one of the air bleeder hole “a” upside. • pour engine coolant. Refe...

  • Page 224

    1f-13 engine cooling system: water pump components b705h11606020 2 2 2 1 3 5 6 4 i705h1160057-02 1. Water pump cover 4. Mechanical seal : apply grease. 2. O-ring 5. Oil seal : apply engine coolant. 3. Impeller 6. Mechanical seal ring : do not reuse..

  • Page 225

    Engine cooling system: 1f-14 water pump construction b705h11606031 water pump removal and installation b705h11606021 removal 1) remove the under cover. Refer to “under cover removal and installation in section 9d (page9d- 16)”. 2) drain engine coolant. Refer to “cooling system inspection in section ...

  • Page 226

    1f-15 engine cooling system: • tighten the water pump mounting bolts to the specified torque. Tightening torque water pump mounting bolt: 10 n·m (1.0 kgf-m, 7.0 lb-ft) • pour engine coolant. Refer to “cooling system inspection in section 0b (page0b-11)”. • pour engine oil. Refer to “engine oil and f...

  • Page 227

    Engine cooling system: 1f-16 6) remove the oil seal using a suitable bar. Caution ! The removed oil seal must be replaced with a new one. Note if there is no abnormal condition, the oil seal removal is not necessary. Assembly assemble the water pump in the reverse order of disassembly. Pay attention...

  • Page 228

    1f-17 engine cooling system: • install the rubber seal (1) into the impeller. • after wiping off the oily or greasy matter from the mechanical seal ring, install it into the impeller. Note the paint marked side “c” of mechanical seal ring faces the rubber seal. • install the new o-rings (2), (3). Ca...

  • Page 229

    Engine cooling system: 1f-18 impeller visually inspect the impeller and its shaft for damage. Replace the impeller if necessary. Specifications service data b705h11607002 thermostat + radiator + fan + coolant tightening torque specifications b705h11607003 reference: for the tightening torque of fast...

  • Page 230

    1f-19 engine cooling system: special tools and equipment recommended service material b705h11608001 special tool b705h11608002 material suzuki recommended product or specification note grease suzuki super grease a or equivalent p/no.: 99000–25010 ) (page1f-14) / )(page1f- 16) / )(page1f-17) 09900–25...

  • Page 231: Fuel System

    Fuel system: 1g-1 fuel system precautions precautions for fuel system b705h11700001 warning ! • keep away from fire or spark. • during disassembling, use care to minimize spillage of gasoline. • spilled gasoline should be wiped off immediately. • work in a well-ventilated area. Caution ! • to preven...

  • Page 232

    1g-2 fuel system: schematic and routing diagram fuel tank hose construction b705h11702001 1. Clamp 7. Cushion “a”: to fuel tank 2. Water drain hose 8. Clamp “b”: black 3. Breather hose 9. Breather hose : pass the breather hose through into the ring part of the tray. “c”: orange 4. Check valve 10. Mo...

  • Page 233

    Fuel system: 1g-3 diagnostic information and procedures fuel system diagnosis b705h11704001 condition possible cause correction / reference item engine will not start or hard to start (gasoline does not reach the intake pipe) clogging, bending or improper routing of fuel filter or fuel hose. Clean, ...

  • Page 234

    1g-4 fuel system: insufficient engine power (control circuit or sensor failure) fuel pressure too low. Repair or replace. Throttle position failure. Replace. Ecm failure. Replace. Throttle position sensor synchronization failure. Adjust. Engine overheats (fuel mixture too lean) fuel injector failure...

  • Page 235

    Fuel system: 1g-5 repair instructions fuel system components b705h11706001 2 4 3 1 “ a ” i705h1170040-01 1. Brake-lock cable 3. Check valve “a”: 5 mm (0.2 in) 2. Water drain hose 4. Breather hose.

  • Page 236

    1g-6 fuel system: fuel tank heat shield construction b705h11706026 fuel cut valve removal and installation b705h11706002 removal 1) remove the front box. Refer to “front box removal and installation in section 9d (page9d-18)”. 2) disconnect the hose (1) and remove the fuel cut valve (2). Installatio...

  • Page 237

    Fuel system: 1g-7 • install the fuel cut valve with its hose attaching section “c” facing the vehicle body right side. • tighten the fuel cut valve bolt to the specified torque. Tightening torque fuel cut valve bolt (a): 3.5 n·m (0.35 kgf-m, 2.5 lb- ft) fuel tank removal and installation b705h117060...

  • Page 238

    1g-8 fuel system: installation install the fuel tank in the reverse order of removal. Pay attention the following points: • tighten the fuel tank bolts. • remove the fuel filler cap (1) and install the fuel drain tray (2) on the fuel inlet. Caution ! After the fuel drain tray (2) has been fitted on ...

  • Page 239

    Fuel system: 1g-9 • when installing the fuel pump assembly, first tighten all the fuel pump mounting bolts lightly and then to the specified torque, in the ascending order of numbers. Tightening torque fuel pump mounting bolt: 10 n·m (1.0 kgf-m, 7.0 lb-ft) • tighten the fuel hose to the specified to...

  • Page 240

    1g-10 fuel system: fuel cut valve inspection b705h11706004 inspect the fuel cut valve in the following procedures: 1) remove the fuel cut valve. Refer to “fuel drain tray and ftpc valve removal and installation (page1g- 9)”. 2) check for the following points and replace if any abnormal condition is ...

  • Page 241

    Fuel system: 1g-11 2) after removing the clamp screw (1), ground wire (2) and lead wire (bl) (3), remove the fuel pump assembly (4). 3) detach the fuel mesh filter (5) and remove the fuel pump (6). 4) disconnect the lead wire (gray) (7) and remove the fuel level gauge assembly (8). 5) remove the fue...

  • Page 242

    1g-12 fuel system: fuel pressure inspection b705h11706005 inspect the fuel pressure in the following procedures: 1) remove the fuel tank bolt and move the fuel tank for vehicle backward. 2) place a rag under the fuel feed hose and disconnect fuel feed hose (1) from the fuel tank. Warning ! • use cau...

  • Page 243

    Fuel system: 1g-13 fuel pump relay inspection b705h11706006 refer to “electrical components location in section 0a (page0a-7)”. Inspect the fuel pump relay in the following procedures: 1) remove the front leg shield. Refer to “front leg shield removal and installation in section 9d (page9d-14)”. 2) ...

  • Page 244

    1g-14 fuel system: 3) inspect the fuel meter. Refer to “fuel level meter inspection in section 9c (page9c-2)”. Fuel pump inspection b705h11706022 turn the ignition switch on and check for operation of the fuel pump for a few seconds. If the fuel pump is not operating properly, replace the fuel pump ...

  • Page 245

    Fuel system: 1g-15 specifications service data b705h11707002 injector + fuel pump + fuel pressure regulator fuel tightening torque specifications b705h11707003 note the specified tightening torque is also described in the following. “fuel tank hose construction (page1g-2)” reference: for the tighten...

  • Page 246

    1g-16 fuel system: special tools and equipment special tool b705h11708001 09900–25008 09915–74521 multi-circuit tester set oil pressure gauge hose ) (page1g-13) ) (page1g-12) 09915–77331 09917–47011 meter (for high pressure) vacuum pump gauge ) (page1g-12) ) (page1g-10) 09940–40211 09940–40230 fuel ...

  • Page 247: Ignition System

    Ignition system: 1h-1 ignition system general description immobilizer description (for e-02, 19, 24, 54) b705h11801001 the immobilizer, an anti-theft system, is installed as a standard equipment. The immobilizer verifies that the key id agrees with ecm id by means of radio communication through the ...

  • Page 248

    1h-2 ignition system: note if the indicator light flashes fast, turn the ignition switch off then on to make judgment again as there is possible misjudgment due to environmental radio interference. Caution ! When the battery performance is lowered in winter (low temperature), the system may at times...

  • Page 249

    Ignition system: 1h-3 diagnostic information and procedures ignition system symptom diagnosis b705h11804005 condition possible cause correction / reference item spark plug not sparking damaged spark plug. Replace. Damaged spark plug cap. Replace. Fouled spark plug. Clean or replace. Wet spark plug. ...

  • Page 250

    1h-4 ignition system: no spark or poor spark b705h11804001 troubleshooting note make sure the engine stop switch is in the “run” position and side-stand is in up-right position. Grasp the front or rear brake lever. Make sue the fuse is not blown and the battery is fully-charged before diagnosing. St...

  • Page 251

    Ignition system: 1h-5 repair instructions spark plug removal and installation b705h11806007 refer to “spark plug removal and installation in section 0b (page0b-3)”. Spark plug inspection and cleaning b705h11806008 refer to “spark plug inspection and cleaning in section 0b (page0b-4)”. Ignition coil ...

  • Page 252

    1h-6 ignition system: 6) repeat above procedures a few times and measure the highest ignition coil primary peak voltage. If the voltages are lower than standard values, inspect the ignition coil and the ckp sensor. Ignition coil primary peak voltage 150 v and more 7) after measuring the ignition coi...

  • Page 253

    Ignition system: 1h-7 2) disconnect the ecm coupler (1). Note make sure that all of the couplers are connected properly and the battery is fully- charged. 3) connect the multi-circuit tester with the peak volt adaptor as follows. Special tool (a): 09900–25008 (multi-circuit tester set) tester knob i...

  • Page 254

    1h-8 ignition system: c) measure the ckp sensor peak voltage in the same manner as on the ecm coupler. If the peak voltage on the ckp sensor lead wire couplers is within specification, but on the ecm coupler is out of specification, the wire harness must be replaced. If both peak voltages are out of...

  • Page 255

    Ignition system: 1h-9 7) disconnect the seat-lock cable (3). Installation installation is in the reverse order of removal. Specifications service data b705h11807001 electrical unit: mm (in) special tools and equipment special tool b705h11808001 2 3 i705h1180028-01 item standard / specification note ...

  • Page 256: Starting System

    1i-1 starting system: starting system schematic and routing diagram starting system diagram b705h11902001 component location starting system components location b705h11903001 refer to “electrical components location in section 0a (page0a-7)”. Starter motor starter relay safety relay starter button f...

  • Page 257

    Starting system: 1i-2 diagnostic information and procedures starter motor will not run b705h11904001 note make sure the fuses are not blown and the battery is fully-charged before diagnosing. Troubleshooting engine does not turn though the starter motor runs. • faulty starter clutch. Step action yes...

  • Page 258

    1i-3 starting system: repair instructions starter motor components b705h11906002 starter motor removal and installation b705h11906001 removal 1) remove the air cleaner box. Refer to “air cleaner box removal and installation in section 1d (page1d-9)”. 2) remove the starter motor (1). 1 3 8 9 4 5 (a) ...

  • Page 259

    Starting system: 1i-4 installation install the starter motor in the reverse order of removal. Pay attention to the following points. • apply grease to the o-ring. : grease 99000–25010 (suzuki super grease a or equivalent) • tighten the bolts to the specified torque. Tightening torque starter motor m...

  • Page 260

    1i-5 starting system: • align the match mark on the starter motor case with the match mark on the housing end. • apply a small quantity of thread lock to the starter motor housing bolts and tighten them to the specified torque. : thread lock cement 99000–32050 (thread lock cement 1342 or equivalent)...

  • Page 261

    Starting system: 1i-6 oil seal check the seal lip for damage. If any damage is found, replace the housing end (inside). Starter relay removal and installation b705h11906004 refer to “electrical components location in section 0a (page0a-7)”. Removal 1) remove the upper meter panel. Refer to “meter pa...

  • Page 262

    1i-7 starting system: 3) measure the relay coil resistance between the terminals using the multi-circuit tester. If the resistance is not within the specified value, replace the starter relay with a new one. Special tool (a): 09900–25008 (multi-circuit tester set) starter relay resistance 3 – 6 Ω 4)...

  • Page 263

    Starting system: 1i-8 4) connect the side-stand switch coupler. 5) install the left footboard. Refer to “footboard removal and installation in section 9d (page9d- 21)”. Turn signal / side-stand relay the turn signal/side-stand relay is composed of the turn signal relay, side-stand relay and diode. S...

  • Page 264

    1i-9 starting system: starter clutch component b705h11906008 starter clutch removal and installation b705h11906009 removal 1) drain engine oil. Refer to “engine oil and filter change in section 0b (page0b-9)”. 2) remove the muffler. Refer to “exhaust pipe / muffler removal and installation in sectio...

  • Page 265

    Starting system: 1i-10 starter clutch inspection b705h11906010 inspect the starter clutch in the following procedures. 1) 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...

  • Page 266

    1i-11 starting system: • apply thread lock on the starter clutch bolts and tighten them to the specified torque. Tightening torque starter clutch bolt: 26 n·m (2.6 kgf-m, 19.0 lb-ft) : thread lock cement 99000–32050 (thread lock cement 1342 or equivalent) caution ! After installing the starter drive...

  • Page 267

    Starting system: 1i-12 special tools and equipment recommended service material b705h11908001 note required service material is also described in the following. “starter motor components (page1i-3)” “starter clutch component (page1i-9)” special tool b705h11908002 material suzuki recommended product ...

  • Page 268: Charging System

    1j-1 charging system: charging system schematic and routing diagram charging system diagram b705h11a02001 component location charging system components location b705h11a03001 refer to “electrical components location in section 0a (page0a-7)”. Lgnition switch main fuse battery load regulator/rectifie...

  • Page 269

    Charging system: 1j-2 diagnostic information and procedures charging system symptom diagnosis b705h11a04009 condition possible cause correction / reference item generator does not charge open- or short-circuited lead wires, or loose lead connections. Repair or replace or retighten. Short-circuited, ...

  • Page 270

    1j-3 charging system: battery runs down quickly b705h11a04001 troubleshooting battery overcharges • faulty regulator/rectifier. • faulty battery. • poor contact of generator lead wire coupler. Step action yes no 1 1) check accessories which use excessive amounts of electricity. Are accessories being...

  • Page 271

    Charging system: 1j-4 repair instructions battery current leakage inspection b705h11a06001 inspect the battery current leakage in the following procedures: 1) turn the ignition switch to the off position. 2) remove the battery cover (1). 3) disconnect the (–) battery lead wire. 4) measure the curren...

  • Page 272

    1j-5 charging system: generator coil resistance inspection b705h11a06004 inspect the generator coil resistance in the following procedures: 1) disconnect the generator coupler (1). 2) measure the resistance between the three lead wires. If the resistance is out of specified value, replace the stator...

  • Page 273

    Charging system: 1j-6 3) measure the voltage between the terminals using the multi circuit tester as indicated in the following table. If the voltage is not within the specified value, replace the regulator/rectifier with a new one. Special tool : 09900–25008 (multi-circuit tester set) tester knob i...

  • Page 274

    1j-7 charging system: installation install the generator in the reverse order of removal. Pay attention to the following points: • install the oil seal (1) using the special tool. Special tool (a): 09913–75821 (bearing installer) caution ! • install the oil seal with the marked code toward outside. ...

  • Page 275

    Charging system: 1j-8 battery components b705h11a06011 battery initial charging b705h11a06007 filling electrolyte 1) remove the aluminum tape (1) which seals the battery filler holes (2). 2) remove the caps (3) from the electrolyte container. Note • do not remove or pierce the sealed areas (4) of th...

  • Page 276

    1j-9 charging system: 7) after the electrolyte container is completely empty, remove it from the battery and wait about 20 minutes. 8) insert the caps (3) firmly into the filler holes, so that the top of the caps do not protrude above the upper surface of the top cover of the battery. Caution ! • ne...

  • Page 277

    Charging system: 1j-10 battery recharging b705h11a06009 caution ! When recharging the battery, remove the battery from the motorcycle. Note while recharging, do not remove the caps on the top of the battery. 1) measure the battery voltage using the multi circuit tester. 2) if the voltage reading is ...

  • Page 278

    1j-11 charging system: specifications service data b705h11a07003 electrical unit: mm (in) tightening torque specifications b705h11a07004 reference: for the tightening torque of fastener not specified in this section, refer to “tightening torque specifications in section 0c (page0c-7)”. Special tools...

  • Page 279: Exhaust System

    Exhaust system: 1k-1 exhaust system precautions precautions for exhaust system b705h11b00001 warning ! • to avoid the danger of being burned, do not touch the exhaust system when the system is hot. Any service on the exhaust system should be performed when the system is cool. • make sure that the ex...

  • Page 280

    1k-2 exhaust system: exhaust pipe / muffler removal and installation b705h11b06002 removal 1) remove the ho2 sensor lead wire coupler (1). 2) loosen the exhaust pipe connecting bolt (2). 3) remove the muffler mounting bolts (3) and remove the muffler (4). 4) remove the ho2 sensor (5). 5) remove the ...

  • Page 281

    Exhaust system: 1k-3 installation install the exhaust pipe/muffler in the reverse order of removal. Pay attention to the following points: caution ! Replace the exhaust pipe gasket (1) and exhaust pipe connector (2) with the new ones. • install the exhaust pipe gasket (1) and exhaust pipe connector ...

  • Page 282

    1k-4 exhaust system: exhaust system inspection b705h11b06005 inspect the exhaust pipe connection and muffler connection for exhaust gas leakage and mounting condition. If any defect is found, replace the exhaust pipe or muffler with a new one. Check the exhaust pipe bolts, exhaust pipe connecting bo...

  • Page 283

    Exhaust system: 1k-5 specifications tightening torque specifications b705h11b07001 note the specified tightening torque is also described in the following. “exhaust system components (page1k-1)” reference: for the tightening torque of fastener not specified in this section, refer to “tightening torq...

  • Page 284

    1k-6 exhaust system:.

  • Page 285: Section 2

    Table of contents 2- i 2 section 2 contents suspension precautions .................................................2-1 precautions............................................................. 2-1 precautions for suspension .................................. 2-1 suspension general diagnosis............

  • Page 286: Precautions

    2-1 precautions: precautions precautions precautions for suspension b705h12000001 refer to “general precautions in section 00 (page00-1)”. Warning ! All suspensions, bolts and nuts are an important part in that it could affect the performance of vital parts. They must be tightened to the specified t...

  • Page 287: Suspension General Diagnosis

    Suspension general diagnosis: 2a-1 suspension general diagnosis diagnostic information and procedures suspension and wheel symptom diagnosis b705h12104001 condition possible cause correction / reference item wobbly front wheel distorted wheel rim. Replace. Worn front wheel bearings. Replace. Defecti...

  • Page 288: Front Suspension

    2b-1 front suspension: front suspension repair instructions front fork components b705h12206001 fwd fw d (a) 1 2 3 4 9 7 6 5 16 15 13 12 11 17 (b) 18 19 10 14 8 i705h1220035-06 1. Front fork top cap 7. Rebound spring 13. Oil seal retainer 19. Front axle pinch bolt 2. O-ring 8. Inner tube 14. Guide m...

  • Page 289

    Front suspension: 2b-2 front fork removal and installation b705h12206007 removal 1) remove the front leg shield. Refer to “front leg shield removal and installation in section 9d (page9d-14)”. 2) remove the front wheel assembly. Refer to “front wheel assembly removal and installation in section 2d (...

  • Page 290

    2b-3 front suspension: 3) install the washer and temporarily tighten the front fork cap bolt and tighten the front fork clamp bolts (1) to the specified torque. Tightening torque front fork clamp bolt (a): 23 n·m (2.3 kgf-m, 16.5 lb-ft) 4) tighten the front fork cap bolt (2) to the specified torque ...

  • Page 291

    Front suspension: 2b-4 2) invert the fork and stroke it several times to drain out fork oil. 3) hold the fork inverted for a few minutes to drain oil. 4) remove the cylinder bolt (2) using the special tools. Special tool (a): 09940–34520 (t handle) (b): 09940–34531 (attachment a) 5) remove the cylin...

  • Page 292

    2b-5 front suspension: 9) remove the spring (13) from the oil lock piece (14). Assembly assemble the front fork in the reverse order of disassembly. Pay attention to the following points: caution ! • thoroughly wash all the component parts being assembled. Insufficient washing can result in oil leak...

  • Page 293

    Front suspension: 2b-6 • install the oil lock piece into the inner tube. • install the inner tube into the outer tube with care not to drop the oil lock piece out. Note after installing the inner tube into the outer tube, keep the oil lock piece into the inner tube by compressing the front fork full...

  • Page 294

    2b-7 front suspension: • apply thread lock to the cylinder bolt and tighten it to the specified torque using the special tools. Caution ! Use a new cylinder bolt gasket to prevent oil leakage. Note check the front fork for smoothness by stroking it after installing the cylinder. : thread lock cement...

  • Page 295

    Front suspension: 2b-8 • hold the front fork vertically and adjust the fork oil level using the special tool. Note when adjusting the fork oil level, remove the fork spring and compress the inner tube fully. Special tool (a): 09943–74111 (fork oil level gauge) fork oil level “a” 87 mm (3.43 in) fron...

  • Page 296

    2b-9 front suspension: specifications service data b705h12207002 suspension unit: mm (in) tightening torque specifications b705h12207003 note the specified tightening torque is also described in the following. “front fork components (page2b-1)” reference: for the tightening torque of fastener not sp...

  • Page 297

    Front suspension: 2b-10 special tools and equipment recommended service material b705h12208001 note required service material is also described in the following. “front fork components (page2b-1)” special tool b705h12208002 material suzuki recommended product or specification note fork oil fork oil ...

  • Page 298: Rear Suspension

    2c-1 rear suspension: rear suspension repair instructions rear suspension components b705h12306012 fwd fw d 13 10 12 (e) 14 (d) 11 5 6 7 8 7 3 (b) 4 2 (a) 1 6 (c) 9 i705h1230034-01 1. Rear shock absorber bolt 8. Cushion lever : 50 n ⋅m (5.0 kgf-m, 36.0 lb-ft) 2. Rear shock absorber 9. Cushion lever ...

  • Page 299

    Rear suspension: 2c-2 rear suspension assembly construction b705h12306013 “ a ” “ a ” “ a ” “ a ” “ a ” “ a ” (a) 1 (a) 2 (a) 4 (a) 5 (b) 3 2 1 3 5 4 “a” fwd i705h1230041-04 1. Rear shock absorber mounting bolt 5. Cushion rod mounting nut : 80 n ⋅m (8.0 kgf-m, 58.0 lb-ft) 2. Cushion lever nut “a”: a...

  • Page 300

    2c-3 rear suspension: rear swingarm components b705h12306027 1 (a) 2 3 4 5 fwd fw d i705h1230035-01 1. Rear swingarm 3. Dust seal 5. Dust seal : do not reuse. 2. Rear swingarm mounting bolt 4. Bearing : 50 n ⋅m (5.0 kgf-m, 36.0 lb-ft).

  • Page 301

    Rear suspension: 2c-4 rear shock absorber and rear shock absorber assembly removal and installation b705h12306014 removal 1) place the motorcycle on the center stand and support the motorcycle with a jack to be no load for the rear shock absorber. 2) remove the right and left footboards. Refer to “f...

  • Page 302

    2c-5 rear suspension: rear suspension inspection b705h12306015 refer to “rear suspension inspection in section 0b (page0b-16)”. Rear shock absorber inspection b705h12306016 inspect the rear shock absorber in the following procedures: 1) remove the rear shock absorber. Refer to “rear shock absorber a...

  • Page 303

    Rear suspension: 2c-6 warning ! • be sure to wear protective glasses since drilling chips and oil may fly off with blowing gas when the drill bit has penetrated through the body. • make sure to drill at the specified position. Otherwise, pressurized oil many spout out forcefully. Rear suspension adj...

  • Page 304

    2c-7 rear suspension: installation install the rear swingarm in the reverse order of removal. Pay attention to the following points: • install the collar to swingarm. Caution ! When installing the swingarm to the frame, pay attention to the difference of the collar. • after install the rear swingarm...

  • Page 305

    Rear suspension: 2c-8 bearing inspect the play of the bearings by finger while they are in the rear swingarm. Rotate the inner race by finger to inspect for abnormal noise and smooth rotation. Replace the bearing in the following procedures if there is anything unusual. Refer to “rear swingarm dust ...

  • Page 306

    2c-9 rear suspension: installation install the dust seal and bearing in the reverse order of removal. Pay attention to the following points: caution ! The removed dust seal and bearings must be replaced with the new ones. • apply grease to the bearing. : grease 99000–25010 (suzuki super grease a or ...

  • Page 307

    Rear suspension: 2c-10 spacer 1) remove the spacers from the cushion lever. 2) inspect the spacers for any flaws or other damage. If any defects are found, replace the spacers with the new ones. Cushion lever bearing 1) insert the spacers into bearings. 2) check the play by moving the spacers up and...

  • Page 308

    2c-11 rear suspension: installation install the cushion lever bearing in the reverse order of removal. Pay attention to the following points: caution ! The removed bearings must be replaced with the new ones. • press the bearings into the cushion lever using the special tool. Note when installing th...

  • Page 309

    Rear suspension: 2c-12 crankcase bracket removal and installation b705h12306021 removal 1) remove the engine. Refer to “engine assembly removal and installation in section 1d (page1d-6)”. 2) remove the crankcase bracket nut (1) and rubber damper bolts (2) (l & r). 3) remove the rubber dampers (3) (l...

  • Page 310

    2c-13 rear suspension: bearing 1) insert the spacers into the bearings. 2) check the play by moving the spacers up and down. If excessive play is noted, replace the bearing with a new one. Refer to “crankcase bracket bearing removal and installation (page2c-13)”. Rubber parts inspect the rubber damp...

  • Page 311

    Rear suspension: 2c-14 specifications service data b705h12307002 suspension unit: mm (in) tightening torque specifications b705h12307003 note the specified tightening torque is also described in the following. “rear suspension components (page2c-1)” “rear suspension assembly construction (page2c-2)”...

  • Page 312

    2c-15 rear suspension: special tools and equipment recommended service material b705h12308001 note required service material is also described in the following. “rear suspension assembly construction (page2c-2)” “crankcase bracket construction (page2c-11)” special tool b705h12308002 material suzuki ...

  • Page 313: Wheels and Tires

    Wheels and tires: 2d-1 wheels and tires precautions precautions for wheel and tire b705h12400001 warning ! • proper tire pressure and proper tire loading are important factors. Over loading tire can lead to tire failure and loss of motorcycle control. • under-inflated tires make smooth cornering dif...

  • Page 314

    2d-2 wheels and tires: repair instructions front wheel components b705h12406003 fwd fw d (a) 5 (b) 8 3 4 1 10 (b) 8 4 9 11 2 3 6 7 7 i705h1240028-05 1. Front wheel 7. Brake disc : 23 n ⋅m (2.3 kgf-m, 16.5 lb-ft) 2. Spacer 8. Brake disc bolt : apply grease. 3. Bearing 9. Tire : apply thread lock to t...

  • Page 315

    Wheels and tires: 2d-3 front wheel assembly construction b705h12406019 (b) 2 (c) 3 (b) 2 (a) 1 (c) 3 “ a ” left right i705h1240030-02 1. Front axle “a”: clearance : 23 n ⋅m (2.3 kgf-m, 16.5 lb-ft) 2. Front brake caliper mounting bolt : 65 n ⋅m (6.5 kgf-m, 47.0 lb-ft) : apply grease. 3. Front brake d...

  • Page 316

    2d-4 wheels and tires: front wheel assembly removal and installation b705h12406020 removal 1) support the motorcycle with a jack or a wooden block. 2) remove the brake calipers. Refer to “front brake caliper removal and installation in section 4b (page4b-3)”. Caution ! Do not operate the brake lever...

  • Page 317

    Wheels and tires: 2d-5 3) tighten the front axle (2) to the specified torque using the special tool. Special tool (a): 09900–18710 (hexagon socket (12 mm)) tightening torque front axle (a): 65 n·m (6.5 kgf-m, 47.0 lb-ft) 4) tighten the brake caliper mounting bolts (3) to the specified torque. Tighte...

  • Page 318

    2d-6 wheels and tires: axle shaft using a dial gauge, check the axle shaft for runout. If the runout exceeds the limit, replace the axle shaft. Special tool (a): 09900–20607 (dial gauge (1/100 mm, 10 mm)) (b): 09900–20701 (magnetic stand) (c): 09900–21304 (v-block (100 mm)) axle shaft runout service...

  • Page 319

    Wheels and tires: 2d-7 3) remove the bearings (2) using the special tool. Special tool (b): 09921–20240 (bearing remover set) 4) remove the spacer (3). Installation caution ! The removed dust seals and bearings must be replaced with the new ones. 1) apply grease to the wheel bearings. : grease 99000...

  • Page 320

    2d-8 wheels and tires: 3) install the dust seals using the special tool. Special tool (b): 09913–70210 (bearing installer set) 4) apply grease to the lip of dust seals. : grease 99000–25010 (suzuki super grease a or equivalent) 5) install the front wheel assembly. Refer to “front wheel assembly remo...

  • Page 321

    Wheels and tires: 2d-9 rear wheel assembly removal and installation b705h12406025 refer to “exhaust pipe / muffler removal and installation in section 1k (page1k-2)”. Refer to “rear brake caliper removal and installation in section 4c (page4c-3)”. Removal 1) remove the helmet box front cover. Refer ...

  • Page 322

    2d-10 wheels and tires: installation refer to “rear wheel related parts inspection (page2d-11)” and “wheel/tire/air valve inspection and cleaning (page2d-13)” install the rear wheel in the reverse order of removal. Pay attention to the following points: • install the rear swingarm mounting bolts and...

  • Page 323

    Wheels and tires: 2d-11 rear wheel related parts inspection b705h12406026 refer to “rear wheel assembly removal and installation (page2d-9)”. Refer to “rear wheel components (page2d-8)”. Inspect the rear wheel related parts. Tire refer to “tire inspection in section 0b (page0b-15)”. Rear brake disc ...

  • Page 324

    2d-12 wheels and tires: note when removing the tire in case of repair or inspection, mark the tire with a chalk to indicate the tire position relative to the valve position. Even though the tire is refitted to the original position after repairing puncture, the tire may have to be balanced again sin...

  • Page 325

    Wheels and tires: 2d-13 7) when the bead has been fitted properly, adjust the pressure to specification. 8) as necessary, adjust the tire balance. Refer to “wheel balance check and adjustment (page2d- 14)”. Cold inflation tire pressure 9) install the wheel assembly. Refer to “front wheel assembly re...

  • Page 326

    2d-14 wheels and tires: inspect the valve core seal (1) for wear and damage. If any defect is found, replace the valve core with a new one. Refer to “air valve removal and installation (page2d-14)”. Air valve removal and installation b705h12406029 removal 1) remove the wheel assembly. Refer to “fron...

  • Page 327

    Wheels and tires: 2d-15 specifications service data b705h12407002 wheel unit: mm (in) tire tightening torque specifications b705h12407003 note the specified tightening torque is also described in the following. “front wheel components (page2d-2)” “front wheel assembly construction (page2d-3)” “rear ...

  • Page 328

    2d-16 wheels and tires: special tools and equipment recommended service material b705h12408001 note required service material is also described in the following. “front wheel components (page2d-2)” “front wheel assembly construction (page2d-3)” “rear wheel components (page2d-8)” special tool b705h12...

  • Page 329: Section 3

    Table of contents 3- i 3 section 3 contents driveline / axle precautions .................................................3-1 precautions............................................................. 3-1 precautions for driveline/axle............................... 3-1 drive chain / drive train / dri...

  • Page 330: Precautions

    3-1 precautions: precautions precautions precautions for driveline/axle b705h13000001 refer to “general precautions in section 00 (page00-1)”..

  • Page 331

    Drive chain / drive train / drive shaft: 3a-1 drive chain / drive train / drive shaft diagnostic information and procedures drive chain and sprocket symptom diagnosis b705h13104001 condition possible cause correction / reference item noisy drive chain (noise seems to come from final gear case) worn ...

  • Page 332

    3a-2 drive chain / drive train / drive shaft: repair instructions final gear components b705h13106001 2 1 3 5 6 7 8 8 9 11 10 12 13 14 15 16 16 17 18 18 4 18 (a) 19 (b) 20 (c) 21 (d) i705h1310001-05 1. Bearing retainer 11. Bearing 21. Oil drain bolt. 2. Bearing 12. Drive shaft : 23 n ⋅m (2.3 kgf-m, ...

  • Page 333

    Drive chain / drive train / drive shaft: 3a-3 final gear assembly removal and installation b705h13106002 removal 1) remove the drive v-belt. Refer to “drive v-belt removal and installation in section 0b (page0b- 11)”. 2) remove the oil level bolt (1). 3) remove the oil drain bolt (2) and drain oil. ...

  • Page 334

    3a-4 drive chain / drive train / drive shaft: • tighten the final gear cover bolt (1) to the specified torque. Caution ! Tighten the final gear cover bolts diagonally and evenly. Tightening torque final gear cover bolt (a): 22 n·m (2.2 kgf-m, 16.0 lb-ft) • tighten the oil drain plug (2) to the speci...

  • Page 335

    Drive chain / drive train / drive shaft: 3a-5 4) remove the bearing (7) using the special tool. Special tool (c): 09913–70210 (bearing installer set) 5) remove the magnet (8). Idle gear / idle shaft 1) remove the washers (1), snap ring (2) and idle gear (3). 2) remove the snap ring (4) and idle shaf...

  • Page 336

    3a-6 drive chain / drive train / drive shaft: final gear case 1) remove the bearing retainer (1). 2) remove the bearing (2) using the special tool. Special tool (a): 09913–75830 (bearing installer) 3) remove the oil seal (3) using the special tool. Special tool (b): 09913–50121 (oil seal remover) 4)...

  • Page 337

    Drive chain / drive train / drive shaft: 3a-7 • install the oil seal (3) and bearings (4) using the special tool. Caution ! • replace the o-ring with a new one. • replace the bearings with the new ones. • install the bearing so that its stamped mark faces outside. Special tool (a): 09913–70210 (bear...

  • Page 338

    3a-8 drive chain / drive train / drive shaft: • tighten the oil level bolt (5), oil filler bolt (6) and final gear cover bolts (7) to the specified torque. Caution ! • replace the gasket washer with a new one. • apply engine oil to each gear and bearing. • tighten the final gear cover bolts diagonal...

  • Page 339

    Drive chain / drive train / drive shaft: 3a-9 specifications tightening torque specifications b705h13107001 note the specified tightening torque is also described in the following. “final gear components (page3a-2)” reference: for the tightening torque of fastener not specified in this section, refe...

  • Page 340

    3a-10 drive chain / drive train / drive shaft:.

  • Page 341: Section 4

    Table of contents 4- i 4 section 4 contents brake precautions .................................................4-1 precautions............................................................. 4-1 precautions for brake system .............................. 4-1 brake fluid information........................

  • Page 342

    4-ii table of contents parking brake system (brake-lock system) disassembly and assembly ..............................4d-7 parking brake cable (brake-lock cable) removal and installation...................................4d-7 specifications .......................................................4d-...

  • Page 343: Precautions

    Precautions: 4-1 precautions precautions precautions for brake system b705h14000001 refer to “general precautions in section 00 (page00-1)”. Brake fluid information b705h14000002 warning ! • this brake system is filled with an ethylene glycol-based dot 4 brake fluid. Do not use or mix different type...

  • Page 344

    4a-1 brake control system and diagnosis: brake control system and diagnosis schematic and routing diagram front brake hose routing diagram b705h14102003 2 2 2 1 1 3 5 5 4 “a” “a” “b” “c” “ a ” “ a ” “ b ” “b” “b” “d” “e” i705h1410028-02 1. Rear brake hose “b”: after touching the clamp to the stopper...

  • Page 345

    Brake control system and diagnosis: 4a-2 rear brake hose routing diagram b705h14102004 1 1 4 2 3 “b” “a” 1 “a” 1 2 5 1 “b” “c” “ a ” “d” “ b ” i705h1410029-03 1. Rear brake pipe “b”: after positioning the clamp with the stopper on the swingarm, tighten the clamp bolt. 2. Rear brake hose “c”: after t...

  • Page 346

    4a-3 brake control system and diagnosis: diagnostic information and procedures brake symptom diagnosis b705h14104001 repair instructions brake light switch inspection b705h14106008 front brake light switch inspect the front brake light switch in the following procedures: 1) remove the handlebar cove...

  • Page 347

    Brake control system and diagnosis: 4a-4 rear brake light switch inspect the rear brake light switch in the same manner as the front brake light switch. Refer to “brake light switch inspection (page4a-3)”. Rear brake light switch brake fluid level check b705h14106017 refer to “brake system inspectio...

  • Page 348

    4a-5 brake control system and diagnosis: 7) close the air bleeder valve and disconnect the hose. 8) fill the reservoir with brake fluid to the top of the inspection window. Tightening torque air bleeder valve (front brake): 6.0 n·m (0.6 kgf- m, 4.5 lb-ft) 9) install the reservoir cap. Rear brake ble...

  • Page 349

    Brake control system and diagnosis: 4a-6 7) close the air bleeder valve (1) and disconnect the clear hose. Tightening torque air bleeder valve (front brake) (a): 6.0 n·m (0.6 kgf-m, 4.5 lb-ft) 8) fill the reservoir with new brake fluid to the upper line of the reservoir. Rear brake brake fluid repla...

  • Page 350

    4a-7 brake control system and diagnosis: front brake master cylinder components b705h14106023 (a) 2 1 3 5 4 (b) 6 fwd fw d i705h1410026-06 1. Reservoir cap 4. Master cylinder : 10 n ⋅m (1.0 kgf-m, 7.0 lb-ft) : do not reuse. 2. Plate 5. Piston/cup set : 23 n ⋅m (2.3 kgf-m, 16.5 lb-ft) 3. Diaphragm 6....

  • Page 351

    Brake control system and diagnosis: 4a-8 front brake master cylinder assembly removal and installation b705h14106002 removal 1) remove the handlebar cover. Refer to “handlebar cover removal and installation in section 9d (page9d-13)”. 2) remove the rear view mirror. 3) drain the brake fluid. Refer t...

  • Page 352

    4a-9 brake control system and diagnosis: • after setting the brake hose union to the stopper, tighten the union bolt to the specified torque. Caution ! The seal washers should be replaced with the new ones to prevent fluid leakage. Tightening torque brake hose union bolt (b): 23 n·m (2.3 kgf-m, 16.5...

  • Page 353

    Brake control system and diagnosis: 4a-10 assembly assemble the master cylinder in the reverse order of disassembly. Pay attention to the following points: caution ! • wash the master cylinder components with new brake fluid before reassembly. • do not wipe the brake fluid off after washing the comp...

  • Page 354

    4a-11 brake control system and diagnosis: rear brake master cylinder components b705h14106026 (a) 2 1 3 4 5 (b) 6 fwd fw d i705h1410027-04 1. Reservoir cap 4. Master cylinder : 10 n ⋅m (1.0 kgf-m, 7.0 lb-ft) : do not reuse. 2. Plate 5. Piston/cup set : 23 n ⋅m (2.3 kgf-m, 16.5 lb-ft) 3. Diaphragm 6....

  • Page 355

    Brake control system and diagnosis: 4a-12 rear brake master cylinder assembly removal and installation b705h14106027 refer to “front brake master cylinder assembly removal and installation (page4a-8)”. Removal remove the rear brake master cylinder in the same manner as the front brake master cylinde...

  • Page 356

    4a-13 brake control system and diagnosis: specifications service data b705h14107002 brake + wheel unit: mm (in) tightening torque specifications b705h14107003 note the specified tightening torque is also described in the following. “front brake master cylinder components (page4a-7)” “rear brake mast...

  • Page 357

    Brake control system and diagnosis: 4a-14 special tools and equipment recommended service material b705h14108001 note required service material is also described in the following. “front brake master cylinder components (page4a-7)” “rear brake master cylinder components (page4a-11)” special tool b70...

  • Page 358: Front Brakes

    4b-1 front brakes: front brakes repair instructions front brake components b705h14206011 (a) 1 (b) 2 (c) 8 3 4 5 6 7 9 10 (d) (e) 11 12 fwd fw d i705h1420026-02 1. Air bleeder valve 8. Pin bolt : 18 n ⋅m (1.8 kgf-m, 13.0 lb-ft) 2. Pad mounting pin 9. Washer : 35 n ⋅m (3.5 kgf-m, 25.5 lb-ft) 3. Brake...

  • Page 359

    Front brakes: 4b-2 front brake pad inspection b705h14206004 the extent of brake pad wear can be checked by observing the grooved limit line “a” on the pad. When the wear exceeds the grooved limit line, replace the pads with the new ones. Refer to “front brake pad replacement (page4b-2)”. Caution ! R...

  • Page 360

    4b-3 front brakes: 9) install the front brake pads. 10) install the front brake pad mounting pins temporarily. 11) install the front brake caliper. 12) tighten the front brake caliper mounting bolts (1) to the specified torque. Tightening torque front brake caliper mounting bolt (a): 35 n·m ( 3.5 kg...

  • Page 361

    Front brakes: 4b-4 • after setting the brake hose union to the stopper, tighten the union bolt to the specified torque. Caution ! The seal washers should be replaced with the new ones to prevent fluid leakage. Tightening torque front brake hose union bolt (c): 23 n·m (2.3 kgf- m, 16.5 lb-ft) • bleed...

  • Page 362

    4b-5 front brakes: 6) remove the pin bolt from the front brake caliper bracket. Assembly assemble the front brake caliper in the reverse order of disassembly. Pay attention to the following points: • wash the caliper bores and pistons with specified brake fluid. Particularly wash the dust seal groov...

  • Page 363

    Front brakes: 4b-6 brake caliper piston inspect the brake caliper piston surface for any scratches or other damage. If any damage is found, replace the piston with a new one. Front brake disc removal and installation b705h14206015 removal 1) remove the front wheel assembly. Refer to “front wheel ass...

  • Page 364

    4b-7 front brakes: brake disc runout 1) remove the front brake caliper. Refer to “front brake caliper removal and installation (page4b-3)”. 2) measure the runout using the dial gauge. Replace the disc if the runout exceeds the service limit. Special tool (a): 09900–20607 (dial gauge (1/100 mm, 10 mm...

  • Page 365

    Front brakes: 4b-8 special tools and equipment recommended service material b705h14208001 note required service material is also described in the following. “front brake components (page4b-1)” special tool b705h14208002 material suzuki recommended product or specification note brake fluid dot 4 — ) ...

  • Page 366: Rear Brakes

    4c-1 rear brakes: rear brakes repair instructions rear brake components b705h14306011 (d) 21 22 23 18 17 19 20 14 15 16 (c) 13 9 12 (b) 11 10 11 7 5 4 3 2 1 (a) 6 8 9 fwd fw d i705h1430001-02 1. Lock-nut 12. Bracket 23. Brake pad 2. Arm 13. Pad mounting pin : 22 n ⋅m (2.2 kgf-m, 16.0 lb-ft) 3. Adjus...

  • Page 367

    Rear brakes: 4c-2 rear brake pad inspection b705h14306004 the extent of brake pad wear can be checked by observing the grooved limit line “a” on the pad. When the wear exceeds the grooved limit line, replace the pads with the new ones. Refer to “rear brake pad replacement (page4c-2)”. Caution ! Repl...

  • Page 368

    4c-3 rear brakes: 5) assemble the new pads (4), shims (5) and back plates (6). Caution ! Replace the brake pad as a set, otherwise braking performance will be adversely affected. 6) locate the projection “a” of the brake pad to the center of caliper piston groove. Note make sure that the projection ...

  • Page 369

    Rear brakes: 4c-4 installation install the brake caliper in the reverse order of removal. Pay attention to the following points: caution ! The seal washers should be replaced with the new ones to prevent fluid leakage. • tighten the caliper mounting bolts (1) to the specified torque. Tightening torq...

  • Page 370

    4c-5 rear brakes: 3) remove the piston (back side) with turning counterclockwise. 4) remove the dust seals (3) and piston seals (4) from the cylinder. Caution ! • use care not to cause scratch on the cylinder bore. • do not reuse the piston seal and dust seal that have been removed. 5) remove the br...

  • Page 371

    Rear brakes: 4c-6 • apply silicone grease to the brake-lock shaft (3) and o-ring (4). : grease 99000–25100 (suzuki silicone grease or equivalent) caution ! Replace the o-ring with a new one. • install the brake-lock shaft (5) so as the punch mark “a” may position between “b” of housing when tighteni...

  • Page 372

    4c-7 rear brakes: • apply the brake fluid to piston seal (6) and dust seal (7). Caution ! Replace the piston seal (6) and dust seal (7) with the new ones. Bf: brake fluid (dot 4) • install the piston seals as shown in the figure. • set back the rear caliper piston (8) (back side) into the caliper wi...

  • Page 373

    Rear brakes: 4c-8 assembly assemble the brake caliper piston (bottom side) in the reverse order of disassembly. Pay attention to the following point: • when assembling, position the adjust nut so as to fit to the seat inside the piston. Caution ! When installing the snap ring, use the utmost care no...

  • Page 374

    4c-9 rear brakes: rear brake disc removal and installation b705h14306001 removal 1) remove the rear wheel. Refer to “rear wheel assembly removal and installation in section 2d (page2d-9)”. 2) remove the rear brake disc. Installation refer to “rear brake disc inspection (page4c-9)”. Install the rear ...

  • Page 375

    Rear brakes: 4c-10 specifications tightening torque specifications b705h14307001 note the specified tightening torque is also described in the following. “rear brake components (page4c-1)” reference: for the tightening torque of fastener not specified in this section, refer to “tightening torque spe...

  • Page 376: Parking Brake

    4d-1 parking brake: parking brake general description parking brake system (brake-lock system) description b705h14401001 parking brake (brake-lock) operation the brake-lock arm turns through the brake-lock cable as soon as pulling the brake-lock lever. The turning movement is converted to axial move...

  • Page 377

    Parking brake: 4d-2 5 4 6 8 9 “a” 7 10 11 “b” i705h1440011-04 4. Brake pad 9. Sleeve piston 5. Caliper piston 10. Brake-lock adjuster 6. Adjust nut 11. Brake-lock arm 7. Adjust bolt “a”: thread 8. Adjust bolt spring “b”: the adjust bolt presses the adjust nut..

  • Page 378

    4d-3 parking brake: automatic parking brake adjuster system (automatic brake-lock adjuster system) the automatic brake-lock adjuster system is equipped on the brake-lock. If the brake pad worn, the adjust-bolt/nut adjust the position of caliper piston so as to keep the certain clearance between brak...

  • Page 379

    Parking brake: 4d-4 operation (brake pads are worn → braking → automatic adjuster operate) if braking when the brake pad being worn, the caliper piston/adjust nut move “a” until the clearance depended on abrasion is done away. The axial movement “b” is converted to rotary movement and acts on the ad...

  • Page 380

    4d-5 parking brake: over-adjust prevention mechanism when rapid braking “a”, the automatic brake-lock adjuster operation works too fast “b”. The caliper piston/adjust nut is forced to stop “c” as soon as the brake pad contacts with brake disk, but the adjust bolt turns by inertia force “d” after tha...

  • Page 381

    Parking brake: 4d-6 the spring is equipped between the caliper piston and the adjust-nut for preventing the over-adjust, serves damper in term of rapid caliper piston movement. The spring compress “a” as soon as the caliper piston moves exponentially “b”, the adjust-nut moves “c”, “d” behind time. H...

  • Page 382

    4d-7 parking brake: repair instructions parking brake system (brake-lock system) inspection b705h14406001 refer to “parking brake (brake-lock) inspection in section 0b (page0b-20)”. Parking brake system (brake-lock system) removal and installation b705h14406002 refer to “rear brake caliper removal a...

  • Page 383

    Parking brake: 4d-8 3) pull the brake-lock lever (4) one notch. 4) tighten the brake-lock cable adjust bolt (5) by hand until it contacts the holder (6). 5) tighten the brake-lock cable lock-nut (7) to the specified torque. Tightening torque brake-lock cable lock-nut (a): 10 n·m (1.0 kgf- m, 7.0 lb-...

  • Page 384

    4d-9 parking brake:.

  • Page 385: Section 5

    Table of contents 5- i 5 section 5 contents tranmission / transaxle precautions .................................................5-1 precautions............................................................. 5-1 precautions for transmission/transaxle............... 5-1 automatic transmission.............

  • Page 386: Precautions

    5-1 precautions: precautions precautions precautions for transmission/transaxle b705h15000001 refer to “general precautions in section 00 (page00-1)”..

  • Page 387: Automatic Transmission

    Automatic transmission: 5a-1 automatic transmission schematic and routing diagram drive train system b705h15102001 2 3 5 6 7 8 9 11 12 10 4 1 “a” i705h1510001-07 1. Crankshaft 6. Fixed driven face 11. Final gear 2. Movable drive face 7. Driveshaft 12. Rear axle shaft 3. Fixed drive face 8. Clutch sh...

  • Page 388

    5a-2 automatic transmission: diagnostic information and procedures automatic transmission symptom diagnosis b705h15104001 repair instructions outer clutch cover cushion construction b705h15106012 condition possible cause correction / reference item excessive engine noise gear worn or abnormal contac...

  • Page 389

    Automatic transmission: 5a-3 clutch in / stall speed inspection b705h15106001 refer to “automatic clutch inspection in section 0b (page0b-19)”. V-belt type continuously variable automatic transmission removal and installation b705h15106002 removal clutch cover 1) remove the side leg shield. Refer to...

  • Page 390

    5a-4 automatic transmission: clutch and movable driven face 1) hold the clutch housing using the special tool and remove the clutch housing nut (1) and remove the clutch housing (2). Special tool (a): 09930–40113 (rotor holder) 2) remove the clutch shoe and movable driven face assembly (3). Installa...

  • Page 391

    Automatic transmission: 5a-5 3) apply grease to the o-ring. : grease 99000–25010 (suzuki super grease a or equivalent) 4) hold the clutch housing using the special tool and tighten the clutch housing nut (1) to the specified torque. Caution ! • degrees the clutch housing surface. • replace the o-rin...

  • Page 392

    5a-6 automatic transmission: 5) continue to turn the fixed drive face until it moves simultaneously with the movable driven face in order to have the v-belt broken in. Drive v-belt inspection b705h15106003 perform the inspection in the following procedures: 1) remove the drive v-belt. Refer to “v-be...

  • Page 393

    Automatic transmission: 5a-7 inner clutch cover bearing inspection b705h15106013 inspect the play of the inner clutch cover bearings by finger while they are in the inner clutch cover. Rotate the inner race by finger to inspect for abnormal noise and smooth rotation. Replace the bearing in the follo...

  • Page 394

    5a-8 automatic transmission: movable drive face component b705h15106005 movable drive face disassembly and assembly b705h15106006 refer to “v-belt type continuously variable automatic transmission removal and installation (page5a-3)” and “movable drive face component (page5a-8)”. Disassembly 1) remo...

  • Page 395

    Automatic transmission: 5a-9 assembly refer to “movable drive face parts inspection (page5a- 9)”. 1) assemble the rollers (1) to the movable drive face (2). Note check that the roller inside the movable drive face is not running off the groove. 2) assemble the damper (3) to the movable drive plate (...

  • Page 396

    5a-10 automatic transmission: roller inspection inspect the roller for abnormal wear or other damage. If any defects are found, replace the roller with a new one. Oil seal inspect the oil seal for wear or other damage. If any defects are found, replace the oil seal with a new one. Oil seal removal a...

  • Page 397

    Automatic transmission: 5a-11 clutch shoe / movable driven face components b705h15106011 fwd fw d 10 (b) 16 (a) 14 15 13 12 11 9 8 7 6 5 4 3 2 1 17 i705h1510063-05 1. Needle bearing 8. Movable driven face 15. Clutch housing 2. Snap ring 9. Oil seal 16. Clutch housing nut 3. Bearing 10. O-ring 17. In...

  • Page 398

    5a-12 automatic transmission: clutch shoe / movable driven face disassembly and assembly b705h15106009 refer to “v-belt type continuously variable automatic transmission removal and installation (page5a-3)” and “movable drive face component (page5a-8)”. Disassembly 1) engage the “a” of the special t...

  • Page 399

    Automatic transmission: 5a-13 8) remove the o-ring (8) and oil seal (9). 9) remove the oil seal (10). 10) remove the needle bearing (11) using the special tool. Special tool (c): 09921–20240 (bearing remover set) 11) remove the snap ring. 12) remove the bearing using the special tool. Special tool (...

  • Page 400

    5a-14 automatic transmission: 3) install needle bearing (3) using a spacer, the size being appropriate for the outside diameter of the bearing. Caution ! • use a new bearing. • the stamp mark on the needle bearing should face outside when installed. 4) apply the grease both to the bearing and needle...

  • Page 401

    Automatic transmission: 5a-15 9) install the movable driven pin (7) to the pin hole with the grease lightly coated. : grease 99000–25010 (suzuki super grease a or equivalent) 10) check that the movable driven face can move smoothly. 11) install the movable driven face seat (8). 12) install the sprin...

  • Page 402

    5a-16 automatic transmission: clutch shoe and movable driven face parts inspection b705h15106010 refer to “clutch shoe / movable driven face disassembly and assembly (page5a-12)”. Inspect the following parts. Clutch housing inspection check for the following items and if any defects are found, repla...

  • Page 403

    Automatic transmission: 5a-17 driven face inspection inspect the driven face surface for stepped wear. If any defects are found, replace if with a new one. Movable driven pin inspection inspect the movable driven pin for abnormal wear or damage. If any defects are noted, replace the pin with a new o...

  • Page 404

    5a-18 automatic transmission: special tools and equipment recommended service material b705h15108001 note required service material is also described in the following. “movable drive face component (page5a-8)” “clutch shoe / movable driven face components (page5a-11)” special tool b705h15108002 mate...

  • Page 405: Section 6

    Table of contents 6- i 6 section 6 contents steering precautions .................................................6-1 precautions............................................................. 6-1 precautions for steering ....................................... 6-1 steering general diagnosis.............

  • Page 406: Precautions

    6-1 precautions: precautions precautions precautions for steering b705h16000001 refer to “general precautions in section 00 (page00-1)”..

  • Page 407: Steering General Diagnosis

    Steering general diagnosis: 6a-1 steering general diagnosis diagnostic information and procedures steering symptom diagnosis b705h16104001 condition possible cause correction / reference item heavy steering over tightened steering stem nut. Adjust. Broken bearing in steering stem. Replace. Distorted...

  • Page 408: Steering / Handlebar

    6b-1 steering / handlebar: steering / handlebar repair instructions handlebars components b705h16206008 2 2 1 3 5 5 1 6 7 8 9 10 4 “a” (a) (b) (b) fwd fw d fwd fw d i705h1620033-05 1. Throttle grip 6. Handle cover “a”: apply handle grip bond. 2. Rubber grip 7. Handlebar holder : apply thread lock to...

  • Page 409

    Steering / handlebar: 6b-2 handlebars removal and installation b705h16206016 removal remove the handlebar cover. Refer to “handlebar cover removal and installation in section 9d (page9d-13)”. Left side 1) remove the rear view mirror (1). 2) disconnect the rear brake light switch lead wire couplers (...

  • Page 410

    6b-3 steering / handlebar: installation install the handlebars in the reverse order of removal. Pay attention to the following points: • set the handlebars so that its punch mark “a” aligns with the mating surface of the left handlebar holder. • apply thread lock to the handlebar clamp bolts. • tigh...

  • Page 411

    Steering / handlebar: 6b-4 left side • install the left handlebar switch box (1) to the handlebars by engaging the stopper “a” with the hole “b” on the handlebars. • install the brake master cylinder onto the handlebars, align the master cylinder holder’s mating surface with punch mark “c” on the ha...

  • Page 412

    6b-5 steering / handlebar: steering components b705h16206010 1 6 9 10 (a) 2 (b) 3 (c) 4 (d) 5 7 8 fwd fw d 11 11 i705h1620035-06 1. Handlebar holder 7. Upper bearing : 55 n ⋅m (5.5 kgf-m, 40.0 lb-ft) 2. Handlebar holder set bolt 8. Lower bearing : 30 n ⋅m (3.0 kgf-m, 21.5 lb-ft) 3. Handlebar holder ...

  • Page 413

    Steering / handlebar: 6b-6 steering removal and installation b705h16206011 removal 1) support the motorcycle with a jack or wooden block. 2) remove the front box. Refer to “front box removal and installation in section 9d (page9d-18)”. 3) remove the front forks. Refer to “front fork removal and inst...

  • Page 414

    6b-7 steering / handlebar: 10) remove the lock-nut (8) and washer (9) using the special tools. Special tool (a): 09940–14911 (steering stem nut wrench) (b): 09940–11420 (steering stem nut socket) 11) remove the steering stem nut (10) using the special tools and remove the steering stem. Note hold th...

  • Page 415

    Steering / handlebar: 6b-8 note this adjustment will vary from motorcycle to motorcycle. • install the washer with its tab “a” engaged with the steering stem groove. • tighten the lock-nut (2) to the specified torque using the special tools. Note tightening the lock-nut can affect the steering stem ...

  • Page 416

    6b-9 steering / handlebar: • install the front brake hose clamp (4). Caution ! Take care not to make air come in to the front brake system. • perform the steering inspection after assembly has been completed. Steering related parts inspection b705h16206012 refer to “steering removal and installation...

  • Page 417

    Steering / handlebar: 6b-10 installation install the steering stem bearings in the reverse order of removal. Pay attention to the following points: caution ! The removed bearings and races should be replaced with the new ones. Outer race • press in the upper and lower outer races using the special t...

  • Page 418

    6b-11 steering / handlebar: 4) do the same on the other grip end. 5) if the initial force read on the scale when the handlebar starts turning is either to heavy or too light, adjust it till it satisfies the specification. A) first, loosen the front fork clamp bolts, lock-nut and steering stem nut, a...

  • Page 419

    Steering / handlebar: 6b-12 special tools and equipment recommended service material b705h16208001 note required service material is also described in the following. “handlebars components (page6b-1)” “steering components (page6b-5)” special tool b705h16208002 material suzuki recommended product or ...

  • Page 420

    6b-13 steering / handlebar:.

  • Page 421: Section 9

    Table of contents 9- i 9 section 9 contents body and accessories precautions .................................................9-1 precautions............................................................. 9-1 precautions for electrical system ......................... 9-1 component location .............

  • Page 422

    9-ii table of contents helmet box front cover removal and installation.......................................................9d-16 front frame cover removal and installation ...9d-17 seat removal and installation ..........................9d-17 center leg cover removal and installation .....9d-17 fr...

  • Page 423: Precautions

    Precautions: 9-1 precautions precautions precautions for electrical system b705h19000001 refer to “general precautions in section 00 (page00-1)” and “precautions for electrical circuit service in section 00 (page00-2)”. Component location electrical components location b705h19003001 refer to “electr...

  • Page 424: Wiring Systems

    9a-1 wiring systems: wiring systems schematic and routing diagram wiring diagram b705h19102002 refer to “wire color symbols in section 0a (page0a-5)”..

  • Page 425

    Wiring systems: 9a-2 e-02, 19, 24, 54 rear turn signal light(r) rear turn signal light(l) licence pla te light brake light / t aillight stv a stp sensor b a tter y st ar ter relal y st ar ter m oto r genera t o r ho2 sensor to sensor inject or ia t sensor diode regula to r/ rectifier main fuse (30 a...

  • Page 426

    9a-3 wiring systems: e-03, 28, 33 rear turn signal light(r) rear turn signal light(l) licence pla te light brake light/ t aillight stv a stp sensor b a tter y st ar ter relal y st ar ter m oto r genera t o r ho2 sensor to sensor inject or iap sensor diode regula tor/ rectifier main fuse (30 a) fuse ...

  • Page 427

    Wiring systems: 9a-4 wiring harness routing diagram b705h19102001 1 2 8 9 8 10 12 11 20 21 22 25 26 6 3 4 5 7 13 14 15 16 17 18 19 19 24 “e” “d” “c” “b” “a” i705h1910905-04 1. Clamp : clamp the handlebar switch lead wires (lh and rh), brake hoses (front and rear) and throttle cables. 12. Clamp : cla...

  • Page 428

    9a-5 wiring systems: 2 4 3 1 5 6 7 “b” “c” “d” “ a ” fwd “a” i705h1910906-06 1. Wiring harness 5. High tension code “b”: to iat sensor 2. Clamp : clamp the starter motor lead wire and wiring harness. 6. Ignition coil “c”: to main harness 3. Clamp : clamp the starter motor lead wire and brake-lock ca...

  • Page 429

    Wiring systems: 9a-6 4 1 2 (a) (b) (c) 3 (d) 45 6 (e) 5 i705h1910901-04 1. Ckp sensor 5. Outer clutch cover : 11 n ⋅m (1.1 kgf-m, 8.0 lb-ft) 2. Generator cover 6. Speed sensor : 160 n ⋅m (16.0 kgf-m, 111.5 lb-ft) 3. Battery (–) lead wire : tighten the rear side bolt first. : 3 n ⋅m (0.3 kgf-m, 2.0 l...

  • Page 430

    9a-7 wiring systems: 2 1 3 i705h1910904-01 1. Ambient air temperature sensor 3. Coupler : do not attempt to disconnect the coupler from the sensor. 2. Clamp.

  • Page 431

    Wiring systems: 9a-8 specifications service data b705h19107002 electrical unit: mm (in) tightening torque specifications b705h19107003 note the specified tightening torque is also described in the following. “wiring harness routing diagram (page9a-4)” reference: for the tightening torque of fastener...

  • Page 432: Lighting Systems

    9b-1 lighting systems: lighting systems repair instructions front combination light components b705h19206001 8 6 9 7 3 4 10 6 7 9 8 2 1 10 5 fwd fw d i705h1920011-03 1. Front combination light (rh) 5. Headlight high beam bulb 9. Socket 2. Front combination light (lh) 6. Position light bulb 10. Cover...

  • Page 433

    Lighting systems: 9b-2 front combination light removal and installation b705h19206014 removal 1) remove the front leg shield. Refer to “front leg shield removal and installation in section 9d (page9d-14)”. 2) remove the front combination light. Note to facilitate the work, remove the left front comb...

  • Page 434

    9b-3 lighting systems: 4) remove the left headlight bulb from the socket. 5) install the new left headlight bulb paying attention to the direction of the socket. 6) after finishing the headlight bulb replacement, reinstall the removed parts. Front turn signal light bulb refer to “front combination l...

  • Page 435

    Lighting systems: 9b-4 headlight beam adjustment b705h19206034 adjust the head light beam. Caution ! Do not bend the brake hose to frame head pipe side. Note • use a (+) screw driver for adjuster (1) and (2). • to adjust the headlight beam, adjust the beam horizontally first, then adjust vertically....

  • Page 436

    9b-5 lighting systems: rear reflector / rear combination light / license light removal and installation b705h19206017 rear reflector removal 1) remove the mat of the helmet box. 2) remove the reflector nuts (1) and reflector (2). Installation install the rear reflector in the reverse order of remova...

  • Page 437

    Lighting systems: 9b-6 rear combination light bulb / license light bulb replacement b705h19206018 refer to “rear reflector / rear combination light / license light components (page9b-4)”. Caution ! • a fouled glass can cause damage to the bulb when lit. If the bulb is contacted with bare a hand, wip...

  • Page 438

    9b-7 lighting systems: license light bulb replace the license light bulb in the following procedures: 1) remove the lens by turning it counter clockwise. 2) replace the license light bulb. 3) after finishing the license light bulb replacement, reinstall the removed parts. Turn signal / side-stand re...

  • Page 439

    Lighting systems: 9b-8 3) inspect the dimmer switch for continuity with the tester. If any abnormality is found, replace the left handlebar switch assembly with a new one. Refer to “handlebars removal and installation in section 6b (page6b-2)”. Special tool : 09900–25008 (multi-circuit tester set) t...

  • Page 440

    9b-9 lighting systems: horn button inspection b705h19206028 inspect the horn button switch in the following procedures: 1) remove the meter panel. Refer to “meter panel removal and installation in section 9d (page9d- 14)”. 2) disconnect the left handlebar switch coupler (1). 3) inspect the horn butt...

  • Page 441

    Lighting systems: 9b-10 engine stop switch inspection b705h19206025 inspect the engine stop switch in the following procedures: 1) remove the meter panel. Refer to “meter panel removal and installation in section 9d (page9d- 14)”. 2) disconnect the right handlebar switch coupler (1) and (2). 3) insp...

  • Page 442

    9b-11 lighting systems: ignition switch inspection b705h19206033 inspect the ignition switch in the following procedures: 1) remove the front leg shield. Refer to “front leg shield removal and installation in section 9d (page9d-14)”. 2) disconnect the ignition switch coupler (1). 3) inspect the igni...

  • Page 443

    Lighting systems: 9b-12 specifications service data b705h19207001 wattage unit: w special tools and equipment special tool b705h19208001 item standard / specification e-02, 19, 24, 54 e-03, 28, 33 headlight hi 60/55 ← lo 55 ← parking/position light 5 x 2 ← brake light/taillight 21/5 x 2 ← turn signa...

  • Page 444

    9c-1 combination meter / fuel meter / horn: combination meter / fuel meter / horn repair instructions combination meter components b705h19306001 combination meter removal and installation b705h19306014 removal 1) remove the meter panel. Refer to “meter panel removal and installation in section 9d (p...

  • Page 445

    Combination meter / fuel meter / horn: 9c-2 combination meter inspection b705h19306015 check that the illumination led on the meter panel lights up and the indicating needle each on fuel meter, speedometer, tachometer and coolant temperature sensor once moves to the maximum and then returns to the h...

  • Page 446

    9c-3 combination meter / fuel meter / horn: fuel level gauge inspection b705h19306017 refer to “fuel level gauge inspection in section 1g (page1g-13)”. Speedometer inspection b705h19306018 if the speedometer, odometer or trip meter does not function properly, inspect the speedometer sensor and conne...

  • Page 447

    Combination meter / fuel meter / horn: 9c-4 specifications service data b705h19307001 wattage unit: w item standard / specification e-02, 19, 24, 54 e-03, 28, 33 speedometer/tachometer light led ← engine coolant temp. Gauge light led ← fuel level gauge light led ← immobilizer indicator light led ← o...

  • Page 448: Exterior Parts

    9d-1 exterior parts: exterior parts schematic and routing diagram seat lock cable routing diagram b705h19402001 1 2 3 4 5 “a” “c” “b” “d” 5 4 inner upper 3 6 “e” “f” i705h1940050-04 1. Seat lock cable no. 1 “a”: pass the seat lock cable no. 2 through front of the seat lock cable no. 1. 2. Seat lock ...

  • Page 449

    Exterior parts: 9d-2 component location exterior components location b705h19403001 1 3 4 5 6 7 8 9 10 11 12 13 14 15 22 21 20 19 16 18 17 2 i705h1940051-02 1. Wind screen 7. Helmet box front cover 13. Center frame cover 19. Rear handlebar cover 2. Front leg shield cover 8. Front frame cover 14. Lowe...

  • Page 450

    9d-3 exterior parts: removal procedures flow chart b705h19403002 (17) upper meter panel (7) f ront helmet bo x co v e r (8) f ront fr ame co v e r (12) pillion r ider handle co v e r (6) pillion r ider handle (15) f rame co v e r rear combination light (10) f ootboard (5) helmet bo x assemb ly (9) c...

  • Page 451

    Exterior parts: 9d-4 repair instructions exterior parts components b705h19406002 1 2 3 4 5 7 6 8 i705h1940053-02 1. Wind screen 3. Meter panel assembly 5. Front leg shield cover 7. Front box assembly 2. Upper meter panel 4. Front panel 6. Front leg shield 8. Lower leg shield.

  • Page 452

    9d-5 exterior parts: 1 3 2 4 5 7 8 6 9 10 11 12 i705h1940052-01 1. Frame cover (rh) 4. Side leg shield (rh) 7. Frame cover (lh) 10. Footboard (lh) 2. Footboard (rh) 5. Center frame cover 8. Lower frame cover 11. Side leg shield (lh) 3. Center leg cover (rh) 6. Front frame cover 9. Center leg cover 1...

  • Page 453

    Exterior parts: 9d-6 “a” “b” 1 “c” 1 i705h1940054-02 1. Front reflex reflector (for e-03, 28, 33) “b”: set the reflector to the edge of front leg shield. “a”: adhere the front reflex reflector on to the front leg shield. “c”: align the projection of reflector with the joint part of meter panel and f...

  • Page 454

    9d-7 exterior parts: 1 2 3 4 5 7 9 8 10 6 “ a ” “ b ” “ c ” i705h1940055-04 1. Fuel lid 6. Cushion “a”: 0 mm 2. Front box inner cover (lh) 7. Fuel lid “b”: 0 – 3 mm (0 – 0.12 in) 3. Battery cover 8. Inner cushion “c”: 4 mm (0.16 in) 4. Front box inner cover (rh) 9. Cushion 5. Front box 10. Front box...

  • Page 455

    Exterior parts: 9d-8 1 2 2 3 “a” “ a ” 2 i705h1940060-01 1. Front panel box lid “a”: 2 mm (0.08 in) 2. Cushion “a”: do not exchange the right one and left one. 3. Front panel box : apply silicone grease..

  • Page 456

    9d-9 exterior parts: 1 2 “a” i705h1940056-03 1. Pillion rider handle 2. Pillion rider handle cover “a”: to frame.

  • Page 457

    Exterior parts: 9d-10 1 “a” “ a ” 2 3 4 5 7 8 10 9 “a” 7 12 6 11 i705h1940061-02 1. Seat molding 6. Mat 11. Lower helmet box 2. Helmet box front cover 7. Frame 12. License plate light cover 3. Helmet box lid (lh) 8. Seat “a”: 0 – 1 mm (0 – 0.04 in) 4. Helmet box lid (rh) 9. Tool band “a”: outside 5....

  • Page 458

    9d-11 exterior parts: 1 fwd 1 “a” “b” 1 fwd 1 “c” 2 i705h1940063-02 1. Fuel tray mudguard sheet “b”: face the clamp locking part inside and clamp end backward. 2. Frame “c”: clamp the seat with the wiring harness. “a”: the seat must be assembled behind the horn..

  • Page 459

    Exterior parts: 9d-12 inner cover construction b705h19406025 1 2 2 2 2 2 1 i705h1940062-01 1. Inner cover 2. Clamp : clamp ends should face inside. The clamps are not fastened too much..

  • Page 460

    9d-13 exterior parts: seat lock cable removal and installation b705h19406001 refer to “seat lock cable routing diagram (page9d- 1)”. Handlebar cover removal and installation b705h19406003 removal 1) remove the rear handlebar cover (1). 2) remove the front handlebar cover (2). Installation install th...

  • Page 461

    Exterior parts: 9d-14 wind screen removal and installation b705h19406006 removal 1) remove the front leg shield cover. Refer to “front leg shield cover removal and installation (page9d-13)”. 2) remove the wind screen (1). Installation install the wind screen in the reverse order of removal. Front pa...

  • Page 462

    9d-15 exterior parts: 3) remove the screws and fasteners. 4) remove the front leg shield (3) by disconnecting the turn signal light coupler (4), position light couplers (5) and headlight couplers (6). Side leg shield removal and installation b705h19406010 removal 1) remove the left and right rear fl...

  • Page 463

    Exterior parts: 9d-16 under cover removal and installation b705h19406011 removal 1) remove the side leg shields. Refer to “side leg shield removal and installation (page9d-15)”. 2) remove the fasteners. 3) remove the under cover (1). Installation install the under cover in the reverse order of remov...

  • Page 464

    9d-17 exterior parts: front frame cover removal and installation b705h19406014 removal 1) remove the helmet box front cover. Refer to “helmet box front cover removal and installation (page9d- 16)”. 2) remove the front frame cover (1). Installation install the front frame cover in the reverse order o...

  • Page 465

    Exterior parts: 9d-18 front box removal and installation b705h19406017 removal 1) remove the lower leg shield and front frame cover. Refer to “lower leg shield removal and installation (page9d-16)” and “front frame cover removal and installation (page9d-17)”. 2) remove the ambient temperature sensor...

  • Page 466

    9d-19 exterior parts: pillion rider handle cover removal and installation b705h19406018 removal open the seat and remove the pillion rider handle cover (1). Installation install the pillion rider handle cover in the reverse order of removal. Pillion rider handle removal and installation b705h1940601...

  • Page 467

    Exterior parts: 9d-20 frame cover removal and installation b705h19406022 removal 1) remove the front frame cover, center leg covers, pillion rider handle, center frame cover and lower frame cover. Refer to “front frame cover removal and installation (page9d-17)”, “center leg cover removal and instal...

  • Page 468

    9d-21 exterior parts: helmet box removal and installation b705h19406023 removal 1) remove the frame covers. Refer to “frame cover removal and installation (page9d-20)” 2) remove the mat (1). 3) remove the helmet box by removing the seat lock bolt (2) and helmet box bolts. Installation install the he...

  • Page 469

    Exterior parts: 9d-22 special tools and equipment recommended service material b705h19408001 note required service material is also described in the following. “exterior parts components (page9d-4)”.

  • Page 470: Body Structure

    9e-1 body structure: body structure repair instructions body frame construction b705h19506010 2 1 3 3 5 5 6 7 10 11 11 12 12 4 4 (a) 8 (b) 9 fwd fw d i705h1950003-02 1. Frame 6. Collar 11. Bearing 2. Crankcase bracket bolt 7. Crankcase bracket 12. Collar 3. Bushing 8. Crankcase bracket nut : 102 n ⋅...

  • Page 471

    Body structure: 9e-2 engine mounting bracket bushing replacement b705h19506011 replace the engine mounting bracket bushing if necessary. Refer to “body frame construction (page9e-1)”. Engine mounting bushing replacement b705h19506012 replace the engine mounting bushing if necessary. Refer to “body f...

  • Page 472

    9e-3 body structure: side-stand removal and installation b705h19506016 removal 1) support the motorcycle with the center stand. 2) remove the side-stand. Refer to “side-stand construction (page9e-2)”. Installation install the side-stand. Refer to “side-stand construction (page9e-2)”. Center stand co...

  • Page 473

    Body structure: 9e-4 center stand removal and installation b705h19506018 removal 1) support the motorcycle using a jack. Caution ! Make sure that the motorcycle is supported securely. 2) remove the center stand. Refer to “center stand construction (page9e-3)”. Installation install the center stand. ...

  • Page 474

    Prepared by april, 2006 part no. 99500-34100-01e printed in japan 476.

  • Page 475

    Printed in japan k7.