L4 december ’13 (tk) 21 99505-01134-01e © copyright suzuki motor japan foreword this motorcycle has been designed and produced utilizing suzuki’s most modern technology. The finest product, however, cannot perform properly unless it is cor- rectly assembled and serviced. This set-up manual has been ...
1 preparation workshop a: packed vehicle b: working space self protection caution assembling the vehicle in poor working condi- tion can be hazardous. Place the packed vehicle on a level floor where it is clean and spacious. caution assembling the vehicle without proper clothes and protective ge...
2 uncrating the motorcycle cut the strap by using scissors. A: strap remove the carton. A: crate caution metal crates may have sharp edges and may cause injury. Wear proper protective clothes and gear..
3 remove the strap. Take out the front wheel assembly from the crate base. A: strap b: front wheel assembly remove the strap. Take out the various component parts packaged from the crate base. A: strap b: component parts remove the bolts of the bracket. A: bolt.
4 remove the bolts from the crate. A: bolt lift the steel frame to separate it from the base of the crate. Carefully remove the various component parts pack- aged around the motorcycle. A: steel frame b: crate base caution careless steel frame separation can injure a person. Lift the steel frame w...
5 location of parts check all the components which have been removed from the base of the crate. Parts listed above are installed respectively into the positions as follows. Item part name q’ty remarks a windscreen 1 stepped allen screw 4 6 × 20 mm rubber cushion 4 od:18.0 t:10.0 rubber cap 4 b hand...
6 the photograph shown indicates the parts dismounted from the motorcycle in addition to the items shown in the preceding page. A: front brake master cylinder b: throttle assembly c: clutch master cylinder d: left switch e: right switch f: front wheel abs sensor assembly g: case lock assembly a a a ...
7 before assembling the motorcycle, thoroughly understand the “safety check out” described on page 52. After completion of assembly, carefully check the motorcycle referring to the “safety check out”, then deliver the motorcycle to the customer. Assembly left right removing the bracket remove the bo...
8 handlebars loosen the right switch retaining screws and throttle housing retaining bolts. Insert the right switch and throttle assembly onto the handlebars. A: throttle assembly b: right switch c: handlebars install the handlebars assembly with the two clamps, four bolts and washers. A: clamp b: 8...
9 a: front brake hose b: throttle cables c: right switch wiring harness d: clutch hose e: left switch wiring harness throttle install the throttle assembly with two allen bolts. A: throttle assembly b: allen bolt c: dot mark right switch insert the boss of right switch housing into the hole on the h...
10 front brake master cylinder install the front brake master cylinder onto the handle- bars. A: holder b: front brake master cylinder c: 6 × 22 mm flange bolt d: 6 × 22 mm flange bolt e: dot mark tighten the front brake master cylinder mounting bolts to the specified torque. front brake master cy...
11 left switch insert the boss of left switch housing into the hole on the handlebars. Install the left switch assembly with two screws. A: boss b: hole c: 5 × 25 mm screw clutch master cylinder install the clutch master cylinder onto the handlebars. A: holder b: clutch master cylinder c: 6 × 22 mm ...
12 connect the lead wires to the clutch lever position switch. A: clutch lever position switch b: lead wire right clamp clamp the right switch wiring harness and front brake hose union with strap. A: strap l:140 mm b: front brake hose union c: right switch wiring harness left clamp the left switch w...
13 handlebar balancer assemble the handlebar balancer parts as shown. A: balancer weight b: 6 × 105 mm screw c: flange rubber cushion l:34.0 mm d: spacer l:50.0 mm e: washer od:16.0 mm id:6.5 mm t:1.6 mm f: rubber cushion l:15.0 mm g: 6 mm spacer nut tighten the screw a little. Insert the balancer s...
14 taking out the motorcycle bind a hoist band around the handlebar clamps as shown in the photograph. A: hoist band remove the crate axle bracket from the crate base. A: crate axle bracket b: bolt 1 . Lift the front of motorcycle by using a hoist. 2 . Raise the rear of motorcycle. 3 . Pull the crat...
15 front fender install the front fender to the front fork legs. A: front fender b: 6 × 16 mm stepped allen screw c: front fork leg (for limited specifications) install the front fender to the front fork legs. A: front fender b: 6 × 16 mm stepped allen screw c: front fork leg d: reflex reflector ass...
16 front rear brake disc to prevent brake squeaking and pad contamination, carefully clean the front and rear brake disc plates with alcohol or other non-petroleum based solvent. This will remove the rust-preventive coating and dirt. Front wheel when installing the front wheel onto the axle, special...
17 loosen the axle clamp bolts. Remove the front axle from the fork legs. A: axle clamp bolt b: front axle mount the front wheel assembly properly. A: right fork leg b: left fork leg c: front wheel spacer (right) d: front axle e: axle nut (24 mm flange nut) temporarily remove the right front brake c...
18 left remove the supporter from the brake pad of the left front brake caliper. A: supporter right left attach the front wheel spacer to the front wheel hub. Carefully insert the front brake disc plate between the caliper brake pads. A: front wheel spacer b: oil seal (lip) c: pads d: disc plate ins...
19 tighten the front axle nut to the specified torque while holding the front axle. front axle nut: 100 n·m (10.0 kgf-m) a: axle nut front brake caliper remove the supporter from the brake pad of the right front brake caliper. A: supporter b: brake caliper (right) set the front brake caliper so th...
20 abs sensor install the front wheel abs sensor assembly. A: front wheel abs sensor assembly b: hole c: 6 × 12 mm flange bolt install the front wheel abs sensor lead wire bracket to the fork leg. A: front wheel abs sensor lead wire bracket b: stopper (groove) c: 6 × 12 mm flange bolt arrange the fr...
21 place the motorcycle on the side-stand, then remove the hoist hook. Extract the side stand. Move the front fork up and down hard 4 or 5 times. Right left tighten the axle clamp bolts to the specified torque. front axle clamp bolt: 23 n·m (2.3 kgf-m) a: axle clamp bolt place the motorcycle on th...
22 windscreen install the rubber cushion to the windscreen. A: windscreen b: rubber cushion od:18.0 mm t:10.0 mm set the windscreen to the windscreen brace. A: windscreen b: 6 × 20 mm stepped allen screw c: hole (windscreen brace) tighten the screws to fix the windscreen to the wind- screen brace. A...
23 rear view mirror remove the lock bolt. Turn in the lock nut as far as possible. A: lock bolt b: rear view mirror stay c: lock nut d: opposite thread tighten the lock bolt. Install the rear view mirror and tighten lock nuts securely after positioning them properly. Place the rubber boot. A: lock b...
24 license plate a: washer od:13.0 mm id:6.5 mm b: rear fender c: license plate (for limited specifications) a: washer od:13.0 mm id:6.5 mm b: rear fender c: license plate warning label (for e-21 cc and e-21 cd selection) select the appropriate language label for your country. Stick the labels suita...
25 owner’s manual remove the seat by using the key. A: key b: seat store the owner’s manual in place. A: owner’s manual set reinstall the seat. Insert the seat hook into the seat hook retainer. Push the seat down to lock it. A: seat assembly b: seat hook c: seat hook retainer d: seat lock striker e:...
